Fabric as a flexible formwork for concrete is an alternative giving builders, engineers, and architects the ability to form virtually any shape. This technique produces a superb concrete surface quality which requires no further touch up or finishing. Woven polyole-fin fabrics are recommended for this application. A permeable woven fabric allows excess water from the concrete mix to bleed through the mold wall, and therefore reduce the water-cement ratio of the concrete mix. Due to the reduction in water-cement ratio, higher compressive strength in fabric formed concrete may be achieved, as also suggested by earlier research. The current research study was conducted to investigate and document the changes in concrete strength and overall quality due to use of commercially available woven polyolefin fabrics. Use of fabric formwork will contribute to decreased construction cost, construction waste, and greenhouse gas emissions. Two sets of tests were conducted as a part of this research study including comparison of compressive strength of fabric formed versus PVC formed concrete cylinders and comparison of be-haviour of the fabric formed reinforced columns versus cardboard formed reinforced concrete columns. Variables in this research were limited to two types of fabric with dif-ferent permeability (Geotex 104F and Geotex 315ST) and two types of concrete; concrete made with conventional Portland cement and no flyash herein called normal concrete (NC) and concrete with 30 percent flyash in its mix design (FAC). The laboratory results revealed that fabric Geotex 315ST is an ideal geotextile for forming concrete. It was also found that the effects of fabric formwork on concrete quality in a large member are limited mostly to the surface zone and the core of the concrete remains the same as a conventionally formed concrete. Even though fabric formed cylinder tests showed an average of 15% increase in compressive strength of the concrete samples, compressive strength of the reinforced columns did not dramatically change when com-pared to the companion cardboard formed control columns. This research confirmed that fabric formwork is structurally safe alternative for forming reinforced concrete columns.

Fabric as a flexible formwork for concrete is an alternative giving builders, engineers, and architects the ability to form virtually any shape. This technique produces a superb concrete surface quality which requires no further touch up or finishing. Woven polyole-fin fabrics are recommended for this application. A permeable woven fabric allows excess water from the concrete mix to bleed through the mold wall, and therefore reduce the water-cement ratio of the concrete mix. Due to the reduction in water-cement ratio, higher compressive strength in fabric formed concrete may be achieved, as also suggested by earlier research. The current research study was conducted to investigate and document the changes in concrete strength and overall quality due to use of commercially available woven polyolefin fabrics. Use of fabric formwork will contribute to decreased construction cost, construction waste, and greenhouse gas emissions. Two sets of tests were conducted as a part of this research study including comparison of compressive strength of fabric formed versus PVC formed concrete cylinders and comparison of be-haviour of the fabric formed reinforced columns versus cardboard formed reinforced concrete columns. Variables in this research were limited to two types of fabric with dif-ferent permeability (Geotex 104F and Geotex 315ST) and two types of concrete; concrete made with conventional Portland cement and no flyash herein called normal concrete (NC) and concrete with 30 percent flyash in its mix design (FAC). The laboratory results revealed that fabric Geotex 315ST is an ideal geotextile for forming concrete. It was also found that the effects of fabric formwork on concrete quality in a large member are limited mostly to the surface zone and the core of the concrete remains the same as a conventionally formed concrete. Even though fabric formed cylinder tests showed an average of 15% increase in compressive strength of the concrete samples, compressive strength of the reinforced columns did not dramatically change when com-pared to the companion cardboard formed control columns. This research confirmed that fabric formwork is structurally safe alternative for forming reinforced concrete columns.

Concrete has many advantages as a low cost and sustainable material. However, more than 5% of the planet’s total carbon emissions are associated with the production of cement, which, in fact, is predominantly due to the large volume of concrete used worldwide. It is known that traditionally designed concrete structures typically use more material than structurally required and, therefore, an important question is whether material demand can be reduced through structural optimisation. A major drawback from optimised design, however, is the cost and complexity of producing conventional rigid moulds. Fabric formwork is emerging as a new method for construction, gaining popularity among architects and engineers for the opportunity to build unique forms and to shape concrete elements efficiently. Porous fabrics, acting as controlled permeability formwork, also have proven effect on the durability characteristics of concrete. While fabric formwork has a profound potential to change the appearance of concrete structures, the shapes cast in fabrics are not defined in advance and have been often created unintentionally. The design of load-bearing reinforced concrete structures, however, requires accurate form-prediction and construction methods for securing steel reinforcement inside flexible fabrics, which presents a number of constructability challenges. For example, cover formers cannot be used to ensure adequate thickness of protective cover, inevitably affecting the acceptance of such structures in practice. This research has demonstrated that non-corrodable FRP reinforcement can be incorporated more easily than steel bars in fabric-formed concrete due to its light weight and flexibility, while it is possible to ensure ductility of such structures through confinement of concrete using FRP helices. A novel splayed anchorage system has been developed to provide end anchorage for optimised sections where standard bends or hooks cannot fit. This work also provides an experimentally verified methodology and guidance for the design and optimisation of fabric-formed elements.

Concrete, our most widely used construction material, is a fluid that offers the opportunity to economically create structures of almost any geometry. Yet this unique fluidity is seldom capitalised on, with concrete instead being cast into rigid prismatic moulds to create high material use structures with large carbon footprints. Our rate of concrete consumption means that cement manufacture alone is estimated to account for some 5% of global Carbon Dioxide emissions. This dissertation shows that by replacing conventional orthogonal moulds with a flexible system comprised primarily of high strength, low cost fabric sheets, the fluidity of concrete can be utilised to create structurally optimised concrete structures. Flexible formwork therefore has the potential to facilitate the change in design and construction philosophy that will be required for a move towards a less material intensive, more sustainable, construction industry. Optimisation and design processes developed in this thesis show that material savings of up to 40% are possible in flexibly formed concrete beams. Full scale structural testing of these processes is undertaken to verify the flexural and shear behaviours of non-prismatic elements. This is supported by further experimental and theoretical investigations into the durability of concrete cast in a permeable, flexible mould. Detailed analysis is provided alongside practical guidance for designers. Coupled with innovation in design and analysis techniques, flexible formwork is shown to provide a globally accessible method for the construction of low carbon, materially efficient and architecturally interesting concrete structures. Recognising the impact construction has on the environment, design philosophies centred around the need to put material where it is required are becoming increasingly desirable. This can now be achieved by replacing rigid formworks with systems comprised of flexible sheets of fabric. This is a step change in the way we think about our new concrete structures.

An investigation has been carried out to reduce the deformation behavior of polyethylene (PE) woven geotextile fabric by making PE fabric-glass yarn composite structure using stitching and laminating. The results showed that reinforcement significantly reduced the creep and IED as long as the tensile stress is lower than the total load bearing capacity of the glass yarns in the composite structure. However, the strength of PE-glass composite fabric was solely dependent on the strength of the glass yarns. The strength from PE yarns only contributes when all glass yarns are broken. Cast result of concrete columns using the glass yarn reinforced PE fabric by stitching method suggested that the glass yarn must face outside of the fabric formwork to avoid damage of both fabric surface and column surface.

This research includes a preliminary study prior to the commencement of the Ph.D. work and three phases of design, construction and testing of three generations of moment-shaped beams. Each phase of the research brought a better understanding of curved beams which follow the shape of the moment diagram. The moment diagram in this study was for simply supported beams supporting a uniformly distributed load as would be the case in the majority of building designs. The original theory for this research can be described as follows: Moment-shaped beams are the natural outcome of a fundamental understanding of stress paths in a horizontal load bearing member. By following these stress paths we may provide materials where required to most efficiently carry the compression and tension stresses to the supports. Allowing stresses to follow their naturally desired paths reduces regions where stresses cross paths called disturbed regions. The outcome of the final phase of this research was the development of the third generation of curved beams with a camber. These beams, designated as Cambered Curve beams (CCBs), exhibited the same behaviour as the rectangular control beam design using CSA-A23.3 up to the serviceability failure of L/360 (12mm). The CCB moment-shaped beams require 20% less concrete and 40% less reinforcing steel (no shear stirrups) to carry the ultimate load which is only 12% less than that carried by the CSA-designed control beam. Due to a closed system of internal forces, the moment-shaped beams remain intact and are able to sustain self weight, even after total failure. A significant part of this research was to modify and verify a FORTRAN-based finite element analysis program: FINIT-Y. This program was reconstructed to analyse a full size beam, and enabled the researcher to model and correctly predict the maximum load, crack pattern and failure mode. This study found that moment-shaped beams with no shear reinforcement have the same stiffness and load carrying capacity as the CSA-designed rectangular control beam with shear reinforcement up to serviceability failure (L/360). The study also found that moment-shaped beams have significantly lower ductility at the ultimate load.

This research includes a preliminary study prior to the commencement of the Ph.D. work and three phases of design, construction and testing of three generations of moment-shaped beams. Each phase of the research brought a better understanding of curved beams which follow the shape of the moment diagram. The moment diagram in this study was for simply supported beams supporting a uniformly distributed load as would be the case in the majority of building designs. The original theory for this research can be described as follows: Moment-shaped beams are the natural outcome of a fundamental understanding of stress paths in a horizontal load bearing member. By following these stress paths we may provide materials where required to most efficiently carry the compression and tension stresses to the supports. Allowing stresses to follow their naturally desired paths reduces regions where stresses cross paths called disturbed regions. The outcome of the final phase of this research was the development of the third generation of curved beams with a camber. These beams, designated as Cambered Curve beams (CCBs), exhibited the same behaviour as the rectangular control beam design using CSA-A23.3 up to the serviceability failure of L/360 (12mm). The CCB moment-shaped beams require 20% less concrete and 40% less reinforcing steel (no shear stirrups) to carry the ultimate load which is only 12% less than that carried by the CSA-designed control beam. Due to a closed system of internal forces, the moment-shaped beams remain intact and are able to sustain self weight, even after total failure. A significant part of this research was to modify and verify a FORTRAN-based finite element analysis program: FINIT-Y. This program was reconstructed to analyse a full size beam, and enabled the researcher to model and correctly predict the maximum load, crack pattern and failure mode. This study found that moment-shaped beams with no shear reinforcement have the same stiffness and load carrying capacity as the CSA-designed rectangular control beam with shear reinforcement up to serviceability failure (L/360). The study also found that moment-shaped beams have significantly lower ductility at the ultimate load.

Following a well-documented rise in the popularity of concrete shell application in the 20th century, thin concrete shells have experienced a global decline despite their potential as efficient structures with an economy of material use with aesthetics benefits. This phenomenon is subject to geographically determined socio-economic conditions and competition from other building solutions as a result of technological advancement in alternative construction systems. Importantly, their decline was attributed to limitations inherent to concrete shell formwork and construction methods. Being able to produce efficient shaping did not ensure that this method of construction is most cost efficient as it still remains difficult to construct double curved surfaces. The thesis addresses the limitations associated with past and present concrete shell building by proposing the use of actively-bent gridshells as re-configurable and reusable formwork for concrete shells to be designed and built. The hypothesis uses deployable scissor-jointed actively-bent gridshells as re-configurable and reusable formwork for concrete shell construction. This was developed from a series of Flash research (Benjamin, 2012) as student construction workshops to investigate the design and creation of actively-bent gridshells held between December 2008 and March 2011 in Sheffield. In this study, to understand this new system, scaled models of actively-bent gridshells were used as preliminary design aid. Deployed into three dimensional forms from a flexible flat grid mat, the structures were rigidized by bracing through triangulation restraints. The temporary rigid structure was subsequently enveloped with fabric onto which concrete was applied to create the concrete shell, thus acting as formwork. This formwork was then removed following the curing of the concrete cast to be reused repeatedly, or reconfigured into another concrete shell form. Hence, the thesis draws on the concepts, principles and ideas pertaining to three key architectural technologies: 1. concrete shell, 2. actively-bent gridshells and 3.fabric formwork. The thesis then presents a series of four prototype concrete shells constructed from different materials spanning between 1.3 meters and 2.45 meters in the workshops at the University of Edinburgh built between August 2014 and September 2015. For each experimental construction, the process of gridshell construction, fabric formwork preparation, concrete casting, gridshell formwork decentring and different design elements of openings, edges and anchorage abutments were analysed and discussed under the themes of construction, architectural tectonics and structure. The tectonic of process and material is understood and discussed based on the idea of stereogeneity (Manelius, 2012). Specifically, the relationship between gridshell as formwork and the concreting process was studied, analysed and assimilated in concrete shells built with progressive sophistication and elegance, culminating in a doubly-curved concrete shell that demonstrated both synclastic and anticlastic geometries, with further abutment simplification, edge leaning and physical openings incorporation. The study concludes with a physical concrete shell model formed by applying concrete onto fabric formwork to cover the Weald and Downland Jerwood gridshell. In the 1:20 scaled model, the proposed method is speculatively applied onto fabric stretched between pre-determined curvatures of the as-built gridshell. This formwork was subsequently removed for reuse, re-deployed and reconfigured. Using finite element analysis, the structural behaviour of the gridshell made of glass-fibre reinforced tubes and structural characteristics of the resultant concrete shell was checked. The interaction between the three technologies are discussed architectonically and structurally to inform guidelines for potential life-scale application. The thesis evidences the feasibility of the proposed system. It re-purposes a scaled model of a deployable gridshell as a physical modelling tool to facilitate concrete shell design, for both pure compression shells and "improper" shells, demonstrating its adaptability. It also promotes and reinvigorates concrete shells as possible architectural systems serving to instigate future research to revive concrete shell construction as an intelligent and intuitive way of creating structures with material economy, structural efficiency and visual elegance.