YUNJING GUAN Z3383621 ARCH9006 COMPLEMENTARY FABRICATION TECHNIQUES
ARCH 9006 CONTEMPORARY FABRICATION TECHNIQUES DOCUMENTATION OF PROCESS
PROJECT 1 BES PAVILION 1:1 ROOF STRUCTURE MODEL
PROJECT 2 THE MUTENDE PROJECT II 1:2 STRUCTURAL JUNCTION MODEL
PROJECT 3 SCHOOL FOR EL COPORITO 1:2 ROOF STRUCTURE MODEL
PROJECT 1 BES PAVILION
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1:1 ROOF STRUCTURE MODEL
PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT
PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT
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YUNJING GUAN Z3383621 ARCH9006 COMPLEMENTARY FABRICATION TECHNIQUES
TIME content
hrs no.
misc:
research of the junction detail CAD drawing experiment 1 for casting experiment 2 for casting traveling to and staying in bunnings consultation (WORKSHOP TECHNICIAN/BUILDER) CUTTING bolts
bamboos:
cutting bamboos knocking out the bamboo knots marking drilling holes of bamboos 3 drilling bamboos
making mold for casting:
cutting plywood measuring and assembling components screwing components together setting up the strategy for making slanted surfaces
Sum
2 3 6 1 3 3 0.5 1 0.5 3 1 3 1 8 8 0.2 10 2 0.2 2 0.4
0.20 10 2 1.00 5 5 1 3 1.5 2 3
y
0.5 1 0.5 2 1 2 0.5 1 0.5 0.5 1 0.5
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hrs no. sum
setting up plastic sheet on the floor and preparing equipment mixing colour and water and plaster pour cleaning up the surface
casting the concrete cap:
casting the earth wall:
setting up plastic sheet on the floor and preparing equipment scoring the surface of the concrete cap mixing colour and water and plaster pour
stirrup: marking drill holes, cuts and edge for bending drilling holes for bolts, changing drill bits bending adjusting total:
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0.2 1 0.5 1 0.5 1 0.3 1
0.2 0.5 0.5 0.3
c 0.2 1 0.2 1 0.5 4 0.5 4
0.2 0.2 2 2
0.5 0.6 0.1 0.3
9 0.5 1 0.1 6 0.05 2 0.3 1
46.8
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Structural members: Bamboo: 8x 1800mm
connections:
Tasmanian Oak DAR Molding 20 x 12mm 1.2m strings Bolts: galvanised M10 120mm and nuts Bolts: galvanised M12 300mm and nuts Washers: zinc coated M10 Washers: zinc coated M12 Ramset Dynabolt 10 x 75mm Hex Nut Bolt Aluminium bar: 3x50x1000mm x 1
casting:
price no. sum 24.5 3
w 5.27 1 4.95 1 3.5 2 6.5 2 0.6 4 0.5 4 0.86 2 13.95 1
73.5 5.27 4.95 7 13 2.4 2 1.72 13.95
bucket
w 11.37 4 45.48 20 2 40 0 0 0 0 0 0 3 1 3
builder’s oxide powder(brick red) 500g x 1 acrylic paint(black) small tube x 1
11.5 1 3.95 1
Plaster of paris 6kg x 3 Plywood for mold: 12x 1200x1200mm nails screws: 4g x 25mm
stain:
total:
w
11.5 3.95
227.72
YUNJING GUAN Z3383621 ARCH9006 COMPLEMENTARY FABRICATION TECHNIQUES
1. STRUCTURAL BAMBOO
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1. Bamboo is commonly known that it spli ts very easily(although this was proofed to be inaccurate. If the bamboo is well seasoned and is relatively thick, splitting is not a concern). In order to address this issue, I decided to cut near the knots where the fiber is structurally stronger. 2. As bamboo usually comes in irregular shape, a measure stand is used for making precise marks. 3. Marking the central line.
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4. Drill through both sides of bamboo pole at once so that the holes align with each other. 6. However, getting all the holes aligned is dif ficult, as the diameters vary at each end of bamboo. 7.Had to re-drill the bamboo rafters with a potable drill( Perhaps this is a more suitable strategy for drilling bamboo). 8.The new hole turned out to be 1.5 cm away from the original one.
9. Marking holes perpendicular to the pre vious ones. Bolts are used for leveling the bamboo. 10. Drilling holes. Bolts are used for leveling the bamboo. 11. File was used to clean up the edges, as there are some tiny splits around the holes.
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15. The bolts are a bit too long, and hack saw was used to cut the bolts.
16. Band saw and a particular support for cylinder objects were used to cut bamboo in half. 18. Files in different sizes were used to remove the knots. 20. As the diameter of bamboo was smaller than expected, more roof panels were made.
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2. ROOF PANELS
Strategy for making cutouts at the same position on each panel:
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21. Panels lining up on a piece of ply wood. Two strips of soft wood were used to stop the panels from moving. 22. A timber measure tool was used for adjustment. 23. Set the height of panel saw to the depth of cutouts and move the plywood base horizontally.
YUNJING GUAN Z3383621 ARCH9006 COMPLEMENTARY FABRICATION TECHNIQUES
24. Unfortunately, the cutouts were slightly shallower than desired. Further adjustment was needed. 25. Small hand saw was used to deepen the edges of the cutout(two cuts at the orange lines). 26. Chisel was used to knock out the remaining part. (at the orange line)
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3. STIRRUP
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4. STRING
27. Measuring and marking the position of the holes. 29. Use small drill bits before drilling big hole, as the large drill bits were not as sharp as the small ones. 30. Bending machine was used for bending. However, this machine is not capable for making a U shape. I could only bend the second arm(as shown on the photo) for 45 degrees. The rest needed to be done by hammering.
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5. BASE
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MAKING A SLANTED TOP SURFACE
37. Set up the plastic sheet so that it is easier for later cleanup. 38. Dissolve acrylic paint in water first. 39. 20KG bag of casting plaster. It is slightly rougher and more yellowish than plaster of paris.
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YUNJING GUAN Z3383621 ARCH9006 COMPLEMENTARY FABRICATION TECHNIQUES
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40. The process of mixing plaster and water is crucial. - A bucket of water has to be prepared before hand. - Slowly sprinkle plaster into water. - Keep sprinkling until an island of plaster appear in the mixture. - Add a few more handfuls of plaster. - Put hand in mixture and break the lumps of plaster. - Pour while the mixture is still liquid.
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43. Simply repeating the previous procedure. 46. Drying condition is crucial for large piece of plaster. In my case, as there is no sun and proper ventilation, the plaster could never be completely dry, which resulted in molds growing on the surface.
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6. ASSEMBLING 49. Bamboo is not very practical when working with bolts, as its diameter is not consistent. If they have be connected with bolts, I would recommend the bamboo to be drilled and bolted on site, otherwise it is difficult to get the holes lined up with each other.
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Bamboo is more efficient working with strings, as this type of connection is not so sensitive with precision.
APPENDIX 1: EXPERIMENTS OF CASTING PLASTER
MIXING ACRYLICS PAINT WITH PLASTER • When acrylic was added in
water before adding plaster, the colour was smoothly blended with the mixture.
• When acrylic was added into
the mixture after plaster was added, particles appeared in the mixture.
• Pigment used for colouring the plaster. It turned out to be much more efficient than acrylic paint.
• As the powder is made from rust, it cannot dissolve in water.
• The process in adding/mixing plaster and water is cru-
cial, especially for big casting like this. The failure of this attempt was due to the fact that too much plaster was added to water at once, and too much time was spent on mixing the plaster.
• First attempt in making a mold.
Due to the lack of experience, it leaked and fell apart.
• For large form work, clamping is
not sufficient in holding such big amount of plaster, screws and nails have to be used.
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1:2 STRUCTURAL JUNCTION MODEL
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AL PRODUCT
PROJECT 2 THE MUTENDE PROJECT II
AL PRODUCT
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YUNJING GUAN Z3383621 ARCH9006 COMPLEMENTARY FABRICATION TECHNIQUES
T
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content
hrs no. sum
research of the junction detail CAD drawing traveling to and shopping in bunnings consultation (WORKSHOP TECHNICIAN/BUILDER)
2 3 6 1 3 3 1 7 7 0.2 10 2
misc:
timber columns: cutting timber marking drilling holes 0.05 drilling holes re-adjusting and re-aligning the holes
0.20 4 0.8 0.05 8 0.4 0.05 8 0.4 0.3 4 1.2 metals: consulting and experimenting ways of cutting thick steel bar 0.5 1 0.5 0.05 4 0.2 cutting steel bar 0.05 9 0.45 cutting aluminium square washers 0.15 16 2.4 marking, drilling holes,swapping drill bits, clamping 0.1 4 0.4 Cutting bolts
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CONTENT
Structural members: Standard & Better Pine DAR 70 x 30mm 2.4m Porta connections:
Bolts: galvanised M10 150mm and nuts x2 Aluminium bar: 3x50x1000mm x 1 steel bar: 3x50x1000mm x 2 Aluminium bar: 3x50x1000mm x 1
casting:
price no. sum 13.5 1 13.5
1 3 3
3.5 2 13.95 1 18.95 2 13.95 1
7 13.95 37.9 13.95
casting Plaster 20kg x1 Plywood for mold: 12x 1200x1200mm x1 nails screws: 4g x 25mm bucket
22 1 22 20 1 20 0 0 0 0 0 0 3 1 3
acrylic paint(black) small tube x 1
stain:
total:
3 3.95 1
3.95
135.25
content
making mold for casting:
cutting plywood measuring and assembling components screwing components together
hrs no. sum
0.5 1 0.5 2 1 2 0.5 1 0.5
setting up plastic sheet on the floor and preparing equipment 0.20 1 0.2 mixing water and plaster 0.5 2 1 pour 0.5 2 1 cleaning up the surface 0.3 1 0.3 colouring the plaster base afterwards 30.55 total casting PLASTER:
YUNJING GUAN Z3383621 ARCH9006 COMPLEMENTARY FABRICATION TECHNIQUES
1. TIMBER COLUMNS
The 45 degree angle is cut with plain.
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3. Water based clear vanish(satin finish).
4. 3 layers of vanish were applied to the timber. 1 hour was allowed for the vanish to dry between each apply. 7. File was used to clean up the holes so the bolts can still fit in.
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2. METAL PLATES
4. Use small drill bits before drilling big hole, as the large drill bits were not as sharp as the small ones. 11. 8 pieces of small square washers 4pieces of metal bars
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3. PLASTER BASE
FORMWORK
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PLASTER AND METAL PLATES
14. Strip of wood(90mm think) was placed between the timber columns to make sure the metal plates are in correct position 15. The clamp was to support the timber strips that filled the gabs.
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19. File was used to smooth the edges. 20. 3 pours of plaster were made for this base, and as it is difficult to make the shade of grey identical in different pours, I was suggested to add colour later on.
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YUNJING GUAN Z3383621 ARCH9006 COMPLEMENTARY FABRICATION TECHNIQUES
3. ASSEMBLING
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21. I was suggested to apply a layer of watery paint on the surface. However, water was absorbed by the plaster before I could paint it evenly. 22. Eventually, a layer of opaque acrylic was applied to cover the water mark.
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24. There are two tricks of easily making the holes aligned with each other. - Drill all the components at once. - Drill bigger holes.
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1:2 ROOF STRUCTURE MODEL
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PROJECT 3 SCHOOL FOR EL COPORITO
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YUNJING GUAN Z3383621 ARCH9006 COMPLEMENTARY FABRICATION TECHNIQUES
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content
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CONTENT
price no. sum
research of the junction detail CAD drawing traveling to and shopping in bunnings consultation (workshop technician/ builder)
2 1 2 2 1 2 1 3 3 0.2 5 1
pine 19x89x1200mm pine 45x90x1200mm pine 12x140x1200mm
4.2 1 4.2 12.4 1 12.4 6.6 1 6.6
aluminium angle 40x40x1000mm Bolts: galvanised M6 60mm Washers: galvanised M6
11 1 11 1.5 8 12 0.2 8 1.6
clear matt finish paint brush
11 1 11 3 1 3
misc:
timber columns:
ff
ff
cutting timber marking drilling holes drilling holes re-adjusting and re-alligning the holes applying vanish
0.20 6 1.2 0.05 20 1 0.05 20 1 0.1 16 1.6 0.5 4 2
cutting aluminium angle marking, drilling holes,swapping drill bits, clamping
0.1 4 0.4 0.15 20 3
metals: total:
ff
18.2
Structural members:
connections:
finish: total:
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EE
EE
61.8
1. TIMBER COLUMN
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1. Marking the cutout. 2. The wedge was too small. 3. The strategy of making an angled cutout is to place a wedge under the timber and cut it with band saw. 4. Adjusting the cutout to accommodate the rafter. 5. Chisel was used for minor adjustment. The other tool was used for mark ing sure the angles are the same at different points.
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2. DRILLING HOLES
3. PLAINING SURFACE 7. Drill all the pieces together to ensure the rods fit. Bolts were used to fixed the components
8. Plain was used to smooth the top surface.
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YUNJING GUAN Z3383621 ARCH9006 COMPLEMENTARY FABRICATION TECHNIQUES
4. DRILLING HOLES
9. I didn’t put the angle in the first time I drilled. 10. The holes were offset with each other. 11. Had to stack all the components together and re-drill the holes.
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5. SMOOTHING SURFACE 12. File was used to make all the edges flush.
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Great thanks to Peter and Ian for their help with the models!