Matter, Making & Testing: Designing with Next Generation Precast Concrete

MATTER, MAKING & TESTING Designing with Next Generation Precast Concrete

MATTER, MAKING & TESTING

Designing with Next Generation Precast Concrete University of Pennsylvania Stuart Weitzman School of Design Fall 2019 | ARCH 732-005 in collaboration with Northeast Precast with Richard Garber, AIA & Amanda Gruen, Catherine Shih, Karen Toomasian Lauren Hunter, Alexander Jackson, Yongkyu Hong Ian Lai, Quan Hao Huynh, David Forero Abdullah Alsahafi, Huadong Lin, Xiaoyi Peng

Stuart Weitzman School of Design 210 S 34th Street Philadelphia, PA 19104

Table of Contents Introduction

The Premise Northeast Precast

07 09

Prototype Wall Assemblies

Team A Team D Team E Team F

10 18 24 32

Learning through Making

Site Visit

38

6 | Introduction

Designing with Next Generation Precast Concrete | 7

The Premise This seminar focused on precast concrete and specifically it’s history, materiality – how it is manufactured and the logistics of its assembly - and cultural affects through both its traditional uses within the urban environment as well as new approaches to building typologies such as housing. Through a strategic partnership with Northeast Precast (NEP), based in Millville, NJ, students gained access to places where precast concrete is made, formed, and put into action. The class was organized as a seminar, with a group of 18 students. In addition to readings and case studies via traditional seminar delivery, students had access to Northeast Precast’s state-of-the-art facility where they: 1. Over two weekends, attended two six-hour sessions to learn about the precast concrete manufacturing process.

Students were exposed to the fabrication process from material selection, to formwork production, to pour, and disassembly.

2. Utilized NEP’s facilities and their workforce, a group of professional engineers and concrete experts. Students worked in teams to produce panel prototypes for wall assemblies that respond to structural, thermal, and water-proofing performance; and received feedback from NEP’s expert staff on the construction feasibility and applicability of studentproposed prototypes.

3. Developed a delivery workflow utilizing digital tools to communicate with and transmit panel, assembly and formwork concepts to NEP staff, fostering a collaboration opportunity for students that is not regularly experienced in architecture school. This workflow allowed students to virtually study panelization schemas and jointing ahead of actual prototype preparation.

8 | Introduction

Designing with Next Generation Precast Concrete | 9

Northeast Precast Northeast Precast is a state-of-the-art precast concrete manufacturer located in Millville, New Jersey that offers commercial products and residential foundation wall systems.

In 2001 John Ruga started selling Superior WallsÂŽ in New Jersey and started precast manufacturing in 2004. Starting as only a Superior Walls franchise, the company diversified and became known as Northeast Precast, a leader in custom precast products. Today Northeast Precast continues to expand to meet the demands of the residential, commercial building, highway infrastructure and heavy marine construction markets.

10 | Prototype Wall Assemblies

Designing with Next Generation Precast Concrete | 11

Team A Amanda Gruen, Catherine Shih, Karen Toomasian The panel design originates from a studio project which involved an exploration of apertures and surface texture. At the scale of the panel, we are interested in the interplay of deep, cavernous pockets or impressions, juxtaposed against thin, sinuous, and sharp edges or seams. The pocketed openings of varying sizes give depth and variation to the panel, allowing light to dance over the surface in rhythms.

The pockets have both sharp corners as well as more smooth curvilinear edges, creating both dramatic and soft shadow effects on the surface as the sun changes position throughout the day. The space between each of the disparate impressions create interstitial seams that read as a network of flat, sinuous, sharp edges. Overall, the collection of pockets creates an overall reading of a curvilinear form. The tension between the cavernous area of the panel and the flattened surface is heightened by the thin reveal that runs between the two.

12 | Prototype Wall Assemblies

10"

LPA27434G

LPA2T634G

20"

CI5634412P 2’-0”

1’-4”

EPO8 10"

11”

PSA 4535 8-7/8”

PSA 4535 EP08

10"

LPA2T434G (TIF)

CI5634412P (TIF)

20"

LPA2T634G

3’-1/2"

CI5634412P

LPA2T434G (TIF)

PENNDESIGN PROJECT:

UPENN PRECAST

JOB NO.

PIECE MARK

DETAILS

TEAM A

SHEET NO.

1 OF 7

PSA 4535 (TIF)

EP08 (TIF)

1’-4”

LPA2T634G (SIF)

2’-0”

1’-4”

11"

10"

8-7/8”

PSA 4535

LPA2T634G (SIF)

EP08 (TIF)

PSA 4535 NUT TYPE SLOTTED INSERT

LPA2T634G

2T LIFTING PIN 6 3/4” LENGTH

LPA2T434G

2T LIFTING PIN 4 3/4” LENGTH

2 2 4

EP08

PL3/8X8X8 W/ (4) 1/2” DIA X 5” LONG HCAs

CI5634412P

COIL INSERT 3/4” CI5634412P

#40608

#4 REBAR X 6’-8” LONG

#40708

#4 REBAR X 7’-8” LONG

3

#40308

#4 REBAR X 3’-8” LONG

11

#40202

#4 REBAR X 2’-2” LONG

#4BB01

#4 BENT REBAR X 9’-3 LONG

#4BB02

#4 BENT REBAR X 6’-11” LONG

2 1 1

1 1 1

MARK

FORM VIEW

QTY. UOM

CONCRETE MIX

PSA 4535 (TIF)

MIX

CY

NEP-15

PIECES REQ'D:

B/F F

WEIGHT:

3,200 LBS

S/F = 32

f'c (28 DAYS)

5,000 PSI

EP08

LPA2T434G

CI5634412P

LPA2T434G

f'c (SHIPPING)

PSA 4535

L/F =

PSI

f'ci (RELEASE)

PSI

5” LPA2T634G

REV.

NOTES: 1. ALL REBAR IS TO BE 1 1/2” CLR. UNO 2. ALL DIMENSIONS ARE TO CENTERLINE UNO SYMBOLS: SIF= SIDE IN FORM TIF= TOP IN FORM BIF= BOTTOM IN FORM

DESCRIPTION

DATE

DRAWN:

TEAM A

CHECKED:

BY

10/23/19

FOR REVIEW

0

SECTION VIEW

ENGR:

TEAM A

PLOTTED:

SCALE 1/8” = 1’-0”

5-1/2”

7”

1’-2”

1’-6”

1’-0”

2’-0”

10"

PENNDESIGN

5-1/2"

PROJECT:

UPENN PRECAST

JOB NO.

#40308

#40308

#40308

#40308

#40308

PIECE MARK

DETAILS

TEAM A

#40308

SHEET NO.

2 OF 7

3”

3”

#40308

1’-0”

11”

#40708

1’-2”

10”

#40708

1’-3”

#4BB01

10” 6”

6”

#40608

3”

PSA 4535 NUT TYPE SLOTTED INSERT

LPA2T634G

2T LIFTING PIN 6 3/4” LENGTH

LPA2T434G

2T LIFTING PIN 4 3/4” LENGTH

#4 REBAR X 6’-8” LONG

LENGTH

3 11

#40202

#4 REBAR X 2’-2” LONG

#4BB01

#4 BENT REBAR X 9’-3 LONG

#4BB02

#4 BENT REBAR X 6’-11” LONG

MIX

10”

CY

26”

60

#4 X 6’-11”

BEND DIAMETER : 2”

19”

#4BB02

B/F F

WEIGHT:

3,200 LBS

S/F = 32 L/F =

PSI PSI

REV.

SECTION VIEW - UPPER MAT

24”

1

PIECES REQ'D:

10”

7”

12”

f'ci (RELEASE)

2”

#4 X 9’-3”

1 QTY. UOM

5,000 PSI

f'c (SHIPPING)

60

1

MARK

f'c (28 DAYS)

56”

#4BB01

1

#4 REBAR X 7’-8” LONG #4 REBAR X 3’-8” LONG

CONCRETE MIX

DESCRIPTION

2 1

#40708 #40308

NEP-15

GR

4

PL3/8X8X8 W/ (4) 1/2” DIA X 5” LONG HCAs COIL INSERT 3/4” CI5634412P

#40608

FORM VIEW - UPPER MAT

ITEM MARK

2 2

EP08 CI5634412P

3”

#40708

PSA 4535

0

DESCRIPTION

DATE 10/23/19

FOR REVIEW

40”

DRAWN:

TEAM A

CHECKED:

SCALE 1/8” = 1’-0”

ENGR:

PLOTTED:

BY TEAM A

Designing with Next Generation Precast Concrete | 13

1’ 6-1/2”

1’-9”

4’-3”

PENNDESIGN

5-1/2"

PROJECT:

UPENN PRECAST

JOB NO.

PIECE MARK

DETAILS

TEAM A #40308

#40308

SHEET NO.

3 OF 7

#40308

7”

#40308

2’-8”

3’ 3-1/2” PSA 4535

#40202

#4BB02

8-1/2”

9”

PSA 4535 NUT TYPE SLOTTED INSERT

LPA2T634G

2T LIFTING PIN 6 3/4” LENGTH

LPA2T434G

2T LIFTING PIN 4 3/4” LENGTH

#4 REBAR X 6’-8” LONG

#40708

#4 REBAR X 7’-8” LONG

3

#40308

#4 REBAR X 3’-8” LONG

11

#40202

#4 REBAR X 2’-2” LONG

#4BB01

#4 BENT REBAR X 9’-3 LONG

#4BB02

#4 BENT REBAR X 6’-11” LONG

LENGTH

MIX

CY

F

#4 X 6’-11”

f'ci (RELEASE)

12”

60

26”

2”

SECTION VIEW - LOWER MAT

BEND DIAMETER : 2”

19”

24”

3,200 LBS

S/F = 32 L/F =

PSI PSI

10” 7”

#4BB02

WEIGHT:

10”

#4 X 9’-3”

1 1

PIECES REQ'D:

B/F

5,000 PSI

56”

60

1

f'c (28 DAYS)

f'c (SHIPPING)

#4BB01

1

QTY. UOM

CONCRETE MIX

DESCRIPTION

2 1

MARK

NEP-15

GR

2 4

PL3/8X8X8 W/ (4) 1/2” DIA X 5” LONG HCAs COIL INSERT 3/4” CI5634412P

#40608

FORM VIEW - LOWER MAT

ITEM MARK

2

EP08 CI5634412P

REV.

DESCRIPTION

DATE

BY

10/23/19

FOR REVIEW

0

TEAM A

40”

DRAWN:

TEAM A

CHECKED:

ENGR:

PLOTTED:

SCALE 1/8” = 1’-0”

PENNDESIGN PROJECT:

UPENN PRECAST

JOB NO.

PIECE MARK

TEAM A

DETAILS

PSA 4535

PSA 4535 NUT TYPE SLOTTED INSERT

LPA2T634G

2T LIFTING PIN 6 3/4” LENGTH

LPA2T434G

2T LIFTING PIN 4 3/4” LENGTH

SHEET NO.

4 OF 7

2 2 4

EP08

PL3/8X8X8 W/ (4) 1/2” DIA X 5” LONG HCAs

CI5634412P

COIL INSERT 3/4” CI5634412P

#40608

#4 REBAR X 6’-8” LONG

2 1 1

#40708

#4 REBAR X 7’-8” LONG

3

#40308

#4 REBAR X 3’-8” LONG

11

#40202

#4 REBAR X 2’-2” LONG

#4BB01

#4 BENT REBAR X 9’-3 LONG

#4BB02

#4 BENT REBAR X 6’-11” LONG

1 1 1

MARK

QTY. UOM

CONCRETE MIX MIX

CY

PIECES REQ'D:

B/F WEIGHT:

S/F =

f'c (28 DAYS)

5,000 PSI

f'c (SHIPPING)

f'ci (RELEASE)

DRAWN:

PC. FOUND ON E-DRAWING:

PSI

REV. 0

L/F =

PSI

DESCRIPTION

DATE 10/23/19

FOR REVIEW

TEAM A

CHECKED:

ENGR:

PLOTTED:

BY TEAM A

14 | Prototype Wall Assemblies

PENNDESIGN PROJECT:

UPENN PRECAST

JOB NO.

PIECE MARK

DETAILS

TEAM A

PSA 4535

SHEET NO.

5 OF 7

PSA 4535 NUT TYPE SLOTTED INSERT

LPA2T634G

2T LIFTING PIN 6 3/4” LENGTH

LPA2T434G

2T LIFTING PIN 4 3/4” LENGTH

2 2 4

EP08

PL3/8X8X8 W/ (4) 1/2” DIA X 5” LONG HCAs

CI5634412P

COIL INSERT 3/4” CI5634412P

#40608

#4 REBAR X 6’-8” LONG

#40708

#4 REBAR X 7’-8” LONG

3

#40308

#4 REBAR X 3’-8” LONG

11

#40202

#4 REBAR X 2’-2” LONG

#4BB01

#4 BENT REBAR X 9’-3 LONG

#4BB02

#4 BENT REBAR X 6’-11” LONG

2 1 1

1 1 1

MARK

QTY. UOM

CONCRETE MIX MIX

CY

PIECES REQ'D:

B/F WEIGHT:

S/F =

f'c (28 DAYS)

5,000 PSI

f'c (SHIPPING)

PC. FOUND ON E-DRAWING:

PSI

REV.

DESCRIPTION

DATE

DRAWN:

TEAM A

CHECKED:

BY

10/23/19

FOR REVIEW

0

ISO VIEW - REBAR

L/F =

PSI

f'ci (RELEASE)

ENGR:

TEAM A

PLOTTED:

TOP VIEW - REBAR

PENNDESIGN PROJECT:

UPENN PRECAST

JOB NO.

PIECE MARK

DETAILS

TEAM A

PSA 4535

PSA 4535 NUT TYPE SLOTTED INSERT

LPA2T634G

2T LIFTING PIN 6 3/4” LENGTH

LPA2T434G

2T LIFTING PIN 4 3/4” LENGTH

EP08

PL3/8X8X8 W/ (4) 1/2” DIA X 5” LONG HCAs

CI5634412P

COIL INSERT 3/4” CI5634412P

#40608

#4 REBAR X 6’-8” LONG

SHEET NO.

6 OF 7

2 2 4 2 1 1

#40708

#4 REBAR X 7’-8” LONG

3

#40308

#4 REBAR X 3’-8” LONG

11

#40202

#4 REBAR X 2’-2” LONG

#4BB01

#4 BENT REBAR X 9’-3 LONG

#4BB02

#4 BENT REBAR X 6’-11” LONG

1 1 1

MARK

QTY. UOM

CONCRETE MIX MIX

CY

NEP-15

PIECES REQ'D:

B/F F

WEIGHT:

3,200 LBS

S/F = 32

f'c (28 DAYS)

5,000 PSI

f'c (SHIPPING)

f'ci (RELEASE)

PSI PSI

REV. 0

DRAWN:

DESCRIPTION

DATE 10/23/19

FOR REVIEW

TEAM A

ISO VIEW

L/F =

CHECKED:

TOP VIEW SCALE 1/8” = 1’-0”

ENGR:

PLOTTED:

BY TEAM A

Designing with Next Generation Precast Concrete | 15

PENNDESIGN PROJECT:

UPENN PRECAST

JOB NO.

PIECE MARK

TEAM A

DETAILS

PSA 4535

PSA 4535 NUT TYPE SLOTTED INSERT

LPA2T634G

2T LIFTING PIN 6 3/4” LENGTH

LPA2T434G

2T LIFTING PIN 4 3/4” LENGTH

EP08

PL3/8X8X8 W/ (4) 1/2” DIA X 5” LONG HCAs

CI5634412P

COIL INSERT 3/4” CI5634412P

#40608

#4 REBAR X 6’-8” LONG

SHEET NO.

7 OF 7

2 2 4 2 1 1

#40708

#4 REBAR X 7’-8” LONG

3

#40308

#4 REBAR X 3’-8” LONG

11

#40202

#4 REBAR X 2’-2” LONG

#4BB01

#4 BENT REBAR X 9’-3 LONG

#4BB02

#4 BENT REBAR X 6’-11” LONG

1 1 1

MARK

QTY. UOM

CONCRETE MIX MIX

CY

PIECES REQ'D:

B/F WEIGHT:

PLYWOOD TEMPLATE PIECE 1

PLYWOOD TEMPLATE PIECE 2

PLYWOOD TEMPLATE PIECES COMBINED

PLYWOOD TEMPLATE OVER THE CAST PANEL

5,000 PSI

f'c (SHIPPING)

f'ci (RELEASE)

SANDBLASTED FINISH

S/F =

f'c (28 DAYS)

PC. FOUND ON E-DRAWING:

PSI

REV. 0

L/F =

PSI

DESCRIPTION

DATE 10/23/19

FOR REVIEW

PLYWOOD TEMPLATE

DRAWN:

TEAM A

FINISH DIAGRAM

CHECKED:

ENGR:

PLOTTED:

BY TEAM A

16 | Prototype Wall Assemblies

Final completed wall panel

Designing with Next Generation Precast Concrete | 17

Formwork test fit

Rebar installation

18 | Prototype Wall Assemblies

Designing with Next Generation Precast Concrete | 19

Team D Lauren Hunter, Alexander Jackson, Yongkyu Hong Poetics of Waste We want to prioritize waste into a new tectonic expression of the prefabrication processes used to manufacture concrete wall panels. The most interesting expression we found at the plant was the casts of the leftover concrete deposits. This stratification of the material is rendered in an almost haphazard way; a beautiful expression of the materiality of concrete.

The proposal taxonomizes on the waste to create a new expression in wall panel surface treatment. The walls are assembled from any leftover concrete that is simply poured into the formwork until it is filled. Blends and mixes of the concrete become the new ornament of the panel, selfexpressive of the process. These new panels take advantage of recycling processes and showcase the character and act as a billboard to expose the re-used nature of the wall. Each panel becomes a unique assemblage of mixes and transforms the seemingly banal into the beautiful.

20 | Prototype Wall Assemblies team trash

NOTES: Concrete panel to be treated with Basf Silane Sealer, MasterProtect H1000 sealant after curing.

4'-0"

RV1

"

EH1

1/2

1

1 3/4"

45°

2"

3

SECTION - CHAMFER

PLAN - TOP

4'-0"

8"

HARDWARE SCHEDULE:

8"

2'-8"

CL

CL

1'-0"

3

EH1

PL1

PL1

CL PSA

Low RPM vibrator - less than 14,000 VPM under load for vibrating concrete.

1. 1/2” Chamfer at corner 2. 1/2“ bolt to concrete slab 3. Epoxy rebar at front face

2 1/2" 1 1/2"

REVEAL DETAIL

1'-0"

1'-0"

3'-6" Top of Reveal

°

135

3'-6"

1/2"

1'-0"

135°

Top of Reveal

3/4"

3

Lauren Hunter Alex Jackson Yongkyu Hong Matt Hicks

PL1 - (4) 4”x4”x3/8” Steel Angle PL2 - (2) 6”x6”x1/2” Steel Angle EH1 - (2) Erection Head Anchor (QL403SPG) CI1 - (2) Coil Insert (CI16124P) PSA - (4) 4 1/2” Slotted insert short studs (4535 PSA) RV1 - GOLD Poly-Comp Reveal (RVL-050-150-050X10’) AC1 - (16) 4” x1/2” HCA Anchor CONCRETE: Strength - 5000 psi Volume - 25 cubic ft (25 x 150 = 3750 lbs. per panel)

8'-0"

RV1

REBAR: ASTM Grade 60 rebar

4'-6"

4'-6"

(5) 7’-6” #4 rebar (vertically) (5) 7’-6” #4 rebar w/ epoxy coat AC1 PL1 CL 1'-0"

PL2

(8) 3’-6” #4 rebar (horizontal) (8) 3’-6” #4 rebar w/ epoxy coat

PL2 CI1 10/24/2019

ELEVATION - FRONT

ELEVATION - BACK

2

ELEVATION - SIDE

A101

Architectural Precast Panel

Designing with Next Generation Precast Concrete | 21 team trash

3

3

Lauren Hunter Alex Jackson Yongkyu Hong Matt Hicks

1

2

1

NOTES: 1. Foam 2. HDO Plywood 3. HDO Plywood Siderail

2

PIECES: F1 - Foam 1 P1 - Plywood 1

4'-6"

3'- 7 1/4"

F1

ELEVATION - SIDE

1

1 1/2"

3’ - 6 1/2"

6 1/4"

1/2"

6 1/4"

4'-5"

F2 - Foam 2 P2 - Plywood 2

F2

1"

1" 4'-6"

3'- 6 3/4"

ELEVATION - SIDE - F1

ELEVATION - SIDE - F2

F1

4’

PLAN - TOP - F1

F2

3'- 6 3/4"

PLAN - TOP - F2

F1 2

F2 2

3'- 6 1/2"

4’

4’

4'-5"

1

1/2"

1/2"

4’

1

4'-6"

10/24/2019

PLAN - TOP - F1

PLAN - TOP - F2

P1

P2

team trash

F101

Formwork

NOTES: 1. 1/2” Diameter hole.

2. 3/8” Steel 3. 1/2” Steel

Lauren Hunter Alex Jackson Yongkyu Hong Matt Hicks

ISOMETRIC

ISOMETRIC

3

2

2

3 4"

1

6"

CL

SECTION

3 4"

1

CL CL

4"

SECTION

2

4" 6"

PLAN + ELEVATION

PLAN + ELEVATION

PL2

PL1

10/24/2019

S101

Steel Fabrication

22 | Prototype Wall Assemblies

Finished residual concrete panel

Designing with Next Generation Precast Concrete | 23

Utilization of residual concrete pours from other prototypes

24 | Prototype Wall Assemblies

Designing with Next Generation Precast Concrete | 25

Team E Ian Lai, Quan Hao Huynh, David Forero Topologically Optimized Concrete Structural Tee Precast concrete has benefits of much lighter weight construction than typical steel frame building types and can withstand much higher building loads per weight of structure.

Precast panels traditional have been limited to modular and rectilinear units for ease of fabrication, while the standard single and double Ts have been used for long span efficiency parking garages. These T units are already optimized in their industrial form for quick production and low cost of fabrication, but have not been structurally optimized for even higher structural optimization from minimizing material use.

In the current age where buildings, either from embodied energy or cost of transportation due to weight are the greatest contributor to greenhouse gases, calls for not only a cost effective standard modular unit for precast building systems, but also material efficient units. Our choice was to focus on the single T as a point of departure for structural optimization and fabrication assessment. Following would be our examination into the execution of the structural member.

26 | Prototype Wall Assemblies

2'-8 21"

Designing with Next Generation Precast Concrete | 27

0'-1 21" 0'-3 21"

0'-3"

0'-4 21"

0'-3 21"

10'-3 21"

10'-3 21"

0'-3"

1'-7 21"

0'-10 21"

0'-5 21"

5'-2 21"

STEM PLAN & ELEVATION

SLAB RCP

ARCH 732-005: MATTER, MAKING, AND TESTING: DESIGNING WITH NEXT GENERATION PRECAST CONCRETE F19 PROFESSOR: RICHARD GARBER STUDENTS: DAVID FORERO, IAN LAI, QUAN HAO HUYNH (TEAM E)

0'-10 21"

SLAB ELEVATION

ROTATED AXONOMETRIC

WEITZMAN SCHOOL OF DESIGN AT THE UNIVERSITY OF PENNSYLVANIA IN COLLABORATION WITH NORTH EAST PRECAST PROJECT MANAGER: SHEA JONES

28 | Prototype Wall Assemblies

Formwork

Designing with Next Generation Precast Concrete | 29

Rebar detail with spacers

First precast assembly

30 | Prototype Wall Assemblies

Final precast assembly

Designing with Next Generation Precast Concrete | 31

Final precast assembly

32 | Prototype Wall Assemblies

Designing with Next Generation Precast Concrete | 33

Team F Abdullah Alsahafi, Huadong Lin, Xiaoyi Peng We see the panel as a screen rather than a solid wall. The openings create visual continuity between the two sides.

Ample light can pass through, while shadows are cast at different angles due to the openings’ slanted side walls.

The design creates a structural challenge since there is no continuous line in the Y axis. Therefore, steel reinforcements must loop around the openings to transfer forces. As an aggregate, we imagine the panel to a horizontal long yet vertically short façade.

34 | Prototype Wall Assemblies

24”

3”

12”

3.00"

24.00" 12.00"

24” 24.00"

Rebar

96.00"

96”

24.00"

6.00"

2.00"

Mini V

Anchor

Hanger

48.00"

AXON AXON

PLAN SPECULATIVE SECTION

Taylor Wigglesworth | Team Members: Abdullah Alsahafi, Huadong Lin, Xiaoyi Peng

PLAN PLAN

Team

F

CNC CNC NEGATIVE MOULD MOULD 3/16" 3/16" Layers LayersNEGATIVE (whole) (whole) Designing with Next Generation Precast Concrete | 35

00"

00"

17.40

3.00

3.00 3.00

4x 4x 4x 4x 2.00

1x 1x 1x 1x PLAN SHOWING SECOND LAYER OF REBAR

CNC PANEL 3/16" Layers CNC NEGATIVE MOULD ers NEGATIVE MOULD ayers PANEL 3/16" Layers (whole) 20.17

16.71

17.60 17.60

20.17

17.66 17.60

17.66 17.66

3.00

4x4x 4x4x

x

4.06 4.06

4.06

20.17

19.77

2.00

19.77 19.77

10.70

3.00

17.66

17.60

x

2.40

17.66

6.12

14.40

6.12 6.12

7.60

14.40 14.40 15.40

4.06

14.40 15.40 15.40

Project Manager: Taylor Wigglesworth Project | TeamManager: Members:Taylor Abdullah Alsahafi, Huadong Lin, XiaoyiAbdullah Peng Alsahafi, Wigglesworth | Team Abdullah Members: Huadong XiaoyiPeng Peng Taylor Wigglesworth | Team Members: Alsahafi, Huadong Lin,Lin, Xiaoyi

3.19

19.77 19.77

3.19

19.77

3.00

19.60

19.60 20.10

20.10 19.60 20.10

20.10

*GENERAL NOTE: ALL REBAR USED #3 REBAR USED IS #3 *GENERAL NOTE:ISALL

3.19

5.81

5.81 5.81

7.20 7.20

16.71

1.00

5.81

5.79 7.20

20.17

16.71

1.00 1.00

19.60

3.19 3.19

19.77

20.17

15.40

8x8x 8x8x

3.19 3.19

5.79 5.79

7.20

1x 1x

3.00 17.60

6.50

2.40 2.40

3.60

2.40

3.60

3.60

x

3.60

14.40 15.40 14.40 15.40

3.19

4.06 6.12

7.17 8.20 8.20

20.17

20.17

5.60 5.60

5.60

3.19

3.19

16.71

16.71

1x 1x

7.20

17.60

7.20

17

6.50 3.00

1x

17.60

17.66

1x

17.66

8.20

7.17 8.20 20.17

5.60

5.60 5.60

4.06

6.12

4x4x

4.06

8.20

20.17 19.77

19.77

5.60 5.60

3.00

5.60

3.60

14.40

1x 2.00

16.71

2.00

17.40

3.00

18.40

15.40

3.19

15.40

7.60

8x 8x4x 4x

1.00

19.60

6.12

17.40

3.19

1.00

1x

19.60

7.17 20.10

6.50

17.60

17.66

10.70

5.79

19.77 6.12

10.70

5.81 5.60 5.60

5.79

5.60

2.40

3.60

8x 8x

6.12

4.06

14.40

14.40 15.40

15.40

3.19

8x

Project Manager: Taylor Wigglesworth Project | TeamManager: Members:Taylor Abdullah Alsahafi, Huadong Lin, XiaoyiAbdullah Peng Alsahafi, Wigglesworth | Team Abdullah Members: Huadong XiaoyiPeng Peng Taylor Wigglesworth | Team Members: Alsahafi, Huadong Lin,Lin, Xiaoyi

3.19

3.19

19.77 19.77

8x8x

14.40

6.50

6.50

8.20

8x 8.20

19.60

8x

5.79 19.60

20.10

14.40

15.40

5.81 5.81 3.19 7.20

5.79 3.19 6.50

7.17

20

5.79

3.60 3.19

20.10

20 7.60

5.81 1.00

5.81

*GENERAL NOTE: ALL REBAR USED ISALL #3 REBAR USED IS #3 *GENERAL NOTE: 3.19

4x

10.70 7.60

20.10

2.40

1.00

19.60

7.20

10.70

15.40

5.79 7.20

10.70 17.40

7.60

19.60

8x

4x

3.60

7.60

1.00

3.19

4.06

19.77

2.40

3.60

17.66

6.12

17.40 10.70 2.00

1.00 5.60

7.17

5.81

4.06

2.40

17.40

6.50 7.20

18.40 4.06

10.70

4x

10.70

14.40

2.00

7.20

10.70

17.66

2.40

10.70

7.60

17.66

16.71 3.00

2.40

2.40

20.17

17.60

16.71 3.00

8x 8x

17.40

3.60

10.70

3.19 3.19

16.71

18.40

2.40

3.00

17.40

18.40

17.40 6.12

5.60

5.60

20.17

19.77

2.00

17.40

10.70

5.60

3.00

6.50

7.17 8.20 7.17

2.00

17.40

7.20

3.00 6.50

3.00

3.19

7.20

4x 4x

8.20

3.00

5.60 5.60

17.40 4.06

6.50

3.19

3.19

6.50

3.00 6.50 6.50

5.60

17.66

19.77

7.17 7.17 8.20

5.60

F

17.66

Team Team F 6.12

5.79

15.40

3.19 3.19

x

PLAN SHOWING FIRST LAYER OF REBAR

15.40

14.40

3.00

4x 4x 4x 4x 1x 1x 7.17

F

Team

17.60

17.40

2.40

5.79

3.00

7.60

1.00

3.19

4.06

7.60 7.60

6.12

4.06

5.79 5.79 3.00

1x 1x

3.60

17.66

20.10

5.81

10.70

2.40

3.60 3.60

8x 8x 8x 8x

17.66

17.60

.06

2.40 2.40

3.60

19.60 20.10 20.10

5.81 5.81

5.79

10.70

16.71

3.00

7.60

1.00

19.60 19.60 20.10

5.81

10.70

3.00

7.60 7.60

18.40

10.70

10.70 16.71

19.60

18.40

18.40

10.70

19.77

16.71

3.00

10.70

1.00 1.00

8x 8x 8x 8x

2.00 18.40 17.40

10.70

16.71

7.60

1.00

17.40

17.40

20.17

10.70 10.70

17.40

2.00

17.40

20.17

18.40

10.70

6.12 2.00

4.06 20.17

10.70 10.70

10.70

17.40 17.40

6.12 6.12

18.40 18.40

NEGATIVE MOULD (whole) NEGATIVE MOULD (whole)

17.66

17.40

6.12

2.00

17.40 18.40

10.70

3.00

3.00 3.00

17.40

2.00 2.00

17.40 17.40

17.40

16.71

3.00 3.00

(whole) 1x 1x 1x 1x 17.60

20.17 20.17

16.71 16.71

3.00

3.00

17.40 17.40

3.00

8.20

Team

F

F

Team F Team

36 | Prototype Wall Assemblies

Finishing the voids

Comparison of void elements to cup of coffee

Designing with Next Generation Precast Concrete | 37

Assembling the voids

Final pour of concrete mixture

38 | Learning Through Making

Designing with Next Generation Precast Concrete | 39

Learning Through Making Students visited Northeast Precast’s state-of-the-art facility to manufacture their prototype walls. Groups learned how to mix concrete, assemble and create formwork, and cast the prototypes.

40 | Learning Through Making

Designing with Next Generation Precast Concrete | 41

42 | Learning Through Making

Designing with Next Generation Precast Concrete | 43

44 | Learning Through Making

Designing with Next Generation Precast Concrete | 45

46 | Learning Through Making

Designing with Next Generation Precast Concrete | 47

48 | Learning Through Making

Designing with Next Generation Precast Concrete | 49

50 | Learning Through Making

Designing with Next Generation Precast Concrete | 51