Materials matter: The key to success in 3D concrete printing

3D concrete printing continues to make headlines, with residential, commercial, infrastructure and industrial projects around the world being built using this innovative method of construction. 3D construction utilizes a robotic arm, gantry or crane-like systems that convert digital building plans to physical walls by “printing” walls layer by layer. It is a technique that automates much of the traditional, manual masonry process that is related to structure.

As an innovative build method, early adoption of 3D concrete printing came primarily in the form of residential projects. After years of pilot projects and small-scale communities, engineers and architects are finally seeing the potential to integrate form with function.

The industry is still in its early stages but gaining traction rapidly as pilot projects gain acclaim and the entire value chain – including training facilities, higher-education organizations and professionals – expands its investments in 3D concrete printing equipment. Major players in construction have started to recognize and integrate 3D as well for commercial, industrial and infrastructure projects. Designing a project that goes from digital to real without the risk of misinterpreting plans is valuable enough, but there are also added benefits of 3D builds being termite-proof as well as wind-, flood- and fire-resistant.

As the number of companies involved in 3D concrete printing expand and new applications and techniques arise, there is a common denominator to success. Proper planning, execution and, most importantly, choosing the correct materials that match the design and performance goals of your project are essential.

MAPEI has been active in 3D-concrete-materials research, development and manufacturing for many years – the result was the development of Planitop 3D. This product is a cementitious, high-strength mortar that outperforms traditional masonry by curing at over three times the strength of traditional cement-masonry construction. Designed for printing structural load-bearing walls for residential, industrial and commercial buildings, Planitop 3D and its highly printable formula are now being tested by companies for even more types of applications – these future applications include marine, energy, industrial (data center) and custom precast-like elements.

Planitop 3D is a premixed, ready-to-print formula that is designed to be printed with just water added onsite; it has a wide workability across many different temperatures and environmental conditions. It was designed to meet ICC-ES criteria for printing structural walls with excellent workability, to have the ability to support each layer above itself and to have excellent interlayer bond strength.

In selecting Planitop 3D, MAPEI customers receive:

• Reliable performance in terms of strength, interlayer bonding and cure time.
• Material that was tested in-house by established 3D-concrete-printing companies and that has undergone evaluation by world-renowned, external testing organizations.
• Material that was used in owner-occupied structures that rely on the print bead to support the roof.
• Structural capability that allows builders, architects and engineers to meet exact project goals in terms of strength, energy efficiency and long-term building performance.
• Expertise and guidance throughout the printing process – from first layer to finishing – with MAPEI’s catalog of products that are compatible with Planitop 3D.

For more information on Planitop 3D and MAPEI’s suite of coatings, finishing solutions and maintenance/restoration products, visit www.mapei.com.