A

Project Report On

A comparison study on material cost of 3D

printing and conventional construction.
In the partial fulfilment of the requirement for Bachelor Degree in Civil Engineering

Submitted by

Vinod Kamble : 71938939K

Sachin Jagtap: 71938935G
Gayatri Patil: 71938960H
Harshada Thakare : 71938976D

Guided by PROF

PROF: A.B.RAUT

DEPARTMENT OF CIVIL ENGINEERING

JSPM’S NARHE TECHNICAL CAMPUS
SAVITRIBAI PHULE PUNE UNIVERSITY, PUNE
2020-2021

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 JSPM’S NARHE TECHNICAL CAMPUS
(SAVITRIBAI PHULE PUNE UNIVERSITY, PUNE)

CERTIFICATE

This is to certify that the following student have satisfactorily in our B.EProject
work entitled “A comparison study on material cost of 3D printing and
conventional construction ”. This work is being submitted for the award of
degree of Bachelor of Civil Engineering. It is submitted in the partial fulfillment of
the prescribed syllabus of Savitribai Phule Pune University, Pune for the
academic year 2020 – 2021

Prof .A.B.RAUT Prof.

(Project Guide) External Examiner

Dr. S. A. Choudhari Dr. R.K. Lad

(Head of Department) (Director)

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 ACKNOWLEDGEMENT

We take this opportunity to express our profound thanks and gratitude towards
our Guide, Respected Prof. A.B.RAUT (Department of Civil Engineering) for their valuable
guidance and untiring encouragement during the preparation of this report. Also, that they
spared their valuable time from the busy academic and administrative schedule for the expert
suggestions. A sincere note of thanks to them for motivating me through out.

We expressed ours sincere thanks to Prof. Dr. S.A.Chaudhari , (HOD), & my teachers
for their encouragement and support to complete this work, we much obliged towards all
the our friends and most important our family for their immense support. Last but not least
we are very much thankful to our Principal Prof. Dr. R.K Lad and the College for cooperation
and supportin the entire course.

We will keep our improvement curve on the rise and thereby enhance the
reputation of my College.

We are also thankful to our family and friends for their support. Let we express our
sincere thanks to all those persons from whom we received co-operation, help and
motivation directly or indirectly during the preparation of this report.

Thanking You

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 Abstract

3D printing concrete is an emerging technology in additional form-work during construction

and also the human resource required is comparatively which structures are made only using
concrete in layers with the help of Software. With this technology, even geometrically intricate
structures, heavy load bearing structures and hydraulic structures can be made easily in no time
with less wastage of materials and minimum costs. It does not require any less. It is a sustainable
technology which can also be used for aesthetic purpose. 3D printing (3DP) is a promising new
technology that has the potential to not only be an effective means of increasing project efficiency
and profitability in the field, but also have positive environmental impacts. However, as it exists
today, this technology is highly limited by size, material, skilled labor, and industry reluctance.
The 3D printingtechnologies, comparing to traditional techniques of constructing the
buildings, could be considered as environmental friendly derivative giving almost unlimited
possibilities for geometric complexity realizations. This is a research paper on 3D printing and the
various materials used in 3D printing and their properties which become a notable topic in
technological aspect. Also, see the advantages of 3D printing as compared to additive
manufacturing.

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 INDEX

SR.NO. CONTENT PAGE NO.

CHAPTER 1: INTRODUCTION
1.1 AIM : 6
1.1.1 INTRODUCTION
OF PROJECT WORK
1.1.2 HISTORY OF 3DP
1.1.3 Approach of 3D
Printing Construction
with Construction
Management
1.2 PROBLEM 9
STATEMENT
1.3 OBJECTIVES 10

CHAPTER 2: LITERATURE REVIEW 11

CHAPTER 3: METHODOLOGY 13

CHAPTER 4: TYPES OF 3D PRINTING 14

CHAPTER 5: EFFECT ON TIME, COST 17

AND ENVIRONMENT OF
CONVENTIONAL
CONSTRUCTION
METHOD
CHAPTER 6: CONVENTIONAL
METHOD VS 3D 18
PRINTING
6.1 ADVANTAGES
6.2 LIMITATIONS 20

REFERENCES 21

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 CHAPTER 1:

INTRODUCTION

1.1 AIM:
To Study The Most Favorable Technology In Construction Management

1.1.1 INTRODUCTION OF PROJECT WORK :

The current construction industry has serious issues with sustainability. In general, the current construction methods
and materials are not environmentally friendly. The entire construction process, including off-site manufacturing,
transportation of materials, installation and assembly, and on-site construction, emits huge amounts of greenhouse
gases and consumes large quantities of energy. In addition,
conventional concrete made by ordinary Portland cement (OPC) is not sustainable. Manufacture of OPC
is highly energy and carbon intensive.
The significant amount of wastage generated in the construction is another challenge. Formwork is a significant
source of waste, since all of it is discarded sooner or later, contributing to a generally growing amount of waste in the
construction industry.
Furthermore, the conventional approach of casting concrete into a formwork limits geometrical freedom for the
architects to build in various geometries, unless very high costs are paid for bespoke formworks. Rectilinear forms not
only limit the creativity of the architects, but they are also structurally weaker than curvilinear forms owing to stress
concentration. Another challenge is the slow speed of construction. The concrete construction often comprises many
steps including material production, transportation, and in-situ manufacture of formwork, and each step is time
consuming.
Application of three-dimensional (3D) printing techniques in concrete construction could solve the aforementioned
challenges. 3D printing technology is recently gaining popularity in construction industry. In the last few years,
different 3D concrete printing (3DCP) technologies have been explored. The inhibitions in the use of 3D printing in
construction come from technical, economic and social point of view. The technical inhibitions involve the assembly
and production of 3D printer and development of materials with suitable properties.

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1.1.2 HISTORY OF 3DP

3D printing (sometimes referred to as Additive Manufacturing (AM)) is the computer-

controlled sequential layering of materials to create three-dimensional shapes. It is
particularly useful for prototyping and for the manufacture of geometrically complex
components. It was first developed in the 1980s, but at that time was a difficult and expensive
operation and so had few applications. It is only since 2000 that it has become relatively
straightforward and affordable and so has become viable for a wide range of uses including
product, design, component and tool manufacture, consumer, electronic, plastic,
metalworking,aerospace engineering, dental and medical applications, and footwear. The
sales of AM machines or '3D printers' has grown rapidly and since 2005,the first 3D printed
model casted in Minnesota, USA this completes in 2014 ,the home use of 3D printers has
become
practical. Systems developed for the construction industry are referred to as construction 3D
printers. A 3D digital model of the item is created, either by computer-aided design (CAD) or
using a 3D scanner. The printer then reads the design and lays down successive layers of
printing medium (this can be a liquid, powder, or sheet material) which are joined or fused to
create the item.

First 3D printed castle in Minnesota ,USA , complete in 2014

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1.1.3 Approach of 3D Printing Construction with Construction Management

Design uniformity is an essential part of creating affordable and constructible buildings.

However,clients in recent years have begun requesting more
unique and less uniform buildings and concept designs, which are often abandoned because
of the extra costs involved. This constraint on original thinking can be overcome by large-
scale 3Dp methods that are able to deliver non-repeating components at a cost effective price
provided relatively low volumes of production are required Of this aspect, Pegna (1997)notes
that, because the technology offers on-site construction automation, it would be able to
reduce the dependence on labour and hence reduce the risk of injuries and weather stoppages.
As a result, it is estimated that the technology would be able to reduce construction costs by
up to 30%.These techniques are also able to drastically reduce the lead-time to production as
well as the cost of design and manufacture of more complex parts that would bedifficult or
impossible to make with more traditional construction methods.

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1.2 PROBLEM STATEMENT

• The main purpose of the present study was Benefits include improved not only
efficiencies of the environment and financial resources but also the capacity to
customize designs for aesthetic and structural applications to increase
architectural freedom.

• To apply 3D printing as an alternative to conventional construction according to its

ability in reducing the construction time and cost.

• An understanding of 3D printing procedure, mechanism of action, and its impact on

the future of construction and architecture through economical, structural, and
environmental parameters is achieved.

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1.3 OBJECTIVES

1. Reduction of construction costs by eliminating formwork.

2. Reduction of injury rates by eliminating dangerous jobs (e.g., working at

heights), which would result in an increased level of safety in construction.

3. Creation of high-end-technology-based jobs.

4. Reduction of on-site construction time by operating at a constant rate.

5. Minimizing the chance of errors by highly precise material deposition.

6. Increasing sustainability in construction by reducing wastages of formwork.

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 CHAPTER 2
LITERATURE REVIEW

1. Conventional Construction and 3D Printing: A Comparison

Study on Material Cost in Jordan Rawan Allouzi,1 Wael Al-Azhari,1 and
Rabab Allouzi
This paper presents a state-of-the-art review of the advancesin 3D printing construction of
concrete. (is research has presented an alternative construction method (3D printing)to
conventional construction.The 3D printing features are summarized to highlight how 3D
printing solves problems that conventionalconstruction is facing. Economically, it is a faster
and more accurate construction method for complex members and low labor costs and has zero
generated waste. At aconstruction rate of about three minutes per square meter,a modest-sized
230 square meter (m2) home could beconstructed in about 18 or 19 hours with a workforce of
about four people. Architecturally, it could create more efficient and interesting designs as 3D
printing can
achieve shapesthat conventional procedures cannot with architectural flexibility and high
precision. Environmentally, 3D printing could be recognized as a sustainableprocess which
reduces the consumed raw materials, the produced CO2
emission, and the consumed embodied energy.

2. An Analysis of the Viability of 3D-Printed Construction as an Alternativ to

Conventional Construction Methods in the entional Construction Methods in the
Expeditionary Environment.Jenee A. Jagoda
This paper presents the results of a systematic review of the viability of 3D-printed
construction. The goal of this review was to determine if 3D-printed construction is now, or
could be, a viable replacement for conventional construction methods, particularly in remote
environments. More specifically, the analysis identifies whether 3D-printed construction is
reliable, cost-effective, and efficient compared to conventional construction. In this paper,
remote environments are defined as locations characterized by geographic isolation, an
underdeveloped economy,or hazardous conditions. Given the existing limitations of
conventional construction in remote environments, these locations provide greater opportunity
to leverage the benefits of 3D-printed construction than locations where conventional
construction is already an established and prevalent method.

3. A Review of 3D Printing in Construction and its Impact on the Labor Market Md.
Aslam Hossain 1, Altynay Zhumabekova

Construction is one of the labor-intensive industries which is characterized by low

productivity with low technological usage. Along with robotics and other automation
technologies, 3DP has received increasing attention in construction. This study made a
comprehensive review on the current progress and future prospects of 3D printing in
construction. With the possibility of large-scale adoption of 3DCP,this paper also investigated
how the construction labor market would be affected by this technology.
It is evident from the literature that 3DCP has a great potential to positively influence the
construction industry such as fast construction, reduced material waste, less intense labor
requirements, improved worksite safety, etc. Although the use of 3DP in construction is still in
the research and development stage with very limited number of buildings and small bridges
are found for practical use around the world, the literature showed that more and more
constructions are to be done with 3DCP in the coming
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 years. As Dubai has announced that 25% of its buildings are to be constructed using this
innovative technology by 2030, the market of 3DCP is expected to grow in other countries as
well.The literature suggests that 3DCP significantly reduces the number of labors in the
construction process and could save labor costs by 50–80%. to provide
outlets and drainage so that if water does get inside, it is not allowed to sit

4. Comparison of Construction with Traditional Method and 3D Printing

TechnologySNEHABHUSAL1SWATIKSHIRSAGAR

3D printing in construction context is an innovative technology that creates 3D objects by

reproducing physical objects with continuous layers. The basic research will be a comparative
study comparing 3D construction printing with traditional methods of concrete usage. 3D
printing technologies may improve lthe time and cost management in construction, lean
construction, green approaches, and sustainability in construction industry. This finding
indicates that studies in 3D printing technology field will be more valuable in the near future.
The concept of contour crafting, allowing in-situ printing of dwellings may require the new
architectural approach to building design. This technique will require development of new
materials appropriate for 3D printing process, but also considering sustainability issues,
materials in which traditional concrete ingredients will be replaced with environment friendly
ones. Creating the buildings with complicated shapes, may become one of the biggest
advantages for most architects. Their imagination will be able to defeat previous obstacles
related to limitation of traditional techniques of building.

5. Subversion of conventional construction: Building 3D printing technology

W J LUO,Z C MAO

In recent years, building 3D printing technology has gradually transformed from imagination
to practice and from concept to production. In the upcoming future, 3D printing will be
widely used in the construction industry. Building 3D printing technology is the fruit of
multidisciplinary collisions in architecture, civil engineering, materials science, computer
science, and automatic control. It exerts the most advanced scientific research results to bring
subversive influence to the field of building construction. But at the same time, due to the
intersection of multiple disciplines, the problem of acting blindly is inevitable. Only by
strengthening the exchange and cooperation of various disciplines and paying attention to the
actual capabilities and demands of the construction industry can we promote the vigorous
development of 3D printing technology in construction.

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 CHAPTER 3 :
METHODOLOGY

•Desk research of the existing literature on different technologies and management use for
conventional construction and 3D printing Technology
•Optimization of additive manufacturing takes virtual blueprints From CAD or animation
modelling
software system through out detail information of it.
•Used the cad software to analysis data.

3D Printing Technology Conventional Construction Technology

Model Assemble Mold

Stereo Lithography Place Parts

Slicing & Layering Cast Concrete

3D Printing Cure Concrete

Finishing Strip Mold

Finishing

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CHAPTER 4 : Types of 3 D Printing
There are various types of 3 D printing currently existing and certain types are more suitable for
construction than the others. The major types of concrete printing suitable for construction are
Contour crafting, concrete printing and D Shape.

1. Contour crafting:

It is fabrication technique in which the concrete is crafted layer by layer and was
developed by Khoshnevis (2004)in California. This is the most promising 3D printing
technology and allows the fabrication of the complete house in situ. Two or more nozzles
move simultaneously along the gantry and simultaneously print various
components of the structures. This method also enables the printing of accessories and
conduits along with the buildings. The Potential areas of applications for contour crafting are:
i) low income housing or emergency sheltered housing and ii)
architectural buildings involving complex shapes.

Contour Printing

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2. Concrete Printing :

It is an extrusion based printing process in which the nozzle extrudes material

while moving in a predetermined path in a continuous process. There are three categories of
concrete printers presently available and widely used in real time construction viz. gantry,
robotic and crane system along with a printing nozzle with
continuous supply of materials. Gantry has a fixed height of operation whereas the cranes are
adjustable in vertical direction. Robots typically have a fixed dimension and are difficult to
scale up however they accommodate all operational direction and enable continuous and
complete in-situ printing.

Concrete printing

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3.D shape printing :

It uses layers of powders and adhesive sprinkled on it at desired locations. In D

shape printing the powder material is laid and compacted to required thickness. Then the
binder is injected at required places using a nozzle. Once the hardening is complete, the
loose powder can be removed and the hardened model can be taken separately. Additive
manufacturing techniques including ink jet printing and laminated object printing are also
binder jetting and are used in construction. These methods are more suitable for polymers,
metals and ceramics.

D shape Printing

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CHAPTER 5 : EFFECT ON TIME, COST AND ENVIRONMENT OF
CONVENTIONAL CONSTRUCTION METHOD

Construction industry plays a key role in socio-economic development of any country.

Nowadays construction industry is rapidly growing because of increase in standard of
living, demands of infrastructure projects, changes in consumption habits, as well as
natural increase in population. This growth has contributed significantly in waste
generation.

1. Effect of Construction Materials:

The materials used in building construction also have a serious impact on the
environment. First of all, many of the materials used in the construction of buildings
are produced in a non-sustainable way. The factories that make the materials produce
damaging CO2 emissions. Then there’s the issue of transportation. Materials that are
not produced locally are often shipped from across the country or even from
overseas. The transportation required for shipping these materials has a considerable
impact on air quality. There is a huge environmental impact associated with the
extraction and consumption of raw materials for the use of building materials. Not to
mention the actual production of those materials in their final form. According to the
USGBC, 40% of the world’s raw materials are used in the construction of buildings.

2. Waste from Building Construction and Demolition:

The destruction and renovation of buildings result in a large amount of waste.

Building waste often includes concrete, metals, glass, plastics, wood, asphalt,
bricks and more. This waste is often disposed of in either landfills or incinerators. Not only
does this pollute the land and the air, but the transportation required to remove such waste
has a major impact on the environment as well. According to
the Environmental Protection Agency, there were already over 170 million tons of debris
generated in the construction and demolition of buildings in the U.S. alone in 2003. 61
percent of which were produced by nonresidential buildings.

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CHAPTER 6 : CONVENTIONAL METHOD VS 3D PRINTING

Globally construction industry has highest carbon impacts which accounts

for 40% of global energy consumption, 38% of carbon emission as well as 12% of
water eutrophication. Thus, there is great demand for decarburization in this
industry. 3D printing or additive manufacturing has emerged as a potential
solution to reduce the energy demands, water wastage and carbon emissions. 3D
printing in construction context is an innovative technology that creates 3D
objects by reproducing physical objects with continuous layers. Recently, from
polymer and steel the industry has leaped forward using concrete with potential
applications in the construction engineering. Anecdotally, these technologies
proved to reduce production time, minimize wastage and reduce laborcosts
significantly.
The current challenges in 3D printing commercialization are lack of standard
building codes, large scale investment, functional performance and architectural
designs. In this research, concrete prototypes were printed for tests and a
comparative study was established with the conventional manufactured concrete
to analyze performance standards, cost benefits and lifecycle assessments. Future
scope of this research is to develop a performance standards based on benefits for
large scale implementation in construction industry.

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19
6.1 ADVANTAGES :

• Environmentally friendly: You can use raw soil and natural waste from the
rice production chain for 3D printing. Theoretically, the material for a 3D
printed house can also be plastic – and we’ve got plenty of that.
• Inexpensive: Large-scale industrial buildings can be constructed for a
relatively low price.

• Shorter construction periods: 3D printing shelters, for example, can be

beneficial for victims of natural disasters.

• Uncommon shapes: 3D printing can generate shapes that are impossible or

too expensive to manufacture otherwise.

• Otherworldly potential: NASA already has plans to use 3D printing for

colonies on Mars

6.2 LIMITATIONS :

• Though the cost of construction maybe reduced by 3D printing, the cost of

the printers is huge this is a drawback.
• Skilled laborers who can work efficiently with the 3D printers and CAD are
required.
• 3D printers consume high amount of energy. According to a research it has
been shown that it consumes about 100 times more electrical energy than
the conventional methods.
• Since the size of the printers is huge it creates problems in the onsite
storage.

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 CONCLUSION

3D printing in construction context is an innovative Technology that creates 3D

objects by reproducing Physical objects with continuous layers. The basic
Research will be a comparative study comparing 3D Construction printing with
traditional methods of Concrete usage. 3D printing technologies may improve The
time and cost management in construction, lean Construction, green approaches,
and sustainability in Construction industry. This finding indicates that Studies in
3D printing technology field will be more Valuable in the near future. The concept
of contour Crafting, allowing in-situ printing of dwellings may Require the new
architectural approach to building Design. This technique will require
development of New materials appropriate for 3D printing process, but Also
considering sustainability issues, materials in Which traditional concrete
ingredients will be replaced With environment friendly ones. Creating the
buildings With complicated shapes, may become one of the Biggest advantages
for most architects. Their Imagination will be able to defeat previous obstacles
Related to limitation of traditional techniques of Building.

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 REFERENCES

[1] Ibrahim Engin Ozturk and Gozde Başak Oztur. The Future of 3D Printing Technology in the
Construction Industry: a Systematic Literature Review

[2] Jake Kidwell Best Practices and Applications of 3D printing in the Construction Industry.

[3] Behzad Nematollahia, Ming Xiab and Jay Sanjay. Current Progress of 3D Concrete Printing
Technologies.

[4] Alexandru Pîrjan and Dana-Mihaela Petroşanu .The Impact Of 3d Printing Technology on the
Society and Economy.

[5] Izabela Hager, Anna Golonka and Roman Putanowicz .3D printing of buildings and building
components as the future of sustainable construction? International Conference on
Ecology and new Building materials and products, ICEBMP 2016.

[6] Deepika R, Gokulakrishnan T and Srinithi K .A Research on 3d Printing Concrete.

[7] Vinod G. Gokhare and Dr. D. K. Shinde. A Review paper on 3D-Printing Aspects and Various
Processes Used in the 3D-Printing.

[8] Yoon-Si Lee and Sihyun Kim.3D Printing in Concrete Materials and its Application

[9] Subhav Singh and Anju Bala. Critical Analysis Of Causes Of Delay In Residential Construction
Projects In India.

[10] Salim S. Mulla , Ashish P. Waghmar. Influencing Factors caused for Time & Cost Overruns in
Construction Projects in Pune-India & their Remedies.

[11] Mr. Dinesh Bhatia 1, Prof. Emeritus M. R. Apte.Schedule Overrun And Cost Overrun In The
Construction Of Private Residential Construction Project: Case Study Of Pune India.

[12] Ms. Leena Mali1, Mr. A. A. Warudkar. Causes of Delay in the Construction Industry in Pune region
of India.

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