Page 1

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


Innovative Molded Facades - Case Study  
Innovative Molded Facades - Case Study  

Facade + | Chicago Conference | Laufs Engineering Design Presentation