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Providing additional water to the hydrating cementitious particles is essential to achieve the optimal mechanical performance of the low w/b concrete mixes preferred for 3D printing. This study incorporates superabsorbent polymers (SAP) and additional water in 3D printed concrete (3DPC) to promote the hydration process through delayed internal water release. The study shows that a retentive SAP modifies the rheological development by absorbing the pore fluid for a short period after printing. The absorption-induced stiffening increases the thixotropy and buildability by 49% and 25%, respectively. A retentive SAP increases the flexural strength and interlayer adhesion by 19% and 10%, respectively. This is due to the internal water release that promotes hydration. Evaporation of the interlayer moisture during the pass time has the opposite effect— evaporation reduces the interlayer adhesion. Based on this assumption, an analytical model is proposed. The model accounts for the pass time, bleeding, and the environmental evaporation rate to estimate the surface moisture and predict the lack of interlayer adhesion. In this study, the model accurately (RMSE = 2.5%) predicted an interlayer adhesion reduction from 30% to 50%. The interlayer adhesion results of other studies could also be predicted.

3D printed concrete exhibits a high magnitude and rate of plastic shrinkage (early age drying-induced shrinkage) compared to conventional cast concrete. This study investigated if restraining this shrinkage adversely affects the long-term durability and mechanical performance. Shrinkage was restrained by inserting reinforcement-like rods into the fresh concrete and exposing the specimen to a moderate evaporation rate . The interlayer bond strength, permeability and ion penetration of the unrestrained and restrained specimens were then compared. The results show that shrinkage causes shear strain concentrations at the interlayers due to a lack of particle interlocking and non-uniform pore water evaporation from the undulated evaporation face. Consequently, discrepancies in the transfer of shrinkage between layers occur, a phenomenon coined as interlayer slip. Evidence is presented of a 12% reduction in interlayer bond strength, a 70% higher permeability and 17% higher chloride ion penetration. These adverse consequences were due to interlayer slip and microcracking. Nonetheless, the durability of uncracked printed concrete is satisfactory, even with localised interlayer slip and microcracking.

Plastic shrinkage cracking (PSC) in concrete is related to the amount and rate of free pore water loss due to evaporation. This study investigates the influence of solar radiation on evaporation, the concrete temperature, plastic shrinkage and cracking. Literature suggests that exposure to solar radiation can either: increase the concrete temperature and, consequently, increase the rate of tensile strength gain resulting in less severe PSC or can increase the concrete temperature, resulting in a higher amount and rate of pore water loss to produce more severe PSC. The results of this study indicate that exposure to solar radiation significantly increases the amount and rate of pore water loss as well as plastic shrinkage and severity of PSC. To study PSC, many authors have estimated the evaporation rate from wind speed, air and concrete temperature and humidity which would result in significantly underestimating the actual evaporation rate if the concrete is exposed to moderate or high solar radiation. The accuracy of several radiation-related evaporation estimation models was evaluated by comparing the models to the actual rate of evaporation from specimens placed in the sun. A more accurate model was identified to estimate the evaporation in concrete specimens when exposed to solar radiation.

In the past, industrial waste and by-products have successfully been used to improve the properties of concrete. Used engine oil is a waste product which is burdensome to discard of and, due to frequent replacement, is produced in high quantities in the construction industry. The utilisation of used engine oil in concrete has shown potential as an admixture by reducing slump and increasing air-content. The main disadvantage is a reduction in long term compressive strength. This study investigates used engine oil (UEO) and used hydraulic oil (UHO) as admixtures to concrete, focusing on its effect on the rheological properties. Slump, air-content, compressive strength and rheometer tests are conducted for concrete containing different dosages of UEO and UHO. Adding low dosages of UEO and UHO have no noteworthy effect on the compressive strength, although increasing air-content and altering the rheological properties significantly. UEO and, to a lesser extent UHO, reduced the energy required to initiate flow (static yield stress) as well as decreased the plastic viscosity. Adding UEO has a similar effect on the static yield stress and plastic viscosity as increasing water content or substituting cement with a proportion of fly-ash. In conclusion, UEO shows potential as an air-entrainer or water-reducing admixture.

In concrete, early age pore water evaporation results in volumetric shrinkage that, if restrained, can cause plastic shrinkage cracking (PSC). 3D printed concrete (3DPC) is vulnerable to PSC due to a lack of formwork, minimal bleeding water, low aggregate to binder ratio and high quantities of fines in the mixture. A novel experimental method was developed to determine the PSC risk, evaluating the efficacy of PSC prevention measures and understanding the behaviour of PSC in early age 3DPC. This study evaluated the free shrinkage of 3DPC specimens as well as identified and systematically introduced sources of restraint to induce PSC. The free shrinkage results showed a rate of strain gain and peak strain significantly higher than commonly found in ordinary concrete. Severe cracking was observed when the shrinkage was restrained under a moderate evaporation rate. Cracks formed within the first 2 h after printing, earlier than in ordinary concrete. The proposed method was employed to study the fundamental behaviour of crack formation and propagation in 3DPC. The unique filament interlayer plane has a notable effect on the transfer of shrinkage deformation in the specimen. Differential horizontal deformation in consecutive layers and consequential interlayer slip was observed when the shrinkage was restrained. It is reasonable to conclude that interlayer slip caused by early age shrinkage has the potential to reduce the long-term interlayer bond strength and the durability of 3DPC.

The degradation of sisal fibre in a cement-based matrix due to the highly alkaline environment reduces the strength of the composite. In this research, to avert this degradation, alkaline treatment and acetylation were respectively performed with sodium hydroxide (NaOH) and Acetic Acid or Acetic Anhydride to improve the resistance of the fibre to alkaline attack. In addition, single fibre pull-out (SFP) tests were performed to evaluate the influence of chemical treatment on fibre strength, fibre-matrix interaction and also determine the critical fibre length. Specimens were tested in indirect tension (flexure) at 28 days to determine the strength of the composite. Additional ageing tests by extended curing in water at 24 °C, lime saturated hot water at 70 °C, and alternate cycles of wetting and drying were done. Aged samples were further tested at 90 days to evaluate the durability of the fibre. It was found that a combination of alkali treatment and acetylation was the most effective treatment condition, followed by that of alkali treatment at low concentrations of sodium hydroxide. At higher concentrations of sodium hydroxide, a significant reduction in strength was observed. Chemical treatment improves the durability of sisal fibres in concrete, albeit slight degradation still occurs.