The construction of traditional underground utility tunnels faces prominent challenges, including high costs, long construction cycles, and limited workspace. Although 3D printing technology offers an effective solution to these issues, its practical application is largely constrained by key performance factors such as the printability, early strength, and interlayer bonding of concrete materials. This study aims to develop a 3D-printable concrete material specifically suited for the construction of underground utility tunnels. Through collaborative optimization of parameters such as the water–binder ratio, additives, and fiber content using single-factor and orthogonal tests, the optimal mix proportion was determined: a water–binder ratio of 0.30, a 10% dosage of rapid-hardening sulphoaluminate cement (R·SAC), a sand-to-binder ratio of 1.0, 20% mineral admixtures (15% fly ash + 5% silica fume), and a 1.0% volume fraction of polypropylene fibers. The results indicate that the fresh paste achieved a flowability of 192 mm, demonstrating excellent printability. Specimens printed using a sawtooth toolpath reached a 3-day compressive strength of 37.8 MPa, with 28-day compressive and flexural strengths increasing to 56.3 MPa and 7.8 MPa, respectively, and an interlayer bond strength of 3.5 MPa. Crucially, the compressive and flexural anisotropy coefficients were as low as 0.023 and 0.066, respectively, showing a preliminary exploratory trend superior to levels reported in some literature and suggesting the potential of printed components to improve structural performance consistency. This material system not only meets the requirements of 3D printing for early strength and workability but also, by introducing R·SAC to form a low-alkalinity binder system, provides a potential pathway for enhancing long-term durability in corrosive environments. This study offers a reliable theoretical and experimental basis for the application of 3D printing technology in underground engineering. Long-term durability will remain a primary focus of subsequent research.

To investigate the failure characteristics of 3D-printed concrete utility tunnels under loading, a 1:25 scaled model was designed using similarity theory. Vertical loading tests were conducted under soil lateral confinement, and the load–displacement curves, discrete-point strain responses, and crack evolution process were obtained. The test results show that the structure successfully undergoes an elastic stage, a crack development stage, and a plastic failure stage. The incorporated polypropylene fibers exert a bridging effect, enabling the component to retain a certain load-bearing capacity after cracking. Crack distribution was highly heterogeneous: cracks were densest on the top slab, widest on the side walls, and multi-directional on the inner wall. A clear correspondence exists between strain response and crack distribution, with tensile strain zones highly coinciding with crack opening zones. The failure mode generally agrees with the “top slab compression–side wall tensile cracking” characteristic of traditional closed-frame structures. However, the wall thickness deviations induced by the 3D printing process are amplified during internal force redistribution in the statically indeterminate structure, resulting in markedly asymmetric failure of the left and right side walls.