New balloon method to build large concrete shells

Grant Prior 11 years ago
Share

A new construction technique to build large concrete shell structures has been developed by scientists in Austria.

The “balloon” method does not require any expensive supporting structures which have previously put developers off building large concrete shells.

The technique devised at the Vienna University of Technology uses a flat concrete slab which hardens on the ground before an air cushion below the plate is inflated bending the concrete and forming a sustainable shell.

Professor Johann Kollegger said: “It is similar to an orange peel, which is regularly cut and then flattened out on the table.

“We do it the other way around, starting with a flat surface and then bending it to a shell.”

A flat slab is first created using standard concrete.

Kollegger said It is crucial to get the geometric shape exactly right.

The slab consists of several segments and wedge-shaped spaces are left between these segments, so that the segments fit together perfectly when the structure is bent.

Once the slab is hardened, an air cushion below is inflated. The cushion consists of two plastic sheets welded together.

At the same time, a steel cable is tightened around the concrete segments, so that the concrete is lifted up at the centre and pushed together from outside.

To ensure that all the concrete segments move in perfect synchronicity, they are connected with metal beams.

In the first trial the whole process was finished after about two hours and the final height of the concrete structure was 2.90m.

When the concrete is bent, many tiny cracks appear – but this is not a problem for the stability of the shell.

Kollegger said: “We can see that in old stone arches.

“If the shape is right, each stone holds the others in place and the construction is stable.”

In the end, the structure can be plastered, then it has just the same properties and is just as stable as a concrete shell constructed in a conventional way.

Kollegger said the method could be used to build shells with a diameter of 50 metres.

He added: “As the new construction method renders timber structures obsolete, it not only helps to save time and resources, it also saves a lot of money.

“About half of the construction cost can be saved – even more in large structures.”

The new construction method has already been patented and trialled by the Austrian Federal Railways to build a deer pass over two high speed rail tracks in Carinthia.

 

Latest news

Rayner unveils £39bn plan to build 300,000 social homes

Council building revival and rent reform feature in social and affordable homes plan
5 hours ago

Keltbray bounces back with £3.2m profit

Tighter controls and smarter project selection fuel strong turnaround
5 hours ago

VINCI JV wins 500-home twin town centre revamps

Chester Northgate phase 2 and Northwich Weaver Square schemes move to delivery stage
5 hours ago

80 energy projects unlocked as Ofgem backs grid expansion

£24bn energy networks deal gets green light from regulator
1 day ago

How to see your stories on the Enquirer

Join our Suppliers and Buyers directory to get your news published
5 hours ago

Henley lands Midland Mill revamp on Leeds tower scheme

Restoration of 18th-century mill kicks off on South Bank regeneration project
4 hours ago

New boss at Eric Wright Civil Engineering

Gavin Hulme takes top job as Diane Bourne moves to group role
13 hours ago

Pinewood submits £1bn data centre plan

Studio giant adds green and learning spaces to tech hub blueprint
1 day ago

Record results after TClarke goes private

Britain's biggest M&E contractor flourishes after de-listing
1 day ago

Dalkia lands £200m nuclear maintenance deal

1,000 nuclear FM staff to join M&E contractor
1 day ago

Construction comeback to outpace wider economy

Arcadis forecast fueled by spending review optimism
2 days ago

First steel goes up on giant car battery site

Severfield gets to work on McAlpine Somerset site
2 days ago

Permasteelisa wins cladding deal on Bovis city tower

Facade specialist lands package at 60 Gracechurch Street
1 day ago

Fox buys recycled asphalt specialist Fisher

Acquisition adds major recycled asphalt capacity in north west
2 days ago

Major Building Safety Regulator shake-up to end tower delays

HSE stripped of control and top fire chiefs brought in to fast-track stalled schemes
2 days ago

Hinkley trio sign Sizewell civils deal

Balfour,Bouygues and Laing O'Rourke form Civil Works Alliance for new power station
2 days ago

£3.9bn data centre plan for Ravenscraig steelworks

Green energy to power massive new steel to silicon AI campus
2 days ago

Breakthrough on HS2’s second longest tunnel

8.4 mile Northolt to Old Oak Common drive completes
2 days ago

Neilcott on fast-track to debt-free employee ownership

£22.5m loan nearly paid down after big profit year
2 days ago

TfL kicks off race for £700m Tube station upgrade

South Kensington and Elephant & Castle top the pipeline list
2 days ago

Corbyn Plant Hire fleet goes under the hammer

Kit to be sold off by sister firm to collapsed groundworks contractor
2 days ago

Government wields procurement stick on late payment

New rules would block slow payers from bidding on big public jobs
5 days ago

Hercules buys power line labour firm for £15.7m

Labour supply specialist snaps up Advantage NRG to tap booming electricity upgrade market
5 days ago

Universal bid to fast-track planning for theme park

Entertainment giant eyes 2026 start at Bedford site
5 days ago

Developer Breck to transform former Ibstock brick factory

Ravenhead works to become 300-home development
5 days ago

SP Energy Networks awards contracts worth £1.4bn

First round of awards under £5.4bn national electricity grid upgrade programme
6 days ago

Travelodge to convert Liverpool Street office building

Office-to-hotel conversion in City of London
5 days ago

Plans lodged for 1m sq ft City of London office

Barbican landmark building will reuse 40% of existing structure
6 days ago

PTSG acquires roofing specialist HD Sharman Group

Premier Technical Services Group expands building maintenance division
5 days ago

Balfour Beatty lands £833m carbon capture power plant job

Work to start later this year on Teesside carbon capture gas-fired power station
6 days ago