Design and construction of a concrete shell by active bending of a flat plate

Complex formed concrete shells are widely used in building environments as thin, lightweight, and cost-effective solutions. To simplify the formwork required for such structures, this study explores the potential to form complex shells from flat, flexible concrete plates through a controlled uplifting process. Flexible concrete is characterised by a thin concrete layer with highly ductile reinforcement, allowing cracking under stress. This behaviour reduces stiffness and facilitates the formation of curved structures. To demonstrate the feasibility of the method, a demonstrator was developed using paper models, CAD and non-linear finite element calculations. This demonstrator, built from a plate measuring 7.0 × 7.0 × 0.04 m, reached a height of 2.0 m after deformation. Findings indicate that this approach enables the construction of complex curved structures from flexible concrete. This research presents new perspectives for the application of flexible concrete in architecture and construction, emphasising the potential for innovative, cost-effective, and resource-efficient building techniques.