3d Printed Concrete Forms for Architectural Post Tensioned Concrete Sculptures Answered
I am looking at the feasibility of 3D printing concrete forms to make a staircase that goes up a 4' retaining wall. The forms would be cylindrical, split in half, and during the pour would be supported using a wood support system.
Ideally I would have one main highly curved support "column" (think more of a snake or spaghetti noodle) with then stairs that slide in via a mortise and tenon type connection. The stairs would be poured individually in a separate production process than the main support.
I plan on using a combination of a wire mesh, rebar and tension cables for the concrete reinforcement. The tension cables would run the length of the main support beam and would be hydraulically tensioned just before the formwork was removed.
I have ample concrete experience as a civil engineer and a construction manager but this idea seems like I need some outside input.
Does anyone have any experience 3d printing concrete forms. What is the best material that will hold up to the moisture and high alkalinity of concrete?
At this point I have no real conceptual drawings but I'm looking to see if any similar projects have been attempted and hopefully learn and improve on them!