Computational Optimization of 3D-Printed Concrete Walls for Improved Building Thermal Performance

Three-dimensional printing technologies are transforming various sectors with promising technological abilities and economic outcomes. For instance, 3D-printed concrete (3DPC) is revolutionizing the construction sector with a promise to cut projects’ costs and time. Therefore, 3DPC has been subjected to extensive research and development to optimize the mechanical and thermal performance of concrete walls produced by 3D printing. In this paper, we conduct a comparative investigation of the thermal performance of various infill structures of 3DPC walls. The targeted outcome is to produce an infill structure with optimized thermal performance to reduce building energy consumption without incurring additional material costs. Accordingly, a computational model is developed to simulate the thermal behavior of various infill structures that can be used for 3DPC walls. The concrete composition and the concrete-to-void fraction are maintained constant to focus on the impact of the infill structure (geometric variations). The thermal performance and energy-saving potential of the 3DPC walls are compared with conventional construction materials, including clay and concrete bricks. The results show that changing the infill structure of the 3DPC walls influences the walls’ thermal conductivity and, thereby, the building’s thermal performance. The thermal conductivity of the examined infill structures is found to vary between 0.122 to 0.17 W/m.K, while if these structures are successful in replacing conventional building materials, the minimum annual saving in energy cost will be about $1/m2. Therefore, selecting an infill structure can be essential for reducing building energy consumption.