Automated force-flow-oriented reinforcement integration for Shotcrete 3D Printing

Abstract

The construction industry faces various challenges, e.g. reducing its carbon footprint and the extensive use of materials. Therefore, Computational Design and Additive Manufacturing gain more importance throughout the industry. In combination, they offer the possibility of manufacturing individually designed building components, which can be less material-consuming and structurally improved. The presented research displays and discusses the effect of force-flow-oriented reinforcement design in concrete beams concerning the flexural strength and the required amount of steel. For this purpose, different reinforcement layouts were designed and integrated into conventionally cast and additively manufactured beam components. For the design of the force-flow-oriented reinforcement layouts, a digital workflow is established, and FEM simulations are utilised. The load-bearing capacity of the beams is compared based on four-point bending tests. Due to the optimised reinforcement layout, an increase of flexural strength of more than 60% was achieved while keeping the reinforcement amount constant. It is also shown that using force-flow-oriented reinforcement layouts can save nearly 60% of the reinforcement needed to achieve the same flexural strength as a beam with a conventional reinforcement cage. Finally, the potential for automated force-flow-oriented reinforcement integration within additively manufactured components is discussed. • Simulation-based approach for force-flow-oriented reinforcement layouts in concrete elements. • Experimental validation with cast and Shotcrete 3D printed beams. • Force-flow-oriented layouts can increase flexural strength by 60% for same reinforcement content. • Rebar content can be reduced by around 60% keeping similar load-bearing capacity. • Conceptual ideas for automated production of material efficient concrete components.

Topics & Concepts