Tailor Crete The start of a minor revolution

Tailor. Crete 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)

New possibilities with robots

New possibilities with advanced 3 D digital tools

The main goal of Tailor. Crete 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 Tailor. Made concrete structures at mass production costs. The concept involves both on-site and prefabricated elements and both load-carrying and facade elements.

Proof of concept in Denmark

MDF formwork

Pistons to tailor-make formwork

Foundry sand

Spraying formoil

Partners Architects/designers: ØSuperpool, Turkey (SME) ØDesign. To. Production, Switzerland (SME) Manufacturers concrete: ØUnicon, Denmark ØEl Caleyo, Spain (SME) Construction : ØDragados, Spain Raw material manufacturers: ØGrace, Germany ØBekaert, Belgium Robot supplier: ØGiben, Denmark (SME) Formwork suppliers: Ø Paschal, Denmark (SME) Research: ØDanish Technological Instsitute, Denmark (Co-ordinator) ØETH, Zurich ØChalmers, Sweden ØCzech University, Czech ØUniversity of Southern Denmark, Denmark

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

A new bridge Oparno on the Prague – Dresden highway n n n Bridge under construction (20082010) Arch span 135 m Budget ~20 mil. € 25

Optimal position of cooling pipes n n 2. 3 m n n Arch casting continues through the whole year – varying temperature Massive casted arch segments could attain temperature over 90 o. C during summer which is unacceptable 12 cooling pipes inserted in the arch Two criteria Temperature bellow 70 o. C (possible delayed ettringite formation) Reasonable stress field and temperature gradients 26

Progress in 03/2009 27

Progress in 07/2009 28

Progress in 09/2009 29

Ready-mix concrete composition q Cement CEM I 42. 5 R Prachovice Ca. O 63. 2, Si. O 2 20. 8, Al 2 O 3 5. 8, Fe 2 O 3 3. 3, Mg. O 3. 6, K 2 O+Na 2 O 2. 1, free Ca. O 0. 88, SO 3 2. 85 Bogue: C 3 S 43. 76, C 2 S 26. 63, C 3 A 9. 79, C 4 AF 10. 04 Blaine fineness 320 m 3/kg q Concrete C 45/55 XF 2 Cement 431 kg/m 3 in which 5% SCM Water 178 kg/m 3, w/b = 0. 413 Aggregates 1785 kg/m 3 Superplasticizer 4. 19 kg/m 3 Silica fume 30 kg/m 3 Limestone 30 kg/m 3 Entrained/entrapped air 2. 8 % 30

Multiscale modeling approach . . . n Coupled cement hydration model on microscale with FEM on macroscale Eight cement microstructures 50 x 50 mm assigned to color regions Simulation runs ~30 minutes covering several weeks after casting Axis of symmetry # 1 nn #8 31

Multiscale simulation with coupled mechanics 1. No cooling 3. Optimized cooling 2. Original cooling 32 4. Stress distribution

Effect of pipe cooling in summer n Ambient air temperature 30 o. C 33

Effect of pipe cooling in winter n Ambient air temperature 5 o. C 34