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Automated Reinforcement Integration in Shotcrete 3D Printing Through Green State Milling (2024-09)

10.1007/978-3-031-70031-6_37

 Dörrie Robin,  Kloft Harald,  Sawicki Bartłomiej,  Freund Niklas,  Lowke Dirk
Contribution - Proceedings of the 4th RILEM International Conference on Concrete and Digital Fabrication, pp. 319-326

Abstract

In Digital Fabrication with Concrete (DFC), reinforcement integration is one of the key challenges to enable large-scale application, and further adoption of DFC by industry. This paper presents an investigation on green state milling as a novel approach to reinforce 3D printed concrete elements, in particular for reinforcement integration during fabrication utilising Shotcrete 3D Printing (SC3DP). To enable force-flow oriented freeform reinforcement installation, grooves providing space for reinforcement are robotically milled in green state. Subsequently, standard steel rebars or other reinforcing materials are installed, and a cover layer is sprayed. Two key parameters influencing the bond quality and integrity of reinforced elements are explored here: time of milling after SC3DP, and groove geometry. The results are qualitatively assessed in terms of the presence of voids and imperfections, in particular around rebars. The identified optimal set of parameters is then used for the fabrication of a second set of specimens: 1) elements for rebar pull-out testing and 2) full-scale beams for structural testing and quantitative analysis.

12 References

  1. David Martin, Freund Niklas, Dröder Klaus, Lowke Dirk (2023-09)
    The Effects of Nozzle-Diameter and Length on the Resulting Strand Properties for Shotcrete 3D Printing
  2. Dobrzanski James, Buswell Richard, Cavalaro Sergio, Kinnell Peter et al. (2021-09)
    Milling a Cement-Based 3D Printable Mortar in Its Green State Using a Ball-Nosed Cutter
  3. Dörrie Robin, David Martin, Freund Niklas, Lowke Dirk et al. (2023-10)
    In-Process Integration of Reinforcement for Construction Elements During Shotcrete 3D Printing
  4. Dörrie Robin, Freund Niklas, Herrmann Eric, Baghdadi Abtin et al. (2023-09)
    Automated Force-Flow-Oriented Reinforcement Integration for Shotcrete 3D Printing
  5. Dörrie Robin, Kloft Harald (2022-06)
    Force-Flow Compliant Robotic Path-Planning Approach for Reinforced Concrete Elements Using SC3DP
  6. Freund Niklas, David Martin, Böhler David, Mai (née Dressler) Inka et al. (2023-12)
    Shotcrete 3D Printing:
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  7. Hack Norman, Kloft Harald (2020-07)
    Shotcrete 3D Printing Technology for the Fabrication of Slender Fully Reinforced Freeform Concrete Elements with High Surface Quality:
    A Real-Scale Demonstrator
  8. Kloft Harald, Empelmann Martin, Hack Norman, Herrmann Eric et al. (2020-09)
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  9. Lindemann Hendrik, Gerbers Roman, Ibrahim Serhat, Dietrich Franz et al. (2018-09)
    Development of a Shotcrete 3D Printing (SC3DP) Technology for Additive Manufacturing of Reinforced Freeform Concrete Structures
  10. Mai (née Dressler) Inka, Freund Niklas, Lowke Dirk (2020-07)
    Control of Strand Properties Produced with Shotcrete 3D Printing by Accelerator Dosage and Process Parameters
  11. Mechtcherine Viktor, Buswell Richard, Kloft Harald, Bos Freek et al. (2021-02)
    Integrating Reinforcement in Digital Fabrication with Concrete:
    A Review and Classification Framework
  12. Wu Zhengyu, Memari Ali, Duarte José (2022-01)
    State of the Art Review of Reinforcement-Strategies and Technologies for 3D Printing of Concrete

4 Citations

  1. Sawicki Bartłomiej, Düking Peter, Placzek Gerrit, Masur Lukas et al. (2026-01)
    Human-Robot Collaboration in Digital Fabrication with Concrete:
    Quantifying Productivity and Psychophysiological Strain of Human Workers
  2. Sawicki Bartłomiej, Chen Zhuo, Leusmann Thorsten, Kloft Harald (2026-01)
    Shotcrete 3D Printed Reinforced Concrete Beam:
    Design, Testing, and Comparison Against Conventional Cast Reinforced Concrete Solution
  3. Dörrie Robin, Gantner Stefan, Amiri Fatemeh, Lachmayer Lukas et al. (2025-04)
    From Digital to Real:
    Optimised and Functionally Integrated Shotcrete 3D Printing Elements for Multi-Storey Structures
  4. Kloft Harald, Sawicki Bartłomiej, Bos Freek, Dörrie Robin et al. (2024-09)
    Interaction of Reinforcement, Process, and Form in Digital Fabrication with Concrete

BibTeX 
@inproceedings{dorr_klof_sawi_freu.2024.ARIiS3PTGSM,
  author            = "Robin Dörrie and Harald Kloft and Bartłomiej Sawicki and Niklas Freund and Dirk Lowke",
  title             = "Automated Reinforcement Integration in Shotcrete 3D Printing Through Green State Milling",
  doi               = "10.1007/978-3-031-70031-6_37",
  year              = "2024",
  volume            = "53",
  pages             = "319--326",
  booktitle         = "Proceedings of the 4th RILEM International Conference on Concrete and Digital Fabrication",
  editor            = "Dirk Lowke and Niklas Freund and David Böhler and Friedrich Herding",
}
Formatted Citation

R. Dörrie, H. Kloft, B. Sawicki, N. Freund and D. Lowke, “Automated Reinforcement Integration in Shotcrete 3D Printing Through Green State Milling”, in Proceedings of the 4th RILEM International Conference on Concrete and Digital Fabrication, 2024, vol. 53, pp. 319–326. doi: 10.1007/978-3-031-70031-6_37.

Dörrie, Robin, Harald Kloft, Bartłomiej Sawicki, Niklas Freund, and Dirk Lowke. “Automated Reinforcement Integration in Shotcrete 3D Printing Through Green State Milling”. In Proceedings of the 4th RILEM International Conference on Concrete and Digital Fabrication, edited by Dirk Lowke, Niklas Freund, David Böhler, and Friedrich Herding, 53:319–26, 2024. https://doi.org/10.1007/978-3-031-70031-6_37.