TailorCrete

The start of a minor revolution in the construction industry.

The most well known usage of concrete

Liquid stone – design freedom not for everyday use

Challenges - formwork

Challenges - reinforcement

New possibilities with Self compacting concrete (SCC)

New possibilities with robots

New possibilities with advanced 3D digital tools

The main goal of TailorCrete is to develop and demonstrate an industrialised process for producing unique, tailor-made structures using a radically new

and cost effective approach =production of singular TailorMade concrete

structures at mass production costs.

The concept involves both on-site and pre-fabricated elements and both load-carrying and

facade elements.

Proof of concept in Denmark

MDF formwork

Pistons to tailor-make formwork

Foundry sand

Spraying formoil

Partners

Architects/designers:Superpool, Turkey (SME)DesignToProduction, Switzerland (SME)Construction :Dragados, Spain

Manufacturers concrete:Unicon, DenmarkEl Caleyo, Spain (SME)

Raw material manufacturers:Grace, GermanyBekaert, Belgium

Formwork suppliers: Paschal, Denmark (SME)

Robot supplier:Giben, Denmark (SME)

Research:Danish Technological Instsitute, Denmark (Co-ordinator)ETH, ZurichChalmers, SwedenCzech University, CzechUniversity of Southern Denmark, Denmark

Time table: August 2009- July 2013

Budget: 8,5 million euro (5,9 financed by EC)

25

A new bridge Oparno on the Prague – Dresden highway

Bridge under construction (2008-2010)

Arch span 135 m Budget ~20 mil. €

26

Optimal position of cooling pipes

Arch casting continues through the whole year – varying temperature Massive casted arch segments could attain temperature over 90oC during

summer which is unacceptable 12 cooling pipes inserted in the arch Two criteria

Temperature bellow 70oC (possible delayed ettringite formation)Reasonable stress field and temperature gradients

2.3

m

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Progress in 03/2009

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Progress in 07/2009

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Progress in 09/2009

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Cement CEM I 42.5R PrachoviceCaO 63.2, SiO2 20.8, Al2O3 5.8, Fe2O3 3.3, MgO 3.6, K2O+Na2O 2.1, free CaO 0.88, SO3 2.85

Bogue: C3S 43.76, C2S 26.63, C3A 9.79, C4AF 10.04

Blaine fineness 320 m3/kg

Concrete C45/55 XF2Cement 431 kg/m3 in which 5% SCMWater 178 kg/m3, w/b = 0.413Aggregates 1785 kg/m3

Superplasticizer 4.19 kg/m3

Silica fume 30 kg/m3

Limestone 30 kg/m3

Entrained/entrapped air 2.8 %

Ready-mix concrete composition

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Multiscale modeling approach

Coupled cement hydration model on microscale with FEM on macroscale Eight cement microstructures 50x50x50 mm assigned to color regions Simulation runs ~30 minutes covering several weeks after casting

# 1

# 8

......

Axi

s of

sym

met

ry

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Multiscale simulation with coupled mechanics

1. No cooling 2. Original cooling

3. Optimized cooling 4. Stress distribution

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Effect of pipe cooling in summer

Ambient air temperature 30oC

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Effect of pipe cooling in winter

Ambient air temperature 5oC