Injection 3D Concrete Printing (I3DCP): Basic Principles and Case Studies

Today, the majority of research in 3D concrete printing focuses on one of the three methods: firstly, material extrusion; secondly, particle-bed binding; and thirdly, material jetting. Common to all these technologies is that the material is applied in horizontal layers. In this paper, a novel 3D concrete printing technology is presented which challenges this principle: the so-called Injection 3D Concrete Printing (I3DCP) technology is based on the concept that a fluid material (M1) is robotically injected into a material (M2) with specific rheological properties, causing material M1 to maintain a stable position within material M2. Different to the layered deposition of horizontal strands, intricate concrete structures can be created through printing spatially free trajectories, that are unconstrained by gravitational forces during printing. In this paper, three versions of this method were investigated, described, and evaluated for their potential in construction: A) injecting a fine grain concrete into a non-hardening suspension; B) injecting a non-hardening suspension into a fine grain concrete; and C) injecting a fine grain concrete with specific properties into a fine grain concrete with different properties. In an interdisciplinary research approach, various material combinations were developed and validated through physical experiments. For each of the three versions, first architectural applications were developed and functional prototypes were fabricated. These initial results confirmed both the technological and economic feasibility of the I3DCP process, and demonstrate the potential to further expand the scope of this novel technology

Low-cost UAV monitoring: insights into seasonal volumetric changes of an oyster reef in the German Wadden Sea

This study aims to quantify the dimensions of an oyster reef over two years via low-cost unoccupied aerial vehicle (UAV) monitoring and to examine the seasonal volumetric changes. No current study investigated via UAV monitoring the seasonal changes of the reef-building Pacific oyster (Magallana gigas) in the German Wadden Sea, considering the uncertainty of measurements and processing. Previous studies have concentrated on classifying and mapping smaller oyster reefs using terrestrial laser scanning (TLS) or hyperspectral remote sensing data recorded by UAVs or satellites. This study employed a consumer-grade UAV with a low spectral resolution to semi-annually record the reef dimensions for generating digital elevation models (DEM) and orthomosaics via structure from motion (SfM), enabling identifying oysters. The machine learning algorithm Random Forest (RF) proved to be an accurate classifier to identify oysters in low-spectral UAV data. Based on the classified data, the reef was spatially analysed, and digital elevation models of difference (DoDs) were used to estimate the volumetric changes. The introduction of propagation errors supported determining the uncertainty of the vertical and volumetric changes with a confidence level of 68% and 95%, highlighting the significant change detection. The results indicate a volume increase of 22 m³ and a loss of 2 m³ in the study period, considering a confidence level of 95%. In particular, the reef lost an area between September 2020 and March 2021, when the reef was exposed to air for more than ten hours. The reef top elevation increased from -15.5 ± 3.6 cm NHN in March 2020 to -14.8 ± 3.9 cm NHN in March 2022, but the study could not determine a consistent annual growth rate. As long as the environmental and hydrodynamic conditions are given, the reef is expected to continue growing on higher elevations of tidal flats, only limited by air exposure. The growth rates suggest a further reef expansion, resulting in an increased roughness surface area that contributes to flow damping and altering sedimentation processes. Further studies are proposed to investigate the volumetric changes and limiting stressors, providing robust evidence regarding the influence of air exposure on reef loss

Oyster Reef Surfaces in the Central Wadden Sea: Intra-Reef Classification and Comprehensive Statistical Description

The Pacific oyster (Magallana gigas) is an invasive species in the Wadden Sea transforming parts of it permanently. M. gigas, as an ecosystem engineer, builds reef structures that are characterized by highly complex and variable surfaces consisting of densely packed, sharp-edged individuals connected with cement-like bonds. To investigate the interactions between reef structure, shape and formation and wave as well as tidal currents, an understanding of the surface roughness is essential. This work reports on observations of oyster reefs for which seven new structural classes (Central Reef, Transitional Zone, Cluster I, Cluster II, Patch I, Patch II, and Garland) are proposed. For each class, high resolution Digital Elevation Models (DEMs) have been elaborated based on Structure-from-Motion (SfM) photogrammetry and analyzed using spatial statistics. By determining probability density functions (PDFs), vertical porosity distributions, abundances, orientations and second-order structure functions (SSFs), topographical parameters that influence the hydraulic bed roughness have been determined. The results suggest, that by applying the structural classification and their distinct topographical roughness parameters, the oyster reef surfaces can be described appropriately accounting for their complexity. The roughness accounts to a total roughness height kt = 103 ± 15 mm and root-mean-square roughness height krms = 23 ± 5 mm. These values were found similar across all structural classes, yet the shape of the PDFs reveal differences. With decreasing abundance, the distributions become more positively skewed and are characterized by more extreme outliers. This is reflected in the higher statistical moments, as the skewness ranges between Sk = 0.4–2.1 and the kurtosis between Ku = 2.2–11.5. The analysis of the orientations and the SSFs confirms anisotropic behavior across all structural classes. Further, the SSFs reveal the oyster shells as significant roughness elements with exception of Cluster I and II, where the clusters are identified as significant roughness elements. The provided set of topographical roughness parameters enhances the knowledge of oyster reef surfaces and gives insights into the interactions between biogenic structure and surrounding hydrodynamics. The new intra-reef classification allows for more accurate determination of the overall roughness as well as the population dynamics of the habitat forming oyster. Combined with hydraulic measurements, the results can be used to estimate the hydraulic bed roughness induced by the oyster reef surfaces. Copyright © 2022 Hitzegrad, Brohmann, Pfennings, Hoffmann, Eilrich, Paul, Welzel, Schlurmann, Aberle, Wehrmann and Goseberg

Oyster Reef Surfaces in the Central Wadden Sea: Intra-Reef Classification and Comprehensive Statistical Description

The Pacific oyster (Magallana gigas) is an invasive species in the Wadden Sea transforming parts of it permanently. M. gigas, as an ecosystem engineer, builds reef structures that are characterized by highly complex and variable surfaces consisting of densely packed, sharp-edged individuals connected with cement-like bonds. To investigate the interactions between reef structure, shape and formation and wave as well as tidal currents, an understanding of the surface roughness is essential. This work reports on observations of oyster reefs for which seven new structural classes (Central Reef, Transitional Zone, Cluster I, Cluster II, Patch I, Patch II, and Garland) are proposed. For each class, high resolution Digital Elevation Models (DEMs) have been elaborated based on Structure-from-Motion (SfM) photogrammetry and analyzed using spatial statistics. By determining probability density functions (PDFs), vertical porosity distributions, abundances, orientations and second-order structure functions (SSFs), topographical parameters that influence the hydraulic bed roughness have been determined. The results suggest, that by applying the structural classification and their distinct topographical roughness parameters, the oyster reef surfaces can be described appropriately accounting for their complexity. The roughness accounts to a total roughness height kt = 103 ± 15 mm and root-mean-square roughness height krms = 23 ± 5 mm. These values were found similar across all structural classes, yet the shape of the PDFs reveal differences. With decreasing abundance, the distributions become more positively skewed and are characterized by more extreme outliers. This is reflected in the higher statistical moments, as the skewness ranges between Sk = 0.4–2.1 and the kurtosis between Ku = 2.2–11.5. The analysis of the orientations and the SSFs confirms anisotropic behavior across all structural classes. Further, the SSFs reveal the oyster shells as significant roughness elements with exception of Cluster I and II, where the clusters are identified as significant roughness elements. The provided set of topographical roughness parameters enhances the knowledge of oyster reef surfaces and gives insights into the interactions between biogenic structure and surrounding hydrodynamics. The new intra-reef classification allows for more accurate determination of the overall roughness as well as the population dynamics of the habitat forming oyster. Combined with hydraulic measurements, the results can be used to estimate the hydraulic bed roughness induced by the oyster reef surfaces. Copyright © 2022 Hitzegrad, Brohmann, Pfennings, Hoffmann, Eilrich, Paul, Welzel, Schlurmann, Aberle, Wehrmann and Goseberg

Large Particle 3D Concrete Printing - A Green and Viable Solution

The Large Particle 3D Concrete Printing (LP3DCP) process presented in this paper is based on the particle bed 3D printing method; here, the integration of significantly larger particles (up to 36 mm) for selective binding using the shotcrete technique is presented. In the LP3DCP process, the integration of large particles, i.e., naturally coarse, crushed or recycled aggregates, reduces the cement volume fraction by more than 50% compared to structures conventionally printed with mortar. Hence, with LP3DCP, the global warming potential, the acidification potential and the total non-renewable primary energy of 3D printed structures can be reduced by approximately 30%. Additionally, the increased proportion of aggregates enables higher compressive strengths than without the coarse aggregates, ranging up to 65 MPa. This article presents fundamental material investigations on particle packing and matrix penetration as well as compressive strength tests and geometry studies. The results of this systematic investigation are presented, and the best set is applied to produce a large-scale demonstrator of one cubic meter of size and complex geometry. Moreover, the demonstrator features reinforcement and subtractive surface processing strategies. Further improvements of the LP3DCP technology as well as construction applications and architectural design potentials are discussed thereafter