With increasing interest in the use of additive manufacturing techniques in the construction industry, static rheological properties of fresh concrete have necessarily come into focus. In particular, the knowledge and control of static yield stress (SYS) and its development over time are crucial for mastering formwork-free construction, e.g. by means of layered extrusion. Furthermore, solid understanding of the influences of various concrete constituents on the initial SYS of the mixture and the structural build-up rate is required for purposeful material design. This contribution is concentrated on the effect of aggregates on these rheological parameters. The volume fraction of aggregates was varied in the range of 35 to 55 % by volume under condition of constant total surface area of the particles. The total surface area per unit volume of cement paste was equal to 5.00, 7.25 and 10.00 m²/l, conditioned on the constant volume fraction of aggregates. Both variations were enabled by changing the particle size distributions of the aggregates while holding the cement paste composition constant for all concrete mixtures. To characterise the SYS and the structural build-up, constant shear rate tests with a vane-geometry rotational rheometer were performed. It was found that in the ranges under investigation the variation in volume fraction had a more pronounced effect on the static rheological properties of concrete than did the variation in surface area. An accurate mathematical description of the relationship between the initial SYS of concrete and the relative volume fraction of aggregate based on the Chateau-Ovarlez-Trung model was proposed. Challenges in deriving a similar relationship for the structural build-up rate of concrete were highlighted.

The performance of a normal-strength SHCC under impact loading was studied using the results obtained from a split Hopkinson tension bar (SHTB). The focus of the investigation is to explain the mechanisms behind the peculiar rate-dependent behavior of SHCC under tensile loading. With the help of frames obtained by high-speed cameras and the subsequent Digital Image Correlation (DIC) analysis, the stress-strain relation of the SHCC obtained in SHTB was analyzed. The investigation of the composite’s behavior was supported by constituent-level experiments on the non-reinforced matrix of the SHCC and on the fiber-matrix bond. In the case of the constituent matrix, the well-known apparent increase in the tensile strength of the cement-based matrix and its influence on the behavior of SHCC was studied. For this purpose, experiments on the SHCC specimens with different geometries were performed in the SHTB. The results obtained from these experiments and those obtained by DIC show that commonly used analytical models, in which the specimen is assumed elastic, cannot capture the effects of structural inertia on the results. Thus, an alternative novel method based on the results of DIC has been used to explain and quantify the contribution of structural inertia. The rate-dependent behavior of the fiber-matrix bond was studied by performing high-speed single fiber pullout tests in a miniaturized split Hopkinson tension bar. This novel experimental technique enabled explanation of the rate-dependent bridging action of the fibers in SHCC. Based on the results, the enhanced behavior of SHCC under impact loading is explained.

Interfaces between layers in 3D-printed elements produced by extrusion-based material deposition were investigated on both macro- and micro-scales. On the macro-scale, compression and bend tests were performed on two 3D-printable cement-based compositions (3PCs), namely C1 and C2. The influences of binder composition and time interval between layers on layer-interface strength were critically analyzed. In the context of additive manufacturing, the optimized composition C2, containing pozzolanic additives, exhibited mechanical performance superior to that of the mixture with Portland cement as the sole binder. In particular, Mixture C2 showed a less pronounced decrease in interface tensile strength. Even for time intervals between depositions of two layers as long as 1 day the loss in corresponding flexural strength was below 25%, as compared with C2 specimens tested in the perpendicular direction. In contrast, the decrease in flexural strength measured for C1 specimens amounted to over 90% for the same set of parameters. Higher porosity at the interfaces of the printed concrete layers was identified as the cause for the lower interface strengths of C1. Microscopic observations supported the findings of the macroscopic investigations. While a pronounced recovery (“self-healing”) of the porous, discontinuous interlayers was observed with increasing age for Mixture C2, in case of C1 the filling products grown in the porous interlayer were found to be non-strengthening.

Buildability, i.e. the ability of a deposited material bulk to retain its dimmensions under increasing load, is an inherent prerequisite for formwork-free digital construction (DC). Since DC processes are relatively new, no standard methods of characterization are available yet. The paper at hand presents practice-oriented buildabilty criteria by taking various process parameters and construction costs into consideration. In doing so, direct links between laboratory buildability tests and target applications are established. A systematic basis for calculating the time interval (TI) to be followed during laboratory testing is proposed for the full-width printing (FWP) and filament printing (FP) processes. The proposed approach is validated by applying it to a high-strength, printable, fine-grained concrete. Comparative analyses of FWP and FP revealed that to test the buildability of a material for FP processes, higher velocities of the printhead should be established for laboratory tests in comparison to those needed for FWP process, providing for equal construction rates.

This paper presents a numerical two-scale framework for the simulation of fiber reinforced concrete under impact loading. The numerical homogenization framework considers the full balance of linear momentum at the microscale. This allows for the study of microscopic inertia effects affecting the macroscale. After describing the ideas of the dynamic framework and the material models applied at the microscale, the experimental behavior of the fiber and the fiber-matrix bond under varying loading rates are discussed. To capture the most important features, a simplified matrix cracking and a strain rate sensitive fiber pullout model are utilized at the microscale. A split Hopkinson bar tension test is used as an example to present the capabilities of the framework to analyze different sources of dynamic behavior measured at the macroscale. The induced loading wave is studied and the influence of structural inertia on the measured signals within the simulation are verified. Further parameter studies allow the analysis of the macroscopic response resulting from the rate dependent fiber pullout as well as the direct study of the microscale inertia. Even though the material models and the microscale discretization used within this study are still simplified, the value of the numerical two-scale framework to study material behavior under impact loading is shown.

To enable purposeful design and implementation of automated concrete technologies, precise assessment and prediction of the complex material flow at various stages of the process chain are necessary. This paper investigates the intermediate stage of the extrusion and deposition processes in extrusion-based 3D-concrete-printing, using a numerical model based on the Particle Finite Element Method (PFEM). In PFEM, due to the Lagrangian description of motion, remeshing algorithms and the alpha shape method are used to track the free surface during large deformation scenarios. The Bingham constitutive model was used for describing the rheological behaviour of fresh concrete. This model is validated by comparing the numerically predicted layer geometries with those obtained from laboratory 3D printing experiments. Extensive parametric studies were then conducted using the numerical simulation, delineating the influence of process and material parameters on the layer geometries, the dynamic surface forces generated under the extrusion nozzle and the inter-layer interactions.

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.

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.

This paper presents a comparison between indirect methods for assessing the buildability of 3D printed cementitious materials, including CRV or CSR test using rotational rheometry, unconfined uniaxial compression test (UUCT), a newly proposed confined uniaxial compression test (CUCT), and fast penetration test. The experimental program was conducted on the extruded samples of six printable mortars and two printable concretes with various rheological behavior achieved by the use of different additives and admixtures. Predictions of the material failure and the stability failure in hollow cylindrical structures are provided and compared with the results of the direct printing test. Benefits and disadvantages of the employed test methods are discussed, also taking into consideration a perspective of their use for automated in-situ control of the materials’ buildability.

The ductile behavior of strain hardening cement-based composites (SHCC) under direct tensile load makes them promising solutions for applications where high energy dissipation is needed, such as earthquake, impact by a projectile, or blast. However, the superior tensile ductility of SHCC due to multiple cracking does not necessarily entail compressive and shear ductility. As an effort to characterize the behavior of SHCC under impact compressive and shear loading, relevant to the mentioned high-speed loading scenarios, the paper at hand studies the performance of a SHCC and its constituent cement-based matrices using the split-Hopkinson bar method. For compression experiments, cylindrical specimens with a length-to-diameter ratio (l/d) of 1.6 were used. The selected length of the sample led to similar failure modes under the quasi-static and impact loading conditions, which was necessary for a reliable comparison of the obtained compressive strengths. The impact experiments were performed in a split-Hopkinson pressure bar (SHPB) at a strain rate that reached 110 s-1 at the moment of failure. For shear experiments, a special adapter was developed for a split-Hopkinson tension bar (SHTB). The adapter enabled performing impact shear experiments on planar specimens using the tensile wave generated in the SHTB. Results showed a dynamic increase factor (DIF) of 2.3 and 2.0 for compressive and shear strength of SHCC, respectively. As compared to the non-reinforced constituent matrix, the absolute value of the compressive strength was lower for the SHCC. Contrarily, under shear loading, the SHCC yielded the higher shear strength than the non-reinforced matrix.

3D-printing with foam concrete, which is known for its distinct physical and mechanical properties, has not yet been purposefully investigated. The article at hand presents a methodological approach for the mixture design of 3D-printable foam concretes and a systematic investigation of the potential application of this type of material in digital construction. Three different foam concrete compositions with water-to-binder ratios between 0.33 and 0.36 and having densities of 1100 to 1580 kg/m³ in the fresh state were produced with a pre-foaming technique using a protein-based foaming agent. Based on the fresh-state tests, including 3D-printing as such, an optimum composition was identified and its compressive and flexural strengths were characterised. The printable foam concrete showed compressive strength above 10 MPa and low thermal conductivity, which make it suitable for 3D-printing applications, while fulfilling both load-carrying and insulating functions.

Despite all their advantages, load-bearing concrete shell structures with double curvatures are not frequently in use. The main reason is the complexity of their construction. In such a context, this article starts with a brief, critical review of existing technologies while their pros and cons are highlighted. Against that background the authors then propose a new approach for the highly automated fabrication of gridshell structures from variable modules. To demonstrate the feasibility of such a new technology, a demonstrator called ConDIT 1.0, a sphere-like shell structure composed of several frames was designed and built. The frame modules were fabricated automatically using extrusion-based 3D printing and a printable, strain-hardening cement-based composite (SHCC). This article presents the design of ConDIT 1.0, the mechanical material characterization of printed SHCC, the technology of module production, the results of geometry verification for print modules using 3D scanning, and the procedure for the demonstrator’s assembly.

Shell-like, double curved and thus above-average performance structures, are usually produced monolithically on site. For industrial advancement, however, they must be divided into transportable modules which can be assembled on the construction site (design for assembly). Models are lattice shells made of steel and glass, in which predominantly flat sub-surfaces (modules) are used. Therefore, the main question is: Which modularizations are suitable for flow production with mineral building materials? In this paper designed free-form surface is going to be discretized as PQ circular mesh system, suitable modules for 3D concrete printing. Moreover, the multi-criteria optimization is done with Response Surface Methodology (RSM) in order to get optimal final shape. The goal is to start from the arbitrary shape, that can be generated from two curves, with possible two-way division into modules and compare it with the resulted discretized PQ circular mesh system, realized with new algorithm. The comparison can be defined through two main criteria: geometrical and structural.

The determination of crack propagation velocities can provide valuable information for a better understanding of damage processes of concrete. The spatio-temporal analysis of crack patterns developing at a speed of several hundred meters per second is a rather challenging task. In the paper, a photogrammetric procedure for the determination of crack propagation velocities in concrete specimens using high-speed camera image sequences is presented. A cascaded image sequence processing which starts with the computation of displacement vector fields for a dense pattern of points on the specimen’s surface between consecutive time steps of the image sequence chain has been developed. These surface points are triangulated into a mesh, and as representations of cracks, discontinuities in the displacement vector fields are found by a deformation analysis applied to all triangles of the mesh. Connected components of the deformed triangles are computed using region-growing techniques. Then, the crack tips are determined using principal component analysis. The tips are tracked in the image sequence and the velocities between the time stamps of the images are derived. A major advantage of this method as compared to established techniques is in the fact of its allowing for spatio-temporally resolved, full-field measurements rather than point-wise measurements and that information on crack width can be obtained simultaneously. To validate the experimentation, the authors processed image sequences of tests on four compact-tension specimens performed on a split-Hopkinson tension bar. The images were taken by a high-speed camera at a frame rate of 160,000 images per second. By applying to these datasets the image sequence processing procedure as developed, crack propagation velocities of about 800 m/s were determined with a precision in the order of 50 m/s.

Strain-hardening cement-based composites (SHCC) are a novel class of fiber-reinforced concretes which exhibit high tensile strain capacity prior to failure localization. Although the tensile behavior of SHCC has been a matter of study in numerous research works, the behavior of these composites under other loading modes has scarcely been investigated. The article at hand addresses the mechanical behavior of two types of normal-strength SHCC subject to uniaxial tension, torsion, and combinations of torsional and axial loading. The SHCC under investigation were made with polyvinyl-alcohol (PVA) and ultra-high molecular weight polyethylene (UHMWPE) fibers, respectively. Digital Image Correlation (DIC) was applied to evaluate the multiple cracking process and crack opening modes in conjunction with the concretes’ axial and torsional loading histories. The study demonstrates the suitability of torsion experiments to assess the multi-axial and shear performance of SHCC, highlights the relation between multiple cracking and transfer capacity for shear forces, and emphasizes the importance of the type of reinforcing fibers on the shear strength and ductility of such composites.