Flow Production of Variable Curved Modules for Thin-Walled Concrete Shell Structures (2024-09)¶

Thin concrete shells enable considerable material savings. However, the conventional production methods for concrete shells, which are based on concreting in a formwork, are uneconomical from today's perspective. The modular approach can make shell construction significantly more cost-efficient, especially if modules are manufactured with a high degree of automation. The ongoing project "Formwork-free flow production of adaptive load-bearing structures from variable frame elements - ACDC and beyond" aims to develop an approach for the fully automated production of concrete shell modules with variable geometry. Particular attention is paid to the reinforcement of the modules, which is carried out by means of automated laying of carbon yarns. The contours of the modules are 3D-printed with highly ductile concrete (Strain-Hardening Cementitious Composite, SHCC). This paper presents the results achieved in the project and gives an overview of the ongoing work, which includes the production of non-planar modules, the introduction of post-processing techniques and improving the sustainability of the technology.