bW PROJECTS //
BARCELONA WORKSHOP
Geometry
Gt
Geometry A process of Form Finding.
Using Rhino to find the ideal form. Moving to Processing “relaxation script� to create the catenary geometry of each component, then back to Rhino to generate the final structure. The process went through 20 varations according to different tipology of the structure. Starting from four different connections to just two connection with the ground and one with the wall. The final model is created by two arches which leanes on the core structure of IAAC building, generating in this way a private space under it. The position of the structure magnifizes the main view towards the city center and the sea, meanwhile creating shaded space. The final shape is made by 72 different components that generate s a small pavillion of 10 mq.
diagrid pattern
diagrid pattern
target surface
target surface
applied diagrid pattern
applied diagrid pattern
rebuild surface pattern
rebuild surface pattern
surface contour
surface contour
final surface subdivision
anchor point to wall 8 points anchor point to wall 8 points
mesh lines 121 lines
anchor point to floor 5 points
mesh and anchor points
mesh and anchor points
mesh lines 121 lines
anchor point to floor 5 points
final surface subdivision
Top view
00
Side view
Plan
01
02
03
04
05
Front view
2.50m 1.90m
0.00m
west elevation 3.
2. 1.
2.50m 1.90m
0.00m
north elevation
1. wall connection 2. first ground connectio 3. second ground connection
2.50m 1.90m
0.00m
south elevation 00
01
02
03
04
05
prototype model
0.8m 0.2m elevation
1.1m
1m
1.1m
plan
1.2m
step 01 | flatten mesh
step 02 | anchor points
step 03 | bumped mesh
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+ + + + maximum height 210 cm + + + + +
+
+
+ entrance + + main
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
bumped concrete modules + + + + +
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
step 01 | flatten mesh
Entrance
Section
Under the pavillion
Outside view
Automation
Am
Automation in architecture. In a process of automation we generated Rhino Python script which labels and unrolls all components of the mesh structure. These components are used to create molds for casting the concrete shells. We used Rhino Nest to achive the minimal waste of material in the laser cutting process. Finally, 72 components were nested on 11.5 sheets of 122/250 cm.
nesting process wood stick
wood framework
textile framework number of component
edge number textile framework
18
61
63
64
65
25 25
24
22
23
18
Formwork + Casting
FC
Formwork + Casting
The physical production of the components needed developing a method for molding and casting that would ensure their structural performance aswell as their aesthetical one. Several tests were conducted both in the casting time and process, material composition and the shape of the mold frames. Any change in one of these methods would infulence the others. The development of the optimal method of production for the final 82 different pieces was a process of trial and error. Finally, a method of mass production of the molds and the pieces was ellaborated with recycling the used molds and minimising the material loss and time in casting.
Process Different types of cement mix and gypsum were used to figure the appropiate mix to cast the molds.
Mold formwork
Step : Mixing
Wood + Lycra cloth + Staples Mold assemblage: 3 min./frame
Material Mix Proportions Ultracal Plaster Water
1L 2L 1.75 L
Step 2 : Pouring, leveling
Casting time Pouring Lifting = 3 min. after pouring Cutting edges = 6-8 min. after pouring Total drying time = 45 min.-90 min.
Step 3 : Lifting
Step 4 : Cutting
Testing
Scaffolding
Sf
The scaffolding system is optimizated to distribute the load of each panel by its edges. This consists of 71 units of cardboard columns, 13 stools and 5 tables. The stools and tables are stacked on site prior to the generation of the cardboard scaffolding to reduce the amount of material used. The cardboard extrusions are created by using the parametric model of the vaulted structure. The resulting surfaces are unrolled and nested for laser cutting. The pieces are constructed and assembled using zip ties and masking tape.The entire process took one day for design and three days for assembly.
Prototype model
prototype model
260 cm
260 cm
260 cm
1000 cm
1000 cm
1000 cm
1000 cm
1000 cm
38 cm | the heightest point
Generating shape
Using Grasshopper and Rhinocerous in design processs
using edges of panels for generateing column
Using tables and stools for reducing the amount of cardboards
Creating the final shape of the cardboard columns by using computer software
tables and stools
196 cm | The highest positiion of the support
80x1600x600 cm | Table
40x40x76 cm | Stool
cardboards 210 cm | maximun height
Cutting cardboards with the laser cutting machine.
71 units of Scaffolding
cardboard 1000x2000 cm
cardboard 1000x1000 cm
Joints
Jt
Connection of the parametrically design components holds a particular significance, because it needed to adapt each edge condition to the next. The compression vaulted structure needed a special joinery to succeed, what was decided upon was a smooth joint similar to brick or tile construction. The mortar joint snaked its way 70 meters throughout the installation.
Successful test when the failure occured within the component and not within the joint itself
Inside joint detail before finishing layer of mixture has been applied
Joints The joint system comprised of a number of layers in order to achieve a successful smooth finish. The hydrocal panels were spaced slightly apart in order to allow for the composite material to bind the panels properly. An adhesive tape was applied to the bottom of this gap in order to hold the material and prevent it from seeping through. A layer of hydrocal acting as mortar was then applied to the gap. While this layer was still wet, a strip of fiberglass mesh tape was applied in order to provide structural rigidity between the connecting panels. Another secondary layer of hydrocal mortar is applied on top as a finish.
Precast Hydrocal panels Secondary layer of Hydrocal mortar
Fiberglas mesh tape
Primary layer of Hydrocal mortar
Adhesive tape
Jt
-50
-60
-35 -60
.5 0
0.00
3 89 17
.96
19
59. 53
2080.59
.80
23
3515 .2 5
21 42 .41
25 9
0. 10
31
59 49
45 22 .5 8
4.20 396
9
2518.27
9. 40
. 30
.29
95
62
2 .7
.2 63 2 5
69
41
302
34 38
A base was designed to attach the whole structure to the ground as well as provide a flat platform from the unplanar roof ground. The construction of the base followed 4 steps: 1_locate each point of the structure to the real site and measure the height. 2_fabricate the base and assemble 3_adjust the position of the base according the the real condition of the components and scarffolding and drill the base into the ground 4_as well as the the assembling of the components, pour the base with concrete to make it more stable and take off the wooden mold.
-50
3299.3
Joints
19
0 .1 2 4
-40
-40
-60
Joints
Jt
A base was designed to attach the whole structure to the ground as well as provide a flat platform from the unplanar roof ground. The construction of the base followed 4 steps: 1_locate each point of the structure to the real site and measure the height. 2_fabricate the base and assemble 3_adjust the position of the base according the the real condition of the components and scarffolding and drill the base into the ground 4_as well as the the assembling of the components, pour the base with concrete to make it more stable and take off the wooden mold.
Casted piece rest on the base
Drill to the ground
Place with scaffolding
poured together with the components to be more stable
Attached to the wall with a wood beam