Design and Fabrication of a Non-standard, Structural Concrete Column Using Eggshell: Ultra-Thin, 3D Printed Formwork
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Date
2020
Publication Type
Conference Paper
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yes
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Abstract
This paper describes the design and fabrication process of a concrete column cast in ultra-thin, 3D printed formwork, using a process known as Eggshell. The column was prefabricated as part of a real-world construction project, serving as the main load-bearing element for a reciprocal timber frame structure. The fabrication of the column required upscaling of the Eggshell process, to allow for the fabrication of elements of an architectural scale. Furthermore, several challenges had to be addressed such as: integration of reinforcement, establishing the formwork design space, and scaling up the 3D printing process. For the production of the final column a 1.5 mm thin formwork was 3D printed, after which it was combined with a prefabricated reinforcement cage and filled with concrete in a set-on-demand casting process. The successful realization of the project provides a first example of a full-scale building element produced with the Eggshell fabrication process. By 3D printing the formwork, geometrical freedom in concrete construction is greatly expanded, as well as formwork waste reduced.
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published
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Book title
Second RILEM International Conference on Concrete and Digital Fabrication
Journal / series
Volume
28
Pages / Article No.
1104 - 1115
Publisher
Springer
Event
2nd RILEM International Conference on Concrete and Digital Fabrication (Digital Concrete 2020) (virtual)
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Software
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Date created
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Organisational unit
09469 - Kaufmann, Walter / Kaufmann, Walter
03709 - Kohler, Matthias / Kohler, Matthias
03708 - Gramazio, Fabio / Gramazio, Fabio
03891 - Flatt, Robert J. / Flatt, Robert J.
02284 - NFS Digitale Fabrikation / NCCR Digital Fabrication