Investigation of Axial Load Capacity of 3D Printed Concrete Wall (2024-05)¶

Three-dimensional (3D) concrete printing is increasingly becoming popular because it provides a powerful platform for the fabrication of structural components in freeform architectural shapes. Although manufacturing technology and material property improvement are advancing rapidly, the development of methods to predict the structural capacity of printed elements is lagging. This paper presents an experimental and numerical investigation to predict the axial load capacity of a printed concrete wall module. The module geometry contains two parallel thin wall sections connected by an internal sine wave. The thin wall section reduces the concrete consumption, and the internal sine wave provides lateral stability during printing and in the hardened state. It is a popular pattern printed by many researchers and in some real constructions. Two wall module specimens with the prescribed geometry were 3D-printed and tested under compression. The maximum loads of 2,890 and 2,924 kN were obtained for the first and second wall specimens, respectively. Additionally, samples were taken from different locations of a printed prototype to identify printed material characteristics. These experimental characteristics were then introduced to a finite-element numerical model for predicting the structural performance of the printed wall module under compression load. The results showed that the experimental maximum load and stiffness have 1% and 5% differences with numerical outputs, respectively. Based on such a validated model, the failure modes are discussed, and an analytical method is proposed for predicting the axial capacity for the prescribed geometry.