Design for future refurbishment

Oct. 2021

Interdisciplinary design project

Hackathon

TABLE OF CONTENTS

The design process

future

INTRODUCTION01

AbstractThe main idea of Hackathon 2021 was to develop a wall element from recyclable materials in one week. The wall needs to withstand Danish weather conditions and fulfil requirements in compliance with BR18. To make it more specific, the designed system needs to be appliable to existing residential buildings in Grundlag.

This project was developed in a group of students from DTU and carpenters from NEXT. Since the beginning, our team wanted to develop a system that would fulfil all the requirements but at the same time was easy to build by unskilled users.

Thinking about the number of unused wood o cuts that are being produced in the building site, we decided to incorporate the new product.

Design

future

INTRODUCTION01

Objectives & context

Work in an interdisciplinary environment. Support each other with everyone’s personal skills

Design an exterior wall for a residential building. The wall should be attachable to the existing stucture of the building

Design the wall in a way that it can be assembled and disassembled as needed for repairing or replacing of some parts

Analyse the design of the wall taking into consideration its physical properties (energy-balance, U-value, LCA categories, ...)

Use the maximum amount of recycled materials in order to reduce the amount of waste and CO2 emissions in Copenhaguen

Target buillding

PROCESS

Container resourcing

Before starting to plan and design our proposal, we searched the container for recyclable materials to have an idea of the options and potential we had.

Individual ideas

To make sure we had the biggest amount of ideas possible, each one of the members elaborated a few basic sketches independently.

After the first weekend, the sketches and ideas were presented by each one of us to the rest of the team. In addition, we shared small presentations about how each one of us works and what personal abilities we all have that could be helpful during the design process of the wall.

DESIGN PROCESS

Individual ideas

THE DESIGN PROCESS

First drafts

After analyzing all of the individual proposals, we started tackling the challenge as a team. We generated multiple ideas and considering all the problems that each one of them could have.

OCT. 5th

PROPOSAL

Final sketches

All the di erent ideas and iterations helped us get a clear view of what would work best and what would be better to avoid when designing the wall.

We decided to develop the idea of using small modules, which would help make the assembly process much easier and fast. With this system, only the gypsum boards, internal insulation and cladding would need to be assembled directly at the building.

FINAL PROPOSAL

Physical properties Technical drawings

I. CONNECTION OF TWO 600 mm MODULES

THE FINAL PROPOSAL

Physical properties Technical drawings

II. CONNECTION OF THE MODULE TO THE BASEMENT SLAB III. CONNECTION OF THE MODULE WITH THE FLOOR SLAB

FINAL PROPOSAL

Physical properties Technical drawings

DETAIL OF WINDOW PLACEMENT

THE FINAL PROPOSAL

Physical properties Ubakus calculations

Thermal protection

U =

Moisture proofing

Heat protection

Temperature amplitude damping: 54 phase shift: 11,3 h

GEG

Bestand*: U<0,24

excellent insufficient

No condensate excellent insufficient

Design for future refurbishment outside

Thermal capacity inside: 72 kJ/m²K excellent insufficient

FINAL PROPOSAL

Physical properties

Ubakus calculations

Inside

Outside

sd-value:

The

Thickness: 42 cm Weight: 101 kg/m²

Heat capacity: 107 kJ/m²K

THE FINAL PROPOSAL

Physical properties Ubakus calculations

Temperature profile

Design for future refurbishment RIGHT: The component, drawn to scale.

Temperature Dew

outside

Temperature profile inside

Inside

LEFT: Temperature and dew-point temperature at the place marked in the right figure. The dew-point indicates the temperature, at which water vapour condensates. As long as the temperature of the component is everywhere above the dew point, no condensation occurs. If the curves have contact, condensation occurs at the corresponding position.

03THE FINAL PROPOSAL

Physical properties Ubakus calculations

Layers (from inside to outside)

# Material λ R Temperatur [°C] Weight [W/mK] [m²K/W] min max [kg/m²]

Thermal contact resistance*

0,130 18,8 20,0

1 1,9 cm Spruce 0,130 0,146 18,0 19,2 8,6

2 4,5 cm mineral wool 035 0,035 1,286 14,6 18,8 0,8

4,5 cm Spruce (7,5%) 0,130 0,346 15,5 18,2 1,5

3 2,6 cm Gypsum Fibreboard 0,350 0,074 14,4 15,5 29,9

4 4,5 cm Spruce 0,130 0,346 12,6 15,2 20,3

5 20 cm mineral wool 035 0,035 5,714 -0,5 14,0 3,4 20 cm Spruce (15%) 0,130 1,538 -0,4 12,9 13,5

Thermal contact resistance*

0,130 -0,6 -0,3

6 4 cm Rear ventilated level (outside air) -0,6 -0,6 0,0

7 4,5 cm Spruce -0,6 -0,6 20,3 42 cm Whole component 6,117 100,9

* Thermal contact resistances according to DIN 6946 for the U-value calculation. Rsi=0,25 and Rse=0,04 according to DIN 4108-3 were used for moisture proofing and temperature profile.

Surface temperature inside (min / average / max): 18,8°C 19,2°C 19,2°C

Design for future refurbishment Surface temperature outside (min / average / max): -0,5°C -0,5°C -0,3°C

03THE FINAL PROPOSAL

Physical properties

Ubakus calculations

Moisture proofing

For the calculation of the amount of condensation water, the component was exposed to the following constant climate for 90 days: inside: 20°C und 50% Humidity; outside: -0.6°C und 94% Humidity (Climate according to user input).

Design for future refurbishment This component is free of condensate under the given climate conditions.

# 1 2

# Material

sd-value Condensate Weight [m] [kg/m²] [Gew.-%] [kg/m²]

1 1,9 cm Spruce 0,38 - - 8,6 2 4,5 cm mineral wool 035 0,05 - 0,8 4,5 cm Spruce (7,5%) 0,90 - - 1,5

3 2,6 cm Gypsum Fibreboard 0,10 29,9

4 4,5 cm Spruce 2,25 20,3

5 20 cm mineral wool 035 0,40 3,4 20 cm Spruce (15%) 10,00 13,5 42 cm Whole component 3,44 100,9

03THE FINAL PROPOSAL

Physical properties Ubakus calculations

Relative humidity (%) saturation point

Design for future refurbishment The temperature of the inside surface is 18,8 °C leading to a relative humidity on the surface of 54%.Mould formation is not expected under these conditions. The following figure shows the relative humidity inside the component.

Humidity inside

humidity (%) OutsideInside

1 Spruce (19 mm)

2 mineral wool 035 (45 mm)

3 Gypsum Fibreboard (26 mm)

[mm]

4 Spruce (45 mm)

5 mineral wool 035 (200 mm)

6 Rear ventilated level (40 mm)

255

outside

7 Spruce (45 mm)

Notes: Calculation using the Ubakus 2D-FE method. Convection and the capillarity of the building materials were not considered. The drying time may take longer under unfavorable conditions (shading, damp / cool summers) than calculated here.

03THE FINAL PROPOSAL

Physical properties Ubakus calculations

Heat protection

The following results are properties of the tested component alone and do not make any statement about the heat protection of the entire room:

Temperature profile

Temperature at 3pm, 11am and 7am

Temperature at 7pm, 11pm and 3am

1 Spruce (19 mm)

2 mineral wool 035 (45 mm)

3 Gypsum Fibreboard (26 mm)

4 Spruce (45 mm)

5 mineral wool 035 (200 mm)

6 Rear ventilated level (40 mm)

7 Spruce (45 mm)

The surface temperature during the day

Outside Inside

Phase shift: 11.3h

[°C] [time of day]

Left: Temperature profile within the component at different times. From top to bottom, brown lines: at 3 pm, 11 am and 7 am and red lines at 7 pm , 11 pm and 3 am.

Right: Temperature on the outer ( red ) and inner ( blue ) surface in the course of a day. The arrows indicate the location of the temperature maximum values The maximum of the inner surface temperature should preferably occur during the second half of the night.

Phase shift* 11,3 h

Heat storage capacity (whole component): 107 kJ/m²K

Thermal capacity of inner layers: 72 kJ/m²K TAV *** 0,018

Amplitude attenuation ** 54,3

* ** ***

Design for future refurbishment The temperature amplitude ratio TAV is the reciprocal of the attenuation: TAV = 1 / amplitude attenuation

The phase shift is the time in hours after which the temperature peak of the afternoon reaches the component interior.

The amplitude attenuation describes the attenuation of the temperature wave when passing through the component. A value of 10 means that the temperature on the outside varies 10x stronger than on the inside, e.g. outside 15-35 °C, inside 24-26 °C.

Note: The heat protection of a room is influenced by several factors, but essentially by the direct solar radiation through windows and the total amount of heat storage capacity (including floor, interior walls and furniture). A single component usually has only a very small influence on the heat protection of the room.

The calculations presented above have been created for a 1-dimensional cross-section of the component.

THE FINAL PROPOSAL

Physical properties Repairing and replacing parts

The wall has been designed in a way that allows the user to repair or replace any of the cladding panels (interior or exterior) without having to disassemble the whole wall or a big part of it.

5. First ideas IV

THE FINAL PROPOSAL

Physical properties Insulation and security

The materials used to build structural modules and internal part of the wall are the perfect combination of recycled materials that allow the structure to be resistant to the weather conditions and fulfill BR18 requirements.

Structural wood

Structural wood 2x Gypsum board

Insulation

Structural batten

Insulation

Burnt wood

external cladding Internal cladding

THE FINAL PROPOSAL

Assembly/Disassembly

Material requirements (for a 1810x1925 part)

Long module

1x 1200mm facade wood

1x 1200mm back wood

4x 240mm separation piece

2x 130mm insulation block

2x 240mm insulation block

1x 260mm insulation block

16x DIN 965 / M5x80

Short module

1x 600mm facade wood

1x 600mm back wood

2x 240mm separation piece

2x 130mm insulation block

1x 240mm insulation block

8x DIN 965 / M5x80

Wall assembly (1810x1925 part)

11x Short module

11x Long module

4x 905x1925 Gypsum board

3x 45x45 wood batten

2x 277,5x1925x45 insulation

2x 560x1925x45 insulation

12x 905x300 interior cladding

2x 905x125 interior cladding

12x DIN 965 / M5x80

68x DIN 965 / M5x50

ASSEMBLING INSTRUCTIONS

Modular external facade wall

PART I. LONG MODULE

Components

1200 mm facade wood LM001 (x1)

1200 mm back wood LM002 (x1)

240 mm separation piece LM003 (x4)

130 mm insulation block LM004 (x2)

240 mm separation piece LM005 (x2)

260 mm insulation block LM006 (x1)

DIN 965 / M5 x 80 LM007 (x16)

PART I. LONG MODULE

Assembly

Attach the separation pieces to the external facade panels

01. 02.

Attach the back wood piece to the separation pieces

LM007

LM003LM001

LM007

LM002

PART I. LONG MODULE

Assembly

Attach the insulation blocks in the spaces between the two panels

LM006

03.

LM004

LM005

Your long module is ready for transportation and assembly

PART II. SHORT MODULE

Components

600 mm facade wood SM001 (x1)

600 mm back wood SM002 (x1)

240 mm separation piece SM003 (x2)

130 mm insulation block SM004 (x2)

240 mm insulation block SM005 (x1)

SM006 (x8)

PART II. SHORT MODULE

Assembly

Attach the separation pieces to the external facade panels

01. 02.

Attach the back wood piece to the separation pieces

SM006

SM003

SM001

SM006

SM002

PART II. SHORT MODULE

Assembly

Attach the insulation blocks in the spaces between the two panels

SM005

03.

SM004

Your short module is ready for transportation and assembly

Components

905x1925 Gypsum board F001 (x4)

45 x 45 x 1925 wood batten F002 (x3)

600mm Short module F005 (x11) 905x125 interior cladding F007 (x2)

277,5 x 1925 x 45 insulation F003 (x2)

560 x 1925 x 45 insulation F004 (x2)

DIN 965 / M5 x 50 F009 (x68)

1200 mm Long module F006 (x11)

905x300 interior cladding F008 (x12)

DIN 965 / M5 x 80 F010 (x12)

PART III. FACADE (1810x1925mm)

Assembly 01. 02.

Mount the modules on top of each other alternating short and long in each row

Attach the Gypsum boards to the interior part of the stacked modules

F006

F001

F005

F009

PART III. FACADE (1810x1925mm)

Assembly 03. 04.

Attach the wood battens to the Gypsum boards

F006

Mount the insulation in between the wood battens

F003

F004

F010

PART III. FACADE (1810x1925mm)

Assembly 05.

Mount the modules on top of each other alternating short and long in each row

F007

The wall is fully assembled

F009 F008

THE FINAL PROPOSAL

Photographic documentation of the design and construction process

THE FINAL PROPOSAL

Photographic documentation of the design and construction process

THE FINAL PROPOSAL

Photographic documentation of the design and construction process

THE FINAL PROPOSAL

Photographic documentation of the design and construction process

CONCLUSION & REFLECTION

With the support from DTU, CIRCUIT and the Sydhavn Genbrugscenter, it was possible to build the wall element and present it to the public. Ideally, more development and testing would be made if the time allows.

The Hackaton week was a great experience in developing new products and implementing all the di erent ideas collected during brainstorming with all team members. Hard work, precision and team spirit made the ideas come true. The wall element outshined our expectations and we received very positive comments from the jury members.

It was a great opportunity to be part of Hackaton 2021!

THANK YOU

Alina, Maria, Theodor & Mads