Abstract
The rapid advancement of robotics holds the potential to revolutionise the future of construction. One promising application is the robotic assembly and disassembly of modular concrete shells – a structural system that reduces material use and improves cost-efficiency by eliminating the need of scaffolding. Traditionally, complex modular shell structures (e.g., domes, saddle surfaces) are built with scaffolding to ensure stability during construction. This project proposes a fabrication method for the scaffold-free assembly of full-scale modular shells.
The key innovation lies in designing the modular concrete segments so that they can support structural loads throughout the robotic fabrication process – both in intermediate stages and in the completed structure. The shell modules will be constructed using low-carbon cementitious composites reinforced with discrete and continuous flexible fibers to develop high-performance materials. The project aims to enable free cantilevering of shell elements, eliminating the need for temporary support. Additionally, the shell segments will be designed for reusability, so that they can be reused in other load-bearing structures such as flat wall panels. The proposed methodology will be validated through construction of a physical demonstrator, alongside static analysis of the modules as manipulated by robotic systems. This approach builds upon our preliminary work, which focused on the robotic assembly of modular shells using temporary falsework.
