Digital Prefabrication of Lightweight Building Elements for Circular Economy: Material-Minimised Ribbed Floor Slabs Made of Extruded Carbon Reinforced Concrete (ExCRC)
Abstract
:1. Introduction
2. Materials and Methods
2.1. Design of Ribbed Slabs Made of ExCRC
2.2. Materials
3. Laboratory-Scale Implementation of a One-Way ExCRC Slab
3.1. Design Selection
3.2. Production of the Concrete
3.3. Concrete Extrusion Process
3.4. Assembly of the Demonstrator
3.5. Testing of the Demonstrator
4. Results and Discussion
4.1. Test Results
4.2. Upscaling for Real-Scale Applications
5. Conclusions
- For the first time, an innovative ribbed slab with load-adjusted webs was designed and implemented using extruded variably shaped CRC strips with two layers of textile CFRP grids and a conventionally cast CRC top slab.
- The method developed here allows the production of ExCRC web components with a variable cross-section that can be automatically incorporated into ribbed slabs. The easy and formwork-free production allows very economic realisation compared with conventionally cast ribbed slabs.
- Testing of the ExCRC slab demonstrator showed the sufficient strength of the joints between the slab and the webs, resulting in flexural failure of the webs. The flexural capacity of the tested ExCRC slab demonstrator could be accurately estimated by a simple iterative calculation.
- Based on the test results, the technical requirements for the implementation of the innovative ribbed slab made of ExCRC on a plant scale for one-way and two-way slabs were demonstrated.
- The addition of a bottom concrete layer for the integration of longitudinal reinforcement and the use of corrugated extruded CRC webs for the realisation of a honeycomb core for the ceiling are important measures to further increase efficiency.
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Parameter | Unit | Extrusion (C1) | Casting (C2) |
---|---|---|---|
CEM I 42.5 R | kg/m3 | 700 | - |
CEM II/C-M | - | 707 | |
Silica fume powder | 70 | - | |
Fly ash | 210 | - | |
Water | 278 | 165 | |
Sand 2.0–4.0 mm | - | 596 | |
Sand 1.0–2.0 mm | - | 149 | |
Sand 0.5–1.0 mm | - | 227 | |
Sand 0.1–0.5 mm | 670 | 220 | |
Sand 0–0.250 mm | - | 296 | |
Quartz powder 0–0.250 mm | 278 | - | |
Methylcellulose | 7.0 | - | |
Superplasticiser | M% of cement | - | 1.53 |
PVA microfibres, ∅/L = 0.026/6 mm | Vol.—% | 0.50 | - |
Compressive strength at 28 d | MPa | 65 | 100 |
Flexural tensile strength at 28 d | 11 | 11 | |
Intensity of CO2 per unit of compressive strength | kgCO2eq/(m3·MPa) | 7.3 | 3.0 |
Manufacturer’s Designation | Impregnation | Tensile Strength 1 | Young’s Modulus 1 | Mesh Size 1 | Cross-Section 1 |
---|---|---|---|---|---|
[MPa] | [GPa] | [mm] | [mm2/m] | ||
SITgrid044 KK | PA | 2000/1840 | 150/150 | 12 | 35.3 |
Q95-CCE-38-E5 | Epoxy resin | 3710/3490 | 231/244 | 38 | 95.0 |
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Bosbach, S.; Kalthoff, M.; Morales Cruz, C.; Adam, V.; Matschei, T.; Classen, M. Digital Prefabrication of Lightweight Building Elements for Circular Economy: Material-Minimised Ribbed Floor Slabs Made of Extruded Carbon Reinforced Concrete (ExCRC). Buildings 2023, 13, 2928. https://doi.org/10.3390/buildings13122928
Bosbach S, Kalthoff M, Morales Cruz C, Adam V, Matschei T, Classen M. Digital Prefabrication of Lightweight Building Elements for Circular Economy: Material-Minimised Ribbed Floor Slabs Made of Extruded Carbon Reinforced Concrete (ExCRC). Buildings. 2023; 13(12):2928. https://doi.org/10.3390/buildings13122928
Chicago/Turabian StyleBosbach, Sven, Matthias Kalthoff, Cynthia Morales Cruz, Viviane Adam, Thomas Matschei, and Martin Classen. 2023. "Digital Prefabrication of Lightweight Building Elements for Circular Economy: Material-Minimised Ribbed Floor Slabs Made of Extruded Carbon Reinforced Concrete (ExCRC)" Buildings 13, no. 12: 2928. https://doi.org/10.3390/buildings13122928