Possibilities of Extrusion-Production in Concrete Construction (2023-09)¶

Traditional concrete production methods prioritize standardized forms for precast or in situ applications, focusing on minimizing formwork requirements and labor costs rather than material efficiency. However, the utilization of textile-reinforced concrete (TRC) offers the opportunity to increase the load-bearing capacity through the high strength of the reinforcing materials, while reducing the concrete cover and component dimensions. While extrusion has previously been employed as an innovative manufacturing technique for TRC without the need for formwork, its application has been limited to uniform elements, thus hindering the production of shape-optimized components. This study presents significant advancements in the production of TRC, highlighting the practicality of producing components with varying cross-sections using the adaptable mouthpiece extrusion technique. The profile´s width can be adjusted between 60 and 30 mm, while the profile height can be reduced from 10 to 5 mm. Moreover, the incorporation of stepper motors enabled rapid and accurate cross-section variations, enabling precise adjustments of the concrete strand to align with the precut textile strips. By employing mat-like reinforcements, the ExTRC were able to achieve transverse radii of up to 76 mm, longitudinal radii of up to 80 mm, and even double-curved shapes following the initial horizontal extrusion process. The findings highlight the potential for enhanced design flexibility and structural optimization in concrete construction. Further research and implementation of these techniques can contribute to the advancement of TRC technology and its application to automated serial manufacturing of individualized precast concrete components.