Constitutive response and failure progression in digitally fabricated (3D printed) concrete under compression and their dependence on print layer height

Among the several geometry and process-related characteristics that determine the ultimate product quality of 3D printed concrete, one that has gained considerable importance is the height/thickness of the individual layers. Layer height dictates the number of interlayer interfaces, and influences the properties of the layer and the interfaces (both interlayer and inter-filament), for a given mixture and printer characteristics. This paper examines the influence of layer height on the constitutive response and failure of 3D printed concrete specimens under compression, investigated along the direction of layer build-up (or perpendicular to the layer interfaces), which is the dominant plane of loading in 3D printed walls and columns. Plain and steel fiber-reinforced wall elements with two different layer heights (7.5 mm and 15 mm) are printed, from which cylindrical and prismatic specimens are extracted and tested. The uniaxial compressive strength is seen to decrease with increasing layer height. The constitutive relationships of the specimens with different layer heights, along with volumetric strains, enable the extraction of crack initiation stress and unstable crack propagation stress, which are influenced by layer height and the presence of fiber reinforcement. The unstable crack propagation stress is lower than the peak stress, and it decreases with increasing layer height. Digital image correlation (DIC) is used to demonstrate the dominant effect of inter-filament interfaces on the crack propagation response and resultant failure.