Design of Earthquake-Resistant 3D Printed Concrete Walls (2026-03)¶

The structural application of 3D-printed concrete in seismic regions is constrained by limited large-scale experimental evidence and the lack of performance-based assessment frameworks compatible with codal design provisions. This study investigates the cyclic in-plane seismic response of 3DPC structural walls through a combined experimental and numerical approach, integrating full-scale testing with nonlinear finite element simulations. Three wall systems are examined: a plain mortar wall (3DPM), a wall incorporating a strain-hardening ductile concrete mix (3DPC-CF), and a modularly reinforced wall using the same ductile mix with prefabricated steel cages (3DPC-CFR). The walls are designed with an optimized internal infill geometry compatible with the printing process, and the reinforcement layout—comprising a centrally aligned grid and confined boundary reinforcement—is detailed in accordance with IS 13920:2016, ACI 318-19, and Eurocode 8. Quasi-static cyclic tests are conducted at the wall level, and the seismic response is evaluated in terms of lateral strength, deformation capacity, ductility, hysteretic energy dissipation, stiffness degradation, and failure mechanisms. Experimental observations are discussed in conjunction with corresponding nonlinear finite element micro-modelling results, enabling consistent interpretation of damage evolution and strength degradation. Relative to 3DPM, the 3DPC-CF wall demonstrates a 128% increase in peak lateral strength and a 40% increase in ductility, while the 3DPC-CFR wall exhibits the highest performance, with a 197% increase in strength, a 260% increase in displacement capacity, and stable post-peak response. Based on the wall-level response, a multi-linear backbone idealization is developed and employed within the numerical framework to predict the cyclic lateral strength of a full-scale single-storey 3DPC housing unit. The results confirm the applicability of the proposed experimental–numerical framework for seismic strength prediction of large-scale 3DPC structural systems, thereby supporting the development of safe, efficient, and structurally reliable additive manufacturing practices.