ROBLOX Robotic Assembly of Ultra High Performance Concrete Blocks
Research Cluster 4 Gilles Retsin, Manuel Jimenez Garcia, Vicente Soler Senent A-HEY team: Anna Uborevich-Borovskaya, Yenfen Huang, Chenghan Yu, Hungda Chien
2017 Bartlett School of Architecture UCL
01| PROJECT OVERVIEW 1.1 Studio Brief 1.2 Thesis Statement 1.3 Thesis Orientation 02| DESIGN RESEARCH 2.1 Tile Design 2.2 Loop + Long tile 03| MATERIAL + FABRICATION 3.1 Material Research 3.2 Material Tests 3.3 Fabrication 04| REVERSIBILITY: JOINTS 4.1 Joint Studies 4.2 Joint Test 05| ROBOTIC ASSEMBLY 5.1 Robotic Arm 5.2 End Effector 5.3 Test 06| COMPUTATIONAL LOGIC 6.1 Choosing a System 6.2 Combinatorics Library 6.3 Dom-ino Versions 07| ARCHITECTURAL SCALE 7.1 Wall and floor systems 7.2 Physical Prototype
PROJECT RENDER
01 | PROJECT OVERVIEW
PROJECT OVERVIEW| Studio Brief
The research cluster (RC4) explores the use of such technologies as Robotic arms and 3D printing in the arhictectural design. The studio is interested in architecture that is both digital by design and digital as physical object. (Retsin and Jiménez). Essential for the cluster researches is the theory of “Digital Material” originated at the MIT by professor Neil Gershenfeld. For Gershenfeld (2006) it is a material that is treated as a set of independent units that have a discrete representation in both the design process and as a physical output. There are many references in architecture which explores discrete assembly of the different pieces.
MickeyMatter (Bartlett RC4, 2016)
WireVoxels (Bartlett RC4, 2016)
Furniture - Column
Abstract Structure
ROBOTIC ASSEMBLY
INT (Bartlett RC4, 2016)
DISCRETE DESIGN SMALL SCALE 8
Furniture
PROJECT OVERVIEW| Project Brief
The case-study project «Roblox» considers the possibilities of using robotics at the large architectural scale and contributes to the discrete and digital architecture. Today, a conventional building process is “close-ended”, meaning that the outcome is irreversible and not modifiable. This project aims to introduce an “open-ended” construction process which can be further modified due to a reversible, discrete and combinatorial system. A digital building block have been created that combines with itself in several ways, and that is suitable for the robotic assembly. Rather than creating hundreds of different elements, the research is focused on creating high-varied and articulated space with only one type of standardised building block and its elongated version. The block is reversible due to its unique interlocking system that allows snapping units together like Lego pieces. As the project aims to be fully reversible, we avoid usage of glue or any other joining material. Instead, the pieces are connected with steel joints and screws.
Based on the appliance of a concrete pre-casting system, we use moulding method for the mass-fabrication of the pieces. Building blocks can be robotically assembled into different structures, from small pavilions up to large-scale buildings, with the possibility of being constructed whether on-site, by one robot, or off-site using a Gantry system with hanging robots. The coding of the block and engineering calculations allow to automate the design of the structure and lead to a space optimisation. The design of a building particularly depends on the amount of building blocks. The number can be reduced or increased according to different circumstances, such as cost, time available for construction or user preferences. The long piece is also a part of the coded design, and it helps to reduce the amount of blocks needed for a construction and therefore makes the structure more stable. Additionally, this research explores the possibilities and limitations of Ultra High Performance Concrete (UHPC) which is 6 to 8 times stronger than conventional concrete and its longevity is 2 to 3 times longer.
RobloX (Bartlett RC4, 2017) Key points of the project are:
REVERSIBLE MATERIALS
SCALE OF ARCHITECTURE
- Reversibility and Dicreteness - Material and Geometry optimization - Automated Robotic assembly
Pavillion/Small House
LARGE SCALE 9
PROJECT OVERVIEW| Thesis Statement
Discrete element
Interlocking system
Architectural scale
Automated On-site Assembly
10
Common concrete block
Weight Optimization
Scalability
Automated Off-site Assembly
11
PROJECT OVERVIEW| Thesis Statement
On-site Concrete Casting Pros:
High Laborious/High Flexibility
Cons:
Time-Consuming/ Low-Accuracy
Prefabricated Concrete
12
3D-Printed Concrete Wall (XTreeE, 2015)
Prefabricated/3D-Printed Villa Roccia (Gardiner J.B., 2010)
Pros:
Efficient Building Process/ High Accuracy/Durable
Free-form
Efficient Building Process/ High Accuracy/Durable
Cons:
Low Flexibility
Time Consuming/Costly
Time Consuming/Costly/ Mass-Customized
Flexibility Discrete Blocks
Sustainable Reversible Joint
Efficient Prefabricate Tile
Durable + Light UHPC +Foam
RobloX (Bartlett RC4, 2017)
Fast Built Automatic Assembly
13
Pre-Fab Construction SYstem
PROJECT OVERVIEW| Pre-Fabricated System 2.0
High-efficient Mass-production Line
Heavy-weigh
One-type Building Components (combinatorics system)
Standardized Mass-Production Line
Light-wei ments(Aut
RobloX Pre-Fabricated System 2.0
Multi-type Building Components (Slab/Column/Stair)
14
ht Building Elements (crane)
ight Building Eletomatic Assembly)
Pre-embedded Connection Part
Homogeneous/ Standardized Result
Easily-Assembled Connection Part (Reversibility)
Heterogeneous/ Highly-variated Form Generation
15
PROJECT OVERVIEW| Thesis Orientation
In order to fulfill the appliance of Digital Material at the scale of architecture, this project explores the potential aggregation method with same unit to maximized the shelter space with minimal numbers of units. In order to increase the efficiency of forming space in certain number of units, this project applies loop aggregation system to form the larger space with less number of units. Looking to the references such as “Bloom” project and “Cuboct Lattice” we are exploring the maximal potential of interlocking system. We have create unique joints which makes the architectural process being open-ended.
CLOSE-ENDED ARCHITECTURAL PROCESS Continious Design
3D Printed Concrete (Andrey Rudenko, 2014)
16
Fossilized by Amalgamma (Bartlett RC4, 2015)
ICD/ITKE Research Pavilion (University Stuttgart, 2015-16)
Acoustic Bricks (ETH Zurich, 2012-14)
DIGITAL MATERIAL
The concept of Digital Material (Gerschenfeld et al 2015) originated at MIT Center for Bits and Atoms, and is designated to refer to such materials can be reversibly assembled from a discrete set of parts to other configuration with infinite translation by relative positions and orientations in space (Gerschenfeld et al. 2015).
OPEN-ENDED
Discrete Design + User Engagement
Climbable Wooden Pavilion (Kengo Kuma, 2015)
Bloom (Andrasek et el, 2012)
Cuboct Lattice (MIT Center for Bits and Atoms, 2013 )
Polyomino 3 (USC, J. Sanchez, 2014)
17
PROJECT OVERVIEW| Thesis Orientation REVERSIBILITY - JOINTS
Reversibility - Joints Our project aims to be fully reversible. To achieve this we have create unique joints which makes the architectural process being open-ended. Scale of Discrete Design In order to fulfill the appliance of Digital Material at the scale of architecture, this project explores the potential aggregation method with same unit to maximized the shelter space with minimal numbers of units. Robotic Assembly The industrial robot is used for pick-and-place tasks, replacing manual work in order to commit repetitive, dull motions assembling the blocks together. The robot is controlled through computational data and programmed to pick-up the blocks one by one, orient them and put at the right place in accordance with the design order. The original motive of using automatic assembly is to increase the productivity and economy of building construction which also leads to higher accuracy and a diminution of construction errors. Two scenarios of the robotic assembly are developed: for both on- and off-site assembly construction.
Interlock (25%) + Glue (75%)
Mickey Matter (Bartlett RC4, 2016)
Interlock (60%) + Glue (40%)
Fully Revfersible
INT (Bartlett RC4, 2016)
Interlock(100%)
Interlock(100%)
18
RobloX (Bartlett RC4, 2016)
SCALE OF DISCRETE DESIGN
USER ENGAGEMENT
Large
Bloom (Andrasek et el, 2012)
Bloom (Andrasek et el, 2012)
Robotic Assembly and User Engagement
Mickey Matter (Bartlett RC4, 2016)
Mickey Matter (Bartlett RC4, 2016)
Scale of Architecture
INT (Bartlett RC4, 2016)
Acoustic Bricks (ETH Zurich, 2012-14)
INT (Bartlett RC4, 2016)
Small
Climbable Wooden Pavilion (Kengo Kuma, 2015)
WireVoxels (Bartlett RC4, 2016)
Acoustic Bricks (ETH Zurich, 2012-14)
RobloX (Bartlett RC4, 2016)
Roblo X (Bartlett RC4, 2016)
ROBOTIC ASSEMBLY
19
02 | DESIGN RESEARCH
21
DESIGN|Tile Design
Every geometry can be divided to triangles which means that its flexibility allowes adaptation of various directions for combinatorics. On the other hand, square and rectangle are always growing in vertical and horizontal directions. We combine both in order to create complexity and controllable discrete assembly. The tile is generated from 7 regular triangles and extruded with the same length of side. There are 8 faces for each tile, which is separated to two combinational systems. The red faces are generated from squares and the blue faces are from the regular triangles. Faces can be only combined with the same faces of color.
a
a a
a a
a a
3a 2a
a
22
a
1
2
4
5
7
8
3
6
23
DESIGN| Combinational Areas
All the possible Combinational Areas
24
DESIGN| Initial Design
Front view
Back view
6 different design types were invented, one is chosen according to the Joint type and Robotic assembly strategy
25
DESIGN| Loop System
With less tiles needed to be assembled, the process will be more efficient. One loop can be seen as two the same parts which are combined by rotating. There are 8 faces that can be connected to each. Full hierarchical approach : from single unit to single loop to pattern part to Meta-Part Takes less time for aggregation. Minimizes amount of units in order to create maximum of space. a
e
b
f
c
g
d
h
Vertical
Horizontal
Loop Tile A
26
Loop Tile B
Loop A + Loop AL
oop A + Loop AL
oop A + Loop A
Loop A + Loop AL
oop A + Loop AL
oop A + Loop A
Loop A + Loop AL
oop A + Loop AL
oop A + Loop A
Loop A + Loop AL
oop A + Loop AL
oop A + Loop A
Loop A + Loop AL
oop A + Loop B
Loop A + Loop B
Loop A + Loop B
Loop A + Loop B
Loop A + Loop B
Loop A + Loop B
Loop A + Loop B
Loop A + Loop B
Loop A + Loop B
Loop A + Loop B
27
DESIGN| Long Tile
Long tile is 5 times length of the small tile. The small tile generates many weak points when it be connected to the long element. Usage long loop tiles also makes the building lighter (instead of many small loop tiles).
a
28
5a
29
03 | MATERIAL + FABRICATION
31
PHYSICAL MODELS| 10mm 1:1 Concrete Block
• Phase I: Plywood | LaserCut
Joint System Cons 32
Clipping System Cannot be Mass-Produced
• Phase II: Conventional Concrete| Molding, Casting
Sliding System Weak Joint/ Material Strength
• Phase III: UHPC (Ultra-High-Performance Concrete)| Molding, Casting
Nuts +Screw High Difficult Molding Techniques
• Phase IV: Geometrical Optimization for UHPC
Nuts +Screw Easier to be Cast 33
34
First Physical model prototypes Lasercut plywood
35
MATERIAL & FABRICATION| Methods Comparison
MASS PRODUCTION
Pros & Cons
Materials
Molding/Casing
36
Thermoforming (vacuum forming/ Blow thermoforming)
MASS CUSTOMIZATION
Extrusion/ FDM (Fused Depostition Modeling)
CNC Milling
Laser Cutting
Concrete, Plaster, Thermoplastic (PETG, PVC, PETE, Acrylic, epoxy, polyester, urethane)
Thermoplastic (PETG, PVC, PETE, Acrylic, epoxy, polyester, urethane)
Premium-grade polymers: ABS, PLA, PC (polycarbonate)
Wood, aluminium, steel, plastic, foam, fiberglass, brass, copper, titanium and others)
Paper, wood, acrylic, aluminium, steel, plastic and others)
Easy Deformation and Mass production, a need in a male and female mold to fabricate
Easy Deformation and Mass production, a need in a male and female mold to fabricate
Quite high printing resolution, however it is very time consuming
Easy to operate, presize, however only “2D fabrication�
Injection/pouring position matters a lot
Joint parts - need to take into consideration
2D bottom-up milling method, very material consuming (object cannot be hollow), thus, also cost consuming
MATERIAL & FABRICATION| Material Properties Chart
PLA PLA
ABS ABS
PETG(PETE) (PETE) PETG plastic plastic
Fabrication Method
Extrusion (3D Print)
Extrusion (3D Print)
Vacuum/Blow Thermal Forming
Flexibility (Elasticity)
fair
high
high
Strength
fair
fair
high
high
Acrylic Acrylic
Thermal Properties
Concrete
UHPC UPHC
Steel Steel
CNC milling
Molding
Molding
Water Jet milling
poor
poor
poor
poor
high
high
ultra-high
high
none
none
none
none
£/m2
1mm-11.9 £/m2
Laser Cutting
fair
fair
fair
fair
fair
fair
fair
high
high none
none
1mm-11 £/m2 light
light
light
excellent
excellent
excellent
173 oc
105 oc
Weight Water resistance
Hardwood Hardwood
Laser Cutting/ CNC milling
25 £/m2
Cost
MDF
Laser Cutter
Transparency 25 £/m2
Plywood Plywood
260 oc
1mm-10 £/m2
fair
excellent
160 oc
6mm-13.6£/m2
6mm- 4.3 £/m2
3.7 £/1000cm2
1.5 £/kg
heavy
fair
heavy
heavy
heavy
heavy
poor
poor
poor
good
good
good
100 oc
100 oc
100 oc
inflammable
inflammable
1370 oc
37
MATERIAL & FABRICATION| Concrete Fabrication
There are two main factors while initially conducting material and fabrication tests. First was that the fabrication method can be mass-produced at the scale of economy and time and the second was such material can be applied at the scale of architecture. In this project, it is aimed at looking into the molding techniques in appliance of concrete. As solid concrete blocks are heavy and hardly could be lifted by human beings, the material exprements focuse on the integration of multiple materials for blocks optimization. The tile was first tested by placing different thickness of polystyrene inside concrete blocks. Yet, with such optimazation method, the strength of building blocks might be insufficient if it is casted by conventional concrete. In order to tackle this issue, the new material was introduced, called UHPC (Ultra-High Performance Concrete). Its strength is 6 to 8 times greater than that of conventional concrete. At the meanwhile, it contains glass fibers that make it ductile as well as help this new concrete resist bending and withstand major transformation, such as compression or tension, without breaking. Through introducing such material, the desired qualities of light-weight, high-strength and efficient production process can be obtained.
Concrete Framework Polystyrene Balls + Concrete Concrete Concrete Framework Framework Polystyrene Polystyrene Balls Balls + Concrete + Concrete
Concrete Prefabrication Connection 1.Hollow Slab to Reduce Self-weight Concrete Concrete Prefabrication Prefabrication Connection Connection (Metal Pipe/ Polystyrene Balls) Concrete Prefabrication Connection 1.Hollow 1.Hollow Slab Slab to to Reduce Reduce Self-weight Self-weight 1. Hollow Slab to Reduce Self-weight (Metal Pipe/Polystrene Balls) (Metal (Metal Pipe/ Pipe/ Polystyrene Polystyrene Balls) Balls)
2.Pre-Embedbed Connection Part for Joint 2.Pre-Embedbed 2.Pre-Embedbed Connection Connection 2. Pre-Embedbed Connection Part Part for for Joint Joint Part for Joint
Concrete Framework Polystrene Balls + Concrete
38
Molding Work Molding Molding Work Work Molding Work
#8 mm
Foam balls
# 3mm
# 3mm + Aggregates + PVA (unsuccessful)
# 3mm + PVA
Weight
279g
369g
196g
124g
194g
Pros
High-Pressure Strength/ High Fluidity
High-Pressure Strength/ Easy Deform/ Very High Fluidity
Light
Light/ Elastic
Light and Solid
Cons
Heavy
Heavy/ Shuttered Edges
Shuttered Edges/ Fragile
Long Solidification Process
Low fluidity
Decision
V
39
CONCRETE FABRICATION| Molding of 10mm 1:1 Concrete Block
PouringPosition Position Pouring
From Top
Number Molding Piece Number of of Molding Piece
7 Pieces
Thickness ofofConcrete Thickness Concrete of Polystrene) (Size(size of Polystyrene)
Pre-embedded Pre-embedded Connection Parts Parts + Washer Connection
10 mm
From Top
Height ←→ -- Pressure Height Pressure
40
Number of Pieces Number of Piece -- Convenience ←→ Convenience
Thickness Self-weight Thickness ←→-- Self-Weight
Secondary Structure Secondary Structure + Joint parts + Joint Parts
CONCRETE FABRICATION| Molding test
Casting Material
Cement Proportion
8:
Weight
2000 g
UHPC
Mixture
Hydrocal
Water
PVA
3:
1
Filling
Polymorph
Polystyrene
Polystyrene Balls
Offset 8mm
Metal Wool
Metal Wires
slightly
slightly
1000 g
Top
Thickness Thickness Weight Front
Weight
5-8 mm 5-8 mm 3470 g (unsucessful)
3470 g (unsucessful)
41
CONCRETE FABRICATION| Molding of 8mm Concrete Block
PouringPosition Position Pouring
Number Molding Piece Number of of Molding Piece
From Top
From Top
Height ←→ -- Pressure Height Pressure
42
Thickness ofofConcrete Thickness Concrete of Polystrene) (Size(size of Polystyrene)
Pre-embedded Pre-embedded Connection Parts Parts + Washer Connection
5-8 mm
4 pieces
Number of Pieces Number of Piece -- Convenience ←→ Efficiency
Thickness Self-weight Thickness ←→-- Self-Weight
Secondary Structure Secondary Structure + Joint parts + Joint Parts
CONCRETE FABRICATION| Molding test
Casting Material
Cement Proportion
8:
Weight
2000 g
UHPC
Mixture
Hydrocal
Water
PVA
3:
1
Filling
Polymorph
Polystyrene
Polystyrene Balls
Offset 8mm
Metal Wool
Metal Wires
slightly
slightly
1000 g
Top Top
Thickness Thickness
Front Front
5-8 mm 10 mm
Thickness 10mm Weight g3470 (unsucessful) Weight 34703470 g Weight g
43
CONCRETE FABRICATION| Internal Structure
Male Piece Female Piece Threaded Rods Hollow Steel Stick
Metal struture is inserted in order to apply the joint system. a. Primary Structure:Steel stick (rectangular in section) b. Secondary StructureThreaded rod c. Joint PiecesScrew nuts + metal sheets (using waterjet and bending machines) With internal metal structural frame the joint strength is high enough for the concrete unit.
Polystyrene
(+) Male Unit
Physical model photos
44
(-) Female Unit
+
Internal metal structure
45
CONCRETE FABRICATION| Molding 10mm 1:1 Concrete Block
Pouring PouringPosition Position
From Top
Number of of Molding Piece Number Molding Piece
7 Pieces 7 Pieces
Thickness Concrete Thickness ofofConcrete (size of Polystrene) (Types of Polystyrene)
Pre-embedded Structure Frame Connection (ThreadedParts rod/ Nuts)
#10mm
Foam10mm Block+Foam block + Foam Balls Foam Balls
From Side
Height -- Pressure
Height ←→ Pressure
46
Number of Pieces -- Convenience Number of Piece ←→ Convenience
Centre of Weight
Centre of Weight
Secondary Structure + Joint parts Structure Frame + Joint Parts
CONCRETE FABRICATION| Molding (improved) Test
Casting Material
Cement Proportion
8:
Weight
3000 g
UHPC
Mixture
Hydrocal
Water
PVA
3:
1
Filling
Polymorph
Polystyrene
Polystyrene Balls
Metal Wool
Metal Wires
Partial(#10mm )
Partial
slightly
slightly
1500 g
Top
Thickness 10-12mm + foam balls Thickness 10-12 mm + Foam balls Weight 5350 g Front
Weight
Front
Left
Right
5350 g Top
Bottom
Back
47
CONCRETE FABRICATION| Comparison Among Conventional Concrete Blocks
#10 mm
# 8mm + Joint
# 10mm + Foam Balls+ Joint
Weight
3470g
3750 g
5350g
Pros
Easy Cast/ Light
Cons Decision
48
Stronger Concrete Piece Hard to be Casted
Heavy V
CONCRETE FABRICATION| Conclusion
1. Weak Joint: Triangle Joint Block’s Own Weight ←→ Joint Strength
2. Material Strength Concrete Thickness ←→ Material Properties
49
CONCRETE FABRICATION| UHPC material
This research explores the possibilities and limitations of Ultra High Performance Concrete (UHPC) which is 6 to 8 times stronger than conventional concrete and its longevity is 2 to 3 times longer. “Ductal UHPC is an innovation that is ideal for architectural and structural creativity and for renovation, which helps to reduce construction costs and extend the usage life of buildings and structures.” (c) Ductal
Ductal Concrete Formula
a. Ductal Concrete Formula
Ductal F4 Cement
DuctalF4 F4 Ductal Cement Cement
Water
Weight
Proportion
2086 g
12
2086 2086 gg 170 g
24.9 g
Fiber
38 g
→
High Proportion of Cement 12 Surface 12 ←→ Mold
High Proportion of Cement ←→ Mold Surface
MDF
Plywood
Tape
MDF
0.3
0,15 0.15 Increase Tension Force
3838 g g
0,3 0.3
(O) Tension (with Fibers)
(X) Tension
Increase Tension Force (O) Compression
50
→
PVC Sheet
11
(O) Compression
Fiber Fiber
PVC Sheet
0.15
25gg 24.9
Fluidizer Fluidizer
Proportion Proportion
1
170170 gg
Water Water Fluidizer
Weight Weight
(O) Tension (with Fibers)
Jean Bouin Stadium, France; UHPC Roof and Faรงade Panels
51
TEST 1 Casting Material
Cement
UHPC
Mixture
Hydrocal
Water
PVA
Filling
Plasticizer
Polystyrene
Polystyrene Balls
Metal Wool
Glass Fiber
Proportion
84
7
1
1.5
Weight
1250
85
12.5
19
Top
Mold Material Result Mold Material Thickness Weight Result
Thermal Plastic Sheet Sticky/ Low-Fluidity Thermal Plastic Sheet Whole UHPC 750Sticky/ g Low-Fluidity
Thickness
Whole UHPC
Weight
Front
750 g
TEST 2 Casting Material
Cement
UHPC
Mixture
Hydrocal
Water
PVA
Filling
Plasticizer
Polystyrene Offset #3-5mm
Proportion
84
8
1
Weight
1043
100
12.5
Polystyrene Balls
Metal Wool
Glass Fiber 1.5 19
Top
Mold Material
Mold Material
Thermal Plastic Sheet
Thermal Plastic Sheet
Thickness 3-5 mm + Foam block
Result
Weight Thickness
52
Front
Weight
Light, Medium Fluidity
300 g mm + Foam block 3-5
300 g
TEST 3 Casting Material
Cement
Mixture
UHPC
Hydrocal
Water
Filling
PVA
Plasticizer
Polystyrene Offset #5-8mm
Proportion
84
8
1
Weight
1043
100
12.5
Polystyrene Balls
Metal Wool
Glass Fiber 1.5 19
Top
Mold Material Mold Material Result
Thermal Plastic Sheet Thermal Plastic Sheet Light, Medium Fluidity
Result
Light, Medium Fluidity
Weight
350 g
Thickness 5-8 mm + Foam block Weight 350 Thickness 5-8g mm + Foam block Front
TEST 4
Cement Proportion Proportion Weight Weight
Casting Material Casting Material
Cement
UHPC 100
Mixture
UHPC Hydrocal Hydrocal Water 100
1250
1250
16
Water 16
PVA
Mixture
PVA
Filling
Polystyrene Plasticizer Polystyrene Metal Wool Glass Fiber Polystyrene Balls Plasticizer Polystyrene Metal Wool Glass Fiber Balls 1 Offset #10mm 1.5 1
200
200
Filling
Offset #10mm 12.5
1.5
12.5
Mold Material
Limitation of Water Limitation of Water
19
19
MDF + Plywood
Mold MDF MDF + Plywood MoldMaterial Material + Plywood Result High Fluidity, Half Successful Result High fluidity, Half Successful Thickness 10-12 mm + Foam block Result High fluidity, Half Successful Weight 110 g Thickness 10-12 mm + Foam block Front Front
Top Top
Thickness Weight Weight
10-12 mm + Foam block 110 g 110 g
53
UHPC| Fabrication Process
Powder + Water + 1/2 Fluidizer
54
Mixing (Chemical Reaction)
Another 1/2 Fluidizer
Add Glass Fibers
Mixing
Casting: pouring material into the mold
55
TEST 5 Casting Material
Cement
UHPC
Mixture
Hydrocal
Water
PVA
Filling
Plasticizer
Polystyrene Offset #5-8mm
Proportion
84
8
1
Weight
1043
100
12.5
Polystyrene Balls
19
Thickness
TEST 6
Proportion Proportion Weight Weight
Casting Material Casting Material
Cement Cement
UHPC UHPC 84
Mixture Mixture
Hydrocal Hydrocal
Water Water 8
MDF + Plywood Light,MDF Medium Fluidity + Plywood 5-8mm + Foam block inside 1250 g Medium Fluidity Light,
5-8 mm + Foam block
Weight
Top
PVA PVA
Glass Fiber 1.5
Mold Material Result Mold Material Thickness Weight Result
Front
Metal Wool
1250 g
Filling Filling
Plasticizer Plasticizer 1
84 1043
8 100
1 12.5
1043
100
12.5
Polystyrene Polystyrene
Offset #5-8mm Offset
Polystyrene Balls Polystyrene Balls
Metal Wool Metal Wool
Glass Fiber Glass Fiber
#5-8mm
1.5
1.5 19 19
Mold Material
Plywood + Tape/ Spray Painting
Mold Material Plywood Tape/Spray Mold Material Plywood + +Tape/ Spray Painting Painting Result Light, Mediun Fluidity Result Light, Medium Fluidity Thickness 5-8mm Foam block Result Light,+Medium Fluidity Thickness 5-8gmm + Foam block Weight 1500
56
Side (Spray Painting)
Front (Tape)
Side (Spray Painting)
Front (Tape)
Thickness Weight Weight
5-8 mm + Foam block 1500 g 1500 g
UHPC
# 5mm
# 8mm
# 10mm + Plywood/MDF
# 8mm + Plywood
Mold
Thermal Plastic
Thermal Plastic
Thermal Plastic
MDF/Plywood
Plywood + Tape/Spray Paint
Weight
750 g
300 g
350 g
1250 g
1500 g
Result
Glossy Surface
Glossy Surface
Glossy Surface
MDF-Furry Surface Plywood- Coarse Surface
Tape- Glossy Spray Paint- Mat Glossy
Decision
V
Conclusion of testing
57
CONCRETE FABRICATION| Molding 8mm 1:1 UHPC Block (no joint)
Pouring Position
From Top
Height -- Pressure
58
Number of Molding Piece
7 pieces
Number of Pieces -- Convenience
Thickness of Concrete (size of Polystrene)
Pre-embedded Connection Parts
8 mm
Thickness -- Self-weight
Secondary Structure + Joint parts
MATERIAL TESTING| 8mm UHPC Plain Block and 8-10mm UHPC Block with Engraved Pattern Casting Material
Cement
UHPC
Mixture
Hydrocal
Water
PVA
Filling
Plasticizer
Polystyrene offset #8mm
Proportion
84
8
1
Weight(g)
5215
500
62.5
Polystyrene Balls
Metal Wool
Glass Fiber 1.5 95
Top
Mold Material Mold Material Result Thickness Result Weight
Plywood + Tape Plywood + Tape to be continued 8mm + Foam block To be continued xxx g
Thickness Weight
Front
Casting Material
Cement
UHPC
8 mm + Foam block XXX g
Mixture
Hydrocal
Water
PVA
Filling
Plasticizer
Polystyrene offset #8-14mm
Proportion
84
8
1
Weight(g)
5215
500
62.5
Polystyrene Balls
Metal Wool
Glass Fiber 1.5 95
Top
Mold Material Result Mold Material Thickness Result Weight
Thickness Front
Weight
Plywood to be continued Plywood 8mm + Foam block xxx gTo be continued
8mm + Foam block XXX g
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CONCRETE FABRICATION| Rubber Joint Part
Bottom
Vinamold rubber is used for the fabrication process. It helps to take easily the concrete out of the wood mold. (X) Wood Joint Mold Cannot Remove ↓ (O) Rubber Joint Mold Elastic, Easy too be Removed
Bottom Top
(X) Wood Joint Mold Cannot Remove ↓ (O) Rubber Joint Mold Elastic, Easy too be Removed Top Front
Front
Vinamold Rubber Vinamold Rubber
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Vinamold Rubber Melting Point： 140-150°C
Vinamold Mold Parts
Vinamold Mold Parts
Vinamold Joint Pockets
Vinamold Rubber Vinamold Joint Pockets
Vinamold Rubber Melting Point: 140-150C
Vinamold Rubber Melting Point 140-150°C
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CONCRETE FABRICATION| New Molding Techniques – Wood + Rubber
Pouring Position
Number of Molding Piece
Thickness of Concrete (size of Polystrene)
Pre-embedded Connection Parts
Thickness -- Self-weight
Secondary Structure + Joint parts
From Top
From Top
Height -- Pressure
(Top) Photo of the Mold and Foam
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Number of Pieces -- Convenience
(Persp) Photo of the Mold and Foam
Phtoto of the ready concrete section
Tubes
Coating (Spray Paitnting/Tape) Plywood Mold
UHPC
Threaded Rods Polystyrene (offset 5-11mm)
Rubber Packets (Joint Piece Mold)
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Physical model of the section with a steel joint (UHPC /steel)
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ISOMETRIC DIAGRAMS| New Molding Techniques
Weight Optimization Parts
Molding Parts
Rubber Packets (Joint Piece Mold)
Coating (Spray Painting/ Tape) Plywood Mold
Polystyrene (offset 8-10mm)
Tube
Connection Parts
Threaded Rods
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PHYSICAL MODELS| Molding Parts of UHPC Blocks with Polystyrene
Polysyrene (Foam Blocks)
Rubber Joint Mold
Rubber Pockets (Joint Part)
Pilers
Scissor
Gapper Nail
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Adhesive
Mold Piece (Plywood + Tape)
Threaded Rods
PVC Tubes
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PHYSICAL MODELS| 10mm 1:1 Concrete Block Photos
Front
Left
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Right
Top
Bottom
Back
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Physical model of UHPC blocks
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TILE OPTIMIZATION| From a Concave Tile to a Convex Tile
In order to further optimize the UHPC building block, we looked back to the combinatorics system in RobloX (2017). The connection method in the combinatorics system is based on a bounding box of an extrusion of 7 triangles. In other words, as long as the bounding box remains the same, the geometry of tile can be adjusted. Hence, instead of creating pattern by engraving pattern on a solid volume of the 7-triangle-based extrusion, we reversed the old approach by making the pattern as the block’s volume itself. It can be seen that the core section of the building block has changed from a square one to a cruciform shape. This change brings two advantages. The first is the greater strength of building tile. It is due to the increasing depth of the block’s profile and the removal of polystyrene. Secondly, it creates the smaller volume of the building tile as the redundant part has been removed. As it is mentioned before, the method of removing volume to lower the block’s weight is not feasibly only when the polystyrene is placed inside.
MetaPart Conceptual Tests with New Cruciform Tile
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120 mm 120 mm
Existing Concave Tile (rectangular section)
New Convex Tile (cruciform section)
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PHYSICAL MODELS| Cruciform-shaped UHPC Blocks
Front
Left
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Right
Top
Bottom
Back
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ISOMETRIC DIAGRAMS| Regular Tile Molding Techniques
Weight Optimization Parts
Molding Parts
Acrylic Packets (Joint Piece Mold)
Coating (Spray Painting/ Tape) Plywood Mold
Timber Blocks (Weight Optimization Parts)
Connection Parts
Tube
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Threaded Rods
ISOMETRIC DIAGRAMS| 5-times Elongated Tile Molding Techniques
Acrylic Packets (Joint Piece Mold)
Molding Parts
Plywood Mold
Spruce Timber Blocks (Weight optimization)
Two-Part Casting Mold
Weight Optimization Parts
Plywood Mold
Coating (Spray/ tape) Plywood Mold Pre-embedded Rivet Nuts
Upper Molding Part Bottom Part
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PHYSICAL MODELS| Molding Parts of Cruciform-shaped UHPC Blocks
Automatic Screw Driver
Mold Piece (Plywood with Tape Coating)
Joint Part A (Acrylic + Plywood)
Joint Part B (Acrylic + Plywood)
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Timber Blocks (Weight Optimaztion Parts)
Threaded Rods
Rivet Nuts (Pre-embedded Joints)
Piler
PVC Tubes
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80
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GEOMETRICAL OPTIMIZATION| New Cruciform-shaped Tile
Since the new block has removed the polystyrene, will this new geometrical approach of weight optimization reduce more weight than having a polystyrene block inside the block? To respond this question, we made a comparison among three scenarios, a UHPC block without polystyrene, a UHPC block with polystyrene and engraving pattern, and a cruciform-shape UHPC block without polystyrene. The original UHPC block (without polystyrene) is 12.8 kg in weight while in the second UHPC block with engraving pattern and polystyrene can significantly reduce the weight by 50% with merely 6.4 kg left. Yet, through the geometrical approach of weight optimization, it can further decrease 1 kg, which is only 5.4 kg. If this cruciform-shape UHPC block is compared to the original one, the weight optimization is almost 40% in total. In addition to the optimization in weight, the cruciform-shape block is also visually thinner and lighter.
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Concrete
8mm Concrete + Styrofoam inside
Concrete (UHPC)
Volume
5,237cm3 (100%)
2,619cm3 (50%)
2,200cm3 (42%)
Density
0.00245 kg/cm3
0.00245 kg/cm3
0.00245 kg/cm3
Weight
12.8 kg
6 kg
5 kg
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Comparisons Between Concave Tile and Convex Cruciform-shaped Tile
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PHYSICAL PROTOTYPE| Assembly Process
In order to fully understand the difficult degree of manual assembly process as well as the feasibility of the connection method, I conducted a 1-to-1 scale physical testing by assembling 12 UHPC blocks into a meta part. There are three main findings: 1.Assembly Sequence To assemble these pieces into a whole, it is necessary to understand the overall hierarchical relationship of the final aggregation before assembly. It is the way to increase the efficiency of the assembly process. In this case, there are only three hierarchies: final aggregation (a meta part), 3 loop tiles, and 12 single tiles. In contrast to the sequence of the top-down hierarchical relationship, the assembly sequence needs to be reversed from bottom-up. Hence, the first step starts with assembling 12 UHPC blocks into 3 loop tiles (figure 3.3.6-7). After three loop tiles are ready, the next step is to assemble 3 loop tiles into a whole (figure 3.3.8). 2.Temporary Support Due to the tile design being based on 7 regular triangles, every building block will rotate in a 30-degree angle or a 60-degree angle to the next one. As a result, it requires support underneath to ensure the next tile will be placed in the correct orientation during the assembly process. 3.Assembly Tolerance As the pre-fabricated system in RobloX (2017) applies the mechanical joint system (interlocking system with screws and nuts), it cannot absorb the tolerance as ‘Usonian Automatic System’ by pouring mortar in. In this assembly testing, I introduce two materials in male joint part to ensure the success of assembly. Firstly, I keep the thickness of the female part remains in 12mm and reduce the thickness of metal male joint from 12mm to 8mm to increase the tolerance. And followed by adding an extra 4mm layer on top of the male joint, which is made of rubber. By applying a soft and elastic material, it helps to absorb the tolerance and also maintaining the stability.
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Assemble Single Tiles into Loop Tiles
Three Loop Tiles are Ready
Assemble Loop Tiles into a Whole
Final Aggregration
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04| REVERSIBILITY Interlocking System
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JOINTS| Combinatorics
1
2
3
4
5
6
1
2
3
4
5
6
7
(+) (-)
7
(+)
(-)
1
2
3
4
5
6
7
(+) (-)
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1
2
3
4
5
6
1
2
3
4
5
6
(+) (-) 7
7
(+) (-)
1
2
(+)
3
(-) (-)
4
5
6
7
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JOINTS| Options Comparison
Our project aims to be fully reversible. To achieve this we have create unique joints which makes the architectural process being open-ended. The triangular joint is based on the basic geometry of tile, which has high tolerance, and high potential to increase efficiency. Also, it just need two types of joint, reducing the complexity of aggregation
Option A
Option B
Option C
Option D
JOINTS (Female Joint Part)
UNITS (Female Joint Part)
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Robotic Assembling Tolerance
1 (highest)
2
3
4 (lowest)
Joint Strength
2
4 (weakest)
1 (strongest)
3
Pros
High tolerance (with the help High tolerance Create Elegant Secondary of Spherical Joint) (with the help of bowl-shape Joint) Patterns
Cons
Hard to be picked by robots Difficult to fabricate
The strength of joints is not firmed Screw-fixed joints require high enough at the scale of architecture accuracy
Create Secondary Patterns
Join type Extremely is extremely difficult for Robotic Assembling
JOINTS| Joint Types - A,B,C,D
Loop Joint Type
Loop Joint Types (type A,B,C & D)
Loop Aggregation
Loop-to-Loop Joint Types (type I, II)
Overall Joint Types (type A,B,C & D) (type I, II)
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JOINTS| Development 1 - Screw system
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Screws + Tracking marks on Aggregation Objects (pink dots)
Two Types Joint Parts (Loop Jounts and Loop to Loop Joints)
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JOINTS| Development 2 - Clipping system
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JOINTS| Development 2 - Clipping system
Clipper (female) on Aggregation Objects (pink area)
Two Types Joint Parts (Loop Jounts and Loop to Loop Joints)
Click !
Metal Clipper (Male Part)
Metal Clipper (Female Part)
Click !
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JOINTS| Development 3 - Sliding systems
Roblox studied form previous version, improve the old system, combine the joint with the structure of unit itself. In this system, unit has to be divided into male and female unit again, although it’s more complex for aggregation, it still has high potential. The structure will be divided into two part. The primary structure is steel stick in the middle of the piece with rectangular in section, and the secondary structure is threaded rods that go through the primary one. These structures are embedded on male units, and n-shape steel sheet with hook parts are fixed on female units. With internal metal structural frame, the joint strength is high enough for the concrete unit. However, the problem of this system is that instead of using the characteristics of concrete properties efficiently, such as compression by itself, it relies on metal pieces’ strength. In addition, through the test of physical model, we found that when pieces aggregate too each other, it would have a gap between the units, because of the weight of the concrete pieces. When the scale of aggregation become larger, it means that more pieces will be requires, the tolerance will also start to become bigger, which will cause the problem while aggregating and the final result.
Clipping system
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Sliding system
Triangular system
JOINTS| Development 4 - Triangular system
Respond to the basic geometry of the unit, 7 regular triangles, the triangular joint then be developed. In this system, unit and joint are separated, which means that the unit as a role of female, triangular joint as male. It requires only one type of unit, which helps to simplify the design system. There are several holes for male joint in unit, the positions of it come from the aggregation rules. Based on the properties of concrete and the basic geometry of tile, it needs two types of joint, flat joint and cross joint. For creating a loop, it requires cross joint, and for head-tohead or side-to-side, it require flat joint. Joint piece is cut from 8millimeter steel; the thickness has considered the strength and the tolerance for robotic assembly. In addition, for cross joint, after cutting into several triangle pieces, the need to be welded together. When aggregating, male joint pieces have to be put into female units, and fixed by screws. The nuts are embedded in the female unit in advance, which makes the assembly process much more simple and easier. Triangular joint not only creates a high tolerance for robotic assembly, but also has high potential to increase efficiency.
01/ Loop-Tile Joint B _Cross Plate
02/ Head-to-head 01 Joint A_Flat Plate
03/ Head-to-head 02 Joint A_Flat Plate
04/ Side-to-side Joint A_Flat Plate
05/ Overlapping Joint A_Flat Plate
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JOINTS| Development 4 - Triangular system
1. Separate Male and Female parts
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2. Joint - male part Unit - female part
3. Combined units
4. Inserted Pipes + Rods + Rivet Nuts in order to fix the sctructure
Photo of 3D printed units with triangular joint system
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JOINTS| Development 4 - Triangular system
Roblox conduct two triangular cross joint test. First one is two triangle pieces with male and female part, which enable two pieces lock physically. Furthermore, with the help of welding, it will be more stable. However, it is still not strong enough, in order to increase the strength of the joint, we increase the overlapping parts to distribute forces.
(X) Triangle Joint (Original) All the forces come to the weak Point
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(O) Triangle Joint (Optimized) Increase overlapping parts to distribute forces
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05|ROBOTIC ASSEMBLY
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ROBOTICS| Automated Assembly
The case-study project ÂŤRobloxÂť considers the possibilities of using robotics at the large architectural scale and contributes to the discrete and digital architecture. A digital building block have been created that combines with itself in several ways, and that is suitable for robotic assembly. Rather than creating hundreds of different elements, our research is focused on creating high-varied and articulated space with only one type of standardised building block. The block is reversible due to its unique interlocking system that allows snapping units together like Lego pieces. As the project aims to be fully reversible, we avoid usage of glue or any other joining material. Instead, the pieces are connected with triangular joints and screws. Using the combinatory library, coding and aesthetic preferences, fabricated building blocks can be assembled forming different shaped constructions. This prototype can be viewed as a skeleton of the building. We additionally create a curtain wall system by using a clipping panel which is also suitable for the robotic assembly. The industrial robot is used for pick-and-place tasks, replacing manual work in order to commit repetitive, dull motions assembling the blocks together. Among the robotics provided by the university (ABB and Kuka brands), we chose ABB 1600 due to its larger scale which is essential in our case as it allows the building of a bigger structure. Initially, we designed the robot wrist, which is formally called an end-effector. Considering the shape and scale of the units, a gripper based on a pneumatic solenoid was chosen, and unique steel clamps have been cut. The custom-made pneumatic gripper attaches to the robotic arm, being mechanically fixed with screws.
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ROBOTICS| Robotic Type
ABB IBB 1600 x/1.45 Payload 10kg Rich 1.45m Number of axes 6 + 3 Robot base 484x648 Robot weight 250kg
Gripper
Picked-up unit
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ROBOTICS| End Effector Types
Initially, we designed the robot wrist, which is formally called an end-effector. Considering the shape and scale of the units, a gripper based on a pneumatic solenoid was chosen, and unique steel clamps have been cut. The custom-made pneumatic gripper attaches to the robotic arm, being mechanically fixed with screws.
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Various options
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ROBOTICS| End Effector
There were defined two places where the robot can grip the block, from two opposite sides, so the robot has more flexibility in aggregating. We indicated special spots by grooving them, so the robotic gripper could grip with a slight adjustment that allows some tolerance.
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Gripping Part
m
30m
Closed postion
Opened postion
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ROBOTICS| End Effector
Calibration gripper (used for calibrating base points)
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Pneumatic gripper (used for pick & place)
Small pneumatic gripper
Solenoid valve
Screw nuts
Steel clamps
Multicore wire
Screw nuts
Steel plate for attaching the gripper
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ROBOTICS| Assembly Strategies
ON-SITE ASSEMBLY
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+ + +
simple logistics simple technique human and robot interaction
- - -
low flexibility: assembly only small parts time-consuming only half-automated
OFF-SITE ASSEMBLY
+ + +
high flexibility - assembly of large structures in a time fast assembly of large building elements can fully automate the construction
-
should be quite close to the actual site (for cheaper logistics)
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ROBOTICS| On-site Assembly
Pedestal allows to increase the space for robotic assembly
Could be assembled up to 16 units at one time
1:1 scale units are assembled one by one
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Units are put in the same position
Conveyors for the units
Wooden base
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ROBOTICS| Limitations
There is a limitation on a number of pieces the robot can assemble at a time due to the robotic range . Thus, we can only robotically build part by part and then mechanically assemble them into the desired outcome. The on-site scenario of the Roblox project performs better for smaller constructions and includes a human and robot interaction. The benefit is that the assembly executes by a single robotic operator that can be sent in a truck together with the building elements.
Can be assebmled up to 16 blocks
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ROBOTICS| Off-site Assembly
Nonetheless, there are larger-scale machines, and if we imagine them being in a kind of moving track system, then we would be able to build pavilion-scale aggregations at a time. So, we introduce a second scenario of an automatic assembly using a Gantry system with hanging robots. Off-site construction experiments at the large-scale are possible with an existing in ETH Laboratory Gantry system where 6-axis ABB robotic arms are hanging from a ceiling-mounted surface portal. The robots can cooperatively work, moving on a 3-axis gantry system that can cooperate on architectural fabrication tasks within a maximum building volume of 43 x 16 x 6m into it. The assembly strategy is similar with the on-site one, but the principal advantage of the Gantry system is the extended robotic operational range. The assembly may be fully automated with the following idea: one robot performs pick-and-place of the building members which already include the joints while the other screw them together. Such cooperative robotic building approach requires only two workers for the whole construction process.
Moving in X direction
One is for the conveyors that should be manually fed by a human worker and one specialist that keeps track of the machines. Ultimately, large building elements that are robotically assembled in a factory environment are being transported to the site where they can be quickly combined with the help of a crane-like lifting machine in one day.
Refilling conveyors with units Robots grab the pieces from 4 spots
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Moving in Y direction
2 hanging 6 axes robots operating together
Construction up to 5 meters high can be assembled in a time
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ROBOTICS| Off-site Assembly
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ROBOTICS| Logistics
Even though the described off-site strategy allows for building large-scale structures without dividing them into parts, we also need to deliver the construction to the actual site. For this, when the building prototype is digitally designed, we define so-called meta-parts that would fit on the standard-size truck for transport to the construction site. Eventually, the building can be sliced into four main meta-parts, five floor-ceiling slabs and some smaller parts like columns. The maximum weight of one meta-part is 780kg, and the slabs are about 250kg each. Therefore, these building elements fit in just seven standard trucks: 4 trucks deliver massive meta-parts, and three trucks fill in with slabs and columns
1 meta-part (615kg)
1 meta-part (615kg)
1 meta-part (615kg)
1 meta-part (615kg)
1 meta-part (615kg)
1 meta-part (615kg)
1 meta-part (615kg)
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Building’s Meta-parts
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ROBOTICS| Logistics
Ultimately, large building elements that are robotically assembled in a factory environment are being transported to the site where they can be quickly combined with the help of a crane-like lifting machine in one day (Fig. 35). The minimum of two human workers is required for such a bulding process. Finally, the volume of logistics costs in the Roblox project, compared to a construction project of the similar scale, are about the same level.
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13.6 m 2.7 m
Assembly of robotically pre-assembled (offsite) big parts of the house
Assembly field
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06| COMPUTATIONAL STRATEGY
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AGGREGATION STRATEGY| Choosing a System
Layered system: No hierarchical approach, always belong to single tile’s combinatorics. - takes more time for aggregation - using more units for space creation. Loop system: Full hierarchical approach : from single unit to single loop to pattern part to Meta-Part. - takes less time for aggregation. - minimizes amount of units for creating maximum space.
Layered System
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Loop System
AGGREGATION STRATEGY| The model test for loop system
Physical Model The model made by plywood with more than 600 pieces. It demostrates to use single blocks to achieve column like sculpture by designer’s intuition. The combinatorial logic of this model then becomes the basic combinatorics library for project RobloX.
Loop System
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TILE COMBINATORICS LIBRARY| Single Tile + Loop + Metapart PROJECT OVERVIEW|
138 2
139 3
TILE COMBINATORICS LIBRARY| Single Tile + Loop + Metapart PROJECT OVERVIEW|
140 2
141 3
COMPUTATIONAL STRATEGY| BESO Test (2D Floor)
Reduce 0% of the structure
Reduce 30% of the structure
Reduce 50% of the structure
Reduce 70% of the structure
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We would like to transform the combinatorics to computational logic and to generate the horizontal floor through structural optimization system (BESO: Bidirectional Evolutionary Structural Optimization )from support points to load points
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STRUCTURE OPTIMIZATION| Diamond Grid
Topology optimization is widely used in industrial design and especially in the realm of car design for reduce structural weight. Nowadays, several of researches applied this approach to architecture design (Chan et al. 2012; Dombernowsky and Søndergaard 2011; Søndergaard, Amir and Knauss 2013 ). Nevertheless, it had not been applied for the assembly way of discrete elements. Transforming the aggregation to the combination of simple lines. There are 4 directions of the diamond face in grid system.
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28 combination ways
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STRUCTURE OPTIMIZATION| Diamond Grid
Loop A Loop A The process of optimization can be seemed as both structural and spatial optimization simultaneously. Space is generated by various typology of support and load behavior which means that we can get bidirectional consequences from the change of bidirectional factors. I would like to figure out if it is possible to create the guide for discrete assembly. In this step, I will also compare with different approaches of structural optimization, such as BESO (Bidirectional Evolutionary Structural Optimization).
Original (1,0,0)
Oiginal (1,0,0)
(-1,0,0) (0,0,-1)
-1,0,0) (0,0,-1)
(0,0,-1)
(-1,0,0)
Grasshopper’s canvas
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(0,0,-1)
(-1,0,0)
Loop B
Loop B
Loop C
Loop C
Loop D
Loop D
Diamond grid - Bidirectional Evolutionary Structural Optimization
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COMPUTATIONAL STRATEGY
Random faces are generated correctly (without error in combinations)
- taking grids from the result of BESO
- extracting grid points
- filling 5 faces geometry for each points
- generating 4 directions of diamond face from each points
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0,0 0,1 0,2 0,3 1,1 1,2 1,3 2,3 3,3
Each point can generate 2 faces To give the rule to avoid overlaping situation and make the list
0,0 0,1 0,2 0,3 1,1 1,2 1,3 2,3 3,3
Diamond grid: Bidirectional Evolutionary Structural Optimization
The grid can be occupied by 4 directions of diamond polylines
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COMPUTATIONAL STRATEGY| Dom-ino Version I
This version is organized in the notion of “Meta-part” which is the abstract bigger parts by combining several lower parts such as loop-blocks and single blocks, simultaneously generates its self-rules in combinatorics. From parts, this study creates the vertical architectural “Chunks”, which are large parts to be seen as the architectural elements. The logic of aggregation process is from horizontal pattern generation to join vertical chunks at specific connection areas. Step by step, it creates three levels space and the position of vertical chunks can be adjusted and adapting to structure condition. This model has improved the conventional space configuration to be more diver-sified, variable and multidirectional. Whereas, the composed mechanism persists the same perspective of existing Dom-ino system from Le Corbusier, which consists of slabs and columns. The interaction process is unidirectional, to see the structure as the first priority rather than space. It means that the system is difficult to adapt to spatial demand with its restrained architectural elements.
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COMPUTATIONAL STRATEGY| Dom-ino Version I
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COMPUTATIONAL STRATEGY | Dom-ino Version I
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COMPUTATIONAL STRATEGY| Dom-ino Version II
The second approach responds to the issue of the first version, in that it aims to turn space and structure become two directional relations. This interaction means that space is not dispatched by structural condition, but as the variable to influence where the structure is. Two factors are equal and have no priority in each, as Jose Sanchaz ar-gued: “Any given variable of a design problem establishes a degree of freedom that can be catalogued and cross referenced to other variables� (2016, p.46). To provide structure behavior from different permutation, this approach defines series of strength in each connection of parts to parts. By using automatic generation in computation, miscellaneous patterns also can be defined as several levels of structure performance, to allow operating in parts of the entire structure. The transition test from one kind of combination way switch to another, conducts how to join distinct patterns in space and also maintains the proper structure operation from different parts to the whole architecture. For generating the reasonable composition of the whole, the strate-gy of aggregation introduces topology optimization to export the stress lines as the ad-ditive path. The density of stress lines converts to several levels of strength for corre-sponded patterns to import. The result of the aggregation performs how different patterns transform with each other, meanwhile contribute to the whole structure system. Without unchanged vertical chunks, parts can follow the path generated by topology optimization and pre-sent various transitions between vertical and horizontal. The relationship between Space and structure become the communicated process. Numerous sub-spaces are generated during structural transition process.
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COMPUTATIONAL STRATEGY| Dom-ino Version II
[1] 4
[2] [3
[a1-1,a1-1] -pi/2 4
[a1-1,a1-3] pi
[a1-1,a1-3] 0
5
[a1-3,a1-5] pi
3
[a1-3,a1-5] 0
[a1-2,a1-3] 0 5
[a1-1,a1-3] –pi/2
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[2] [3]
[4]
[4]
[a1-2,a1-3] pi/2 5
[a2,a3] 0 [a1-1,a1-2] 0
[a1-4,a1-5] 0
5
[2] [3] [a1-1,a1-2] pi/2
[a1-4,a1-4] 0 5
5
[a1-2,a1-2] -pi/2
[a1-1,a1-3] pi/2
1
[a1-3,a1-3] pi
[a1-2,a1-4] pi
5
5
[a1-1,a1-2] -pi/2 5
[a1-2,a1-2] pi/2
5
5
5
5
2
[a1-1,a1-1] pi/2 5
5
5
[a2,a3] 0
[a4,a4] 0
[a4,a4] 0
[a4,a4] pi
[a4,a4] pi
[a1-2,a1-3] -pi/2
[b2,b3] 0
[b2,b3] 0
[b4,b4] 0
[b4,b4] 0 To detect structural condition and to calibrate the location of columns
[b1-1,a1-1] pi/2
[b1-1,a1-2] pi/2
[b1-2,a1-1] pi/2
[b1-2,a1-2] pi/2
[b1-3,a1-3] 0
[b1-1,a1-1] –pi/2
[b1,a1-2] -pi/2
[b1-2,a1-1] -pi/2
[b1-2,a1-2] –pi/2
[b1-3,a1-3] pi
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Tile Combinatorics Library| Grasshopper Test
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TILE COMBINATORICS LIBRARY| Grasshopper Test
a+b [1-1,1-2,1-3,1-4,1-5] 0, pi Count:200 a+b [1-1,1-2,1-3,1-4,1-5] 0, pi Count:200 var addFaces = availableFaces .OrderByDescending addFaces = availableFaces (x =>var x.plane.Origin.Z).Take(200); .OrderByDescending (x => x.plane.Origin.Z).Take(200);
a + b [1-1,1-2,1-3,1-4,1-5] 0, pi a [2,3] 0 a +0,bpi[1-1,1-2,1-3,1-4,1-5] 0, pi a [4,4] a [2,3] b [2,3] 0 0 a [4,4] b [4,4] 0, pi0, pi b [2,3] 0 Count:300 b [4,4] 0, pi Count:300 var addFaces = availableFaces .OrderByDescending addFaces = availableFaces (x =>var x.plane.Origin.Z).Take(100); .OrderByDescending (x => x.plane.Origin.Z).Take(100);
a + b [1-1,1-2,1-3,1-4,1-5] 0, pi a [2,3] 0 a +0,bpi[1-1,1-2,1-3,1-4,1-5] 0, pi a [4,4] a [2,3] b [2,3] 0 0 a [4,4] b [4,4] 0, pi0, pi b [2,3] 0 Count:300 b [4,4] 0, pi Count:300 var addFaces = availableFaces .OrderByDescending addFaces = availableFaces (x =>var x.plane.Origin.Z).Take(100); .OrderByDescending (x => x.plane.Origin.Z).Take(100);
C + D [1]0 , pi Count:300 C + D [1]0 , pi Count:300= availableFaces Var addFaces
.OrderByDescending addFaces = availableFaces (x =>Var x.plane.Origin.Z).Take(100); .OrderByDescending (x => x.plane.Origin.Z).Take(100);
A + B + C +D [1][2,3] Count:300 A + B + C +D [1][2,3] Count:300= availableFaces var addFaces
.OrderByDescending addFaces = availableFaces (x =>var x.plane.Origin.Z) .Take(100); .OrderByDescending (x => x.plane.Origin.Z) .Take(100);
A + B + C +D [1][2,3] Count:300 A + B + C +D [1][2,3] Count:300= availableFaces var addFaces
.OrderByDescending addFaces = availableFaces (x =>var x.plane.Origin.Z) .Take(100); .OrderByDescending (x => x.plane.Origin.Z) .Take(100);
161 3
TILE COMBINATORICS PROJECT OVERVIEW| LIBRARY| Grasshopper Test
a [1-1,1-2,1-3,1-4,1-5] 0, pi Count:200 var addFaces = availableFaces .OrderByDescending (x => x.plane.Origin.Z) .Take(200);
A [1]pi [2,3]0 Count:200
A + a [1-1,1-2]0 , pi
var addFaces = availableFaces .OrderByDescending (x => x.plane.Origin.Z) .Take(20);
var addFaces = availableFaces .OrderByDescending (x => x.plane.Origin.X) .Take(150);
A [1]pi [2,3]0 Count:200
A+B [1-1,1-2]0,pi Count:300
var addFaces = availableFaces .OrderByDescending (x => x.plane.Origin.X).Take(50);
2
162
Count:200
var addFaces = availableFaces .OrderByDescending (x => x.plane.Origin.X).Take(50);
a+b 0,0,pi a+b[1-1,1-2,1-3,1-4,1-5] [1-1,1-2,1-3,1-4,1-5] a+b [1-1,1-2,1-3,1-4,1-5] pi 0, pi Count:200 Count:200 Count:200
CC++DDC[1]0 pi [1]0 + D, ,[1]0 pi , pi Count:300 Count:300 Count:300
var ==availableFaces varaddFaces addFaces var addFaces availableFaces = availableFaces .OrderByDescending .OrderByDescending .OrderByDescending (x(x=> x.plane.Origin.Z).Take(200); =>(x x.plane.Origin.Z).Take(200); => x.plane.Origin.Z).Take(200);
Var ==availableFaces VaraddFaces addFaces Var addFaces availableFaces = availableFaces .OrderByDescending .OrderByDescending .OrderByDescending (x(x=> x.plane.Origin.Z).Take(100); =>(x x.plane.Origin.Z).Take(100); => x.plane.Origin.Z).Take(100);
aa++bba[1-1,1-2,1-3,1-4,1-5] 0,0,pi [1-1,1-2,1-3,1-4,1-5] + b [1-1,1-2,1-3,1-4,1-5] pi 0, pi aa[2,3] [2,3] a 0[2,3] 0 0 aa[4,4] [4,4] a 0, [4,4] 0,pi pi 0, pi bb[2,3] 0 [2,3] b [2,3] 0 0 bb[4,4] [4,4] b 0, [4,4] 0,pi pi 0, pi Count:300 Count:300 Count:300 var ==availableFaces varaddFaces addFaces var addFaces availableFaces = availableFaces .OrderByDescending .OrderByDescending .OrderByDescending (x(x=> x.plane.Origin.Z).Take(100); =>(x x.plane.Origin.Z).Take(100); => x.plane.Origin.Z).Take(100);
AA++BBA+++CCB+D +D + C[1][2,3] [1][2,3] +D [1][2,3] Count:300 Count:300 Count:300 var ==availableFaces varaddFaces addFaces var addFaces availableFaces = availableFaces .OrderByDescending .OrderByDescending .OrderByDescending (x(x=> x.plane.Origin.Z) .Take(100); =>(x x.plane.Origin.Z) => x.plane.Origin.Z) .Take(100); .Take(100);
AA++BBA+++CCB+D +D + C[1][2,3] [1][2,3] +D [1][2,3] Count:300 Count:300 Count:300 var ==availableFaces varaddFaces addFaces var addFaces availableFaces = availableFaces .OrderByDescending .OrderByDescending .OrderByDescending (x(x=> x.plane.Origin.Z) .Take(100); =>(x x.plane.Origin.Z) => x.plane.Origin.Z) .Take(100); .Take(100);
163 3 3
COMPUTATIONAL STRATEGY| Dom-ino Version II
Architect Le Corbusier established “Domino System” to face the massive providing of house need after war and also published his idea of space generation. On constructional side, it aimed to generate maximum space via using minimum structural elements. But it also affects the principle of space to display as the relationship between slabs and columns. In comparison with architecture before modernism, space is generated as cellular with load-bearing walls. Therefore, what is the feature of space in contemporary? It does not only involve the concept of function in space but also the fabrication method of construction. These are all concerned with ideas of efficiency. According to this, to explore contemporary concept of space using and the way of fabrication will contribute to describe new value of space to approach efficiency and toward beyond efficiency. In this part, I will talk about the difference idea of space, space using and method of construction in history. Then, to provide the new notion of space construction or deconstruction, such as we are discussing about: “discrete design”, “reversible”, “mereology” in contemporary and make the statement.
[a1-2,a1-3] 0
[a1 [a1-
[a
164
1-2,a1-3] 0 -1,a1-1] 0
[a1-2,a1-4] pi [a1-4,a1-4] 0
[a1-2,a1-4] pi [a1-4,a1-4] 0 [a1-1,a1-3] 0
a2,a3] 0
[a2,a3] 0
[a2,a3] 0
[a1-3,a1-5] 0,pi [a1-4,a1-5] 0,pi [a1-1,a1-3] 0,pi [a1-1,a1-4] 0,pi [a2,a3] 0
165
COMBINATORICS RESEARCH| New Space Generation
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70%
20%
50%
40%
40%
70%
70%
60%
90%
20%
70%
40%
50%
20%
50%
40%
30%
30%
100%
100%
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COMPUTATIONAL STRATEGY| Dom-ino Version II
Bounding Box (18*14*6m)
Structure-Form Optimization
Stress Field
Compression
168
Tension
Discretizing the Stress Field
Bending Moment
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COMPUTATIONAL STRATEGY| Dom-ino Version II
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171
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COMPUTATIONAL STRATEGY| Dom-ino Version III
Nevertheless, these two versions of Dom-ino are focused on the capacity of combination but have not focused on material property. The idea of topology optimiza-tion is the strategy of composition with structural logic. The output presents the struc-tural trend by ratios. The quantity does not represent the real structure. Regarding to this research aims to improve the existing pre-cast system, the test then introduces UHPC (ultra-high performance concrete ) as the material of blocks. The result from these two versions manifests too much redundancy of units for structural need. On the other hand, architectural chunks in version two are mass-customised. The huge amount of micromanagement needs to be conducted during the aggregation process. About the redundancy and non-well controlled in meta-parts using, the test of the third version introduces real-time structure analysis and input the property of UHPC as the fixed variable. Three meta-parts are used in this version.
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COMPUTATIONAL STRATEGY| Dom-ino Version III
In sequence, it generates the fundamental slab for space orientation. Then it grows and generates several levels, which perform average loads to the whole structure. At this moment, the strategy remains the same idea of version two, to generate the addi-tive path from topology optimization and start to add vertical parts.
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The max displacement is the real-time information for aggregation system to estimate that structure still need to be reinforced or not. When structure is closed and with no free el-ements inside the system, the structure analysis is conducted to detect weak points and keep combining new parts until displacement is relevant.
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COMPUTATIONAL STRATEGY| Dom-ino Version III
Because of the real-time structural analysis, version three subtracts the number of redundant units rather than previous versions. With the efficient use of structure gen-eration, it also remains more space than before. The model performs high resolution of transition in various patterns, which consist of hierarchical parts. The outcome can be divided into single blocks, loop-blocks, architectural-chunks to architectural-sections. It displays the complete hierarchical relations from part to whole, presenting aesthetics which is unique and heterogeneous. The series of part to whole relations is not only the strategy of combinatorics, but also the implication of how architecture work flow operates on site and off site, as the module system responds to its delivery and physical assembly method.
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COMPUTATIONAL STRATEGY| Dom-ino Version III
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COMPUTATIONAL STRATEGY| Dom-ino Version IV
After the experiment via three iterations, the research uses Maison Dom-ino by Le Cobusier (1914) as the target to make the comparison and to see the extent of material efficiency in the test of version three. From the drawing of Domino House, the slab thickness is around 40 centimeters. The core-section of the column is around 20 centi-meters. The volume is 69 cube meter, and the whole weight is 166 tons. In order to make the standard reference, we make the UHPC Dom-ino with the same composition by fixing the max displacement, and to evaluate the area of core-section from beams and columns. The analysis then got the result that UHPC Dom-ino only remains 45 tons with 90 square meter core-section of beams and 144 square meter core-section of col-umns. It reduces 75% of weight because of the property of the material, which
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Due to the new proportion of the UHPC Dom-ino, Obviously, the test of Dom-ino version three remains redundancy. Because of the essential parts for horizontal slab are loop-blocks, which have larger core-section than actual structure need. The conse-quence of the comparison presents the more flexible resolution for horizontal composi-tion is required. On the other hand, as is common knowledge, architecture typically in-cludes a structural system and an enclosure system. The connotation of three Dom-ino above is trying to use blocks to create space. Some parts cannot be explained precisely as the structure or the enclosure parts. In order to reach economic use and compare to existing Domino system, the research should separate architecture as two parts such as skeleton(structure) and enclosure system.
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COMPUTATIONAL STRATEGY| Dom-ino Version IV
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Another series of test start from using blocks to design the same structure behavior with existing Dom-ino, which has six support points. The result then made by UHPC blocks is only 15 tons. According to this, we can see that the whole weight reduced 30% again because of the geometry of the block and its combinatorics. With the same logic, this system can apply to different situations of support point such as three, two and one points. When support points are not a regular distribution, combinatorics have to adapt to the structure behaviour and to generate non-uniform slab.
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COMPUTATIONAL STRATEGY| Dom-ino Version IV
The UHPC Domino version four is generated from only five supports. Each floor performs high resolution of block use in various density with structural logic. The trend of aggregation from support points stretches to the four corners of the space boundary. The key connections can be seen as the beams of the structure, which are more thicker than the others. The whole aggregation process relates to the theory of BESO (bidirec-tional evolutionary structural optimization) ( Querin et al. 1998), which is to add structural elements in weak parts and to subtract the redundancy parts as the bidirectional iterations until max displacement reaches the reasonable number.
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COMPUTATIONAL STRATEGY| Dom-ino Version IV
The final output is the structure of architecture which is efficient with high reso-lution aesthetic performance. The project designs the enclosure system by utilising the geometry feature of UHPC block. To compare to existing pre-cast system, this version broke the constraint of homogeneous population and standardised result and to reach heterogeneous with highly-variated form generation.
The boundary of the skeleton in architecture remains the specific form of zigzag, which implies the possibilities for curtain wall system. The conceptual proposal of cladding curtain wall system is to utilize original joint system to connect with the structure of architecture. The system can be further developed for different function use. The different type of output might turn back to make new combinatorial rules, which deals with the parts of the architectural boundary. Similarly, the interior panel system is to utilize the grabbing slots of robotic assembly as the clipping parts for panels. However, due to the diverse orientations from each block, it will need to develop a computation agent to calculate every slot and generate proper orientation of panel clipping joints. This further research will also contribute to the geometry of block design.
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07| ARCHITECTURAL SCALE
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ARCHITECTURE| Wall and floor systems
Curtain Wall System
Glass
Frame
3300 mm UHPC Block
m
0m
50 300 mm
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Floor System
Floor panel (including surface sheet and Clipping system UHPC Block The same part for Robotic
Staris
UHPC Blocks
Modularized Curtain Wall System(Pre)
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ARCHITECTURE| Wall and floor systems
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COMPUTATIONAL STRATEGY| Dom-ino Version IV
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COMPUTATIONAL STRATEGY | Dom-ino Version IV
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COMPUTATIONAL STRATEGY| Dom-ino Version IV
Besides the strategy of combinational design, the whole research includes the material test with the geometry optimization of the block, joint research in real mock-up testing and physical robotic assembly testing. This process-based research displays comparisons between numbers of iteration and how single blocks through simple com-binatorics can achieve light weight stable structure of architecture. The previous test of three Dom-ino versions studies multi-hierarchical part to whole relations. At the second approach, starting use topology optimization to create the additive path and introduce real-time structure analysis at the third approach. Step by step, these improvements generate unique aesthetics with stable structure in high efficient, hierarchical combinatorics. The consequence in version three completely cor-responds to the philosophy of "strange mereology", which means all parts are inde-pendent or autonomous from one another (Bryant 2011). However, the outcome is not relevant to the material property of UHPC and re-mains much redundancy. By the experiment of the UHPC Dom-ino, it proves that mate-riality of UHPC can reduce material consumption and persist the same structural behav-ior. The series of test then also confirm that the geometry of block and its combinator-ics cause the combinatorial system to become more efficient. The efficiency performs on composing to structure and adapting to the non-uniform situation. According to final approach in Dom-ino version four, the combinatorial logic re-mains only single tile’s rules, but it still maintains its high flexibility in combination. It responds to the main idea of the digital material. The limited rules can generate a highly efficient aggregation process. The different density of slab display how single blocks compose to the structure of architecture and transform to the specific pattern on the boundary of space for curtain wall cladding. This strategy of combinatorial design, lead discrete units composition with digital organization, in aesthetics, structure configura-tion and toward the real digital architecture.
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ARCHITECTURE| A Series of Vertical Building Elements
A field of cloning chunks generated by the same combinatorics system. The chunks are aggregated by two types of repeated concrete blocks that can achieve a series of highly-variated vertical building elements. With the achievement of geometrical complexity, it uncovers the limitations of geometrical constraints in pre-cast concrete systems.
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ARCHITECTURE| A Series of Vertical Building Elements
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ARCHITECTURE| BPro Show Physical Prototype 94
Joints
70
Blocks
Physical 1:1 scale model is going to be built for the B-Pro show in The Bartlett School of Architecture by September 2017. The aproximate cost of construction is 5900 pounds. 252 concrete blocks and 315 joints needed.
5.8 sqm
1300 GBP
1
KN
0.9
mth/team
208
Long Tile Long Tile (5-times)
Medium Tile Medium Tile (3-times)
Regular Tile Regular Tile
Number Number
44
20 20
46 46
Expense Expense
4*(£5.1*5)= 4*(£5.1*5)= £102 £102
20*(£5.1*3)= 20*(£5.1*3)= £306 £306
46*£5.1= 46*£5.1= £234.6
4*25kg 4*25kg = 100 kg
20*15kg 20*15kg = 300 kg
46*5.4kg= 46*5.4kg= 248.4 kg
Weight Weight
Time Time
= 100 kg
= 300 kg
£234.6
248.4 kg
4*(65mins*5)+20*(65*3)+46*65mins 4*(65mins*5)+20*(65*3)+46*65mins = 8,052 mins =134.2 hours = 8,052 mins =134.2 hours = 17 days (8hrs/day) = 17 days (8hrs/day) = 3.4 weeks (5days/week) = 3.4 weeks (5 days/week)
Joint A Regular Tile
Joint B Regular Tile
56 56
38 38
(Flat)
(Cross)
94*£7= £658 94*£7= £658
94*500g= 47 kg 94*500g= 47,000 g= 47 kg
38*5mins= 190mins 38*5mins= 190mins = 3.17 hours = 3.17 hours = 0.5 day = 0.5 day
Regular Tile
Total
£1,300 £1300.60
731.4kg 731.4kg= 0.73 kn = 0.73 kn
17.5 days 17.5 days = 3.5 weeks = 3.5 weeks
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Research Cluster 4, 2016-2017 M.Arch Architectural Design UCL, The Bartlett School of Architecture