Alyssa A. Fellabaum - Master of Architecture Thesis 2020 University of Michigan | SOM Chicago

FINAL PRESENTATION

TAUBMAN COLLEGE OF ARCHITECTURE AND URBAN PLANNING | UNIVERSITY OF MICHIGAN

SOM GUEST INSTRUCTORS: RYAN CULLIGAN, KYLE VANSICE, RAHUL ATTRAYA, DEMI FANG

ADVISORS: TSZ YAN NG + WESLEY MCGEE TEAM: ALYSSA FELLABAUM + AUSTIN WISKUR

TOPOLOGY FORMWORK OPTIMIZED CONCRETE COMPONENTS: UTILIZING 3D PRINTED CLAY

ARCH. 662 | WINTER 2020 | THESIS

Taubman College of Architecture and Urban Planning of Michigan | Winter | ARCH Fall 662 | Taubman College of Architecture and Urban| University Planning | University of 2020 Michigan Instructor: Tsz Yan Ng, Wesley McGee 2019 | ARCH 660-006 SOM | Thesis Seminar | Friday 1-4pm, room 2222 Guest Instructors: Ryan Culligan, Kyle Vansice, Rahul Attraya, Demi Fang Instructor: Tsz Yan Ng, Wesley McGee SOM Guest Instructors: Ryan Culligan, Kyle Vansice, Rahul Attraya, Demi Fang

Topology Formwork Optimized Concrete Components: Topology Formwork Optimized Concrete Utilizing 3D PrintedComClay Alyssa Fellabaum + Austin Wiskur ponents: Utilizing 3D Printed Clay

THE TEAM ADVISORS TSZ-YAN NG

ALYSSA FELLABAUM

AUSTIN WISKUR

MASTER OF ARCHITECTURE UNIVERSITY OF MICHIGAN

MASTER OF ARCHITECTURE UNIVERSITY OF MICHIGAN

TAUBMAN COLLEGE OF ARCHITECTURE +

TAUBMAN COLLEGE OF ARCHITECTURE +

URBAN PLANNING

URBAN PLANNING

WESLEY MCGEE

STUDIO INSTRUCTOR

ADVANCED FABRICATION INSTRUCTOR

UNIVERSITY OF MICHIGAN

UNIVERSITY OF MICHIGAN

ASSISTANT PROFESSOR IN ARCHITECTURE

ASSOCIATE PROFESSOR IN ARCHITECTURE

SKIDMORE, OWINGS & MERRILL RYAN CULLIGAN, AIA

RAHUL ATTRAYA

KYLE VANSICE

DEMI FANG

STUDIO HEAD + ASSOCIATE

ARCHITECTURAL

ARCHITECTURAL DESIGNER

GRADUATE STUDENT AT MIT

DIRECTOR AT SOM

DESIGNER AT SOM

AND RESEARCHER AT SOM

BUILDING TECHNOLOGY

THESIS ABSTRACT

“ Topology Formwork Optimized Concrete Com-

ponents: Utilizing 3D Printed Clay, investigates additive manufactured (or 3D printed) clay formwork for concrete casting. The objective is to expand on the architectural potential of leave-in-place formworks, where printed clay molds receive poured concrete in strategic areas as a vertical index for reinforcement. “ This manufacturing method minimizes material waste by integrating the clay formwork as part of the final component. It leverages the use of only necessary material to produce each component, thus generating zero waste.

In this case study, it explores the potential of composite building components, utilizing clay and concrete to explore as an integrated system.

Clay molds are printed with geometric specification, unfired and dried, then assembled together before casting in-place with concrete for reinforcement. It introduces opportunities for cured concrete to fracture, due to differential shrinkage, releasing its bond from the clay mold

where the clay could then be recycled for re-use. Not only is clay a low embodied energy building material, correlating to our research within a sustainable construction initiative, but using 3d printed clay also gains an aesthetic expression from the ribbed contours of the clay print coils.

3D printing offers customized robotic precision in mold fabrication, allowing for more complex geometries. Our proposal investigates undercuts, which are impossible to cast with conventional concrete molding processes. The designs of masonry-scaled units are optimized at several levels; in terms of speed for printing during fabrication, as well as thermal performance within a wall system due to clay and concrete’s unique thermal capacity to retain heat. The proposed thermal mass wall leverages both physical material characteristics as well as computational and digital optimization to direct design decisions. The final desi n considers the earthen quality and expressive potentials of clay 3D printing, integrated with the structural strength of concrete as a thermal wall system.

WHAT WE ARE LEVERAGING CLAY + CONCRETE AS A COMPOSITE BUILDING SYSTEM Our thesis seeks to leverage the architectural potential of 3-D Printed composite systems; creating a no-waste/low embodied energy alternative to traditional masonry construction.

HOW 3D PRINTING CLAY COMPONENTS FOR CONCRETE INFILL

Our team has 3D printed clay building components, by means of composite system prototypes, with the ability to selectively infill clay formwork with concrete as a means of structural gain, unit interlocking, and connection for reinforcement.

HOW 3D PRINTING CLAY COMPONENTS FOR CONCRETE INFILL

WHY ZERO MATERIAL WASTE + MANUFACTURING AUTOMATION

ur thesis seeks to optimi e the efficiency and sustainable applications of clay formwork production by leveraging its aesthetic advantages, developing complex geometries, shifting human labor, and eliminate material waste without depending on extensive one-off formworks and falsework.

CASE STUDY:

MODULATING THERMAL MASS BEHAVIOR THROUGH SURFACE FIGURATION DANA CUPKOVA

MASS REGIMES II

5

BACKGROUND

GEOMETRIC FINDINGS

Relationship between surface geometry and heat transfer coefficients in thermal massin passive systems

Capability of delaying heat absorption and re-radiation by altering the geometric surface patterning

Instrumentalizes design principles for thermal patterning

Complex geometries can be used to leverage both the aesthetic and thermodynamic performance of passive building systems

n increase in surface area si nificantly increases the rate of convective heat transfer.

Strategically delays heat re-radiation throu h the fi uration of mass to surface related to solar geometry

SURFACE GEOMETRY 4 4. Photograph during the concrete pouring process of fabrication.

5. Sample surface topology of thermal mass concrete panel detail during steamed curing process. ample photo raphs of Cupkova’s study.

uilt

eometric surface confi urations used in

Photos taken from: http://www.epiphyte-lab.com/mass-regimes-ii

6

SURFACE AREA

Exploiting concrete’s formal and topological principles of thermal mass surface geometry in an effort to better understand effective form-making

SOLAR GEOMETRY

CASE STUDY: YRYS CONCEPT HOUSE 3D - PRINTED CONCRETE PARTITION WALL

X TREEE

2

BACKGROUND

RESPONSE

3D printed formwork (envelope) for concrete infill

Expand on complex geometries that oneoff formworks often struggle to obtain

Engineered concrete mixes, which includes hi h performance concrete, fi er reinforced concrete,and insulation material

Manufacturing technique can allow for a more efficient production time

Leave-in-place formwork Manufacturing automation by use of industrial robot

ENGINEERED CONCRETE MIX 1 artition

all

ree

ranch desi n for office space in

oncept

ouse

oom in on concrete infill prototype 3.

3-D Printed concrete framework before poured concrete is implemented on site.

3

Utilize 3D printed formwork as an outer shell,then selecti ely infill with concrete Implement and combine computational design techniques with new construction building methods

LEAVE-IN-PLACE FORMWORK

COMPOSITE SYSTEM

CASE STUDY: CERAMIC CONSTELLATION PAVILLION

8

BACKGROUND

9

RESPONSE

2,000 3D-printed terra-cotta bricks that were individually printed in a unique contour and size Uses computational design, clay extruders, and automation Prints at a fast rate with incredible versatility

easi ility of ro otically printed clay components Design process allows for distinct shapes and densities alsework, or secondary structures, were not ideal in the quest for material reduction

Standardization and Mass Production e uired permanent

alsework

COMPUTATION + AUTOMATION 7 erra otta ricks y aculty of Studio, Photo courtesy of 3ders.org.

rchitecture

lasma

8. Close up of Terra-Cotta brick assembly.

9. Top view of brick assembly, highlighting twisting vessel shape.

STANDARDIZATION +MASS PRODUCTION

PRINT TIME

MATERIAL CONSIDERATIONS

ADVA NTAGES OF CLAY

ADVA NTAGES OF CLAY IN SERVICE TO CONCRETE

Clay is biodegradable and recyclable as it is an earthen material t is e tremely heat, fire, wind, and hail resistant and is also more colorfast.

Clay is a low embodied energy building material, which directly correlates to our research within a sustainable construction initiative.

A D V A N T A G E S O F C L AY

BIODEGRADABLE Clay is more expressive than concrete, with more successful advanced surface applications such as preturbs, undulations, and creasing.

LOW EMBODIED ENERGY

The thermal mass of clay has a greater capacity in storing daytime heat gains, and releasing the heat during the night.

EXPRESSIVE Clay is ultimately 2-3 times stronger in compression than concrete, and offers a longer period of durability lasting 100 years.

THERMAL STORAGE

COMPRESSIVE STRENGTH

Within thermal wall systems, clay provides advantages for thermal storage properties and humidity balancing qualities.

Clay is a more malleable material that has a greater aesthetic quality within a faster production time.

MALLEABILITY

HUMIDITY BALANCING

MATERIAL CONSIDERATIONS CONTINUED

ADVA NTAGES OF CONCRETE

ADVA NTAGES OF CONCRETE IN SERVICE OF CLAY

A D VA N TA G E S O F C O N C R E T E

Concrete is more dense thus maximizes the structural performance.Clay would not withhold pressures without concrete.

Concrete will be used as a means of unit interlockin and connection etween each mass confi uration of clay leave-in-place formwork.

DENSITY

Concrete will act as a reinforcement as clay cannot withhold the same pressures alone.

UNIT INTERLOCKING

Concrete will work in service to clay as a composite building system that accounts for material bond and unit variability.

REINFORCEMENT

In achieving structural strength, concrete offers durability and is an impact resistant material.

COMPOSITE SYSTEM

IMPACT RESISTANT

Cracking occurs due the difference in material dehydration times. Less cracking occurs when concrete is poured into the clay envelope at 50% dehydration.

ach mass confi uration utili es concrete for its strength in mechanical and compressive properties.

MECHANICAL STRENGTH

CRACKING

MATERIAL EXPLORATIONS PROTOT YPES

DESIGN PAR A METER TICAL PLANE

WALL PROPERT Y

BENDING

PERTURB

UNDULATING

NON-PLANAR

SINGLE WALL

WALL THICKNESS

DOUBLE WALL

1/12” NOZZLE

POUR TIME

POUR LOCATION

1/8” NOZZLE

INNER WALL

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

OUTER WALL

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

PROTOTYPING

Prototypes I, II, + III

PAR AMETERS

PROTOTYPE I

Top view of Prototype I, utilizing a thicker concrete mix with less water, more sand, and more superplasticizer.

POUR LOCATION: INNER WALL

PROTOTYPING

Top view of Prototype II, utilizing a thinner concrete mix with more sand, and more superplasticizer.

PAR AMETERS

Top view of Prototype II, utilizing a thinner concrete mix with more sand, and more superplasticizer.

PROTOTYPE II POUR LOCATION: OUTER WALL

PROTOTYPING

Top view of Prototype III, no concrete mix was added due to the fragile formwork.

PAR AMETERS

Top view of Prototype III, no concrete mix was added due to the fragile formwork.

PROTOTYPE III

POUR TIME: N/A POUR LOCATION: N/A

PROTOTYPING

Top view of Prototype I, utilizing a thicker concrete mix with less water, more sand, and more superplasticizer.

PAR AMETERS

Top view of Prototype I, utilizing a thicker concrete mix with less water, more sand, and more superplasticizer.

PROTOTYPE IV. STACKING

POUR LOCATION: INNER WALL

PROTOTYPING

Render of block ‘Bending” Capabilities

PAR AMETERS

View of inner and outter wall at 1/8” thicknesses, providing further lateral support and crack testing.

PROTOTYPE V

Eight Configurations of Mass Customization

MASS CUSTOMIZATION POUR LOCATION: INNER WALL

PROTOTYPING

Render of Indoor Outdoor Application

PAR AMETERS

View of inner and outter wall at 1/8” thicknesses, providing further lateral support and crack testing.

PROTOTYPE VI

POUR LOCATION: OUTER WALL

PROTOTYPING

Top view of Prototype VIII, observing where cracking occured.

PAR AMETERS

DESIGN PARAMETER: UNDULATION

POUR LOCATION: OUTER WALL

PROTOTYPE VII

PROTOTYPING

Front view render of modular components stacked together .

PAR AMETERS

Front view of two modular components ,observing cracking

PROTOTYPE VIII

Front view of two modular components stacked together with poured concrete.

POUR LOCATION: OUTER WALL

PROTOTYPING

Render of Modular column

PAR AMETERS

DESIGN PARAMETER: PERTURB, , UNDULATION

PROTOTYPE IX

Three modular column components where bottom two were interlocked together with poured concrete.

POUR LOCATION: OUTTER WALL

PROTOTYPE DERIVATION

DESIGN PROCESS COMPUTATIONAL DESIGN

ASSEMBLY PROTOTYPE-PROOF OF CONCEPT

DESIGN INTEGRATION

RESPOND-3D PRINT CLAY

SURFACE DESIGN + VENTILATION WIND FLOW_PRECIPITATION

WEATHER RESISTANT

SURFACE AREA SURFACE AREA W/ GEOMETRIC APPLICATION

FLAT SURFACE AREA

Area = 1260 Square Inches

Area = 1020 Square Inches

rom lat urface _We can estimate an additional 10% increase in surface, as a result of individual layer height/thickness-a factor not considered in model space.

SOLAR ORIENTATION

SURFACE DIAGRAM

. 1 .7”

72

°

25°

ap

pr

ox

.

2”

72

°

30°

Printable Angle Site: Ann Arbor

app

25°

Winter Sunray Angle

rox

Summer Sunray Angle

WALL DESIGN

A0

B0 C0

E0

A0 D0

F0 G0

B0

02

C0

E0 H0

01

F0 G0

Grid layout of Units for Wall Design Proposal

AXONOMETRIC OF COMBINED UNITS

CONCRETE INTERLOCKING RUNNING BOND/EASY ASSEMBLY MASS CUSTOMIZATION INSULATION VENTILATION

01 Self tangent joint to give lateral surface stability.

02 Openings for concrete pour to give structural reinforcement.

SET REPEATABILITY

A0

B0 C0

E0

A0 D0

F0 G0

A0

E0 H0

B0 C0

E0

D0

G0

B0 C0

F0

E0

B0

A0

F0

E0

A0 D0

F0 G0

C0

E0 H0

A0

G0

A0

F0 G0

B0 C0

E0 H0

B0 C0

F0 G0

A0 D0

F0 G0

B0 C0

B0 C0

E0 H0

F0 G0

DIGITAL WORK FLOW rom enerated eometry in hino and rasshopper, to Robotic Program generation in SMT. Working back and forth between processes of design, research, and implementation of the printing process.

Rhinoceros

Grasshopper

AR

BR

CR

DR

ER

FR

GR

HR

//3-D Rhino Model

A0

B0

C0

D0

E0

F0

G0

H0

Super Matter Tools

//Printed Model

H0 OVERALL UNIT SCALE UNIT DIMENSIONS

NOMINAL DIMENSIONS OF TYPICAL CMU BLOCK

5”

5”

8”

8”

6”

20”

16”

H0 OVERALL UNIT DIMENSIONS

20”

NOMINAL DIMENSIONS OF TYPICAL CMU BLOCK

H0

8”

6”

UNIT DESIGN Vertical Forces

Horizontal Forces

Print layers with radius on its edges. Notches of beads create stress concentrations at layer edges

5”

5”

8”

INNER REINFORCEMENT UNDULATING SURFACE GEOMETRY NON-PLANAR SURFACING NON-PLANAR EDGE CONDITION APERTURES FOR WIND/AIR FLOW

20”

16”

DESIGN THROUGH PROTOTYPING The wall design proposal was informed by previous research in prototyping of printed units ow each prototype has in uenced the current iteration is shown throughout this diagram.

V. Inner Wall Insulation + Concrete Fill

DESIGN THROUGH PROTOTYPING The wall design proposal was informed by previous research in prototyping of 3-D printed units. How each prototype has in uenced the current iteration is shown throughout this diagram.

V. Inner Wall Insulation + Concrete Fill

DESIGN THROUGH PROTOTYPING The wall design proposal was informed by previous research in prototyping of 3-D printed units. How each prototype has in uenced the current iteration is shown throughout this diagram.

V. Inner Wall Insulation + Concrete Fill

DESIGN THROUGH PROTOTYPING The wall design proposal was informed by previous research in prototyping of 3-D printed units. How each prototype has in uenced the current iteration is shown throughout this diagram.

V. Inner Wall Insulation + Concrete Fill

DESIGN THROUGH PROTOTYPING The wall design proposal was informed by previous research in prototyping of 3-D printed units. How each prototype has in uenced the current iteration is shown throughout this diagram.

V. Inner Wall Insulation + Concrete Fill

VII. Non-Planar Surfacing

DESIGN THROUGH PROTOTYPING The wall design proposal was informed by previous research in prototyping of 3-D printed units. How each prototype has in uenced the current iteration is shown throughout this diagram.

V. Inner Wall Insulation + Concrete Fill

VII. Non-Planar Surfacing

DESIGN THROUGH PROTOTYPING The wall design proposal was informed by previous research in prototyping of 3-D printed units. How each prototype has in uenced the current iteration is shown throughout this diagram.

V. Inner Wall Insulation + Concrete Fill

VII. Non-Planar Surfacing

IV. Inner Reinforcement Concrete Connection

DESIGN THROUGH PROTOTYPING The wall design proposal was informed by previous research in prototyping of 3-D printed units. How each prototype has in uenced the current iteration is shown throughout this diagram.

V. Inner Wall Insulation + Concrete Fill

VII. Non-Planar Surfacing

IV. Inner Reinforcement Concrete Connection

VI. Overhang + Undercut

DESIGN THROUGH PROTOTYPING The wall design proposal was informed by previous research in prototyping of 3-D printed units. How each prototype has in uenced the current iteration is shown throughout this diagram.

V. Inner Wall Insulation + Concrete Fill

VII. Non-Planar Surfacing

IV. Inner Reinforcement Concrete Connection

VI. Overhang + Undercut

DESIGN THROUGH PROTOTYPING The wall design proposal was informed by previous research in prototyping of 3-D printed units. How each prototype has in uenced the current iteration is shown throughout this diagram.

V. Inner Wall Insulation + Concrete Fill

VII. Non-Planar Surfacing

IV. Inner Reinforcement Concrete Connection

VI. Overhang + Undercut

VIII. Edge Cut Condition

THERMAL MASS WALL ASSEMBLY

Taubman College of Architecture and Urban Planning | University of Michigan | Winter 2020 | ARCH 662 | Instructor: Tsz Yan Ng, Wesley McGee SOM Guest Instructors: Ryan Culligan, Kyle Vansice, Rahul Attraya, Demi Fang

Topology Formwork Optimized Concrete Components: Utilizing 3D Printed Clay Alyssa Fellabaum + Austin Wiskur

OVERALL FINDINGS

When casting concrete into wet clay formwork, the dehydration of concrete is shorter than that of the clay in the drying process.

In the wet and bone-dry prototypes, the dehydration in the clay shrinks against the solid concrete, causing more cracks, fractures and deformation.

In the leather-dry, we found that the dehydration in the clay and concrete produced less cracks and deformation most likely because the clay absorbed much less water due to a lower water content in the concrete mix and the the materials were able to dry/shrink at a closer rate together.

Increasing the width parameter to 1/8”, rather than 1/16” and 1/12”, allowed for the reduction of the overall displacement within the height of the clay formwork.

A lower printing layer height at 1.5mm, rather than 2mm and 2.2mm, also contributed to the smaller displacement, as well as increasing the bonding density.

WHY THIS IS IMPORTANT

“CEMENT PRODUCTION IS THE THIRD RANKING PRODUCER OF ANTHROPOGENIC (MAN-MADE) CO2 IN THE WORLD AFTER TRANSPORT AND ENERGY GENERATION. “ -GREEN SPEC UK 2020

HTTP://WWW.GREENSPEC.CO.UK/BUILDING-DESIGN/ENVIRONMENTAL-IMPACTS-OF-CONCRETE/

STRONG AND DUR ABLE

3D Printed clay earth blocks are able to meet and exceed concrete block strengths that are mass produced and reatly e ceed fired rick stren ths ur uildin system is reinforceable with vertical steal rods, allowing modern engineering designs to be applied so that buildings can withstand even the most disastrous circumstances.

SUSTAINABILIT Y

Clay Earth Blocks have a low embodied energy compared too many building materials.

Clay Earth Blocks can alsoo be easily made to be carbon neutral. Earth Blocks make the most ener y efficient structures y takin the strain off of heatin and cooling systems through thermo-geometric applications.

HEALTHY

Clay earth blocks are all natural and will not emit toxic gases from chemicals such as glues and preservatives. Earth Blocks create buildings that are able to naturally regulate heat, humidity, and moisture inside the structures they create. This regulation of humidity greatly increases indoor air quality. This method of additive manufacturing accounts for zero material waste and minimal human labor during the production process.

ENVIRONMENTALLY FRIENDLY

lay arth locks are a le to create structures that are superior in ener y efficiency do the manufacturing process and thermo-geometric applications. Additionally, Clay Earth Blocks are able to regulate temperature and humidity naturally which requires less energy to maintain a comfortable indoor environment.

Taubman College of Architecture and Urban Planning | University of Michigan | Winter 2020 | ARCH 662 | Instructor: Tsz Yan Ng, Wesley McGee SOM Guest Instructors: Ryan Culligan, Kyle Vansice, Rahul Attraya, Demi Fang

Topology Formwork Optimized Concrete Components: Utilizing 3D Printed Clay Alyssa Fellabaum + Austin Wiskur