Fabrication of Lightweight, Carbon Textile Reinforced Concrete Components with Internally Nested Lattice Structure Using 2-Layer Extrusion by LabMorTex (2023-06)¶

This paper describes the concept, form finding, fabrication and experimental testing of prototype innovative concrete components made of extruded and transformed carbon textile reinforced concrete (TRC). The components consist of two thin-walled concrete facings that are connected by an internally nested lattice structure made of carbon TRC. Through an innovative process, thin carbon TRC stripes with a width of 10 mm were extruded with 2 textile grids and then shaped into a counter arched structure following a sinusoidal wave. The components with internally nested lattice structure represent a lightweight structural system with a drastic saving of dead load compared to conventional steel reinforced concrete (SRC) components. The design process as well as the manufacturing process, concrete mixing, material and experimental testing are presented. The results indicate that sandwich wall components with up to 76 % less use of materials in comparison to steel reinforced constructions can be realized. In addition, an outlook for the production of further components from extruded TRC components is given, which are suitable for use as ribbed ceilings and which show up to 30 % less emissions in Global Warming Potential (kg CO2e/(service life)) than a comparable component with steel reinforcement based on the Life Cycle Assessment (3cradle-to-gate) with up to 77 % concrete saving.