Shaha Raphael 'Casting the Landscape'

Casting the landscape

Technical Studies Shaha Raphael

Term 2 2017/18 Intermediate 9, 2017

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The project started by looking at the restaurant Maaemo in Oslo and the way they are shaped by the produce of the season. This highly contextual approach becomes the basis of the design strategy and this TS document will explore the way the specificity of the site shapes the proposal.

The project is about harnessing whats inside the earth and inverting it by bringing it to the surface, using it to cast and build against the landscape of Ekebergpark.

Granite, extracted from a boring field, would be used in the different stages of casting against the escarpment and define both the external geometry and the interior spaces.

This TS responds to an existing condition of tunneling in the bedrock around Oslo, and wants to harness the byproduct of it by bringing it up to the surface and using it’s demolition waste as both casting material and void forming.

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Table of Content Ts statement 1.

Project construction sequence

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A brief introduction i. Introduction to Maaemo through a dish ii. Introduction to Ekebergparken

3.

Ekeberg’s Granite bedrock as a material resource

i.Norwegian vernacular architecture ii. Tunneling under Oslo iii.Sorting and bringing up granite demolition waste

4.

Byproduct of tunelling as cast and mould material

i. Material study - Sand ii. Using sand as a void forming material iii. Using granite aggregate as part of a concrete mix iv. Site specific application - Casting against the rampart and using sand as a space generator v. Rock as permanent formwork

5.

The Proposal

Conclusion Appendix

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1 The construction sequence laid out in this chapter has the following intentions: 1. Reveal a site specific process and building technique that will be used for the construction of the project.

2. Create a hierarchy to the relationship with the bedrock, first extracting from it and then inverting it to cast on top of it.

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Project construction sequence

Section through ekeberg park - Site as a material resource Scale [ 1 : 200 ] Dimensions in cm

Extracting rock boulders

Extracting granite sand

Rock boulder Boulder is a rock fragment with size greater than 25.6 centimetres in diameter.

Sand Fine aggregates consist of natural sand or crushed stone with most particles passing through a 10 mm sieve.

Crane Hydraulic power unit

Auger piling machine Rotary drilling machine Boring 10 cm vertically to insert screw conveyors in order to bring the sand up

Granite bedrock

Drill bit

Screw conveyor Bringing up rock boulders.

Screw conveyor Bringing up fine aggregates.

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9 Screw conveyor Bringing up coarse aggregates.

Tunnel boring machine - boring through granite MIDLINE

MIDLINE

VEE W.P.

VEE W.P.

VEE W.P.

VEE W.P.

MIDLINE UPPER (LOWERFACE OF BELT)

MIDLINE

UPPER (LOWERFACE OF BELT)

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UPPER (LOWERFACE OF BELT)

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water tank

discharge chute

Rotating mixing drum

Aggregate weighing and discharge conveyor Feeder Cement weighing hopper

Utsiken cafe Exsisting kiosk on site Coarse aggregates are any particles greater than 5 mm, but generally range between 10 and 40 mm in diameter.

Mobile concrete batching plant

Extracting aggregates

In situ making of site spesific concrete

Building a formwork that adapts to the topography

Wind coming from the west transporting sand particles that will be retained by the shutter formwork built on the escarpment of the site.

Formation of natural shapes with sand

Casting the natural shape

Loose particles of sand are damped by rain water, can now be shaped and held in surface tension in order to be cast against without it collapsing or mixing with the concrete mix.

Shutter concrete temporary formwork to cast concrete against

Also acting as a retaining wall for the sand creating natural shapes to cast against

Shutter formwork, layer of rocks added as a permenant formwork, becoming part of the facade by binding with the poured concrete.

Falsework Formwork Supports

Damp sand held together by surface tension

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First layers of concrete cast in layers to not damage the shape of the sand

Casting the natural shape Controlling the depth of pour to maintain the shape

Casting and adapting to different parts of the landscape

Spaces obtained after excavation of Sand

Rock facade- Formwork residue

Second layer of sand connecting the space previously formed. Concrete poured layer by layer until reaching the to of the formwork.

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2 Moving the restaurant Maaemo from the center of Oslo to a park on the periphery of the city, Ekebergparken

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A brief introduction

Introduction to Maaemo through a dish Autumn beetroot dish

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‘I want my cooking to reflect the rugged nature and climate of Norway. I want to create a progressive environment that has a emphasis on the outstanding produce of our region.’

At Maaemo, my focus is on a complete experience. In doing so, I want to highlight the relationship between the raw nature, produce and our cultural history. Welcome to my universe.

I want my cooking to reflect the rugged nature and climate of Norway. I want to create a progressive environment that has a emphasis on the outstanding produce of our region.

We take a lot of inspiration from nature and produces.

Especially from the producers that put their heart and soul to make fantastic produces for us.

Maaemo – an old Norse word meaning «Mother Earth» – is focused on creating a narrative around the clean, bright flavours of Norway.

Esben Holmboe Bang — Chef

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GRONLAND

GAMLE OSLO

Current Location of Maaemo Restaurant in a corporate building in the center of the expanding area where the Barcode Project is a section of the Bjørvika portion of the Fjord City redevelopment on former dock and industrial land in central Oslo. It consists of a row of new multi-purpose high-rise buildings, that was completed in 2016.

The views of access to nature from the restaurant are blocked by high rises.

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EKEBERG

NORTH SEA

Ekeberparken Proposed site for the move of Maaemo. A park from which the restaurant forages some of it’s ingredients such as pines, mushrooms, flowers and specific leaves. The site has a proximity to the north sea, it sits on a bedrock at +80m from the sea and has a spectacular view on the Oslo fjords.

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Norwegian landscape- Ethos of Maaemo

“We opened Maaemo to have something that we felt was the right way to let Norwegian nature shine through on the plate.”

Maaemo chef Esben Holboe Bang

Maaemo, an old Norse word meaning «Mother Earth» is focused on creating a narrative around the clean, bright flavours of Norway.

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terrace 12 m2

Entrance 10.66 m2 Test table 16.14 m2

Stairs connecting kitchen area to hall Kitchen 31.36 m2

The space the restaurant is currently in does not follow the ethos of the retaurant which is the norwegian landscape. It sits in a corporate building with no relationship to nature whatsoever.

Therefore, the project proposes to redefine the identity of the restaurant in Ekebergparken, a site comprising different elements of the natural environment such as a stream, a forest, an escarpment and a field, with a view to the Oslo Fjords.

Hall 68 m2

Waiter room 6.50 m2 Winecellar 5.33 m2 Stairs to research lab 40 m2

[ 1 : 100 ] Axonometric drawing of exsisting restaurant

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Main view from the field of ekebergparken - overlooking the Oslofjords

Malmøya

Rambergøya

Østre Hovedøya

Bleikøya

The Oslofjords Oslofjord is not a fjord in the geological sense - in Norwegian the term fjord can refer to a wide range of waterways. The bay is divided into the inner and outer Oslofjord at the point of the 17 by 1 kilometre.

Each of the islands in the innermost part of the fjord has its own identity and distinguishing history. Among them are Hovedøya, Lindøya, Nakholmen, Bleikøya, Gressholmen, and Langøyene.

Hovedøya contains monastery ruins, Gressholmen for its rabbits, Nakholmen, Bleikøya, Lindøya for their cosy cabins at the water’s edge, and finally Langøyene for its camping possibilities and beach.

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Exsisting building on site - Alongside a stream

Utsikten Cafe (The View Cafe) In the Ekeberg slope there is a small building known as Café Utsikten, currently abandoned. Many have stopped here for a summer day to eat an ice cream or buy a waffles. The view is phenomenal so the name is justifed. The place is also called the Talon by older people. Café Utsikten has the address Kongsveien 45.

Oslo Municipality was and is the owner of the cafe building that they rented out. The kiosk had then got a new location by the stream and close to the appearance it has today, but a bit shorter, with only 2 windows. An extension was made later, so the building was extended by a third and became as we know it is today with 3 windows.

The café is now closed due to sanitation since 2009. The owner Oslo Municipality must install washing facilities and water closet for any future use.

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The projec’t intentions - Building on the escarpment of the site The rampart as the ultimate trade with the landscape

Understanding the exsisting building on site as a cultural icon for the people of Oslo

Keeping the field situated at + 80 m from the sea clear

Building on the edge condition, following the topography of the site.

[ 1 : 100 }

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The view from the park

2018

2005

1927

Ekeberkparken has always been a recreational area for the people of Oslo as they culturally have this connection to nature.

Over the years the parc has been used specifically in it’s platform areas as viewing points and seating places.

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Conclusion/ Moving the restaurant to Ekebergparken allows the integration and experience of the landscape itself, along with the experience of the landscape on a plate. The project preserves the field of Ekeberg and begins it’s construction on the hill.

How to use the site as a material resource?

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Ekebergparken’s bedrock as a material resource

This chapter is going to expand on the context and current tunneling through bedrocks in Oslo as a part of the city’s development.

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Scale [ 1:100 ] 27

Case study - Appropriating the site as a material resource

Typically Norwegian farms are located where trees grow, and near a water source. The settlement cut some trees to harvest wood for construction, tools and heating and also to create lands to farm.They are organized like small towns, as they are self-sufficient, with one road connecting them to the closest town.

In most farms; the parcels are often long, going down the slope to reach the water. They are either separated because of inheritance or spread around one domain. Some farms are linear, they follow the contours being parallel to the slope, while other lie as squares in flat areas.

The construction materials are basic. Wood is the dominant material used for the structure, with clay, straw and earth typically used as insulation. Some wealthy houses have groutless stones bedrocks, planking and tiling as improvements.

The houses are built with criss-cross massive logs. This kind of method is called “Laft” construction. It is a very developed subject, and the predominant type of structure in Norwegian farms. Often, the outside structures are made with braced gates. There is no ridge beam because of the central chimney above the fire place, located in the main room.

A stone path leads people from house to house. The staircases are also made of stone. They are dry, strong and comfortable, as we expect from public spaces.

Outside arcades are shelters and lead to a set of doors, where you can enter the main room: the stove.

Observation/ Norwegian building techniques and architecture has a long tradition of appropriating the materials that are available in order to construct the early settlments.

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Case Study - Building Following the topography

Each building was placed first in relation to the topology and then in relation to the other buildings, while striving to maintain the general square tun layout.

OLD FORGE

SAUNA

COOKHOUSE DWELLING HOUSE

STABLE

COW BARN

GRAIN BARN

STORE HOUSE

Observation/ Adapting to the landscape topography and slopes was always part of the norwegian traditional way of building farms. Using surrounding stones to build walls or foundations in order to level the settlment.

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Oslo’s current underground condition and geology

Weathering material Thick marine deposits - Shale / Dolomite Thin marine deposits - Quartzite Bare mountain - Migmatime / Norwegian granite InďŹ ll - Sandstone / Limestone River deposition Chanorchite / Anorthosite

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Heavy traffic on older roads and streets have the effect of destroying many urban areas. The new primary roads are not a supplement to the existing roads and streets. They replace those that are overloaded with traffic. Tunnels are being more frequently used than previously, to pr prevent the destruction of the original dense city structure. As much as 70 % of the new road network in Oslo will be tunnels.

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2 <59 °53’40.9”N.10°45’38.7”E>

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1. Vaalerenga Tunnel 2. Ekeberg tunne; 3. E 18 road 4. Oslo tunnel 5. Interchange at vestbanen TUNNELING THROUGH THE ROCKS OF OSLO’S UNDERGROUND [ 1:4000 ] 31

Osloâ&#x20AC;&#x2122;s forecoming plans for tunneling roads in the bedrock

Site - Ekebergparken

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Tunnels- burrying roads

One of the three tunnels shown in this drawing, the lowermost one is passing underneath the site and the project will utulise the Demolition waste from the tunnel, bringing them vertically up to the site and using it as a material recource to build on the escarpment of the site.

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south

Scale [ 1 : 1000 ]

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Understanding tunneling through rocks - Tunnel Boring Machine

The cutterhead covered in rotating disks spins as the machine moves forward, pulverizing and moving up to 760 tons of rock per hour

The demolition waste is slurped out in the muck chamber from what is called the â&#x20AC;&#x2DC;bucket lipsâ&#x20AC;&#x2122; located on the cutterhead

Scale [ 1 : 50 ]

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The demolition waste moves from the muck chamber and is taken out by a screw conveyor.

Conveyor belt displacing the demolition waste onto wagons to then be transported out of the tunnel

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UPPER (LOWERFACE OF BELT)

UPPER (LOWERFACE OF BELT)

MIDLINE

MIDLINE

VEE W.P.

VEE W.P.

The first Tunnelling Boring Machines (TBM) was put into use in Norway in 1972. Since then some 260 km has been bored., Compared with conventional tunnelblasting, the use of TBMs has reduced or completely eliminated environmental pressures such as blasting fumes, diesel exhaust, oil mist at the face and blockfall, but at the same time has resulted in increased pressures elsewhere. Around 10 million tons of rock spoil will be removed during tunnel construction.

Following an invitation of interest, the Norwegian National Rail Administration has established contact with various public and private sector parties who can make use of the spoil. It is important that the rock spoil is recycled in a socially and environmentally acceptable manner. It is assumed that the Follo Line project could recycle up to 20 % of the TBM excavation material for concrete production purposes.

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Sorting the demolition waste Before the extraction of the material by boring the surface, the blasted rocks are sorted into three different categories, in order to be used in wanted construction materials.

Sand as fine aggregates, coarse aggregates and rock boulders are sorted.

Conveyor belt 1

Dump hopper

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Crusher

Feeding of unsorted material

Separation by compressed air

/ Sizer

Conveyor belt 2

Crusher / Sizer

Conveyor belt 3

For the purpose of the project, the demolition waste is going to be sorted into three different rock sizes before being extracted up.

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Drilling to extract different rock sizes

Rock boulder Boulder is a rock fragment with size greater than 25.6 centimetres in diameter.

Sand Fine aggregates consist of natural sand or crushed stone with most particles passing through a 10 mm sieve.

Crane Hydraulic power unit

Auger piling machine Rotary drilling machine Boring 10 cm vertically to insert screw conveyors in order to bring the sand up

Granite bedrock

Drill bit

Screw conveyor Bringing up rock boulders.

Screw conveyor Bringing up fine aggregates.

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39 Screw conveyor Bringing up coarse aggregates.

Tunnel boring machine - boring through granite MIDLINE

MIDLINE

VEE W.P.

VEE W.P.

VEE W.P.

VEE W.P.

MIDLINE

MIDLINE

UPPER (LOWERFACE OF BELT)

UPPER (LOWERFACE OF BELT)

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UPPER (LOWERFACE OF BELT)

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In 2020, the tunneling works will begin and quickly reach the underground of the site, during this perios the site will become a boring site with a few bore holes to bring up the aggregates demolition waste that will be used for the construction of the project. water tank

discharge chute

Rotating mixing drum

Aggregate weighing and discharge conveyor Feeder Cement weighing hopper Coarse aggregates are any particles greater than 5 mm, but generally range between 10 and 40 mm in diameter.

Utsiken cafe Exsisting kiosk on site Mobile concrete batching plant

The main rock formation of the area is Drammensgranitt, a strong red granite.

Granite aggregates are crushed hard rock of granular structure, being the most common on Earth. Granite rock comes from magma that erupted on the ground surface and then hardened. It is the best aggregate for high-grade concrete.Granite is also used as a decorative stone.

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Processing of resources

10 cm

2 cm

Sand as a mould

2200 cm

2 cm

Sand as a fine aggregate Part of a concrete mix

2.2 cm

2.8 cm 9.1 cm

10cm 30 cm

6.2 cm

Coarse aggregate Part of a concrete mix

Used in a facade Included in the wall formwork to cast against

2176 cm

Gabion wall Wall held together with mortar

26.9 cm

Wall held together with string (Gramazzio Kohler )

60 cm

Extracting three different sizes of rocks by boring on site after sorting them underground in the ongoing tunnel.

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Conclusion/ The byproduct of the exsisting condition of tunneling is sorted into three different rock size particles and extracted through vertical shafts to the surface of the ground.

How to use the site specific material as a building material?

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Byproduct of tunneling as cast and mould material

This chapter is going to explore different ways of using the byproduct, firstly the artificial sand as a void forming material in casting, and secondly as aggregates in a concrete mix to cast with.

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Byproduct of tunneling as cast and mould material i. Material study - Sand

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Angle of repose

The angle of repose of a granular material is the steepest angle of descent relative to the horizontal plane to which a material can be piled without slumping. At this angle, the material on the slope face is on the verge of sliding. The angle of repose can range from 0 ° to 90 °. Smooth rounded sand grains cannot be piled as steeply as can rough interlocking sands. If a small amount of water is able to bridge the gaps between particles, electrostatic attraction of water to mineral surfaces will increase soil strength

Various materials and their angle of repose

Material ( Condition )

Angle of Repose (Degrees)

Ashes

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Asphalt ( crushed )

30-45

Bark

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Bran

30-45

Chalk

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Clay (dry lump)

25-40

Clay ( wet excavated )

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Coffee beans

35-45

Earth

30-45

Flour ( corn )

30-40

Granite

35-40

Gravel (crushed stone )

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Gravel ( naural )

25-30

Sand ( dry )

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Snow

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The following function provides a ood approximation of the angle of repose by knowing the friction of the material. tan (a) = x x being the coefficient of static friction, and (a) the angle of repose

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Angle of repose and properties of sand

3 5 .0

0°

0°

3 5 .0

Fine sand

Dry sand

∞

0¬

.0

90

∞

040.0

Coarse sand

Moist sand

∞

00¬

45.

10.00°

Angular pebbles

Water-saturated sand

R

Fr

mg

W

The object is in equilibrium, so taking the forces acting along the plane, we can say: Fr

m g

sin

R

Observation/ Loose sand has a limitation of creating a space of maximum 35 degrees, adding water and re

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Case Study - Sand sculpture method Form making

Dry sand

Wet sand

Grain to grain frictional contact

Step 1 Add lose sand to a bucket

Step 2 Add water to the sand until you find the good consistency

Water saturated sand

Surface tension of thin film of water holds the grains together

Step 3 Mix the two materials together until it becomes compact

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Water completely surrounds all grains and eliminates all grain to grain contact

Step 4 Flip the bucket and let the compact sand get out of it

Step 5 Start sculpting with the ideal tools. Work from top to bottom to avoid collapsing

Sandcastles constructed by Calvin Seibert

When you add sand to water, the surface tension of the water forms little elastic bridges between the grains of sand. When the ratio of sand to water is just right these bridges are the perfect strength for building sand castles. Surface tension is the attraction that happens between water molecules.

Water molecules are attracted to each other. The surface of water has an elastic quality because the molecules are hugging close together. This is why some insects can walk on water.

Observation/ Sand as a material can also be shaped and form angular shape for a different spacial quality when water is added at the right dose.

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Byproduct of tunneling as cast and mould material ii. Using sand as a void forming material

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Construction process of the inverted shell - casting on sand then flipping it into foundation

3. Filling in foundation to stabilize structures

3. Positioning the two walls

3. Flipping wall on foundation

3. Casting foundation and wall

3. Shaped metal rebar inserted

2. Excavation of the soil in a specific shape to cast in

1. Deposit and displacement of soil and sand to create a mound

Metal Reinforcement Concrete Soil

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Construction process of the vaulted structure - Casting using earth and sand from the building site

6. Excavation of cast

5. Waiting for the concrete to set in the soil

4. Concrete pouring and adding more sand on top to lighten the structure

3. Metal reinforcement rods placed in the shape of the structure before pouring the concrete

2. Excavation of the soil in a specific shape to cast in

1. Deposit and displacement of soil and sand to create a mound

Metal Reinforcement Concrete Soil

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Understanding retaining walls

earth pressure vector gravity vector of wall reactive force vector

Gravity wall

Piling wall

Standard wall type that hold the earth mainly through its own weight.

Can pivot and topple relatively easily, as the internal leverage of the earth pressure is very high.

Using long piles, this wall is fixed by soil on both sides of its lower length.

If the piles themselves can resist the bending forces, this wall can take high loads.

Cantilever wall

Anchored wall

Standard wall type that hold the earth mainly through its own weight.

Can pivot and topple relatively easily, as the internal leverage of the earth pressure is very high.

This wall keeps itself from toppling by having cables driven into the soil or rock, fixed by expanding anchors (can be combined with other types of walls).

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Material experiment - Sand casting

Plaster mix

Pressed sand Loose sand

rectangular wooden mould

Void formed by the sand temporary mould

Rough texture formed by loose sand

Smooth texture formed by packed sand

Smooth surface formed by the plywood mould

Observation / The sand doesnâ&#x20AC;&#x2122;t mix with plaster which has similar characteristics as plaster.

Void forming by sand can give the plaster different textures roughnesses.

Sand does not stick to plaster, after brushing the surface the experiment proved that the sand can come off.

Understanding a sediment holder

Longshore transport

Longshore transport

updrift

Sediment build up

downdrift

groin field

sand trapped and retained by groin

A groine is a rigid hydraulic structure built from an ocean shore or a river bank that interrupts water flow and limits the movement of sediment. In the ocean, groynes create drift. In a river, groynes prevent erosion and ice-jamming, which in turn aids navigation. Ocean groynes run generally perpendicular to the shore, extending from the upper foreshore or beach into the water. all of a groyne may be underwater, in which case it is a submerged groyne. The areas between groups of groynes are groyne fields. Groynes are generally made of wood, concrete, or rock piles, and placed in groups. They are often used in tandem with seawalls. Groynes, however, may cause a shoreline to be perceived as unnatural.

Observation/ A series of artifial stone walls recreate natural dune shapes by retaining sediments carried away by the sea waves.

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Form making by casting materials on site in layers - Sand and Ice

Layer 5

Layer 4

Layer 3

Layer 2 layer of moist sand shaped geometrically also linked to the first layer of sand

Layer 1 temporary sand mould first layer of plaster

Rectangular plywood box as an overall mould

There is a level at which the cast can be controlled Controlled: square mould to cast in Not controlled: shapes made with sand andreaction of materials to each other

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Form making by layering - Sand and Ice T = 0 min

T = 2 hrs min

T = 4 hrs

Step 5 Ice melts as plaster sets and is absorbed by the previous layer of sand

Step 9 Third layer of sand shaped from the inside

T = 30min

T = 2.3 hrs

T = 4.5 hrs

Step 2 Pour ďŹ rst layer of plaster

Step 6 Second layer of sand deposited in cavity created by the ice

Step 10 Plaster poured over shaped sand

T=1h

T = 3 hrs

T = 5 hrs

Step 3 First ice layer covering both plaster and sand layers

Step 7 More sand added and shaped

Step 11 Layer of ice added on sand and plaster

T = 1.30 hrs

T = 3.5 hrs

T = 5.5 hrs

Step 4 Setting of the plaster layer on top of ice

Step 8 Plaster poured on top of shaped sand

Step 12 Last layer of plaster poured on ice and previous layer of plaster

Step 1 Layer of sand, left in its original shape ( not condensed )

Ice Sand

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Process - Angle of repose

Revealing the spaces

Observation/ Casting layers of sand and plaster one after the other allowed more controle over theshapes and angles of repose, angle up to 90 degrees were achieved . The layering permitted the formation of interconnected spaces and vertical connections between the layers.

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Casting concrete on ice

Observation / The concrete sets before the ice completely melts While the ice is melting it creates shapes and channels up until the surface of the cast. Organic shapes and textures are formed.

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Thickness of concrete as a natural reinforcement

Load

Compression ( concrete )

Crack pattern with concrete under load

Compression ( concrete ) Tension ( steel ) Cracked pattern in concrete with steel reinforcement

Observation/ Due to the cold and icy weather in Norway, concrete constructions without rebars would last longer considering the fact that rebars causes fast decay as the water penetrates, rusts and induces cracks in the concrete by expanding.

Case study - Unreinforced dome

Force of supports

Weight of stone

Force of supports

Romans are the pioneers of the concrete revolution. Their structures have lasted close to 2000 years - pantheon Rome, constructed 126AD is the worlds largest unreinforced dome,

Redirected force

the tremendous weight of the stone on top of the entryways, windows, and passages coiuld cause them to collapse. The achitects solved this problem with the use of aches. Arches take the force of the stone above it and redirects this force through its sides to the Pantheon’s support walls and piers. These support walls and pillars provide o horizontal normal force to counteract the force of the stone obove the arches. The Structure’s weight is channeled through the piers to it’s foundation.

layers of concrete with flakes of tuff and volcanic rocks layers of concrete alternating with flakes of tuff and bricks layers of concrete with flakes bricks

layers of concrete with flakes of travertine, tuff, and bricks

layers of concrete with flakes of travertine and tuff

layers of concrete with flakes of travertine foundation

The aggregates used in the castes concrete get lighter as the construction goes up, in order to resist and respond to the forces.

This method is used instead of using metal reinforcement in the concrete.

How to cast concrete on sand without it breaking?

Sand trapped in a corner ready to be casted on

6m 5m 4m 3m 2m 1m

Sand + water ready to be casted on

0m

Pouring concrete on sand all at once Shape of sand altered 6m 5m

Concrete pouring pipe

4m 3m

Pressure of concrete collapsing the sand

2m 1m

Sand losing itâ&#x20AC;&#x2122;s shape

0m

Observation/ The high pressure of the concrete going out of the concrete pipe messes up the shape of the sand help by surface tension. The pressur ecauses the sand pile to collapse.

Pouring the concrete all at once doesnt allow the sand to create spaces.

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Sand trapped in a corner ready to be casted on 6m 5m 4m 3m 2m 1m

Sand + water ready to be casted on

0m

Controlling depth of pour 6m 5m 4m 3m

Concrete pouring pipe

2m 1m

First layer of concrete keeping the sand in shape

0m

Shape of sand not altered 6m 5m

After 6 layers of concrete, the wanted shape is obtained without collapsing the sand

4m 3m 2m

Sand intact, ready to be taken away after the curing of the concrete

1m

Conclusion/ Controlling the depth of pour would preserve the initial shape of the sand. Therefore, the concrete must be poured in multiple layers 50 cm at a time.

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Conclusion/ Loose sandâ&#x20AC;&#x2122;s angle of repos is of only 35 degrees and therefore does not allow the creation of inhabitable spaces, this angle of repos can go up to 90 degrees by keeping the mix damp, due to surface tension which holds together itâ&#x20AC;&#x2122;s particles.

Casting on sand to obtain a natural like void is possible on a real scale by controlling the depth of pour of the concrete.

The dome like shape obtained from the sand casting and the thickness of the concrete used allows a construction without steel reinforcement.

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4

Byproduct of tunneling as cast and mould material iii. Using granite aggregates as part of a concrete mix

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Basic concrete mix - understanding aggregates

The aggregates ( sand and gravel) are the main constituent of concrete, at over 70 % by volume. The type and quality of the aggregates are therefore vitally important for the properties of the concrete, both fresh and hardened Concrete aggregates, consisting of sand and gravel, represent the grain skeleton of the concrete. All the cavities within the skeleton have to be filled with binder paste as complete as possible. Concrete aggregates sum up to approximately 80% of the concrete weight and 70 % of its volume.

Aggregates can occur naturally (fluvial or glacial), industrially produces like lightweight aggregates as well as recycled aggregates. For high quality concrete they are cleaned and graded in industrial facilities by mechanical processes such as crushing, washing, screening and mixing together.

Concrete aggregates should have a strong bond with the hardened cement paste, should not interfere with he cement hardening, and should not have negative effect on concrete durability.

Particles or grains

Grade

Diameter (mm)

Stone (Boulders)

Derrick One-Man Cobbles

>500 200-500 50-200

Gravel

Coarse Medium Fine

20.0 - 50.0 5.0 - 20.0 2.0 - 5.0

Coarse Medium Fine

0.5 - 2.0 0.2 - 0.5 0.05 - 0.2

Coarse Medium Fine

0.02 - 0.05 0.05 - 0.005 0.005 - 0.002

Coarse Medium Colloidal

0.002 - 0.0005 0.0005 - 0.0002 0.0002 - 0.0001

Sand

Silt

Clay

Scale

Classification of sedimentary rocks

Aggregates

Density

Source

Standard

2.2 - 3.0 kg/dm3

From natural deposits, e.g. river gravel, moraine, gravel, etc

Heavy-weight

> 3.0 kg/dm3

Such as barytes, iron ore, steel granulate for heavy concrete ( e.g. radiation shielding concrete )

Lightweight

< 2.0 kg/dm3

Such as expanded clay, pumice, polystyrene for lightweight concrete, insulating concretes

Hard

> 2.5 kg/dm3

Such as quartz, carborundum for granolithis concrete surfacing

Recycled granulates

approx 2.54kg/dm3

From crushed old concrete etc.

Material round or crushed ( e.g excavated tunnel )

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Using the raw material as aggregates for a concrete mix

Coming in different sizes the aggregates are the biggest constituent of the final product. They give the concrete its strength and cohesion and are from various sources, sizes and colors, affecting the mix in different ways.

4 parts sand 2 parts gravel

Very logically called the glue of the concrete, it is the element creating the bonds between all others. Also of various kind the cement is certainly the most energy user and waster.

3 parts cement

AGGREGATES

CEMENT

Water is like the cement necessary little brother. To create the reaction, heat of hydration, the cement absolutely need water. The ratio of water will also deeply affect the outcome qualities of the concrete.

WATER

CONCRETE

ADDMIXTURES They are used as a ratio of about 5% and inserted generally at the end of the mixing process. They can have many effect but all act and transform the basic chemical reactions of the concrete.

Observation/ The concrete that is going to be used will be specific to the site, the aggregates (sand and gravel) are granite aggregates from beneath the site, the cement is the only added material.

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Concrete characteristics - textures

Textures

Formwork

Wool strings

Plywood strips with a gap in between the strips

Plywood strips with minimal gap in between the strips

Perforated metal sheet Obersation/ Even within the confines of a seemingly simple panel wall cast, concrete affords many possi­bilities of texture variation. The plasticity of it means that it readily pick up the texture concrete, of the material against which it is cast.

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Revealing the aggregates

Max Lamb Terazzo Tile 4 types of aggregates used in the making of tiles, then revealed after grinding and polishing the surface

Power controller Dust clean handle Dust collector

Grinding motor

Vacuum motor

Grinding unit

Self propelled grinding/pollishing machine Observation/ Grinding the concrete is a way of revealing the aggregate which is made ou t of the rocks of the underground of the park.

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Pre cast concrete casting This is a well established modern method of construction, delivering robust components in factory conditions. The maximum size of a precast component will be limited by the road transport regulations and access to the site.

Pros: Excellent quality control Precision moulds with a close controle of tolerances Large components which are simple and rapid to install.

The load exerted on the precast concrete elements during transportation and erection need to be carefully considered at an early stage. In a precast concrete cladding panel, often the fixing details will also act as the points for lifting and temporary support.

Cons: The transportation of heavy components.

The need for repetition to offset the cost of the mould.

Pre cast element Pre cast element

Crane lifting up and placing pre cast concrete elements on site

Pre cast concrete stairs Modular structures

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In situ concrete casting The main strength of in situ concrete is itâ&#x20AC;&#x2122;s formability, which facilitates the creation of bespoke or one-off geometry that is design and especially site-specific.

In essence there is no limitations on the dimensions or forms, provided the right reinforcement, formworks and falsework is prepared for the cast.

Pros: Flexible site-based processes can be achieved Repetitive and reusable formwork is now common It allows the integration of details and services Cons: The tolerances of in situ needs to be well understood Attention needs to be paid to weather conditions.

Extra falsework and scaffolding need to be used.

plywood

wale spacing

wales studs

form ties lateral brace

brace stud spacing anchor

In situ concrete stairs - Site specific

tie spacing

Observation/

Alvaro siza pools in porto

Given the particularities of the proposal, the in situ concrete method will be adapted in order to construct the mould accorning to the topography making it possible for the built to be an extension of the natural.

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Preparing the concrete mix on site/ Mobile concrete batching plant

Sand hopper

Aggregate hopper

Aggregate weighing and discharge conveyor belt

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Controle cabin

Cement weighing hopper

Water tank

Water weighing tank

Rotating mixing drum Discharge chute

Conclusion/ Given the particularities of the proposal which is about the relationship with the surroundings, using site specific concrete, mixed and poured in situ with a composition of 80% aggregate coming from the underground of the site is the construction process that will be elaborated on for the project.

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Case study - Shaping the formwork to the topography Villa Busk Sverre Fehn

Villa busk stands on the edge of a rocky outcrop with a view of the sea.

A work that orchestrates the persons experience of and relations with their surroundings. â&#x20AC;&#x153;The rampart is the ultimate trade with the landscape.â&#x20AC;?

The project is site specific it could not be the same anywhere else, chose to position it on the natural outcrop of rock, amongst mature trees, and with a view to the sea. The purpose is to enhance and exploit the inherent potential of this place. The project begins with a simple trade with the landscape, a rampart.

Elevation scale [ 1 : 100 ]

Section scale [ 1 : 100 ]

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Shutter formwork adapted to the landscape of the site

Plywood shutter formwork built on site, piece by piece cut according and in relation to the beneath bedrock surface that will be casted on

Escarpment

The way the architect approaches the site and itâ&#x20AC;&#x2122;s escarpment and the relationship between the built and the natural is one that I am looking to explore in my project.

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Adapting the formwork to the land

Plywood The formwork surface on the Maini form Curved System is phenolic resin-coated plywood.

Depending on the pressure of the wall, there are two thicknesses and resistan es: 50 kN/mm2 (with phenolic of 18 mm) 45 kN/mm2 (with phenolic of 12 mm)

Aligners of 3, 6 and 9 m Accessory to stabilize and to plumb the wall shuttering.

Wedge clamp

Adjustable clamp

The Wedge Clamp joins and braces the panels in one single process without needing any tools.

The Wedge Adjustable Clamp joins two Maini form modules with a wood filler up to 26 cm wide

Beam HT-20

Main beam

Structural component made of wood which supports the surface formwork and the main beam. The distribution of the wood beams varies depending on the count made by the Technical Department.

Resistant component manufactured in steel that supports the tie rods.

The inde­pendent arrangement of the tie bars on the module allows the Maini Curved system to be customized to the archi­tect's project.

1

2

3

Configuration 1

1

2

Configuration 2

3

1

2

3

Configuration 3

Reconfigurable shutter formwork

1. 12 mm plywood board 2. Beam HT-20 3. Main beam

Observation/ The curved wall formwork and its different configusations allows the casted elements to follow the shape of the land.

Lateral concrete pressure - hydrostatic pressure

x

Fresh concrete

Hydrostatic pressure

Hydrostatic Pressure Concrete poured in formwork in one continuous go

2x

Fresh concrete

2 x Pressure

2 x Pressure

Height of concrete pour: Before concrete hardens, it acts like a liquid and pushes against the forms the way water presses against the walls of a storage tank. The amount of pressure at any point on the form is directly determined by the height and weight of concrete above it. Pressure is not affected by the thickness of the wall.

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Controlling height of pour to minimise hydrostatic pressure

Concrete level

Concrete level

Fresh concrete

Fresh concrete

Hardened concrete

1 hour

2 hours

Concrete level

Concrete level

Fresh concrete

Hardened concrete Hardened concrete

3 hours

Form design pressure

Observation/ If concrete begins to harden before the pour is complete, the full liquid head will not develop and the pressure against the forms will be less than if the pour were completed before any of concrete hardened.

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4

Byproduct of tunneling as cast and mould material iv.

Site specific application - Casting against the rampart and using sand as a space generator

83

Plan view model os site fragment [ 1 : 75 ] 84

Site specific application - Casting against the rampart and using sand as a space generator

Site escarpment

Metal shutter shaped and bended according to the escarpment

Plywood shutter

Step 1/ reconstruct the escarpment

Step 2/ Build the walls Site specific walls following the topography Step 3/ CLose off any possible leaking points Step 4/ Start shaping spaces as a first layer with sand

Step 5/ First layer of concrete Shaped metal shutters Step 6/ Wait for it to dry - to minimise pressure on the shutter

Step 7/ Repeat step 5 and 6 until wanted height

Step 8/ Wait for the concrete to set

Step 9/ Take out the shutters

Step 10/ Remove the sand from to reveal formation of spaces

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Site specific application - Casting against the rampart and using sand as a space generator

1/ first retaining wall built on slope

2/ wind dragging the grinded sand down the slope

3/ sand retained in its natural shape

4/ Rain water compresses the sand and allows for it to be shapeable

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5/ first layer of concrete is poured

6/ another layer of sand is retained against the wall on the concrete layer

7/ rain allowing for the particles to be compact

8/ second layer of concrete and unmoulding of the retaining wall and sand used as formworks

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Site specific application - Casting against the rampart and using sand as a space generator The void

The concrete

28 m

3m

7m 3m

4m

Second layer of sand First layer of sand to cast on space generator

Metal shuttering to cast against

Sand shaped space Concrete cast on metal shutter

Bedrock landscape

1:75 fragment model

88

Metal shutter 2

Concrete cast against landscape

Concrete cast against sand - rough texture

Metal shutter 1

Conclusion/ This fragment of casted landscape is very specific to the site, the external shape is the direct product of the topography of the land. Indeed, the shutter sits directly on the bedrock and defines the shape of the structure, while the sand creates organic cavities that create the interior spaces while contrasting with the smoothness of the curved wall.

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4

Byproduct of tunneling as cast and mould material v. Rocks as a permanent formwork

91

Gabion wall Modular Gabion Systems are engineered welded wire mesh products for earth retention and soil stabilization; erosion control and flood control; and landscape and architectural applications. In simplest terms, gabions are stone filled baskets used to stabilize soil and prevent erosion

Gabion wall

Gabion barrier

Gabion corner wall

Gabion gap

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Individual gabions

Gabion wall detail

A gabion is a cage, cylinder, or box filled with rocks, concrete, or sometimes sand and soil for use in civil engineering, road building, military applications and landscaping.

Steel cage Basket welded mesh

Rock boulders

40 cm of soil

Granite bedrock

Scale [ 1 : 10 ]

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Flint House - Skene Catling de la Pena

It embodies the idea of the geological extrusion, infinite age and of revealing something already there. This was the fundamental generator for the design, and carries through from the form itself into the materiality and final detail.” To be more specific the landscape is covered with flint filled soil and chalk and this is shown in their design through flints, that are arranged by colour to give the structure a tonal gradient.

“Described by judges as a marvel of geological evolution and construction, Flint House is a celebration of location, material and architectural design at its best,” said a statement from the RIBA. trainstation helsinki The innovation and beauty of the scheme is particularly evident in the detail of the cladding. It consists of a varying use of flint that starts at its base as snapped flint and slowly changes in construction and texture until it becomes chalk walling at the highest point. This gives both a feeling of varying geological strata with the building dissolving as it reaches to the sky.

The building is an example of an innovative piece of architecture that suggests a typology for the oneoff house that is not an object in the landscape but is of the landscape; yet is not so deferential to nature

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Binding technique - using string as an alternative to mortar Gramazio Kohler research - Rock print

The column was constructed inside wooden formwork, with layers of string laid down by a robotic arm following an algorithmically-determined pattern. In between these string layers, thin layers of stone were spread by hand. After the installation had reached full height, the formwork was removed, leaving only the string-bound sections of the print still standing.

Gravel layers in to be binded together by string

String pattern dictated by an algorithm binding layers of rocks layed down by hand layer by layer Plywood temporary formwork

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the process is essentially the same as powder-based 3D printing techniques, the only difference in this case being that the granules are significantly larger, and instead of a chemical binder, it uses string as a mechanical binder. The strength of the structure is reliant on the balance between the "jamming phenomenon" - a result of a large number of particles crammed into one space - and the binding tension provided by the string.

Observation/ The use of a non destructive (non adhesive) binder of string to hold structural formations of gravel in place is a good alternative to cement or mortar which are extremely fuel intensive materials.

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Shutter formwork - Plywood Rock and sand

Shutter formwork components Height of pour of concrete

Plywood formwork

Concrete 5m Falsework 4m

3m Support 2m

Rock shutters Sand mixed with water

1m

Bedrock

Rocks bound to the poured concrete

Rocks collapsing after taking out the formwork

Sand shaped space

Concrete wall

Rocks that were part of the shutter formwork become part of the facade by binding with the concrete

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Residue of shutter formwork that becomes part of the facade

Rock facade

Concrete facade

Sand shaped space

Bedrock

Scale [ 1 : 100 ]

Facade fragment

99

100

5

101

The proposal

Phase 2: Building the shutters Rock metal and plywood shutters

Phase 1: extracting and sorting granite from the grounds Phase 2: Building the shutter formwork

+ 80 m The view cafe 55 sq.m

Underground tunnel used for material excavation The field The stream Beginning of the escarpment 4

3 Starting the construction of the walls from the bottom up

2

1

1.

2.

3.

4.

Site plan [ 1 : 100 ]

first area of appropriation +30 m from sea level second area of appropriation +40 m from sea level third area of appropriation +46 m from sea level fourth area of appropriation +70 m from sea level

102

Phase 4: Starting to cast from the bottom up

Concrete casting against shutters against the escarpment and sand for void forming

Phase 3: Moving the view cafe to the edge of the escarpment as a starting point for the project Phase 4: Starting to cast from the bottom up Phase 5: Unmoulding the shutters - Residue of rocks on the facades Phase 6: Sand coming out of spaces with the help of gravity and wind and revealing the spaces

+ 80 m

[ 1 : 100 ]

Pink Granite Sand as a temporary mould - building up the negative of the wanted space Granite and sand aggregate concrete poured in layers of 50 cm at a time to preserve and controle to a certain degree the sand shape

103

Phase 7

A path from the exsisting view cafe down the escarpment, experiencing the restaurant and the landscape

Phase 7: Creating a Granite path connecting the casted spaces together into one continous Maaemo experience

+ 80 m

fig 1

fig 2

Site plan [ 1 : 100 ]

104

Detailing

A path from the exsisting view cafe down the escarpment, experiencing the restaurant and the landscape

2 3 50 cm

Section [ 1 : 50 ]

1

Plan [ 1 : 50 ] 2. staircase on bedrock

1. glass in between bedrock and concrete

2. window embedded in concrete

Concrete

Concrete Concrete

inside

Bedrock

Bedrock

scale [ 1 : 5 ] 105

fig 1

fig 2

106

Scale [ 1 : 75 ] site model

107

108

This TS exploration has enabled an understanding of the potential of reutulising the demolition waste of an exsisting condition of tunneling in granite bedrocks . Natural shapes and spaces were

109

A

ppendix

[ 4000:1 ] Early studies of fermentation at the microscopic scale have led me to look at the underground of the site and how the project can use it.

Fermenting rice grains in order to grow koji, requires an exchange between the inner rice and itâ&#x20AC;&#x2122;s envelope, causing the rice to bloom.

112

113

1 2

3

4 5 6

7 32 °C

8

9

10

11 12

39 °C

13

14 44.9 °C

15

16

114

[ 1 : 10 ] koji apparatus 1. Inkbird thermostat regulating humidity inside the room at %80 2. Inkbird thermostat regulating temperature inside the room at around 33 C 3. Perforated lid for air circulation made out of 1.2 cm plywood 4. Plywood facade, cutouts to be able to see through 5. Perspex windows (0.5 mm) 6. Rice container (1kg each) with perforated 6mm plywood bottom for the hot air to be in direct contact with the fermenting rice.

7. Metal rod (1cm thick) supporting the wooden trays 8. Plywood base with 5 elliptical cutouts for the insertion of vynil tubes that transfers heat and humidity 9. Metal stand 10. Five vynil tubes 3.5cm of diameter transfering heat and humidity directly under each of the 5 trays for equal distribution.

11. Perspex container part of the manifold system from which heat and hot air are diffused to the rest of the apparatus, in this box, the air is demoisturised for it to be purer for the koji growth.

12. Vynil tubes directing the flow to the bottom of the containerin order to cget rid of excess moisture 13. Two vynil tubes transferring heat and humidity from box 14 to the bottom of box 11 14. Container in which the humidifier is in, the water in the humidifier heats up and evaporates by being in direct contact with the heater fan.

15. Humidifier to maintain a constant humidity of 80 % 16. Heater fan, half in the box, hitting directly on the air tank of the humidifier.

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MICROSCOPIC IMAGES [ x 250 ] [ SCALE 2000 :1 ]

0 µm

100 µm

200 µm

300 µm

400 µm

500 µm

600 µm

700 µm

800 µm

t = 0 hrs 900 µm

1000 µm

rice put in the fermentation room at a temperature of 32 and %80 humidty

t = 7 hrs

t = 14 hrs

t = 21 hrs

t = 29 hrs

t = 36 hrs

Surface transformation caused by displacement at a microscopic scale (x200 magnification) through time -36 hours- The smooth surface of the rice begins to wrinkle and grow to mecome a dense network of mycellium composed of koji flowers - the fungi -

Blooming rice grain - Rice grain as a landscape The displacement and transformation of sugars from the interior of the rice grain to the exterior, induces growth of a filamentous fungus that will change the flavour texture and consistency of the initial grain.

Fermented rice grain covered with koji - Maximum growth of mycellium after 36 hours [ x24 ] 117