A New Robotic Spray Technology for Generative Manufacturing of Complex Concrete Structures Without Formwork

Neudecker, Stefan; Bruns, Christopher; Gerbers, Roman; Heyn, Jakob; Dietrich, Franz; Dröder, Klaus; Raatz, Annika; Kloft, Harald

doi:10.1016/j.procir.2016.02.107

Cited by 68 publications

(19 citation statements)

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“…Furthermore, the thickness of the shell and placement of the reinforcement could be optimised without additional manufacturing complexity, leading to further potential material savings. Alternative formwork strategies, including inflatable membranes or formless construction methods [41], could also be investigated.…”

Section: Future Workmentioning

confidence: 99%

Design, Construction and Testing of a Low Carbon Thin-Shell Concrete Flooring System

et al. 2019

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Rapid global urbanisation and population growth is driving unprecedented levels of building construction, with the total worldwide floor area expected to almost double over the next 40 years. Since most of the structural material in a building exists within the floors, these present a significant opportunity for structural engineers to contribute to a more sustainable construction industry. This paper examines a novel flooring system of textile-reinforced concrete shells with a foamed concrete fill, which has the potential to halve the amount of materials in a building's entire structure. A new design and geometry optimisation method is described, as well as the construction and testing of two prototypes; each 18mm thick, 2m in span and 200mm tall.These textile-reinforced concrete shells are unconventional in their low total depth, low reinforcement content and lack of rigid supports. Both were reinforced with AR-glass fibre textile and constructed using fine-grained concrete, however only one featured a foamed concrete fill. Each was tested to destruction under an asymmetric load. In both cases, a hinged collapse mechanism was formed rather than sudden catastrophic failure, with positive implications for safety and robustness.A non-linear finite element model was developed which replicated the observed behaviour well, including cracking patterns. Inaccuracies in geometry arising from the hand-made construction methods were measured and their structural impact was assessed and found to be small.The investigations confirm the strength, robustness and buildability of the structural system, and establish a reliable analysis method.

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Section: Future Workmentioning

confidence: 99%

Design, Construction and Testing of a Low Carbon Thin-Shell Concrete Flooring System

et al. 2019

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“…single use moulds [3]; adaptive formwork [4,5]; b) Stay-in-place formworks [6]; fabric formworks [7]; c) Formwork-free strategies, e.g. 3D Concrete Printing [8,9] and robot-assisted generative manufacturing [10]; d) Tailored reinforcement strategies, e.g. MeshMould and integrated thin-shell roof [11,12]; e) Adapted slip-forming approach, e.g.…”

Section: Scrim -Sparse Concrete Reinforcement In Meshworkmentioning

confidence: 99%

“…As for integrated reinforcement strategies, MeshMould [11] is one of the latest technologies that provides means to robotically fabricate spatial meshes that compose reinforced concrete without formwork. Likewise, a generative approach for manufacturing of complex concrete structures without formwork and using robotic spray technology is proposed in [10]. In essence, SCRIM could be interpreted as a variation of the above mentioned approaches, since they rely on a spatial reinforcement as the support base for concrete.…”

Section: State-of-the-artmentioning

confidence: 99%

SCRIM – Sparse Concrete Reinforcement in Meshworks

Ayres

Silva

Nicholas

et al. 2018

Robotic Fabrication in Architecture, Art and Design 2018

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“…These initial results confirmed both the technological and economic feasibility of the I3DCP process, and demonstrate the potential to further expand the scope of this novel technology.Materials 2020, 13, 1093 2 of 17 approaches of additive manufacturing in construction (AMC) are mainly based on the following methods: particle bed printing [2] and material extrusion [3]. A third emerging technology, the so-called Shotcrete 3D Printing, is based on material jetting [4].Particle bed printing is a process where fine particles are selectively bound through the localized application of binder. For this, a thin layer of particles is evenly distributed inside a given building envelope.…”

mentioning

confidence: 99%

“…Materials 2020, 13, 1093 2 of 17 approaches of additive manufacturing in construction (AMC) are mainly based on the following methods: particle bed printing [2] and material extrusion [3]. A third emerging technology, the so-called Shotcrete 3D Printing, is based on material jetting [4].…”

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confidence: 99%

Injection 3D Concrete Printing (I3DCP): Basic Principles and Case Studies

et al. 2020

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Today, the majority of research in 3D concrete printing focuses on one of the three methods: firstly, material extrusion; secondly, particle-bed binding; and thirdly, material jetting. Common to all these technologies is that the material is applied in horizontal layers. In this paper, a novel 3D concrete printing technology is presented which challenges this principle: the so-called Injection 3D Concrete Printing (I3DCP) technology is based on the concept that a fluid material (M1) is robotically injected into a material (M2) with specific rheological properties, causing material M1 to maintain a stable position within material M2. Different to the layered deposition of horizontal strands, intricate concrete structures can be created through printing spatially free trajectories, that are unconstrained by gravitational forces during printing. In this paper, three versions of this method were investigated, described, and evaluated for their potential in construction: A) injecting a fine grain concrete into a non-hardening suspension; B) injecting a non-hardening suspension into a fine grain concrete; and C) injecting a fine grain concrete with specific properties into a fine grain concrete with different properties. In an interdisciplinary research approach, various material combinations were developed and validated through physical experiments. For each of the three versions, first architectural applications were developed and functional prototypes were fabricated. These initial results confirmed both the technological and economic feasibility of the I3DCP process, and demonstrate the potential to further expand the scope of this novel technology.Materials 2020, 13, 1093 2 of 17 approaches of additive manufacturing in construction (AMC) are mainly based on the following methods: particle bed printing [2] and material extrusion [3]. A third emerging technology, the so-called Shotcrete 3D Printing, is based on material jetting [4].Particle bed printing is a process where fine particles are selectively bound through the localized application of binder. For this, a thin layer of particles is evenly distributed inside a given building envelope. In a subsequent step a binder is deposited onto the particle layer, which selectively bonds the particles. Next, the particle bed is lowered, a new layer of particles is applied, and the binding process is repeated. In a layered manner, complex geometries can be fabricated, resting loosely inside the bed of unbound particles. This technology is used, for example, for the production of complex molds in metal foundry [5], but also in architecture as formwork for casting high resolution concrete parts [6]. Instead of using the printed element merely as formwork, there are also attempts to entirely print structural elements using large, room-sized particle bed printers [7].In the extrusion-based approach to additive manufacturing, strands of fine concrete are printed layer-wise on top of each other, progressively creating a three-dimensional object. Here, predominantly two differen...

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A New Robotic Spray Technology for Generative Manufacturing of Complex Concrete Structures Without Formwork

Cited by 68 publications

References 1 publication

Design, Construction and Testing of a Low Carbon Thin-Shell Concrete Flooring System

Design, Construction and Testing of a Low Carbon Thin-Shell Concrete Flooring System

SCRIM – Sparse Concrete Reinforcement in Meshworks

Injection 3D Concrete Printing (I3DCP): Basic Principles and Case Studies

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