Patterns for gridshells with negligible geometrical torsion at nodes

Abstract Curved envelope structural building envelopes have been quite popular in architecture in the past decades, and pose many challenges in their design, manufacturing and planning. In gridshells, a popular structural morphology for curved structure, designers will often strive to orient beams such that their top face is parallel to the envelope surface. However, this tends to induce geometrical torsion along the beam centerline, which complexifies significantly the manufacturing of the connection nodes or of the beams themselves. It is well known that such issue can be avoided by aligning beams with principal curvature directions of the envelope surface, thus yielding a quadrangular paneling. In this article, we study how other types of patterns (non-quadrangular) can be used to design torsion-free grid-shells. Based on asymptotic considerations, we derive a set of geometrical rules which, if fulfilled by a pattern, insure that a surface can be covered by this pattern with negligible torsion and limited deviation of beams from surface normals. A wide variety of patterns fulfill these rules, offering interesting possibilities for the design of curved architectural envelopes (Figure 1) is shown. As these rules are based on first order asymptotic analysis, we perform global validation on case studies. One main application is for structures in which face planarity is not necessary, for example ones cladded with ETFE cushions.