Robotic Fabrication Clay Printing - Grégoire Gagneux

PORTFOLIO GAGNEUX

GRÉGOIRE

BA Architectural Studies 4th Year Studio Christian J. Lange January - April 2019

I. T H E

THE

USE

PRECEDENTS

CASE

STUDIES

OF

BRICK

THE

IN

HISTORY

Project : Great Mosque of DjennĂŠ Location : DjennĂŠ, Mali Architecture : Sudano-Sahelian architectural style ; build in the XIIIth Century, rebuilt in

1907 with adobes bricks

The adobe’s material come directly from the location. We only keep the clay as main material, which is only a part in % of the elements of the ground.

1 - Vegetable residue

2 - Water

1 2

3 3 - Clay

4 - Silt

4

5 6

5 - Sand

6 - Gravels

In a handful of earth, the clay that will be used to make the brick is present in only 32% of earth.

The adobe (Arabic: ‫ )بوطلا‬is "clay that, mixed with water and a small amount of chopped straw or other binder, can be shaped into sun-dried bricks"

Adobes, also called mud bricks, are air-dried clay bricks without kiln firing. Traditionally, they are molded by hand in a wooden mold and then dried at room temperature. It is a multi-millennial technique, still used today in many places around the world. The molds used can be wood or metal. For better sized bricks and a stronger mold, it is better to use metal molds. On average, up to 600 adobes can be manufactured in one day.

Fabrication process _

The bell ends of the Great Mosque are made in advance, to be directly posed and cemented with the rest of the wall. They are assembled with customized adobes, in order to obtain this effect bell, whose curves will then be softened when they will be under mortar.

3m

Informative page

Ax o n omet r ic dr aw ing Axonometric drawing

Adobe

Plaster

Sand and earth based mortar

Final result : adobe + mortar + plaster

The walls of the Great Mosque are made of sun-baked earth bricks (called ferey), and sand and earth based mortar, and are coated with a plaster which gives the building its smooth, sculpted look.

The combination of mortar and adobes provide this brown color throughout the building. Together, these are the two major elements of the Mosque, which from a structural point of view is stable. However, other facteruses come into play. Since 1907, date of the rehabilitation of the Mosque, an annual event has been put in place: the coating of the facades.

Because of the location of the project, the weather conditions are sometimes very wet, which weakens the land of adobe by returning it to the wet state.

Cement serves both to stop this moisture, but also to provide strong protection against the winds and heat of the sun, as well as potential pests (insects, animals, wild vegetation etc.).

The adobe bricks are then completely covered, and gives the cement the freedom to play with the curves of the Great Mosque. Today this aesthetic is considered by many architects to be one of the greatest achievements of the Sudano-Sahelian architectural style.

The walls of the building are decorated with bundles of rodier palm (Borassus aethiopum) sticks, called toron, that project about 60 cm from the surface. In addition to their decorative aspect, they play an essential role in the architectural composition of the Great Mosque. The sticks are arranged at equidistant distance from each other. The adobes are organized around them, to guarantee a solidity and a structural point of attachment.

Also, the sticks serve to play a role of ventilation. In case of rain, a large part of the water will be rejected by the pre-disposed cement layer. However, if water can penetrate into the heart of the adobes, it becomes problematic. The sticks serve to receive the introduced water, absorbing it, and distributing it throughout the stick. Once the sun is back, the end of the stick outside will dry which will also affect the part of the stick inside the material. The toron also serves as readymade scaffolding for the annual repairs.

Exploring ideas

Project : Mila Casa’s attic Location : Barcelona, Spain Architecture : Modernism & Baroque style, Antonio Gaudi’s last project,

1912. Area 1835m2

Gaudi was fascinated by the natural world. Soem authors say that the drawing of the attic comes from the shape of a whale’s ribcage.

The arches remind of the shell of a sailing vessel.

The longitudinal rib of the attic might be planted inspired.

Fundamental principles The construction of an vault is based on calculs and proportions.

The shape, size and weight of the structure are the major factors to consider.

Calcul of the angle

Calcul of the weight

The initial bricks are laid on a counter-form, allied to each other by means of a morter. They are deposited first on the flank, up to the arrow.

Once connected, we gently remove the counterform.

G W Rx

F

I

M

E

C

II

U

N

Y V

Fy . 7 = O

T

1

P

Calcul of the proportions

Informative page

When creating la Casa Mila’s attic Gaudi made use of construction ressources employed in some of his formers works to seek maximum functionalism, while at the same time formulating an aesthetically pleasing ot structure.

For the mould, the carpenters manufactured wooden arches using the parabolic curves that Gaudi has previously traced as basis. Seeking maximum structural efficiency, in la Mila Casa’s attic Gaudi created a constructive systme that was quite remote from the solutions used by his contemporaries.

Supported by a wooden framework, labourers were responsible for constructing the different arches.

Source from The Pedrera’s attic.

Brick Types Bricks, according to their positioning in front of the arch, have different characteristics. Those on the curve of the parable, according to the lightest, with 3 layers, in order to support the structural bricks that rest on them.

Parabolic Attic The parabolic arches rest on complex counter-forms, which must determine exactly the right forces throughout the structure.

The arches of the Mila Casa are all of different sizes, but give an organic effect wanted by Antonio Gaudi. At the time, it was the result of a wonder of construction in frame, which rested on custom frames, by appealing to the best Spanish carpenters.

Nesting between the brics on the parabola and the horizontal bricks

Vertical brics on parables

Insertion of the brics on the counterform in frame

Exploring ideas

Ax o Axonometric nomet r ic drawing dr aw ing

II. T H E

T H E P U R P O S E C O L L E C T I N G

CONCEPT

OF

THE

T H E

BRICK WATER

The emergence of new technologies in the manufacturing field has revealed some important potentials for the 21st century. The use of brick - a thousand-year-old component in architecture - also has great potential.

It is a material that can be used around the world, from natural and ecological resources. The 3D printing of clay with the aid of a robot makes it possible to manufacture with great precision particular brick protoypes, massively, adaptable, with unique characteristics.

The question asked for this project has been from the beginning: how the use of a robotic arm can create a brick project that is useful, easy to assemble, and that can be adapted to a variety of environments by serving a cause?

Previous research has led us to focus on the relationship between the brick and the rainwater. The clay, an element derived from the earth, is able to filter water by its only chemical composition. Thus, our project was to develop a brick whose design allows to collect the rainwater, then serve it via an internal pipe system. Applied on a large scale, the brick system can be applied on a facade, and collect a maximum of rainwater, to serve gardens in balconies, or be stored and served for equipment such as toilets, showers, washbasins. This makes the building sustainable not only in the use of energy, but also during its manufacture.

The design of the bricks is based on important climatic analyzes. Their length, orientation and shape change according to the wind and rainwater of the environment,in order to collect a maximum amount of rainwater.

Each brick becomes unique, and the performance of the robotic arm becomes indispensable in their production.

pt and Development

0_ Col

-

1_ San

Piping to usage

2_ Cla

Rain harvesting facade

catchment lead

Catchment tank

nal Schematic

General System Overview

1 - Creation of bricks collecting the water to be then used to serve people.

2 - Easy application of the bricks everywhere in the world (= intuitive system of assembly).

ethod

Start

3- Optimise the shape and size of the bricks based on climatic analysis to collect of a maximum of water in an environnement.

180°

Spee

Brick Concept and Development Brick Concept and Development

Speed: 5

r printing

Printing whole component in one line

P steep and thin curves and patterns 0_ Collect

ls

-

No. of Layers: 3 Condition: Bisque Type of Glaze: Glossy Texture: Printed

No. of Layers: 4 Condition: Bisque Type of Glaze: Glossy Texture: Printed

No. of Layers: 5 Condition: Bisque Type of Glaze: Glossy Texture: Printed

No. of Layers: 3 Condition: Bisque 1_ Sand & Rocks Type of Glaze: Glossy Texture: Smooth

Piping to usage Rain harvesting facade

No. of Layers: 5 Condition: Bisque Type of Glaze: Glossy Texture: Smooth

No. of Layers: 4 Condition: Bisque Type of Glaze: Glossy Texture: Smooth

2_ Clay

No. of Layers: 5 Condition: Greenware Type of Glaze: Glossy Texture: Printed

Piping to usage Rain harvesting facade

No. of Layers: 3 Condition: Greenware Type of Glaze: Glossy Texture: Printed

catchment lead

catchment lead Catchment tank

hanges Through Drying

Corner Iterations

Sectional Schematic

General System Overview

Catchment tank

40 mm

Printing Method

Sectional Schematic

General System Overview

S ch em ati c s e c ti o n

Schemat ic sy st em of filt r a t i on

Start

Speed: 100%

180°

Printing Method 3D Model

Bisqueware

Start

Greenware

block

End of walll Speed: 50%strecher bond block

Side o

S c he m ati c p er for mance of t he br ick

III. T H E P R O C E S S

ROBOTIC P R O T O T Y P E S

&

FABRICATION EXPERIMENTATION

T H E

FABRICATION

&

THE

EVOLUTION

The robotic arm prints the brick in layers of soft clay. It is programmed to follow a series of points designing the exact geometry of the 3D model.

^ The HAL robotic arm is programmed in manual control. During the printing process, it is essential to control the robot’s movements, namely the printing speed, its height, its special operations –which are not defined in the code– and the good fluidity of the clay fitting in its extruder.

^ Printing various sections at different speeds to alter line thickness and to build steep, thin curves and pattern.

Once printed, the clay undergoes deformation due to the hygrometry and temperature of its environment. The desired final form must take these factors into account. Therefore it is necessary to experiment massively and analyse these deformations that can cause cracks in the printed layers if they are not sufficiently controlled.

^ Corner iterations.

The design of the bricks is based on many climatic analyses. Their length, orientation and shape change according to the wind and rainwater of the environment, in order to collect a maximum amount of water. Each brick is unique, and the performance of the robotic arm becomes indispensable in their production.

^ First prototype of the wall designed to collect the rainwater.

^ Printed method : flipping the brick to shape its internal curve.

Structural Prototypes & Parameters

Then, the bricks pile up due to their shape: the hole of their basis serves as a pipe to let rainwater pass through. The autonomous system can reach more than two meters high, over a length of three meters. In the form of slabs, the brick system can be hung on concrete structures, and can therefore be applied to large areas, at heights never reached before in a brick building. Once baked and glazed, the bricks are strong enough to withstand severe weather conditions.

^ Printing the whole component in one line.

^ Structural prototypes and different parameters.

The construction process of the brick system requires a perfect mastery of the object, in its 3D design, in its printing and then, in its assembly. Each brick is unique, and the degree of detail obtained with the robot has never been achieved in the history of clay construction.

Code generated by Grasshopper, translated into numbers informing the robot the geometry points to follow.

Programming of the geometry and assembly system.

Printed brick unit.

Assembly in a precise order of the bricks together following their geometry.

Programming the assembly robotic arm for massive production.

Final prototype obtained of the wall, made of baked and glazed 3D bricks.

The possibility of building massively with automated tools makes us wonder what the future building industry will be like. Is the complete construction of buildings with pre-programmed robots possible? The question arises when the robotic arm is able to replace the know-how of a worker, changing the status of the architect who is no longer only the designer, but also becomes the programmer and thus the builder.

Printing the internal attic

Reverse

Collecting brick

Top view of the corner bricks on top of each others

IV. T H E F I N A L W A L L

ASSEMBLY R E S U L T O B T A I N E D

T H E A N D

BRICKS EFFICIENCY

G l a z i ng th e b ri c k s : m ak i n g t hem imper meable and and more res i s tant to wi nd and s o met imes v iolent w eat her condit ions

Ca t a l o g an d s o rt the b ri cks according t o t heir char act er ist ics, th e i r s i z es , the ir shapes, t heir or ient at ions

V. T H E

PROJECT

WAH

FU

ANALYSIS

&

ESTATE APPLICATION

Urban analysis and location in the Hong Kong Island

Units and Layout DN

Material S

UP B A

A

Three Unit Types Ranging from 33.1 to 39.9 SQM

A

C

C

A

A

A

A

A

A

C A

A

A

DN

UP

B

DN UP

Structural Concept Structural Shear Walls with perpendicular beams and diaphragm flooring

Water Dra

Drains for hou hold utilities a connected by centralized dr pump and ven pump

Water is pump to the top of th building and d tributed by gra

Cl i m ati c analysis of t he sit e

S o l ar rad i ati o n

W ind / r ain or ient at ion

W i n d p res s u re o n t he Wah Fu t est at e t ow er s

Th e wi nter-g ard e n : a way t o apply t he collect ing w at er ’s br icks.

1 _ E x i s ti ng f ac ad e

3 _ A d d i t i o n o f wi nd o ws and s l i ding d o o rs

2_ Remove exist ing facade

4_ A ddit ion of a balcony, appli ca t i on of t he br ick syst em, addit ion of s ma l l gardens feeded by t he w at er col l ect ed by t he br icks

Se c ti o n an d ap p licat ion of t he w int er garden

Typology

1

Typology

2

Typology

3

Typology

4

Ax o no m e t r ic view of t he project

GA GNEUX

GRÉGO IRE

BAA S 4 - St udio C hr ist ian J. LA NG E Facult y of A rchit ect ure & HKU Ur b a n L a b T he Univer sit y of Hong Kong Januar y - Apr il 2019