Innovative Molded Facades - Case Study

FACADES + INNOVATION 2012 Chicago AIA

Innova&ve Molded Facades—Case Studies

by Will Laufs

PhD, PE, IWE, LEED AP www.laufsed.com

Overview

global product

‘@le’ loca@ons

New York Florida Mexico City

Paris

Berlin Basra

Previous Example: Long‐ Span Mega Panels GFRP stadium enclosure

architect: 360 architecture engineer: Thornton TomaseS (work with previous employer) images: www.skyscrapercity.com & personal Basra Sports City Soccer Stadium (Iraq)

Woven Geometry

self‐spanning, double‐ curvature panels

span L = 100’ (30.5m)

From Digital FabricaHon to Mold‐ Making CATIA‐ defined 3D shape

E

D

C

B

A

From Idea to RealizaHon molded curvature

Overview work

parasi@c

tectonic

digital

ParasiHc over‐clad

ar@st/architect: elegant embellishments (Berlin) engineer: Buro Happold (work with previous employer) images: www.elegantembellishments.tumblr.com 2,000 m2 hospital façade over‐clad (Mexico City)

Penrose Tiling non‐repe@@ve

the “I” the “X”

AddiHon

a‐periodic sets of proto‐@les

the “I” the “X”

ParasiHc

wall is curved – panels allow for geometrical flexibility

ar@sts: Allison Dring & Daniel Schwaag (Berlin)

Closed InjecHon Molding – ABS P6 yield strength (ISO 527)

yield strain (ISO 527)

rupture strength (ISO 527)

rupture strain (ISO 527)

Young’s Modulus E

(4‐point bending EN ISO 178) Poisson’s ra@o

limit bending strength (DIN 53452) thermal expansion (ISO 7991) material density (ISO 1183)

46 5 39 40 2200

MPa % MPa % MPa

0.38 ‐ 80 MPa 9.2 * 10‐5 1/K 1150 kg/m3

tensile stress σ [%]

duc@le, thermoplas@c material as polycarbonate blend

elonga@on ε [%]

Closed InjecHon Molding – ABS P6

thermoplas@c material as polycarbonate blend

CNC‐ machined nega@ve back @le posi@ve front side final molded parts styrofoam prototype CNC’d solid alu block cast alu for vacuum ABS P6 material

AnH‐ Corrosive TiO2 CoaHng & Shipping from Germany to Mexico

ReducHon of Air PolluHon –up to 5 Years

NOx radicals‐ reducing paint, based on @tanium dioxide TiO2 • TiO2 paint coa@ng with high oxida@ve poten@al, (ac@ve hydroxyl and peroxyl radicals) • photo‐catalyst under UV‐ light + humidity (nano‐ hydrolysis catalyst) • neutralizes radicals such as NOx , SO2, CO and VOC’s • re‐pain@ng required ater its life‐ span (5 years), visible by dis‐coloring

ConstrucHon

pre‐fabricated, light‐weight

ConstrucHon

conven@onal sub‐ structure, low‐tech installa@on

Tectonic

branding fashion label skin

architectural design: Louis Vuiuon (Paris) detail engineering: LED images: LED & personal fashion store façade (Florida)

Sub‐ Structure Approach

under‐cut fixings with aluminum linear railing

Structural Layers

site condi@ons extracted from 3D laser point cloud

exis@ng + main structure sub‐railing system undercut fixings & Ductal @les

Flow Chart – Structural Integrity

lack of US code requires verifica@on strategy 3D SOLIDWORKS master model determine loads (hurricane wind) structure models: 3D‐beam & FEM

rain‐screen Ductal façade: finalize façade geometry & @ling layout

check shear/N interac@on to rule ETA‐03/0055 perform 1:1 small‐ scale and large‐ scale tes@ng calibrate FEM models and verify all panels

verify deflec@ons verify stresses verify stability verify connec@ons

Structural Capacity ‐ Undercuts

1:1 anchor tes@ng, both for shear and tension (pull‐out)

Structural Capacity ‐ Undercuts

detailed finite element modeling including undercut cone

Mold‐ Making: Example Corner Piece silicone rubber‐ based

Site Mock‐ Up, with Overlapping Petals verify color and appearance

Tectonic Precision total joint width < 1/8’’

very smooth surfaces no bubbles sharp corners possible high flexibility for pauerning

Digital – What’s Next? adap@ve

sg2012 cluster, Troy New York: images: sg2012 & personal “bio‐responsive envelopes”

What if …

we could trigger adap@ve IGU rela@ve to user preference sensor

adap@ve window user: views & energy

AdapHvity

programmable sunshades, flexible spandrel pane zones

Flexible Views & Privacy

local views, local shading/glare protec@on

AdapHve Solar Heat Gain Coefficient energy savings over the course of a year

cold winter harvest sunlight

hot summer

protect from sunlight

intermediate spring/fall adap@ve to user preference

Fun & Branding

digitally ‘screen‐ print’ your personal window!

Summary

beauty of molded surfaces

parasi@c

tectonic

digital

thank you

by Will Laufs

PhD, PE, IWE, LEED AP cell: +1 917 971 2577 200 Park Avenue South, Suite 1401 New York City, NY 10003, USA www.laufsed.com