Coupled Thermo-Mechanical Modelling of Early-Age Interlayer Degradation in 3D-Printed Concrete

This study presents a coupled numerical–experimental investigation into the early-age thermo-mechanical behaviour of 3D-printed concrete (3DPC), with particular emphasis on strength development, interlayer bonding, and thermally induced cracking that govern structural buildability and performance. A coupled multiphysics modelling framework was developed in COMSOL Multiphysics by integrating hydration kinetics, maturity theory, thermo-mechanical coupling, and a cohesive-zone-based interlayer damage formulation through user-defined time-dependent constitutive relationships and domain activation functions. The model simulated the temporal evolution of temperature, stiffness, stress development, and interlayer degradation during the early-age printing process. The model simulates the temporal evolution of temperature, stiffness, and interlayer damage and was validated against experimental results from compression, interlayer bond, and fracture tests conducted under varying printing time gaps and curing temperatures. The results demonstrate that increasing interlayer deposition intervals up to 60 min leads to reductions of approximately 38% in interlayer bond strength and a significant reduction in apparent compressive strength exceeding 80% between 0 and 60 min deposition delay. It should be noted that this reduction primarily reflects interlayer-dominated failure and loss of structural continuity rather than intrinsic degradation of the bulk cementitious matrix, primarily due to hydration discontinuity, moisture loss, and progressive substrate stiffening. Elevated curing temperatures further intensify thermal gradients, resulting in higher residual stresses and increased crack susceptibility at interlayer interfaces. The numerical predictions showed good agreement with the experimental responses, with peak-force prediction errors below 5% and RMSE values of approximately 0.30–0.45 kN along the post-peak softening, confirming the reliability of the proposed modelling approach. The findings highlight the critical importance of printing continuity and thermal control in governing early-age structural performance and provide quantitative guidance for optimising process parameters in extrusion-based 3D concrete printing.