VBLOCKS OVO
A PROJECT IN FULLFILLMENT OF THE EMERGENT ARCHITECTURE RESEARCH & DEVELOPMENT STUDIO BY KIERSTENN ZETTE L. DIONISIO JANELLE ERICA Y. GAN LANCE MITCHELL B. SY 2022
The intensive plastic pollution and carbon emissions generated by unevolving construction methods in the Philippines are justifications for the growing need for a resolution. Through repurposing recycled PET into modular building blocks, this project aims to create a viable alternative to the traditional concrete hollow block and significantly promote plastic waste circularity and reduce carbon emissions produced within the construction industry. The proposed rPET module designs are tested based on a variety of quantitative and qualitative parameters that will produce the most optimal low-carbon, self-interlocking, and lightweight module that will allow democratization in construction by offering easy-to-build modular assemblies that can be accomplished more efficiently than the current standard in construction.
ABSTRACT
Background of the Study Statement of the Problem ExperimentationsMethodology & Observations DiscussionResults TABLE OF CONTENTS1911153347
200 MM 400 MM 100 MM CHB Composition For Non-Load Bearing Blocks VOLUME 0.008 CU M EXPOSED SURFACE AREA 0.08 SQ M
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The CHB requires a binding agent and extensive curing period.
Replacing An Outdated Assembly
The Philippines has long been accustomed to the economical masonry construction method that is the Concrete Hollow Block [CHB] due to its accessibility, fire and sound resistance and long lifespan; however, what lies beneath the surface is a method that shares its respective disadvantages as well:The CHB is relatively weak against lateral loads from extreme typhoons and earthquakes unless reinforced with steel bars and situated between concrete columns and beams.
BACKGROUND OF THE STUDY
The CHB assembly requires semi-skilled laborers for Cementconstruction.isoneof the main producers of carbon dioxide in the construction industry. Concrete then causes harmful carbon emissions which are detrimental to the environment. VOVO is disrupting the local industry that has failed to move forward and innovatively respond to the times. We are offering speed and efficiency by introducing democratization in construction through our self-interlocking, low-carbon building construction alternative.
MASONRY CONSTRUCTION IN THE PHILIPPINES
PLASTIC POLLUTION IN THE PHILIPPINES
Photo by Jes Aznar 04
VOVO is motivated by the desire to mitigate the severe plastic pollution crisis in the Philippines. We aim to boost the circularity movement and provide a second life to waste by recovering valuable PET plastics and turning them into a viable building construction product. A Plastic Waste Initiative
The Philippine economy relies heavily on the plastic industry, in which the production and consumption of predominantly single-use plastics are being depended on by low to- middle-income families. The country’s insufficient solid waste management strategies has led the nation to a severe plastic pollution problem, wherein approximately 2.7 million tons of plastic waste are generated annually (The World Bank, 2021).
The Pasig River accounts for 63,000 tons of plastic entering oceans from rivers per year (Climate Change Commission), making Metro Manila one of the highest plastic waste densities in the world, producing around 900 metric tons of plastic waste per kilometer (Business Mirror, 2018). Among the solid plastic wastes generated in the Philippines, PET- specifically PET bottles used for food and beverage packaging- are considered most valuable due to its high residual value or predicted value after consumption, with a recovery rate of 90 percent. Because of this, there is a higher viability of PET plastics being collected from disposal sites to be resold or recycled by various existing establishments (Business Mirror, 2018).
BACKGROUND OF THE STUDY
A child collects trash in Manila Bay to sell to recyclers.
Polyethylene Terephthalate (PET)
Polyethylene Terephthalate (PET) is the world’s 4th most common polymer/plastic resin that is used in various products such as food packaging to polyester in clothing, and creation of tents due to its unique set of properties.
The creation of PET involves the extraction of crude oil from the ground, which is very damaging to the environment. Moreover, its decomposition period will last around 700 years. Properties ThermoplasticEasilymolded into any desired shape when heated; Retains strength when cooled Lightweight Can show relative stiffness for its lightweight Highly ChemicallyImpact-proofDurableResistantNon-absorbenttowards
organic material and water Recycled Polyethylene Terephthalate (rPET)
The process of recycling PET involves taking plastic products and breaking them down into tiny flakes to be melted. The PET retrieved from this process can be used to create another product. How does rPET relieve the plastic waste phenomenon? This process saves 50% of energy used to make PET from scratch, discontinues its journey to landfill, and prevents more environmental damage from crude oil extraction (Greener Fabrics).
A Plastic Waste Initiative BACKGROUND OF THE STUDY06
Opportunity To Introduce Widespread Plastic Circularity In The Philippines Via Architectural Solutions LANDFILLUSERSRETAILERMANUFACTURERCOLLECTIONREDESIGN
SIGNIFICANCE OF THE STUDY Reducing Carbon Footprint In Building Construction / Building Systems For every rPET module created, n of PET is saved from landfill, and n of CHB is otherwise saved from emitting harmful gas emissions. Democratization In Construction The module design allows users to safely construct their own assemblies without the need for external support or assistance. Users also have freedom to create various types of assemblies. 08
Sub-Problems Additional to minimizing carbon emissions otherwise produced by a concrete hollow block, how can rPET exhibit comparable or enhanced properties to CHB when designed as a building system? How can we enhance the kinematic structure and pattern of interconnection of module design to make modules more self-interlocking and efficient in construction of modular assemblies?
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STATEMENT OF THE PROBLEM
Project Goal The proposed module and modular assembly should be more self-sufficient compared to conventional concrete hollow blocks and will exhibit comparable yet enhanced characteristics to conventional CHB construction provided the set parameters, such as: carbon emission, embodied energy, kinematic structure, configurability, weight by volume, impermeability, among others.
Mixed Methods Research Both qualitative and quantitative data collection and analysis methods will be used to answer research questions Quantitative: Parameters Iterative MeasurableProcessandcomputational variables Statistical analysis Qualitative: Properties & Characteristics Tangible and observational examinations Prototyping and surveying METHODOLOGY
METHODOLOGY Initial Research Identify main problems, research questions, significance of the study, proposed solutions and goals Set Parameters Identify the different determinants to creating the optimal design Iterative Process Utilize parameters to generate different iterations and compare with the constant variable (CHB) Data Collection Gather quantitative data/results from iterations and calculations Data Analysis & Evaluation Determine the most optimal design based on quantitative & qualitative efficiency Refining Final Iteration Polishing and improving on the chosen design Prototyping Physical modelling of the chosen design Testing Prototype Verifying design through tangible examination of the prototype Conclusions Identifying results, recommendations, summary 12 Research Method & Tasks
The embodied carbon and embodied energy required in the production of rPET modules should be below the standard embodied carbon and embodied energy of the standard CHB wall assembly. The carbon emission in the production of each rPET module should be unvarying. The eachconsistentlyproducedother of various
Using blow-molding method, wherein the recycled plastic is melted then extruded into a mold, the module will remain hollow in nature with a fixed thickness of the enveloping plastic. With this, the module is expected to serve non-loadbearing purposes.
Longevity Being non-biodegradable in nature, the rPET module will last for a lengthy period of time
Determining Qualitative Factors for Optimal Module Design
Impermeability
Lightweight
Self-Interlocking Modules are tessellated with strategic geometrical pattern to enhance interconnectedness and force-lock of the assembly without need for supplementary Inadhesives.thisstudy, to determine whether the module is self-interlocking in nature, geometrical pattern should possess an evident linkage on each side.
Quality Management
In this study, to determine whether the module is more lightweight than CHB, the proponents will be comparing the two based on weight by volume. In its lightweightedness, the plastic module must exhibit relative stiffness by fixating on a desired thickness.
With the chemical resistance of PET that explains its utility in food and beverage packaging, the base module will exhibit high resistance to moisture, especially from rain or humid air. Compared to CHB, where waterproofing and plaster are necessary, in the construction of rPET modular assemblies, this is not much of a priority.
METHODOLOGY Parameters Determining Quantitative Factors for Optimal Module Design Embodied Energy Embodied Energy Carbon Footprint Embodied Carbon Embodied Carbon Carbon Footprint Weight by Volume Weight Volume Quantity of rPET by Weight Weight Quantity of rPET Quantity of Modules per SQM Geometry Optimization Module Size Lightness & Portability No. of /SurfaceModule Area & Volume Configurability Modularity No. of Working Applications 14 Management Standards produced module must consistently interlock with other in the formation configurations. The overall weight of each rPET must be significantly less in comparison to the standard CHB while maintaining a surface area that is equal to the standard CHB. Each rPET block should be at least equal or surpass the standard CHB properties in terms of impermeability and longevity.
Regular Dual TripleSemi-RegularSemi-Regular
EXPERIMENTATIONS & OBSERVATIONS
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Monohedral Exploring Tessellations
Tessellations are essentially infinitely repeating geometries that tile on a plane without any gaps or overlaps. Exploring a variety of tessellation patterns for this project would allow the team to analyze different geometries that would bring about diffferent options regarding the vertices and edges of geometries that would serve better and more secure interlocking strategies for the product design.
Calculating Total Surface Area Total surface area of a standard 25 module unit assembly for each tessellated iteration shows how much surface is covered by a certain type of geometrical pattern. The Goal Determine which module pattern encloses the most surface area in comparison to a concrete hollow block and to each other. Per 25 Module Units Total Surface Area 2 SQ. M Total Volume 0.111 CU. M No. of Geometrymodules/surfaceOptimization Calculating Total Volume Total volume of a standard 25 module unit assembly for each tessellated iteration shows the expected weight of the module. The Goal Determine which module pattern is the lightest for modularity/portability. WeightVolume
EXPERIMENTATIONS & OBSERVATIONS Initial Iterations To maintain a constant variable, the surface area of each tessellated iteration of the module is based off of standard CHB dimensions. Total Surface Area 1.922 SQ. M Total Volume 0.022 CU. M Total Surface Area 2.012 SQ. M Total Volume 0.020 CU. M Total Surface Area 2.024 SQ. M Total Volume 0.021 CU. M Total Surface Area 2.024 SQ. M Total Volume 0.021 CU. M Total Surface Area 1.728 SQ. M Total Volume 0.021 CU. M 18
Module size is based off of dimensions of traditional CHB
Least weight by volume and surface area The geometry was explored further to provide functional interlocking details and varying configurations of the same nature to suit different architectural purposes.
Module geometry is based off of strength of hexagonal geometry Applying tessellated principle allows interlocking of modules
After the general exploration, the geometric patterns were narrowed down in accordance to their compliance with the different parameters that need to be met. The basic geometrical block that was chosen to move forward with possessed the following functions:
EXPERIMENTATIONS & OBSERVATIONS Refining Iteration 20 Lorem ipsum
PET Neck Grooves/Ridges for Finishes Hollow Tessellated Block Interlocking Joint Blow Molding Starter
The module will remain hollow in nature with a fixed thickness of the enveloping plastic. With this, the module is expected to serve non-loadbearing purposes.
Taking blow molding effect into consideration, the team had integrated an interlocking design that would be reminiscent of the recycled plastic water bottles and gallons used to create the modules.
EXPERIMENTATIONS & OBSERVATIONS Chosen Iteration 22
Recycling rPET into a product requires melting the plastic into tiny flakes. The team had then decided to utilize blow molding technology in order to produce the individual blocks in a quick and efficient manner.
Employing this method of manufacturing allows recycled plastic to be melted then extruded to the desired shape through a mold.
Main Module Side BaseModuleModuleSCREW Height 800 MM Width 400 MM Depth 200 MM Height 800 MM Width 250 MM Depth 200 MM Height 500 MM Width 400 MM Depth 200 MM
EXPERIMENTATIONS & OBSERVATIONS Iteration Variations 24 Corner Module L Top CornerModuleModule R Height 970 MM Width 400 MM Depth 200 MM Height 970 MM Width 400 MM Depth 200 MM Height 400 MM Width 400 MM Depth 200 MM Different variations of the module were created in order to serve different parts of an ideal architectural structure.
EXPERIMENTATIONS & OBSERVATIONS Modular Assembly 26 The modules come together to form the different components of a basic wall assembly.
MATERIAL DENSITY (kg/cu.m) MATERIAL VOLUME CHB 2406.53 PET 1380 CALCULATING EMBODIED MATERIAL EMBODIED ENERGY (MJ/kg)MATERIAL MASS (kg) CHB 0.67 MORTAR 1.33 *20 KG BAG IS APPROX. FOR 20 BLOCKS (1KG PER BLOCK) STEEL REBARS 32 *EVERY OTHER HOLE, 2 HOLES PER BLOCK W/ 5 BLOCKS (10 PCS) TOTAL NEW PET 84 RECYCLED PET 33.6 *40 PERCENT OF NEW PET TOTAL Embodied Energy of rPET is significa CALCULATING MATERIAL EMBODIED CARBON (CO2/kg)MATERIAL MASS (kg) CONCRETE 0.0725 MORTAR 0.208 STEEL 1.37 TOTAL rPET 0.98 TOTAL Embodied Carbon of rPET is signi For a 25 module wall assembly:
EXPERIMENTATIONS & OBSERVATIONS Reviewing Quantitative Parameters 28 (cu.m)MATERIAL MASS (kg) 0.11 264.7183 0.00146734 2.0249292 EMBODIED ENERGY (kg) TOTAL EMBODIED ENERGY PER UNIT TOTAL EMBODIED ENERGY PER 25 UNITS 264.7183 177.361261 25 46950.7715 1 1.33 25 1.33 0.7 22.4 10 15.68 201.091261 46967.7815 2.0249292 68.03762112 25 137.7713657 68.03762112 137.7713657 ficantly less than that of CHB Embodied Energy of rPET Wall is significantly less than that of CHB Wall CALCULATING EMBODIED CARBON (kg) TOTAL TOTAL PER 25 UNITS 264.7183 19.19207675 25 479.8019188 25 5.2 25 130 0.7 0.959 10 9.59 25.35107675 619.3919188 2.0249292 1.984430616 25 4.0183315 1.984430616 4.0183315 significantly less than CHB Embodied Carbon of rPET Wall is significantly less than CHB Wall
Ideal Module Production Roadmap Complete files necessary for prototype Produce prototype via 3D-printing to test functionality of product Design changes and edits based on 3D-printing prototype Completed the files and have contracted with blow molding company Initial blow mold production period Initial production run of blocks with quality management testing to verify functionality and properties Final production testing of interlocking system before mass production of blocks
Due to the current limitations of the research group in accessing the required rPET material and blow-molding technology within the duration of this project, the researchers utilized 3D printing technology to create scale models in order to test its interlocking capabilities and examine possible inconsistencies in the design of the blocks. The researchers limited the number of moduled to be printed into one simple wall assembly just to check the interlocking technology utilized by the designed blocks as well as the functionality of the different module types.
Due to the nature of 3D-printing, the prototype showcases some limitations in terms of production quality, process, and outcome that differs from the actual production method that would be used for the product: blow-molding.
The 3D-printed prototype uses black PLA plastic and is filled not only in its envelope but also in its interior for structural integrity during the 3D-printing process. In the actual production of the product, blow-molding will keep the module hollow, with varying exteriorfinishes.color
EXPERIMENTATIONS & OBSERVATIONS Prototyping 30
32 EXPERIMENTATIONS & OBSERVATIONS Surveying Prototype The team fixed minor inconsistencies within the 3D-printed prototype before assembling the prototype to test the ease of construction and the iteration’s interlocking capabilities.
34 Prototype: Modules
36 Prototype: Modular Assembly
Water Refilling Station
Modular Assembly Application Scenarios 40
Water Refilling Station
Modular Assembly Application Scenarios 42
Water Refilling Station
Modular Assembly Application Scenarios 44
Building Interior Walls
Modular Assembly Application Scenarios 46
Pop-Up Shelters
Modular Assembly Application Scenarios 48
Quantitative Results
Qualitative Results
Feasibility
From the qualitative factors listed previously to determine the optimal module design, the researchers were only able to verify the self-interlocking capabilities of the final module design due to the limitations brought about by the different production method for the Theprototype.modules were able to clasp easily to one another to form a modular wall assembly that stands securely in place and stays interlocked in spite of force acted against it. However, the researchers are unable to verify its true structural integrity, given that the prototype material used differs from the actual material required for the product.
As early as the iteration process, the researchers were able to opt for a geometric pattern for the module that showcases the least weight by volume and maximum surface area in order to assume the lightweight nature of the product and maximization of rPET material per unit. As per calculations, the researchers were able to verify that a rPET modular wall assembly contributes significantly less embodied energy and embodied carbon as compared to a CHB wall assembly with the same number of module units. The team was also able to provide a number of application scenarios to showcase the modules’ configurability and modularity.
In essence, the reseachers were able to answer the sub-problems identified for the project by producing a module with a kinematic structure that permits its self-interlocking feature, and that emits significantly less carbon emissions that the standard CHB.
For future developments of this project, the researchers would recommend gaining access to the necessary rPET material and blow-molding technology for prototype production in order to test other qualitative factors, such as its lightweight, impermeability, and longevity.
Recommendations
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DISCUSSION
Moreover, due to lack of time, the team was only able to generate a number of configurations for the wall assembly. With this, for further study, the researchers would also recommend exploring more interlocking configurations and application scenarios that can be generated from the different modules created. Lastly, the team would recommend exploring the hollow nature of the blow-molded module. The team acknowledges the untouched potential of the inner capacity of the hollow module for different volumes that may be added in order to enhance the module’s structural integrity.
VBLOCKS OVO
