Abstract: The use of fibre-reinforced concrete (FRC) in structural applications is increasing significantly as a result of (1) the acceptance of this composite into design guidelines and (2) the improvement in terms of sustainability performance that has been reported for cases where FRC has been used. In this context, fibre orientation and distribution are factors that govern the post-cracking response of the FRC. Researchers have already dealt with the analysis of both variables from an experimental and numerical perspective, and design-oriented recommendations were included in existing design guidelines (i.e., fib Model Code 2020). Nonetheless, there are still technical aspects to be answered within a research framework before the influence of these variables on the mechanical response of FRC could be covered with sufficient reliability. In this regard, this research is aimed at shedding light on the influence of the mould geometry and concrete pouring/vibration procedures on the fibre orientation and distribution variables as well as on the post-cracking performance of the FRC. An extensive experimental programme aimed at characterising these variables using novel testing techniques (i.e., an inductive non-destructive approach for quantifying fibre amount and orientation and the BCN test for assessing the pre- and post-cracking responses of the FRC) was carried out for this purpose. A relationship has been found between the shape of the formwork and the direction of pouring, along with the direction and distribution of the fibres, both of which proved to have an influence on the residual tensile strength of the concrete. However, it has been confirmed that the first crack resistance depends on the concrete matrix, with the addition of fibres having no relevant influence on that mechanical parameter. The results and conclusions derived from this experimental programme can be extended to FRCs and boundary conditions similar to those established herein.

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