Design, casting and fracture analysis of textile reinforced cementitious shells

The high potentials of thin, light-weight and slender textile reinforced cementitious (TRC) composites permits multi-layered, effective, highly-aesthetic and elaborated designs as launched nowadays: domes, vaults, free-form structures. Their casting and installation appear challenging requiring textiles secure mounting and in-time mortar casting. In this study, TRC roof shells are cast into a reusable formwork that provides controlled thickness and smooth surfaces. Casting is limited to a few hours with the minimum labor. TRC shells are tested under distributed loading. Digital Image Correlation measures online, in full-field the deflection and cracks opening. Acoustic Emission tracks cracks onset. It is demonstrated that at the early loading, TRC shells behave as a compressive element. Beyond cement strength, the textiles elongate to bear loading. In higher curvature shells, the stiffness rises and several wider cracks form. The catastrophic collapse is evaded, and ductility is achieved. TRCs demonstrate optimal performance with non-confined supports, offering new perspectives on free-form designs.