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UNIVERSITY OF MANITOBAFACULTY OF ARCHITECTURE

THE CENTRE FOR ARCHITECTURALSTRUCTURES AND TECHNOLOGY

CONSTRUCTION

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COLUMNS 01

PRE-CAST PANELS

SHOTCRETE SHELL PANELS

LIGHT-WEIGHT BEAMS

STRUCTURAL RESEARCH

FABRIC-CAST TRUSSES

BATCH COLUMN

BULGE WALLS

BULGE WALL COLUMNS

VAULTS

MASONRY

SCULPTURE 12

11

10

09

08

07

06

05

04

03

02

C.A.S.T. NETWORKS AND OUTREACH 13

CAST RESEARCH HAS BEEN SUPPORTED BY:

CFI - Canada Foundation for InnovationWED - Western Economic Diversification CanadaSSHRC - Social Sciences and Humanities Research Council of CanadaCPCI - Canadian Precast Concrete Institute Manitoba ChapterCAC - Cement Association of CanadaNSERC - Natural Sciences and Engineering Research Council of CanadaCMRI - Canadian Masonry Research Institute

CDRN - Canadian Design Research NetworkLafarge Building Materials Winnipeg CanadaOver 90 construction companies and suppliers from theNorth American construction industry.

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C.A.S.T. UNIVERSITY OF MANITOBA FACULTY OF ARCHITECTURETHE CENTRE FOR ARCHITECTURAL STRUCTURES AND TECHNOLOGY

WINNIPEG, CANADA

The Centre for Architectural Structures and Technology seeks new boundaries for architectural thought,design, and building technology through physical explorations of materials, tools, and methods, the study of

natural law, and the free play of imagination. A wide range of methods for research and creation are usedogether at C.A.S.T., mixing traditions of fine arts, engineering and architectural design.

The inventions illustrated in this booklet were all developed at C.A.S.T. using simple construction methodsand common building materials, making these new technologies accessible to both high and low capitalbuilding cultures and economies. Common to all these new methods is a concentration on material reductionin construction. In some of this work, antique structural forms are reexamined and reintroduced in the formof efficient and sustainable compression structures, while others provide entirely unprecedented forms andgeometries with extraordinary poetic and structural potential.



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1.

Studentpre

paringscaffoldingforfull-scaleconstruction

tests2.

TheC.A.S.T.

Building:designedandconstructedspecificallytosupportspecula

tivearchitecturalresearch.

1

2

3. recast concrete columns constructed for the ManitobaTheatre for Young People, Winnipeg, Canada. 4. abric cast col-umns at the College of the Atlantic, Bar Harbor, Maine, U.S.A. 5.Variable diameter fabric column formwork filled with concrete6. Detail of a precast column constructed for the Manitoba

Theatre for Young People, Winnipeg, Canada.

3

COLUMNS01

nexpensive rectangular sheets of fabric

can be used to create a multitude ofcolumn designs. These reusable light-weightformworks use hundreds of times lessmaterial than conventional rigid plywoodor steel column forms, and are even moreefficient than cardboard tube forms. Theflexibility of the fabric membrane tube offersopportunities for the natural production of

new architectural and sculptural forms.



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.CastPlastermodels(foreground)andfull-scaleformwo

rktests(background)

-

r

2.

TheC.A.S.T.

Buildin

gswallsusedaschalkboardsfordrawinga

ndconversation.

3.

ModelconstructioninaC

.A.S.T.workshopclass.

1

2

3

4. tudent models of fabric-cast panel designs 5. Full-scalefabric-cast concrete panels designed and built by architecturestudent Mike Monette at the Lafarge precast factory, Winnipeg,Canada . Full-scale fabric-formed shell panel designed andbuilt by Mark West at the Lafarge precast factory, Winnipeg,Canada. . Full-scale precast panel formwork designed andbuilt by architecture student Jeff Machnicki at the Lafargeprecast factory, Winnipeg, Canada. 8. Full-scale fabric-castconcrete panel designed and built by architecture students KenBorton, Andrea Flynn, Jonathan Trenholm, being prepared for

use as a mold.

4

PRE-CAST PANELS02

Precast Panels can be produced in flexible

fabric molds using a flat rectangular sheetof fabric stretched in a steel frame. Multipledesigns can be produced by altering thepattern of supports placed beneath thefabric sheet. Fabric-cast concrete panelscan also be used as molds to produce light-

weight, funicular shell-shaped panels.



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7 8



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1.

DrawingWorkshopatC.A.S.T.

2.

Electronicmusicperfo

rmanceatC.A.S.T.

1

2

3. hotcrete being applied to hanging fabric mold 4. odel ofa thin-shell wall panel made by spraying plaster on a hangingfabric sheet. 5. Close-up view of a fabric-formed thin-shellplaster model. Full-scale thin-shell wall panel made by spray-ing fibre-reinforced concrete on a hanging geotextile sheet

Lafarge Precast factory, Winnipeg, Canada

3

SHOTCRETE SHELL PANELS03

The latest research at C.A.S.T. is developing

methods of producing very light, thin-shellpanels by spraying fibre-reinforced shotcrete

against a suspended sheet of fabric.



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4 5

6



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1.

GraduateR

esearchAssistantJoshRuddandPhDengineeringcandidateFariborzHashemianwithC.A.S.T.s

500kn(110,0

0lb.)

hydraulicpres

s.

.

...

.

.

2.

GraduateResearchAssistantsMikeJ

ohnson,

JoshRudd,and

. single rectangular sheet of geotextile fabric weighing lesshan 10 kg. can be used to form a 12-metre (40 ft.) beam. .2-metre (40 ft.), variable section, double cantilever, reinforcedoncrete beam constructed at the Conforce Structures precast

factory, Winnipeg, Canada. 5. Fabric formwork for a 5-metre16.5 ft.) variable section T-beam, constructed by Ronnie Araya,004-2005 C.A.S.T. Visiting Researcher. 6. Prototype formwork

rig for the 12-metre beam shown in images (4) and (7). .olume of variable-section bending moment-shaped beam visu-lly compared to a conventional rectangular beam of the same

ajor dimensions.

1

2

3

JiamengZengworkingatC.A.S.T.

LIGHT-WEIGHT BEAMS04

C.A.S.T. has invented and developed various

methods of forming cast-in-place andprecast beams using simple fabric molds.The flexibility of these molds makes it easyo form efficient, variable-section beamshat follow structural curves dictated by

natural law. Our tests have produced fabric-cast beams up to 12 metres in length from a

single rectangular sheet of fabric.



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1.

Preparation

ofC.A.S.T.

hydraulicactuatorpressforstructuraltests

2.

TheC.A.S.T.

Buildingatnigh

.

1

2

3. Fabric beam formwork rig developed for precast production4. -metre variable section beam cast at the Lafarge precastfactory, Winnipeg, Canada. . 5-metre variable section beamcast from image 3 formwork at the Lafarge precast factory,Winnipeg, Canada. 6. hysical testing at C.A.S.T. of a 5-metrefabric-cast beam. 7. The fabric formwork for a 5-metre beam

weighs only 3 kg and costs less than $10 (US).

3

STRUCTURAL RESEARCH05

Beams shaped to the proportions andcurves of their bending moment can beeasily produced in flexible fabric molds.These variable-section beams behavedifferently from conventionally formeduniform-section rectangular beams. PhDengineering research at C.A.S.T. is studyinghe structural behaviour of these efficiently

curved beams. Structural research on our

fabric-formed beams is also being carriedout in other universities around the world

(see C.A.S.T. Research Network below).

BENDING MOMENT-SHAPED BEAMS



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1.

C.A.S.T.La

boratoryproductionfloorseenfromthemezzaninelevel.2.

ArchitecturestudentsSean

RadfordandPaulR

ajotteworkoutbeamformworkdesignsinmodelformpriortofull-sc

aletrials.

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.

1

2

3. rototype formwork for a 4-metre cast truss, testing differ-ent fabrics on either half 4. 2-metre prestressed plaster mod-els of cast truss designs. 5. -metre reinforced concrete trusshanging above its mold parts: a simple plywood base covered

y a rectangle of fabric prestressed to form the mold wall.

3

FABRIC-CAST TRUSSES06

C.A.S.T. has developed a new method of

constructing low-cost molds for reinforcedconcrete trusses. Flat sheets of fabric,stretched over simple rigid frames, are usedas the mold wall, allowing the formation ofefficient truss designs that can dramaticallyreduce dead weight and concrete volumes.



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.PublicreviewsofstudentworkatC.A.S.T.

2.

Full-scale

testsofBulgeWallcolumncontructiona

tC.A.S.T.

-

s

....

1

2

3. Illustration of construction method used to place wet con-crete above a previous cast. 4. iagram of how small pieces offabric are used to sequentially form a tall column. . Model of a

oncrete column constructed of stacked, small volume pours.

3

BATCH COLUMN07

C.A.S.T. invented this column formwork

method specifically for use in low-capitalbuilding cultures where concrete is hand-mixed in small batches. This columnformwork uses an absolute minimum ofmaterial to contain the volume of a singlebatch of hand-mixed concrete. Columnsare formed by sequential pours using these

small, reusable formwork sections.



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.C.A.S.T.atnight,showingplastermodelcasts.

2

1

2. laster model of a cast-in-place bulge wall 3. Detail ofan opening and pilasters in a plaster bulge wall model. 4.Full-scale bulge wall for a new sports facility at the Open Cityin Ritoque Chile, by Mark West, David Jolly, Victoria Jolly, andMiquel Equem . etail of openings and pilasters in a plaster

bulge wall model.

BULGE WALLS08

This technology was invented to allow

builders to construct fabric-formed wallswithout having to learn entirely new skillsor techniques. This technology recombinesordinary materials, tools, and techniques thatare standard in contemporary cast-in-placeconcrete construction. Using a geotextilefabric form-liner installed in standardplywood wall formwork, this method providesarchitectural and geometrical freedom byaking advantage of the flexibility of thefabric liner within the rigid limits set by the

plywood wall forms.



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3



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.Engineerin

gPhDcandidateFariborzHashemianconstru

cting4-metretestbeamsatC.A.S.T.

2.

ConcertatC.A.S.T.

bytheMontreal-basedsaxo

phonequartet,Quasar.

1

2

3. Bulge Wall type column design constructed at the OpenCity, Ritoque Chile, and Winnipeg, Canada. 4. ketch illustrat-ing how standard plywood wall forms are used to cast bulgewall column shapes 5. laster model of a buttressed bulgewall column 6. Plaster models of braced columns, designedto support compression vaults while providing resistance to

horizontal thrust.

3

BULGE WALL COLUMNS09

Columns with unprecedented sculptural and

structural shapes can be easily formed usingstandard plywood wall formwork with a fabricliner. Block-outs within the wall form set theprofile of the column along one axis, whilehe fabrics deflections produce beautiful

and efficient variable section forms.



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6



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1.

Electronic

musicperformanceatC.A.S.T

byComposer

Eliot

ritton.

...

B

.2.

SolocelloconcertbyDanishcellistJakobKullberg.

.Electronicmusic

improvisationsonthetablesaw.

1

2

3

4. Fiber-reinforced, funicular, thin-shell compression vaultsproduced from fabric-cast mold. Constructed by architecturestudents Cory Leniuk, Melissa Sarrasin, and Scott Staniul with as-sistance from Gerry de Roqu igny at the Lafarge precast factory,Winnipeg, Canada. . Students setting up the hanging geotextile

sheet used to fabricate the compression shell mold in image (4).

4

VAULTS10

C.A.S.T. has developed a method of

prefabricating funicular compression vaults.This ancient structural strategy offers muchhigher efficiency than reinforced concretebeams and slabs, particularly in high deadload applications (for example with greenroofs). This efficiency can help reduce thevolume of concrete and steel consumed inconstruction. A hanging fabric sheet is usedo produce a funicular mold for precast thin-shell production using either fibre-reinforced

or steel-reinforced concrete. This methodallows the economical production andindustrialization of compression structures.



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1.

.2.Fu

ll-scalefabricmoldrigbeingdevelopedand

prepared.

1

2

3. Catalan timbrel masonry vault being constructed by archi-tecture students with Prof. Natalija Subotincic. . refabricated6-metre (20 ft) funicular brick compression vault designedand constructed by C.A.S.T.based architecture thesis studentNeil Prakash, with assistance from Fariborz Hashemian, RonnieAraya, and Brian Gebhardt . ricks suspended on a flexiblemesh form themselves into a perfect funicular curve. . Mastermason Brian Gebhardt and students mortar joints in the vault at

ed River College, Winnipeg, Canada.

3

MASONRY11

C.A.S.T. is also home to research and

education in structural masonry construction.Projects in this area include studies ofhin-shell timbrel (catalan vault) dome

construction, and a new use of flexibleformwork techniques applied to theprefabrication of efficient funicular masonry

compression vaults.



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SCULPTUREOur research is producing new realms

of constructed form through simplecombinations of inexpensive materials, tools,and techniques. As in natural systems, wefind physical simplicity producing sculpturaland geometric richness with a refinedstructural elegance. By following this path ofsimplicity, a complex new language of form

is emerging and waiting to be explored.

12

1.

Graduate

ResearchAssistantsbuildingfull-scaleproto

typeformwork.

2.

ArchitecturestudentsJon

Reid,

JasbirSinghBhamra,andPaulRajotte

removingformworkfromamodelbeamcast.

3.

Graduate

ResearchAssistantsLeifFriggstadandKyleMartensdesigningthin-shellwallpanelform

workusingmodelrigs.

1

2

3

4

4. Fabric-cast bollards by Mark West for Festival Plaza at Ot-tawa City Hall, Ottawa, Canada. . abric-cast sculpture byMark West. 6. Fabric-cast column designs by Mark West. 7.

Fabric-cast bollard by Mark West.



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C.A.S.T. NETWORKS AND OUTREACH13

C.A.S.T is dedicated to expanding access

o the open source technologies we areinventing and developing. Our commitmento using simple and inexpensive materials,ools, and techniques makes these newechnologies accessible to people living inboth high and low-capital building cultures.C.A.S.T. is the centre of a growing networkof associated academic and professionalcollaborations. Together we are exploringand developing new methods of construction

hat can reduce material consumption whileopening up new realms of architectural andstructural form for architects, engineers,

artists, and builders.



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C.A.S.T. INTERNATIONAL EDUCATIONLECTURESInvited lectures to present research findings at over twenty professional organizations and schools of architecture and engineering, andprofessional continuing education classes: CHILE, ENGLAND, MEXICO, SCOTLAND, TURKEY, KANSAS, MISSISSIPPI, NEW YORK, NEBRASKA, NORTH CAROLINA, OREGON,

PENNSYLVANIA, TEXAS, VERMONT, MONTREAL, WINNIPEG, VANCOUVER MAA Professional continuing education class (at CAST), RAIC / AIBC Professional continuing education class (VANCOUVER),Two invited lectures at RAIC annual National Conferences (WINNIPEG, VANCOUVER)

WORKSHOPS Seven multi-day construction workshops to transfer CAST technology to schools of architecture in: MEXICO, CHILE, EDINBURGH,KANSAS, MONTREAL, VERMONT. Three Catalan Vault Masonry Workshops held at CAST (Canadian Masonry Research Institute) One Manitoba Association of Architects (MAA) professional continuing education workshop



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C.A.S.T. PUBLICATION AND EXHIBITIONEXHIBITIONSCAST architectural research findings in fabric formwork (models, photographs of built work, drawings) have been included in gallery andmuseum shows internationally: CANADA: The Eric Arthur Gallery, University of Toronto

ENGLAND: Royal Institute of British Architects (RIBA) Gallery, London USA: National Building Museum, Washington, D.C. FRANCE: Muse des Arts et Mtiers, Paris

PUBLICATIONS - MAGAZINES/JOURNALSCAST fabric formwork research has been widely published in professional and industry journals and magazines in eight countries, on fourcontinents, and in four languages. 8 articles authored at CAST (published in CANADA, USA, TURKEY, GERMANY) 1 article co-authored with collaborating engineers (POLAND AND LIBYA) (Published in UK) 14 articles about CAST research written by others (published in CANADA, USA, U.K., FRANCE, INDIA, CHILE, ARABIA)



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C.A.S.T. RESEARCH NETWORKACADEMIC RESEARCH FOLLOWING C.A.S.T. INVENTIONSCATHOLIC UNIVERSITY OF VALPARAISO School of Architecture and Design: Full scale fabric-formed concrete construction at the Open CityUNIVERSITY OF EDINBURGH School of Architecture: fabric formwork design/research; full scale construction; PhD engineering research: fabric-formed beamsUNIVERSITY OF EAST LONDON School of Architecture: fabric formwork design, research and proof of concept construction

UNIVERSITY COLLEGE LONDON The Bartlett School of Architecture: PhD work in fabric-formed architecture.DELFT TECHNICAL UNIVERSITY: Masters of engineering thesis work, optimization of fabric-formed beams.UNIVERSITY OF BATH Deptartment of Architecture and Civil Engineering: Masters thesis in fabric-formed beams

OTHER RESEARCH PARTNERSHIPSUMI ARCHITECTURE ATELIER (TOKYO, JAPAN) Architect Kenzo Unno (inventor of fabric-formed wall systems),

VISITING RESEARCHERSTwo six-month residences at C.A.S.T by visiting researchers, architect Ronnie Araya (VALPARAISO, CHILE) and Lancelot Coar

(PHILADELPHIA, U.S.A). Two-week Residence by Architect Ryan Coover (AUSTIN TEXAS). One-week residence by architects CsarMarrufo and Ral Cardea from the Universidad Autnoma de Yucatn (MXICO)



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Professor Mark WestDirector, C.A.S.T.Centre for Architectural Structures and TechnologyUniversity of Manitoba Faculty of Architecture

:C.A.S.T. Building (204) 474-7427FAX: (204) 474-7533

MAIL:University of ManitobaFaculty of ArchitectureRoom 201, J.A. Russell Building

innipeg, MB R3T 2N2CANADA

http://www.umanitoba.ca/cast_building/

UNIVERSITY OF MANITOBAFACULTY OF ARCHITECTURE

THE CENTRE FOR ARCHITECTURALSTRUCTURES AND TECHNOLOGYC.A.S.T.

ResearchAssistantChrisWiebethinksthingsover.

Printed on paper from well managed forests with 30% post consumer waste recycled content.


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