Tectonics and Material Transformations. Exploring Concrete in Architecture Through Digital Fabrication Processes

Abstract

In the global architectural context of recent decades, the integration and exploration of digital design and fabrication tools has sparked a growing interest in designing progressively more complex and personalized spatial and constructive solutions. While these interests pose significant challenges to the construction industry, they also offer important opportunities for innovation in the field of architecture. At the same time, concrete remains one of the most widely used construction materials in our built landscape and is a traditional material of choice for many architectural styles. Therefore, concrete remains a very relevant material for architecture, but it also holds significant economic and environmental relevance due to its widespread use. In this context, the general theme of this thesis focuses on digital fabrication technologies and their impact and potentials in the production of concrete architecture. This thesis argues that by integrating digital fabrication technologies with the design process, it is possible to not only overcome the limitations of traditional concrete architecture but also enable new architectural possibilities in line with both traditional and emerging desires for this material. Therefore, the central question it seeks to answer is: How can digital fabrication technologies expand the lexicon of traditional concrete architecture in terms of form, surface, and composition, using accessible, sustainable, and tectonically relevant methodologies? In order to answer this question, this thesis evaluates the impact of the integration of these technologies in the concrete design and construction process, focusing on three concepts: form, surface and composition. Aiming to expand current possibilities, it proposes and explores a robotic technology (RHWC) as a viable and tectonically significant strategy for a non-standard architecture in concrete, defending its potential both at a constructive and creative level. Through the realization of experimental prototypes, focused on robotic hot wire cutting of EPS moulds, this thesis demonstrates the architectural potential of this technology in terms of creating complex geometries, textured surfaces and variable compositions. Alternating experimentation in laboratory and industrial environments, the technical and economic viability of this technology is also demonstrated, as well as its relevance for the development of new products in this material.