At most 3D concrete printing (3DCP) sites, a robotically controlled extruder nozzle moves parallel to the floor in straight lines, creating walls one horizontal layer at a time. The hollow center of these forms is then filled with reinforcement and concrete – that’s it, the walls are ready.

According to scientists from the University of Michigan’s DART laboratory, such installations use more concrete than necessary. They also limit the architectural features of buildings to fairly simple forms. Both problems are solved by the Shell Wall system.

How does new technology work?

First, a computer model of the structure is created, It is based on the most efficient distribution of the material needed to provide the required strength. in every part of the building. In other words, material is not used where it is not needed.

Based on this model, the printing nozzle creates multi-layered wall elements consisting of curved vertical structural ribs with thinner curved membranes covering the spaces between them. Concrete layers are not necessarily parallel to the ground. As each element is constructed, vertical reinforcement sections are placed inside the hollow ribs and thermal insulation is laid inside the hollow membranes.

Concrete printing process / Photo Shell Wall

Bench tests compared to conventional walls of the same size constructed from solid concrete, Shell Wall elements reduce weight by 72% while maintaining the same structural strength. Full-scale tests of the technology on real construction sites are now planned.

Element printed from concrete / Photo Shell Wall