One of the major limitations of the current 3D-concrete-printing technology is incorporation of reinforcement. Furthermore, there is a need to decrease the ecological footprint of printable concrete. As a possible solution for these challenges, this paper presents a 3D-printable strain-hardening geopolymer composite (3DP-SHGC) that shows pseudo-ductile behaviour under direct tension. The developed 3DP-SHGC is composed of one-part (just-add-water) geopolymer binder made of slag (GGBFS), fly ash (FA) and solid activator. The one-part geopolymer binder eliminates the need for elevated temperature curing and handling of corrosive alkaline liquids. At first, an optimum matrix was identified by studying the effects of FA to GGBFS ratio on the rheological properties and compressive strength. Subsequently the optimum matrix was reinforced by PVA fibres to make the 3DP-SHGC, which printing performance and rheological properties were evaluated. In addition, the influences of curing temperature on the compressive, flexural and tensile performances of the printed specimens were also investigated. The results were compared with those obtained for the mould-cast specimens. The 3DP-SHGC exhibited superior flexural performance, higher tensile strength, and comparable tensile strain capacity to the mould-cast counterpart. Further, the curing temperature had influence on the mechanical properties of both 3D-printed and mould-cast SHGCs. The underlying reasons for the differences are discussed.

This paper presents the systematic development and performance characterization of a non-proprietary 3D-printable ultra-high-performance fiber-reinforced concrete (UHPFRC) for digital construction. Several fresh and hardened properties of the developed 3D-printable UHPFRC matrix (without fiber) and composite (with 2% volume fraction of steel fibers) were evaluated and compared to that of conventionally mold-cast UHPFRC. Additionally, the effects of testing direction on the compressive and flexural strengths of the printed UHPFRC were investigated. The fresh properties of the UHPFRC developed in this study satisfied the criteria for extrudability, buildability, and shape-retention-ability, which are relevant for ensuring printability. The printed UHPFRC exhibited superior flexural performance to the mold-cast UHPFRC due to alignment of the short fibers in the printing direction. The high compressive and flexural strengths, along with the deflection-hardening behavior, of the developed UHPFRC can enable the production of thin 3D-printed components with significant reduction or complete elimination of conventional steel bars.

The extrusion-based 3D concrete printing (3DCP) technology allows the fabrication of permanent formwork with intricate shapes, into which fresh concrete is cast to build structural members with complex geometry. This significantly enhances the geometric freedom of concrete structures without the use of expensive temporary formwork. In addition, with proper material choice for the permanent formwork, the load-bearing capacity and durability of the resulting structure can be improved. This paper investigates 3DCP of permanent formwork for reinforced concrete (RC) beam construction. A 3D-printable engineered geopolymer composite (3DP-EGC, or strain-hardening geopolymer composite, 3DP-SHGC) recently developed by the authors was used for fabrication of the permanent formwork. The 3DP-EGC exhibits strain-hardening behaviour under direct tension. Two different printing patterns were used for the soffit of the permanent formwork to investigate the effect of this parameter on the flexural performance of RC beams. A conventionally mould-cast RC beam was also prepared as the control beam for comparison purposes. The results showed that the RC beams constructed using the 3DP-EGC permanent formwork exhibited superior flexural performance to the control beam. Such beams yielded significantly higher cracking load (up to 43%), deflection at ultimate load (up to 60%), ductility index (50%) and absorbed energy (up to 107%) than those of the control beam. The ultimate load was comparable with or slightly higher than that of the control beam. Furthermore, the printing pattern at the soffit of the permanent formwork was found to have a significant influence on the flexural performance of the RC beams.