Abstract. The article presents overview of additive manufacturing for concrete structures. Study focuses on specific tests used to determine suitability of high performance mixes for 3D printing. The tests include determination of compressive strength and evaluation of printing speed, extrudability and overall surface quality. Tests were performed on a HighPerformance Concrete mix with fine natural aggregate up to 2 mm. Mineral additives such as silica fume and fly ash, and superplasticizer were added to obtain proper consistency. The tests were performed using specially designed site consisting of Cartesian robot and pumping module. The design of printed paths were tailored for specific tests. The evaluation of pump performance was made by measuring pumped mix volume in time. The determination of correct pumping speed was made based on the visual quality of the printed layers. Study determines also the ability to print multilayered structures and printability window of proposed mix.

Technological developments in construction have led to an increase in the use of 3D modelling using CAD environments. The popularity of this approach has increased in tandem with developments in industry branches which use 3D printers to print concrete based printing materials in construction, as these allow freedom in shaping the dimensions of supporting elements. One of the biggest challenges for researchers working on this highly innovative technology is that of cement material shrinkage. This article presents the findings of research on an original method of measuring deformations caused by shrinkage in 3D-printed concrete elements. It also discusses the results of tests on base mixes, as well as comparisons between the influence of internal and external curing methods on the development of deformations and their final outcomes. Furthermore, the article discusses differences between deformations formed after seven days of hardening without curing, with those which occur when two common, traditional concrete curing methods are used: foil insulation and shrinkage reducing admixtures. In addition, the article examines the effects of internal curing on the 1, 7, 14, 21 and 28 day mechanical properties of concrete, in accordance with EN 196-1 and EN 12390-2. Studies have shown that the optimal amount of shrinkage reducing admixtures is 4% (in relation to the mass of cement), resulting in a reduction in total shrinkage of 23%. The use of a shrinkage reducing admixture in 3D-printed concrete does not affect their strength after 28 days, but slows the strength development during the first 7 days.

Despite the rapid development of 3D printing technology for cement composites, there are still a number of unsolved issues related to extrusion printing. One of them is proper mix design that allows for meeting criteria related to the printing of cementitious materials, such as pumpability, buildability, consistency on the materials, flowability and workability, simultaneously incorporating sustainable development ideas. In the case of mixes for 3D printing, the modification of the composition which increases the overall performance does not always go hand in hand with the reduction of negative environmental impact. The article presents the results of tests of eight mixtures modified with reactive and inert mineral additives designed for 3D printing. The mixes were evaluated in terms of their rheological and mechanical properties as well as environmental impact. Initial test results were verified by printing hollow columns up until collapse. Later, the differences between the compressive strength of standard samples and printed columns were determined. In order to summarize the results, a multi-faceted analysis of the properties of the mixes was carried out, introducing assessment indicators for its individual parameters. The article proves that appropriate material modification of mixes for 3D printing can significantly reduce the negative impact on the environment without hindering required 3D printing properties.

The presented research’s main objective was to develop the solution to the global problem of using steel waste obtained during rubber recovery during the tire recycling. A detailed comparative analysis of mechanical and physical features of the concrete composite with the addition of recycled steel fibres (RSF) in relation to the steel fibre concrete commonly used for industrial floors was conducted. A study was carried out using micro-computed tomography and the scanning electron microscope to determine the fibres’ characteristics, incl. the EDS spectrum. In order to designate the full performance of the physical and mechanical features of the novel composite, a wide range of tests was performed with particular emphasis on the determination of the tensile strength of the composite. This parameter appointed by tensile strength testing for splitting, residual tensile strength test (3-point test), and a wedge splitting test (WST), demonstrated the increase of tensile strength (vs unmodified concrete) by 43%, 30%, and 70% relevantly to the method. The indication of the reinforced composite’s fracture characteristics using the digital image correlation (DIC) method allowed to illustrate the map of deformation of the samples during WST. The novel composite was tested in reference to the circular economy concept and showed 31.3% lower energy consumption and 30.8% lower CO2 emissions than a commonly used fibre concrete.

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