The applicability of glass in structures is continuously ascending, as the transparency and high compressive strength of the material render it the optimum choice for realizing diaphanous structural components that allow for light transmittance and space continuity. The fabrication boundaries of the material are constantly stretching: visible metal connections are minimized and glass surfaces are maximized, resulting to pure all-glass structures. Still, due to the prevalence of the float glass industry, all-glass structures are currently confined to the limited forms and shapes that can be generated by planar, 2D glass elements. Moreover, despite the fact that glass is fully recyclable, most of the glass currently employed in buildings is neither reused nor recycled due to its perplexed disassembly and its contamination from coatings and adhesives. Cast glass can be the answer to the above restraints, as it can escape the design limitations generated from the 2-dimensional nature of float glass. By pouring molten glass into moulds, solid 3-dimensional glass components can be attained of considerably larger cross-sections and of virtually any shape. These monolithic glass objects can form repetitive units for large all glass-structures that do not buckle due to slender proportions and thus can take full advantage of the stated compressive strength of glass. Such components can be accordingly shaped to interlock towards easily assembled structures that do not require the use of adhesives for further bonding. In addition, cast glass units–due to their increased cross section– can tolerate a higher degree of impurities and thus can be produced by using waste glass as a raw source.

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Cast glass components are a promising solution for engineering pure glass structures of high transparency and load-carrying capacity due to their large cross-sectional area and monolithic nature. Currently, the few realized structures employing cast glass components rely either on a steel substructure or on an adhesive of high bonding strength and typically less than 2 mm thickness, to ensure the stiffness and stability of the construction. Whereas the first solution compromises the overall level of transparency, the second results to a permanent construction requiring intensive and meticulous labour and extreme accuracy. This paper explores the potential of a novel, reversible all-glass system comprising dry-assembly, interlocking cast glass components as a promising and sustainable solution that can avoid the above-mentioned challenges. Owing to its interlocking geometry, the proposed system can attain the desired stiffness and stability with the aid of minimal, if any, metal framing. Furthermore, the suggested system circumvents the use of adhesives by using a dry, colourless interlayer as an intermediate between the glass components to accommodate any dimensional tolerances and allow for an even load distribution; moreover, it allows for the disassembly and circular use of the components. To validate the concept, different component geometries and interlocking mechanisms are developed. As a proof of concept, the most promising interlocking forms are kiln cast in 1:2 scale and assessed in terms of mechanical interlocking capacity, mass distribution, residual stress generation and ease of fabrication. In parallel, research is conducted on different materials for the dry, transparent interlayer. From the developed designs, blocks with osteomorphic interlocking mechanisms are selected as the most promising concept and are further assessed by numerical modelling to study the influence of the interlocking geometry to the overall structural performance. The results highlight the structural potential of the proposed system and demonstrate its feasibility.@en