Sweet CoRncrete

SWEET CORNCRETE

PORTFOLIO I RC7 2019 Tutor: Richard Beckett Andrew Metzler, Mariana Madriz-Bonilla, Hegen Wu, Danyang Li

INTRODUCTION This project focuses on the novel utilization of the bioreceptive material CoRncrete, and its potential applications in architecture.

Being one of the first studies of CoRncrete, the relationship between CoRncrete and architectural digital design is rigorously explored and tested throughout this group studio project as well as through associated individual theses.

The goal of this research is to discover new methodologies and technologies of architectural fabrication in addition to testing the potential benefits of materials sourced from renewable, biological resources.

TABLE OF CONTENTS 01. Case study and background information 1.1 Case Studies and Research 1.2 Previous Individual Work

08 10 18

02. Biomaterial 2.1 CoRncrete

2.1.1 Hardness test

2.1.2 Additives tests

2.1.3 Heating duration tests

2.1.4 Water ratio tests

2.1.5 Water retention + additives

2.1.6 Water retention + textures

20 22 28 30 54 56 58 62

03. Fabrication 3.1 Unit production process 3.2 Species 3.3 CNC Milling methong

66 68 92 96

04. Digital study and analysis 4.1 Unit & point system 4.2 Early geometry shape study 4.3 Shape study: growth and Decay

4.4 Geometry Library 4.5 Materiality

4.6 Aggregation studies

4.7 Furniture

4.8 Architectural Elements

4.8.1 Mesa Maize

4.8.2 Partition

4.8.3 Vertical transition

4.8.4 Maize Stair

4.8.5 Catenary structures

4.9 Microwave Army

4.10 Further CoRncrete applications & systems

104 106 112 118 134 144 152 176 188 192 216 262 278 300 310 326

05. Architecture Speculation 5.1 CoRncrete + Branching facade speculation

5.1.1 Zoomed-in facade detail speculation

344 346 362

06. References

378

PROJECT OVERVIEW

MATERIAL RESEARCH

FABRICATION

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DIGITAL BUILDING BLOCK

ASSEMBLY

UNIT INTERFACING

SYSTEMS

COMBINATORIAL LOGIC

AGGREGATION

ARCHITECTURE SPECULATION

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Bioconcrete by Dr. Henk Jonkers, 2015 Source: https://spinoff.com/bioconcrete

CHAPTER I. CASE STUDY AND BACKGROUND INFORMATION

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1.1 CASE STUDIES & RESEARCH

Figure 1: International corn production, 2019. (https://www.statista.com/statistics/254292/global-corn-productionby-country/)

Corn, also known as maize, is a grain plant cultivated for food. The origin of this grain remains unknown, however, many historians believe that corn was first domesticated in Mexico’s Tehuacan Valley. Types of corn include sweet corn, popcorn, pod corn, flint corn, flour corn, waxy corn and dent corn. As seen in the chart above, the largest producer of corn in the world is the United States followed

by China.

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Figure 2: Cornstarch making process, 2016. (https://hlagro.com/blog/a-brief-description-of-the-corn-starchproduction-process)

The process of separating starch from corn is one which involves several steps and procedures. The corn starch is obtained from the endosperm of the corn kernel. The main aim of the corn starch production process is to release the starch from the cell structure and ensure that the germ is not damaged. When the process is over, 4 main derivatives are obtained. They are: starch, fiber, germ and gluten.

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1.1 CASE STUDIES & RESEARCH

Figure 3: CoRncrete, TU Delft, 2015, http://resolver.tudelft.nl/uuid:0919b058-4499-493f-b02488c948ade7ff.

First tested by TU Delft, CoRncrete is a corn starch based bio-material formed by mixing corn starch with water and sand, and heating the mix in a microwave or oven. This heating process results in the formation of a hardened material. This research work addresses CoRncrete as a potential precursor to a new class of construction materials, which gain strength rapidly by heating at relatively low temperature (~100 C) and via quotidian instruments such as microwaves.

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Figure 4: Things which necrose, Francoise Roche, 2010, https://new-territories.com/twhichnecrose.htm.

Things which necrose is an installation made from CNC-casted bio-plastic containing hydrosoluble polymers. Both the integrated membrane and structure are exposed to mist nozzles to control the rate of humidity and thus degradation of the entire structure.

It is an exploration into a sense of a decaying system.

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1.1 CASE STUDIES & RESEARCH

Figure 5: Ant Bridge, 2015, https://earthsky.org/earth/army-ants-build-living-bridges.

Swarm Intelligence displayed by the bridge-making of ants. Their different roles are seen through the detailed deformations of their body and greater massing arrangements.

“These ants are performing a collective computation. At the level of the entire colony, they’re saying they can afford this many ants locked up in this bridge, but no more than that. There’s no single ant overseeing the decision, they’re making that calculation as a colony.”

-Matthew Lutz, Princeton

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Figure 6: Polyomino, 2015, https://www.plethora-project.com/polyomino-1.

Polyomino explores serial repetition and mass production through aggregation studies. Units are the same, but their arrangement or ‘pattern’ is different depending on their configurations and interfacing with neighbors, allowing for a much more efficient design strategy for complex forms.

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1.1 CASE STUDIES & RESEARCH

Species integration precedents

Figure 7: Dune project, Magnus Larrson, 2009, https://thefunambulist. net/architectural-projects/students-dune-by-magnus-larsson.

Dune Architecture Magnus Larrson

With this project, Magnus Larsson attempts to respond to the issue of desertification of Africa and the extension of the Sahara desert by introducing a bacteria on its border that dry the sand into stone.

Controlled well enough, this bacteria allow to create a troglodyte city that prevents the desert from spreading any further.

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Figure 8: Mycellium Brick, Philip Ross, 2014, https:// inhabitat.com/phillip-ross-molds-fast-growing-fungi-intomushroom-building-bricks-that-are-stronger-than-concrete/ mushroom-furniture-5.

Mycelium Brick Phillip Ross

“It has the potential to be a substitute for many petroleum-based plastics. It’s left the art world and seems to have entered a Science Fiction novel or something like that.”

-Phillip Ross

Figure 9: Bioconcrete by Dr. Henk Jonkers, 2015, https://spinoff. com/bioconcrete

BioConcrete Henk Jonkers

“What makes this limestone-producing bacteria so special is that they are able to survive in concrete for more than 200 years and come into play when the concrete is damaged. For example, if cracks appear as a result of pressure on the concrete, the concrete will heal these cracks itself.”

-Henk Jonkers

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1.2 PREVIOUS INDIVIDUAL WORKS

Self-Assembly

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Water Flow Mesh

Decay

Bioluminescence

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CHAPTER 2.

BIOMATERIAL: CoRncrete

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2.1 CORNCRETE

~760 MILLION METRIC TONS OF CORN TOP FIVE PRODUCING COUNTRIES

1 acre

~ 71,120 units

1 ACRE = 140 bushels2 1 BUSHEL of corn = 25.40 kg corn starch

1 ACRE = 3,556 KG CORN STARCH 1 kg corn starch = ~20 coRncrete units

3,556 KG x 20 units = ~ 71,120 coRncrete units / acre

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CoRncrete

Concrete

-MADE WITH PLENTIFUL RESOURCE -RAPID CURE TIME -CAN DEGRADE WHEN EXPOSED TO WATER

-MADE WITH CEMENT -HIGH ENVIRONMENTAL IMPACT -LONGER CURE TIME -IMPERVIOUS

VS

To Make 1 Unit...

To Make 1 Unit...

4 MINS HEAT

24-48 HOURS SET

+ 12 HOUR CURE TIME

TOTAL: ~12 HOUR 4 MINS

+ 4 WEEKS CURE TIME

TOTAL: ~ 4 WEEKS

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2.1 CORNCRETE

The essential ingredients of CoRncrete are simple.

The mixture consists of: Corn Starch, Sand, and Water.

These ingredients are easily obtained from a grocery store and a local hardware store.

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Standard ratio of coRncrete

1x Corn Starch

5x Sand

1x Water

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2.1 CORNCRETE

The fabrication methodology of CoRncrete is also simple.

A mixture of CoRncrete is measured and stirred thoroughly in correct ratios and amounts. The mixture is then poured into a mold to take shape. The mold is put into the microwave for several minutes and then taken out once the timer is done. The cooking time varies, however, depending on the size and geometry of the mold. A resting period of at least ten minutes is advised to allow for the mold to cool down and for most of the moisture to evaporate.

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2.1.1 HARDNESS TESTS

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TEST I

TEST II

1 Part - Water 5 Part - Sand 1 Part Corn - Starch **measured in volume Notes: create a first attempt at CoRncrete that would retain shape under gravity load, slow pour

1 Part - Water 4 Part - Sand 1 Part Corn - Starch **measured in volume Notes: less sand, same part water in order to test smoothness of surfaces, slow pour

TEST III

TEST IV

1.25 Part - Water 4 Part - Sand 1 Part Corn - Starch **measured in volume Notes: less sand, more water in order to test

1.5 Part - Water 4 Part - Sand 1.25 Part Corn - Starch **measured in volume Notes: two kinds of sand, even more water, a little more corn starch in order to test smoothness

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2.1.2 ADDITIVES TESTS

Numerous different additives were mixed with CoRncrete and tested to see the various results. Some additives such as salt made the test mixture more porous and eroded. Others such as the bread additive began to mold on the CoRncrete. These tests informed future material studies.

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H20 solvent

white sand mass

recycled glass

corn flour binding agent

red dye colour

small rocks small aggregate

rock salt dissolvable additive

molded bread dissolvable additive

tree twigs burnable additive

sand mass

river rocks large aggregate

polystyrene foam beads lightweight aggregate

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2.1.2 ADDITIVES TESTS

Numerous different additives were mixed with CoRncrete and tested to see the various results.

These specific tests illustrated the different textures, coloration, and porosities of CoRncrete when various mixtures were added to a geometry mold output (in this case, an halved octahedron).

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Additives tests

1 Part - Water 4 Part - Sand 1 Part - Corn Starch + 0.5 - Salt

1 Part - Water 4 Part - Sand 1 Part - Corn Starch + 0.5 - Bread

1 Part - Water 4 Part - Sand 1 Part - Corn Starch + 0.5 - Wooden twigs

1 Part - Water 4 Part - Sand 1 Part - Corn Starch + 0.5 - Polystyrene

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2.1.2 ADDITIVES TESTS

Three different size aggregates were tested next to one another in the same cast to observe the material differentiation. The objective was to create a material gradient on a single unit scale. Further testing of smoother transitions between each ‘border’ will be tested.

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Three different types of aggregates were used in a section of material test to create a gradient transition from the solid to the porosity.

Three different types of aggregates were used in a section of material test to create a gradient transition from the solid to the porosity.

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2.1.2 ADDITIVES TESTS

0.1-0.4mm aggregates

Solid

0.5-0.8mm aggregates

1-2mm aggregates

Porous

The third experiment is about the sizes of aggregates we use , the three types of different aggregates of different sizes are used to test the porosity property .

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The fourth experiment: Mixture of aggregates, the lightest glass aggregates and the medium aggregates are mixed to make the material test.

Aggregate sizes tests

37

2.1.2 ADDITIVES TESTS

The fourth experiment: Mixture of aggregates, the lightest glass aggregates and the medium aggregates are mixed to make the material test.

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39

2.1.2 ADDITIVES TESTS

Pattern

Oil

Sea salt

Oil

The third experiment: the different additives were added to explore the physical and geometry features.

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Oil

Black dye

Oil and recycled glass aggregate were used in the sample above

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2.1.2 ADDITIVES TESTS

Three different size aggregates were tested on small scale molds and cast as individual units. The objective was to create a material gradient throughout a proposed larger aggregation structure.

Small, medium, and large aggregates were all tested to ensure enough grain differentiation between each unit.

Heavier units were on the bottom, and lighter units were on the top.

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Ratio: medium aggregates 40ml : small aggregates 40ml : cornstarch 20ml : water 10ml

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2.1.2 ADDITIVES TESTS

Additives After the experiment of sand aggregates, some other additives were added to test the influence on the surface of the material. Each additive has different effects on the surface, such as the formation of interesting texture and color on the surface. In addition, after adding vegetable oil to the experimental sample, the surface is relatively flat and has a certain glisten.

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a. 80ml sands (12mm), 20ml water, 20ml corn starch, 20ml big pieces tree bark.

b. 80ml sands (12mm), 20ml water, 20ml corn starch, 30ml wax.

c. 80ml sands (12mm), 20ml water, 20ml corn starch, 50ml big stone.

d. 80ml sands (0.40.8mm), 20ml water, 20ml corn starch, 20ml tea.

e. 80ml sands (0.4-0.8mm), 20ml water, 20ml corn starch, 30ml flower segment.

f. 80ml sands (0.40.8mm), 20ml water, 20ml corn starch, 10ml small ice block.

g. 80ml sands (0.40.8mm), 20ml water, 20ml corn starch, 15ml sycamore tree hair.

h. 80ml sands (0.40.8mm), 20ml water, 20ml corn starch, 10ml sea salt.

i. 80ml sands (0.10.3mm), 20ml water, 20ml corn starch, 15ml brown paper.

j. 80ml sands (0.40.8mm), 20ml water, 20ml corn starch, 25ml medium sands.

k. 80ml sands (0.40.8mm), 20ml water, 20ml corn starch, 20ml oil.

l. 80ml sands (0.40.8mm), 20ml water, 20ml corn starch, 25ml small tree bark.

Additives tests

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2.1.2 ADDITIVES TESTS

fine building sand 4:2(water):1 ratio use of sparkling water Figure A

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Figure A.2

fine building sand 4:1:1 ratio 1 1/2 tsp of bicarbonate of soda per 1.6 kg of sand

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2.1.2 ADDITIVES TESTS

Figure B

fine building sand 4:1:1 ratio 1 1/2 tsp of bicarbonate of soda, 1 tbs of salt & 50ml of oil per 1.6kg of sand

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Figure B.2

fine building sand 4:1:1 ratio acrylic spheres & 50ml of oil per 1.6kg of sand

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2.1.2 ADDITIVES TESTS

Acrylic spheres were used in an attempt to generate new textures to coRncrete

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Polished-like surface texture from the use of acrylic.

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2.1.2 ADDITIVES TESTS

Medium white sand

Large white sand

4 :2(water):1 ratio

4 :1:1 ratio

non

non

More water into a mix of medium and small sand grain, tend to produce bubbles on the surface.

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Less water and larger sand grains produce a more solid surface and accurate ledges of the shape.

medium white sand 4:1:1 ratio non

Medium sand grain it’s been, so far, the best sand type for accurate edges.

fine building sand 4 :2(water):1 ratio non

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2.1.3 HEATING DURATION TESTS

The principle behind the CoRncrete is due to the heated corn with water will expand in the gaps between the aggregates, and the expanded corn will play an important role in the sticking the aggregates together into an integrated part.

Fig : CoRncrete: A corn starch based building material,2017.

The experiment is carried in a circle mold with the already stirred materials in the plastic cup, and the materials in mold will be put into the microwave to be heated for optimal time for harding.

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1 min

1.5 min

2 min

2.5 min

3 min

3.5 min

The first experiment: the duration of heating is tested by using microwave, and it comes to a conclusion that the CoRncrete will get harder and dryer by increasing the heating time, and it appears that the 3min-3.30min is the optimal time for the CoRncrete tests.

4 min

4.5 min

Heating duration tests

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2.1.4 WATER RATIO TESTS

20ml 5ml

20ml 10ml

80ml

20ml 15ml 80ml

80ml

20ml 20ml 80ml

Corn Starch : Water : Aggregates

The second experiment: the different water ratio were tested in 5ml , 10ml , 15ml , 20ml water. The different properties were found in terms of the hardness and porosity, and the ones with the good hardness happened in the range between the 5ml and 10ml, and the porosity will increase by the amount of water.

Water ratio tests

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20ml 5ml

20ml 10ml

80ml

20ml 15ml 80ml

80ml

20ml 20ml 80ml

Corn Starch : Water : Aggregates

The second experiment: the different water ratio were tested in 5ml , 10ml , 15ml , 20ml water. The different properties were found in terms of the hardness and porosity, and the ones with the good hardness happened in the range between the 5ml and 10ml, and the porosity will increase by the amount of water.

Water ratio tests

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2.1.5 WATER RETENTION +ADDITIVES

A series of water retention tests are conducted to investigate the bioreceptivity of coRncrete. The experiment aims to test for specific variables including ingredient ratio, additives and geometrical texture in material samples of the same size and preparation method. First the experiments record dry weight. Each sample is then soaked in cold water for four hours, and the weight recorded at maximum absorption. A scale, monitored through a b spoke algorithm (figure x), registers changes in weight over a period of 24 hours as the sample releases water. Weight reduction is taken as a proxy for water retention over time.

1 2 3 1.

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4 5 6

Sample Sample Sample Sample Sample Sample

R1 R2 R3 R1 R4 R5

with with with with with with

Ingredient Ingredient Ingredient Ingredient Ingredient Ingredient

ratio ratio ratio ratio ratio ratio

(sand : cornstarch : water) 4 : 1 : 1 4 : 0.8 : 1 4 : 1.2 : 1 4:1:1 4 : 1 : 0.8 4 : 1 : 1.2

A higher ratio of both water and cornstarch led to higher water retention in coRncrete, while water had a stronger influence in the first 10 to 20 hours, and a lower impact after that, than cornstarch. However, sample R3 with 1.2 units of cornstarch had the lowest water release rate during the period and thus contained the most water of the five samples after 12 hours. In general, a higher ratio of water helps to improve water absorption and retention in the first 12 hours and a higher cornstarch content contributes to lowering coRncrete’s water release.

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2.1.5 WATER RETENTION +ADDITIVES

1 3 5

2 4 6

1. Sample AE6 with black earth color 2.5g 2. Sample AE7 with black earth color 5.0g 3. Sample AF8 with foam beads 0.15g 4. Sample AF9 with foam beads 0.30g 5. Sample AB10 with bread 3g 6. Sample AB11 with bread 6g * The basic Ingredient content ( sand, cornstarch, water ) of the six samples are the same: 80ml, 20ml, 20ml

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The three additives each influenced the water behaviour of coRncrete to different extents. The presence of bread and foam beads had a more considerable influence than earth colour, with a higher ratio of additive causing stronger retention capacity. Nevertheless, earth colour decreased water retention in the first few hours. Two water release phases were observed, fast release in the first 12 hours and slow release in the next 12 hours. Generally, sample R1 without any additive released water the fastest and thus retained the least amount of water during the last five hours. In contrast, sample AB11, which contained 6 g of bread, exhibited the best performance in water retention and retained the lowest level of water evaporation during the test and highest level of water retention after the eighth hour.

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2.1.6 WATER RETENTION +TEXTURES

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2 5 8

3 6 9

Houdini script: copy to points Houdini script: attribute vop Houdini script: connect adjacent pieces Digital texture A Digital texture B Digital texture C Sample T12 Sample T13 Sample T14

The three samples displayed a reduction in water loss, which was improved by their rugged and uneven surfaces. The water release trend remained similar, rapid in the first 12 hours and slowing down afterwards, with the water release rate ranging from 1 to 2 per cent.

In general, the unevenness of the coRncrete surface reduced the water absorption rate by varying degrees, but at the same time, water evaporation was slowed down, making the moisture content of the concave test piece greater than that of the rigid sample after more than ten hours.

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2.1.6 WATER RETENTION +TEXTURES

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Raw material ratio, additives and geometrical texture affect water retention in coRncrete. Generally, the higher the water content and the cornstarch content, within limits, the better water retention is shown by the sample. Additives including foam and breadcrumbs can also improve water retention by different degrees, while earth colour exerts no significant effect. Increasing surface roughness by applying a texture to the sample reduces water retention rate in the early stage while the water holding time increases due to the delayed water release. Sample AF9, with a more significant amount of foam, and sample AB11, with more bread, absorbed and held the most water, while sample T12, with the bulging texture, retained the least.

Experiments also indicate that coRncrete has excellent water absorption and water retention capacities, which can be further manipulated by changing different parameters in order to provide appropriate moisture for biological growth. The plasticity of coRncrete in terms of its composition, colour and morphology also exhibits a variety of choices for its design and application.

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CHAPTER 3.

FABRICATION

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3.1 UNIT PRODUCTION PROCESS

To create individual units at multiple scales, we model units in Maya, transfer them to Rhino for mesh check and cleanup, and then export them to Makerbot for 3D printing. 3D printing proves an effective way at making units quickly with low expense. It also allows us to push physical geometries that are difficult to manually model in such a rapid timeframe. Complexity of the units is also constrained by the physical properties of coRncrete and considerations of larger structural aggregations.

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3.1 UNIT PRODUCTION PROCESS FABRICATION PROCESS

4 MINS

3D model

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3D print

silicone mold

MINS 44MINS

hardcast cast hard

MINS MINS44MINS MINS 44MINS MINS MINS 4444MINS

microwave microwave

component component

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3.1 UNIT PRODUCTION PROCESS

We then move onto larger 3D printed models. These models are tested as 1:1 scale prototype units (building scale design). 18 cm from face to face proved to be the largest unit we could 3D print with the model of Makerbot at hand. However, we found that unit size did not satisfy other requirements such as fabrication time in the microwave, thus we eventually chose to use 13 cm units from face to face. The different design patterns and geometries can be seen very clearly at this scale and the block is large enough to be structural.

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3d printed units

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3.1 UNIT PRODUCTION PROCESS

To test smaller aggregations at varying scales, we explore different aggregations and interfaces with specific functions such as a staircase and a pavilion. These tests begin to inform the digital design direction of our project and help indicate which massings work both structurally and aesthetically.

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stair study

aggregation study

decaying aggregation study 75

3.1 UNIT PRODUCTION PROCESS 4 MINS

4 MINS

silicone mold 3D model

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hard cast 3D print

4 MIN

From digital to fabrication

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3.1 UNIT PRODUCTION PROCESS

To create CoRncrete units that can be created multiple times in a quick timeframe, we utilize the silicone mold casting. We test 3 different silicone mold methods: solid cast, paint-on, and paint-on with paper mache. In all cases, silicone proves to be a good material to create a solid cast around our 3D printed units. However, to save material, the best method is the paint-on method.

The general methodology employed:

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1) 2) 3) 4) 5)

3D print octahedron mold paint two-part silicone mold cast pour in coRncrete microwave for 4 minutes on high setting extract model out of mold

SOLID SILICONE MOLD

PAINT ON METHOD

4 MINS TO MAKE 1 UNIT...

4 MINS SILICON MOLD

4

4 MINS 1X CORN STARCH 5X SAND 1x water

4 MINS

4 MINS

4 MINS

4 MINS HEAT + 12 HOUR CURE TIME

4 MINS

4 MINS

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3.1 UNIT PRODUCTION PROCESS Moldmaking via paper mache shell method

+ less material + less cost - flimsy shell - added time

3D PRINT

PAINT ON SILICONE

4 MINS

HARD CAST

4 MINS

DEMOLD

BAKE

UNIT 4 MINS

80

4 MINS

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3.1 UNIT PRODUCTION PROCESS

Microwave The microwave is the main mode of fabrication in producing the CoRncrete units. It’s ease of use and quick cook time allow patrons to make many units rapidly. However, there are a few considerations to take into account whilst using a microwave for CoRncrete fabrication:

component size

amount of material (density of unit)

cook time

watt power output

required electricity

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26 cm

31 cm 38 cm

Microwave constraints of the specific microwave we used: Daewoo KOR6M17R 20 Litre 700 watt power output

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3.1 UNIT PRODUCTION PROCESS

6 MINUTES

Cook Times + Shape fabrication study

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7 MINUTE

ES

8 MINUTES

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3.1 UNIT PRODUCTION PROCESS

building sand test

bumpiness study

color with building sand

smoothness study

thinness test

component orientations Various scales of units

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two-material aggregation study

wood ‘end caps’ connection

first aggregation study fabricated in small scale Various scales of aggregations

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3.1 UNIT PRODUCTION PROCESS

structural packing model

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middle connection, change of direction

bridging

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3.1 UNIT PRODUCTION PROCESS

Structural Packing Model A few considerations in regard to packing of the different octahedrons:

component size

type of CoRncrete mixture

density of material

type of connection

color coordination

texture composition

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Units made with silicone method 91

3.2 SPECIES

Species [incubation] before microwave fabrication

4 MINS

4 MINS

4 MINS

4 MINS

4 MINS

4 MINS

4 MINS 92

Mycelium coRncrete [incubation] without microwave fabrication

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3.2 SPECIES

Species [incubation] before microwave fabrication

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Mushroom fruiting and hyphae growth + distribution

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3.3 CNC MILLING METHOD

We use CNC milling to create a back wall panel that could ‘receive’ CoRncrete units. In this way, we create a dynamic wall system that is both static (the CNC solid wall) and reconfigurable with customized pieces (CoRncrete units). The idea is to connect the units to the wall panel via their geometries (inverse relationships). The octahedron shape is the backside of each ‘plug-in’ geometry.

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CNC milling foam

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3.3 CNC MILLING METHOD

Initial high-density foam block

100 mm thick foam material

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CNC Milling was used to create a wall panel Time to mill: 3 hours

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3.3 CNC MILLING METHOD

Here we test different fitting units or components that can be placed on the wall panel. The connections between the two are interfaced hexagons. The panel is seen as a long-standing mass while the units act a secondary pieces - aesthetic and ephemeral.

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3.3 CNC MILLING METHOD

soft

tactile

demold

tactile

tactile

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geometrical

geometrical

tactile

geometrical

porous

soft

soft

millennial color palette

monochrome color palette

First attempt at CNC milling wall fabrication pieces

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CHAPTER 4.

DIGITAL STUDY AND ANALYSIS

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4.1 UNIT & POINT SYSTEM

Truncated [octahedron] as a packing brick

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UNIT

LOCAL PACKING

CLUSTER

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4.1 UNIT & POINT SYSTEM

POINT AS A PLACEHOLDER

BULKY BOLD HEAVY

UNIT

placeholder

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Grid of points based on the octahedron

Vertical grid variations

Horizontal grid variations

Central grid variations

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4.1 UNIT & POINT SYSTEM

POINT SYSTEM AND TRANSFORMATIONS

more exposure to sun

less shadow

more exposure to rain

more shadow

TYPE I

TYPE III

TYPE II

TYPE IV

type variations depending on external facts

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original grid

truncated alternated cubic grid 2

2

1

2

2

1

2 2

13 12

2 2

21 31

1 1

2

gro pat + 1

2

ORIGINAL GRID material material gradients gradientsunit unit

exploded view

exploded view

+

+

1

2

2

+ 3

3

GRID material WEAIRE-PHELAN growth material growth gradient patterns gradientaggreg. patterns aggreg.

aggregation WEAIRE-PHELAN CONNECTIONS

hidden lines

aggregation

overall GRID variationplan view elevation view plan view elevation view

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4.2 EARLY GEOMETRY SHAPE STUDY

We start to create a geometry catalog of the various units we could create from a truncated octahedron base shape.

Our objective is to lose the strict aesthetic and edges of the octahedron shape while retaining its packing logic. We investigated several methods of shape morphologies to discover new ways of interpreting and expressing the truncated octahedron packing logic.

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CONTRAST

fractal

SKELETON

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4.2 EARLY GEOMETRY SHAPE STUDY

truncated octahedron shape growth

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Point population on wireframe

Point population on surface Early texture studies 115

4.2 EARLY GEOMETRY SHAPE STUDY

Early deformation studies from a truncated octahedron shape

truncated octahedron

sharp angle

collector

leaf and bone

bone

wireframe double

habitat

high

medium Fractal density study

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low

smooth bone

smooth bone

wireframe

collector

clam

clam

striped

inner/outer

double

naked clam

shelf

inner/outer

double

117

4.3 SHAPE STUDY: GROWTH AND DECAY

decay

118

growth

119

4.3 SHAPE STUDY: GROWTH AND DECAY

Decaying studies

120

Decaying studies

121

4.3 SHAPE STUDY: GROWTH AND DECAY

1 2

1. DEFORMATION TYPE I :Bone 2. DEFORMATION TYPE II : Collector

122

1 2

1. DEFORMATION TYPE III : Habitat B 2. DEFORMATION TYPE IV : Truncated Octahedron

123

4.3 SHAPE STUDY: GROWTH AND DECAY

We understand the decaying condition of this material, and we think there are relevant uses for this specific condition such as temporal structures, variability, adaptiveness.

The images shown are a digital process some components going through a decaying process,

124

125

4.3 SHAPE STUDY: GROWTH AND DECAY

This is an early study to understand the possibility of using a more permanent structure in contrast with one that decays

126

127

4.3 SHAPE STUDY: GROWTH AND DECAY

Figure 33 Large white sand 4 :1:1 ratio non

30 min after

128

As a biomaterial, coRncrete degrades fast; specially when in contact with water, since the cornstarch will start to dissolve. To understand the performance of coRncrete with water, two pieces were submerged into a water container:

Hot water: This is a piece baked 3 months ago, and it was recently submerged into hot water. (50-70 Celsius degrees) For 30 min. The piece couldn’t be taken out from the hot water container without crumbling down.(see figure 33)

129

4.3 SHAPE STUDY: GROWTH AND DECAY

Cold water: A similar a piece baked 3 months ago, was recently submerged into cold water. (10 Celsius degrees approx.) For 30 min. The piece stood without deforming or crumbling down, even though it was a little bit spongy, the piece could be taken out.(see figure 34)

130

Figure 34 Large white sand 4 :1:1 ratio non

30 min after, the piece kept it’s shape

on the surface it started to show some jelly-like substance.

131

4.3 SHAPE STUDY: GROWTH AND DECAY

132

Figure 35: These images are showing a process of the degradation of a coRncrete component. By using again hot water and squeezing the component with the hand. A jelly-like substance appears on top of the residual material. During this process, when the coRncrete component was completely dissolved, water was drained, and the residual material was used again.

However, the results were not positive, the material tended to grow much more than usual while it was baking.

133

4.4 GEOMETRY LIBRARY

Double aggregation study

134

Melting octahedron aggregation

135

4.4 GEOMETRY LIBRARY

Double aggregation study

136

Inner/outer condition

137

4.4 GEOMETRY LIBRARY

FINAL DIGITAL UNITS TO BE USED FOR FURTHER AGGREGATION STUDIES + FABRICATION OF FINAL PIECES

shelf

boat

spike+coral 138

small spike

clam

smooth

wave

spike

coral

horn

leaf 139

4.4 GEOMETRY LIBRARY

140

From the final components, we have developed a catalogue of components to develop further aggregation studies. Known as Component Haven, these components are showcased as the most successful components in terms of fabrication ability and aesthetic.

141

4.4 GEOMETRY LIBRARY 5 7

9

8 6

10

7

8

7

1

10 6 8

5

3

10

142

9 10

6

5

3 9

6

1

4

7

4 12

8

143

4.5 MATERIALITY

144

Materiality To transfer from digital to physical, we create a palette containing possible variations for each components regarding: component number, texture, grain size and color.

145

4.5 MATERIALITY COMPONENTS

1

2

3

4

5

6

7

8

9

10

11

12

pick a component 146

TEXTURE / AESTHETIC

GEOMETRICAL / HARD

GRAIN SIZE

PERVIOUS

SOFT / SQUIDGY

POROUS

TACTILE

SOLID

define the aesthetic

COLOR

select a grain size

pick a color 147

4.5 MATERIALITY

Mixtures example: COMPONENT_5 (as test case)

Color: white Texture: bumps Hardness: low

148

Color: pink Texture: bumps Hardness: low

Color: green Texture: bumps Hardness: low

Color: black Texture: bumps Hardness : high

149

4.5 MATERIALITY

Large [scale]

Medium [scale]

Small [scale]

The testing of different Houdini scripts run over the surfaces of sculpted units to add visual and physical complexity.

[Copy to Points] 150

[Shortest Path]

[Turbulent Noise] 151

4.6 AGGREGATION STUDIES

Aggregation studies From the previous component development, we developed some aggregation systems with building and structural purposes in mind.

152

153

Type A Double

Type A Type A Type A Basic Unit Type B Triple Quadruple I Quadruple Double II

Type B Type B Type B Type B Triple Quadruple I Quadruple Quadruple II III

Type B Quadruple IV

4.6 AGGREGATION STUDIES

Combinatorial logic chart

154

Octahedron Combinatorics of Two Triple Sets 155

4.6 AGGREGATION STUDIES

Geometrical aggregation study

Bone aggregation study

Bone aggregation study

156

Rings aggregation study

Tuba aggregation study

Bone aggregation study

Collector aggregation study

Rings aggregation study

Bone aggregation study

Large aggregation using a point grid developed in Houdini

157

4.6 AGGREGATION STUDIES

Decaying aggregation studies

158

Aggregation studies

159

4.6 AGGREGATION STUDIES

Early digital point clouds

areaA:

areaB:

in certain areas of the top, there are higher ratio of collectors.

in external spaces of the geometry, the decay speed is higher due to the more intimate connection with the environment.

skeleton: deep decay: middle decay: less decay: collector:

160

2 2 1 1 4

skeleton: deep decay: middle decay: less decay: collector:

3 4 2 1 0

TYPE III

TYPE I

TYPE II

First attempt at grouping a large aggregation via Houdini point logic

161

4.6 AGGREGATION STUDIES

Decaying aggregation studies 162

Aggregation cloud 163

4.6 AGGREGATION STUDIES

Ceiling study

component

twisted

double unit

half

164

ceiling configuration

ceiling grid

reflected ceiling plan view

165

4.6 AGGREGATION STUDIES

Double component aggregation color and texture tests

166

Material and color contrast study with double melt octahedron

167

4.6 AGGREGATION STUDIES

Bouldering / high density cluster

diagonal cladding cluster

168

Stacked arching cluster

Fluid rotation pivot cluster

169

4.6 AGGREGATION STUDIES

Early branching study

bone component

base

170

bone arches

scatter

connect

polywire

Early wall study

171

4.6 AGGREGATION STUDIES

Smooth component that allows variation

172

early branching studies

173

4.6 AGGREGATION STUDIES

174

soft component aggregation that allows a variety of surfaces

175

4.7 FURNITURE

Furniture To expand on the aggregation studies and to ground the purpose of further aggregations, we explore some preliminary conceptual furniture pieces.

176

seat

bench

mesa

partition

177

4.7 FURNITURE

small

A

B

A

B

A

B

medium

large

178

seat

C

D

table/bench

C

D

bridge/stairs

C

D

179

4.7 FURNITURE

Digital design process showing a grouping logic plan

front elevation

external influence

plan growth areas

180 external influence

Seat design process

massive

lighter

181

4.7 FURNITURE

Seat design process

182

Table design process

183

4.7 FURNITURE

Seat: component variation

184

Panel study

185

4.7 FURNITURE Bench

Seat studies 186

Chain aggregation study

187

4.8 ARCHITECTURAL ELEMENTS

Architectural elements In order to understand the point system and aggregation system in a more architectural scale, we developed some architectural studies that will be displayed as followed.

188

189

4.8 ARCHITECTURAL ELEMENTS

mesa

190

partition

vertical transition

maize stairs

catenary structures

architecture

191

4.8.1 MESA MAIZE

table reconfiguration

00 00 00.00

Mesa Maize Table design based on reconfigurable outcome and surrounding contextual demands such as size, number of people. orientation, spatiality, etc.

00 01 30.00

192

00 00 30.00

00 02 00.00

00 01 00.00

00 02 30.00

193

4.8.1 MESA MAIZE

mesa elevation

194

top pattern study

195

4.8.1 MESA MAIZE

SMOOTHNESS

SOFTNESS

TACTILE

GEOMETRICAL / HARD

TACTILE FLAT

GROOVED

ROCKY

196

MESA MAIZE DESIGN STUDIES

197

4.8.1 MESA MAIZE

short mesa maize

stepped mesa maize

long meza maize

digital explorations of mesa configuration

198

final mesa maize prototype to be built

199

4.8.1 MESA MAIZE

Mesa Maize digital process

component A component B component C component D

point grid

GRID

200

bounding box

BOUNDING BOX

select points

SELECT PTS

point groups

GROUP PTS

component A component B component C component D

point groups

placer holder

POPULATE

mesh

WIREFRAME

shortest path

SHORTEST PATH

201

4.8.1 MESA MAIZE

Top pattern design

202

Color variation study

Sand pigment test

203

4.8.1 MESA MAIZE

Final mesa digital model

Elevations

Top view

204

Point grid

Metal tube

Structural connection

205

4.8.1 MESA MAIZE

Initial prototype: SMALL MESA MAIZE

206

Component types

Table top Component #15

Table body Component #2

Table body Component #9

Table foot Component #9 207

4.8.1 MESA MAIZE Component Type

Component #15

Component #2

Component Color

White

Pink

Sand type

Performance

208

Silica sand 0.5 - 1.2 mm gravel

Silica sand 1 - 1.5 mm gravel

Crumby edge, high intensity

Crumby edge, low intensity

Component #9

Component #9

Red

Dark purple

Building sand

Black sand

Nice clean edge, medium intensity

Clean edge, medium intensity 209

4.8.1 MESA MAIZE

Initial prototype: SMALL MESA MAIZE

1

2 3

1. Top view of the table 2. Table top with golden edge 3. Close up of the table foot

210

211

4.8.1 MESA MAIZE

Final prototype: LARGE MESA MAIZE building process and final pieces

base

212

shelf

half

canteliver

Final prototype built

213

4.8.1 MESA MAIZE

Built prototype 214

color variation 215

4.8.2 PARTITION

Partition Three different types of point distribution on the wall assembly were explored: scattered, tiered, and attractor. Various types of units were assigned to these different distributions of points to express different typologies and variations.

216

components to be added to each point

Partition point grid

components to be added to each point 217

4.8.2 PARTITION

Partition design i This wall design type shows a distinct attractor curve affecting the point distribution. It could be used as a simulation for external forces shown upon the wall such as environmental forces.

218

[Attractor] Wall Assembly Variation logic 219

4.8.2 PARTITION

Partition design ii This wall design type shows a simple approach of tiered distribution or stacking. It could be interpreted as difference of structural support or tectonic expression.

220

[Tiered] Wall Assembly Variation logic

221

4.8.2 PARTITION

Partition design iii This wall design type shows a border between upper and lower; it also explores a multiunit scatter in both ‘main’ zones.

This type of wall showcases a randomized pattern.

222

[Scatter] Wall Assembly Variation logic

223

4.8.2 PARTITION

Partition design i This wall design type shows a distinct attractor curve affecting the point distribution. It could be used as a simulation for external forces shown upon the wall such as environmental forces.

224

[Attractor} Wall Assembly Variation logic

225

4.8.2 PARTITION

Partition design ii This wall design type shows a simple approach of tiered distribution or stacking. It could be interpreted as difference of structural support or tectonic expression.

226

[Tiered} Wall Assembly Variation logic

227

4.8.2 PARTITION

Partition design iii This wall design type shows a border between upper and lower; it also explores a multi-unit scatter in both ‘main’ zones. This type of wall showcases a randomized pattern.

228

[Varied} Wall Assembly Variation logic

229

4.8.2 PARTITION Time scale

230

00 00 00.00

00 00 30.00

00 01 00.00

00 03 00.00

00 03 30.00

00 04 00.00

00 06 00.00

00 06 30.00

00 07 00.00

00 01 30.00

00 02 00.00

00 02 30.00

00 04 30.00

00 05 00.00

00 05 30.00

00 07 30.00

00 08 00.00

00 08 30.00 [Tiered} Wall Assembly Variation logic 231

4.8.2 PARTITION Partition configuration study

gradient study

232

color variation study

233

4.8.2 PARTITION

From these previous explorations, a section of a wall was selected and developed in order to be built .

234

[Varied} Wall Assembly Point Variation 235

4.8.2 PARTITION

Final digital model selected to be built

236

237

4.8.2 PARTITION

In order to build the wall, there was a need to have a back structure that would support the wall components, we decided to use a piece of foam, of 10 cm width, to CNC the shape of the back wall and design a plug-in system to attache each component to this back foam wall

238

239

4.8.2 PARTITION

CNC process

240

4 MINS

241

4.8.2 PARTITION

12

8

7

Waves

Bumps

1

Waves

6

Non-Texture

3

Waves

11

242

Non-Texture

Non-Texture

Partition Point logic

243

4.8.2 PARTITION

12

12

12

12 7

7

1

8

1

1

6

6

6 3

3 3 3 3

3

11

8 6

3 3 3

11

1

11 6

8

3 6

3

3

3 11

7

7

3

3

1

8

1 7

12

8

1

8

1

7

1

12

3 3

11

11 1

3

11

1 1

Partition building layout

244

Partition components per number

Partition Component-to-Point logic

245

4.8.2 PARTITION

CoRncrete casting tests The mixtures of different sizes of aggregates are poured in the different mold with the same but optimal ratio 5:1:1.

Component number: 1 Aggregates size: Heating time:

Component number: 8

0.1mm

1.2mm

10min

16min

0%

100%

Success rate :

Component number: 6

Heating time: Success rate:

0.1mm

1.2mm

10min

16min

0%

100%

Component number: 15

Aggregates size: 0.1mm

1.2mm

10min

16min

0%

100%

Heating time:

Aggregates size:

0.1mm

1.2mm

10min

16min

0%

100%

Heating time:

Success rate :

246

Aggregates size:

Success rate:

Component number: 13

Component number: 7

Aggregates size:

Aggregates size: 0.1mm

1.2mm

10min

16min

0%

100%

Heating time:

Heating time:

Success rate :

Success rate :

Component number: 3 Aggregates size: Heating time: Success rate :

0.1mm

1.2mm

10min

16min

0%

100%

Component number: 2

0.1mm

1.2mm

10min

16min

0%

100%

Aggregates size:

0.1mm

1.2mm

10min

16min

0%

100%

Heating time: Success rate :

247

4.8.2 PARTITION

CNC milling process

248

Finished Product

249

4.8.2 PARTITION

Partition building diagram

7

11

1

8

12

Component numbers 250

3

6

Facade application 251

4.8.2 PARTITION

Prototype displayed in gallery setting

252

Prototype displayed in gallery setting

253

4.8.2 PARTITION Further wall configuration through time

254

255

4.8.2 PARTITION

256

257

4.8.2 PARTITION

Wall installed at Barbican exhibition

258

Sharing fabrication process

259

Project display case

260

CoRncrete workshop

261

4.8.3 VERTICAL TRANSITION

TYPE_A LAYERED / ITERATION_

262

jawbreaker column stairs i: component_stairs_A edge tiered edge i: component_edge_A edge ii: component_edge_B wall tiered wall i: component_scale_B wall ii: component_scale_C

263

4.8.3 VERTICAL TRANSITION

TYPE_B JAWBREAKER / ITERATION_i

264

jawbreaker column stairs i: component_stairs_A edge tiered edge i: component_edge_A edge ii: component_edge_B wall tiered wall i: component_scale_B wall ii: component_scale_C

265

4.8.3 VERTICAL TRANSITION

TYPE_C HYBRID / ITERATION_

266

jawbreaker column stairs i: component_stairs_A edge tiered edge i: component_edge_A edge ii: component_edge_B wall tiered wall i: component_scale_B wall ii: component_scale_C

267

4.8.3 VERTICAL TRANSITION

Vertical system study

268

Plinths and vertical system studies

269

4.8.3 VERTICAL TRANSITION

Vertical transition/ digital design process

270

Material and color variation

271

4.8.3 VERTICAL TRANSITION

Floor transition showing material and color variation

272

273

4.8.3 VERTICAL TRANSITION

274

Floor to Ceiling Transitions Iteration _II

275

4.8.3 VERTICAL TRANSITION

276

Floor to Ceiling Transitions Iteration _II

277

4.8.4 MAIZE STAIRS

Maize Stairs We took the same three types of logic from the wall designs and developed it into a more 3-dimensional language, incorporating a solid architectural element : the staircase.

278

ii.

i.

iii.

279

4.8.4 MAIZE STAIRS

We explored many different preliminary staircase designs to achieve a certain balance between weight and transparency as well as standard building members alongside CoRncrete units.

280

281

4.8.4 MAIZE STAIRS

~~CORNCRETE

282

STAIRCASE~~

283

4.8.4 MAIZE STAIRS

284

285

4.8.4 MAIZE STAIRS

286

287

4.8.4 MAIZE STAIRS

288

289

4.8.4 MAIZE STAIRS

TYPE_A SCATTER / ITERATION_N

290

stairs scatter stairs i: component_stairs_A stairs ii: component_stairs_B stairs iii: component_stairs_C edge scatter edge i: component_edge_A edge ii: component_edge_B wall scatter wall i: component_catchment_A wall ii: component_scale_A

291

4.8.4 MAIZE STAIRS

TYPE_C TIERED / ITERATION_i

292

stairs tiered stairs i: component_stairs_A edge tiered edge i: component_edge_A edge ii: component_edge_B wall tiered wall i: component_scale_B wall ii: component_scale_C

293

4.8.4 MAIZE STAIRS

TYPE_B ATTRACTOR / ITERATION_i

294

stairs attractor stairs i: component_stairs_A stairs ii: component_stairs_C edge attractor edge i: component_edge_A wall attractor wall i: component_scale_B wall ii: component_scale_A wall iii: component_catchment_A

295

4.8.4 MAIZE STAIRS

attractor zones scatter catchment

attractor zones scatter catchment

attractor zones scatter catchment

attractor zones scatter catchment

attractor zones scatter catchment

attractor zones scatter catchment

Staircase Assembly Variation logics 296

density type scatter

density type scatter

density type scatter

density type scatter

density type scatter

density type scatter

Railings Assembly Variation logics 297

4.8.4 MAIZE STAIRS

298

when architecture becomes object contextless ................................................................................. how do you connect it back to reality?

299

4.8.5 CATENARY STRUCTURES

Vault - shape studies

300

301

4.8.5 CATENARY STRUCTURES

Vault - shape studies

1

2

3

4

5

Form diagram 302

Force diagram

Wireframe

Color analysis 303

4.8.5 CATENARY STRUCTURES

Dark Camoflauge

Centre Concentrated

304

Light Camouflage

Dark Centre Concentrated

Regional Division

Regional Division II

Half n’ Half

Half n’ Half Concentrated

305

4.8.5 CATENARY STRUCTURES

Centre Concentrated

306

Component 8

Component 1

Compressive force analysis

Component 4

Component 7

Component 5

Form diagram

Force diagram

307

4.8.5 CATENARY STRUCTURES

Contextual integration

308

User Experience

309

4.8.6 MICROWAVE ARMY

This proposed multi-disciplinary system enables patrons to contribute to the design of civic structures through the active participation of learning to fabricate their own units. The microwave is a revolutionary architectural tool that is easy to use and widely available, making it a perfect tool to allow for quick customization on the fly, no matter what context.

310

fabrication method

DIY fabrication

end design

QUICK construction

Design feedback

311

4.8.6 MICROWAVE ARMY

LOCAL ribution

LOCAL DIY distribution fabrication

DIY LOCAL brication ribution

QUICK LOCAL DIY construction distribution fabrication

LOCAL DIY ribution brication

LOCAL DIY QUICK distribution fabrication construction

312

DIY QUICK fabrication construc

~~MICROWAV

DIY QUICK fabrication construc

DIY QUICK fabrication construc

LOCAL DIY distribution fabrication

VE ARMY~~

DIY QUICK fabrication construction

LOCAL DIY distribution fabrication

DIY QUICK fabrication construction

LOCAL DIY distribution fabrication

DIY QUICK fabrication construction

313

4.8.6 MICROWAVE ARMY

Distribution Systems [ready-made packages] [amount of material]

water

coRncrete package

sand corn starch

Design

314

Mold

Unit

Unit

Manufacture

Manufacture

Assembly

Assembly

315

4.8.6 MICROWAVE ARMY

Unit Customisation [community involvement] [plug-in components] [makeshift, on-the-fly]

316

make

LOCAL LOCAL distribution distribution LOCAL distribution

local distribution

arrange

DIY DIY fabrication fabrication DIY fabrication

DIY fabrication

plug-in

QUICK QUICK construction construction QUICK construction

rapid construction time

317

4.8.6 MICROWAVE ARMY

Aggregation Study growth of structure throughout time citizen-developed plug-in units

318

319

4.8.6 MICROWAVE ARMY

320

Pixelated Pavilion initial proposal for small-scale community-led intervention

321

4.8.6 MICROWAVE ARMY

322

Pixelated Pavilion showing early concepts of massing and programme organization 323

4.8.6 MICROWAVE ARMY

324

Pixelated Pavilion showing the conceptual framework of community DIY involvement and civic participation 325

4.9 FURTHER CORNCRETE APPLICATIONS AND SYSTEMS

326

327

4.9 FURTHER CORNCRETE APPLICATIONS AND SYSTEMS

Plinth and Column study

328

00 00 00.00

00 01 00.00

00 04 00.00

00 05 00.00

00 02 00.00

00 03 00.00

00 06 00.00

00 07 00.00

329

4.9 FURTHER CORNCRETE APPLICATIONS AND SYSTEMS

330

331

4.9 FURTHER CORNCRETE APPLICATIONS AND SYSTEMS

332

333

4.9 FURTHER CORNCRETE APPLICATIONS AND SYSTEMS

334

335

4.2.6 FURTHER CORNCRETE APPLICATIONS AND SYSTEMS

To further push the architecture, we began to explore the shortest path script that could wrap around the packing octahedrons to serve as secondary structure and also as a dynamic sprawling spatial grid.

Shortest Path Scaffold

336

337

4.2.6 FURTHER CORNCRETE APPLICATIONS AND SYSTEMS

branching abstraction

338

detail of unit catchment

shortest path scaffold on a column design

semi-solid octahedron lattice column

339

4.2.6 FURTHER CORNCRETE APPLICATIONS AND SYSTEMS

Hybrid System Scaffolding plug-in

aperture

340

Future Possibilities Architecture Elements

staircase

horizontals

341

4.2.6 FURTHER CORNCRETE APPLICATIONS AND SYSTEMS

342

staircase digital design study

343

344

CHAPTER 5.

ARCHITECTURE SPECULATION

345

5.1 CORNCRETE + BRANCHING FACADE SPECULATION

To accommodate the hybrid system of the shortest path and truncated octahedron packing, we tested the script in a traditional townhouse that could be found in London. This type of system showcases a new paradigm of facade construction methodologies and design.

346

347

5.1 CORNCRETE + BRANCHING FACADE SPECULATION

infill site

levels

filled structure

add-on balconies

ISOMETRIC VIEW: GROWTH FACADE STUDY UNITS CAN BE BAKED AND ADDED OVER TIME DEPENDING ON TIME RESTRAINTS AND PATRONS’ PREFERENCES

348

scaffolding

base units

base units

......

......

completion

349

5.1 CORNCRETE + BRANCHING FACADE SPECULATION

350

scaffolding

base build-up

base completion

add-on balconies

ELEVATION VIEW: GROWTH FACADE STUDY UNITS CAN BE BAKED AND ADDED OVER TIME DEPENDING ON TIME RESTRAINTS AND PATRONS’ PREFERENCES

351

352

353

5.1 CORNCRETE + BRANCHING FACADE SPECULATION

EXPLODED AXONOMETRIC GROWTH FACADE STUDY UNITS CAN BE PERSONALIZED AND BUILT TO INDIVIDUAL TIME PREFERENCES OR PROGRAMMATIC SPATIAL REQUIREMENTS SHELF

BOAT

354

CORAL

BOAT SPIKE

SPIKE

SMOOTH

BASE

BASE

WAVE

BRANCHING

355

356

357

358

359

5.1 CORNCRETE + BRANCHING FACADE SPECULATION

The CoRncrete aggregations displayed here are fabricated and installed by the community members. Some of the units are even hosting microbial and flora growth. The microwave army has invaded the neighborhood!!

360

361

5.2 ZOOMED-IN FACADE DETAIL SPECULATION

furniture condition

362

elevation

external

potential facade exploded view

363

5.2 ZOOMED-IN FACADE DETAIL SPECULATION

364

Final

facade detail piece to be built

reconfigurable installation

window detail acts as bottom sash and bench

365

5.2 ZOOMED-IN FACADE DETAIL SPECULATION

366

Final

facade detail piece to be built 367

5.2 ZOOMED-IN FACADE DETAIL SPECULATION

Components to be used for the facade detail

boat component spike+coral component shelf component half component smooth component

base component

connection pieces: metal tube

368

Connection system

metal tube

structural system: metal tube connection piece

point grid to be filled with components

369

5.2 ZOOMED-IN FACADE DETAIL SPECULATION Early facade detail studies

Generation of flat surfaces out of previously designed components

370

Spatial grid design on facade detail studies

truncated octahedron spatial grid detail

truncated octahedron spatial grid could be less controlled

371

5.2 ZOOMED-IN FACADE DETAIL SPECULATION

Final facade piece exploded view

Components #

0

372

10

5

4

1

16

Final facade piece views

component’s contrast

outer facade

inner facade

373

5.2 ZOOMED-IN FACADE DETAIL SPECULATION

374

Details views

375

5.2 ZOOMED-IN FACADE DETAIL SPECULATION

376

377

CHAPTER 6.

REFERENCES

378

1. “Army Ants Build Living Bridges.” EarthSky. Accessed

October 29, 2018. https://earthsky.org/earth/army-ants- build-living-bridges.

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