Using 3D-Printed Formwork to Enable Controlled Crack Creation in Concrete Specimens

The employment of automated non-destructive testing (NDT) methods for crack characterization in concrete, needs calibration and benchmarking in a controlled environment. This requires test specimen with comparable and ideally reproducible cracks. To this end, in this paper a method is presented that aims to mimic cracked concrete specimens with a high degree of control over the resulting crack parameters width, depth and length for material testing and calibration of automated (NDT) methods. The method comprises 3D-printing of formwork with integrated crack patterns. The obtained crack width accuracy is tested by comparing printed cracks and resulting cracks in the concrete with the desired width from the print file. This procedure enables the realization of crack widths ≥ 0.2 mm with a deviation in the range of 25% between desired and resulting crack width. Further, the proposed methodology is independent of intrinsic material properties which enables this accuracy.