Automated fabrication of single-curved carbon textile-reinforced concrete shells using extrusion-based printing

Concrete shells offer a more sustainable alternative to simple plates due to their efficient use of concrete in compression. When reinforced with a lightweight, corrosion-resistant material such as carbon, it becomes possible to create extremely thin shells by reducing the required concrete cover. However, manufacturing these geometrically complex structures presents a significant challenge and requires substantial manpower.

This investigation focuses on the automated fabrication of single-curved concrete shells using concrete printing by extrusion. The article presents the digital construction of a reusable framework and discusses the path generation for the printing process using a robotic arm. Additionally, it details the production of printed and laminated thin-walled concrete shells for experimental testing. To assess shell performance and analyze deformations and crack patterns, a four-point bending test is performed using a linear variable differential transformer and a photogrammetric system.

This promising work makes an early-stage contribution to the digital production of single-curved shells, paving the way for more complex, material-efficient carbon textile-reinforced concrete shell structures.