Pathways to formulate lightweight and ultra-lightweight 3D printable cementitious composites

Zandifaez, Peyman; Shen, Zhenglai; Sorgenfrei, Reese; Li, Yucen; Dias-da-Costa, Daniel; Zhou, Hongyu

doi:10.1016/j.conbuildmat.2024.135874

Pathways to formulate lightweight and ultra-lightweight 3D printable cementitious composites

Journal Article · Fri Mar 22 20:00:00 EDT 2024 · Construction and Building Materials

DOI:https://doi.org/10.1016/j.conbuildmat.2024.135874· OSTI ID:3012555

Zandifaez, Peyman ^[1]; ^[2]; Sorgenfrei, Reese ^[3]; Li, Yucen ^[3]; ^[4]; Zhou, Hongyu ^[3]

University of Tennessee, Knoxville, TN (United States); The University of Sydney (Australia)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
University of Tennessee, Knoxville, TN (United States)
The University of Sydney (Australia)

Here, this paper studies the pathways to formulate lightweight and ultra-lightweight 3D printable cementitious composites. A hybrid approach was proposed by combining the advantages of traditional chemical-induced foaming (foaming approach) and lightweight particulate inclusions (synthetic foam approach). A comprehensive experimental program was conducted to evaluate the effects of foaming agents and fly ash cenosphere (FAC) on the printability, microstructure, mechanical and thermal properties of 3D printed samples. The results showed that the hybrid approach could produce a mixture with a density as low as 470 kg/m³ while ensuring good flowability and buildability owing to the lubricating effect of foaming and supporting skeleton formed by FAC. In addition, a three-step homogenization procedure was also developed to predict the effective elastic modulus and thermal conductivity of 3D printable cementitious composites and cementitious foam. The findings of the study highlighted the effectiveness of the hybrid approach in formulating 3D printable ultra-lightweight cementitious composites in thermal insulation and acoustic applications.

View Accepted Manuscript (DOE)

Research Organization:: The University of Alabama, Tuscaloosa, AL (United States); University of Tennessee, Knoxville, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Building Technologies Office

Grant/Contract Number:: EE0008677; AC05-00OR22725

OSTI ID:: 3012555

Alternate ID(s):: OSTI ID: 2327048
OSTI ID: 2372967

Journal Information:: Construction and Building Materials, Journal Name: Construction and Building Materials Vol. 424; ISSN 0950-0618

Publisher:: Elsevier BVCopyright Statement

Country of Publication:: United States

Language:: English

References (43)

Solutions for effective shear properties in three phase sphere and cylinder models Christensen, R. M.; Lo, K. H. Journal of the Mechanics and Physics of Solids, Vol. 27, Issue 4 https://doi.org/10.1016/0022-5096(79)90032-2	journal	August 1979
Effect of constituents on rheological properties of fresh concrete-A review Jiao, Dengwu; Shi, Caijun; Yuan, Qiang Cement and Concrete Composites, Vol. 83 https://doi.org/10.1016/j.cemconcomp.2017.07.016	journal	October 2017
Predicting effective thermal and elastic properties of cementitious composites containing polydispersed hollow and core-shell micro-particles Shen, Zhenglai; Zhou, Hongyu Cement and Concrete Composites, Vol. 105 https://doi.org/10.1016/j.cemconcomp.2019.103439	journal	January 2020
Hardened properties of layered 3D printed concrete with recycled sand Ding, Tao; Xiao, Jianzhuang; Zou, Shuai Cement and Concrete Composites, Vol. 113 https://doi.org/10.1016/j.cemconcomp.2020.103724	journal	October 2020
Evolution of elastic and thermal properties of cementitious composites containing micro-size lightweight fillers after exposure to elevated temperature Shen, Zhenglai; Zhou, Hongyu; Brooks, Adam Cement and Concrete Composites, Vol. 118 https://doi.org/10.1016/j.cemconcomp.2021.103931	journal	April 2021
Properties of foamed concrete with Ca(OH)2 as foam stabilizer Yuanliang, Xiong; Baoliang, Li; Chun, Chen Cement and Concrete Composites, Vol. 118 https://doi.org/10.1016/j.cemconcomp.2021.103985	journal	April 2021
3D printing eco-friendly concrete containing under-utilised and waste solids as aggregates Bai, Gang; Wang, Li; Ma, Guowei Cement and Concrete Composites, Vol. 120 https://doi.org/10.1016/j.cemconcomp.2021.104037	journal	July 2021
Technologies for improving buildability in 3D concrete printing Muthukrishnan, Shravan; Ramakrishnan, Sayanthan; Sanjayan, Jay Cement and Concrete Composites, Vol. 122 https://doi.org/10.1016/j.cemconcomp.2021.104144	journal	September 2021
Sustainable materials for 3D concrete printing Bhattacherjee, Shantanu; Basavaraj, Anusha S.; Rahul, A. V. Cement and Concrete Composites, Vol. 122 https://doi.org/10.1016/j.cemconcomp.2021.104156	journal	September 2021
Influence of hydroxypropyl methylcellulose and silica fume on stability, rheological properties, and printability of 3D printing foam concrete Liu, Chao; Wang, Xianggang; Chen, Yuning Cement and Concrete Composites, Vol. 122 https://doi.org/10.1016/j.cemconcomp.2021.104158	journal	September 2021
From analytical methods to numerical simulations: A process engineering toolbox for 3D concrete printing Perrot, A.; Pierre, A.; Nerella, V. N. Cement and Concrete Composites, Vol. 122 https://doi.org/10.1016/j.cemconcomp.2021.104164	journal	September 2021
Incorporating PCM-enabled thermal energy storage into 3D printable cementitious composites Brooks, Adam L.; He, Yawen; Farzadnia, Nima Cement and Concrete Composites, Vol. 129 https://doi.org/10.1016/j.cemconcomp.2022.104492	journal	May 2022
Enhancing the properties of foam concrete 3D printing using porous aggregates Pasupathy, Kirubajiny; Ramakrishnan, Sayanthan; Sanjayan, Jay Cement and Concrete Composites, Vol. 133 https://doi.org/10.1016/j.cemconcomp.2022.104687	journal	October 2022
Early age mechanical behaviour of 3D printed concrete: Numerical modelling and experimental testing Wolfs, R. J. M.; Bos, F. P.; Salet, T. A. M. Cement and Concrete Research, Vol. 106 https://doi.org/10.1016/j.cemconres.2018.02.001	journal	April 2018
Rethinking reinforcement for digital fabrication with concrete Asprone, Domenico; Menna, Costantino; Bos, Freek P. Cement and Concrete Research, Vol. 112 https://doi.org/10.1016/j.cemconres.2018.05.020	journal	October 2018
3-D printing of concrete: Beyond horizons Khan, Mohammad S.; Sanchez, Florence; Zhou, Hongyu Cement and Concrete Research, Vol. 133 https://doi.org/10.1016/j.cemconres.2020.106070	journal	July 2020
On sustainability and digital fabrication with concrete Flatt, Robert J.; Wangler, Timothy Cement and Concrete Research, Vol. 158 https://doi.org/10.1016/j.cemconres.2022.106837	journal	August 2022
Rheology and application of buoyant foam concrete for digital fabrication Cho, Seung; Kruger, Jacques; van Rooyen, Algurnon Composites Part B: Engineering, Vol. 215 https://doi.org/10.1016/j.compositesb.2021.108800	journal	June 2021
Lightweight cement mortars: Advantages and inconveniences of expanded perlite and its influence on fresh and hardened state and durability Lanzón, Marcos; García-Ruiz, P. A. Construction and Building Materials, Vol. 22, Issue 8 https://doi.org/10.1016/j.conbuildmat.2007.05.006	journal	August 2008
Comparative study of the mechanical and thermal properties of lightweight cementitious composites Brooks, Adam L.; Zhou, Hongyu; Hanna, Dominic Construction and Building Materials, Vol. 159 https://doi.org/10.1016/j.conbuildmat.2017.10.102	journal	January 2018
Mechanical properties of layered geopolymer structures applicable in concrete 3D-printing Al-Qutaifi, Sarah; Nazari, Ali; Bagheri, Ali Construction and Building Materials, Vol. 176 https://doi.org/10.1016/j.conbuildmat.2018.04.195	journal	July 2018
Effects of foaming agent type on the workability, drying shrinkage, frost resistance and pore distribution of foamed concrete Sun, Chao; Zhu, Yu; Guo, Jian Construction and Building Materials, Vol. 186 https://doi.org/10.1016/j.conbuildmat.2018.08.019	journal	October 2018
Thermal and mechanical properties of structural lightweight concrete containing lightweight aggregates and fly-ash cenospheres Zhou, Hongyu; Brooks, Adam L. Construction and Building Materials, Vol. 198 https://doi.org/10.1016/j.conbuildmat.2018.11.074	journal	February 2019
Mixture Design Approach to optimize the rheological properties of the material used in 3D cementitious material printing Liu, Zhixin; Li, Mingyang; Weng, Yiwei Construction and Building Materials, Vol. 198 https://doi.org/10.1016/j.conbuildmat.2018.11.252	journal	February 2019
Development of sustainable lightweight concrete using fly ash cenosphere and sintered fly ash aggregate Satpathy, H. P.; Patel, S. K.; Nayak, A. N. Construction and Building Materials, Vol. 202 https://doi.org/10.1016/j.conbuildmat.2019.01.034	journal	March 2019
Designing spray-based 3D printable cementitious materials with fly ash cenosphere and air entraining agent Lu, Bing; Qian, Ye; Li, Mingyang Construction and Building Materials, Vol. 211 https://doi.org/10.1016/j.conbuildmat.2019.03.186	journal	June 2019
Influence of cenospheres and fly ash on the mechanical and durability properties of high-performance cement mortar under different curing regimes Danish, Aamar; Mosaberpanah, Mohammad Ali Construction and Building Materials, Vol. 279 https://doi.org/10.1016/j.conbuildmat.2021.122458	journal	April 2021
Thermal performance of cement-leca composites for 3D printing Araújo, Rísia A.; Martinelli, Antônio E.; Cabral, Kleber C. Construction and Building Materials, Vol. 349 https://doi.org/10.1016/j.conbuildmat.2022.128771	journal	September 2022
AI-Assisted optimisation of green concrete mixes incorporating recycled concrete aggregates Zandifaez, Peyman; Asadi Shamsabadi, Elyas; Akbar Nezhad, Ali Construction and Building Materials, Vol. 391 https://doi.org/10.1016/j.conbuildmat.2023.131851	journal	August 2023
Energy-saving potential of 3D printed concrete building with integrated living wall He, Yawen; Zhang, Yamei; Zhang, Chao Energy and Buildings, Vol. 222 https://doi.org/10.1016/j.enbuild.2020.110110	journal	September 2020
Characteristics and utilization of sugarcane filter cake waste in the production of lightweight foamed concrete Makul, Natt; Sua-iam, Gritsada Journal of Cleaner Production, Vol. 126 https://doi.org/10.1016/j.jclepro.2016.02.111	journal	July 2016
Development of a high-temperature inorganic synthetic foam with recycled fly-ash cenospheres for thermal insulation brick manufacturing Brooks, Adam L.; Shen, Zhenglai; Zhou, Hongyu Journal of Cleaner Production, Vol. 246 https://doi.org/10.1016/j.jclepro.2019.118748	journal	February 2020
Study of MgO-activated slag as a cementless material for sustainable spray-based 3D printing Lu, Bing; Zhu, Weiping; Weng, Yiwei Journal of Cleaner Production, Vol. 258 https://doi.org/10.1016/j.jclepro.2020.120671	journal	June 2020
Formulating eco-friendly geopolymer foam concrete by alkali-activation of ground brick waste Pasupathy, Kirubajiny; Ramakrishnan, Sayanthan; Sanjayan, Jay Journal of Cleaner Production, Vol. 325 https://doi.org/10.1016/j.jclepro.2021.129180	journal	November 2021
Towards building homeostasis through a low-cost biomimetic synthetic foam for building surface cooling and energy saving He, Yawen; Brooks, Adam; Li, Yucen Journal of Cleaner Production, Vol. 385 https://doi.org/10.1016/j.jclepro.2022.135626	journal	January 2023
Data-driven multicollinearity-aware multi-objective optimisation of green concrete mixes Asadi Shamsabadi, Elyas; Salehpour, Masoud; Zandifaez, Peyman Journal of Cleaner Production, Vol. 390 https://doi.org/10.1016/j.jclepro.2023.136103	journal	March 2023
Young’s modulus and thermal conductivity of closed-cell, open-cell and inverse ceramic foams – model-based predictions, cross-property predictions and numerical calculations Pabst, Willi; Uhlířová, Tereza; Gregorová, Eva Journal of the European Ceramic Society, Vol. 38, Issue 6 https://doi.org/10.1016/j.jeurceramsoc.2018.01.019	journal	June 2018
A systematic review on energy-efficient concrete: Indicators, performance metrics, strategies, and future trends Zandifaez, Peyman; Nezhad, Ali Akbar; Zhou, Hongyu Renewable and Sustainable Energy Reviews, Vol. 194 https://doi.org/10.1016/j.rser.2024.114306	journal	April 2024
Prediction of the Effective Thermal Conductivity of Hollow Sphere Foams Jia, Zian; Wang, Zhen; Hwang, David ACS Applied Energy Materials, Vol. 1, Issue 3 https://doi.org/10.1021/acsaem.7b00264	journal	February 2018
The effect of cracks on the compressibility of rock Walsh, J. B. Journal of Geophysical Research, Vol. 70, Issue 2 https://doi.org/10.1029/JZ070i002p00381	journal	January 1965
Investigations on the foam concrete production techniques suitable for 3D-printing with foam concrete Markin, V.; Sahmenko, G.; Nerella, V. N. IOP Conference Series: Materials Science and Engineering, Vol. 660, Issue 1 https://doi.org/10.1088/1757-899X/660/1/012039	journal	November 2019
Material Design and Performance Evaluation of Foam Concrete for Digital Fabrication No authors listed Materials, Vol. 12, Issue 15 https://doi.org/10.3390/ma12152433	journal	July 2019
Mori-Tanaka Based Estimates of Effective Thermal Conductivity of Various Engineering Materials Stránský, Jan; Vorel, Jan; Zeman, Jan Micromachines, Vol. 2, Issue 2 https://doi.org/10.3390/mi2020129	journal	April 2011

Similar Records

Incorporating PCM-enabled thermal energy storage into 3D printable cementitious composites

Journal Article · Tue Mar 15 00:00:00 EDT 2022 · Cement and Concrete Composites · OSTI ID:1976934

Development and characteristics of ultra high-performance lightweight cementitious composites (UHP-LCCs)

Journal Article · Thu Jul 15 00:00:00 EDT 2021 · Cement and Concrete Research · OSTI ID:23206265

Related Subjects

36 MATERIALS SCIENCE
3D printing concrete
3D printing foam concrete
Foam concrete
Lightweight cementitious materials

Pathways to formulate lightweight and ultra-lightweight 3D printable cementitious composites

Citation Formats

References (43)

Similar Records

Related Subjects