Flexural load performance for 3D-printed fiber reinforced cementitious composite beams: coupling materials with design optimization
Document Type
Article
Publication Date
6-1-2026
Abstract
The present study reported a framework that integrated materials sustainability and structural optimization to enhance the performance of 3D-printed fiber-reinforced cementitious composite (3DP-FRCC) beams. The framework systematically assessed the flexural behavior of 3DP-FRCC-optimized beams, examining different mixtures and reinforcement configurations (straight and truss-type) to advance sustainable building practices. Mechanical characterization was performed under varying loads for three distinct mix designs incorporating silica fume, blast-furnace slag, and ceramsite sand. This was done to explore their efficacy as alternative construction materials in fiber-reinforced 3D-printed concrete. Subsequently, the flexural load characteristics of optimized 3DP-FRCC beams for different reinforcement configurations were evaluated. The material characterization revealed that using ceramsite sand effectively reduced the structural weight at the expense of compressive strength, which was compensated by incorporating blast furnace slag and silica fume, while maintaining overall sustainability. The presence of truss reinforcement significantly improved performance, increasing the cracking load (5.5 to 5.9 times), peak load capacity (2.3 to 2.4 times), and deflection (' 4.95 times) compared to beams with straight longitudinal reinforcement. Implementing truss reinforcement enhanced the crack resistance by inhibiting propagation into the critical tie and strut members. The global warming potential analysis revealed that the optimized 3DP-FRCC beams achieved nearly an 85% reduction in carbon emissions compared to the conventional reference structure, underscoring the significant environmental benefits of integrating sustainable design into 3D-concrete printing. This study highlighted the potential of 3DP-FRCC-optimized structures for innovative sustainable design and reinforced the need for further exploration of material and structural optimization.
Publication Source (Journal or Book title)
Results in Engineering
Recommended Citation
Basha, S., Wu, Y., Xie, X., Hu, H., Su, Y., & Pasbani, M. (2026). Flexural load performance for 3D-printed fiber reinforced cementitious composite beams: coupling materials with design optimization. Results in Engineering, 30 https://doi.org/10.1016/j.rineng.2026.111051