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Tectonic Tessellation

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Ceramic Structural Surfaces Ceramic LAB - Harvard GSD
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Tectonic Tessellation Ceramics Structural Surfaces SCI 0642900 Material Processes and Systems: Ceramic LAB Prof. Martin Bechthold | Jonathan King Matias Imbern Felix Raspall Qi Su
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  • Tectonic TessellationCeramics Structural Surfaces

    SCI 0642900 Material Processes and Systems: Ceramic LAB

    Prof. Martin Bechthold | Jonathan King

    Matias ImbernFelix RaspallQi Su

  • [Contents]

    1 - Introduction and Precedents2 - Design Proposal a. LARGE Scale

    b. PANEL Scale

    c. MODULE Scale

    3 - Prototype Construction4 - Conclusions and Further Development

  • 1 - Introduction and Precedents2 - Design Proposal a. LARGE Scale b. PANEL Scale c. MODULE Scale

    3 - Prototype Construction4 - Conclusions and Further Development

  • Tectonic Tessellation: Ceramic Structural Surface GSD 6429: material processes and systems: ceramics LAB

    Topic: TECTONIC

    Sub-Areas:

    -Structural SurfaceEfficient / Expressive

    -One-Off FabricationNew Design Attributes / Extended Possibilities

    Proposal [>Experiments] Felix RASPALL - DDes / Qi SU - MDesS / Matas IMBERN - MDesS / TECTONICS

  • Tectonic Tessellation: Ceramic Structural Surface GSD 6429: material processes and systems: ceramics LAB

    Proposal [>Experiments] Felix RASPALL - DDes / Qi SU - MDesS / Matas IMBERN - MDesS / TECTONICS

    Why ceramic components?-Cheaper-Lighter-Rougher formwork-Delicate finishing

    Ceramic Structural Surface Today:

    -Disappearing / Not affordable anymore

    Problems:

    -Cost of hand labour-Cost of formwork-Lack of skills

  • Tectonic Tessellation: Ceramic Structural Surface GSD 6429: material processes and systems: ceramics LAB

    Eladio Dieste (1917-2000)

    Main Characteristics / Innovations:

    -Reinforced masonry

    -Reusable movable formwork.

    -Standardized bricks with different sizes, aproximately 2 inches (50mm) thick and 5 inches (125 mm) by 10 inches (250 mm) across. He also used square ceramic hollow bricks in his vaults.

    Proposal [>Experiments] Felix RASPALL - DDes / Qi SU - MDesS / Matas IMBERN - MDesS / TECTONICS

    Rafael Guastavino (18421908)

    Main Characteristics / Innovations:

    -Increase in scale.

    -Introduction of graphic analysis (previously was mostly empirical).

    -Massive application/commercial enterprise.

    -Construction without centering.

    -Terracotta tiles are standardized but with different sizes, less than an inch thick, and approximately 6 inches (150 mm) by 12 inches (300 mm) across.

  • Tectonic Tessellation: Ceramic Structural Surface GSD 6429: material processes and systems: ceramics LAB

    Gramazio & Kohler

    Main Characteristics / Innovations:

    -Robotic arm assembly.

    -Fabrication of complex geometry.

    Proposal [>Experiments] Felix RASPALL - DDes / Qi SU - MDesS / Matas IMBERN - MDesS / TECTONICS

    Solano Benitez

    Main Characteristics / Innovations:

    -Combines traditional masonry with simple prefabrication methods.

    -Prefabrication of one-ply components (folded or ribbed),

    -Large scale Vierendel-like beams, using simple or no formwork.

    -Rustic/texture ceramic slabs accentuating the material expresion.

  • 1 - Introduction and Precedents

    2 - Design Proposal a. LARGE Scale

    b. PANEL Scale

    c. MODULE Scale

    3 - Prototype Construction4 - Conclusions and Further Development

  • Tectonic Tessellation: Ceramic Structural Surface GSD 6429: material processes and systems: ceramics LAB A. Large Scale.

    The proposed system aims to create structural surfaces including compression only and shells.

    B. Panel Scale.

    The structure is subdivided in parts that are fabricated and mounted on-site.

    Compression Only Structures

    Panelization of the structure

    Simple scaffolding

    Self-supporting panelsShell Structures

  • 3- MODULE Scale A. Module Description: Two types of ceramic modules are set, one with triangu-lar shape for the first layer and another with round shape for the second layer.

    The modules of the first layer (inner layer) are hollow and have a lip with two functions: 1- provide a separation between pieces enough to pour the reinforced concrete2- produce a smooth interior surface (hiding the mortar in the joints)

    The modules of the second layer (outer) are solid tiles and they cover the panels assembling concrete as finish-ing, following a glazing pattern.

    B. Interlocking Overlapping technique requires two different triangu-lar modules, one with an inner lip and another with an slightly upper lip. The combination produces a flexible hexagonal pattern that can populate any surface.

    C. Curvature AbsorptionThe inner layer deals with curvature by producing a small separation in the lips overlapping. In the outer surface, the mortar separation is going to absorb the differences.

    Free-Form Ceramic Structural Surfaces gsd 6429: material processes and systems: ceramics LAB

    Proposal [>Experiments] Felix RASPALL - DDes / Qi SU - MDesS / Matas IMBERN - MDesS / TECTONICS

    40mm

    150mm

    30mm

    260mm

    105mm

    40mm

    150mm

    30mm

    260mm

    105mm

    FLEXIBLE HEXAGONAL GROUPINGMODULES - SIZES AND OVERLAPPING

    MODULE STUDY

    Triangle ComponentType A

    Triangle ComponentType B

    Circular Tile

    INTERLOCKING

    Tectonic Tessellation: Ceramic Structural Surface GSD 6429: material processes and systems: ceramics LAB C. Module Scale. The proposed system aims to cre-ate structural surfaces including compression only and shells.

    Module Geometry

  • Tectonic Tessellation: Ceramic Structural Surface GSD 6429: material processes and systems: ceramics LAB

  • Tectonic Tessellation: Ceramic Structural Surface GSD 6429: material processes and systems: ceramics LAB

    First Reinforcement

    Panel 1

    Reusable Form.

    Panel 2

    Second Reinforcement

    Exterior Cladding

    Panel Assembly

  • [Formwork Alternatives: Pinmold / Sand Milling]

  • Tectonic Tessellation: Ceramic Structural Surface GSD 6429: material processes and systems: ceramics LAB

    Sect

    ion

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    out c

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    Pane

    l 1

    Pane

    l 2

    Sect

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  • Tectonic Tessellation: Ceramic Structural Surface GSD 6429: material processes and systems: ceramics LAB C. Module Scale. Weight estimation

    [m2]1

    ConcreteVolume Weight

    Ceramic ModulesNumber Volume Weight

    Total Weight [kg]

    Hexagon [m2] Per Square Meter [m2] Whole Structure [m2]2.131811.0

    1.17430.01400.0]3m[8.10624.3848.9]gk[

    4.68518.056]u[0.15030.06300.0]3m[0.76318.3471.5]gk[

    7.86932.7210.51

  • 1 - Introduction and Precedents2 - Design Proposal a. LARGE Scale b. PANEL Scale c. MODULE Scale

    3 - Prototype Construction

    4 - Conclusions and Further Development

  • Module Construction - Plaster Mold

  • Module Construction - Ceramic Pieces [Casting]

  • Module Construction - Ceramic Pieces [Kiln - ConeO6]

  • Module Construction - Production Statistics

    Day Time Qty BodySlip Technique Characteristic Result Observations10Nov Afternoon 2 Porcelain Casting CompleteCap BAD TooThin15Nov Afternoon 2 WhiteStoneware Casting CompleteCap BAD Melted16Nov Afternoon 1 Porcelain Pressing CompleteCap OK16Nov Afternoon 1 WhiteStoneware Casting CompleteCap BAD Bumped17Nov Afternoon 1 WhiteStoneware Pressing CompleteCap OK

    1 WhiteStoneware Casting CompleteCap OK18Nov Afternoon 2 WhiteStoneware Casting Bricks(Solids) BAD TooHeavy19Nov Morning 2 WhiteStoneware Casting HollowCap OK

    Night 2 WhiteStoneware Casting HollowCap OK20Nov Morning 2 WhiteStoneware Casting HollowCap OK

    Night 2 WhiteStoneware Casting HollowCap OK21Nov Morning 2 WhiteStoneware Casting HollowCap OK

    Night 2 WhiteStoneware Casting HollowCap OK22Nov Morning 2 WhiteStoneware Casting HollowCap OK

    Night 2 WhiteStoneware Casting HollowCap OK23Nov Night 4 WhiteStoneware Casting HollowCap OK24Nov Morning 4 WhiteStoneware Casting HollowCap OK

    Night 4 WhiteStoneware Casting HollowCap OK25Nov Night 4 Porcelain Casting Singularities OK26Nov Night 4 Porcelain Casting Singularities OK27Nov Morning 3 Porcelain Casting Singularities OK

    1 Porcelain Casting Singularities BAD Bumped28Nov Night 2 Porcelain Casting HollowCap OK30Nov Night 4 WhiteStoneware Casting HollowCap BAD TooThickNewSlip1Dec Morning 3 WhiteStoneware Casting HollowCap OK

    1 Casting Singularities OKNight 4 WhiteStoneware Casting HollowCap OK

    2Dec Morning 4 WhiteStoneware Casting HollowCap OKNight 4 WhiteStoneware Casting HollowCap OK

    2Dec Morning 4 WhiteStoneware Casting HollowCap OKNight 4 WhiteStoneware Casting HollowCap OK

    TOTAL 80OK 68 FINALPRODUCTION FIREDBAD 12 Standard: 55 2(1exploded,1lostCAP)

    Singularities:SmallOpening 6BigOpening 3Shadow 4

    13

  • Formwork Milling - Low Density White FOAM

  • [Robotic Pick and Place]

  • [Reinforcement Layers]

  • 1 - Introduction and Precedents2 - Design Proposal a. LARGE Scale b. PANEL Scale c. MODULE Scale

    3 - Prototype Construction

    4 - Conclusions and Further Development

  • [Pick and Place Crash]

  • Tectonic Tessellation: Ceramic Structural Surface GSD 6429: material processes and systems: ceramics LAB

    Proposal [>Experiments] Felix RASPALL - DDes / Qi SU - MDesS / Matas IMBERN - MDesS / TECTONICS

    1- Re-Design the Module-Industrialization: Produce the pieces using heavy machinery and pressing technique.

  • [Pouring Concrete]

  • Tectonic Tessellation: Ceramic Structural Surface GSD 6429: material processes and systems: ceramics LAB

    Proposal [>Experiments] Felix RASPALL - DDes / Qi SU - MDesS / Matas IMBERN - MDesS / TECTONICS

    2- Reinforced Concrete-Study the possibility of robot assistance in the reinforcement placement and in the concrete pouring.

    3- Structural Performance-Provide the system with a calculation background in order to be more effective in sections.

    4- Formwork-Create a Pin Mold capable of dealing with large panels (1,5 x 1,5m).

    5- Panelization Strategy-Develop a panelization method capable of discretice complex geometries into tesselated panels, following the module logic.

    6- Assembly Sequence-Study the assembly sequence to achieve panel interlocking.

    7- New Prototype-Build a small scale structure as a first application of the construction system.

  • [Construction Sequence]

  • Tectonic TessellationCeramics Structural Surfaces

    SCI 0642900 Material Processes and Systems: Ceramic LAB

    Prof. Martin Bechthold | Jonathan King

    Matias ImbernFelix RaspallQi Su


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