Geometric Conformability of 3D Concrete Printing Mixtures from a Rheological Perspective.

The effectiveness of 3D concrete printing (3DCP) relies on understanding the rheological properties of cementitious materials and their time-dependent evolution. These materials exhibit shear-thinning viscosity, an elastic region, and both static and dynamic yield stress, which are challenging to balance in 3DCP. Layer deformation can be caused by factors such as self-weight, the weight of subsequently deposited layers, and the stress induced by the nozzle pressing. Starting at the level of a single filament, the final geometrical conformity of a 3D-printed object is the sum of individual filament conformities. Hence, the control of layer deformation during the printing process is critical. The failure of 3D-printed objects can occur due to two primary mechanisms: material failure, which occurs when the material's strength is exceeded, resulting in fracture or uncontrolled deformation; and stability failure, where the object cannot retain equilibrium of forces. These mechanisms often interact; extensive deformations resulting from material failure can lead to stability loss, or conversely, stability loss generates local excessive stresses leading to material failure. The governing mechanism depends on various factors, including material and process characteristics, as well as the transient nature of material properties, print strategy, and object design. With this in mind, this research aimed to broaden the understanding of the connection between rheological material properties-primarily yield stress-and the geometric conformability of printed objects. Experimental tests were conducted on pastes using a rheometer, and correlated mortars, allowing for the evaluation of realistic extrusion properties.

Numerical Reliability Study Based on Rheological Input for Bingham Paste Pumping Using a Finite Volume Approach in OpenFOAM.

Rheological quantification is important in many industries, the concrete industry in particular, e.g., pumping, form filling, etc. Instead of performing expensive and time-consuming experiments, numerical simulations are a powerful means in view of rheological assessment. However, due to the unclear numerical reliability and the uncertainty of rheological input data, it is important for the construction industry to assess the numerical outcome. To reduce the numerical domain of cementitious suspensions, we assessed the numerical finite volume simulations of Bingham paste pumping flows in OpenFOAM. We analysed the numerical reliability, first, irrespective of its rheological input by comparison with the literature and theory, and second, dependent on a certain rheological quantification by comparison with pumping experiments. Irrespective of the rheological input, the numerical results were significantly accurate. Dependent on the rheological input, a numerical mismatch, however, existed. Errors below 1% can be expected for proposed numerical rules of thumb: a bi-viscous regularisation, with pressure numbers higher than 5/4. To improve bias due to uncertain rheology, a rheological configuration close to the engineer's aimed application should be used. However, important phenomena should not be overlooked. Further assessment for lubrication flows, in, e.g., concrete pumping, is still necessary to address concerns of reliability and stability.

Effect of Ca(OH)2 Addition on the Engineering Properties of Sodium Sulfate Activated Slag.

Alkali-activated slag is considered as a sustainable construction material due to its environmentally friendly nature. To further promote the sustainable nature of alkali-activated slag, a sodium sulfate activator is suggested to be used since it can be obtained naturally and generates lower greenhouse gas emissions. However, the mixtures activated by sodium sulfate exhibit low early strength and very long setting times. This study investigates the effects of calcium hydroxide (Ca(OH)2) addition on some engineering properties such as rheology, setting time, mechanical properties, porosity, and microstructure of sodium sulfate activated ground granulated blast furnace slag (GGBFS). Furthermore, the changes of chemical groups in reaction products and phase identification have been evaluated by Fourier transform infrared spectroscopy (FTIR) and X-ray diffraction. Test results showed that Ca(OH)2 addition can substantially increase the reaction rate and the compressive strength at early ages. In addition, the very long setting times of the sodium sulfate-activated mixtures were shortened by the addition of Ca(OH)2. SEM analysis confirmed that the incorporation of excessive amounts of Ca(OH)2 could lead to a less well-packed microstructure although the reaction degree of GGBFS remained the same at later ages as compared to the sodium sulfate mixture. It was also revealed that in case of the Ca(OH)2 addition into sodium sulfate activator, the main reaction products are chain-structured C-A-S-H gels and ettringite.

Rheological Properties of Cement Paste with Nano-Fe3O4 under Magnetic Field: Flow Curve and Nanoparticle Agglomeration.

Understanding the influence of magnetic fields on the rheological behavior of flowing cement paste is of great importance to achieve active rheology control during concrete pumping. In this study, the rheological properties of cementitious paste with water-to-cement (w/c) ratio of 0.4 and nano-Fe3O4 content of 3% are first measured under magnetic field. Experimental results show that the shear stress of the cementitious paste under an external magnetic field of 0.5 T is lower than that obtained without magnetic field. After the rheological test, obvious nanoparticle agglomeration and bleeding are observed on the interface between the cementitious paste and the upper rotating plate, and results indicate that this behavior is induced by the high magnetic field strength and high-rate shearing. Subsequently, the hypothesis about the underlying mechanisms of nanoparticles migration in cementitious paste is illustrated. The distribution of the nanoparticles in the cementitious paste between parallel plates is examined by the magnetic properties of the powder as determined by a vibrating sample magnetometer. It is revealed that the magnetization of cementitious powders at different sections and layers provides a solid verification of the hypothesis.

Numerical Validation of a Population Balance Model Describing Cement Paste Rheology.

Rheology control is essential during the period in which cement and concrete pastes are encountered in the fresh state, due to the fact that it directly affects workability, initial placement and the structural performance of the hardened material. Optimizations of clinker formulations and reductions in cement-to-water ratios induced by economic and environmental considerations have a significant effect in rheology, which invokes the need for mechanistic models capable of describing the effect of multiple relevant phenomena on the observed paste flow. In this work, the population balance framework was implemented to develop a model able to relate the transient microstructural evolution of cement pastes under typical experimental conditions with its macroscopic rheological responses. Numerical details and performance are assessed and discussed. It was found that the model is capable of reproducing experimentally observed flow curves by using measured cluster size distribution information. It is also able to predict the complex rheological characteristics typically found in cement pastes. Furthermore, a spatially resolved scheme was proposed to investigate the nature of flow inside a parallel-plates rheometer geometry with the objective of assessing the ability of the model of qualitatively predicting experimentally observed behavior and to gain insight into the effect of possible secondary flows.

Structure-property relationships for polycarboxylate ether superplasticizers by means of RAFT polymerization.

HYPOTHESIS: Polycarboxylate ether (PCE) comb-copolymers are widely used as water reducing agents in the concrete industry while maintaining a high fluidity via the polymer adsorption to the cement particles. PCE copolymers with a broad range of structures are well established by Free radical polymerization, however, understanding the structure-property relationship is still complex due to the high polydispersity of PCE copolymers prepared by conventional polymerization. The influence of different structural parameters using well-defined polymeric structures is yet to be explored. EXPERIMENTS: In this study, two different types of comb-like random copolymers, namely polycarboxylate ether (PCE; poly(oligo(ethylene glycol) methyl ether methacrylate/methacrylic acid)) and polysulfonate ether (PSE; poly(oligo(ethylene glycol) methyl ether acrylate/sodium 4-styrenesulfonate)), were synthesized by RAFT polymerization to enable the synthesis of polymers with controlled features. The effect of charge types and side chain lengths on the adsorption, rheology, and dispersing ability of cement pastes have been studied. FINDINGS: RAFT polymerization could be used to prepare PCE random copolymers with good control over the polymer molecular weight and narrow polydispersity (D < 1.3). Results revealed that the ζ-potential values depend on both the charge type and side chain lengths. Copolymers containing SO3- exhibited higher absolute negative ζ-potential values than COO- while PCE copolymers with shorter side chains developed higher absolute negative ζ-potential values. On the other hand, the adsorption study demonstrated that decreasing the side chain lengths lead to higher adsorption of PCE copolymers while Copolymers with COO- groups were found to be adsorbed more than SO3- counterparts. These results are further confirmed with the rheological studies and it is found that the shorter the side chain, the lower the yield stress and the higher the dispersion of cement pastes but to a limited effect. Additionally, the charge types have a major influence on the performance of superplasticizers. This study could make further progress in establishing superplasticizers with controlled architectures for better performance.

Active control of properties of concrete: a (p)review.

Concrete properties to a large extent depend on mix design and processing, currently leaving only limited options to actively modify concrete properties during or after casting. This paper gives a (p)review on a more advanced active control of properties of concrete, based on the application of external signals to trigger an intended response in the material, either in fresh or hardened state. Current practices in concrete industry that could be considered as active control are briefly summarized. More advanced active control mechanisms as studied in other fields, e.g. based on hydrogels and other functional polymers, are reviewed and some principles are listed. A specific focus is further given on potential methods for active rheology control. Based on the concepts developed in other fields, substantial progress could be made in order to achieve active control of fresh and hardened concrete properties. However, several challenges remain, like the stability and functioning of the responsive material in a cementitious environment, the applicability of the control signal in a cementitious material, and the economy, logistics and safety of a control system on a construction site or in precast industry. Finding solutions to these challenges will lead to marvelous opportunities in general, and for 3D and even 4D printing more particularly.