Robotically 3D Printed Formwork for Concrete Structures

Abstract

No other building material has influenced our contemporary built environment like concrete has. Its qualities include high structural strength, widespread availability, and the ability to take almost any form. Typically, concrete building elements are given their shape using formwork made from timber or steel. However, the fabrication of these formworks is labour-intensive and wasteful, especially for complex, non-standard concrete structures. The difficulty of formwork fabrication is one of the reasons why designs in concrete tend to be standardised and confined to orthogonal shapes. Although standard shapes in concrete are simple to construct, they often use more material than structurally necessary. In contrast, one defining characteristic of material-efficient concrete structures is that they typically have complex, non-standard geometries. As the concrete construction industry is responsible for a large portion of anthropogenic CO2 emissions, sustainability must be considered a key driver in the design and fabrication process of architectural concrete structures. Therefore, effective methods for producing non-standard formwork must be developed to enable material-efficient concrete structures. This research responds to these challenges and investigates the use of robotically 3D printed formwork to expand geometrical freedom and allow for the prefabrication of material-efficient concrete structures. Several types of structural building elements are explored through the design and fabrication of prototypes. The architectural potential of this fabrication process is explored through three case studies: a non-standard structural column, an optimised floor slab, and a pavilion combining both elements. The results of this research expand the possibilities for digital design and fabrication of non-standard concrete elements, aiding the transition toward more sustainable construction using concrete.