Design and fabrication of optimised ribbed concrete floor slabs using large scale 3D printed formwork
[Display omitted] •Developed a design-to-fabrication workflow for optimised ribbed concrete floor slabs.•Fabricated an optimised 2.7×2.7m reinforced concrete floor slab.•Achieved a material reduction of up to 40% compared to a flat slab.•Demonstrated the potential of 3D printed formwork for ribbed c...
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| Published in: | Automation in construction Vol. 144; p. 104599 |
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| Main Authors: | , , , , , |
| Format: | Journal Article |
| Language: | English |
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Elsevier B.V
01.12.2022
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| ISSN: | 0926-5805, 1872-7891 |
| Online Access: | Get full text |
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| Abstract | [Display omitted]
•Developed a design-to-fabrication workflow for optimised ribbed concrete floor slabs.•Fabricated an optimised 2.7×2.7m reinforced concrete floor slab.•Achieved a material reduction of up to 40% compared to a flat slab.•Demonstrated the potential of 3D printed formwork for ribbed concrete floor slabs.
This paper describes the design, fabrication, and testing process of an optimised, reinforced concrete ribbed floor slab fabricated using robotically 3D printed formwork. The design of the floor slab is based on the alignment of ribs along the trajectories of the principal bending moments. A workflow is described that generates a rib layout based on structural analysis, which is used to create a three-dimensional model of the slab. A full-scale prototype is fabricated by using an industrial robotic arm with a pellet extruder mounted as an end effector to 3D print the formwork. Reinforcement is inserted and the formwork is cast using self-compacting concrete. The successful design, fabrication, and structural testing of the full-scale floor slab prototype showed that the described workflow is suitable for realizing material-optimised, ribbed reinforced concrete floor slabs using 3D printed formwork. |
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| AbstractList | [Display omitted]
•Developed a design-to-fabrication workflow for optimised ribbed concrete floor slabs.•Fabricated an optimised 2.7×2.7m reinforced concrete floor slab.•Achieved a material reduction of up to 40% compared to a flat slab.•Demonstrated the potential of 3D printed formwork for ribbed concrete floor slabs.
This paper describes the design, fabrication, and testing process of an optimised, reinforced concrete ribbed floor slab fabricated using robotically 3D printed formwork. The design of the floor slab is based on the alignment of ribs along the trajectories of the principal bending moments. A workflow is described that generates a rib layout based on structural analysis, which is used to create a three-dimensional model of the slab. A full-scale prototype is fabricated by using an industrial robotic arm with a pellet extruder mounted as an end effector to 3D print the formwork. Reinforcement is inserted and the formwork is cast using self-compacting concrete. The successful design, fabrication, and structural testing of the full-scale floor slab prototype showed that the described workflow is suitable for realizing material-optimised, ribbed reinforced concrete floor slabs using 3D printed formwork. |
| ArticleNumber | 104599 |
| Author | Burger, Joris Gramazio, Fabio Huber, Tobias Mata-Falcón, Jaime Kohler, Matthias Lloret-Fritschi, Ena |
| Author_xml | – sequence: 1 givenname: Joris surname: Burger fullname: Burger, Joris email: burger@arch.ethz.ch organization: Institute of Technology in Architecture, ETH Zurich, Stefano-Franscini-Platz 1, Zurich 8093, Switzerland – sequence: 2 givenname: Tobias surname: Huber fullname: Huber, Tobias organization: Institute of Structural Engineering, ETH Zurich, Stefano-Franscini-Platz 5, Zurich 8093, Switzerland – sequence: 3 givenname: Ena surname: Lloret-Fritschi fullname: Lloret-Fritschi, Ena organization: Institute of Technology in Architecture, ETH Zurich, Stefano-Franscini-Platz 1, Zurich 8093, Switzerland – sequence: 4 givenname: Jaime surname: Mata-Falcón fullname: Mata-Falcón, Jaime organization: Institute of Structural Engineering, ETH Zurich, Stefano-Franscini-Platz 5, Zurich 8093, Switzerland – sequence: 5 givenname: Fabio surname: Gramazio fullname: Gramazio, Fabio organization: Institute of Technology in Architecture, ETH Zurich, Stefano-Franscini-Platz 1, Zurich 8093, Switzerland – sequence: 6 givenname: Matthias surname: Kohler fullname: Kohler, Matthias organization: Institute of Technology in Architecture, ETH Zurich, Stefano-Franscini-Platz 1, Zurich 8093, Switzerland |
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| Cites_doi | 10.1089/3dp.2019.0197 10.1016/j.cad.2014.02.011 10.1016/j.cad.2007.10.014 10.1038/nmat4930 10.1145/3328939.3329003 10.1016/j.cemconres.2020.106071 10.1089/3dp.2021.0024 10.1002/suco.202200633 10.21809/rilemtechlett.2022.161 10.3390/ma15103468 10.1016/j.cemconres.2020.106047 10.1016/j.rcim.2018.12.016 10.1088/1748-3182/9/1/016013 10.1016/j.compositesb.2017.05.013 10.1089/3dp.2020.0350 10.52842/conf.acadia.2018.434 10.5406/j.ctt1vw0s2n 10.2307/j.ctt1tp3c5w.31 |
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