This paper presents a formwork system consisting of a bending-active gridshell that simultaneously serves as falsework and integrated reinforcement for realising a ribbed funicular concrete skeleton shell. Encased by a knitted textile shuttering, the formwork system was demonstrated through KnitNervi, an architectural-scale, funnel-shaped demonstrator measuring 9 m in diameter and 3.3 m in height. The gridshell is materialised from straight steel rebar actively bent into curvilinear, double-layered rebar cages. Regular stirrups and pairs of inclined stirrups forming triangulated shear connectors provide the necessary shape control and stiffness for the load-bearing falsework. The rebar cages define the shape of the concrete ribs by supporting a knitted closed sectional mould and stay in place to structurally reinforce the resulting ribs. The focus of this paper lies on the falsework and reinforcement system with its interrelated design drivers. The geometric design includes the funicular form finding of the target shell with Thrust Network Analysis and the incremental form finding of the bending-active gridshell with its informed assembly sequence towards the funicular target with Finite Element Analysis. The engineering of the falsework demonstrates its sufficient load-bearing capacity and deflection control to support the weight of the wet concrete at an architectural scale. Sensitivity studies reveal the effectiveness of activating the double layer through the shear-connecting stirrups, the relevance of the internal connection design, and the geometric integrity during a potential stepwise casting sequence. The construction of the demonstrator verified the shape control and fabrication design. In only 36 h, the bespoke falsework gridshell was efficiently assembled from its kit-of-parts of standard rebar elements with adequate precision, logistics, time, and material resources. It was relatively lightweight, compact for transport, and employed low-tech construction techniques common to the rebar industry. Its structural geometry and informed bending-active logic enabled its efficient construction without digital fabrication or wasteful, costly moulds, which typically present the bottleneck for custom concrete structures. The resulting funicular concrete skeleton shell saves structural mass, hence embodied carbon, compared to unarticulated bending-dominant typologies. The overarching motivation of the research is to outline a strategy that could mitigate the environmental impact of the construction sector, applicable to a broad range of technological contexts.@en

A novel formwork system is presented as a material saving, labour reducing and cost-effective solution for the casting of bespoke doubly curved concrete geometries. The approach uses a custom knit technical textile as a lightweight stay-in-place formwork with integrated solutions for the insertion of additional elements, and is fabricated as a nearly seamless fabric. Using weft knitting as the textile formation technique minimises the need for cutting patterns, sewing, welding or gluing, when compared to conventional weaving and gives the possibility to integrate channels, openings, have varying widths and directional material properties, thus broadening the geometric design space. The system has been tested through a small-scale concrete footbridge prototype, built using a pre-stressed hybrid knitted textile and a bending-active structure that acted as a waste-free, stay-in-place, self-supporting formwork. Through the gradual buildup of strength in thin layers of concrete, formwork deformations during casting were minimised. This allowed for low tensioning levels of the fabric and the possibility to use higher pressure (e.g. during shotcreting) in applying the subsequent concrete without intermediate support from below. The computational design and fabrication of the knitted textile formwork included integrated channels for the insertion of bending-active rods, tensioning ribbons and features for controlling the concrete casting. The analysis and process of increasing the stiffness of the lightweight and flexible formwork is presented. The hybrid approach results in an ultra-lightweight formwork that is easily transportable and significantly reduces the need for falsework support and scaffolding, which has many advantages on the construction site.@en

A novel formwork system is presented as a material saving, labour reducing and cost-effective solution for the casting of bespoke doubly curved concrete geometries. The approach uses a custom knit technical textile as a lightweight stay-in-place formwork with integrated solutions for the insertion of additional elements, and is fabricated as a nearly seamless fabric. Using weft knitting as the textile formation technique minimises the need for cutting patterns, sewing, welding or gluing, when compared to conventional weaving and gives the possibility to integrate channels, openings, have varying widths and directional material properties, thus broadening the geometric design space. The system has been tested through a small-scale concrete footbridge prototype, built using a pre-stressed hybrid knitted textile and a bending-active structure that acted as a waste-free, stay-in-place, self-supporting formwork. Through the gradual buildup of strength in thin layers of concrete, formwork deformations during casting were minimised. This allowed for low tensioning levels of the fabric and the possibility to use higher pressure (e.g. during shotcreting) in applying the subsequent concrete without intermediate support from below. The computational design and fabrication of the knitted textile formwork included integrated channels for the insertion of bending-active rods, tensioning ribbons and features for controlling the concrete casting. The analysis and process of increasing the stiffness of the lightweight and flexible formwork is presented. The hybrid approach results in an ultra-lightweight formwork that is easily transportable and significantly reduces the need for falsework support and scaffolding, which has many advantages on the construction site.@en

Several structural systems rely on a specific hierarchy between their constitutive elements, which results in topological constraints on the feasible patterns that can describe them. Folded, corrugated, or creased surface structures require this bipartition, also called two-colouring, between independent wavy and smooth directions. Finding a valid pattern for complex design problems is not straightforward and identifying relevant ones is important as creasing can either strengthen or weaken a structure. This paper presents a way of tackling such a design problem, by focusing on the roof of the Great Courtyard of the British Museum, revisiting this structure with a creased shell to increase its bending stiffness in the key directions. The methodology includes two-colour topology finding of corrugated patterns, parametric structural analysis, and simple structural optimisation through data analysis for topological combination, which opens new research avenues for performance-informed topological exploration.@en

Facing the challenges of our environmental crisis, the AEC sector must significantly lower its carbon footprint and use of first-use resources. A specific target is the reduction of the amount of concrete used. Funicular structures that base their strength on their structurally-informed geometry allow for material efficiency. However, a bottleneck for their construction lies in their costly and wasteful formworks and complex reinforcement placement. This research presents an alternative flexible formwork system consisting of a bending-active gridshell falsework and fabric shuttering for ribbed funicular concrete shells. The falsework becomes structurally integrated as reinforcement and is designed as two connected layers offering shape control and sufficient stiffness to support the wet-concrete load. The paper focuses on the development of a design-to-fabrication workflow and a graph-based data structure for gridshell falsework and reinforcement in the computational framework COMPAS. The implementation utilises, customises and creates packages for the form finding of the ribbed shell with TNA and the gridshell with FEA. The research is based on a demonstrator realised in the context of the Technoscape exhibition at the Maxxi Museum in Rome, Italy. The computational workflow was used to design this system and translate it for materialisation. The demonstrator serves as proof-of-concept for the novel material-efficient construction system. Its key to efficiency lies in the structurally-informed geometry for both the formwork and the resulting ribbed concrete shell.@en

Failure of tall slender masonry structures during earthquakes often involves partial collapse of the structure well-above ground level. Consequently, the elastic response of the structure needs to be considered, which often requires modal analysis using finite element models — the generation of which can be labour-intensive and time-consuming. This paper presents a new integrated modelling approach which combines finite element analysis with rocking dynamics to model the seismic response of complex structural geometries in a computationally-efficient manner. The modelling strategy is implemented within the open-source computational framework COMPAS and is incorporated within the broader framework of a tool being developed for the seismic collapse assessment of masonry structures. The framework of this tool is first outlined, and the utility of the new modelling approach then demonstrated through application to the seismic assessment of a three historic masonry towers in North-Eastern Italy. The importance of accounting for elastic amplification effects, as well as the influence of varying boundary conditions on the dynamic response, is also illustrated.@en

This paper describes the structural design, digital fabrication and construction of KnitCandela, a free-form, concrete waffle shell with KnitCrete, a falsework-less formwork approach using a custom prefabricated knitted textile as multi-functional, structural shuttering layer and a form-found cable net as the main load-bearing formwork. The digitally designed and fabricated textile provided integrated features for inserting and guiding elements such as cables and inflatables that helped shape the sophisticated mould. With a total weight of only 55 kg, the 50 m2 formwork was easy and compact to transport. On site, the formwork was tensioned into a timber and steel rig, the pockets were inflated, and then coated with a thin layer of custom-developed, fast-setting cement paste. This paste served as a first stiffening layer for the textile, minimising the formwork's deformations during further concrete application. Fibre-reinforced concrete was manually applied onto the formwork to realise a 3 cm-thick shell with 4 cm-deep rib stiffeners. The novel approach, for the first time applied at architectural scale in this project, enables the building of bespoke, doubly-curved geometries in concrete, with a fast construction time and minimal waste, while also reducing the cost and labour of manufacturing complex parts.@en

This paper describes the structural design, digital fabrication and construction of KnitCandela, a free-form, concrete waffle shell with KnitCrete, a falsework-less formwork approach using a custom prefabricated knitted textile as multi-functional, structural shuttering layer and a form-found cable net as the main load-bearing formwork. The digitally designed and fabricated textile provided integrated features for inserting and guiding elements such as cables and inflatables that helped shape the sophisticated mould. With a total weight of only 55 kg, the 50 m2 formwork was easy and compact to transport. On site, the formwork was tensioned into a timber and steel rig, the pockets were inflated, and then coated with a thin layer of custom-developed, fast-setting cement paste. This paste served as a first stiffening layer for the textile, minimising the formwork's deformations during further concrete application. Fibre-reinforced concrete was manually applied onto the formwork to realise a 3 cm-thick shell with 4 cm-deep rib stiffeners. The novel approach, for the first time applied at architectural scale in this project, enables the building of bespoke, doubly-curved geometries in concrete, with a fast construction time and minimal waste, while also reducing the cost and labour of manufacturing complex parts.@en

This paper presents the design, engineering and digital fabrication strategies for a circular pedestrian bridge to be built as part of “De Groene Boog” development of the A16 highway north of Rotterdam, The Netherlands. The bridge is designed as a lightweight funicular unreinforced concrete gridshell with openings based on the principle of a three-hinged arch extrapolated to 3D geometry. In its realisation, it demonstrates a model of circular construction using recent material developments (such as recycled concrete) and an efficient flexible formwork system using knitted textiles. The presented design and fabrication process is developed collaboratively by the Block Research Group at ETH Zurich and De Groene Boog. The structure is commissioned by the Dutch Ministry of Infrastructure and Water Management (Rijkswaterstaat).@en

This paper presents the design, engineering and digital fabrication strategies for a circular pedestrian bridge to be built as part of “De Groene Boog” development of the A16 highway north of Rotterdam, The Netherlands. The bridge is designed as a lightweight funicular unreinforced concrete gridshell with openings based on the principle of a three-hinged arch extrapolated to 3D geometry. In its realisation, it demonstrates a model of circular construction using recent material developments (such as recycled concrete) and an efficient flexible formwork system using knitted textiles. The presented design and fabrication process is developed collaboratively by the Block Research Group at ETH Zurich and De Groene Boog. The structure is commissioned by the Dutch Ministry of Infrastructure and Water Management (Rijkswaterstaat).@en

Structural design is a search for the best trade-off between multiple architecture, engineering, and construction objectives, not only mechanical efficiency or construction rationality. Producing hybrid designs from single-objective optimal designs to explore multi-objective trade-offs is common in the design of structural forms, constrained to a single parametric design space. However, producing topological hybrids offers a more complex challenge, as a combinatorial problem that is not encoded as a finite set of real numbers but as an unbonded series of grammar rules. This paper presents a strategy for the generation of hybrid designs of quad-mesh pattern topologies for surface structures. Based on a quad-mesh grammar, an algebra is introduced to measure the distance between designs, find their similar features, and enumerate designs with different degrees of topological similarity. Structural design applications are shown to highlight the use of topologically hybrid designs as a surrogate for obtaining multi-objective trade-offs.@en

This paper presents initial results of research focused on developing a novel type of formwork for concrete based on pre-stressed fabric formwork principles. It aims at creating geometries that are fabricated in one piece by knitting technical fibers, which could ultimately be used as reinforcement for concrete. This approach would result in a spatial textile that minimises the need for patterning, sewing, welding or gluing compared to a conventional approach to fabric formwork and textile reinforcement based on woven fabrics. It makes it possible to create directional material properties aligned to the internal force flow. This paper presents an overview of the proposed prefabrication technique and exemplifies its feasibility through small-scale experiments.@en

Conventional construction of doubly-curved concrete structures is a time-, labour- and cost-intensive process. Flexible formworks have already been identified as a possible solution to produce such structures more efficiently. The KnitCrete technology developed at ETH Zurich uses 3D weft-knitted fabrics as stay-in-place formwork, which deliver multiple advantages over woven textiles due to their wider range of feasible geometries and possibility to include features and local material properties. The textile is initially coated with a fast-setting high-strength cement paste. The stiffened membrane is stable enough to serve as formwork for the final concrete layer. This paper discusses potential reinforcing strategies to guarantee structural safety and serviceability in KnitCrete structures. Possible approaches range from the use of the textile as a stay-in-place formwork as well as final reinforcement (by utilising high-strength fibrous materials such as aramid, glass or carbon fibre) to the implementation of geometric features, such as channels within the textile to guide conventional reinforcement or post-tensioning tendons. The feasibility and efficiency of the proposed reinforcement strategies have to be experimentally verified, for which a systematic methodology is proposed. Preliminary analyses of the experimental campaign show the beneficial effect of the knitted reinforcement on the cracking behaviour of the textile-concrete composite material. Additional research is needed to exploit the potential of possible hybrid solutions using short steel fibres, post-tensioning or linear steel or glass fibre reinforcement.@en

Knitting offers the possibility of creating 3D geometries, including non-developable surfaces, within a single piece of fabric without the necessity of tailoring or stitching. To create a CNC-knitted fabric, a knitting pattern is needed in the form of 2D line-by-line instructions. Currently, these knitting patterns are designed directly in 2D based on developed surfaces, primitives or rationalised schemes for non-developable geometries. Creating such patterns is time-consuming and very difficult for geometries not based on known primitives. This paper presents an approach for the automated generation of knitting patterns for a given 3D geometry. Starting from a 3D mesh, the user defines a knitting direction and the desired loop parameters corresponding to a given machine. The mesh geometry is contoured and subsequently sampled using the defined loop height. Based on the sampling of the contours the corresponding courses are generated and the so-called short-rows are included. The courses are then sampled with the defined loop width for creating the final topology. This is turned into a 2D knitting pattern in the form of squares representing loops course by course. The paper shows two examples of the approach applied to non-developable surfaces: a quarter sphere and a four-valent node.@en