In-place 3D Concrete Printing of One-way Floor and Roof Slabs
Research Poster Engineering 2025 Graduate ExhibitionPresentation by Ali Baghi
Exhibition Number 7
Abstract
Recent advancements in Additive Construction (AC), particularly 3D Concrete Printing (3DCP), have demonstrated promising potential in addressing the housing crisis by enabling faster, customizable, and more cost-effective construction. However, a key challenge in 3DCP is the viscoelastic behavior of fresh concrete. While this property ensures pumpability, it also limits the feasibility of printing spanning elements, restricting most industry-level 3DCP applications to vertical components such as walls. Although conventional formwork can be used to overcome this limitation, it significantly increases construction costs and requires extensive human intervention, making its elimination a critical objective. Alternative solutions have been proposed but introduce new challenges, including higher material consumption, limited span lengths, longer lead times, and difficulties in automation and assembly. Our study demonstrated that automatically integrating reinforcement into 3D-printed concrete filaments when they are being printed enables self-supporting structures, making in-place, formwork-free printing of spanning elements feasible. By expanding the structural capabilities of 3DCP, this work paves the way for longer-span, more resilient, and eco-friendly construction techniques, shaping the future of the built environment.
Importance
This research advances the technical capabilities of 3D Concrete Printing (3DCP), laying the groundwork for efficient, cost-effective, and sustainable construction methods. By developing a framework for in-place 3DCP filaments with integrated reinforcement, this work eliminates the need for traditional formwork, reducing construction costs, labor demands, and project timelines. Beyond economic benefits, this innovation can play a critical role in addressing housing shortages, particularly in rapidly urbanizing regions and low-income communities. Furthermore, the ability to construct durable, self-supporting structures without formwork makes 3DCP a viable solution for disaster-prone areas (e.g., earthquakes, hurricanes, tornadoes) and military applications, such as shelters and barracks. Additionally, this research contributes to environmentally responsible construction by minimizing material waste, reducing embodied carbon, and enhancing automation-driven sustainability.