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TailorCrete

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).

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TailorCrete

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  1. TailorCrete The start of a minor revolution in the construction industry.

  2. The most well known usage of concrete

  3. Liquid stone – design freedom not for everyday use

  4. Challenges - formwork

  5. Challenges - reinforcement

  6. New possibilities with Self compacting concrete (SCC)

  7. New possibilities with robots

  8. New possibilities with advanced 3D digital tools

  9. 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.

  10. Proof of concept in Denmark

  11. MDF formwork

  12. Pistons to tailor-make formwork

  13. Foundry sand

  14. Spraying formoil

  15. Partners • Architects/designers: • Superpool, Turkey (SME) • DesignToProduction, Switzerland (SME) • Manufacturers concrete: • Unicon, Denmark • El Caleyo, Spain (SME) • Raw material manufacturers: • Grace, Germany • Bekaert, Belgium • Construction : • Dragados, Spain • Robot supplier: • Giben, Denmark (SME) • Formwork suppliers: • Paschal, Denmark (SME) • Research: • Danish Technological Instsitute, Denmark (Co-ordinator) • ETH, Zurich • Chalmers, Sweden • Czech University, Czech • University of Southern Denmark, Denmark

  16. Time table: August 2009- July 2013Budget: 8,5 million euro (5,9 financed by EC)

  17. A new bridge Oparno on the Prague – Dresden highway Bridge under construction (2008-2010)‏ Arch span 135 m Budget ~20 mil. €

  18. 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

  19. Progress in 03/2009

  20. Progress in 07/2009

  21. Progress in 09/2009

  22. Cement CEM I 42.5R Prachovice CaO 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 XF2 Cement 431 kg/m3 in which 5% SCM Water 178 kg/m3, w/b = 0.413 Aggregates 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

  23. 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 ...... Axis of symmetry # 8

  24. Multiscale simulation with coupled mechanics 1. No cooling 2. Original cooling 3. Optimized cooling 4. Stress distribution

  25. Effect of pipe cooling in summer Ambient air temperature 30oC

  26. Effect of pipe cooling in winter Ambient air temperature 5oC

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