Ice Formwork for Ultra-High Performance Concrete: Simulation of Ice Melting Deformations

Abstract

This research project asks how can we efficiently solve structural problems with much smaller masses of concrete while maintaining the same level of cement consumption, through the use of Ultra-High Performance Concrete (UHPC), degradable ice formwork and through an active involvement of digital simulation. A survey undertaken in the recent advancements of concrete-related technologies has revealed an opportunity to propose a new concept of casting. The new method of fabrication of UHPC elements employs ice as the main material of the temporary formwork construction, involves automation of the fabrication process and solves the problems of waste material and manual labor at the stage of demolding. This casting method is being developed for cases, where unique and customized concrete elements of complex geometry are needed, e.g. topology-optimized structural elements. To impose a desirable geometry onto ice, the concept considers the use of 2.5D CNC milling operations. To minimize machining time, milling is thought to be combined with controllable melting of ice that allows to achieve high-quality surface finish on a large scale in a very simple way. The main hypothesis of the research is, that the control over melting could be possible through digital simulation, that is the melting deformations can be pre-calculated if parameters of the material system are known.

Robotically Fabricated Ice Formwork: An Exploration on Casting Morphologically Programmed Complex Concrete Elements with Robotically Milled Ice Formworks

“…For this has been developed a novel approach using a concept of a simulation-based method of hybrid fabrication, where minimal and elementary milling interventions in a volume of a regular ice block can develop into a more complex geometry through the following process of melting. [7] It should be mentioned that the intention to link computer-generated geometry of optimized structures to the natural phenomenon of melting deformations is driven both by the necessity to minimize the effort during fabrication and to provide a natural materialization strategy, that does not solely rely on the transitory machining equipment, but strives to involve new physical processes in the culture of fabrication (Figure 3).…”

“…Once the cast concrete is dried and solidified, the ice formwork can be defrosted, and the water collected to be reused for another mould. This technique can create a complex structural architectural element efficiently, in a sustainable way [7].…”

Design Transactions

“…Second, the survey identified the potential of recently-developed high-performance concrete (HPC) in reducing the weight of constructions, while providing the same level of structural capacity. Lighter constructions deliver savings on transportation and raw materials (Sitnikov, 2017). Third, the use of non-ferrous fibre reinforcement presented significant benefits over traditional steel rebar.…”

A sustainable formwork system based on ice pattern and sand mould for fabricating customised concrete components

“…Additionally, concrete casting on ice formwork was investigated by Sitnikov (2019). Based on the idea of waste-free production, free-form prefabricated concrete elements were cast using the CNC-milled ice formwork (Sitnikov, 2018). Compared with conventional formwork materials, a decreased embodied energy and carbon footprint was achieved.…”