The need for methods for forming concrete has existed for as long as concrete has been used in constructing the built environment. Creating flat, rectilinear formers have traditionally been the cost and time efficient default for the majority of applications. The desire for greater design freedom and the drive to automate construction manufacturing is providing a platform for the continued development of a family of processes called Digital Fabrication with Concrete (DFC) technologies. DFC technologies are many and varied. Much of the material science theory is common, but the process steps vary significantly between methods, creating challenges as we look towards performance comparison and standardisation. Presented here is a framework to help identify and describe process differences and a showcase of DFC application case studies that explain the processes behind a sub-set of the technologies available.@en

The form freedom enabled by digital fabrication with concrete technologies provides advantages for a wide range of concrete based objects, from architectural to structural elements. The current chapter focuses on the specifics of structural design and engineering of DFC with emphasis on those technologies based on Additive Manufacturing with extrusion. Since it is a new and innovative way to build, a clear common approach to structural engineering has not yet been developed. As a result, this chapter aims to introduce the specific challenges of structural design and engineering with the additive manufacturing technology, providing an overview of structural typologies that have been developed (especially concerning the reinforcement strategies, including fibre reinforcement). Furthermore, the structural principles adopted in DFC and the codified approaches used in conventional reinforced concrete is compared, and putative structural testing procedures and validation methods for DFC are reported.@en

Digital Fabrication with Concrete (DFC) encompasses 3D Concrete Printing (3DCP) and many other methods of production. DFC is emerging from an era of invention and demonstration to one where the merits of one principle over another needs to be quantified systematically. DFC technologies vary in characteristics, complexity and maturity which hampers the synthesis of research and comparisons of performance. The interdependence of design geometry, material properties and process characteristics is well recognised. Materials research has made significant progress in recent years and there have been many applications with varying design geometries demonstrated. Far less has been done to guide the definition and description of the processes used. This work takes a step forward by presenting classification and process description guidance for DFC. The approach was developed by engaging a broad cross-section of the international community through the activities of the RILEM Technical Committee 276 between 2016 and 2020.

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This article presents the results of an interlaboratory experimental study performed by 13 international research groups within the framework of the activities of the RILEM Technical Committee 225-SAP “Applications of Superabsorbent Polymers in Concrete Construction”. Two commercially available superabsorbent polymers (SAP) were tested in terms of their influence on the freeze–thaw resistance of ordinary concrete. To test the robustness of the method, all participating laboratories used locally produced materials. Furthermore, following this aim, various accelerated methods were used to estimate the resistance of the concrete to freeze–thaw cycles. The effect of adding SAP was from insignificant to considerably positive in terms of improvement in material performance as determined by reduced mass loss after freeze–thaw cycles; only one participant observed worsening of the material behaviour. At the same time, due to the addition of SAP, a much less pronounced decrease in the dynamic Young’s modulus was observed as a result of freeze–thaw testing without deicing salt.

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