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Integrative Computational Design and Construction for Architecture (T3.0)
Research
Research Projects
RP 2-1 – Cyber-Physical Fabrication of Functionally Graded Concrete

Cyber-Physical Fabrication of Functionally Graded Concrete Components

Research Project 2-1 (RP 2-1)

IntCDC Research Project 2 – Cyber-Physical Fabrication of Functionally Graded Concrete

CYBER-PHYSICAL FABRICATION OF FUNCTIONALLY GRADED CONCRETE COMPONENTS FOR MULTI-STOREY BUILDINGS

The project concerns the development of a fabrication platform for functionally graded concrete components (Research Project RP 1-1), which are optimised for resource efficiency in terms of load-bearing capacity, taking into account the specific requirements for multi-storey buildings.

Based on the geometric, mechanical and building physics requirements from Research Project RP 1-1, the work will focus on conceptualising the overall design-to-production process chain, defining production processes for internal gradients, joints, external formwork, and casting and assembly systems. The process integrates digital implementations of design and optimisation methods with physical processes – such as fine-tuned mixing of high-performance concrete and its precise extrusion – and digital methods for process planning and control.

The overall requirement is to minimise the weight of the components, to extend the capabilities of fabrication to on-site application and to minimise the environmental impact of their manufacture in order to meet today's social and ecological challenges and to ensure the creation of a liveable environment for future generations.

The project will be carried out in close collaboration with the Research Projects Co-Design of Functionally Graded Concrete Building System (RP 1-1), Cyber-Physical Construction Platform (RP 8-1), robotic platform for cyber-physical assembly (RP 16-1) and Holistic Quality Model (RP 18-1).

PRINCIPAL INVESTIGATORS

Prof. Dr.-Ing. Harald Garrecht
Institute of Construction Materials (IWB), University of Stuttgart
Prof. Dr.-Ing. Dr. h.c. Dr.-Ing. E.h. Werner Sobek
Institute for Lightweight Structures and Conceptual Design (ILEK), University of Stuttgart
Prof. Dr.-Ing. Lucio Blandini
Institute for Lightweight Structures and Conceptual Design (ILEK), University of Stuttgart
Prof. Dr.-Ing. Oliver Sawodny
Institute for System Dynamics (ISYS), University of Stuttgart

TEAM

Dr.-Ing. Walter Haase (ILEK)
Boris Blagojevic (ISYS)
Oliver Gericke (ILEK)
Daria Kovaleva (ILEK)
Alexander Teichmann (IWB)

PEER-REVIEWED PUBLICATIONS

2023
1. Blagojevic, B., Gienger, A., Nigl, D., Blandini, L., & Sawodny, O. (2023). Modelling, Feedforward Control and Constrained Trajectory Generation for a Concrete Conveyance System. Journal of Dynamic Systems, Measurement, and Control.
  - BibTeX
  BibTeX
  @article{blagojevic2023modelling, author = {Blagojevic, Boris and Gienger, Andreas and Nigl, David and Blandini, Lucio and Sawodny, Oliver}, journal = {Journal of Dynamic Systems, Measurement, and Control}, title = {Modelling, Feedforward Control and Constrained Trajectory Generation for a Concrete Conveyance System}, year = 2023 }
2. Blagojevic, B., Gienger, A., & Sawodny, O. (2023). Dynamics of Path Following and Constrained Path Synchronization Applied to Graded Concrete Element Fabrication. 2023 IEEE 19th International Conference on Automation Science and Engineering (CASE), 1–6. https://doi.org/10.1109/CASE56687.2023.10260681
  - BibTeX
  - DOI
  BibTeX
  @conference{blagojevic2023dynamics, author = {Blagojevic, Boris and Gienger, Andreas and Sawodny, Oliver}, booktitle = {2023 IEEE 19th International Conference on Automation Science and Engineering (CASE)}, doi = {10.1109/CASE56687.2023.10260681}, pages = {1-6}, title = {Dynamics of Path Following and Constrained Path Synchronization Applied to Graded Concrete Element Fabrication}, year = 2023 }
  DOI
  10.1109/CASE56687.2023.10260681
3. Blagojevic, B., & Sawodny, O. (2023). Path Planning for Graded Concrete Element Fabrication. Construction Robotics.
  - BibTeX
  BibTeX
  @article{blagojevic2023planning, author = {Blagojevic, Boris and Sawodny, Oliver}, journal = {Construction Robotics}, title = {Path Planning for Graded Concrete Element Fabrication}, year = 2023 }
2022
1. Blandini, L. (2022). Lightweight and Sustainable Concrete Structures: The ILEK Research Strategy. Proceedings of the Fib International Congress 2022 in Oslo, Norway.
  - BibTeX
  BibTeX
  @inproceedings{blandini2022lightweight, author = {Blandini, L.}, booktitle = {Proceedings of the fib International Congress 2022 in Oslo, Norway}, title = {Lightweight and Sustainable Concrete Structures: The ILEK Research Strategy}, year = 2022 }
2. Frost, D., Gericke, O., Di Bari, R., Balangé, L., Zhang, L., Blagojevic, B., Nigl, D., Haag, P., Blandini, L., Jünger, H. C., Kropp, C., Leistner, P., Sawodny, O., Schwieger, V., & Sobek, W. (2022). Holistic Quality Model and Assessment—Supporting Decision-Making towards Sustainable Construction Using the Design and Production of Graded Concrete Components as an Example. Sustainability, 14(18), Article 18. https://doi.org/10.3390/su141811269
  - BibTeX
  - DOI
  BibTeX
  @article{su141811269, abstract = {This paper describes a holistic quality model (HQM) and assessment to support decision-making processes in construction. A graded concrete slab serves as an example to illustrate how to consider technical, environmental, and social quality criteria and their interrelations. The evaluation of the design and production process of the graded concrete component shows that it has advantages compared to a conventional solid slab, especially in terms of environmental performance. At the same time, the holistic quality model identifies potential improvements for the technology of graded concrete. It will be shown that the holistic quality model can be used to (a) consider the whole life cycle in decision-making in the early phases and, thus, make the complexity of construction processes manageable for quality and sustainability assessments and (b) make visible interdependencies between different quality and sustainability criteria, to help designers make better-informed decisions regarding the overall quality. The results show how different quality aspects can be assessed and trade-offs are also possible through the understanding of the relationships among characteristics. For this purpose, in addition to the quality assessment of graded concrete, an overview of the interrelations of different quality characteristics is provided. While this article demonstrates how a HQM can support decision-making in design, the validity of the presented evaluation is limited by the data availability and methodological challenges, specifically regarding the quantification of interrelations.}, article-number = {11269}, author = {Frost, Deniz and Gericke, Oliver and Di Bari, Roberta and Balangé, Laura and Zhang, Li and Blagojevic, Boris and Nigl, David and Haag, Phillip and Blandini, Lucio and Jünger, Hans Christian and Kropp, Cordula and Leistner, Philip and Sawodny, Oliver and Schwieger, Volker and Sobek, Werner}, doi = {10.3390/su141811269}, issn = {2071-1050}, journal = {Sustainability}, number = 18, title = {Holistic Quality Model and Assessment—Supporting Decision-Making towards Sustainable Construction Using the Design and Production of Graded Concrete Components as an Example}, url = {https://www.mdpi.com/2071-1050/14/18/11269}, volume = 14, year = 2022 }
  DOI
  10.3390/su141811269
2021
1. Blagojevic, B., Nitsche, A., & Sawodny, O. (2021). Modeling of transient incompressible concrete mass flow through a hose. 2021 IEEE Conference on Control Technology and Applications (CCTA), 424–429. https://doi.org/10.1109/CCTA48906.2021.9659068
  - BibTeX
  - DOI
  BibTeX
  @inproceedings{blagojevic2021modeling, address = {Piscataway}, affiliation = {Blagojevic, B (Corresponding Author), Univ Stuttgart, Inst Syst Dynam, D-70563 Stuttgart, Germany. Blagojevic, Boris; Sawodny, Oliver, Univ Stuttgart, Inst Syst Dynam, D-70563 Stuttgart, Germany. Nitsche, Alexander, Univ Stuttgart, Inst Construct Mat, D-70563 Stuttgart, Germany.}, author = {Blagojevic, Boris and Nitsche, Alexander and Sawodny, Oliver}, booktitle = {2021 IEEE Conference on Control Technology and Applications (CCTA)}, doi = {10.1109/CCTA48906.2021.9659068}, eventdate = {2021-08-09/2021-08-11}, eventtitle = {2021 IEEE Conference on Control Technology and Applications (CCTA)}, isbn = {978-1-6654-3643-4 and {978-1-6654-3644-1}}, language = {eng}, pages = {424-429}, publisher = {IEEE}, title = {Modeling of transient incompressible concrete mass flow through a hose}, unique-id = {WOS:000808092400065}, venue = {Online}, year = 2021 }
  DOI
  10.1109/CCTA48906.2021.9659068
2. Blagojevic, B., Schönemann, B., Nigl, D., Blandini, L., & Sawodny, O. (2021). Trajectory Planning for Concrete Element Fabrication with Optimal Control. IECON 2021 - 47th Annual Conference of the IEEE Industrial Electronics Society, 1–6. https://doi.org/10.1109/IECON48115.2021.9589695
  - BibTeX
  - DOI
  BibTeX
  @inproceedings{blagojevic2021trajectory, affiliation = {Blagojevic, B (Corresponding Author), Univ Stuttgart, Inst Syst Dynam, D-70563 Stuttgart, Germany. Blagojevic, Boris; Schoenemann, Benjamin; Sawodny, Oliver, Univ Stuttgart, Inst Syst Dynam, D-70563 Stuttgart, Germany. Nigl, David; Blandini, Lucio, Univ Stuttgart, Inst Lightweight Struct & Conceptual Design, D-70563 Stuttgart, Germany.}, author = {Blagojevic, Boris and Schönemann, Benjamin and Nigl, David and Blandini, Lucio and Sawodny, Oliver}, booktitle = {IECON 2021 - 47th Annual Conference of the IEEE Industrial Electronics Society}, doi = {10.1109/IECON48115.2021.9589695}, eventdate = {2021-10-13/2021-10-16}, eventtitle = {47th Annual Conference of the IEEE-Industrial-Electronics-Society (IECON)}, isbn = {{978-1-6654-3554-3} and {978-1-6654-0256-9}}, language = {eng}, pages = {1-6}, publisher = {IEEE}, research-areas = {Automation & Control Systems; Engineering}, title = {Trajectory Planning for Concrete Element Fabrication with Optimal Control}, unique-id = {WOS:000767230603114}, venue = {Online}, year = 2021 }
  DOI
  10.1109/IECON48115.2021.9589695
3. Lauer, A. P. R., Blagojevic, B., Lerke, O., Schwieger, V., & Sawodny, O. (2021). Flexible Multibody System Model of a Spider Crane with two Extendable Booms. IECON 2021 - 47th Annual Conference of the IEEE Industrial Electronics Society. https://doi.org/10.1109/IECON48115.2021.9589471
  - BibTeX
  - DOI
  BibTeX
  @inproceedings{lauer2021flexible, author = {Lauer, Anja Patricia Regina and Blagojevic, Boris and Lerke, Otto and Schwieger, Volker and Sawodny, Oliver}, booktitle = {IECON 2021 - 47th Annual Conference of the IEEE Industrial Electronics Society}, doi = {10.1109/IECON48115.2021.9589471}, publisher = {IEEE}, title = {Flexible Multibody System Model of a Spider Crane with two Extendable Booms}, url = {https://doi.org/10.1109/IECON48115.2021.9589471}, venue = {Toronto, ON, Canada}, year = 2021 }
  DOI
  10.1109/IECON48115.2021.9589471
4. Yang, Y., Balangé, L., Gericke, O., Schmeer, D., Zhang, L., Sobek, W., & Schwieger, V. (2021). Monitoring of the Production Process of Graded Concrete Component Using Terrestrial Laser Scanning. Remote Sensing, 13(9), Article 9. https://doi.org/10.3390/rs13091622
  - BibTeX
  - DOI
  BibTeX
  @article{rs13091622, abstract = {Accepting the ecological necessity of a drastic reduction of resource consumption and greenhouse gas emissions in the building industry, the Institute for Lightweight Structures and Conceptual Design (ILEK) at the University of Stuttgart is developing graded concrete components with integrated concrete hollow spheres. These components weigh a fraction of usual conventional components while exhibiting the same performance. Throughout the production process of a component, the positions of the hollow spheres and the level of the fresh concrete have to be monitored with high accuracy and in close to real-time, so that the quality and structural performance of the component can be guaranteed. In this contribution, effective solutions of multiple sphere detection and concrete surface modeling based on the technology of terrestrial laser scanning (TLS) during the casting process are proposed and realized by the Institute of Engineering Geodesy (IIGS). A complete monitoring concept is presented to acquire the point cloud data fast and with high-quality. The data processing method for multiple sphere segmentation based on the efficient combination of region growing and random sample consensus (RANSAC) exhibits great performance on computational efficiency and robustness. The feasibility and reliability of the proposed methods are verified and evaluated by an experiment monitoring the production of an exemplary graded concrete component. Some suggestions to improve the monitoring performance and relevant future work are given as well.}, article-number = {1622}, author = {Yang, Yihui and Balangé, Laura and Gericke, Oliver and Schmeer, Daniel and Zhang, Li and Sobek, Werner and Schwieger, Volker}, doi = {10.3390/rs13091622}, issn = {2072-4292}, journal = {Remote Sensing}, number = 9, title = {Monitoring of the Production Process of Graded Concrete Component Using Terrestrial Laser Scanning}, url = {https://www.mdpi.com/2072-4292/13/9/1622}, volume = 13, year = 2021 }
  DOI
  10.3390/rs13091622

OTHER PUBLICATIONS

2022
1. Kovaleva, D., Nistler, M., Verl, A., Blandini, L., & Sobek, W. (2022). Zero-waste Production of Lightweight Concrete Structures with Water-Soluble Sand Formwork. Proceedings of the 3rd RILEM International Conference on Digital Fabrication with Concrete (Digital Concrete 2022).
  - BibTeX
  BibTeX
  @conference{kovaleva2022zerowaste, author = {Kovaleva, D. and Nistler, M. and Verl, A. and Blandini, L. and Sobek, W.}, booktitle = {Proceedings of the 3rd RILEM International Conference on Digital Fabrication with Concrete (Digital Concrete 2022)}, title = {Zero-waste Production of Lightweight Concrete Structures with Water-Soluble Sand Formwork}, year = 2022 }
2020
1. Yang, Y. (2020). Investigation for position determination of hollow sphere integrated in concrete components during component production.
  - BibTeX
  BibTeX
  @mastersthesis{yang2020investigation, annote = {Examiner: Prof. Dr.-Ing. Volker Schwieger. Supervisor: Dr.-Ing. L i Zhang, Dipl.-Ing. Oliver Gericke, M.Sc. Laura Balangé}, author = {Yang, Yihui}, note = {Master Thesis at Institute of Engineering Geodesy (Institut für Ingenieurgeodäsie Stuttgart) in cooperation with Institute for Lightweight Structures and Conceptual Design (Institut für Leichtbau Entwerfen und Konstruieren)}, school = {University of Stuttgart}, title = {Investigation for position determination of hollow sphere integrated in concrete components during component production}, year = 2020 }

DATA SETS

Prof. Dr.-Ing. Lucio Blandini

Principal Investigator

Phone: +49 711 685 61760

E-Mail

Prof. Dr.-Ing. Harald Garrecht

Principal Investigator

Phone: +49 711 685 63323

E-Mail

Prof. Dr.-Ing. habil. Dr. h.c. Oliver Sawodny

Board of Directors

Phone: +49 711 685 66302

E-Mail

Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Werner Sobek

Principal Investigator