How To Assemble The Future Of Design Pavilion

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

CONTENTS

INTRODUCTION RESPONSIBILITIES COMPONENTS TOOLS + FIXINGS STRUCTURAL PRINCIPLES SETTING OUT SEQUENCE DISASSEMBLY

INTRODUCTION

The Future of Design Pavilion was an educational design-and-build project for GCSE students in London. Following two days of lectures and workshops the winning student design was developed and realised during Clerkenwell Design Week 2016.

For more information on the project please visit:

www.scalerule.org/FutureofDesign

The project was organised by Scale Rule - engineers and architects who like teaching, designing, building and learning.

RESPONSIBILITIES

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

The Future of Design Pavilion was disassembled at the close of Clerkenwell Design Week 2016, when insurance cover from the festival organisers finished.

The component parts of the pavilion have been gifted to Hylemo. Their intention is to rebuild to pavilion on Obonjan Island, an Arts and Wellbeing Island in Croatia.

Scale Rule retain the intellectual property of the pavilion design, however on donation of the components to Hylemo, Scale Rule relinquish all responsibility for how these components are used. All responsibility rests with Hylemo and the festival organisers.

COMPONENTS

RIBS

SLATS

BENCHES

BENCH STIFFENERS

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

COMPONENTS

Each component is tagged to locate it in the pavilion structure. The ribs are alphabetical (A to U) from the tail to the curl.

The slats, benches and bench stiffeners have composite tags. The first part of the tag is a letter – this identifies which bay the component is part of. The second part of the tag identifies what type of component it is, and where it goes in that bay.

The slats are numbered (1 to 10) from the bottom to the top.

The benches are tagged with γ for the lower level bench, and ε for the higher level bench.

The bench stiffeners are tagged with α for the low level front angled stiffener, β for the low level vertical stiffener, and δ for the high level vertical stiffener.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

A U

10

ε

1 γ

δ β

α

COMPONENTS

The location and orientation of the tag on a component defines the components orientation in a bay.

Horizontal components (slats and benches) have the tag on the top, reading left to right from the front.

Vertical components (bench stiffeners) have the tag facing the front, reading left to right.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

COMPONENTS

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

BENCH STIFFENER

TAGGED CORRECTLY

BENCH STIFFENER TAGGED LESS CORRECTLY...

COMPONENTS

NOTES: 1. The tags on the bench stiffeners were not all CNCed correctly, so the tag does not always face the front, and is not always the right way up. To overcome this the inside of the bench stiffeners have been marked to indicate which way is up, and the tags of the ribs which they locate into at each end.

2. The CNC guys had trouble with the 'O' tags and 'Q' tags, routing nearly all of them as 'Os'. Luckily the 'O' and 'Q' sets are identical so the it doesn't matter which one is used. Don't be alarmed when you see two sets of components tagged with 'O'.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

FRONT RIB F

F

E

RIB E

BACK

RIB F

RIB E

TOOLS + FIXINGS

Ladder

x2

Rubber Mallet

x2

Spanner (adjustable or M8)

x2

Power Drill

x1

M10 drill bit

x1

Pozi bit

x4

Bar clamps

x 10

Sandbags

x5

Woodscrews (8x13/4 countersunk pozi)

x 168

M8 hex bolt + 1 washer + hex nut

x 120

M8 coach bolt + 2 washer + wing nut

x 200

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

STRUCTURAL PRINCIPLES

Stability across the bench is provided by a series of cantilever ribs springing from a bench base acting as a fixed support. The stiffness of the bench base is achieved through the curvature of the pavilion at the curl end, sandbags installed between the stiffeners at the tail end, and the inclusion of vertical stiffeners tied through the bench.

Stability along the bench is provided by the slats, raking down across the rib bays to tie the ribs to the bench base.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

STRUCTURAL PRINCIPLES

During construction – up until more than 6 bays are installed – sufficient raking slat lines are not present and the pavilion is flexible, requiring temporary lateral support.

It is suggested that at least 7 bays are completed before the pavilion is left unattended by the assembly team.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

STRUCTURAL PRINCIPLES

Four different connections are used in the pavilion:

1. End grain screws / slats at rib A and U

2. Cross grain screws / benches

3. Coach bolt and wing nut / slats at ribs B to T

4. Hex bolt and hex nut / bench stiffeners

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

WOOD SCREW

COACH BOLT

HEX BOLT

OVERSIZE WASHER

WING NUT

1

2

OVERSIZE WASHER

3

HEX NUT

4

STRUCTURAL PRINCIPLES

1. End grain screws / slats at rib A and U

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

2. Cross grain screws / benches

STRUCTURAL PRINCIPLES

3. Coach bolt and wing nut / slats at ribs B to T

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

4. Hex bolt and hex nut / bench stiffeners

SETTING OUT

The pavilion is to be assembled on a flat rectangular site of:

12m long x 6m wide x 3m vertical clearance.

The pavilion can be set out by laying out the bench components - tagged Îł and Îľ - in position on the ground.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

SEQUENCE

1. Hold ribs A and B in place

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

SEQUENCE

2. Insert bench stiffeners Aα and Aβ and place a sandbag between them, followed by bench piece Aγ and slats A1 to A10. Hold the ribs in place so the components can't fall out. The top slot in rib B should be unoccupied.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

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SEQUENCE

3. Clamp the bar clamps on the slat tabs protruding through rib B, and screw into the end grains of all the slats and bench stiffeners at rib A.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

SEQUENCE

4. Hold rib C in place, and place in position the bench stiffeners Aα and Aβ. Align the bolt holes through the protruding tabs with the bolt holes through the part of Bα and Bβ and bolt through with hex nuts and hex bolts, with the bolts pointing inwards.

The rubber mallet may be useful if some of the holes are tight.

Place a sandbag between bench stiffeners Bα and Bβ.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

SEQUENCE

5. Place the tab of slat B1 into the lowest diagonal slot in rib C, and drop it down so the flat end rests on the protruding tab of rib A2. Align the bolt hole in the tab of A2 and the flat end of B1 and secure with a coach bolt/wing nut fixing, with the bolt pointing downwards.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

SEQUENCE

6. Repeat step 5 for slat B2 to B9. While installing these slats rib C should be secured to stop the tabs from the B series slats falling out of the slots. This could either be through the use of bar clamps on the protruding tabs, or by holding the rib in place.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

SEQUENCE

7. Insert slat B10 in the top position between ribs B and C, with both tabs in the slots. The top slot in rib C should be unoccupied.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

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SEQUENCE

8. Hold rib D in place, and place in position the bench stiffeners Cι and Cβ, bolting through the aligned holes with hex nuts and hex bolts, with the bolts pointing inwards.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

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SEQUENCE

9. Place a sandbag between bench stiffeners Cα and Cβ, and place in position bench piece Cγ.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

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SEQUENCE

10. Place in position bench Bγ, and screw through into the protruding tabs below of bench Aγ and Cγ.

Notice that while the slats 1-10 always fix into the protruding tab of the bay before like a sawtooth wave, the bench pieces alternate in position up and down like a square wave.

Bench pieces Aγ, Cγ, Eγ, Gγ etc are locked in place between the ribs, while bench pieces Bγ, Dγ, Fγ etc are free and screwed in place into the tabs of their neighbouring benches.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

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SEQUENCE

11. Place the tab of slat C1 into the lowest diagonal slot in rib D, and drop it down so the flat end rests on the protruding tab of rib B2. Align the bolt hole and secure with a coach bolt/wing nut fixing, with the bolt pointing downwards.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

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SEQUENCE

12. Repeat step 5 for slat C2 to C9. While installing these slats rib D should be secured to stop the tabs from the C series slats falling out of the slots. This could either be through the use of bar clamps on the protruding tabs, or securing the rib in place.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

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SEQUENCE

13.Insert slat C10 in the top position between ribs C and D, with both tabs in the slots. The top slot in rib D should be unoccupied.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

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SEQUENCE

14.Repeat steps 4 to 12 until rib J and the components in bay I are installed.

Placing sandbags between the stiffeners is only required for the first 6 bays (A to F), however if more are available they can be placed in between stiffeners ι and β in each of the bays.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

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SEQUENCE

15.At this stage the higher level bench is introduced between ribs J and K.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

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SEQUENCE

16.The assembly process is much the same as before, with the inclusion of an additional bench stiffener piece Îł and bench piece Îľ.

Note that the sawtooth pattern in the higher level bench is the opposite of the saw tooth pattern in the lower level bench.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

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SEQUENCE

17. Continue the assembly process until rib T and the components in bay S are installed, excluding the final high level bench SÎľ.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

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SEQUENCE

18. At this stage the higher level bench is lost, with only stiffeners Tα and Tβ present, and the larger Tγ bench is installed between ribs T and U. Screw in to the end grain for the final higher level bench piece, Sε.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

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SEQUENCE

19. Slats T1-T10 are installed as before.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

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SEQUENCE

20. Conclude by screwing into the end grain of the slats at rib U, as was done on rib A.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

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SEQUENCE

21. Some of the benches may have a little play in them, particularly the higher level bench in the middle of the curl. This movement can be reduced by placing thin wooden shims between the bottom of the bench tabs and the slats in the ribs which they protrude through.

Any rough edges can be sanded down, and an additional lick of varnish can be applied to any exposed plywood surfaces.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

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SEQUENCE

21. Bingobango, a completed pavilion.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

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HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

DISASSEMBLY

Disassemble the pavilion in the reverse order of assembly.

A crowbar, used to pry the bolted pieces apart, will make the whole process significantly easier.

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION

PHOTO CREDITS

Erica Choi Nigel Barker Annabel Koeck Sophie Mutevalian

HOW TO ASSEMBLE THE FUTURE OF DESIGN PAVILION