1. TailorCrete The start of a minor revolution in the construction industry.

2. The most well known usage of concrete

3. Liquid stone – design freedom not for everyday use

4. Challenges - formwork

5. Challenges - reinforcement

6. New possibilities with Self compacting concrete (SCC)

7. New possibilities with robots

8. New possibilities with advanced 3D digital tools

9. The main goal of TailorCrete is to develop and demonstrate an industrialised process for producing unique, tailor-made structures using a radically new and cost effective approach = production of singular TailorMade concrete structures at mass production costs. The concept involves both on-site and pre- fabricated elements and both load-carrying and facade elements.

10. Proof of concept in Denmark

16. MDF formwork

17. Pistons to tailor-make formwork

18. Foundry sand

19. Spraying formoil

22. Partners Architects/designers:  Superpool, Turkey (SME)  DesignToProduction, Switzerland (SME) Construction :  Dragados, Spain Manufacturers concrete:  Unicon, Denmark  El Caleyo, Spain (SME) Raw material manufacturers:  Grace, Germany  Bekaert, Belgium Formwork suppliers:  Paschal, Denmark (SME) Robot supplier:  Giben, Denmark (SME) Research:  Danish Technological Instsitute, Denmark (Co-ordinator)  ETH, Zurich  Chalmers, Sweden  Czech University, Czech  University of Southern Denmark, Denmark

23. Time table: August 2009- July 2013 Budget: 8,5 million euro (5,9 financed by EC)

25. 25 A new bridge Oparno on the Prague – Dresden highway n Bridge under construction (2008- 2010)‏ n Arch span 135 m n Budget ~20 mil. €

26. 26 Optimal position of cooling pipes n Arch casting continues through the whole year – varying temperature n Massive casted arch segments could attain temperature over 90 o C during summer which is unacceptable n 12 cooling pipes inserted in the arch n Two criteria Temperature bellow 70 o C (possible delayed ettringite formation)‏ Reasonable stress field and temperature gradients 2.3 m

27. 27 Progress in 03/2009

28. 28 Progress in 07/2009

29. 29 Progress in 09/2009

30. 30  Cement CEM I 42.5R Prachovice CaO 63.2, SiO 2 20.8, Al 2 O 3 5.8, Fe 2 O 3 3.3, MgO 3.6, K 2 O+Na 2 O 2.1, free CaO 0.88, SO 3 2.85 Bogue: C 3 S 43.76, C 2 S 26.63, C 3 A 9.79, C 4 AF 10.04 Blaine fineness 320 m 3 /kg  Concrete C45/55 XF2 Cement 431 kg/m 3 in which 5% SCM Water 178 kg/m 3, w/b = 0.413 Aggregates 1785 kg/m 3 Superplasticizer 4.19 kg/m 3 Silica fume 30 kg/m 3 Limestone 30 kg/m 3 Entrained/entrapped air 2.8 % Ready-mix concrete composition

31. 31 Multiscale modeling approach n Coupled cement hydration model on microscale with FEM on macroscale Eight cement microstructures 50x50x50 mm assigned to color regions n Simulation runs ~30 minutes covering several weeks after casting # 1 # 8...... Axis of symmetry

32. 32 Multiscale simulation with coupled mechanics 1. No cooling2. Original cooling 3. Optimized cooling4. Stress distribution

33. 33 Effect of pipe cooling in summer n Ambient air temperature 30 o C

34. 34 Effect of pipe cooling in winter n Ambient air temperature 5 o C