Tectonic Tessellation Ceramics Structural Surfaces
Material Processes and Systems: Ceramic LAB
SCI 0642900
Prof. Martin Bechthold | Jonathan King Matias Imbern Felix Raspall Qi Su
[Contents] 1 - Introduction
and Precedents 2 - Design Proposal a. LARGE Scale b. PANEL Scale c. MODULE Scale
3 - Prototype
Construction 4 - Conclusions and Further Development
1 - Introduction
and Precedents
2 - Design Proposal a. LARGE Scale b. PANEL Scale c. MODULE Scale 3 - Prototype
Construction 4 - Conclusions and Further Development
Tectonic Tessellation:
Ceramic Structural Surface
GSD 6429: material processes and systems: ceramics LAB
Topic: TECTONIC Sub-Areas: -Structural Surface Efficient / Expressive -One-Off Fabrication New Design Attributes / Extended Possibilities
Proposal [>Experiments] Felix RASPALL - DDes / Qi SU - MDesS / MatĂas IMBERN - MDesS / TECTONICS
Tectonic Tessellation:
Ceramic Structural Surface
GSD 6429: material processes and systems: ceramics LAB
Why ceramic components? -Cheaper -Lighter -Rougher formwork -Delicate finishing Ceramic Structural Surface Today: -Disappearing / Not affordable anymore Problems: -Cost of hand labour -Cost of formwork -Lack of skills
Proposal [>Experiments] Felix RASPALL - DDes / Qi SU - MDesS / MatĂas IMBERN - MDesS / TECTONICS
Tectonic Tessellation:
Ceramic Structural Surface
GSD 6429: material processes and systems: ceramics LAB
Rafael Guastavino (1842–1908) Main Characteristics / Innovations: -Increase in scale. -Introduction of graphic analysis (previously was mostly empirical). -Massive application/commercial enterprise. -Construction without centering. -Terracotta tiles are standardized but with different sizes, less than an inch thick, and approximately 6 inches (150 mm) by 12 inches (300 mm) across.
Eladio Dieste (1917-2000) Main Characteristics / Innovations: -Reinforced masonry -Reusable movable formwork. -Standardized bricks with different sizes, aproximately 2 inches (50mm) thick and 5 inches (125 mm) by 10 inches (250 mm) across. He also used square ceramic hollow bricks in his vaults.
Proposal [>Experiments] Felix RASPALL - DDes / Qi SU - MDesS / MatĂas IMBERN - MDesS / TECTONICS
Tectonic Tessellation:
Ceramic Structural Surface
GSD 6429: material processes and systems: ceramics LAB
Solano Benitez Main Characteristics / Innovations: -Combines traditional masonry with simple prefabrication methods. -Prefabrication of one-ply components (folded or ribbed), -Large scale Vierendel-like beams, using simple or no formwork. -Rustic/texture ceramic slabs accentuating the material expresion.
Gramazio & Kohler Main Characteristics / Innovations: -Robotic arm assembly. -Fabrication of complex geometry.
Proposal [>Experiments] Felix RASPALL - DDes / Qi SU - MDesS / MatĂas IMBERN - MDesS / TECTONICS
1 - Introduction
and Precedents
2 - Design
Proposal
a. LARGE Scale b. PANEL Scale c. MODULE Scale 3 - Prototype
Construction 4 - Conclusions and Further Development
Tectonic Tessellation:
Ceramic Structural Surface
GSD 6429: material processes and systems: ceramics LAB
A. Large Scale.
B. Panel Scale.
The proposed system aims to create structural surfaces including compression only and shells.
The structure is subdivided in parts that are fabricated and mounted on-site.
Panelization of the structure
Compression Only Structures
Simple scaffolding
Shell Structures
Self-supporting panels
Ceramic Structural Surface 40mm
Tectonic Tessellation:
C. Module Scale. The proposed system aims to creFree-Form Ceramic Structural Surfaces ate structural surfaces including compression only and shells.
gsd 6429: material processes and systems: ceramics LAB
3- MODULE Scale
m 0m 26 mm 0 15
105mm
A. Module Description: Two types of ceramic modules are set, one with triangular shape for the first layer and another with round shape for the second layer.
mm
30
GSD 6429: material processes and systems: ceramics LAB
40mm
The modules of the first layer (inner layer) are hollow and have a lip with two functions: 1- provide a separation between pieces enough to pour Module Geometry the reinforced concrete 2- produce a smooth interior surface (hiding the mortar in the joints)
MODULES - SIZES AND OVERLAPPING
FLEXIBLE HEXAGONAL GROUPING
The modules of the second layer (outer) are solid tiles and they cover the panels assembling concrete as finishing, following a glazing pattern. B. Interlocking Overlapping technique requires two different triangular modules, one with an inner lip and another with an slightly upper lip. The combination produces a flexible hexagonal pattern that can populate any surface.
Circular Tile
C. Curvature Absorption The inner layer deals with curvature by producing a small separation in the lips overlapping. In the outer surface, the mortar separation is going to absorb the differences.
Triangle Component Type A Triangle Component Type B INTERLOCKING
Proposal [>Experiments] Felix RASPALL - DDes / Qi SU - MDesS / MatĂas IMBERN - MDesS / TECTONICS
MODULE STUDY
Tectonic Tessellation:
Ceramic Structural Surface
GSD 6429: material processes and systems: ceramics LAB
Tectonic Tessellation:
Ceramic Structural Surface
GSD 6429: material processes and systems: ceramics LAB
Exterior Cladding
First Reinforcement
Second Reinforcement Panel 2
Panel 1
Panel Assembly
Reusable Form.
[Formwork Alternatives: Pinmold / Sand Milling]
Ex t rei ensi nfo on rce of me firs Se nt t cti wit o ho n of ut co pane nc ret l e
l2
Pa ne
Se c wit tion ho ut of pa co nc nel Ex ret ten e rei nfo sion rce of me firs nt t
Pa ne l
1
Tectonic Tessellation: Ceramic Structural Surface GSD 6429: material processes and systems: ceramics LAB
Tectonic Tessellation:
Ceramic Structural Surface
GSD 6429: material processes and systems: ceramics LAB
C. Module Scale. Weight estimation
Hexagon [m2] 0.118
Per Square Meter [m2] 1
Whole Structure [m2] 31.2
1 [m2]
Concrete Volume [m3] Weight [kg]
0.0041 9.84
0.0347 83.4
1.1 2601.8
Ceramic Modules Number [u] Volume [m3] Weight [kg]
6 0.0036 5.17
50.8 0.0305 43.8
1586.4 1.0 1367.0
Total Weight [kg]
15.0
127.2
3968.7
1 - Introduction
and Precedents 2 - Design Proposal a. LARGE Scale b. PANEL Scale c. MODULE Scale
3 - Prototype 4 - Conclusions
Construction
and Further Development
Module Construction - Plaster Mold
Module Construction - Ceramic Pieces [Casting]
Module Construction - Ceramic Pieces [Kiln - ConeO6]
Module Construction - Production Statistics Day
Time
10‐Nov 15‐Nov 16‐Nov 16‐Nov 17‐Nov
Afternoon Afternoon Afternoon Afternoon Afternoon
18‐Nov 19‐Nov
25‐Nov 26‐Nov 27‐Nov
Afternoon Morning Night Morning Night Morning Night Morning Night Night Morning Night Night Night Morning
28‐Nov 30‐Nov 1‐Dec
Night Night Morning
20‐Nov 21‐Nov 22‐Nov 23‐Nov 24‐Nov
2‐Dec 2‐Dec
Night Morning Night Morning Night
Qty 2 2 1 1 1 1 2 2 2 2 2 2 2 2 2 4 4 4 4 4 3 1 2 4 3 1 4 4 4 4 4
TOTAL
80
OK BAD
68 12
Body ‐ Slip
Technique
Characteristic
Result
Observations
Porcelain White Stoneware Porcelain White Stoneware White Stoneware White Stoneware White Stoneware White Stoneware White Stoneware White Stoneware White Stoneware White Stoneware White Stoneware White Stoneware White Stoneware White Stoneware White Stoneware White Stoneware Porcelain Porcelain Porcelain Porcelain Porcelain White Stoneware White Stoneware
Casting Casting Pressing Casting Pressing Casting Casting Casting Casting Casting Casting Casting Casting Casting Casting Casting Casting Casting Casting Casting Casting Casting Casting Casting Casting Casting Casting Casting Casting Casting Casting
Complete Cap Complete Cap Complete Cap Complete Cap Complete Cap Complete Cap Bricks (Solids) Hollow Cap Hollow Cap Hollow Cap Hollow Cap Hollow Cap Hollow Cap Hollow Cap Hollow Cap Hollow Cap Hollow Cap Hollow Cap Singularities Singularities Singularities Singularities Hollow Cap Hollow Cap Hollow Cap Singularities Hollow Cap Hollow Cap Hollow Cap Hollow Cap Hollow Cap
BAD BAD OK BAD OK OK BAD OK OK OK OK OK OK OK OK OK OK OK OK OK OK BAD OK BAD OK OK OK OK OK OK OK
Too Thin Melted
White Stoneware White Stoneware White Stoneware White Stoneware White Stoneware
FINAL PRODUCTION Standard: Singularities: Small Opening Big Opening Shadow
Bumped
Too Heavy
Bumped Too Thick ‐ New Slip
FIRED 55 ‐2 (1 exploded, 1 lost CAP) 6 3 4 13
Formwork Milling - Low Density White FOAM
[Robotic Pick and Place]
[Reinforcement Layers]
1 - Introduction
and Precedents 2 - Design Proposal a. LARGE Scale b. PANEL Scale c. MODULE Scale
3 - Prototype
Construction
4 - Conclusions
and Further Development
[Pick and Place Crash]
Tectonic Tessellation:
Ceramic Structural Surface
GSD 6429: material processes and systems: ceramics LAB
1- Re-Design the Module -Industrialization: Produce the pieces using heavy machinery and pressing technique.
Proposal [>Experiments] Felix RASPALL - DDes / Qi SU - MDesS / MatĂas IMBERN - MDesS / TECTONICS
[Pouring Concrete]
Tectonic Tessellation:
Ceramic Structural Surface
GSD 6429: material processes and systems: ceramics LAB
2- Reinforced Concrete -Study the possibility of robot assistance in the reinforcement placement and in the concrete pouring.
3- Structural Performance -Provide the system with a calculation background in order to be more effective in sections.
4- Formwork -Create a Pin Mold capable of dealing with large panels (1,5 x 1,5m).
5- Panelization Strategy -Develop a panelization method capable of discretice complex geometries into tesselated panels, following the module logic.
6- Assembly Sequence -Study the assembly sequence to achieve panel interlocking.
7- New Prototype -Build a small scale structure as a first application of the construction system.
Proposal [>Experiments] Felix RASPALL - DDes / Qi SU - MDesS / MatĂas IMBERN - MDesS / TECTONICS
[Construction Sequence]
Tectonic Tessellation Ceramics Structural Surfaces
Material Processes and Systems: Ceramic LAB
SCI 0642900
Prof. Martin Bechthold | Jonathan King Matias Imbern Felix Raspall Qi Su