Additive Manufacturing of Thermally Enhanced Lightweight Concrete Wall Elements with Closed Cellular Structures
DOI:
https://doi.org/10.7480/jfde.2021.1.5418Keywords:
Additive Manufacturing, Lightweight concrete extrusion, Computational design, Thermal performance, Functionally graded materialsAbstract
Building envelopes incorporate a multitude of functions, such as structure, room enclosure, insulation,
and aesthetic appeal, typically resulting in multi-material layered constructions. With the technology
of additive manufacturing, geometrical freedom can instead be utilised to integrate functional
requirements into mono-material building components. In this research, the additive manufacturing
method of lightweight concrete extrusion and its potential for thermal performance via geometric
customisation is explored. It investigates whether the insulating performance of wall components can
be increased through the creation of closed cellular structures, and further, whether these performance
features can be functionally graded by locally adapting the geometric properties. A design tool for closedcell wall geometries is created, which integrates lightweight concrete extrusion related fabrication
constraints and takes into account thermal and structural performance considerations. Through the
simulation of heat transfer, generated wall geometries are analysed for their thermal performance.
By calculating the layer cycle times and determining the overhang during extrusion, the structural
capacity during printing is validated. Finally, experimental manufacturing of 1:1 scale architectural
prototypes is executed to test the feasibility of the concept.
References
Agustí-Juan, I., & Habert, G. (2017). Environmental design guidelines for digital fabrication. Journal of Cleaner Production, 142, 2780–2791. https://doi.org/10.1016/j.jclepro.2016.10.190
Association for Robots in Architecture. (2020). KUKA|prc. https://www.robotsinarchitecture.org/kukaprc
Bankvall, C. (1972). Natural convective heat transfer in insulated structures. https://portal.research.lu.se/ws/files/4596708/8227870. pdf
Bekkouche, S. M.A., Cherier M. K., Hamdani, M., Benamrane, N., Benouaz, T., & Yaiche, M. R. (2013). Thermal resistances of air in cavity walls and their effect upon the thermal insulation performance. International Journal of Energy and Environment, 4(3), 459–466. http://www.ijee.ieefoundation.org/vol4/issue3/IJEE_11_v4n3.pdf
Bos, F., Wolfs, R., Ahmed, Z., & Salet, T. (2016). Additive manufacturing of concrete in construction: potentials and challenges of 3D concrete printing. Virtual and Physical Prototyping, 11(3), 209–225. https://doi.org/10.1080/17452759.2016.1209867
Bos, F., Wolfs, R., Ahmed, Z., & Salet, T. (2019). Large scale testing of digitally fabricated concrete (DFC) elements. In RILEM Bookseries (Vol. 19, pp. 129–147). Springer Netherlands. https://doi.org/10.1007/978-3-319-99519-9_12
Buswell, R. A., Leal de Silva, W. R., Jones, S. Z., & Dirrenberger, J. (2018). 3D printing using concrete extrusion: A roadmap for research. In Cement and Concrete Research (Vol. 112, pp. 37–49). Elsevier Ltd. https://doi.org/10.1016/j.cemconres.2018.05.006
Dubai Future Foundation. (n.d.). Office of the Future. Retrieved September 4, 2020, from https://www.dubaifuture.gov.ae/ our-initiatives/office-of-the-future/
EnEV. (2007). https://www.gesetze-im-internet.de/enev_2007/BJNR151900007.html
Falliano, D., Crupi, G., De Domenico, D., Ricciardi, G., Restuccia, L., Ferro, G., & Gugliandolo, E. (2020). Investigation on the
Rheological Behavior of Lightweight Foamed Concrete for 3D Printing Applications. In RILEM Bookseries (Vol. 28, pp. 246–254). Springer. https://doi.org/10.1007/978-3-030-49916-7_25
Furet, B., Poullain, P., & Garnier, S. (2019). 3D printing for construction based on a complex wall of polymer-foam and concrete. In Additive Manufacturing (Vol. 28, pp. 58–64). Elsevier B.V. https://doi.org/10.1016/j.addma.2019.04.002
Gibson, L. J., & Ashby, M. F. (2014). Thermal, electrical and acoustic properties of foams. In Cellular Solids: Structure and Properties, Second Edition (pp. 283–308). Cambridge University Press. https://doi.org/10.1017/CBO9781139878326
Goldman, R., Schaefer, S., & Ju, T. (2004). Turtle geometry in computer graphics and computer-aided design. CAD Computer Aided Design, 36(14), 1471–1482. https://doi.org/10.1016/j.cad.2003.10.005
Henke, K., Talke, D., & Matthäus, C. (2020). Additive Manufacturing by Extrusion of Lightweight Concrete - Strand Geometry, Nozzle Design and Layer Layout (pp. 906–915). https://doi.org/10.1007/978-3-030-49916-7_88
Huizenga, C., Arasteh, D., Finlayson, E., Mitchell, R., Griffith, B., & Curcija, D. (1999). THERM 2.0: a building component model for steady-state two-dimensional heat transfer. https://escholarship.org/uc/item/66n7n302
Jaugstetter, F. (2020). Design Tool for Extrusion Based Additive Manufacturing of Functionally Enhanced Lightweight Concrete Wall Elements with Internal Cellular Structures. Technische Universität München.
Jin, Y. an, He, Y., Fu, J. zhong, Gan, W. feng, & Lin, Z. wei. (2014). Optimization of tool-path generation for material extrusion-based additive manufacturing technology. Additive Manufacturing, 1, 32–47. https://doi.org/10.1016/j.addma.2014.08.004
Keating, S. J., Leland, J. C., Cai, L., & Oxman, N. (2017). Toward site-specific and self-sufficient robotic fabrication on architectural scales. Science Robotics, 2(5). https://doi.org/10.1126/scirobotics.aam8986
Markin, V., Ivanova, I., Fataei, S., Reißig, S., & Mechtcherine, V. (2020). Investigation on Structural Build-Up of 3D Printable Foam Concrete. In RILEM Bookseries (Vol. 28, pp. 301–311). Springer. https://doi.org/10.1007/978-3-030-49916-7_31
Matthäus, C., Back, D., Weger, D., Kränkel, T., Scheydt, J., & Gehlen, C. (2020). Effect of Cement Type and Limestone Powder Content on Extrudability of Lightweight Concrete (pp. 312–322). https://doi.org/10.1007/978-3-030-49916-7_32
McNeel & Associates. (n.d.). Rhinonoceros (Rhino) Version 6.0. Retrieved September 4, 2020, from https://www.rhino3d.com/
Roudsari, M. S., & Pak, M. (2013). LADYBUG: A PARAMETRIC ENVIRONMENTAL PLUGIN FOR GRASSHOPPER TO HELP DESIGNERS CREATE AN ENVIRONMENTALLY-CONSCIOUS DESIGN.
Van Der Putten, J., Van Olmen, A., Aerts, M., Ascione, E., Beneens, J., Blaakmeer, J., De Schutter, G., & Van Tittelboom, K. (2020). 3D Concrete Printing on Site: A Novel Way of Building Houses? In RILEM Bookseries (Vol. 28, pp. 712–719). Springer. https://doi. org/10.1007/978-3-030-49916-7_71
Vantyghem, G., Steeman, M., De Corte, W., & Boel, V. (2017). Design of cellular materials and meso-structures with improved structural and thermal performances. Proceedings of the 12th World Congress of Structural and Multidisciplinary Optimisation. http://hdl.handle.net/1854/LU-8524436
Vantyghem, G., Steeman, M., De Corte, W., & Boel, V. (2020). Design Optimization for 3D Concrete Printing: Improving Structural and Thermal Performances. In RILEM Bookseries (Vol. 28, pp. 720–727). Springer. https://doi.org/10.1007/978-3-030-49916-7_72
Wangler, T., Lloret, E., Reiter, L., Hack, N., Gramazio, F., Kohler, M., Bernhard, M., Dillenburger, B., Buchli, J., Roussel, N., & Flatt, R. (2016). Digital Concrete: Opportunities and Challenges. RILEM Technical Letters, 1, 67. https://doi.org/10.21809/ rilemtechlett.2016.16
Weger, D., Kim, H., Talke, D., Henke, K., Kränkel, T., & Gehlen, C. (2020). Lightweight Concrete 3D Printing by Selective Cement Activation – Investigation of Thermal Conductivity, Strength and Water Distribution (pp. 162–171). https://doi.org/10.1007/978-3030-49916-7_17
Downloads
Published
How to Cite
Issue
Section
License
Copyright (c) 2021 Gido Dielemans, David Briels, Fabian Jaugstetter; Klaudius Henke; Kathrin Dörfler
This work is licensed under a Creative Commons Attribution 4.0 International License.
Author(s) hold their copyright without restrictions.