RESUMO
Concrete construction harms our environment, making it urgent to develop new methods for building with less materials. Structurally efficient shapes are, however, often expensive to produce, because they require non-standard formworks, thus, standard structures, which use more material than is often needed, remain cheaper. Digital fabrication has the potential to change this paradigm. One method is Digital Casting Systems (DCS), where the hydration of self-compacting concrete is controlled on the fly during production, shortening the required setting time and reducing hydrostatic pressure on the formwork to a minimum. This enables a productivity increase for standard concrete production. More importantly, though, it enables a rethinking of formworks, as the process requires only cheap thin formworks, thus, unlocking the possibility to produce optimised structural members with less bulk material and lower environmental cost. While DCS has already proven effective in building structural members, this process faces the challenge of moving into industry. This paper covers the next steps in doing so. First, we present the benchmark and expectations set by the industry. Second, we consider how we comply with these requirements and convert our fast-setting self-compacting mortar mix into a coarser one. Third, we present the next generation of our digital processing system, which moves closer to the industrial requirements in terms of size and the control system. Finally, two prototypes demonstrate how DSC: (a) increases standard bulk production by 50% and (b) can be cast into ultra-thin formworks. We discuss the results and the short-term industrial concerns for efficiency and robustness, which must be addressed for such a system to be fully implemented in industry.
RESUMO
The magnitude of the thermal stresses that originate in an acrylic-based repair material used for the reprofiling of natural sandstone is analyzed. This kind of artificial stone was developed in the late 1970s for its peculiar property of reversibility in an organic solvent. However, it displays a high thermal expansion coefficient, which can be a matter of concern for the durability either of the repair or of the underlying original stone. To evaluate this risk we propose an analytical solution that considers the viscoelasticity of the repair layer. The temperature profile used in the numerical evaluation has been measured in a church where artificial stone has been used in a recent restoration campaign. The viscoelasticity of the artificial stone has been characterized by stress relaxation experiments. The numerical analysis shows that the relaxation time of the repair mortar, originating from a low T g , allows relief of most of the thermal stresses. It explains the good durability of this particular repair material, as observed by the practitioners, and provides a solid scientific basis for considering that the problem of thermal expansion mismatch is not an issue for this type of stone under any possible conditions of natural exposure.
