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Use of Waste Materials to Reduce Cement and Natural Aggregates in 3D Printing Mortars

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3D Printing for Construction with Alternative Materials

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Abstract

3D printing (3DP) is an example of a sustainable technology capable of replacing traditional manufacturing processes. One of its advantages is the use of optimized production processes, even for customized products, as well as the almost non-existence of waste. 3DP mortars (3DPM), therefore, rely heavily on Portland cement (PC), a material with high carbon emissions and energy consumption related to its manufacture. In order to comply with the growing environmental regulations and concerns, it is imperative that its use becomes more moderate and, as such, alternatives to PC or additives to reduce its percentage are being sought. At the Faculty of Engineering of University of Porto, research has been conducted to produce 3DPM with different waste materials. This study has the following objectives: (i) reduce PC by adding sugarcane bagasse ash (SCBA), with a strong emphasis on performance; (ii) substitute natural sand with recycled brick sand (RBS), aiming at replacing a natural aggregate while exploring new aesthetic possibilities. As to assess their viability as 3DPM, several mortars with different amounts of SCBA and RBS were formulated, taking into account some of its fresh and hardened properties as well as exploring different colours and textures. In the end, the best compositions were printed using material extrusion equipment.

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Acknowledgements and Funding

This work is financed by National Funds through the FCT—Fundação para a Ciência e a Tecnologia (Portuguese Foundation for Science and Technology) within the project MIT-EXPL/TDI/0041/2019. Manuel Jesus would like to thank FCT for financial support through the doctoral grant UI/BD/151533/2021. Sofia Pessoa would like to thank FCT for financial support through the doctoral grant PD/BD/150398/2019. João Teixeira would also like to thank FCT—Fundação para a Ciência e a Tecnologia, I.P. for the PhD grant 2020.07482.BD through FSE/NORTE 2020 funding. This work is funded by national funds through FCT—Fundação para a Ciência e a Tecnologia, I.P., under the Scientific Employment Stimulus—Institutional Call—CEECINST/00049/2018. Finally, this work was financially supported by Base Funding—UIDB/04708/2020 of the CONSTRUCT Instituto de I&D em Estruturas e Construções—the Base Funding—UIDB/00145/2020 of the CEAU—Center for Studies in Architecture and Urbanism both funded by national funds through the FCT/MCTES (PIDDAC).

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Authors and Affiliations

  1. CONSTRUCT, Faculty of Engineering (FEUP), University of Porto, Rua Dr. Roberto Frias s/n, 4200-465, Porto, Portugal

    Manuel Jesus, João Teixeira, Sofia Pessoa, Ana Sofia Guimarães, Bárbara Rangel & Lino Maia

  2. Master in Product and Industrial Design, University of Porto, Praça Gomes Teixeira, 4099-002, Porto, Portugal

    Joana Costa

  3. INEGI/Faculty of Engineering (FEUP), University of Porto, Rua Dr. Roberto Frias s/n, 4200-465, Porto, Portugal

    Luís Moreira, Rui Neto & Jorge Lino Alves

  4. Faculty of Exact Sciences and Engineering, University of Madeira, Campus Universitário da Penteada, 9020-105, Funchal, Portugal

    Lino Maia

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Correspondence to Manuel Jesus .

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  1. Department of Civil Engineering, Faculty of Engineering of University of Porto, Porto, Portugal

    Bárbara Rangel

  2. Department of Civil Engineering, Faculty of Engineering of University of Porto, Porto, Portugal

    Ana Sofia Guimarães

  3. Department of Mechanical Engineering, Faculty of Engineering of University of Porto, Porto, Portugal

    Jorge Lino

  4. Department of Mechanical Engineering, Federal University of Santa Catarina (UFSC), Florianópolis, Brazil

    Leonardo Santana

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Jesus, M. et al. (2023). Use of Waste Materials to Reduce Cement and Natural Aggregates in 3D Printing Mortars. In: Rangel, B., Guimarães, A.S., Lino, J., Santana, L. (eds) 3D Printing for Construction with Alternative Materials. Digital Innovations in Architecture, Engineering and Construction. Springer, Cham. https://doi.org/10.1007/978-3-031-09319-7_6

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  • DOI: https://doi.org/10.1007/978-3-031-09319-7_6

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