Cast glass arches, vaults and domes: case studies and design methodology

Cast glass is an excellent candidate for achieving fully transparent arch, vault and dome structures. By casting, voluminous, free-form glass components can be produced that fulfil the complex geometry requirements, offer increased compressive strength and maximize the incoming sunlight. Nonetheless, the application of cast glass in such structures is seldom seen; manufacturing challenges, uncertainties over the strength of the material, missing guidelines on the assembly methods of the components, lack of engineering norms, and the associated research and development costs to overcome those barriers, are some of the key discouraging factors. This paper explores several realised case studies of small-scale, cast glass arches, vaults and domes, where the TU Delft Glass Research group was involved in the R&D process, as well as unrealised case studies developed by the group (Fig. 1). The main challenges and developed solutions for each project are described, focusing on three main aspects: (i) the manufacturing challenges linked with achieving the desired curvature, (ii) the assembly method and mechanical validation of the system, and (iii) the construction ease of the system. Based on the comparative study of the selected projects, the paper aims to provide a design methodology for future projects employing cast glass curved structures.