Topological interlocking for mortar-free masonry building system: optimizing for sustainability and mass production - Research grant awarded by the Ministry of Science and Technology of Taiwan (MOST)

From Egyptian Pyramids and Mesoamerican pyramids to Inuit Igloos and prehistoric Neolithic Stonehenge, amazing built objects of different cultures all deploy the same building techniques. Through the testament of time, these cultures all concluded that masonry is the most efficient building technique. In the pursuit of sustainability in architecture, we are proposing the possibility of a mortar-free masonry system utilizing topological interlocking, Truchet tiling and post tensioning.

Topological interlocking allows for a mortar-free system where elements of different materials can be mixed and matched to achieve both visual and structural optimum. This also allows for the possibility of replacing elements without deconstructing the whole structure, or the reassembly of the structure to meet future needs or relocation, thus improving sustainability and adaptivity.

Through Truchet tiling, infinite permutations and combinations can be arranged using limited elements. This characteristic allows for the design of each usage to be unique while maintaining the sustainability of mass production of finite elements. This will become a main consideration for both designer and manufacturer to adopt our system, as designs can still be expressive while being economically feasible to fabricate.

External frames are typically required for topologically interlocked structures to prevent collapses due to unconstrained boundary elements. Such frames are usually specifically made for each use case. By experimenting with both external and internal post-tensioning, it should be possible to eliminate the need for such a frame, allowing for sustainability and adaptivity to future needs.

The expected outcome includes the development of prototypical systems that can be used for building envelopes and interior partitions. This prototypical system would open new possibilities to improve sustainability of building elements of unique one-off designs in both usage and production.

 Keywords: Mortar-free, Masonry, Topological interlocking, Truchet tiling, Post tension, Sustainability, Building blocks.