Iago Ferreira_Y5 | Unit 14 | Bartlett School of Architecture by UNIT 14

CARBON COMPOSITE

IAGO FERREIRA YEAR 5

UNIT

Y5 IF

JUTAI EXPLORER 3

@unit14_ucl

All work produced by Unit 14 Cover design by Charlie Harris www.bartlett.ucl.ac.uk/architecture Copyright 2020 The Bartlett School of Architecture, UCL All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording or any information storage and retrieval system without permission in writing from the publisher.

@unit14_ucl

IAGO FERREIRA YEAR 5 Y5 IF

iago.ferreira.18@alumni.ucl.ac.uk @unit14_ucl

J U TA I E X P LO R E R 3 CARBON COMPOSITE Amazon Rainforest, Brazil

YXEʧ )\TPSVIV MW E GEVFSR ƼFIV VIMRJSVGIH plastic research centre hung from the canopy layer of the Amazon rainforest. The project reacts to the current political atmosphere in Brazil and the future of its rainforest. The design intends to give researchers access to unexplored areas by innovating lightweight architecture focusing on form, material and integration. The majority of the Amazon rainforest and its biodiversity are still not very well understood by science members today. This is caused by the lack of accessibility to the rainforest itself and also the canopy layer of forest. More than 90% of the rainforest biomass sits at 30 to 40 meters above the forest ground level called the canopy layer. Unfortunately, all methods used today to explore this layer are short term based and unable researchers to fully understand its biomass. .YXEM )\TPSVIV YWIW GEVFSR ƼFIV XIGLRSPSK] XS EHHVIWW XLMW EGGIWWMFMPMX] MWWYI 'EVFSR ƼFIV enables the structure to be lightweight and therefore hang between the trees at the canopy layer of the rainforest. In order to reduce the weight even further a monocoque structural frame is used integrating all services and architectural components. This method increase space saving but it also enables components such as furniture and external components to be as lightweight as possible.

JUTAI EXPLORER 3 4

Content: Jutai Explorer 3

Introduction 1.1 1.2 1.3 1.4

Amazon Rainforest Accessibility Layers Within the Rainforest Existing Methods of Access Amazon Rainforest Tree Types

Material Research 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8

CFRP Composition & Performance CFRP History & Production Summary Splicing Innovations in Formula 1 Boeing 747 Carbon Fiber Spatial Optimization The Berkeley Hotel - RSHP Carbon Fiber Beam Prototype Carbon Fiber Continuous Double-Sided Surface Carbon Fiber Continuous Double-Sided Surface 2 Current CFRP Manufacturing Processes Available Spatial Requirements

3.1 3.2 3.3 3.4 3.5 3.6 3.7

Spatial Requirements Tree Structure Typology Global Shape of Each Specimen (Section) Structural and Spatial Development Access + Attaching Parasite Walkway Conditions + Typologies Specimen Arrangement + Access Explorer One - Spatial Synthesis

4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10

Dragonfly Integrated Structural System Three Hanging Structure Morphology Structural Specimen Table Tensegrity Principles Structural Morphology Summary Science Lab Specimen Structural Principles Cavity Description Integration Mechanism/System Specimen Access Cavity Inhabitation

Explorer Two - Structural Resolution 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10

Reserva Extrativista do Rio Jutai - Site Plan Specimen Typology + Allocation Hanging Methods + Stability Global Shape of Each Specimen Hanging + Structural Strategy Specimens’ Allocation and Form Finding Primary Optimization CFRP and Timber Composite Prototype Structural Layering Hierarchy Interior Integration

Assembly 6.1 6.2 6.3

Assembly Steps Specimen in Context Access Walkway Explorer Three - Design Resolution

7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13 7.14 7.15 7.16 7.17 7.18 7.19 7.20

Specimen’s Evolution Specimen’s Layering Hierarchy Primary Structure Secondary Structure Specimen Organ Allocation Specimens’ Organ Details External Skin Structural Unification - Monocoque Organ Allocation Skin Assembly Overall Weight Spatial Arrangement Section Cut Specimen’s Gills Aerial View + Elevation Specimen’s Underbelly Research Lab + Office Entry Level Plan Basement Level Plan Section

Appendix 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10

Optimized Material Potential Carbon Fiber Layering Optimization One Surface Architectural Forms Surface Analysis/ Material Reduction Surface Analysis/ Material Reduction 2 Specimens Interior + Materiality CFRP Components Breakdown Spatial Integration CFRP Chasis Assembly Spatial Arrangement-Large Specimen

INTRODUCTION Section One

SECTION ONE

Boa Vista Mitu Belem

Santarem Manaus Iquitos Itaituba

Tabatinga

Maraba

Porto Velho Rio Branco Manaus

0km

1,200km

2,400km

3,600km

4,800km

6,000km

Amazon Rainforest Boundary Brazilian Territory Protected Biodiverse Areas Other South American Countries Cities of Access to Rainforest

Amazon Rainforest Accessibility Looking at the scale of the rainforest it becomes clear that accessibility in the rainforest is an issue. The main cities highlighted are known to be checkpoints in which researchers and visitors have to go to before explores the edges of the forrest. for this reason, some parts of the Amazon rainforest are still not explored, and there are still some species to be observed and understood.

The main issue for researchers in the Amazon rainforest today is accessibility. This is because protected areas in which most species are intact are located far from checkpoint cities. This causes researchers to never be able to stay inside the forest for long period of times. Making some of the Amazon rainforest still unresearched, but also it enables crinal activitiesd to happen.

Amazon Rainforest Accessibility

2% 60m

Emergents

Harpy Eagle Bats Snakes Butterflies Insects Spider Monkeys Hummingbird Sloth Under Canopy GiantTarantula Macaw Parrot Other Birds Various Fruits

40m

90%

Canopy

Squirrel Monkeys Toucans Tree Frogs Ants Howeler Monkey Emerald Boa Green Iguana Toco Tucan Bromeliad Cecropia Leaf Orangutan Caterpillars Moths Unau

5% 20m

Under Canopy

Jaguars Leopards Lizards Bees Bullet Ants Geckos Salamanders Ocelots Tiger Cassowaries Gorillas Armadillos Warthogs Wild Boars

3% 0m

Shrub Layer

Looking at the division of layers within the rainforest it shows why so many spcies are not very well understood. 90% of the animals in the rainforest are located within the canopy of the forest, standing 40 meters high . This makes it extremly difficult for researchers to Stay in those areas for long periods of time.

Layers Within the Rainforest

Blimp Emergent Net Blimps are used as a method of transport to carry nets and lay them of the emergent layer above the trees. This enables researcheers to look at the canopy layer from above, this is a useful method as researcheers can stay for many days. However, this does not provide any of the researchers with the heavy lab equiptment to do test on site. The distance from the canopy layer is also an issue for researchers.

Hot Air Balloon It is common for researchers to use a idividual hot air balloon to reach the canopy layer. This is a great method as researchers can get very close to the layer. However this can only be done for a short period of time, and also it is limited by wind direction.

LIEBHERR

Netted Walkway in Canopy Level

Crane Cage at Canopy Level

This method is very useful as its permanent and allows multiple ressearched to be located on site. Over time the biomass within the area gets familiar with the structure and carry out acting normally. However this makes the structure difficult to move around in needed and also does not allow researchers to do tests on site.

This method enables researches to move up and down throuhgout the canopy layer. However due to the small size of the cage researches can only stay there for a few hours, and also the crane can only be located near places with easy accessibility.

Suspended Tent at Canopy Level

Helicopter Drop off

This enables researches to be lcoated anywhere within the canopy layer for many days. This is a good method as as researches can set this up anywhere the forrest as the equipment is minimum and lightweight. Again the problem with this method is that no scientific examination can be taken palce of site.

This allows researchers to pick areas in the forrest to come down. However this is limited by the number of researchers allowed to participate and also is limited to places in which te helicopter can fly over. The loud noise of the helicopter also disrupts the biomass of the area.

All methods of access used today are extremely uneficient. All of them allow researchers to stay on site for a maximum amout of a few days. They also not allow researchers to do experiements on site, this makes it very difficult for the amazon rainforest to be undertood and protected.

Existing Methods of Access

Family Tree Species Average Height 0 Carpotroche Hydnocarpus Lindackeria Mayna 38.3m

39.2m

38.8m

Fusispermum

122.5Tons 175Tons

Before Ocilation

1.065m

1.014m

1.111m

1.097m Clavija

1.017m

Paradrypetes

1.121m

Geissospermum

Type 1

Bonellia

40.7m

Cornutia

39.3m

37.5m

37.9m

38.6m 1.089m

1.133m

Brachychiton

Simaba

174Tons 185Tons

1.153m Ayenia

1.176m

Geissospermum

40.4m

39.9m

41.4m

41.1m 1.112m

Cyrilla

Before Ocilation

Before Failure

Bernardinia Connarus Pseudoconnarus Rourea

1.169m Geissanthus

Type 2

Morisonia

Euphronia

1.202m

1.198m

Geissospermum

1.207m Pamphilia

42.4m

41.9m

Agarista Diogenesia Disterigma Ericoides Gaultheria Notopora Orthaea Pernettya Satyria Thibaudia Vaccinium

41.6m

Curatella Davilla Doliocarpus

42.3m

Dichapetalum Stephanopodium Tapura

1.236m Peritassa

Urera

Allamanda

143.5Tons 205Tons

Before Ocilation

Duckesia Endopleura Humiria Humiriastrum Hylocarpa

1.197m

1.252m Annona

Bernardinia

43.4m

43.1m

41.7m 1.245m

42.2m

Before Failure Gyrocarpus Hernandia Sparattanthelium

1.286m Calanthea

Type 3

Mammea

Hydrangea

43.6m

45.1m

45.4m

1.296m Hylocarpa

1.399m

1.387m

Acanthocladus Caamembeca Diclidanthera Monnina Moutabea Polygala

45.2m

44.1m 47.3m

Vismia

171.5Tons 245Tons

1.434m

1.699m

1.474m

1.691m

1.684m Castilla

Blastemanthus

Type 5

Strychnos

49.1m

Apeiba

47.6m

Guarea

45.7m

47.2m

46.9m 1.476m

Phytolacca

48.5m

1.496m

1.645m Ficus

Acanthocladus

182Tons 260Tons

Before Ocilation

1.698m

1.611m

1.624m Moutabea

Phytolacca

1.711m

1.601m Cespedesia

1.699m Agonandra

48.1m

Before Failure

1.798m Clavija

Type 6

Trichostigma

1.753m Morus

Helicostylis

Polylepis Prunus

199.5Tons 285Tons

Before Ocilation

1.782m

1.774m Tyleria

1.767m Calanthea

50.7m

Picrasma Picrolemma Quassia Simaba Simarouba

51.4m

Before Failure 49.9m

Amorphospermum Chromolucuma Chrysophyllum Diploon Ecclinusa Elaeoluma Mimusops Planchonella

Before Ocilation

Before Failure

Euplassa Oreocallis Panopsis Roupala

Cassipourea Paradrypetes Rhizophora Sterigmapetalum

1.469m Lozania

49.2m

Amanoa Antidesma Astrocasia Chonocentrum Croizatia Didymocistus Discocarpus Hieronyma Jablonskia Kaluhaburunghos Margaritaria Phyllanthus

Type 4

Ericoides

1.417m Rusbyi

Cyrillopsis Blastemanthus Camptouratea Campylospermum Cercouratea Cespedesia Elvasia Froesia Godoya Krukoviella Lacunaria Ouratea Perissocarpa Philacra Poecilandra Polyouratea Quiina Rhytidanthera Touroulia Tyleria Wallacea

1.296m Orthaea

46.1m

Cabralea Carapa Cedrela Guarea Ruagea Swietenia Toona Trichilia

1.277m Endopleura

Before Ocilation

46.3m

1.240m

44.7m

43.9m Antonia Bonyunia Spigelia Strychnos

225Tons Before Failure

51.1m

Ardisia Bonellia Clavija Ctenardisia Cybianthus Geissanthus Gentlea

157.5Tons

50.4m

Gallesia Phytolacca Seguieria Trichostigma

Dichapetalum

Lacistema Lozania

48.1m

Agonandra

1.320m

Stephanopodium

50.1m

Antiaris Bagassa Batocarpus Brosimum Castilla Clarisia Ficus Helianthostylis Helicostylis Maclura Maquira Morus

1.299m Davilla

45.9m

Abutilon Aguiaria Apeiba Ayenia Bastardiopsis Berrya Brachychiton

1.259m Doliocarpus

46.2m

Aegiphila Callicarpa Cantinoa Cornutia Hyptidendron Orthosiphon

1.330m

48.7m

Cyrillopsis Ochthocosmus

Pozuzoensis Ramuliflora Reichardtiana Rusbyi Sandwithii Schultesii Sessilifolia Sprucei Steyermarkii

44.9m

Vismia

1.742m Mimusops

Type 7

Geissanthus

1.943m

Bulnesia OpenIzozogia

1.932m Bulnesia

1.979m Planchonella

227.5Tons

Gordonia

325Tons

Before Ocilation

1.813m

1.979m Oreocallis

Amazon Rainforest Tree Types

Acanthocladus

1.990m

53.5m

Before Failure

52.9m

Amphirrhox Corynostylis Fusispermum Gloeospermum Hekkingia Hybanthus Leonia Noisettia Paypayrola Rinorea Rinoreocarpus

1.977m

Chromolucuma

52.1m

Aloysia

Cecropia Coussapoa Myriocarpa Phenax Pourouma Pouzolzia Urera

52.7m

Pamphilia Styrax

Gordonia

51.9m

Discophora

52.5m

Euscaphis Staphylea Turpinia

Looking at the 1400 species of trees in the amazon only 240 of them are the most common. Analysis those species I was able to break down these trees into 8 types, all with average trunk size and height. These tree types are going to be used to inform my design.

1.084m Picrasma

Before Failure

Noisettia Anisocapparis Belencita Calanthea Capparicordis Capparidastrum Capparis Crateva Cynophalla Morisonia Neocalyptrocalyx Preslianthus Quadrella Steriphoma

1.013m Clusiella

39.7m

Cheiloclinium Elachyptera Elaeodendron Goniodiscus Gymnosporia Haydenia Maytenus Peritassa Plenckia Pristimera

1.026m

Hydnocarpus

40.1m

Calophyllum Caraipa Clusiella Haploclathra Kielmeyera Mahurea Mammea

Auxemma Bourreria Cordia Gerascanthus Heliotropium Lepidocordia Montjolya Tournefortia Varronia

1.077m

39.2m

Adenocalymma Crescentia Cuspidaria Cybistax Delostoma Digomphia Godmania

Allamanda Ambelania Aspidosperma Bonafousia Condylocarpon Couma Geissospermum Hancornia Himatanthus

37.7m

Saurauia Anaxagorea Annona Asimina Bocageopsis Cardiopetalum Cremastosperma Cymbopetalum

48.9m

Acanthaceae Achariaceae Achatocarpaceae Actinidiaceae Adoxaceae Alzateaceae Anacardiaceae Anisophylleaceae Annonaceae Apocynaceae Aquifoliaceae Araliaceae Arecaceae Asteraceae Bignoniaceae Bixaceae Bonnetiaceae Boraginaceae Burseraceae Buxaceae Cactaceae Calophyllaceae Canellaceae Cannabaceae Capparaceae Cardiopteridaceae Caricaceae Caryocaraceae Celastraceae Chloranthaceae Chrysobalanaceae Clethraceae Clusiaceae Columelliaceae Combretaceae Connaraceae Convolvulaceae Cornaceae Cunoniaceae Cyrillaceae Dichapetalaceae Dichapetaleae Dilleniaceae Dioscoreae Dipentodontaceae Dipterocarpaceae Droseraceae Ebenaceae Elaeocarpaceae Ericaceae Erythroxylaceae Euphroniaceae Fabaceae Gelsemiaceae Gentianaceae Gesneriaceae Goupiaceae Haemodoraceae Halorageae Hernandiaceae Hederaceae Heliotropieae Hernandiaceae Hippocrateaceae Humiriaceae Hydrocharideae Hydroleaceae Hymenophylleae Hypericaque Hypoxideae Icacineae Humiriaceae Hydrangeaceae Hypericaceae Icacinaceae Ixonanthaceae Lacistemataceae Lamiaceae Lauraceae Lecythidaceae Lepidobotryaceae Linaceae Loganiaceae Loranthaceae Lythraceae Magnoliaceae Malpighiaceae Malvaceae Marcgraviaceae Melastomataceae Meliaceae Menispermaceae Metteniusaceae Monimiaceae Moraceae Moringaceae Muntingiaceae Myricaceae Myristicaceae Myrtaceae Nothofagaceae Nyctaginaceae Ochnaceae Olacineae Oleaceae Onagraceae Ophioglosseae Orchidaceae Osmundaceae Oxalideae Papaveraceae Passifloraceae Pentaphylacaceae Peridiscaceae Phyllanthaceae Phytolaccaceae Picramniaceae Picrodendraceae Piperaceae Podocarpaceae Polygalaceae Polygonaceae Plumbagineae Podostemaceae Polygaleae Polygonaceae Polypodiaceae Pontederiaceae Portulacaceae Potamogetonaceae Primulaceae Proteaceae Putranjivaceae Rhabdodendraceae Rhamnaceae Rhizophoraceae Rosaceae Rubiaceae Rutaceae Sabiaceae Salicaceae Santalaceae Sapindaceae Sapotaceae Schlegeliaceae Schoepfiaceae Scrophulariaceae Simaroubaceae Siparunaceae Solanaceae Staphyleaceae Stemonuraceae Styracaceae Symplocaceae Tapisciaceae Tetrameristaceae Theaceae Thymelaeaceae Trigoniaceae Ulmaceae Urticaceae Verbenaceae Violaceae Vochysiaceae Winteraceae Ximeniaceae Zannichelliaceae Zingiberaceae Zygophyllaceae

49.6m

50.9m

53.4m

53.1m

1.968m Noisettia

Elaeoluma

Type 8

227

From the 16,000 tree species in the Amazon, (only 1.4% of these species) make up 56% of the estimated 400 billion tress that live there.

MATERIAL RESEARCH Section Two

SECTION TWO 11

1 Technical Ceramics

SIN

BC SIC AIO AIN

Carbon Fiber

Silica glass Soda glass

Nontechnical Ceramics

AI alloys

Stone

Specific Modulus (GPa/(kg/m3))

Composites

Silicon

10 -1

Brick

Steels Mg alloys TI alloys

Concrete

-2

Cast Irons Wood

Metals

GFRP Zinc Alloys CU Alloys PA Lead alloys

PAMMA PC

-3

Polymers

Epoxies PS PP PE

Foams

Ionomers PTFE Leather

Rigid Polymer foam

10 -4

Cork

EVA Polyurethane

Elastomers

Silicones

10 -5 10 -4

10 -3

10 -2

10 -1

Specific Strenght (MPa/(kg/m ))

Planar (2D)

n N Knit

Woven

Pan - Polyacrylonitrile

Braided

Aligned Rovings

Biaxial Carbon Fiber Fillament on a Human Hair

Triaxial

Biaxial

Weft

Warp Bi-directional Fabric

Carbon Fiber Fillaments and Fabrication Carbon Fiber fillaments are crystalised carbon molecules put together through a heating process. These fillaments are then joint together with organic polymers to form a carbon fiber thread.

Triaxial

Continuous

Linear

Discontinuous

Carbon fiber play a huge role in the manufacturing industry because it can be controlled from a molecular level. This enables carbon fiber parts to be optmized from a very early stage to peforme structurally.

CRP Composition & Performance

Pseudo-Unidirectional Fabric

Price Per Kg (£)

CRP Foot Bridge The first CFRP bridge to be built n Michigan, US. It replaces traditional black steel reinforcement with a combination of stainless steel and carbon fiber materials.

1958

High-Performance Carbon Fibers Roger Bacon created high-performance carbon fibers at the Union Carbide Parma Technical Center located outside of Cleveland, Ohio.

Manufacturing cost/energy

20% Carbon

Carbon

2003

1880

150

125

100

Lewis Latimer developed a reliable carbon wire filament for the incandescent light bulb, heated by electricity.

2008

Consumption (Mkg)

Light Bulb Filaments

Recession Technical problems and global recession slowed plans for expanding manufacturing of carbon fibre.

55%

Dr. Akio Shindo at Agency of Industrial Science and Technology of Japan, using polyacrylonitrile (PAN) as a raw material.

2017

1960

Polyacrylonitrile Fiber

Boeing’s 777X In order to fabricate the largest Carbon Fiber coponent ever created by men, Boeing developed their own Auto-Clave in the US.

2019

1961

99% Carbon High Carbon Content Richard Millington of H.I. Thompson Fiberglas Co. developed a process (US Patent No. 3,294,489) for producing a high carbon content (99%) fiber using rayon as a precursor.

The company has inversted £50 million poounds to research the reduction of cost of carbon fiber.

1963

Rolls-Royce took advantage of the new material's properties to break into the American market with its RB-211 aero-engine with carbon-fiber compressor blades.

Carbon Fiber

Steel 1903

1958

403–221 BC

1971

Aluminium

High-Performance Tensile Carbon Fibers

3.5 3.0 Market Value (Bn)

T400 from Toray with a tensile strength of 4,000 MPa and M40, a modulus of 400 GPa.

2.5

The Market value of carbon fiber is only increasing. Similarly to steel this increase in market value will allow more resources into research, leading to the decrease of manufacturing cost.

2.0 1.5 1.0

McLarenMP4/1 represented a major step forward in F1 car design. first raced in 1981, pioneered the use of carbon fibre for chassis construction.

Lance Armstrong first Tour de France victory in 1999 was on a carbon fiber Trek 5500, a carbon fiber framed bike.

2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027

CRP Road Car The McLaren F1 is a sports car designed and manufactured by McLaren Cars and was the first road car to have a carbon fiber chasis.

2000

Trek 5500 Tour of France

0.5

1981

F1 Monocoque Chasis

1992

Manufacturing cost/energy

Jet Engine Fans

MCLaren Research Centre

Other Industry

Polyester Composites

USA + Mexico

Aerospace + Defense

Thermoplastic Composites

Rest of the World

Sports

Epoxy Composites

India

Marine

Vinyl Ester Composites

South Korea

Transportation

Phenolic Composites

Taiwan

Other Thermoset Composites

China Japan Turkey Hungary UK France Germany

In the early 2000’s Carbon fiber cost went under its production line. According to research CRP technology will become cheaper and more accessible allowing it to be used more in the architectural industry.

CRP History & Production Summary

Reinforced Bolted Connection This method is only used for some of the skin componets of the car. And it sandwiches a think aluminium mesh in the bolting hole areas in order to spread the stress throughout the component.

Bolted Connection Skin Component Alluminim Mesh

Monocoque Chasis

Steel Plate Connection

Component 1 Connection Point Steel plate

Carbon rbon Ceramic Break eak Disk Three hree times lighter than Stainless inless Steel break disks, ks, carbon ceramic combines mbines the best of both th worlds. The ceramic colting ting on the carbon fiber er disk, allows the disk to reach temperatures as highh as 1000C without deforming. orming.

Component 1

Segment Flange Connection Segment flange connections are reinforced folds within the Carbon Fiber monocoque skin which allows bolts to hold parts together without creating concetrated stress points.

Component 2 Internal Bolt

Component 1

Component 2 External Bolt

Formula one cars are made 85% of carbon fiber, this caused engineers to innovate in many aspects when designing parts for races. Therefore some of these innovations can be taken forwards to contribute into future CRP Design.

Splicing Innovations in Formula 1

Carbon Fiber Componet 300C

Carbon Ceramic Componet 1000C

During the production of the carbon fober component steel plates are added together with the mold, this merges the steel with the pre-stress carbon fiber, allowing this part to be connected from the steel end.

Spatial Arrangement

Carbon Fiber

Due to weight constrictions, airplanes are extremely optimized Spatially. And in many cases those spaces are doing more than one thing. This is similar to the dragonfly wing concept in which the veins become the structural element. .

Carbon Fiber + Aluminium Mesh Aluminium Mesh Or Stainless Steel

Boeings Carbon Fiber fusilage enables the pressure inside the cabin to be higher than normal airplanes, enabling users to suffer less jetlag.

Boeing 747 Carbon Fiber Spatial Optimization

CFRP Monocoque Beam Intro This project argues the use and transfer of existing material technologies from the automotive and aviation industry and implementation thereof in a prototypic trial assembly for structural static, dynamic and architectural validation. The prototype is a beam component part of a proposal for an assembly of an entry structure of a high specification development in the UK. The composite carbon fibre beam component provides all necessary milled stainless steel connection fittings within its carcass for further component interfaces like façade and column connections, resulting in a highly integral solution. Structurally it is classified as a monocoque that supports loads via its external stressed skin, as opposed to a frame or truss which carries shear through the section itself.

Digital Workflow

The aim was to sculpture the morphology of the component to reflect connection requirements as well as defection and stress analysis, resulting in a differentiated sectional composite beam geometry. Along its section the geometry responds to in plane forces and mitigates against secondary forces caused by flexural deformation. This leads to a form that legibly reflects the forces it carries and responds in a highly material efficient way. At the same time all connection fittings were to be embedded within the actual carcass to achieve the highest degree of structural and functional integration.

5 4 6

7 8

Berkeley Hotel in Knightsbridge - London uses carbon fiber in order to achieve biggest spam with minimum structural components. The component does not work as a beam but instead it works as a monocoque structure.

The Berkeley Hotel - RSHP Carbon Fibre Beam Prototype

This exercises chanleges the forms in which carbon fiber can be achieved depending on the process it is manufactured. Ideally This form will show the capability of each manufacturing process due to its form.

Carbon Fiber Continuous Double-Sided Surface

Similar to the first test, this form intends to chalange the manufacturing process of carbon fiber. Due to the surface going back on itself and also weaving both edges, will enable me to understand the moulding process to create complex forms.

Carbon Fiber Continuous Double-Sided Surface 2

Operating Valve (Hot Air) Safety Valve Pressure Gauge

Door

Air Suction Chamber

Perfurated Shelf

Operating Valve (Hot Air)

Digital Model

Mould (Foam, 3D Print, Fiber Glass)

Prepeg Carbon Fiber Layering

Vacum Auto-clave

Mould Realease with Hot Water

One Continious Double Curved Model

Digital Model

Mould (Foam, 3D Print, Fiber Glass)

Carbon Fiber Layering + Gel Coat

Hot Air Air Vacuumed

ADVANTAGES

DISADVANTAGES ES

-Remove all air bubbles due to the pressured chamber. -Ensures an even distribution of heat through the process. -Creates the strongest form of carbon fiber component as we know today. -Avoids human interaction with epoxy resin. -Enables doouble curves and continous shapes.

-Limited by the size and availability off an auto-clave. -Takes much longer than other methods of CRP production. -Requires Knowledge on how to use the auto-clave, limiting its uses to trained workers.

Autoclave -Pressure Cooking Process uses a pressure cooker to infuse the resin and maintain its shape.

Vacuum Pump

Selant Tape

Resin Distribution Mesh

Vacum Bag

Preform Stack

Mould Tool Resin

Epoxy Resin

ADVANTAGES

DISADVANTAGES

-Can be done to any size as it heats up using a chemical reaction. -Does not require existing technologies in order to build components. -It is the cheapest method to produce CRP parts. -The hardening process is resonably quickly.

-It is difficult to spread the heating equally through mould. -It is also unlikely to avoid all bubbles as it needs to be places manually. -Exposes people working with it to o Epoxy resin. -Does not allow continuety with material.

Vacum Plastic Bag Plastic Mesh Carbon Fiber Layer

Resin Infusion - Chemical Reaction in Vacum Uses a chemical reaction to heat up the resin and harden the carbon fiber.

Laser Source

Resin Infusion

Mould Realease

Two Carbon Fiber Componets to be Joint

Digital Model

Robotic CRP Layer+Laser+Resin Placing On Mold

One Continious Carbon Fiber Component

Digital Model

Robotic CRP Layer+Laser+Resin Placing without Mold

One Continious Carbon Fiber Component

Resin Distributor

UV Sensor

Resin Tank

Epoxy Resin Hardening Laser

ADVANTAGES

DISADVANTAGES

-Allows layering process to be done without a mould. -Dries the Part almost instantly as laser dries as robots arms layers. -Enables complex shapes to be made and be continuous. -Allows big structures to be built.

-It is almost imposible to create an even surface. -It is the weakest method to create CRP components. -Known to be most expensive method to create carbon fiber parts.

Robotic Layering - Laser Hardening Resin Uses directed laser to harden the resin as the Carbon Fiber is being layered.

Looking at the current available manufacturing process of CRP it is clear that in the architectural industry resin infusion is the best method of fabrication. As small bubbles does not affect architectural performance compared to the aviation industry and others. It also enables components to be fabricated anywhere.

Current CRP Manufacturing Processes Available

SPATIAL REQUIREMENTS Section Three

SECTION THREE

Gorvermental Representatives

x20

Cultural Representatives

x10

x40

Security

x50

Tourists

x350

Scientists

39 Tons

Total - 470 members Average Weight of a Brazilian Male - 83kg 3

Science Department

Protection

- Access Core 3

- Policia Federal Office

- Ornithologist Lab

- View Point

- Arboriculturist Department

- Drone Station

- Entomology Department

- Ibama Research Facility

- Naturopathic Lab

- Conference Room

- Control Room

- Electricity Plant

- Water Treatment Plant

5 4

Cultural Representatives

23 24

- Stuff WC

- Canopy Platforms

- View Point

- Stuff Accomodation

- Cantine

21 22

- HeliPad

- Conference Room

- Govermental Office

- Govermental Accomodation

- Public WC - Indigineous Findings Display

- Board Room

- Access Core 1

Tourists

Govermental Representatives 15

- Indigineous Protection Representatives

- Tourist Accomodation

- Cantine

- View Point

- Access Core 2

313Kg 7 11

Total -

1790 Tons

24 16

13 15

28 14

11 31 29

74,600

1,400

Rural properties registered in the Rural Environmental Registry (CAR).

162,000 Public Circulation

People benefited from sustainable productive activities.

Staff Circulation

687 Environmental inspection missions carried out.

Govermental Department

65%

Cultural Department

Of the Amazonian indigenous lands’ area supported.

Protection Department

1,200 Million Dollars Donated

View Point

1,000 800 600 400 200 0

2012

2013

2014

2015

2016

2017

2018

190 Protected areas supported

US$ 1.3 Billion

Tourism Department 30

465 Scientific or informative publications produced.

Science Department 11

Acess From Ground

338 Institutions supported directly and through partners

Donations Received in Total.

93.8% Norway

5.7% Germany

0.5% Petrobras

Looking at existing research centers in the Amazon I developed a room list that would furfill the requirement for all the areas of which the amazon fund goes to.

Spatial Requirement

Suspended from branches + Stabilised by trunk.

Supported on a beam between trunks.

Bridging betwee trees, supported by two tree trunks.

Supported only by the trunk.

Supported by tension cables attached to two trees.

Diagnal bridge supported by two tree trunks.

Around the trunk + Branch supports.

Supported by multiple tension cables attached to multiple tree trunks.

Tension cables attached to two tree trunks in different heights.

Around the trunk, supported only by the trunk.

Supported by two trunks + support from the ground of the forrest.

Beams attached to two tree trunks.

Deconstructed platforms with enclosed inhabitations.

Tension cables holding bridge shape inbetween trees.

Around the trunk, diving the load with tension cables supported by other tree trunks.

Depending on the tree size and type there are muliple methods to place a structure. Hangning seems to be the prefered method to be used by researches as it affects the existing biomass the least.

Tree Structure Typology

Dead Load of Structure on Tree

Science Lab Specimen 1

Science Lab Specimen 2

Science Lab Specimen 3

Science Lab Specimen 4

-Fresh water tanks sit at the top in order to use gravity to pump water around the pod. - Brown water tanks and chemical waster tanks hang bellow.

-The tanks are exposed to the outside as they do not need to be in the interior spaces. -The core also hangs in the center of the structure.

-The toilets would also hang from the core as it would be easier as there is where the structure would be the strongest.

-Use the spaces between the floors to not just run the services but to also hide the furniture which are not being used.

Access Platform + Power Plant Specimen 1

Access Platform + Power Plant Specimen 2

Access Platform + Power Plant Specimen 3

Access Platform + Power Plant Specimen 4

-Due to the weight of the helicopter, the platform will only have the space to deliver goods and supplies. -The platform will also hold a hot air balloon in case of an emergency.

-In order to distribute the weight equally, The fuel tanks and the generator room will be shared evenly underneath the platform.

-This also provides a better distribution and allows only the tanks that need access to be hanging in strategic points.

This minimize the amount of tanks as some of them can be combined together. This makes it easier to organise and arrange them together.

Living Quarters + Lounging Specimen 1

Living Quarters + Lounging Specimen 2

Living Quarters + Lounging Specimen 3

Living Quarters + Lounging Specimen 4

-This options explores storage spaces integrated with the sealing and floor, similar to an airplane. This will help the space to stay open and pleasant for users.

-This option moves the tanks to the outside of the pod enables the space to open even more.

-In order to preserve the view of the floor below the tanks shifted down. This is also helpful as the it enables to gravity to do all the work as the tanks are going to be places under the windows.

-The storage spaces under and above the lounge can also be used to store the furnitures, allowing the overall space to be smaller but adapt when more people are using it.

Private Quarters Specimen 1

Private Quarters Specimen 2

Private Quarters Specimen 3

Private Quarters Specimen 4

-This is a smallest specimen and therefore is the lightest one. Its constitutes of a sleeping cabin above followed by a small private living area bellow.

-This option integrates an AC system together with a water tank and a waste tank as well. It also has a support cable.

-In this option the support cable was removed as the weight of this specimen would allow it to hang from a tree by itself.

-In this option the direction of the spaces change as the access to this specimen would be from the opposite side from its hanging one.

Medical Bay + Workshop Specimen 1

Medical Bay + Workshop Specimen 2

Medical Bay + Workshop Specimen 3

Medical Bay + Workshop Specimen 4

-Due to the uses of this pod most of the spaces are storage oriented. There is a separation between workshop and medical bay through both floor to keep the spaces sterile.

-By pushing the tanks down this design was able to gain more lateral space and also preserve the view from the floor bellow.

-This option takes advantage of the space between the tanks and use it as storage unit.

-By adding an angle to the wall this design is able to achieve enough head space in the circulation areas and minimise the space in the overall shape.

Hydroponics + Resources Platform Specimen 1

Hydroponics + Resources Platform Specimen 2

Hydroponics + Resources Platform Specimen 3

Hydroponics + Resources Platform Specimen 4

This page explores in section the spatial qualities and arrangement of each specimen. This is explroed by the optimizing the tank arrangement together with the usable spaces.

Global Shape of Each Specimen (Sections)

8 2

Primary Structure

Research Area

Meeting Room

Tension Cables

Fresh Water Tanks

WC Pods

Waste Tanks

1 2

10 12

Sleeping Pods

Science Lab

Animal Storage

Cold Lab Storage

Micro Lab

AC System

Control Platform

2 3

13 4

6 9

In order to integrate all the spaces with the structure, the design intends to create spaces carved into the structure in order to maximise the use of all spaces.

Structural and Spatial Development

PARASITE ONE Parasite one is an existing method of tree attachment used to hang tents and smaller objects. It uses a ratchet strap to press rubber plates against.

PARASITE TWO Parasite two releases some of the stress caused by the previous deigns. This specimen focus on the parts of the tree supporting the tension load.

PARASITE THREE This parasite attempts to spread the tension load between multiple trees in order to maximise how much weight it can hold.

PARASITE FOUR In order to integrate access to clamping methods, this design also attaches itself to the bottom of the tree. This will provide stability and access to the structure.

PARASITE FIVE This parasite develops an opening within the support cables which enables a walkway structure to be placed above the existing connection.

PARASITE SIX To maximise support and spread the load between the tree another clamping attachment will be added to the tree to create the netting + structural support.

3 This page explores the integration of access to the canopy layer together with the specimen's attachment. This integration enables the tension cables used to hold up the pod to also serve as a pathway.

Access + Attaching Parasite

This are the circulation typologies within the canopy layer of the rainforest. Using a carbon fiber component which holds the tension cables together in place.

Walkway Conditions + Typologies

Spicimen Arrangement + Access

EXPLORER ONE - SPATIAL SYNTHESIS Section Four

SECTION FOUR

Ernst Haeckel Ernst drawings illustrate some of the structural principles used in nature. His drawings highlight symmetry and structural logic.

Corals/Silicoflagellates Looking at the structural system of silicoflagellates (a marine algae) and corals can be useful due to the way its formed. Both skeletal systems are formed by the slow acceleration of minerals building up and therefore are distributed for maximum effect.

Dragonfly wing Structural Integration The wings of a dragon fly is a super optimized system. The light weight wing structure uses the vaine and the support for the wing skin. This makes the entire wing multi-purpose, this can be transferred into architecture for spatial arrangements.

Material saving and structural integration are architectural aspects which can be understood by looking at examples in nature. Ernst Haeckel drawings where he explores some of nature forms and structures.

Dragonfly Integrated Structural System

Plan

Elevation

Plan n

an Plan

Elevation

Plan

Elevation

Plan

Elevation

Plan

Elevation

Plan

Elevation

Through the deformation of a box shape being hung from certain directions I developed a shape of which responded to that deformation which then was analysed through stress lines.

Tree Hanging Structure Morphology

SPECIMEN ONE

SPECIMEN TWO

Specimen one is a personal structure used by individual researchers. Mostly used as a private living pod.

Specimen two uses a 3 point support and is a large living pod. The height of this pod does not allow individuals to stand up, however its a large living pod.

SPECIMEN THREE

SPECIMEN FOUR

Specimen three enables user to stand in the middle of the pod. This pod could be used as a combination of living and working lab.

Specimen four enables used to stand around the whole structure, however it is the smallest of the ones you can stand on.

SPECIMEN FIVE

SPECIMEN SIX

Specimen five is one of the heavy weights of the specimens it can be used for medium size labs and can also be combined with living spaces.

Specimen six is the largest specimen, it is efficient to use this specimen for large labs as its force divisions enables it to carry a lot of weight.

STRUCTURAL SPECIMENS TABLE

1.X Module