Skip to content

Design and Fabrication of Optimised Ribbed Concrete Floor Slabs Using Large-Scale 3D Printed Formwork (2022-10)

10.1016/j.autcon.2022.104599

 Burger Joris,  Huber Tobias,  Lloret-Fritschi Ena,  Mata-Falcón Jaime,  Gramazio Fabio,  Kohler Matthias
Journal Article - Automation in Construction, Vol. 144

Abstract

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.

18 References

  1. Bischof Patrick, Mata-Falcón Jaime, Burger Joris, Kaufmann Walter (2022-06)
    Digitally Fabricated Keyed Concrete Connections
  2. Boscaro Federica, Quadranti Elia, Wangler Timothy, Mantellato Sara et al. (2022-02)
    Eco-Friendly, Set-on-Demand Digital Concrete
  3. Burger Joris, Lloret-Fritschi Ena, Scotto Fabio, Demoulin Thibault et al. (2020-04)
    Eggshell:
    Ultra-Thin Three-Dimensional Printed Formwork for Concrete Structures
  4. Burger Joris, Lloret-Fritschi Ena, Taha Nizar, Scotto Fabio et al. (2020-07)
    Design and Fabrication of a Non-Standard, Structural Concrete Column Using Eggshell:
    Ultra-Thin, 3D Printed Formwork
  5. Burger Joris, Wangler Timothy, Chiu Yu-Hung, Techathuvanun Chanon et al. (2021-09)
    Material-Informed Formwork Geometry:
    The Effects of Cross-Sectional Variation and Patterns on the Strength of 3D Printed Eggshell Formworks
  6. Gebhard Lukas, Burger Joris, Mata-Falcón Jaime, Lloret-Fritschi Ena et al. (2022-03)
    Towards Efficient Concrete Structures with Ultra-Thin 3D Printed Formwork:
    Exploring Reinforcement-Strategies and Optimization
  7. Hack Norman, Lauer Willi (2014-04)
    Mesh Mould:
    Robotically Fabricated Spatial Meshes as Reinforced Concrete Formwork
  8. Jipa Mihail-Andrei, Dillenburger Benjamin (2022-04)
    3D Printed Formwork for Concrete:
    State of the Art, Opportunities, Challenges, and Applications
  9. Jipa Mihail-Andrei, Giacomarra Federico, Giesecke Rena, Chousou Georgia et al. (2019-06)
    3D Printed Formwork for Bespoke Concrete Stairs
  10. Lloret-Fritschi Ena, Quadranti Elia, Scotto Fabio, Fuhrimann Lukas et al. (2022-05)
    Additive Digital Casting:
    From Lab to Industry
  11. Lloret-Fritschi Ena, Scotto Fabio, Gramazio Fabio, Kohler Matthias et al. (2018-09)
    Challenges of Real-Scale Production with Smart Dynamic Casting
  12. Lloret-Fritschi Ena, Shahab Amir, Linus Mettler, Flatt Robert et al. (2014-03)
    Complex Concrete Structures:
    Merging Existing Casting Techniques with Digital Fabrication
  13. Lloret-Fritschi Ena, Wangler Timothy, Gebhard Lukas, Mata-Falcón Jaime et al. (2020-05)
    From Smart Dynamic Casting to a Growing Family of Digital Casting Systems
  14. Mata-Falcón Jaime, Bischof Patrick, Huber Tobias, Anton Ana-Maria et al. (2022-09)
    Digitally Fabricated Ribbed Concrete Floor Slabs:
    A Sustainable Solution for Construction
  15. Meibodi Mania, Jipa Mihail-Andrei, Giesecke Rena, Shammas Demetris et al. (2018-10)
    Smart Slab:
    Computational Design and Digital Fabrication of a Lightweight Concrete Slab
  16. Ranaudo Francesco, Mele Tom, Block Philippe (2021-09)
    A Low-Carbon, Funicular Concrete Floor System:
    Design and Engineering of the HiLo Floor
  17. Reiter Lex, Wangler Timothy, Anton Ana-Maria, Flatt Robert (2020-05)
    Setting-on-Demand for Digital Concrete:
    Principles, Measurements, Chemistry, Validation
  18. Wangler Timothy, Flatt Robert (2018-09)
    Proceedings of the 1st RILEM International Conference on Concrete and Digital Fabrication:
    Correction

26 Citations

  1. Zhang Nan, Sanjayan Jay (2025-08)
    Concrete 3D Printing and Digital Fabrication Technologies for Bridge Construction
  2. Guan Jingyuan, Wang Li, Bai Gang, Ma Guowei (2025-06)
    Enhancing 3D Printed Formwork Columns via FRP Hoop Shear Connection Reinforcement
  3. Huang Shuyi, Anton Ana-Maria, Dillenburger Benjamin, Xu Weiguo (2025-06)
    Lamella-Inspired 3D Concrete Printed Column-Slab System:
    Balancing Act for Productivity and Sustainability
  4. Sakha Mahsa, Raza Saim, Wang Xiaomeng, Fan Haifeng et al. (2025-06)
    Assessment of Post-Tension Capacity in Novel 3D-Printed Topology:
    Optimized Formwork via Load Transfer Testing
  5. Hua Hao, Liu Yizhuo, Hovestadt Ludger, He Siyuan et al. (2025-04)
    Digital Nervi:
    Performance‐based Design of Lightweight Isostatic Ribbed Slab with 3D Printed Concrete Formwork
  6. Jia Lutao, Dong Enlai, Xia Kailun, Niu Geng et al. (2025-04)
    Initial Plastic Shrinkage of 3D-Printed Concrete Incorporating Recycled Brick Fine Aggregates:
    Insights from Water Transport and Structural Evolution
  7. Zhang Yuying, Zhu Xiaohong, Li Muduo, Zhang Chao et al. (2025-04)
    3D Printing Technology in Concrete Construction
  8. Ramirez Rodriguez Fatima, Pancho Paolo, Sanchez Daniela, Poudel Suman et al. (2025-02)
    Design and Development of a Lean Robotic Cell for Concrete 3D Printing
  9. Guan Jingyuan, Wang Li, Huang Yimiao, Ma Guowei (2024-12)
    3D Printed Concrete Composite Slabs Fabricated by Pre-Stressed Reinforced Permanent Formwork:
    Design, Manufacturing, and Performance
  10. He Lewei, Pan Jiahui, Hee Yu, Chen Hao et al. (2024-09)
    Development of Novel Concave and Convex Trowels for Higher Inter-Layer Strength of 3D Printed Cement-Paste
  11. Ammann Rebecca, Gebhard Lukas, Thoma Karel, Mata-Falcón Jaime et al. (2024-09)
    Environmental Benefits of Concrete Floor Slabs Produced with Digitally Fabricated Formworks:
    A Case Study
  12. Baz Bilal, Nana W., Mothe Loïc, Florentin Jérôme et al. (2024-09)
    Structural Behavior of 3D Printed Load Bearing Elements
  13. Lowke Dirk, Anton Ana-Maria, Buswell Richard, Jenny Ercan et al. (2024-09)
    Digital Fabrication with Concrete Beyond Horizontal Planar Layers
  14. Gebhard Lukas, Mata-Falcón Jaime, Ammann Rebecca, Pressmair Nadine et al. (2024-08)
    Enhancing Structural Efficiency with Digital Concrete:
    Principles, Opportunities and Case Studies
  15. Du Guoqiang, Sun Yan, Qian Ye (2024-08)
    3D Printed Strain-Hardening Cementitious Composites (3DP-SHCC) Reticulated Shell Roof Inspired by the Water Spider
  16. Duarte Gonçalo, Brown Nathan, Duarte José (2024-07)
    Workflow for Generating, Simulating, and Optimizing Form and Tool-Path in 3D Concrete Printing of Vaults
  17. Breseghello Luca, Hajikarimian Hamed, Naboni Roberto (2024-05)
    3DLightSlab:
    Design to 3D Concrete Printing Workflow for Stress-Driven Ribbed Slabs
  18. Zuo Zibo, Corte Wouter, Huang Yulin, Chen Xiaoming et al. (2024-05)
    Strategies Towards Large-Scale 3D Printing Without Size-Constraints
  19. Gappmeier Peter, Reichenbach Sara, Kromoser Benjamin (2024-03)
    Advances in Formwork Automation, Structure and Materials in Concrete Construction
  20. Silveira Marcos, Wagner Juliana, Khanverdi Mohsen, Das Sreekanta (2024-02)
    Structural Performance of Large-Scale 3D Printed Walls Subjected to Axial Compression Load
  21. Burger Joris, Lloret-Fritschi Ena, Akerman Marc, Schwendemann Daniel et al. (2023-11)
    Circular Formwork:
    Recycling of 3D Printed Thermoplastic Formwork for Concrete
  22. Mata-Falcón Jaime, Gebhard Lukas, Lee Minu, Bischof Patrick (2023-10)
    Advances in Structural Applications of Digital Fabrication With Concrete
  23. Duarte Gonçalo, Duarte José, Brown Nathan, Memari Ali et al. (2023-07)
    Design-Optimization Workflow for 3D Concrete Printing of Spanning Structures
  24. Huber Tobias, Burger Joris, Mata-Falcón Jaime, Kaufmann Walter (2023-03)
    Structural Design and Testing of Material-Optimized Ribbed RC Slabs with 3D Printed Formwork
  25. Burger Joris, Aejmelaeus-Lindström Johan, Gürel Şeyma, Niketić Filip et al. (2023-02)
    Eggshell Pavilion:
    A Reinforced Concrete Structure Fabricated Using Robotically 3D Printed Formwork
  26. Dörrie Robin, Laghi Vittoria, Arrè Lidiana, Kienbaum Gabriela et al. (2022-10)
    Combined Additive Manufacturing Techniques for Adaptive Coastline Protection Structures

BibTeX 
@article{burg_hube_llor_mata.2022.DaFoORCFSULS3PF,
  author            = "Joris Jan Burger and Tobias Huber and Ena Lloret-Fritschi and Jaime Mata-Falcón and Fabio Gramazio and Matthias Daniel Kohler",
  title             = "Design and Fabrication of Optimised Ribbed Concrete Floor Slabs Using Large-Scale 3D Printed Formwork",
  doi               = "10.1016/j.autcon.2022.104599",
  year              = "2022",
  journal           = "Automation in Construction",
  volume            = "144",
}
Formatted Citation

J. J. Burger, T. Huber, E. Lloret-Fritschi, J. Mata-Falcón, F. Gramazio and M. D. Kohler, “Design and Fabrication of Optimised Ribbed Concrete Floor Slabs Using Large-Scale 3D Printed Formwork”, Automation in Construction, vol. 144, 2022, doi: 10.1016/j.autcon.2022.104599.

Burger, Joris Jan, Tobias Huber, Ena Lloret-Fritschi, Jaime Mata-Falcón, Fabio Gramazio, and Matthias Daniel Kohler. “Design and Fabrication of Optimised Ribbed Concrete Floor Slabs Using Large-Scale 3D Printed Formwork”. Automation in Construction 144 (2022). https://doi.org/10.1016/j.autcon.2022.104599.