3D Printed Concrete Bridge | Designed by topology optimization

Ghent University has built a second topology optimized concrete footbridge named OptiBridge.

The design of the 5-metre-long bridge girders were based on a 2D topology optimization by Technion - Israel Institute of Technology (Team led by Prof. Oded Amir) and redesigned at Ghent University by Ticho Ooms and Gieljan Vantyghem into a realistic 3D structure.

The bridge was constructed by joining four hollow segments that were printed in less than 1.5 hours. The rapid setting and the increased early-age strength of the 3D-printed concrete mixture were achieved by extensive experimentation in the Magnel-Vandepitte laboratory where Yaxin Tao developed a unique solution. Many improvements compared to the first realization can be observed.

The project was supported by the Department of Structural Engineering and Building Materials at Ghent University. Within the 3DP group, we aim to tackle complex 3D printing problems from different angles. Prof. Geert De Schutter: rheology | Prof. Kim Van Tittelboom: durability | Prof. Wouter De Corte: structural aspects and optimization.

More information at: https://www.ugent.be/ea/structural-en...

Ghent University | Faculty of Engineering and Architecture
https://www.ugent.be/ea/en

Project leader Gieljan Vantyghem | Ticho Ooms | Yaxin Tao
Topology Optimization by Oded Amir | Emad Shakour

Music: www.bensound.com

Upcoming presentation at DC2022 by Ticho Ooms
Abstract:
In the last few years, the development of 3D concrete printing (3DCP) technology has flourished exponentially both in academics and the construction industry. Many problems inherent to 3DCP are already being tackled on a material level. However, in the practical realization of large-scale components there are still a lot of questions to be answered. In this study, we discuss the production process of a structurally optimized 3D-printed concrete bridge structure. As the entire process is largely different compared to the manufacturing of traditional concrete structures, the problems, workarounds, and insights gathered from this project are valuable for future constructions using 3DCP. The complex geometry of the bridge was extrapolated from topology optimization results from literature and was further developed through the use of parametric modelling techniques. After careful considerations, the entire bridge geometry was discretized into four segments and printed as integrated formwork. Several measures were taken during the printing process in order to successfully fabricate the separate sections. The assembly process entailed the transportation of the printed components, the placement of reinforcement and prestressing tendons, the production of the end blocks, and the handling and joining of the printed sections. For the latter, also the process of pouring self-compacting concrete in the printed formwork is discussed and more details about the post-tensioning procedure are provided.