Characterization of 3D Concrete Printed Horizontal Structures through Early-Age Deformation Analysis

Current limitations of 3D concrete printing primarily stem from the early-age mechanical properties of the material used. Beyond spatial geometry and printing speed, the characteristic parameters evolving in time such as Young’s modulus and cohesion exert a predominant impact on the stability of freshly printed elements. This study employs time-dependent finite element simulations using ABAQUS software to quantify early-age deformations of concrete printed elements. The primary objective is to anticipate material failure during printing and to optimize the material performance by precisely defining the required properties for desired geometries. The subsequent quantitative analysis of deformations was carried out using Digital Image Correlation (DIC), enabling a comparison between numerical and experimental results. Various printed elements with diverse geometries were scrutinized for validation purposes. This tracing methodological approach was developed to adapt the printing process to site conditions, enhancing inverse material characterization and quality control. Deformations were investigated through parametrically designed horizontal structure elements utilizing the Grasshopper module in Rhino software. The models were designed to be printed without supporting formwork at some point as displacements are particularly significant in such cases. The feasibility of printing at large overhangs promises broader application for 3D printing technology in concrete construction, especially in realizing unique structural shapes.