D1. Assembly sequence

Objectives

We will see the main steps required to go through in the construction process of the simple prototype, linking them back to the fabrication constraints during the design process. For form-active structures, the intermediate stages and their structural behaviour are an important design part to consider.

a. Determine Boundary Conditions

Placement on site

Exact measurement of boundary conditions

b. Place Supports

Steel support plates placement

Steel support plates

Temporary steel brackets placement

Temporary steel brackets in place

c. Install Formwork

Primary arches formwork

Transverse girders and temporary bracing

Option: Assembly from layercut plywood sheets

Typical shop fabrication drawings

d. Install knitted fabric

Install knitted fabric and tighten at extremities

Edge details for installation and tightening of fabric

Knitted fabric strips - halves joined at central support

typical bill of Quantities (BoQ) for sundries and fasteners

e. Apply hardening paste

Hardening paste (1 - 2 mm) applied to freeze geometry

f. Apply concrete and remove formwork

Apply fiber-reinforced concrete (30 - 35 mm average thickness)

Section detail of local thickening of concrete shell at supports

Remove all remaining formwork at temporary supports

g. Install deck elements

2D CNC cut elements span the corrugations, extruded steel mesh in-between