Variable Casting of Voussoirs for a Stereotomic Shell

Abstract

The project for an acoustic shell in the Italian city of Matera was looked as an opportunity to explore an alternative stereotomic approach. The semi-vaulted space was initially thought to be built with discrete blocks of stone following a structural system in compression bounded by tie-rods, but practical and economic sustainability issues led to a different approach to that of classic cutting and carving raw stone. The collaboration between two different research teams led to the incorporation of a reusable mold technology; with the help of robotic technology and flexible moulding, it became possible to create customized heavy blocks discarding the need for disposable one-off moulds for casting voussoirs. By surveying stereotomy as a classic discipline within the scope of this project, this paper extrapolates and reflects on the validation of a different production process facing the classic ones that have defined stereotomy in architecture and construction.