.fabfield structural design and development for CNC-milled based wood construction Aloysius Kevin Gunawan/4502396 The version of this thesis has been shortened in order to protect COLOPHON confidential data provided by company ECOnnect involved in this research. For more information regarding non-disclosed items Report P5 please contact ir. PMM Stoutjesdijk at [email protected] Master Thesis Title FabField : Structural Design and Development for CNC-milled Based Wood Construction University Technical University of Delft Faculty of Architecture & the Built Environment Master Building Technolofy Tutors Dr. Ing. Marcel Bilow Ir. Peter Eigenraam Ir. Pieter Stoutjesdijk External Examinator Henri van Bennekom Date 06-07-2016 Student Aloysius Kevin (Kevin) Gunawan 4502396 [email protected] 01 RESEARCH 6 Research framework 7 Environmental problem 8 Adaptability problem 8 Efficiency problem 9 IFD building 10 Flexible structure 13 02 PRECEDENT STUDY 16 PO-Lab 18 Building system 20 03 PROBLEM STATEMENT 28 Original Hypothesis 28 Calculation 34 Problem Statement 35 04 METHODOLOGY 38 table of contents Methodology sequence 42 05 CONCEPT DEVELOPMENT 46 Weight 48 Matrix 49 00 Wall to wall connection 50 Wall to wall connection calculation 50 Design alternatives 53 Floor to floor connection 64 Floor to floor connection calculation 64 Design alternatives 65 Design concept 72 06 DESIGN 74 Design proposal 75 07 PROTOTYPE 78 Floor, wall blocks, and beam 80 Assembly 82 Remarks 83 08 CONCLUSION & RECOMMENDATION 84 Conclusion 85 Future recommendation 87 09 BIBLIOGRAPHY 88 10 APPENDICES 90 Research//RESE FrameworkARCH FRAMEWORK ENVIRONMENTAL ADAPTABILITY EFFICIENCY PROBLEM PROBLEM PROBLEM CONCLUSION The needs for IFD BUILDING INDUSTRIAL FLEXIBLE DEMOUNTABLE research PROBLEM The needs for dynamic STRUCTURAL calculation 01 LITERATURE RESEARCH IFD Buildings references Structural calculation of the references Dynamic structural calculation + interface references TECHNICAL BASIS Parametric Design Structural Design Digital Product Manufacturing Development Grasshopper Flexible structure CNC Milling Industrial Karamba OSB Structure Flexible Rhino Demountable Figure 1 (own illust.) : Research framework 1. Environmental Problem Following today’s trends of fast-cycling market changes, Satisfying user requirements depends on the supplied it becomes very difficult to predict future scenarios for quality of the building. If user requirements are expect- In 2010, more than half of the world’s population are liv- share of embodied energy in a building is going to play ed to increase over time, the importance of improve- ing in man-made environments and this statistic will still a significant role as the percentage of embodied energy ment of the level of functionality in the initial building grow rapidly. Meanwhile, the emissions of carbon diox- compared to the total energy balance is rising (Mumma, design is tantamount. The supplied functionality is, ide - which causes global warming - are expected to in- 1995). therefore, larger and the decrease may be less substan- crease up to 45% - 90% and the total energy consumption tial (see figure 5). User requirements change during the by 2005 will have doubled (UN estimates). Recent studies The impact of the amount of energy needed for building, lifespan of a building. People roughly spend 80% of their also stated that the construction industry is the greatest maintaining and demolishing a building is well illustrat- time inside buildings; logically the user always looks for consumer of world’s natural resources and energy (40% ed by an analysis by Ding (2007)of 20 Australian schools. the solution that meets his/her demands best. of worldwide energy consumption), as well as the great- According to this analysis, the amount of energy needed Figure 3: The pulse of change in dwellings (Rigo, 1999) est dumper of waste. for building maintaining and demolishing those is about the use of buildings. Recent research done by one of the 3. Efficiency Problem the same as 37 years of energy to operate a school. This biggest housing corporations in Amsterdam illustrates Currently, reducing the energy consumption of the build- includes heating, cooling and electricity use. Problems of conventional construction method is: that the recurrence of changing sequences in dwellings ing industry is a crucial issue. The conventional focus in is increasing. Dwellings whose design life is 50 years be- reduction effort in Quality x Scope = Cost x Time gin to change within three years. On average, the whole the operational en- 2. Adaptability problem ergy consumption, dwelling is transformed within 25 years (Figure 3). Buildings should be able to adapt to different life phases In automotive, shipbuilding, and aircraft : e.g. smart HVAC and of their users and to maintain building standards since The types and terms of change in user requirements in lighting system or PV Quality x Scope > Cost x Time human behavior does not remain constant. the use of buildings are characterized and illustrated in panels integrated in figure 4 .They are defined with the help of related re- building envelopes It seems to easy to dismiss the manufacturing industries search projects executed by Hek et al. (2004), Dobbel- to generate ener- for having no relevance for architecture. (Kieran & Tim- If these requirements cannot be met within the context of steen (2004) and Post et al. (2006). This shows that users gy. However, energy berlake, 2004) inhabited spaces, these spaces are abandoned. This, for tend to change their preferences throughout the year, reduction potential example, is the problem with social housing in the Neth- which shows the needs of adaptability aspect in their lies in the initial part erlands. Decision-making on construction of dwellings dwellings. of the design itself: 3.1. Current Situation material choices, was based on the short-term view of the current state of manufacturing pro- housing, and not on a long-term survey of users’ needs and market conditions. Nowadays, architect is excluded from the making pro- cesses, and end-of cess. Yet back then, architects, engineers, and con- life possibilities. Therefore, most apartment blocks are demolished be- tractors were all the same person. Architect worked as “master builder” who controlled the whole design and The conventional cause of their inability to adapt to new requirements. It has been recently reported that demolition contractors making process. Since then, design and construction building industry are treated as two independent products. This results has a limited under- in the Netherlands expect to demolish hundreds of thou- Figure 2 : Dominant linear model of life cycle of sands of apartment blocks in the coming decade. This will in a conflict in between these two phases which ended materials and components (Durmisevic, 2006) standing of building with lots of “waste” , e.g. incomplete and inaccurate de- efficiency. Buildings result in the creation of 25 million tonnes of waste mate- rials each year. Recent changes in technologies and soci- signs, conflicts between design and construction, lack of are always conceived as fixed and permanent structures buildable designs. Designers struggle with, and usually although they may be subject to transformation. Conse- ety, coupled with changes in the lives of users, dynamic market activities, and environmental awareness, justi- ignore, the production conditions in which their designs quently, most of the building structures need to be bro- will be implemented. (Sarhan & Fox, 2013) ken down, in order to be changed, adapted, upgraded, or fy the need for new planning approaches that focus on buildings as economic and sustainable solutions during replaced. The material flow is one-directional, starting To conclude, these waste are caused mostly by the seg- from material extraction, and ending with landfill (dis- their whole life cycle. Conventional building cannot facil- itate such demands. regation between roles . The architect has been sepa- posal of waste by burying it underground). This will re- rated from the contractor and the materials scientist is sult in huge waste production and material consumption. Apartments were built to minimum standards to satis- not on a par with the product engineer. This results in Figure 4 : Types of change of user requirements (Dobbelsteen, 2004) problems in communication between all disciplines. fy basic needs. The development of housing projects to- 1.1. Embodied energy day has a similar strategy. Although energy and acous- tic performance has improved, spatial performance has Buildings can be seen as complex combinations of var- remained at a very low level, since the spatial system is 2.2. Effect to user CONCLUSION: ious materials of which each contributes to a building’s unable to transform from one use pattern to another. total amount of embodied energy. Besides the energy Environmental : the needs of recyclable material and required to extract and process the raw materials into The main problem facing building transformation today low emissive construction process. components and the energy needed for the transport is the fact that in the past, developers, architects and Adaptability : the needs of demountable system. and installation of the components, the energy involved builders visualized their buildings as being permanent, Efficiency : the needs of integration of roles and design in maintaining, removing and recycling or disposing can and did not make provisions for future changes.