Tom Rothe, Christian Hühne, Stefan Gantner, Norman Hack
The integration of load path compliant fibre reinforcement structures into additive manufactured concrete elements opens up new potential in the field of construction. The new design language made possible by 3D concrete printing requires reinforcement structures to be provided in a highly individual shaped manner. Digital and robot-based production processes make it possible to produce on-site, on demand, fully automated and just-in-time. In this paper, a concept for an on-site ready fibre reinforcement production is presented. Based on previous works a Dynamic Winding Machine (DWM) for the on-demand production of individualizable reinforcement strands is developed. The concept and technical functionalities of the machine are presented in detail. The functionality is validated based on the production of single reinforcement bars as well as the production of entire, additively manufactured and reinforced concrete structures. With an industrial robot and adjusted end effectors, freely shaped reinforcement structures can be produced automatically. Different concepts for the use of the DWM with mobile robots are discussed. Due to the flexibility of the process, both filigree reinforcement structures, e.g. for use in particle bed printing, and large structures, e.g. for combination with Shotcrete 3D Printing, can be produced.
{"title":"Dynamic Winding Process of Individualized Fibre Reinforcement Structures for Additive Manufacturing in Construction","authors":"Tom Rothe, Christian Hühne, Stefan Gantner, Norman Hack","doi":"10.52825/ocp.v3i.187","DOIUrl":"https://doi.org/10.52825/ocp.v3i.187","url":null,"abstract":"The integration of load path compliant fibre reinforcement structures into additive manufactured concrete elements opens up new potential in the field of construction. The new design language made possible by 3D concrete printing requires reinforcement structures to be provided in a highly individual shaped manner. Digital and robot-based production processes make it possible to produce on-site, on demand, fully automated and just-in-time. In this paper, a concept for an on-site ready fibre reinforcement production is presented. Based on previous works a Dynamic Winding Machine (DWM) for the on-demand production of individualizable reinforcement strands is developed. The concept and technical functionalities of the machine are presented in detail. The functionality is validated based on the production of single reinforcement bars as well as the production of entire, additively manufactured and reinforced concrete structures. With an industrial robot and adjusted end effectors, freely shaped reinforcement structures can be produced automatically. Different concepts for the use of the DWM with mobile robots are discussed. Due to the flexibility of the process, both filigree reinforcement structures, e.g. for use in particle bed printing, and large structures, e.g. for combination with Shotcrete 3D Printing, can be produced.","PeriodicalId":507525,"journal":{"name":"Open Conference Proceedings","volume":"430 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2023-12-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139178199","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Gözdem Dittel, Martin Scheurer, Clara Evers, Fabian Meyer-Brötz, Ankiet Patel, Michael Osswald, Thomas Gries
The aim of this study is to verify the industrial feasibility of integrating textile reinforcement into the 3D concrete printing process and to determine the flexural strength of 3D-printed concrete reinforced with alkali-resistant glass textiles. Due to the non-corrosiveness of the textile reinforcement, thin-walled concrete elements are feasible, reducing material consumption by up to 80 percent compared to steel reinforced concrete. The proposed method of the authors aims to combine 3D concrete printing with a single-sided, movable formwork in order to reduce the time-, personnel-, cost- and material-intensive formwork effort. As a first step towards that goal, in this study, a single-sided stable formwork following the printing path is designed and tested for its applicability on an industrial scale. The prototypical implementation of the printing method through a textile reinforcement is tested. For this purpose, test panels reinforced with textiles vertically and horizontally are printed with concrete. The flexural tensile strength of the printed, reinforced elements is investigated in a four-point bending test. Based on the results of the investigations, the requirements for a movable formwork are defined for the industrial application of this study. The movable formwork will replace the formwork frames in the future, so that the 3D concrete printing process can be optimized in a material-saving way and in terms of circular economy.
{"title":"Structural Performance of Textile Reinforced 3D-Printed Concrete Elements","authors":"Gözdem Dittel, Martin Scheurer, Clara Evers, Fabian Meyer-Brötz, Ankiet Patel, Michael Osswald, Thomas Gries","doi":"10.52825/ocp.v3i.429","DOIUrl":"https://doi.org/10.52825/ocp.v3i.429","url":null,"abstract":"The aim of this study is to verify the industrial feasibility of integrating textile reinforcement into the 3D concrete printing process and to determine the flexural strength of 3D-printed concrete reinforced with alkali-resistant glass textiles. Due to the non-corrosiveness of the textile reinforcement, thin-walled concrete elements are feasible, reducing material consumption by up to 80 percent compared to steel reinforced concrete. The proposed method of the authors aims to combine 3D concrete printing with a single-sided, movable formwork in order to reduce the time-, personnel-, cost- and material-intensive formwork effort. As a first step towards that goal, in this study, a single-sided stable formwork following the printing path is designed and tested for its applicability on an industrial scale. The prototypical implementation of the printing method through a textile reinforcement is tested. For this purpose, test panels reinforced with textiles vertically and horizontally are printed with concrete. The flexural tensile strength of the printed, reinforced elements is investigated in a four-point bending test. Based on the results of the investigations, the requirements for a movable formwork are defined for the industrial application of this study. The movable formwork will replace the formwork frames in the future, so that the 3D concrete printing process can be optimized in a material-saving way and in terms of circular economy.","PeriodicalId":507525,"journal":{"name":"Open Conference Proceedings","volume":"176 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2023-12-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139177930","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Jaime Mata‐Falcón, Lukas Gebhard, Minu Lee, P. Bischof
The construction industry needs to reduce its large environmental footprint drastically. Building with less material is one of the main levers for reducing this negative impact. This material reduction can be achieved with structurally efficient geometries requiring a higher degree of complexity than typically applied in conventional construction practices. Digital fabrication with concrete has been proposed as one of the solutions to facilitate the fabrication of efficient structures. Over the last few years, extensive research has been conducted within the National Centre of Competence in Research (NCCR) Digital Fabrication at ETH Zurich to investigate digital fabrication with concrete for structural applications. Various digital technologies were investigated, including 3D concrete printing, digital casting, Mesh Mould, printed polymer formworks and knitted formworks. This contribution highlights the main findings of these investigations with a particular focus on the development of reinforcement strategies, as these strategies are an essential step to ensure compliance with existing design guidelines and ease of mass-market adaptation. Promising future research areas are identified based on the assessment of the technology readiness and sustainability potential of the investigated approaches.
{"title":"Advances in Structural Applications of Digital Fabrication With Concrete","authors":"Jaime Mata‐Falcón, Lukas Gebhard, Minu Lee, P. Bischof","doi":"10.52825/ocp.v3i.190","DOIUrl":"https://doi.org/10.52825/ocp.v3i.190","url":null,"abstract":"The construction industry needs to reduce its large environmental footprint drastically. Building with less material is one of the main levers for reducing this negative impact. This material reduction can be achieved with structurally efficient geometries requiring a higher degree of complexity than typically applied in conventional construction practices. Digital fabrication with concrete has been proposed as one of the solutions to facilitate the fabrication of efficient structures. Over the last few years, extensive research has been conducted within the National Centre of Competence in Research (NCCR) Digital Fabrication at ETH Zurich to investigate digital fabrication with concrete for structural applications. Various digital technologies were investigated, including 3D concrete printing, digital casting, Mesh Mould, printed polymer formworks and knitted formworks. This contribution highlights the main findings of these investigations with a particular focus on the development of reinforcement strategies, as these strategies are an essential step to ensure compliance with existing design guidelines and ease of mass-market adaptation. Promising future research areas are identified based on the assessment of the technology readiness and sustainability potential of the investigated approaches.","PeriodicalId":507525,"journal":{"name":"Open Conference Proceedings","volume":"675 ","pages":""},"PeriodicalIF":0.0,"publicationDate":"2023-12-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139177419","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Robin Dörrie, Martin David, Niklas Freund, D. Lowke, Klaus Dröder, H. Kloft
The current state of the art for additive manufacturing often utilises horizontal layer printing approaches for a variety of materials and applications. However, it imposes restrictions on the integration of utilities, mounting fixtures, installations, and reinforcement. Particularly the integration of reinforcement into 3D concrete printing still faces many challenges. It is currently restricted by the nozzle to strand distance, the lack of bond quality, automation, and geometric limitations of the respective 3D concrete printing techniques. The following research presents a case study on additively manufactured concrete construction elements utilising the Shotcrete 3D Printing (SC3DP) technique, focusing on interlayer- and short rebar reinforcement. To demonstrate the potential benefits for an automated reinforcement integration and to uncover further challenges and research questions, a wall segment was produced using a unique combination of Interlayer Reinforcement (ILR) and Short Rebar Insertion (SRI). By incorporating these methods, it was possible to generate three-dimensional continuous reinforcement structures within the wall. The innovative approach showcased takes full advantage of the SC3DP technique, enabling the integration of reinforcement during the printing process itself, thus utilising the geometric freedom, the fast build up rate and the kinetic energy during application. This eliminates the need for premanufactured reinforcement structures, enabling a more efficient and flexible manufacturing process. Furthermore, the discussion includes the potential for surface finishing and attainment of geometrical accuracy through the direct integration of reinforcement. An outlook is given as future construction elements can be produced structurally reinforced without formwork and with a high degree of geometric freedom.
目前的增材制造技术通常采用水平层打印方法，适用于各种材料和应用。然而，这对公用设施、安装夹具、装置和钢筋的集成造成了限制。特别是在三维混凝土打印中整合钢筋仍然面临许多挑战。目前，它受到喷嘴与钢绞线距离、粘结质量、自动化程度以及相应 3D 混凝土打印技术的几何限制等因素的制约。以下研究介绍了利用喷射混凝土三维打印（SC3DP）技术进行混凝土建筑构件添加制造的案例研究，重点关注层间加固和短钢筋加固。为了展示自动加固集成的潜在优势，并揭示进一步的挑战和研究问题，我们使用层间加固（ILR）和短钢筋插入（SRI）的独特组合制作了一段墙体。通过采用这些方法，可以在墙体中生成三维连续加固结构。所展示的创新方法充分利用了 SC3DP 技术的优势，在打印过程中实现了加固的整合，从而利用了几何自由度、快速成型率和应用过程中的动能。这样就不需要预制加固结构，从而实现了更高效、更灵活的制造工艺。此外，还讨论了通过直接集成钢筋进行表面处理和实现几何精度的潜力。展望未来，建筑构件可在无模板和高几何自由度的情况下进行结构加固。
{"title":"In-Process Integration of Reinforcement for Construction Elements During Shotcrete 3D Printing","authors":"Robin Dörrie, Martin David, Niklas Freund, D. Lowke, Klaus Dröder, H. Kloft","doi":"10.52825/ocp.v3i.224","DOIUrl":"https://doi.org/10.52825/ocp.v3i.224","url":null,"abstract":"The current state of the art for additive manufacturing often utilises horizontal layer printing approaches for a variety of materials and applications. However, it imposes restrictions on the integration of utilities, mounting fixtures, installations, and reinforcement. Particularly the integration of reinforcement into 3D concrete printing still faces many challenges. It is currently restricted by the nozzle to strand distance, the lack of bond quality, automation, and geometric limitations of the respective 3D concrete printing techniques. The following research presents a case study on additively manufactured concrete construction elements utilising the Shotcrete 3D Printing (SC3DP) technique, focusing on interlayer- and short rebar reinforcement. To demonstrate the potential benefits for an automated reinforcement integration and to uncover further challenges and research questions, a wall segment was produced using a unique combination of Interlayer Reinforcement (ILR) and Short Rebar Insertion (SRI). By incorporating these methods, it was possible to generate three-dimensional continuous reinforcement structures within the wall. The innovative approach showcased takes full advantage of the SC3DP technique, enabling the integration of reinforcement during the printing process itself, thus utilising the geometric freedom, the fast build up rate and the kinetic energy during application. This eliminates the need for premanufactured reinforcement structures, enabling a more efficient and flexible manufacturing process. Furthermore, the discussion includes the potential for surface finishing and attainment of geometrical accuracy through the direct integration of reinforcement. An outlook is given as future construction elements can be produced structurally reinforced without formwork and with a high degree of geometric freedom.","PeriodicalId":507525,"journal":{"name":"Open Conference Proceedings","volume":"100 11","pages":""},"PeriodicalIF":0.0,"publicationDate":"2023-12-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139177304","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Niklas Freund, Robin Dörrie, Martin David, H. Kloft, Klaus Dröder, D. Lowke
Integrating reinforcement into existing concrete 3D printing processes represents one of the key challenges in further automating the additive manufacturing of structural concrete components. A number of different approaches are currently being investigated. In this context, the integration of prefabricated reinforcement structures as well as the process-parallel assembly of reinforcement, e.g. by additive metal arc welding or joining of short rebars, are potential strategies. A common feature of both of these reinforcement strategies is that rebars protrude from the concrete surface in variable orientations during the printing process and need to be enclosed in concrete. Due to the spray application, Shotcrete 3D Printing (SC3DP) offers a good basis for realizing such reinforcement enclosures without the use of specially adapted nozzles. However, it is essential to systematically analyze material properties, e.g. accelerator dosage, and process properties, e.g. reinforcement orientation, in order to define limits for the application. For this reason, the present study investigates the influence of accelerator dosage (0 - 4 %) and reinforcement geometry (spacing, inclination, crossings) on the formation of voids. It is observed that with increasing accelerator dosage, the reinforcement structure increasingly acts as a blocking element for material spreading. The adhesion of the concrete to the reinforcement during spraying creates a shielding effect that increasingly leads to void formation. Finally, the potential and limitations of using prefabricated reinforcement structures in SC3DP are discussed.
{"title":"Enclosing Reinforcement Structures in Shotcrete 3D Printing","authors":"Niklas Freund, Robin Dörrie, Martin David, H. Kloft, Klaus Dröder, D. Lowke","doi":"10.52825/ocp.v3i.227","DOIUrl":"https://doi.org/10.52825/ocp.v3i.227","url":null,"abstract":"Integrating reinforcement into existing concrete 3D printing processes represents one of the key challenges in further automating the additive manufacturing of structural concrete components. A number of different approaches are currently being investigated. In this context, the integration of prefabricated reinforcement structures as well as the process-parallel assembly of reinforcement, e.g. by additive metal arc welding or joining of short rebars, are potential strategies. A common feature of both of these reinforcement strategies is that rebars protrude from the concrete surface in variable orientations during the printing process and need to be enclosed in concrete. Due to the spray application, Shotcrete 3D Printing (SC3DP) offers a good basis for realizing such reinforcement enclosures without the use of specially adapted nozzles. However, it is essential to systematically analyze material properties, e.g. accelerator dosage, and process properties, e.g. reinforcement orientation, in order to define limits for the application. For this reason, the present study investigates the influence of accelerator dosage (0 - 4 %) and reinforcement geometry (spacing, inclination, crossings) on the formation of voids. It is observed that with increasing accelerator dosage, the reinforcement structure increasingly acts as a blocking element for material spreading. The adhesion of the concrete to the reinforcement during spraying creates a shielding effect that increasingly leads to void formation. Finally, the potential and limitations of using prefabricated reinforcement structures in SC3DP are discussed.","PeriodicalId":507525,"journal":{"name":"Open Conference Proceedings","volume":"322 14","pages":""},"PeriodicalIF":0.0,"publicationDate":"2023-12-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139177816","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Jean-François Caron, N. Ducoulombier, L. Demont, Victor De Bono, R. Mesnil
Significant developments in 3D concrete have been made over the past few decades. Yet, unreinforced printed components generally do not comply with existing construction standards or regulations and are therefore not used as load-bearing components. There is still a gap between research and use, and despite several proposals, standard commercial solutions for the reinforcement of 3D-printed structural members are still awaited. The proposed technology is inspired by the composites industry and called flow-based pultrusion for additive manufacturing. The reinforcement is provided by long and aligned fibers, and produces a transverse isotropic composite mortar. Here we show the first experimental setup, and the material tests performed on the printed material. An increase in tensile strength and ductility is shown. An industrial prototype, in collaboration with the company XtreeE, is being developed. This new equipment has made it possible to print beams of 1m50 whose intrados is reinforced with carbon fibres.
{"title":"3D Printing of Continuous-Fibers Cementitious Composites","authors":"Jean-François Caron, N. Ducoulombier, L. Demont, Victor De Bono, R. Mesnil","doi":"10.52825/ocp.v3i.193","DOIUrl":"https://doi.org/10.52825/ocp.v3i.193","url":null,"abstract":"Significant developments in 3D concrete have been made over the past few decades. Yet, unreinforced printed components generally do not comply with existing construction standards or regulations and are therefore not used as load-bearing components. There is still a gap between research and use, and despite several proposals, standard commercial solutions for the reinforcement of 3D-printed structural members are still awaited. The proposed technology is inspired by the composites industry and called flow-based pultrusion for additive manufacturing. The reinforcement is provided by long and aligned fibers, and produces a transverse isotropic composite mortar. Here we show the first experimental setup, and the material tests performed on the printed material. An increase in tensile strength and ductility is shown. An industrial prototype, in collaboration with the company XtreeE, is being developed. This new equipment has made it possible to print beams of 1m50 whose intrados is reinforced with carbon fibres.","PeriodicalId":507525,"journal":{"name":"Open Conference Proceedings","volume":"3 4","pages":""},"PeriodicalIF":0.0,"publicationDate":"2023-12-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139177566","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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