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Researchers from ETH Zurich have built a prototype of an ultra-thin, curved concrete roof using innovative digital design and fabrication methods. The tested novel formwork system will be used in an actual construction project for the first time next year.

A prototype for an ultra-thin, sinuous concrete roof using innovative design and fabrication methods has been designed and built by researchers from the ETH Zürich. The shell is part of a roof-top apartment unit called HiLo that is planned to be built next year on the NEST, the living lab building of Empa and Eawag in Dübendorf. The penthouse will provide living and work space for guest faculty of Empa. Researchers led by Philippe Block, Professor of Architecture and Structures, and Arno Schlüter, Professor of Architecture and Building Systems, want to put the new lightweight construction to the test and combine it with intelligent and adaptive building systems.

The self-supporting, doubly curved shell roof has multiple layers: the heating and cooling coils and the insulation are installed over the inner concrete layer. A second, exterior layer of the concrete sandwich structure encloses the roof, onto which thin-film photovoltaic cells are installed. Eventually, thanks to the technology and an adaptive solar façade, the residential unit is expected to generate more energy than it consumes.

Read the full press release here.

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