Published in Cement and Concrete Composites, Volume 149 (2024), Article 105509.
Publisher page (DOI) · Full text on ResearchGate
This study developed printable lightweight concrete by replacing sand with expanded polystyrene (EPS) particles. Mixtures spanning densities of approximately 500–1900 kg/m³ were successfully printed, including mixtures with up to 100% volumetric sand replacement.
A composite aggregate model was introduced to calculate excess paste volume and account for the different paste-layer thicknesses associated with sand and EPS particles. The calculated excess paste thickness was consistent with the measured rheological behavior of the mortars.
The results also showed that the relatively high static yield stress required for 3D printing helped limit EPS particle flotation, improving particle uniformity within the printed concrete.
Key contributions
- Production of printable EPS concrete across a wide density range.
- Extension of excess paste theory to mixtures containing composite aggregates.
- A more precise method for relating excess paste thickness to mortar rheology.
- Evidence that static yield stress can help stabilize lightweight EPS particles during printing.
Citation
Niu, G., Liu, C., Jia, L., Ma, L., Shi, Y., Jiang, Y., Jia, Z., Chen, Y., Banthia, N., & Zhang, Y. (2024). Preparation and performance analysis of 3D printed lightweight EPS concrete: Insights from the excess paste theory. Cement and Concrete Composites, 149, 105509. https://doi.org/10.1016/j.cemconcomp.2024.105509