TOVA: Spain’s first 3D printed building using earth

Project: TOVA by IACC/WASP, Valldaura Labs, Barcelona (Photo: IAAV/Gregori Civera)

Housing is a problem worldwide, especially when housing shortages are acute as a result of natural disasters or war. In such a case, it would be useful if shelters could be built quickly and cheaply, preferably without having to bring in materials from far and wide. The first 3D-printed building in Spain has recently been installed in Spain: TOVA. It is made (almost) entirely from local clay and was completed in a matter of weeks. And that with 100 percent local materials and local labour, with no waste and with almost zero CO2 emissions. According to the Institute for Advanced Architecture of Catalonia (IAAC), which was responsible for the development and construction of TOVA, this concept can be used anywhere in the world, for example when dealing with people in emergency situations.

According to IAAC, the concept can be a solution for acute housing problems anywhere in the world (Artist Impression IAAC/YouTube)

TOVA is the first architectural construction made with earth and a 3D printer in Spain, the project has been developed by the 3DPA postgraduate research program at the IAAC. According to IAAC, the project is a prototype that represents the bridge between the past - vernacular earthen architecture - and the future - large scale 3D printing technology - which will not only serve to change the architecture of the future, but will also be very useful when facing the current climate and housing crisis across the globe. TOVA is the beginning of a larger project in collaboration with WASP in which a complete house made with 3D printing technology is projected. WASP is an Italian 3D printing company that has carried out several projects with 3D printed earth in recent years. One of the most talked-about is the Tecla house: a 3D-printed eco-home made of clay and designed by Italian architecture studio Mario Cucinella Architects (MCA). At the time, it was the world's first house to be completely 3D printed from a mixture of mostly local soil and water. (The name is also a contraction of 'technology' and 'clay'. The 3D printing technology Crane WASP from WASP was used for the building, which is now also used for the building in Barcelona. TOVA is the first building of this type in

WASP/TECLA

January 2021, Italian 3D printer manufacturer WASP made headlines worldwide with the completion of a similar project to TOVA: TECLA, a 3D-printed house made of natural materials - mainly earth in this case. TECLA is made with multiple 3D printers working simultaneously. The house was developed by WASP and designed by Mario Cucinella Architects. It is intended as a new circular residential house principle, made entirely with local, reusable, recyclable materials, CO2 neutral and adaptable to any climate and environment.

Innovative Materials 2021 Volume 1> 2020, WASP CRANE in action at the TECLA project (Innovative Materials 2021 volume 1)

(Photo: IAAC)

Spain and stands out for being one of the most sustainable and environmentally friendly construction forms that can be applied today. The construction took 7 weeks time to complete, a Crane WASP, the architectural 3D printer and km zero materials.

During the entire construction process, zero waste is generated, as the materials were sourced within a 50 meter radius. The structure is made of local earth, mixed with additives and enzymes, to ensure the structural integrity and material elasticity necessary for the optimized 3D printing of the house. The foundation is made of geopolymer and the roof, wooden construction. To ensure the longevity of the material in resistance to weather, a waterproof coating is added using raw extracted materials.

The design of the building takes into account the climatic conditions of the Mediterranean: the volume is compact to protect from the cold in winter, but expandable during the other three seasons of the year, allowing the use of the immediate outdoor surroundings. The walls are made up of a network of cavities that contain airflow and allow great insulation to prevent heat loss in winter and protect from solar radiation in summer. 3D printing (or additive manufacturing) is a great example of km zero construction. According to the zero-km philosophy, a construction must meet a number of conditions, such as (among others) use of local materials, reduction of CO2 emissions caused by the transport of building materials and the use of local labor. That is exactly what the TOVA project meets. The possible applications of this construction model are endless; from homes, to public spaces, interiors and exteriors.

Worldwide

The project was conceived as a prototype for sustainable housing that could be built anywhere in the world. This promising technique opens the door to quickly solving problems of access to housing in vulnerable areas or temporary settlements, offering new solutions for the creation of more sustainable and affordable spaces.IAAC responds with this and other projects to increasingly serious climate and migration emergencies, providing new solutions that contribute positively to the global housing emergency problem that will have to be faced in the future due to large migrations or natural disasters. The use case

of this rapid construction method can be a solution for increasing spaces that require emergency response for housing solutions of masses such as communities for asylum seekers.

More at IAAC>

Video IAAC

Project ‘Openings In 3d Printing With Earth’ (Photo: IAAC)

3D Printing Architecture (3DPA)

While the 3D-printed building at Valldaura Labs is still modest in size, IAAC's vision is not. The Institute for Advanced Architecture of Catalonia sees 3D printing with local materials - especially clay and loam - as an important option for 21st century construction and architecture, with all the challenges that come with it. The institute has set up a special research program for this purpose and a training program under the name 3D Printing Architecture (3DPA) aimed at additive manufacturing of sustainable architecture. The program is being carried out in close collaboration with the 3D printing industry Printing clay plays an important role in the project. When it comes to the ecological footprint, clay has significant advantages over, for example, concrete. It's usually available locally and production has a very low carbon footprint. In the context of the 3DPA programme, for example, research has been carried out into the properties of the raw materials and additives in terms of extrudability and 3D printability.

The experimental research was carried out in two phases. In the first phase, the experiments were performed to define the properties of the raw materials (clay, brick dust and marble dust) and the additives (enzymes, collagens and starch) in terms of miscibility, and drying properties (drying time and shrinkage). On that basis, the most successful mixtures/compositions with additives (casein, wheat and rice) were determined.

Much more on 3D-printen with clay, and the 3DPA-activities of IAAC can be found here>

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Co-Consolidated TitaniumThermoplastic Composite Joints: a study on the mechanisms governing adhesion and durability

The main drivers for technological innovation in the aviation industry are the reduction of the CO2 emissions along with the reduction of operating costs. Multimaterial design that joins advanced metals, such as titanium, to high-performance thermoplastic composites represents an appealing solution, as metal inserts are often required for load introduction purposes. Besides, composites and metals can be combined to form hybrid materials called Fibre Metal Laminates, typically used in fuselage panels. The moldability of the thermoplastic matrix allows for a cost-efficient joining method, known as co-consolidation, where composite consolidation and joining to the metal are achieved simultaneously during a standard composite consolidation or forming process.

Vanessa Marinosci with one of the samples (Photo: Gijs van Ouwerkerk)

For the implementation of the co-consolidation technology, it is essential to develop guidelines which ensure reliable and predictable metal-thermoplastic composite interfaces. Therefore, the objective of this research is to understand and optimize the interfacial bonding mechanisms between metal and thermoplastic composites, more specifically, between the titanium alloy Ti6Al4V and C/PEKK composites.

Scanning Electron Microscopy picture showing the crystalline phase of the polymer (called PEKK) on the crack surface of a titanium-PEKK joint (Picture by Nick Helthuis)

Video

It has been demonstrated that the attraction between Ti6Al4V and PEKK relies on physical interactions. As evidence, the loss of adhesion in the presence of water is recovered when redrying. Additionally, it has been found that the mechanical interlocking, promoted by the titanium surface roughness, has a beneficial effect on the fracture toughness in dry conditions. The metal surface irregularities alter the local stress state at the crack tip and may cause a transition from adhesive to cohesive failure. A stable Ti6Al4V-C/PEKK interface in both dry and humid conditions has been obtained by combining the toughening effect of the surface roughness and the moisture barrier provided by a silane-based coating. Altogether, this work

Scanning Electron Microscopy picture showing the crystalline phase of the polymer (called PEKK) on the crack surface of a titanium-PEKK joint (Picture by Nick Helthuis)

constitutes a fundamental basis towards reliable titanium-thermoplastic composite joints manufactured via a co-consolidation process. This research was performed by Vanessa Marinosci at the ThermoPlastic composites Research Center (TPRC) and the University of Twente and financed by the Dutch Research Council (NWO).

The dissertation can be found online>

Publications

A Comprehensive Study on the Rejuvenation Efficiency of Compound Rejuvenators for the Characterization of the Bituminous Binder, Mortar, and Mixture

Materials, August 2022

This study aims to comprehensively investigate the rejuvenation efficiency of various self-developed compound rejuvenators on the physical, mechanical, and aging properties of aged bitumen, asphalt mortar, and mixture. The results revealed that the restoration capacity of vacuum distilled-oil rejuvenators on high-and-low temperature performance-grade of aged bitumen is more significant. In contrast, an aromatic-oil based rejuvenator is good at enhancing low-temperature grade and aging resistance. Moreover, the temperature and time of the curing conditions for mixing recycling of asphalt mixture were optimized as 150 °C and 120 min. Furthermore, the sufficient anti-rutting, structural stability, and moisture resistance of recycled asphalt mixture affirmed the rejuvenation efficiency of compound rejuvenators.

The article is online>

Lignin as a Renewable Building Block for Sustainable Polyurethanes

Materials, September 2022

Currently, the pulp and paper industry generates around 50–70 million tons of lignin annually, which is mainly burned for energy recovery. Lignin, being a natural aromatic polymer rich in functional hydroxyl groups, has been drawing the interest of academia and industry for its valorization, especially for the development of polymeric materials. Among the different types of polymers that can be derived from lignin, polyurethanes (PUs) are amid the most important ones, especially due to their wide range of applications. This review encompasses available technologies to isolate lignin from pulping processes, the main approaches to convert solid lignin into a liquid polyol to produce bio-based polyurethanes, the challenges involving its characterization, and the current technology assessment. Despite the fact that PUs derived from bio-based polyols, such as lignin, are important in contributing to the circular economy, the use of isocyanate is a major environmental hot spot. Therefore, the main strategies that have been used to replace isocyanates to produce non-isocyanate polyurethanes (NIPUs) derived from lignin are also discussed.

The article is online>

Systematic derivation of safety factors for the fatigue design of steel bridges

Structural Safety, July 2022

This paper presents a probabilistic framework to derive the safety factors for fatigue of steel and composite steel concrete road bridges. Engineering models are used for the design and the safety factor is derived in such a way that the design meets the target reliability set by international Eurocode and ISO standards, estimated using measured data and advanced probabilistic models. Engineering model uncertainties and dynamic amplification factors are established through comparison of measurements and models. The value of visual inspections is quantified based on observations from practice and expert opinions. The safety factors are derived for Eurocode’s Fatigue Load Model 4 and Eurocode’s tri-linear S-N curve. The study shows that the safety factors for fatigue as currently recommended by the Eurocodes need to be raised. (Technische Universiteit Eindhoven)

The article is online>

The realities of additively manufactured concrete structures in practice

Cement and Concrete Research, June 2022

Extrusion-based 3D Concrete Printing (3DCP) is rapidly gaining popularity in the construction industry. Trial projects are now being realized at an increasing rate around the world to test the viability of the technology against real-world requirements. This step, from the ‘simple’ deposition of filaments of self-stable concrete to its application in buildings and structures, with all associated requirements and interfaces, comes with challenges. These range from matching the design

intent to the manufacturing capabilities (through structural analysis and approval, and reinforcement) to quality consistency (robustness) on large scale, and compatibility with other materials. In many of these areas, much simply remains unknown due to a lack of experimental data or information from projects where 3DCP has been applied. This paper aims at reducing this knowledge gap by presenting a systematic discussion, based on the analyses of eight realized 3DCP projects from around the world. It was found that the structural application of printed concrete is limited, due to a lack of regulatory framework for expedient approval, as well as limited reinforcement options which require to resort to unreinforced masonry analogies. The application of the technology features a host of practical issues that relate to the print process, material, site conditions, building integration and design - or to the 3DCP technology in general. Although some potential risks, such as shrinkage cracking and quality consistency are generally recognized, the measures taken to mitigate them vary considerably, and are largely based on individual expertise. The actual effectiveness is generally unknown. Finally, it was observed that, while the printing itself is fast, the preparation time is generally considerable. This is partially due to a lack of knowledge amongst professionals. In the practical production of a 3DCP project, three expertise areas are crucial: one for the digital part, one for the machine side, and one for the material side. Thus there is a strong need for educational institutions to develop dedicated training courses and incorporate relevant topics into their curricula. (TU Eindhoven)

The article is online>

Concrete with a High Content of End-of-Life Tire Materials for Flexural Strengthening of Reinforced Concrete Structures

Materials, July 2022

This research investigates the performance of Steel Fiber Reinforced Rubberized Concrete (SFRRC) that incorporates high volumes of End-of-life tire materials, (i.e., both rubber particles and recycled tire steel fibers) in strengthening existing reinforced concrete (RC) beams. The mechanical and durability properties were determined for an environmentally friendly SFRRC mixture that incorporates a large volume (60% by volume aggregate replacement) of rubber particles and is solely reinforced by recycled tire steel fibers. The material was assessed experimentally under flexural, compressive and impact loading, and thus results led to the development of a numerical model using the Finite Element Method. Furthermore, a numerical study on full-scale structural members was conducted, focusing on conventional RC beams strengthened with SFRRC layers. This research presents the first study where SFRRC is examined for structural strengthening of existing RC beams, aiming to enable the use of such novel materials in structural applications. The results were compared to respective results of beams strengthened with conventional RC layers. The study reveals that incorporation of End-of-life tire materials in concrete not only serves the purpose of recycling End-of-life tire products, but can also contribute to unique properties such as energy dissipation not attained by conventional concrete and therefore leading to superior performance as flexural strengthening material. It was found that by incorporating 60% by volume rubber particles in combination with recycled steel fibers, it increased the damping ratio of concrete by 75.4%. Furthermore, SFRRC was proven effective in enhancing the energy dissipation of existing structural members.

The article is online>

High-strength lithography-based additive manufacturing of ceramic components with rapid sintering

Additive Manufacturing November 2022

Additive manufacturing technology enables the fabrication of technical ceramics and multi-materials with unprecedented geometrical accuracy and complexity, opening the path to new

Ceramic processing applying lithography-based ceramic manufacturing (LCM). (a) LCM technology based on digital light processing (DLP). (b) Photo-polymerized network forming the matrix to organize the ceramic particles in a 3D-printed shape. (c) The removal of the polymeric network leads to an open-porous fragile structure

functionalities for engineering applications. A crucial step to consolidate 3D-printed ceramic parts is 'sintering', a time and energy (temperature) intensive densification process. Here we present a strategy for rapid sintering ~ 300 - 450 °C/min) of lithography-based additively manufactured alumina ceramics enabling consolidation of ceramic components of complex shapes within minutes. Highly dense, fine-grained microstructures were achieved by controlling densification and limiting grain growth through rapid radiation heat transfer. The high mechanical strength and toughness measured in additively manufactured alumina (~ 810 MPa and ~ 4.3 MPa m1/2) sintered at 1600 °C within 2 min was superior to that of conventionally sintered reference parts. This study opens the path for rapid sintering of complex shaped ceramic architectures of high density with tailored microstructure and properties.

Advanced recycling 14 - 15 November 2022, Keulen

Formnext 2022 15 - 18 November 2022 Frankfurt am Main

VETECO 2022 15 - 18 november 2022, Frankfurt am Main

Şişecam 37th International Glass Conference 17 - 18 November 2022, Istanbul

Münchener Forum Verbindungstechnologie 2022 23 - 24 November 2022, Munich

Hagener Symposium Pulvertechnologie 24 - 25 November 2022, Hagen

AESAN Ceramics Thailand 30 nov - 2 December 2022, Bankok

Meeting Materials 2022 13 December 2022, Noordwijkerhout

InfraTech 2023 17 - 20 January 2023, Rotterdam

47th International Conference and Expo on Advanced Ceramics 22 - 27 January, 2023 Daytona Beach

Bouwbeurs 2023 6 - 10 February 2023, Utrecht

Glassman Europe 2023 8 - 9 February 2023, Istanbul Fastener Fair Stuttgart 21 - 23 March 2023, Stuttgart

European Coatings Show 2022 28 - 30 March 2023, Nurnberg

MaterialDistrict Utrecht 2023 5 - 7 April 2023, Utrecht

Conference on CO2-based Fuels and Chemicals 2023 19 - 20 April 2023, Keulen

KUTENO Kunststofftechnik Nord 9 - 11 May 2023, Rheda-Wiedenbrück

Renewable Materials Conference 2023 23 - 25 May 2023, Siegburg/ Cologne

Maintenance Dortmund 24 - 25 May 2023, Dortmund

NEWCAST 12 - 16 June 2023, Düsseldorf

METEC 12 -16 June 2023, Düsseldorf

GIFA 12 - 16 June 2023, Düsseldorf

Moulding Expo 2023 13 - 16 June 2023, Stuttgart

LightCon 13 - 14 June 2023, Hannover

Enterprise Europe Network (EEN) supports companies with international ambitions

The Enterprise Europe Network (EEN) is an initiative of the European Commission that supports entrepreneurs in seeking partners to innovate and do business abroad. The Network is active in more than 60 countries worldwide. It brings together 3,000 experts from more than 600 member organisations – all renowned for their excellence in business support.

Database

Every company can participate by adjusting its profile to the database. This company will be brought to the attention in the country in which it wants to become active. At the same time it is possible to search for partners. EEN advisers actively assist in compiling the profile, which is drawn up in a certain format. The EEN websites also contain foreign companies that are looking for Dutch companies and organizations for commercial or technological cooperation. The EEN advisers support the search for a cooperation partner by actively deploying contacts within the network. In addition, Company Missions and Match Making Events are regularly organized. All these services are free of charge.

There are five types of profiles:

• Business Offer: the company offers a product

• Business Request: the company is looking for a product

• Technology Offer: the company offers a technology

• Technology Request: the company is looking for a technology

• Research & Development Request: the organization seeks cooperation for research

When a company has both a Business Offer and a Business Request (or another combination), two (or even more if applicable) profiles are created. The profile includes the most essential information about the nature of the supply or demand, the ‘type of partner’ that is intended and the expected cooperation structure.

Get in touch with your local network contact point by selecting the country and city closest to where your business is based. They can help you with advice, support and opportunities for international partnerships.

For sustainable building and the creative industry, contact ir. drs. Hans Kamphuis: T: +31 (0) 88 042 1124 M: 06 25 70 82 76 E: hans.kamphuis@rvo.nl

For Materials contact Nils Haarmans: T: +31 (0) 88 062 5843 M: 06 21 83 94 57

More information websites can be found at the Europe Network websites:

Video: How Enterprise Europe Network works

www.enterpriseeuropenetwork.nl

http://een.ec.europa.eu

The Enterprise Europe Network Materials Database:

Request for partnership: November 2022.

Interested? contact hans.kamphuis@rvo.nl>

An eco-friendly French SME is looking for foreign partners to supply cotton-lined cork, vegetable fibers or cellulose fabrics to produce high-end vegan bags

A French entrepreneur had a solid experience in luxury products as a leather goods maker. In 2019, she started her own activity on the basis of eco-responsibility, as designer and producer of leather goods and jewellery for men and women. She is currently looking for new suppliers of cotton-lined cork, vegetal fibers or cellulose in rolls in several colours. Manufacturers of such types of quality and natural materials, are sought as long-term partners under supplier agreements.

A Greek animal feed supplements producer is looking for raw materials

A Greek company active in the field of various animal feed supplements is looking for four types of raw materials for their production. The company is looking for producers or suppliers of Sugar beet Molasses, Dry yeast, Monocalcium phosphate, and Dicalcium phosphate.

A Finnish company is seeking for a supplier or manufacturer of foam plastic components

A Finnish eco-design company is looking for a supplier or manufacturer of designed and round shape-cut foam plastic components. The diameter of the component is 90 mm. The desired form of cooperation is a manufacturing or a subcontracting agreement.

A French yacht equipment manufacturer is looking for new neoprene fabrics suppliers located in Europe

This neoprene fabrics should come in rolls, 10 000-15 000 meters per year.

Greek technological start-up company is looking for multiple waste materials, for procurement agreement

A Greek start-up technological company is working in the fields of industrial minerals & metals, materials and energy. The company is looking for multiple sources of waste materials such as bauxite residue, residue from metal-making or steel industry, bricks & tiles and other demolishing waste, glass waste and fly ash from biomass incineration. The company needs to have a procurement agreement.

Innovative Materials, the international version of the Dutch magazine Innovatieve Materialen, is now available in English. Innovative Materials is an interactive, digital magazine about new and/or innovatively applied materials. Innovative Materials provides information on material innovations, or innovative use of materials. The idea is that the ever increasing demands lead to a constant search for better and safer products as well as material and energy savings. Enabling these innovations is crucial, not only to be competitive but also to meet the challenges of enhancing and protecting the environment, like durability, C2C and carbon footprint. By opting for smart, sustainable and innovative materials constructors, engineers and designers obtain more opportunities to distinguish themselves. As a platform Innovative Materials wants to help to achieve this by connecting supply and demand.

Innovative Materials is distributed among its own subscribers/network, but also through the networks of the partners. In 2021 this includes organisations like M2i, MaterialDesign, 4TU (a cooperation between the four Technical Universities in the Netherlands), the Bond voor Materialenkennis (material sciences), SIM Flanders, FLAM3D, RVO and Material District.