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.

Successful implementation of extrusion-based three-dimensional (3-D) printing requires the development of print materials with adapted rheology. In this study, filtration characteristics coupled with rheological properties of mortar mixtures are investigated to characterize the extrudability of print materials and establish a “printability window” (that is, the acceptable range of material properties for successful extrusion and shape stability). The extrudability was measured as the maximum force needed for the ram extrusion of the material. The fluid filtration rate was assessed in terms of desorptivity of the fresh mixture under pressure. The yield stress, plastic viscosity, and desorptivity were varied by changing the water-cement ratio (w/c), high-range water-reducing admixture (HRWRA) dosage, and welan gum (WG) content. Regression analysis indicated that during extrusion-based printing, the yield stress and desorptivity values can exhibit a more significant effect on extrudability than plastic viscosity.

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.

This paper assesses the suitability of geopolymers (GPs) for use as adhesives for ceramic tile fixing, including their compliance to relevant EN 12004 specifications. Two series prepared with different percentages of metakaolin (MK), blast furnace slag (BFS), and limestone materials activated by an alkaline NaOH/Na2SiO3 solution are investigated. Tested properties included the thixotropy, setting, compressive strength, open time, and adhesion bond strength under different exposure conditions (i.e., dry, wet, heat, or freeze/thaw cycles). Compared to cement-based mortars containing adjusted proportions of cellulose and redispersible polymers, the GPs exhibited higher thixotropy reflecting additional energy for spreading the material over the substrate, yet better maintaining of the alternating patterns of ripples and grooves at rest. The bond strengths tested under different exposure conditions were remarkably high for the MK-based GP, given the fine MK particle sizes that foster geopolymerization and cross-linking of solid bonds in the hardened structure. The BFS-based GP exhibited relatively lower bond strengths (compared to MK) due to coarser particles. Such results can be of interest to civil engineers and manufacturers of ready-to-use building materials that aim at reducing the Portland cement footprint while assuring the performance and sustainability of tiling applications.

In light of the effort for decarbonization of the energy sector, it is believed that common geopolymer binding materials such as fly ash may eventually become scarce, and new geological aluminosilicate materials should be explored as alternative binders in geopolymer concrete. A novel, tension-hardening geopolymer concrete (THGC) that incorporates high amounts of semi-reactive quarry wastes (Metagabbro) as a precursor and coarse quarry sand (granite) was developed in this study using geopolymer formulations. The material was optimized based on the particle packing theory and was characterized in terms of mechanical, physical, and durability properties (i.e., compressive, tensile, flexural resistance, Young’s Modulus, Poisson’s ratio; absorption, drying shrinkage, abrasion, and coefficient of thermal expansion; chloride ion penetration, sulfate, and salt-scaling resistance). The developed THGC with an air-dry density of 1,940 kg/m³ [121 lb/ft³], incorporates short steel fibers at a volume ratio of 2% and is highly ductile in both uniaxial tension and compression (uniaxial tensile strain capacity of 0.6% at an 80% post-peak residual tensile strength). Using DIC, multiple crack formation was observed in the strain-hardening phase of the tension response. In compression the material maintained its integrity beyond the peak load, having attained 1.8% compressive strain at 80% post-peak residual strength whereas upon further reduction to 50% residual strength, the sustained axial and lateral strains were 2.5% and 3.5%, respectively. The material exhibited low permeability to chloride ions and significant abrasion resistance due to the high contents of Metagabbro powder and granite sand. The enhanced properties of the material, combined with the complete elimination of ordinary Portland cement from the mix, hold promise for the development of sustainable and resilient structural materials with low CO₂j, emissions while also enabling the innovative disposal of wastes as active binding components.