3D Printable Concrete using MSW ash

Guided by Presented By
Dr. Manu S Nadesan Silpa Sasidharan
Associate Professor ASI17CE052
CE Dept. ASIET 2017-2021
Department of Civil Engineering ASIET
 CONTENT
• INTRODUCTION
• OBJECTIVE
• METHODOLOGY
a) Experimental Methodology
b) Test method
c) Test results
• CONCLUSION
• REFERENCE

3D Printable Concrete using MSW ash 1

 INTRODUCTION

 Rapid industrialization and urbanization with growth of human population

increases solid waste each year
 Poor management of municipal waste produce adverse effect on the health of
people and environment
 Waste Management Strategies :-
i. Source reduction,
ii. Collection
iii. Recycling
iv. Composting
v. Incineration, pyrolysis
vi. Gasification, land filling

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 Incineration – process of burning MSW – heat and ash residue

 Main Components :-
Table 1
Bottom Ash Fly Ash
• It is discharged at the • It is produced by capturing
bottom of the incinerator and removing dust
contained in burning gases
• It consists of ash and low • It consists of high heavy
heavy metal metal concentration(Ni, Zn,
concentration(Fe, Al) Pb)

 Incineration reduces mass and volume of MSW

 Less environmental and social impact

3D Printable Concrete using MSW ash 3

 Lower emission of greenhouse gas

 Produced heat energy can be used for power generation

 Problems – emission of pollutant gases and production of ash

 MSW incineration ash in Concrete 3D Printing – New digital construction

paradigm
 Concrete 3D Printing – Application of 3D printing technology

 Rapid method of construction without using formwork

 Minimum labor involvement and reduced material wastage

 Layer by layer construction along predefined geometrical path

 Fresh properties required for concrete 3D printing different from formwork

based construction method
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 Table 2

3D Printing Concrete Conventional Concrete

• It can support self-weight and • It cannot supports its weight

weight of subsequent layers
• It can retain its extruded shape
without the help of formwork
• It does not require compaction
• It needs formwork to retain its
shape
• It requires compaction(except
for self-consolidating concrete

 Printable concrete containing MSW ash –

• fulfill the rheological requirements of extrusions
• shows higher early compressive strength
• sufficient shear strength

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 OBJECTIVES
• To reduce the environmental and social impact due to waste management
strategies
• To reduce the problems associated with the recycling of wastes
• To increase the construction speed of the 3D printing by replacing incinerated
fly ash

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 METHODOLOGY
1. Experimental Methodology
OPC, FA(silica sand), incineration ash, nylon fibers and high performance super
–plasticizers were used in the development of 3D printable concrete.
• Water – binder ratio = 0.40
• Binder – FA ratio = 0.66
• Dosage of super plasticizers = 2%
• Nylon fiber = 0.14%
Nylon fibers were added to restrain shrinkage strain at early age. Bottom ash
particles were sieved through mesh openings, which is acquired from MSW
incineration process. The ashes collected from different places have different
properties. Therefore,
• Micro structural characterization
• Laser diffraction particle size analysis – to study about particle size of
incineration ashes (range from nm – mm), Instrument – Beckman
Coulter, LS 13 320 Laser Diffraction Particle Size Analyzer

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2. Test Methods

Flow table test and Setting time test

• Metal cone(100x70x50mm dia) at center of flow table
• Then concrete placed in two parts
• 25 times compacted using tamping rod(20mm dia)
• Flow table moved vertically 25 times, 15 sec
• Spread of concrete is measured
• Gilmore needle – to test setting time
• Needle for initial setting time – 2.13mm dia and 113.4g
• Needle for final setting time – 1.06mm dia and 453.6g
• Setting time is measured by placing needle carefully on the surface of
concrete which is put on the glass plate

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Yield stress test
• Shear vane tester – used to measure yield stress of concrete(size 90x67mm)
• Instrument commonly used for evaluation of shear strength of cohesive soil
• Tester consist of a vane and torque head
• Calibration of vane size is according to BSI
• Shear vane is positioned vertically to the surface of the concrete and
carefully inserted into sample to avoid excessive lateral movement
• Torque head – rotated slowly – 1 rotation/min
• Pointer shows maximum deflection required to shear concrete
Yield stress, Tf = M/K
K = 𝜋 D2H/2(1 +D/3H)10-6
where, M – torque to shear
K – constant (0.0195)
D and H – diameter and height

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 • Six containers is used to prevent agitation (300mm dia and 330mm height)
• Concrete is filled in 6 containers up to 120mm depth
• Then yield stress is measured

Compressive strength and bond strength test

• Specimen – cube mould (50x50x50mm) cured in lime water solution and
tested at the age of 1, 3, 7 and 28 days
• Bond strength of concrete – Bi-surface direct shear test is used, since 3D
printing concrete has layered structure, the interface b/w its layers act as
weak point
• Mould size is 150x150x150mm
• Then shear bond measured

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Physical properties of materials used A schematic illustration of the bi-surface
Materials Physical properties direct shear tests

• Cement Ordinary Portland

Cement, Type I
Specific gravity : 3.16
Fineness : 3214cm2/g
• Silica sand Ignition loss : 0.78%
Specific gravity : 2.65
• Super Grading : 0.1~0.6mm
plasticizers Polycarboxylate
superplasticizer
• Fiber Viscous brown liquid
form
Nylon fiber
Length : 6mm
Aspect ratio : 30

Table 3 Figure 1

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4. Test Results
 Microstructural properties of MSW incinerated ash
• Incinerated fly ash had finer particles than bottom ash

Item Fly ash Bottom ash

• Average particle • 29.2µm • 732µm

size
• 19.1µm • 626.2µm
• Median particle
size • 71.5µm • 1598µm
• Diameter(90%
particle) • 1.89 • 1.76
• Specific gravity

Table 4

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Particle size distribution of MSW ashes (a) fly ash (b) bottom

Figure 2

Seminar Topic 13
 • Crystalline phases detected:-
Portlandite, anhydrate, quartz, sylvite,
gehlenite, calcite, alite, mullite, periclase, halite, belite
• Alite – reactive crystalline phase – reduces the setting time of cement and
increase the rate of early strength gain of concrete(early hydration of
cement)
• Belite contributes to strength development

Flow table test and setting time

• The workability of concrete decreased with increasing amount of
incinerated fly ash and bottom ash.
• Reduced spread of concrete due to the presence of incinerated ash can be
beneficial for shape retention of extruded concrete from printing nozzle.
• A decrease in the setting time with the increased dosage of incineration
ashes is visible.

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• The initial setting time was shortened by 3.7min(4.9%) and final setting
time was shortened by 10.5(4.5%) per replacement rate of incineration fly
ash.
• The effect of incinerated fly ash upon the setting time was more prominent
than that of incinerated bottom ash, due to
o Presence of alite in fly ash
o Finer particle of fly ash

Variation of flow with the addition of ashes; (a) waste incinerated fly ash
(b) waste incinerated bottom ash

Figure 4

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Variation of setting time with the addition of ashes: (a) waste incinerated fly ash
(b) waste incinerated bottom ash

Figure 3

• Better performance of fine particles of incinerated fly ash than coarse

particles of incinerated bottom ash.
• Incinerated fly ash can be used as an accelerator to reduce the setting time
of 3D printing concrete and increase the buildability of concrete

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Yield stress
• Shear vane test – To measure yield stress
• With the passage of time, the yield stress of all mix proportions increased
• The increase in yield stress with time due to,
o Colloidal interaction of cement particles
o Nucleation of cement grains
• Optimal yield stress and sufficient open time is required for efficient result,
optimal value of yield stress for concrete 3D printing is 0.33 kPa (suitable
range 0.3 ̴ 0.9 kPa)
• Open time – Time period during which concrete is pumpable and
extrudable
• Higher the yield stress, then the mix will be stiff and pumping stress will be
high
• Open time exceeds – stiff – due to structuration and cement hydration –
leads block the hose and nozzle

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Buildability
• Ability of the extruded concrete layer to support self-weight of layer built
over it without deformation
• It measured by comparing the vertical stress acting on the printed layer
with yield strength
• If the time gap b/w the printing of 2 layers is large, then the former printed
layer will become hardened and bond with new layer will be weakened
Compressive strength
• The capacity or a resistance of a material to withstand the load without
breaking under the compression
• The presence of incinerated fly ash increases the compressive strength
• The better behavior of incinerated fly ash compared to bottom ash in terms
of compressive strength is due to the pozzolanic activity of amorphous
silica present in fly ash and filling effect by very fine powder of fly ash.

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Bond strength b/w layers
• Shear strength b/w layers decreases with increase of replacement ratio of
cement with incinerated fly ash
• Minimum time gap – better bond strength – faster construction rate
• Bond strength b/w printed layers is measured by bi-surface direct shear
test

Failure mode of concrete in bi-surface direct shear test: (left) with 0 time gap,
(right) with 30 min time gap.

Figure 5

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Seminar Topic 20
 CONCLUSION
The controlled replacement ratios of MSW incineration ash in order to examine
its applicability to concrete 3D printing. The important material properties
necessary for concrete 3D printing such as workability, open time, buildability,
and bonding b/w layers. The use of incinerator fly ash will ensure the ability to
maintain the shape of concrete after extrusion and will be helpful for obtaining
a rapid construction rate. A higher replacement ratio of fly ash improves
buildability by accelerating the evolution of yield stress. The use of incinerated
fly ash up to 10 % can increase the initial compressive strength without a
significant effect on the compressive strength at 28 days Use of incinerator fly
ash can modify the rheology of 3D print-able concrete in favor of a rapid
construction rate and better shape stability. It is a suitable candidate to replace
cement in concrete for 3D printing. Use of incinerated fly ash in concrete3D
printing is recommended to solve current problems related to recycling
incineration ash and also to create valuable products from recycled waste.

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 REFERENCES

1. Atta Ur Rehman, Sang - Min Lee, Jung-Hoon Kim ” Use of municipal solid waste incineration ash
in 3D printable concrete ”, (2020)
2. Shi ,H.,S., Kan,L.-L, “ Leaching behavior of heavy metals from municipal solid waste incineration
(MSWI) fly ash used in concrete ” , (2009)
3. Cheng, A., “ Effect of incinerators bottom ash properties on mechanical and pore size of blended
cement mortars ” , (2012)
4. Das, S., Lee, S. H. Kumar. P., Kim, K. -H, Lee, S. S, Bhattacharya, S. S., “ Solid waste management
scope and the challenge of sustainability ” , (2019)
5. Van Der Putten, J., Deprez, M., Cnudde, V., De Schutter, G., Van Tittelboom, K. J. M, “ Micro
structural characterization of 3D printed cementetious materials ” , (2019)
6. Giro-Paloma, J., Ribas-Manero, V., Maldonado-Alameda, A., Formosa, J., Chimenos, J. M., “ Use of
municipal solid waste incineration bottom ash and crop by-product for producing lightweight
aggregate ” , (2017)
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Thank you

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