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Sustainable 3DCP
Developing sustainable mixture design
T
he number of large-scale projects featuring the use of While the combination of these characteristics is claimed
extrusion-based three-dimensional concrete printing to deliver a robust, cost effective, and sustainable solution
(3DCP) as a construction technology had a steep compared to conventional construction, the topic of
increase in 2020 and 2021. The most remarkable examples “sustainability” in 3DCP is still open for debate, and to date,
have included apartment and residential buildings in Canada, only a handful of studies provide full-depth insights on the
Germany, Malawi, and the Netherlands.1-4 Regardless of sustainability aspects of 3DCP.5-9 Most of these publications
which 3DCP company (or partnership) is involved in these point to the fact that the impact of the digital fabrication
projects, a few common characteristics can be identified process is rather negligible when put against the impact from
among them: materials manufacturing. In other words, it is generally
• Extrusion-based 3DCP is the most widespread technology understood that digital fabrication applications that help reduce
when it comes to digital fabrication in a large scale materials consumption yield an overall lower environmental
(specifically, in the housing market); impact when compared to conventional construction methods,
• 3DCP is mainly used to print the contour (hollow walls/ especially in the production of complex elements.
shells) of the building, followed by complementary The path to a more sustainable 3DCP in large-scale
processes such as casting and inclusion of reinforcement; applications includes several aspects ranging from the design
and to the construction phase and from materials to machinery.
• Dry mortars (with aggregates up to 4 mm [0.16 in.]) One of these—the main scope of this article—is the scaling up
remain the main feedstock used in the process. of the solid constituents (Fig. 1), because the material amount
Fig. 1: Upscaling mortar to concrete to enable sustainable large-scale 3DCP using green concrete (Note: 1 mm = 0.04 in.)
Table 1:
Main cement performance parameters and composition requirements per EN 197-120
FutureCEM
Aalborg White RAPID Cement CEM I CEM II/B-M(Q-LL)
Parameters CEM I 52.5 R SR5 EN 197-1 52.5 N (MS) (LA) EN 197-1 52.5 N EN 197-1
Clinker content, % 100 95 to 100 96 95 to 100 67 65 to 79
Minor additional
0 0 to 5 4 0 to 5 — 0 to 5
constituents’ content, %
Calcined clay and
— — — — 33 21 to 35
limestone contents, %
fc, 2d, MPa 44 ≥ 30 36 ≥ 20 29 ≥ 20
Density, kg/m 3
3130 — 3130 — 3000 —
Note: 1 MPa = 145 psi; 1 kg/m3 = 0.06 lb/ft3
Acknowledgments
(c) The authors would like to acknowledge the support of the Innovation
Fund Denmark (Grant No. 8055-00030B: Next Generation of 3D-printed
Fig. 4: Normalized CO2 emission of 3DCP mortars and concrete. The Concrete Structures) and all N3XTCON project partners: Danish
reference value stems from: (a) our typical 3DCP mortar composition
Technological Institute, Technical University of Denmark, University
(517 kg/m3 [871 lb/yd3] of CEM I 52.5 R SR5); (b) a 3DCP mortar
composition produced with FutureCEM (508 kg/m3 [856 lb/yd3] of
of Southern Denmark, Henning Larsen Architects A/S, Bjarke Ingels
CEM II/B-M(Q-LL) 52.5 N); and (c) a 3DCP concrete mixture using Group A/S, CRH Concrete A/S, COBOD International A/S, NCC
RAPID Cement (360 kg/m3 [607 lb/yd3] of CEM I 52.5 N (MS) (LA) and Danmark A/S, Aalborg Portland A/S, FB Gruppen A/S, and AP Pension
0 to 8 mm aggregates Livsforsikringsaktieselskab.