Urban Tectonics_a morphological biocomposite research by lea.garguet-duport

URBAN TECTONICS [A MORPHOLOGICAL BIOCOMPOSITE RESEARCH]

URBAN TECTONICS

URBAN TECTONICS [A MORPHOLOGICAL BIOCOMPOSITE RESEARCH]

Research developed by Léa Garguet-Duport Studio: C.Bioma Thesis Supervisor: Marcos Cruz and Kunaljit Chadha “Thesis presented to obtain the qualification of Master Degree from the Institute of Advanced Architecture of Catalonia” Institute of Advanced Architecture of Catalonia Masters of Advanced Architecture (MAA02) 2019-2021

Barcelona September 2021

URBAN TECTONICS

URBAN TECTONICS [A MORPHOLOGICAL BIOCOMPOSITE RESEARCH]

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ACKNOWLEDGEMENTS

I would like to thank my supervisor Marcos Cruz, for this tough year of online learning and the guidance and dedication he has given us in this unpredictable year throughout this research project. His knowledge and constant suggestions along the process were a key in the development of this thesis. I would also like to thank Kunaljit Singh Chadha for his support in the thesis development as well as fabrication, material and prototype processes carried out. In addition, I would like to acknowledge the fabrication support team Shyam Zonca and Ricardo Mayor for their digital fabrication support they have provided over this period, and without whom I would have not achieved the final prototypes.

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INDEX

01_FRAMEWORK 1_Abstract 2_Introduction 3_Scientific Interest 4_Aims and Objectives 5_Context

02_ECOLOGIES

03_STATE OF THE ART

04_MATERIALS 1_Biocomposite 2_Material Catalogue 3_Brick Composition 4_Strength Test

05_GEOMETRY 1_Geometry Exploration 2_Cliff Forms 3_Eroding Surface 4_Digital Surface Exploration

06_ FABRICATION 1_Process 01 2_Process 02 3_Process 03

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07_DESIGN APPLICATION 1_Dredging 2_Port of Rotterdam 3_Base system 4_Developed system 5_Design growth 6_Urban Tectonics

138

08_CONCLUSION

154

09_BIBLIOGRAPHY

158

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01 FRAMEWORK

Fig.1 _ Rafi Youatt, n.d.

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ABSTRACT

This research aims to investigate different material and construction methods to address the current urbanization and ecological crisis in the built environment; through a focused research and understanding of cliff tectonics and its ecological system. By addressing the ageing buildings and the way they have been conditioned in the existing environmental surrounding, suggests new morphological systems to be developed. The current static nature of our urban areas does not allow for any formal changes within its skin condition, generating problems in the longevity of the construction system. This research proposes a multilayered biocomposite made from a mixture of waste and raw materials as a fabrication framework. Its aim is to generate microclimates that dynamically respond to its context and allow various biodiverse ecosystems to take place. The biocomposite will be evaluated through different material densities and formations that could allow different levels of growth and geological structures to occur. Through the means of a subtractive manufacturing process, the layers will start to be exposed and create different tectonics for pockets, cavities and fold to develop within the surface. The material system will focus on generating its own cliff system that is responsive to the natural phenomenon’s that occur in nature as a possible solution for the built morphologies that exist. This investigation proposes a new language for a morphological architecture that focuses on creating various microclimates that allow for different biodiverse systems to occur within a vertical surface that is dynamic and responsive within an urban context.

KEY WORDS Biocomposite, BioIntegration, Responsive systems, Subtractive manufacturing, Urban Cliff, Morphologies, Tectonics, Growth

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INTRODUCTION

The current building environment is built up of unsustainable mechanisms that are generating large amounts of carbon dioxide and greenhouse gases. Concrete as being a major factor in this current crisis needs to be reconsidered as the main material for our territory. “Concrete is how we try to tame nature. Our slabs protect us from the elements. They keep the rain from our heads, the cold from our bones and the mud from our feet. But they also entomb vast tracts of fertile soil, constipate rivers, choke habitats” (Watts, 2019) Our current construction model accounts for “40% of energy consumption and a third of CO2 emissions” (Chayaamor-Heil and Hannachi-Belkadi, 2017). Hence, concrete has become a delicate subject in the world of technological, biological and ecological innovation due to its inability to meet new demanding sustainability policies and ecological protocols. Researchers are currently investigating alternative material systems that could encompass the new terrain of sustainability goals; for the future urbanization crisis. (Lee, 2005). Our current social and environmental understanding is being reconditioned in order to focus on conservation of natural resources and sustainable living. The current methods of construction are based on the paradigm shift of the Industrial revolution and lacks the potential of interaction. New notions are starting to take action towards a 4th industrial revolution “characterized by a fusion of technologies that is blurring the lines between the physical, digital, and biological spheres“, in the words of Klaus Schwab, Founder and Executive Chairman of the World Economic Forum” (Hebel and Heisel, 2017, pg.8). In this period of change, nature and all the complexities it faces starts to offer some suggestions of how this new built environment can incorporate ecologically driven designs of material life cycles, biodiverse life systems and environmental responses. The influence of implementing principles found in nature has recently led to the multidisciplinary field of biomateriality, where biology plays a key role in

Fig.2 _ United Nations Environment Programme and Bajornas, n.d

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developing a new architectural language. This new tectonic is a means to align natural materials together with technological innovations in order to develop systems that are self-adaptive, resilient and cohabits within the environment. The effect that nature has on vertical surfaces is a direct response of how a material is interacting with the environment. Currently “Surfaces have been explored extensively by architects and designers of the digital era as topologically fascinating models of spatial organization” (Hensel and Achim Menges, 2008, pg 89). The material in which the surface is made of plays an essential role in this interaction, hence the chemical and physical characteristics of the material might define its skin condition. By understanding the root system of the natural phenomenon’s that have continuously readapted and reacted to the environmental elements; there is no reason why our built form cannot emulate what is currently happening in nature. Moreover, an interest in living organisms for scientists arises from its natural capacity to adapt and become self-healing, or even tolerant or resistant to new environmental exposure. “Biomimetics has given rise to new technologies inspired by such biological solutions at macroand nanoscales” (Hebel and Heisel, 2017, pg.157) The merging of the different fields can create a new rich culture of design principals to emulate ecological wealth within the urban realm. This thesis aims to propose a strategy of combining new advanced technologies and develop a biocomposite living system that can respond and harness the energy from its built environment. To feed into a dynamic and responsive system as a means to achieve a biodegradable mechanism. The future of the built environment relies on a future that needs to be self-sufficient and waste-conscious. Hence, the need to

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investigate a new urban framework for an interconnected responsive system that reacts to the conditions it may be surrounded by becomes essential. The current static form of the built world must change and adapt now through different use of scale to allow this new system to respond, adapt and regulate to interior and exterior environments. By understanding the fundamental behaviors and functions that occur in nature at a micro-scale in order to create an interactive, responsive, and functioning skins that can be used at both micro and macro scale of our built architecture. This research will be segmented by creating a base understanding of our current natural cliff formations and how they have been conditioned over time through different environmental factors. In order to develop a new biocomposite system, that is using raw and waste materials to generate a biodegradable and resilient structure that can dynamically respond and contribute to the environmental sustainable goals. The prototypes aims to suggest a new design process allowing for erosion to take place within the fabrication system as a geological and morphological iterative process. As time occurs the leaching, deposition and erosion of the material will be embedded within the system for growth to start forming. The project aims to constitute a complex, multilayered prototype through a cross discipline of biology, computation, geology and architecture; where a relationship between organisms and their environment will take place.

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SCIENTIFIC INTEREST

Through this research some questions have come to the surface and are discussions that will be present throughout this research document. Can we answer the challenges of our climate crisis and urbanization through biotechnology, responsive and performative technologies that could as well contribute to biodiversity? Creating a biomaterial that can regenerate or biodegrade when its cycle is over. Generating a responsive and living system that adapts to changes in the environment.

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AIMS AND OBJECTIVES

This thesis aims to address the ageing buildings and the way they have been conditioned in the existing environmental surrounding, by generating different morphological systems with a biocomposite that can create microclimates that dynamically responds to its context and allow various biodiverse ecosystems to take place 1. To develop a bio-composite: by integrating a multilayered system that can be affected by different environmental conditions. Through a study of morphological systems that are currently present in cliff formations. different material densities and formations to generate a composite with various geological forms using the different properties of the waste and natural resources 2. To investigate different advanced manufacturing techniques in order to cast a multilayered biocomposite. By investigating various techniques of subtractive manufacturing to achieve the most suitable process for sustainable fabrication procedure. 3. To propose the Urban Tectonic that focuses on creating different microclimates that allow for different bio diverse systems to occur within a vertical surface. To use the prototypes developed as parameters to propose a new Morphological architectural system that is dynamic and can allow for different biodiverse life to cohabit in an urban context.

Fig.3 _ piqsels, n.d.

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CONTEXT

CLIMATE CHANGE

“We are facing a global emergency” (Rifkin, 2019) Cities need to transform urgently, to meet shared climate and sustainable development goals, but also to provide a livable future for the coming generations. As cities keep growing there is a necessity for more resources to be available to generate the future built environment. However, resources are becoming scarcer and induce significant amounts of waste and pollution in our environment.

“Just because we can make all of our buildings out of concrete and steel doesn’t mean we should. But it will require big change” (Michelle Oyen) Discussions are being made for the future of our cities and what it means for the urbanization that is currently happening. What are the different ways in which we can build in order to reduce the carbon emission of our cities. “Populations in the world’s largest 750 cities are expected to grow by 410 million between now and 2030” (UN, 2015). How can we accommodate for this shift? How can we accommodate for this shift? Currently 40% of the global carbon emission is generated by the built environment (UN, 2015), and considering what still needs to be built in the upcoming years will add to this already alarming number. How can we challenge this current methodology and find new ways to address this emergency? In addition to urbanization issues, there is an outburst in scale that is the ‘Urban territory’ which has become a representational catalogue of the

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Building industry Environmental Impact

40%

Global Carbon Emission

ECOLOGICAL FOOTPRINT

BUILT ENVIRONMENT

The built environment has left an enormous ecological footprint responsible for 40% of global carbon emissions alone, while natural resources are becoming increasingly scarce.

URBANIZATION

68%

of the world population projected to live in urban areas by 2050

BUILDING MORE

ACCOMODATING CHANGE

Today, 55% of the world’s population lives in urban areas, a proportion that is expected to increase to 68% by 2050

Biodiversity

47%

reduction in global indicators of ecosystem

ECOLOGICAL FABRICATION

EARTH SYMBISOS

1 million animal and plant species are now threatened with extinction Biodiversity awareness (UN, 2015)

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unnatural. The human disturbance occurring in our set environment has obstructed the habitation of our species. There has been a 47% reduction in global indicators of ecosystems (UN, 2015), as a result over “1million plant and animal species are threatened to extinction” (UN, 2015). Our current city model because of rapid urbanization goes from “cities that were originally regarded as green are gradually being transformed into concrete” (Karanja and Matara, 2013). This drastic shift is a result of land use change, from a vegetated state to a new built-up environment to accommodate for the current urbanization crisis. These shifts over the years have caused damages not only within the biodiversity of species and organisms but has had huge impacts on our soils. There are still possibilities of change, but we need to be willing to change the way we build. Nature can offer some of these solutions if we can adapt and harness and research all that it can produce. Urban tectonics aims to address how our current buildings have been conditioned in the existing environmental surrounding, by investigating different morphological systems through a biocomposite that can generate microclimates that dynamically responds to its context and allow various biodiverse ecosystems to take place. By understanding our current crisis in the way we build, there is a need for our construction process to change and to see what resources could be used in order for our ecological footprint to be minimized and for the ecosystem to keep growing. By investigating into natural cliff formations and the way they have been conditioned over time, patterns and geological forms can be taken apart and used as principals for the way we build. Understanding the fundamental behaviors and functions that occur in nature at a micro-scale to create interactive, responsive, and functioning skins that can be used at both micro and macro scale of our built architecture. By creating dynamic skins that adapt to the climate, this can offer new methods of looking at structural and thermal designs that will be more efficient.

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“Constructing buildings out of entirely new materials would mean completely rethinking the whole industry. But if you want to do something really transformative to bring down carbon emissions, then I think that’s what we have to do.” Michelle Oyen

Fig.4_Rahman, 2016

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02 CLIFF ECOLOGIES

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SOIL

Functioning of the ecosystem relies on soil health. The health within our grounds relies on the microorganisms that live within the grounds. Pockets in soil to catch the CO2. 26

depth of soil

To address this crisis we can start investigating the richness within our soils. Looking specifically at clay and its rich nutrient based soil, offers a large reservoir of biodiverse life. Clay, because of its density, retains moisture well. It also tends to be more nutrient-rich than other soil types. Nutrients within the soil include hydrous aluminium phyllosilicates (clay minerals) that develops plasticity when wet. Geologic clay deposits are most often composed of ‘phyllosilicate minerals’, this means that they contain different amounts of water that are trapped in the mineral structure of the clay. Soils have the ability to sequester carbon, it is a natural process that occurs in nature where the removal of carbon dioxide is being done. (Cho, 2018) This sequestration of carbon within the soils is an effective natural process that removes excess carbon dioxide from the atmosphere. The soils organic matter can be used as a carbon sink for the atmospheric carbon gases that are produced (Churchman et al., 2020). Soils can store these carbon molecules which is estimated to be around “20 Pg C in 25 years, more than 10 % of the anthropogenic emissions”. (Food and Agriculture Organization of the United Nations, 2020).

Layering Verticality Growth within cavities biodiversity Animals

Plants

C02 absorption Cliffs worldwide are known to be reservoirs of relict biodiversity. Despite the presence of harsh abiotic conditions, large endemic floras live in such environments.

CO2 from environment

c02

c02c0

c02

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CLIFFS

As well as being a carbon sink, this process adds other benefits within the soils such as prevention of erosion and desertification. Hence, an increase or stability of biodiversity can occur. These natural cycles of carbon sinks offer great potential for material innovation systems to be integrated in future built forms. Cliffs are able to accommodate for various biodiverse types of species due to its large vertical span and enables different species to cohabit within its walls. CLIFFS Cliffs have a regenerative system where it reacts to its environment by being able to remove layers of its skin as a response to its exposure. Coastal cliffs are faced with harsh conditions where its skin retreats and sediments accumulate at the bottom. This displacement of material creates a buildup of matter that can encourage growth and give rise to a new ecological system. Cliffs allow for a large biodiverse ecosystem to inhabit its surface layers, through all of its folds, joints, faults, cavities and pockets, along its entire cliff face. Species are able to adapt to these different micro environments created along its verticality.

Cliff formations

Shelf / Bench

Cliff

More extreme cliff

Less extreme cliff

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Ecosystem BIO_diversity

COMMUNITY PLANTS AND ANIMALS

PLANT SPECIES ANIMAL SPECIES LIVING ORGANISMS _COMMUNITY OF PLANT, ANIMAL AND MICROBE

BIOLOGICAL CONSTITUENTS BIOTIC

ABIOTIC Non living organism that affect the environment, they are the physical factors such as air, temperature, moisture, rock and soil. They contribute to the organism’s habitat. BIOTIC On the other spectrum is the living organisms and components of an ecosystem such as organic matter This difference between adjacent land and cliffs is partly attributable to cliffs being “‘permanent habitat edges’ characterized by abrupt changes in soil, topography, geomorphology and microclimate combined with local conditions” (Matheson & Larson, 1998). The formations of these extreme surfaces form different tectonics that allow various species to adapt and start inhabiting these zones.

PHYSICAL ENVIRONMENT

SITE DEFINED BY CLIMATE SITE DEFINED BY GEOLOGICAL CONDITIONS

PHYSICAL MORPHOLOGY ABIOTIC

BIODIVERSITY Biodiversity and ecosystem functions of plants and bacteria species are a response to local factors of soil pH, moisture and temperature, geological terrain it inhabits as well as the rock and weathering formations. The geology formation and its reaction to the environment is a direct representation of what species and life can occur in an area. In mountainous regions a link “between geological processes and biological communities has been recently revealed by showing the effect of erosion and soil heterogeneity on biodiversity” (Hu et al., 2020). These areas are faced with “tectonic boundaries, such as sutures and faults” and through the various stages of elevation different species will live in those micro environments. The relationship between species and habitats that are formed along these zones offers for more biodiversity to occur.

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By having different topographic roughness and a greater horizontal and vertical structure than other systems in nature the vegetation appear to be responsible for an increased bird species diversity. Bird species adapt better to conditions that are alternating in vegetation, where there might be different species of plants and animals along the surface of these environments. (Ward & Anderson, 1988). Cliffs worldwide are known to be reservoirs of biodiversity. Despite the presence of extreme abiotic conditions, large endemic floras are able to survive and adapt to such environments. In addition, the specificity of cliffs is the wide range and variation of ground conditions it offers. The various forms cavities, crevices and ledges that form within cliffs provide different habitat for a large number of species. There are various ways in which plants grow on a cliff face for example between ledges, cracks, undercuts. The sediment accumulation act as perfect opportunities for species to habit. The different species of trees and shrubs tend to grow on the top of the larger cracks. The biodiversity within the species that grow in these cliff faces vary on the smoothness of the face of the cliff. A lot of the plants will be more likely to grow in areas inside cracks due to large sediment build up and the ability to have larger surface area and material composite to plant its roots. These natural systems that have been generating in nature throughout time can suggest a tectonic system to be incorporated within our built environment. Where material weathering and growth can cohabit and create new pockets to promote biodiversity in urban areas.

GEOLOGICAL FORMATIONS “Cities are dominated by exotic or invasive species drawn from distant biogeographical provinces and the action of human disturbance and technology has resulted in the creation of physical and chemical environments that do not occur in nature” (Lundholm, 2004) Factors affecting the cliff morphologies WIND Cliffs are responsive mechanisms to its surroundings and wind has a direct impact on the organisms that inhabit and colonize the rock surface. There is a correlation that can be drawn of the wind and air patterns surrounding the cliffs and the way the cliff and its ridges perform along its verticality. Cliff surfaces are subject to high wind speed and turbulence due its large exposure of the façade. The turbulent wind speed that cliffs face and the organisms that inhabit these cliffs has a strong influence on the micro climate it generates “Wind speed controls the size of the boundary layer, the thin layer of air that is directly adherent to the rock surface.” (Lundholm, 2004, pg 64). According to the elevation points of the cliff its exposure to high winds and turbulence will differ, causing different reactions to the rock face. (Larson, Uta Matthes and Kelly, 2005). High wind speed will often lead to a drying and cooling effect of the cliffs that are more damp whereas surfaces that are below dewpoint will most likely cause condensation along its skin.

Fig.9_ Ying, 2021

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Fig.10 _ Alkefjellet magic, n.d.

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Fine, wind blown layer of sand

WATER Vertical cliffs rock formations do not retain a lot of water, whereas “sandy soils hold around 25 per cent of water by volume when fully saturated, and clay soils as much as 60 per cent” (Larson, Uta Matthes and Kelly, 2005, pg 57). This does not however affect the living organisms or life of species. The ability for cliff rocks and faces to absorb or hold water will depend drastically on the geological formations and the materials porosity and its weathering characteristics.

Quaterney head deposit of poorly consolidated clay, silt sand and gravel

Uncemented sand layer 10

TEMPERATURE Temperature considers many different elements, the factors interacting within a cliff formation will perform and generate a result on the cliffs skin. The local conditions “such as thermal and hydrologic isolation, rock type and local climate” (Larson, Uta Matthes and Kelly, 2005, pg 64) will have drastic influence on the physical properties of the cliff face.

Interbedded sandstone and mudstone

Layer of coarse grained shingle at the cliff toe, varying in thickness and steepness

SEDIMENTATION DISPLACEMENT buildup

Fig.11 _ Earlie, Masselink and Russell, 2018

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Fig.12_ Ernst J. van Jaarsveld, 2015

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COAST CONDITION Seaweed growth on rock Green Algae – are dark to bright green in color and show up on the glass and rock of fresh and saltwater. They can be a single cell or live in colonies and range in size. They can be free floating which turn water green or grown on rock or even shells of animals. With low and high tide differentiation the seaweed clings onto wet surface and stays in place.

HUMID AREA

Fig.6_Jungle Dragon, n.d.

OPEN AREA

Fig.7_ Difference Between Algae and Moss, n.d.

Brown seaweed

Fig.8_ The outer shores, 2021

Green seaweed

DRY CONDITION This coastal condition in a dry area and the species that grow in these area tend to not require too much water.

DRY CONDITION

OPEN AREA

Fig.13_ Ernst J. van Jaarsveld, 2015

Fig.14_ Ernst J. van Jaarsveld, 2015

Lidakense

Bulbine spongiosa

Fig.15_ nationalparks, n.d.

Juniper

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Fissures

Ledges

Deep Cliff-Face Caves

Shallow Crevices

Cliff cavities and grooves formed from different environment factors. These formations of pockets and crevices along the different vertical zones contributes to the ecology biodiversity. (Larson, Uta Matthes and Kelly, 2005)

INland CONDITION The biodiversity within the species that grow within these cliff faces vary on the smoothness of the face of the cliff. A lot of the plants will be more likely to grow in areas inside cracks due to large sediment build up.

HUMID AREA

Fig.16_ moss covered rocks, n.d.

Moss

ENCLOSED AREA

Fig.17_ Alamy, n.d.

Penstemon rupicola

Fig.18_Jutting stone Cliff, n.d.

Vines

Fig.19_ Jottings Of the Journal of Threatened Taxa, 2019

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FLORA

TOP OF CLIFF Potentilletum sacifrage

An understanding of cliff habitat can be understood through the various ecosystems. How can we read the verticality through the different organisms that live at different levels of altitude? How can we interrogate and create new life and biodiversity at different scales? FLORA Often cliffs are the sites for species that are rare elsewhere. The reasoning for this is that generally cliffs are faced with more extreme environmental conditions. Therefore, the plant and animal species that are usually found in such location have to be able to deal with the more extreme environmental fluxes. These cliffs can often be unprotected which allows species to have to be able to survive such harsh conditions. In addition, due to the usually large span and often verticality of cliffs there is very few disturbances which allows species to not compete with one another. Thus, all cliffs, including sea cliffs and artificial cliffs, can be described as habitats with minimal disturbance by humans and other species which allows for specific species that are slow growing to adapt and colonize over time. Most inland cliffs and man-made cliffs support a sparse vegetation of lower plants which include “bryophytes, lichens, epilithic algae and endolithic algae or lichens” (Larson, Uta Matthes and Kelly, 2005, pg. 112)

BASE OF CLIFF

Found on the upper sections of cliffs Cupressus sempervirens

Grips to limestone cliff between crevices

Geranium robertianum

Species that grows on the face of the cliff Fungi

Adiantum capillus veneris

Growth in the crevices Parietaria officinalis

Vine like species that attaches to flatter sections Growth in the crevices towards the base

Pinguicula vulgaris Ferns

Often grounded at base of cliff

Growth in the crevices

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FAUNA Raptors

Raven

Raccoon

Minuscule ledges to small grassy banks on sea cliff. Raccoons use cracks, fissures, ledges and trees to scale the cliff face.

A gyrfalcon

FAUNA Cliffs worldwide support a variety of protists and animals including a vast array of invertebrates, amphibians, reptiles, birds and mammals. Cliffs appear to support a greater species richness of birds than equal areas within the surrounding habitat. The animals and organisms that start to inhabit these vertical surfaces need to adapt to sparse resources. The ecology in cliffs are very rich but do offer very specific conditions that are not suited for all life.

Rough legged Hawk

Use the gaps within the cliff Kittiwakes Can be found at various heights of cliffs.

Raven

Minuscule ledges to small grassy banks on sea cliff.

Nest height usually closer to the bottom

Fig. 5 _ Larson, Uta Matthes and Kelly, 2005

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SYSTEM SCHEME

URban tectonics BUILT MORPHOLOGY

GROUND CONDITION

Cliff face + Crevices, Ridges, Grooves, Channels + Abiotic & Biotic Factors

ENVIRONMENT SOIL EROSION DEGRADES INTO THE GROUND

PROMOTES BIODIVERSITY IN AN AREA that is limited to dense urbanization

RAW MATERIAL WASTE MATERIAL

BIOCOMPOSITE SYSTEM THAT REFLECTS THE ENVIRONMENT

PHYSICAL WEATHERING

No Changes in composition

CHEMICAL WEATHERING -Changes in composition -Dissolution of minerals -Assimilation of minerals

MICRO DISPLACEMENT OF MATTER RESPONSIVE SKIN

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ECOLOGIES

Harvard biologist Edward O. Wilson, “the extinction of species by human activity continues to accelerate, fast enough to eliminate more than half of all species by the end of this century”— (Rifkin, 2019) In the other spectrum of natural formations, we are dealing with “Urban settlements are characterized by hard surfaces, at least on the outsides of stone, brick and wooden buildings.” (Lundholm, 2004). This contrast in man made and the natural causes problems for our ecology and natural landscapes. How can we remediate this system that has been going on for so long. Our procedures of building today need to change mindsets and work alongside nature to create rich environments for both man and nature to co-exist. By going through the ecological wealth that can be found in cliff conditions and soils a new architectural system could be investigated where the two work in symbiosis. “In the natural world, form and metabolism have a very different relationship. There is an intricate choreography of energy and material that determines the morphology of living forms, their relations to each other, and which drives the self-organisation of populations and ecological systems.” (Hensel, Achim Menges and Architectural Association (Londyn, 2008)

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LANDSCAPE EROSION_HOUDINI EXPERIMENT

Fig.20 _ Vaganski Vrh, n.d.

Fig.21_NPS national park service

Fig.22_Aaron Reed

Erosion is the geological process in which materials are torn away and transported by natural forces such as wind or water.

Base terrains were created in Houdini, and erosion simulation were being tested. Through these simulations, an understanding of geological changes that are occurring in the ground formation can start being analyzed. These early experiments were carried out to start visualizing the way the different physical and environmental conditions affect our grounds over a certain amount of time.

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03 STATE OF THE ART Project references that were looked at for thesis development.

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STATE OF THE ART

Projects that were looked at for their research on similar topics as reference projects for this thesis development.

Algae Cellunoi This installation is a system developing cellular components that act as scaffold for algae to grow. The geometry contains gaps and crevices that aim to interact with its environmental surrounding. The introduction of living organisms within the cellular components allows for growth along the various ridges and patterns to form. This integration of natural species within a formwork allows for a bioreceptive façade to evolve, generating an ecology of natural elements Team: Marcos and Marjan, Richard Beckett and Guan Lee Fig.23 _ marjan-colletti, 2013

The Global Change institute This project developed for the university campus in Australia is the first carbon neutral building in Australia. This project aims to achieve the highest levels of sustainability for ground of ecological transformation. The use of reclaimed waste from industrial waste products such as fly ash produced by coal-fired power stations to generate material efficient structure meeting sustainable building schemes. “Production of this novel concrete requires about 36% less energy and emits up to 76% less carbon dioxide as compared to conventional bendable concrete made of cement,” says Dr Nematollahi. Fig.24 _ Angus Martin, 2014

Team: Concrete manufacturer Wagners, Bligh Tanner Consulting Engineers and architects HASSELL

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Responsive Manifolds This project developed at IAAC, aims to address the possibility of using living organisms as a responsive element through a Bioreceptive façade system by investigating geometrical surface quality for bacterial receptivity. The Bio integrated system performs to create a material system that hosts, controls and manipulates growth. This material and surface exploration for growth behaviors to develop a responsive skin as a new architectural element is one that can inform the development of this research. Fig.25 _ Material Research Group, 2016

Yessica Mendez Iaac 2015/2016

Bio Concretion

Fig.26 _ Tobias Grumstrup Lund hrstrøm, 2015

This project developed in IAAC, aims to develop a nature-based solution for building designs. Looking into traditional hatching roof structures made of seagrass and transitioning it into a new innovative system using computational tools following principals in nature. These nature-based solutions in parallel with innovative fabrication systems proposes a new typology with functional, structural and environmental performances for a sustainable construction. In addition, to using a biomaterial the system integrates the ecology surrounding nature. The material being used therefore, offers ground for new parallels between the natural ecologies and the built form. Tobias Grumstrup Lund Hrstrom Iaac 2015

Design for ageing buildings

Fig.27 _ Yessica Gabriela Mendez Sierra, 2016

This thesis project developed in IAAC , aims to address the ageing conditions of the vernacular buildings and the reaction they form when being exposed to the environment. The research focuses on generating a bio receptive system that integrates Bio deterioration and erosion in its materiality on a vertical surface. By the aid of computational simulations a system is developed to create a controlled vertical system reflected its environmental surrounding. The correlations drawn between the built and the natural environment represents groundwork for the development of this thesis. Team: Nina Jotanovic Iaac 2015/2016

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04 Materials Material composition, looking at biocomposite using natural and raw materials.

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BIOMATERIALS

“The 21st century will face a radical paradigm shift in how we produce materials for the construction of our habitat. While the period of the first industrial revolution, in the 18th and 19th century has resulted in a conversion from regenerative (agrarian) to nonregenerative material sources (mines)” (Hebel and Heisel, 2017, pg.8)

BIOCOMPOSITE: Biocomposites are natural fibre-reinforced biopolymers. Current researchers have been investigating these materials as an alternative to current material systems that are nonrenewable or are significantly damaging to the environment due its production process. Many possible uses are being generating within different fields to create alternative building systems that are reinforced with natural fibers. In recent years a lot of natural fibers such as flax, hemp, jute … are being analyzed to understand the chemical and physical properties they contain and how they could potentially be used or replace current non-natural reinforcements methods. In addition, aggregates will also be integrated within the development of the biocomposite to add structural properties to the system. As of now the building industry uses aggregates within its construction process, however this is often in association with cement to form

concrete. In this instance the biocomposite alongside the aggregates will perform as a sustainable material system.

“Biocomposites with both bio-fibre(s) and bio-based matrix, commonly called ‘green composites’ are biodegradable; prone to environmental and microbial degradation after disposal, without having an adverse environmental effect” (Oluwarotimi Ismail and Dhakal, 2020, pg. 124). WASTE MATERIAL: Marble dust is a material is a byproduct of waste generated from cutting and polishing of marble stone, it is a large industry that produces a significant amount of waste material. Marble dust contains high quantities of calcium, silica, alumina which can be a way of stabilizing soils. Some parameters of this waste material include improvement in shear strength, as well as has having a role in the hydration process due to its calcium content. Furthermore, this material would be reused and aid in the decrease in environmental pollution and would be a great contribution to the economy and conservation of material. The current resources for construction materials damages the environment due to continuous exploitation. This is done through the processes of obtaining and transporting these

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ture

INSPIRED BY STRUCTURAL PROOPERTIES OF NATURAL ORGANISMS

Materials with thermal behaviour

Materials with load bearing behaviour

c Fun

tion

BIOMATERIALS

INSPIRED BY FUNCTIONAL PROPERTIES OF NATURAL ORGANISMS

materials with water proofing / harvesting mechanism

Materials with intelligent response mechanism

cess o r p

Bioplastics

RECYCLING PROCESS IN NATURE Biocomposites

cess o r p

reproductive materials

INSPIRED BY BIOLOGICAL PROCESSES

CREATE A SYSTEM THAT IS RESPONSIVE/ADAPTATIVE, THAT INCORPORATES NATURAL SYSTEMS FOR GROWTH TO OCCUR

uc r t s

Growing materials

Fig.28 _ Imani, Donn and Balador, 2018

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MATERIAL COMPOSITION

resources generating high concentrations of polluting gases (carbon monoxide , sulfur dioxide….) The exposure of such toxic gases released to the environment does lead to major contamination in air, water, soil, and our flaura and fauna. Nonetheless, these resources are being used and causes this byproduct which will be wasted. Therefore, repurposing this waste material could be very valuable. RAW MATERIAL: The abundance and richness that can be found within our soils has the potential to integrated within the composite system. Due to high transportation cost of resources and their environmental impact the necessity to find substitutes to our current construction process becomes essential. By understanding the current crisis and the need for energy saving and conservation of resources with

efficient recycling of solid waste. The use of raw and waste materials can offer a wide range of new applications and maximize use of existing technologies for a sustainable and environmental management of the building industry. Clay and WATER The initial tests consisted of understanding the base relationship between clay and water. Clay is largely influenced by moisture content and its viability to hold together needs to be tested for additional samples to be examined. BIOPOLYMER Cellulose is a common organic compound found on Earth it forms a hard and strong, solid material that provides structure and strength to other materials. It is the basic structural component that can be found in all plant fibers. This plant based biopolymer has a

clay Marble particles Marble dust water

Marble particles: 10g Marble Dust: 5g Clay: 5g Water: 5ml

Marble particles: 10g Marble Dust: 5g Clay: 10g Water: 5ml

Marble particles: 5g Marble Dust: 5g Clay: 10g Water: 10ml

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water

clay

chitosan

Marble dust

Agar

water

Marble particles Marble dust Clay

Water: 10ml Chitosan: 0.5g Agar: 1g Marble Particles: 5g Marble Dust: 5g Clay: 5g

Marble Dust: 10g Clay: 5g Water: 5ml

Marble particles Cellulose chitosan water

Marble Dust: 15g Clay: 5g Water: 10ml

Marble particles: 15g Chitosan: 0.5g Cellulose: 1g Water: 10ml

Marble particles: 10g Marble Dust: 5g Chitosan: 0.5g Cellulose: 1g Water: 10ml Cellulose

Marble Dust: 10g Clay: 15g Water: 10ml

water

marble dust

chitosan

Marble particles

Agar

water

Marble particles Clay

Water: 10ml Chitosan: 0.5g Agar: 0.5g Marble Particles: 5g Clay: 5g

Water: 10ml Cellulose: 5g Marble Dust: 5g Marble Particles: 5g water

water

cellulose

chitosan

Marble particles

Agar

Marble dust

Marble particles

Clay

Marble dust

Water: 10ml Cellulose: 5g Marble Dust: 5g Marble Particles: 5g Clay: 5g

Water: 10ml Chitosan: 0.5g Agar: 1g Marble Particles: 5g Marble Dust: 5g

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Marble particles PINE RESIN

high production rate and is estimated “annual production to be around 10 11 tons” (Berglund and Peijs, 2010, pg 201) making this organic compound as one of the most abundant in the biosphere. The natural fibers have significant potential to be used as a new sustainable reinforcing material within composite system. In addition, the performance and effectiveness of natural fibers as reinforcements are highly influenced by their environmental surrounding “(temperature and humidity) and the presence of surface defects and the hydrophilic nature of fibres itself” (Faruk et al., 2012). Throughout the experimentation procedure carried out cellulose was added to create a paste and add strength to the material. Some of the benefits of using cellulose include low density, nonabrasive processing, abundant, recyclability, biodegradability, strength and stiffness added to the composite being developed. (Oluwarotimi Ismail and Dhakal, 2020, pg. 51). AGAR Agar can be easily blended with other polymers to form composites to add mechanical and structural properties. This material is also being used as an initial growth medium within the biocomposite system.

Marble particles: 15g Resin: 10g

Marble particles Marble dust PINE RESIN

Marble Dust: 10g Marble Particles: 10g Resin: 20g

clay Marble particles Marble dust PINE RESIN

Marble Dust: 5g Marble Particles: 5g Clay: 5g Resin: 10g

Marble dust PINE RESIN

Marble Dust: 15g Resin: 10g water cellulose

Cellulose

Marble particles

marble dust

Marble dust

water

Clay Resin

Water: 10ml Cellulose: 5g Marble Dust: 15g Marble Particles: 10g Clay: 5g Resin: 5g

Water: 10ml Cellulose: 5g Marble Dust: 5g

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Layer 0 Marble dust = 30g Marble grain = 30g Mortar = 20 g Water = 30 ml

Layer 0 Marble dust = 30g Marble grain = 30g Water = 15ml Cellulose = 5g

Layer 0 Marble dust = 30g Marble grain = 30g Mortar = 15g Water = 15 ml

Layer 1 Marble dust = 30g Mortar = 30g Clay = 30g Cellulose = 5g Water = 40ml

Layer 1 Marble dust = 30g Mortar = 20g Clay = 30g Water = 15ml

Layer 1 Marble dust = 30g Mortar = 30g Clay = 30g Water = 20ml

Layer 2 Clay = 10g Marble dust = 10g Water = 10ml

Layer 2 Marble dust = 30g Marble grain = 30g Clay = 30g Water =15ml

Layer 2 Marble grain = 20g Clay = 30g Mortar = 30g Water = 15ml 55

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MATERIAL CATALOGUE

achieve a multilayered system the material needed to react in a specific way for the layers to be able to interact with each other without separating and disintegrating.

A systematic approach was carried out in order to understand how the material reacts according to various quantity change. These samples were conducted from the results of the initial material tests explored. From each sample a composition was chosen once it had dried as a base for the different layers that will later be tested. By trying to

% U 90 E D Y A BL CL AR M

CHANGING CLAY MARBLE DUST

WET MIX

INGREDIENTS

back

4 Days

front

CONSTANT WATER

% U 80 E D Y A BL CL AR M

% U 70 E D Y A BL CL AR M

% U 60 E D AY BL L C AR M

% U 50 E D Y A BL CL AR M

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back

4 Days

CONSTANT WATER CLAY MARBLE DUST

front

CHANGING SAND

WET MIX

INGREDIENTS

OS UL L L

LO LU L E

CHANGING CELLULOSE

4 days

CONSTANT WATER CLAY MARBLE DUST SAND

WET MIX

INGREDIENTS

E BL

N AI

E BL

N AI

E BL

CONSTANT WATER CLAY SAND CELLULOSE

4 days

CHANGING MARBLE GRAIN

WET MIX

INGREDIENTS

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BRICK COMPOSITION

This secondary series of experimentation consisted of understanding the material properties that occurred when each layer was cast one on top of the other. These bricks give an insight on the binding of each of the layers, as well as its strength.

BASE Material

These bricks 5*3*3 cm were cast inside a 3d printed formwork. The overall understanding of how each of the layers worked together could only be understood once they were dry. The overall casts took 1 week to dry before they were removed from their formwork, and before an understanding of the layers could be made. It was visible that some of the brick layers started to separate from each other, and it seemed that the Arabic gum brick samples were the ones that caused the largest separation.

Layer 1

To further analyze these samples, they were evaluated under a one point load system to see changes and crack formations.

CLAY MARBLE DUST SAND CELLULOSE WATER

CLAY MARBLE DUST SAND CELLULOSE

WATER

47% 22% 17% 0.2%

13%

Layer 2 CLAY MARBLE DUST SAND CELLULOSE WATER

55% 20% 8.7% 0.5% 15%

Layer 3 CLAY MARBLE DUST SAND CELLULOSE WATER

48% 5% 15% 0.2% 15%

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CRoss section

Layer 3

Brick 1

Layer 1

Brick 2

+Arabic Gum

Brick 3

+Alginate

+Alginate +Arabic Gum

+Arabic Gum +Calcium Carbonate +Alginate

Brick 6 Brick 7

+Calcium Carbonate +Alginate

Brick8

+Arabic Gum +Calcium Carbonate

Brick 5

Brick 4

+Calcium Carbonate

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STRENGTH TEST

A strength test was conducted on these bricks to get an understanding for the strength and structure that could arise from these multilayered systems. The most noticeable element from these bricks was the separation of the layers when using Arabic gum. All the bricks that had Arabic Gum failed, apart from the last brick that had all three binders. Throughout this study one brick had very few cracks and no separation in its layers and did not break through the strength test. Th material composition in brick 4 was used as a base for the rest of the project. The multilayered casting mechanism carried out would need to be properly further examined in a controlled environment for this system to be analyzed. Nonetheless, this process has demonstrated a certain structure and rigidity that can be used for further exploration and used along the fabrication process. After considering this catalogue as a matrix further prototyping could arise.

BASE Material CLAY MARBLE DUST SAND CELLULOSE WATER

Layer 1 CLAY MARBLE DUST SAND CELLULOSE

WATER

47% 22% 17% 0.2%

13%

Layer 2 CLAY MARBLE DUST SAND CELLULOSE WATER

55% 20% 8.7% 0.5% 15%

Layer 3 CLAY MARBLE DUST SAND CELLULOSE WATER

48% 5% 15% 0.2% 15%

FAIL

Brick 1

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FAIL

Brick 2

+Arabic Gum

Brick 3

PASS

Brick 4

+Alginate

PASS

+Arabic Gum +Calcium Carbonate +Alginate

FAIL

Brick 6

PASS

FAIL

+Alginate +Arabic Gum

Brick 7

+Calcium Carbonate +Alginate

Brick 8

+Arabic Gum +Calcium Carbonate

Brick 5

+Calcium Carbonate

PASS

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05 Geometry explorations Digital and physical exploration of surface patterned erosion. What could these surfaces start creating, how these different folds and cavitites can start creating pockets for different life to occur.

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GEOMETRY EXPLORATION

The current land formations are continuously evolving. From erosive to degradation within their soils, there is a battle of the elements. These intricate natural phenomenon’s offers possibilities of exploration within the new built environment. These were explored through digital means to replicate the physical properties that occur in nature. A base simulation was carried out using Houdini in order to start generating different geometrical formulations of natural phenomenon’s. SERIES A Explored the layering and peeling of its skin, using displacement nodes. SERIES B Is investigating through vector fields with directionality and using different noise parameters. SERIES C Is using the same principals as series B but adding points of deviation along the vertical face. SERIES D Creating attractor points directionality of the geometry.

through

the

SERIES E Generating vector field formations, afterwards simulation a terrain erosion.

and

These explorations were visualizing starting to replicate the natural phenomenon’s of erosions that could be seen within soil and rock surfaces. 64

SERIES A

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SERIES B

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SERIES C

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SERIES D

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SERIES E

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CLIFF FORMS THE ORGANIC VS THE RIGID

Replicating cliff formations, through simulation production by integrating geological forms and function, there is an ability to start visualizing these new cliffs in digital format. This abstract representation of Cliff forms starts forming a new tectonic language for this future built environment. The initial simulations can be categorized in two separate structures: the “ORGANIC CHOAS” vs “THE RIGID STRUCTURE”. ORGANIC CHAOS Nature is unpredictable with constant changes occurring within its geological bones. No two surfaces will resemble the other, its basic ‘DNA’ might be composed of the same genetics but its composition along its verticality will differ. This material composition change along the surface is the reason for its surface complexity. RIGID STRUCTURE Extrapolating the base vertical geometry of a cliff form to a more rigid base is another language that can start being explored. Combining nature with current built morphology can create this structured morphology. It implies changing the dynamics of what naturally occurs in nature, but takes into account what is currently built in the urban areas.

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ERODING SURFACE

Erosion simulations based on attractor points were investigated on a surface. The intricate complex geometries that are being generated could start actively performing for growth to occur.

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Phase 1

Phase 2

Phase 3

Phase 4

Phase 5

Phase 6

Phase 7

Phase 8

Phase 9

Phase 1

Phase 2

Phase 3

Phase 4

Phase 5

Phase 6

Phase 7

Phase 8

Phase 9

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GROWTH POCKETS

EROSION POROSITY

SEDIMENTATION RUNNOFF

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SURFACE EROSION

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DIGITAL SURFACE EXPLORATIONS

These series of simulations were carried out to visualize the complexity that can be seen in nature. These multilayered dynamic surfaces are investigating the micro scale using the previous base eroding simulation experiments carried out in houdini. The cavities and grooves that are starting to form on the surface can be derived from water or wind erosion against specific vertical conditions in our environment.

Fig.29 _ Comell, 2019

Fig.30 _ Erosion, n.d.

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06 FABRICATION Exploration of different fabrication technique to develop a multilayered biocomposite cast.

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Process 01

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[FABRICATION PROCESS]

Removing the material following the design for the frameword to cast

Casting Casting the three composite materials through layers

Robotic manipulation Robotically carve out the soft material while it is still in the drying process

Material Composition Create the 3 diferent mixes of the composite to then cast inside mold

LAYER 1

CNC

DESIGN PROCESS The designs were an evolution of the simulations that were investigated earlier on in this research. Developing a physical system that can mirror the basis for displacement of material to occur just as it does in nature through erosion and weathering.

Top surface to be thin and porous to let material interact with the environment

LAYER 2

SUBTRACTIVE MANUFACTURING

Modelling a framework / design of a cliff formation

Soft layer with the growth medium to allow for pockets to form and to let growth appear through the surface

LAYER 3

DESIGN

By integrating all the learnings from the research, fabrication investigation needs to be carried out. Through this advanced manufacturing process, a catalogue of casting a multilayered biocomposite will be defined in order to achieve the highest level of resolution with a system that is able to create micro displacement for sedimentation to occur along the vertical tile system.

Hard surface, the least porous

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CNC A formwork will be created to cast the multilayered biocomposite material system defined. This formwork will be reutilized to minimize waste in the fabrication process. CASTING The multilayered system will than be cast one by one inside the formwork and will be checked on to understand how the material reacts and dries in these new conditions. A matrix of the

MODELLING

prototypes will be formed to reach conclusions on this fabrication technique. SUBTRACTIVE MANUFACTURING An advanced manufacturing technique will be explored in order to extract further material from the cast system, to exposes the different layers that were cast.

CASTING

CNC

Roughing

Finishing

CAST 1

CAST 2

CAST 3

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CLAY SAND MARBLE DUST MARBLE GRANULES CELLULOSE WATER C.C

COMPOSITE 1

CLAY SAND MARBLE DUST CELLULOSE WATER C.C AGAR

CLAY SAND MARBLE DUST CELLULOSE WATER C.C

[FABRICATION PROCESS CASTING]

COMPOSITE 2

COMPOSITE 3

MODELLING Based on the previous geometrical studies, a series of patterns were chosen. These starting elements were than translated for machine production. FORMWORK Eva foam was chosen as a base material for casting. Due to the materials flexibility, removal of the cast would be simplified. In addition, a releasing agent “vaseline” was added to be easily able to remove the biocomposite from the formwork. SUBTRACTIVE MANUFACTURING The CNC machine was used to extract the material and achieve a negative mold of the desired geometries. Each geometry took around 1h 30min to do both the base roughing and the parallel finishing. CASTING The material composition was based on to the matrix that was defined in the early sections. This was than cast inside the formwork layer by layer. Starting off with the more brittle layer, followed by the growth layer and finally the hard layer. Due to varying depths of the geometries the amount of material cast differed slightly, therfore; the volume of the cast was calculated beforehand.

For each cast that was being produced, the external environment in which the drying occurred effected the final output. The casts took minimum a week to dry before it was removable from the formwork. Through the progression of this technique more detail was able to be defined due to an understanding of how the material reacted to its formwork.

STEP 1 MODELLING

STEP 2 CNC SUBTRACTIVE MANUFACTURING

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STEP 3

CATALOGUE

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CROSS SECTIONS

CAST Each of the tiles compositions and layering were done according to how growth can start occurring along its system. The base cast already offered a certain geometry with different grooves, cavities, and pockets. Therefore, some initial material reaction and micro displacement of sedimentation would occur once the tile would be exposed to the environment. By understanding the base geometry of the cast there is an ability to start visualizing where the natural progression of these carved pockets would start to emerge. These carved out elements will serve as nutrient pockets where the growth medium in the material composition will start reacting with its surroundings. GROWTH To understand this system, the cross section serves as a natural formalization of the material composition. By having varying densities in porosity and material composition the chemical reaction that would occur from the overlaying of the material is the one forming these growth pockets. The varying material densities from soft to hard allows for natural formations of material depositions, in addition to the material porosity each tile will recreate its cavities.

PROCESS TO CAST HARD LAYER SOFT LAYER MEDIUM LAYER

CAST MEDIUM LAYER SOFT LAYER HARD LAYER

CARVING

GROWTH

LAYER CROSS SECTIONS LAyer 1 LAyer 2

LAyer 3

LAyer 1 LAyer 2

LAyer 3

LAyer 1 LAyer 2

LAyer 3

Nutrient pockets

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CROSS SECTION By breaking apart a tile the clear overlap of the different material compositions, the three layers become visible. Starting off with the fragile layer than a soft layer to end with the base acting as the hard layer. The first layer seen in (diag.1) acts as a porous layer that slowly starts to peel away its layers. The second layer is the growth section where nutrient pockets start to form due its cavities starting to be exposed. And lastly the hard layer is the structural layer, holding the system together.

Layer 1

Layer 2 Layer 3 Layer 1

Layer 2

Layer 3

Water Cellulose Marble Dust Sand Clay

Layer 2

Water Cellulose Agar Arabic gum Marble Dust Sand Clay

Layer 3

Water Cellulose Arabic gum Marble Dust Marble granules Sand Clay

diag .1

1 2 3 1 2 3

Porous layer: Layer starts to peel away Nutrient pockets start to appear due to exposure to environment Rigid layer

Surface changing according to environmental fluxes

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ROBOTIC FABRICATION

ROBOTIC MANIPULATION To further enhance and expose the layers of the composite tile, there was a research carried out on how to further manipulate the surface.

CREATING TOOL

SUBTRACTIVE MANUFACTURING To add another layer to the system a second subtractive manufacturing method was researched. This exploration included creating a tool that would be attached to the robot and that would be able to hold a carving tool. To limit the resistance of the material, the tile was slightly humid to start the process.

ENGRAVING AND EXTRACTION The process of engraving was one done to reveal the second layer of the tile. The exposure of the cavities that would be created from the surface manipulation of the tile by the robot, will create the pockets necessary for the growth medium to be exposed to the environment. The difficulties faced with this method included the lack of control and the resolution of the extracted material on the tile.

Develop a fabrication tool

FIRST VERISON

TOOL HANDLE The initial tool that was explored included a spring like system that would allow for the attachment piece to be able to move. The reasoning behind this system is due to the resistance of the tile and its material state. Trying to extract a material while dry meant a lot of force was being applied for the material to be extracted. Therefore, a spring system for the tool needed to be developed.

ENGRAVING

Draging of material

EXTRACTING

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EXTRACTING MATERIAL

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EVALUATION

RESOLUTION

DRYING PROCESS

Through this casting method there was an absence of resolution achieved in the end product of the tile. The EVA foam formwork used throughout this method had too large pores which is translated on the cast. The irregularity of the formwork had an impact on the final output of the tile. Further reasoning for the lack of resolution was visible from the drying process.

The drying process caused a lot of issues throughout the entire experimentation time. Firstly, due to the multilayered casting system there is natural separation of the layers that can occur as a result of the different drying capacity of each of the layers. The last layer is exposed to the air and therefore will be able to dry quicker than the rest, leaving the rest of the cast still wet. In addition, the Eva foam did not allow for the lower layers to be exposed to the air to facilitate the drying of the cast.

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Cracking

residue

Due to the inability for the bio composite to dry in its formwork, when being unmolded the cast faced cracking issues. The flexibility of the rubber formwork was not helping the bio composite to dry accordingly, which lead the cracking and separation of the three different layers of the multilayered system. Once removed from its formwork the drying occurs too quickly for the areas that are still wet which leads to further fractures on the tiles.

Furthermore, the rubber that was being utilized in the formwork for the cast often transferred onto the cast tile. The overall lack of readability of the base geometry is the accumulation of these factors. The material biocomposite developed needs a certain criteria in order to behave in the intended way. These observations are a starting point for the next technique explored.

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Process 02

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PROCESS 02 CASTING TO CNC

EP 1

EP 2

BOX FRAME

CASTING BIOCOMPPOSITE

CNC

MAKING A FRAME

MULTI-LAYERED SYSTEM

SUBTRACTIVE MANUFACTURING

Creating a formwork that can be used to cast

Clay Sand Marble dust Marble grains Celluslose Calcium carbonate Agar

This following fabrication method is reversing the first approach. The investigation carried out for another fabrication technique was done to achieve better resolution and detail, maintain a low waste production and to create the base pockets for growth to occur. STEP 1 To develop this method an initial base frame was created. A base formwork that can be cheap to fabricate, easy to replicate and can be used over and over again.

EP 3

BASE

Different strategies for removing the material Generating the surface Pattern

BINDERS GROWTH

STEP 2 The following step is to cast the three layers of the system developed within the frame that was built. STEP 3 Lastly, advanced manufacturing tools would be used to generate the geometry. Along this process a series of tests were carried in order to understand how the material responds to the machine.

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FRAME CASTING

STEP 1

Making a wooden frame

STEP 2

Making a wooden frame with joints so that the blocks can be assembled together

PROCESS

STEP 3

Pass tubing through the frames

STEP 4

Cast

STEP 5

CNC each section seperately

STEP 6

Assemble the two cnc sections by connecting the two blocks with a tension cable

100

The base material for the formwork that was investigated was made of wood. WOOD FORMWORK The properties of wood allowed for a base formwork to be designed. Wood is a commonly used material due to its accessibility both in location, cost and various dimensions and forms that might be needed for different designs. The porosity, strength, and capacity to take humidity and its adaptability to shrinkage and swelling made for a great base to create a formwork that can be cast into. For initial testing a rectangular formwork was created. This formwork had the ability to evolve to start integrating a joint system where further along the process connections between tiles could be made. A lap joint was initially explored to mesh two cast tiles together. In addition, a study was explored to add reinforcement possibilities to than be able to attach the tiles together with tension cables.

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101

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CROSS SECTION

CASTING The wooden base frame (17* 25 * 5 cm) was tested for casting in a block form. The three layers of the biocomposite were each cast one by one into the frame. Part of the water content from the biocomposite mixture was absorbed by the wood surround while it was in the process of drying. The casts took too long to dry, and the conditions could not be highly controlled and therefore, shrinkage became an issue and caused a lot of breakage along the cast. In addition, the rods that were inserted in the wooden frame effected the shrinkage due to the material separating. The shrinkage that occurred along the top surface that was exposed to the air was creating weak points along the cast and breaking the cast into three pieces. These undesired results had then to be dried to use them as small prototypes on the CNC.

102

CURVATURE FROM SHRINKAGE Frame

Rods Shrinkage

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WEAK POINT // Breaking point

Ends up cracking through the surface. Material starts shrinking around the rods and creates a WEAK point.

CURVATURE FROM SHRINKAGE

Layer 3 Layer 2 Layer 1

103

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lF lle a r

inishing

Parameters:

Tool Cut depth Spindle speed Feed rate

Tool Spindle speed Feed rate

SUBTRACTIVE MANUFACTURING The initial step consisted of removing the material to achieve the base shape or outline of the geometry. ROUGHING The roughing process consists of removing the bulk of the material following the base geometry but without getting any detail. This was conducted with an 8mm flatmill piece with a cut depth that was worked out to 2 mm. Since it is removing the bulk of the material, the machine had to perform not to its full capacity, and the feed rate was dropped to around 80% and a spindle speed that is around 4. This

ng e ti k c

Parameters:

Once the blocks were cast, the cnc was used to extract the material and expose the layers of the biocomposite.

104

g hin

CNC STRATEGIES

Tool Cut depth Spindle speed Feed rate

entire step takes a very long time, and without any results at this point. PARALLEL FINISHING To get the level of resolution needed a second pass was needed to finish the cast. A 6mm ballmill tool was used with a spindle speed at 3 and a feed rate that had to be dropped to around 50-65% depending on the areas that were being cut. Due to the feed rate being so low the cutting time is lengthy. POCKETING In order to achieve specific cavities and grooves pocketing was tested. In comparison to the previous method this is a single point extraction process, that needed to be done in different steps. An increment of 3 mm was used to create these pockets.

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105

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TILE 01

18 cm

22 cm

106

This experiment was done to test how the biocomposite reacted to the machine. This piece required a base geometry roughing and then the parallel finishing was added for detail. The final result is barely visible due to the large pores of the material that is overshadowing the geometry. An issue of scale between the material porosity and geometry was also an issue.

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107

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TILE 02

The second experiment consisted of creating more resolution and depth with the CNC. This design took 3h to run, 2h was needed for the roughing stage and another 1h was needed for the parallel finishing. In comparison to the first tile definition is starting to be seen, but the pores of the material are still too big in relation to the geometry.

108

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109

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TILE 03 POCKETING

110

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111

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TILE 04 PARALLEL FINISHING

This last tile was able to achieve the highest resolution and detail. However, it took 4h 30 min to cut and do the finishing. This tile measured 17*13 *4 cm and the cutting time would be too long for large prototypes. Therefore, a new technique will have to be explored in order to achieve similar results but with significantly less production time.

112

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113

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114

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Process 03

115

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PROCESS 03

By integrating all the learnings from the previous fabrication method this next technique aims to combine the two to create a multilayered biocomposite tile with high level of resolution with reasonable production time. By focusing on achieving the crevices and grooves that were earlier analyzed in the cliff formations.

116

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1 EP ST

CNC BASE SHAPE

POSITIVE MOLD 2 P E

PROCESS DONE ONCE Strategies 1_Horizontal roughing: 1h 05 mins 2_Parralell finishing: 1h 43 mins Step over: 25% Tools: 1_8mm MillFlatmill 2_6mm MillBallmill

GEOMETRY

Houdini Simulation Of Growth // Erosion Looking Into Porosity

CNC -Reusable to cast into -Only done once Silicone cast -Only done once (or as many times that you want to make a mold) -Very strong -Can recast as many times as you want

CAST MULTILAYERED BIOCOMPOSITE

STEP 1 CAST [SILICONE]

NEGATIVE MOLD

P3 TE

-High level of detail -Flexible mold -Very strong -Reusable

P4 TE

-Extra step -Expensive

CNC -Machine Time -Material Silicone cast -Extra casting step -Drying time -Expensive material for large quatities

POSITIVE CAST

CASTING Layer 1: Soft layer Layer 2: Soft layer with growth Layer 3: Hard layer 20kg of initial material to make a tile that is 50x50cm Full tile

E ST CNC THE CAST

Casting inside the base frame with a flexible material allows for greater levels of detail.

Detail

SUBTRACTIVE MANUFACTURING

CASTING Layer 1: Soft layer Layer 2: Soft layer with growth Layer 3: Hard layer 20kg of initial material to make a tile that is 50x50cm Full tile

Detail

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FORMWORK

Starting Block

Step 3

Step 4

To do this a base formwork was made out of wood 60*60*8 cm this was CNC’d in order to achieve a positive formwork geometry. This process will

only need to be carried out once, with a running machine time of 4 hours and 20 mins. The base plywood that was used offered a high level of detail with all the pockets and crevices in place. This mold will then be used to cast a silicone mold to achieve a tough yet flexible formwork for the biocomposite to be cast into. SILICONE MOLD Silicone was chosen due to its strength, this tough rubber is highly flexible but is stiff enough to not rip. The material is highly durable and is able to gather all details within a surface due to its liquid state when cast.

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Roughing

Preparing the first mold _ 1 time process

Step 2

PLYWOOD MOLD The two previous techniques explored served as a matrix to understand what works with the material developed. This method is split into two sections one that is done once and the other that allows you to replicate the process as many times desired.

PROCESS

Step 1

Finishing

Detail

Plywood Mold Positive formwork

Silicone Cast

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TO FABRICATE

MATERIAL MIX In order to start casting a large homogeneous mix needs to be formed. This preparation is done according to the biocomposite developed in the previous chapter; with each of the defined layers. The total dry material mix to make a 60*60* 6 cm tile was calculated at 20kg of raw material, with each layer amounting to 2 cm each. A metal mixer was added to a drill and used to mix the large quantities of material to try and achieve the most homogeneous mix. This drill mixing of material generated a paste that would be cast layer by layer in the silicone formwork. Each composite material needed to be mixed for 15 mins each to achieve the desired paste condition for the cast. Once the first layer was uniformly applied in the formwork using spatulas and levels, the following layer could be made and applied above the first layer. Following the previous processes of drying, the initial experiment was left to air dry over 48h. CAST 1 The initial experiment cracked in half, due to the large scale of the tile. The technique to flip the cast turned out to be more complicated due to the overall weight of the cast. The small initial fold in the cast as it dried turned bigger and broke the cast in half. This needed to be solved in order to produce the desired final prototype. 120

MATERIAL PREPERATION

Layer 1

MIX 1 WATER CLAY MARBLE DUST SAND CELLULOSE CALCIUM CARBONATE

13% 47% 22% 17% 0.2% 0.8%

Layer 2 MIX 2 WATER CLAY MARBLE DUST SAND CELLULOSE CALCIUM CARBONATE AGAR

13% 55% 20% 8.7% 0.5% 0.8% 2%

Layer 3 MIX 3 WATER CLAY MARBLE DUST MARBLE GRANULES SAND CELLULOSE CALCIUM CARBONATE

15% 48% 5% 15% 15% 0.2% 1.8%

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CASTING Multilayered casting system

48H before removing from mold

MAterial DRY MIX

CAsting material inside Silicone Mold

CAst Removed

Mix with drill LAYER 1

LAYER 2

LAYER 3

48h of drying

CRACKS

REMOVAL FROM CAST

AFTER 5 DAYS

AFTER 1 WEEK

Just after having removed it from the mold

Visible crack on the surface of the cast

Two disconnected pieces Break has gone through the entire cast

AFTER 1 WEEK

Visible layers

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SHRINKAGE

FAN Fan for accelerated drying process

FAN -Accelerated drying process -Able to remove cast within 48h -Shrinkage is more prominent -Corners lift from being dryer than the center

CAST

SILICONE MOLD

Cast after a couple of hours being exposed to the fan

Cast after 2 days

Longer time to dry

Reacts to the fan first and therefore dries quicker. Making it shrink and lift off the surface

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WET CAST

Layer 1 Material Layer cast 24H OF DRYING

Shrinkage on all 4 sides 48H OF DRYING

Layer 2

Layer 3

DRYING The drying of the biocomposite through this experimentation was the most performative. Due to the wood frame surrounding the silicone base, the wood was able to absorb part of the water content within the biocomposite accelerating the drying process. Furthermore, due to the removal of excess water content in the material composition it allowed the cast to shrink, detaching itself from the wooden base border within the first 24h. Reasoning for such short initial drying time was also based on using a fan to accelerate the process. This will lead to inaccuracies that have to be taken into account in the final prototype, however, this was a necessary step due to time restrictions. Nonetheless, the first 24 hours were critical to understand how the cast reacted to its formwork and performed a uniform shrinkage. Once this step was done the wood surround was removed exposing all edges of the cast, this allowed for all the layers of the cast to breath and be exposed to air to dry accordingly. WARPING Following the first 48h after casting the three layers, the cast started to warp. This natural phenomenon occurring, partially had to do with the reaction to the accelerated drying process of the fan. This rise in the cast would not have developed as drastically if the drying had been in a controlled environment with a constant humidity level and a clean environment. For further testing a clean and controlled environment would need to be used to have a uniform tile formation.

Curve and lift of the material cast

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FINAL PROTOTYPE AFTER CASTING

UNMOLDING The final cast with dimensions of 52 * 52* 5cm after curing for 48 hours was able to be removed and flipped from its silicone mold. The easy removal process of the silicone also attributed to a very detailed and natural forming cavities. Due to the flexibility and toughness of silicone the peeling of the formwork was easy and

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could be used many times. The cavities of the cast did not cause any issues and no breaking of the cast occurred. Without any releasing agents the silicone was removed. Therefore, the general composition of the biocomposite determined in the earlier research was intact.

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TOOL PATH

CAST The first full prototype showed the potential of the level of detail that could be achieved compared to the two previous fabrication techniques that were being explored. TOOL PATH The high level of detail from the first cnc step of the plywood has translated onto the silicone mold and later on to the actual cast tile. This textured resolution that is visible from the cast adds an additional dimension of ridging on the surface of the tile.

Tool path lines that are visible from the initial CNC mold.

CREVICES

CREVICES The pockets serve as nutrient rich spaces for the growth to develop along the surface. As seen from the prototype these air bubbles and gaps add an organic and unpredictable layer for these grooves to develop overtime. Organisms can start inhabiting these pockets and create a new climatic condition.

Holes and cavities both created by the mold but also by the material casting system.

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CNC

1 tepS

MACHINE PROGRESS

2 tepS

30 mins of run time 3 tepS

SUBTRACTIVE MANUFACTURING To enhance the intended properties that were designed for the tiles a second subtractive manufacturing process was explored. Considering the early robotic fabrication technique of removing sections of the top layer of the material and therefore, exposing the second layer of the cast was an initial starting point. This growth layer that is partially exposed due to the casting inside the mold will be further exposed to create larger cavities and folds for deposition to occur.

Step 4

1h and 15 mins of run time

CNC The tile that had an already predefined geometry was then added to further changes. Considering the previously mentioned changes that the tile endured during the curing process, (shrinkage and warping) caused an inaccuracy with where the existing cavities were situated. This would need to be subjected to further research including scanning and analyzing the changes of the tile. For this process a measurement was carried out and a uniform shrinkage was deduced, to carry out the next steps.

1h and 45mins of run time

2h and 15mins of run time

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The biocomposite tile had to be robust to endure high speeds and strengths that the machine would force on the tile the moment it would become in contact. Therefore, the initial surface was firstly humidified slightly to facilitate the extraction process. Secondly an air pressure element was added in front of the mill piece to avoid overheating and breaking. The biocomposite can be quite fragile and the

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Corner brackets to hold geometry in place Geometry slightly lifted of the base from shrinkage

Tool: mill bit 6mm

tool bit had to go slowly or else it will break of the corners and part of the cavities from the tile. TOOLS By casting the biocomposite in an already predefined shape the CNC run time was reduced by more than 50% as a result of the initial roughing being done. The following step than included a parallel finishing stage with a 6mm ball mill tool, this programming needed to be relatively slow in order to limit the cracking and breaking of the tile. MACHINE PARAMETERS: Run time: 4h 40 mins Spindle Speed: 3.5 Feed rate: 60%

GEOMETRY The geometry that was projected onto the tile was based on further simulations of erosion. With larger cavities, pockets and folds in order for each tile to act in various different ways and to not resemble one another. By subtracting the material of the tile, further exposure of the layers could occur to encourage growth along this multilayered vertical system.

Air pressure to cool down the mill bit

Parallel finishing to go over the existing cast geometry.

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CNC FINISHING RESOLUTION

TILE

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Detail

SUBTRACTIVE MANUFACTURING After more than 4h of machine time, a new level of resolution will appear on the cast. The dual relationship between the cast and the extraction of material leaves two different finishes on the tile. A more porous side and a less porous quality. The least porous resolution is from the initial casting of the biocomposite. By having a wet material mix cast inside a rubber that has a smooth finish allowed for the material to behave in the same manner.

Due to the shrinkage of the cast the cnc was not touching the surface of the panel and we can see the different resolution of the material

Material being removed and exposes the porous material which affects the level of detail of the geometry

The more porous resolution of the tile arises from the extraction of the material, using the mill bit. By digging inside the cast it is exposing the different porosities of each of the materials within the cast. The different aggregates used within therefore, will come to the surface and create this complex system with varying porosity along its facade. POROSITY With an overall increase in porosity along the surface there is an abstraction made from the initial geometry explored, the overall geometry looks less prominent and visible. However, it allows for a new complex geometrical language to form.

Pocketing depth of the cavities in the geometry.

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CAST VS CNC

CAST

Resolution of tile The finished outcome of this prototype just after casting offers a smooth finish on the surface with changes in texture in the crevices where the second layer of the cast start being exposed. The geometry becomes this complex system, where visible grooves and channels start interacting with each other.

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CNC OVER THE CAST

Resolution of tile Due to CNC process the material grains are exposed, creating a more porous material surface. This allows for more grip on the surface of the tile, which creates attachment and areas for the material deposition to grab onto. Due to the larger pores of the material the depth of the geometry becomes less prominent. However, this offers greater potential for varying each of the tiles.

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MICRO DISPLACEMENT OF MATERIAL

WATER FLOW MOVEMENT

+ +

+ + +

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CAVITIES ON CLIFF SURFACES

RIDGES By gravitional forces these vertical panel systems will further develop the natural ridges that can occur in nature. The base for directionality of water movement is based on the geometrical simulation previously explored. These water channel will very slowly remove matter from the first layer of the biocomposite and reveal the second layer. The growth layer will be exposed to the environment and allow organisms to start inhabiting these ridges. CAVITIES The cavities generated from the fabrication will create high concentration of material accumulation over time and will contribute to potential microorganism life once it is exposed to external environmental conditions.

Natural formation of these cavities in cliff forms offers spaces for new diverse ecosystem to start inhabiting these pockets.

POCKETS The pockets along the surface create a textured and pocketed system for material to be deposited in these cavities. Additional accumulation of nutrient rich deposition will collect in these areas. DEPOSITION OF MATERIAL FOR GROWTH Accumulation of material in these larger cavities to generate spaces for growth to happen.

MICRO DISPALCEMENT OF MATERIAL ALONG THE CHANNEL Long sections, ridges for water to move through was part of the geometrical exploration. With time material will start to move along the surface within these grooves, creating micro displacement of matter. The accumulation of material at the end of the channels will eventually build up to create rich nutrient base system.

MICRO DISPLACEMENT OF MATTER Due to the directionality of this specific tile, water has a specific path in which it will flow along the surface. Along this process small amounts of the material will start to move alongside these water channels and accumulate at the bottom. This process of micro displacement will create a new material sedimentation process along the tile where the layers of the biocomposite will start interacting with each other and where new organisms can start inhabiting NUTRIENT RICH POCKETS Along these channels accumulation of sedimentation will naturally occur, and a formation of rich nutrients-based soils and aggregates will start to evolve over time.

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EVALUATION

This fabrication technique offered the most potential for further exploration and development. The level of resolution that can be achieved just through the casting in comparison to the other two processes is considerable as a manufacturing system. By adding an extra step early on the process, allowed for high levels of accuracy in the development of the tile. The wood and silicone formwork are both reusable and can be used to make as many formworks without any extra machine time needed. Creating a durable mold with silicone might be expensive at first but due to the durability of the material it will

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facilitate all the future processes in the casting system. The second cnc step added to extract from the biocomposite is one that needs to be further developed, it offers great potential in making each tile unique, by further extracting material and enhancing the layers of some areas. Thus, this fabrication technique is suggesting a way of using one base mold that can create various outputs in its tectonic vertical surface. The overlap between casting and advanced manufacturing methods is bridged to create a new language for fabrication.

URBAN TECTONICS CNC EVA FOAM

CAST

+ PROCESS 01

CNC -Reusable cast -Machine use once -Flexible CAST - Added texture from mold

CAST A BLOCK

CNC

+ PROCESS 02

CAST BRICK -Frame is cheap -Can produce a lot of molds CNC -Finish is very detailed

PROCESS 03

CNC POSITIVE

CNC -Not porous so air does not go through -Mold breaks -Expensive for large fabrication CAST -Material doesnt dry -Very long drying time -Level of detail is Poor -Cast breaks easily from removal

SILICONE CAST

BIOCOMPOSITE CAST

CAST BRICK -Takes a long time to dry CNC -Machine Time very long -Roughing -Finishing -A lot of MATERIAL WASTE from the (subractive manufacturing process)

CNC

CNC 1 -Reusable to cast into -Only done once Silicone cast -Only done once (or as many times that you want to make a mold) -Very strong -Can recast as many times as you want CAST -High level of detail -Smooth finish -Dries relatively easily -Easy to remove from mold CNC 2 -Added level of cavities and pockets -Can achieve a clean finish

CNC 1 -Machine Time -Material Silicone cast -Extra casting step -Drying time -Expensive material for large quatities CAST -Fragile to flip over CNC -Due to shrinkage its hard to not break the cast when its milling -The speed rate has to be very low 135

TILE 03

TILE 02

TILE 01

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07 Design Application

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DREDGING

Throughout the development of this research and material development there was interest in using waste materials. An early investigation was carried out on dredging and its material composition in parallel to the biocomposite studied. Some material types that can be found within the sediment build up include sand, silt, clay, gravel, coral, rock, boulders and peat (Vivian and Murray, 2001). Dredged material can be used for different purposes including land reclamation but most often it is disposed of. Dredged material over the years has become one of the largest wastes deposited in oceans. There is an opportunity to use this waste sedimentation material and repurpose it to form a new life cycle.

Considerations of physical and chemical characteristics do need to be assessed for their biological impact. The nature of all dredged material will vary due to their origins and base chemical properties “grain-size, mineralogy, bulk properties, organic matter content, and exposure to contamination” (Vivian and Murray, 2001). Nonetheless, around 90% of dredged materials worldwide tend to be uncontaminated or with little contamination. Therefore, an opportunity for dredged material being regarded as resources rather than a waste byproduct of natural systems is being investigated. How can we repurpose these sediments that will be dumped as a rich resource for further ecological welfare?

DREDGED MATERIAL

SAND

SILT

SOILS

CLAY

ROCK

DEBRIS

main elements within my material system

MATERIAL COMPOSITION DEVELOPED

SAND

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CLAY

MARBLE DUST

MARBLE GRAIN

CELLULOSE

AGAR

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Fig.31 _ BirdLife Europe, 2013

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PORT OF ROTTERDAM

BioCOMPOSITE System

The Port of Rotterdam is located in the RhineMeuse estuary, it is a transition zone between a river environment flowing from the east. The areas surrounding the port is influenced by the river discharge as well as the sea conditions resulting in large sedimentation of both fluvial and marine types of deposited sediment. Dredging has become essential to be able to maintain navigable depths along ports and harbors. For this site location areas of sediment build up accumulate along the river and could be used as material testing purposes on site. There could be potential for the material to be dredged and tested within the same area and to inform the development of these biocomposite panel systems that were investigated throughout this research. This feasibility would need to be further investigated but could offer grounds for a new morphological system to be developed by integrating these waste byproducts of the environment.

SLUFTER: Dredged material from the river SITE LOCATION

Fig.32 _ Tom Kisjes, n.d.

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Sedimentation build up

RIVER FLOW

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BASE SYSTEM

Throughout the fabrication process the scheme was developed in an isolated system, but the there is potential for this to be conceived as a base for a vertical structure.

50 cm

Gradient change

VERTICAL SCHEME The base mechanism developed throughout the fabrication method could be assembled into a wall system. The initial base tiles following the fabrication process 3 developed will all be the same but through the integration of subtractive manufacturing as the last step of the process, a new additional parameter is added and can therefore change the tiles surface. Each one of the tiles will than vary from one another before being assembled. Once a desired wall is designed an assembly of the tiles can be drawn to create a varied wall system.

50 cm

An overall simulation can be run on the entirety of the wall creating a new geometry that will be split into each area of the tile, this new geometry will be simulated and applied to the cnc to finalise each of the tiles. This two step procedure consists of adapting each designed system to the environment it will sit in, each panel will be different to the next while having one fabrication method.

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Gradient change

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2 meters

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DEVELOPED SYSTEM

Different Fabrication Outputs These diagrammatic sketches is the principal of how each tile could vary, according to different growth simulations. Each tile can than become independent from the other. The procedure for this system was developed as a tile, however, there is future possibilities to develop this into brick or other blocks. BLOCK WORK The tile offers an isolated system that can be applied to a wall but may lose its 3 dimensionality. By using the same principals of the fabrication technique, a block could be developed with a structural system for it to stacked. By having a block cast inside a larger formwork (silicone) more depth could be created with more varied results. The possibilities of these large blocks could be a new language for this new urban reality.

TILE

BLOCK

ADAPTIVE TILE

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DESIGN GROWTH

The design basis was generated from the initial research of cliff formations, and canyon structures. Each cliff created its own microclimate along its surface layers. This chosen site is along the river and therefore, will be faced with a lot of different environmental conditions such as wind and rain due to its lack of protection around the site. By integrating three structures along the site each communicating to one another they form their own conditions among themself. By taking one of the base building blocks a simulation for growth was implemented. This second skin of the building could be the new geometry input that will be used to cnc as the final step to the fabrication technique explored earlier on. This early diagrammatic scheme is an iteration of the urban language that these tectonics can start forming. URBAN TECTONICS This new organic language for the urban sphere is an open discussion of what could be done for the current crisis we are facing. By investigating and understanding how nature functions and the resources it holds can allow for the built world to create its own adaptive skins with enriched resources in the urban land.

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Second skin to tile system. Geometry that will be used to cnc

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The new responsive urban language, with embedded resources in its skin.

POCKETS

TEXTURE

CAVITIES

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08 CONCLUSION

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CONCLUSION

Our current way of building is destructive not only for our environment and the sustainability of our planet but also for the lost potential of using resources that are readily available. Nature has always been adaptive, responsive with ingrained behaviors that are consistently changing. Why can this not be the case for the built landscapes? The research carried out made a link between the natural habitat of cliffs and the way they have been conditioned, in order to develop a material-based system that can offer similar properties within an urban context. To understand the implications of such changes in our urban reality a shift needs to be done by demonstrating the potential of nature as a natural resource for material innovation. With all this knowledge brought together by different researchers across multiple disciplines we can start to form an integrated system for the current urbanization crisis. The biodegradable based biocomposite research was established using natural available resources as well as waste material to redefine a new morphological framework. The initial material experimentation is just a preview of the possibilities that nature has to offer. The material sampling matrix

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has the potential to be further explored and investigated in a much more controlled fashion to perform in the desired way. However, its material principals allowed for a fabrication driven exploration to be carried out. To process the material sampling a geometrical research and explorations was investigated alongside the prototyping. This system was explored to further understand the physical parameters that occur when such a phenomena of weathering occurred. The results created intricate surface geometries that mimic what can be found in nature, and suggested performances along the cavities and ridges for displacement of matter to occur. Fabrication was the final step to visualize this procedure of the urban tectonic. Each of the digital fabrication techniques offered different qualities of the biocomposite casting system. The three methods of production offered different results in the material porosity and surface resolution which as a result contributed to the overall understanding of the mechanism. The fabrication technique was able to conclude a two-step process, where two molds were generated, a positive and a negative mold in order to achieve the highest level of resolution. Each mold holding

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different characteristics, one being flexible, and the other rigid allow for the casting of the biocomposite to take full advantage of manufacturing techniques with minimal waste being produced. The multilayered casting biocomposite is just at its initial phase and will need further exploration, in order to fully understand the implication of generating a system within an urban framework. However, a base scheme can be suggested for a more responsive system. Throughout this research, and the understanding of the natural ecologies that form in cliffs a link can be drawn between the ‘wild’ and the ‘stoic’. Nature which is often defined as ‘wild’ or chaotic and the ‘stoic’ as the current representation of our cities. The two elements should not have to be distinguished in such a manner but rather “participate and encounter a nature that is both urban and wild. The acknowledgment that cities may be functionally “natural” to nonhuman organisms may yield tangible benefits as well as provide a strong foundation for revitalizing our conceptions of urban places.” (Lundholm, 2004). Lundholm encompasses a nature-based city where the two can cohabit and respond to each other to achieve a more

sustainable and functional way of building our cities. The response of the biocomposite and its ability to change according to its environmental conditions presents interesting opportunities for performance-oriented design possibilities. The research carried forwards is an initial investigation to open up new discussions in response to our current environmental crisis that is upon us. Explorations of sustainable and advanced digital fabrication techniques are key in this innovative framework for material and fabrication processes. Within this framework many dialogues of material prototyping still needs to be developed to create the desired responsive skin. In addition, the introduction to the possibilities of using sedimentation from dredging adds another layer of investigation that could result in a new climatic formulation of the system. The overall research stems larger questions on the future of our built environment and reappropriating the landscapes for biodiversity to be brought back into an urban context.

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BIBLIOGRAPHY

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