Skip to main content
SpringerLink
Log in

Computational modeling for structural element analysis using cement composites in 3D printing

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The construction industry has incorporated 3D printing as an innovative technology. However, there are still challenges involving the complexity of the necessary parameters, such as the geometric characteristics, strength, and rigidity of the printed objects, depending on the studied material. Therefore, this study proposes a new tridimensional computational modeling for dimensioning 3D-printed structures. The model is based on the physical non-linearity of the material and the geometric non-linearity of the structure. It consists of a numerical reproduction of an experimental test using frame finite elements and considers the material properties’ evolution over time by construction phases. The printing speed used is 60 mm/s, and the time interval between layers is 11 s. The results obtained revealed good agreement with those from experimental tests and validated the theoretical formulation. The differences between computational and theoretical methods varied from 0.58 to 3.38% for different building rates. In terms of vertical normal stress at the base of the walls, the maximum percentage variation between the models is of 5.22% and less than 1 mm in absolute values for vertical displacements. The model successfully predicted the failure moment of the structure. The parametric analyses showed that the proposed model is an accessible, effective, and accurate tool to reveal the effects of printing speed on the construction process.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2

Source: Author (2022)

Fig. 3
Fig. 4

Source: Author (2022)

Fig. 5

Similar content being viewed by others

References

  1. Chia HN, Wu BM (2015) Recent advances in 3D printing of biomaterials. J Biol Eng 9(1):1

    Article  CAS  Google Scholar 

  2. Stansbury JW, Idacavage MJ (2016) 3D printing with polymers: challenges among expanding options and opportunities. Dent Mater 32(1):54–64

    Article  CAS  PubMed  Google Scholar 

  3. BOS F et al (2016) Additive manufacturing of concrete in construction: potentials and challenges of 3D concrete printing. Virtual Phys Prototyp 11(3):209–225

    Article  Google Scholar 

  4. Vaidyanathan R, Walish J, Lombardi JL (2000) The extrusion freeforming of functional ceramic properties. J Miner Metals Mater Soc TMS 52(12):34

    Article  CAS  Google Scholar 

  5. Grida I, Evans JRG (2003) Extrusion freeforming of ceramics through fine nozzles. J Eur Ceram Soc 23:629–635

    Article  CAS  Google Scholar 

  6. Brooks H, Lupeanu ME, Piorkowski B (2013) Research towards high speed extrusion freeforming. Int J Rapid Manuf 3(2/3):154–171

    Article  Google Scholar 

  7. Liu CB, Gao JM, Tang YB, Chen XM (2018) Preparation and characterization of gypsum-based materials used for robocasting. J Mater Sci 53(24):16415–16422

    Article  ADS  CAS  Google Scholar 

  8. MASOOD SH. Advances in fused deposition modelling. Comprehensive Materials Processing Elsevier pp 69–91 2014

  9. Gross BC, Erkal JL, Lockwood SY, Chen C, Spence DM (2014) Evaluation of 3D printing and its potential impact on biotechnology and the chemical sciences. Anal Chem 86(7):3240–3253

    Article  CAS  PubMed  Google Scholar 

  10. Godoi FC, Prakash S, Bhandari BR (2016) 3D printing technologies applied for food design: status and prospects. J Food Eng 179:44–54

    Article  Google Scholar 

  11. Dimitrov D, Schreve K, de Beer N (2006) Advances in three dimensional printing - state of the art and future perspectives. Rapid Prototyp J 12(3):136–147

    Article  Google Scholar 

  12. Gao W et al (2015) The status, challenges, and future of additive manufacturing in engineering. Comput Aided Des 69:65–89

    Article  Google Scholar 

  13. Wolfs RJM, Bos FP, Salet TAM (2018) Early age mechanical behaviour of 3D printed concrete: numerical modelling and experimental testing. Cem Concr Res 106:103–116

    Article  CAS  Google Scholar 

  14. Le TT et al (2012) Hardened properties of high-performance printing concrete. Cem Concr Res 42(3):558–566

    Article  ADS  CAS  Google Scholar 

  15. Suvash CP et al (2018) Fresh and hardened properties of 3D printable cementitious materials for building and construction. Arch Civ Mech Eng 18:311–319

    Article  Google Scholar 

  16. Suiker ASJ (2018) Mechanical performance of wall structures in 3D printing processes: theory, design tools and experiments. Int J Mech Sci 137:145–170

    Article  Google Scholar 

  17. Kruger J, Zeranka S, Van Zijl G (2019) 3D concrete printing: a lower bound analytical model for buildability performance quantification. Autom Constr 106:102904

    Article  Google Scholar 

  18. Kruger J. et al. 3D concrete printer parameter optimisation for high rate digital construction avoiding plastic collapse Compos Part B Eng 183 2020

  19. Mettler LK et al (2016) Evolution of strength and failure of SCC during early hydration. Cem Concr Res 89:288–296

    Article  CAS  Google Scholar 

  20. Wolfs RJM, Bos FP, Salet TAM (2018) Correlation between destructive compression tests and non-destructive ultrasonic measurements on early age 3D printed concrete. Constr Build Mater 181:447–454

    Article  Google Scholar 

  21. Wolfs RJM, Bos FP, Salet TAM (2019) Triaxial compression testing on early age concrete for numerical analysis of 3D concrete printing. Cement Concr Compos 104:1

    Article  Google Scholar 

  22. Wolfs RJM, Suiker ASJ (2019) Structural failure during extrusion-based 3D printing processes. Int J Adv Manuf Technol 104(1–4):565–584

    Article  Google Scholar 

  23. Perrot A, Rangeard D, Pierre A (2016) Structural built-up of cement-based materials used for 3D-printing extrusion techniques. Materials and Structures/Materiaux et Constructions 49(4):1213–1220

    Google Scholar 

  24. Roussel N. et al. Numerical simulations of concrete processing: from standard formative casting to additive manufacturing. Cement and Concrete Research Elsevier Ltd, 2020

  25. COMMINAL, R. et al. Modelling of material deposition in big area additive manufacturing and 3D concrete printing. Ecole Centrale de Nantes, France, September 2019 Disponível em: <www.euspen.eu>

  26. Wolfs RJM; Salet, TAM; Roussel, N. Filament geometry control in extrusion-based additive manufacturing of concrete: the good, the bad and the ugly. Cement and Concrete Research 150 2021

  27. Reiter L et al. The role of early age structural build-up in digital fabrication with concrete Cement and Concrete Research Elsevier Ltd 2018

  28. Roussel N Rheological requirements for printable concretes. Cement and Concrete Research Elsevier Ltd 2018

  29. Roussel N et al (2012) The origins of thixotropy of fresh cement pastes. Cem Concr Res 42(1):148–157

    Article  CAS  Google Scholar 

  30. Roussel, N. et al. Numerical simulations of concrete processing: from standard formative casting to additive manufacturing. Cement and Concrete Research. Elsevier Ltd 1 set. 2020

  31. Roussel N (2006) A thixotropy model for fresh fluid concretes: theory, validation and applications. Cem Concr Res 36(10):1797–1806

    Article  CAS  Google Scholar 

  32. Ooms T, Vantyghem G, van Coile R, de Corte W (2021) A parametric modelling strategy for the numerical simulation of 3D concrete printing with complex geometries. Addit Manuf 38:101743

    Google Scholar 

  33. Khan SA, Koç M (2023) Buildability Analysis of 3D concrete printing process: a parametric study using design of experiment approach. Processes 11:782

    Article  Google Scholar 

  34. Araújo RA et al (2022) Thermal performance of cement-leca composites for 3D printing. Constr Build Mater 349

  35. Yu S, Sanjayan J, Du H (2022) Effects of cement mortar characteristics on aggregate-bed 3D concrete printing. Addit Manuf 58:103024

    Google Scholar 

  36. Chen M et al (2020) Yield stress and thixotropy control of 3D-printed calcium sulfoaluminate cement composites with metakaolin related to structural buildup. Constr Build Mater 252:119090

    Article  CAS  Google Scholar 

  37. Panda B et al (2021) Use of magnesium-silicate-hydrate (M-S-H) cement mixes in 3D printing applications. Cem Concr Compos 117:103901

    Article  CAS  Google Scholar 

  38. Duan Z et al (2022) Effect of metakaolin on the fresh and hardened properties of 3D printed cementitious composite. Constr Build Mater 350:128808

    Article  CAS  Google Scholar 

  39. Zhu B et al (2021) 3D concrete printing of permanent formwork for concrete column construction. Cem Concr Compos 121:104039

    Article  CAS  Google Scholar 

  40. Liu C et al (2021) Influence of hydroxypropyl methylcellulose and silica fume on stability, rheological properties, and printability of 3D printing foam concrete. Cem Concr Compos 122:104158

    Article  CAS  Google Scholar 

  41. Chen Y et al (2021) 3D printing of calcined clay-limestone-based cementitious materials. Cem Concr Res 149:106553

    Article  CAS  Google Scholar 

  42. Sanjayan JG et al (2018) Effect of surface moisture on inter-layer strength of 3D printed concrete. Constr Build Mater 172:468–475

    Article  Google Scholar 

  43. Barbosa MS et al (2022) Development of composites for 3D printing with reduced cement consumption. Constr Build Mater 341:127775

    Article  CAS  Google Scholar 

  44. Klyuev S et al (2022) Fresh and mechanical properties of low-cement mortars for 3D printing. Constr Build Mater 338:127644

    Article  CAS  Google Scholar 

  45. ASSOCIAÇÃO BRASILEIRA DE NORMAS TÉCNICAS (2016) NBR 13276: Mortars applied on walls and ceilings ― Determination of the consistence index. Third edition. Rio de Janeiro, p 2

  46. Lopes AC, Nascimento Neto JA, Medeiros KA, Maciel DN (2020) Three-dimensional modelling of wall-beam interaction in structural masonry buildings. Rev IBRACON Estrut Mater 13(4):e13414

    Article  Google Scholar 

  47. Lopes ACS, JAN, Neto, Barros R (2021) Analysis of structural masonry buildings taking into account the construction sequence loads and soil-structure interaction. Rev IBRACON Estrut Mater 14(6):e14607. https://doi.org/10.1590/S1983-41952021000600007

  48. ASSOCIAÇÃO BRASILEIRA DE NORMAS TÉCNICAS (2014) NBR 6118: Design of structural concrete - Procedure. Rio de Janeiro, p 238

  49. ASSOCIAÇÃO BRASILEIRA DE NORMAS TÉCNICAS (2014) NBR 13279: Mortars Applied on walls and ceilings – Determination of the flexural and the compressive strength in the hardened stage. Second edition. Rio de Janeiro, p 9

  50. INTERNATIONAL FEDERATION FOR STRUCTURAL CONCRETE(FIB)(2014) Model Code 2010, Final draft – Volume 1, p 350

  51. EUROPEAN STANDARD (2004) EN 1992-1-1: Eurocode 2: Design of concrete structures - Part 1-1: General rules and rules for buildings. p 225

  52. AMERICAN CONCRETE INSTITUTE (2008) ACI 209.2R-08: Guide for Modeling and Calculating Shrinkage and Creep in Hardened Concrete. Farmington Hills, p 44

Download references

Funding

This work was supported by the Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES).

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior

Author information

Authors and Affiliations

  1. Department of Materials Science and Engineering, Cement Laboratory, Federal University of Rio Grande Do Norte, University Campus, Natal, RN, Brazil

    Anna Christinna Secundo Lopes Nóbrega, Cleanto Carlos de Queiroz Junior & Antônio Eduardo Martinelli

  2. Department of Engineering, Federal Rural University of the Semi-Arid, Gamaliel Martins Bezerra Street, 587, Teachers Block I, Room 33, Angicos, RN, Brazil

    Wendell Rossine Medeiros de Souza

  3. Department of Engineering, Federal Rural University of the Semi-Arid, Gamaliel Martins Bezerra Street, 587, Teachers Block II, Room 4, Angicos, RN, Brazil

    Kleber Cavalcanti Cabral

Authors
  1. Anna Christinna Secundo Lopes Nóbrega
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Cleanto Carlos de Queiroz Junior
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Wendell Rossine Medeiros de Souza
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Kleber Cavalcanti Cabral
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Antônio Eduardo Martinelli
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Anna Christinna Secundo Lopes Nóbrega.

Ethics declarations

Conflict of interest

The authors declare no competing interests.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Nóbrega, A.C.S.L., de Queiroz Junior, C.C., de Souza, W.R.M. et al. Computational modeling for structural element analysis using cement composites in 3D printing. Int J Adv Manuf Technol 131, 1467–1478 (2024). https://doi.org/10.1007/s00170-024-13198-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-024-13198-3

Keywords

Search

Navigation