An integrated digital design and construction approach for falsework-minimal masonry vaults

Masonry vaults, mechanically efficient structures, are challenging to build because they require significant tailored falsework as temporary structures for centering, guidework, and scaffolding, which decreases construction productivity and increases financial cost and environmental impact. Traditional building techniques combined with recent digital technologies can eliminate such temporary construction. An integrated digital design and construction approach that leverages the benefits of four construction strategies (namely, thin-tile vaulting, loxodrome tessellation, augmented reality, and prefabricated spine) within a 4D funicular design framework is presented in this paper and illustrated by a large-scale demonstrator, innixAR. This structure demonstrates that the combination of the vernacular craft of thin-tile vaulting with augmented reality technology to produce a digital guidework, informing a 4D funicular design process that considers the entire construction sequence from a prefabricated spine, minimizes the required falsework, making the construction of masonry vaults more efficient and affordable. This approach is benchmarked against alternative conventional vault falsework. Combining thin-tile vaulting and prefabricated spine allowed a reduction of 82% of the falsework mass, making transport lighter. Whereas combining digital guidework and prefabricated spine allowed a reduction of 91% of the falsework elements, making assembly faster. This research contributes to the development of structures that are efficient both mechanically and constructionally.