3D-Printing of Ultra-High-Performance Concrete for Robotic Bridge Construction

Automation and robotics are integral parts of many industries but their potential for field implementation has not been significantly recognized by the construction industry. This is mainly attributed to conventional construction and design practices which undermine the benefits offered by these new technologies such as repetitions, precision, time savings, and increased safety. There is a need for advanced materials and 3D-printing systems which are capable of constructing structural elements with performance that emulates conventionally cast elements. This study presents a detailed framework and performance metrics for materials and 3D-printing systems for bridge applications. In addition, a study was carried out on ultra-high-performance concrete (UHPC) which showed sufficient extrudability and workability for 3D-printing applications. A 3D-printing system was developed for 3D-printing of continuous additive layers of UHPC with accelerated heat curing. Accelerated heat curing was used to enhance buildability, expedite the printing of the UHPC layers, and maximize the number of printed layers within the material open time. The effect of heat curing on material properties was also evaluated to obtain the optimal temperature to satisfy compressive strength requirements. This research effort aims to augment automated construction techniques and develop solutions to extend the applications of accelerated bridge construction.