BRICK CONSTRUCTION
290 MULBERRY New York, NY
Architect: SHoP Architects Client/Owner/Developer: Cardinal Real Estate Investments Structural Engineer: Robert Silman Associates MEP Engineer: Laszlo Bodak Engineer General Contractor: KISKA Group 290 Mulberry Street is a 27,000 square foot combined residential and commercial building constructed in 2008. The building’s 12 floors in- clude a ground floor retail space, 8 full floor resi- dences and a three story rooftop penthouse apart- ment. View from North
Ground Floor Retail North View of Penthouse View from South
INTRODUCTION M127 Porter House
SHoP Architects, the New York based firm that designed 290 Mulberry was founded in 1996 by a group by five principles: Christopher Sharples, Coren Sharples, William Sharples, Kimberly Holden and Gregg Pasquarelli. Today the firm employees sixty designers and staff who collectively bring a wide range of back- grounds to the practice from English to Fine Arts to Engineering. The firm actively seeks this diversity with the belief that is contributes to their ability to pro- duce innovative solutions to unique design challenges. Despite being a young firm, they have already won the 2010 Chicago Athenaeum American Architecture Award, the 2009 National Design Award for Architecture Design. They have completed many notable projects including commercial, cultural and institutional proj- ects as well several other nearby Manhattan based residential projects including the Porter House and M127 condominiums.
Proposed and Completed Projects by SHoP. Left to Right: F.I.T, NY, NY; South Street Seaport, NY, NY; P.S 1, Brooklyn, NY; Virgin Atlantic Clubhouse, JFK Airport, Long Island, NY; Mitchell Park, Greenport, NY
INTRODUCTION
Situated on the corners of Mulberry and East Houston, 290 Mulberry is part of the Nolita (North of Little Italy) neighborhood in Manhattan, New York. The neighborhood is bordered by Little Italy to the south, the East Village to the north, Soho to the west and the Lower East Side to the east. The buildings in the immediate area include many older masonry buildings such as the historically significant Puck Building located across the street at 285 Lafayette Street and the DeVinne Press Building located three blocks North on Lafayette Street and East 4th Street.
Former occupation of site
NEARBY BRICK BUILDINGS
Typical Nolita City Block Devinne Press Building Puck Building Adjacent Brick Building
INTRODUCTION The design process at SHoP was tested and altered as a result of this project. Because 290 Mulberry falls within a special zoning district, code require- ments mandated that it be clad in masonry along all street facing facades. This same zoning requirement also included a code parameter that allowed the plane of the building envelope to be broken at 10 percent for every 100 feet. Although originally intended for classical ornamentation, SHoP manipulated it to create an entirely new form based on restrictions intended for the preservation of traditional ones.
The challenge of most effectively manipulating the code parameter to produce this innovative facade required an integrated approach to design as well as a new set of tools. From the earliest stages, the architects, fabricators and construction teams worked together with the goal of producing a building whose material choices and construction methods mached it’s architectural rigor. Within the firm, new computer programs including BIM, Revit and parametric software were uti- lized to test and create various innovative forms with bricks. The final result of these efforts was a curtain wall of L-shaped brick-faced concrete panels. The brick patterning was allowed to move forward and backward on the panels to create undulations. The code parameter was employed to create the spacing between each of the panels.
The result is a unique building without precedent whose facade pays homage to it’s neighbors through the use of brick, while presenting an entirely new articula- tion of form.
Photo: Building Facade Photo: Close-up brick panel Rendering: Building Facade
INTRODUCTION Parametric software was used to test Panel layout generated throughout and create forms. Test panels were parametric design. then produced through digital fabrica- tion
One objective of the facade was to maximize the undulating pattern of the brick while minimizing the thick- ness to reduce the weight of the load on the frame of the building. Each brick is limited to move only 3/4” beyond it’s neighboring brick. The concrete which supports the brick is carved out on the back where pos- sible to reduce weight load.
INTRODUCTION Floors 2-8 Living Room Floors 2-8 Kitchen Penthouse Staircase
Private Terrace 85’ linear x 7’ wide
Bedroom Bedroom Living / Dining 13’-6” x 10’-6” Bedroom 13’-6” x 10’-6” 22’-3” x 24’-10” Living / Dining 13’-6” x 10’-6” Living / Dining 22’-3” x 24’-10” 22’-3” x 24’-10”
Living / Dining 24’-9” x 22’-4”
Kitchen Kitchen Bath Kitchen Bath Bath
W/D W/D Kitchen W/D
Bath Bath Bath Bedroom Bedroom Bedroom 10’-1” x 10’-9” 10’-1” x 10’-9” 10’-1” x 10’-9”
Bedroom Bath W/D 10’-2” x 10’-10”
WIC WIC WIC
Master Bedroom 14’-11” x 15’-11” Master Bedroom Master Bedroom 14’-11” x 15’-11” 14’-11” x 15’-11” Bedroom Master Bath Master Bath Master Bath 11’-2” x 10’-3” Bath
Private Balcony Private Balcony 13’-9” x 9’-10” 13’-9” x 9’-10”
N N Common Terrace N 16’ x 36’-8”
FLOORS 4, 6, 8 PENTHOUSE FLOOR 10 FLOORS 3, 5, 7, 9 N 1,922 sf 2,613 sf 1,922 sf 3 bedrooms p. +1.212.726.07963 bedrooms p. +1.212.726.0796 p. +1.212.726.0796 3 bedrooms 3 bathrooms w. www.290mulberry.com3 bathrooms w. www.290mulberry.com w. www.290mulberry.com Penthouse Penthouse Penthouse Floor 2 3 bathrooms Floors 3,5,7 private balcony 135 sf Floors 4,6,8 e. [email protected] private terraces 1,649 sf e. [email protected] private balcony 135 sf e. [email protected] FLOOR 2 Floor 1 Floor 2 Floor 3 Exclusive Sales Exclusive Sales 1,802 sf Exclusive Sales & Marketing by & Marketing by 3 bedrooms p. +1.212.726.0796 & Marketing by Sponsor: East Houston Partners, LLC. The complete offering terms are in an Offering Plan available from the sponsor. File No. CD07-0574. All renderings are artist’s images. Purchasers areSponsor: advised Eastthat Houston Partners, LLC. The complete offering terms are in an Offering Plan available from the sponsor. File No. CD07-0574. All renderings are artist’s images. Purchasers are advised that 3 bathrooms w. www.290mulberry.comSponsor: East Houston Partners, LLC. The complete offering terms are in an Offering Plan available from the sponsor. File No. CD07-0574. All renderings are artist’s images. Purchasersany are quoted advised floor that areas are approximate and may exceed the usable area of the premises. East Houston Partners, LLC and Core Group Marketing make no representation as to the dimensionsany andquoted actual floor areas are approximate and may exceed the usable area of the premises. East Houston Partners, LLC and Core Group Marketing make no representation as to the dimensions and actual e. [email protected] quoted floor areas are approximate and may exceed the usable area of the premises. East Houston Partners, LLC and Core Group Marketing make no representation as to the dimensionssquare footand actualarea of the premises. We are pledged to the letter and spirit of U.S. policy for the achievement of equal housing opportunity throughout the Nation. We encourage and support ansquare affirmative foot area of the premises. We are pledged to the letter and spirit of U.S. policy for the achievement of equal housing opportunity throughout the Nation. We encourage and support an affirmative common terrace 737 sf square foot area of the premises. We are pledged to the letter and spirit of U.S. policy for the achievement of equal housing opportunity throughout the Nation. We encourage and supportadvertising an affirmative and marketing program in which there are no barriers to obtaining housing because of race, color, religion, sex, handicap, familial status, or national origin. advertising and marketing program in which there are no barriers to obtaining housing because of race, color, religion, sex, handicap, familial status, or national origin. advertising and marketing program in which there are no barriers to obtaining housing because of race, color, religion, sex, handicap, familial status, or national origin.
Exclusive Sales & Marketing by
Sponsor: East Houston Partners, LLC. The complete offering terms are in an Offering Plan available from the sponsor. File No. CD07-0574. All renderings are artist’s images. Purchasers are advised that any quoted floor areas are approximate and may exceed the usable area of the premises. East Houston Partners, LLC and Core Group Marketing make no representation as to the dimensions and actual square foot area of the premises. We are pledged to the letter and spirit of U.S. policy for the achievement of equal housing opportunity throughout the Nation. We encourage and support an affirmative advertising and marketing program in which thereINTRODUCTION are no barriers to obtaining housing because of race, color, religion, sex, handicap, familial status, or national origin. Section Detail through brick + concrete panel
North wall section South wall section through brick + concrete through aluminum pan- panels els
Exterior Curtain Wall Interior Structural Wall
290 Mulberry employs a dual-layer method of construction on the north and west facing facades. The exterior layer, an innovative curtain wall com- prised of brick and concrete panels clads a more normative structural inte- rior layer. Both the curtain wall and interior layer contain insulation while the interior layer provides all the structural support for the building.
INTRODUCTION On-site and pre-fabrication construction methods were employed at 290 Mulberry. The brick and concrete panel curtain wall was pre- fabricated outside Manhattan while the remaining construction was completed on-site. For the on-site portion of construction, the first step involved clearing and preparing the site. A foundation was then poured to support cast in place concrete columns and beams. The columns and beams form rigid joints (as op- posed to diagonal bracing or shear panels) to provide lateral support. The east facade is constructed of CMU and the south facade is clad with aluminum panels. The street facing north and west facades are clad with the brick and concrete panels. These panels were constructed off-site in a four part process before being trucked to the site. In the first phases of construction of the panels, rubber forms were created to hold the bricks in their proper position as determined by the employed parametric software. The form was placed face down and the bricks were positioned in it accordingly. Once the bricks were laid, a wooden form was built around the rubber one and concrete was poured into the form. Once dry, both the rubber and wood forms were removed and the panel was complete.
Many considerations pertaining to passive and sustainable design will be further discussed, but perhaps the most significant contribution to sustainability is the method of production and construction at 290 Mulberry. The pre-fabrication process played a major role in SHoP’s ecological approach to the building. The abil- ity to produce a large portion of the building off-site (in this case the concrete and brick panels) allowed for considerable ecological benefits as well as econom- ic ones. The economic benefits are critical allowing it to serve as an example that pre-fabricated buildings can be both interesting and economically viable. More broadly speaking, pre-fabrication provides a level of control not available on site. This is particularly true in Manhattan where space is severely limited. Off-site production can also increase accuracy, allow for re-use of forms and reduce material waste and the need for scaffolding on site. Although not marketed as a sus- tainable building 290 Mulberry serves as an important model, particularly within the architectural community of how construction methods in conjunction with conscious material and orientation consideration (which will be discussed further) can have meaningful ecological, socioeconomic and architectural results.
CONSTRUCTION ON SITE
I: Clear and prepare site for II: Pour cast-in place founda- III: Pour cast-in place col- IV: Secure Panels to Struc- V: Install Windows, Glass construction tion umns and floors. Construct ture. Secure aluminum panels Doors at Street Level and CMU fire wall on east fa- to south facade. Finish Interior. cade.
OFF SITE
1+11: Create Forms for ar- III: Pour concrete onto back of IV: Remove Forms and trans- ranging brick + Lay Bricks brick while in form port to site into Form (prototype rubber form pictured)
CONSTRUCTION North + West Facade (left to right) West + South Facades (left to right) South + East Facades (left to right)
Primary Materials: The ground floor, penthouse apartment and south facade are clad in aluminum paneling. The east facade is constructed of CMU. The remaining north and west facades are clad in a curtain wall of brick faced concrete panels. Glass is employed in windows and doors throughout the building, but most extensively on the ground floor and the penthouse. It also used for railing on the east and south ends of the penthouse terraces.
MASSING + MATERIAL MODEL OF BUILDING MASSING MODEL OF SITE SOUTH VIEW OF SITE
December 21 March 21
September 21 June 21 SOLAR ANIMATIONS UPPER VIEW OF SITE
March 21 December 21 March 21
September 21 June 21 SOLAR ANIMATIONS INTERIOR: LIVING ROOM FLOOR 4
December 21 March 21
September 21 June 21 SOLAR ANIMATIONS INTERIOR: LIVING ROOM PENTHOUSE 1
March 21 December 21 March 21
September 21 June 21 SOLAR ANIMATIONS SHoP historically places strong emphasis on ecologically conscious design. Their project “Garden Street Lofts” in Hoboken, New Jersey won the 2008 “Beyond Green” award given by the Sustainable Buildings Industry Council. They have also been commissioned to design a master plan for sustainable development in a region outside Delhi, India and an innovation hub in Botswana which as a requirement needed to use the most cutting-edge green technologies available. 290 Mul- berry is not overtly sustainable like many other of the firm’s projects, but there was most certainly an effort to incorporate sustainable methods.
The climate of New York City is seasonally-affected with record temperatures ranging from -15F in January to 106F in July. Despite this, New York is technically classified as a subtropical climate by the Koppen climate classification. While winters are cold, temperatures are not consistently low enough to support persis- tent snow cover resulting in this seemingly inappropriate classification. Rather than snow filled, winters are generally cold and wet with average temperatures in the 20s and 30s In contrast, summers are hot and humid. Average daily temperatures often exceed 90F. Spring and fall are usually mild and more pleasant, but weather patterns can also be less predictable during these seasons. Prevailing winds come from the south-west and the area averages 234 days of sunshine yearly.
Other factors not directly related to weather patterns also contribute to the overall climate of Manhattan. New York is the most densely populated city in the United States. Despite being incredibly energy efficient overall (New Yorkers have one of the smallest carbon footprints in the country), the city still suffers from considerable localized pollution as a result of it’s density. Manhattan is also affected by UHI, urban heat island phenomenon. UHI occurs in metropolitan areas where the urban area is notably warmer than it’s surrounding suburban and rural areas. This is a result of the thermally massive materials of the built environment retaining greater heat than the less thermally massive surrounding suburban and rural areas. Generally, temperature differences as a result of UHI are most promi- nent at night when rural areas are unable to retain heat from the daytime sun and urban areas are unable to release that heat from their thermally massive infra- structure.
Unlike most other areas of the north-east where passive solar design focuses on retaining heat during colder months, the micro-climate of Manhattan arguably re- quires a stronger emphasis on designing for reduced heat transmission during hotter months. Examination of layout and materials at 290 Mulberry reveals many passive solar considerations that seek to do so.
Normally in colder climates, the south facade is employed to maximize thermal retention in the winter (while generally also providing shading devices for use in the summer). Often the result is a south facade with large glass expanses or thermally massive material. At 290 Mulberry, the south facade (with the exception of the penthouse which has large floor to ceiling to windows in the stairwell) contains only small windows and glass patio doors that are shielded from direct sun- light most of the day by an overhang from the patio above. The south facade is clad in aluminum panels which have a high SRI value, or solar reflectivity. This means that rather than absorb heat from the sun, they reflect it away from the building serving to keep it cool. Aluminum is also particularly suitable because it has a low R-value and would therefore quickly cool once out of direct sunlight thereby reducing the nighttime effects of UHI. Beyond passive solar considerations, aluminum also offers some ecological benefits. Although not generally thought to be a sustainable material due to it’s manufacturing process, when life cycle anal- ysis is taken into account it becomes a logical option. Aluminum is recyclable, long lasting, requires practically no maintenance and withstands corrosion extreme- ly well, an important factor in polluted areas like Manhattan where corrosion can greatly reduce life cycle and thereby increase need for replacement and waste.
Wind was also likely considered as a passive cooling device. The prevailing SW winds in Manhattan would create cross breezes in the living space allowing for a cooling effect. The penthouse levels which include extensive use of glass would likely be very hot during the summer, but would benefit from the most exposure to winds and the greatest capacity to move that wind from exterior to interior due to the use of french doors on both levels of the terrace.
Despite the aforementioned advantages of passive design to decrease cooling needs during the summer, 290 Mulberry would seemingly provide less passive solar benefits in colder months. With an assumed lower R-value on the south facade, heat from the interior would escape quickly. It is important to note that the alu- minum panels likely contain some degree of insulation so they would offer some degree of insulation, but to what degree is not known. The more thermally mas- sive north and west facades receive less light than the south facade, but would retain more of it reducing flow of heat to the exterior.
It could be argued that the floor plan was arranged to mitigate any concerns about occupant comfort level by syncing the solar and seasonal cycles with human occupation cycles. The living spaces which are positioned toward the north and west facades would likely experience minimal temperature swings between day and night due to the thermal mass of those facades. Their placement was likely based on their more frequent use and the resulting need for consistent conditioning. In contrast, the master bedroom would experience greater fluctuations. Without significant thermal mass, the nighttime temperatures would likely be much cooler than the daytime temperature. Since the bedroom is typically only used in the evening (and a colder temperature is often desirable) these fluctuations wouldn’t necessarily be problematic. CLIMATE RESPONSE ASSESSMENT AVERAGE HIGH AND LOW TEMPERATURES
Jan Feb Mar Apr May June July Aug Sept Oct Nov Dec 90F 80F
70F
60F
50F
40F Average High
30F Average Low 20F Average temperatures in New York City reveal a seasonally affected climate with a cold winter and hot summer.
UHI: URBAN HEAT ISLAND PHENOMENON
Daytime Temp (Average) Urban Heat Island Phenomenon occurs in cities. High density of thermally massive materials creates high heat absorption and retention. This creates higher aver- age temperatures in urban areas relative
Temperature to surrounding suburban and rural commu- Evening Temp nities. The condition is particularly pro- nounced at night due to the slow release (Average) of heat from the thermally massive urban Rural Suburban Urban Suburban Rural structure and the much quicker release of heat from suburban and rural areas with little thermally massive building.
CLIMATE RESPONSE ASSESSMENT WIND RELATED MICRO-CLIMATE
Winds in New York range in speed from 10-13mph and come from the S + SW directions. Rising above surround- ing buildings and with terraces facing prevailing winds, the penthouse would experience a windy micro-climate. LOCAL WIND PATTERNS - EFFECTS ON THE PENTHOUSE
Wind plays a significant role in occupant comfort level of the pent- house. Extensive use of glass on these levels would result in high interior temperatures during warm months. However, the cooling ef- fect of S and SW winds would provide alleviation of this condition. Because wind speeds are generally calmer during warmer months (see chart in Design Intervention section), this creates an ideal gen- tle breeze, rather than a more aggressive and uncomfortable one as would be experienced during winter months.
MICRO-CLIMATE + PASSIVE DESIGN DIAGRAMS LOCAL WIND PATTERNS
Similar to the penthouse, upper level apartments are not blocked by surrounding buildings and receive more sunlight during the day causing increased temperatures in compari- son to lower floors. Along with the the sun, these apart- ments are also exposed to the prevailing winds. If windows are opened on the west and north facades, SW breezes have the potential to create a cross-breeze in the living space providing cooling in the space.
Living spaces in the upper floor apartments receive considerable passive heat from the sun.
Cross breezes alleviate excessive heat in these rooms.
MICRO-CLIMATE + PASSIVE DESIGN DIAGRAMS EFFECTS OF DENSITY
EFFECTS OF UHI ON THE SITE
During the day, heat from the sun is absorbed by the ther- mal mass of the city. At night, air temperatures cool and buildings release heat, but much of it is retained creating a warm evening micro- climate in New York.
MICRO-CLIMATE + PASSIVE DESIGN DIAGRAMS POLLUTED MICRO-CLIMATE
Street level pollution created by car traf- fic travels up through the urban infra- structure and into the atmosphere. Lower level apartments closest to the higher density pollution levels are also blocked by surrounding buildings from prevailing winds. With windows open, these apart- ments would be introducing polluted air to the apartment with less ability than upper level apartments to create circulation.
MICRO-CLIMATE + PASSIVE DESIGN DIAGRAMS Daytime Daytime REFLECTIVITY + R-VALUE Evening Evening
MATERIALS + TEMPERATURES DURING THE DAY MATERIALS + TEMPERATURES AT NIGHT
EFFECTS OF MATERIAL PROPERTIES ON PASSIVE SOLAR
The two main facade materials, brick and aluminum, have very different thermal properties. Brick is a non-reflective surface with a higher R-value. It absorbs heat during the day and retains and re- leases that heat slowly at night allowing for a more constant temperature during a 24-hour period. Aluminum is a reflective surface with a low R-value. As a result, it absorbs little heat throughout the day and cools quickly at night creating greater fluctuations in temperature.
MICRO-CLIMATE + PASSIVE DESIGN DIAGRAMS LAYOUT CONSIDERATIONS
MATERIALS + TEMPERATURES AT NIGHT Living spaces, which are used throughout the day and arguably benefit more from consistent temperatures, are positioned near the more thermally massive north and west facades which absorb and release heat more slowly creating less dramatic temperature changes throughout the day than the aluminum facade which re- tains little heat and cools quickly at night. The master bedroom, which is used most extensively at night, and therefore more tolerant of day to night temperature swings, is placed along this facade.
DAY TIME INTERIOR TEMPERATURES NIGHT TIME INTERIOR TEMPERATURES
MICRO-CLIMATE + PASSIVE DESIGN DIAGRAMS Bricks are a small unit building material made from clay that come in a wide array of sizes and types and can be arranged in various pat- terns, or bonds (see diagram at right) based on structural requirements of the building and aesthetic preference. Assembly of bricks into bonds requires mor- tar which is laid between the bricks to bond them together.
BRICK SIZES AND TYPES SOLID BRICK VS. CORED BRICKS
Cored bricks have holes in them while SOLID BRICK solid bricks do not. Solid brick is a strong material, but cored brick offers two main advantages over solid brick. It is lighter and therefore cheaper to ship. It is also able to create a stronger bond with the mortar because the mortar is able to sink into the brick and grab onto it.
ADDITIONAL BRICK TYPES CORED BRICK BUILDING BRICK (Common or Hard Brick): Generally used for backing cours- es. Has no special markings, texture or color.
FACE BRICK: High quality with strong durability. Available in various colors including brown, red, gray, yellow and white. Generally used in exposed wall faces.
PRESSED BRICK: Regular, smooth faces, sharp edges and perfectly square corners. Like face brick, it is used for exposed walls.
FIRE BRICK: Made from clay with few im- purities and able to withstand high tem- peratures. Larger than most bricks. Used in fireplaces, boiler rooms or areas with potential exposure to high temperatures or fire.
MATERIAL ASSESSMENT MASONRY ASSEMBLY: KEY TERMS
Stretcher - masonry unit laid horizontally with the longer edge exposed or parallel to the surface
Header - masonry unit laid horizontally with the shorter end exposed or parallel to the surface
Course - continuous horizontal range of masonry units
Bed Joint - horizontal joint between two masonry units
Head Joint - vertical joint between two masonry units
BOND TYPES
Running bond - overlapping stretchers
Common - headers placed every five or six courses of stretches
Flemish - alternating headers and stretchers in each course
Stack - successive courses of stretchers
English - Alternate courses of headers and stretchers
MATERIAL ASSESSMENT The long history of brick construction is a testament to its many advantages Brick is the oldest known building material, the first discovered use of which dates back approximately 6000 years to the city of Babylonia. It remains a widely used building material today. While there are myr- iad types with varying physical and thermal properties, generally brick is extremely durable, relatively inexperience and requires little maintenance. It can with- stand extreme weather and provides excellent fire resistance and thermal massing. Despite a high embodied energy due to it’s manufacturing process, brick can be a sustainable material choice when considered in regard to life cycle analysis. It’s durability and low maintenance make it an extremely long lasting material and should the need arise, brick can also be recycled. Despite an energy intensive production process, very little clay is wasted during that process since damaged or less than perfect bricks can be crushed and used for other applications.
There are also disadvantages to consider when using brick. Although generally a durable material, brick is susceptible to moisture penetration. In particular, this can present concerns in colder climates where frost can further contribute to water damage. Brick is also prone to deterioration as a result of pollution and plants such as a moss which introduce compounds to the brick that can react negatively with it’s own compounds and lead to decay. Unlike bricks, the mortar used to bind them together (referred to as pointing) does deteriorate naturally over time. Quality mortar will generally last 30-40 years at which point it will start to crumble and require re-pointing, a process which requires removing loose mortar and laying new mortar.
DISADVANTAGE: ADVANTAGE: ADVANTAGE: Brick lasts hundreds of years, but Brick is extremely fire resistant. The above Brick provides thermal mass to a building. The above dia- mortar deteriorates over time and diagram details assembly for a 2-hour fire rated gram examines various construction methods and their rela- will require repointing every 30-40 brick veneer wall. tive ability to insulate buildings from heat. years.
MATERIAL ASSESSMENT HISTORICAL EXAMPLES OF BRICK CONSTRUCTION
Restored walls of the palace of Nebuchadne- zzar in Babylon. circa 600 BC Shibam - the “Manhattan of the Desert” was con- structed in the 16th century by mud bricks.
Washington Mills (originally the Bay State Mills), The Rotunda, University of Virginia, Charlottesville, VA. Lawrence, MA. 1846 1822-1826
MATERIAL ASSESSMENT Today, brick is most commonly used as a veneer on existing or new construction. Brick veneers require the construction of a wood, CMU or steel load bearing wall onto which the veneer is applied by an anchoring system. Brick veneers increase the thermal mass and R-value of a wall. They also pro- vide acoustic dampening and increase fire resistance.
Brick
Structural CMU
Anchors
A wide variety of anchors are used to tie brick veneers to the structure of the building. Brick veneer walls require a structural wall which they are attached to through the use of an anchoring system.
MATERIAL ASSESSMENT Structural brick construction offers the advantage of providing both the structural and aesthetic functions of a wall. Rather than being attached to a separately constructed and load bearing wall, unreinforced brick provides the structure of the building. One or more layers of stretcher bricks are laid in cours- es. Mortar is laid between the bricks to bind them together forming mortar joints. Mortar joints are typically 3/8” thick, but can vary from 1/4” to 1/2” thick. Both brick veneers and structural bricks can be laid in a wide range of patterns (see diagram “Bond Types” on previous page), but the structural construction of brick limits pattern choice. Only overlapping patterns can be used and for this reason stock bond, for example, can only be used on brick veneers.
Structural brick requires some specific considerations. Most importantly, it does not have a high compressive strength and as a result will not withstand twist- ing forces well. Without reinforcement, brick buildings are some of the most vulnerable in earthquakes. Although bricks were originally used in earthquake prone areas and some of those buildings still survive today, unreinforced brick construction is not recommended in earthquake prone areas and is best suited for low and medium rise buildings. Structural brick requires a strong foundation in order to avoid cracking of the mortar joints which can create structural and water penetration problems. Similarly, well-crafted mortar joints in a structural brick wall are extremely important and therefore skilled craftsmen should be employed, Unlike in brick veneers, decaying mortar joints are not just an aesthetic problem, but a structural one. Additionally, while brick does retain heat, it often requires additional insulation in cooler climates.
Structural brick construction does not require a structural wall and supports itself as well as all other elements of the building. Structural brick can be rein- forced to increase strength (above) or it can be unreinforced (left). It is impor- tant to consider application when using unreinforced brick construction as it has limited structural applications.
MATERIAL ASSESSMENT Originally made by mud and produced by hand, brick manfacturing moved to factories following the mid-19th cen- tury. While brick in developing nations is often still made by hand, nearly all brick in the United States and most of the developed world is made in factories today. Although manufacturing processes can vary between individual plants, it is relatively standard.
The first step in the manufacturing process involves acquiring the raw materials necessary to form the brick. The process of extracting clay from a quarry is called “clay winnning”. Since no clay can be used in it’s raw state, once it is winned the clay must be “prepared”. The preparation process involves grinding or breaking up the material to eliminate any large clay lumps and stones and mixing it with water, if necessary, to form a mouldable material. The resulting material, both malleable and free of large particles, is formed into the desired brick size and shape using one of the following processes, the most common of which is extrusion.
I: EXTRUDED (STIFF MUD): prepared clay is put into a machine that introduces water to the mixture, removes trapped air and then transfers the mixture to an auger machine. The auger forces or extrudes the wet clay through a die that forms a continuous rectangle-shaped column. The column is cut with steel wires into desired lengths.
II: MOLDED (SOFT MUD): If the mud is too wet to undergo the stiff mud process, the molded or soft mud process is em- ployed. The clay is mixed, extruded, and placed in lubricated molds. Each mold makes six to eight bricks. The drying process takes more time than with stiff mud, but the firing procedure is the same.
III: DRY-PRESSED: If the clay has minimal water content the dry-pressed process is employed. In this process, the prepared material is exposed to high pressure while in the mold.
In each of these cases, once formed, the brick is dried, then fired and finally cooled. At that point the brick is ready for use and is shipped from the factory for distribution.
Production Process Post-Extraction
MATERIAL ASSESSMENT In the past (and still today in developing coun- During the mid 19th-century brick production Today, particularly in the United States and tries), bricks were shaped by hand from mud and moved to factories. other developed nations, bricks are produced laid to dry in the sun. in factories.
Clay being extracted for production. Extruded brick being made.
MATERIAL ASSESSMENT Despite ancient roots, the introduction of the steel girder frame in the mid-1880’s initiated a shift away from the use of brick and towards more modern materials. The steel girder frame eliminated the reliance on brick as a structural material. The rise of the International Style in the 1920’s and 1930’s with its emphasis on functionality created a stigma that since it was not needed for structural properties brick no longer played a role in high architecture. Post modernism would ul- timately reintroduce brick as a legitimate material, but despite that, still today other more modern materials including glass, fabricated wood or concrete, continue to overwhelm brick in their ability to produce innovative, acclaimed architecture. In recent years, firms such as SHoP have been critical to demonstrating the abil- ity of brick to achieve the allure of these other materials.
Although employed as a result of code requirements, 290 Mulberry is at the center of these projects which are legitimizing the use of brick in modern architec- ture. The challenge of creating a new form with a traditional material pushed SHoP to utilize new tools and produce new forms. The resulting udulating facade while unique and innovative, could arguably be classified as part of a larger movement toward the reintroduction of brick as a glamorous modern building material.
Whether veneer or structural, brick is generally meant to read as structure and therefore to give a sense of strength and stability. However, new experimentations with the movement of brick front to back has given brick facades a three-dimensionality not before encountered. Shifting bricks front to back was generally very limited and reserved for ornamentation, but when applied across a facade like at 290 Mulberry it imbues brick with a sense of life and a more flexible, malleable form. At 290 Mulberry, undulating facades created through parametric design give a sense of movement. As you approach the building, the brick appears to flow across the facade. These characteristics are not typical of traditional brick construction, but appear to varying degrees in other recent architectural works as well. including buildings by Mark Koehler and most notably, Office DA.
These results are striking, but they also call into question the performance of the material compared to more traditional uses. The shifting of bricks front to back creates ledges that are easily susceptible to water penetration. Although there is no documented evidence of these concerns at 290 Mulberry or other build- ings, this could create future maintenance issues. Additionally, the placement of brick in many of these buildings reduces thermal mass. At 290 Mulberry, the brick is backed with concrete resulting in thermally massive panels which help to insulate the building. However, at other buildings, this is not the case and in some cases patterns even allow for the selective reduction of brick creating openings and opportunities for thermal loss.
MATERIAL ASSESSMENT Office DA. Casa la Roca
Marc Koehler. Iijburg House. Algorithmic Brick Patterning - the use of computers to create innovative forms with brick has lead to many excit- ing applications of the material in the built environment. MATERIAL ASSESSMENT Rendering completed in Rhino of panel form and partial application of bricks at 290 Mulberry.
Far Left: Typical brick construction does not permit individual bricks to move front to back allowing water to flow down the facade with ease.
Near Left: Movement of brick in the front to back direction at 290 Mul- berry creates ledges and allows water to pool near these mortar joints po- tentially leading to faster decay of the mortar and facade.
MATERIAL ASSESSMENT Daytime Evening
Compared to less thermally mas- sive or relfective materials, brick panels at 290 Mulberry absorb and retain heat creating insu- lation and allowing for a more consistent interior temperature along the north and west fa- cades.
MATERIAL ASSESSMENT Further intervention could improve the overall energy efficiency of 29 Mulberry particularly for heating during the winter. The installation of a wind cowl system on the roof could reduce or eliminate the need for mechanical heating of the building. It also has a local historical reference. The first urban wind- mill, although employing a different technology, was erected on a co-op in New York City. It supplied 110% of common energy needs. The excess 10% was given back to the northeastern power grid.
In incorporating wind power I propose eliminating access from the penthouse apartment to the outdoor space on the top floor. This elimination is justified by the fact that the outdoor space is not annexed to any interior space on the same level and is therefore unlikely to be used as frequently by occupants as the apart- ment’s two other terraces which are both of considerable size. The top floor also houses a small mechanical room which would be maintained for backup heating and cooling needs. Ideally, the wind cowl system would ultimately replace the need for mechanical heating and the room could be eliminated in order to give out- door space back to the penthouse apartment or to install further wind cowls for additional energy production.
Based on the BedZed project in Hackbridge, London, England, the wind cowl system provides fresh, conditioned air using only renewable energy. Wind cowls placed on the roof of a building are positioned in the direction of the most frequent and heaviest winds. Air brought into the cowl is distributed through the building via a network of duct systems. Air being extracted from the building returns through those same ducts. The placement of these ducts in the apartment is critical. Incoming air ducts must be placed low to the ground towards the exterior of the building while outgoing air ducts are placed centrally and higher up. The goal of this placement is to filter out the hotter vitiated air in the building which naturally rises to the ceiling. As this warmer exits through the duct system it is used to heat the incoming air. This is allowed by the placement of a thin plastic divider which separates incoming and outgoing air, but allows for the heating of the incoming air by the outgoing air. The benefits are many: vitiated air is expelled, fresh air is drawn in and warmed and the interior temperature is less prone to drastic fluctuations.
This system is particularly relevant at 290 Mulberry because it can be used to address the issue of heating during the winter which seems to have received less passive design focus than cooling during the summer. It is also a well suited intervention because wind speeds in New York are typically greatest during the cold- er months increasing the system’s effectiveness to provide ventilation. In addition, winds come from the SW direction allowing the terrace to be used since it is open to the SW direction.
Normally such a wind cowl system requires non-operable windows. The concept relies heavily on the fact that air is only circulated through the cowls. However, since the wind provides cross breezes to the building, a considerable benefit during the summer, I propose maintaining the existing windows under the assumption that it would be against the interest of occupant comfort to open the windows during cooler weather when the wind cowl system would be operating.
The anticipated performance of the system, based on performance at BedZed reveals it would operate at least as well, if not better, than the system at BedZed. At BedZed winds of 4 m/s (apx. 9mph), create a flow rate of 50-70 liters per second and allow each cowl to provide natural ventilation for 350m^3 (12,360 feet^3). Since wind speeds are higher in New York, an individual cowl could theoretically produce a flow rate of 77.6liters per second and provide natural venti- lation to apx. 16,000 feet^3. The chart on the following page details the conditions at 290 Mulberry and anticipates the buildings need based on the performance at BedZed.
DESIGN INTERVENTION Rendering of cowl unit
Wind cowls placed on the roof are positioned in the direction of prevailing winds. Air brought into the cowl is distributed through the building via a network of duct systems. Air being ex- tracted from the building returns through those same ducts. Asthe air exits through the duct system it is used to heat the incoming air. This is allowed by the placement of a thin plastic di- vider which separates incoming and outgoing air, but allows for the heating of the incoming air by the outgoing air.
DESIGN INTERVENTION MANHATTAN WIND DATA
Jan Feb Mar Apr May Jun July Aug Sept Oct Nov Dec Wind Direction 225 216 182 197 179 208 179 194 167 215 166 202 (in degrees) 11 12 11 10 10 11 13 Wind Speed 13 13 11 11 13 (in mph)
PERFORMANCE AT BEDZED ANTICIPATED PERFORMANCE AT 290 MULBERRY Average Flow Rate Natural Justification Wind Speed ventilation Level Cubed Units Units provided Footage Required in Design Air has much further to 4 m/s 60 (avg.) 350m^3 Ground travel requiring addi- 20,000- 1.5 2 8.95mph liters per 12,360ft^3 Floor 25,000 tional cowls. second Lower floors will require 6.7 (avg.) 1mph 1,380.2ft^3 Floors 2-9 20,181ft^3 1.26 1.5 more than 1.26 due to dis- liters per tance. Upper floors will second require more due to in- creased sun exposure.
Increased sun expo- 1.72 2 sure requires additional CONDITIONS AT 290 MULBERRY Penthouse 27,436ft^3 cowls. Predicted Average Predicted Natural Wind Speed Flow Rate Ventilation
11.583mph 77.6 (avg.) liters per 15,986.9ft^3 second
DESIGN INTERVENTION <2-8 <2-8 <2-8 <2-8 <2-8 <2-8 <2-8 <2-8 <2-8 <2-8 <2-8 Proposed Placement of Cowls at 290 Mulberry DESIGN INTERVENTION ALUMINUM PANELS http://www.endicott.com/pdf/Endicott_BrickDetails0410.pdf www.metalwerksusa.com http://besharp.archidev.org/spip.php?article66 http://books.google.com/books?id=xPpB4bntJLAC&pg=PA256&lpg=PA256&dq=aluminum+panels+sustainable&source=bl&ots=mvizLc_q5e&sig=z9mboRXSFod6am PL5ZfUoWYz0w8&hl=en&ei=22vkTKTJI8X6lwe79bDLDg&sa=X&oi=book_result&ct=result&resnum=6&ved=0CDoQ6AEwBQ#v=onepage&q&f=false CLIMATE DATA http://www.energy-design-tools.aud.ucla.edu/ www.weather.com www.weatherunderground.com BRICK CONSTRUCTION - TECHNICAL INFORMATION www.gobrick.com Building Constructed Illustrated, Francis D.K. Ching, 4th Edition How Buildings Work, Edward Allen, 3rd Edition http://www.fullbrick.com.au/advantage1.php Complete Concrete, Masonry + Brick Handbook, J.T. Adams, 1983 BRICK HISTORY Brick Work, Andrew Plumridge + Wim Meulenkamp 290 MULBERRY PROJECT INFORMATION + IMAGES www.290mulberry.com www.shop.com Integrated Design in Contemporary Architecture, Kiel Moe, www.curbedny.com www.flickr.com http://www.observer.com/2009/real-estate/building-stories 290-mulberry-confounds-critics-fans-alike www.archdaily.com http://usa.autodesk.com/adsk/servlet/item?siteID=123112&id=12138814 http://www.youtube.com/watch?v=3fN7wxgsteI http://www.lbepc.com/ www.lbepc.com BEDZED + WIND COWL INFORMATION “BedZed” by Chris Twinn from Arup Journal, 1/2003 www.mnn.com/green-tech/research/innovations/stories/a-mightywind http://www.zedfactory.com/loadreduction.pdf ANNOTATED BIBLIOGRAPHY