Digital design optimization and off-site modularization for modern stone masonry construction

This research presents an optimization-driven computational design and fabrication method for off-site construction (OSC) of unreinforced masonry structures. Aimed at modernizing sustainable stone construction, this work first introduces a parametric design model that automates the geometry generation and structural analysis of such structures. A key innovation is the application of truss layout optimization to design a reusable support cassette for holding and transporting pre-assembled stone arches. Furthermore, through controlled laboratory replication of on-site assembly, the structural behavior during the critical lifting and placement phases was closely monitored, revealing the constructed arch’s inherent strength and stability. The optimized truss-like cassette system demonstrated satisfactory performance, with adjustable components effectively securing arch blocks for precise fit, aided by careful fabrication tolerances and laser-cut precision. The inter-block gaps are effectively minimized via either turnbuckles or ratchet straps. Simple assembly experiments underscore the significant potential of OSC to enhance the efficiency of unreinforced masonry construction. The challenges in the design and setup process have been reported and evaluated to provide insights for future work. This study solidifies the effective integration of computational design and digital manufacturing, significantly advancing modern OSC and streamlining sustainable building practices.