RobloX project_Bartlett M.AD RC4

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

59

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

60

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

61

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

62

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)

63

Physical model of the section with a steel joint (UHPC /steel)

64

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

65

PHYSICAL MODELS| Molding Parts of UHPC Blocks with Polystyrene

Polysyrene (Foam Blocks)

Rubber Joint Mold

Rubber Pockets (Joint Part)

Pilers

Scissor

Gapper Nail

66

Adhesive

Mold Piece (Plywood + Tape)

Threaded Rods

PVC Tubes

67

PHYSICAL MODELS| 10mm 1:1 Concrete Block Photos

Front

Left

68

Right

Top

Bottom

Back

69

70

Physical model of UHPC blocks

71

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

72

120 mm 120 mm

Existing Concave Tile (rectangular section)

New Convex Tile (cruciform section)

73

PHYSICAL MODELS| Cruciform-shaped UHPC Blocks

Front

Left

74

Right

Top

Bottom

Back

75

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

76

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

77

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)

78

Timber Blocks (Weight Optimaztion Parts)

Threaded Rods

Rivet Nuts (Pre-embedded Joints)

Piler

PVC Tubes

79

80

81

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.

82

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

83

Comparisons Between Concave Tile and Convex Cruciform-shaped Tile

84

85

86

87

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.

88

Assemble Single Tiles into Loop Tiles

Three Loop Tiles are Ready

Assemble Loop Tiles into a Whole

Final Aggregration

89

90

91

04| REVERSIBILITY Interlocking System

93

JOINTS| Combinatorics

1

2

3

4

5

6

1

2

3

4

5

6

7

(+) (-)

7

(+)

(-)

1

2

3

4

5

6

7

(+) (-)

94

1

2

3

4

5

6

1

2

3

4

5

6

(+) (-) 7

7

(+) (-)

1

2

(+)

3

(-) (-)

4

5

6

7

95

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)

96

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)

97

JOINTS| Development 1 - Screw system

98

Screws + Tracking marks on Aggregation Objects (pink dots)

Two Types Joint Parts (Loop Jounts and Loop to Loop Joints)

99

JOINTS| Development 2 - Clipping system

100

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 !

101

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

102

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

103

JOINTS| Development 4 - Triangular system

1. Separate Male and Female parts

104

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

105

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

106

(O) Triangle Joint (Optimized) Increase overlapping parts to distribute forces

107

05|ROBOTIC ASSEMBLY

109

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.

110

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

111

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.

112

Various options

113

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.

114

Gripping Part

m

30m

Closed postion

Opened postion

115

ROBOTICS| End Effector

Calibration gripper (used for calibrating base points)

116

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

117

ROBOTICS| Assembly Strategies

ON-SITE ASSEMBLY

118

+ + +

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)

119

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

120

Units are put in the same position

Conveyors for the units

Wooden base

121

122

123

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

124

125

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

126

Moving in Y direction

2 hanging 6 axes robots operating together

Construction up to 5 meters high can be assembled in a time

127

ROBOTICS| Off-site Assembly

128

129

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)

130

Building’s Meta-parts

131

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.

132

13.6 m 2.7 m

Assembly of robotically pre-assembled (offsite) big parts of the house

Assembly field

133

06| COMPUTATIONAL STRATEGY

135

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

136

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

137

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

142

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

143

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.

144

28 combination ways

145

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

146

(0,0,-1)

(-1,0,0)

Loop B

Loop B

Loop C

Loop C

Loop D

Loop D

Diamond grid - Bidirectional Evolutionary Structural Optimization

147

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

148

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

149

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.

150

151

COMPUTATIONAL STRATEGY| Dom-ino Version I

152

153

COMPUTATIONAL STRATEGY | Dom-ino Version I

154

155

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.

156

157

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

158

[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

159

Tile Combinatorics Library| Grasshopper Test

160

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

166

70%

20%

50%

40%

40%

70%

70%

60%

90%

20%

70%

40%

50%

20%

50%

40%

30%

30%

100%

100%

167

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

169

COMPUTATIONAL STRATEGY| Dom-ino Version II

170

171

172

173

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.

174

175

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.

176

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.

177

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.

178

179

COMPUTATIONAL STRATEGY| Dom-ino Version III

180

181

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

182

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.

183

COMPUTATIONAL STRATEGY| Dom-ino Version IV

184

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.

185

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.

186

187

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.

188

189

07| ARCHITECTURAL SCALE

191

ARCHITECTURE| Wall and floor systems

Curtain Wall System

Glass

Frame

3300 mm UHPC Block

m

0m

50 300 mm

192

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)

193

ARCHITECTURE| Wall and floor systems

194

195

COMPUTATIONAL STRATEGY| Dom-ino Version IV

196

197

198

199

COMPUTATIONAL STRATEGY | Dom-ino Version IV

200

201

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.

202

203

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.

204

205

ARCHITECTURE| A Series of Vertical Building Elements

206

207

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

209

Research Cluster 4, 2016-2017 M.Arch Architectural Design UCL, The Bartlett School of Architecture