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Belgian Building Research Institute– http://www.bbri.be
SHELL ELEMENTS OF ARCHITECTURAL CONCRETE USING FABRIC FORMWORK
PART 1: CONCEPT
Cauberg N. Parmentier B. M. Vanneste Mollaert M.
BBRI
FRPRCS-9 Sydney, July 2009
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Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009
BBRI
Construction sector
Introduction: Partnership
Textile industry
Architecture
•Non-profit, private research institute• Statutory members, + 70.000 Belgian contractors• Collective research, Development & Innovation• Information transfer
• Non-profit, private research institute• Members: 900 textile producers, 100 associated members• Collective research, Development & Innovation• Information Transfer
• 9000 students, 2500 staff members, 8 faculties• ARCH: Department of Architectural engineering• 25 members, head prof. Mollaert, focussing on:
- Renovation and re-use- Lightweight structures -> Tensile surface structures- 4D Design
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Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009
Introduction
Introduction:Concept
Doubly curved shell elements
1. Flexible formwork
2. Flexible reinforcement
Design, the Nomad Concept
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Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009Introduction
Introduction:Concept
Modern, organic architecture creates the need for new formwork techniques
Shaping and modeling
Materials
ExperimentsConclusions, further work
Introduction
Design central station, Stuttgart
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Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009Introduction
Introduction:Concept
Fabric formwork allows for a great shape flexibility
Shaping and modeling
Materials
ExperimentsConclusions, further work
Introduction
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Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009Introduction
Introduction:ConceptShaping and modeling
Materials
ExperimentsConclusions, further work
Introduction
Thin shell elements, based on shotcrete
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Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009Introduction
Introduction:ConceptShaping and modeling
Materials
ExperimentsConclusions, further work
Introduction
Experiments and case study
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Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009Introduction
Introduction:ConceptShaping and modeling
Materials
ExperimentsConclusions, further work
Introduction
On site, permanent formwork, ... : new possibilities for architectural concrete
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Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009
• Shape flexibility: Creative or organic shapes, intelligentdesign structural members• Surface quality of the concrete• Transport• But: More complex!
Introduction
Ghent Music Centre – Toyo Ito with prof. Andrea Branzi
Concrete, poured in a formwork ≈ fluid
Introduction:Why fabric formwork?
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Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009
• Mark West: Beams, panels, columns, ...
• Pedreschi, Pronk, Schmitz, ...
Introduction
Introduction:Reference work
Practical Solutions• Slope/dike reinforcement, • Under water concreting,• Foundations, ...
Design and Architecture
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Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009
Modeling and shaping
Modeling and shaping
• Shaping• Material choice and prestress condition• Loading conditions (concrete)• Calculation of stresses and deformations• Iteration...
Approach similar to « textile architecture »
• Cutting pattern• Confection step• Actual formwork set-up« Prefabricated »
Manufacturing
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Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009
Materials
Materials
• PP, PE and PVC• Tensile strength: 40-150 kN/m• Young modulus: 0.1 – 1 GPa
-> deformations• Stiffness: 100 – 600 kN/m• Coated and non-coated
-> demoulding, impermeability• Texture
-> surface aspect• Assembly: stitching, welding, ...
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Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009
Experiments:Case studiesColumns, shells, wall panels, ...
Experiments
Columns with specific heads (axial symmetry, square, ...)combined with slab formwork
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Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009
Experiments:Case studiesColumns, shells, wall panels, ...
Experiments
• Arch and column combined• Specific shape adapted for fabric formwork
« PARKgarage » idea of Pronk (TU/e)
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Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009
Experiments:Case studiesColumns, shells, wall panels, ...
Experiments
Mould for precast element
Brodzki
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Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009
Experiments:Case study - Doubly curved shell
Experiments
• Complex geometry fortraditional formwork• Textile choice, confection• Prestress ± 2 kN/m• Sprayed concrete• Small deformations < 2 mm• Reinforcement:important issue
Design The Nomad Concept
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Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009
Experiments
Design The Nomad Concept
Experiments:Case study - Doubly curved shell
• Complex geometry fortraditional formwork• Textile choice, confection• Prestress ± 2 kN/m• Sprayed concrete• Small deformations < 2 mm• Reinforcement:important issue
![Page 18: SHELL ELEMENTS OF ARCHITECTURAL CONCRETE USING FABRIC FORMWORK … 2018-05-08 · SHELL ELEMENTS OF ARCHITECTURAL CONCRETE USING FABRIC FORMWORK PART 1: CONCEPT Cauberg N. ... Reference](https://reader030.vdocuments.net/reader030/viewer/2022040404/5e909a6386b23c5f596443f4/html5/thumbnails/18.jpg)
Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009
Experiments
Design The Nomad Concept
Experiments:Case study - Doubly curved shell
• Complex geometry fortraditional formwork• Textile choice, confection• Prestress ± 2 kN/m• Sprayed concrete• Small deformations < 2 mm• Reinforcement:important issue
![Page 19: SHELL ELEMENTS OF ARCHITECTURAL CONCRETE USING FABRIC FORMWORK … 2018-05-08 · SHELL ELEMENTS OF ARCHITECTURAL CONCRETE USING FABRIC FORMWORK PART 1: CONCEPT Cauberg N. ... Reference](https://reader030.vdocuments.net/reader030/viewer/2022040404/5e909a6386b23c5f596443f4/html5/thumbnails/19.jpg)
Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009
Experiments
Design The Nomad Concept
Experiments:Case study - Doubly curved shell
• Complex geometry fortraditional formwork• Textile choice, confection• Prestress ± 2 kN/m• Sprayed concrete• Small deformations < 2 mm• Reinforcement:important issue
![Page 20: SHELL ELEMENTS OF ARCHITECTURAL CONCRETE USING FABRIC FORMWORK … 2018-05-08 · SHELL ELEMENTS OF ARCHITECTURAL CONCRETE USING FABRIC FORMWORK PART 1: CONCEPT Cauberg N. ... Reference](https://reader030.vdocuments.net/reader030/viewer/2022040404/5e909a6386b23c5f596443f4/html5/thumbnails/20.jpg)
Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009
Experiments
Displacement
Force/pretension
Experiments:Case study - Doubly curved shell
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Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009
Experiments
Design The Nomad Concept
Experiments:Case study - Doubly curved shell
• Complex geometry fortraditional formwork• Textile choice, confection• Prestress ± 2 kN/m• Sprayed concrete• Small deformations < 2 mm• Reinforcement:important issue
![Page 22: SHELL ELEMENTS OF ARCHITECTURAL CONCRETE USING FABRIC FORMWORK … 2018-05-08 · SHELL ELEMENTS OF ARCHITECTURAL CONCRETE USING FABRIC FORMWORK PART 1: CONCEPT Cauberg N. ... Reference](https://reader030.vdocuments.net/reader030/viewer/2022040404/5e909a6386b23c5f596443f4/html5/thumbnails/22.jpg)
Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009
Experiments
Design The Nomad Concept
Experiments:Case study - Doubly curved shell
• Complex geometry fortraditional formwork• Textile choice, confection• Prestress ± 2 kN/m• Sprayed concrete• Small deformations < 2 mm• Reinforcement:important issue
![Page 23: SHELL ELEMENTS OF ARCHITECTURAL CONCRETE USING FABRIC FORMWORK … 2018-05-08 · SHELL ELEMENTS OF ARCHITECTURAL CONCRETE USING FABRIC FORMWORK PART 1: CONCEPT Cauberg N. ... Reference](https://reader030.vdocuments.net/reader030/viewer/2022040404/5e909a6386b23c5f596443f4/html5/thumbnails/23.jpg)
Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009
Experiments
Design The Nomad Concept
Experiments:Case study - Doubly curved shell
• Complex geometry fortraditional formwork• Textile choice, confection• Prestress ± 2 kN/m• Sprayed concrete• Small deformations < 2 mm• Reinforcement:important issue
![Page 24: SHELL ELEMENTS OF ARCHITECTURAL CONCRETE USING FABRIC FORMWORK … 2018-05-08 · SHELL ELEMENTS OF ARCHITECTURAL CONCRETE USING FABRIC FORMWORK PART 1: CONCEPT Cauberg N. ... Reference](https://reader030.vdocuments.net/reader030/viewer/2022040404/5e909a6386b23c5f596443f4/html5/thumbnails/24.jpg)
Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009
Experiments
Design The Nomad Concept
Experiments:Case study - Doubly curved shell
• Complex geometry fortraditional formwork• Textile choice, confection• Prestress ± 2 kN/m• Sprayed concrete• Small deformations < 2 mm• Reinforcement:important issue
![Page 25: SHELL ELEMENTS OF ARCHITECTURAL CONCRETE USING FABRIC FORMWORK … 2018-05-08 · SHELL ELEMENTS OF ARCHITECTURAL CONCRETE USING FABRIC FORMWORK PART 1: CONCEPT Cauberg N. ... Reference](https://reader030.vdocuments.net/reader030/viewer/2022040404/5e909a6386b23c5f596443f4/html5/thumbnails/25.jpg)
Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009
Conclusions and further work
Conclusions and outlook
• Preliminary study, modeling and manufacturing• Preparation depends on element type• On-site construction or precast production
New possibilities for architectural concrete
Further steps
• Optimize formwork manufacturing• Reinforcement: traditional and polymer reinforcement
-> Part 2: Case study!
New Central Station Stuttgart
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Belgian Building Research Institute
Introduction Modeling Materials Experiments Conclusions and outlookFRPRCS-9, Sydney, July 2009
Conclusions and further work
Conclusions and outlook
Further steps and research
• Shell element for permanent formwork (type « wide slab »)
• Integration of steel reinforcement
• Integration of polymer fiber reinforcement
• Use of fabric formwork as actual reinforcement
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Belgian Building Research Institute– http://www.bbri.be
Thank you for your attention!
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VUB
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