Advanced Finite Element Modeling of 3D-Printed Post-Tensioned Concrete Beams with Experimental Validation (2025-10)¶

This study presents a numerical modeling framework for analyzing the structural behavior of 3D-printed post-tensioned concrete structures. A finite element (FE) model was developed in ABAQUS to simulate the nonlinear mechanical response of a 10-meter segmented canopy, which comprises nine 3D-printed concrete segments. The modeling approach was first validated using three small-scale post-tensioned beams (each approximately 1 meter in length, consisting of five segments) before being extended to the full-scale canopy. The numerical model incorporates a homogenized material representation for 3Dprinted concrete, employing a concrete damage plasticity (CDP) model to capture inelastic behavior and damage evolution. Post-tensioning steel cables were modeled as solid elements with linear elastic properties, while contact interactions were precisely defined to represent the interface between concrete segments and post-tensioning tendons. Boundary conditions and loading scenarios were carefully implemented to replicate experimental configurations. The simulations were conducted using a static general analysis scheme with nonlinear geometry to account for large deformations and material nonlinearities. Model calibration was performed through comparative analysis with experimental data from full-scale testing conducted at CERIB, refining key parameters such as material properties, interface behavior, boundary constraints, and load application methods. The validated FE analysis accurately models stress distribution, deformation characteristics, and structural performance, demonstrating strong correlation with experimental observations. The findings confirm the efficacy of the FE model in capturing the structural response of 3D-printed, post-tensioned concrete structures, offering a computationally efficient and reliable methodology for evaluating their mechanical behavior.