Algorithmic Assembly procedure for Upcycled Concrete Rubble
Sebastian Arturo Garcia Nuñez
The thesis project explores a circular approach to architectural design by developing an algorithmic method for vaulted floor slabs using re-assembled upcycled concrete rubble.
The project aims to establish a reflection on the idea of the linear cradle-to-grave design -in which materials have a life ending- and propose a way to give them a new use and transform waste into resources (Lendager, Pedersen 2020). This project reimagines waste concrete as a valuable resource for new structures.
The design process begins with scanning irregular concrete rubble pieces using image processing libraries in Python (OpenCV) and converting 2D contours into scaled 3D geometries. A machine learning pipeline (PCA-based) is used to simulate additional rubble variations, expanding the digital stock of elements and embracing the ad-hoc condition of reclaimed concrete pieces.
Structural analysis and form finding methods are performed using Kiwi3D and Karamba, to simulate funicular vault shapes that efficiently transfer loads. These shapes guide a custom stacking algorithm built in Grasshopper, which uses OpenNest and iterative geometric optimization to minimize voids and maximize material use, achieving more than 90% packing efficiency.
A stability-checking algorithm further ensures that the assembled pieces align correctly within the stress lines, avoiding connections parallel to the structural efforts, reducing the risk of displacements and guaranteeing a correct stable assembly.
Finally, an LCA analysis is performed in a case study project, comparing the environmental impact of using upcycling construction methodologies versus the traditional construction method.
The system will demonstrate not only material and CO₂ reductions, but also adaptability and structural logic. This computational design workflow provides a scalable, replicable strategy for integrating reclaimed concrete into architectural practice, pointing towards a more circular and conscious design approach.