Modelling and Manufacturing of Complex Architectural Elements of Concrete Using Industrial Robots in Formwork Fabrication

Abstract

The article is aimed at the description of design, 3D modelling and simulation of technology for processing and fabrication of the formwork for complex concrete structures. The process of fabrication of complex-shaped elements from the special composite concrete mixture with application of several sophisticated software, technologies and industrial robot KUKA Agilus is also described in this work. The RHWC (Robotic Hot Wire Cutter) technology fully matches the prior aspects of the Industry 4.0 concept. The study consists of four parts. The first part simplified describes the mathematical apparatus of parametric modelling for complex concrete surfaces in Rhino 6.0 software. During the research two figures was precisely designed and modelled. The second part is aimed at the description of contemporary architectural trends in complex concrete structures manufacturing, modelling and analysis of ability to implement the complex-shaped surfaces with the RHWC technology. The third part describes the materials for technology. Expanded Polystyrene foam was chosen as the optimal material for the fabrication of formwork for complex-shaped concrete structures for its cost, weight and processability, as well as the special composite cement mixture which fully met all the requirements for its fluidity and smoothness. The fourth part is demonstration of the whole fabrication process, formwork treatment and concrete pour. This work also contains all necessary aspects for meeting the quality requirements on architectural concrete.