Static- and fabrication-aware segmented concrete shells made of post-tensioned precast flat tiles

This paper introduces a novel structural concept for freeform shells, in which the shape is decomposed into flat tiles to be assembled sequentially with the help of falseworks. Once the structure is completed, the tiles are post-tensioned to minimize the tension forces and avoid detachment. The entire design process, from an input shape to fabrication, is managed by an automatic pipeline. The input shape is segmented into a field-aligned quad mesh, computed from the principal stress of the thin shell. The flat tiles are obtained by extruding each face along the normal of the best-fitting plane per face. The contact between adjacent tiles is ensured only at their edge midpoints so the forces can mainly flow along the cross directions. The best configuration of cable paths and pre-loads is found by solving a constrained optimization problem exploiting a reduced beam model of the shell. All tiles can be prefabricated in the shop with an adaptable and reusable molding system. Once the structure is completed, the top surface is finally completed with an in situ cast that fills the gaps and activates the entire shell behavior. In contrast, the bottom surface maintains its jagged aesthetics.