Sharabi, H; Olesti, GP; Spong, B; Karastathi, N; (2025) Robotically Carved Adaptive Moulds for Rammed Earth Construction: Adaptability for site-specific design. In: Proceedings of the International Conference on Education and Research in Computer Aided Architectural Design in Europe. (pp. pp. 525-534).

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Abstract

Rammed earth has gained renewed architectural interest for its sustainability, thermal performance, and cultural relevance. However, traditional methods remain labourintensive and limited in geometric and design flexibility (Gomaa et al., 2023, pp. 1-3). To address these constraints, this research explores a block-based approach, customizing each façade to suit local contexts. Two mould-making techniques were investigated to enable design adaptability: 3D-printed moulds and robotic sand carving—a novel, zerowaste method. Both techniques allow for intricate, site-specific geometries with functional and aesthetic benefits. To evaluate the potential of site-specific design, a case study was conducted on optimizing façade geometry for the Middle Eastern climate. Physical prototypes featuring self-shading geometries were developed to delay heat transfer and enhance thermal performance. The study concludes with an optimized wall prototype that integrates both fabrication techniques to produce bespoke blocks. This approach offers a bridge between vernacular practices and advanced fabrication, providing a flexible, sustainable construction method adaptable to diverse design challenges.

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