Epoxy Resins Strengthen 3D-printed Concrete

Cast concrete has withstood the test of time for thousands of years. The versatility and strength of poured concrete has made it the preferred building material for a variety of projects. Cementitious material can be poured into forms containing reinforcing steel, or cast into blocks without reinforcement, depending on the planned use. For all cast concrete, epoxy resins serve as protective coatings that reduce wear and erosion, while beautifying this normally dull material.

On the horizon, however, is 3D-printed concrete. The liquid concrete is extruded from a nozzle, much like the icing placed on a decorated cake. While this technique can be extremely precise and create structures that are difficult for poured concrete to copy, there are many challenges to be solved in order for this method of concrete construction to succeed. One of the biggest problems is that 3D-printed concrete simply doesn’t have the strength of cast concrete, and tends to crack due to the layering methods involved during manufacture. Epoxy resins may provide a solution.

Tunnels of Epoxy Resin

Many different forms of reinforcement have been proposed and tested with 3D-printed concrete. Nails, fiber, chains, cable, wire, monofilament, rebar, and plastic have all been tried, and were either extruded along with the concrete or inserted into the concrete afterwards. In most cases, the bond between the extruded concrete and the reinforcing material was poor, limiting the effectiveness. Therefore, a team of concrete researchers proposed using cured epoxy for reinforcing 3D-printed concrete. They hypothesized that the excellent bonding properties of epoxy resins would improve the durability of 3D-printed concrete structures.

The researchers first designed a 3D-printing scheme that would create tunnels in-between the extruded concrete. Epoxy resin was then grouted into these tunnels. The bonding between the tunnels of epoxy and the adjoining concrete was excellent. No visible gaps were reported between the two materials. The cured epoxy in effect acted like a strengthening bar inside the concrete. The researchers concluded that the epoxy “had significantly improved the flexural behavior of the printed beams.” For future study, the research team recommended the development of a double nozzle printing system that would extrude the concrete and the strengthening epoxy resin side-by-side.

Benefit from Epoxy Now

Durability and appearance are important factors in all construction projects and renovations. Epoxy resins are consistently used by experts in the field to improve the strength and durability of concrete floors and foundations. Let California Custom Coatings use this proven material to beautify and protect your home, garage, and workspace. Contact us by phone or online for a free consultation.