Mechanical performance and anisotropic analysis of rubberised 3D-printed concrete incorporating PP fibre

The research investigates the effects of substituting sand with rubber particles derived from waste tyres—up to 40% by volume—and the inclusion of polypropylene (PP) fibres. Unlike steel fibres, which can cause operational challenges and surface irregularities in the printing process, PP fibres’ flexibility integrates well within the concrete matrix. This integration ensures smooth extrusion and a high-quality surface finish, enhancing the printability of the concrete. The study’s findings reveal that including rubber particles and PP fibres impacts the concrete’s properties, showing a general decline in compressive and flexural strengths as the rubber content increases. Nevertheless, the PP fibre–enhanced mixtures maintain sufficient structural strength, demonstrating an anisotropic compressive strength above 30 MPa and a flexural strength of 4 MPa. These results underscore the feasibility of using rubberised 3D-printed concrete with PP fibres in sustainable construction practices, aligning with standards (ACI 318:2018) and contributing to eco-friendly and innovative construction methodologies.