With the continuous depletion of natural river sand resources and the escalating ecological degradation caused by excessive sand mining, manufactured sand has emerged as a sustainable and environmentally favorable alternative aggregate, playing an increasingly important role in the advancement of green construction materials. Nevertheless, the shrinkage behavior of manufactured sand concrete (MSC) exhibits significant deviations from that of conventional natural sand concrete due to differences in the material characteristics. Existing shrinkage prediction models—such as ACI 209, CEB-FIP 2010, B3, and GL 2000—fail to adequately incorporate the specific properties and substitution effects of manufactured sand, thereby limiting their predictive accuracy and applicability. To bridge this gap, the present study conducted a systematic evaluation of the four aforementioned classical shrinkage prediction models based on experimental data from MSC specimens incorporating varying replacement rates of manufactured sand. The findings revealed that models such as B3 and CEB-FIP 2010 neglected the influence of critical characteristics of manufactured sand—namely, particle morphology, gradation, and stone powder content—on the cementitious matrix and interfacial transition zone, which led to substantial prediction discrepancies. Accordingly, a nonlinear regression-based correction function was developed, introducing the manufactured sand content as a key influencing variable to recalibrate and enhance the ACI 209 and GL 2000 models for a more accurate application to MSC. The modified models exhibited markedly improved fitting performance and predictive robustness across the full range of manufactured sand replacement ratios (0–100%), thereby offering a more reliable framework for modeling the shrinkage development of MSC.

To predict the failure lifetime of reinforced concrete, a current accelerating corrosion test was performed on concrete by simulating the environment in an area with saline soil. To study the concrete’s process of deterioration under these conditions, this study selected the corrosion current density of the steel bars and the ultrasonic velocity of the concrete as the main factors in accelerated corrosion degradation. Then, by using the Weibull distribution function to model the degradation process, the study obtained the reliability function of the accelerated failure. The results showed that the corrosion current density of the steel bars and the ultrasonic velocity of concrete can be used as degradation factors of reinforced concrete, but the corrosion current density is more stable, which is propitious for modeling. Further, the Weibull distribution function can describe the durability degradation process of reinforced concrete effectively. Because of the high content of corrosive ions in saline soil, the reinforced concrete cover fails first.

3D concrete printing (3DCP) is an emerging intelligent construction technology that enables the direct transformation of digital models into physical components, thereby facilitating the precise fabrication of complex geometries. This study investigates the anisotropic mechanical properties and construction applicability of low-carbon 3D printed concrete for reusable formwork systems. Axial compression, flexural, and splitting tensile tests were conducted to examine mechanical anisotropy, and the effects of steel slag and iron tailings replacement levels on mechanical performance were evaluated. Carbon emission analysis was also performed. Using the coefficient-of-variation TOPSIS method, an optimal printable low-carbon mixture was identified, comprising 30% steel slag, 40% iron tailings sand, and 0.3% fibre content, balancing both mechanical performance and environmental benefits. To address the challenges associated with printing large monolithic formwork units, such as excessive weight and demoulding difficulties, three connection strategies for curved wall modular reusable formwork were designed. Finite element analyses were conducted to assess the strength and stiffness of each strategy, and an optimized connection configuration was proposed. The findings demonstrate the feasibility of accurately fabricating complex architectural components using low-carbon 3D printed concrete, providing theoretical and practical support for the industrialized production of large-scale, geometrically complex structures.

To elucidate the influence of the extrusion-based 3D printing of concrete on the tensile performance of polyethylene fibre-based engineered cementitious composites (PE-ECC), quantitative analyses of reinforcing filament alignment and pore morphology were carried out using backscattered electron (BSE) imaging and X-ray computed tomography (X-CT). A micromechanics analytical model based on microstructural characteristics was further employed to predict the tensile response of additively manufactured PE-ECC. Due to the extrusion process, fibres in 3D-printed PE-ECC were predominantly oriented along the printing path, resulting in a smaller average inclination angle compared with the randomly distributed fibres in cast specimens. Internal pores exhibited elongated flattened ellipsoidal shapes, with more pronounced anisotropy in axial lengths across the three principal directions. Taking the major semi-axis of the equivalent ellipsoidal voids as a representative pore parameter, the analytical model accurately reproduced the cracking strength, stress-strain evolution, and crack pattern of the printed PE-ECC. This extrusion process enhanced multiple cracking capacity and strain-hardening performance by improving fibre orientation, strengthening interfacial bonding, and altering matrix fracture toughness. The integration of micromechanical modelling with experimentally measured microstructural parameters effectively revealed the intrinsic mechanisms underlying the enhanced tensile behaviour of 3D-printed PE-ECC and provides theoretical support for the optimized design of fibre-reinforced cementitious composites in 3D printing.