Parametric Assessment to Evaluate and Compare the Carbon Footprint of Diverse Manufacturing Processes for Building Complex Surfaces

At present, building design is faced with a need to properly manage complex geometries and surfaces. This fact is not only driven by the increased demand for visually stunning spaces but also stems from the rise of new design paradigms, such as “user-centred design”, that include bespoke optimization approaches. Nevertheless, the escalating adoption of customized components and one-off solutions raises valid concerns regarding the optimal use of energy and resources in this production paradigm. This study focuses on the Life Cycle Assessment of a novel Cement–Textile Composite (CTC) patented material. It combines a synthetic reinforcing textile with a customized concrete matrix, to generate rigid elements that are able to statically preserve complex spatial arrangements, particularly double-curvature surfaces. Moreover, the CTC offers a low-volume cost-effective alternative for custom-made cladding applications. The study performed a comparative carbon footprint assessment of the CTC production process in contrast to other technologies, such as CNC milling and 3D printing. To facilitate meaningful comparisons among diverse construction alternatives and to derive generalized data capable of characterizing their overall capacity, independent of specific production configurations, the present study implemented a generalized parametric shape of reference defined as a bounding box (BBOX), which encloses the volume of the target shape. Comparing different production technologies of the same shape with the same BBOX results in a significant carbon saving, up to 9/10th of the carbon footprint, when the CTC technology is adopted. The study therefore highlights the potential environmental advantages of CTC in the fields of architectural design and building engineering.