This paper investigates the effect of polypropylene (PP) fibres on the fresh and hardened properties of 3D-printed fibre-reinforced geopolymer mortars. Different percentages of PP fibres ranging between 0.25% and 1.00% by volume were added to an optimised geopolymer mixture. All samples showed reasonable workability and extrudability. In addition, shape-retention ability in the fresh state was investigated as a major requirement for 3D-printing. The compressive strength of the printed specimens was tested in the hardened state in three loading directions, viz. longitudinal, perpendicular, and lateral. The flexural strength of samples was also tested in the longitudinal and lateral directions. In addition, the interlayer bond strength was investigated. Fibre addition seems to influence compressive strengths positively only when the loading is perpendicular to the interface plane. This is due to the preferential fibre alignment parallel to the direction of extrusion. The addition of fibre significantly enhanced the flexural performance of the printed samples. The use of fibre dosages of 0.75 and 1.00 vol % caused deflection-hardening behaviour of the 3D-printed geopolymers and, hence, a significantly higher fracture energy in comparison to specimens without fibre or with lower fibre content. However, an increase in the fibre volume caused some minor reduction in interlayer bond strength. With respect to properties in the fresh state, higher fibre volumes caused better shape-retention ability in the printed samples. The results indicate the possibility of printing fibre-reinforced geopolymers which meet all the necessary properties in both the fresh and hardened states.

Incorporating reinforcement into the practice of digital concrete construction, often called 3D-concrete-printing, is a prerequisite for wide-ranging, structural applications of this new technology. Strain-Hardening Cement-based Composites (SHCC) offer one possible solution to this challenge. In this work, printable SHCC were developed and tested. The composites could be extruded through a nozzle of a 3D-printer so that continuous filaments could be deposited, one upon the other, to build lab-scaled wall specimens without noticeable deformation of the bottom layers. The specimens extracted from the printed walls exhibited multiple fine cracks and pronounced strain-hardening characteristics under uniaxial tensile loading, even for fiber volume fractions as low as 1.0%. In fact, the strain-hardening characteristics of printed specimens were superior to those of mold-cast SHCC specimens.