The Selective Paste Intrusion (SPI) method is a layer-by-layer additive manufacturing technique that allows for the production of complex geometries in concrete elements by selectively bonding aggregates with cement paste in a particle bed. To create reinforced concrete, the Wire and Arc Additive Manufacturing (WAAM) process shall be integrated into SPI. This technique allows the production of almost free-formed reinforcement and thus complements the advantage of SPI to produce free-formed structures of almost any geometry. However, integration of WAAM into SPI poses a considerable challenge, as high temperatures are generated during the welding process. These temperatures can negatively affect the rheological properties of the cement paste, in turn the penetration behavior of the paste in the particle bed and, subsequently, the mechanical properties of the hardened concrete. A possible passive cooling strategy is to increase the protruding length of the reinforcement bars out of the particle-bed. This requires that the distance of the print nozzle to the particle bed is as well increased, since it must be possible to move it across the reinforcement. The objective was thus to investigate the effect of that distance on print quality and to quantify a maximum allowable distance for an adequate print quality (for the printer setting used) in terms of shape accuracy and concrete strength. Compressive and flexural strength tests as well as geometrical measurements using a 3D scanning method were performed on specimen, printed with varying print nozzle to particle bed distances. It can be stated that for the used SPI print-heads, nozzle-types and parameter settings, the distance between the nozzle and the particle bed should not exceed 50 mm to ensure sufficient print quality in both shape accuracy and mechanical strength.

Deterioration of concrete subjected to freezing and thawing climatic conditions is one of most important factors affecting the durability of concrete infrastructure in cold climates. The freeze-thaw resistance of cementitious materials like concrete and mortar can be determined by the CDF test (Capillary Suction of De-icing chemicals and Freeze-Thaw Test). Here, concrete specimens are subjected to repeated freeze-thaw cycles with simultaneous addition of de-icing salt and the amount of material weathered near the surface is determined. For concretes with adequate freeze-thaw resistance, this test method works very well. However, specimens with inadequate or unknown performance often experience increased edge weathering, which is caused by the detachment of the lateral isolation tape. The increasing edge influence thus leads to a falsification of the results and consequently to an underestimation of the actual freeze-thaw resistance of the material. In materials research in particular, however, concretes with high levels of weathering are studied in order to be able to investigate various factors of influence on the freeze-thaw resistance of concretes in a targeted manner. This paper presents a novel methodology that delivers new information regarding the weathering of CDF test samples and the associated distribution function of the height decrease using high resolution 3D scan data. The results indicate a correlation between the progression of the distribution function and the sample's maximum aggregate size. The change of the sample volume can be used to support the weathering results of the standard CDF methodology. The increase of the surface area is used to estimate the tortuosity of the sample surface. It indicates an asymptotic curve approaching a specific maximum value, which is dependent on the the weathering depth of the sample.

Damage in concrete structures initiates as the growth of diffuse microcracks that is followed by damage localisation and eventually leads to structural failure. Weak changes such as diffuse microcracking processes are failure precursors. Identification and characterisation of these failure precursors at an early stage of concrete degradation and application of suitable precautionary measures will considerably reduce the costs of repair and maintenance. To this end, a reduced order multiscale model for simulating microcracking-induced damage in concrete at the mesoscale levelis proposed. The model simulates the propagation of microcracks in concrete using a two-scale computational methodology. First, a realistic concrete specimen that explicitly resolves the coarse aggregates in a mortar matrix was generated at the mesoscale. Microcrack growth in the mortar matrix is modelled using a synthesis of continuum micromechanics and fracture mechanics. Model order reduction of the two-scale model is achieved using clustering technique. Model predictions are calibrated and validated using uniaxial compression tests performed in the laboratory.

Concrete is a heterogeneous material with a disordered material morphology that strongly governs the behavior of the material. In this contribution, we present a computational tool called the Concrete Mesostructure Generator (CMG) for the generation of ultra-realistic virtual concrete morphologies for mesoscale and multiscale computational modeling and simulation of concrete. Given an aggregate size distribution, realistic generic concrete aggregates are generated by a sequential reduction of a cuboid to generate a polyhedron with multiple faces. Thereafter, concave depressions are introduced in the polyhedron using gaussian surfaces. The generated aggregates are assembled into the mesostructure using a hierarchic random sequential adsorption algorithm. The virtual mesostructures are first calibrated using laboratory measurements of aggregate distributions. The model is validated by comparing the elastic properties obtained from laboratory testing of concrete specimens with the elastic properties obtained using computational homogenisation of virtual concrete mesostructures. Finally, a 3D-convolutional neural network is trained to directly generate elastic properties from voxel data.

Selective Paste Intrusion (SPI) is an additive manufacturing (AM) process in which thin layers of aggregates are selectively bonded by cement paste only where the structure is to be produced. In this way, concrete elements with complex geometries and structures can be created. Reinforcement is required to increase the flexural strength of the concrete elements and, thus, enable their applicability in practice. Integrating the reinforcement is a difficult task, particularly in the case of SPI due to the layer-wise printing method. Especially with respect to possible complex structures, the production of the reinforcement needs to be adapted to SPI, thereby offering a high degree of freedom. One concept for a reinforcement integration is combining the two additive manufacturing processes SPI and Wire and Arc Additive Manufacturing (WAAM). However, since the two processes serve different fields of application, their compatibility is not necessarily given. Ongoing investigations show that the temperatures caused by WAAM adversely affect both, the cement paste rheology required for sufficient paste penetration into the particle bed and the overall concrete strength. This paper provides an overview of ongoing research focusing on different cooling strategies and their effects on the compressive strength of SPI-printed concrete parts.