Efficient and Expressive Thin-tile Vaulting using Cardboard Formwork

Davis L., Rippmann M., Pawlofsky T. and Block P.
Proceedings of the IABSE-IASS Symposium 2011
London, UK
2011

This paper presents research in the construction of freeform, thin-tile vaulting, demonstrated through a full scale prototype and application of an expandable cardboard guidework system. This form of complex structural design is enabled through Thrust Network Analysis (TNA) – a novel three-dimensional design tool for exploring funicular form. These free form shells present new challenges to the tiling patterns, sequence of building and especially the structural stability and guidework during construction. A continuous formwork system was developed using 2-D CADCAM cutting and gluing processes. The combined implementation of traditional thin-tile vaulting, TNA and the efficient cardboard formwork allows the construction of increasingly complex forms with the same (or even improved) benchmarks of sustainability and economy – radical form with efficient construction.