Simplifying Doubly Curved Concrete - Post-Digital Expansion of Concrete's Construction Solution Space

Abstract

This action research project develops a novel conceptual method for non-standardised concrete construction component fabrication and tests its validity through a speculative design project. The paper questions the practical, procedural and economic drivers behind the design and construction of geometrically complex concrete architecture. It proposes an alternative, simple and economical fabrication method for doubly curved concrete centred on the robotic manufacturing of casting moulds through 5-axis hotwire foam cutting for the making of doubly-curved fiber-reinforced concrete (FRC) panels. These panels are used as light-weight sacrificial formwork for in-situ concrete casting. The methodology's opportunity space is tested, evaluated and discussed through a conceptual architectural design project proposal that operates as demonstrator. The paper concludes by addressing the advantages of a design-and-build architecture delivery setup, the potential from using computational technology to adapt conventional design and construction procedures and the expanded role within the design and construction process this gives to architects.