Buildings are being constructed at ever faster rates, fuelled by population growth and urbanisation. The total worldwide floor area of buildings is expected to almost double over the next 40 years, the equivalent of constructing Paris every five days. The majority of the mass and embodied energy (60% to 70%) in a typical multi-storey building structure exists within the floors, making these a primary target for sustainable structural design. In a typical reinforced concrete slab, much of the concrete is assumed to be cracked and therefore not structurally utilised, but nevertheless adds significant weight. This project proposes a radical re-design of concrete floors, using precast textile-reinforced concrete shells with an in-situ foamed concrete fill. By harnessing membrane action, self-weight savings of 62% have been demonstrated for typical spans (compared to traditional flat slabs).

This paper discusses the design, optimisation, construction, measurement, analysis and structural testing of two prototype shells, one with and one without foamed concrete fill. The construction accuracy was quantified using digital scanner measurements which were then used as a geometry input for the analysis model. Each shell was loaded both uniformly and asymmetrically to beyond the design loading before failure. The foamed concrete was found to provide only a small increase in strength and stiffness. A design methodology for full-scale, practical application is currently under development.