In-process embedded FRP grid for enhanced flexural performance of 3D-printed concrete plates
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Date
2026
Authors
Sun, H.-Q.
Zeng, J.-J.
Wu, C.-L.
Zhou, J.-K.
Zhuge, Y.
Dai, J.G.
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Journal article
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Composite Structures, 2026; 383:120132-1-120132-17
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Hou-Qi Sun, Jun-Jie Zeng, Chao-Lan Wu, Jie-Kai Zhou, Yan Zhuge, J.G. Dai
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Abstract
3D concrete printing technology is well suited to the construction of multi-material functionally graded concrete (FGC) structures. However, the layer‑by-layer deposition nature hinders the placement of conventional steel reinforcement, often resulting in poor flexural performance, while the inherently higher porosity of 3D-printed concrete (3DPC) can accelerate steel corrosion and compromise durability. To address these issues, this paper proposes a dual-nozzle system that is capable of the in-process embedment of corrosion-resistant fiber-reinforced polymer (FRP) grids during the fabrication of FGC using the 3DPC technology. The proposed method was evaluated using three‑point bending tests, mercury intrusion porosimetry (MIP), and scanning electron microscopy (SEM) to examine how FRP grid properties and printing parameters affect the flexural performance and the interface between printed layers. The results demonstrated that the embedded FRP grids significantly enhanced the flexural performance: flexural strength, energy absorption capacity, and ductility increased by up to 110.2%, 1744.3%, and 479.2%, respectively. Flexural performance improved with higher FRP grid content and extrusion rate, whereas it declined with increasing nozzle travelling speed, interval time, and nozzle standoff distance. MIP tests indicated that adding FRP grids raises interlayer interface porosity, especially pores larger than 5000 nm. SEM further confirmed that pore morphology at the FRP grid‑concrete interface critically influences flexural performance. The findings highlight that in-process embedded FRP grid reinforcement offers a practical pathway to automated, durable, and high-performance 3D-printed cementitious composites.
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© 2026 The Author(s). Published by Elsevier Ltd. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/)