Cymaticskin by Wonho Moon

CymaticSkin Self-supported cladding system of free-form geometries for acoustic treatment

Wen-Yu Hsieh, Wonho Moon Tutors : Philippe Morel Thibault Schwartz Guan Lee 2013-2014 GAD Bartlett School of Architecture University College London

Contents

Prologue Acoustic space

2 2

A. Cymatics Geometries 1. Cymatics patterns in nature 2. Chladni patterns 3. Mechanism of patterns

5 6 8 9

B. Experiments of Cymatics 1. Cymatics experiment method 2. Cymatics material experiment

11 12 13

C. Computer Simulation of Cymatics 1. Computer simulation of 2D Chladni Pattern 2. Chladni 3D Formula caucluated in Mathematica 3. Minimul surface 4. 3D computer simulation of Chladni pattern 5. Combining geometries with â&#x20AC;&#x2DC;Mesh machineâ&#x20AC;&#x2122; plug-in on Grasshopper 6. Optimization of combination of geometries

17 18 20 22 24 32

D. Applying geometries to architecture 1. Global geometry 2. Floor planning 3. Generate geometries for interior structure from Chlandi theory 4. Applying geometries to architecture E. Material Research 1. Self-supported cladding system of free-form geometries for acoustic treatment 2. Fabrication improvements of tiles 3. Pre- pressurized laminated concrete tile 4. Thermal proofing simulation 5. Sound proofing simulation 6. Mass-Spring-Mass effects 7. Prototype

42 44 46 48

F. Analysis for Applying the Material to Geometries 1. Re-mesh 2. Operating dual mesh 3. Grouping polygons 4. Manufacturing strategy 5. Cladding

83 84 86 88 90 92

G. Fabrication 1. Fabrication strategy 2. Waffle structure with cardboard 3. Fabric 4. Laminated tiles 5. Ceramic tiles 6. Physical model

95 96 98 100 102 106 108

H. Architectural Scenario 1. Global geometry 2. Auditorium 3. Public space

112 114 116 118

52 59 60 62 70 74 75 76 78

Prologue

Acoustic space This project starts from the architetural design with concrete (material) and the patterns of nature (geometry). The patterns of nature which is based on Cymatics theory is studied for geometry design. According to the theory, each sound frequency has a specific pattern. These are researched in order to obtain a three dimensional geometries. Furthermore, the material is investigated to optimize the free-form geometries. The outcomes of studies are applied to the acoustic space, with geometrical and meterialistic developments.

Figure 1_left. Auditorium Parco della musica ( Source: <http://poltronafraumuseum.com/img/contract/2-pop.jpg>) Figure 2_right. Guangzhou opera house ( Source: <http://www.domusweb.it/content/dam/domusweb/en/architecture/2010/12/21/zaha-hadid-in-guangzhou/ big_315834_6436_RH1963-0024_UPD.jpg>) 2

A. Cymatics Geometries 1. Cymatics patterns in nature 2. Chladni patterns 3. Mechanism of patterns

1. Cymatics patterns in nature The figure demonstrates that the complex geometric shapes include squares, diagonals and perpendiculars or curves, circles and radiating patterns. In other words, cymatics is a process which takes place from inside to outside before becoming a circulation. It depicts a great deal of information; sound, waves, and vibration can bring about and generate a system which looks complicated but which also has symmetry. This project is focused on the patterns of sound in order to design an acoustic space.

Figure 3_left. Image of sound frequency, vibrations: cymatics ( Source: <http://wonderinspirit.wordpress.com/2011/10/11/cymatics-crop-circles-dna-2012/ >) 6

Figure 3_right. Cymatic pattern of turtle ( Source: <http://www.breakthruradio.com/admin/articles/files/Picture-1-1024x634.png>) 7

f = (m+2n)², with m representing the diametric (linear) nodes and n the radial (circular) nodes.

2. Chladni patterns The Chladni Pattern theory was first proposed by Ernst Chladni (1756-1827), he used brass plates and the audio frequency of a violin to create many geometric patterns. These graphs show the relationship between frequency and modes of vibration and will henceforth be known as “Chladni Figures”. Based on the philosophy, it was known that when frequencies increased, the patterns were more complicated. The formula demonstrated how sound produced geometric patterns with wave-live function.

Figure 4._left. Chladni Pattern ( Source:<http://cns-alumni.bu.edu/~slehar/webstuff/hr1/hr2.html>) 8

3. Mechanism of patterns

As clearly seen from the top figure, the arrows indicate the direction of flow of the streams of particles. The second figure shows a plate with number of rotating areas. The direction of rotation of each parts has oposite direction against neighbors

Figure 5._right. Logic of Chladni Pattern ( Source:<Hans Jenny (1974). Cymatics (Volume 2). Basilius Press >) 9

B. Experiments of Cymatics 1. Cymatics experiment method 2. Cymatics material experiment

Figure 6. Cymatic Experiment (Source: <http://cymatica.com/wp-content/uploads/2011/07/IMG_0331.jpg>) 11

1. Cymatics experiment method HRM v 1.8

Water

Amplifier

Figure 7. Diagram of Cymatic Experiment (Source: <http://www.koderburo.co.uk/post/41430577898>)

Speaker

2. Cymatics material experiment In order to compare the variation of vibration with diverse materials, I chose the materials mentioned in Jennyâ&#x20AC;&#x2122;s publication. Each material was tested individually whilst attempts were also made to assemble distinct combinations in this experiment, as seen below:

Water + under 20 hertz

As previously mentioned, power under 20 hertz showed strong energy, meaning that the frequency was loose but the power was forceful. Owing to this, water was sprayed out of the plate, meaning it was difficult to capture the pattern from the water.

Water + 20 to 60 hertz

The frequency changed the pattern; a higher frequency led to a complicated pattern. The graph illustrates the vibration from 20 to 60 hertz. It can be seen that patterns became complicated with intensive vibration. Over 60 hertz there was no longer a significant change from the water.

10hz

20hz

10hz

20hz

10hz

20hz

60hz

Cornstarch + under 20 hertz

Cornstarch

Due to the fact that cornstarch is a non-newton liquid, the viscosity was sticker than previous; as such cornstarch required a lower frequency but stronger power in order to observe the cymatics pattern. On the contrary, higher frequency accompanied by less force made it difficult to see the pattern clearly.

Cornstarch + 20 to 60 hertz

The patterns are more clear than the plaster, but less than cement

Plaster + under 20 hertz

Plaster

Plaster and cement are newton liquids; the only difference relates to the viscosity, whereby plaster is stickier than cement (after sadding the same proportion of water). Indeed, this is the reason behind the emergence of different patterns with the same vibration. Because of the properties of plaster, it will become solid after a few minutes; however, the experiment was only able to test until 20 hertz.

Cement + under 20 hertz Cement

The pattern can be seen visibly from 0 to 60 hertz. When the amplifier exported 10 hertz, the pattern revealed the concentric circles and spread out on both sides. When it increased to 20 hertz, the pattern of the X axis and Y axis interlaced, leading to complex lines, while the cement also started to solidify after half an hour.

Cement + 20 to 60 hertz

With higher frequency, the patterns were more complicated and seemed to be obtained using a basic pattern from 20 hertz.

Compare with different materials with the same vibration . The things are interesting is that each materials have different viscosities / feature. The different proportion ( Mix with Water ) also will influence the result( the pattern). So there is an interesting phenomenon that should be to focus on . Maybe it need to fixed some figures when doing experiment.

1. Computer simulation of 2D Chladni Pattern

Mechanism of the patterns

Twisting

Saddle bending

Cupping

Repeated Root

With 'Millipede' which is a Grasshopper plug-in, The patterns are simulated, following the mechanism of the patterns. The simulated geometries are based on 2 dimensional patterns.

M=1

M=2

M=3

M=4

N=1 N=2 N=3 N=4 N=5 N=6

2. Mathematical computation of Chladni 3D Formula with 'Mathematica' In order to release the logic of cyamtics, the next step was to use the formula to calculate three-dimensional geometries by Mathematica after a series of material tests. As the vaule increases, the model becomes more intense, while the logic of sound geometry can often contrast with the minimal surface.

M=5

M=6

M=7

M=8

M=7/N=6

Chladni pattern formula Cos (n × π ÷ L) × Cos (m×π×y ÷ L) Cos (m×π×x÷L) Cos (m×π×y÷L) = 0

3. Minimal surface

Sound is an invisible energy which also produces power though distinct media. Indeed, a few hundred years ago, ancient civilisations began to explore sound by using diverse machines. From these tests, or natural phenomena, the scientists and mathematicians found cymatics. These patterns have been used to decorate faĂ§ades or windows in many church buildings, with their application maintaining a two- dimensional nature until recent years. Nowadays, there are several artists and architects who use sound patterns or cymatics as inspiration to develop their projects. Moreover, certain mathematicians and scientists have invested a great deal of effort into studying the phenomenon of sound by calculating an accurate formula and innovating precise instruments which can make further research possible. The formula can be inferred from two-dimensional patterns to threedimensional geometries. Based on the basic formula, we can establish the nature of the connection with sound vibration and minimal surface, whilst also recognising that sound patterns are predictable. In light of this, it can be presumed that sound waves could constitute a periodic minimal surface because of their threedimensional algorithm.

Figure 8._left top. Sven Lidin's Lidinoid ( Source:<http://schoengeometry.com/e8-tpms-media/Mackay%20lidinoid(2).jpg>) Figure 9._left bottom. Otto Frei: expĂŠriences sur les structures minimales ( Source:<http://arpc167.epfl.ch/alice/WP_2013_SP/ formery/?author=92&paged=2>)lidinoid(2).jpg>) 22

soap film is the most classic example of minimal surface. Owing to the particular features of the minimal surfaces it has been applied in numerous areas from nanotechnology to architecture, giving rise to completely fascinating applications such as light roof tensile structures.

Catenold, Costa, Ennepeer, Chen Gackstatter

Karcher JE Saddle Tower,Schwarz PD Family Surfaces

Figure 10._right top row.Minimal Surfaces: Catenold, Costa, Ennepeer, Chen Gackstatter ( Source: <http://xahlee.info/surface/gallery_m.html>) Figure 11._right bottom row.Karcher JE Saddle Tower,Schwarz PD Family Surfaces ( Source: <http://xahlee.info/surface/gallery_m.html>) 23

4. 3D computer simulation of Chladni pattern To generate a 3 dimensional geometry, the 2 dimensional patterns are combined to 3 dimensional patterns. Each combinations show the different patterns of geometries.

Double layers of proportype from Chladni pattern

Type 1

Type 2

Type 3

Type 4

Type 5

Type 6

Type 7

Type 8

Type 9

Type 10

According to the theory of minimal surface and logic of the Chladni pattern, the geometries can be generated by utilising this scenario. The pattern is one of the parameters used to create diverse structural models through computation. Firstly, generating the basic prototype from Chladni pattern revealed that each line finds the shortest route so as to connect with the next pattern and to become a continuous geometry in a sense of periodic minimal surface. Secondly, several different patterns were assembled and increased layer by layer in order to gauge the variation of geometries. These patterns were tested from two layers to five layers.

Proportypes from three layers of Chladni pattern Type 1

Type 2

Type 3

Type 4

Type 5

Proportypes from four layers of Chladni pattern Type 1

Type 2

Type 3

Proportypes from five layers of Chladni pattern Type 1

Type 2

m/n -

m/n + Each pattern has symmetry which can subdivid by one half even one quarter.

Six types of optimized geometries

Type A

Type B

Type C

Type D

Type E

Type F

Geometrical optimization of patterns Theoretically, the complex patterns were created by tense frequency, which was dependent on vibration of sound. Moreover, the Chladni pattern can be subdivided into quarters of the same graph and regrouped to make a complicated pattern identical to the initial one. As such, the patterns can be divided in an intelligent way due to the property of symmetry. After subdivision, one of cymatics principle methods (twisting) is used to execute the second computation. Following the previous mode, six types of optimised geometries were generated.

Basic Pattern Twisting

a. M

esh w

hich

are g

ener

ated

by 'M

illipe

de'

b. R

e-me

5. Combining geometries with â&#x20AC;&#x2DC;Mesh machineâ&#x20AC;&#x2122; plug-in on Grasshopper

In order to create smooth shell-like geometries, mesh units are re-meshed with the same length, thus connecting the faces with triangles.

c. Finding verticies on the edges of mesh units

d. Generate mesh from the verticies of the mesh units. To obtain a smooth mesh, the Catmull Clark subdivision of 'Weaver Bird' (Grasshopper plug-in) is applied

e. After the generating connection mesh between two mesh units, the mesh is re-meshed again. This step is necessary to obtain similar numbers of verticies of mesh for comparison analysis of Karamba.

Remesh process a. Combined mesh

b. Re-mesh by mesh machine

c. Re-mesh by mesh machine for 5seconds

d. Re-meshed

Load Points Load Force -10

Support Points

6. Optimization of combination of geometries

The six types of optimised geometries are based on shell structure; a shell structure defined by curved surfaces. The aim is to obtain a simulation of a global geometry by using the dynamic relaxation generative approach in order to build a definition of combined logic which could examine various types of shell structural geometries. To find an appropriate combination for the architecture scenario, four faces of each geometries are connected with the other geometries.

Analysis Structure Combining Collection A / B / C / D / E / F

B B

B (III) B (II) II

A B (I)

III

B (IV)

B B A

C B

C A

D C

D A

E D

E A

F E

III

IV Analysis Structure Combining Collection A / B / C / D / E / F

C C

B C

III

D C

D B D

E D

B E

F E

B F

Structural analysis of â&#x20AC;&#x2DC;Karambaâ&#x20AC;&#x2122; All the possible combinations are computed and compared. This data do not describes an absolute structural strength. Lowest deformation by pressure force

Highest deformation by pressure force Analysis Structure Combining Collection A / B / C / D / E / F

D D C

F E

III

Analysis Structure Combining Collection A / B / C / D / E / F

E E

D E

F E

D F

III

D A E B D C

Global geometry

According to the simulation of Karamba, the optimized combination of six different geometries is investigated. The load and support points are also set up in the same location for structural comparison. It can be seen that type D had stronger structural behaviour when assembled with other models, even though it worked independently. In contrast, type F is not a stable unit without being joined to type D. This means that type D is the main component of the global geometry.

D. Applying geometries to architecture 1. Global geometry 2. Floor planning 3. Generate geometries for interior structure from Chlandi theory 4. Applying geometries to architecture

1. Global geometry The global geometry can applied to a building which has facilities of acoustic space, such as concert hall, auditorium and conference room. The facilities can be located in the spaces which are pointed with orange colour points.

Auditorium Taichung Metropolitan Opera House can be a reference for the auditorium design in the global geometry.

Figure 12._right bottom. Taichung Metropolitan Opera House ( Source: http://2.bp.blogspot.com/_8Lufw3c2g4I/ TJ52MX6ar-I/AAAAAAAAVgQ/29dIXGNby3c/s1600/Toyo+Ito+.+Metropolitan+Opera+House+.+Taichung+(10).jpg) 45

Meeting room or conferene room can be place in this floor.

Auditoriums and public spaces can be place in this floor.

Public spaces can be place in this floor.

Auditoriums and public spaces can be place in this floor.

2. Floor planning The auditoriums and the other public spaces can be designed in this building. The acoustic treatment of the spaces is dealt with interior structures. The geometries of the structures are generated from Chlandi patterns. It will be described in the following pages.

3. Generate geometries for interior structures from Chlandi theory Geometries for interoior strucures are generated from Chlandi patterns. The structural geometries are selected for interior design. Theses are self-supported structure, but it is not considered as a building structure. The interior structures treat the acoustic performance in the building

The prototypes of interior structures Different types of geometries are designed for the interior structures. These are placed as auditoriums, public spaces and furniture in certain areas.

4. Applying to the architecture Global geometry makes a dynamic shape of structures. The interor space can be designed wth a specific function. This building has some facilities which require a acoustic treatment.

Public space of this building Interior sturctures can be located as certain facilities, such as meeting room and conference roo, etc.

Auditorium design

Acoustic ray simulation with Grasshopper Starting point End point Acoustic ray

Sound ovelapping Through the acoustic ray simulation, the shell geometry can be figured out. The several angles are tested to find the geometry which has less overlapped sound.

Capturing sound ray Sound capturing spaces which the acoustic ray is stayed until disappearing the sound is designed in order to avoid sound overlapping

Geomeries which are generated by Chlandi patterns are selected

The geometries are subdivided

Subdivided surfaces are recombined, having the empty spaces between surfaces in order to capture the sound ray.

E. Material Research

1. Self-supported cladding system of free-form geometries for acoustic treatment 2. Fabrication improvements of tiles 3. Pre- pressurized laminated concrete tile 4. Thermal proofing simulation 5. Sound proofing simulation 6. Mass-Spring-Mass effects 7. Prototype

1. Self-supported cladding system of free-form geometries for acoustic treatment The brick and stone have been selected to design and construct structures for several centuries. The masonry shell structures have had influence on architectural fields, providing practical sources to architects and engineer. The materials of the masonry shells have advantages on compression forces and the geometries have shown efficiencies on structural system of its. Due to the fact that the compression of the shells works under gravity, the heavy weight of itself leads to the major loading to the structure (Adriaenssens, et el., 2014, p.65, p.71-2). Regarding this, Catalan vault is historically considered as an architectural practice which is one of the successful methods for multi-compression forces in three dimensional geometries with light-weight of it (Adriaenssens, et el., 2014, p.76; Decker, 2008; Neumann , 1999; Ochsendorf, 2010, p.198). The strategy of Catalan vaulting system is researched to applied to the free-form geometries, with the material which can deal with acoustic treatment. The material research is focused on the improvements of fabrication and acoustic performance. This materialistic strategy can be used for the interior structure to treat sound. Therefore, these can be considered as â&#x20AC;&#x2DC;Self-supported cladding system of free-form geomet for acoustic treatment

Adriaenssens, S. Block, P. Veenendaal, D. Williams C. 2014. Shell Structures for Architecture: Form Finding and Optimization. Newyork: Routledge Decker K.D., 2008. Tiles as a substitute for steel: the art of the timbrel vault, edited by Shameez Joubert & Vincent Grosjean. Low-Tech Magazine. [online] Available at: <http://www.lowtechmagazine.com/2008/11/tiles-vaults.html> [Accessed 16 Feb 2014] Neumann D., 1999. The Guastavino system in context: history and dissemination of a revolutionary vaulting method. APT Bulletin, Vol. 30, No. 4, Preserving historic Guastavino tile ceilings, domes, and vaults (1999), pp. 7-13 Neumann D., 1999. The Guastavino system in context: history and dissemination of a revolutionary vaulting method. APT Bulletin, Vol. 30, No. 4, Preserving historic Guastavino tile ceilings, domes, and vaults (1999), pp. 7-13 Ochsendorf J., 2010. Guastavino vaulting: The art of structural tile. First paperback edition. New York: Princeton architectural press Fig. 13 Guastavino spiral stairs Fig. 2. Ochsendorf J., 2010. Guastavino vaulting: The art of structural tile. First paperback edition. New York: Princeton architectural press 60

2. Fabrication improvements of tiles

The studies are concentrated on decrease the manufacturing time and increase the efficiency of the materials. The Spanish cement tile making strategy is applied to produce tiles.

Fabrication strategy of tiles

Spanish cement tile making 1. Compress pure cement without water 2. Put the solid dried cement under-water to make harder

Pressure force in the Spanish cement tile industry

2000 pound / inch² is required ▪ 1 inch² = 6.4516 cm² (1 inch = 2.54 cm) ▪ 2000 pound = 907.1847 kg ▪ 907.1847 / 6.4516 = 140.61391 → 140.614 kgf / cm² → 8cm x 8 cm needs 8999.296 kgf If. 30cm x 30cm → approxi. 42Ton

Dry cement is filled in the mould Compressing the dry cement with hydraulic press Metal mould is required to tolerate the pressure Solidifying the cement powder without water

Figure 14._right. Mosaic del Sur, 2013. Encaustic cement tiles factory [video online], Available at: <http://www.youtube.com/watch?v=qzc4iwGWiJI> [Accessed 25 April 2014] 62

Fly press Press supporter_MDF

Ply wood mould Cement

Pre-pressurized cement Cement that was not pressed was mixed with water and pre-pressurized cement that was placed under water had been cured for 24 hours in order to make these solid and hard. The outcomes of comparative analysis are shown on the table. 00 : 20 s

00 : 30 s

01 m : 30 s

01 h : 25 m : 30 s

Non-pressurized Cement

Pre-pressurized Cement

Ratio

Cement 50 % : water 50 % (based on weight)

Pure cement 100 %

Size

90mm x 95mm x 28mm

88mm x 93mm x 28mm

Weight

465g

470 g

Compression strength test

Broken under 0.1Ton

Broken ~ 0.2 Ton

Fill metal mould with cement

Pressurizing cement with 5 ton of pressure force

Disassemble the mould

Casting underwater for 24 hours

Compressive force :

3 Ton

3 ton of compressive force is insufficient for making solid cement. Cement powder can be solid and hard with 4 ton and 5 ton of pressure. However, solid cement mass pressed by 4 ton is not able to be maintained the shape of it when it is located underwater

4 Ton

5 Ton

Benefits of compressing technique

Pressurized dry cement units can be kept in storage and the surplus of these can be destroyed and reused the cement. This leads to decrease not only the amount of waste cement but also the energy and resources for cement production.

Product lifecycle management (PLM) Electricity Water Fuels for kiln (fossil fuels, tyres, liquid waste etc.) Pressurized dry cement

Useages of Energy and resources Cement

~ 104.188 kwh ~ 600 kg ~ 90 kg

~ ~

1 Ton

Cement production factory

Construction site

Cement

After casting under water

Return Sell Sell

Cement Compression Factory

Saving energy and resources ~ 83.3504 kwh ~ 480 kg ~ 72 kg

Warehouse

Reuse Cement

800 kg

Return

Pre-cast concrete factory

If 80% of cement is saved

Environment Agency, 2005. Measuring environmental performance. Bristol: Environment Agency Madlool N.A., Saidur R., Hossain M.S. and Rahim N.A., 2011. A critical review on energy use and savings in the cement industries. Renewable and Sustainable Energy Reviews 15 (2011) 2042–2060 Worrell E. and Galitsky C., 2008. Energy efficiency improvement and cost saving opportunities for cement making. Berkeley: Ernest Orlando Lawrence Berkeley National Laboratory University of California Berkeley, California 94720 Xu J.H., Fleiter T., Eichhammer W., Fan Y., 2012, Energy consumption and CO2 emissions in China’s cement industry: A perspective from LMDI decomposition analysis, Energy Policy 50 (2012) 821–832 68

Pre-pressurized dry cement block

3. Pre- pressurized laminated concrete tile

Cement Bio resin and plastic Scotch brite Bio resin and plastic Cement

Developing to laminated tiles for improving the function of sound and thermal insulation The pre-pressurized cement layers can be developed to the laminated pre-cast concrete, in order to improve the sound and thermal insulation. This includes the layers of bio-resin, plastic sheets, scotch brite, ceramic tile and pre-pressurized cement mass.

Ceramic tile finishing

Catalan vaulting

The patterned bricks and binder are joined into unitary material which can effectively resist against compression and tension force. In addition, the thin layers of curved surfaces facilitate to obtain supplementary strength

Top view

Right view

Front view

Figure 15._right middle Tiled vault, [image online] Available at: < http://www.lowtechmagazine.com/2008/11/tiles-vaults.html> [Accessed 22 July 2014]. 71

Ceramic tile(exterior part) Cement Resin and plastic Scotch brite Resin and plastic Cement(interior part)

Material usage

1. Cement : 142g for 1.5cm TH-exterior part 95g for 1cm TH-interior part (TH : thickness) 2. Water : ~ 0.5g 3. Resin : 2g 4. Plastic : 114mm x 64mm 1piece 100mm x 50mm 1piece

Size

Length 10cm Width 5cm Height~ 5cm Weight ~ 375g

C. Pre-pressurized laminated concrete

• Thermal Laminated concrete blocksimulation - Simulation of thermal insulation (by Therm) 4. proofing

Simulation software_’THERM 7’ TH : 42mm

Exterior

Interior

-13.6 ̊ c

Flux vector

A. Thermal conductivity 1. concrete: 2.811 BTU/h.Ft. ̊ F 2. nylon: 0.144 BTU/h.Ft. ̊ F B. Emissivity both 0.9

3.7 ̊ c

Temperature changes (colours) ~ 10 ̊ c decrese

5. Sound proofing simulation Simulation software_’AFMG SoundFlow’ AFMG SoundFlow report page 12-13

Laminated Concrete _New structure 7 (42mm thickness)

Concrete _New structure 8 (42mm thickness) Ceramic tile _New structure 9 (42mm thickness)

6. ‘Mass-Spring Mass’ effects

The material assembling strategy for acoustic treatment of â&#x20AC;&#x2DC;Mass-Spring-Massâ&#x20AC;&#x2122; effects Top part of plastics are larger than the other materials Binder (plaster)

Cement brick (top)

Cement brick (top) Scotch brite Larger plastics protect the bottom parts of the material (scotch brite and cement) from the binder Cement brick (bottom)

Sound Absorption Reflection

Mass

Spring

Mass

7. Prototype Through the studies of layering patterns, a prototype of laminated concrete tiles designed as a crossing layered bricks, leading to the continuous assembling. This is composed with the layers of 5 different materials. The ceramic tile was attached to the exterior part of the block, which the sound, thermal and water proofing factors could be improved. The size of this is approximately fifty millimetres in total and the average weight of the components is 410 grams.

Thermal insulation

Absorption

Spring effect Reflection

Sound

Ceramic tile (exterior part) Binder (plaster) Cement brick (top)

MASS

Plastic and Resin (top) Scotch brite

SPRING

Plastic and Resin (bottom) Cement brick (bottom)

MASS

F. Analysis for Applying the Material to Geometries 1. Re-mesh 2. Operating dual mesh 3. Grouping polygons 4. Manufacturing strategy 5. Cladding

With the Catalan vaulting system of pre-pressurized laminated concrete bricks, the geometries can be a structure self-supported cladding system. In order to apply bricks, the geometries are need to be sub-divided. Due to the fact that this geometry is generated as a mesh, the brick shape can not be computed with rectangle shape. Therefore, mesh is converted into the â&#x20AC;&#x2DC;Dual Meshâ&#x20AC;&#x2122;. The dual mesh can be brick shape itself. The mesh is optimized the multi-dimensional curvature and to analyse the geometry for construction.

1. Re-mesh To obtain a high quality mesh, the selected geometry is re-computed with ‘Weaverbird’s loop sub division and Catmull-Clark sub division’ on Grasshopper. After that this is re-meshed to have similar length of poly lines. ( Size : W 12.5m x L 12m x H 4.7m)

Top view

Original mesh

Front view

Right view

Re-mesh

Length of re-meshed mesh line The mesh edges has asimilar length, with the figure at approximately 150 millimetres. << 150 mm < 150 mm = 150 mm > 150 mm >> 150 mm

Triangular mesh to dual mesh

2. Operating Dual mesh 4353 of numbers of 6 types polygons are generated to build the scale (12.5m x 12m x 4.7m) of self-supported cladding system. Types

Numbers

Total numbers

108 984 2225 4353 851 175 10

3. Grouping polygons To fabricate laminated concrete components, the regular size and shape is required to increase the efficiency on manufacturing. The 6 different types of polygons are divided to 37 groups.

a. Groups divided by area The differences of the areas between neighbour groups is approximately 2.5 cm2. If there are groups which do not have any polygons, the group is cleared. Totally, 37 number of groups are generated

b. Average polygons The average shape of polygons are designed and these can be the laminated concrete tiles.

C. Numbers and area of polygons 2 layers of concrete units for each polygons

138 78 111 135

Total:8706 (4353 x 2) 34 456 822 496 148 12 147 182 216 252 288 323

Number of polygons Area of polygons (cm2)

28 150 638 1082 1172 774 434 154 18 194 237 271 308 346 382 421 458 496

4 64 248 428 430 274 172 72 10 419 422 425 427 429 431 442 446 446

10 44 80 92 70 30 20 4 496 498 499 501 503 504 506 515

4 10 6 476 489 541

4. Manufacturing strategy Over than 100 numbers of components are manufactured with compression skills. And less than 100 of it can be set with wood mould

Made with 2 aluminium moulds Made with 1 aluminium moulds Wood mould casting Total number of components : 8706

138 78 111 135

34 456 822 496 148 12 147 182 216 252 288 323

28 150 638 1082 1172 774 434 154 18 194 237 271 308 346 382 421 458 496

4 64 248 428 430 274 172 72 10 419 422 425 427 429 431 442 446 446

10 44 80 92 70 30 20 4 496 498 499 501 503 504 506 515

4 10 6 476 489 541

Aluminium Mould

Mould top_for cement compression

Fill cement in the mould

Mould edge_ 3 cm thickness / 3cm Height

Comparison between manufacturing methods a. Pre-pressurized strategy Manufacturing time

Moulds

10 hours

22 Aluminium moulds ~ £ 700.69

Wood mould 10 pieces of wood panel (1220 x 2440) is required ~ £ 300

48.83 hours (1 day for casting)

Total mould price : ~ £ 1000.69

b. Traditional casting Manufacturing time

Moulds

10 hours Wood mould 39 pieces of wood panel (1220 x 2440) is required ~ £ 1170

103.5 hours (1 day for casting)

Total mould price : ~ £ 1170

Reference of price Aluminium : http://www.clickmetal.co.uk/Alumini Wood : http://www.cwberry.com/ProductCat.aspx?TreeNodeId=c1ad8e3e-2085-4225-b6a3-4db069431fcd

5. Cladding Cladding strategy is based on the Catalan vault system. The laminated component tile is design for this specific cladding system.

Pre-pressurized cement tile Scotch brite Plastic Pre-pressurized cement tile Ceramic tile

Self-supported cladding system

Front view

Top view

Right view

G. Fabrication 1. Fabrication strategy 2. Waffle structure with cardboard 3. Fabric 4. Laminated tiles 5. Ceramic tiles 6. Physical model

1. Fabrication strategy To fabricate a physical model, the cardboard and fabric are used for the reference of location of tile. The model is a specific part of interior cladding, which is reduced scale.

Physical model (110cm x 110cm x 45cm) Fabric for finding tile location

Cardboard for supporting during cladding_ modelling with Autodesk 123D

2. Waffle structure with cardboard Waffle structure supports the laminated tiles during the cladding work. Due to the fact that this is made with the cardboard, it is not only strong enough to tolerate the pressure force of tiles but also easier to assemble and remove the waffle than plywood.

Reference line for placing fabric Reference numbers for assembling waffle structure

Waffle structure image

Reference number for finding location of each tiles

3. Fabric With the software which is called â&#x20AC;&#x2DC;Unfold 3Dâ&#x20AC;&#x2122;, The mesh is analysed to set the fabric. This fabric provides the location of each components

The model is composed 36 different types of tiles and 143 numbers of it in total. Each components have the own identification number.

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4. Laminated tiles Silicon and aluminium mould can be used to fabricate tiles. The highest number in tile types is 13 which the shape is hexagon. This one type of tile can be manufactured with aluminium mould.

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Laminated tile making a. Cement and plaster is mixed to reduce casting time and weight of it Test to find the ratio (water : cement : plaster ) 38 % : 24 % : 38 % = 95 g : 70 g : 95 g b. Casting with silicon mould c. Tiles Height = 1.8cm : 1 cm (Top part tile : Bottom part tile) To reduce the weight of bottom part, the height is reduced d. Laser cutting the plastic e. Making laminated tiles

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5. Ceramic tiles Ceramic tiles are placed for the exterior part of the structure. These are assembled, following Catalan vault strategy

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6. Physical model

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H. Architectural Scenario 1. Global geometry 2. Public space 3. Auditorium

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6. Global geometry

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2. Auditorium

The geometry and material can be optimized for the auditorium where needs to be dealt with sound performance. The self-supported ceiling tiles are clad from the floor to concrete wall.

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3. Public space

Through the described method of computation, the geometries can be analysed for cladding system. These can be applied to the interior structures in a building, with the high performance of acoustic treatment. Self-supported cladding structure can be placed in a building. It has efficient acoustic treatment.

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Wen-Yu Hsieh, Wonho Moon 2013-2014 GAD Bartlett school of architecture University College London

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