Integrating Timber in Earth-Based Structures with Actively Controlled Supports

In recent years, there has been increased interest in automating earth-based construction methods, yet robust solutions remain limited due to the inherent malleability of earth materials. This paper proposes embedding timber elements into freeform walls created through rapid deposition additive manufacturing (AM) techniques, enabling integrated functionality as embedded supporting elements for a timber roof structure. A cyber-physical, “active” formwork system is introduced to address challenges such as deformation during construction. A custom motorised supporting device supports embedded timber elements during construction, preventing undesired rotations while allowing controlled vertical displacement. Their actuation can be controlled over time in an open or closed-loop system, utilising (IMU) orientation and load sensors as feedback. An adaptive design system is developed whereby additional timber elements are regenerated in response to tolerances after the drying period, maintaining the criteria necessary for supporting an intended roof structure. A proof-of-concept demonstrator validated the approach, achieving minimal deviations in beam orientation and successfully enabling the construction of a roof structure.