Course Reflection - Farnelli

When I first registered for the class I had assumed that the class was going to be about responsive HVAC systems and BIM. Though we did spend quite a bit of time on BIM, a lot more of the class focused on construction than I had expected, which was a pleasant surprise. There were three main aspects of the class: blog posts, lectures and a project. Each gave different experiences and benefits, and as a whole I think that I gained quite a bit from the class.

Blog Posts

The blog posts have required us to research various topics in some detail and be able to explain concepts so that others. Some topics had provided reading, such as the Interoperability chapter in the BIM Handbook available online. Others required a bit of outside research, such as investigating what SQL is and how it works. I did learn quite a bit by reading other blog posts, as well. Reading the impressions and responses from the others in my groups gave me some extra perspective on the topics.

Lectures

The lectures, both those run by Professor Mitchell and those which were presented by outside experts, have given us an opportunity to learn more about the topics in application. For example, the videos showing robotic applications were very interesting. The talks by outside speakers were very interesting as well, as they were able to give examples of when the different programs and equipment worked and what needed work for each. In addition, the guest lectures allowed for at least a small bit of networking, and some also very helpful gave career advice.

Project

The project, in my case on 3D concrete printing, gave me the option to look into a specific topic in depth which interested me. I learned quite a bit about the way that the 3D concrete is produced and about the properties of the material. This may not be particularly helpful immediately, but if 3D printing gains as much ground as it is expected to this knowledge could be very helpful in the future.  

Comments:
Bryan Cummings, James Redus, Mark Lodato

B4- Kuzniarowicz Group E

For our final project, my group will be analyzing the applications of 3-D printing technologies in the construction field today in order to write a research paper for the final project. Over recent years, the technologies of 3-D printing have been a new and booming topic in the engineering and research fields. There have not only been advancements in availability and affordability of 3-D printing for the general public, but also the applications in which it can be used. There are a number of different 3-D Printing technologies that are currently being tested and applied to construction projects, such as the United Arab Emirates Innovation Committee’s plan to 3-D print an entire office building. In addition to fully 3-D printed construction projects, the technology is also being utilized in the creation of innovative and sustainable building materials such as concrete, plastic-based, wood-based, and alloy-based bulk materials.  Although the technology is still up and coming, breakthroughs in 3-D printing are continuously occurring. One of these breakthroughs includes the utilization of 3-D printers to create structures for a manned Mars space mission.

The breakthrough technology of 3-D printing has already made, and will continue to make, significant economic and social impacts in the world today. In the field of construction, the use of 3-D printing technologies could significantly decrease the cost associated with materials as well as simplify the overall construction process to make it more efficient.

A general outline for our final project on 3-D building technologies is as follows:

v  Abstract

Ø   An overall summary of the research, discoveries, and conclusions made about 3-D printing

v  Introduction

Ø  History of 3-D Printing

Ø  Background information about 3-D printing in Construction

Ø  Examples of 3-D printing applications

v  Topic 1: 3-D Printing and Building Materials

Ø  Fully 3-D Printed Materials

§  Concrete

Ø  Using Additives in 3-D Printing

§  Wood-based Bulk Materials

§  Plastic-based materials

§  Alloys

§  Other (moon rocks)

v  Topic 2: 3-D printing in Construction

Ø  Printing Methods

Ø  Structural Components

v  Topic 3: Entirely 3-D Printed Structures

Ø  WinSun China Builds 1^st 3-D Printed Villa and Apartment Building

Ø  UAEIC 3-D Printing Office Building

v  Future of 3-D Printing

Ø  Additional Construction Applications

Ø  Growth of Scale of Printing

v  Conclusions

v  References

1)    Win Sun 3-D Printed Villa/Apartment Building

http://www.3ders.org/articles/20150118-winsun-builds-world-first-3d-printed-villa-and-tallest-3d-printed-building-in-china.html

2) UAEIC 3-D Printed Office Building:

http://search.proquest.com/docview/1698870470?pq-origsite=summon&accountid=10559

3&4) Printing with Regolith (or other moon rocks)

http://ntrs.nasa.gov/archive/nasa/casi.ntrs.nasa.gov/20140002630.pdf

http://www.esa.int/Highlights/Lunar_3D_printing

5) 3-D Printing and Rapid Casting (Concrete and Alloys)

http://search.proquest.com/docview/214028287?pq-origsite=summon

6) 4-D Printing of the Future (Future)

http://search.proquest.com/docview/1650538777?pq-origsite=summon

7) 3-D Printing and its applications (Introduction)

http://search.proquest.com/docview/1432214803?pq-origsite=summon

8) Comparing Environmental impacts of 3-D Printing vs. Traditional Machining

http://search.proquest.com/docview/1648113434?pq-origsite=summon

Comments:

Cathlene Farnelli – 3-D Printed Concrete Properties

Cathlene,

You have stated a number of very good considerations on the topic of 3-D printing of concrete but there are many more thanks that you should consider. I would look into some of the fully 3-D printed buildings that are already in existence (WinSun China, and the UAE Innovation committee’s plan to fully print a building) and consider how they use concrete in their design. I would also look into using concrete material as an additive in 3-D printing. My group is also considering 3-D printing applications so I feel that we could help each other out with sources and information. I have attached sources in my post so feel free to take a look.

Kate Flint – Daylighting Technologies in Intelligent Buildings

Kate,

Like you, I also really enjoyed AE 340 (I hope you had Hartnichek) and I feel that this is a very important topic in building design today. I am currently in the AEI senior design competition and daylighting is one of the major considerations we must account for in the design for our 17-story office building. Daylighting is important in every building from hospitals to schools. This topic is very challenging because you do not only have to consider the building automation aspect of the design but also the economic impact of a satisfactory daylighting design. I would do significant research on how daylighting technologies can reduce of and increase the efficiency of a building. The idea for your topic is very general and there is a lot of information that could be included in your final report depending on which route you take. Good Luck!

B4 - 3D Printed Concrete Properties - Farnelli

I have decided to investigate the mix design and structural properties of the various methods of 3D printing concrete. I chose this topic because I was intrigued by the shapes that can be made by this process but wondered if the pieces would have only architectural value. If the printed members can or will be able to in the future be a part of the structural system of a building, the ability to use the process in Intelligent Building practices would expand greatly. If the process can form members of suitable strength, it would be possible to sketch shapes in a BIM program and have them printed. The 3D shapes are simply sliced into layers and the filled area of each layer is communicated to the printer. Spaces could be left open for utilities to pass through, which could prevent further costs for drilling into the members later, etc.
In the past, the systems available for forming concrete are formwork (either cast-in-place or factory fabricated), "self-compacting" (which uses superplasticizers and still requires vibration), and sprayed concrete (which requires a backing material). 3D printed concrete would be able to be made without vibration or any sort of formwork or backing, which could reduce costs. However, this has not necessarily made it immediately the best option.
The major problem with this investigation is that the process still varies quite a bit, with some forms of 3D Printing using direct extrusion and others using sprayed powders. In extrusion, the most important properties for the wet concrete are the "flowability," the ability of the concrete to be pushed through the printer and form consistent filaments, and "buildability," which is required so that the mix will be rigid enough to stay in the planes and not sag while also being able to bond to the layers above.
For the sprayed powder process, the geometry may be better defined, as the layers would be much thinner. It surprised me that this type is so much less explored, but this may be because it can be considered too closely related to shotcrete. In addition, it is difficult to ensure that the water is incorporated in the powder, especially if a low water content mix is wanted.
Another complication is that 3D printed concrete is an anisotropic material because of the way it is made. Bonding between any extruded tubes and between layers has a great effect on the cured properties of the concrete. This bonding variability can increase based on the time required for formation, so larger pieces are very likely to have poor performance in shear along these planes or in tension pulling planes apart.
These points will be the major discussions to be addressed in my paper, along with the results of current testing and the future outlook for when and how 3D printing could form suitable structural concrete members. For example, I have yet to find any references to experimenting with any reinforcement other than small fiber reinforcement, and was wondering if there is any research into how a printer could perhaps print around larger reinforcement.

Sources:

Feng, Peng, Xinmiao Menga, Jian-Fei Chenb, and Lieping Yea. "Mechanical Properties of Structures 3D Printed with Cementitious Powders." Construction and Building Material 93 (2015): 486-97. Science Direct. Web. 28 Jan. 2016. <http://www.sciencedirect.com/science/article/pii/S095006181500690X>.

Le, T. T., S. A. Austin, S. Lim, R. A. Buswell, A. G. F Gibb, and T. Thorpe. "Mix Design and Fresh Properties for High-performance Printing Concrete." Materials and Structures 45.8 (2012): 1221-232. Springer Link. Web. 28 Jan. 2016. <http://link.springer.com/article/10.1617/s11527-012-9828-z>.

Le, T. T., S. A. Austin, S. Lim, R. A. Buswell, R. Law, A. G. F Gibb, and T. Thorpe. "Hardened Properties of High-performance Printing Concrete." Cement and Concrete Research 42.3 (March 2012): 558-66. Science Direct. Web. 28 Jan. 2016. <http://www.sciencedirect.com/science/article/pii/S0008884611003255>.

Williams, Adam. "Berkeley Researchers Pioneer New Powder-based Concrete 3D Printing Technique." Gizmag. Gizmag, 12 Mar. 2015. Web. 29 Jan. 2016. <http://www.gizmag.com/berkeley-researchers-pioneer-powder-based-concrete-3d-printing/36515/>.

Edit:
Comments on Danielle Schroder and  Kai Waechter's posts.

B1 - Group B - Yasmina Shields

Building information modeling (BIM) technology in the construction industry offers a number of benefits to facilitate the design and construction process. Some of its applications include 3D renderings, incorporating fabrication and shop drawings into the model, code reviews, cost estimating, construction sequencing, forensic analysis, and facilities management (yielding the BIM model still useful after construction is complete). Also by simulating a virtual model of a building, BIM software can also be used to run a clash analysis between mechanical and structural systems—which helps to avoid construction issues, in turn reducing unforeseen costs (savings of about 10% of the contract value have been made through clash detections, according to Azhar’s “Building Information Modeling (BIM): Trends, Benefits, Risks, and Challenges for the AEC Industry”).

In high school I was told that BIM was the technology of the future, next “big thing,” while interning at an architecture firm. Five years later while on co-op for a general contractor, I found that most of my coworkers had not even heard of it; a few were talking of incorporating it in future projects, but it did not seem to be gaining much ground. The technology is readily available, yet there still exists managerial and technical concerns. The main challenges that are hindering widespread use of BIM is that no standardized process nor defined guidelines for BIM use exists, and ways to reduce the learning curve of BIM trainees need to be considered.

As a fundamental building material in construction and the most used substance on earth (other than water), concrete is a large emitter of CO2, with about a ton of CO2 being released for every ton of cement produced. Dr. Behrokh Khoshnevis of USC has developed Contour Crafting system, which works like a conventional 3-D printer—building up layer by layer—but instead uses a fast-drying concrete mix. The concrete material is precisely extruded with near-zero waste, needing less concrete and reducing its negative environmental impact. This is similar to the 3-D printed buildings that companies such as WinSun are developing, as mentioned in blog posts by Danielle Schroeder and others. Contour Crafting is also an automated process, making construction less labor intensive and safer. Another added benefit is that complex formwork is no longer needed using this technology in order to make non-rectilinear walls.

Source: http://www.sculpteo.com/blog/2015/10/07/3d-printing-construction/

I have a particular interest in sustainable structures, and thought it worth mentioning Team Orange County’s entry in last year’s Solar Decathlon in this post. Their net-zero-energy, under 1,000 square feet house is mechanically managed by a radiant heating and cooling system along with a rooftop solar panel capture system, and collects storm water for garden use. They also included in their entry a personal 3-D printer and thermoplastic recycling system that allows the user to break down printed objects that are no longer needed around the house, and reuse the material to produce new household tools or parts for home repairs.

• Azhar, S. (2011). "Building Information Modeling (BIM): Trends, Benefits, Risks, and Challenges for the AEC Industry." Leadership Manage. Eng., 10.1061/(ASCE)LM.1943-5630.0000127, 241-252.
•  Khoshnevis, Berok (2014). “Contour Crafting: The Upcoming Revolution in Construction.” Lecture. Autodesk Building Solutions. https://www.youtube.com/watch?v=u3JdXPjQTMs
•  http://www.solardecathlon.gov/2015/competition-team-orange-county.html

Comments to other students:

Cristian Almendariz

William Whitesell