Evaluation of Cone-Penetration Test as a Rheology Quality-Control Field-Oriented Test for 3D Printing Cement-Based Systems

3D printing (3DP) of cement-based systems (CBSs) is a highly demanded technology in the construction field. Material requirements include specific rheological conditions for proper extrusion, followed by fast stiffening and strength gain to allow the construction process to continue, taking into account variable environmental conditions if the construction is on-site. To guarantee quality control of the process, it is essential to define field-oriented testing methodologies that allow real-time monitoring of mechanical properties’ evolution of the printed material, which will govern construction speed. This study evaluates the cone penetration test (CPT) method as a field-oriented test method to estimate the mechanical properties of 3DP CBSs over time. CPT penetration depth measurements were used to calculate shear yield stress and fresh compressive strength over time for 90 min. The experimental results were compared to two widely used laboratory tests: the fresh compressive strength test (squeeze test—SQT) and DSR test (vane test—VT). CBS pastes with and without fly ash and with three inorganic modifiers (nanoclays) and two types of organic rheology-modifying admixtures were considered. The results showed that CPT is highly conditioned by the stiffness of the paste, measured by the compressive Young Modulus (E), overestimating CBSs’ strength. The increase in E over time showed an inflection point at 130 kPa, corresponding to the evolution from plastic to pseudo-rigid behavior in the pastes. The corresponding time was used to define a linear adjustment for the average strength calculated using the CPT regarding both the fresh compressive SQT and shear yield stress VT.