Cutting in concrete construction. Geometric, technological and material implications.
José Pedro Sousa, Pedro Martins Carvalho, João Carvalho, Rafael Santos, Nohelia González
Research Paper
In recent years, digitally driven concrete fabrication has focused on traditional mold-making with 3D milling and advancements in 3D Construction Printing (3DCP). Both methods face challenges in efficiency, sustainability, and practical application. In this context, Robotic Hot-Wire Cutting (RHWC) has emerged as a promising alternative for concrete formwork, offering potential cost and sustainability benefits, though its use remains limited. This paper presents an industrial application of RHWC in constructing a geometrically complex canopy—the port-cochère—at the W Algarve hotel in Portugal. It details the design-to-production workflow for Glass-Fiber Reinforced Concrete (GRC) molds, addressing construction challenges and showcasing RHWC's potential to support complex architectural designs. Developed by a team connected to the DFL (CEAU/FAUP), the project exemplifies successful technology transfer from academia to industry.