Curved architectural structure of foam and cement

Claim 1

In a method of fabricating a curved architectural structure of the steps of: tensioning a membrane structure into a doubly curved contour of that of at least a portion of a rigid self-supporting doubly curved architectural structure to be fabricated, applying a fluid non-foamed rigidizing material to the doubly curved contour of the curved tensioned membrane, and rigidizing the fluid material to form said rigid self-supporting doubly curved architectural structure having an upper surface and an opposite downwardly facing underside surface; forming a layer of cementitious material having discontinuous reinforcement fibers dispersed therein overlaying said underside doubly curved surface of said doubly curved self-supporting rigid architectural structure, said layer of cementitious material being contoured to the contour of the adjacent doubly curved surface of the rigid architectural structure and being initially supported therefrom generally free of other reinforcing structure and being initially generally free of mechanical devices therein for coupling said cementitious layer to said architectural structure, and said layer being adhered to said underside surface of substantially only by the adhesion of said cementitious material to said doubly curved underside surface; and allowing the fiber reinforced cementitious material to harden and become a rigid self-supporting doubly curved fiber reinforced structural member of an architectural structure of fiber reinforced cementitious material.