RESUMO
Three-dimensional printing of cementitious materials for construction has been extensively investigated in recent years, with several demonstration projects successfully carried out. These efforts aim to leverage the printing process to achieve more efficient production of components compared to conventional concrete technologies. This includes both the process itself (eliminating the formwork stage) and the flexibility in producing complexly shaped elements. To maximize the potential of 3D printing in the construction industry, additional steps must be taken, grounded in a holistic view of the entire process. This involves integration of the production chain, including design, materials, and manufacturing of components, to create elements with optimal performance, encompassing structural, environmental, and architectural aspects. Such multi-functionality requires the viewing of 3D printing not just as a production technology but as a platform enabling the integration of all these components. To advance this approach, quantitative tools are developed to optimize the following three key components: material composition; manufacturing parameters to ensure buildability; and design tools to optimize multiple performance criteria, particularly structural and architectural shape. A demonstration component, namely a post-tensioned beam, featuring two multi-functional characteristics-structural and architectural-is designed, produced, and evaluated. The scientific concepts and research tools used to develop these quantitative design tools are multidisciplinary, including rheological characterization, control of the internal structure and composition of granular materials, simulation of the mechanical behavior of green material during printing, and the hardened properties of the components, all utilizing structural optimization to enhance performance.
RESUMO
Clays are components in the fine portion of aggregates, less than 75 microns in size (micro-fines), which are usually washed away when producing coarse or fine (manufactured sand) aggregates in quarries. When marginal sources of aggregates are being used, the content of this washed portion can be quite high, and there is an incentive to keep as much of it in the aggregate, including the clays. The present paper presents a comprehensive treatment of the role of clays in terms of the characterization of their composition and quantification of their effects on the rheological and mechanical properties of cementitious systems, as well as the means to mitigate deleterious influences. It is shown that the strategy for neutralizing the effect of micro-fines containing clays on increased water demand in concrete can be quantified in terms of the combination of their content in concrete and their nature as characterized by the methylene blue value (MBV); this is a more rational approach to considering their influence than their content in specific aggregates as specified in standards. The effect of low and medium MBV aggregates on the water requirement can be neutralized by lignosulfonates when their content in the concrete is below a threshold value of about 150 kg/m3; polycarboxylates (PC) are required at higher contents; for high MBV aggregates, a combination of PC and clay mitigating admixture (CMA) is required. It is also demonstrated that with proper treatment, such micro-fines can be turned into useful fillers, enhancing the strength of concrete and thus also serving as a means for reducing cement content.