Enhancing the performance of 3D-printed fiber-Reinforced mortar: synergistic effects of clays and bacterial cells as viscosity modifying agents

Abstract

The absence of standardized 3D concrete printing mixtures drives ongoing material exploration. This study investigates mineral and bio-based viscosity modifying agents (VMAs) application in fiber-reinforced cementitious mortar. Nano-montmorillonite, sepiolite, and bacterial cells function as supplementary materials, partially substituting cement with fly ash for sustainability assessment and compatibility evaluation in our study. Mechanical tests encompass compressive, flexural strength, and interlayer bonding in 3D-printed samples. Based on the results, incorporating 0.150% Polyamide (PA) fiber positively affected interlayer bonding strength and deceleration of the flow loss rate. Additionally, adding clays decreased workability and compressive strength but improved interlayer bonding and flexural properties. On the other hand, substituting 20% of cement with FA improved the flowability of the mixture and showed great compatibility with other materials during printing. Applying a cement paste layer was evaluated as a practical method for bond enhancement at the interface. Bacteria incorporation improved flexural strength but weakened interlayer bonding. However, the combination of bacteria and clays resulted in a superior improvement in mechanical properties. This study demonstrates clays and bacteria’s potential in enhancing rheological and mechanical features in cementitious fiber-reinforced mortar. Notably, this study introduces bacteria cells and sepiolite as rheology modifiers in 3D concrete printing for the first time. Additionally, it presents a novel dog-bone-shaped structure test for assessing interlayer bond performance.