In order for off-Earth top surface structures built from regolith to protect astronauts from radiation, they need to be several metres thick. In a feasibility study, funded by the European Space Agency, Technical University Delft (TUD aka TU Delft) explored the possibility of building in empty lava tubes to create rhizomatic subsurface habitats. With this approach natural protection from radiation is achieved as well as thermal insulation because the temperature is more stable underground. It involves a swarm of autonomous mobile robots that survey the areas and mine for materials such as regolith in order to create cement-based concrete reproducible on Mars through in-situ resource utilisation (ISRU). The concrete is 3D printed by means of additive Design-to-Robotic-Production (D2RP) methods developed at TUD for on-Earth applications with the 3D printing system of industrial partner, Vertico. The printed components are assembled using a Human--Robot Interaction (HRI) supported approach. The 3D printed and HRI-supported assembled structures are structurally optimised porous material systems with increased insulation properties. In order to regulate the indoor pressurised environment a Life Support System (LSS) is integrated, which in this study is only conceptually developed. The habitat and the D2RP production system are powered by an automated kite power system and solar panels developed at TUD. The long-term goal is to develop an autarkic, automated and HRI-supported D2RP system for building autarkic habitats from locally obtained materials.@en

Materials are one of the instruments structural engineers use to design and create structures. Besides the obvious aesthetic aspect of material selection, there is a functional aspect related to the use of materials to full structural needs in the design of structural elements. The structural element needs to meet requirements for displacement, strength and safety. This translates into minimum properties for the material in terms of

- Young’s modulus
- tensile, compressive and shear stress
- fracture toughness (as a standard measure of structural material safety).

Although this can be reduced to mere numbers, as illustrated in Figure 5.1 for the major structural materials, an understanding of these numbers will help to make correct design choices. In addition, the twenty-first century structural designer has a responsibility to make choices that minimise eco-impact and as such this aspect also requires some understanding of eco properties.@en

In the original version of the book, on page xi, one of the authors listed for Chapter 2 is “R. Schnmehl”, which should be “R. Schmehl”. On page 21, the same correction needs to be made twice, in the listed authors at the top of the page and also in the footnotes. “Schnmehl” should become “Schmehl” in both the cases. This has now been rectified and the author’s name has been corrected. The correction to this book have been updated with the changes.@en

The four point bending test is one of the most commonly used and standardised tests to determine the mechanical properties of materials. For its use on float glass there are both the ASTM C158-02R17 and European EN 1288-3:2001 standards. However when testing float glass the results tend be a statistical muddle. This impacts the reliability of the design strength of float glass determined using four point bending tests. In an attempt to resolve this problem a series of four point bending tests were conducted which were designed to be more systematic than those previously reported in the literature and which use newly developed digital microscopy techniques for pre- and post-test analysis. By systematically testing, the test results can be divided into different groups based on air side, Sn side and source of failure, allowing the data to be divided into clear and separate statistical groups. Secondly the results can potentially be used to validate the lower bound glass strength theory proposed by Ballarini et al. (J Eng Mech 142(12):04016100, 2016). The glass specimens were industrially cut, ground, chamfered and flat polished on the long sides. Specimens were checked using advanced digital microscopy before and after testing. The results suggest that uni-modal Weibull behaviour only applies above a critical failure stress. Failures at stresses below this critical failure stress as a group have a separate and steeper Weibull slope. This supports Ballarini’s theory for a lower bound failure strength although there are important differences between the air side and Sn side of the specimens which this theory does not currently allow for. These differences seem to be inherent to the differences between the glass and the Sn sides. The results also show that the strength of cut, ground, chamfered and flat polished glass can be high but that inconsistency in process control and the irregular occurrence of surface failures are the main causes for the statistical spread. Digital microscopy can reliably measure the quality of the various surfaces and intersections of surfaces of a glass specimen but there is no absolute relation between the size of a detected defect and the probability that this defect actually leads to failure.@en

Lack of knowledge about the properties of weathered (used) glass is currently a major barrier to glass reuse. This results in probably unnecessary recycling or down-cycling of architectural glass at the end of life. Avoiding this creates a significant opportunity to reduce resource depletion and decarbonize the built environment. This can be done by developing an optical non-destructive test method that estimates the strength of naturally weathered glass by characterizing surface flaws. This allows excessively damaged glass panels to be removed for surface repair or recycling. Specimens were made from 50+-year-old monolithic flat glass taken from a façade in the Hague, Netherlands, where it was exposed to salt in the air, water, cleaning, and abrasion from wind-driven dust and sand particles. The specimens were examined using a microscope and a handheld optical profilometer to determine surface flaw characteristics. The glass specimens were then tested using a ring-on-ring (coaxial double ring) setup. Similar tests were also conducted on new as-received float glass to provide a benchmark. Both the indoor-facing and outdoor-facing sides of the weathered glass and the air and tin side of the new glass were tested. A statistical analysis of the test results was made using conventional Weibull statistics. The results show that after 50+ years of natural aging the strength of the glass is significantly reduced and that the non-destructive scanning method trialed in this study can locate and determine in many cases the size of critical surface defects thereby allowing for direct safe re-use of 70+% of the glass. The handheld optical profilometer can identify severe damage on the glass, but further research and software development is needed to improve the accuracy and consistency of the scanning method and to automate this technique for routine/large-scale applications including as a prerequisite for surface repair.@en

This paper aims to provide a systematical review of the available printing strategies, sustainable cementitious materials and characterization methods for extrusion-based 3D concrete printing (3DCP). The printing strategies, consisting of printing setup, process, and material requirements, were summarized initially. In the material aspect, the high ordinary Portland cement (OPC) content in most printable mixtures is a major issue that impedes the sustainability of 3DCP. This can be resolved by partially substituting OPC with supplementary cementitious materials (SCMs). In this review, the effect of different SCMs on fresh-state behaviors and 3D printing of cementitious materials was comprehensively discussed. Finally, a series of test methods for quantitively characterizing fresh properties, 3D printability and interlayer behaviors were summarized and reviewed.

@en

Neglecting the accidental soccer or golf ball hitting the window of the neighbors in a movie, actual impact on glass is rare. In architecture, the only significant case in the literature is where a fully tempered laminated panel of the New York Apple cube was hit by a small stone launched by a snow blower. Nowadays a lot of glass is used in sound screens next to high ways. These are however subjected to regular impact of small, fast-moving hard bodies. Mostly small stones which are removed from the asphalt road surface due to wear and are launched by car tires. This is a regular occurrence leading to safety questions and also to considerable cost as replacing the sound screen panels not only costs money but also requires closing down at least the outer lane of the highway, thus reducing the traffic flow. Thus a study was made of the impact resistance of annealed, heat-strengthened, and fully tempered laminated glass using test panels. This was followed by the testing of a full-size sound screen panel. The results show that the impact resistance of tempered glass is determined by the amount of compressive surface pre-stress. However, it is also noted that although fully tempered glass better resists impact, it has no residual strength after an impact with the critical energy.@en

Whilst the optical and structural properties of the glasses containing tantalum oxide have been considerably investigated, research into their mechanical properties is not substantially established. This work reports on the mechanical characterization of transparent germanate glass samples, obtained via the melt-quenching technique, with a molar content of Ta2O5 ranging from 0% to 20%. The introduction of Ta2O5 in the samples is related to significant improvements in the mechanical properties. The transition from glass to transparent glass-ceramic via the controlled crystallization of Ta2O5 proved to be a tool to increase both the elastic modulus and the hardness while keeping the transparency of the material. The average elastic modulus of the studied compositions ranged from 69.2 GPa to 99.1 GPa, while the average hardness of the same samples varied from 5.10 GPa to 7.34 GPa.@en

Among the environmental factors affecting glass weathering are humidity, exposure time, temperature, and the presence of pollutants in the atmosphere. Notwithstanding that the weathering produced depends on numerous factors, the important weathering effect of high humidity may be specifically mitigated by using a good chemical composition for the glass. To evaluate this relationship, flat glass samples from three suppliers were studied. The chemical composition of the samples was determined and the variability in compositions was evaluated to verify to what extent these small differences can affect their chemical durability. The chemical durability of the samples was evaluated by determining the hydrolytic resistance of crushed glass powder and using a visual appearance evaluation of bulk samples. The results demonstrate that when the samples are frequently washed, the compositional differences found between the suppliers can cause a significant difference in durability. The samples possessing the highest molar concentrations of Al2O3, and alkaline earth oxides (MgO + CaO) exhibited the highest hydrolytic resistance and the least visual deterioration. Differences encountered for the weathering products of glasses of comparable bulk compositions highlight that the process parameters play a major role in the alteration of the surface compositions of the glasses. For the unwashed samples, no consistent correlation was found between hydrolytic resistance and visual deterioration.@en

The investigation of new compositions is crucial for the expansion of possible applications of glass, from the typical applications for building engineering, in the form of cast blocks or float glass, to more advanced technologies, such as 3D-printed glass or glass-to-metal connections. Since high melting temperatures and brittleness are two important drawbacks of glass, this work aims to improve both properties. Characterisation techniques, such as thermal analysis, nano-indentation, and UV/VIS spectroscopy, are used to evaluate the properties of the samples. The modification of the properties is achieved via changes in the composition of the glass, using compounds such as phosphorus pentoxide, aluminium oxide and boron oxide. Then, the choice of different glass formers and modifiers contributes to the development of compositions with lower melting and glass transition temperatures. The reduction of the melting temperature allows a saving of energy during the manufacturing. The structures of the glasses differ from the standard soda–lime–silica and borosilicate glasses, leading to a different mechanical behaviour. Furthermore, these new compositions incorporate up to 35% of fly ash in their formulas. The valorisation of these by-products reduces costs and gas emission.@en

Cast glass has great potential for diverse load-bearing, architectural applications; through casting, volumetric glass components can be made that take full advantage of glass’s stated compressive strength. However, the lack of engineering, production and quality control standards for cast glass and the intertwined ambiguities over its mechanical properties-particularly due to the variety in chemical compositions and the lack of understanding of the influence of flaws occurring in the glass bulk-act as an impediment to its wide-spread application. Addressing the above uncertainties, this work studies a total of 64 silicate-based glass specimens, prepared in 20 * 30 * 350 mm beam size, either by kiln-casting at relatively low forming temperatures (970–1120 ∘C), or by modification of industrially produced glass. For the kiln-casting of the specimens, pure and contaminated recycled cullet are used, either individually or in combination (composite glasses). The defects introduced in the glass specimens during the casting process are identified with digital microscopy and qualitative stress analysis using cross polarized light, and are categorized as stress-inducing, strength-reducing or harmless. The Impulse Excitation Technique is employed to measure the Young’s modulus and internal friction of the different glasses. Differential Scanning Calorimetry is used on a selection of glasses, to investigate changes in the glass transition range and fictive temperature of the kiln-cast glasses due to the slower cooling and prolonged annealing. The four-point bending experiments are shedding light upon the flexural strength and stiffness of the different glasses, while the fractographic analysis pinpoints the most critical defects per glass category. The experiments show the flexural strength of cast glass ranging between 30–73 MPa, according to the level of contamination and the chemical composition. The measured E moduli by both methods are in close agreement, ranging between 60–79 GPa. The comparison of the flexural strength with prior testing of cast glass involving shorter span fixtures showed a decreasing strength with increasing size for the contaminated specimens, but similar strengths for pure compositions. The results highlight the versatile role of defects in determining the glass strength and the complexity that arises in creating statistical prediction models and performing quality control.@en

This paper explores a novel restoration approach for consolidating historic structures using structural glass to substitute for the missing elements, preserving at the same time the structural integrity of the structure. A restoration design is proposed for the hypothetical consolidation of the remaining tower of Schaesberg Castle, in Limburg, The Netherlands. The masonry walls suffer from a significant loss of material and a temporary steel structure currently prevents the tower from collapsing. It is proposed to use stacked float glass to fill the missing parts of the wall. The connection between the old masonry and new glass is the most challenging aspect given the different physical and mechanical properties of the materials, which need to work together in a coherent way. Shear tests of various connecting materials are carried out in order to evaluate the performance of this connection with respect to aspects of compatibility and feasibility.@en

The emerging interest in the architectural applications of cast glass components reveals a knowledge gap on the mechanical properties of cast glass. Apart from its chemical composition, cast glass is characterized by its manufacturing history and thermal profile, often inheriting a set of defects that define its properties. The role that inhomogeneities in the bulk of voluminous glass components have on the strength of the final product is also uncertain. Systematic testing is therefore necessary for the safe structural application of cast glass. Towards this direction, the presented research aims to experimentally investigate the fracture resistance of cast glass under sharp contact loading, by means of a customized splitting test using a sharp linear indenter. Cubic specimens with 50 mm sides are kiln-cast at low forming temperatures, employing a variety of silicate-based cullet and firing schedules and their inherent defects are documented. The results of the splitting tests show that the borosilicate specimens fail at the highest splitting force, followed by the soda lime float specimens, while the fused or porous specimens have a significantly lower resistance to fracture. The strength order of the various glasses, as this results from the splitting tests- is opposite to that found earlier in four-point bending tests, due to the different fracture mechanisms activated. The fracture resistance of a glass specimen is governed, first by its ability to deform around the indenter to relief the developing stresses and then by its bond strength to resist crack propagation. Thus, a good balance between glass network flexibility and high bond dissociation energy is required, explaining why the tested homogeneous borosilicate and soda lime glasses are more resistant than the modified soda lime compositions with high alkali content. In addition, the fractographic analysis indicates that the non-stress inducing flaws in the bulk have a negligible contribution to the fracture resistance of the specimens.@en

A unique structural design was made for the glass façade of the Co-Creation Center building in Delft. The roof is completely carried by the glass fins. The fins are laterally stabilized by being included in the triple glazed façade. To certify the safety of the design full scale tests on the fins were done at Delft University of Technology. Due to a transportation accident the fins were damaged at one end. This allowed an additional study into the effect of this pre-test damage on the residual compressive stressed induced by the tempering. It was found that the residual stresses were not significantly affected by the damage. During the compression tests no cracks developed at the damaged ends. A load of 200 kN, more than double the maximum design load did not produce failure in the prototypes. After intentionally seriously damaging all plies of the fins, the fins could still carry the 200 kN load for 30 min without buckling or other failures being noted. Measurement of the residual stress in the outer plies of the fins after damage showed that sufficient residual stress was present in the larger fragments of the prototype to provide enough stability in combination with the Sentryglass laminating foil.@en

Connecting glass with heat bonds is a way to create all-transparent glass structures. Two methods have been researched in theory and practice, glass welding, through local heating, and glass fusion through global heating. Both methods have been applied to produce 10 mm thick T-sections of soda lime glass while preventing thermal shock failure and minimizing residual stress. These specimen, and specimen with an adhesive joint, have been tested destructively. It is concluded that it is possible to connect 10 mm thick soda lime glass by welding, if the glass is preheated and the surrounding temperature remains elevated during the welding process. Additionally, glass fusion of a similar product through global heating is possible for the applied temperature schedule. The mould has a paramount influence on the quality of the product. For both production methods, the annealing schedule was adequate to reduce residual stress. The average strength of the fused specimen was 44% larger. The standard deviation of the welded specimen was smaller: the standard deviation relative to the mean value was 9% for the welded specimen and 60% for the fused specimen. However, the amount of tested specimen is little. This research is a proof of concept for heat bonding soda lime glass of a structurally relevant thickness. @en

Currently, tons of high quality commercial glass are down-cycled or landfilled due to contaminants that prevent close-loop recycling. Yet, this glass is potentially a valuable resource for casting robust and aesthetically unique building components. Exploring the potential of this idea, different types of non-recyclable silicate glasses are kiln-cast into 30 × 30 × 240 mm beams, at relatively low temperatures (820–1120∘C). The defects occurring in the glass specimens due to cullet contamination and the high viscosity of the glass melt, are documented and correlated to the casting parameters. Then, the kiln-cast specimens and industrially manufactured reference beams are tested in four-point bending, obtaining a flexural strength range of 9–72 MPa. The results are analysed according to the role of the chemical composition, level of contamination and followed casting parameters, in determining the flexural strength, the Young’s modulus and the prevailing strength-limiting flaw. Chemical compositions of favourable performance are highlighted, so as critical flaws responsible for a dramatic decrease in strength, up to 75%. The defects situated in the glass bulk, however, are tolerated by the glass network and have minor impact on flexural strength and Young’s modulus. The prerequisites for good quality recycled cast glass building components are identified and an outline for future research is provided.@en

It is not obvious to talk about glass recycling when we realize that a mature recycling procedure for glass bottles is already working well. However, apart from glass bottles, unfortunately, that a large amount of glass will disappear into landfills. This large quantity of unrecycled glass indicates that there is a large potential in upgrading the glass recycling process. In the field of architecture, we see a fast-growing interest in using glass, also for structures. The glass bricks of Crystal Houses in Amsterdam are a good illustration. Aiming at maximizing the recyclability of glass, this paper focuses on the structural use of the glass components made from recycled glass through kiln casting method. An overview of the existing glass recycling industry is given at the beginning, followed by a discussion of glass type to be recycled. After this the experimental process of the glass recycling is introduced, which uses coated float glass with tints as the basic material to be recycled. Following this, a further exploration in three structural properties of the recycled products is conducted, namely: Young’s modulus, coefficient of thermal expansion and the fracture strength, with mechanical experiments. Finally, the test results are analyzed together with the chemical composition of the recycled products, which is derived from X-ray fluorescence (XRF) analysis. The result contains the value of mechanical properties and it evaluates the possibility of the structural use as a recycled-float-glass beam. In the end of this paper, the future possibility and feasibility in structural application of recycling waste float glass are discussed.@en

The success of projects such as the Crystal Houses façade in Amsterdam has triggered an increasing interest from architects, engineers and glass producers in the development and application of structural cast glass components. This interest raises, simultaneously, the needs for a controlled manufacturing process, a system for quality control and structural validation, to guarantee the production of safe components. Manufacturing-related flaws, such as stones, cord inclusions, or air-bubbles, occurring in the mesostructure of the components, form weak zones within the material and may lead to “spontaneous” cracking. The casting parameters such as the forming temperature and corresponding glass viscosity, the dwell time at this temperature and the cooling rate, largely determine the homogeneity of the final product. Additional complexity arises once the use of waste/recycled glass is considered, due to the probable presence of variable glass compositions and miscellaneous contaminants in the initial batch. The risk of inhomogeneity and resulting eventual mechanical failure, indicates the necessity of understanding the causes of flaw-formation and the impact of the developed flaws on the structural performance of the cast components. Therefore, a series of 50mm cubic glass components are cast at the TU Delft Glass Lab, using a selection of already formulated discarded soda-lime glasses from different commercial applications. The cubes’ meso-structure is documented and- when required- scanned employing a Computer Tomography scanner and a polariscope to identify possible density differentials and internal stresses respectively. Then the cubes are tested for splitting strength and their performance is analyzed in relation to the previously documented flaws. The destructive tests suggest that there is a correlation between the meso-structure, structural performance and failure pattern of the cast glass components.@en

To investigate the effects of viscosity-modifying admixture (VMA) on the extrudability of limestone and calcined clay-based cementitious materials, three mix designs with different dosages of VMA were proposed in this study. The ram extrusion was utilized as an extrusion model for exploring the fresh properties of printable materials. Two methods were used, based on the ram extruder setup—(a) extruding materials with the same extrusion speed at different rest times to determine how the pressure changes with time; (b) extruding materials with different extrusion speeds at the same rest time to investigate the material flow parameters using the Basterfield et al. model. The main findings of this study could be summarized as—(1) the extrusion pressure of all mix designs exhibited an increasing trend with time. At the same tested age, the extrusion pressure under 0.25 mm/s of piston speed was increased and the shape retention of the extruded filaments was enhanced by increasing the dosage of VMA; (2) the correlation between the experimental results and the Basterfield et al. model was excellent (R-squared value: 0.99). The mixture with a higher content of VMA showed an increased elongational yield stress, flow consistency, and shear yield stress.@en

The applicability of glass in structures is continuously ascending, as the transparency and high compressive strength of the material render it the optimum choice for realizing diaphanous structural components that allow for light transmittance and space continuity. The fabrication boundaries of the material are constantly stretching: visible metal connections are minimized and glass surfaces are maximized, resulting to pure all-glass structures. Still, due to the prevalence of the float glass industry, all-glass structures are currently confined to the limited forms and shapes that can be generated by planar, 2D glass elements. Moreover, despite the fact that glass is fully recyclable, most of the glass currently employed in buildings is neither reused nor recycled due to its perplexed disassembly and its contamination from coatings and adhesives. Cast glass can be the answer to the above restraints, as it can escape the design limitations generated from the 2-dimensional nature of float glass. By pouring molten glass into moulds, solid 3-dimensional glass components can be attained of considerably larger cross-sections and of virtually any shape. These monolithic glass objects can form repetitive units for large all glass-structures that do not buckle due to slender proportions and thus can take full advantage of the stated compressive strength of glass. Such components can be accordingly shaped to interlock towards easily assembled structures that do not require the use of adhesives for further bonding. In addition, cast glass units–due to their increased cross section– can tolerate a higher degree of impurities and thus can be produced by using waste glass as a raw source.

@en