Architectural Engineering | 1:1 Detail by Christina Papadaki

7QX3M0 | ARCHITECTURAL ENGINEERING L. Eshuis, P. van Loon, D. Meijer, C. Papadaki 1

Table of Contents Part A Introduction 2 The design concept 4 Interview with the architect: Rob Meurders The building structure 6 Spatial organization Structural system The realization 10 The construction system The material use / detail analysis Part B Introduction 18 The redesign 19 Design goal Puzzle connections The design components The technical implementation The construction elements The construction system The reusable elements The material use

The building process 34 Reflection 40 Sources 41 Appendix 42

PART

Introduction For the course of Architectural Engineering, a building was to be analysed, and a three-dimensional section was to be redesigned to achieve higher sustainability. Not only by considering the material use, but also by investigating possibilities for reusability and therefore also demountability. In this case, the regenerated ketelhuis, or Ceres building, on the TU/e campus is the chosen project. The renovation has been designed by DiederenDirrix and Part A of this report investigates the design concept, building structure, construction system and the material use through literature- and drawing analysis and an interview with the architect. This provides a broad understanding of the how and why of the building and the chosen detail fragment. In Part B, this fragment will be redesigned to improve sustainability and reusability.

The Design Concept The boiler house Ceres is situated on the campus terrain of the Technical University of Eindhoven. Originally, the Ceres building provided hot water for heating on campus, but as technology developed, it no longer had to fulfill this purpose. The building was transformed into the Institute for Complex Molecular Systems by Diederendirrix Architects in 2012. The design for the research center aims to promote multidisciplinary collaboration and bring together young and experienced researchers. With its solid walls and high window openings, the daylight comes from above, giving the building a certain ‘basilical’ quality. This closed expression is characteristic for the building, but as the function is transformed from a technical service to office and workspace, there is a need for more daylight. With its sun orientation and its position next to the campus routing, the south façade will provide the needed openings and main entrance. To preserve the expression and meet the new demands, the south façade is redesigned with window frames, alternated by hidden ventilation frames. As the building structure consists of a separate façade and loadbearing structure, structurally there is much freedom for the new façade design. The windows have dark tinted glass, and they are alternated by reclined frames. In these reclined frames, there are perforated plates that allow for natural ventilation when the shutter is opened from inside. From the exterior, the perforated plates appear solid, and the dark windows give away little about what happens inside, thus maintaining the closed expression. The closed outside contrasts with the lighter, more open interior, and this contrast is even stronger after the transformation. The new interior structure is very open, having mostly glass separation walls. The detailing of all additions for the transformation is designed separate from the existing structure, making them distinguishable and removal is possible if desired in the future. The building is organized in zones based on the steel column grid, around an open atrium in the middle. The ground floor houses the entrance, a colloquium space, workspace, meeting rooms and a laboratory. On the first floor there is office space.1 2 3 Fig.1 Ceres building. Credits: Diederendirrix

Interview with DiederenDirrix - Rob Meurders How did you approach the transformation of the Ceres building? “That was also about how you intervene within an existing building. The building has two ‘heads’. We could already make form with the huge entrance area. It does not have to be obedient to the space, but does have to be directed towards the ‘Groene Loper’ (the green area alongside the east- and southside of the building). You have to deal with the introverted character, so we tried to think of a system to make it more fluent. It could be a façade that looks solid, but isn’t solid. We also looked at the building itself and the grid system in the rest of the campus buildings, based on the Philips TL lighting, making a grid with 1.24 metre dimensions. We needed daylight and a view, and we also wanted a façade that could provide fresh air by opening parts of it.

Fig.2 “Basilical”light from above in the original building

Besides the solid expression, another important design factor was that we did not want any competition with the existing windows, so we wanted the façade to look new and abstract.” Is that why the windows protrude from the façade? “With that, we wanted to suggest some kind of a body. For the parts that previously consisted of brickwork, we suggested some kind of volume by having the windows stick out, with a matt, dark quality. The glass of the outer sheet is dark-colored glass. The advantage is that it has a beautiful reflection, although low is very clear one that gives a bit of distortion. Both this reflection and the dark tint strengthened the concept of the ‘solid wall’. In between the windows, we made a perforation in steel, and a door behind the panel opens inward to let in ventilation.”

Fig.3 Naturall light in the redesign

There is a clear emphasis on sleekness in the new façade, which we can see in the detailing of the window boxes, but also in the way the ventilation openings are ‘hidden’ behind the flat, perforated steel plates. Are there other ways this sleekness comes back in your design? “Also on the interior in a certain way. We were thinking about how we could make the interior without adding any tubes for air or mechanical installations. These are all embedded in the floor. other mechanical stuff is in the basement or underneath the large staircase.”

Why did you aim for this sleekness of the façade? That’s because the brick wall was also one whole. We didn’t want to compete with the original art of making it, the details and engineering quality. So that’s why we chose to be abstract. So it was not a matter of restoring the original qualities or looks, but creating something entirely new. So, moving slightly more into the matter of construction and detailing, how did you go about this process? Well, of course we made the construction drawings, but we also sent our façade drawings to a company that specializes in façades and they made their own drawings from that. But of course we checked those, so we do make the details ourselves, but the specialist looks into detail to every screw. When we were analysing the details, we discovered some possible thermal bridges I am not sure it was executed exactly like this. The problem with these kind of buildings is that you already accept some kind of thermal bridges. So it would be a silly idea to make a perfect façade while the rest of the building is not well insulated. It is insulated from the inside. So you are right that there is a leak, but it is very minimal. Looking back, is there something about the design or execution that you regret or would have done differently? No, I do regret that some things in the construction were done wrong, and this resulted in some mistakes. But that was not in our design. You have the flaws of time, although they can be flaws only the architect could see. So I can tell you something about the inner walls. They were made in the wrong color. Luckily there are different shades of black in the building, but then you had the tint of the windows, and then in made it a different kind of grey. And of course there was not much budget for this building. So I think we did well under the given circumstances. I think it is smart we said ‘we use the existing furniture’. We made a trip through the basement of the university with the commissioner, and we found some Friso Kramer and Willem Rietveld furniture we could use, and some lab closets, and we chose the budget furniture from a budget office discounter. But in fact it was the best furniture I could find, in another shade of black. And then we had some budget to redesign the trolley and made a desk for having speeches from very few elements. So no, no regrets.

The Building Structure Spatial organization On the renovated South faรงade of the building one can find the main entrance and in the East faรงade a secondary one. Once entering the building one can see the atrium in the middle of the building which acts as circulation space and a meeting point. The atrium is surrounded by offices, labs, study and meeting rooms. On the East side a big staircase leads (smaller staircase also exists on the West side as well as an elevator on the North side) on floor 0. Smaller staircases also exist on the West and North side as well as an elevator on the North side. On floor 0 the same pattern of layout repeats. A corridor is created around the atrium which leads to offices, labs and meeting rooms. Secondary services such as toilets and store rooms are located next to the big staircase. On the North side there is the entrance to a skywalk which links with the rest of the university campus. Lastly, on the North side of the atrium, there is a staircase that leads to the last level. This level is not in use and the entrance to it is not allowed.

Fig.4 Spatial organization - Floor -1

Fig.5 Spatial organization - Floor 0

Fig.6 Spatial organization - Upper level

Structural system Because of its original function to house technical services, the building has a straightforward geometry with a straightforward structural system. The structure is based on a square grid of 6.2m by 6.2m on which a simple steel frame structure is placed. As with any building, the structure is supported by its foundation. The foundations consists of a shallow basement with concrete beams running along the gridlines in longitudinal direction. The foundation beams are supported by piles, to resist the heavy loading of the boilers. On top of the foundation is a 200mm thick concrete slab which forms the basis of the actual building. On top of this floor, steal HE columns are placed at the intersections of the gridlines. Steel beams are placed in between the columns in transverse direction to support the roof, and after the intervention, also to support the new floor 0. Some braces are added in the roof plane as well, to make a stiff and stable roof plane. Furthermore, there is a lot of secondary steel elements. These smaller steel elements are either for supporting faรงade glazing, or for hoisting equipment originally present in the building. These elements do not contribute to the overall structural system, but are essential for the attachment of various objects. After the intervention, an additional floor has been placed in the steel structure on the transversely oriented beams. The stability of the building comes from the brick walls. The brick walls do not support any floors or roof elements, but without them the building would not be able to resist the wind forces. During the intervention, the south facade was removed, which in turn means a stability wall has been taken out. This has been compensated by two new wind braces in the steel skeleton. The building then is finished up by adding the curtain walls and the roofs, providing protection from the outside elements.

Fig.7 The build up of the structural system

The realization The construction system In this overview, a series of renders show the different elements of which the detail is built up. The construction process is shown step by step, by adding the new elements with every next render. The construction process starts off with prefab window box elements, which are assembled on site. These boxes are supported by a steel inner column. This is followed by the placing of the window panes, insulation and window frames. After this, the ventilation door can be placed in between the window boxes. Then the water run-off and the ventilation grill can be placed. After the construction of the exterior elements, the interior elements have to be assembled. This starts with insulation, followed by a top floor and lastly, the heating element can be placed between the top floor and the windows.

Fig.8 The step by step build up of the fragment

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Detail drawing

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Fig.9 Vertical section of the roof-window Scale 1:5

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Fig.10 Horizontal section of the ventilation and windows Scale 1:5

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Fig.12 Vertical section of the floor-window Scale 1:5

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The material use

door insulation aluminium door frame steel reinforced mullion aluminium door cover perforated steel plate insulation aluminium mullion cement screed top floor heating grill pressure provof floor insulation heating element pressure provof floor insulation existing concrete floor aluminium batten water retaining layer fixating profile faรงade insulation aluminium water runoff

Fig.13 Materials of existing fragment

Fig.14 3D image of the existing fragment

Introduction In the second part of this report, the chosen fragment of the Ceres building is redesigned to be more sustainable and its components more reusable. As this is also an architectural exercise, The concept and ambition for this redesign are laid out first. From there, detail drawings, a 1:1 scale model and a step by step construction plan are made.

PART 18

The redesign The Design Goal This particular building already underwent a transformation from the boiler room to office. The most prominent change was the new south faĂ§ade, now housing the entrance and dark window boxes alternated by ventilation openings. The sleek appearance and the solid, dark character of this part of the building work well with the previously existing architecture. But what if this idea was executed with a priority on sustainability and reusability? What would change, and how can the same expression be made? And also, if you use another material, do you want to mimic the properties of the previous material or use its own strong qualities? These questions accompanied us throughout the process of redesigning the fragment. The makeability and demountability of the redesign were also kept in mind, so overcomplicated constructions were avoided and redeveloped into something comprehensible. Puzzle Connections The challenge of this redesign was to make everything as sustainable as possible, and to be innovative. While playing around with possible ways to connect elements without screws or glue, the idea of â&#x20AC;&#x2DC;puzzle connectionsâ&#x20AC;&#x2122; came about: connection elements by having a specific shape on one, and the negative of this on the other, the pieces could fit together and not fall apart. While looking into some existing puzzles, this gave inspiration to make 3D connections: so two elements in the X and Y plane are put together, and by adding a third element in the Z plane, they are connected.

fig.15 sketches of connections and the ventilation panel

However, as reusability is also a vital part in judging the sustainability, complex cut outs creating strange elements would not favor this. Therefore, the ideas of the sliding in and three-way connections are used, but in a subtle way. The Window Box The window box was the primary starting point of the thought process; how can we make this a sustainable material and a demountable construction system? We were inspired by wooden carpenter connections and chose to go with this idea. by having 4 elements interlock with straight sawtooth edges a window box is composed. To ensure the pieces stay together, each corner will be held together by leading a wooden pin through the saw teeth. This is the three-way connection: the two beams are in X and Y direction, and the pin is in Z direction, which then secures X and

fig.16 the three-way connection of the window box

Y. To test this idea, a small model was made, seen in fig.17. Preferably these window boxes are prefabricated in a dry room, as wood expands in a more humid environment. This will increase the stiffness of the sawtooth and pin connections. To achieve the sleek and seamless look, the double layered glass panel of the window will be connected to the box by pulling in the first panel layer with a wooden T-profile that is connected with additional wooden pins through the window box. In this way, the second glass panel facing the exterior has a seamless and frameless fit onto the window box. The Ventilation Opening In between the window boxes is a perforated plate, letting through air for natural ventilation when the internal door is opened. In order to let in air but keep the consistent closed appearance of the exterior faรงade, a perforated panel is also used in the redesign, however this time in a wooden edition. Also in this case a pin-hole connection is used to connect it to two small wooden beams on the sides, with pins the exact size of the perforation holes, so the perforation pattern remains uninterrupted and homogenous. To be sure the panel does not come off, the pin has a cap to keep the panel from falling outward. The internal door is made out of a wooden framework, which holds the two external plates together by having a T-profile glued onto the plate, which then slides into the framework. In this way, the outside appearance is completely flush, and hinges are not visible. The internal space of the door is filled with styrodur isolation, which can easily be removed when demounted. To avoid overcomplication, and as a slide-in or pin-hole connection was feared to give moisture problems, an exception was made for the door and perforated panel beams, to use screws to attach it to the window boxes. These are the only screws currently used in the design. When it comes to glue: this is only used for the T-profile connections of the door plates, and, inevitably, for the double glazed windows. The pin-hole connections can be demounted by drilling a screw into the pin, and then using this as a handle. Another option is to cut off the excess, making the beam appear solid again. The right expression The exterior of the building is made out of black glazed-

fig.17 Window box test model

brickwork, and to keep the smooth and closed expression, it is important to work with this dark color. As the architect also mentioned it was not his intention to compete with the existing openings, with their white frames. So to achieve this dark color, varnish could be used, but a sustainable alternative is preferred. Some research into sustainable methods of darkening wood was conducted, and one of the options was â&#x20AC;&#x2DC;ebonizingâ&#x20AC;&#x2122;. This uses an iron-rich bark tea infusion to soak the wood in4 . As this method is difficult to master, the necessary ingrediĂŤnts were not available in a short timeframe and it had to be shipped overseas, this option was not chosen. The chosen option is natural and eco-friendly wood protection that has a matte black finish. The coating is based on Aureobasidium pullulans, a harmless mold from nature.5 (a sample piece is presented alongside the 1:1 scale model) For the interior, the design by Diederendirrix combines the dark tones with a lighter color palette. As natural wood has a warmer expression than steel, for the interior the wood kept its natural color, to create a soft note, contrasting with the steel structure.

fig.18 Xylho Wood sample

The construction elements An overview of the different construction elements is to be viewed on the right. This overview is subdivided into a number of categories that refer to important elements of the detail. The different building elements are illustrated with line drawings.

window box

The technical Implementation

Using this overview, one can see in one glance which elements in what quantity are needed and used for a certain building element.

2x vertical element

column

window panes

horizontal element

2x window clamp

airtight rubbers

ventilation door

window panes

door panel

door connection

heating element

door insulation

1x Fig.19 The construction elements of the redesigned fragment

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container for heating elements

heating grill element

2x heating grill element connector

water run-off

2x connecting pin

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pressure proof floor insulation

insulation

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The construction system In this overview, a series of renders show the different elements of which the detail is built up. The construction process is shown step by step, by adding the new elements with every next render. The detail is built up using prefab window boxes, that are being assembled on-site using sawtooth as well as pin connections. Then the window panes can be placed using a pin connection, followed by the ventilation door that is located in between the windowboxes. After this, insulation and the water run-off can be placed, followed by the placement of the ventilation grill. Now the exterior elements of the detail are assembled, it is time to construct the interior of the building. The assembly of the interior starts off with the placement of the floor insulation, followed by a top floor. The last step of the assembly of the detail is the heating element, which can be placed in between the window boxes and the top floor. This heating element is closed off by a wooden grill that enables the heating element to warm up the building. The deconstruction of the detail will use the same steps, the other way around.

Fig.20 The step by step construction of the redesigned fragment

In this illustrated overview, it is shown which elements that are left after deconstruction of the detail are to be seen as reusable building elements, which can be used by other builders in order to achieve a circular building system.

window box

The reusable elements

The elements that are blocked off with a grey rectangle, are not re-usable and the rest of the elements are re-usable.

2x vertical element

column

window panes

horizontal element

re-usable

not re-usable

2x window panes

window clamp

airtight rubbers

ventilation door

Using this overview, one can see in one glance which elements are re-usable and which are not.

door panel

door connection

heating element

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1x Fig.21 The reusable elements of the redesigned fragment

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container for heating elements

heating grill element

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water run-off

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waterproofing foil

fixation bar

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insulation

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The material use To get a more clear grasp on the materialization of the redesign, a set of 2D details is used. Detail 1 shows a horizontal section cutting through the windows and the ventilation door near the concrete floor. Detail 1 clearly shows how the glass is fixed to the wooden mullions with the use of wooden t-profiles. Essential for this concept is the elastic behavior of the rubber seals that are applied in between the glass and the wood. During construction, the windowpane should be firmly pressed against the window box so that the rubber seals compress. When the t-profiles are fixed with the wooden pins, the pressure on the windows can be taken off and the rubbers will expand into their original size, leaving an airtight seal. The mullions are treated on the outside with xyhlo biofinish. This is for the architectural expression; it colors the wood black, referencing the black brick façade that was there before – and it makes the wood more durable, so that it can resist the outside conditions better. Besides the mullions, the ventilation grate and the outer panel of the ventilation door are also treated with xyhlo biofinish. These elements will also be exposed to the outside conditions and therefore need improved durability. The ventilation grate is also visible from the outside so the aesthetic should be the same as that of the window box. The ventilation door is fixed to the mullions with the use of two timber slats. These slats are used to house the hinge and the lock cylinder of the door. The hinge is carefully placed behind the triplex cover plate of the door, so that the visual impact is minimal. Lastly, detail 1 shows the wooden heating grill in the background, under which the heating element is placed.

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Fig.22 Horizontal section of the ventilation and windows Scale 1:5

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Fig.23 Vertical section of the floor-window Scale 1:5

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Detail 2 shows a section through the window near the concrete floor. It can be seen that the fixation of the window to the batten is identical to the fixation shown in detail 1. Furthermore, detail 2 shows the relationship between the window box and the existing concrete floor. The reclination of 150mm from the window box to the ventilation grate is also used here to determine the position of the water runoff. Since the redesign is centralized about sustainability, it can be seen that the water runoff is made out of timber as well. Again, all the wood exposed to the outdoor conditions are treated with xyhlo biofinis, to provide the desired durability and dark aesthetic. To better express the warm qualities of the timber redesign, the top floor is reimagined as a plate of underlayment, extending the warm wood aesthetic further into the building. It can also be seen in this detail how the heating grill is flush with the floor, contributing to the overall sleek design.

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Fig.24 Horizontal section of floor-door Scale 1:5

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On the right page detail 4 is shown. This detail has not been elaborated in the physical model, but shows how the redesign could be applied to the roof detail of the building. A similar water runoff as from the previous two details is used to protect the top of the window boxes against ponding. Furthermore the dimensions and shapes of the current building are kept as much as possible. But the parapet is reimagined from timber and underlayment. Again, all the exposed timber will be treated with xyhlo biofinish to improve durability and to create a consistent aesthetic.

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Detail 3 shows a lot of similarities to detail 2, with the main difference being that the section cuts through the ventilation door rather than the window. Here the position of the water runoff can be seen in relation to the ventilation grate. It is positioned such, that water dripping down from the ventilation grate will not accumulate on top of the water runoff, but rather go in front. Also, since the ventilation grate is perforated, water might get behind it. Therefore the water runoff is extended in this detail until the ventilation door. Furthermore the connection of the mullion and batten is shown. The sawtooth principle explained in the chapter of concepts is clearly shown, with the pin running through them. As explained briefly, the window boxes are prefabricated in a dry room. The fact that wood shrinks when moisture content in the air is low, is used to create an airtight connection without glue. To summarize the process, the timber elements should be thoroughly dried, with lower humidity’s than would reasonably occur in outside conditions. When the beams are sufficiently shrunken, the teeth are sawn in and the pin will be applied. After this, the wood will be introduced to normal humidity levels so that the wood expands again, compressing the teeth against each other. These prefabricated window boxes are then applied into the building as shown in this detail.

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Fig.25 Vertical section of the roof-window Scale 1:5

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The material use

stirodur insulation timber door frame timber slat triplex door cover perforated triplex plate wooden t-profile extended outer panel underlayment top floor timber heating grill pressure provof floor insulation heating element pressure provof floor insulation existing concrete floor wooden batten water retaining layer wooden t-profile wood fibre insulation timber water runoff

Fig.26 Materials of the redesigned fragment

Fig.27 3D image of the redesigned fragment

The building process

Making the incisions needed in the window frame

Creating the first puzzl-like connections for the window box

Drilling the holes where the wooden stick will be placed in order to secure the connection

Inserting Close-up theofwooden the finished round joint stick

Fixed window

Close up view of the joint

Creating the frame of the door. Close up of the joint

Sliding in the outer panel of the door

Close-up of the finished joint

Starting the proccess of placing the window. Putting the rubber into the frameâ&#x20AC;&#x2122;s incisions

Placing the dark foil on the glass

Fixing the glass

Inserting the insulation

Attaching the inner panel of the door. The hinge is hidden behind in order to create a sleek finish in the interior space

Attaching the door to the window frame

Attached door

Making the radiator grill

Drilling holes where the round stick will go through to keep the wooden grill together

Putting in the wooden stick. Making sure that the distance between the grill sticks is even

Wooden grill

Close up of the radiator detail

Placing the vapor retarder and the wooden water drainage profile

Placing the wooden bars that willl hold the ventilation plate

Placing the ventilation plate using wooden pins to connect it to the wooden bar

Fig. 28 Step by step assembly of the 1:1 scale model

Final product

Fig.29-32 Photos of the finished 1:1 scale model

Conclusion and reflection In the Architectural engineering course, we got to experience our first true, full-scale experience with hands-on building. The fact you have to be able to execute the manufacturing yourself, as well as the demand for a high level of demountability, change the thought process quite a lot. This is a challenge, but also encourages to discover new materials, and to be creative in where to look for inspiration. For us, our challenge was to provide an equally interesting building, with a faรงade still fitting with the existing structure, but this time with emphasis on sustainability and circularity, which has not been a key point for the architect. By completing this course we realized how interesting it is to figure out way to create buildings that have less impact on the environment, which is a responsibility we should carry in our future careers. As a group we all had something to bring to the table, so we always had several ways to go about an issue and some interesting discussions, maybe about the balance between practicality and innovativity. We think this balance has been achieved in the end, where we took into account both factors. We hope our design can exemplify that demountable, sustainable structures are able to give an architectural quality which does not have to look temporary at all. Thank you for this course and we will take the attained knowledge with us in our further careers

Sources

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