Ultra-high-performance Fiber-reinforced Concrete Research Articles

Effects of specimen thickness and fiber length on tensile and cracking behavior of UHPFRC: Uniaxial tensile test and micromechanical modeling

This study aims to investigate the effects of specimen thickness and fiber length on the tensile and cracking behaviors of ultra-high-performance fiber-reinforced concrete (UHPFRC). To this end, a uniaxial tensile test was conducted with three specimen thicknesses (30, 50, and 100 mm) and two fiber lengths (13 and 20 mm), and the fiber orientation, dispersion and specimen void were quantitatively evaluated based on image recognition. The test results indicated that fiber orientation was improved with the decreased specimen thickness and increased fiber length. Meanwhile, the initial cracking and peak stress, capacity to limit cracking were enhanced with the decreased specimen thickness. A modified prediction model considering the wall effect, flattening and squeezing effect was developed to predict the probability density function p(θ) of fiber orientation angle. Additionally, the uniformity factor μ2 was introduced to predict crack number, and the relationship between the μ2 and parameter ψ = (Vf × lf/df)/t was determined. Furthermore, a model was developed to convert the main crack width into uniaxial tensile strain. All models and relationships were validated using test data. A micromechanical model that considered the predicted p(θ) and conversion model was established to predict the uniaxial tensile response of UHPFRC, which was also successfully validated using test data.

Triaxial compressive behavior of 3D printed PE fiber-reinforced ultra-high performance concrete

The layered deposition process of 3D concrete printing can lead to reduced mechanical properties at the interfaces between filaments. To address this limitation, external confinement devices, such as fiber-reinforced polymer (FRP) wrapping, have been proposed to enhance the strength of 3D-printed concrete concrete. Achieving this requires a solid understanding of the triaxial mechanical performance of 3D-printed concrete. This study presents an experimental investigation of the triaxial compressive behavior of 3D-printed PE fiber-reinforced ultra-high performance concrete (3DP-PEUHPC). A total of 16 pairs of concrete cubes were prepared, including mold-cast and 3D-printed specimens, and subjected to uniaxial and triaxial compression tests. The results revealed that the 3D-printed specimens exhibited either column-type or diagonal shear failures under triaxial compression. Weak bonding was observed at both filament-fusion and layer-fusion interfaces, with these weaker bonding interfaces, particularly when aligned parallel to the axial load, showing susceptibility to stress concentration and crack initiation. This led to a reduction in load-bearing capacity of the 3D-printed specimens compared to the mold-cast specimens. Importantly, as confining stresses increase, the difference in compressive strength between 3D-printed and mold-cast specimens decreases, highlighting the effectiveness of confinement in mitigating the directional weaknesses inherent in 3D-printed concrete. This paper also presents a modified model for predicting the axial stress-strain relationship of 3DP-PEUHPC under confinement, providing insights into the mechanism of FRP confinement on the compressive strength of 3D-printed concrete structures.

Two-lift concrete pavement with advanced fibre reinforced concrete as the top lift and roller compacted concrete as the bottom lift

Roller Compacted Concrete (RCC), developed for pavements and dams due to its low cement content, is constrained by limited fatigue resistance, making it suitable only for low-traffic pavements. This study aims to develop a high-fatigue-resistant Two-lift Concrete Pavement (TLCP) incorporating RCC, with three primary objectives: (i) constructing TLCP with a two-thirds RCC bottom layer and a one-third ultra-high-performance fiber-reinforced concrete (UHPFRC) or engineered cementitious composites (ECC) top layer, (ii) conducting fatigue testing on 225 specimens, and (iii) analyzing fatigue data using statistical methods to determine the best approach. Results showed that TLCP specimens had higher compressive and flexural strengths than RCC, though lower than UHPFRC or ECC. A graphical method was found most accurate for predicting fatigue life. TLCP with UHPFRC achieved 3.85–7.5 times greater fatigue life, while TLCP with ECC showed 2.63–5.96 times higher fatigue life than RCC, with ECC offering significant cost savings.

Punching shear behavior of ultra-high-performance fiber-reinforced concrete and normal strength concrete composite flat slabs

This paper presents the results of tests on flat slabs with partial application of ultra-high-performance fiber-reinforced concrete (UHPFRC) mixtures to improve the punching shear capacity of slab-column connections. One normal strength concrete (NSC) slab and two UHPFRC slabs were tested as a reference for tests on 12 UHPFRC-NSC composite slabs with full depth UHPFRC in the center area of the NSC slab. The main test parameters were the steel fiber volume (0.8 % and 1.6 % volume fractions) and the dimensions of UHPFRC mixtures. The load-column displacement curves, crack patterns, slab rotations at failure, and failure loads are presented and discussed. The failure loads are compared with estimates obtained following the yield line analysis, design codes, and other theoretical models. Test results showed that the use of UHPFRC mixtures led to an increase in initial stiffness, punching shear strength, and deformation capacity, along with a change in the slab failure mode. The shear capacity of the slab improved proportionally to the increase in the dimension of the UHPFRC. These tests confirmed the effectiveness of the UHPFRC mixtures as an alternative to enhance the punching shear capacity for slab-column connections.

Fire resistance of 3D printed ultra-high performance concrete panels

Ultra-high performance fiber-reinforced concrete (UHPFRC) is highly suitable for 3D concrete printing (3DCP) due to its high flexural strength, thereby reducing the need for reinforcements. However, UHPFRC is susceptible to spalling under exposure to fire, limiting its application as structural members. In this paper, the effect of 3D printing process on the fire behavior of UHPFRC is studied, benchmarking against mold-cast panels. The insulation, integrity, and structural adequacy of the panels are investigated using the heat transfer mechanisms, failure modes, and the post-fire compressive strength of the panels, respectively. The presence of interlayers reduced the spalling of UHPFRC under fire and improved the structural integrity of 3D printed specimens compared to mold-cast specimens. Further, the addition of 0.5 % polypropylene (PP) fibers eliminated the interlayer delamination and spalling in 3D printed UHPFRC panels. Similarly, 3D printed panels showed improved structural adequacy than mold-cast specimens. The residual compressive strength of 3D printed UHPFRC panels after being exposed to fire was observed to be above 50 % of the initial mean compressive strength. However, the insulation property of 3D printed panels was reduced compared to that of the mold-cast counterparts due to the high rate of heat transfer via the porous interlayers. The addition of PP fibers improved the insulation resistance of the interlayer region and surface of the 3D printed panels. The strength anisotropy of the 3D printed UHPFRC reduced significantly following the fire exposure. Further, the thermal bowing of 3D printed panels was higher with an increased dosage of PP fibers due to the increase in the thermal strain of UHPFRC. Therefore, adequate care must be given in the design of 3D printed structures for potential fire resistant wall, slab, and façade elements.

Experimental and analytical investigations on bond–slip behavior of steel reinforcement in UHPFRC considering yielding

AbstractThe bond behavior between ultra‐high‐performance fibre‐reinforced concrete (UHPFRC) and steel rebars plays an important role in the load‐bearing capacity and serviceability of structural members. A suitable bond–slip model is essential for predicting the load resistance and deformation capacity of members, after cracking of the UHPFRC. This paper studies the bond strength between ribbed steel bars and the surrounding UHPFRC before and after yielding of the steel reinforcement. To determine the corresponding bond–slip relationship, pull‐out tests, with varying embedment lengths of the reinforcement, namely 2 times and 10 times the rebar diameter, and diameter of reinforcing bars ranging from 10 mm to 16 mm were conducted. The bond stress, strain and slip along the embedment length of the steel rebars were measured by strain gauges and displacement transducers. Based on the test data, a bond stress–slip model was derived before (elastic stage) and after (inelastic stage) yielding of the reinforcement. The slip at the yield point is suggested through theoretical equations. The post‐yield bond–slip model is based on yield bond stress and frictional bond stress. The two‐part model was validated through iterative procedures and is able to predict the applied force, bond stress and strain distribution along the reinforcing bar. A comparison between the test data and analytical results demonstrates a good predictive capacity on the bond behavior of reinforcement in UHPFRC both before and after yielding of the reinforcement.

Experimental characterization of indented dry connections for precast double‐curved concrete shells

AbstractThis paper presents the experimental validation of a connections system to connect segmented precast long‐span thin‐shell structures made with lightweight ultra‐high‐performance fiber‐reinforced concrete (UHPFRC). The work comprises the segmentation of the large‐span ultra‐thin shell to meet the requirements of prefabrication (construction and transport limitations), and the design and characterization of the connections. Once the assembling of the shell required the use of post‐tensioned unbonded prestressing, an indented dry connection was chosen. The connections are experimentally characterized with in‐plane and out‐of‐plane shear tests for different prestressing levels. The results are presented and discussed, demonstrating the balanced behavior of the indented dry connection under shear loading. The connections exhibited high ductility in shear, capitalizing on the use of a UHPFRC to fabricate the shell. The prestressing also demonstrated its efficacy, significantly enhancing both the stiffness and the capacity of the indented dry connection.

Design, modelling and optimisation of ultra high-performance fibre reinforced concrete incorporating waste materials

The adoption of ultra-high-performance fibre-reinforced concrete (UHPFRC) in modern-day construction has gradually increased because of its high compressive and flexural strength at the early production ages. The UHPFRC's high initial cost discourages its production and widespread use. This cost can be reduced by incorporating waste materials in UHPFRC production. This study aims to design, model, and optimise a three-day heat-cured UHPFRC incorporating waste materials. To produce a sustainable UHPFRC mixture, this study combines rice husk ash (RHA) and recycled tire steel fibre (RTSF) as the primary waste components, with Portland limestone cement, river sand, superplasticizer, and water. The concrete is heat-cured in a hot water bath at 90 °C for 3 days, resulting in rapid strength development. A D-optimal mixture design technique was used to optimise the mix proportions, and mathematical models were developed to predict the compressive and flexural strengths. The non-significant lack-of-fit results and the high values of coefficient of determination (R2) revealed the accuracy of the models in predicting the compressive and flexural strengths of the UHPFRC. The low values of standard deviation (SD) and coefficient of variation (CV) confirmed the consistency and reliability of the prediction models. A numerical optimisation revealed that it is possible to design a UHPFRC mixture with a lower cement content of 38.29% of the UHPFRC mix, resulting in a compressive strength of 117.62 MPa and a flexural strength of 36.32 MPa. The study reveals that integrating RHA and RTSF into UHPFRC can yield high-performance properties, offering innovative solutions for resource scarcity and environmental sustainability in the construction sector.

Investigation of the dynamic mechanical response of corroded ultra-high performance fiber reinforced concrete (UHPFRC) with initial defects

This study addresses the dynamic mechanical response of the corroded ultra-high-performance fiber-reinforced concrete (UHPFRC) with initial defects, considering the possibility of corrosion deterioration induced by various pre-existing cracks during the long-term service life. For this purpose, an integrated accelerated corrosion method and Split Hopkinson Pressure Bar (SHPB)/high-speed camera etc. techniques are employed. Results show that increasing pre-impacting damage promotes the crack density and maximum width by 32.4%–62.3 % and 1.11–1.8 times, respectively. In terms of mechanical properties, coupling damages of initial defects and corrosion have adverse effects on the dynamic mechanical response. Typical fib Model Code 2010 applies to predict the DIF evolution of the corroded UHPFRC with initial defects. Numerous shear cracks are created at an angle along the weak interface as the corroded specimens with initial defects are again subjected to axial loading, revealing the associated failure mechanism. These results shed light on the dynamic response of corroded UHPFRC containing various initial defects and the failure mechanism gives some reference to service status evaluation.

Development and properties of cost-effective self-sensing Ultra-High Performance Fiber-Reinforced Concrete (UHPFRC) incorporating steel slags

This study examined the electrical and self-sensing capacities of ultra-high performance fiber-reinforced concrete （UHPFRC） with and without steel slag powder. The inclusion of steel slags provides a reliable way to enhance the electrically conductive and self-sensing capabilities of UHPFRC, which is composed of cement, silica fume, and steel fiber. The conductibility of UHPFRC and its response to external loading were investigated. Additionally, through 3D analysis of fiber structure and pore distribution, the conductive mechanisms were revealed. The results show that the addition of steel slags powder (SSP) can improve both mechanical properties and flowability. The maximum fractional change in electrical resistivity under compressive and flexural loads reached 37.6 % and 54.1 %, respectively. However, the conductive model under compressive loading differs from that under flexural loading. Furthermore, an analysis of carbon emissions and material costs revealed that using SSP reduced carbon emissions by 45.2–96.4 % and lowered costs by 41.8–88.8 %, making this approach both economically and environmentally advantageous.

Fatigue and Ultimate Strength Evaluation of GFRP-Reinforced, Laterally-Restrained, Full-Depth Precast Deck Panels with Developed UHPFRC-Filled Transverse Closure Strips

A depth precast deck panel (FDDP) is one element of the prefabricated bridge element and systems (PBES) that allows for quick un-shored assembly of the bridge deck on-site as part of the accelerated bridge construction (ABC) technology. This paper investigates the structural response of full-depth precast deck panels (FDDPs) constructed with new construction materials and connection details. FDDP is cast with normal strength concrete (NSC) and reinforced with high modulus (HM) glass fiber reinforced polymer (GFRP) ribbed bars. The panel-to-girder V-shape connections use the shear pockets to accommodate the clustering of the shear connectors. A novel transverse connection between panels has been developed, featuring three distinct female-to-female joint configurations, each with 175-mm projected GFRP bars extending from the FDDP into the closure strip, complemented by a female vertical shear key and filled with cementitious materials. The ultra-high performance fiber reinforced concrete (UHPFRC) was selectively used to joint-fill the 200-mm transverse joint between adjacent precast panels and the shear pockets connecting the panels to the supporting girders to ensure full shear interaction. Two actual-size FDDP specimens for each type of the three developed joints were erected to perform fatigue tests under the footprint of the Canadian Highway Bridge Design Code (CHBDC) truck wheel loading. The FDDP had a 200-mm thickness, 2500-mm width, and 2400-mm length in traffic direction; the rest was over braced steel twin girders. Two types of fatigue test were performed: incremental variable amplitude fatigue (VAF) loading and constant amplitude fatigue (CAF) loading, followed by monotonically loading the slab ultimate-to-collapse. It was observed that fatigue test results showed that the ultimate capacity of the slab under VAF loading or after 4 million cycles of CAF exceeded the factored design wheel load specified in the CHBDC. Also, the punching shear failure mode was dominant in all the tested FDDP specimens.

Axial compressive behavior of circular RC stub columns jacketed by UHPC and UHPFRC

This study investigated the axial compressive behavior of circular reinforced concrete (RC) stub columns jacketed by ultra-high performance concrete (UHPC) and ultra-high performance fiber reinforced concrete (UHPFRC). Eighteen composite columns were tested under compressive loadings on the entire section and only the RC section, while three control RC columns were tested under axial compression. Loading on the entire section exhibited a higher maximum compressive load and better expansion restraint than loading on the RC section. Adding 1 % and 2 % steel fibers by volume significantly increased the maximum compressive load and ductility index. However, the difference between 1 % and 2 % fiber content was not substantial. Maximum compressive load when loading on the entire section surpassed that when loading on the RC section, increasing by 75.6 %, 76.18 %, and 76.78 % for 0 %, 1 %, and 2 % steel fiber volume, respectively. Loading on the RC section led to faster cracking and failure, resulting in more tensile stress and lateral strain in the UHPC and UHPFRC jackets. Conversely, loading on the entire section maintained the expansion restraint even after reaching the maximum load. Columns with higher steel fiber volume demonstrated a greater enhancement in strength and ductility. Furthermore, a finite element model (FEM) using ABAQUS software was built to identify the experiments. Material models for UHPC, UHPFRC, and NSC core were proposed. The comparison between FEM and the test results shows that the FEM can predict accurately the behavior of tested columns. Based on developed FEM, a parametric study with the change of two variables, including the thickness and the compressive strength of the UHPC and UHPFRC layers, was conducted. The increase in the thickness of the UHPC or UHPFRC layer led to a remarkable increase in the maximum compressive load and ductility, indicating the importance of the thickness of the UHPC and UHPFRC jackets in restraining the expansion of the RC core. However, increasing the compressive strength of UHPC and UHPFRC had minimal impact on the maximum compressive load and ductility. Derived from these findings, UHPC and UHPFRC can be considered alternative material to provide lateral confinement to RC columns in addition to the traditional materials, indicating the potential application in strengthening or repairing damaged RC columns

Study of the mechanical properties, durability, and microstructure of an ultra-high-performance fiber-reinforced concrete containing recycled fillers

Abstract In this article, a specific mix design of the ultrahigh-performance fiber-reinforced concrete (UHPFRC) was proposed and applied for Algerian materials that are currently in use. In the absence of a general mix design that limits their use and reuses waste materials, the present mix design can help reduce the high manufacturing cost of this type of concrete and make it more environmentally friendly. Here, we have looked for a reference mix design based on local ordinary aggregates, and then, we introduced the recycled fillers from ceramic waste and granulated blast furnace slag into our mix design, and we studied their effects on the properties of the fresh state (density, workability, and air content) and in the hardened state, namely compressive and flexural tensile strength, modulus of elasticity, ultrasonic and sclerometer resistance, as well as durability tests (capillary and immersion absorption, porosity, and chemical resistance). The microstructure analysis was carried out using scanning electron microscopy, complemented by energy-dispersive X-ray spectroscopy. Comparison of the results of UHPFRC using ceramic waste and slag fillers with the control UHPFRC after 28 days shows an increase in compressive strengths of approximately 8 and 7%, respectively, as well as an increase in flexural tensile strengths of 17 and 2%, respectively. In addition, there was a decrease in porosity of 17 and 42%, respectively. The results reveal that it is possible to produce UHPFRC based on local materials and improve its performance, durability, and microstructure with recycled fillers.

Experimental study on bond performance of interface between concrete and UHPFRC incorporating recycled tyre fibers

This paper conducted single-side shear tests on 27 groups specimens with dimensions of 100 mm × 100 mm × 40 mm to investigate the shear bond performance of the interface between concrete and ultra-high performance fiber reinforced concrete (UHPFRC) incorporating recycled tyre fibers, as an eco-friendly and cost-effective material. The effects of concrete strength, interface roughness, interface adhesives, and the substitution rates of recycled tyre fibers in UHPFRC were analyzed by Response Surface Methodology model. The findings revealed the existence of two failure modes, specifically interface failure and concrete failure, and it was observed that the shear load-slip curves exhibited a similar trend across various specimens, characterized by a gradual increase accompanied by an escalating growth rate. The higher concrete strength and interface roughness as well as the lower substitution rates of recycled tyre fibers would enhance the shear bond strength, while interface adhesives had minor effects. Based on the micro-bonding mechanism and experimental data, two theoretical models for shear bond strength and shear load-slip curves were established, demonstrating good agreement between prediction and experimental results. Considering the shear bond strength, the environmental and economic analysis was carried out, and UHPFRC with 25 % substitution rates of recycled tyre fibers exhibited the best benefits.

Shear behavior of pre-damaged RC beams strengthened with UHPFRC-CFRP grid layer

Ultra-high performance fiber reinforced concrete (UHPFRC), incorporating recycled tyre fibers, and carbon fiber-reinforced polymer (CFRP) grid were utilized to strengthen the pre-damaged reinforced concrete beams caused by coupling action of sustained loads and marine environment. The failure modes, characteristic loads, deflection features, and strain behavior of the strengthened beams with various types of UHPFRC, thicknesses of UHPFRC layers, CFRP grid ratios, and CFRP grid layout angles were investigated. The results indicated that they exhibited the typical shear failure, and their characteristic loads increased by 102 %–205 % compared to the undamaged beam. By increasing the thickness of the UHPFRC layer and the CFRP grid ratio, and adopting 45° CFRP layout angle, the cracking stiffness, energy absorption capacity, and shear force sharing ability would be further improved, while adopting the UHPFRC incorporating recycled tyre fibers would decrease the ductility. Moreover, analytical models were developed to calculate the ultimate loads, manifesting reasonable accuracy.

Enhancing the pull-out behavior of ribbed steel bars in CNT-modified UHPFRC using recycled steel fibers from waste tires: a multiscale finite element study

In the current investigation, the effect of recycled steel fibers recovered from waste tires on the pull-out response of ribbed steel bars from carbon nanotube (CNT)-modified ultrahigh performance fiber reinforced concrete (UHPFRC) was considered using the multiscale finite element method (MSFEM). The MSFEM is based on three phases to simulate CNT-modified UHPC, recycled steel fibers (RSFs), and ribbed steel bars. For the first time, a bar ribbed has been simulated to make more realistic assumptions, and RSFs have been distributed in the form of curved cylinders of different lengths and with a random distribution within a concrete matrix. The interaction of the steel bar and the RSFs with the concrete is applied by the cohesive zone model (CZM). After confirming the simulation outcomes with the experimental results, the steel bar pull-out response is investigated using load-slip curves. The impact of the CNT content, RSFs and their aspect ratio on the bond strength of steel bars and CNT-modified UHPFRC was assessed. The results show that using RSFs with a lower aspect ratio (steel microfibers) significantly improves the pull-out characteristics of steel bars from concrete. Accordingly, the proposed MSFEM is considered for simulating the effects of different parameters on the pull-out response of ribbed steel bars from concrete without causing complex, time-consuming, or costly experiments. The results indicated that waste fiber or RSF can be used as a toughening component in CNT-modified ultrahigh-performance concrete and as a replacement for industrial steel fibers.

Enhanced impact resistance of RC beams using various types of high-performance fiber-reinforced cementitious composites

This study investigates the impact resistance of reinforced concrete (RC) beams using various types of high-performance fiber-reinforced cementitious composites (HPFRCCs). A total of ten large-sized RC beams were fabricated and tested under static and impact loading conditions. Four different types of HPFRCCs with 2% by volume of steel, polyvinyl alcohol (PVA), and polyethylene (PE) fibers were considered. Ultra-high-performance fiber-reinforced concrete (UHPFRC) based on steel fibers demonstrated superior compressive and tensile strengths, while high-performance strain-hardening cementitious composite (HP-SHCC) based on PE fibers exhibited the highest strain and energy absorption capacities. The steel-bar reinforced (R-) UHPFRC and HP-SHCC beams showed superior flexural load capacity compared to reinforced normal strength concrete (R-NSC) beams. The highest ductility of 8.02 was found in the R-HP-SHCC beam, almost 5 times higher than that of the R-NSC beam. By drop hammer impact with a kinetic energy of 30 kJ, the R-UHPFRC beam completely failed due to its higher reaction load and lower structural ductility, while other RC beams made of NSC and HPFRCCs withstood the identical impact load. The R-HP-SHCC beam exhibited the best impact resistance, with a 29.1% lower maximum deflection compared to the R-NSC beam, and the largest residual load capacity after the impact damages. The R-HP-SHCC beam, despite being damaged, showed no reduction in flexural stiffness, yet it demonstrated an impressive 5.4% increase in load capacity compared to the undamaged beam.

Residual and damage properties of recycled brick powder-UHPFRC after high temperature

This research explores the impact of temperature, Recycled Brick Powder (RBP) replacement rates, and cooling methods on the mechanical characteristics of Ultra-high-performance fibre reinforced concrete (UHPFRC). Additionally, the material morphology and pore structure at elevated temperatures are thoroughly examined through Scanning Electron Microscope (SEM), X-ray diffraction (XRD), and mercury intrusion (MIP) tests. The findings reveal a pattern in the behavior of residual compressive strength, splitting tensile strength, and residual fracture energy as the target temperature increases. Initially, these properties increase and then decrease. Specifically, a threshold temperature of 400 °C is identified for compressive strength. For splitting tensile strength, threshold temperatures under natural cooling and water cooling are 400 °C and 200 °C, respectively. The threshold temperatures for residual fracture energy at substitution rates of 30%, 0%, and 50% with RBP are determined to be 400 °C, 200 °C, and 200 °C, respectively. when the RBP content is 30%, UHPFRC shows superior mechanical performance during the entire heating process. The performance under water cooling is weaker than that under natural cooling. Additionally, this study also proposed the evaluation and calculation models of residual compressive strength, residual splitting tensile strength and residual fracture energy considering the influence of simulated fire temperature.

Effects of coarse aggregates on 3D printability and mechanical properties of ultra high performance fiber reinforced concrete

3D printing of ultra high performance fiber reinforced concrete (UHPFRC) suffers from high shrinkage and poor interlayer properties. To mitigate these problems, this study develops new mixtures of UHPFRC materials containing coarse aggregates (CA), and critically examines their suitability for 3D printing (3DP). Totally 90 mould-cast and 3DP cylinder and beam specimens with different CA sizes (5–15 mm) and CA-binder ratios (0.3–0.5) were tested under compression and bending in three directions. The internal distribution and volume fractions of steel fibers and pores and the crack trajectories were characterized and analysed by micro X-ray CT scanned 3D images with 37 μm voxel resolution. The results show that adding more and bigger CAs into UHPFRC reduced the flowability but enhanced the buildability with desired extrudability achieved by adjusting 3D printing velocity. Although the compressive strength of the 3DP cylinders was 15–42 % lower than that of the mould-cast ones due to higher porosities, over 100 MPa strength was still achieved for all the 3DP cylinders with less than 10 % anisotropy. The CT images did not show evident interlayers and interlayer delamination under compression, indicating the new 3DP mixtures and printing parameters may have highly promoted cement hydration. The flexural strength of 3DP beams was 3–34 % higher than that of the cast ones, because most fibres were oriented in the printing or beam axis direction as represented by overall orientation indices calculated from CT images, thereby providing significant crack-bridging effects. The developed new mixtures are therefore well suited for 3D printing, particularly for fabrication of structural members with preferred fibre orientation, such as beams, slabs and shells.

Tensile constitutive relationship of UHPFRC from crack hinge based inverse analysis of notched beams

The structural applications of ultra-high performance fiber reinforced concrete (UHPFRC) in the construction industry can be promoted if proper constitutive models can be established for design. The various tension test methods for UHPFRC are being adopted to develop a complete stress-crack width or strain response for design. This study aims to understand the fracture behavior of UHPFRC by testing notched beams under a three-point bending configuration. This testing method helps in quality control checks and obtaining complete tension stress-crack opening behavior that can be used for design. The tensile stress-crack width response of UHPFRC is obtained using the load-CMOD response. The variables considered in this study are the volume fraction of fibers (1 % and 2 %), types of steel fibers (straight, combination of straight and hooked ended), and different cross-section dimensions (100×100×500 mm and 75×75×500 mm). A crack hinge-based inverse analysis method is used for UHPFRC to obtain the complete tensile stress-crack opening response. Stress-strain relations from inverse analysis and direct tension stress-crack opening results are compared and found to be similar. A data-driven tension stress-crack opening response UHPFRC is verified by simulating the girder's response using nonlinear finite element analysis (NFEA). Thus, the proposed inverse analysis can be used to obtain the multi-linear tensile stress-crack opening response which is adequate for capturing the structural response.