The long-term durability of reinforced concrete infrastructure remains a critical challenge, as conventional Portland cement and carbon steel systems are inherently vulnerable to corrosion and environmental degradation.Roman concrete demonstrates exceptional longevity due to slow hydration kinetics, pozzolanic reactions, and self-healing mechanisms, but its integration into modern construction is limited by incompatibility with rapid construction workflows.At the same time, additive manufacturing has enabled advanced geometric control, while rarely addressing durability as a primary design objective.This study proposes a durability-driven construction system integrating Roman-type concrete, stainless steel reinforcement, and permanent additively manufactured thermoplastic formworks.Rather than acting as a temporary construction aid, the formwork is redefined as a permanent protective enclosure that sustains early-age loads, accommodates slow curing, and provides long-term environmental shielding.Stainless steel reinforcement is employed to mitigate corrosion, the dominant degradation mechanism.The system is evaluated using a multi-level methodology that combines material compatibility analysis, finite-element modelling of early-age conditions, and architectural-scale demonstration.The critical pre-and postcasting phases are analysed by modelling the fresh concrete as a fluid-like load acting on the permanent formwork, which represents the load-bearing component prior to setting.A segmented dome inspired by the Pantheon is used to demonstrate scalability and system integration.While direct validation over century-scale timeframes is impractical, the results show that the proposed system satisfies necessary conditions for extended service life, providing a scientifically grounded framework for durability-oriented construction using additive manufacturing.
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