Integrating Continuous Mineral-Impregnated Carbon-Fibers into Digital Fabrication with Concrete (2024-03)¶

Digital concrete technologies, such as 3D concrete printing, have the potential to be game changers in the construction industry by reducing material consumption and offering a high level of automation. This not only provides a solution to the shortage of qualified workers but also makes construction sites more attractive workplaces. However, a significant challenge lies in integrating reinforcement, as traditional methods quickly reach their limits, particularly in geometrically complex, material-minimized structures. A potential solution is the use of mineral-impregnated carbon fibers (MCF) reinforcement, which offers high flexibility for 3D printing and better bonding to concrete compared to polymer coating, among other advantages. This article presents the integration of both freshly impregnated and cured MCF into two different concretes in the context of digital fabrication: 3D-printed concrete (3DPC) and self-compacting concrete (SCC). A particular focus was on the mechanical performance of MCF and MCF-reinforced concrete, as well as on the bond behavior between MCF and concrete. The second focus was on the production method. Therefore, samples were conventionally cast with SCC, while layered pouring or printing were used for producing specimens with 3DPC. It was found that the cured MCF exhibited a notably better bond, enhanced by 50%, to both 3DPC and SCC compared to freshly impregnated yarns. Subsequently, when subjected to uniaxial tensile loading, a significantly higher crack density and more uniform crack distribution could be observed in composites with cured MCF using digital image correlation (DIC). This effect was particularly pronounced in printed specimens and confirmed with computed tomography (CT) and environmental scanning electron microscope (ESEM) images.