Where does real concrete start? In Europe it starts at 4mm gravel size. Up to this size it is mortar.
Certainly, the size of aggregate used in 3D concrete printing ( 3DCP ) plays a significant role in optimizing the properties of the mix and managing costs effectively.
Strength and Durability: Larger aggregates, such as gravel, can enhance the strength and durability of the concrete mix. The interlocking nature of larger stones provides mechanical strength within the concrete matrix, making the structure more resilient to external forces and environmental factors.
Reduced Cement Content: Using larger aggregates allows for a reduction in the amount of cement needed in the mix. Since cement is typically one of the most expensive components of concrete, optimizing its usage can lead to cost savings without compromising structural integrity. This is particularly advantageous in large-scale 3DCP projects where material costs can be significant.
Improved Workability: Larger aggregates can improve the workability of the concrete mix, making it easier to handle during the printing process. The presence of gravel helps to distribute water more evenly throughout the mix, resulting in better flow properties and reduced risk of segregation or clogging in the hose.
Cost Optimization: By using larger aggregates judiciously, it’s possible to optimize the overall cost of the 3D printed structure. This optimization involves finding the right balance between aggregate size, cement content, and other factors to achieve the desired strength, durability, and cost-effectiveness.
Tailored Mix Design: The choice of aggregate size allows for the customization of the concrete mix to suit specific project requirements. By selecting the appropriate aggregate size distribution, engineers can tailor the mix design to meet performance targets while optimizing costs.