Digital Fabrication, Technical Detailing, Constructive Integration, and Cost of 3D Concrete Printed CDW-based Geopolymer Façade Panels

Abstract

The integration of 3D-printed Construction and Demolition Waste (CDW)-based geopolymer panels into building facades presents a technologically significant frontier that bridges digital fabrication, sustainable material science, and constructive detailing. While 3D printing has gained considerable research attention for structural and freeform applications, studies that document the complete process chain - from mix design and laboratory production to full facade system integration - remain limited. This paper presents a design-based experimental study in which CDW-based geopolymer facade panels were produced via 3D Concrete Printing (3DCP) under laboratory conditions. The study systematically documents the production process, the geometric and technical properties of the panels, and the constructive details required for their application to a real facade system. Key topics addressed include substructure selection, connection typology, joint design, and corner and opening solutions. The findings demonstrate that panel design decisions made during the production phase directly condition the feasibility of facade assembly, and that applicability depends not only on material performance but on the coherence of the panel within a broader system of substructure, connection, and joint resolution. The total material and labor cost of the retrofit application was $329.659 for the 13.5 m2 facade, equivalent to approximately $25/m2 - a figure competitive with conventional prefabricated cladding systems applied at comparable scale. Labor accounted for $167.25 (50.73% of total cost) across two installation days with three workers, while materials (aluminum L-profiles and polyurethane adhesive) accounted for $162.409 (50.27% of total cost).

Keywords

• 3D concrete printing
• CDW-based geopolymer
• constructive integration
• cost
• digital fabrication
• façade panel

3B Beton Baskılı CDW Bazlı Jeopolimer Cephe Panellerinin Dijital Üretimi, Teknik Detaylandırması, Yapısal Entegrasyonu ve Maliyeti

Abstract

3B baskı yöntemiyle üretilen inşaat ve yıkım atığı (İYA) bazlı jeopolimer panellerin bina cephelerine entegrasyonu, dijital üretim, sürdürülebilir malzeme bilimi ve yapısal detaylandırmayı bir araya getiren teknolojik açıdan önemli bir dönüm noktasıdır. 3B baskı, yapısal ve serbest biçimli uygulamalar için önemli bir araştırma ilgisi görmüş olsa da karışım tasarımından laboratuvar üretimine ve tam cephe sistemi entegrasyonuna kadar tüm süreç zincirini belgeleyen çalışmalar sınırlı kalmıştır. Bu çalışma, laboratuvar koşullarında 3B beton baskı (3BBB) yöntemiyle üretilen İYA bazlı jeopolimer cephe panellerinin tasarım tabanlı deneysel bir çalışmasını sunmaktadır. Çalışma, üretim sürecini, panellerin geometrik ve teknik özelliklerini ve gerçek bir cephe sistemine uygulanmaları için gerekli yapısal detayları sistematik olarak belgelemektedir. Ele alınan temel konular arasında alt yapı seçimi, bağlantı tipolojisi, derz tasarımı ve köşe ve açıklık çözümleri yer almaktadır. Bulgular, üretim aşamasında alınan panel tasarım kararlarının cephe montajının uygulanabilirliğini doğrudan etkilediğini ve uygulanabilirliğin yalnızca malzeme performansına değil, aynı zamanda panelin daha geniş bir alt yapı, bağlantı ve derz çözümü sistemi içindeki tutarlılığına da bağlı olduğunu göstermektedir. 13,5 m²'lik cephe için toplam malzeme ve işçilik maliyeti 329.659 ABD doları olup, bu da yaklaşık 25 ABD doları/m²'ye denk gelmektedir; bu rakam, benzer ölçekte uygulanan geleneksel prefabrik kaplama sistemleriyle rekabet edebilecek düzeydedir. İşçilik, üç işçiyle iki günlük kurulum süresince 167,25 ABD doları (toplam maliyetin %50,73'ü) iken, malzemeler (alüminyum L profiller ve poliüretan yapıştırıcı) 162.409 ABD doları (toplam maliyetin %50,27'si) düzeyindedir.

Keywords

• 3B beton baskı
• CDW bazlı jeopolimer
• yapısal entegrasyon
• maliyet
• dijital üretim
• cephe paneli

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