Investigation into the Integration of Impregnated Glass and Carbon Textiles in a Laboratory Mortar Extruder (LabMorTex)

A promising process for the automatization of concrete structures is extrusion or extrusion molding. An innovative approach is the extrusion of concrete with imbedded technical textiles as reinforcement. For a successful extrusion, the rheological properties of the fresh concrete have to be optimized, as it must be extrudable and have sufficient early strength after leaving the mouthpiece. Within the scope of this paper, a process was developed which allows the integration of flexible as well as stiff impregnated textiles into the extrusion process. For this purpose, different textile-reinforced mortars (TRM) were extruded and their material characteristics were investigated. The results show that the mortar cross-section is considerably strengthened, especially when using carbon textiles, and that extrusion has considerable potential to produce high-performance TRM composites. In uniaxial tension tests with TRM, as well as in the pure roving tensile strength tests, textile stresses of approx. 1200 MPa were achieved for the glass textile and approx. 2250 MPa for the carbon textile. The position of the textile layer deviated a maximal 0.4 mm from its predesigned position, which shows its potential for producing tailor-made TRM elements. In addition, by adjusting the mortar mix design, it was possible to reduce the global warming potential (GWP) of the extrusion compound by up to 49.3% compared to the initial composition from preliminary studies.