A new type of 3D concrete printing technology is said to offer a more efficient approach to constructing buildings. The Shell Wall system, developed by the University of Michigan’s DART Laboratory, claims to produce walls that are 72% lighter than traditional walls, while providing the same structural strength.
Efficient distribution of material
The Shell Wall system begins by creating a computer model of the structure, which is based on the most efficient distribution of material needed to provide the required strength in each part of the building. By using this method, the print nozzle builds up layered wall elements consisting of curved vertical structural ribs with thinner curved membranes spanning the spaces between them. The layers of concrete are deposited in a non-planar fashion, meaning that they don’t necessarily run parallel to the ground.
Reduced weight, same strength
Tests showed that the Shell Wall elements offer a 72% reduction in weight compared to traditional walls built out of solid concrete, while providing the same structural strength. The vertical sections of rebar are inserted inside the hollow ribs, while thermal insulation is placed inside the hollow membranes. This results in less concrete being used than necessary, and the architectural features of the building are not limited to fairly simple shapes.
Future plans
Full-scale tests of the technology at actual construction sites are now being planned. The Shell Wall system offers a more efficient and environmentally friendly approach to building. With reduced use of concrete and decreased weight, transportation costs could also be lowered. Furthermore, the non-planar deposition of layers opens up new possibilities for architectural design, allowing for more complex and creative shapes to be realized.
The Shell Wall system developed by the University of Michigan’s DART Laboratory is an innovative technology that could potentially revolutionize the construction industry. By using an efficient distribution of material and reducing the weight of walls while maintaining the same strength, the system offers a more environmentally friendly and cost-effective approach to building. Full-scale tests of the technology will show how it performs in real-world construction projects.
