Design and fabrication of optimised ribbed concrete floor slabs using large scale 3D printed formwork

Burger, Joris; Huber, Tobias; Lloret-Fritschi, Ena; Mata‐Falcón, Jaime; Gramazio, Fabio; Köhler, Matthias

doi:10.1016/j.autcon.2022.104599

Cited by 23 publications

(16 citation statements)

References 33 publications

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“…Verify serviceability using a linear-elastic calculation 10. Formwork detailing, adding stiffeners 29 11. Generation of print path and robotic code with extruder commands 29 12.…”

Section: Funding Informationmentioning

confidence: 99%

“…Formwork detailing, adding stiffeners 29 11. Generation of print path and robotic code with extruder commands 29 12. Robotic formwork fabrication 29 Loop back from Step 12 to Step 4 indicates the design information by printing system constraints.…”

Section: Funding Informationmentioning

confidence: 99%

“…However, the correspondingly higher formwork pressure must be considered. As a result, the rib formwork was designed with a slightly increased thickness (4-5 mm) and additional printed stiffeners 29 (Step 10 in Figure 4). The fabrication workflow entails processing the desired geometry within the COMPAS Python framework, 47 including slicing with COMPAS SLICER 48 and robotic print path generation using COMPAS RRC 49 (Steps 11 and 12 in Figure 4).…”

Section: Applied 3d Printing Formwork Technologymentioning

confidence: 99%

“…This study focuses on the structural design of a material optimized slab structure as well as specimen testing, while the fabrication and design of the formwork are covered elsewhere. 29 The necessary structural design steps for solid and ribbed slabs are discussed (Section 2) and integrated into a digital design-to-production workflow for optimized ribbed slabs using 3D printed formwork (Section 3). Finally, specimens representing full-scale parts of the case study (ribs, slab-column transition) are produced and structurally tested as proof of concept (Section 4).…”

Section: Introductionmentioning

confidence: 99%

“…Consequently, this study explicitly targets the use of widely available technologies for concrete and reinforcement while introducing a different formwork concept: polymer‐based 3D‐printed formwork (introduced in 28 for columns) is used to produce various specimens representing essential parts of a material‐efficient, ribbed concrete slab. This study focuses on the structural design of a material optimized slab structure as well as specimen testing, while the fabrication and design of the formwork are covered elsewhere 29 . The necessary structural design steps for solid and ribbed slabs are discussed (Section 2) and integrated into a digital design‐to‐production workflow for optimized ribbed slabs using 3D printed formwork (Section 3).…”

Section: Introductionmentioning

confidence: 99%

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Structural design and testing of material optimized ribbed RC slabs with 3D printed formwork

Huber

Burger

Mata‐Falcón

et al. 2023

Structural Concrete

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Most of the concrete volume in multistorey buildings is cast in solid slabs, which are frequently flat slabs supported on columns. By using two-way spanning ribbed slabs, concrete consumption could be significantly reduced. However, due to the high costs associated with formwork, such a complex rib configuration is rarely used nowadays. With the advent of technologies for automated formwork fabrication, the material-saving potential inherent in this structural system could again be exploited. This paper investigates the feasibility of material-efficient ribbed concrete slabs on a building scale using conventional concrete and steel reinforcing bars cast inside a three-dimensionalprinted plastic-based formwork. To that end, the code-compliant design of ribbed slabs is first discussed, followed by the introduction of a concept for an automated design-to-production workflow. The sustainability of this slab system is compared to a solution using conventional formwork in a case study consisting of a multibay office building with slabs spanning 8 m in both directions, revealing that ribbed slabs use 40% less concrete than solid slabs. Several representative structural elements of the case study (ribs, slab-column transition) were produced at full-scale and tested until failure to investigate the feasibility of production and structural performance. Three T-beams with various rib shapes (straight, kinked with diaphragms, curved) were tested in a threepoint bending configuration, showing a ductile behavior with longitudinal reinforcement yielding and indicating the relevance of torsional effects in curved ribs. Punching tests on two slab-column connections (ribbed, solid) revealed that the optimized ribbed slab could prevent brittle punching failures and achieve an ultimate load 105% higher than the solid reference slab. All specimens' load-bearing behavior could be predicted using established design formulas, showing the feasibility of producing code-compliant ribbed slabs with the applied technology.Discussion on this paper must be submitted within two months of the print publication. The discussion will then be published in print, along with the authors' closure, if any, approximately nine months after the print publication.

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“…Verify serviceability using a linear-elastic calculation 10. Formwork detailing, adding stiffeners 29 11. Generation of print path and robotic code with extruder commands 29 12.…”

Section: Funding Informationmentioning

confidence: 99%

Section: Funding Informationmentioning

confidence: 99%

Section: Applied 3d Printing Formwork Technologymentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Structural design and testing of material optimized ribbed RC slabs with 3D printed formwork

Huber

Burger

Mata‐Falcón

et al. 2023

Structural Concrete

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Eggshell Pavilion: a reinforced concrete structure fabricated using robotically 3D printed formwork

et al. 2023

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This paper discusses the design, fabrication, and assembly of the ‘Eggshell Pavilion’, a reinforced concrete structure fabricated using 3D printed thin shell formwork. Formworks for columns and slabs were printed from recycled plastic using a pellet extruder mounted to a robotic arm. The formworks were cast and demoulded, and the finished elements were assembled into a pavilion, showcasing the architectural potential of 3D printed formwork. The Eggshell Pavilion was designed and fabricated within the scope of a design studio at ETH Zurich. The structure was designed using a fully parametric design workflow that allowed for incorporating changes into the design until the fabrication. The pavilion consists of four columns and floor slabs. Each column and floor slab is reinforced with conventional reinforcing bars. Two different methods are used for casting the columns and floor slabs. The columns are cast using ‘Digital casting systems’, a method for the digitally controlled casting of fast-hardening concrete. Digital casting reduces the hydrostatic pressure exerted on the formwork to a minimum, thereby enabling the casting of tall structures with thin formwork. The floor slabs are cast with a commercially available concrete mix, as the pressure exerted on the formwork walls is lower than for the columns. In this research, 3D printed formwork is combined with traditional reinforcing, casting, and assembly methods, bringing the technology closer to an industrial application.

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Advances in formwork automation, structure and materials in concrete construction

Gappmaier,

Reichenbach,

Kromoser

2024

Automation in Construction

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Design and fabrication of optimised ribbed concrete floor slabs using large scale 3D printed formwork

Cited by 23 publications

References 33 publications

Structural design and testing of material optimized ribbed RC slabs with 3D printed formwork

Structural design and testing of material optimized ribbed RC slabs with 3D printed formwork

Eggshell Pavilion: a reinforced concrete structure fabricated using robotically 3D printed formwork

Advances in formwork automation, structure and materials in concrete construction

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