Computational Design and Robotic Fabrication of Dry-Stacked non-standard spanning Limestone Assemblies

Computational Design and Robotic Fabrication of Dry-Stacked non-standard spanning Limestone Assemblies | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Computational Design and Robotic Fabrication of Dry-Stacked non-standard spanning Limestone Assemblies Chin-Lun Lu, Zhenghao Zhu, Guillem Perutxet Olesti, Peter Scully, and 1 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-8019586/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 18 Feb, 2026 Read the published version in Construction Robotics → Version 1 posted 12 You are reading this latest preprint version Abstract Natural stone, an abundant and low-carbon material, often generates substantial unusable waste through quarrying and masonry processes, including rubble, offcuts, and irregular fragments. While there is growing interest in repurposing these byproducts, their non-standard and irregular geometries pose major challenges for integration, restricting their use in architecture primarily to cladding, flooring, and other non-structural applications. Finding innovative applications for this waste could help revive the use of stone in construction while further lowering its environmental impact. This study introduces a workflow to optimize the geometry of non-standard stone blocks through minimal modifications, enabling construction with highly variable, locally sourced material. The proposed methodology consists of a heuristic generative algorithm based on a library of 3D scanned limestone blocks and guided by a pre-defined global geometry. This enables a data-driven model for the targeted modification of joints between blocks through robotic machining. In turn, robotic machining is thereby optimized to save energy and time. This approach was validated through the fabrication of 18 stones, which were assembled into a three-legged arch, demonstrating the feasibility of using non-standard stone for architectural structural applications. Non-standard materials Material Computation 3D Scanning Multi-Objective Optimization Robotic Fabrication Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Published Journal Publication published 18 Feb, 2026 Read the published version in Construction Robotics → Version 1 posted Editorial decision: Revision requested 12 Dec, 2025 Reviews received at journal 08 Dec, 2025 Reviews received at journal 05 Dec, 2025 Reviews received at journal 29 Nov, 2025 Reviewers agreed at journal 26 Nov, 2025 Reviewers agreed at journal 25 Nov, 2025 Reviewers agreed at journal 19 Nov, 2025 Reviewers agreed at journal 10 Nov, 2025 Reviewers invited by journal 10 Nov, 2025 Editor assigned by journal 10 Nov, 2025 Submission checks completed at journal 06 Nov, 2025 First submitted to journal 03 Nov, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-8019586","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":547574628,"identity":"ae695eb0-0758-41f7-a8cc-4ab779a5e585","order_by":0,"name":"Chin-Lun Lu","email":"","orcid":"","institution":"University College London","correspondingAuthor":false,"prefix":"","firstName":"Chin-Lun","middleName":"","lastName":"Lu","suffix":""},{"id":547574635,"identity":"e420b636-b505-40d7-a140-c1d9938aa74b","order_by":1,"name":"Zhenghao Zhu","email":"","orcid":"","institution":"University College 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While there is growing interest in repurposing these byproducts, their non-standard and irregular geometries pose major challenges for integration, restricting their use in architecture primarily to cladding, flooring, and other non-structural applications. Finding innovative applications for this waste could help revive the use of stone in construction while further lowering its environmental impact. This study introduces a workflow to optimize the geometry of non-standard stone blocks through minimal modifications, enabling construction with highly variable, locally sourced material. The proposed methodology consists of a heuristic generative algorithm based on a library of 3D scanned limestone blocks and guided by a pre-defined global geometry. This enables a data-driven model for the targeted modification of joints between blocks through robotic machining. In turn, robotic machining is thereby optimized to save energy and time. This approach was validated through the fabrication of 18 stones, which were assembled into a three-legged arch, demonstrating the feasibility of using non-standard stone for architectural structural applications.\u003c/p\u003e","manuscriptTitle":"Computational Design and Robotic Fabrication of Dry-Stacked non-standard spanning Limestone Assemblies","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-11-20 10:47:50","doi":"10.21203/rs.3.rs-8019586/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"decision","content":"Revision requested","date":"2025-12-12T13:52:50+00:00","index":"","fulltext":""},{"type":"editorInvitedReview","content":"","date":"2025-12-08T08:45:18+00:00","index":"hide","fulltext":""},{"type":"editorInvitedReview","content":"","date":"2025-12-05T23:56:35+00:00","index":"hide","fulltext":""},{"type":"editorInvitedReview","content":"","date":"2025-11-29T22:21:03+00:00","index":"hide","fulltext":""},{"type":"reviewerAgreed","content":"169722473764192370644843799642481834622","date":"2025-11-26T10:32:04+00:00","index":"hide","fulltext":""},{"type":"reviewerAgreed","content":"50972656450386556587233575712912770221","date":"2025-11-25T21:00:52+00:00","index":"hide","fulltext":""},{"type":"reviewerAgreed","content":"325035941168230450606876342026609015648","date":"2025-11-19T13:45:08+00:00","index":"hide","fulltext":""},{"type":"reviewerAgreed","content":"136094077166521065998154860839452383755","date":"2025-11-10T21:11:03+00:00","index":"hide","fulltext":""},{"type":"reviewersInvited","content":"","date":"2025-11-10T20:20:11+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2025-11-10T12:59:40+00:00","index":"","fulltext":""},{"type":"checksComplete","content":"","date":"2025-11-06T13:57:35+00:00","index":"","fulltext":""},{"type":"submitted","content":"Construction Robotics","date":"2025-11-03T13:09:21+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"construction-robotics","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"coro","sideBox":"Learn more about [Construction Robotics](https://link.springer.com/journal/41693)","snPcode":"41693","submissionUrl":"https://submission.springernature.com/new-submission/41693/3","title":"Construction Robotics","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"stoa","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"e2780975-0cb7-4508-818e-3a041114a5cc","owner":[],"postedDate":"November 20th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"published-in-journal","subjectAreas":[],"tags":[],"updatedAt":"2026-02-23T16:05:42+00:00","versionOfRecord":{"articleIdentity":"rs-8019586","link":"https://doi.org/10.1007/s41693-026-00180-6","journal":{"identity":"construction-robotics","isVorOnly":false,"title":"Construction Robotics"},"publishedOn":"2026-02-18 15:57:14","publishedOnDateReadable":"February 18th, 2026"},"versionCreatedAt":"2025-11-20 10:47:50","video":"","vorDoi":"10.1007/s41693-026-00180-6","vorDoiUrl":"https://doi.org/10.1007/s41693-026-00180-6","workflowStages":[]},"version":"v1","identity":"rs-8019586","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-8019586","identity":"rs-8019586","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}