Implementation of Large-Scale Additive Manufacturing in Reinforced Concrete Structures

This Thesis presents the development, design, and construction of an offshore reinforced concrete part with the implementation of Novel Large-Scale Additive Manufacturing (NLSAM). This includes using a part that was manufactured using conventional methods as a baseline to compare the NLSAM process to. The baseline part that was investigated traditionally requires intensive rebar cage assembling labor, along with the use of expensive molds. Using NLSAM could potentially lower the cost while keeping the same structural strength of the proven traditional method. The part that utilized AM was manufactured and underwent the same structural test as the baseline part to ensure comparable results. A structural and cost analysis have been performed to investigate the cost effects on the implementation of the AM process. The results of this study provide a clearer answer as to whether implementing AM into large concrete parts will save costs, while maintaining structural integrity.