Skip to content

Advancing Structural Reinforcement in 3D Printed Concrete (2025-01)

Current Methods, Challenges, and Innovations

10.3390/ma18020252

 Nan Bo,  Qiao Youxin,  Leng Junjie,  Bai Yikui
Journal Article - Materials, Vol. 18, Iss. 2, No. 252

Abstract

With rapid global urbanization and economic development, 3D concrete printing (3DCP) technology has emerged as an innovative construction method, garnering increasing attention and application. Compared to traditional construction techniques, 3DCP not only reduces resource waste and carbon emissions during the building process but also significantly enhances construction efficiency, demonstrating considerable potential in the construction industry. As 3DCP advances from theoretical studies to real-world applications, providing stable and reliable structural reinforcement solutions becomes essential. This paper focuses on examining various methods to improve the performance of 3D-printed concrete (3DPC) structures. The analysis shows that reinforcement using steel bars, in combination with other materials (mainly fibers and nanomaterials), remains a key strategy for structural enhancement. By integrating diverse reinforcement methods, this study proposes an innovative bidirectional steel mesh layout scheme. Additionally, given the unique nature of 3DPC construction, a critical review of various methods for improving interface bonding strength is included. These findings aim to guide the engineering community in selecting suitable reinforcement solutions for 3DPC.

70 References

  1. Alabbasi Mohammad, Agkathidis Asterios, Chen Hanmei (2023-01)
    Robotic 3D Printing of Concrete Building Components for Residential Buildings in Saudi Arabia
  2. Ali Mohd, Nassrullah Ghaith, Al-Rub Rashid, Khaswaneh Bashar et al. (2024-03)
    Influence of Carbon-Nano-Tubes on Printing Quality and Mechanical Properties of 3D Printed Cementitious Materials
  3. Batikha Mustafa, Jotangia Rahul, Baaj Mohamad, Mousleh Ibrahim (2021-12)
    3D Concrete Printing for Sustainable and Economical Construction:
    A Comparative Study
  4. Bazli Milad, Ashrafi Hamed, Rajabipour Ali, Kutay Cat (2023-02)
    3D Printing for Remote Housing:
    Benefits and Challenges
  5. Bong Shin, Nematollahi Behzad, Nazari Ali, Xia Ming et al. (2018-09)
    Fresh and Hardened Properties of 3D Printable Geopolymer Cured in Ambient Temperature
  6. Butkutė Karolina, Vaitkevičius Vitoldas, Adomaitytė Fausta (2024-07)
    Eco-Friendly 3D Printed Concrete Made with Waste and Organic Artificial Aggregates
  7. Cheikh Khadija, Rémond Sébastien, Khalil Noura, Aouad Georges (2017-04)
    Numerical and Experimental Studies of Aggregate-Blocking in Mortar-Extrusion
  8. Delgado Camacho Daniel, Clayton Patricia, Brien William, Seepersad Carolyn et al. (2018-02)
    Applications of Additive Manufacturing in the Construction Industry:
    A Forward-Looking Review
  9. Dong Liang, Yang Yekai, Liu Zhongxian, Zhang Yan et al. (2024-06)
    Interface Bonding Characteristics of 3D Printed Ultra-High-Performance Concrete After Elevated Temperatures
  10. Dulaj Albanela, Salet Theo, Lucas Sandra (2024-01)
    A Study of the Effects of MWCNTs on the Fresh and Hardened State Properties of 3D Printable Concrete
  11. Habibi Alireza, Buswell Richard, Osmani Mohamed, Aziminezhad Mohamadmahdi (2024-11)
    Sustainability Principles in 3D Concrete Printing:
    Analysing Trends, Classifying Strategies, and Future Directions
  12. Hambach Manuel, Volkmer Dirk (2017-02)
    Properties of 3D Printed Fiber-Reinforced Portland-Cement-Paste
  13. Kazemian Ali, Yuan Xiao, Cochran Evan, Khoshnevis Behrokh (2017-04)
    Cementitious Materials for Construction-Scale 3D Printing:
    Laboratory Testing of Fresh Printing Mixture
  14. Khalil Noura, Aouad Georges, Cheikh Khadija, Rémond Sébastien (2017-09)
    Use of Calcium-Sulfoaluminate-Cements for Setting-Control of 3D Printing Mortars
  15. Khoshnevis Behrokh, Hwang Dooil, Yao Ke, Yeh Zhenghao (2006-05)
    Mega-Scale Fabrication by Contour Crafting
  16. Kondepudi Kala, Subramaniam Kolluru (2021-02)
    Formulation of Alkali-Activated Fly-Ash-Slag Binders for 3D Concrete Printing
  17. Kristombu Baduge Shanaka, Navaratnam Satheeskumar, Zidan Yousef, McCormack Tom et al. (2021-01)
    Improving Performance of Additive Manufactured Concrete:
    A Review on Material Mix-Design, Processing, Inter-Layer Bonding, and Reinforcing-Methods
  18. Le Thanh, Austin Simon, Lim Sungwoo, Buswell Richard et al. (2012-01)
    Mix-Design and Fresh Properties for High-Performance Printing Concrete
  19. Ler Kee-Hong, Ma Chau-Khun, Chin Chee-Long, Ibrahim Izni et al. (2024-08)
    Porosity and Durability Tests on 3D Printing Concrete:
    A Review
  20. Li Zhanzhao, Hojati Maryam, Wu Zhengyu, Piasente Jonathon et al. (2020-07)
    Fresh and Hardened Properties of Extrusion-Based 3D Printed Cementitious Materials:
    A Review
  21. Li Zhijian, Wang Li, Ma Guowei (2020-01)
    Mechanical Improvement of Continuous Steel-Micro-Cable-Reinforced Geopolymer Composites for 3D Printing Subjected to Different Loading Conditions
  22. Li Yu, Wu Hao, Xie Xinjie, Zhang Liming et al. (2024-02)
    FloatArch:
    A Cable-Supported, Unreinforced, and Re-Assemblable 3D Printed Concrete Structure Designed Using Multi-Material Topology-Optimization
  23. Lim Sungwoo, Buswell Richard, Le Thanh, Austin Simon et al. (2011-07)
    Developments in Construction-Scale Additive Manufacturing Processes
  24. Lim Sungwoo, Buswell Richard, Le Thanh, Wackrow Rene et al. (2011-07)
    Development of a Viable Concrete Printing Process
  25. Liu Yi, Wang Li, Yuan Qiang, Peng Jianwei (2023-09)
    Effect of Coarse Aggregate on Printability and Mechanical Properties of 3D Printed Concrete
  26. Luo Qiling, Yu Ke-Ke, Long Wujian, Zheng Shuyi et al. (2024-07)
    Influence of Different Types of Superabsorbent Polymers on Fresh Mechanical Properties and Inter-Layer Adhesion of 3D Printed Concrete
  27. Ma Lei, Jia Zijian, Chen Yuning, Jiang Yifan et al. (2024-03)
    Water Loss and Shrinkage Prediction in 3D Printed Concrete with Varying w/b and Specimen Sizes
  28. Ma Guowei, Li Zhijian, Wang Li (2017-12)
    Printable Properties of Cementitious Material Containing Copper-Tailings for Extrusion-Based 3D Printing
  29. Ma Guowei, Wang Li (2017-08)
    A Critical Review of Preparation Design and Workability Measurement of Concrete Material for Large-Scale 3D Printing
  30. Malaeb Zeina, Sakka Fatima, Hamzeh Farook (2019-02)
    3D Concrete Printing:
    Machine Design, Mix Proportioning, and Mix Comparison Between Different Machine Setups
  31. Marchment Taylor, Sanjayan Jay (2019-10)
    Mesh Reinforcing Method for 3D Concrete Printing
  32. Marchment Taylor, Sanjayan Jay (2021-04)
    Reinforcement Method for 3D Concrete Printing Using Paste-Coated Bar Penetrations
  33. Mechtcherine Viktor, Bos Freek, Perrot Arnaud, Silva Wilson et al. (2020-03)
    Extrusion-Based Additive Manufacturing with Cement-Based Materials:
    Production Steps, Processes, and Their Underlying Physics
  34. Mechtcherine Viktor, Nerella Venkatesh, Will Frank, Näther Mathias et al. (2019-08)
    Large-Scale Digital Concrete Construction:
    CONPrint3D Concept for On-Site, Monolithic 3D Printing
  35. Moeini Mohammad, Hosseinpoor Masoud, Yahia Ammar (2020-05)
    Effectiveness of the Rheometric Methods to Evaluate the Build-Up of Cementitious Mortars Used for 3D Printing
  36. Moelich Gerrit, Kruger Jacques, Combrinck Riaan (2021-09)
    Modelling the Inter-Layer Bond Strength of 3D Printed Concrete with Surface Moisture
  37. Nematollahi Behzad, Vijay Praful, Sanjayan Jay, Nazari Ali et al. (2018-11)
    Effect of Polypropylene Fiber Addition on Properties of Geopolymers Made by 3D Printing for Digital Construction
  38. Nodehi Mehrab, Aguayo Federico, Nodehi Shahab, Gholampour Aliakbar et al. (2022-07)
    Durability Properties of 3D Printed Concrete
  39. Pan Tinghong, Jiang Yaqing, He Hui, Wang Yu et al. (2021-01)
    Effect of Structural Build-Up on Inter-Layer Bond Strength of 3D Printed Cement Mortars
  40. Panda Biranchi, Paul Suvash, Tan Ming (2017-07)
    Anisotropic Mechanical Performance of 3D Printed Fiber-Reinforced Sustainable Construction-Material
  41. Panda Biranchi, Ruan Shaoqin, Unluer Cise, Tan Ming (2018-11)
    Improving the 3D Printability of High-Volume Fly-Ash Mixtures via the Use of Nano-Attapulgite-Clay
  42. Panda Biranchi, Tan Ming (2018-03)
    Experimental Study on Mix Proportion and Fresh Properties of Fly-Ash-Based Geopolymer for 3D Concrete Printing
  43. Pasupathy Kirubajiny, Ramakrishnan Sayanthan, Sanjayan Jay (2023-01)
    3D Concrete Printing of Eco-Friendly Geopolymer Containing Brick Waste
  44. Paul Suvash, Zijl Gideon, Tan Ming, Gibson Ian (2018-05)
    A Review of 3D Concrete Printing Systems and Materials Properties:
    Current Status and Future Research Prospects
  45. Rahul Attupurathu, Santhanam Manu, Meena Hitesh, Ghani Zimam (2018-12)
    3D Printable Concrete:
    Mixture-Design and Test-Methods
  46. Ramesh Akilesh, Rajeev Pathmanathan, Sanjayan Jay, Mechtcherine Viktor (2024-06)
    In-Process Textile Reinforcement Method for 3D Concrete Printing and Its Structural Performance
  47. Razzaghian Ghadikolaee Mehrdad, Pan Zhu, Cerro-Prada Elena, Korayem Asghar (2024-06)
    Fresh and Hardened Properties of 3D Printing Mortar Modified by Halloysite-Nanotube
  48. Rehman Atta, Kim Jung-Hoon (2021-07)
    3D Concrete Printing:
    A Systematic Review of Rheology, Mix Designs, Mechanical, Microstructural, and Durability Characteristics
  49. Riaz Raja, Usman Muhammad, Ali Ammar, Majid Usama et al. (2023-06)
    Inclusive Characterization of 3D Printed Concrete in Additive Manufacturing:
    A Detailed Review
  50. Rushing Todd, Stynoski Peter, Barna Lynette, Chaar Ghassan et al. (2019-02)
    Investigation of Concrete Mixtures for Additive Construction
  51. Sanjayan Jay, Nematollahi Behzad, Xia Ming, Marchment Taylor (2018-04)
    Effect of Surface Moisture on Inter-Layer Strength of 3D Printed Concrete
  52. Shakor Pshtiwan, Nejadi Shami, Sutjipto Sheila, Paul Gavin et al. (2020-01)
    Effects of Deposition-Velocity in the Presence-Absence of E6-Glass-Fiber on Extrusion-Based 3D Printed Mortar
  53. Sun Xiaoyan, Wang Qun, Wang Hailong, Chen Long (2020-03)
    Influence of Multi-Walled Nanotubes on the Fresh and Hardened Properties of a 3D Printing PVA Mortar Ink
  54. Tao Yaxin, Zhang Yi, Schutter Geert, Tittelboom Kim (2024-01)
    Interfacial Bonding of 3D Printable Concrete with Chemically Reactive Coating for Automatic Repair
  55. Tarhan Yeşim, Şahin Remzi (2021-05)
    Fresh and Rheological Performances of Air-Entrained 3D Printable Mortars
  56. Tittelboom Kim, Mohan Dhanesh, Šavija Branko, Keita Emmanuel et al. (2024-08)
    On the Micro-and Meso-Structure and Durability of 3D Printed Concrete Elements
  57. Wang Yuting, Chen Meng, Zhang Tong, Zhang Mingzhong (2024-07)
    Hardening Properties and Microstructure of 3D Printed Engineered Cementitious Composites Based on Limestone-Calcined-Clay-Cement
  58. Wang Zhibin, Jia Lutao, Deng Zhicong, Zhang Chao et al. (2022-08)
    Bond Behavior Between Steel-Bars and 3D Printed Concrete:
    Effect of Concrete Rheological Property, Steel-Bar Diameter and Paste-Coating
  59. Wang Li, Ma Guowei, Liu Tianhao, Buswell Richard et al. (2021-07)
    Inter-Layer Reinforcement of 3D Printed Concrete by the In-Process Deposition of U-Nails
  60. Weng Yiwei, Ruan Shaoqin, Li Mingyang, Mo Liwu et al. (2019-06)
    Feasibility Study on Sustainable-Magnesium-Potassium-Phosphate Cement-Paste for 3D Printing
  61. Xiao Jianzhuang, Chen Zixuan, Ding Tao, Zou Shuai (2021-10)
    Bending Behavior of Steel-Cable-Reinforced 3D Printed Concrete in the Direction Perpendicular to the Interfaces
  62. Xu Yanqun, Yuan Qiang, Li Zemin, Shi Caijun et al. (2021-09)
    Correlation of Inter-Layer Properties and Rheological Behaviors of 3DPC with Various Printing Time Intervals
  63. Yao Hao, Xie Zonglin, Li Zemin, Huang Chuhan et al. (2021-11)
    The Relationship Between the Rheological Behavior and Inter-Layer Bonding Properties of 3D Printing Cementitious Materials with the Addition of Attapulgite
  64. Yu Ke-Ke, Zhao Tai-Qi, Lou Qi-Ling, Ping Yang (2024-10)
    Recycled PET Fibers with Dopamine Surface Modification for Enhanced Inter-Layer Adhesion in 3D Printed Concrete
  65. Zareiyan Babak, Khoshnevis Behrokh (2017-08)
    Effects of Interlocking on Inter-Layer Adhesion and Strength of Structures in 3D Printing of Concrete
  66. Zhang Chao, Deng Zhicong, Chen Chun, Zhang Yamei et al. (2022-03)
    Predicting the Static Yield-Stress of 3D Printable Concrete Based on Flowability of Paste and Thickness of Excess-Paste-Layer
  67. Zhang Daobo, Feng Peng, Zhou Peizhao, Xu Weiguo et al. (2023-06)
    3D Printed Concrete Walls Reinforced with Flexible FRP Textile:
    Automatic Construction, Digital Rebuilding, and Seismic Performance
  68. Zhou Wen, Zhu He, Hu Wei-Hsiu, Wollaston Ryan et al. (2024-02)
    Low-Carbon, Expansive Engineered Cementitious Composites (ECC) In the Context of 3D Printing
  69. Zhu Binrong, Nematollahi Behzad, Pan Jinlong, Zhang Yang et al. (2021-04)
    3D Concrete Printing of Permanent Formwork for Concrete Column Construction
  70. Zou Mengtong, Liu Chuanbei, Zhang Keying, Li Wuqian et al. (2023-11)
    Evaluation and Control of Printability and Rheological Properties of 3D Printed Rubberized Concrete

11 Citations

  1. Agegn Adamu, Regassa Yohannes, Angassa Kenatu, Mekonnen Kebede (2026-01)
    Systematic Review on 3D Concrete Printing Technology:
    Breakthroughs and Challenges
  2. Tong Zhongling, Guan Qingtao, Elabbasy Ahmed, Ateah Ali et al. (2025-12)
    Empowering 3D Printed Concrete:
    Discovering the Impact of Steel Fiber Reinforcement on Mechanical Performance
  3. Sunny Akash, Jayaprakash Jaganathan (2025-12)
    Unveiling the Printing Success of Concrete 3D Printed Models:
    A Simulation Study with Voxel Print and Abaqus Using Design of Experiments
  4. Soshinskiy Olexander, Rashkevich Nina, Shakhov Stanislav, Melnychenko Andrii (2025-11)
    Formulating a Calculation Methodology for Assessing the Strength Characteristics of Building Structures Constructed with a Construction 3D Printer
  5. Ataei Sarah, Jafari Amirhosein (2025-10)
    Comparative Environmental Impact Assessment of 3D Concrete Printing and Precast Techniques in Bridge Construction:
    A Case Study Analysis
  6. Tarhan İsmail, Tarhan Yeşim (2025-09)
    Nonlinear In-Plane Response of 3D-Printed Concrete Walls with Varied Infill Patterns:
    Experimental Mix Design and Numerical Structural Assessment
  7. Chen Wenguang, Liang Long, Ye Junhong, Liu Lingfei et al. (2025-09)
    Machine Learning-Enabled Performance-Based Design of Three-Dimensional Printed Engineered Cementitious Composites
  8. Wang Cheinfei, Lian Junyin, Fang Yunhui, Fan Guangming et al. (2025-08)
    Rheological Optimization of 3D-Printed Cementitious Materials Using Response Surface Methodology
  9. Ding Tao, Dong Haining, Sikora Paweł, Lin Guan (2025-07)
    3D Printed Concrete Reinforced with Flexible Fiber Reinforced Polymer Strips or Grids:
    Concept and Bond Tests
  10. Tarhan Yeşim, Tarhan İsmail, Perrot Arnaud (2025-05)
    Flexural Performance of Glass Fiber Textile Reinforced 3D Printed Concrete
  11. Zhu Wenxuan, Liu Chao, Zhang Yu, Zhang Yunsheng et al. (2025-05)
    Rheological Performance Regulation and Material Optimization of Manufactured Sand Concrete in 3D Printing

BibTeX
@article{nan_qiao_leng_bai.2025.ASRi3PC,
  author            = "Bo Nan and Youxin Qiao and Junjie Leng and Yikui Bai",
  title             = "Advancing Structural Reinforcement in 3D Printed Concrete: Current Methods, Challenges, and Innovations",
  doi               = "10.3390/ma18020252",
  year              = "2025",
  journal           = "Materials",
  volume            = "18",
  number            = "2",
  pages             = "252",
}
Formatted Citation

B. Nan, Y. Qiao, J. Leng and Y. Bai, “Advancing Structural Reinforcement in 3D Printed Concrete: Current Methods, Challenges, and Innovations”, Materials, vol. 18, no. 2, p. 252, 2025, doi: 10.3390/ma18020252.

Nan, Bo, Youxin Qiao, Junjie Leng, and Yikui Bai. “Advancing Structural Reinforcement in 3D Printed Concrete: Current Methods, Challenges, and Innovations”. Materials 18, no. 2 (2025): 252. https://doi.org/10.3390/ma18020252.