| Type of project: | | Materials, products and construction technologies
| | Start of production: |
| not applicable
| | Main author: |
| Povilas Cepaitis, AA School of Architecture, United Kingdom | | Further authors: | | LLuis Enrique, Diego Ordoñez and Carlos Piles, AA School of Architecture, United Kingdom |
 Receiving the Holcim Awards “Next Generation” 1st prize 2011 Europe for Efficient fabrication system for geometrically complex building elements, London, UK (l-r): Povilas Cepaitis, Diego Ordoñez, LLuis Enrique, and Carlos Piles, AA School of Architecture, United Kingdom from Alain Bourguignon CEO Aggregate Industries UK.
Project description
Cast on Cast, efficient and sustainable fabrication process is focused upon the development of a smart but simple methodology to design and prefabricate building elements with complex geometries, which is resource efficient and considerably reduces construction waste. Complex geometries are utilized in contemporary architecture for the construction of concrete or mortar building envelopes, partition walls, horizontal and vertical shading elements and pavements. Building elements that are curved through all three dimensions can only be produced under current methods by using sophisticated formwork installations and highly industrialized prefabrication technologies at high cost. The proposed Cast on Cast methodology uses a parameterization system in which mathematical algorithms subdivide three dimensional elements into smaller components that can be stacked in towers. Furthermore the previous element is used to mold the shape of the subsequent element. This CNC controlled fabrication method relies on the consecutive process of casting elements using digital fabrication technology. These towers of elements are then transported to the site where they are detached and assembled into the desired spatial shape.
Comment of the Holcim Awards jury Europe
The jury commended this project which innovatively challenges new methods of designing and fabricating geometrically complex building elements and in addition provides efficiency improvements in terms of materials, storage, and transportation. Overall, the project presents a way that considers simultaneously the design of free and ambitious shapes, as well as the material efficiency and economy of constructions.
Image gallery
Efficient fabrication system for geometrically complex building elements, London, United Kingdom
The project images and photographs shown below can be downloaded immediately in high-resolution format. To download an image, click on the link next to below any picture. Images may be used for media and academic purposes and must include a photo credit: Photos© Holcim Foundation. For further enquiries please contact info@holcimfoundation.org.
 Efficient fabrication system for geometrically complex building elements, London, UK Cast on Cast components fabricated in towers.  Efficient fabrication system for geometrically complex building elements, London, UK Cast on Cast components assembled in surface.  Efficient fabrication system for geometrically complex building elements, London, UK Cast on Cast process.  Efficient fabrication system for geometrically complex building elements, London, UK Waste in building processes.  Efficient fabrication system for geometrically complex building elements, London, UK a-b-b-c logic.  Efficient fabrication system for geometrically complex building elements, London, UK Assembly.  Efficient fabrication system for geometrically complex building elements, London, UK Angle logic.  Efficient fabrication system for geometrically complex building elements, London, UK Pavilion (Towers and Surface).  Efficient fabrication system for geometrically complex building elements, London, UK Hexagon logic.  Efficient fabrication system for geometrically complex building elements, London, UK Pavilion (Surface).  Efficient fabrication system for geometrically complex building elements, London, UK Team picture.  Efficient fabrication system for geometrically complex building elements, London, UK Receiving the Holcim Awards "Next Generation" 1st prize 2011 Europe for Efficient fabrication system for geometrically complex building elements, London, UK (l-r): Povilas Cepaitis, Diego Ordoñez, LLuis Enrique, and Carlos Piles, AA School of Architecture, United Kingdom from Alain Bourguignon CEO Aggregate Industries UK.  Efficient fabrication system for geometrically complex building elements, London, UK Representatives of all "Next Generation" prize winners for the Holcim Awards 2011 Europe (l-r): Elisa de los Reyes Garcia (2nd); Eduardo Mayoral (3rd); and Povilas Cepaitis, Diego Ordoñez, LLuis Enrique, and Carlos Piles (1st).
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