tc client brochure

New Ways to Design and Build

What is TailorCrete?

According to the European Construction Technology Platform (ECTP), the construction of buildings in the EU consumes around 200 million m³ of concrete annually. This accounts for over approximately 50% of materials, energy, and labour usage in the construction sector. Of this amount, the costs for formwork preparation can take up to 75%. The TailorCrete project has been launched to develop an integrated, automated process to enable cost-effective use of concrete in buildings that embody individualized solutions to challenges of function, climate, location, and aesthetics. TailorCrete will apply new digital design tools, on-site and off-site robotics, and automated formwork and reinforcement systems to bring concrete technology up-to-date with the potentials of contemporary architecture.

The TailorCrete project consists of ten interactive work streams, each drawing on the core expertise of its participating partners.

TailorCrete is an initiative of the Danish Technology Institute and is being implemented together with partner organizations drawn from the public and private sectors within the EU and neighboring states. The project is part of a Europe-wide drive to transform the construction industry from material-intensive to knowledge-intesive and is funded by a multi-year grant from EU’s Seventh Framework Programme. The TailorCrete project commenced in 2009 and is scheduled for completion in 2013.

Design of buildings that surpass the technical and economic limits of present-day concrete technology and serve as test-cases throughout the project.

Architectural Cases

Design, engineering, and bench-scale testing of alternative robotically-operated formwork systems.

New Formwork Concepts

Design ToolsDevelopment of computerized design tools to enable architects to formulate and apply innovative designs for robotic implementation in the field.

New ReinforcementConceptsSpecification and assessment of reinforcement materials, and techniques suitable to robotically formed concrete.

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Identification of possible barriers in European construction standards and codes. Suggestion of necessary modifications to relevant standards and codes.

Compliance

Simulation of concrete flows in relation to selected formwork and reinforcement types and development of optimal concrete composition.

Self Compacting Concrete

Design, engineering, and bench-scale testing of alternative robotically-operated formwork systems.

New Formwork Concepts

New ReinforcementConceptsSpecification and assessment of reinforcement materials, and techniques suitable to robotically formed concrete.

Digital Fabrication TechniquesThe production and testing of full-scale robotic prototypes capable of implementing formwork and reinforcement.

Dissemination The announcement of the TC project results through channels includ-ing: websites, scien-tific papers, workshops, seminars and international conferences.

ApplicationThe design and execution of a full-scale, concrete-based architectural project demonstrating application of the TailorCrete process.

Comparative life cycle analyses of projects designed and built using the TailorCrete process versus present-day craft methods.

Life Cycle Assessments

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Be TailorCrete’s First!The resulting technology of 4 years’ of intense research

will be applied to a real life project.

TailorCrete proposes to make you a part of our team as a client and take your design problem and make it our showcase project.

Why TailorCrete?

Prior to industrialization construction of a straight or curved wall were equally labor intensive. Industrialization, however brought with it a differentiation between the two, defining one as ‘standard’ and the other as ‘non-standard’. Standard shapes are more efficiently built, and if differentiations among elements are minimized, the final product is cheaper. Thus, until recently, production in all fields from textile industry to construction champions standardization as a design and operation mode.

Within the last 15 years, however, a new set of very versatile design and production tools have been available to architects, which have triggered many experiments in optimization and shape making..

With our increased awareness of environmental responsibilities and world-wide economic downturn, ‘Non-Standard’ or ‘Optimized’ design and construction is slowly being recognized as a critical solution. Instead of standardization, optimization of designs and procedures for better efficiency and performance is becoming the new goal. With the available technology for evaluating designs based on a variety of criteria from acoustics to load-carrying capacity; new industry tools that allow for fast manufacturing of customized elements; and a greater market interest in efficiency, optimization is the new driver.

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Denizli Municipality Buidling, Competition Project, design by Superpool, 2009, © Superpool © designtoproduction

Lead Partners

Danish Technological Institute (DTI). This independent, not-for-profit institute develops, applies, and disseminates technological information and know-how in the public and private sectors. DTI’s Concrete Center is one of Europe’s largest organizations providing expertise in self-compacting concrete, sustainable concrete, microstructure analysis, and the use of robots in concrete production. DTI’s Center for Robot Technology is the focal point for advanced robot development in Denmark. www.dti.dk

Dragados. This Spanish construction company, part of ACS Group, is a large international contractor involved in building and civil works. The company has subsidiaries in Spain (Drace, FPS, SEIS, Geocisa, Tecsa, Dravosa), USA (DRAGADOS USA, Schiavone, Pulice Construction Inc., John P.Picone Inc.), Poland (Pol-Aqua), Argentina (DYCASA) and Venezuela (DYCVENSA). Dragados chairs the TC Steering Committee. www.dragados.com

Academic Institutes

Chalmers University of Technology. The Concrete Structures Research Group of this Swedish University focuses on load-carrying capacity, stability, functional design, and durability of concrete structures. www.chalmers.se

Czech Technical University. The University’s faculty of civil engineering brings to TailorCrete advanced expertise in construction technology and life-cycle analysis. www.cvut.cz

ETH Zurich . ETH’s Professorship for Architecture and Digital Fabrication examines the changes that result from introducing digital fabrication techniques into architectural production and design. www.dfab.arch.ethz.ch

University of Southern Denmark. The University’s Maersk McKinney Moller Institute specializes in research and development in the application of robotics for optimization of industrial and medical processes. www.sdu.dk

Czech Technical University

The Partners

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Private Sector Companies

Bekaert. This Belgium-based international company is a long-time leader in drawn steel wire products, coatings, and advanced metal transformation technology. www.bekaert.com designtoproduction (D2P). This Swiss company specializes in the implementation of digital process chains. D2P is expert in implementing customized CAD-based parametric models for design and manufacturing. www.designtoproduction.com

El Caleyo Nuevas Tecnologías S.A. This Spanish company specializes in the manufacture of concrete and concrete components. The company maintains facilities for producing full-scale prototypes of architectural elements from digitally produced molds. www.elcaleyo.es

Gibotech A/S. Is one of Denmark’s largest suppliers of advanced robotics and other automation solutions for industry. www.gibotech.dk

Grace Bauprodukte GmbH. This German subsidiary of Grace Production Products provides concrete admixtures and fibres, products for architectural concrete, cement processing additives, and products for light and heavy precast concrete. www.grace.com

Paschal Danmark A/S. This Danish supplier of formwork solutions provides technical drawings, calculations, on-site support, and hardware for all types of projects involving in-situ concrete. www.paschal.dk

Superpool LTD. Is an Istanbul-based architectural and design practice with training and experience in developing customized design solutions in concert with engineering specialists. www.superpool.org

Unicon A/S. This Danish company is a major producer of ready-mix concrete and has applied its experience in complicated concrete castings to numerous projects throughout Scandinavia. www.unicon.dk

Design & Planning

While a design is taking shape architects, engineers and contractors are united around the goal of planning its execution. During the process each partner team has their own responsibilities.. A design is finalized when fabrication data for all of its components is ready and construction begins.

For an efficient design process, TailorCrete aims to provide seamless communication and exchange between the different teams through the development of TailorCrete software plug-ins.

Under the umbrella of one software, both real-time input for designers and detailed fabrication output for contractors will be possible.

Design

Architect

“I need a software to evaluate the curvature in my design...

How can the design become more cost efficient?”

Engineer

“I need a software to plan the formwork and reinforcement for these geometries...

What is the optimal formwork solution?”

Contractor

“How can I calculate the exact cost?

I need fabrication data for formwork and reinforcement.”

DESIGN TOOL

DESIGN PLANNING TOOL

Optimized Geometry

Initial Geometry

Specific Fabrication

Data

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Design

Architect

“I need a software to evaluate the curvature in my design...

How can the design become more cost efficient?”

Engineer


What is the optimal formwork solution?”

Contractor

“How can I calculate the exact cost?


DESIGN TOOL

DESIGN PLANNING TOOL

Optimized Geometry

Initial Geometry

Specific Fabrication

Data

Construction

Formwork, reinforcement and concrete are essential components of concrete construction. TailorCrete aims to revolutionize the technology behind these components by introducing automated systems and on-site and off-site robotics. The sophistication of these automated systems will be varied to address different complexities of design.

TailorCrete’s integrated software will evaluate any given design to help select the most efficient construction technique and provide the fabrication data required.

“I need to build low, medium and high curvature.”

Formwork

Contractor

“I need to fabricate complex reinforcement geometries.”

Reinforcement

Contractor

“I need a concrete composition suitable for complex formwork shapes.”

Concrete

Contractor

FORMWORK TECHNOLOGY

REINFORCEMENT TECHNOLOGY

SCC TECHNOLOGY

Formwork Fabrication

Data

Reinforcement Fabrication

Data

Concrete Specification

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“I need to build low, medium and high curvature.”

Formwork

Contractor


Reinforcement

Contractor


Concrete

Contractor

FORMWORK TECHNOLOGY


SCC TECHNOLOGY

Formwork Fabrication

Data

Reinforcement Fabrication

Data

Concrete Specification

Unikabeton Januar 2010

Designforudsætninger:

Udgangspunktet for prototypen var et designspace udformet som et volumen mellem to membraner.Membranernes form blev fundet via programmet Rhino Membrane, et software til minimalfladesimulering. Den øverste membran havde grundform af en afrundet trekant. Trekantens form blev valgt forat minimere det overfladeareal, som skulle udfræses i polystyren. Afrundingerne blev valgt for at undgå forstore udkragninger og skarpe hjørner.Membranen kan forstås som en elastisk flade, i hvilke tre punkter ’trykkes ned’. Under disse tre punkter erunderstøtningerne placeret.Den nederste membran havde samme grundform som den øverste, mens de tre forsænkede punkter vartrykket længere ned. Dermed opstod et designspace med en lille volumen ud mod membranernes kanter,og en større volumen under understøtningerne.Dette volumen blev topologioptimeret, idet det blev det forudsat, at pladekonstruktionen var simpeltunderstøttet af søjlerne.

Fig. 6 & 7: dobbeltkrum betonmembran og topologioptimeret ribbestruktur

Prototype:

Den endelige prototype er en fritstående betonkonstruktion udformet som en afrundet ribbeplade simpeltunderstøttet af tre indspændte søjler. Den overdækker et areal på ca. 12 x 5,5 m og har en højde på ca. 3,5m. Ribbepladen består af en 70 mm massiv betonmembran, der understøttes af en topologioptimeretribbestruktur.Som vist på fig. 7 og 8 genererede topologioptimeringen en kompleks ribbeplade karakteriseret ved etorganisk netværk af bøjningspåvirkede ribber. Konstruktionen kan opfattes som et primært system afdobbeltkrumme ribber som i visse områder er forstærket med sekundære ribber.

Bilag 5: En topologioptimeret konstruktion - fra design til udførelse 6


Designforudsætninger:

Udgangspunktet for prototypen var et designspace udformet som et volumen mellem to membraner.Membranernes form blev fundet via programmet Rhino Membrane, et software til minimalfladesimulering. Den øverste membran havde grundform af en afrundet trekant. Trekantens form blev valgt forat minimere det overfladeareal, som skulle udfræses i polystyren. Afrundingerne blev valgt for at undgå forstore udkragninger og skarpe hjørner.Membranen kan forstås som en elastisk flade, i hvilke tre punkter ’trykkes ned’. Under disse tre punkter erunderstøtningerne placeret.Den nederste membran havde samme grundform som den øverste, mens de tre forsænkede punkter vartrykket længere ned. Dermed opstod et designspace med en lille volumen ud mod membranernes kanter,og en større volumen under understøtningerne.Dette volumen blev topologioptimeret, idet det blev det forudsat, at pladekonstruktionen var simpeltunderstøttet af søjlerne.

Fig. 6 & 7: dobbeltkrum betonmembran og topologioptimeret ribbestruktur

Prototype:

Den endelige prototype er en fritstående betonkonstruktion udformet som en afrundet ribbeplade simpeltunderstøttet af tre indspændte søjler. Den overdækker et areal på ca. 12 x 5,5 m og har en højde på ca. 3,5m. Ribbepladen består af en 70 mm massiv betonmembran, der understøttes af en topologioptimeretribbestruktur.Som vist på fig. 7 og 8 genererede topologioptimeringen en kompleks ribbeplade karakteriseret ved etorganisk netværk af bøjningspåvirkede ribber. Konstruktionen kan opfattes som et primært system afdobbeltkrumme ribber som i visse områder er forstærket med sekundære ribber.



fig. 7: Topologioptimeret prototype. Per Dombernowsky & Asbjørn Søndergaard

Realisering:

Prototypen udfræses i negativform af i alt 29 polystyrenblokke. Blokkene samles på pladsen i etkonventionelt forskallingssystem. Negativformen armeres og der udstøbes med beton.I forbindelse med udfræsningen blev det valgt at lade robotten arbejde med store såkaldte step overværdier. Step over værdien bestemmer størrelsen af hver fræsebane, og store værdier giver såledestydeligere aftegninger af fræsningens spor.Ved forsøgsvis fræsning viste dette sig at danne spor, som understreger den komplekse geometri. Sporerneefterlader således – i modsætning til eksempelvis en hel glat flade – en fortælling om konstruktionenstilblivelse. Samtidig reduceres fræsetiden signifikant. Sporene er sammenlignelige med de sportræforskallinger efterlader – her blot i relation til den i denne sammenhæng anvendteproduktionsteknologiDen realiserede prototype bliver dermed ved projekteringsprocessens afslutning så vidt det videsverdens første eksempel på en topologioptimeret fuldskala betonkonstruktion.


Structural Efficiency

The cost of a building’s structure is a high percentage in the overall budget therefore efficiency in structure can become an important saving. While providing economic advantages TailorCrete will also investigate the aesthetics of optimizing structural systems.

The Unikabeton Project, 2007-2009

Four TailorCrete partners (Danish Technological Institute, Paschal Danmark A/S, Gibotech A/S, Unicon A/S) participated in the research project Unikabeton. The project activities included research on optimized architectural shapes, new formwork materials, Information Communications Technology, self-compacting concrete and robotics.

“The full scale prototype of the Unikabeton-project is the world’s first topology optimized concrete structure. Carrying a doubly curved, minimal surface concrete membrane, the flow of forces appears directly in the optimized ribbed structure. The prototype exemplifies the capacity for topology optimization to generate rational structures within a high complexity frame. In simple structural cases, a certain degree of optimization can be reached by empirical design and evaluation.”* However in complex cases the task requires specific design and production tools.

* http://fluxstructures.net/ © Paschal Danmark A/S

© Paschal Danmark A/S



DESIGN

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Unikabeton Pavilion, Research Project, design by Per Dombernowsky and Asbjørn Sondergaard (Aarhus School of Architecture), 2010, © Paschal Danmark A/S

Customized Urban Outdoors

“We have theories, specialisms, regulations, exhortations, demonstration projects. We have planners. We have highway engineers. We have mixed use, mixed tenure, architecture, community architecture, urban design, neighbourhood strategy. But what seems to have happened is that we have simply lost the art of placemaking; or, put another way, we have lost the simple art of placemaking. We are good at putting up buildings but we are bad at making places”*

TailorCrete will open up areas of public design that is restricted with limited budget, to allow communities larger aesthetic choices. Carefully detailed materials and customized designs will help create unique spaces and experiences.

The Perforated Wall, ETH Zurich, 2006

Using digital fabrication methods that do not depend on repetition or uniformity, perforated wall elements can be produced with high differentiation. Through the differing orientations of several openings, permeable areas are created in the wall, their form and transparency changing continuously and gently along with the movement of the observer.

“sustainable placemaking” - Keynote speech by Bernard Hunt of HTA Architects, 22 February 2001

© Architecture and Digital Fabrication, ETH Zurich





DESIGN

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The Perforated Wall, Elective Course at the Chair for Architecture and Digital Fabrication, ETH Zurich , 2006, © Architecture and Digital Fabrication, ETH Zurich

The Disintegrated Wall, Research Course at the Chair of Architecture and Digital Fabrication, ETH Zurich, 2007, © Architecture and Digital Fabrication, ETH Zurich

Benidorm West Beach PromenadeBenidorm, Spain 2009

The 1,2 km long Benidorm West Beach Promenade acts with its organic form as a transition between the city and the sea shore. During 24 months TailorCrete partner Dragados coordinated the trial casts and the construction on site. High quality and durable finish of 4800 m² double curved concrete wall required the use of a special concrete mix and casting techniques.

© Dragados

ARCHITECT

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“I need a software to evaluate the shapes in my design...

What kind of formwork systems are available for these geometries?

How can the design become more cost efficient?

How will the formwork and gap patterns look like? What options do I have to modify them?”

DESIGN TOOL

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The Real Time Design Tool developed by TailorCrete is a software plug-in that assists the architect during the design process. Giving real time interactive visual feedback, it helps to define the building geometry providing critical information about the formwork: cost, gap patterns, etc.


ENGINEER

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CONTRACTOR

Cost estimation for milled formwork

Required material blocks

Milled material blocks


What is the optimal formwork solution?

How can I calculate the exact cost?


TAILORCRETE WP02Sample Geometry Studies, 12th July 2010

MILLING ESTIMATESTIME & COST

Taken from DTI presentation 28/06/10, TBC.

Milling Parameters Milling EstimatesRoughing Low Curvature Medium Curvature

tool path width 0.04 (min radius 15m) (min radius 5m)tool path depth 0.025 Total for samplestool speed (m/sec) 0.33 machine time, roughing (hrs) 163.30 82.49milling rate (m3/sec) 0.00033 machine time, surface (hrs) 10.25 5.91

total machine time (hrs) 173.55 88.40Surface Finishing Total Machine Cost (EUR) 17'355 8'840tool width 0.04 Per Surface Area m2tool speed 0.33 machine time, roughing (mins) 20.12 17.61surface finish rate (m2/sec) 0.0132 machine time, surface (mins) 1.26 1.26

total machine time (mins) 21.38 18.88setup time / piece (mins) 5 setup time (mins) 0.80 3.20Machine cost (EUR/hr) 100 Machine Cost / m2 (EUR) 37 37

Low CurvatureFormwork: 175 m³Min. Bounding: 286 m³

Medium CurvatureFormwork: 88 m³Min. Bounding: 140 m³

PLANNING TOOL

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Task 5.2, Planning ToolGoals » Wide range of control options » Expert fabrication user

Expert Knowledge

Gramazio & Kohler, ETH ZurichArchitecture and Digital Fabrication Presenter: Silvan Oesterle

The Formwork Planning Tool developed by TailorCrete is a software that assists the engineer during the formwork planning process. For a given surface it automatically selects the best suitable formwork from a range of available types. It provides cost calculation and generates planning relevant data: plans, schedules, quantities...

Medium Curvatureradius < 15mFootprint: 137m²Surface Area: 152m²

Low Curvatureradius > 15mFootprint: 244m²Surface Area: 255m²

© designtoproduction

Mercedes Benz MuseumStuttgart, Germany 2005

The double curved, smooth fair-faced concrete surfaces of UN Studio’s Mercedes Benz Museum are a striking reflection of its interior space. The complex geometry was however beyond the scope of existing formwork systems and manual planning methods.TailorCrete partner designtoproduction developed a method that enabled the assembly of the doubly curved formwork from planar boards. The panels – precisely pre-cut on a CNC-router – were bent to the desired shape in situ during the construction process, exploiting their elasticity.


CONTRACTOR

digitally adjustable mould

DIGITAL MOULD

PRE-MOULDED FORMWORK ELEMENT

Wax

Wax

PLACING ON SITE

Wax

formwork on standard scaffolding tower

“I need to build low and medium curvature.”

FORMWORK TECHNOLOGY

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Pre-Moulded Formwork being developed by TailorCrete is a re-usable formwork system applicable to low and medium curved surfaces. It utilizes an adjustable mould to produce pre-moulded formwork elements, from a re-usable material.The production is a durable and low cost process. The material can be re-used numerous times, with low energy consumption.


formwork on standard

scaffolding tower

STANDARDIZED BLOCKOF MATERIAL

MILLING OF FORMWORK

PLACING ON SITE

CONTRACTOR

“I need to build medium and high curvature.”

FORMWORK TECHNOLOGY

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Milled Formwork examined by TailorCrete is a partly re-usable formwork system efficient in medium and high curvature surfaces.Different formwork materials (EPS, Casting Sand, Wax) can be milled according to required geometries. Depending on the milling tool and speed different surface textures can be achieved.

© Danish Technological Institute

CONTRACTOR

“I need to build low and medium curvature.”

custom cut plywood triangles

adjusted telescopic girder system

TRIANGULAR TELESCOPIC GIRDERFORMWORK ON ADJUSTABLE SINGLE PROP SCAFFOLDING

TOWER

PLACING ON SITE

FORMWORK TECHNOLOGY

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The Triangular Telescopic Girder Formwork being developed by TailorCrete is a partly re-usable formwork system applicable to the construction of low and medium curvatures.A telescopic girder system of primary and secondary beams is placed on an adjustable single prop scaffolding tower. Through the vertical adjustment of single props a double curved surface can be achieved. The final layer is made of CNC cut plywood triangles, which is giving the surface a triangulated appearance.

© Superpool

EPFL Learning CentreLausanne, Switzerland 2008

The large, double curved concrete slab of SANAA’s EPFL Learning Center required a specific formwork solution. A smoothly curved surface of 7,500 sqm was constructed in combination with standard scaffolding components, using nearly 1,500 individual wooden boxes.TailorCrete partner designtoproduction automated the planning process, starting with a 3D-model of the slab surface, and resulting in detailed plans for all of the 1,500 formwork tables and the machine data for the CNC-cutting of almost 10,000 individual cleats.


CONTRACTOR

PLACING ON SITE

HANDLING

BENDING



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Digital Fabrication Techniques for Steel Reinforcement developed by TailorCrete use automation and robots to produce complex steel geometries. Robots bend, place into position and weld the steel into stiff cages that are transported to site.

© University of Southern Denmark

CONTRACTOR


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SCC TECHNOLOGY

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Self Compacting Concrete (SCC) is a widely used concrete type, that unlike conventional concrete, doesn’t require compacting using external force from mechanical equipment. Instead, SSC is designed in such as way that it gets compacted using its own weight and characteristics.Currently, the ready mix and prefab industry use SCC mainly for uncomplicated horizontal applications e.g. slabs on grade, foundations and facade elements. Horizontal castings are much easier to control than castings into vertical and complex shaped formworks. TacilorCrete will provide solutions for the execution of unique concrete structures with SCC. The research includes modelling of flow and experimental trial castings for verification.


CONTACTMette GlavindTel: +45 72 20 22 20E-mail: [email protected] www.tailorcrete.com

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