Lead Performer: University of Notre Dame – Notre Dame, IN
Partner: U.S. Army Corps of Engineers Engineer Research and Development Center Construction Engineering Research Laboratory – Champaign, IL
DOE Total Funding: $500,000 (includes CERL IAA Funding)
Cost Share: $352,749
CERL IAA Funding: $250,000
Project Term: July 1, 2020 – June 30, 2023
Funding Type: Advanced Building Construction FOA Award

Project Objective

The goal of this project is to achieve high energy and construction efficiency through additive manufacturing (i.e., 3D printing) of concrete walls in buildings. 3D printing concrete possesses new opportunities for advancing energy efficiency and manufacturing in building construction, with demonstrated savings in construction cost and time. This project will aim to provide improved thermal efficiency while achieving the strength and ductility required for commercial, public works, and multistory residential buildings.

The proposed technology aims to achieve superior thermal performance (i.e., 50% improvement in thermal resistance) without compromising structural performance at no additional first cost. To accomplish this objective, the project team will conduct experimental and numerical thermal and structural investigations to develop design and construction methods. They will then demonstrate and validate the performance of the 3D-printed concrete walls. The project’s key milestones including the following:

  1. Successful printing of 3D-printed walls with varying insulation and reinforcing layouts
  2. Experimental evidence demonstrating behavior, benchmarked numerical modeling approaches, and progress toward target performance criteria
  3. Full-scale prototypes demonstrating target performance criteria are achieved, design/manufacturing recommendations, and technology transition

Project Impact

Achieving the target energy performance of 50% higher thermal resistance while providing 100% strength and ductility as conventional (non-3D-printed) walls at no additional first cost will significantly advance U.S. building construction. The project impact will be on commercial, public works, and multistory residential buildings, particularly in cold, mixed-humid, and marine climates, as these structures have some of the highest average site energy use intensity. An industry advisory board will provide guidance and ensure industry adoption of the research findings.

Contacts

DOE Technology Manager: Charles Llenza, Charles.llenza@ee.doe.gov   
Lead Performer: Ashley Thrall, University of Notre Dame