Ruslan Kucher

This research establishes the first comprehensive project management framework for 3DCP through quantitative standards for design preparation, technological setup, and quality management. Based on systematic analysis of construction projects completed during 2023-2025 by "Geopolimer" LTD (Kharkiv, Ukraine), we developed mathematical models for time estimation incorporating perimeter length, geometric complexity, and feature count parameters. Regression analysis of project data enabled formulation of predictive equations: design preparation time accounts for base setup, perimeter-dependent modeling, and complexity coefficients (complex curved surfaces with architectural details). Technological preparation time integrates G-code generation, trajectory verification per meter, and build step validation. A systematic complexity classification system evaluates four geometric factors: curved surfaces percentage, architectural detail count, protruding elements, and internal cavity complexity, enabling quantitative risk assessment and resource allocation decisions. The framework incorporates a three-level quality management system with standardized defect classification (aesthetic, attention-required, critical) defining acceptance criteria for crack dimensions, surface porosity, and structural integrity. Trajectory verification methodology enables proactive defect identification, detecting 85-90% of potential issues before production begins. Economic analysis demonstrates 8-12% rework cost avoidance, 15‒20% preparation time savings, and 5‒10% schedule compression, with return on investment achieved within 0.5‒1.5 months. Case study validation on a 174 m² residential structure demonstrates framework effectiveness: calculated preparation time of 45.1 hours versus actual 47.2 hours. The framework facilitates 3DCP transition from experimental technology to predictable industrial process, enabling evidence-based project planning, systematic risk management, and competitive market positioning. Future research directions include expansion to additional printer types, integration with Building Information Modeling workflows, real-time computer vision quality monitoring, and long-term performance tracking for continuous standard refinement.

The presented results were obtained during a theoretical and experimental study of the geometric accuracy and surface quality parameters of concrete walls manufactured using additive technologies. Theoretical aspects of the classification of defects and deviations of surfaces obtained by layered concrete construction have been developed. The study examines the influence of layer thickness on printing precision and defect formation in 3D concrete printing (3DCP) processes. Two experimental samples were fabricated with different layer thicknesses: 20 mm and 15 mm. Systematic measurements were conducted to evaluate crack depth on vertical surfaces, pore depth on horizontal surfaces, track width variations, and deviations from straight-line geometry. The experimental methodology involved comprehensive measurement protocols using precision instruments to assess geometrical parameters and surface quality characteristics. Statistical analysis was performed to quantify the relationships between layer thickness and printing accuracy, including calculations of mean values, standard deviations, and coefficients of variation for all measured parameters. Results demonstrate significant improvements in geometrical accuracy when reducing layer thickness from 20 mm to 15 mm. Crack depth on vertical surfaces decreased by 56%, while deviations from straight-line geometry improved by 32%. Most notably, track width stability showed a remarkable enhancement, with the coefficient of variation improving by 91%, indicating substantially improved process repeatability. The 15 mm layer thickness configuration exhibited superior performance across all measured parameters, demonstrating enhanced layer adhesion, reduced surface defects, and improved dimensional consistency. The coefficient of variation for crack depth decreased from 43% to 24%, while deviation variability reduced from 32% to 12%, confirming improved process control and predictability. These findings provide valuable insights for optimizing 3D concrete printing parameters and establishing quality control protocols for additive construction applications. The research contributes to the development of standardized practices for concrete 3D printing technology and demonstrates the critical importance of layer thickness optimization for achieving high-quality printed concrete structures. The results confirm the effectiveness of implementing thinner layers, given the increased requirements for geometric accuracy and surface quality in automated concrete construction processes. This research was conducted at "Geopolimer" LTD to implement innovative technologies in the construction industry.

The study is devoted to a comprehensive analysis of the introduction of additive technologies into modern construction production, revealing the technical, economic, and managerial aspects of concrete 3D-printing of architectural structures. The work systematically analyzes the evolution of additive manufacturing technologies and identifies the main structural types of 3D-printers (an additive machine for layer-by-layer construction of objects), including portal, robotic, mobile, and hybrid systems. A detailed study of the technological parameters of concrete 3D-printing with concrete mixtures is presented, in particular, optimal printing speed modes, layer parameters, criteria for shaping and quality of building structures. A comparative analysis of the technological capabilities of leading world equipment manufacturers, such as ICON, COBOD International, Apis Cor, and WinSun, is conducted. The economic analysis demonstrates significant advantages of additive technologies: reduction of construction time by 2-6 times, reduction of construction cost by 20-35%, and increase in the load-bearing capacity of structures. The study comprehensively explores the structure of capital and operational expenses associated with technology implementation. Special emphasis is placed on the management aspects of introducing additive technologies, highlighting the critical need for an interdisciplinary approach and knowledge integration across architecture, engineering, management, and computer modeling. The study determines the prospects for the development of concrete 3D-printing technology in the construction industry and outlines the main directions of further scientific research and practical implementation of innovative solutions. This study was developed between the Department of "Integrated Technologies of Mechanical Engineering" named after M. Semko of NTU "KhPI" and "Geopolimer" LTD to implement innovative technologies in the construction industry.