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Abstract Modular building systems (MBS) and Origami are two emerging methods used in current construction practice. Origami is directly associated with the principles of the ancient Japanese art of paper folding, characterised by high morphological possibilities and ultimately creates foldable structures with tuneable mechanical properties. However, there is a lack of knowledge on the structural behaviour of origami for architectural engineering applications. MBS is a volumetric prefabricated construction technique enhancing productivity in construction. In this paper, a modular unit is designed which employs origami techniques. The roof and floor panels of the modular units formed with steel joists were substituted with origami sandwich panels, while corner posts were substituted with origami columns. The origami-like foldable system demonstrated superior efficiency in constructability, being highly compact during transportation and requiring few operations for the in-situ installation. The structural performances of the developed and foldable modular units were assessed through finite element analysis. It was found that, without increasing the self-weight of the system, the design of origami-like modular units can be tuned for high structural performances and various structural sizes, which can impact the usability of space and the aesthetics of architecture. While this is a preliminary study and physical testing is needed, the positive results open the possibility of exploring highly deployable modular structures of novel shapes that can be employed during post-disaster and emergencies (Covid-19).

The 3-Dimensional (3D) printing technology in the construction sector has seen an accelerating growth owing to its potential advantages. For this layer-based construction, a detailed investigation on fire performance is necessary. However, there are limited research studies for 3D Printed Concrete (3DPC) walls exposed to fire. Therefore, this paper investigates the fire performance of different types of 3D printed concrete walls using validated Finite Element Models (FEMs). Validated heat transfer FEMs were extended to investigate the fire performance of a range of 3DPC wall configurations (solid, cavity, and composite) under standard fire conditions. The results show that 3DPC non-load bearing cavity walls underperform when subjected to standard fire compared to solid 3DPC walls. The novel composite 3DPC walls with the use of Rockwool as cavity insulation offers superior fire resistance.

The steel Modular Building Systems (MBSs) that have been influenced by the Light-gauge Steel Frame (LSF) techniques have become a prominent culture in the industry. However, the detrimental behaviour of steel structural components at high temperatures has elevated the risk of fatal accidents in the event of a fire. Although several research investigations have addressed the fire performance of steel modular wall systems, the behaviour of modular floor systems has not been adequately addressed in the state of the art. Hence, to promote the fire safety and optimum design techniques in the modular construction industry by addressing the aforementioned research gap, this study investigated 48 conventional LSF and MBS floors for their structural and insulation Fire Resistance Levels using Finite Element Modelling (FEM) and Heat Transfer Analyses (HTA) techniques. Initially, full-scale experimental fire tests were modelled using FEM methods, and the validity of the techniques was verified prior to the analyses of parametric floor systems. Furthermore, the structural behaviour of the channel section joists in the elevated temperatures was studied, and hence a correlation was established to determine the critical steel temperature at the structural fire failure with respect to the applied Load Ratio (LR). An additional 12.5 mm thick plasterboard sheathing on single plasterboard sheathed floors resulted a 30 min improvement in structural and insulation FRLs. In addition, the modular floor systems demonstrated enhanced structural and insulation Fire Resistance Levels (FRLs) against the corresponding conventional LSF floor designs due to double LSF skin build-up. The incorporation of rockwool insulation and the increase in the insulation volume implied increased structural and fire performances. However, insulation material in the modular designs was more effective. The fire-rated conventional and modular LSF floor systems are expected to be practised in the construction industry to achieve required fire resistances with optimum material usage.

Large-scale additive manufacturing (AM), also known as 3D concrete printing, is becoming well-recognized and, therefore, has gained intensive research attention. However, this technology requires appropriate specifications and standard guidelines. Furthermore, the performance of printable concrete in elevated temperature circumstances has not yet been explored extensively. Hence, the authors believe that there is a demand for a set of standardized findings obtained with the support of experiments and numerical modelling of the fire performance of 3D-printed concrete structural elements. In general, fire experiments and simulations focus on ISO 834 standard fire. However, this may not simulate the real fire behaviour of 3D-printed concrete walls. With the aim of bridging this knowledge disparity, this article presents an analysis of the fire performance of 3D-printed concrete walls with biomimetic hollow cross sections exposed to realistic individual fire circumstances. The fire performance of the non-load-bearing 3D-printed concrete wall was identified by developing a suitable numerical heat transfer model. The legitimacy of the developed numerical model was proved by comparing the time–temperature changes with existing results derived from fire experiments on 3D-printed concrete walls. A parametric study of 96 numerical models was consequently performed and included different 3D-printed concrete wall configurations under four fire curves (standard, prolonged, rapid, and hydrocarbon fire). Moreover, 3D-printed concrete walls and mineral wool cavity infilled wall panels showed enhanced fire performance. Moreover, the cellular structures demonstrated superior insulation fire ratings compared to the other configurations.

Awareness of sustainability in construction has led to the utilization of waste material such as oil palm shell (OPS) in concrete production. The feasibility of OPS as alternative aggregates in concrete has been widely studied at the material level. Meanwhile, nonlinear concrete material properties are not taken into account in the conventional concrete wall design equations, resulting in underestimation of lightweight concrete’s wall axial capacity. Against these sustainability and technical contexts, this research investigated the buckling behavior of OPS-based lightweight self-compacting concrete (LWSCC) wall. Failure mode, load-deflection responses, and ultimate strength were assessed experimentally. Numerical models have been developed and validated against experimental results. Parametric studies were conducted to study the influence of parameters like slenderness ratio, eccentricity, compressive strength, and elastic modulus. The results showed that the axial strength of concrete wall was very much dependent on these parameters. A generalized semi-empirical design equation, based on equivalent concrete stress block and modified by mathematical regression, has been proposed. The ratio of average calculated results to test results of the proposed equation, when compared to ACI 318, AS 3600, and Eurocode 2 equations, are respectively improved from 0.36, 0.31, and 0.42 to 0.97. This research demonstrates that OPS-based LWSCC concrete can be used for structural axial components and that the equation developed can serve a good guideline for its design, which could encourage automation and promote sustainability in the construction industry.

Lightweight Steel Frames (LSF) in building construction are becoming more popular due to their fast, clean, and flexible constructability. Typical LSF wall panels are made of cold-formed and thin-walled steel lipped channel studs with plasterboard linings. Due to the high thermal conductivity of steel, these LSF components must be well engineered and covered against unintended thermal bridges. Therefore, it is essential to investigate the heat transfer of the LSF wall of different configurations and reduce heat loss through walls by lowering the thermal transmittance, which would ultimately minimise the energy consumption in buildings. The effect of novel thermal insulation material, Vacuum Insulation Panels (VIP), their position on the LSF wall configuration, and Oriented Strand Board (OSB) and plasterboard’s effect on the thermal transmittance of LSF walls were investigated through numerical analysis. A total of 56 wall configurations and 112 finite element models were analysed and compared with the minimum U-value requirements of UK building regulations. Numerical model results exhibited that using plasterboards instead of OSB has no considerable effect on the U-value of the LSF walls. However, 77% (4 times) of U-value reduction was exhibited by introducing the 20 mm VIP. Moreover, the position of the VIP to the U-value of LSF was negligible. Based on the results, optimum LSF wall configurations were proposed by highlighting the construction methods. Additionally, this study, through literature, seeks to identify other areas in which additional research can be conducted to achieve the desired thermal efficiency of buildings using LSF wall systems.

Three-dimensional-printed concrete (3DPC), which is also termed as digital fabrication of concrete, offers potential development towards a sustainable built environment. This novel technique clearly reveals its development towards construction application with various global achievements, including structures such as bridges, houses, office buildings, and emergency shelters. However, despite the enormous efforts of academia and industry in the recent past, the application of the 3DPC method is still challenging, as existing knowledge about its performance is limited. The construction industry and building sectors have a significant share of the total energy consumed globally, and building thermal efficiency has become one of the main driving forces within the industry. Hence, it is important to study the thermal energy performance of the structures developed using the innovative 3DPC technique. Thermal characterization of walls is fundamental for the assessment of the energy performance, and thermal insulation plays an important role in performance enhancements. Therefore, in this study, different wall configurations were examined, and the conclusions were drawn based on their relative energy performance. The thermal performance of 32 different 3DPC wall configurations with and without cavity insulation were traced using validated finite element models by measuring the thermal transmittance value (U-value). Our study found that the considered 3DPC cavity walls had a low energy performance, as the U-values did not satisfy the standard regulations. Thus, their performance was improved with cavity insulation. The simulation resulted in a minimum thermal transmittance value of 0.34 W/m2·K. Additionally, a suitable equation was proposed to find the U-values of 100 mm-thick cavity wall panels with different configurations. Furthermore, this study highlights the importance of analytical and experimental solutions as an outline for further research

Cracking in concrete structures can significantly affect their structural integrity and eventually lead to catastrophic failure if undetected. Recent advances in sensor technology for structural health monitoring techniques have led to the development of new and improved sensors for real-time detection and monitoring of cracks in various applications, from laboratory tests to large structures. In this study, triaxial accelerometers have been employed to detect and locate micro- and macrocrack formation in plain self-compacting concrete (SCC) and steel-fibre-reinforced SCC (SFRSCC) beams under three-point bending. Experiments were carried out with triaxial accelerometers mounted on the surface of the beams. The experimental results revealed that triaxial accelerometers could be used to identify the locations of cracks and provide a greater quantity of useful data for more accurate measurement and interpretation. The study sheds light on the structural monitoring capability of triaxial acceleration measurements for SFRSCC structural elements that can act as an early warning system for structural failure.

It is challenging to measure the environmental impact of concrete with the absence of a consensus on a standardized methodology for life cycle assessment (LCA). Consequently, the values communicated in the literature for “green” concrete alternatives vary widely between 84 and 612 kg eq CO2/m3. This does not provide enough evidence regarding the acclaimed environmental benefits compared to ordinary Portland cement concrete knowing that the average for the latter was concluded in this study to be around 370 kg eq CO2/m3. Thus, the purpose of this study was to survey the literature on concrete LCAs in an attempt to identify the potential sources of discrepancies and propose a potential solution. This was done through examining 146 papers systematically and attributing the sources of error to the four stages of an LCA: scope definition, inventory data, impact assessment and results interpretations. The main findings showed that there are 13 main sources of discrepancies in a concrete LCA that contribute to the incompatibility between the results. These sources varied between (i) user-based choices such as depending on a cradle-to-gate scope, selecting a basic volume-based functional unit and ignoring the impact allocation and (ii) intrinsic uncertainty in some of the elements, such as the means of transportation, the expected service life and fluctuations in market prices. The former affects the reliability of a study, and hence, a concrete LCA methodology should not allow for any of the uncertainties. On the other hand, the latter affects the degree of uncertainty of the final outcome, and hence, we recommended conducting scenario analyses and communicating the aggregated uncertainty through the selected indicators.