Transforming waste into high-performance 3D printable cementitious composite - TRANSITION

Project summary

Rationale. To make extrusion 3D concrete printing a viable construction technology, its environmental footprint needs to be reduced. Thus, formulations with alternative supplementary cementitious materials need to be developed. Objective. A pre-blended dry product is formulated with a large proportion of oil shale ash. When mixed with water, it forms a high-performance cementitious composite for 3D printing of full-scale structural elements. Collision milling and high-frequency ultrasonic dispersion are employed to manipulate composite properties and induce the setting of the filament. Potential applications. The pre-blended dry product can be used with a variety of extrusion printers to fabricate structural elements with the required mechanical resistance and durability. Impact and potential benefit. Easy-to-use pre-blended dry product has the potential to boost the implementation of 3D printing in construction while at the same time reutilising the waste from oil shale power plants.