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Constructing free-form buildings is very complex due to the difficulty in fabricating the curved façade. To install the façade, the complex geometric shapes of the façade need to be divided into panels. The panels developed are classified into three categories in terms of their curvatures, i.e., planar, single-curved, double-curved panels. The quality of the curved façade is determined by the geometric difference between as-built and as-designed panel shapes. Among the three types of curved panels, the double-curved panel is very difficult to form, showing greater quality discrepancy than the other two panel types. Ensuring the as-built quality of the curved façade is for contractors. The main objective of this study is to enhance small/mid-size contractors’ capacity of managing the as-built quality of the double-curved panel. To meet the study objectives, a case study of a small free-form building and empirical mock-up tests of curved panels were performed and beneficial lessons for the contractors were identified through the tests. Among diverse materials, aluminum and glass-fiber-reinforced concrete (GFRC) were utilized for the mock-up tests. Three-dimensional laser scanning technology was employed to foster the as-built data of the case study project and the mocked-up double-curved panels. The data superimposition method was used to measure the deviation between the as-designed and the as-built data of the case study.

Testing as-Built Quality of Free-Form Panels: Lessons Learned from a Case Study and Mock-up Panel Tests