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Item type:Publication, Eco-friendly additive construction: Analysis of the printability of earthen-based matrices stabilized with potato starch gel and sisal fibers(Elsevier Ltd, 2022-09-12)3D printing for construction purposes is a disruptive technology with the potential for rapid and massive applications making it a feasible alternative for social housing, temporary shelters after disasters, and, recently, for extraterrestrial habitats. However, most of the matrices used for construction by 3D printing are based on hydraulic cement as the main constituent, which is not easily available in remote locations and is an important greenhouse gases generator. Therefore, a good understanding to formulate and evaluate alternative matrices using soil and organic materials with the required fresh and hardened-state properties compatible with this emerging technology is needed. This article studies the printable capabilities of eco-friendly earthen-based matrices which uses potato starch as a natural stabilizer for raw soil mortars aiming to obtain 3D printed filaments with adequate fresh and hardened-states properties. The aqueous starch gel was combined with sisal fibers in the printing mixture to control shrinkage cracking problems during hardening. The optimization of the dosage of the stabilizer was carried out considering different tests in fresh and hardened printed filaments namely, pumpability and extrudability, stacking, shear vane, shrinkage cracking, Vicat needle, compression strength, and capillarity absorption tests. The results indicate that printable earthen-based matrices reinforced with 1 % of sisal fibers by weight of soil and stabilized with aqueous starch gels with concentrations up to 5 % (w/w) showed improved workability and minor cracking and can be used for 3D printing. These promising results in the field of material science combined with novel 3D printing technology that is also presented in the article open new lines of research for eco-friendly alternatives for the construction industry. - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Additive construction of concrete deep beams using low-cost characterization methods and FEM-based topological optimization(Elsevier Ltd, 2024-03-08)Additive manufacturing using concrete for large-scale construction purposes has demonstrated economic, social, and environmental benefits compared to conventional building procedures. These advantages stem from the capabilities of concrete 3D printing, which facilitates a rapid, accurate, and low-waste construction process with substantially less labor and energy requirements compared to traditional casting procedures such as formwork fabrication and stripping, concrete pouring, and concrete consolidation. This technology can pave the way for sustainable and cost-effective housing solutions when coupled with low-carbon concrete formulations and optimized structural designs. However, scientific and industrial experiences have shown that formulating printable concrete requires extensive testing and costly equipment to reach appropriate fresh and hardened-state properties. Therefore, accessible and practical mix-design protocols for the evaluation of printable concrete formulation are needed to enable in-situ control and broader adoption of 3D printing. Once a printable material is developed, innovative design methods, such as topology optimization, that exploit robot-controlled construction to fabricate efficient, safe, and free-form elements can be explored. In this context, this article presents a methodology based on a set of low-cost and accessible experimental tests to develop cement-based matrices with low binder content suitable for layer-by-layer deposition. Furthermore, a framework to design and fabricate efficient structural elements based on numerical-based topological optimization and concrete additive manufacturing is proposed and validated. The systematic experimental campaign carried out indicates that the yield strength obtained from shear vane tests, initially designed for geotechnical field tests, is a reliable reference value for proportioning extrudable, pumpable, and buildable concretes. Employing the proposed framework, four formulations with excellent printing capabilities are presented. These formulations are successfully utilized for additive manufacturing of a topologically optimized deep beam, achieving a remarkable 52% mass reduction compared to a solid element. This showcases the possibility of 3D printing structurally efficient elements with intricate geometries while minimizing material usage, all without the need for formworks.Principio del formulario. - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Soil-Cement Matrices for Additive Construction: 3D Printing System Validation and Printing Tests(Trans Tech Publications Ltd, 2023-01-01)Soil as a building material is gaining renewed interest from academia, and the constructionsector, mainly for fabricating low-environmental impact homes. The fabrication of houses with soilusing traditional methods such as adobe, cob, and rammed earth dates back to ancient times. However, emerging construction technologies, such as 3D printing, can be compatible with this material for building purposes. The article presents the validation of a 3D printing system for construction applications and the evaluation of soil-cement matrices' printability. First, the paper defines the printing parameters through experimental testing on soil matrices. Then, the article evaluates the printability of soil-cement matrices through filament printing and stacking tests. The results show that the 3D printing system prototype can fabricate small and medium-sized elements with soil matrices after correctly defining the pumping speed, printing speed, and layer height. Furthermore, experimental printing test results demonstrate that soil-cement matrices can be easily extruded and stacked; however, their printability capacity is strongly affected by the total water content and printing speed. This research highlights the suitability of soil-cement mixtures for additive manufacturing, a promising outcome that can facilitate the construction of homes in remote areas using 3D printing systems. - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Preliminary Experimental Evaluation of Buildability Improvement Methods for Concrete for 3D Printing(Trans Tech Publications Ltd, 2023-01-01)3D concrete printing is an innovative construction process based on fully auto nomousmaterial deposition. One of the challenges of implementing this technology is the development of printable concrete formulations, as this material must exhibit particular fresh-state properties. Among these, buildability is one of the most important. This property describes the material's ability to support weight at very early ages, allowing a layer-by-layer construction. Therefore, this paper aims to evaluate two approaches for improving concrete buildability: the optimization of the super plasticizer dosage and the external application of quick-setting admixture. The results showed that reducing super plasticizer content improved buildability by increasing the static yield strength.However, this approach has a collateral disadvantage as concretes presented problems duringextrusion. On the other hand, the results of cylinder stability and Vicat tests indicate that the external application of quick-setting admixture leads to concretes with improved buildability without affecting the initial workability and a faster hardening process. According to these results, the latter approachcan potentially be applied in small and large-scale 3D printing. - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Evaluation of Chitosan and Potato Starch as Stabilizers to Improve the Mechanical and Water Durability Properties of Printable Earth-Based Matrices Reinforced with Sisal Fibers(Trans Tech Publications Ltd, 2023-01-01)Due to economic, sustainable, and aesthetic benefits, academia and the construction industry are exploring the use of earth in modern construction is being widely studied. Unfortunately, earth as a construction material has low mechanical, poor water durability resistance, and the potential to swell and crack. Therefore, this paper evaluates chitosan and potato starch, natural biodegradable polymers, as stabilizers to improve mechanical strength and water durability resistance of printable earth-based matrix reinforced with sisal fibers. Although the test results indicated that the chitosan had a better performance as an earth stabilizer than potato starch, adding both stabilizers resulted in earthen composites with higher compressive strength and lower water permeability. These results demonstrate the feasibility of using natural stabilizers to improve the performance of earth-based materials for 3D printing without affecting their printability capacities. - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Additive Construction Using Enhanced Earthen-Based Composites: Improvement of the Mechanical Strength and Water Durability Using Chitosan and Agave Fibers(RELX Group (Netherlands), 2023-01-01) - Some of the metrics are blocked by yourconsent settings
Item type:Publication, Calcium-free geopolymer construction blocks from spent fluid catalytic cracking catalyst: Formulation and optimisation for curing at ambient temperature(Elsevier BV, 2026-05-09)The development of more sustainable masonry construction materials requires alternatives to conventional clay and concrete units, whose production entails high energy consumption and substantial CO₂ emissions. This study aims to upscale the synthesis of ambient-cured geopolymer masonry units derived from residues of spent Fluid Catalytic Cracking (FCC) catalyst by developing, first, a binder and then a mortar (binder + sand) with adequate structural stability and durability for industrial production. The optimised formulation, comprising 15 M NaOH, sodium silicate (Ms = 0.85), an activator-to-FCC ratio of 1.1, and 65 wt% sand, yielded a dense, crack-free mortar. The curing process was optimised to enable early demoulding after 24 h of pre-curing at ambient temperature without moisture protection, followed by six days of sealed curing. This regime promoted stable volumetric behaviour and efficient strength development without thermal input. The optimised mortar achieved 28-day compressive and tensile strengths of 28.8 MPa and 3.9 MPa, respectively, thereby validating the efficacy of the methodology employed. When scaled up to full-sized construction blocks, one solid and two hollow geometries, the FCC-based blocks exhibited apparent densities above 2000 kg/m³ , open porosity between 27% and 30%, and compressive strengths ranging from 13 to 24 MPa, exceeding standard requirements for load-bearing applications.2