Plastic Fantastic - Transparent Load Bearing Facade

PLASTIC FANTASTIC transparent load-bearing facade

Eelko Kroon Reinhard Prophitius

1303031 1311689

June 29, 2010

CONTENTS

scenario facade prototype element total building conclusions recommendations sponsors

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SCENARIO - principles

load-bearing: > free plan: no columns needed > linear distributed load: no beams needed > combine two functions: skin & construction > fast building time: damp free construction

transparent: > optimal daylight > clear experience of the free plan

use one material: > transparent plastic: PMMA no glass: > thoroughgoing investigated for years at TU Delft > more fragile PLASTIC FANTASTIC - transparent load-bearing facade

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SCENARIO - material why transparent plastic? > less applications in building practice > new research area

9

SRP (extrusion & compression molding) 8

7

Young's modulus (GPa)

why PMMA? > high Young’s modulus in relation to other polymers > payable (SRP is not) in relation to glass: > tensile strenght much better > Young’s modulus worse > conductivity better > thermal expansion much worse

6

5

PMMA (heat resistant)

4

3

2

1

0 0.1

mechanical properties

0.15

0.2

0.25

Thermal conductivity (W/m.K)

0.3

0.35

thermal properties

350

80

300

70

250

60

200 150

50

PMMA

40

glass PMMA

30

100

20

50 0

glass

10 Young's modulus (GPa)

tensile strenght (MPa)

compressive strength (MPa)

PLASTIC FANTASTIC - transparent load-bearing facade

0

thermal conductivity (W/m•K)

thermal expansion coefficient (μ-strain/°C) 4

SCENARIO - inspiration

aquariums with polymer walls: > outstanding optical clarity > excellent UV properties > high impact resistance: 17 x greater than glass and 4 x greater than concrete > superb weatherability: won’t yellow or show signs of aging > structural: can be engineered to support weight source: > Reynolds Polymer Technology, Inc., USA

Way Beyond Ordinar y PLASTIC FANTASTIC - transparent load-bearing facade

™ 5

SCENARIO - element type 1: > massive 320 mm plate > different versions: - glass window (with alluminium borders) - total PMMA window - integrated ventilation grilles

type 2 - sunshading down

type 2: > two 160 mm leafes with cavity > sun shading inside transparent from floor to floor: > if this is possible, much applications are thinkable! type 1 - window

PLASTIC FANTASTIC - transparent load-bearing facade

type 1 - ventilation grilles

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FACADE - development demands: > U-value below 1.0 > opening window

cantileverd floors (sunshading)

water-filled rectangular tubes in cavity

parabolic colums (to prevent buckling)

(to regulate temperature of inner leaf)

sliding window (minimalistic details)

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FACADE - building physics temperatures: Physibel TRISCO > ∆T inner leaf ≤ 7 °C → acceptable > splitted outer leaf: - ∆T outer leaf 20 mm ≤ 10 °C → tolerances - ∆T outer leaf 60 mm ≤ 10 °C → tolerances > weakest point: sliding window

acoustics: dirActivity BOA > extreme high sound insulation (high density) > weakest point: sliding window PLASTIC FANTASTIC - transparent load-bearing facade

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FACADE - thermal expansion

scale 1:5

> coefficient = 5•10-5 to 9•10-5 mm / mm °C > inner leaf may not expand (realized by heating the cavity) > outer leaf can expand vertical and horizontal (see corner detail)

corner solution (horizontal)

sliding connection

floor solution (vertical)

-10 °C

fixed connection +30 °C PLASTIC FANTASTIC - transparent load-bearing facade

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FACADE - structural mechanics

factor = 20

forces: TNO DIANA > deflection of facade panel on ground floor is too much (7.5 mm) [due to low E] > all stresses below allowed material properties > a 10 storeys high building can only be achieved with light weight floors

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FACADE - overview

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FACADE - details

scale 1:20

prototype

vertical section

prototype

front view

prototype

PLASTIC FANTASTIC - transparent load-bearing facade

horizontal section

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PROTOTYPE - targets & simplifications targets: > show degree of transparancy and refraction > test sliding window > test glueing methods and connections

PLASTIC FANTASTIC - transparent load-bearing facade

simplifications: > (much) thinner plates > extruded in stead of molded plate quality > smaller grid size (because of standard platesizes) > no water in the tube system

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PROTOTYPE - shop drawings

scale 1:10

axonometric drawing frame

front view

PLASTIC FANTASTIC - transparent load-bearing facade

vertical section

horizontal section

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PROTOTYPE - platesizes

scale 1:10

preparation for lasercutting

tubes and window frame, thickness = 10 mm

PLASTIC FANTASTIC - transparent load-bearing facade

window, thickness = 10 mm

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PROTOTYPE - platesizes

cavity leafs, thickness = 5 mm

PLASTIC FANTASTIC - transparent load-bearing facade

scale 1:10

ventilation grille, thickness = 8 mm

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PROTOTYPE - building proces inner leaf

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PROTOTYPE - building proces rectangular water-tubes

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PROTOTYPE - building proces window frame + window

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PROTOTYPE - building proces outer leaf

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PROTOTYPE - conclusions conclusions: > white spots in glue seams (by use of wrong glue) > dichloromethane is a better glue, but is not useable for extruded plates > in a factory they will use a very expensive two-components glue which will give the best result > sliding window operates well > simplification of window frame (4 glued plates) decreases transparency > too big tolerances in ventilation grille

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ELEMENT - construction sequence inner leaf + rectangular tubes

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ELEMENT - construction sequence parabolic anti-buckling columns

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ELEMENT - construction sequence window frames

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ELEMENT - construction sequence place on floor (use neoprene)

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ELEMENT - construction sequence next floor (use neoprene)

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ELEMENT - construction sequence clamp shoe

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ELEMENT - construction sequence outer leaves + clamp plates

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ELEMENT - construction sequence cantilevered floors

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ELEMENT - construction sequence complete storey

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TOTAL BUILDING - overview

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CONCLUSIONS negative: > sliding window is the weakest point in every technical aspect: - decreases thermal and sound insulation - increases deflection of facade element > window frame decreases degree of transparency and requires complex details > much water needed to regulate temperature in whole facade > 10 storeys is too much: - unacceptable deflection above window (caused by permanent load of the storeys above) > PMMA is very expensive positive: > excellent sound insulation > good load-bearing facade > lower U-value than regular glass (< 1.0) > extraordinary experience for users general: > good transparent load-bearing facade for a few storeys high building (without windows the facade will operate much better)

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RECOMMENDATIONS

30 °C 22 °C

24 °C

25 °C

-10 °C

23 °C

23 °C

> apply thin layer (µm) of glass on outer leaf to prevent against weather conditions > reuse the water of the floor heating system in the facade > apply a sprinkler installation > ventilation grilles can be placed in the cantilevered floors in stead of in the facade (no sound and heat leak) > try to keep the permanent load of the building low (if you want to create a building with more storeys)

scale 1:20

30 °C 22 °C 25 °C heating system application: window strip

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SPONSORS - special thanks to: materials:

finance:

DEN DUNNEN

Bouwonderneming bv http://www.coops-plastics.nl/

Nijmegen

http://www.dendunnenbv.nl/

Hardinxveld-Gâ&#x20AC;&#x2122;dam

PMMA-plates with discount, coordination for free

http://www.creaacryl.nl/

Nijehaske (Heerenveen)

Delft

http://tudelft.nl/

CNC-lasercutting PMMA-plates

http://chconstructions.com/

Gorinchem

http://www.koopmans.nl/

Enschede

steel frame for free

OTTOlin X SP

BV

http://www.ottolinx.nl/ powdercoating frame for free

PLASTIC FANTASTIC - transparent load-bearing facade

Gorinchem

e b d l u o w t i s r o s n o p s ! e e p s y e t h o t t ro p a e without t a e r c o t e l impossib 34