Enhancing structural efficiency with digital concrete – Principles, opportunities and case studies

This paper explores the opportunities of digital fabrication with concrete (DFC) to improve structural efficiency and achieve sustainable construction. Efficient structural solutions that drastically reduce material consumption can be achieved by ensuring direct load flow and placing material where needed. More than 50 % of material savings can be achieved by using flanges or hollow sections, providing continuity in beams or slabs, reducing the span of structures or using structural systems such as arches, trusses or deep beams. These concepts are not fully exploited as they often require expensive and complex formwork. DFC tackles the latter point, as it promises to produce complex geometries, minimising extra effort, cost, or waste. The paper discusses the optimisation potential of DFC for several structural elements and presents existing applications that demonstrate this potential. Five case studies of different technological approaches are discussed in detail, highlighting advantages and disadvantages to be addressed for widespread adoption.