Save on concrete Cement is the most significant carbon diox | Tech for Good

Save on concrete

Cement is the most significant carbon dioxide emitter globally: its production contributes 7% of all CO2 emissions. Making cement involves burning calcium carbonate, which separates calcium and releases carbon into the atmosphere. In addition, the construction industry uses carbon-intensive materials, such as concrete and steel, inefficiently. The study by Cambridge University revealed that most commercial buildings in the UK are overdesigned by up to 50 to 60 percent.

Researchers at ETH Zurich have developed an elegant FoamWork solution to reduce construction's carbon footprint, particularly cement. They used 3D-printed formwork elements made from recyclable mineral foam to create a pre-cast concrete slab, which is lighter and better insulated while using 70 percent less material.

An autonomous robotic arm 3D printed 24 mineral formwork elements in different shapes and sizes. Then they cast and left to cure concrete around them, creating hollow cells throughout the panel. The internal geometry optimized to reinforce the slab along its principal stress lines created the necessary strength while drastically reducing the amount of concrete needed to produce it.

The FoamWork system uses an alternative material developed by Swiss start-up FenX made of a waste product from coal-fired power stations called fly ash. That helps to minimize the carbon footprint of the foam. The final FoamWork elements can either be left in place to improve the insulation of the pre-cast concrete slab or recycled and reprinted to create new formwork.

The researchers say they can customize the shape and configuration of the internal cells to create a range of concrete building elements from walls to entire roofs. With FoamWork, emissions through material consumption would be reduced in the concrete slab. The lower mass would also have secondary effects on the dimensioning of the entire load-bearing structure and would reduce efforts for shipping and handling on construction sites.

Article on DeZeen

#robotics #AI #3dprint #construction