BA3 Technologies Part C Saif Hajazi | &rchitecture

Prototype 1 - Snap On Click Cladding System

Clips Fixing Vertical Battens Container Attachment Shingle Attachment

The vertical battens are screwed into the buildings structure, they provide structural support to the cladding and create separation for ventilation.

The clips that hold the claddings are then attached by a bolt into the battens, allowing for the easy removal of the clips post service life.

The cladding can then be snapped into the containers. They are manufactured to extremely tight tolerances to provide a secure fit.

As the shingles lacks straight edges, a timber batten is screwed into the back of the shingle, this can then be snapped into the cladding clips.

The current cladding system on my fragment uses a typical screw system, where the cladding is attached to the structure by installing screws through the cladding, horizontal and vertical battens and then into the OSB sheathing. It is a fast and efficient system that minimises waste.

Current Cladding System Issues

In the first step, an aligning hole is drilled through the batten and clips, and is attached by a locking nut creating a non permanent fixture.

The cladding can then slide into the clips. This will make an audible click, that affirms that the cladding is securely fitted into the clip.

This same principle applies to the shingle, except the screwed in timber batten provides the needed surface area for the clips to attach.

Since the clips are made with precise tolerances for a snug fit, removing them can be difficult and requires prying, which could damage the clip.

To address the challenge of cladding replacement, I propose a new system that suspends the horizontal battens and cladding, avoiding damage to the sheathing and breather membrane. This approach significantly reduces costs, minimises materials required for building restoration, and simplifies maintenance. Expanding this system into a circular modular cladding system would offer sustainability benefits through the attachment of recycled plastic shingles and containers. This universal system would also allow for the replacement of individual components, improving cost efficiency and maintenance ease.

Prototype 2 - Z Bracket Cladding System

Vertical Battens Horizontal Rails

Cladding Brackets Detailing

The first step of installation is the vertical battens. These connect to the building and provide separation for ventilation.

The Horizontal rails are then attached to the vertical battens, and are shaped to allow the cladding brackets to fit onto them.

Nut & Bolt Holes Tighten

To Bracket

Using a drill, holes are cut into the corners of the cladding aligning to the holes on the Z bracket.

The cladding brackets are prefabricated to the correct spacing that allows the shingles and the containers to be attached.

After the brackets are bolted onto the cladding, they can be fitted onto the horizontal rail, and further secured using nuts and bolts.

Attach to Rail Seamless Finish

After the holes are cut, the Z Bracket can be secured to the cladding with nuts and bolts, allowing for easy disassembly.

The containers are then placed onto the horizontal rails and secured to the rail with nuts and bolts, allowing for a waste free installation.

The final result is a seamless finish. It is a quick and efficient system that allows for easy cladding replacements after its service life.

As the clips alleviate the necessity for screw attachments of the claddings, there is a minimal amount of materials needed in the assembly.

The ability to 3D print plastic clips means they can securely fit any cladding size and shape, thanks to their precise custom manufacturing.

Vertical battens create a 25mm gap for drainage and ventilation, while secure bolts and precise clips help the system withstand weather loads.

While the tools required are minimal, the containers require a significant number of bolts and clips, which can impact the system's sustainability.

Steel L Angle Mesh Attachment Mesh Attachment Cladding Fixing

The Steel L angle is connected to the buildings structure. This provides space for ventilation and holds the perforated metal sheet.

The metal sheet is connected to steel angle using a U bracket and nuts and bolts, allowing for efficient, waste free assembly/disassembly.

The bottom of the sheet has U clip bolted to a metal spring, which provides tension & flexibility in windy conditions, distributing wind loads.

The cladding is then attached simply using nuts and bolts, by utilising the many holes in the sheet. This is a very fast and efficient mounting system.

2mm Holes are cut into the claddings. Unlike the Z Clips, these can be cut anywhere, and do not have to align with any brackets

Required

The Z clip system is a very efficient system that has very few tools. This reduces waste and allows for easy cladding replacement.

Using Nuts and bolts means the system can be installed and removed by hand, which is simple, carbon free and reduces waste.

Climate Performance

Horizontal rails ventilate the cladding to prevent moisture build-up and mould. The close fit of the cladding allows rainwater to shed to the ground.

System's metal use (brackets, nuts, bolts) is a clear negative, but recycled materials & responsible reuse can minimise embodied carbon.

The metal sheet system can be installed easily through only by hand and a drill, creating a sustainable, waste free system.

Using the perforated metal sheet as a “grid” the claddings can be attached and then bolted into one of the many holes on the sheet.

At the end of it service life, the cladding can be easily disassembled by hand through the use of nuts and bolts without any brackets.

A replacement cladding such as the shingles can then be installed quickly, sustainably and efficiently, reusing the same nuts and bolts.

A Universal System Environmental Impact

The use of a perforated sheet acts as a grid, which allows any shapes and sizes of cladding to be installed, allowing for a universal system.

Building Life and Safety

As the envelope is designed to operate independently and allow for many types of materials to be used as a cladding, the envelope without the cladding needs to be efficient enough to provide sufficient thermal performance without the cladding impacting the thermal efficiency.

The envelope's U value is 0.17W/m²k, just above passivhaus 0.15W/mk. The cladding may bring it to the passivhaus number, showing the systems efficiency.

From an embodied carbon perspective, the reuse of materials in a continual cycle in a circular system alleviates the embodied carbon of the cladding.

As demonstrated, a concern I had when using plastic containers as a cladding was that it could melt in exposure to direct sunlight. However, when calculating this possibility, the containers do not reach anywhere close to its melting point, making it a safe cladding material.

Conclusions On Prototypes

The perforations in the sheet allow for a greater level of ventilation, and the use of a metal sheet reflects solar radiation, reducing heat absorption.

In this system, the only change of material is the cladding, as the nuts and bolts can be reused, creating a waste free, sustainable system.

Building Life Cycle Safety - Scaffolds Low Tech Assembly a cladding system, achieved through a universal modular cladding system.

The cladding system is designed to be low risk in installation, but at heights, scaffolding is required. Secure scaffolding can help reduce the dangers involved.

The safety in installation is further emphasised through the use of low tech installation using hand tools and tightening, minimising risks of injuries.

As the system uses minimal parts with the cladding being community donated, this minimises costs whilst contributing to a circular economy.

Supervision by a trained professional is vital during the attachment of the cladding to ensure safety and a secure installation with the

When utilising nuts and bolts, the correct torque must be applied to ensure a safe and secure fitting to the mesh, to avoid a risk of detachment.

PET could crack by debris so it's important to have a simple detachment system to allow for damage repairs, that could pose a safety risk.

Suspended Mesh Cladding System | Plastic Container Fixing

| 1:5@A2

Reflections on Technologies Position & Design Insights

Suspended Mesh Cladding System | Recycled Plastic Shingle Fixing Top Attachment | 1:5@A2

Key:

1. M6 Locking Nut & Bolt (1)

The locking nut connects the bracket to the horizontal L plate. This allows the bracket to be easily detached if it needs to be replaced.

2. Horizontal L Plate

The Horizontal L plate spans across the top of the cladding and suspends the metal sheet from the structure. This gives separation for ventilation, preventing mould and mildew, and keeps water from ingressing into the buildings structure.

3. Steel U Bracket (1)

The steel U bracket is an important joint, as it connects the suspended perforated sheet to the horizontal L plate. They are spaced in 100mm increments, allowing it to handle the load of the cladding. The system is attached exclusively by nuts and bolts, allowing the metal sheet to be easily replaced at the end of its service life, and minimising waste by disassembly through hand tools only.

4. M6 Locking Nut & Bolt (2)

The locking nut connects the metal sheet to the horizontal batten. Using the holes already existing in the sheet, it is tightened on the opposite side by a nut, creating a secure connection suspending the metal sheet from the structure.

5. Self Tapping Screw

The self tapping screw connects the horizontal L plate to the buildings structure. Self tapping screws do not require pre drilled holes, therefore this allows for faster installation. This is designed to be a more permanent fixture, as the horizontal L plate does not need to be replaced, and it has to carry the loads of the metal sheet and the attached cladding.

6. 5mm Perforated Zinc Metal Sheet

The Perforated Zinc metal sheet acts as a “grid system” where the multitude of holes allow for different sizes and shapes of cladding to be attached using nuts and bolts, creating a universal cladding system. The use of zinc is a conscious decision, as it has a service life of up to 100 years, which allows it to be used for 2-3 cycles of cladding. Moreover zinc is the fourth most recycled metal in the world, and can be recycled without any loss of quality, contributing to a circular economy.

7. Waterproofing Membrane

Suspended Mesh Cladding System | Recycled Plastic Shingle Fixing Bottom

| 1:5@A2

The waterproofing membrane is exposed on the exterior, and is used a second barrier of protection after the cladding to protect the cladding from the elements, if any water was to make it through the cladding and the ventilation gap.

8. 18mm OSB Sheathing

The 18mm OSB sheathing is lightweight, which allows it to be efficiently installed. Furthermore, as its constructed from recycled wood chips, this lowers the embodied carbon of the envelope system.

9. Plastic Containers / Recycled Plastic Shingle

In this system, I have chosen to use plastic containers and recycled plastic shingles ,to use recycled plastics donated by the community to avoid landfill waste and contribute to a circular economy. However in this universal system, any item can be attached, but its crucial that is thoroughly tested, such as being able to resist weather loads and to be fire resistant to ensure occupant safety.

10. M6 Locking Nut & Bolt (3)

M6 Locking nuts and bolts can be used to attach and secure the cladding items to perforated metal sheet, creating an efficient securing system through the use of hand tools, allowing for the quick attachment and detachment of the cladding. The nuts and bolts can be reused for different claddings, further minimising waste.

11. Steel U Bracket (2)

A steel U bracket is used to attach the spring system at the bottom of the cladding system. This attaches by using an M6 nut and bolt to secure it to the metal sheet, allowing for the springs to be easily replaced.

12. M6 Locking Nut & Bolt (4) The M6 nut and bolt is used to attach the bracket to the metal sheet. This allows is to be easily assembled and removed, incase of failure to the springs.

13. Tension Spring

The tension spring aids in improved wind resistance, keeping the zinc sheet stable under wind loads as the sheet is only 5mm thick. This further helps the sheet not detach from the building, improving the systems safety. These are spaced every 100mm to provide sufficient stability.

14. M6 Locking Nut & Bolt (5)

The spring is attached the U bracket using a nut and bolt, securing it to the bracket and to the metal sheet. The use of disassembly through hand tools is crucial, as springs often have a low service life as they are under constant tension.