SMART PAPER FACTORY Gleaning paper cellulose to create a post-industrial smart paper factory in Maastricht where design, exhibition and production are intertwined
Zilin Zhou 5238927 Urban Architecture Graduation Studio 2021-2022 Delft University of Technology Department of Architecture
WHAT TO GLEAN?
1
MAASTRICHT From Industrial City to Smart City
SAPPI PAPER FACTORY Rebirth of Industry
PAPER CELLULOSE Catalyst for Architecture and Design
Urban scale
Architectural scale
Material scale
2
MAASTRICHT From Industrial City to Smart City Urban scale
3
Sphinx Belvédère Industrial heritage preservation Started in 2008
Sappi Paper Factory in operation
What's the tomorrow?
Céramique Urban renewal over heritage in the 1980s
"Without a past, no today and no tomorrow" (Belvédère Maastricht, [brochure)
ENCI Closure of the Netherland\s oldest cement factory in 2020
"Limburg 1839-1939. Van ploeg tot afbouwhamer"
4
MIGRANT CITY Diversity in Maastricht 5
An interdisciplinary site of research
Researcher Monuments Commodity transportation
Transport
Museum
Good Student Tourist
Worker Artist & Designer
Shop
Market
LBB culture freezone
Creative industry
From selling goods to service and knowledge production
GLEAN AGENT Interaction Activates the City 6
Sappi island Maas
Sphinxkwartier
Bassin
LBB
Frontenpark
City center
7
GLEAN MATERIAL Nature, landscape, buildings, machines, etc. 8
GLEAN MATERIAL Bassin 9
Clarifier
Tank
Storage
1986
1986
Tank
PM6 Rolling Lead
Maas water cleaning
PM6 Coating
Tank
PM6 Machine hall 1961
PM6 Sheet Finishing Expedition
Cellar off coater PM6 Finishing room
Sheet Finishing Power Plant 1979
1999
1961 1961
Cellulose Storage
Cellulose Storage 1962
Storage/Machine Maintenance
Energy Plant
1935
1951
Warehouse 1926
PM-5
PM-1 PM-4
Storage
1920
PM-1/4
Storage
Affuitenloods/Storage
10
PM-5
Pump
1827
GLEAN MATERIAL Time and history
1966
Office/Laboratory Office
1920
Warehouse/Archive
1883
1920
1920
GLEAN MATERIAL Factory space 11
ct
a mp
co se
loo
URBAN STRATEGY Reconnect 12
Demolish
URBAN STRATEGY Reconnect 13
New
URBAN STRATEGY Reconnect 14
URBAN STRATEGY Reconnect 15
16
17
18
0m
New Old
Green Water
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10m
20m
50m
0m
New Old
Green Water
20
10m
20m
50m
0m
New Old
Green Water
21
10m
20m
50m
SAPPI PAPER FACTORY Rebirth of Industry Architectural scale
22
SAPPI PAPER FACTORY Machine space and leftover space 23
Paper machine
Paper cellulose
Structure
Form WHAT TO GLEAN? 24
1968 Teepee paper dress
2014 Semi-transparent paper / stlandsutstillingen
2011 paper furniture pavilion / Shigeru Ban
2008 Paper Chair / Mario Stadelmann
2006 Sculptural Cardboard / ball nogues studio
1968 Aalto exhibition / Shigeru Ban
2018 Paper pulp / Beer Holthuis
Honeycomb Wall / ECOCELL fastbuilding system
Furniture
Space Plan
Skin
Structure
1995 Paper log house / Shigeru Ban
1995 Paper house / Shigeru Ban
2019 Barjeel Installation / Miskavi Architecture Studio
2013 IE Paper pavilion / Shigeru Ban
2009 Cardboard pavilion / Cambridge University
2010 Paper composite / Finland pavilion Shanghai EXPO
2007 Digital Origami / CHRIS BOSSE
2001 Veneer Grid roof house / Shigeru Ban
GLEANING PAPER AS CATALTST Attract multiple agents 25
2014 paper tube wall / Perkins + Wills
2016 Wallpapering acoustic insulation / Dear Human
2003 Paper Dome in Amsterdam
2007 Paper composite / Shigeru Ban
2007 Papercut / dARCH studio
Paper cellulose insulation / ECOCELL
2011 Cardboard Column / Michael Hansmeyer
2006 paper cardboard / NOGUES STUDIO
THE POTENTIAL OF PAPER Origami 26
THE POTENTIAL OF PAPER Cast paper 27
THE POTENTIAL OF PAPER Regular structure 28
THE POTENTIAL OF PAPER Spatial experience 29
THE POTENTIAL OF PAPER Spatial experience 30
DESIGN PHASE Form 31
DESIGN PHASE Flexible space 32
DESIGN PHASE Curved folding roof 33
DESIGN PHASE Return to human scale 34
DESIGN PHASE Return to human scale 35
Old
Renovation New
36
0m
10m
20m
30m
Old
Renovation New
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0m
10m
20m
30m
FACTORY MUSEUM
SPORTS CENTER
COMMUNITY CENTER
WORKSHOP
MANUFACTURING
ENTRANCE EXHIBITION
SHOP
ART STUDIO
HOSTEL
TEST GROUND
RESIDENTIAL
Old
Renovation New
38
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10m
20m
30m
Old
Renovation New
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10m
20m
30m
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40
10m
20m
0m
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10m
20m
PAPER CELLULOSE Catalyst for Architecture and Design Material scale
42
Paper cellulose
Paper honeycomb
Paper cardboard
Wood Pallet
Load-bearing ceilings and walls
Foundation
Insulation layer
Load-bearing ceilings and walls
biodegradability and recycled nature the R-value 3.2 to 3.8 per inch with fire retardant (Boric acid) accept high humidity levels
the direction of force is perpendicular to the surface of the paperboard
Secondary processing
Insulation layer
lightweight 30-90kg/m3
WHAT TO GLEAN? 43
Entire load-bearing structure of the buildings Span 6m ceiling elements with three honeycombs of 65 mm thickness each have a total height of 27.5 cm and enable a span of up to 6.00 m
Water and fire retardant coated with mineral cement
ECO Solar Houses (ECOCELL)
CASE STUDY Paper honeycomb 44
Entire load-bearing structure of the buildings through rolling cardboard Thickness 24 layers of cardboard Water and fire retardant
Wikkel House
coated with a protective film and a shell of wooden slats
Life expectancy 50 years
CASE STUDY Paper cardboard 45
Two-layered wood panel folding structures All four panels can be joined directly along folded edges, the double tenons also serving as spacers between the two layers and absorbing shear forces. Wikkel House
Span 16-20m CLT Plate thickness 45mm Hollow interspace 210mm
CASE STUDY Glue-free double layered folded plate 46
Tensile strength MD(machine direction) 15-45MPa CD(cross-machine direction) 0.3-0.5MD
l
r rol
e Pap
Compression strength MD(machine direction) 0.3-0.5Tensile strength CD(cross-machine direction) 0.3-0.5MD
CD
Anisotropic
MD
Structural Safety When facing compression, there's no significant plastic deformation before breaking. So, paper load with maximum force can still carry some forces.
Co
rru
ga
ted
pa
pe
rbo
ard
Paper cardboard is stronger in tension than in compression. co
mp
res
sio
ten
n
sio
n
compression tension
Structural rigidity balance
Building structure
Each layer of cardboard is oriented perpendicular to adjacent layers to achieve better structural rigidity in both directions.
Cardboard is used as a tensile structure, mainly as the internal load-bearing structure of the envelope, and the external is CLT panel, forming a double-layer structure.
Cross laminated cardboard
Cardboard as tensile structure CARDBOARD PERFORMANCE 47
Optimal moisture content
Ignition temperature of paper 230oC
5%-7%
If moisture level is exceeded, strength is reduced by 10% for every 1% increase in moisture content
thiicker cardboard is similar to timber in the flammability performance.
Waterproof Method
Fireproof Method
- a layer of waterproof liner - cover pvc sheet (not environmentally friendly) - paraffin to impregnate paper (applied by Shigeru Ban) - polyurethane liquid or polyurethane film (transparent) - polyethylene (coated layer can be inside / internal impregnation of fibres) - cement
- cover with intumesscent coating - coated with flame retardant in either solid or liquid form (kiilto) - double-sided spraying Hydroflam (class M1)
Waterproof
Fireproof
CARDBOARD PERFORMANCE 48
Cross laminated cardboard
Composite board
Composite Panel
(Cross laminated cardboard+honeycomb core)
(Cross laminated cardboard+cellulose insulation)
Vertical structural elements
Paper tube
Tube truss
Composite board
Cross laminated cardboard
Horizontal structural elements
(Cross laminated cardboard+honeycomb core)
STRUCTURAL ELEMENT 49
CONNECTION tongue-and-groove system 50
45mm cross laminated timber panels 210mm paper honeycomb 100mm cross laminated paper cardboard
CONNECTION tongue-and-groove system - wall 51
CONNECTION tongue-and-groove system - floor 52
Compsite loadbearing panel (cross laminated cardboard + honeycomb core) - 10mm flooring tiles - waterproof layer - 45mm 3 layer CLT Panel - 210mm 4 layer honeycomb paper layer with heating system - 100mm cross laminated paper cardboard - 5mm film solid waterproof polycarbonate sheet
Compsite loadbearing panel (cross laminated cardboard + honeycomb core) - 5mm film solid waterproof polycarbonate sheet - 45mm 3 layer CLT Panel - 210mm paper cellulose insulation layer - 100mm cross laminated paper cardboard - 5mm film solid waterproof polycarbonate sheet
CONNECTION tongue-and-groove system - floor 53
0mm
100mm
300mm
500mm
CONNECTION tongue-and-groove system - roof 54
Compsite loadbearing panel (cross laminated cardboard + cellulose insulation) - 10mm polycarbonate roofing sheet - 220mm ventilated air cavity with purlins - waterproof layer - 45mm 3 layer CLT Panel - 210mm paper cellulose insulation layer with purlins - 100mm cross laminated paper cardboard - 5mm waterproof polycarbonate film
- Motorized solar shade
- Glulam Beam (structural beam)
CONNECTION tongue-and-groove system - roof 55
- 5mm film solid waterproof polycarbonate sheet - 45mm 3 layer CLT Panel - 210mm paper cellulose insulation layer - 100mm cross laminated paper cardboard - 5mm film solid waterproof polycarbonate sheet
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100mm
300mm
500mm
STRUCTURAL SCHEME Beams supporting the roof 56
STRUCTURAL SCHEME 57
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2m
3m
ASSEMBLE PROCESS 59
ASSEMBLE PROCESS 60
ASSEMBLE PROCESS 61
ASSEMBLE PROCESS 62
ASSEMBLE PROCESS 63
ASSEMBLE PROCESS 64
ASSEMBLE PROCESS 65
ASSEMBLE PROCESS 66
ASSEMBLE PROCESS 67
ASSEMBLE PROCESS 68
ASSEMBLE PROCESS 69
ASSEMBLE PROCESS 70
ASSEMBLE PROCESS 71
ASSEMBLE PROCESS 72
ASSEMBLE PROCESS 73
ASSEMBLE PROCESS 74
75
0m
1m
2m
3m
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0m
1m
2m
3m
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DOUBLE FACADE 79
0m
1m
2m
3m
- 10mm polycarbonate roofing sheet - 220mm ventilated air cavity with purlins - waterproof layer - 45mm 3 layer CLT Panel - 210mm ventilated air cavity with purlins - 100mm cross laminated paper cardboard - 5mm film solid waterproof polycarbonate sheet
- Roofing batten
- Optional vent hole for ventilation
- Soffit vent (air flows along underside of roof) - Box gutter - Gutter boards - Varying depth packers to create gall - Waterproof layer - 45mm 3 layer CLT Panel with inserted
- Laminated glass louvre blade
- Hydraulically operated arm to operate louvres
- Hinge
Open louvres - Glulam beam (facade structure)
80
0mm
100mm
300mm
500mm
Exhaust air
Supply air
DOUBLE FACADE Open 81
External air curtain / summer shading
Internal air curtain / winter air buffer
DOUBLE FACADE Close 82
RAISED FOUNDATION 83
0m
1m
2m
3m
- 10mm flooring tiles - waterproof layer - 165mm honeycomb paper as insulation layer with heating system - 150mm glulam panel - 100mmx150mm wood beam
- Angle steel to fix loadbearing wall
- 210mmx260mm glulam wood beam - metal bracket
- Hexagon Thread Bolts - Concrete foundation
RAISED FOUNDATION 84
0mm
100mm
300mm
500mm
ROOF DRAINAGE AND VENTILATION 85
0m
1m
2m
3m
- Exhausted air exits ridge vent
- Wind baggles (limit infiltration of windblown rain and snow) - Roofing batten
ROOF DRAINAGE AND VENTILATION 86
0mm
100mm
300mm
500mm
- Prefab valley gutter - Gutter boards - Varying depth packers to create gall - Waterproof layer
- Roofing batten
- Glulam Beam (structural beam)
ROOF DRAINAGE AND VENTILATION 87
0mm
100mm
300mm
500mm
Mec
hani
MECHANICAL VENTILATION 88
cal r
oom
Paper honeycomb thickness: 65mm for underfloor heating
MECHANICAL HEATING 89
SPACE & STORY
DESIGN TOOL
NEXT PHASE & REFLECTION 90