PSI - Issue 64

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ScienceDirect Structural Integrity Procedia 00 (2023) 000 – 000 Structural Integrity Procedia 00 (2023) 000 – 000 Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Available online at www.sciencedirect.com ScienceDirect

www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia

Procedia Structural Integrity 64 (2024) 1200–1207

SMAR 2024 – 7th International Conference on Smart Monitoring, Assessment and Rehabilitation of Civil Structures Digital Fabrication of Ribbed Slabs With Post-Tensioned 3D Printed Concrete Formwork Saim Raza a, * , Mahsa Sakha a , Behzad Manshadi b , Haifeng Fan b , Xiaomeng Wang b Moslem Shahverdi a a Empa, Ueberlandstrasse 129, Dubendorf, 8600, Switzerland b BBR VT International Ltd, Ringstrasse 2, 8603 Schwerzenbach, Switzerland Abstract This paper presents a novel digital prefabrication concept for the ribbed slabs, wherein post-tensioned 3D printed concrete (3DPC) serves as a lightweight stay-in-place formwork. The formwork is designed to withstand the dead loads from its own weight and the cast concrete topping, along with live loads from construction equipment. The proposed concept simplifies the construction process for reinforced concrete (RC) slabs by eliminating the need of temporary formwork, temporary shoring or scaffolding typically required in traditional construction. To evaluate the feasibility of the concept, design calculations were performed for a ribbed slab formwork with 30 mm thickness. The results showed that the proposed concept is feasible for span lengths of 4 to 6m for various eccentricities of the post tensioning tendons. The printing feasibility of this slender formwork design was evaluated by printing it to a height of 2 m. The paper concludes with a discussion on the design implications of the corrugated surface of 3DPC compared to flat surface of conventional concrete. For this purpose, a detailed analysis was conducted to assess the stress concentration arising from the corrugated geometry of 3DPC and its consequent effects on the cracking loads. © 2024 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of SMAR 2024 Organizers Keywords: Digital fabrication, 3D concrete printing, stay-in-place formwork, Post-tensioning SMAR 2024 – 7th International Conference on Smart Monitoring, Assessment and Rehabilitation of Civil Structures Digital Fabrication of Ribbed Slabs With Post-Tensioned 3D Printed Concrete Formwork Saim Raza a, * , Mahsa Sakha a , Behzad Manshadi b , Haifeng Fan b , Xiaomeng Wang b Moslem Shahverdi a a Empa, Ueberlandstrasse 129, Dubendorf, 8600, Switzerland b BBR VT International Ltd, Ringstrasse 2, 8603 Schwerzenbach, Switzerland Abstract This paper presents a novel digital prefabrication concept for the ribbed slabs, wherein post-tensioned 3D printed concrete (3DPC) serves as a lightweight stay-in-place formwork. The formwork is designed to withstand the dead loads from its own weight and the cast concrete topping, along with live loads from construction equipment. The proposed concept simplifies the construction process for reinforced concrete (RC) slabs by eliminating the need of temporary formwork, temporary shoring or scaffolding typically required in traditional construction. To evaluate the feasibility of the concept, design calculations were performed for a ribbed slab formwork with 30 mm thickness. The results showed that the proposed concept is feasible for span lengths of 4 to 6m for various eccentricities of the post tensioning tendons. The printing feasibility of this slender formwork design was evaluated by printing it to a height of 2 m. The paper concludes with a discussion on the design implications of the corrugated surface of 3DPC compared to flat surface of conventional concrete. For this purpose, a detailed analysis was conducted to assess the stress concentration arising from the corrugated geometry of 3DPC and its consequent effects on the cracking loads. © 2024 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of SMAR 2024 Organizers Keywords: Digital fabrication, 3D concrete printing, stay-in-place formwork, Post-tensioning © 2024 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of SMAR 2024 Organizers

* Corresponding author. Tel.: +41 58 765 4726; fax: +41 58 765 6955. E-mail address: saim.raza@empa.ch * Corresponding author. Tel.: +41 58 765 4726; fax: +41 58 765 6955. E-mail address: saim.raza@empa.ch

2452-3216 © 2024 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of SMAR 2024 Organizers 2452-3216 © 2024 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of SMAR 2024 Organizers

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