Digitally Fabricated Concrete (DFC) is emerging as a prominent theme in construction, with case studies being showcased globally at an increasing rate. However, there remains a significant gap in the reporting of these projects, particularly concerning the structural requirements met and the methods used to ensure compliance. Often, the research published on DFC materials is not directly linked to these practical implementations, raising questions about the scalability of laboratory results to full-sized structures. This discrepancy is concerning since the effects of scaling are not well-understood and could significantly impact the structural integrity of larger constructions.
To bridge this knowledge gap, it is essential to conduct large-scale testing, ideally ranging from 1:5 to actual size, particularly when DFC is intended for real-world applications. This paper highlights the outcomes of such large-scale tests conducted on two specific projects: a pavilion planned in Denmark and a successfully realized bridge in the Netherlands, both involving elements printed at the Eindhoven University of Technology's 3D Concrete Printing facility. These structures were designed to bear actual loads, and while the conservative designs met the test requirements, the experiments led to significant insights regarding manufacturing processes and structural behaviors. These findings underscore the necessity of large-scale testing for DFC structures, especially when introducing new concepts, to ensure a comprehensive understanding of all relevant technological aspects.
