3D printing with concrete is a new, innovative technology with promising benefits for the construction industry. Additive manufacturing of concrete has the potential to save costs on labor, formwork, and material and is a more sustainable...
more3D printing with concrete is a new, innovative technology with promising benefits for the construction industry. Additive manufacturing of concrete has the potential to save costs on labor, formwork, and material and is a more sustainable means of producing the built environment for the future. Although potential exists, there are many obstacles to overcome before concrete 3D printing can be applied on a construction scale. This project first aimed to determine an optimal mixture design for printable concrete by experimenting with two different viscosity modifying admixtures: Acti-Gel and polyacrylamide. Polyacrylamide, a polymer-based flocculent, was found to enhance the rheology and cohesiveness of concrete in doses as low as 0.6% by weight of binder. Secondly, this project investigated improvements to the interfacial bond between layers of concrete using a liquid adhesive and sinusoidal layer geometries. Although there was insufficient data to make specific conclusions on the ideal bond improvement, test results indicated an enhanced shear strength from the sinusoidal layer geometries and an enhanced tensile strength from the adhesive. Finally, scanning electron microscopy completed on the interface between printed layers with polyacrylamide revealed the polymer's microstructure bridging across the interface and anchoring to the hydrated C-S-H structure. It is concluded that polyacrylamide is the most suitable viscosity modifying admixture for printable concrete. Our project team would like to recognize the contributions of a few individuals to this project. Firstly, we thank Professor Nima Rahbar for inspiring this research into the innovative field of concrete 3D printing. Without his guidance and technical knowledge, this project would not have been possible. Secondly, we acknowledge Jessica Rosewitz for her commitment to the success of this project. Without being asked, Jessica took on the role of co-advisor for this project providing assistance with lab work, sample preparation, technical analysis, and writing on a day to day basis. Her contributions to this project were selfless and impactful. Russel Lang assisted with lab work and the ordering of materials, and we acknowledge and thank him for his contributions. Finally, this group acknowledges Mason Guarino from SSG Pools for generously donating two admixtures for use in this project. As a member of the American Shotcrete Association, Mason also invited us to observe the shotcrete process on a construction site, and provided information and advice which was critical to the success of this project. Through research and iterative design, an economical mix design was developed for enhancing the performance of printed concrete in structural applications. The scope of the project included two main components. The project began with a literature review on the most current research and developments in the field of concrete 3D printing. It was discovered through our research that one of the main difficulties with printed structures is the lack of Professional licensure statement Professional licensure indicates that an engineer has a certain level of competency within his or her engineering discipline. For civil engineers, a professional engineering license allows an engineer to prepare, sign, and seal engineering plans and drawings. Licensure is a legal requirement for private and consulting engineers who are responsible for their work. It is also a requirement for many governmental engineering jobs as well as educational positions in many states. However, professional licensure is not easily obtained. It is a long-term commitment that lasts for the entire career of a practicing engineer. To begin with, an engineer must complete at least a four-year college degree from an ABET-accredited engineering program and pass the Fundamentals of Engineering (FE) Exam to become an Engineer in Training (EIT). The FE exam is a six hour exam comprised of 110 questions. Following this, an engineer has to accumulate four years of experience underneath a licensed professional engineer. Accurate records of this experience need to be kept and endorsed by a supervising professional engineer. These records are part of the review process as each state requires a detailed work history before the final step toward licensure can be taken: successful completion of Principles and Practice of Engineering (PE) exam. Once an engineer's credentials have been verified, he or she can register to take the PE exam. It is an eight hour exam which consists of 80 questions covering all five areas of civil engineering: construction, geotechnical, structural, transportation, and water resources and environment. Both the FE and PE exams are organized by the National Council of Examiners for Engineering and Surveying (NCEES). Once professional licensure is obtained, the process of maintaining licensure through continued industry education begins. Each state has varying requirements for maintaining professional licensure, but in 42 states, there is a certain standard of continued education that must be completed before an engineer's license can be renewed. There are online courses, conferences, webinars, and other forms of continuing education for professional engineers, all of which count for a certain number of Professional Development Hours (PDHs). Each state has its own requirements as to how many PDHs are needed to renew a license and how often an engineer needs to renew his or her license. It is important for a professional engineer to remain up to date on the requirements of any of the states within which he or she is registered. There is some reciprocity between states that allows engineers to obtain and maintain a PE license in multiple states, but in some instances the PE exam must be retaken to obtain a license in another state depending on the requirements. Professional licensure is crucial for the public, the individual, and the civil engineering profession as a whole. Prior to 1907, no state regulated who was permitted to offer engineering services to the public. This meant that there was no standard method for designating who was and was not competent enough to practice as an engineer which was a significant danger to the public. However, in 1907, Wyoming passed the first engineering licensure law which established a minimum level of competency for engineers to protect the safety of the public and uphold a certain standard of ethics. Today, professional licensure continues to uphold the safety of the public. It is also beneficial to the individual. It enables engineers to take on more responsibility and often reach a higher and more lucrative position within the industry. Further, becoming a professional engineer opens the gate to a community of high achieving individuals and resources that can help an engineer develop his or her career. It is a mark of integrity and achievement that sets an engineer apart in the industry. Finally, professional licensure is beneficial to the civil engineering profession as it ensures that the field of civil engineering continues to develop and grow, continually reaching higher standards of safety and creativity.