THE DAIRY FACTORY
BURSLEM STOKE - ON - TRENT
PRODUCTION
REDUNDANCY
REGENERATION
CONTENTS 01 .............................................................................................................Context 02 ................................................................................... The Farmer - Potter 03 ......................................................................................................Programme 04 ........................................................................................................................Site 05 .......................................................................................Material Approach 06 ..................................................................................Intervention Strategy 07 ...............................................................................................Spatial Strategy 08 ......................................................................................Materials Assembly 09 ...........................................................................................Design Drawings
01 CONTEXT Burslem, ‘Mother Town’ of the Potteries is one of six towns that form the unique, polycentric city of Stoke-on-Trent. It was once at the heart of a thriving, global ceramics industry. At its industrial height 2000 bottle ovens were in use and the potteries employed 79,000 people, half the workforce of Stoke-on-Trent. Subsequent industrial decline however led to factory closures and a reduced workforce, resulting in today’s struggling local economy. Several Potteries which were once hives of activity now lie dormant and decaying.
THE DAIRY FACTORY Location - Burslem, Stoke-on-Trent
MANCHESTER & THE NORTH
PEAK DISTRICT & STAFFORDSHIRE MOORLANDS
TUNSTALL
BURSLEM
Burslem ASHBOURNE
HANLEY
NEWCASTLE UNDER- LYME
STOKE
FENTON
LONGTON
STOKE
BIRMINGHAM & THE SOUTH
Middleport
THE DAIRY FACTORY Decline of Industry
1720
1947
1947
1 Price Bros. (Burslem), Ltd. / Kensington Pottery, Ltd. 2 Thos. Hughes & Son, Ltd. 3 Arthur Wood & Son (Longport), Ltd. 4 Dunn, Bennett & Co., Ltd. 5 Burgess & Leigh, Ltd. 6 Leighton Pottery, Ltd. 7 A. J. Wilkinson, Ltd. 8 Newport Pottery Co., Ltd. 9 Susie Cooper Pottery, Ltd. 10 H. J. Wood, Ltd. 11 Wood & Sons, Ltd. 12 Ford & Sons (Crownford), Ltd. 13 Wade, Heath & Co., Ltd. 14 George Wade & Son, Ltd. 15 W. R. Midwinter, Ltd. 16 John Maddock & Sons, Ltd.
17 James Sadler & Sons, Ltd. 18 Barratt’s of Staffordshire, Ltd. 19 Alcock, Lindley & Bloore, Ltd. 20 Doulton & Co., Ltd. 21 R. Sudlow & Sons, Ltd. 22 Albert Potteries, Ltd. 23 Gibson & Sons, Ltd. 24 Gibson & Sons, Ltd. 25 Davison & Son, Ltd. 26 W. Moorcroft, Ltd. 27 A. G. Richardson & Co., Ltd. 28 Simpsons (Potters), Ltd. 29 North Staffordshire Pottery Co., Ltd. 30 Furnivals (1913), Ltd. 31 Portland Pottery, Ltd. 32 Myott, Son & Co., Ltd.
2018
1 Burleigh, Middleport Pottery 2 William Edwards, Middleport 3 Steelite, Dale Hall Works 4 Walpole 5 Royal Stafford 6 Moorland 7 Denise O’Sullivan, Albany Works
THE DAIRY FACTORY Context - Industrial Wasteland Past and Present
Potteries
Hills & Holes 1947 Historic Map
Potteries
Green Space
Brownfield 2019 Map
Disordered Nature
Ordered Nature
THE DAIRY FACTORY Context Analysis
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2
3
4
5
6
7
8
9
Reading B Occupied buildings
Roads
j
Redundant buildings 1
PRESENT - ALL TRANSPORT NETWORKS
Towards Tunstall
2
3
4
5
Reading Burslem
h
[ Burslem ]
The present day Burslem area has a mixture of rail, road, canal and cycle networks that connect the area with it’s neighbouring potteries towns of Tunstall and g Longport (City Centre) and Hanley more broadly 1 2 Manchester, 3 h Stoke-on-Trent and Birmingham.
gj
e [ Longport ]
Burlsem Towards Newcastle -underLyme
Middleport
A plan of Burslem town centre illustrating the amount and location Redundancy of redundant buildings.
Occupied Redundant
Towards Hanley
h f Steelite
Key: 28
g e
j
AT ACME MARLS LTD
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6
7
8
Three Bottle Kilns at Acme Marl Ltd is Grade II listed building. Ith is the only remaining downdraught type of potters ovens.
9
[ Burslem ] [ Longport ]
Acme Marls were founded in 1932 by J W A Lovatt, initially they processed the clays (marl) THREE BOTTLE KILNS -gjespecially fire clay which loAT pottery ACME MARLS LTDto make cal firms used [ Middleport ] //HISTORIES Key: saggars. Later the firm made the saggars and sold the finished Three Bottle Kilns at Acme Marl Dual Carriageway article to the potteries Ltd is Grade II listed building. A Road B Road Ith is the only remaining downf 2000 J&J Dyson acquired In Main Road draught type of potters ovens. Acme Marls, the kiln equipment Secondary Road [ Burslem ] Pedestrian Route company, for £1.9m, and consoli Acme Marls were founded in [ Middleport ] Cycle Route dated its business onto the Acme Towards 1932 by J W A Lovatt, initially Canal Marls site in Tunstall - this ment Hanley they processed the clays (marl) Railway that the Burslem site was sold off One Way Road -egespecially fire clay which lofor development. Transport Open Spacefirms used to make cal pottery // Location _ Three Bottle Kilns Present map of Burslem area with transport networks saggars.overlaid Later the firm made the 18 Greenspace saggars and sold the finished article to the potteries Steelite
Towards M6
gport
4 Burlsem
f
Longport Station
THREE BOTTLE KILNS //HISTORIES
Middleport
Towards Manchester
Towards M6
The present day Burslem area has a mixture9of rail, 7 8 road, canal and cycle networks that connect the area with it’s neighbouring potteries towns of Tunstall and Hanley (City Centre) and more broadly Manchester, Stoke-on-Trent and Birmingham.
PRESENT - ALL TRANSPORT NETWORKS j
Towards Tunstall
4
6
Towards M6
d
Present map of Burslem area showing only transport networks
DualCarriageway Carriageway Dual Road AA Road Road BBRoad Main Road Road Main f d Secondary SecondaryRoad Road Pedestrian PedestrianRoute Route Cycle CycleRoute Canal Canal Railway Railway One OneWay WayRoad Road
c [ Longport ]
Brownfield
f 2000 J&J Dyson acquired d In Acme Marls, the kiln equipment company, for £1.9m, and consoli dated its business onto the Acme Marls site in Tunstall - this ment that the Burslem site was sold off ce development. for
Steelite
b
[ Middleport// Location ] _ Three Bottle Kilns 18
ce
Present map of Burslem area showing only transport networks
Present map of Burslem area with transport networks overlaid
29
a d b
d b
18 ca
1
2
// Location _ Three Bottle Kilns 3 4
5
6
7
8 ca
9 Brownfield
Green spaces
THE DAIRY FACTORY Social & Economic Analysis
EDUCATION
EMPLOYMENT & BENEFITS
HEALTH
Burslem has a higher level of residents with either no qualifications or qualifications equal to 1 or more GCSE at grade D or below; lower than the national average
Burslem has a higher rate of unemployment, suggesting that finding a job in the area is difficult. Burslem has a higher benefits claim rate.
The percentage of Burslem residents rating their health as ‘very good’ is lower than the national average. The percentage of residents rating their health as ‘very bad’ is also higher than the national average.
BURSLEM
UK
BURSLEM
UK
BURSLEM
UK
02 THE FARMER POTTER Investigation into the Potteries’ history identified that Burslem’s earliest potters were also farmers, producing butter pots to supply Stoke’s prominent dairy industry. The combination of the two occupations supported each other, providing a balance. Pottery would support a bad harvest and farming would support cracked wares.
SPRING / HARVEST DAY SUPPORTS CRACKED WARES
WINTER NIGHT SUPPORTS BAD HARVEST
THE DAIRY FACTORY The Farmer - Potter
1 Early potters were farmers. Engaging in farming during busier times of the agricultural year.
THE DAIRY FACTORY The Farmer - Potter
2 Developing dual occupations farmer and potter. During less busy periods of the year they would devote their time to producing pottery. Butter pots became the first items that were mass produced.
THE DAIRY FACTORY The Farmer - Potter
3 Cottage craft became an industrial activity, potbanks developed and increased in number. The pottery produced became more refined.
THE DAIRY FACTORY The Farmer - Potter
4 Excessive mining required for fuel to fire the ovens of the potworks. Burslem had a variety of different clays, marl holes and slag heaps formed, scarring the landscape.
THE DAIRY FACTORY The Farmer - Potter
5 From the 1960s onwards there began a general decline in the British manufacturing industry. Some potteries shifted their production to factories in the far east, whilst many closed altogether.
THE DAIRY FACTORY The Farmer - Potter
6 Several potteries lie dormant and crumbling, nature inhabits and begins to retake control.
6
1
Given that Burslem can in some respects no longer solely rely on its pottery industry, the project proposes a return to Stoke’s initial form of industry, dairy farming in order to readdress the balance, whilst also retaining the idea of dual production.
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4
2
3
03 PROGRAMME Given that the sole production of pottery is no longer a reliable source of industry within Burslem, this project argues for a return to the dairy farm. Exploring key themes of evolution and adaption of place and production, it re-imagines the farm in a more contemporary and sustainable manner through promotion of a form of dual production. 50 cows are utilised to produce food as well as materials including bio-plastics derived from their by-products.
THE DAIRY FACTORY Programme Collage
THE DAIRY FACTORY The New Farmer - Potter
DAIRY FARMER FOOD PRODUCTION FROM MILK
RESEARCHER MATERIAL PRODUCTION FROM COW BY PRODUCTS
THE DAIRY FACTORY Dual Production - The Cow
SUSTAINABLE PACKAGING
DAIRY PRODUCTION
BY PRODUCTS
LABS
ENVIRONMENTAL
AR C H RESE
SEMINAR SPACE
WORKSHOPS
SHOP
EDUCATION
CAFE
FOOD
THE COW
MILK
MATERIAL
PRODUCTION
THE DAIRY FACTORY Cow Metrics
Scientific Name: Bos Tauras
BLIND SPOT
Height (Overall): 1.6-1.8m Height (Withers): 1.37-1.5m Length: 2.3-2.6m Weight: 635-907kg Lifespan: 4-5 years (farming), 20 years (natural) Uses: Milk, meat (beef), leather, gelatin, medicinal
Handler position to stop movement
Handler position to start movement
60o
1.7m
Turning circle
Outer edge of flight zone
45o
Point of balance
1.0m
Eye balance point
2.45m
90o
0.7m
Preference to move anticlockwise Tendency to align along north-south axis
THE DAIRY FACTORY Daily Cow Production Statistics Dual Production
BARLEY
CORN
OATS
SILAGE
HAY
WATER
25kg /90ltrs
FOOD
MATERIAL
MILK 28ltrs
MANURE 52kg
FOOD
MATERIALS
ENERGY
CREAM 2.5ltrs
PAPER
BIOGAS
BUTTER 1kg
CARDBOARD
FERTILISER
CHEESE 2.8kg
TEXTILES
ICE CREAM 4.2kg
BIOPLASTIC
THE DAIRY FACTORY Spatial Strategy
COWS
160m2
70m2
20m2
HEIFERS (3)
24m2
MANURE STORE
20m2
22m2
EXTERNAL GRAZING
CALF PEN (3-5) GRAIN STORE (12 COWS)
15m2
FARM HOUSE FREE ROAM BARN (12 DAIRY COWS)
BIOGAS TANK (12 COWS)
CALVING PEN
16m2
HOLDING PEN
PRODUCTION 45m2
50m2
TOILET 8.5m2
MATERIAL RESEARCH
FOOD PRODUCTION OFFICE 8.5m2
RESEARCH 30m2
MILK STORE
MILKING PARLOUR
35m2
10m2
MOTOR ROOM
45m2
125m2
MATERIALS LAB STORE
10m2
MATERIALS RESEARCH LAB
MEETING ROOM
MATERIALS OFFICE
30m2
65.5m2
10m2 MEDICINAL LAB STORE
PACKAGING
DAIRY PRODUCTION SPACE
COMBINING RESEARCH & FOOD
10m2
35m2 MEDICINAL RESEARCH LAB
35m2
MEDICINAL OFFICE LECTURE/ SEMINAR SPACE 30m2
10m2
60m2
ENVIRONMENTAL LAB STORE
PUBLIC FOOD WORKSHOP
PUBLIC MATERIAL WORKSHOP
10m2 60m2 ENVIRONMENTAL RESEARCH LAB
15m2
15m2
ENVIRONMENTAL OFFICE EXHIBITION SPACE
35m2
15m2
15m2
TOILETS
M CHANGING
TOILET
TOILET
CAFE
15m2 STAFF KITCHEN F CHANGING
PUBLIC ENGAGEMENT
THE DAIRY FACTORY Plausibility
TOTAL: 50 COWS Food Requirements:
20 Acres Grazing 40 Acres Fodder Production (Hay & Grain)
Yearly feed programme:
2/3 grazed outdoors 1/3 in barn
Winter food consumption:
153 hay bales (5x5ft) 66,500kg grain (3 silos)
Manure production:
1130 tons/year 30% ---> Biogas (339 tons) 60% ---> Fertiliser (678 tons) 10% ---> Material Research & Production (113 tons)
Milk production:
18,625 pints/ week
Cheese production:
1058kg cheese / week 12kg wheel (345mm x 105mm) = 88 / week
Cheese Tower capacity:
27 x 12kg cheeses per shelf - single depth 45 shelves = 1215 cheeses (maturing)
Maturation rates:
Fresh cheese - not matured Soft cheese - 1 month Semi soft cheese - 1.5 months Medium soft cheese - 2 months Hard cheese - 3 - 15 months
Ice cream production:
100kg/week 90 Cows 200 Acres (230 Grazed / 135 Barn) 31,000 pints/week Supplies: 950 Doorsteps 110 Small businesses Sheffield Population: 518,090
Business Precedent
Fodder Production
Area for Grazing
Access Points
04 SITE Grade II former Calcining Mill. Located in Middleport, 10 minutes from the centre of Burslem, it sits on the edge of the Trent and Mersey Canal, adjacent to Middpleort Park. Brownfield land previously used as a refuse for the pottery industry is located opposite. Middleport Pottery, still in production is located close by. Largely early C19, but with later additions reflecting long period of use. Predominantly brick with tiled roofs. Brick with tiled roofs. The Mill comprises a collection of buildings arranged around a courtyard with a kiln at the centre, square in section, with two flues separated only at the apex. Early C20 additions extended the building upwards, incorporating a triple height narrow slip tower. Later C20 edition to incorporate a garage / workshop. The Mills historic programme involved the heating and grinding up of cattle bones for the production of bone china. Since ceasing operation in 1972, the Mill is dormant, and has decayed due to weathering and vegetation taking over .
Cattle Bone
Ground Bone
Bone China
THE DAIRY FACTORY Site Location
A
B
C
D
E
F
1
2
3
BURSLEM
LONGPORT 4
MIDDLEPORT
5
Site 6
Potteries Potteries
Green Space Wildscape
Green Space Potteries
Potteries
Green Space
Wildscape
Greenspace
2018 Map 1:10000
2018 Map 1:10000 Wildscape Green Space 2018 Map 1:10000
Brownfield
Wildscape 2018 Map 1:10000
THE DAIRY FACTORY Site Context
Burslem Centre 0.5 miles
04
08
02
05
03
06 01 07
06 02
01 Site - Former Calcining Mill 02 Trent & Mersey Canal 03 Port Vale Flour Mill (disused) 04 Middleport Pottery (in use) 05 Allotments 06 Brownfield 07 Middleport Park 08 Area of Residential
Existing Site Context Middleport, Stoke-on-Trent
THE DAIRY FACTORY History
1775
1855
1890
1920
1970
1972
Area of agricultural land and farmhouse - tenant John Bagnall - a famer potter and producer of butterpots
Site used as canal wharf
First operation of site as Calcining Mill - owned by Thomas Smith
Mill owned by Goodwin and Sons, known as Middleport Mills Company. Additional building to add second storeys to existing built units
Mill owned by Wood and Sons Pottery Company. Addition of workshop / garage unit
Mill ceases operation
Historic Photos 1960s
THE DAIRY FACTORY Visibility
A
A
View from Canal edge
B C
View from Milvale Street B
C
View from Canal edge
THE DAIRY FACTORY Existing Plans
Po Flo rt ur Val e ila pid Mil ate l d)
(D
et
tre
le S
lva
Mi
Tr en
t&
M
M
er
se yC
an
al
idd Pa lepo rk rt
Existing Ground Floor Plan (nts)
THE DAIRY FACTORY Existing Plans
Existing First Floor Plan (nts)
Existing Second Floor Plan (nts)
Existing Third Floor Plan (nts)
THE DAIRY FACTORY Existing Materiality
THE DAIRY FACTORY Existing Site Elevations
Non- original fencing
Garage C20th
Adjacent Flour Mill
Kiln Chimney
Non- original fencing
A. Milvale Street Elevation
Area of Brownfield
Slip Tower
Collapsed Roof
C. Middleport Park Elevation
Flour Mill
Decorative brickwork
B. Footpath Elevation
Existing Bridge
Kiln Chimney
Large Wharf Opening
Slip conveyor
Slip tower triple height
Garage
Middleport Park
D. Canal Edge Elevation
B A
D C
THE DAIRY FACTORY Existing Internal Images
6
OR VE Y CON
5
7
4
1. Washing Room
2. Grinding Mill
3. Calcining Kiln
4. Boiler House
5. Wharf Building
6. Slip Loading Tower
7. Unknown Use
8. Slip House
9. Garage / Workshop
9
8
3
2
1
Historic Uses
THE DAIRY FACTORY Existing Site Sections
Section AA (nts)
Section BB (nts)
A
Section CC (nts)
C B C A B
05 MATERIAL APPROACH Carefully considered intervention with the existing built structures allows for accommodation of the new programme, along with sympathetic new build. A conceptual approach to inserting new forms into the existing building applies the pottery method of clay slipcasting. This process begins with a plaster mold into which clay slip is poured. As the plaster mold absorbs the water, a hard shell of clay forms. Excess slip is removed, leaving behind the clay shell. As the shell dries it shrinks, creating a gap between the clay form and the plaster. This gap is employed architecturally to subtly distinguish between the old and the new, existing and contemporary. A simple material palette to the proposed new forms inserted into the existing includes corrugated stainless steel cladding which reflects an agricultural style. Exploration of contemporary materials including bioplastic cladding derived from cow’s milk forms translucent façades to the cowsheds and milking parlour, echoing the translucency of bone china and referencing the site’s former use.
THE DAIRY FACTORY Slip Casting the Site
THE DAIRY FACTORY Slip Casting Process
THE DAIRY FACTORY Slip Casting - The 'Gap'
Plaster (Existing Form)
Clay (Proposed Form)
PRECEDENT: Hedmark Museum, Sverre Fehn
PRECEDENT: Dovecote Studio, Haworth Tompkins
THE DAIRY FACTORY Slipcasting Massing to Existing Building
Existing
1:200 Model
Proposed
THE DAIRY FACTORY Development of Translucency
Historic - Bone China
Development of Materials Derived from Cows
Future - Casein (Milk) Bio-plastic Cladding
THE DAIRY FACTORY Material Investigation - Bioplastic Panels
MAKING PROCESS
Experimentation of Colour Clays and Natural Dyes
Experimentation of Texture
Addition of Clay
Molds for casting
Overlapping panels Casein based: Addition of natural dye
Casein based: Larger rib structure
Casein based: Addition of grey clay
Casein based: Waffle structure
Casein based: Addition of red clay
Casein based: Smaller rib structure
Non overlapping panels
06 INTERVENTION STRATEGY Careful consideration and appraisal of the existing buildings has been undertaken to consider areas for retention and removal to allow for subsequent appropriation and intervention. Weathering and vegetation damage to the existing roofs has caused considerable decay. Therefore it was deemed appropriate for these to be removed. Non-original features including the current site fencing has also been removed. Existing detailed brickwork and openings have been retained. Appropriation and intervention seeks to utilise the existing retained building whilst also proposing where necessary appropriate and sensitive new built forms. These include laboratories, farmhouse and cow sheds. The proposed echoes the forms of the existing, aligns with existing openings and sensitively introduces new openings.
THE DAIRY FACTORY Retention & Removal
Slip T ower Ro
of
Slip T ower Co
nvey or
Conc re
te Ro
of
Wharf
Roof
Boile
r Hou
Slip H
ouse
Retention of existing openings
se Ro
Wharf Floor Intermed ia
te
Roof
Offic
e Roo
Wall to
f
Cana l
Garag e Interm / Worksh op ediate Floor, N&W Ro Facin of & g Wa ll
Grind
ing R
Steel
Grind
ing R
Struc ture & Roo f
Retention of brickwork details
Wash in
l Corr
ugate
ediate
of
d Fen
ce
Roof
Interm
m Ro
Wall
Meta
Removal of decaying roofs and unstable, dangerous elements
oom
g Roo
Brick
Removal of non-original fencing
oom
Floor
of
THE DAIRY FACTORY Appropriation & Intervention
Grain Si
los
Cow Sheds
Milkin g Parlo ur
Cow Br id
ge
Sensitive echoing of existing form
Che e Tow se er
C Circ hees e ula tion
Lab
Circ
ulat
ion
Offi c Past es & euriz atio n
Ne sup w Roo f por t Sp to ace
Roo
m
Addition of new roof & materials Circ
ulat
ion
Site Offi ce
Lab
orat orie
s
Farm
hou
se
Cafe Pub & lic C ook
ing
Wor ks
Pub li Exh c Farm ibitio sh n Sp op & ace
hop
Addition of new considered forms
Retention of existing openings and sensitive introduction of new ones
07 SPATIAL STRATEGY The following series of diagrams demonstrates the spatial strategies undertaken in order to sympathetically accommodate the proposed programme into the existing building whilst also proposing carefully considered elements of new build where appropriate.
THE DAIRY FACTORY Initial Sketch Strategy
UT B ILIS FO ROW ATI O R GR NF N O AZ IEL F IN D G
CO W
S
PR MA OD TER UC IAL TI ON
RE
SE
AR
CH
M
ILK
FO
OD
PR
LO U
R
OD
UC
FA R
PA R
TI
ON
M
HO
US
E
W PU O BL & RKS IC CA HO FE P S FA EPA RM RA SH TE OP
CO N AL NE LO CT TM IO EN N TS TO
THE DAIRY FACTORY Spatial Strategy
01
Existing site
THE DAIRY FACTORY Spatial Strategy
02
Site appraisal
Removal of garage wall
Removal of roofs
Removal of site fencing
THE DAIRY FACTORY Spatial Strategy
03
Cows - sheds & parlour
3 cow sheds on opposite side of canal
Milking parlour
THE DAIRY FACTORY Spatial Strategy
04
Cow route
Cow route from sheds to milking parlour bridging the canal
THE DAIRY FACTORY Spatial Strategy
05
Line of dairy production
Cheese tower
Packaging & distribution Pasteurization & Cheese making
THE DAIRY FACTORY Spatial Strategy
06
Research facilities
Labs Research support space - seminar room - offices -meeting rooms
THE DAIRY FACTORY Spatial Strategy
07
Public engagement
Cafe & public workshop
Exhibition space & farmshop
THE DAIRY FACTORY Spatial Strategy
08
The farmhouse and creating street frontage
Farmhouse
Proposed wall creating new frontage to street
THE DAIRY FACTORY Spatial Strategy
09
Circulation cores
Research circulation
Production circulation
THE DAIRY FACTORY Spatial Strategy
10
Proposal
THE DAIRY FACTORY Route of Production
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6
2 5
4 3
7
1
2
3
4
5
6
7
Cows grazed and housed across the canal
Cows cross new bridge to get to milking parlour
Milking parlour, 3 cows milked at a time. Total milking time for 50 cows = 1 hour Milked 3 times per day
Milk processed and turned into cheese
Cheese matured in cheese tower, placed on shelves and rotated depending on type of cheese and required maturation time
By products from cows utilised to produce packaging for dairy products
Produce supplied to proposed farmshop and cafe
08 MATERIAL ASSEMBLY It was essential to explore the connections created between the existing and the proposed. Developing on from the conceptual approach to the slipcast ‘gap’ it was important to create this subtle distinction between the old and the new at a visual level. This therefore presented challenges with the ‘gap’ created. Through research of precedents, it was often found that the new build element ‘carries over’ the existing in the form of flashings and roof profiles in order to prevent water and debris ingress. However this was not the intended approach. Further exploration considered details which hid the flashings behind the existing and enabled an approach to add channels, gutters and mesh to prevent water ingress and debris, allowing the structure to breathe while also creating a subtle, visual gap between the existing and proposed. A steel frame was initially considered as the primary structure to the proposed, connecting back into the existing to provide support, however this resulted in cold bridging. Resolution was achieved by proposing a timber frame structure instead, pinning back to the existing whilst maintaining support. Several approaches to the proposed foundations were considered. These included, piling, underpinning and localised foundations at the primary structural columns. It was suggested that piling was too difficult to achieve within a small space, underpinning was also suggested as too intrusive and not necessary for all of the existing walls. Therefore the detail chosen was localised foundations at column positions. The idea being that the existing walls and foundations would be initially shored up and concrete poured in, with the depth of the foundation to be determined.
THE DAIRY FACTORY Detailed Section - Connection of Proposed & Existing
8mm corrugated steel panel Concrete cap cut into existing wall Aluminium flashing 25mm gap to allow ventilation and bug mesh to prevent debris
4
1) Floor 20mm wood floor finish Movement joint 125mm sand cement screed 120mm rigid insulation Damp proof membrane 200mm reinforced concrete slab Existing concrete slab
Detail 1
2) Wall 225mm existing masonry 280mm gap 100mm foil faced rigid insulation Breather membrane 18mm ply 140mm timber frame structure 140mm insulation within frame 20mm timber panel finish 3) Intermediate Floor 20mm timber floor 18mm particle board 20mm routed insulation 18mm particle board 254mm Easi-Joist at 600mm centres 100mm insulation within beam 18mm board 210mm metal frame ceiling 20mm timber panel finish
Detail 2
Existing wall
Detail 1 (1:20) - Top of Existing Wall Connection Existing wall Cavity tray bracing plate Timber frame panel structure with 140mm insulation Cavity tray Cavity closer DPM Existing wall and existing lintel Aluminium flashing
Detail 2 (1:20) - Window Head
4) Roof 8mm corrugated steel cladding Helping hand bracket on thermal coupling 100mm foil faced rigid insulation Breather membrane 254mm Easi-Joist Metal frame ceiling 20mm timber panel finish
Detail 3
Concrete cap existing wall
cut
into
Aluminium flashing 25mm bug mesh EPDM Timber Stainless steel pins DPM Timber frame structure
5) External Treatment 60mm paving 120mm sand 300mm hardcore
3
Anodised aluminium window frame
Thermal break Thermal break timber finish, shadow gap to timber frame Breather membrane
Detail 3 (1:20) - Window Cill 2
Acoustic flanking strip 20mm Timber floor finish 65mm screed
5
120mm rigid insulation New concrete slab DPM
1
Existing slab
Detail 4
Detailed Section (nts)
Detail 4 (1:20) - Foundation
Existing masonry wall Cavity tray bracing plate Timber column connecting to steel footing Channel New steel frame Steel footing to pin to timber column Insulation Retention of existing masonry foundation Temporary boarding to shore up existing masonry foundation whilst new localised concrete foundation is poured Localised concrete foundation at column positions
THE DAIRY FACTORY Basic Construction of Proposed Form into Existing Shell
Corrugated steel cladding panels Pre-fabricated panels containing insulation to fit between primary structure Proposed primary structure pinned back to support existing masonry
Existing masonry structure with roof and south east facing wall removed
New concrete slab cast over existing post debris clearance
THE DAIRY FACTORY Material Investigation - Model
1:50 Model
THE DAIRY FACTORY Bio Plastic Assembly - Dairy Parlour (Non-Insulated) Exploring Openings Interface Between Old and New Translucent bioplastic panels
Existing structural reports have highlighted that the building is structurally stable, however work would be required to replace the roof and floor slab.
Secondary structure supporting bioplastic panels
Elevation highlighting area of existing building for CMA
Development of Form The proposed space considers the application of a non insulated facade construction. This treatment therefore has an impact on the appropriate internal function. As a small dairy parlour this process would not necessarily require an insulated space.
Glass panel fixed over existing opening
Bioplastic panels recessed and attached to proposed new glulam structure
Conceptually the application of a casein based bioplastic facade is most appropriate to a space where the raw material is harvested.
Potential openings within recessed bioplastic panels
20mm Toughened bioplastic washer 40mm steel screw 16mm Bioplastic textured panel
Primary glulam structure
40 x 40mm Timber batten
The proposed form sits within the existing shell of the building. The form and roof echoes the shape of the existing. Extruding the form upwards allows for the new structure to more visible and accommodates greater expanse of translucent facade. This is particularly important during darker hours as the space will be lit from within to create a glowing form.
Sketch Detail: Bioplastic Panel Fixing
Glulam beams and steel bolt pinned connections Gap between proposed cladding and existing masonry allowing ventilation Gap between proposed glulam structure and existing masonry
Existing building
Glulam structure pinned back to existing masonry to provide lateral stability
Gap between floor structure and glulam timber structure created by steel support base New cast concrete floor to replace existing slab. Slab depth increased to support load for up to 6 cows New cast concrete floor slab Proposed Elevation
A dairy cow produces 28 litres of milk per day. As such, the size of the bioplastic panels chosen reflects the amount of casein that can be separated from the daily milk volume (580cm2). Sketch Section - Emphasising the ‘Gap’
Exploded Axo - Construction
09 DESIGN DRAWINGS Elements from programme, approach to structure and materiality have be carefully and consciously designed to reference the past whilst adding new layers, imagining an alternative future production.
THE DAIRY FACTORY Masterplan
Middleport Pottery
Allotments
Flour Mill Fodder Production
Middleport Park
Grange Park
Grazing
Fodder Production
Fodder Production
Grazing
Fodder
Site Masterplan Scale1:5000
Public Cafe Mee
ting
Spa
ce
Sem
inar
Spa
ce
First Floor Plan 1:100
5
6
4
Cheese Making Space Cheese Processing
Pasteurization & Milk Store
Space
Dairy Testing
6 Packaging Spac
e
Material Store
9
12
8
Ice Cream Production
7 3
2 Lab
Store
11
Store
Public Workshop
Biog
as Ta
10
nks
1 Farmhouse
Farmshop / Exhibition Space
Milv
ale S
Ground Floor Plan 1:100
Ground Floor Plan Scale 1:200
Key Plan 1. Farmshop 2. Public Workshop 3. Ice Cream Production 4. Pasteurisation Room 5. Cheese Making Space 6. Packaging Space
7. Material Store 8. Store 9. Laboratory 10. Biogas Kiln 11. Farmhouse 12. Courtyard
tree
t
Cow Shed
Cow Shed
Cow Shed
5
4
Trent & Mersey Canal
Milking Parlour
Production Office
3 7
2
Cheese Store
Reception
8
11
10 Lab
Site
9
Store
Offi
ce
1 13
Public Cafe Mee
ting
12
Spac
e
Sem
inar
Spac
e
First Floor Plan Scale 1:200
Key Plan 1. Public Cafe 2. Production Office 3. Dairy Parlour 4. Raised Cow Route 5. Cow Sheds 6. Grain Silos 7. Cheese Store
8. Laboratory Support Space 9. Seminar Space 10. Meeting Space 11. Laboratory 12. Farmhouse 13. Site Office
Cheese Making Space
Cheese Processing
Space
Pasteurization & Milk Store
Dairy Testing
3 Laboratory Supp
ort Space
4
1
Lab
Store
2
Mee
ting
Room
Second Floor Plan 1:100
Second Floor Plan Scale 1:200
Key Plan 1. Lab Support Space 2. Meeting Room 3. Cheese Tower 4. Laboratory
Grain Silos
THE DAIRY FACTORY Milvale Street Elevation
Delivery Space
Research Facilities
Dairy Production
Public Engagement
Existing Bridge
Dilapidated adjacent Flour Mill Milvale Street Elevation 1:200
THE DAIRY FACTORY Courtyard Section
Middleport Park
Laboratories
Laboratory Support Space Material Store
Seminar Space Store
Courtyard
Cafe Public Workshop
Existing Bridge across Canal
Dilapidated Flour Mill Courtyard Section 1:200
THE DAIRY FACTORY Line of Production Section
Dilapidated Flour Mill
Public Footpath
Site Production Offices Milk Storage & Pasteurisation Rooms
Dairy Parlour Cheese Production
Cheese Storage Tower Cheese Storage Preparation Room
Labs Line of Production Section 1:200
THE DAIRY FACTORY Canal Elevation
Canal Elevation 1:200
THE DAIRY FACTORY Cow Shed to Parlour Section
Grain Silos
Cow Shed
Footpath
Footpath
THE DAIRY FACTORY Cow Shed to Parlour Section
Dairy Parlour Canal
Cheese Making Room
Site Office Courtyard
Repurposed Biogas Kiln
Milvale Street
Residential
Cow Shed to Milking Parlour Section 1:200
THE DAIRY FACTORY Cows Grazed across Canal
THE DAIRY FACTORY View from Canal - Shed to Parlour
Bone China
Bioplastic Cladding
THE DAIRY FACTORY View from Milvale Street
THE DAIRY FACTORY View from Existing Bridge
THE DAIRY FACTORY Cheese Maturation Tower
Middleport Pottery: Mould Store
THE DAIRY FACTORY Seminar & Laboratory Support Space
THE DAIRY FACTORY View from Courtyard
THE DAIRY FACTORY Return to Sheds following Milking