geopolymer cement-based 3d printing concrete technology...super hydrophobic coating frp construction...

Opening Minds · Shaping the Future

Geopolymer Cement-based 3D Printing Concrete Technology

基於地聚物水泥的3D混凝土

Annual Concrete Seminar 2019

Prof. Jian-Guo DAI

(戴建國教授)

(FIIFC, FHKIE, FHKCI)

Department of Civil and Environmental Engineering

The Hong Kong Polytechnic University

Hong Kong, 2 April 2019


Outline of Presentation

1. Construction Industry 4.0

2. 3D Concrete Printing Technology

3. Geopolymer Cement-based 3D Printing

4. Conclusion


Construction Industry 4.0


Prefabricated Construction

http://gosmartbricks.com/prefabricated-construction/www.sasac.gov.cn/n2588025/n2588149/c9341371/content.html

Modular Integrated Construction



https://upload.wikimedia.org/wikipedia/commons/thumb/6/6a/Woolworth_Building_2_Feb._1912_LC-USZ62-105567.jpg/800px-Woolworth_Building_2_Feb._1912_LC-USZ62-105567.jpg

Hollow core slabsWoolworth Building, 1912



HPFRC

Utilization of Sustainable Materials

TRCGeoplymer concrete

Super hydrophobic coating FRP



Building Information Modeling (BIM)



Prefabrication


SEKISUI CHEMICAL CO., LTD,


Factory-outStock-in

Stock-out

Stock-in

StockDelivery

Courtesy of Prof ZL Ma, Tsinghua UniversityRadio Frequency Identification(RFID)



SMART Automated Construction, SHIMIZU Co. Ltd. Robotized Construction


https://www.youtube.com/watch?v=mP2AtqcitbQ

https://www.youtube.com/watch?v=mP2AtqcitbQ


Big data and smart city

Monitoring, Pre-warning, Optimization, Emergency Treatment etc.



Industrialized building construction

（IBC）

Building Information Technology （BIM）

3D print technology

• Digitalization (数字化驱动)

• Customization

• Formwork free and zero

construction waste

• Prefabrication

• Mechanisation

• Automation

• Informationisation

• Customisation https://www.psfk.com/2014/12/concrete-3d-printer.html



3D Concrete Printing Technology

Head of Global Center of Excellence Industry 4.0

Traditional Numerical Control Manufacturing



3D printing

in global market

0

500

1000

1500

2000

2500

3000

3500

4000

4500

Year 2010

2018

Num

ber

of P

ublic

ations

1983

Number of

Publications

3D printing

in Chinese market

3D打印商業化趨勢

Web of Science3D printing

2012 2013 2014 2015 2016 2017 20180

2

4

6

8

10

7.6

6.0

4.4

3.1

1.7Acco

un

t (H

un

dre

ds o

f m

illio

ns o

f R

MB

)

Time (Year)

3D printing share in Chinese market

1.0



Web of Science(As of 14-March-2019)Keywords:3D printingConcrete



Buswell 2018, CCR


3D Printing Concrete Technology

required object

Building model

Printing Simulation PrintingCourtesy of Dr Cao XP


Nozzle

Deliver pipe

Pump

Output pipe

Concrete

container

A printed sample

Extrusion

Printing

Direct

Deposition

Build

plate

💧💧

Roller

Powder Feeder

Powder Feeder PistonBuild Piston

Powder Bed

Roller

Binder

Feeder Z

XY

Powder-bed

Printing

Selective

Reaction


• Well-mixed slurry• Control rheology, viscosity,

setting time• Control extruding rate, slurry

continuity• Printing time per layer

• Well-homogenized particles• Control setting time• Accurate Positioning



Courtesy of Dr Cao XP



Advantages

• Reduce need for labor and improve the construction safety

• Create mid-size homes in low cost;

• High Handle geometries that would be difficult for traditional construction techniques

to handle. The modern building design has made features like exposed concrete walls

and geometrically complex roofs more popular;

• High build speed: designing and building a home can be an expensive and time-

consuming task;

• Nearly no material is wasted during the production process, making it more

environmentally friendly than traditional techniques;

• No need for construction companies to make molds to actualize their structures, saving

time, money and energy.


Robotic arm: 6 degree of freedomGantry: 4 degree of freedom

Extrusion based 3D Printing system is composed of two parts: pumping

system and printing system.


Courtesy of Dr Qian Y, NTU, Singapore



2016


Geopolymer Cement-based 3D Printing

Raw materials

Fly ash Slag NaOH Water glass

Metakaolin MgO PhosphateFly ash

Alkali-based Acid-based

One-part geopolymerTwo-part geopolymer

Solico-aluminophosphategeopolymer

• Utilization of industry waste

• Low carbon• Fast strength gain• Good chemical

resistance• Good fire resistance


Extrusion-based

Powder-based



Development ofPrinting Marterials

Trail-and-Error ofPrinting Methods & Matched Materials

Flowability

Extrusion-based 3D printing

Powder bed-based 3D printing

Design

Optimization

BuildabilityOpen time

Extrudability

Strength

Fineness Concentration

Setting time

Compatibility

Strength

Development of3D Printers

Design

Optimization

Print speed

Print path

Nozzle opening

Print height

Extrusion rate

Roller speed

Ink rate

Elevator speed

Inkjet head

“Ink”Powder+Liquid

“Ink”Slurries

PrinterParameters

PrinterParameters

2

1



X Y Z

抗壓強度測試

原材料及配合比

Paste layer

Paste layer

層間粘結強度測試

1.流動性測試 (flow)

The fluidity was further assessed by comparing the relative slump values calculated by the following Eq. 1:

𝛤𝑃 = (𝑑

𝑑𝑜)2−1 ….. (1)

where 𝚪p is the relative slump, d is the average of 3 measured diameters of the spread and do is the cone bottom

diameter.

2、粘度及剪切應變測試 ()

A rotational and oscillatory rheometer (Anton Paar MC302)

3. 凝結時間測試

ASTM C191-13

4. 機械性能測試

ASTM C109/C109M-16a




1min13mins

Poor fluidity

Excellent fluidityHigh

Low

48hours

Setting

time

Viscocity

Fluibility

27mins

0 20 40 60 80 100 120 140

0

5

10

15

20

25

30

35

40

45

Final setting

Pe

netr

atio

n d

ep

th o

f V

ica

t ne

ed

le (

mm

)

Time (min)

R0

SC20

SC50

SC80

Initial setting

0 100 200 300 400 500

0

5

10

15

20

25

30

35

40

45

Pe

netr

atio

n d

ep

th o

f V

ica

t ne

ed

le (

mm

)

Time (min)

R1

SC50

SA02

SA05

SA10

Initial setting

Final setting

A wide range of

parameters

0

1

2

3

4

5

6

7

SA10SA05SA02R1SC80SC50SC20

self-flow

Re

lative f

low

R0

after 25 blows (ASTM: C1437)



Two

extreme

cases for

instance



Ma G. et al .2018



0

50

100

150

200

1200

1250

1300

1350

1400

Final setting time

Initial Final

H30H20H10L30L20L10

Settin

g tim

e (

min

)C

Initial setting time

Metal

ions Aluminosilicate Precursor

Crystalline phosphates

e.g., Newberyite, Brushite

Amorphous phosphates

e.g.,

Aluminum/calcium/magnesi

um phosphate

Si-Al-P phase

Al-P phase

P-activator

UnreactedMetal sources

Unreactedaluminosilicates

0

5

10

15

20

25

30

0

1

2

3

4

5

6

13.2%

19.0%

0-15s 0-60s

H30H20H10L30L20L10

Flo

w d

iam

ete

r (c

m)

C

13.3%17.2%

12.0%

8.0%

1.1%

15.3%

16.9%14.9%

2.3%

1.9%

Incre

ased

flo

w d

iam

ete

r (c

m)

Increment in16-60s

0

10

20

30

40

50

60

28-d

3-d

H30H20H10L30L20L10

Co

mpre

ssiv

e s

tre

ng

th (

MP

a)

1 day 3 days 28 days

C

1-d

Increment in 3-28 days

Increment in 1-3 days

Flow

Setting time

Compressive strength



0

5

10

15

20

25

30

SA05

Co

mpre

ssiv

e s

tre

ng

th (

MP

a)

X direction Y direction Z direction

SA020.0

0.5

1.0

1.5

2.0

2.5

3.0

Inte

rla

ye

r b

on

d s

tre

ng

th (

MP

a)

SA02 SA05

Compressive strength Interlayer bonding strength

sample

Failure of sample



未反應的粉煤灰顆粒

化學反應生成的C-(A)-S-H 凝膠


3.2 酸激發系列地聚物的微觀結構測試結果

化學反應生成的 S-A-P-(H) 凝膠



• CAD Modeling

• Slicing 3D 2D 1D

• Printing 1D 2D 3D

PolyU Logo



在某一點的打印體積 =注射速度 ∗ ∆𝑡 ∗ 移動速度 ∗ ∆𝑡 ∗ 打印厚度

1. 粉床材料激光硬化機制改為化學反應機制2. 激光激發方式改為化學激發方式


Conclusions

• 3D printing concrete is an important dimension for

building industry 4.0.

• More and more successful projects have been completed

with concrete 3D printers, the legal obstacles that may

hinder the technology will ease up as time progresses.

• As time goes, more and more cities will adopt new rules

and standards that will support the use of concrete 3D

printing technology.


Thank you for your attention.

PROF. J.G. DAI’S RESEARCH GROUP

DEPARTMENT OF CIVIL AND ENVIRONMENTAL ENGINEERING

THE HONG KONG POLYTECHNIC UNIVERSITY

World’s first commercial 3D-concrete printing housing project (Netherlands)

geopolymer cement-based 3d printing concrete technology...super hydrophobic coating frp construction...

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