Load-bearing 3D-printed concrete elements subjected to compression

Evaluation of an innovative Structural Concept for a Central Control Building

Author: Sina Fluri
Language: English

Abstract

3D-printed concrete offers significant advantages, such as eliminating the need for formwork, precise material placement, and the ability to create complex shapes. This study examines whether 3D-printed concrete could replace the conventional construction methods used for the Central Control Building at the Fadhili oil field in Saudi Arabia while meeting the same structural and functional requirements. The high temperatures of up to 50˚C during construction, combined with the need to design for explosion loads, were identified as key challenges that were carefully considered in the construction process and the selection of structural concepts. To protect the interior area of the building from explosions, walls are placed around the building. Inside, supports ensure optimal vertical load transfer and are additionally designed to withstand impacts.

The fundamental principles of 3D-printed concrete, including material composition, reinforcement strategies, and construction techniques, were analysed. A structural concept for load-bearing walls and columns was developed to replace the conventional concrete elements of the original project while addressing the specific environmental requirements. Structural calculations demonstrated that the proposed 3D-printed concrete elements meet the necessary safety and performance standards. Furthermore, the construction time for columns and walls was reduced by 50% compared to a conventional construction method with cast-in-situ concrete.

These findings highlight that 3D-printed concrete holds great promise for load-bearing structures in industrial construction, enabling more efficient construction processes and shorter construction times. Environmental conditions must be carefully considered during project execution, and the shapes of columns and wall cross-sections should be tailored to the load requirements. Future research should focus on further developing the structural system by integrating the roof structure and conducting a final comparison of the proposed concept with the original project in terms of material consumption and sustainability.