In the ever-evolving landscape of construction technology, a groundbreaking study has emerged that could significantly impact the energy sector and beyond. Researchers at King Mongkut’s University of Technology Thonburi in Bangkok, Thailand, have developed a hydrophobic mortar tailored for three-dimensional (3D) printing applications, potentially revolutionizing the way we build and maintain structures.
The study, led by Natthanicha Sakolaree from the Research Laboratory for Sustainable Concrete and Construction Materials, explores the incorporation of calcium stearate (CS) and polypropylene (PP) microfiber into mortar mixtures. The goal? To create a material that is not only printable but also resistant to water absorption and dust accumulation—qualities that are highly desirable in the energy sector, where harsh environments and extreme weather conditions can take a toll on infrastructure.
The research, published in *Case Studies in Construction Materials* (translated from Thai as “Studies on Building Materials”), reveals that increasing the CS content delays the setting time and reduces the compressive strength of the mortar. However, the addition of PP microfiber effectively enhances the compressive strength, striking a crucial balance between workability and structural integrity.
One of the most striking findings is the significant reduction in water sorptivity—a whopping 91%—achieved with the use of 15% CS. This translates to a water contact angle of up to 142°, imparting hydrophobic properties to the mortar surface. “This hydrophobic nature not only reduces water absorption but also facilitates dust removal, which is a game-changer for maintaining the efficiency and longevity of energy infrastructure,” Sakolaree explains.
The study also highlights the reduction in plastic shrinkage, a common issue in 3D-printed structures. The inclusion of CS and PP microfiber reduces shrinkage by 53%, with further improvements observed when both additives are combined. This enhancement in printability and structural stability opens up new possibilities for the construction of durable, low-maintenance structures in the energy sector.
Microstructural analysis revealed that CS increases pore generation within the matrix. However, this does not adversely affect water absorption due to the presence of CS on pore surfaces, confirmed by a high proportion of carbon detected by EDS analysis. This finding underscores the innovative approach taken by the researchers to balance porosity and hydrophobicity.
The implications of this research are far-reaching. In the energy sector, where structures are often exposed to harsh environmental conditions, the development of hydrophobic, dust-resistant mortar could lead to significant cost savings in maintenance and repair. Moreover, the enhanced printability and structural stability of the mortar could accelerate the construction of energy infrastructure, making it more efficient and resilient.
As the construction industry continues to embrace 3D printing technology, this research paves the way for the development of advanced materials that can withstand the rigors of the energy sector. The combination of 15% CS and 0.2% PP microfiber has been identified as the optimal mix for 3D printing applications, offering a promising solution for the future of construction.
In the words of Sakolaree, “This study not only advances our understanding of 3D-printed mortar but also opens up new avenues for innovation in the construction industry. The potential applications are vast, and we are excited to see how this research will shape the future of building and infrastructure development.”
As the energy sector continues to evolve, the development of hydrophobic mortar tailored for 3D printing applications represents a significant step forward. This research not only highlights the importance of innovation in construction materials but also underscores the potential for collaboration between academia and industry to drive progress in the field. The future of construction is here, and it is hydrophobic.