Integrating Concrete 3D-Printing and UHPC Spray Techniques for Improved Structural Performance

Concrete 3D printing has gained rapid momentum as an emerging construction method offering reduced labor, faster construction, enhanced design flexibility, and minimal formwork requirements. However, its broader adoption in structural and bridge applications remains limited due to inherent weaknesses, including insufficient interlayer bonding, lack of conventional reinforcement, and early-age shrinkage cracking. These limitations reduce durability and restrict the load-carrying capacity of 3D-printed elements. Currently, Innovative Bridge Technologies/Accelerated Bridge Construction University Transportation Center (IBT/ABC-UTC) at Florida International University (FIU) has pioneered the development and successful field deployment of pneumatic spray technology for ultra-high-performance concrete (UHPC). This technique provides high-quality, rapid, and cost-effective strengthening solutions for deteriorated or deficient bridge components. Recent full-scale demonstrations have shown that sprayed UHPC can deliver superior bonding, enhanced toughness, and substantial improvements in structural performance. Despite the individual advancements of concrete 3D printing and UHPC spray technology, their integration remains largely unexplored. This project aims to evaluate the feasibility of using pneumatically sprayed UHPC as an external reinforcement layer for 3D-printed concrete components. The research will: (1) quantify the interfacial bond strength between sprayed UHPC and 3D-printed substrates; (2) assess structural enhancements through flexural strength, ductility, and post-cracking performance; and (3) investigate improvements in durability, including resistance to chloride penetration and freeze-thaw deterioration. The findings will provide foundational knowledge for advancing a hybrid construction approach that merges concrete 3D printing with sprayable UHPC. The expected outcomes will support the development of practical guidelines, promote adoption in bridge infrastructure, and enable future field-scale validation studies.

• Record URL:
  • https://abc-utc.fiu.edu/integrating-concrete-3d-printing-and-uhpc-spray-techniques-for-improved-structural-performance/

Language

• English

Project

• Status: Active
• Funding: $70,000.00
• Contract Numbers:

  69A3552348322

• Sponsor Organizations:

  Innovative Bridge Technologies/Accelerated Bridge Construction University Transportation Center (IBT/ABC-UTC)

  Florida International University
  Miami, FL  United States 

  Office of the Assistant Secretary for Research and Technology

  University Transportation Centers Program
  Department of Transportation
  Washington, DC  United States  20590
• Performing Organizations:

  Florida International University

  10555 West Flagler Street
  Miami, FL  United States  33174
• Principal Investigators:

  Ramezani, Mahyar

• Start Date: 20260101
• Expected Completion Date: 20270630
• Actual Completion Date: 0
• USDOT Program: University Transportation Centers

Subject/Index Terms

• TRT Terms: Adhesive bond strength; Bridge construction; Durability; Feasibility analysis; Reinforcing materials; Three dimensional printing; Ultra high performance concrete
• Subject Areas: Bridges and other structures; Construction; Highways; Materials;

Filing Info

• Accession Number: 01998451
• Record Type: Research project
• Source Agency: Innovative Bridge Technologies/Accelerated Bridge Construction University Transportation Center (IBT/ABC-UTC)
• Contract Numbers: 69A3552348322
• Files: UTC, RIP
• Created Date: Aug 7 2026 8:26AM