The early-age material parameters of three-dimensional (3-D)-printable concrete defined under the umbrella of printability, namely, pumpability, extrudability, buildability, and the “printability window/open time,” are subjective measures. The need to correlate and successively substitute these subjective measures with objective and accepted material properties, such as tensile strength, shear strength, and compressive strength, is paramount. This study validates new testing methodologies to quantify the tensile and shear strengths of printable fiber-reinforced concretes still in their fresh state. A tailored mixture with high sulfoaluminate cement and nonstructural basalt fibers has been assumed as a reference. The relation between the previously mentioned parameters and rheological parameters, such as yield strength obtained through International Center for Aggregates Research (ICAR) rheometer tests, is also explored. Furthermore, in an attempt to pave the way and contribute toward a better understanding of the mechanical properties of 3-D-printed concrete, to be further transferred into design procedures, a comparative study analyzing the work of fracture per unit crack width in three-point bending has been performed on printed and companion nominally identical monolithically cast specimens, investigating the effects of printing directions, position in the printed circuit, and specimen slenderness (length to depth) ratio.

Reinforcing strategies for three-dimensional printing (3DP) of cementitious materials (mostly mortars) have been extensively studied in recent years. Among various reinforcement strategies available for 3DP of cementitious materials, the use of fibers is frequently mentioned as a promising approach to enhance their mechanical performance. This work aims to evaluate the influence of four types of fibers (polyvinyl alcohol [PVA], nylon, rayon, and basalt) on the flowability and flexural strength of mortars used in 3DP. The flexural behavior of 3DP beams was compared with that of cast specimens, and the digital image correlation (DIC) technique was used to evaluate the development of the cracks. The fiber orientation in the reference (cast) and 3DP samples was examined using optical microscopy. The results revealed that, among four types of fibers used, the PVA fibers were most effective in increasing the flexural strength of both the cast and 3DP specimens. In addition, the results show that all fibers preferentially aligned parallel to the printing direction. 3DP specimens with filaments aligned in the direction perpendicular to the direction of the applied load showed superior flexural strength when compared to the cast specimens.

The need to constantly improve the quality and properties of manufactured products leads to the development of hybrid materials that combine different elements, complementing one another. Fiber-reinforced mortar is one of those products, as the fibers are used to improve cementitious materials’ flexural weakness. Experimental data on different metallic fibers dispersed in mortar demonstrate the correlation between early-age rheological properties and long-term mechanical strength. Both quantities depend on the ratio of the solid volume fraction of the fiber to a critical solid volume fraction characteristic of the form factors of the fiber. It is demonstrated that both effects arise from the packing stress of the fibers in the mortar when their concentrations are close to their maximum packing fraction. Geometrical arguments are used to explain how this critical volume fraction is related to the fiber form factor. Then, it enables the building of master curves using geometrical arguments.

The U.S. National Ocean Service estimates 95,741 miles (154,080 km) of shoreline in the United States, where 163 miles per year are hardened by bulkheads and riprap. These shoreline protection techniques are costly and require frequent maintenance. Different agencies are examining “nature-based” solutions that combine vegetation with traditional concrete. Digital construction, advanced manufacturing, and innovative cementitious composites have also been proposed as potential means to lower material use, cost, and environmental impact. This paper presents a novel advanced manufacturing technique using a reactive-diffusion morphological process, called “dry-forming,” to three-dimensionally (3-D) printed concrete structures of various shapes, sizes, and complexities with standard concrete mixtures. This technology has reduced 60% of material use, enhanced local habitats, and increased the resiliency of the shoreline to sea level rise. The widespread use of this technology would increase the resiliency of coastal communities, protect aquatic life, and protect waterfront public and private real estate investments.

Ultra-high-performance concrete (UHPC) is a cementitious concrete material known for its sustained post-cracking tensile performance. Various specimen geometries and different test approaches have been used to establish the tensile characteristics of UHPC. Intending to standardize a direct tension test method, this paper independently evaluates a procedure developed by the Federal Highway Administration (FHWA), which has been adopted into AASHTO T 397. To verify the reliability and repeatability of the test method, 216 tensile specimens were cast from three different UHPC types with fiber-volume fractions of 1, 2, and 3% and tested at six laboratories. The measured responses were characterized for different phases of the tensile behavior and analyzed to understand the scatter in the test data. It was found that testing can be executed with a 60 to 70% success rate with carefully prepared samples and some modifications to the proposed test method. The test results show an increase in both the tensile strength and multicracking phase with an increase in fiber-volume fraction, but the crack straining phase depends primarily on the type of UHPC. Using the test data, average and characteristic tensile responses were established, which are intended, respectively, for analysis and design purposes.