Evaluation of mix design parameters based on basic constitutive relationships for 3DCP printing

Dias, Leonardo de Souza; Anjos, Marcos A. S.; Barbosa, Marcella S.; Bezerra, Ulisses T.

doi:10.1590/ZXBR6170

Leonardo de Souza Dias ^* * leonardo.dias@academico.ufpb.br

Federal University of Paraíba, 58051-900, João Pessoa, PB, Brazil

https://orcid.org/0000-0001-6008-3600

Marcos A. S. Anjos

Federal Institute of Education, Science and Technology of Paraíba, 58015-435, João Pessoa, PB, Brazil

Marcella S. Barbosa

Federal University of Paraíba, 58051-900, João Pessoa, PB, Brazil

Ulisses T. Bezerra

Federal Institute of Education, Science and Technology of Paraíba, 58015-435, João Pessoa, PB, Brazil

* leonardo.dias@academico.ufpb.br

(AE: A. E. Martinelli)

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Figure 1:
Granulometric characterization of aggregate.

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Figure 2:
Granulometric characterization of cement and metakaolin.

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Figure 3:
a) and b) Definition of the optimum water to dry material ratio for the printing conditions, reference mixture (1:2).

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Figure 4:
Experimental flowchart.

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Figure 5:
3DCP printing equipment.

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Figure 6:
(a) Print speed and print rate determination (b) Printed layers, 1:1.5 mixture

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Figure 7:
Production and procurement of the samples for the vertical displacement and interlayer adhesion test.

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Figure 8:
Schematic of the execution of the bond strength test between the layers.

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Figure 9:
a) direction of extraction and load application; b) example of test setups.

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Figure 10:
Slump and spreading of the mixture and its Va/Vaglo and Cpaste ratios.

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Figure 11:
Shape retention and spreading.

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Figure 12:
Appearance of the printable mixtures: (a) 1:1.5; (b) 1:2.0 and (c) 1:2.5.

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Figure 13:
Constitutive parameters of the compositions.

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Figure 14:
Flowchart for dosing a 3DCP mixture.

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Figure 15:
Appearance of the printable 1:0.25:3 mixture.

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Figure 16:
Squeeze flow of the printable samples.

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Figure 17:
Squeeze flow of the printable samples. a) mix 1:1.5, b) mix 1:2, c) mix 1:2.5, and d) mix 1:0.25:3.

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Figure 18:
Flexural strength of printed mixtures at 28 days.

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Figure 19:
Compressive strength (Fz) of the printable mixtures after 1 and 28 days, and bulk density and porosity at 28 days.

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Figure 20:
Loss of workability of mixtures (open time).

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Figure 21
Bond strength between layers at different intervals.

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Table I:
Compilation of compositions from different references.

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Table II:
Parameters of the materials to be studied and their correlated standards.

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Table III:
Physical properties of aggregate.

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Table IV:
Compositions adopted.

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Table V:
Dosage parameters for printable mixtures.

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Table VI:
Statistical analysis of the mechanical behavior of bending by Anova at Fx Direction and Tukey Test (TT) for each ratio.

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Table VII:
Statistical analysis of the mechanical behavior of bending by Anova at Fy Direction and Tukey Test (TT) for each ratio.

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Table VIII:
Statistical analysis of the mechanical behavior of bending by Anova at Fz Direction and Tukey Test (TT) for each ratio.

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Table IX:
Statistical analysis of the mechanical behavior of bending by Anova at Fx Direction and Tukey Test (TT) for each ratio.

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Table X:
Statistical analysis of the mechanical behavior of bending by Anova at Fx Direction and Tukey Test (TT) for each ratio.

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Table XI:
Statistical analysis between mixtures at initial time (T0) by Anova and Tukey Test (TT) for each ratio.

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Table XII:
Statistical a nalysis of the mixtures at T0, T15 and T30 by Anova and Tukey Test (TT) for mixture 1:1.5.

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Table XIII:
Statistical analysis of the mixtures at T0, T15 and T30 by Anova and Tukey Test (TT) for mixture 1:2.0.

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Table XIV:
Statistical analysis of the mixtures at T0, T15 and T30 by Anova and Tukey Test (TT) for mixture 1:2.5.

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(A)

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(B)

Reference	Mix cem:sand: w/b	SCM	Other materials	s/b	Cement consumption (kg/m³)
Zhang et al. ⁹9 Zhang Y, Zhang Y, She W, Yang L, Liu G, Yang Y. Rheological and harden properties of the high-thixotropy 3D printing concrete. Construction and Building Materials Internet]. 2019 Mar 20;201:278-85.	1:0.6:0.35	silica fume	-	0.6	≈ 1094
	1:0.8:0.35	silica fume	-	0.8	≈ 1011
	1:1.0:0.35	silica fume	-	1.0	≈ 939
	1:1.2:0.35	silica fume	-	1.2	≈ 877
	1:1.5:0.35	silica fume	-	1.5	≈ 798
Buswell et al. ¹³13 Kaszyńska M, Skibicki S, Hoffmann M. 3D Concrete Printing for Sustainable Construction. Energies. 2020 Dec 1;13(23):6351.	1:1.47:0.40	fly ash and silica fume	limestone powder	1.47	588
	1:1.47:0.40	fly ash and silica fume	-	1.47	588
	1:1.55:0.28	-	limestone powder	1.55	840
	1:1.55:0.28	-	-	1.55	840
	1:2.45:0.40	fly ash and silica fume	limestone powder	2.45	448
	1:2.54:0.28	-	limestone powder	2.54	640
Ding et al. ¹⁴14 Ding T, Xiao J, Zou S, Wang Y. Hardened properties of layered 3D printed concrete with recycled sand. Cement and Concrete Composites. 2020 Jun;103724.	1:1:0.305	-	-	1.00	≈ 980
	1:1:0.305	-	recycled sand	1.00	≈ 967
Hasse, et al. ¹⁵15 Hasse JA, Rubin AP, Quintanilha LC, Repette WL. Increasing structuration rate of 3D printable concretes: the effect of viscosity enhancing admixtures. Revista IBRACON de Estruturas e Materiais. 2020;13(4).	1:1.67:0.41	silica fume	-	1,67	706
Xiao et al. ¹⁶16 Xiao J, Zou S, Yu Y, Wang Y, Ding T, Zhu Y, et al. 3D recycled mortar printing: System development, process design, material properties and on-site printing. Journal of Building Engineering. 2020 Nov;32:101779.	1:1:0.35	-	-	1.00	≈ 939
	1:1:0.35	-	recycled sand	1.00	≈ 933
Ding et al. ¹⁷17 Ding T, Xiao J, Zou S, Zhou X. Anisotropic behavior in bending of 3D printed concrete reinforced with fibers. Composite Structures. 2020 Dec;254:112808.	1:1:0.35	-	-	1.00	≈ 947
Ma et al. ¹⁸18 Ma G, Li Z, Wang L, Wang F, Sanjayan J. Mechanical anisotropy of aligned fiber reinforced composite for extrusion-based 3D printing. Construction and Building Materials . 2019 Mar;202:770-83.	1:1.20:0.38	fly ash and silica fume	-	1.20	≈ 726
Marchment and Sanjayan ¹⁹19 Marchment T, Sanjayan J. Bond properties of reinforcing bar penetrations in 3D concrete printing. Automation in Construction . 2020 Dec;120:103394.	1:1.5:0.3	fly ash and silica fume	-	1.5	≈ 652
Pham et al. ²⁰20 Pham L, Tran P, Sanjayan J. Steel fibres reinforced 3D printed concrete: Influence of fibre sizes on mechanical performance. Construction and Building Materials . 2020 Jul;250:118785.	1:1:0.37	silica fume and blast furnace slag	-	1.0	483*
Rahul and Santhanam ²¹21 Rahul AV, Santhanam M. Evaluating the printability of concretes containing lightweight coarse aggregates. Cement and Concrete Composites . 2020 Feb;103570.	1:1.5:0.40	fly ash	-	1.5	660
Nerella et al. ²²22 Nerella VN, Hempel S, Mechtcherine V. Effects of layer-interface properties on mechanical performance of concrete elements produced by extrusion-based 3D-printing. Construction and Building Materials [Internet]. 2019 Apr;205:586-601.	1:2.2:0.42	-	-	2.2	627
	1:1.8:0.42	fly ash and silica fume	-	1.8	391*
Xiao et al. ²³23 Xiao J, Han N, Zhang L, Zou S. Mechanical and microstructural evolution of 3D printed concrete with polyethylene fiber and recycled sand at elevated temperatures. Construction and Building Materials . 2021 Jul;293:123524.	1:1:0.35		nano-clay	1.00	320**
Ye et al. ⁽²⁴24 Ye J, Cui C, Yu J, Yu K, Xiao J. Fresh and anisotropic-mechanical properties of 3D printable ultra-high ductile concrete with crumb rubber. Composites Part B: Engineering . 2021 Apr;211:108639.	1:0.30:0.55	fly ash and silica fume	-	0.30	655

Materials	Properties	Technical standards
Aggregate	Granulometry	NBR NM 248 ²⁸28 ABNT NBR NM 248./ ASTM D6913²⁹29 ASTM D6913.
	Specific mass	NBR NM 52 ³⁰30 ABNT NBR NM 52./ ASTM C128³¹31 ABNTC128.
	Unit mass	NBR NM 45 ⁽³²/ ASTM C128³¹31 ABNTC128.
	Percentage of fines	NBR NM 46 ³³33 ABNTNBR NM 46./ ASTM C128³¹31 ABNTC128.
Cement and metakaolin	Specific mass	NBR NM 23 ³⁴34 ABNTNBR NM 23. /ASTM C188³⁵35 ABNTC188. (ABNT, 2000)
Cement and metakaolin	Laser granulometry	-

Dry specific mass (g/cm³)	Specific mass saturated dry surface (g/cm³)	Specific mass (g/cm³)	Compacted unit mass (g/cm³)	Loose unit mass (g/cm³)	Fineness modulus (%)	Maximum diameter (mm)	Powder content (%)
2.56	2.58	2.61	1.71	1.58	1.42	2.20	4.15

Mix	Cement (kg/m³)	Sand (kg/m³)	Water (kg/m³)	SP (%)	HPMC (%)	W/Md (%)	A/C (kg/kg)
1:1.0	1085.5	1085.5	234.5	0.89	0.15	10.8	0.22
1:1.5	859.2	1288.8	232.0	0.89	0.15	10.8	0.27
1:2.0	710.4	1420.9	230. 9	0.89	0.15	10.8	0.33
1:2.5	606.3	1515.8	229.2	0.89	0.15	10.8	0.38
1:3.0	528.6	1585.7	228.3	0.89	0.15	10.8	0.43

Paste volume/aggregate volume (Vp/Vag) (dm³/dm³)	Fines consumption (Cf) (kg/m³)	Water-to-fine ratio (Va/Vf) (l/m³)	Pulp volume (Vp) (l/m³)	Sand/Solids (%)
0.75 to 1.06	606 to 859	0.82 to 1.15	428 to 514	60 to 71

Group ratio	Variance	Source of variation	SQ	gl	MQ	F	P-value	F critical	TT 1:1.15	TT 1:2.0	TT 1:2.5
1:1.15	2.23567	Between groups	49.76723	2	24.88361	24.36501	0.001318	5.143253	-	0.06412	0.001077*
1:2.0	0.02963	Within the groups	6.127709	6	1.021285	-	-	-	4.05600	-	0.01536*
1:2.5	0.79854	-	-	-	-	-	-	-	9.82300	5.76700	-

Group ratio	Variance	Source of variation	SQ	gl	MQ	F	P-value	F critical	TT 1:1.15	TT 1:2.0	TT 1:2.5
1:1.15	0.64566	Between groups	80.42367	2	40.21184	28.47706	0.000866	5.143253	-	0.003809*	0.0008584*
1:2.0	3.53504	Within the groups	8.472469	6	1.412078	-	-	-	7.71400	-	0.25100
1:2.5	0.05551	-	-	-	-	-	-	-	10.24000	2.53100	-

Group ratio	Variance	Source of variation	SQ	gl	MQ	F	P-value	F critical	TT 1:1.15	TT 1:2.0	TT 1:2.5
1:1.15	0.61806	Between groups	45.8367	2	22.91835	50.16214	0.00018	5.143253	-	0.009449*	0.0001426*
1:2.0	0.563741	Within the groups	2.741312	6	0.456885	-	-	-	6.40700	-	0.003752*
1:2.5	0.18884	-	-	-	-	-	-	-	14.14000	7.73700	-

Group ratio	Variance	Source of variation	SQ	gl	MQ	F	P-value	F critical	TT 1:1.15	TT 1:2.0	TT 1:2.5
1:1.15	27.69371	Between groups	1271.7	2	635.85	28.14011	0.000134	4.256495	-	0.009449*	0.0001426*
1:2.0	29.88468	Within the groups	203.3627	9	22.59586	-	-	-	6.693	-	0.003752*
1:2.5	10.20919	-	-	-	-	-	-	-	10.48	3.782	-

Group ratio	Variance	Source of variation	SQ	gl	MQ	F	P-value	F critical	TT 1:1.15	TT 1:2.0	TT 1:2.5
1:1.15	8.23706	Between groups	178.0213	2	89.01063	8.950319	0.009102	4.45897	-	0.03197*	0.01307*
1:2.0	11.33652	Within the groups	79.55974	8	9.944968	-	-	-	4.473	-	0.8436
1:2.5	11.96923	-	-	-	-	-	-	-	5.361	0.7942	-

Group ratio	Variance	Source of variation	SQ	gl	MQ	F	P-value	F critical	TT 1:1.15	TT 1:2.0	TT 1:2.5
1:1.15	0.032719	Between groups	15.09998	2	7.549988	55.31025	0.000136	5.143253	-	0.03883	0.000121
1:2.0	0.025696	Within the groups	0.819015	6	0.136503	-	-	-	4.632	-	0.001019
1:2.5	0.351093	-	-	-	-	-	-	-	14.56	9.925	-

Group time	Variance	Source of variation	SQ	gl	MQ	F	P-value	F critical	TT T0	TT T15	TT T30
T0	0.02094	Between groups	13.79339	2	6.896696	6.113745	0.035668	5.143253	-	0.03113	0.1561
T15	0.785404	Within the groups	6.768384	6	1.128064	-	-	-	4.893	-	0.4488
T30	1.359539	-	-	-	-	-	-	-	3.065	1.828	-

Group time	Variance	Source of variation	SQ	gl	MQ	F	P-value	F critical	TT T0	TT T15	TT T30
T0	0.016445	Between groups	5.80339	2	2.901695	1.560021	0.28475	5.143253	-	0.3623	0.3266
T15	2.051158	Within the groups	11.16021	6	1.860035	-	-	-	2.098	-	0.9957
T30	1.503665	-	-	-	-	-	-	-	2.223	0.1249	-

Group time	Variance	Source of variation	SQ	gl	MQ	F	P-value	F critical	TT T0	TT T15	TT T30
T0	0.224699	Between groups	0.437254	2	0.218627	0.926077	0.446157	5.143253	-	0.5486	0.4728
T15	0.1841	Within the groups	1.416471	6	0.236079	-	-	-	1.555	-	0.9885
T30	0.044472	-	-	-	-	-	-	-	1.76	0.205	-

[1] * leonardo.dias@academico.ufpb.br

Brasil

Brasil

Evaluation of mix design parameters based on basic constitutive relationships for 3DCP printing

Abstract