Porous interlocking assembly: performance-based dry masonry construction with digital stereotomy

Abstract

Architected porosity in masonry structures can be created by transforming stock materials into a lattice of interlocking units through an automated batch process. Porous masonry forms numerous enclosed cavities for thermal performance and reduces material usage while maintaining structural integrity. This work investigates the potential and limits of digital tectonics of porous masonry through a complete process of design, manufacturing, and construction. The confluence of digital fabrication with tectonic exploration opens new dimensions unattainable by traditional stereotomy. Interlocking materials inspired by Abeille vault and digital stereotomy have made rapid progress. Following the theory of poetic construction, this work proposes that masonry construction should evoke visual or haptic enhancement through the fulfillment of pragmatic functions. We formulated a design challenge for a confined dry masonry wall for the envelope of the 2226 building. It assumes batch-cutting bespoke units out of large blocks of high-strength foam. Through a process of cutting and reassembling, the stock material is topologically expanded into a porous structure. A series of prototypes were developed to explore novel articulation, structural and thermal performance, and economical manufacturing. One can perceive the logic of porous construction through visual and haptic empathy. The materialization process interacts with the design masonry units and the interlocking mechanism. For future practice in masonry, the porosity should be planned at multiple scales (molecular scale, aggerate scale, construction scale) across the life cycle of the material.