Materials, Completed
Integrating Additive Manufacturing with Accelerated Bridge Construction Techniques
The main objective of this study is to investigate the feasibility of using 3D concrete printing (3DCP) for manufacturing prefabricated bridge elements in accelerated bridge construction (ABC) projects. A literature review is first conducted to survey the applications of 3DCP within the construction and building domains. This phase entails exploring diverse additive manufacturing techniques and materials relevant to construction. Incorporation of reinforcement in 3DCP stands as a significant challenge to advancing the 3DCP technology for ABC projects. Therefore, emphasis is placed on examining a range of reinforcement strategies for 3DCP. On this basis, multiple concrete beams are 3D printed with different reinforcement strategies. Three-point bending tests are conducted on the 3D printed specimens and conventionally cast counterparts to characterize their mechanical properties. The beam samples manufactured for the comparative study include cast plain beam, cast rebar-reinforced beam, plain beam with printed formwork, rebar-reinforced plain beam with printed formwork, plain beam with printed studs formwork, rebar-reinforced plain beam with printed studs formwork, fully printed plain beam, fully printed rebar-reinforced beam, and fully printed metal staple-reinforced beam. An important finding is that beams created using the reinforced 3DCP formwork with studs strategy exhibit the highest flexural strength compared to the beams fabricated using other casting and printing methods. Given the substantial costs associated with traditional concrete casting formwork, employing 3D printed formwork with studs can significantly reduce expenses while maintaining optimal performance. Therefore, this strategy is employed for the 3D printing of a small-scale prefabricated bridge element specifically identified as a pier cap. The results of the three-point bending tests indicate that the 3D printed pier cap demonstrates a comparable flexural strength to a conventionally cast prefabricated pier cap, while also exhibiting higher stiffness. The proposed experimental study reveals both promising possibilities and inherent limitations in the current 3DCP technology. Additional research directions and recommendations are presented to enhance the efficiency of 3DCP in ABC projects.
