Design Research Proposal. Investigation into Concrete
William Stephen Ives-Keeler Northumbria University Design School Student: w10013434
Contents Abstract
Page 3
Introduction
Page 4
Manufacture of Cement
Page 5
Concrete Additives
Page 6
Variations among concrete blends
Page 7
Current Consumer Concrete Products
Page 8
Perceptions of Concrete
Page 9
What I am intending to Achieve
Page 10
Innovations among concrete products
Page 11
Market Gap
Page 12
Research Visit
Page 13
Timeline
Page 14
Brief
Page 15
Bibliography
Pages 16 - 17
2|Page
Abstract Concrete is a grey, heavy weight material that has the ability to be moulded into any shape when in an uncured state. The material is perceived to be for industrial purposes only, however the material lends itself in for innovation and more refined uses. New intriguing innovations are helping the development of new functional products. Creating an item that is fit for the research market gap generating an instant product demand. Therefore the aim of this project is to change the general public’s negative perception of concrete by developing an innovative product that stretches current boundaries. Something which has never been seen before.
Figure 1 Glass Chips in Polished Concrete
Figure 2 Unpolished Concrete Corner
3|Page
Introduction As a keen problem solver, it is frustrating when other designers do not push the boundaries of their chosen materials, not fulfilling the innovative potential of the chosen material. This is what has prompted this research, to explore new ideas and focus on previously ignored areas. To illustrate this, many images will be shown to present initial ideas for this material.
Figure 3 Pouring Resin
Preliminary research presented three different materials that could potentially be suitable for a final project. Firstly Balsa Wood, which is a slow growing soft wood that is often used in model making. It is lightweight, flexible and has not been used very extensively therefore would make an interesting project. However it is not particularly strong or durable along with having a high cost price. This steered research towards an altogether different type of man-made material, Resin. It is a low cost, composite material that starts as a liquid but once cured becomes a durable, transparent solid. When in liquid form it can be dyed, moulded and cast which gives it great potential to create the desired shape. However this is also to its detriment as it is prone to cracking when in contact with extreme temperatures. This prompted research into the cheap and easily available material of Concrete. This prompts the question, why concrete? Concrete is the most used man-made product in the world. There are many formulations of concrete which all provide a variation of properties. A composite material made primarily with aggregate, cement, and water it is moldable, tough and temperature resistant. Often used in the construction industry, however there is potential for more refined product uses. An age old material which still has innovation concepts to be exploited, for example investigating the making of a comfortable seating object from a single hard solid material. This has the potential to create an innovative, final major product. An everyday material overlooked, transformed into and individual unexpected product. Figure 4 Balsa Wood
4|Page
Manufacture of Cement Cement Cement is one of the three components of a concrete mix along with aggregate and water. Companies often have their own slight variations on the quantities of the mix, however cement is the basic ingredient. Cement is made up of two main components; mortar and plaster. The limestone and clay get mixed together and heated up and limestone produces the source of calcium. This produces Clinkers more commonly known as cement. Sulphates are produced from this process, with the most common form being Gypsum, which is a soft salt that helps when activating it with water.
Figure 5 Industrial Cement Mixer
Aggregates Fine or course aggregates are the bulking material in concrete, sand natural gravel or crushed stone are the used main for this purpose. Recycled aggregates are more commonly used from demolished buildings due to the cheaper cost. Aggregates hold concrete together, creating its robust consistency. However when cement is pure it has a brittle consistency.
Figure 6 Hand full of Aggregates
Water Water is then mixed with this dry composite, which enables it to be shaped (typically poured) and then solidified and hardened into rock-hard strength through a chemical process called hydration. The water reacts with the cement, which bonds the other components together, creating a robust stone-like material. Figure 7 Killington reservoir
5|Page
Concrete Additives Ancient additives
Figure 8 Volcanic Ash
Concrete additives have been used since Roman and Egyptian times, when it was discovered that adding volcanic ash to the mix allowed it to set underwater. Similarly, the Romans knew that adding horse hair made concrete less liable to crack while it hardened, and adding blood made it more frost-resistant.
Modern additives In modern times, researchers have experimented with the addition of other materials to create concrete with improved properties, such as higher strength or electrical conductivity
Figure 9 Horse Hair
Figure 10 Modern Chemical Additives
6|Page
Variations among Concrete blends C7.5 (low strength) 1:3:6 or7 (Cement/Sand/Coarse Aggregate) For general non-structural use – bedding in kerbs, posts, stabilising underground pipes etc. C10 to C15 (medium strength) 1:4:6 to 1:4:5 (Cement/Sand/Medium Aggregate) Used in typical house foundations, footings for garden walls, load-bearing areas etc. C20 (strong) 1:2:4 (Cement/Sand/Medium Aggregate) Used as a footing mix in house construction in softer ground. Also as the slab foundation to floors, bases for caravans and pathways, hard landscaping. C25 (stronger) 1:1.5:3 (Cement/Sand/Medium Aggregate) Can be used for foundations to larger houses and for creating floors, and can also take light traffic. Allowing it to also be suitable for lining pools and fosse septic. C30 (very strong) 1:2:3 (Cement/Sand/Fine Aggregate) A general-purpose, easy-to-remember mix for many hard-wearing applications. C35 (industrial strength) 1:1.5:2.5 (Cement/Sand/Fine Aggregate) Structural concrete for major construction work and roadways
7|Page
Current Consumer Concrete Products Mass produced Concrete products Due to the fact that concrete is the most used man-made product there are many products that are produced on mass readily available on the market, ranging from concrete slabs displayed in figure 11 for a garden through to skateboard ramps.
Figure 11 Mass produced Paving
High end Concrete products Currently there is a very limited range of high-end concrete designer products, there is an innovation through the innovation into ‘Concrete Cloth’ shown in figure 12. This Cloth has leaded on to create further innovative products including knitted together concrete seating shown in figure 13.
Figure 12 Concrete Cloth
Leading from one innovative aspect, another innovative object is produced. Due to the weight of the material it often holds some designs back. For example in commercial areas where furniture is often moved for cleaning, these products are designed to be lightweight.
Figure 13 Concrete Cloth Knitted stools
8|Page
Perceptions of Concrete Concrete is perceived to be a cheap grey material that is extremely hard wearing and cold to the touch. There are different variations which all have slightly different properties.
The Disadvantages of Concrete -
Heavy Bulky Grey Cold to touch Rough
Figure 14 Grey Concrete Texture
People often forget the materials advantages.
The Advantages of Concrete -
Readily available material Cheap to purchase Mouldable Durable Weather proof Heat resistant
I am looking to use these points to reduce the number of disadvantages hopefully getting product users to question the material the product is made from. Figure 15 Heavy Concrete Ball
9|Page
What I am intending to achieve I am driving to change people’s perceptions of products and materials that are often misunderstood. The material Concrete has the potential to solve many current problems in some designer products. Whilst lifting the status value of the material and overall surprising product users with innovative uses for the material. Creating a high-end quality product made from a cheap mass production easily accessible raw material concrete, creating something innovative and unseen using this material.
10 | P a g e
Innovations among concrete products Innovations using concrete have been produced from individuals that have chosen to experiment rather than create a specific innovative concrete company. Designer and author Fu-Tung Cheng launches a complete line of concrete countertop products, he is one of the top designers working with concrete worktops. Fu-Tung Cheng produces custom, one-off worktops that were originally experiments as other materials were added to ‘concrete blanks’ and then polished back to looking similar to stones alternative. The experiments where so successful that clients commissioned several individual pieces from Cheng for expensive hotels, bars and residential homes. Other designers are experimenting with the materials structure. Mike Frost has been reducing the aeration that the material accesses by curing concrete in a large vacuum, the research found that the aeration the material uses in the standard atmosphere greatly increases the number of trapped air bubbles, this is known as a void and makes it rather brittle. Playing with the materials structure after 3 years of experimenting Frost has produced a fully functioning coiled spring. The idea is to move into air travel and he is currently designing an aircraft wing.
Figure 16 Fu-Tung Concrete Worktop
Figure 17 Fu-Tung Concrete Side table
Figure 18 Fu-Tung Modern Kitchen
11 | P a g e
Market gap Concrete is frequently used on a daily basis, currently it is being used for mass produced products like; building brick, highways curbing, fly over bridges ect. This leaves opportunities to look into refining the material moving away from the norm, as a durable material its product life out ways many other similar materials. Concrete is widely variable tweaking the one of the three material ingredient quantities can have an effect on the final cured specification. There are currently very few refined concrete products on the market. This opportunity is the basis and focus for my final major project.
12 | P a g e
Research Visit ‘Dimension Pre-Cast’ Dimension Precast specialize in manufacturing bespoke concrete lintels, cills and architectural details for the Construction and Restoration Industry including ‘pitched’ faced limestone. They also design and create decorative concrete interior surfaces for the home, commercial and retail environments from counters, facias and cladding to worktops and stair-treads. Along with an interest into innovative uses for concrete uses Dimension Precast is located in Kindle ‘LA9 7QS’ Roger the company owner came from a ceramics back round, with great knowledge into tooling and moulding. Figure 19 Dimension Precast Logo
13 | P a g e
Timeline Research, Generate ideas
Evaluating Ideas
Wk 4 Wk 3
Presentations
Wk 5
Wk 6
CAD
Ideas Development & model making
Wk 7
Product Making
Presentation Boards
Final Design
Wk 8
Wk 9
DRP Due Date 3 Week Easter Break in-between
Photographs
Wk 10
Wk 11
Wk 12
Wk 13
Wk 14
Major Project Due in
Wk 15
Critical Design Hand in
14 | P a g e
Brief To investigate the potential to produce an innovative seating product made from Concrete that will change people’s perceptions on the material. Which will specifically focus on eliminating the negative preconceptions of the material.
15 | P a g e
Bibliography Books Stacey, M. (2010)’ Concrete: A Studio Design Guide’ RIBA, England Forty, A. (2012) ‘Concrete and Culture: A Material History’ Reaktion Books, England Cheng, F. (2005) ‘Concrete at Home: Innovative Forms and Finishes’ Taunton Press, America Hulse, R. (2012) ‘Reinforced Concrete Design: to Eurocode 2’ Palgrave Macmillan, England Cheng, F. (2002) ‘Concrete Countertops: Design, Forms and Finishes for the New Kitchen and Bathroom’ Taunton Press, America Mukesh, C (2012) ‘Excellence in Concrete Construction through Innovation’ Taylor & Francis, England Peck, M (2006) ‘Detail Practice: Concrete: Design, Construction, Examples’ Birkhäuser GmbH, England
Websites Concrete society, (2006) http://www.concrete.org.uk/ (Last accessed 24/02/13) Concrete centre, (2010) http://www.concretecentre.com/ (Last accessed 24/02/13) Dimension Precast, (2004) http://dimension-precast.co.uk/ (Last accessed 24/02/13)
16 | P a g e
Site Visits Dimension Precast, (visited 15/02/13) Kendal LA9 7QS Videos Concrete Network . com, (2010) Available at : ‘http://www.youtube.com/watch?v=QuqryhFu9w8’ (Last accessed 24/02/13) Maxex, (2011) Available at : ‘http://www.youtube.com/watch?v=U7GuE2O2Dao’ (Last accessed 24/02/13)
17 | P a g e
Produced By
18 | P a g e