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... of PVC coated polyester or polyamide textiles. The advantages of such constructions lie in the reusability of the formwork material and a quick assembly/disassembly of the formwork structure. The disadvantage lies in the spectrum of application; generally said it can only be used for synclastically shaped load-bearing structures (cupolas) (see Fig. ...
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Citations
... To enhance the constructability of a freeform building or structure, it is important to make the corresponding formwork accurately, quickly, and cheaply [2]. In general, when constructing concrete buildings or structures, the cost of manufacturing and installing formworks is 40% to 60% of the total construction cost [3]. To accomplish this type of construction, various methods for the actual construction of freeform buildings have been studied. ...
Recently, as “Freeform buildings” have increased in number, studies on ways to increase productivity in the construction of freeform buildings are increasing. In the case of 3D printing in construction, many studies are being conducted using the material extrusion method; among the 3D printing methods, manufacturing freeform forms using laminated object manufacturing (LOM) can overcome the limitation presented above. However, there is a lack of cases used in LOM construction sites, so it is necessary to increase the productivity of construction work and study the slicing method suitable for construction. Therefore, in this paper, we propose using study criteria and adaptive slicing methods to combine both the shape error and the manufacturing time of freeform construction. A case study was conducted to verify the results of this study; the freeform concrete form manufacturing with the algorithm that proposed this study could save 66.1% of the manufacturing time compared with CNC milling, and it needs 19.8% less manufacturing time than the existing uniform slicing method. This is a result of the production of one freeform form, and it can be expected to have a greater effect if applied to many freeform forms used in construction sites. In addition, the results of this study can be used as a decision-making tool that can determine the shape and manufacturing time of production according to the on-site situation.
... Adjustable formwork is one of the most technologically advanced methods of creating curved modules for shell structures [32][33][34][35][36][37][38]. Most commonly such a formwork consists of vertical beams which can be moved in the vertical direction to bent a flexible surface lying on top of the beams. ...
Despite all their advantages, load-bearing concrete shell structures with double curvatures are not frequently in use. The main reason is the complexity of their construction. In such a context, this article starts with a brief, critical review of existing technologies while their pros and cons are highlighted. Against that background, the authors propose a new approach for the highly automated fabrication of gridshell structures from variable modules reinforced with textile meshes. To demonstrate the feasibility of such a new technology, a demonstrator called ConDIT 1.0, a sphere-like shell structure composed of several frames, was designed and built. The frame modules were fabricated automatically using extrusion-based 3D printing and a printable, strain-hardening cement-based composite (SHCC). This article presents the design of ConDIT 1.0, the mechanical material characterization of printed SHCC, the technology of module production, the results of geometry verification for print modules using 3D scanning, and the procedure for the demonstrator’s assembly.
... 25 Classifications distinguish in general between standardized formwork systems and custom formworks. 26 However, the distinction between single functionally predefined elements might not always be useful to describe an architectural space and its geometry. Catenary structures, for example, which, due to their shape are mainly subject to compressive stress and thereby represent a suitable structural geometry for the use of concrete, 27 cannot simply be divided into ceiling and wall. ...
The pursuit for more load‐adapted, individualized, and at the same time precise building geometries is driving innovation in digital fabrication with concrete towards greater formal freedom and higher degrees of prefabrication. This paper reviews the opportunities of using 3D‐Printed formwork in the context of pre‐fabricated concrete construction. It identifies the geometric specificities future planning tools need to address in order to incorporate the steps of modularization and fabrication into automatized planning processes from design to production. By reviewing the state‐of‐the‐art fabrication methods for non‐standard concrete geometries, we highlight possible applications and challenges for additive formwork and introduce a volumetric modeling approach to modularize surface and mesh‐based 3d design models into solid segments that can form the basis for further formwork planning.
... In the case of concrete shells-which are relevant to the current research-the construction of formworks is estimated to be as much as 40% of their overall construction cost, and the expense of the formworks increases dramatically if free-form shells are used. 4,5 To tackle this problem, some previous researchers have sought to integrate mass customization techniques into mass-production methods and thus generate a range of adaptive formwork systems with the ultimate goal of avoiding conventional molds. Notable early work in this area included conceptual designs created by Piano. ...
The design and manufacturing of concrete elements need to be reconsidered in light of current trends in architectural geometry. Today, there is a movement toward greater customization and adaptability of concrete elements using “reconfigurable formworks” and “additive manufacturing.” Our study approached the issue of fabricating non-standardized concrete elements from the perspective of a “reconfigurable fabrication platform.” Specifically, we developed a method of fabricating geometrically diverse concrete joints by combining flexible pressure-enduring tubes with a rigid mechanism, resulting in an adaptive concrete-casting machine. This platform, which we named “Flexi-node,” can be used in conjunction with a relevant fabrication-aware digital design tool. Users can computationally design and fabricate a great variety of concrete joints using just one mold, with a minimum of material waste and with no distortion from hydrostatic pressure as would typically occur in a fully flexible formwork.
... With regard to the formwork construction, the cost of conventional approaches is approximately estimated at 10% for the total cost of the building and at 40-60% for structural systems [48]. In particular, the cost of formworks for shells is estimated at 30-40% of their overall construction [49], which, in the case of free-form shells, is dramatically increased, especially with regard to labor cost [50]. A series of cost estimations regarding construction of free-form shells, and in particular the development of formworks for concrete casting can be found [38,51,52], however the development of comprehensive methods to analyse the cost or time of formworks construction in order to increase productivity are very limited and is influenced by local or regional factors including cost of materials, labor cost, and so on. ...
... A series of cost estimations regarding construction of free-form shells, and in particular the development of formworks for concrete casting can be found [38,51,52], however the development of comprehensive methods to analyse the cost or time of formworks construction in order to increase productivity are very limited and is influenced by local or regional factors including cost of materials, labor cost, and so on. All the above have prevented the expansion and development of this type of structures [38], despite the fact that automation and robotics have been introduced into the construction to overcome such obstacles, for instance by the use of flexible formworks [49,53]. This is more obvious nowadays, where a growth trend in the design and fabrication of freeform structures is observed based on such manufacturing mechanisms, which seems to have no corresponding response in the way are being implemented in order to reduce cost and construction time. ...
This paper demonstrates an integrated computational design and fabrication workflow, implemented in actual construction scale, in order to test its feasibility towards a productive and customizable manufacturing process. The project suggests the computational development and the semi-automated fabrication of a free-form shell structure that consists of customized concrete members. The development process is based on two pillars of investigation that are bi-directionally connected; the computational design optimization and the fabrication. The first part of investigation refers to the form-finding of the overall shell structure, as well as its structural members by using topology optimization principles. The second part deals with the development of a reconfigurable modular formwork, which adapts to all shape alternations of the structural components, enabling their effective fabrication by using a single mechanism. Within this framework, decisions taken in the optimization stage are evaluated based on limitations and potentials of the suggested formwork, whose reconfigurability influences fabrication outcomes and vice versa.
... Within the context of concrete fabrication, the literature evidences modern digital approaches having contributed to: a) Formwork strategies supporting free-form geometry, e.g. 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. ...
This paper introduces a novel hybrid construction concept, namely Sparse Concrete Reinforcement In Meshworks (SCRIM), that intersects robot-based 3D Concrete Printing (3DCP) and textile reinforcement meshes to produce lightweight elements. In contrast to existing 3DCP approaches, which often stack material vertically, the SCRIM approach permits full exploitation of 6-axis robotic control by utilising supportive meshes to define 3D surfaces onto which concrete is selectively deposited at various orientation angles. Also, instead of fully encapsulating the textile in a cementitious matrix using formworks or spraying concrete, SCRIM relies on sparsely depositing concrete to achieve structural, tectonic and aesthetic design goals, minimising material use. The motivation behind this novel concept is to fully engage the 3D control capabilities of conventional robotics in concrete use, offering an enriched spatial potential extending beyond extruded geometries prevalent in 3DCP, and diversifying the existing spectrum of digital construction approaches. The SCRIM concept is demonstrated through a small-scale proof-of-concept and a larger-scale experiment, described in this paper. Based on the results, we draw a critical review on the limitations and potentials of the approach.
... The development in digital planning and CAD software has led to a new type of architecture, which is "manifested in the process of development from the rectangular 'box' to the free-form 'blob' " (Hickert & Knaack 2015). First, let's take the modernist architecture (modernistic approach). ...
There is an ever-increasing population and therefore an increased demand for infrastructure, living space, energy, and reduction of CO2 emission worldwide. The development of a system for the construction industry that meets such requirements is the goal of an ongoing effort to develop a prefabricated modular system consisting of active facade elements for energy harvesting (thermal and electrical) and smart wall elements for energy distribution and storage that are suitable for mass-customization or mass-production fabrication. The feasibility of the modular elements was demonstrated by integrating it into the architectural design of a proposed new two-story building, and a proposed building retrofit, both in Dresden, Germany. The exterior panels are comprised of textile reinforced concrete (TRC) elements with integrated photovoltaic (PV) and capillary system. An adaptive smart modular envelope was envisioned by activation of a diversity mode in which the overall integrated capillary system can be divided into branches that are activated independently in a flexible manner. Such a division can be determined based on the shape of the facade shell using a parametrical, generative approach. A form-finding optimization approach was used to optimize the carbon reinforced concrete elements for energy harvesting considering the panel's orientation (in regards to the solar radiation), the latitude, and seasonal changes. Several planning tools were connected to provide a design with parametrical properties and to interact with a FORTRAN based program for the energy optimization of the carbon concrete panel and 3D rendering applications.
... Within the context of concrete fabrication, the literature evidences modern digital approaches having contributed to: a) Formwork strategies supporting free-form geometry, e.g. 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. ...
This paper introduces a novel hybrid construction concept, namely Sparse Concrete Reinforcement In Meshworks (SCRIM), that intersects robot-based 3D Concrete Printing (3DCP) and textile reinforcement meshes to produce lightweight elements. In contrast to existing 3DCP approaches, which often stack material vertically, the SCRIM approach permits full exploitation of 6-axis ro-botic control by utilising supportive meshes to define 3D surfaces onto which concrete is selectively deposited at various orientation angles. Also, instead of fully encapsulating the textile in a cementitious matrix using formworks or spraying concrete, SCRIM relies on sparsely depositing concrete to achieve structural, tectonic and aesthetic design goals, minimising material use. The motivation behind this novel concept is to fully engage the 3D control capabilities of conventional robotics in concrete use, offering an enriched spatial potential extending beyond extruded geometries prevalent in 3DCP, and diversifying the existing spectrum of digital construction approaches. The SCRIM concept is demonstrated through a small-scale proof-of-concept and a larger-scale experiment, described in this paper. Based on the results, we draw a critical review on the limitations and potentials of the approach.
... The excessive manpower, time, and materials required to make and adjust formworks also constitute a noteworthy price factor. The cost of formworks for reinforced concrete can often make up 30% to 40% of the overall cost for the building shell (Sascha et al, 2015). Custom-made milled formworks for double-curved precast cladding elements with moderate curvatures can account for the primary share of the total concrete work's cost. ...
Despite all their advantages, load-bearing concrete shell structures with double curvatures are not frequently in use. The main reason is the complexity of their construction. In such a context, this article starts with a brief, critical review of existing technologies while their pros and cons are highlighted. Against that background the authors then propose a new approach for the highly automated fabrication of gridshell structures from variable modules. To demonstrate the feasibility of such a new technology, a demonstrator called ConDIT 1.0, a sphere-like shell structure composed of several frames was designed and built. The frame modules were fabricated automatically using extrusion-based 3D printing and a printable, strain-hardening cement-based composite (SHCC). This article presents the design of ConDIT 1.0, the mechanical material characterization of printed SHCC, the technology of module production, the results of geometry verification for print modules using 3D scanning, and the procedure for the demonstrator’s assembly. TRANSLATE with x English ArabicHebrewPolish BulgarianHindiPortuguese CatalanHmong DawRomanian Chinese SimplifiedHungarianRussian Chinese TraditionalIndonesianSlovak CzechItalianSlovenian DanishJapaneseSpanish DutchKlingonSwedish EnglishKoreanThai EstonianLatvianTurkish FinnishLithuanianUkrainian FrenchMalayUrdu GermanMalteseVietnamese GreekNorwegianWelsh Haitian CreolePersian TRANSLATE with COPY THE URL BELOW Back EMBED THE SNIPPET BELOW IN YOUR SITE Enable collaborative features and customize widget: Bing Webmaster Portal Back
