Abstract

Textile Reinforced Concrete (TRC) is a class of material with massive potential to strengthen existing or build entirely new thin-walled structures. However, state-of-the-art polymer-based textile reinforcements commonly suffer under weak compatibility with concrete and insufficient reinforcing efficiency at elevated temperatures. Mineral-impregnated carbon-fiber (MCF) composites represent instead a promising alternative reinforcement with a wide-ranging innovation potential regarding digital and automated processability, freedom design, chemical compatibility and ecological and environmental footprints. Among the existing variants of mineral impregnation, geopolymer (GP) impregnation for carbon fiber (CF) enables stable early-age rheological properties and fast-setting by moderate-temperature activation. The paper at hand presents a methodology to automatically manufacture textile reinforcements made of MCF composites via a continuous pultrusion and robotic–assisted structuring process to meet future market demands. After an advanced geopolymerisation process by thermal curing, the resulting gridlike reinforcements were implemented in a fine-grained, alkali-activated material (AAM) based concrete matrix and characterized with respect to their uniaxial tensile performance. By further applying AAM as cement-free binder, sustainable and fireproof reinforced concrete can be designed with an evident reduction in CO2 emission as compared to conventional cementitious systems. The improved chemical affinity facilitated by GP impregnation governs the cracking phase, resulting in a finer and more diffuse pattern, whereas the higher unidirectional strength of epoxy (EP)-impregnated yarns is responsible for the higher ultimate strength of the composite.