In the rapidly evolving world of construction, 3D-printed concrete is emerging as a game-changer, promising faster builds, reduced labor costs, and intricate designs that were once impossible. However, as with any innovative technology, ensuring the long-term durability of these structures is paramount, especially in harsh environments. Recent research published in the journal Advances in Civil Engineering, translated from Russian as Progress in Civil Engineering, sheds light on the durability and cracking defects associated with 3D-printed concrete, offering crucial insights for the energy sector and beyond.
At the heart of this study is Gintautas Skripkiunas, a researcher from the Department of Building Materials and Fire Safety. Skripkiunas and his team set out to understand the long-term performance of 3D-printed concrete, focusing on its resistance to freezing and thawing cycles, as well as the causes of cracking during maintenance. “As we push the boundaries of what’s possible with 3D printing in construction, it’s vital that we also push the boundaries of our understanding of these materials,” Skripkiunas stated.
The team tested a fine-grained concrete mixture with an expanded perlite additive, a material known for its insulating properties and lightweight nature. They produced 3D-printed concrete specimens using industrial equipment and subjected them to various tests, including determining density and compressive strength, and measuring mass loss after freeze/thaw cycles.
One of the key findings was the impact of the water-to-cement ratio on the strength of the concrete. By reducing this ratio to just 11%, the strength of the concrete with the expanded perlite additive increased from 68.2 MPa to 71.1 MPa. This is a significant improvement, especially considering the potential for reduced material costs and enhanced structural integrity.
However, the study also revealed some challenges. For concrete with a water-to-cement ratio of 0.47, the mass loss of 3D-printed specimens reached 2.09 kg/m² after 28 freeze/thaw cycles, and a staggering 9.17 kg/m² after 56 cycles. Moreover, large surface defects were observed, indicating a need for optimized mix designs and printing parameters.
Skripkiunas emphasized the importance of these findings for the energy sector, where structures often face harsh environmental conditions. “In the energy sector, we need buildings and infrastructure that can withstand extreme temperatures and weather conditions,” he said. “This research brings us one step closer to understanding how to create durable, long-lasting 3D-printed structures that can meet these demands.”
The study also analyzed the origins of cracks in 3D-printed products and provided recommendations for prevention. This is crucial for the energy sector, where structural integrity is non-negotiable.
As the construction industry continues to embrace 3D printing, this research serves as a reminder that innovation must be accompanied by rigorous testing and understanding. The findings underscore the need for continued research and development in this field, paving the way for more durable, efficient, and sustainable construction practices.
For those in the energy sector, this research offers a glimpse into the future of construction, where 3D-printed concrete could revolutionize the way we build and maintain infrastructure. However, it also serves as a cautionary tale, highlighting the importance of understanding and addressing the unique challenges posed by this innovative technology. As Skripkiunas and his team continue to delve into the world of 3D-printed concrete, their work will undoubtedly shape the future of construction, one layer at a time.
