KKnitlock Thesis

Studio Knitlock

Master Thesis Studio K E LV I N K A R E L

Masters Design Thesis Studio Studio 3: Knitlock Special thanks to Professor Philip James Goad for making this project possible _________________ Author: Kelvin Karel | 629642 Studio Leader: Prof Philip James Goad

University of Melbourne Melbourne School of Design Masters of Architecture Semester 2 of 2016

Content

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103 35 123

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007 Thesis Statement 009 Hypothesis 012 Knitlock 029 Griffins 035 Griffins Pholiota 045 The Brief 049 The KKnitlock 067 The Kpholiota 097 Two Bedroom House 103 Three Bedroom House 113 The Site 123 Group Housing 137 Knitlock Making 159 Bibliography

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Thesis Statement

The thesis seeks to formulate an approach to design an architecture that reflects upon the minimal living vision of Walter Burley Griffin. As a result, it brings about a heightened spiritual dimension, as the architecture aims to strip inessential elements to achieve the essence of truth.

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Hypothesis

Contemporary living nowadays has turned most dwellings into image products isolated from existential depth and sincerity.

They use different materials to cover up the flaws of buildings, to create a clean outlook that would be appealing to the eyes.

This inarticulates the experience of our being-in-the-world and makes us mere spectators of pretty pictures.

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Knitlock

Knitlock was a patent system of concrete block constructed in 1917 by Walter Burley Griffin.

It was used for only perhaps a couple of dozen buildings, and is one of the least influential aspects of the use of concrete in Australia.

Knitlock is a system based on engineering principles to achieve economy of design. It is based on machines for cheap manufacture, and lightness and compactness for minimizing transport, and on standard units assembled without hand fitting, cutting, bedding or plastering for speedy erection.

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Knitlock

Knitlock Components

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It was Griffin’s attempt to develop a dry system of masonry construction that joins together like lego blocks. The teeth will ‘knit’ itself with the opposing block to create a sturdy connection without the use of mortar. However, was forced to compromise upon hand grouting of vertical joints to enhance connection between the knitlock blocks.

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Knitlock

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With the intention of enabling individuals to be self-reliant in building their own home, Griffin has manufactured a knitlock machine. The builder would either purchase it or rent it to manufacture the knitlock modules on-site. This Knitlock machine is hand operated, but took the drudgery out of casting concrete blocks with hand held tools and hand-manipulated molds.

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Knitlock

Knitlock Machine

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The hinged arm of the machine swung over and pressed into the concrete lying in the mold on the table to complete the indented profile of the block.

These compression on the mixture in the mold enabled a faster set to the concrete, making a speedier tile production.

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Knitlock

Knitlock Machine

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What is so special about the Knitlock blocks were the use of only 7 typical blocks to construct a home.

There are only two types of segments - Vertebral, which lock together to make the frame work or skeleton, and Tesseral, which lock together for two-ply curtain walls, attaching to and stretching between the vertebral columns.

The double wall provides for lap joints everywhere, and between the inner and outer layers there is an insulation layer of bitumen.

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Knitlock

Full Tesseral Block

Half Tesseral Block

Double Female Quadrant

Male/Female Quadrant

Double Male Quadrant

Male/Female Tangent

Double Male Tangent

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The possible connection of Knitlock blocks shown in this image, proves the system to be rather flexible. It is able to achieve what a normal wall could but at a dimension that would be divisible by 6 inch.

This is due to the 12 inch by 6 inch length of a half Tesseral piece.

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Knitlock

Half Column

Straight wall

Standalone Half Column

Full Column with 180 degree connection

Full Column with degree connection

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Another means of construction method that are similar in comparison to the Griffin’s Knitlock system would be Frank Lloyd Wright’s Textile Block. It is still unknown whether whom influences who, but they both have the same goal in mind.

Frank Lloyd Wrights design intent was to convey a sense of “true mass” while offering the possibility of a “rich encrustation” of integral decoration. It had to look “permanent”, yet have the intefrity of a “system”.

To achieve a system that is economical, cheap in materal and its’ labor reduced to the barest minimum.

This has been proven in some of his built homes such as the Millard house and Ennis house

Even with the same goal, Wright’s design of the block is rather different from the Knitlock’s.

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Textile Block

Frank Lloyd Wright Textile Blocks

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The measurements for the textile block is sixteen-inch square tile, it is less than four inches thick at its borders but hollowed out on the rear. Semicircular grooves that is found along the sides are left to contain reinforcements and grout to tie the tiles up firmly. It is meant to be a double wall with 600mm width of air gap for insulation purpose.

His intentions of a “true mass� was a success, but in terms of an economical system, it was a let down. More than forty different patterns were ultimately required, and the blocks proved to be difficult to mould, fragile and highly water absorptive.

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Millard house Textile block

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Walter Burley Griffin (1876– 1937) was born and raised near Chicago. He was an american architect who worked in the United States, Australia and India. His professional career spanned nearly forty years: the early years as a young architect in turn of the century Chicago (1899-1914), the following twenty years in Australia (1914-1935) and the last two years India (1935– 1937) before his untimely death in India aged 59.

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Griffins

Walter Burley Griffin

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Nature was to be his great source of inspiration. The young architect worked for Frank Lloyd Wright, and we have a sense that his work at that time was suffused with the ‘Spirit of Nature’ in the great tradition of the American transcendentalists, Emerson and Thoreau. This was combined with a search for pure form–a geometric, abstract ideal–inspired by the patterns of nature. This love of nature was evident not only in his and Marion Mahony Griffin’s work, but also in their lives. One example of their work would be the Glenard Estate in Victoria, Australia.

Walter Burley Griffin was inspired by ideals of equity and democracy and a passionate regard for nature.

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Griffins

Walter Burley Griffin & Marion Mahony Griffin behind their ‘Pholiota’

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The Glenard Estate, Eaglemont is a residential estate designed

by Walter Burley Griffin and Marion Mahony Griffin in 1915. A residential subdivision that harmonises with topography and indigenous vegetation in the vicinity. The Griffins took account of the topography of the site and its native vegetation, as well as existing exotic plantings dating from the 1860s. They provided safe internal public spaces within the estate to cater for community needs.

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The shared back garden behind homes were intended to be a playing space for children, safe from motor traffic and easily supervised. Fencing between houses, were avoided to allow the ‘flow’ of landscape from communal to private areas and encourages neighbourliness in the community.

Glenard Estate

Glenard Estate, Eaglemont, 1916

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Griffins’ Pholiota

The idea of creating a Pholiota, Griffin’s Melbourne home, was to prove that Knitlock is evidently buildable. Griffins found inspiration in the idea to build the pholiota that reflects their minimal way living.

The spaces arranged revolves round the living area, while services area, such as kitchen, bathroom are placed in the corners.

The Pholiota is 6.6m by 6.6m wide and has a minimum ceiling height of 2.4m and gradually increases in the living area.

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Pholiota

Kelvin Karel 629642 Studio Knitlock

B

Griffins’ Pholiota

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2

3

8

9

4

A

A

Ground Floor Plan Total Area :43.56m²

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B

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5

1. Toilet 2. Bed Alcove 1 3. Dressing 4. Lounge 5. Entryt 6. Bed Alcove 2 7. Kitchen 8. Fire Place 9. Living Area

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Pholiota

North Elevation

South Elevation

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Kelvin Karel 629642 Studio Knitlock

Pholiota

Griffins’ Pholiota

Kelvin Karel 629642 Studio Knitlock

East Elevation

West Elevation

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The play in height shown in the section, is intended to create a more comfortable height space for the private areas while a grander experience in the central space.

Typical windows has also been placed all around the house to allow natural light to brighten the house.

Separation of private spaces such as the bed alcoves and toilet are by curtains that will be drawn when guests arrives.

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Pholiota

Griffins’ Pholiota

Kelvin Karel 629642 Studio Knitlock

Section A

Section B

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Overall, the pholiota achieved their vision of creating a new lifestyle, new form and a different way of living. And with the integration of Knitlock system, it makes the construction much simpler and cleaner.

However, things to consider improving would be the thermal issues, electrical switches, privacy. Floor to wall integration has to be thought of to make the availability of second floor possible within the close system.

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Griffins’ Pholiota

Griffin’s Pholiota

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The Brief

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The Brief

1. Design a new ‘Pholiota’ A 21st century tiny house that makes use of a system derived from Griffins’ Knitlock. The house is to be for a single person or couple and represent only the essentials for suburban living. It is to be minimal and affordable and climatically responsible.

2. Design a new set of Knitlock-inspired houses.

Each student is allocated a set of eight blocks on Glenard Estate, Eaglemont. The site must contain the new ‘Pholiota’ and doubling the density on the remaining area. Students have to come up with 14 two and three bedroom Knitlock houses to produce an ideal suburbia.

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The KKnitlock

The Griffins’ Knitlock system has been a success in expressing their idea of minimal living, away from the conventional.

However, there is still room for improvements to better enhance the Knitlock system’s thermal capacity and to open up the possibilty for second storey housing in the future.

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The KKnitlock

Full Tesseral Block

Half Tesseral Block

Double Female Quadrant

Male/Female Quadrant

Double Male Quadrant

Male/Female Tangent

Double Male Tangent

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Full Tesseral Block

Half Tesseral Block

Double Female Quadrant

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Male/Female Quadrant

Double Male Quadrant

Male/Female Tangent

Double Male Tangent

The KKnitlock

Tesseral

Half Tesseral

Quadrant

Tangent

Griffin’s Knitlock

KKnitlock

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The aim of KKnitlock is to improve the thermal property, structural capacity and minimise the number of modular blocks.

The three Double Gender Vertebral has thus been removed as the four remaining pieces is sufficient to build a home made out of Knitlock.

The KKnitlock block size has now increased to 500mm wide to thicken the concrete.

The teeth of the modules has also been reduced to half to create a 50mm air gap in between teeth for insulation purposes. Insulation Batts can be introduced in these air gaps to increase its thermal performance.

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KKnitlock Tesseral V2.0 has also been designed to support the load of a floor slab above.

It is in the shape of a Tesseral piece but with a corbel casted into it. The upper part of the Tesseral V2.0 will be 100mm thick while the lower part stays the same. Half Tesseral pieces also exist.

The KKnitlock

KKnitlock Tesseral V2.0

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The connection of KKnitlock are similar to the Griffins’.

Reinforcement bars are placed at every point where two ends meet and grouted over to form a sturdier wall.

Hardie Break­ ™ Thermal strip is being introduced to KKnitlock system. It is a 10mm thick, compliant thermal break strip that caps the teeth of the KKnitlock blocks. This prevents the contact of exterior piece with the interior, reducing the chances of thermal bridge.

Shown on the bottom right are the different ways to cap the teeth.

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The KKnitlock

Straight Wall Connection

Half Column Connection Full Column Connection

Hardie Break Opt 1

Hardie Break Opt 2

Hardie Break Opt 3

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Isonometric of full column connection

The KKnitlock

Half column Connection Standalone full column

Right angle corner connection

Full column connection at 180 degrees

Full column connection at 90 degrees Three Quarter Column connection

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A detailed drawings of the connection between the walls and the flat roof. 150mm thk Hollow core slab has been used as the concrete roof to allow services, such as communication cables, to run through the slab. Between the exterior and interior KKnitlock blocks are core fill grout with reinforcement bars, ending off with concrete coping at the top.

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The KKnitlock

Upper floor to roof Details

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Roof connection

Upper floor slab connection

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The KKnitlock

Floor to Wall Details 63

Construction Sequence 1. 500mm long Precast Concrete Coping with Dowel Rod and Anchor Pin. 2. 150mm Thk Hollow Core Slab with 50mm of Screed to fall.

3. Embedded Corbel in Knitlock Module to support roof/floor above.

4. Reinforced bars from slab to be placed in between modules to create a firmer tie when grouted.

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The KKnitlock

1.

2.

3.

4.

Exploded geometry of floor to roof 65

The KPholiota

Sawmill House

by Archier Studio The Sawmill House uses large reclaimed one tonne blocks of reclaimed concrete which anchor it into the landscape and a dynamic active building envelope to regulate the internal environment. The dwelling is a hand crafted upgrade from an existing rather rustic, bohemian abode, befitting a regionally based sculptor.

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In terms of context, the texture mimic the sedimentary layers of earth still exposed from the site’s former life as a gold mine before becoming the local sawmill. The untreated rough sawn macrocarpa screens reference the site’s recent history and over time as they pale to grey will settle the building into its perch on the quarry’s edge.

Precedence

Sawmill house by Archier Studio

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The Sawmill house became the main inspiration to built the new Pholiota. Not only was it a modern home that was built recently but it has flexibility in spaces where modern houses has.

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Prototype 1

Decking 21.7 m²

Dining 13.7 m²

Living 9.4 m²

Study 9.6 m²

Courtyard 16.6 m² Entry 6 m²

Ground Floor Plan

Kitchen 6 m²

Toilet 4 m²

Q(1.5x1.9)

Bedroom 8.1 m²

Total Area :95.1m²

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This was however denied in the mid semester. The spaces are too huge, doubling the total area of Griffins’ Pholiota.

Furthermore, the house

looks conventional and it shy away from the Griffins’ vision of minimal living.

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Prototype 1

Decking 21.7 m²

Dining 13.7 m²

Living 9.4 m²

Study 9.6 m²

Courtyard 16.6 m² Entry 6 m²

Ground Floor Plan

Kitchen 6 m²

Toilet 4 m²

Q(1.5x1.9)

Bedroom 8.1 m²

Total Area :95.1m²

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What is minimal living ?

What makes a house minimal ?

What is a conventional home ?

How is pholiota different compared to conventional homes ?

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Minimal architecture simplifies living spaces to reveal quality of buildings. It is an idea to reduce all parts, such as details and joinery to a stage where no one can remove anything further to improve the design.

It is stripping down everything to its essential, revealing the inner qualities of materials.

This is in line with the Japanese Zen philosophy. The ideas of freedom and essence of living.

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This is very much different from conventional architecture, in which most cases, aims to create pretty pictures that appeals to the eyes. This results in the use of different materials to cover up flaws in buildings, detaching them from existential depth and sincerity.

Minimal Living

Buildings conveying a minimalist lifestyle

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As minimal living means to strip everything to its essential, i began to ask myself what really is essential to us ?

According to Maslow’s Hierarchy of Needs, focusing only on the bottom two levels, our basic needs are air, food, water, shelter, sleep, security.

Next i applied these answers into the spaces of the pholiota, to only take those spaces that are a real neccessity for our living needs.

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Minimal Living

Maslow Hierachy of Needs

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Pholiota

B

Kelvin Karel 629642 Studio Knitlock

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2

3

8

9

4

A

A

Ground Floor Plan

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6

B

7

5

1. Toilet 2. Bed Alcove 1 3. Dressing 4. Lounge 5. Entryt 6. Bed Alcove 2 7. Kitchen 8. Fire Place 9. Living Area

Pholiota

Kelvin Karel 629642 Studio Knitlock

B

Griffins’ Pholiota

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2

3

8

9

4

A

A

Ground Floor Plan Total Area: 43.56m²

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B

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5

1. Toilet 2. Bed Alcove 1 3. Dressing 4. Lounge 5. Entryt 6. Bed Alcove 2 7. Kitchen 8. Fire Place 9. Living Area

Griffins’ Pholiota

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Neccessary spaces in homes

Toilet

Dining

Laundry

Kitchen

Bed

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Necessity

Private

Toilet

Bed

Public

Dining

Kitchen

Laundry

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Private

Public

Toilet

Dining

Bed

Kitchen

Laundry

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Necessity

Private

Public

Toilet

Dining

Bed

Kitchen

Laundry

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The design intent of the new Kpholiota is therefore a revised plan that reflects the minimal living attitude of the Griffins’.

Spaces are reduced to its essential areas in homes that could provide users with the basic necessity of living needs such as food, water, shelter, sleep and security.

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Kpholiota

1

2

3

A 7

6

4 5

Kpholiota Ground Floor Plan

Total Area :50.29m² 1.

2.

3.

4.

5.

6.

7.

Bed Alcove Kitchen Timber deck Dining Entry Toilet Bathtub

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A

Kpholiota Ground Floor Plan

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Kpholiota

Private

Public A

Kpholiota Ground Floor Plan

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Fire place is attached to Kpholiota to give resemblance to the original pholiota. It is also placed near the kitchen and dining as owners usually spent most of their time in this spaces.

A play of ceiling height between the walkway and other spaces exist to create a more comfortable head space in the private areas and a grander experience when one steps in.

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Kpholiota

1

Kpholiota Section A

2

1. Dining 2. Bathtub

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Kpholiota Entry

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Kpholiota kitchen and dining

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“The tactile sense connects us with time and tradition: through impressions of touch we shake the hands of countless generations.�

Juhani Pallasmaa

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Kpholiota Bed Alcove

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Two Bedroom House

Two bedroom house of KKnitlock are similar to the Kpholiota with addition of a bathroom with wardrobe and bed alcove near the fire place. The roof will be flat with concrete coping covering the gaps of the KKnitlock. This is to emphasize on the verticality and accentuate the unique profile of the Knitlock’s vertebral element.

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Two Bedroom

A

1

3

2

4

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7

5

6

8 Ground Floor Plan

Total Area :65.77m² 1. Bed Alcove 1 2. Kitchen 3. Timber Deck 4. Dining 5. Fire place 6. Bed Alcove 2 7. Toilet 8. Entry 9. Bathroom

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1

2

Two Bedroom House Section A

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3

1. Kitchen 2. Fireplace 3. Bed Alcove

Two Bedroom

Two Bedroom House Outlook

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Three Bedroom House

A

1

2

3 B 4

9

5

8

7

Ground Floor Plans

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6

Total Area :71.70m² 1. Bed Alcove 1 2. Kitchen 3. Timber Deck 4. Fireplace 5. Dining 6. Entry 7. Store room 8. Toilet 1 9. Bathtub

Three Bedroom

A

1

2 B

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5

3

4

First Floor Plans

Total Area :64.89m² 1. Bed Alcove 2 2. Balcony 3. Toilet 2 4. Living 5. Study 6. Bed Alcove 3 105

1

2

3

Three Bedroom House Section A

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5

4

1. Balcony 2. Kitchen 3. Fireplace 4. Entry 5. Living

Three Bedroom

1

2

3 4

Three Bedroom House Section B

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1.

2.

3.

4.

5.

Bed Alcove 1 Balcony Bed Alcove 2 Walkway Kitchen

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Three Bedroom House Stairs

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Three Bedroom House Living Area

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The three bedroom KKnitlock house has a second storey creating more variety in the given plot of land. It caters to the need for young families. Living area are found on the second storey to allow for quality time with the family.

The three bedroom houses will be placed nearer to the back garden in the Glenard Estate as it will be more likely for them to house kids.

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Three Bedroom

Three Bedroom House Outlook

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Mel

b

e ourn

CBD

Flinders Street Railway Station

Heidelberg Station

Eaglemont Station

Glenard Estate

13.7 KILOMETERS

The site

Travelling Time -----

46 Minutes

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35 Minutes

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58 Minutes

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159 Minutes

The site located at Glenard drive is 13.7km away from the city. It is a peaceful estate where lush of greenery could be found. Yarra valley parkland is right beside it, making it convenient for residents to take a breather, such as cycling or taking the family out. It gets noisy at the North-West edge of the Glenard Estate, the junction, during the peak hours.

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The Site

Glenard Estate, Eaglemont

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The site is approximately 43m x 137m in length, which would be more than sufficient to double up the density with KKnitlock houses and altering the houses to get the optimal natural light. The tricky part would be the contours that goes down 7m diagonally across the site, Southern part being the highest. This is due to having a concept of self sufficiency, reduce excessive negative influence on the natural environment. This ties back to the concept of minimal living.

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The Site

Sun Analysis

Wind Analysis

Contour Analysis 117

The idea behind the KKnitlock masterplan is to reflect the vision of the Griffins Glenard estate into a smaller and denser plot of land. Not only will it show the improved version of minimal living, but also allow for a flow of nature in and out of the private and public spaces due to the inexistent of fencing among the KKnitlock houses.

This will overall bring a stronger bond among the community, making it the ideal suburbia estate in Eaglemont.

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A

A

Steps are introduced all across the site. Not only will it allow for a more comfortable walking environment, but also acts as a playground to children as they get lost within the KKnitlock community.

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The Site

Site Section A

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Group Housing

Schindler House

by Rudolph Schindler Schindler House is a masterpiece that incorporates both architectural and social theory, it unfolds formally, spatially and intellectually with a coherence unparalleled in early modern architecture. It was a shared vision of Schindler and his wife then, as a communal living house to be shared with another couple. What started of with an experiment of commnunal living has led to the house becoming the focus of constant social gatherings.

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Group Housing

Schindler House by Rudolph Schindler

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In order to achieve the same effect of a constant social gathering in the community, I began to close up on four houses as a base point to design the KKnitlock masterplan.

As you have come to realise, the houses has all been removed of living areas, except for the three bedrooms, due to the believe that it was not a necessity.

Living areas are a space for social interaction and relaxation and thus, would be more applicable to placed them outside, as a shared living space.

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The diagram has therefore, shown how houses are being placed in a way a shared living space is right by their doorstep.

All the houses faces either the North or the back garden, giving them an unobstructed view of the landscape.

Furthermore, this creates the blurring of boundary of where private courtyard actually ends.

In terms of privacy, more trees will be proposed to reduce the visibility of next door neighbour and achieve the sense of living with nature.

Group Housing

Shared Living Space

Illustration of proposed shared living space Two-Bedroom House Three-Bedroom House Pathway 127

There will be a total of 4 shared living spaces that are connected together through 1.5m~2m wide pathway. And in these shared living spaces, there will be 3 different features that will cater for the KKnitlock community.

First, will be a pergola made out of KKnitlock blocks to allow people to have Barbeques.

Second, concrete seats with a planter box in the middle for a more intimate interaction.

Lastly, a sheltered outdoor space for other various events such as birthday parties.

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Group Housing

Pergola

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Knitlock Benches

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Group Housing

Sheltered Outdoor living

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To ‘Knit’ the whole KKnitlock community as one, vertebral elements are placed at random aligning them with columns of the adjacent home. Some will also be use as a support to hold up timber joist for sunshading purposes at different parts of the community.

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Group Housing

Group housing Isonometric

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Fin.

Knitlock Making

Manufacturing a knitlock machine similar to the Griffin’s will be a long and tiring process to complete as not much blueprint is available online. With only twelve weeks of study period, our group has decided to choose another way of casting the knitlock module. It is by the use of silicon module.

This is a much simpler process as silicon does not stick to any materials and would allow for mass production using a single mould.

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Knitlock Making

Illustration of a Knitlock negative mould

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1. The positive mould will be achieved through 3d printing or laser cutting of multiple pieces of MDF. 2. A boundary will be formed to create a negative of the module when the silicon is poured in. It is to prevent any silicon to leak out during the curing process.

3. When the silicon is cured, concrete will be poured into the negative mould of the silicon to get a Knitlock module.

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Knitlock Making

Boundary

Positive mould

Puctured Base to hold positive mould in place

Base

Dowel

Exploded Geometry of positive mould

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All listed items on the right are made by 3mm thk MDF. Positive mould will be stacked one on top of another and connected with a dowel. This allow for authoration in height if the first prototype was a success. The stacked positive mould is then slotted in to the punctured base to lock it in place. The boundary is then stacked on top before the silicon is poured in.

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Knitlock Making

Boundary

Positive Mould

Base

Dowel

Punctured Base

Layout of MDF pieces for laser cutting

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Laser cut file is collected and fixed accordingly. Prototype is 30mm high compared to the actual 300mm to reduce wastage of materials if product fails.

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Knitlock Making

The making of negative mould

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Pinky Silicon mixture comes in two parts, solution A & solution B. Both solutions are placed in a plastic bowl and is mixed thoroughly. This should happen within 2-3 minutes as the solution will start to hardens.

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Knitlock Making

Mixing of Pinky silicon solution

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After about 2-3 minutes, mixture is then poured to the moulding box to let it cure for a day.

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Knitlock Making

Filling positive mould with pinky silicon solution

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Next day, dowels are taken out and the boundaries are removed layer after layer.

Resulting in a negative silicon mould.

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Knitlock Making

Cured pinky silicon negative mould

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Concrete is mixed with water and is stirred continuously until it thickens. The negative silicon mould is then placed in the moulding box before concrete is poured in, preventing any distortion. Light tapping of the boundary to give a little vibration to the set concrete helps to remove the bubbles of the concrete resulting in a smoother outcome.

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Knitlock Making

Making of concrete mould

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After 7 days of keeping it in a dry and cool place, its time to get the Module out. 7 days is the optimal amount of time needed for the concrete to cure.

We removed the boundary of the negative mould layer by layer. And suprisingly, the mould came out easily.

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Knitlock Making

Cured Knitlock concrete block

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Fin.

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