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Complex concrete structures: Merging existing casting techniques with digital fabrication
Affiliation:1. XtreeE SAS, 157 boulevard MacDonald, 75019 Paris, France;2. Digital Knowledge, Ecole Nationale Supérieure d''Architecture Paris-Malaquais, 14 rue Bonaparte, 75006 Paris, France;3. PIMM, Arts et Métiers-ParisTech/CNAM/CNRS UMR 8006, 151 bd de l''Hôpital, 75013 Paris, France;4. EZCT Architecture & Design Research, 157 boulevard MacDonald, 75019 Paris, France;1. SINTEF Building and Infrastructure, PO Box 4760, Sluppen, NO-7465 Trondheim, Norway;2. Structural Engineering Department, Norwegian University of Science and Technology, Richard Birkelands vei 1a, Trondheim, N-7491, Norway;3. Department of Architectural Design, History and Technology, Norwegian University of Science and Technology, Alfred Getz vei 3, N-7491, Norway;1. Department of Civil and Environmental Engineering, University of California, Berkeley, CA 94720, USA;2. Department of Civil Engineering and Engineering Mechanics, Columbia University, New York, NY 10027, USA;3. French Institute of Science and Technology for Transport, Development and Networks (IFSTTAR), Department Materials and Structures (MAST), Université Paris EST, 77447 Marne la Vallée, France;4. Institute of Building Materials, ETH Zurich, 8093 Zurich, Switzerland;5. Concrete Group, Department of Architecture, Building and Construction, SINTEFF Building and Infrastructure, Trondheim, Norway
Abstract:Over the course of the 20th century, architectural construction has gone through intense innovation in its material, engineering and design, radically transforming the way buildings were and are conceived. Technological and industrial advances enabled and challenged architects, engineers and constructors to build increasingly complex architectural structures from concrete. Computer-aided design and manufacturing (CAD/CAM) techniques have, more recently, rejuvenated and increased the possibilities of realizing ever more complex geometries. Reinforced concrete is often chosen for such structures as almost any shape can be achieved when placed into a formwork. However, most complex forms generated with these digital design tools bear little relation to the default modes of production used in concrete construction today. A large gap has emerged between the possibilities offered by the digital technology in architectural design and the reality of the building industry, where actually no efficient solutions exist for the production of complex concrete structures. This paper presents construction methods that unfold their full potential by linking digital design, additive fabrication and material properties and hence allow accommodating the construction of complex concrete structures. The emphasis is set on the on-going research project Smart Dynamic Casting (SDC) where advanced material design and robotic fabrication are interconnected in the design and fabrication process of complex concrete structures. The proposed fabrication process is belonging to an emerging architectural phenomenon defined first as Digital Materiality by Gramazio & Kohler (2008) or more recently as Material Ecologies by Neri Oxman  1].
Keywords:Complex concrete structures  Casting techniques  Formwork  Slipforming  Digital fabrication  Smart Dynamic Casting
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