Bucky- Trespa Care- TU Delft 2019 by YAMINI PATIDAR

Bucky Lab - Delft University of Technology

Trespa Care Care with less for more

Trespa-Care

27 January 2020 TRESPA Care - Robust Shelter Design from Second-Life TRESPA AR1B015-D1 Bucky Lab Design The Docents: Marcel Bilow a.k.a. Dr. Bucky Lab Nadia Remmerswaal Project by : 5020379 Puji Nata Djaja 5029058 Leonardo Caldoni 5048664 Shriya Balakrishnan 5055288 Yamini Patidar 5140242 Olympia Apostolopoulou

Trespa-Care

Table of Contents

1. Introduction

7. Structural

2. Individual concepts

8.Computational Optimization

3. Mission and vision

9. Final design

4. Case Studies

Paper log house by Shigeru Ban Better Shelter by IKEA U-build

5. Design evolution

Stage 1: Trespa sandwich panels Stage 2: Brick-like sandwich panels Stage 3: Square frames Stage 4: Finger joint Stage 5: Bridle joint Stage 6: Bridle joint with wedge connection for panels Evolution of Final concept

6. Building weeks

Design drawings Components and details Technical drawings

10. Improvements

11. Conclusion

What’s Next?

Reflection

References

Appendix

Trespa-Care

1. Introduction

Retrieved from URL: 2Fpin%2F537124693053011059%2F&psig=AOvVaw0Y8kpR30IAPZwR5h-w8hfH&ust=1579958025638287

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Bucky Lab is a “get-your-hands-dirty” approach for Master students of Delft University of Technology (hereinafter referred to as TU Delft) in Building Technology Track to explore the process of a design thoroughly, where a prototype will be built at the end of the course. For the academic year 2019/2020, the challenge is to improve either the Sustainability or the Circularity of Trespa, a decorative high-pressure compact laminate made of wood-based fibers for outdoor application. We decided to improve the circularity of Trespa panels with the help of the ‘Trespa Second Life Program’. The program focusses on extending the life of the panels which are collected after dismantling the facade, instead of being disposed of.

Trespa Second Life Program The program aims to encourage the re-use of the panels for other applications, such that the life cycle of the product is extended beyond the lifespan in a building. The construction of the buildings, their renovation and demolition have a certain environmental footprint. After taking out Trespa panels, they are mostly discarded and left as a waste material, although the structural and aesthetic properties remain intact even longer than the lifespan of the buildings. The Second Life Program aims to solve this issue by extending its life.

Material Composition The Trespa panels are highly durable due to its composition. It consists of layers of wood-based fibres (paper and/or wood) impregnated with thermosetting resins and surface layers on one or both sides, having decorative colours/designs. Furthermore, the panel is protected by weather conditions by adding a transparent topcoat to the surface layers. The different layers are bonded together under and pressure to form a sheet with high density.

Figure 1: Material composition of Trespa Source: trespa.com

Figure 2: Trespa Second Life Program scheme Source: trespa.com

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2. Individual concepts

Photo credits: Marcel Billow

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TRESPA Tent Puji Nata Djaja- 5020379

HELP

reduce waste!

us you

TRESPA Second Life

TRESPATent in action!

RESPA ENT

TRESPATent Unit

Puji 5020379

TRESPATent Modules variety & joints: and TRESPATent Module varied

The jaw-dropping number of tents abandoned by festival-goers all around the globe has caught the attention of environment-conscious individuals in recent years. Not only the amount of waste itself that’s overwhelming but also the fact that these tents are mostly made from materials under the umbrella of plastic, e.g. nylon, polyester, PVC, etc. This plastic will last more than 10 generations of human living on this earth as it takes up to 1000 years to decompose. It’s absurd to think that we only use these tents once because it’s easier and cheaper to do so?! With the aim to improve the circularity of TRESPA panels by participating in the Second Life program, I wanted to utilize Trespa’s beauty and durability by making a structure that can replace these plastic tents for good. First, the collected Trespa panels will be cut into a TRESPATent unit size of 1x1 m. Then, these units will be joined with fixed and flexible (foldable hinge) connections that will become the TRESPATent modules with variations of 1, 2, or 3 units size. Finally, TRESPATent can be built from these modules following the number of people that will use it. Voila! Very easy! Business models to use this TRESPATents can be proposed to the festival sites, as they’re the ones who had to pay a huge amount of money for cleaning all the abandoned tents. There have been other organizations trying to solve the same problems, i.e. KarTent and CompA-Tent, but both seem to focus on recycling. This is where TRESPATent differs as the focus is to reduce and reuse. As Trespa is very strong, it is expected to last for more than 10 years.

Trespa-Care

Por TRESPA ouse Shriya Balakrishnan- 5048664

POR

PORTABLE TRESPA HOUSE

OUSE

Simple slide in- slide out technique R eusing existing materials with TRESPA Lasts Forever Take your Home wherever you go

Shriya Balakrishnan 5048664

This proposal is in response to the informal settlements in the slum-dwelling regions of India. Slums are one of the main types of housing in the growing urban cities with poor living conditions, affected by chronic diseases, cramped and unventilated spaces. In order to improve these issues, this housing model addresses the bleak housing conditions of the urban poor with a lowcost sustainable approach. The design consists of modular components that can be easily constructed by the local people with the help of the ‘Learn to Earn’ scheme. Using the existing materials such as timber, as the main skeleton of the shelter, and Trespa as the infill between the structural systems, connected by simple slide in-slide out technique and corrugated sheet as the roofing material, the shelter can last for a longer duration. Trespa being waterresistant, more durable than timber, better fire resistivity as compared to timber and has a high yield strength is one of the main reasons to use just not as a cladding material but as a structural system itself. The design is built to withstand seasonal floods with a raised platform in each unit and a sloping roof that directs the rainwater away from the dwelling. To address the lack of space, each unit has a floor area of 150 sq ft and two units can be joined together to form a corridor in between that can be used for cooking and other miscellaneous activities for better ventilation in the indoors. The housing model is engineered in a way that you can take your home wherever you go.

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_Shape...shifting Olympia Apostolopoulou- 5140242

Nowadays, migration constitutes a regular occurrence in our contemporary societies. A large number of people are forced to abandon their homes due to political, economic or/ and environmental factors. It is unfortunately estimated that by 2050, there will be about 400 million international migrants and 200 million climate change refugees. For these reasons, it is of paramount importance that these vulnerable social groups can find quickly sufficient, durable and adequate accommodation, capable of adjusting to their needs. Because of these, it would be logical to link Trespa panels as an effective solution to this phenomenon and its detrimental effects. Thanks to Trespa panels’ properties, namely durability, sun-, water resistance, mechanical properties, variety of sizes and finishes, a system of reused Trespa panels can be created and provide shelter. By connecting different panels with each other, compact, portable as well as modular units are produced, able to unfold in space, both vertically and horizontally, offering various functional options, with a minimum spatial occupancy.

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TRESPA Cares Leonardo Caldoni- 5029058

Humanitarian emergencies all over the world keep feeding the demand for shelters and prefabricated structures quick and easy to assemble. What Trespa can do to play an active role for this cause is designing a new fixing method with a continuous steel rail system, so that when a façade is dismissed each panel would have at least two rails fixed behind it. So, if you flip the panel you also flip vertically these elements that can be used to combine two panels, obtaining a sandwich panel with a pointy steel structure that can be used to realize walls and shelters. This is how, with this technology for sandwich panels, Trespa could take care of this paramount issue.

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TRESPA home Yamini Patidar- 5055288

For the Trespa Second Life Program, I proposed a shelter design for the construction workers with the aim to improve the life of the community. These construction workers are mostly migrants from rural to urban areas in search of work but mostly end up with deteriorating living conditions. With the excellent properties of Trespa for its durability, impact resistance, ease of cleaning and maintenance, the material offers the best solution for this problem. The proposed design uses the Trespa panels for building a pre-fab modular shelter which can be easily assembled on site. For high strength and insulation, the Trespa sheets are used as sandwich panels. The folding concept for the shelter reduces the assembly time on site and is realized by providing hinge connections for movement. The modules can be arranged on site as clusters with improved community spaces to upscale the living conditions of the construction workers.

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As has been elaborated in the previous pages, the 5 of us came as one group in Bucky Lab since we all had the following things in common in our design using Trespa:

1. Utilizing the Trespa Second Life program The source of our Trespa is those panels that have served its purpose as exterior cladding and have been collected to be re-purposed and reused, instead of being disposed of.

2. Making a structure (e.g. shelters, tents) out of Trespa We were determined to help those without roofs, e.g. refugees, postdisaster victims, construction workers, even festival-goers. Trespa can be a sustainable yet robust option than plastic or cardboard shelters.

3. Aiming for Circularity by aiming for a closed-loop use With careful planning and design i.e. Design for Disassembly, our shelter design can provide a closed-loop use of Trespa, starting from production, building cladding use (first life), recollection, our design: Trespa shelter (Second Life), disassembly, reuse Trespa Shelter (third life), and so on, as shown in the graphic.

Figure 3: Closed loop circular design

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Retrieved from URL: https://time.com/4063674/zaatari-/

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3. Mission and Vision

Retrieved from URL: https://middle-east-online.com/en/un-says-7000-syrians-have-quit-jordan-border-camp

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Why?

What?

How?

A large number of people all over the world are affected by physical and man-made disasters. This new reality has detrimental effects on their lives not only in physical or economic level but also in emotional and social aspects. People are forced to change their everyday routine and adjust to new, unforeseen circumstances. Comfort, safety, and control are values that need to be re-considered. The loss occurs in multiple levels of life and it is imperative that people pave the way to recover. It goes without saying that space plays a fundamental role in this process and is capable of creating qualities that go beyond the minimum living requirements, offering more of an environment that resembles a real home.

Due to the aforementioned reasons, it is vital that a transitional living environment be made that creates appropriate and suitable living conditions. The purpose of a shelter is to provide protection and a feeling of security not only from the environment but also from other humans. Moreover, these values can also be linked to intangible elements that have to do with the psychological and social presence of the subject. Because of all these, the design outcome has to be durable and resistant. Despite its temporary character, it is worth mentioning that such shelters can fulfil their purpose for more than ten years if caution and maintenance are taken into consideration during their design. In addition, since the residents are instrumental in determining the best spatial configuration of their future house, adaptivity and flexibility are also key elements in the design process. This way, personal taste, transportation, and assembly are possible. Self-built solutions come to the surface, where uniformity gives its place to a more diverse environment. This can occur, when the construction is based on a modular that is so strong and dynamic that from one simple principle it produces a wide variety of results.

All the above values are intrinsic to the design of a safe and healthy shelter and in order to be supported, they need a material with similar properties and abilities. At this point, it would be logical to connect the design of a shelter to Trespa panels, since they meet the desired criteria. Trespa constitutes a very robust and durable material, able to protect the people in need from sun, wind and other weather conditions in general but also from other human beings that threaten their lives. Although their initial use is as cladding elements, tests have proven its strength and resistance. Furthermore, since the panels are available in multiple colors and sizes, it offers a huge variety of different configurations, based on people’s needs. Flexibility and modularity can be easily realized and create spacious rooms. With the help of a certain pattern, refugees themselves can assemble their own house within hours, which is direct and effective. Another considerably positive aspect of using Trespa as the main material of the design is its cost-effectiveness. Trespa company, as part of our contemporary society, needs to rethink and re-evaluate sustainability and circularity. Due to this, a new campaign is launched and panels that previously functioned as façade elements have to find a new totally different use instead of being destroyed or thrown away. This way, not only the environment is protected and sustainability is promoted but also the economy is boosted.

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Facts & Figures...

Figure 4: World-wide data for the population of concern. Source: UNHCR 2020

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According to the data from UNHCR (The United Nations High Commissioner for Refugees) about populations of concern, that includes refugees, asylum-seekers, IDPs (Internally Displaced Persons) and so on, from the year 1951 up to 2017 shown above, it is evident and shocking that the numbers have nearly quadrupled from the 1990s. The solutions need to be adaptable in terms of both materials and technologies used, to enable the affected population to transition back into more durable homes (IFRC, 2011). Moreover, it is increasingly sensitive yet important to reduce the use of plastics and to find a stronger alternative of cardboard when making an affordable and sustainable shelter. The affected people are provided with tents and plastic sheeting due to the lack of available resources and economic constraints. Most often these tents break in high winds or rainfall with water leakages inside the tents. Many shelters lack insulation and ventilation. Proper solutions are thus needed for the betterment of the lives of the affected people. These non-durable materials can be replaced by Trespa to make a durable shelter. We believe by utilizing the durability, strength, economic, sustainability and circularity that Trespa Second Life can provide, a shelter that is durable, easy to assemble and transport, modular and adaptable to develop dignified living conditions for the affected can be a dream come true.

Figure 5:The temporary shelters provided by UNHCR Source: UNHCR Emergency Handbook

Figure 6: UNHCR data for the affected people. Source: UNHCR 2020

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In order to proceed with the design of the shelter, certain criterion were set as follows: 1. Longevity Apart from providing a safe and secure place to live, it is important to consider the kind of housing needed and how long would it last. This can be divided into a multi-phase approach by dividing the shelter type into three different phases: emergency, transitional and durable housing. With the durability and strength of Trespa, it is envisioned to last for 10 years or so. The design solution generated could be used for providing shelter for emergency situations for the initial phases but could also be converted into durable quick assembly housing solutions.

Figure 7 : Longevity diagram for the Trespa shelter

2. Modular The shelter would be designed to have a modular system with a standard module for the structure and panels which could be connected to each other. The module size would be 4mx4m for the shelter. The entire shelter would act as a module in itself with the possibility to offer various layouts resulting in an interactive community space. Each structural element could be assembled on-site easily with minimum use of bolts/screws. The design focuses on the ‘Learn to Live’ technique which would encourage the local people to build their own shelter with some initial help in the building process.

Figure 8 : Cluster arrangement possibilities for the shelter module

3. Ease of transportation The emergency situation in any place would require for quick and easy transportation of the shelter to the affected areas. The ease of transportation is thus an important criterion for the design of the shelter prototype. The concept to make the shelter modular simultaneously acts as a solution for the ease of transportation. The criteria to use 1mx1m modules of cladding panels, 1m high beams and columns would make the shelter easy to pack and transport to the disaster affected site. The idea behind choosing such dimensions developed from the fact that panel can be carried around by maximum of 2 people, which would make the elements more user-friendly.

Figure 9 : Modular design for the beam, column and panel

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4. Optimized geometry The geometry of the structure should fulfil the functional requirements and the space should improve the living conditions of the displaced people enabling them to carry out their domestic activities. Many shelters have insufficient headroom making it impossible to organize the space as per the functional requirement. Besides indoor activities like sleeping, cooking, eating, childcare, a lot of different activities are performed outdoors like, washing, drying clothes, farming, socializing with neighbours. The shelter should account for both the indoor and outdoor functions in a manner that the affected people get a sense of belonging the space acting as their homes.

Space for outdoor activities Figure 10 : Optimization of the form as per spatial requirements.

5. Flexibility The shelter would accommodate a family of 4 and the spatial dimensions would be worked out accordingly. But there should always be a flexibility to enlarge the space to accommodate a larger family or to provide room for the common community spaces. Therefore the design should incorporate the aspect of flexibility by simply adding another framework of the beam, column and the cladding panels for the extension of the space. Another option could be to mirror the entire shelter leading to a large space appropriate for the community activities. Apart from providing the flexibility for spatial expansion, the shelter should also provoke a home-like environment for the affected people by giving them flexibility to adapt the space as per their needs.

Figure 11 : Expansion of the proposed shelter.

6. Easy to assemble In a situation of crisis, the affected areas have to be provided with housing in less time. The shelter prototypes should be designed such that they are easy to assemble on-site in less time and with less labour. The idea of having modular pre-fabricated structural elements minimizes the labour work on-site and makes the structure easy to assemble. Additionally, the number of joints have to be minimized so that the process of assembly is shortened.

Figure 12 : Order of assembly for the proposed shelter

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4. Case Studies

Source: https://bettershelter.org/about/

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Paper log house by Shigeru Ban The Paper log house is an innovative project which uses paper tubes as its main structural material. The idea was proposed by renowned architect Shigeru Ban for providing shelter to the refugees and solving the housing crisis arose after an earthquake in Kobe in 1995. The wall is made out of 106 mm diameter, 4mm thick paper tubes placed next to each other. The insulation for the shelter is taken care of by adding a waterproof sponge tape backed by adhesive, sandwiched between the paper tubes of the wall. The foundation consists of donated beer crates loaded with sandbags. This also ensures easy assembly and disassembly of the shelter on site. The paper tubes used in the structure can be easily re-used or disposed of after its life. The fact that Shigeru Ban’s shelter is made of paper contributes not only to the reuse and recycle of materials but also to circularity and costefficiency. He designed a temporary shelter to meet the emergency needs of people that got affected by an earthquake. The shelter can withstand harsh weather conditions and tremors, is cheap and quite comfortable compared to the tents that ordinarily are used in such situations. In addition, it offers ease concerning transportation and assembly, since it can be built in less than ten hours by the victims themselves. Each shelter provides 16 m2 space and the cost of materials for one 52 square meter unit is below $2000. The plywood flooring rested on donated recyclable beer cases weighted down with sand and the assembled tubes formed the walls and the roof poles, make sure that the tarpaulin roof will not collapse. Nevertheless, despite its low cost, easy accessibility ,and simple application, the main material is still paper and remains dangerous in case of a fire. Although there is space left between the shelters, no one can ensure that a fire combined with a strong wind can’t have detrimental effects on the area and its people. What is more, these units are fixed and aren’t capable of offering different spatial configurations to adjust to its users’ needs. Each group of people has other needs and priorities that have to be taken into account during design.

Figure 13 : Paper tube Shelter

Retrieved from URL: https://popupcity.net/wp-content/uploads/2013/08/ Emergency-shelters-by-Shigeru-Ban-4.jpg Paper sheets

Paper tube roof framework

Plywood 106mm , 4mm thick paper tubes

Plywood pegs Paper tubes Plywood Beer crate foundation loaded with sandbags

Figure 14 : Different components in the paper tube shelter

Retrieved from URL: https://www.behance.net/gallery/47456181/Study-of-the-Paper-Log-House-by-Shigeru-Ban-2015

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Better Shelter by IKEA The first advantage of the IKEA shelter compared to a tent is the fact that the former offers a kind of privacy, as it isn’t just a piece of clothing, which is always moving. On the contrary, it creates a more protected, introverted space that resembles a house. That kind of protection doesn’t only occur in a mentally but also in a tangible level, since people in need have the opportunity to be protected from harsh weather conditions in both diurnal and seasonal level, without having constantly their health and physical integrity in jeopardy. In addition, it would be worth mentioning that the walls of the IKEA shelter are stabproof, a potentially life-saving feature given that such shelters are often placed in violence-oriented sites. Since the main material of our shelter is Trespa, this feature can also apply and protect people not only from the environment but also from other people. Another positive aspect of this shelter is the fact that it can be packed into the smallest self-assembly package possible, an inherent part of the company’s policy and years of expertise in squeezing complex items of furniture. This way, a robust 17.5 sq m shelter fits inside two boxes and can be assembled by four people in just four hours, following the familiar picture-based instructions, substituting an allen key for a hammer. The idea of a flat-pack shelter together with the use of the minimum number of tools aligns perfectly with our vision. Moreover, it is of paramount importance the participation of the refugees themselves in the assembly of their future accommodation and the aforementioned factors make that possible. IKEA provides a set of materials that can be put together in different ways, using the same module but creating different spatial conditions. This Lego-based philosophy resembles our idea of one module that can be multiplied and produce units of different dimensions according to the user’s needs. Furthermore, the IKEA shelter is reusable, because when the plastic panels might degrade, the frame can be reused and clad with available local materials from mud bricks to corrugated iron. Circularity, low cost and second life of materials are constituent elements of Trespa shelter. However, one negative aspect of the current shelter is that it isn’t fire-resistant and could pose a serious threat to an area full of these shelters. Although there are strict rules about the distance between shelters and no cooking is allowed inside, the material still remains unsuitable to fulfil the requirements of a durable and resistant construction that offers both safety and protection.

Figure 15 : IKEA shelters cluster on disaster affected site.

Retrieved from URL: https://www.theguardian.com/artanddesign/2017/jan/27/why-ikea-flatpack-refugee-shelter-won-design-of-the-year

Figure 16 : Structural framework for the IKEA shelter. Source: bettershelter.org

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U- Build U-Build is an innovative system of flat pack building boxes that can be turned into walls, pieces of furniture or even small spaces. The way these blocks are designed offers one the ability to obtain a multiple numbers of them and only by using a mallet a drill, 1-2 people can actually assemble them. As a result, robust frames are created with the use of supplied connections and in case these constructions are going to be used outside, membranes are also supplied from the company. This way, buildings become more affordable and adaptable by designing, creating and adapting your own spaces. U-Build is closely connected to the idea of a circular economy. That’s why their system uses a selection of durable non-toxic materials, the walls are insulated with natural sheep’s wool insulation and can be clad in a variety of materials. The simplification of the construction process and the ability of the user to participate in that, even if they have limited construction experience are instrumental in changing the way people see constructions. However, although that system promises robust, affordable, easy to build, self-build solutions that comply with sustainability, modularity, flexibility and cost-effectiveness, they can’t be produced massively and provide shelter. Wood is dominant and there is always a fire risk. Moreover, most of their applications are related to interior spaces and there is only one house that has been built based on that system in an area that is not so densely populated compared to a refugee camp. In addition, it isn’t mentioned anywhere that the construction materials are reused, meaning that in comparison to free reused Trespa panels, this system is more expensive and less environmental friendly.

Figure 17 : A shelter made using U-build system. Retrieved from URL: https://u-build.org/

Figure 18 : Stages involved in making a shelter using U-build system.

Retrieved from URL: https://lh3.googleusercontent.com/gv10o0GAZ6K0ALxEqx7wW2xdbTwMF0YcKhqbnbogGsH345cFB2Ogpintj-70sqCzDJZMsw=s85

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5. Design evolution

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Process overview

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Stage 1

Stage 2

This solution imagined a sandwich panel with insulating material between two Trespa panels and an aluminum/steel frame. These metallic profiles would have worked as structural elements both for the single panel and, if joined together, for the entire shelter. Even if this proposal seemed feasible for a wall, it had many limitations when applied to the entire shelter: -Is it easy to transport? -How do you design a profile so that it is possible to make corners? -How do you imagine and connect a roof designed with the same idea? -How do you reduce the cost of most probably non-standard metallic profiles? These were only some of the questions that came to mind. The research, at this stage, was therefore limited to the possible perfect shape of an aluminum profile. Different attempts were made, imagining the panels joined with or without an extra-pointy structure.

Figure 19 : Analysis for the sandwich panel system.

To improve the transportability and the speed of construction, the second idea was to realize a series of modular 1x1 m elements, composed of two panels and a wood linear substructure. These small sandwich panels were then supposed to be stacked one over the other in a brick-like structure. The design of different sizes for the two panels enabled us to realize corners and replace more expensive metallic profiles with wood. However, the connection between walls and roof had still to be designed.

Figure 20 : Analysis for the brick-like Trespa sandwich panel system.

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Stage 3 In order to solve the problem, an attempt was made to improve the previous idea with a new connection system. It consisted of Trespa frames with insulation in the middle, linked together by an extra wood element, which is supposed to friction fit between four of these frames providing enough strength to the structure. The same connection element can be used to realize corners and wall-roof connection. Also, in this case, the design had many limitations: -Is the system too complex? -Is it feasible on a large scale? -Does Trespa have enough friction to make the system work? -Is it safe and stable?

Figure 21 : Analysis for the square frame system.

Figure 22 : Physical models representing the square frame system having insulation in the middle and Trespa for cladding.

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Stage 4 At this point in the design a new question was asked: can Trespa be considered a structural material itself? Would it be safe and feasible? Knowing that the material in the Second Life project would be given for free, using Trespa not only for cladding could make a bigger impact. Therefore, the design shifted from a focus on connection to one of the best structural system applicable to the material. At first, single layers joint with lap or groove and tongue joints were researched. The main doubts about these solutions were about their safety when used for loaded beams and columns and their extreme diversity. A homogeneous system for both the element had to be found in order to simplify the building phase.

Figure 23 : Analysis for the finger joint system.

Figure 24 : Physical models for the proposed system using cardboard as a representation of Trespa.

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Stage 5 For this reason, we started to research finger joints. The first result was a combination of small modular elements for beams, columns and lateral beams that could interlock together on the corner connection, providing stability in all the main directions. The problem with this solution was mainly its complexity. The number of different slots and their exact alignment could be very difficult to manage.

Figure 25 : Analysis for the bridle joint system.

Figure 26 : Physical models for the proposed system

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Stage 6 Conscious of all these steps, we arrived at the idea for the final design. At this point, the general system was decided but many more challenges had to be faced when going more in detail. It was decided to use modular elements of the length of 1 m to build the structure. Those elements would be composed of many layers of Trespa stacked one over the other and then joint in beams and columns thanks to the combined use of bridle joints and fasteners like screws or bolts. Lateral beams can then be attached to these elements and offer support to the cladding Trespa panels that would be applied both on the façade and the roof. It is clear that many questions had still to be answered, like: - What is the best number of layers for beam and columns? - How do we join all these layers? - Is it better to use screws or bolts? How many of them? - How do we connect the lateral beams? - And how the panels? - How can we use the panels for roofing and make them watertight? The first general stage of the design was in this point replaced on a phase of testing, modelling and detailing, in order to realize a feasible design that could answer our initial design vision.

Figure 27 : Analysis for the proposed bridle joint with wedge connection for panels.

Figure 28 : Physical models for the proposed system.

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Evolution of final design Different components involved in the design

Primary beam

Lateral beam Column Intermediate column

Panel

Figure 29 : Different components of the shelter.

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Number of layers

How to join the layers

The number of layers (considering Trespa sheets 0.8 cm thick), was related to the width of the cross-section of both beam and column. The best solution was defined after many changes and attempts verified after laser-cutting scale models of the two elements. The first attempt considered 9 layers for both, then changed first to 11 and then to 13 layers. This decision was mainly caused by the will to avoid an excessively slender column. However, due to the high weight of the material and to the technical effort of joining all the layers, it was decided to reduce them again to 9 for the beam and 11 for the columns. The difference between the number of layers in the beam and column elements is caused by the connection chosen to join the beam and the intermediate columns, that will be explained in one of the following paragraph. As it concerns, the depth and the overall dimension of the cross-sections, after starting with just one standard element it was decided to work on a square section for the column and a rectangular shape for the beam, as they have to bear different stresses.

Choosing to work on multiple layers of Trespa led to the question of how to join them. The idea was to include that connection within the production process so that the modular elements could be prefabricated and just joined together on site. The first idea was to use adhesives in order to glue the layers together. Tests have been made on smaller pieces of material with both normal strong and wood glue and in some samples, the contact surfaces were sanded in order to make them less smooth. Due to the extremely low friction coefficient of Trespa, the results were not excellent and the curing process required a lot of time and precision. Doing that with high precision for bigger and multiple layers seemed highly unlikely and made us shift to different fixing methods. The use of adhesives also meant the addition of extra material which would increase the gap between the panels. In fact, the layers can also be fixed by using screws or bolts to obtain a stable connection.

(a) Figure 30 : Physical model showing the layers of the column.

(b)

Figure 31 : Sketch showing (a) the use of glue (b) use of screws for joining the layers.

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How to join the components The concept for joining the modular elements has stayed the same from the beginning and it works with the combination of two different methods. The first system is the mortise and tenon connection generated by the layers of different lengths of each component, but as the friction force between Trespa sheets is very low and their weight high, this cannot be considered enough to build a stable connection. To achieve that, adding either bolts or screws was considered. The final design involved bolts, but due to the width of the element, they would have to be particularly long and thick. Using screws from both sides offered also, in this case, the possibility of using smaller elements while realizing a stable connection.

Figure 32 : Physical models showing the joinery system between two components.

Connection of primary beam to intermediate columns The inclination of the beams created the need for intermediate columns with different heights to support them. The question was how to connect them, as the columns would have to be attached at the junction of the modular beam to beam connection. To solve this, the external two layers of the columns are longer than the others, in order to let the beam fit between them and be then screwed all together.

Figure 33 : Physical models showing the joinery system between primary beam and intermediate column.

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Lateral beam to column and primary beam In order to provide support for the cladding panels and enough stability towards horizontal forces to the structure, it was clear from the beginning that horizontal beams had to be designed. Therefore, the connection between them and the main elements became a key element. The aim was to design a sliding connection that could work by gravity and without the use of any extra blocking element. Different attempts were made before reaching the final result.

Figure 34 : Physical models showing the sliding mechanism for the lateral beam to column connection.

Panel connection to the structure The first idea to fix the cladding panels to the structure was to glue them on the lateral beams in the factory to reduce the assembly time on site resulting in much heavier module making it difficult to carry and attach to the column on site. Hence the design was changed to have separate lateral beams and panels which can be attached on site. At this point the panels were considered not only as cladding elements but also as the active parts of the structure, providing stiffness to it and enough resistance to horizontal forces. To do so, a new joint between the lateral beams and the panels was needed. The first attempt was to realize a bridle connection between those elements, cutting multiple holes in the panel and the same number of teeth in the beam. This idea has been tested in a model, that made evident its high level of complexity and required precision. For this reason, the number of tenons has been reduced to two close to the edge and the panel. In order to provide additional structural stability, the final design uses wooden wedges to tightly connect the panels to the structure. The same joint is used to connect the panels to the primary beams and columns too. Figure 35 : Physical models showing the panel connection to the structure by using wooden wedges.

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Foundation Several attempts have been made to analyze the link between the ground and the shelter by testing it in the physical models. The first idea was to develop a wooden base with the same bridle connection of the column modules, in order to simply fit them in it. This resulted to be a particularly delicate and easy to break shape and did not provide the stability that was expected. Attempts were made for increasing its size and the depth of the bridle, but none of them were feasible. A second idea was to stack more layers of Trespa one over the other in different shapes and making slots in them for the column element to fit in it. The main problem with this design is the amount of material required and its considerable volume, which could affect the shape of the shelter and of the first row of cladding panels. As this kind of proposals did not seem successful, it was decided to change the approach completely. The final design for the ground connection is to have small concrete underground foundations in which a metal rod is fixed. A slot is then cut in the first column module so that the rod is inserted in it and fixed to the structure.

Figure 36 : Evolution of the foundation system.

Figure 37 : Physical model for the bridle connection system.

Figure 38 : Physical model for the slot system.

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6. Building Weeks

Photo credits: Marcel Billow

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After a series of different solutions and concepts for the design development phase, the next step was to build a part of our proposed design, which is to say, a prototype in a real scale, which took place during the building weeks. Since second life Trespa panels constitute the main focus of Bucky Lab this year, our design solution was meant to be made of that material. However, due to Trespa’s stiffness and the possibility of its difficult manipulation regarding the tools, there was an alternative of using MDF for certain parts in the prototype. The building weeks took place in the Tec Factory, Delft and lasted two weeks from 09.12.2019 until 20.12.2019. A model of our entire final optimized prototype was hard to build in 1:1 scale since we focus on shelter construction. For this reason, a corner connection of a the main column- primary beam had to be produced, using Trespa layers of the same thickness as the basic material. The size of the model is 850*540*540 mm, length, height and depth respectively. Apart from Trespa, stainless steel round-head screws were used for the connection of the different layers, MDF for the representation of lateral beams (wall and roof) and of an interior panel, wood for the wedges and a metal rod as an additional support for the exhibition weeks in the orange hall. The main idea was to build a model, able to best show all the different details and connections that exist both in the interior and exterior space of the construction. The corner sectional model that we chose to realize offers this opportunity and let the passers-by observe them. Since the construction of such a model required several stages like cutting and fixing, we tried as a team to help each other and participate in as many different tasks as possible, in order to gain knowledge in fields that for most of us was new.

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Introduction to tools An introduction to various tools and machinery took place from the very first day of the building weeks, as safety was of paramount importance, especially when dealing with equipment that we were not familiar with. Because of this and in order to enhance the safety factor, each person needed safety shoes, glasses, and gloves. We were divided into three groups for a better and more direct understanding. The demonstrations were done from experts that made sure to point us out how to use them, how to turn them on and off, hold them in the right way, adjust them according to the material type or thickness and the like. Moreover, they both mentioned and showed us the steps, in which the majority of the users make mistakes, so that we can avoid them. At the end of each demonstration, a student had the chance to use the tool or machine but always in the presence of the current expert, in case help or instructions were needed. This way, not only did we gain both knowledge and confidence in new techniques, but we also were able to have a clearer picture of the equipment and value its suitability based on our prototype needs.

Cutting Trespa panels and MDF From the second day we could start cutting pieces of the Trespa panels we were provided with. However, in the beginning, we tried to cut wood and not Trespa, in order to familiarize ourselves with the equipment and not make uncorrectable mistakes, obvious in our final model. Each group had a white Trespa panel available and they were also some blue and green, which were more suitable for certain designs. For an optimal utilization of the limited colourful panels, a plan was made and only after all groups had their needed pieces from the same panel, the next panel could be ready for cutting. With the help of first day’s demonstrations along with our construction designs, we were in a position to evaluate which machines and tools could perform better regarding the material’s thickness, prototype’s dimensions, and design. So different parts of the model could be cut in different machines, always taking into account our own safety and the safety of the others. We would always be together with at least one member of our team and ask for reminders from the experts that were present during that time.

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Fixing the panels together One of our design goals is to use Trespa as much as possible not only in our prototype but also in the construction. For this reason, main and secondary columns and beams, as well as interior and exterior panels, are made of second-life Trespa panels. So, after cutting the necessary parts, it was time to attach the pieces that created the main column and beam individually. After we numbered the layers to avoid mistakes in the order, holes needed to be made in specific spots by using a driller. With the help of clamps and hammer to align the layers, precision and perfection were achieved at an adequate level, which was pivotal for the final joining of our prototype. Following this, screws were used to fix the component itself and create one independent beam and column respectively. In the next step, the aforementioned parts were going to be fixed together following the same steps. Since our design is based on creating a structure that can be easily assembled in situ, lateral beams and panels don’t need to be screwed on the beams or columns. On the contrary, slots in the latter elements are able to provide joining and stability, using gravity as their principle and wedges to ensure that the panels won’t be detached or moved.

Assembling the prototype in 1:1 Once our two main components were fixed together, it was time for the final assembly by adding the secondary elements, namely lateral beam to horizontal panels, lateral roof beams, interior and exterior panel in the existing slots. This way, the final composition was created by carefully attaching the different parts. Caution, time and precision were key factors in the process, in order to avoid unpleasant situations. It would be important to highlight that due to the fact that since Trespa is a very dense material, our model was quite heavy, which could cause problems regarding its stability. Together with the fact that only one column was produced, meaning that the inclined beam was only supported in its one edge, an additional support, in our case a metal rod, was intrinsic to the final design. Another minor settlement that had to be made was the addition of one more roof beam in the opposite direction of the existing one for the sake of stability since the model was going to be exhibited and exposed to people for days and supports in both horizontal and vertical directions had to be taken into consideration.

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Prototype- Scale 1:1

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1:10 model for the entire shelter

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Research Questions

7. Structural Analysis

For Beam-Column and Beam-Beam bridle-bolted connection: a) How many bolts are necessary for the beam/ column? b) How many bolts are necessary for beam/beam connection? c) Is the beam/column connection safe for vertical loads? d) Is the beam/beam connection safe for vertical loads? For Panel wedge connection: e) Is the wedge-sliding connection safe to endure wind load? f) Is the wedge-sliding connection strong enough to endure the panel (weight) load?

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Part 1: Column-Beam connection Columns with Fixed support: In this part of the analysis, the column to beam, i.e., the Mortise and Tenon joint ,are to be tested under the prevailing loading conditions and supports. For the hand calculations, the portal frame with the inclined beam is simplified to a straight one. The supports at the bottom of the columns are considered fixed, while the corner connections between column and beam are considered rigid. For what it concerns the connection method, the screws have been in this case converted into bolts, easier to understand and simulate. In the prototype, the number of fasteners will be considered sufficient if close to twice the calculated required number of bolts. The total load on the structure is considered as follows: Self weight of Beam

5.8 kN

Self weight of Panels

1.5 kN

Wind Load

2.6 kN

Total Load (w)

0.95 kN/m

Bolts provide strength to the structure by resisting shear forces, perpendicular to their axis. In order to calculate the force applied on each bolt of the connection beam-column, the bending moment in the corner point was calculated which came upto 0.5 kN/m. With the calculated Bending moment, Maximum resisting shear force provided by the bolts were found. Figure 37 shows the type of bolt selected. From the above data, the required results were found out. Maximum shear force (Pmax) for one bolt

Figure 39 : Diagram for reaction forces and bending moments.

Figure 40 : Beam-Column Connection: Section with a 14.5° Inclination

7.9 kN

Distance between the centre of each bolt (d) d1 d2

55.5 mm 65.5mm

Total resisting moment (MR) from bolts

1.90 kNm

Bending moment at the corner point of the portal frame

0.5 kNm

Figure 41 : Summary for beam-column connection calculation

The resistance offered by the bolts is almost 4 times higher than the bending moment measured at the corner.

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Maximum Deflection of Beam: In order to evaluate the maximum deflection in the beam for our final design, it is necessary to choose a maximum acceptable value for the displacement. According to Eurocode 5 the limiting values for deflection of beams supported on two sides is taken as l/250 to l/350. On the contrary, a limiting value of l/200 is considered in our design in order to design a light weight, easy to transport and a temporary structure. Therefore, Maximum value that the beam can deform is: Δlim = 20 mm Maximum deflection at the centre of the beam is: ∆max = 3.35 mm This value is lower than the maximum deflection allowed. Finite Element Analysis: In order to verify the accuracy of the hand calculations regarding the maximum deflection, the structure was modelled into DIANA. The same values for the loads and the geometric properties were used as inputs for the simulations.

Figure 42 : DIANA Results of Cross-Section Moments Mz (fix-support)

This analysis of the behaviour of the portal frames has provided interesting and positive results. Due to the relatively low weight of the whole structure and cladding, the deformations are acceptable. These results are encouraging for the future progress of our research and for the design. Figure 43 : DIANA Result for Beam Displacement DtY (fix-support)

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Part 2: Panel connection Wedge connection with the Panel: For analytical hand calculation, the panel is imagined as 2 different panel A and B, divided from the horizontal fix-support in the middle, as shown in Figure 40. Panel A is fixed-supported along the left and right edge, fix-supported along the bottom edge, and has no support whatsoever on the top edge, whereas Panel B would also be fixed-supported along the left and right edge but fixsupported along the top edge, and has no support whatsoever on the bottom edge. However, due to the limitation of what hand calculation can perform, it is sufficient to only calculate Panel A (600 x 1000 mm) for this analysis. The total load on the structure is considered as follows: Self weight of Panel

63.5 N

Wind Load

402 N

Total Load (w)

465.5 N Figure 44 : Simplification of the panel for analytical calculations

From the analytical calculations, the maximum bending moment Mxx is calculated as 9.60 N, whereas Myy is 26.76 N. From this data, the maximum stress was calculated; Sxx as 0.9 N/mm2 and Syy as 2.51 N/mm2. Furthermore, maximum deflection at the center was calculated as 5.52 mm. Finite Element Analysis: In this simulation, we had to make the model from 12 rectangles in DIANA, in order to place the node supports at a specific location on the plane without adding any more material ‘nodes’ into the software. Following table shows the comparison between the analytical and numerical calculations: Figure 45 : Diana results for bending moment and deflection in model 1

From the above data,it can be concluded that for the real situation, the deflections are expected to arise in two directions and probably supports on the entire edge might be more structurally sound than the wedge connections at certain points. But since the shelter is expected to have a certain lifetime pertaining to its temporary usage, the wedge connection seems to be a better connection design, as it is also demountable.

Figure 46 : Diana results for bending moment and deflection in model 2

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8. Computational Optimization

The current design has been optimized also in Grasshopper. The idea of the computational approach towards the project has been that of realizing a design tool that could help to define certain parameters of the structure starting from different sizes of Trespa panels. When a façade is demounted in fact, it is possible to get panels of different dimensions and it is relevant to reduce as much as possible the cutouts that a rigid design could need. That’s why in a range of total dimensions that can go from 4 to 5 m, some changes have been made possible. Starting from the dimensions of the panels, the script helps in customizing the design, providing, for example, the optimal length for the beams and the façade that minimizes the required cuts. It also implements a structural evaluation and an optimization of the beam’s cross-section, in order to keep the deflection in an acceptable range while minimizing the weight. Once that the structure is defined, the roof panels are defined and the final optimal design can be baked and turned into working drawings.

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Figure 47 : Concept for the Computational Optimization of the proposed shelter.

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9. Final design

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Layout of the shelter The layout of the shelter was finalized with the aim to have a small shelter for 3-4 people, that could provide dignified living conditions and safety with a relatively simple shape and design. The result is a square floor plan composed of one big room and an external semi-open area for outdoor activities protected by an overhang. The dimension of these spaces was influenced by the design criteria of having modular panels of 1 m length aligned on four-element rows that generate a space of 4x4 m The roof is designed with a single slope in order to maximize the usable surface for PV panels and help natural ventilation through chimney effect. Moreover, for the places prone to snowfall, the sloping roof is an essential design criteria for the ease of maintenance.

Figure 48 : Layout of the shelter.

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Sectional views

Figure 49: Section through the shelter.

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Figure 50: Section through the shelter.

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Components and details

Figure 51 : Illustration representing the different components of the shelter and their specifications.

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Fixing details for different components

Figure 52 : Details of the joinery system.

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Technical drawings Primary beam layers joinery

Detail of the sliding connection for the lateral beams - Scale 1:2 Beam’s layers dimensions - Scale 1:10

a. mm

Side 1

Side 2

Total pattern

Note: All dimensions are in cm unless specified otherwise.

Side 1

Side 2

Total pattern

Order of assembly of the 9 layers of the beam’s module.

Figure 53 : Fixing detail for the different layers of the beam.

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Column layers joinery

Column’s layers dimensions - Scale 1:10

Order of assembly of the 11 layers of the column’s module. Note: All dimensions are in cm unless specified otherwise.

Figure 54: Fixing detail for the different layers of the column.

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Panel to lateral beam joinery

Assembling method of lateral beams and panels.

Detail of the lateral beam - Scale 1:2 Note: All dimensions are in cm unless specified otherwise.

Lateral beam and panel’s dimensions - Scale 1:10

Figure 55: Fixing detail for the panel and the lateral beam connection.

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Column to foundation joinery

Note: All dimensions are in mm unless specified otherwise.

Figure 56: Details for the column to foundation joinery.

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Interior view of the shelter

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Adaptation to the context

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Cluster formation with dignified living spaces

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12. Improvements

Throughout the design process, a number of improvements took place, so that the final outcome could be in accordance with functionality, ease of transport and assembly as well as modularity and sustainability. Nevertheless, there is always room for improvement and during the building weeks and the construction of the prototype, many observations took place. A possible future improvement, for instance, is the overlapping of the roof panels, in order to ensure better insulation and prevent leaking due to rain or snow. This could also ensure a more stable and stronger roof when dealing with wind loads. The use of CNC milling machines is also of paramount importance when manufacturing beams and columns, as these elements have to be extremely precise since ease of assembly on site is one of the main principles of our design. Furthermore, based on the effectiveness of the construction derived from the structural analysis, there is a chance of using smaller cross-sections and fewer layers, maintaining the durability of the structure and saving energy, money, and material at the same time. Finally, it would be wise to mention that these shelters will work as a temporary living condition, becoming what is called home for many people. Electricity, water supply, heat and the like constitute commodities of great importance. The use of solar panels, the idea of a solar chimney or even thermal energy storage in a diurnal or/and seasonal level for the entire community are issues that could come to the surface, when such spatial conditions start being formed.

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Figure 57: Different improvements done in the design and possibilities for future improvements.

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11. Conclusion

Retrieved from URL: http://www.aumentaty.com/community/pin/ficha/conclusion-7/

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After the completion of the Bucky Lab project, a number of conclusions and observations arose. The construction phase that followed the design steps of the finalization of our idea was instrumental in drawing conclusions and gaining valuable insight into technical and practical matters. It is worth mentioning that the prototype created during the building weeks proved that our idea of a shelter made of reused Trespa panels, is feasible. It was shown that a construction consisting of elements like beams and columns exclusively made of those panels can be realized. Its applicability was further enhanced by our structural analysis that focuses on the durability of column-beam connections and wedges when subjected to dead and wind loads. In both cases, their strength and resistance were ensured. Although the structure is slender and seemed incapable of effectively carry any load, our assumptions were false. Nevertheless, it would be wise to say that further research can be conducted concerning the dimensions of the building elements since there is always room for improvement and there is a high chance of smaller cross-sections and thinner or/and lighter but still robust elements will be used. Furthermore, based on our experience during the building weeks, it is important to highlight that such elements need to be extremely precise, in order to ensure both functionality and effectiveness. For this reason, it is vital that CNC milling machine is used, since in these kinds of connections there is no room for mistakes. What is more, it is of paramount importance to mention that after all these steps, it was deduced that the outcome of our research and efforts is not simply a shelter construction but an innovative engineering system. This construction method that has reuse, circularity, and modularity as its moving forces, seems promising and shows potentials for a broader range of uses like mass-housing when many units must be quickly assembled by a minimum number of people. One has the opportunity to adjust and shape their personal space according to their own criteria. Provided that beams and columns are prefabricated and easily transported to site, a variety of different configurations can be realized, increasing the impact of the system.

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Retrieved from URL: https://bulldogcatholic.org/wp-content/uploads/2018/04/series-what-next-hero-next-wod.png

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Having a roof on top of our head is one of our primary needs as human beings. To be specific, we need safety and security. This goes back as far as when our ancestors were living in dark caves thousands of years ago. Fast forward to the year 2020, when on top of security, we also need durability, safety, reliability, and sustainability. Trespa Care covers all of these values, plus one sensitive value that seems lacking recently in the wake of digital technology – compassion. It is just not a prototype for developing an emergency shelter but it is a smart engineering system that can be adapted to any given situation from shelters to mass housing projects in an urban context. TRESPA CARE is•Durable Trespa material properties that are much stronger and weather-proof than woods •Safe and strong yet easy-to-assemble flat-pack structures •Reliable -one-stop agency that gives trainings on how-to-assemble and disassemble, maintain and store the modules properly, as well as track the records •Sustainable- Second-Life program that gives new purpose instead of merely disposing •Compassionate- helping and giving to those in need. It will provide: 1.Product: Trespa Care Module 2.Service: a. Communication with related entities b. Module assembly/disassembly training c. Data tracking & follow up: numbers, condition, feedback, storage (when necessary) d. Research and innovation universities & engineering firms e. Final collection of the modules once no longer used In return, TRESPA will get: 1.Positive publicity for all the 5 values above (as CSR?) 2.Progress on its Second Life program: less waste, more sustainability, better earth 3.Close connection with university and firms to encourage more innovation

Figure 58: Business model for the project

“Design so that people can adapt to new values, instead of optimizing the current values, as even values itself changes over time, thus we have to think long term and at scale”

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Reflection

Personally, Bucky Lab was one of the reasons that convinced me to go to TU Delft instead of other leading universities in Architecture. The laid-back atmosphere, real-life real-client project, and hands-on approach were the top 3 features about Bucky Lab that I enjoyed. I was astonished by the freedom and trust given to us, the students, to develop our own ideas, to which we can directly discuss when necessary with the different experts teaching at TU Delft. I also love my bright course-mates who come from various backgrounds and have contributed to this project in their own unique way. I believe this is a conducive environment for research and development and I felt fortunate to be able to experience one. Started from Elevator Pitch, we learned how to ‘sell’ our idea in an efficient manner. At the same time, we also have Material Science, Building Physics, Structural Mechanics, and CAD course to complement our design by incorporating all these aspects into a good design. As much as I’d like to complain at how much assignments some of these courses have, I have to admit that the sweat paid off when my knowledge and perspective broadened. Business concept was another important thing that I didn’t think we would have the chance to develop: the what’s-next and how to make our project feasible, as we have a real Client. Aside from whether our design has a market prospect or not, being able to propose the idea to the Client is really motivating and humbling, and helped us steer our project for real production and not merely over-the-top imaginative artsy concepts that other architectural schools seem to thrive in. On the other hand, collective money-contribution for parties within the course could have been improved both in transparency and economical value, as we are just poor students with no part-time job yet haha! Last but not least, I thank both Marcel and Nadia for their eye-opening pieces of advice and expertise, but most importantly: for their fun and humble characters, making the learning process so effortless! - Puji Nata Djaja

Bucky lab course has been an exciting and wonderful journey since the beginning of the semester and is a good way to start with the Master’s program. I particularly enjoyed the elevator pitch phase of the course to hear lots of innovative ideas from my fellow classmates which would not be possible without the constructive inputs of Marcel and Nadia. The tour to the Trespa factory was really useful to get an insight into the detail and specifications of the material. The design development phase in the group was equally constructive in terms of working with people from different backgrounds and learning from them. It was an enriching experience and I am very satisfied and proud with the result of our group. The most exciting part of the course was building weeks as it provided a real practical exposure to the construction process of the design. It was extremely new and exciting for me to learn how to work with all the tools and realize the 1:1 prototype (never got such an opportunity in the Bachelor’s). I certainly feel a room of improvement in the integration of other Bucky lab courses into the design as it was somehow limited due to the design brief when compared to the last years. For our particular design, we could not involve the concept of building physics and hence it was a little theoretical for me. Also for the Material Science design exercise, since the material for our design was fixed as Trespa, comparing it with wood, steel or other materials did not really help to come up with some new solution for the development of our design. In terms of organization of the entire program, I feel things went pretty smooth except sometimes when there are submissions/ deadlines/ exams all together at the same time. All in all, Buckylab has definitely broadened my knowledge in the field of technical design and I would really like to thank Marcel and Nadia for their inputs and advice into the project. -Yamini Patidar

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Bucky Lab has come to an end, and so the first semester of this Master. It has been an intense course full of challenges in different subjects and a new positive experience in almost all its aspects. The whole concept of a course such as Bucky Lab is still incredible to me and I consider the choice of having it in the first semester of the first year particularly smart. For people coming from a Bachelor’s in architecture, the course represents at first an important change of scale and approach towards the built environment. I personally felt this change, but I can now say that it has helped me understanding more the whole focus of this program and the practical effects that it can produce in reality. In fact, the second exciting element at the beginning of the course has been its connection to the real world. Designing with a specific material, visiting the factory where it is produced and pitching our first ideas to their managers and researchers has been a unique chance. However, Trespa itself can in a way be considered the first limitation to the positivity of the course, as it sometimes represented a strong constraint to creativity, especially if compared to the topics for the Bucky Lab of the previous years. On the other hand, these constraints have helped us to always care about the feasibility of our design and stimulated us to find an innovative way to think about the material and manipulate it. For what it concerns instead of the general structure of the course and how all the different modules interact with each other in order to finalize the final design, there is still room for improvement. In my opinion, the study load related to assignments during the quarters is sometimes excessive for certain subjects and it affects the amount of time that could go into the design part, for which especially close to the building weeks we felt a bit in a rush. Another limitation regards the contribution of each subject to the design: focusing on materials at the very beginning of the semester instead of closer to the building

For what it concerns instead the general structure of the course and how all the different modules interact with each other in order to finalize the final design, there is still room for improvement. In my opinion, the study load related to assignments during the quarters is sometimes excessive for certain subjects and it affects the amount of time that could go into the design part, for which especially close to the building weeks we felt a bit in a rush. Another limitation regards the contribution of each subject to the design: focusing on materials at the very beginning of the semester instead of closer to the building weeks, when it could be more helpful for the prototype or the report, and starting CAD when the design is already at an advanced stage are the main doubts. Besides the other subject and the overall organization, the most important aspect to talk about are the building weeks. Designing and realizing a 1:1 prototype of our design with real Trespa has been an amazing and unique experience, worth of all the studying and work that have led to it. The Factory, which hosted us, was a cool place to work in and the mobile workshop was perfectly equipped for all our needs and request. However, all these tools would have been for an unexperienced student like me useless without the wise and patient help of Martin and Marcel, that tried to teach us how to build our ideas. Therefore, now that the prototype is built I can say that I am satisfied and proud of the result. It feels like it has been a long way that required many attempts and change of direction, but the aspect of which I am more happy about is having shared all of it with the rest of my crazy group. Working with new people from different nationalities and different backgrounds is always challenging but enriching at the same time and if at the beginning we were five people who really did not know that much about the others, I now feel that everyone of us has learned a lot from and of the other ones. To conclude I think it is important to thank Marcel, who represents the Bucky Lab itself and everything that it means, for its constant guidance and assistance and Nadia, who was always there to help us and give advice that I think will also follow us further in our career. It has been a pleasure. -Leonardo Caldoni

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Bucky Lab Design Studio constitutes a good starting point for the MSc of Building Technology, a course that gives a great insight into more technical and structural design aspects. From the very beginning, it was clear that thinking out of the box was instrumental in determining someone’s personal progress in the workshop. Starting from an introduction of the main purpose and material of this year’s studio, in our case, the reuse of Trespa panels, each one of us had to come up with new applications and uses of it that could ideally deviate from the conservative, traditional or the expected. After our elevator pitches and based on the similarity of our concepts, we were expected to create a group able to combine the ideas of its group members and that’s how our group was made. Offering protection and safety to people in need all over the globe was one of the constituent elements of our concept and lead us to design a shelter in a modular way. Since Trespa had to be our main material, we focus on designing and producing construction elements, namely beams and columns out of Trespa, which we all find not only innovative but also interesting, as it offers a totally different use and approach of the material and its properties. Finally, during the building weeks, we had the chance to actually realize a part of our design, test it and face any implications that came up with it. I strongly believe that at the end of this journey, I was able to gain knowledge and experience in fields different from my previous architectural background. During my five years of education, I mainly focused on elements like design concepts, construction drawings, 3D visualization and the like. Unlike these, Bucky Lab took me one step further into more technical issues that in my opinion play a leading role in today’s construction field and offer a more spherical view of architecture in general. As far as our final design and model is concerned, I could say that I am satisfied from the result since it constitutes the product of many experimentations and modifications that their purpose was not only to improve and optimize our design but also to offer us a big variety of alternatives, capable of functioning as impetus for future use and thought. It goes without saying that there is always a place for improvement in specific matters but the general feeling of this workshop was substantially positive for me. -Olympia Apostolopoulou

To begin my master’s course with Bucky Lab was very fascinating. We were introduced to this very interesting material Trespa and were expected to come out with an interesting engineered design solution for the project Second life Trespa. The topic itself was very interesting as I have personally never worked with this kind of material in my professional or academic tenure. The idea to pitch the design in front of the client and the entire BT batch was brilliantly executed and increased competition among everyone to present the best and assemble a team to execute it for the rest of the semester. In my opinion, we were bound by a material that is so difficult to deal with that it partially acted as a barrier between great ideas and practical execution. This challenge was something we had to deal with the entire course. Not to forget the interdisciplinary courses of Bucky Lab with Material Science, Structural Mechanics, CAD, and Research Methodology. I personally wanted to learn a lot from these courses and weave them together into the design proposal. According to me the Material Science course could have been structured in a better way to suit the requirements of the given proposal. As the material was already given to us, the analysis part of the material was something we couldn’t do. Then came the building weeks, where we realized a lot of intricate details were missed out during the conceptual evolution. That gave us a great opportunity to also test out different options practically for the model and then select the best one. In my opinion, 2 weeks of construction were the best ones of the course where I experimented with the fancy tools, drilling, cutting and a lot of other interesting things really brought out the engineer in me, something that I never did in Bachelors of Architecture. To sum up, Bucky Lab was a fun roller coaster ride for me where I met new people with great ideas and developed a lot of new skills. Not to forget, the mentors of the Bucky Lab course, thank you for pushing us to think to the level of technicality and practicality. -Shriya Balakrishnan

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References

Lundgren, J., & Tassi Carboni, F. (2014). From Emergency Shelters to Homes (Master’s Thesis). Department of Architecture, Chalmers University of Technology. “Better Shelter.” Bettershelter.Org, 2018, bettershelter.org/. Accessed 18 Jan 2020. “U-Build by Studio Bark Is a Revolutionary Self-Build System.” U-Build, 2019, u-build.org/. Accessed 20 Jan. 2020. ILUMY Digital Innovation. “High Quality HPL Panels | Trespa International B.V.” Trespa.Com, 2020, www.trespa.com/. Accessed 15 Jan. 2020. “DIN EN 1991-1-1:2010 - Eurocode 1: Actions on Structures - Part 1-1: General Actions - Densities, Self-Weight, Imposed Loads for Buildings; German Version EN 1991-1-1:2002 + AC:2009 (Foreign Standard).” Ansi.Org, 2010, webstore. ansi.org/Standards/DIN/DINEN19912010. Accessed 20 Jan. 2020. Nations, United. “UNHCR - The UN Refugee Agency.” Unhcr.Org, 2019, www.unhcr.org/. Rosenfield, Karissa. “TEDxTokyo: Emergency Shelters Made from Paper / Shigeru Ban.” ArchDaily, 14 Aug. 2013, www.archdaily.com/415751/tedxtokyo-emergency-shelters-made-from-paper-shigeru-ban. Accessed 219 Jan. 2020.

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Appendix Properties of Trespa

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Climate data for Lesbos, Greece

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Build with less for more

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