Constructing hybrid gridshells using bending-active formwork

Aiming to promote a more sustainable approach to material utilization in architecture, this article presents an alternative construction method for lightweight and efficient concrete structures. The strategic focus is placed on building wide-spanning roof structures like vaults, domes, and freeform shells with the lowest possible input of raw materials and energy. To achieve this objective, the article explores the novel idea of using bending-active structures, made from millimeter-thin carbon fiber strips, as lost formwork and structural reinforcement for the production of hybrid gridshells. After a general introduction to the state-of-the-art in concrete construction, the authors discuss opportunities and challenges related to flexible formwork designs and their possible impacts on the building industry. Relying on the example of a built prototype, the authors present a promising design methodology and analyze the gridshell’s geometrical and structural characteristics throughout different stages of the construction process. The article concludes by discussing the added value of this research and identifying the key aspects that need to be considered in the further development of this construction method.