Simulation and analysis of Automated Generalised Interleaved Layered Execution (AGILE) process for concrete shell structures

There has been increased research and interest in new methods of automated construction. This study presents a novel computational model for an augmented and generalised version of an automated construction process that was previously tested experimentally only for vertical concrete walls. The Automated Generalised Interleaved Layer Execution (AGILE) utilises a robotic arm for the alternating deposition of formwork and concrete, aiming to facilitate the creation of free-form concrete shell structures with enhanced design and construction versatility, overcoming the constraints of previous methods. The paper proposes an FEA analysis framework for this construction methodology, evaluating its implications, limitations, and challenges via a detailed case study that includes calculating lateral pressures and displacements throughout the construction process. Moreover, it introduces new failure criteria specific to this construction method, enabling the optimisation of the design and geometry of the shell and formwork, as well as the construction process details and parameters. The proposed computational analysis method allows designers to improve the performance of a broader range of shell structures while reducing construction costs, time, complexity, and environmental impact by replacing early-stage experimental methods with finite-element analysis. In conclusion, apart from generalising the limited process and identifying its design options and parameters, this study proposes a new and straightforward computational method for analysis of the AGILE construction method in its general form in the absence of any other analysis method and where only the experimental method in one particular case was used before, identifies four different construction failure modes, and paves the way for experimental verification and calibration of this analysis method for different specific setups and applications of this general construction process.