Penetration of cement pastes into sand packings during 3D printing: analytical and experimental study

3D printing processes of concrete and cement based materials could bring architectural and structural innovation in construction industry. Additive manufacturing and digital fabrication methods in civil engineering have recently been developed at laboratory scale. Among the 3D printing processes that could bring new perspectives in innovative and designed architectural elements, one of the most interesting is called the selective paste intrusion method. The component is built layer by layer by selectively applying cement paste on an aggregate packing using a 3D printer nozzle and a subsequent penetration of the paste into the aggregate layer. The implementability of the selective paste intrusion method requires the prediction of the flow of a yield stress fluid through a porous media. The rheological behaviour of the cement paste must be adapted for its penetration through the porous network of the aggregate particle packing. An adequate penetration depth of the cement paste produces homogeneous materials that are capable of sustaining a high mechanical stress. We show in this paper that the compressive strength of component made by such a technique is directly linked to the penetration depth of the cement paste into the aggregate layer; consequently, this paper aims at predicting the penetration depth of cement pastes into sand layers. A theoretical framework has been developed to propose an evaluation of penetration depth as a function of the average sand grain diameter and the yield stress of the cement paste, which is experimentally validated with specific penetration measurements. Finally, we stress that the prediction of penetration with an analytical model is an effective technique to ensure building homogeneous cement based materials with the 3D printing selective binding method.