The objective of the contribution is to understand the fatigue bond behaviour of brass-coated high-strength micro steel fibres embedded in ultra-high performance concrete (UHPC). The study contains experimental pullout tests with variating parameters like load amplitude, fibre orientation, and fibre-embedded length. The test results show that fibres are generally pulled out of the concrete under monotonic loading and rupture partly under cyclic tensile loading. The maximum tensile stress per fibre is approximately 1176 N/mm², which is approximately one third of the fibre tensile strength (3576 N/mm²). The load-displacement curves under monotonic loading were transformed into a bond stress-slip relationship, which includes the effect of fibre orientation. The highest bond stress occurs for an orientation of 30° by approximately 10 N/mm². Under cyclic loading, no rupture occurs for fibres with an orientation of 90° within 100,000 load changes. Established S/N-curves of 30°- and 45°-inclined fibres do not show fatigue resistance of more than 1,000,000 load cycles for each tested load amplitude. For the simulation of fibre pullout tests with three-dimensional FEM, a model was developed that describes the local debonding between micro steel fibre and the UHPC-matrix and captures the elastic and inelastic stress-deformation behaviour of the interface using plasticity theory and a damage formulation. The model for the bond zone includes transverse pressure-independent composite mechanisms, such as adhesion and micro-interlocking and transverse pressure-induced static and sliding friction. This allows one to represent the interaction of the coupled structures with the bond zone. The progressive cracking in the contact zone and associated effects on the fibre load-bearing capacity are the decisive factors concerning the failure of the bond zone. With the developed model, it is possible to make detailed statements regarding the stress-deformation state along the fibre length. The fatigue process of the fibre-matrix bond with respect to cyclic loading is presented and analysed in the paper.

Ultra-high-performance fibre-reinforced concrete (UHPFRC) can preferably be used for lean and thin-walled structures due to its very high compressive strength. Based on the adverse relation between the increased load bearing capacities and the condensed dead weight of UHPFRC-structures, the impact of live loads in the design gets bigger and, in case of traffic loads, the effects of a cyclic loading have to be considered in more detail. In this context, this study investigated the material behaviour of UHPFRC, especially the tensile fatigue behaviour of high-strength micro steel fibres and the bond behaviour between those fibres and plain UHPC. The test programme included once tensile tests of high-strength micro steel fibres under monotonic and cyclic loading. Based on the test results, an S/N-curve was set up with the characteristic values. Furthermore, the test programme included pullout tests of fibre groups with different embedded lengths and orientations under monotonic and cyclic loading. It was observed that some fibres rupture under certain test configurations like the angle of orientation and the load amplitude.

The study described in this contribution contains a fundamental strategy to select geometries for dry joint profiles in 3D-printed concrete constructions. A database, here called the ‘joint catalogue’, contains a variety of joint types adapted from timber, steel, and bionic connections. Weighting factors and different criteria evaluate and score the various joint profiles (e.g., manufacturability, duration of manufacturing, and mechanical behaviour). Therefore, an algorithm sums up the scores leading to the preselection of better suitable profiles. The preselected joint profiles were afterwards analysed by the finite element method, determining the load capacity of the joint in a unit specimen. According to the joint catalogue, a smooth, triangular, truncated cone and arc joint profile appeared to be the optimal combination for dry joints in additive manufacturing of construction (AMC).