Fabricación Aditiva de Geopolímeros para Un Entorno Construido Sostenible
Fabricación Aditiva de Geopolímeros para Un Entorno Construido Sostenible
a r t i c l e i n f o a b s t r a c t
Article history: This paper evaluates the potential of fly ash based geopolymer cement for large scale additive
Received 21 February 2017 manufacturing (AM) of construction elements. Geopolymer is considered as a green construction ma-
Received in revised form terial and its use in AM may contribute towards sustainable environment since in AM process material is
1 July 2017
only deposited whereby it is necessary. As part of this research, an industrial robot was employed to print
Accepted 19 August 2017
Available online 22 August 2017
geopolymer mortar in layer-by-layer manner directly from 3D computer-aided design (CAD) model. The
characteristic of raw materials and fresh properties were examined by rheology, x-ray diffraction (XRD),
Handling Editor: Yutao Wang and scanning electron microscopy (SEM). Mechanical tests such as compression, flexural and tensile
bond strength were conducted on the printed geopolymer in different printing directions and their
Keywords: performance was compared with casted samples. It was found, from the experimental results, that the
Digital construction mechanical properties of 3D printed geopolymer are mostly dependent of loading directions due to
Geopolymer anisotropic nature of the printing process and retains intrinsic performance of the material.
Additive manufacturing © 2017 Elsevier Ltd. All rights reserved.
sustainable environment
1. Introduction major categories i.e. D-shape and contour crafting (Wu et al., 2016;
Kreiger et al., 2015; Labonnote et al., 2016; Shape, 2017). Both
After more than 25 years of research and development, additive technologies have proven to be effective means of printing complex
manufacturing (AM) is still continuing to grow in various industrial geometrical structures as part of rapid construction technique (Lim
domains, such as aerospace, automobile and medical, with intro- et al., 2012). Though the printing processes in both technologies are
duction of new technologies, methods and applications (Chua and similar in a sense that objects are directly made from the CAD
Leong, 2014; Gibson et al., 2009; Khoshnevis, 2004). Out of all, models, actually they are developed for different applications and
building and construction (B&C) sector appears to be lagging in materials. In D-shape, sand and binder are used together to create
terms of technology and innovation unlike other manufacturing stone-like free-form structures (Shape, 2017), where, sand is
industries. Our current construction process continues to be rela- initially deposited over the build plate and then the binder is
tively simple and systematic; requiring cumbersome formwork and injected as per the digital model to hold the sand particles at that
much skilled labor to build any kind of freeform structures precise location. Once the printing is finished, excess sand is
(Khoshnevis et al., 2006). With evolution in time, the construction washed away from the built plate by a blowing air to the part ge-
designs are becoming more complicated and the workers involved ometry (Tibaut et al., 2016). The major limitation of this method is
in this process are increasingly exposed to unhealthy environments that only limited materials can be allowed whereas, in contour
(Kittusamy and Buchholz, 2004). This compels many researchers crafting, a wide variety of materials can be extruded out layer-by-
and industry experts to explore technologies like large scale addi- layer to print a single house or a colony of houses, while imbe-
tive manufacturing or 3D printing to bring automated solutions in dding conduits for electrical, plumbing and air-conditioning
the construction process. (Khoshnevis, 2004). Soon after the development counter crafting,
3D concrete printing technology can be categorized in two few researchers and industries have successfully printed and
characterized various cementitious material using Ordinary Port-
land Cement (OPC) as a key binder in their mix compositions (Le
et al., 2012a, 2012b; Feng et al., 2015; Rushing et al., 2017; Perrot
* Corresponding author. et al., 2016; Hambach and Volkmer, 2017; Kazemian et al., 2017).
E-mail address: [email protected] (B. Panda).
http://dx.doi.org/10.1016/j.jclepro.2017.08.165
0959-6526/© 2017 Elsevier Ltd. All rights reserved.
282 B. Panda et al. / Journal of Cleaner Production 167 (2017) 281e288
To reduce global warming effect of the OPC, some authors have Material having high yield stress was found to show less defor-
tried to replace the cement with some industrial by-products such mation on loading and to achieve this property we optimize the
as fly ash and slag that are collected from different power plant packing density by grading different raw materials in Microtrac
industries. However, 100% replacement of cement or development S3500 Particle Size Analyzer. However, due to high yield stress, the
of new environmental friendly material have never been an easy material was not extrudable through a 25-mm diameter hose pipe.
task. In this regard, recently, Xia et al (Xia and Sanjayan, 2016). Then referring an article by Choi et al. (2016), we adjusted the paste
presented a new methodology of formulating geopolymer material volume to enable a lubrication layer that helped us for smooth
for powder-based 3D printers. As discussed before, powder-based flowing of geopolymer inside the hose. Note that, due to stick na-
printing is highly suitable for small-scale building components ture of alkaline reagent the pressure during extrusion was fluctu-
which limits the technology for large scale construction. Therefore, ating between 10 and 15 bar, i.e 75 part of maximum allowable
this research aims to develop an extrusion based fly ash geo- pressure as mentioned by the pump manufacture.
polymer for large scale concrete printing application. Geopolymer Based on trial-and-error, we obtained a geopolymer mixture
is considered as a green construction material since its main in- that can be extrudable and retain its shape after printing. From the
gredients such as fly ash and slag are collected from industrial experimental trails, a printable thixotropic zone (Fig. 1(b)) was also
wastes. It is synthesized by the reaction of aluminosilicate materials identified, within which the custom made geopolymer was suitable
with user friendly alkaline reagents i.e sodium or potassium sili- for extrusion based 3D printing application. More details of the
cates (Habert et al., 2011; Davidovits, 1991; Nazari and Sanjayan, used materials and experiments are described in the later sections
2015). Successful application of fly ash based geopolymer is of this paper.
believed to reduce our dependency on the OPC.
The main goal of this paper is to develop 3D printable geo-
polymer material that have never done before for extrusion based 3. Materials and methods
large scale printing system. No-slump, extrudable geopolymer was
formulated by performing preliminary investigation as described in 3.1. Collection of raw materials
section 2. Later, mechanical properties of printed samples were
investigated and compared with conventionally casted (in-situ) The commercially available CEMGUARD® fly ash in India was
geopolymer to reveal anisotropy behavior resulting from the used as key binder in this research. Fig. 2 shows the typical
extrusion process (Panda et al., 2017). Additionally, microstructure morphology (spherical in shape) of the as-received fly ash. It is
analysis was carried out to verify the geopolymer formulation and classified as class F according to ASTM C618-12a,
final product. (SiO2 þ Al2O3 þ Fe2O3 ¼ 89.15% > 70% and CaO < 10%)
(ASTMC618-15, 2015). Ground granulated blast-furnace slag (GGBS)
and micro silica (silica fume) were provided by Engro and Elkem
2. Preliminary investigations Pvt Ltd Singapore respectively. The chemical compositions of both
fly ash and GGBS are presented in Table 1. Due to restrictions of
Prior to experimental method presented in the third part of nozzle diameter, we have used river sand as fine aggregates in this
this paper, a preliminary investigation was conducted to develop research. The particle size distribution of all the raw materials are
printable geopolymer material, i.e the material must poses high plotted in Fig. 3.
yield stress at the beginning (rest period) and become less For the geopolymerization, potassium hydroxide and potassium
viscous when agitated or stressed, but again rebuilds or re- silicate solutions were used as the alkaline reagent. Potassium sil-
flocculates to initial state once comes to rest (Wallevik, 2009). icate (SiO2 ¼ 24.94%, K2O ¼ 19.09%and water ¼ 55.97%) was ob-
Unlike conventional casting, 3D concrete printing process re- tained from Noble Alchem Pvt. Ltd, India whereas potassium
quires a continuous, high degree control of material during hydroxide is prepared in the lab by dissolving pallets in distilled
printing where traditional concrete cannot be used directly. water to obtain 8 M molarity. Both potassium hydroxide and po-
Shape retention and extrudable are two contradicting charac- tassium silicate were mixed together to obtain 1.8 M ratio and
teristics that need be to be fulfilled while developing new ma-
terials for concrete printing application.
In this investigation, a typical fly ash based geopolymer was
formulated using potassium silicate as alkaline reagent. The mix
proportion was then manipulated by changing the type and
amount of admixtures and/or additives (like magnesium
aluminum-silicate, nano clay) to achieve shape stability. For
buildability, we used our custom-made plate stacking test (Fig. 1) to
monitor the deformation upon subsequent loading of the layers.
Fig. 1. (a) Green strength characterization using plate stacking test (1. Dial gauge 2.
Added weights 3. Fresh geopolymer) (b) Early age property obtained from Rheometer. Fig. 2. Scanning electron microscope (SEM) micrographs of fly ash.
B. Panda et al. / Journal of Cleaner Production 167 (2017) 281e288 283
Table 1 first generated from the 3D model of the desired object, using 3D-
The chemical composition of Fly ash and GGBS. 2D slicing software, which slices the 3D shape of the object into
SiO2 Al2O3 Fe2O3 CaO MgO TiO2 K2O SO3 layers of constant thickness. A six axis Denso® robot, mounted on a
Fly ash 58.59 30.44 4.66 1.21 0.776 2.02 1.51 0.09
holonomic platform, printed 500 300 85 mm rectangular slab
GGBS 30e40 7e17 0.1e1.8 30e50 2e14 NA NA NA while depositing geopolymer mortar at a speed of 120 mm/s.
During the entire printing process, hose pipe length (3 m) and
pump flow rate (3 L/min) were kept constant to avoid any inad-
vertent effect on print quality. Fig. 5 shows the overview of our
printing process starting from modeling to layer-by-layer deposi-
tion. After the printing, 50 mm cubes and 40 40 160 mm prisms
were taken out from the slab in different directions (by sawing) to
carry out a comparative mechanical test of the casted samples. For
casting, similar dimensions of cube (50 mm) and prism
(40 40 160 mm) were used and cured simultaneously with the
printed samples.
4.1. Rheology
Fig. 6. The testing directions for mechanical properties. Fig. 7. Geopolymer rheology with time.
B. Panda et al. / Journal of Cleaner Production 167 (2017) 281e288 285
(a) (b)
(c)
Fig. 9. Variation of (a) compression (b) flexural-28 days (c) tensile bond strength-28 days (with time gap) of printed geopolymer compared to standard casted samples where CS:
Casted sample; PX, PY and PZ: printed sample loading in X, Y and Z direction (refer Fig. 6).
286 B. Panda et al. / Journal of Cleaner Production 167 (2017) 281e288
(a) (b)
Fig. 11. (a) SEM micrograph (b) Interfacial transition zone (ITZ) of fly ash geopolymer.
B. Panda et al. / Journal of Cleaner Production 167 (2017) 281e288 287
6. Conclusion
5.3. Multi-material printing The research reported here has been supported by National
Research Foundation Singapore (NRF) and Sembcorp Design &
The real benefit of concrete printing lies in depositing different Construction Pte Ltd. The authors are thankful to Control Robotic
materials as per the need of applications. In order to happen this, Intelligence (CRI) group at Nanyang Technological University,
the structure must be optimized based on loading conditions and Singapore for the assistance in robotic printing.
then a multi head printed can simultaneously deposit materials like
light weight, self-cleaning, self-healing as per the digital program References
fed in to the machine. This approach will bring a radically new and
exciting way to our building designs. Ahari, R.S., Erdem, T.K., Ramyar, K., 2015. Thixotropy and structural breakdown
properties of self consolidating concrete containing various supplementary
cementitious materials. Cem. Concr. Compos. 59, 26e37.
5.4. Standard developments ASTM C618-15, 2015. Standard Specification for Coal Fly Ash and Raw or Calcined
Natural Pozzolan for Use in Concrete. ASTM International, West Con-
Currently there is no guidelines available for 3D printing of shohocken, PA.
Banfill, P.F., 1991. The rheology of fresh mortar. Mag. Concr. Res. 43 (154), 13e21.
construction materials. Therefore, for acceptance and use of printed Bos, F., Wolfs, R., Ahmed, Z., Salet, T., 2016. Additive manufacturing of concrete in
parts in building and construction sectors, standards for materials, construction: potentials and challenges of 3D concrete printing. Virtual Phys.
288 B. Panda et al. / Journal of Cleaner Production 167 (2017) 281e288
Prototyp. 11 (3), 209e225. Autonomous and Robotic Construction of Infrastructure. Ames. Iowa (pp.
Bos, F.P., Ahmed, Z.Y., Wolfs, R.J., Salet, T.A., 2018. 3D printing concrete with rein- 149e158).
forcement. In: High Tech Concrete: where Technology and Engineering Meet. Labonnote, N., Rønnquist, A., Manum, B., Rüther, P., 2016. Additive construction:
Springer, Cham, pp. 2484e2493. state-of-the-art, challenges and opportunities. Automation Constr. 72,
Choi, M., Park, K., Oh, T., 2016. Viscoelastic properties of fresh cement paste to study 347e366.
the flow behavior. Int. J. Concr. Struct. Mater. 10 (3), 65e74. Le, T.T., Austin, S.A., Lim, S., Buswell, R.A., Law, R., Gibb, A.G., Thorpe, T., 2012.
Chua, C.K., Leong, K.F., 2014. 3D Printing and Additive Manufacturing: Principles Hardened properties of high-performance printing concrete. Cem. Concr. Res.
and Applications (With Companion Media Pack) of Rapid Prototyping. World 42 (3), 558e566.
Scientific Publishing Co Inc. Le, T.T., Austin, S.A., Lim, S., Buswell, R.A., Gibb, A.G., Thorpe, T., 2012. Mix design
Davidovits, J., 1991. Geopolymers: inorganic polymeric new materials. J. Therm. and fresh properties for high-performance printing concrete. Mater. Struct. 45
Analysis Calorim. 37 (8), 1633e1656. (8), 1221e1232.
Demie, S., Nuruddin, M.F., Shafiq, N., 2013. Effects of micro-structure characteristics Lim, S., Buswell, R.A., Le, T.T., Austin, S.A., Gibb, A.G., Thorpe, T., 2012. Developments
of interfacial transition zone on the compressive strength of self-compacting in construction-scale additive manufacturing processes. Automation Constr. 21,
geopolymer concrete. Constr. Build. Mater. 41, 91e98. 262e268.
Feng, P., Meng, X., Chen, J.F., Ye, L., 2015. Mechanical properties of structures 3D Nazari, A., Sanjayan, J.G., 2015. Synthesis of geopolymer from industrial wastes.
printed with cementitious powders. Constr. Build. Mater. 93, 486e497. J. Clean. Prod. 99, 297e304.
Franchin, G., Scanferla, P., Zeffiro, L., Elsayed, H., Baliello, A., Giacomello, G., Panda, B., Paul, S.C., Tan, M.J., 2017. Anisotropic mechanical performance of 3D
Colombo, P., 2017. Direct ink writing of geopolymeric inks. J. Eur. Ceram. Soc. 37 printed fiber reinforced sustainable construction material. Mater. Lett. http://
(6), 2481e2489. dx.doi.org/10.1016/j.matlet.2017.07.123.
Gibson, I., Rosen, D.W., Stucker, B., 2009. Additive Manufacturing Technologies: Perrot, A., Rangeard, D., Pierre, A., 2016. Structural built-up of cement-based ma-
Rapid Prototyping to Direct Digital Manufacturing. Springer Publishing Com- terials used for 3D-printing extrusion techniques. Mater. Struct. 49 (4), 1213.
pany. Incorporated). Provis, J.L., Van Deventer, J.S., 2007. Geopolymerisation kinetics. 1. In situ energy-
Gosselin, C., Duballet, R., Roux, P., Gaudillie re, N., Dirrenberger, J., Morel, P., 2016. dispersive X-ray diffractometry. Chem. Eng. Sci. 62 (9), 2309e2317.
Large-scale 3D printing of ultra-high performance concreteea new processing Rushing, T.S., Rushing, T.S., Al-Chaar, G., Al-Chaar, G., Eick, B.A., Eick, B.A., Barna, L.,
route for architects and builders. Mater. Des. 100, 102e109. 2017. Investigation of concrete mixtures for additive construction. Rapid Pro-
Habert, G., De Lacaillerie, J.D.E., Roussel, N., 2011. An environmental evaluation of totyp. J. 23 (1), 74e80.
geopolymer based concrete production: reviewing current research trends. Salet, T.A., Bos, F.P., Ahmed, Z.Y., Wolfs, R.J., Ahmed Zeeshan, Y., 2018. 3D concrete
J. Clean. Prod. 19 (11), 1229e1238. printing e a structural engineering perspective. In: High Tech Concrete: where
Hambach, M., Volkmer, D., 2017. Properties of 3D-printed fiber-reinforced Portland Technology and Engineering Meet. Springer, Cham pp. X1iiieX1vii.
cement paste. Cem. Concr. Compos. 79, 62e70. D Shape: www.d-shape.com. (accessed on 5th July 2017).
Kazemian, A., Yuan, X., Cochran, E., Khoshnevis, B., 2017. Cementitious materials for Tay, Y.W., Panda, B., Paul, S.C., Tan, M.J., Qian, S.Z., Leong, K.F., Chua, C.K., 2016.
construction-scale 3D printing: laboratory testing of fresh printing mixture. Processing and properties of construction materials for 3D printing. In: Mate-
Constr. Build. Mater. 145, 639e647. rials Science Forum, vol. 861. Trans Tech Publications, pp. 177e181.
Khan, M.Z.N., Hao, Y., Hao, H., 2016. Synthesis of high strength ambient cured Tay, Y.W.D., Panda, B., Paul, S.C., Mohamed, N.A.N., Tan, M.J., Leong, K.F., 2017. 3D
geopolymer composite by using low calcium fly ash. Constr. Build. Mater. 125, printing trends in building and construction industry: a review. Virtual Phys.
809e820. Prototyp. 1e16.
Khoshnevis, B., 2004. Automated construction by contour crafting - related robotics Tibaut, A., Rebolj, D., Perc, M.N., 2016. Interoperability requirements for automated
and information technologies. Automation Constr. 13 (1), 5e19. manufacturing systems in construction. J. Intell. Manuf. 27 (1), 251.
Khoshnevis, B., Hwang, D., Yao, K.T., Yeh, Z., 2006. Mega-scale fabrication by contour Wallevik, J.E., 2009. Rheological properties of cement paste: thixotropic behavior
crafting. Int. J. Industrial Syst. Eng. 1 (3), 301e320. and structural breakdown. Cem. Concr. Res. 39 (1), 14e29.
Kittusamy, N.K., Buchholz, B., 2004. Whole-body vibration and postural stress Winsun: 3dprint.com, 2016. Available from: https://3dprint.com/138664/
among operators of construction equipment: a literature review. J. Saf. Res. 35 huashang-tengda-3d-print-house/ [Accessed June 2017].
(3), 255e261. Wu, P., Wang, J., Wang, X., 2016. A critical review of the use of 3-D printing in the
Kovler, K., Roussel, N., 2011. Properties of fresh and hardened concrete. Cem. Concr. construction industry. Automation Constr. 68, 21e31.
Res. 41 (7), 775e792. Xia, M., Sanjayan, J., 2016. Method of formulating geopolymer for 3D printing for
Kreiger, M.A., MacAllister, B.A., Wilhoit, J.M., Case, M.P., 2015. The current state of 3D construction applications. Mater. Des. 110, 382e390.
printing for use in construction. In: The Proceedings of the 2015 Conference on