2020 Material Exploration - Algae Anatomy

algae anatomy Tutors: Daniel Widrig | Guan Lee | Adam Holloway Project by Bryan Law | Dinel Mao | Jie Song Material Architecture Lab, M. Arch Architectural Design, 2019-2020 The Bartlett School of Architecture | UCL

CONTENTS Chapter 1

INITIAL APPROACH

Chapter 5

ALGAE + CLAY

- Introduction - Collection - Green Algae Research - Global Algae Bloom Incidents - China Algae Bloom Incidents - Precedents

- Introduction - Algae + Clay Blocks - Design Application - Column - Wall

Chapter 2

Chapter 6

MATERIAL EXPLORATION

LANGUAGE EXPLORATION

- Introduction - Initial Exploration Diagram - Algae Research Diagram - Initial Explorations

- Thickness Analysis - Topological Optimisation - Agent Behaviours - Design Application

Chapter 3

Chapter 7

ALGAE BRICK

ECOVILLAGE SITE

- Biodegradability + Material Family - Raw Material and Tools - Algae Fiber Block - Binding Chemical Process - Other Shapes - Tiles - Connection Study - Middle Scale Chunks - Components - Large Scale Structure

- China Algae Harvesting Coast - Huang’bi’ao, Xiangshan, Ningbo - Existing Land Use - Site Photo - Eco Village Lifestyle Transition - Site Drawings - User Journey

Chapter 4

Chapter 8

ALGAE FIBERBOARD

- Fabrication Research - Sheet Manufacture Process - Algae + Pulp Ratio Study - Board Manufacture Process - Fiberboard Interlocking Study - Design Application - Corrugated Algaeboard Fabrication - Algae Box Fabrication - Design Application

ECOVILLAGE DESIGN

- Approach - Component Distribution - Topological Optimisation - Interlocking Aggregation System - Unit Tests - Final Design

Chapter 1

INITIAL APPROACH - Introduction - Collection

- Green Algae Research

- Global Algae Bloom Incidents

- China Algae Bloom Incidents

- Precedents

5

Material Architecture Lab | Materials Research | UCL 6

INITIAL APPROACH

Introduction

Our project, Algae Anatomy, deals with the specific type of algae classified as green macro algae. Green macro algae, or seaweed, is typically found in many different marine environments and can grow year round. In its natural state it is able to filter the water and when exposed to sunlight it is a natural source of oxygen. Additionally , it is easy to grow and harvest within a controlled environment.

Its uses are continually being discovered and developed. Currently, its uses are primarily rooted in bioenergy and food industries. In our project we focus on exploring its various chemical and physical properties through extraction and manipulation of the material. We initially explored how it can be used as a natural dye and its potential as an individual material - examining its structural integrity and ability to be formed within a mold. As our project begins to evolve, structural or architectural applications are considered. Therefore, various additives and aggregates will be integrated into our material in order to contribute to its strength and ability to carry various weight loads. We will also explore other naturally sourced fibrous materials.

7

Our intial approach towards the collection of green macro algae was through hand harvesting methods, on the southern most tip of the United Kingdom.

There are over 30,000 species of algae and some of them are harmful and undesirable. Algal blooms are one of the examples of harmful phenomena related to green macro algae. All species of algae share similar physical properties and our study aims to observe alternate uses for a seemingly undesirable material.

Green macro algae is a naturally occuring material within our environment and can be found near wet environments with the right growing conditions. They require light, carbon dioxide, moisture, and simple nutrients to grow. In addition its fast growth allows collection for ample research and manipulation.

Observing its physical properties, it possesses an attractive natural coloring. In its wet or dried state its potential to be manipulated changes - its wet state provides an increased density that allows for easier sculpting of the material. Whereas in a dried state it can be easily utilized in coloring methods. Due to its natural occurance, green algae is able to be reintegrated into the ecosystem if needed.

Material Architecture Lab | Materials Research | UCL 8

COLLECTION

UK Coast Collection

UK Harvest Statistics

20,000,000 Tons

Amount of wet green algae growing on shores

Scotland

5,000,000 Tons

By wild harvest in the UK on average per year

Northern

2,000 - 3,000 Tons

Ireland

Exported out of the UK per month

England

Ireland

Wales + +

Seven Sister Cliffs

Margate

+

Wild Harvest Location Ulva Lactuca Ulva Intestinalis Red Seaweed

Harvesting algae at the Seven Sister Cliffs, UK, 2019

9

Material Architecture Lab | Materials Research | UCL 10

GREEN ALGAE RESEARCH

Green Macro Algae

Physical Attributes Ulva Lactuca

MACRO ALGAE

10 - 45 cm

Ulva Intestinalis

ULVA LACTUCA [Sea Lettuce]

ULVA INTESTINALIS

ULVA PROLIFERA

[Gutweed]

[Algal Bloom]

5 - 10 cm

Wild Harvest Statistics UK

Primary Industries

Negative Environmental Impact

5,000,000

China

10,000,000

Japan

8,500,000

Korea

6,000,000

South East Asia

7,500,000

O2 Food

Kills marine life

Biofuel

Positive Environmental Impact

O2

Oxygen production

11

Elements for Growth NO3-

50%

Biomass accumulation

Food for marine life

Increase photosynthetic rates

Nitrate

N

Nitrogen

P

Phosphorus

K

Potassium

Growth Rate

Toxic gas

Blocks sunlight to seabed

Depletes oxygen

Habitat

Regular Growth 20 - 50 cm / day Algal Bloom 50+ cm / day

Freshwater

Seabed

Ocean

Material Architecture Lab | Materials Research | UCL 12

13 05 - 28

09 - 02

05 - 30

07 - 21

09 - 14

08 - 20

07 - 18

06 - 09

04 - 23

05 - 05 03 - 21

09 - 26

10 - 04

03 - 14

01 - 21 02 - 20

12 - 02

11 - 20

05 - 14

06 - 05 12 - 23

07 - 09

07 - 05

09 - 06

04 - 23

05 - 12

08 - 12

08 - 30

06 - 13

07 - 09

08 - 15

05 - 22

05 - 31 05 - 02 07 - 07 06 - 11

07 - 20

06 - 20

07 - 12

08 - 20

05 - 24 07 - 14

07 - 20 06 - 13

04 - 13 08 - 20

Noted incidents cover areas over 2000 mi2

06 - 11

Data provided by: Environmental Working Group 05 - 20

Algal Bloom

07 - 04

08 - 15

08 - 21

09 - 05

03 - 15

06 - 21 04 - 12

06 - 17

05 - 12

04 - 20

05 - 28

+ 09 - 13

08 - 20

ALGAE BLOOM

Major Global Incidents in 2018

Material Architecture Lab | Materials Research | UCL 14

ALGAE BLOOM

China Algae Bloom Incidents, 2013 - 2017

Algae bloom off the coast of Jiangsu, 2015 Hebei Shandong

Jiangsu Zhoushan Islands

Zhejiang 浙江省

Fujian

+

Chosen Site Locations Affected by Algal Blooms

+

15

Algal Blooms

1000 km

Algae bloom on a Qingdao beach, 2013 Material Architecture Lab | Materials Research | UCL 16

ALGAE BLOOM

International

Algae bloom in Lake Erie, USA, 2011

One of two annual algae blooms that occur in the Baltic Sea, 2019

Satellite imagery of Lake Tai, China a hotspot for algae blooms , 2018

Image Sources 1. CNN 2. PopSci 3. IJC

17

Material Architecture Lab | Materials Research | UCL 18

PRECEDENTS

Blond & Bieber

Blond & Bieber are a design agency based in Berlin. Their project, Algaemy, experiments with microalgae and its potential as a natural dye. They developed a manual application method that is relatively sustainable in that it is analogue based and does not require external power. The dyes developed ranged in color, and shades of brown and red are also able to be derived from microalgae. This project inspired us to explore the natural dye potential in green algae and also the variety of colors that can come out of the natural material.

Image Sources 1. Dezeen

2. Blond & Bieber 3. Blond & Bieber

19

PRECEDENTS Klarenbeek & Dros

Klarenbeek & Dros are a dutch design firm that experimented with 3D printing and green algae.

They developed an algae polymer that is able to be used in 3D printers. They explore the implications of using algae as a way to 3D print objects emphasizing its sustainability and potential in completely replacing plastics in the future. This inspired us to explore green algae and its structural qualities.

Image Sources 1. Klarenbeek & Dros 2. Dezeen

3. Architizer

Material Architecture Lab | Materials Research | UCL 20

PRECEDENTS

Jonas Edvard and Nikolaj Steenfatt Jonas Edvard and Nikolaj Steenfatt are Royal Danish Academy of Fine Arts students that have produced home products based on a kelp and paper mixture. The paper and kelp mixture is ground and moulded into a variety of geometric forms which are then dried and heated to create a rigid material. Due to the starch and sugar molecular makeup of kelp, referred to as Alginate, combined with paper, the mixture is able to bind naturally without the addition of any synthetic glues. The project is named the Terroir Project Collection. The colors of the end products are directly derived from the natural appearance of the brown seaweed.

Image Sources 1. Dezeen

2. Royal Danish Academy of Fine Arts 3. Dezeen

21

PRECEDENTS Cork House

Matthew Barnett Howland’s Cork House is a project which utilized expanded cork as its main structural material. The Cork House is an experiment and exploration in the feasibility of expanded cork in construction. Expanded cork is made from leftover cork found from wine bottling. The surplus cork is then heat pressed within a mould to create a soundproof and weatherproof block.

The Cork House is a display of minimal processing of a material and truly sustainable construction, as there was no synthetics used and construction was completed using a slotting system between the individual cork components.

Image Sources 1. RIBA

2. Dezeen

3. Matthew Barnett Howland

Material Architecture Lab | Materials Research | UCL 22

Chapter 2

MATERIAL EXPLORATION - Introduction

- Initial Exploration Diagram

- Algae Research Diagram

+ Dye

+ Starch Membrane

+ Membrane Gradients

+ Skeletal Frame

23

- Initial Explorations

+ Bones

+ Membrane Elasticity

Material Architecture Lab | Materials Research | UCL 24

MATERIAL EXPERIMENT Introduction

INITIAL APPROACH

Through progression of our research, we realized that the starch elements of algae was worth to be explored further. This chapter details our experiments towards the extraction of starch from different species of algae.

Experimentation Diagram The extracted product was a membrane like material that possessed different levels of strength, elasticity, and transparency. As these membranes are directly derived from green algae itself, they are able to be seamlessly reintegrated into its natural environment and is completely biodegradable. Our experiments aim to determine which type of starch provides the most ideal combination of flexibility, strength, rigidity, and transparency. We experiment with starches extracted from red, brown, and green algae, combining it with predetermined quantities of water and glycerin. The results were a product of a controlled experiment.

INITIAL APPROACH Experimentation Diagram

Algae

SEA

s Br

ic

k

Co m

e

at

eg

pr es

gr

Ag

BOILING

Extract

ALGAE

t in

Pa

BOILING

St

Pigment

r

de

25

w Po

PRODUCT

SHEET

ar

ch

DISSOLVE

Material Architecture Lab | Materials Research | UCL 26

MATERIAL EXPERIMENT Initial Exploration Diagram

GREEN ALGAE

RED ALGAE

Extract

Starch

Extract

k Br ic

te ga

Co

m

pr es

s

r

de

w

Po

Pigment

t

in

Pa e gr Ag

27

Agar

Carrageenan Kappa

Carrageenan Iota

Material Architecture Lab | Materials Research | UCL 28

MATERIAL EXPERIMENT

Algae Research Diagram

MACRO ALGAE

[CHEMICAL COMPOSITION]

% OF MATTER

PHYSICAL ATTRIBUTES

LIGHT/DARK GREEN

GREEN

ALGAE

95 %

18 %

10 %

MOISTURE

PROTEIN

STARCH

STARCH

RED

ALGAE STARCH CARRAGEENAN, AGAR, ALGINATE

29

25 %

MOISTURE

PROTEIN

75 % STARCH

FURNITURE DESIGN SEAWEED HOUSE INDUSTRIAL DESIGN

THIN TUBULAR FRONDS

ALGAECRETE NATURAL DYE

LONG LENGTH

82 %

PRECEDENCES

ENERGY PRODUCTION BIOPLASTIC PACKAGING

LIGHT/DARK RED

MATERIAL ENGINEERING

HIGH PLASTICITY

FARMING

DIFFUSE GROWTH PATTERN

PLASTIC ALTERNATIVE

Material Architecture Lab | Materials Research | UCL 30

INITIAL EXPLORATION

INITIAL EXPLORATION

Extraction : Dye

Extraction : Dye

Green Algae Bag

Green Algae

Blend

+ Powder

Boil

Ethanol

Pigment

+ Powder

Blender

+ Pigment

31

Blender Material Architecture Lab | Materials Research | UCL 32

MATERIAL EXPERIMENT Extraction : Starch

Properties of Starch Found in Algae

Carrageenan Kappa

Carrageenan Iota

Agar

Sodium Alginate

Formula

Derivation

Properties

33

Red Seaweed

Red Seaweed

Red Seaweed

- Thickening/binding agent - Gellified in higher temperatures - Can form strong elastic gels

- Thickening/binding agent - Soluble in cold water - Less elasticity than Kappa

- Thickening/binding agent - Thermoreversible - Low viscosity

Brown Algae

- Sodium salt substance with starch-like properties - Used to produce heat-resistant gels and foams - Thickening agent

Material Architecture Lab | Materials Research | UCL 34

MATERIAL EXPERIMENT Starch Experimentation - Membrane Starch Combination Study

a

Agar

c

d

e

f

g

Shape Retention

Shape Retention

Shape Retention

Shape Retention

Shape Retention

Shape Retention

Shape Retention

Shrinkage

Shrinkage

Shrinkage

Shrinkage

Shrinkage

Shrinkage

Shrinkage

Time to Dry

Time to Dry

Time to Dry

Time to Dry

Time to Dry

Time to Dry

Time to Dry

Agar

Carrageenan Kappa

Carrageenan Kappa

Carrageenan Iota

Carrageenan Iota

Sodium Alginate

Sodium Alginate

Glycerin

Glycerin

Water

35

b

Water

Material Architecture Lab | Materials Research | UCL 36

MATERIAL EXPERIMENT Starch Experimentation - Membrane

a

Agar

Water (ml)

+

100

Glycerin (g)

+

4.5

100

Sample

3

9.5

100

Agar (g)

Elasticity Strength Transparency Shrinkage Time to Dry

+

100

Glycerin (g)

+

1.5

100

Elasticity Strength Transparency Shrinkage Time to Dry

8

Carrageenan Lota

Water (ml)

Elasticity Strength Transparency Shrinkage Time to Dry

3

4.5

Observations

c

4

3

100

1.5

Carrageenan Kappa

Water (ml)

100

100

100

37

+

Glycerin (g)

Observations

Elasticity Strength Transparency Shrinkage Time to Dry Elasticity Strength Transparency Shrinkage Time to Dry

4

Elasticity Strength Transparency Shrinkage Time to Dry

2

a b

Sample

Lota (g)

c +

Kappa (g)

1

1.5

3

4

3

1

b

Sample

Observations Elasticity Strength Transparency Shrinkage Time to Dry Elasticity Strength Transparency Shrinkage Time to Dry Elasticity Strength Transparency Shrinkage Time to Dry

d

Sodium Alginate

Water (ml)

100

+

Glycerin (g)

1.5

+

Sodium Alginate (g)

Sample

Observations Elasticity Strength Transparency Shrinkage Time to Dry

3

d

Material Architecture Lab | Materials Research | UCL 38

MATERIAL EXPERIMENT Starch Experimentation - Membrane

Agar

Optimal Ratio Study

Moving forward from our agar and glycerin experimentation, we decided to experiment with other forms of starch found within green algae in addition to agar to create more sheets / membranes. These starches are carrageenan iota, carrageenan kappa, and sodium alginate. We experimented with these starches along with water and glycerin to find the ideal ratio between the ingredients. The qualities we were looking for were overall strength of the sheet, transparency, amount of shrinkage and time taken to dry after pouring into the mold. Quantities of the ingredients were determined through trial and error.

a Water (ml) + Glycerin (g) + Agar (g) 100 9.5 3

Elasticity Strength Transparency Shrinkage Time to Dry

High Strength

Glycerin

Elasticity Shrinkage

Agar

Elasticity Shrinkage

Carrageenan Kappa

Water (ml) + Glycerin (g) + Kappa (g) 100

1.5

2

Elasticity Strength Transparency Shrinkage Time to Dry

b No Elasticity

High Transparency

Glycerin

Elasticity Transparency

Strength Kappa

Transparency Shrinkage

Carrageenan Iota

c Low Shrinkage

Long Time to Dry

39

Elasticity Glycerin

Transparency Shrinkage

Iota

Elasticity Strength

Material Architecture Lab | Materials Research | UCL 40

MATERIAL EXPERIMENT

MATERIAL DEVELOPMENT

Starch Experimentation - Membrane

Starch Experimentation - Membrane

Optimal Ratio Study

Optimal Thickness Study

The next step of our starch experimentation was to combine these starches with agar. We observed how carrageenan kappa, carrageenan iota, and sodium alginate reacted with agar and which proved to be the best combination. We measured its qualities using the same criteria as before, focusing on strength, transparency, amount of shrinkage and time taken to dry. The amount of each ingredient used in the experimentation was determined by our previous trials.

e

Agar + Sodium Alginate

Water (ml)

+ Glycerin (g)

100

9

f

+ Agar (g) 3

Agar + Carrageenan Kappa

Water (ml) 100

+ Glycerin (g)

+ Agar (g)

11

3

+ Sodium Alginate (g)

Sample

Observations Elasticity Strength Transparency Shrinkage Time to Dry

1

e + Carrageenan Kappa (g)

From our experimentation with different types of starch found within green algae, we concluded that agar combined with glycerin and water was the best combination as it provided ideal strength and transparency with minimal shrinking. Our next step was to test this combination within the same mold but with varying levels of thickness.

Water (ml)

50

100

Sample

+ Glycerin (g)

4.75

Agar + Carrageenan Iota

Water (ml)

+ Glycerin (g)

100

9

+ Agar (g) 3

1

Elasticity Strength Transparency Shrinkage Time to Dry

9.5

Pour Thickness (mm)

Final Thickness (mm)

2

0.5

200

19

Elasticity Strength Transparency Shrinkage Time to Dry

1.5

8

12

Elasticity Strength Transparency Shrinkage Time to Dry Elasticity Strength Transparency Shrinkage Time to Dry

1

4

6

Observations

Elasticity/Transparency/Strength to Thickness

Sample

Observations Elasticity Strength Transparency Shrinkage Time to Dry

g 41

Sample

Observations

1

+ Carrageenan Iota (g)

Agar (g)

3

f g

+

relative value

9

Elasticity 6

Transparency 3

Strength

2

4

8

thickness (mm) Material Architecture Lab | Materials Research | UCL 42

INITIAL EXPLORATION

INITIAL EXPLORATION

Starch Experimentation - Membrane Gradients

Starch Experimentation - Membrane Gradients

The second portion of our material research centered around the extraction of the starch within green algae. Agar is a form of starch found within green algae. We decided to explore its structural and visual properties, examining its potential as a bioplastic. We created a mold and combined agar with glycerin (binder) to form different sheets, or a “membrane�. These preliminary experiments showcased algae as an aggregate as well.

+

+

Mould

Agar

Agar sheet

Glycerin

Algae fragment sheet

Algae powder sheet

Algae sheet

Heating Mixture Powder

Fragment

Algae

Texture + Color Variations Texture

25grams

20grams

amount of algae

15grams

10grams

Section

5grams

binder

pigment

agar

alginate

concrete

material used for manipulation

43

Material Architecture Lab | Materials Research | UCL 44

MATERIAL EXPERIMENT

MATERIAL DEVELOPMENT

Starch Experimentation - Membrane Gradients

a

Agar

Water (ml)

100

100

100

100

100

45

+

Glycerin (g)

9.5

9.5

9.5

9.5

9.5

Starch Experimentation - Membrane Gradients

+

Agar (g)

3

+

Powder(g)

Elasticity Strength Transparency Shrinkage Time to Dry

0

3

0.25

3

3

3

Observations

Elasticity Strength Transparency Shrinkage Time to Dry

0.5

Elasticity Strength Transparency Shrinkage Time to Dry

1

Elasticity Strength Transparency Shrinkage Time to Dry

2

Amount of Algae Powder to Elasticity/Transparency/Strength relative value

9

6

Shrinkage Elasticity Transparency

3

0.5

1

1.5

2

Algae Powder(g)

Elasticity Strength Transparency Shrinkage Time to Dry

Material Architecture Lab | Materials Research | UCL 46

MATERIAL EXPERIMENT Starch Experimentation

To supplement our tests of the membranes formed from the starch extracted from different types of algae, we tried to introduce a rigid structure to the membrane in order to see whether or not the two materials would bind successfully. The rigid structure came in the form of coiled metal wire that would be applied into the mixture shortly after it was boiled and poured into the mould. Progressing from this, we experimented with more complex geometries that were created using 3D printing and CNC methods. The results showed that the membranes did not bind successfully in most cases, due to the large surface areas in most of the designs. However, in the laser cut and 3D printed designs, the membranes were able to bind more successfully due to the relatively smaller surface area the membranes have to cover. In addition, we created a tensile strength test which would measure how far the membrane could stretch before it tore.

47

Material Architecture Lab | Materials Research | UCL 48

STRUCTURE EXPERIMENT Starch Experimentation - Bones Steel Wire Framework From our experimentation with the various starches derived from algae and seaweed, we found that the combination of carrageenan kappa with glycerin and water provided an ideal “bone” structure that is firm and rigid in comparison to the other mixtures. Additionally, agar combined with glycerin and water created a “skin” like material that possessed good flexibility. We explored this further by introducing a new rigid material, metal, into our models.

Water (ml)

100

+

Glycerin (g) 9.5

+

Carrageenan Kappa (g)

+

Agar (g)

3

Manual Coiled Steel Wire

Water (ml) 100

49

+

Glycerin (g) 9.5

3

Material Architecture Lab | Materials Research | UCL 50

STRUCTURE EXPERIMENT Starch Experimentation - Skeletal Frame Steel Wire Framework + Mould

Manual Coiled Steel Wire

To make the steel wire structures more organic, we created a CNC wooden mould to interact with the steel wires. The concept remains the same, we used the carrageenan kappa mixture to coat the steel wire “bones”. Afterwards, we poured the agar mixture to create the “skin” of the structure.

Birch Plywood Mould Birch Plywood Mould

Birch Plywood Skeletal Frame

51

Material Architecture Lab | Materials Research | UCL 52

STRUCTURE EXPERIMENT

Starch Experimentation - Skeletal Frame Material Laser Cut + 3D Printed Framework Further testing the ability of the agar mixture to be used as a skin material, we created a web-like design for the agar to be applied on.

Frame materialďźšNylon powder

High ahesive property

Frame materialďźšBirch plywood

Low adhesive property

Density test

53

Material Architecture Lab | Materials Research | UCL 54

STRUCTURE EXPERIMENT

Starch Experimentation - Membrane Elasticity Laser Cut Plywood Framework An extension of the skeletal frame study, the membrane surface study further explores the possibilities of the agar mixture as a skin. In this study, we created a 3D model that tests the tensile strength and flexibility of our agar mixture.

The model itself possesses two moving parts which stretch the agar mixture vertically in different directions.

Casting Membrane

55

Whole Structure

Tensile Strength Diagram

Membrane Simulation

Material Architecture Lab | Materials Research | UCL 56

Chapter 3

ALGAE BRICK

- Biodegradability + Material Family - Raw Material and Tools

- Algae Fiber Block

+ Time & Methods

+ Texture

+ Density

- Binding Chemical Process

- Other Shapes - Tiles

- Connection Study

- Middle Scale Chunks

- Components

- Large Scale Structure

57

Material Architecture Lab | Materials Research | UCL 58

ALGAE APPLICATION

Biodegradability + Material Family

Green Algae PRODUCT

DISSOLVE

COMPRESS

ALGAE

59

SEA

ALGAE BRICK

ALGAE PAPER BOARD

ALGAE CLAY COLUMN

Material Architecture Lab | Materials Research | UCL 60

ALGAE BRICK

Raw Material and Tools

Through extensive research and experimentation, we were able to create an algae brick. The process of the creation of the algae brick consists of creating a mold to hold the algae. Once the algae is in the mold, we compress it in order to remove excess water. Afterwards, we secure the compressed algae with a clamp to retain its shape.

Algae

61

Mold

Compression Machine

Clamp

Collecting the algae from seven sister cliff and margate

Mold making

Measuring the quantity of algae

Using the compression machine to remove 80% water

Algae Brick

Material Architecture Lab | Materials Research | UCL 62

ALGAE BRICK

Algae Fiber Block - Time & Methods Phase 1 Sample: 6-17 Time:

+ Mo

ld M

Harves 1HR

7hr

Temperature:

50t

akin

t

Cle

g

Phase 2

an i 1H ng R

R

Dry

+

5H

+ Kiln

7 HR

C 100 °

Sample: 6.7.8.9

Sample: 10.11.12.13

Time:

Sample: 14.15.16.17

Time: 41hr 3hr

Temperature:

Time: 41hr 3hr

Temperature: 50t

5 HR ry

Air D

We experimented with different methods of drying the blocks.

We dried the blocks in the dehydrator using three methods - held within the mould and secured with clamps to maintain the pressure, with the block in the mould without clamps, and with the block by itself. We found that the best method of drying was maintaining the clamps on the mould to preserve the shape of the block, as removing the clamps and mould would cause warping.

Dry process

Air

Our process of creating the blocks of algae consisted of placing the algae within a mould and pressing it throughout the drying process with clamps. The drying process was accelerated through the use of a kiln and a dehydrator. The kiln drying was more intensive and short, while the drying within the dehydrator was longer and at a lower temperature.

18hr 3hr

Temperature: 50t

30t

50t

30t

30t

Result C 50 ° R

44 H

R

30 H

R 20 H tor ydra h e D

Sample: 6.7.8.9

63

Sample: 10.11.12.13

Sample: 14.15.16.17

Material Architecture Lab | Materials Research | UCL 64

ALGAE BRICK

Algae Fiber Blocks - Density

Long Fiber Algae

Section A

Section B

Section C

Section D

Density 20g

Density 60g

Density 100g

Density 140g

Section A

Section B

Section C

Section D

Density 40g

Density 60g

Density 80g

Density 100g

Long Fiber Algae Block

Crushed Algae

Crashed Algae Block

65

Material Architecture Lab | Materials Research | UCL 66

ALGAE BRICK

Algae Fiber Blocks - Texture

C

Our experimentation with the densities of the algae blocks led to explorations of the texture found in the blocks. We cut each side of the block to see the section.

A

E

F

+

+ Long Fiber Algae

67

D

Process

B

A

B

C

D

E

F Material Architecture Lab | Materials Research | UCL 68

ALGAE BRICK

Binding Chemical Process Polysaccharides

Ulvan

Mannan

Galactans

Xylans

Cellulose

Lignin

Therionine

Valine

Lysine

Leucine

Methionine

Amino Acids

Isoleucine

[ NATURAL ADHESION & BONDING] [ NATURAL ADHESION & BONDING]

Polysaccharide

Protein Binding Reaction

BONDED ALGAE FIBERS

Bonded Algae Fibers

Binding Reaction between Polysaccharides Amino Acids

[ NATURAL BINDING & BIODEGRADABILITY ] 69

CUT

RAW ALGAE

BONDED ALGAE FIBERS

Binding Reaction between Polysaccharides Material Architecture Lab | Materials Research | UCL 70

MATERIAL DEVELOPMENT Other Shapes

In addition to creating cubes/blocks of algae, we also experimented with the potential of using this material to create different, more complex shapes. We explored how using both short and long fibers would affect the structural integrity of the shapes as well.

Long Fiber

Ulva Intestinalis

Block

71

Long Fiber

Crushed

Ulva Intestinalis

Ulva Lactuca

Tile

Long Fiber

Crushed

Ulva Intestinalis

Ulva Lactuca

Stick

Crushed

Long Fiber

Long Fiber

Ulva Intestinalis

Ulva Intestinalis

Ulva Intestinalis

Sheet

Curvature

Frame

Material Architecture Lab | Materials Research | UCL 72

MATERIAL DEVELOPMENT Tiles

Moving on from our material explorations, we thought of different applications of our material and at a larger scale. We created three 20 cm by 20 cm tiles using long and crushed algae fibers and red algae starch extract. The results were not succesfull due to their extensive drying time and irregular shape.

Long Fiber

Ulva Intestinalis

Crushed Ulva Lactuca

Long Fiber

Ulva Intestinalis

Crushed Ulva Intestinalis

Ulva Intestinalis Powder

+ Agar

Gradient Effect Tile 73

Whole Tile

Sorbitol

Powder Tile

Gradient Effect Tile

Whole Tile

Powder Tile Material Architecture Lab | Materials Research | UCL 74

MATERIAL DEVELOPMENT Connection Study

Brick

Mortar

Intermediate Fastenings Detail 1

Mortar Recipe 1

Algae

Clay

Mortar Recipe 2

Detail 2

Pure Algae Brick 50*50*50 mm

Clay

Sand

Mortar Recipe 3

PVA

Sand

Mortar Recipe 4

Detail 3

+

Tool

Agar

75

Sorbitol

Material Architecture Lab | Materials Research | UCL 76

DESIGN APPLICATION Middle Scale Chunks

Top View

77

Material Architecture Lab | Materials Research | UCL 78

MATERIAL DEVELOPMENT Components

Progressing from block and cube shapes, we created more complex moulds with indentations and protrusions to create components made of compressed green algae that are able to fit and slot into one another.

Male component

Female component

+ Mixture of Ulva Intestinalis& Ulva Lactuca

79

+ Clamp

+ Mold

Cap

Material Architecture Lab | Materials Research | UCL 80

DESIGN APPLICATION Large Scale Structure

In addition to the curved wall application of the algae block, we also experimented with larger scale applications that display elements of porosity and transparency. Due to the nature of the green algae cubes, we would have to maintain their smaller size and use these cubes and building blocks. We propose the design process for this larger scale application to involve some sort of voxelization.

Wall Pattern 1

81

Wall Pattern 2

Material Architecture Lab | Materials Research | UCL 82

Chapter 4

ALGAE FIBERBOARD - Fabrication Research

- Sheet Manufacture Process - Algae + Pulp Ratio Study

- Board Manufacture Process

- Fiberboard Interlocking Study

- Design Application

- Corrugated Algaeboard Fabrication

- Algae Box Fabrication - Design Application

83

Material Architecture Lab | Materials Research | UCL 84

ALGAE FIBER BOARD Fabrication Research

Containts formaldehyde

Containts Melamine Melamine formaldehyde Urea PolyvinylUrea Artificial Polyvinyl manufacturing Artificial manufacturing process process Phenol Phenol Formaldehyde Formaldehyde

In addition to algae blocks, we also looked into the manufacturing process of fibreboards, to see how algae could be integrated into a fibreboard. Expanding upon this, we researched various binders to add strength to the algae fibreboard. The manufacturing process of fiberboards has evolved greatly over recent years, and the results range Used in plastic Used in plastic Solvent-based resins Solvent-based resins from more traditional rectilinear shapes to more free form organic shapes. Through heatingmanufacturing and compression, manufacturingwe Containts Melamine expanded upon the potential of algae as a feasible candidateformaldehyde for mass fiberboard production.

Urea

Polyvinyl

Artificial manufacturing process

Phenol Formaldehyde Used in plastic manufacturing

Fiber

Crush

Containts formaldehyde

Binder

Weave

Containts formaldehyde

Melamine Urea

Polyvinyl

Solvent-based resins

manufacturing

Used in plastic

Used in plastic

manufacturing Flexible manufacturing

formaldehyde

Urea

Polyvinyl

Phenol Formaldehyde

Orient

Solvent-based Heat resistant resins

Flexible

Stack

High strength

Bio-Resin

Low to no VOC’s and formaldehyde Heat resistant

Naturally derived

Flexible Polysaccharides

Urea

Polyvinyl

Lignin

Polysaccharide binders

Biodegradable

VOC’s

Heat resistant

VOC’s High strength

Flexible

Flexible

resistantHeat HeatHeat resistant

High strength

Flexible resistant Flexible

VOC’s

High strength High

VOC’s

Low to no VOC’s Low to no VOC’s and formaldehydeand formaldehyde High strength

Flexible strength

Pectin

VOC’s

Low to no VOC’s Lignin and formaldehyde Cellulose

High strength

Polysaccharide binders Biodegradable

Biodegradable

Naturally derived

Naturally derived

Lowformaldehyde to no VOC’s and and formaldehyde

Polysaccharide binders

Naturally derived

Naturally derived

Low to no VOC’s and formaldehyde

VOC’s

Pectin Naturally derived Lignin

Pectin Cellulose

Pectin

Lignin

Low to no VOC’s Found in natural andmaterials formaldehyde like algae Found in natural Polysaccharide binders Biodegradable Found in natural Polysaccharide binders Lignin Cellulose binders Polysaccharide Cellulose

materialsPectin like algaematerials like algae Lignin

Lignin

Cellulose

Free Form

Heat Press

Laminate

Naturally derived Naturally derived Heat resistant

Flexible

High strength

Found in natural materials like algae

Pectin

Pectin

Cellulose

Cellulose

Lignin

Lignin

VOC’s

Low to no VOC’s and formaldehyde

Naturally derived

Cellulose

Polysaccharide binders

Found in natural materials like algae

Biodegradable Pectin

Traditional

Polysaccharide binders Polysaccharide binders Found in natural Found in natural Naturally derived materials like algaematerials like algae Biodegradable

Pectin

Found in natural materials like algae

Lignin

Cellulose

Pectin

Polysaccharide binders

Lignin

Cellulose

Polysaccharide binders

85

Solvent-based resins

Press

Naturally derived

Low to no VOC’s

CelluloseBiodegradable

Low to no VOC’s Biodegradable and formaldehyde

Formaldehyde

Naturally derived

Low to no VOC’s and formaldehyde

Lignin

Found in natural materials like algae

High strength

Artificial manufacturing process

Artificial manufacturing process

High strength

Flexible

Pectin

Cellulose

Polyvinyl

Solvent-based resins

Biodegradable

Pectin

Used in plastic manufacturing

Urea

Mold Phenol

Solvent-based resins High strength resins Solvent-based

Artificial manufacturing process

Biodegradable

High strength Flexible

Melamine

Melamine

VOC’s Low to no VOC’s

VOC’s

Phenol Formaldehyde

Containts formaldehyde

Artificial manufacturing process

Heat resistant Heat resistantFlexible Solvent-based resins

VOC’sand formaldehyde

VOC’s

Polyvinyl

Polyvinyl Melamine Artificial manufacturing Melamine process Phenol Urea Polyvinyl Urea PolyvinylArtificial manufacturing Artificial manufacturing Formaldehyde processprocess Phenol Phenol Formaldehyde Formaldehyde Solvent-based resins

Phenol Formaldehyde

Heat resistant

Polypropylene

VOC’s

Containts formaldehyde

Used in plastic manufacturing

Melamine

Urea

Artificial manufacturing process Melamine

Solvent-based resins Used in plastic

Artificial manufacturing

Containts resins Solvent-based

Heat resistant

Polyvinyl

manufacturing formaldehyde formaldehyde

process resistant SyntheticHeat Resin

Used in plastic manufacturing

Urea

Containts

Used in plastic manufacturing

Melamine

Melamine Phenol formaldehyde Used in plastic Urea Containts FormaldehydeContaints

Phenol Formaldehyde

Used in plastic manufacturing

Containts formaldehyde

Biodegradable

Found in natural materials like algae

Found in natural materials like algae

Material Architecture Lab | Materials Research | UCL 86

ALGAE FIBER SHEET

ALGAE FIBER SHEET

Pulp Ratio Study

Sheet Manufacture Process

After extensive research on the manufacturing aspect of fiberboards, we chose paper as a feasible binder due to its naturally derived properties and lack of chemical processing. Additionally, paper provided adequate strength to the algae fiberboard The steps to the fabrication process can be seen below.

In addition to the aforementioned fabrication process involving paper as a binder, we streamlined the process further as seen below. The process below highlights the expedited fabrication process for our algae fiberboard.

Algae Sheet Proportion

Proportion 25%

35%

40%

45%

75%

65%

60%

55%

55%

60%

65%

75%

45%

40%

35%

25%

Algae

Scale

Compression Machine

Dissociation Machine

Dryer

Pulp

Paper Making Machine

Cold Press Machine

Algae Sheet

Algae

Pulp

87

Material Architecture Lab | Materials Research | UCL 88

ALGAE FIBER BOARD Manufacture Process

The production process illustrated below shows an expedited fabrication process of our algae board. The manufacturing process involves factory line machinery with the algae board ingredients being fed into a machine to be pressed and glued.

Fabrication Process

89

Production Trial

Mixture of fiber and binder within mold

Glue application

Cold Press

Heated Press

Material Architecture Lab | Materials Research | UCL 90

ALGAE FIBER BOARD Fiberboard Interlocking Study

91

Material Architecture Lab | Materials Research | UCL 92

DESIGN APPLICATION

Fiberboard Interlocking Study- Rectangular Algae Board

93

Material Architecture Lab | Materials Research | UCL 94

DESIGN APPLICATION

Algae Fiberboard Interlocking - Polygon Algae Board

Polygon Algae Board

95

Square Algae Board

Material Architecture Lab | Materials Research | UCL 96

ALGAE BOX

Corrugated Algaeboard - Fabrication Process The honeycomb paperboard approach serves as a strengthening agent to be placed within the algae box formed by algae fiberboards. The honeycomb algaeboard provides both density and added structure. The process of manufacturing consists of a factory line of machinery and a step by step procedure detailed below.

Corrugated Algaeboard Fabrication

Feed Algae Paper into unwinding unit

97

Vertical glue application

Cutting + Compression + Lamination

Drying

Transverse cutting

Material Architecture Lab | Materials Research | UCL 98

ALGAE BOX

Algae Fiberboard Box - Fabrication Process

Materials

Honeycomb Algae Board

Manufacture

Fabrication

x2

x2

Final Product

x2

Algae Fiberboard

99

Material Architecture Lab | Materials Research | UCL 100

DESIGN APPLICATION

Algae Box Interlocking System Study - Wall

101

Material Architecture Lab | Materials Research | UCL 102

DESIGN APPLICATION

Algae Box Interlocking System - Study 1

103

Material Architecture Lab | Materials Research | UCL 104

DESIGN APPLICATION

Algae Box Interlocking System - Study 2

105

Material Architecture Lab | Materials Research | UCL 106

DESIGN APPLICATION

Algae Box Interlocking System - Study 3

107

Material Architecture Lab | Materials Research | UCL 108

DESIGN APPLICATION

Algae Box Interlocking System - Study 4

109

Material Architecture Lab | Materials Research | UCL 110

Chapter 5

ALGAE + CLAY - Introduction

- Algae + Clay Blocks

+ Density + Texture

- Design Application

- Column

+ Fabrication Process

+ Robotic Arm Carving

+ Fabrication Process

111

+ Texture Variations

+ Rammed Earth - Wall

+ Robotic Arm Carving

Material Architecture Lab | Materials Research | UCL 112

ALGAE + CLAY

Introduction

Through our extensive experimentation and research on the structural abilities of pure algae and the functional and aesthetic qualities of its extracted starch, we realized that in order to move forward with a larger scale architectural application, we needed an aggregate to help algae become a stronger, structural load bearing material. Air dried clay, due to its malleability, non-toxic makeup, and low processing, became a strong direction forward for the material development of green algae. This chapter highlights the structural and visual qualities of mixing air dried clay and algae together, showcasing the interplay between the two materials. Our experimentations involved mixing different types of green macro algae with the same type of air dried clay, and researching different methods of fabrication including a rammed earth method, stacking clay and algae together in different ways and observing the outcomes.

113

Material Architecture Lab | Materials Research | UCL 114

ALGAE + CLAY EXPLORATION

Algae + Clay Blocks - Density

We also experimented with the density aspects of the blocks we made using clay and green algae. We used long and crushed green algae fibers, and algae in powder form mixed with the same amount of clay and observed the results. The results showed both varying structural and visual properties.

+ Long Fiber Algae(g)

20

50

+ Clay(g)

240

240

Sample

Properties

Crushed Algae(g)

+ Clay(g)

Sample

Properties

Algae Powder(g)

Clay(g)

Sample

Properties

Density:

Density:

Density:

Strength:

Strength:

Strength:

Shrinkage

20

160

Shrinkage

Time to Dry

Time to Dry

Density:

Density:

Strength:

Strength:

Shrinkage Time to Dry

60

160

Shrinkage Time to Dry

10

120

Shrinkage Time to Dry

Density: Strength:

20

120

Shrinkage Time to Dry

Density: Strength:

80

240

Shrinkage Time to Dry

Density: Strength:

140

115

240

Shrinkage Time to Dry

Material Architecture Lab | Materials Research | UCL 116

ALGAE + CLAY EXPLORATION Algae + Clay Blocks - Texture

Clay was a material that we decided would supplement the structural properties of green algae. In addition to being an aggregate to strengthen the green algae, it also has the same reusable properties of green algae. By submerging the type of clay we used into water, we were able to reuse it, similar to the way we are able to reuse our green algae, by submerging our formed dried blocks into water.

This creates a circular economy for the way we both of these materials together.

Furthering our experimentations with clay, we mixed clay using different methods and with different combinations of forms of algae.

This was an exercise to explore the different textures and aesthetics able to be achieved with both clay and algae.

Long Fiber Algae

Clay

Long Fiber Algae

Clay

Crushed Algae

Algae Powder Clay

117

Material Architecture Lab | Materials Research | UCL 118

DESIGN APPLICATION Middle Scale Components

119

Material Architecture Lab | Materials Research | UCL 120

ALGAE + CLAY COLUMN Column - Texture Variations

Further expanding upon our study on the integration of clay as a structural agent to algae, we devised different variations of columns that display varying amounts of algae combined with clay. We played with concepts of layering and texture gradients.

121

Material Architecture Lab | Materials Research | UCL 122

ALGAE + CLAY COLUMN

Algae + Clay Column - Fabrication Process Materials:

Tools:

Clay

Algae

Backfill Tamper

Reinforced Cylindrical Framework

Fabrication Process

1

2

3

4

5 24 - 30 Hours

Place clay within reinforced framework

123

Press first layer with tamper

Place algae atop clay layer

Place and press in desired order

Remove framework

Material Architecture Lab | Materials Research | UCL 124

ALGAE + CLAY COLUMN

Rammed Algae + Clay Column

125

Material Architecture Lab | Materials Research | UCL 126

ALGAE + CLAY COLUMN Column - Rammed Earth Texture

In addition to column sculpting, we also investigated the visual aesthetics of rammed earth and how they can be applied to our algae and clay column. The results show how different textures can be seen through different directions of cutting away at the algae clay component.

127

Material Architecture Lab | Materials Research | UCL 128

ALGAE + CLAY DOME Dome - Rammed Earth Texture

The structural applications of our rammed earth concept can be seen below. Through layering the algae strategically amongst the clay, we achieved different visual expressions every time the structure was cut in a different direction.

129

Material Architecture Lab | Materials Research | UCL 130

ALGAE + CLAY SHAPE EXPLORATION Other Shapes - Rammed Earth Texture

In addition to spherical forms, we also experimented with other circular, cylindrical shapes to apply the rammed earth concept to.

131

Material Architecture Lab | Materials Research | UCL 132

ALGAE + CLAY SHAPE EXPLORATION Other Shapes - Rammed Earth Texture

Other, thinner forms resembling paper were also experimented with, observing the interplay between the rammed clay and algae texture. The thin ribbon-like shapes shown below aim to push the boundaries of the shape of our rammed material. The shapes are more speculative in their nature.

133

Material Architecture Lab | Materials Research | UCL 134

ALGAE + CLAY SHAPE EXPLORATION Middle Scale Components - Rammed Earth Texture

Our final exploration into the rammed earth concept consisted of component based architecture, where components came together to form a larger structure. We experimented with the concept of a structure that allowed the user to have access to the roof.

135

Material Architecture Lab | Materials Research | UCL 136

ALGAE + CLAY COLUMN EXPLORATION

Rammed + Carved Column - Fabrication Process Materials:

Tools:

Clay

Algae

Reinforced Cylindrical Framework

Backfill Tamper

Milling Tool

Robot

Fabrication Process

1

2

Placement

3

Press

4

Placement

Ramming Algae + Clay Process

137

5

Orient + Press

6

7

Remove Framework

Carve Using Robotic Arm Milling

Carved Column

Material Architecture Lab | Materials Research | UCL 138

ALGAE + CLAY COLUMN EXPLORATION

Rammed + Carved Column

139

Material Architecture Lab | Materials Research | UCL 140

ALGAE + CLAY WALL

Algae + Clay Carved Wall - Fabrication Process Materials:

Tools:

Clay

Algae

Reinforced Framework

Backfill Tamper

Robot

Milling Tool

Fabrication Process

1

2

Place algae in between clay within framework

3

Press to lay foundation of wall

4

Maintain positioning of clay and algae throughout pressing

Ramming Algae + Clay Process

141

Remove Framework

Carve Using Robotic Arm Milling

Carved Wall

Material Architecture Lab | Materials Research | UCL 142

ALGAE + CLAY WALL

Algae + Clay Carved Wall

143

Material Architecture Lab | Materials Research | UCL 144

Chapter 6

ALGAE + CLAY LANGUAGE EXPLORATION - Thickness Analysis

- Topological Optimisation

- Agent Behaviours

145

- Design Application

+ Pavilion

+ Courtyard Housing

+ Hakka Housing

Material Architecture Lab | Materials Research | UCL 146

LANGUAGE EXPLORATION Lattice Pattern & Texture - Thickness Analysis

Taking all of our material research and design explorations into account, we decided to implement a thickness analysis approacth to the combination of algae and clay. In order to implement a more systematic approach towards the selective placement of algae in clay other than visual texture, we took the approach of analyzing thickness in a geometry.

Through analyzing a geometry’s thickness, we were able to determine the ideal mixture and amount of algae and clay for each area. For example, in a geometry’s thicker portions, the mixture would consist more of clay than algae, due to the need for more structure in the thicker areas. For the thinner and finer parts of the geometry, algae would be a more suitable option, as it is more flexible and porous than clay. Shown here are some examples of geometry where the aforementioned concept of analyzing thickness is applied to.

Lattice Pattern

Lattice Panel

Lattice Volume

147

Material Architecture Lab | Materials Research | UCL 148

LANGUAGE EXPLORATION

Column Form & Texture - Topological Optimisation Another approach to the systematic placement of algae in clay was the implementation of generative design.

Through generative design, we were able to optimize a geometry to withstand a certain amount of weight.

Through this approach, we were able to come up with many different organic forms that followed a number of geometrical constraints. The same idea of analyzing the thickness comes into play here, as thinner portions of the geometry consist mainly of algae, while the thicker portions consist of clay.

149

Material Architecture Lab | Materials Research | UCL 150

LANGUAGE EXPLORATION Growth Simulation - Agent Behaviours

Our third and final design language exploration consists of flocking, a simulation technique that mimics swarming particle behavior which we then used as a path for our geometry to follow.

151

Material Architecture Lab | Materials Research | UCL 152

LANGUAGE EXPLORATION Approach

The thickness analysis portion of our approach informs how the algae and clay will be mapped on the geometry.

The topological optimisation portion informs the overall shape of our geometry, and the agent behaviors populate the geometry. Through the integration of these three approaches, we explored different architectural applications.

+

153

+

Thickness Analysis

Topological Optimisation

Agent Behaviors

- Clay + Algae Mapping

- Generative Design

- Growth Particle Simulation

Material Architecture Lab | Materials Research | UCL 154

DESIGN APPLICATION Pavilion

Our next steps are to combine the three previously discussed design languages and integrate them together to form larger scale structures. We first explored the idea of a pavilion.

155

Material Architecture Lab | Materials Research | UCL 156

DESIGN APPLICATION Pavilion

157

Material Architecture Lab | Materials Research | UCL 158

DESIGN APPLICATION Pavilion

159

Material Architecture Lab | Materials Research | UCL 160

DESIGN APPLICATION Courtyard Housing

In addition to the pavilion, we decided to experiment with more traditionally shaped dwellings and structures. We explored how our design language and approach would be able to swarm and grow around an existing structure.

We decided to explore housing options further, choosing traditional Chinese courtyard housing as a starting point.

Image Sources 1. FRAME 2. South China Morning Post 3. That’s Beijing 4. China Times

161

Material Architecture Lab | Materials Research | UCL 162

DESIGN APPLICATION Courtyard Housing

163

Material Architecture Lab | Materials Research | UCL 164

DESIGN APPLICATION Hakka Housing

Expanding into different typologies of traditional Chinese housing, we also explored another type of courtyard housing, the circular Hakka Housing, native to South China. Like the HuTong, Hakka Housing is housing with a communal courtyard, however its size is substantially larger.

Image Sources 1. National Geographic 2. The Vintage News 3. Easy Tour China 4. South China Morning Post

165

Material Architecture Lab | Materials Research | UCL 166

DESIGN APPLICATION Hakka Housing

167

Material Architecture Lab | Materials Research | UCL 168

DESIGN APPLICATION Hakka Housing

169

Material Architecture Lab | Materials Research | UCL 170

DESIGN APPLICATION Hakka Housing

171

Material Architecture Lab | Materials Research | UCL 172

DESIGN APPLICATION Hakka Housing

Further developping our design language and combining our previous experiments with rammed earth, we explored a combination of rammed clay and algae walls with the previously explored combination of thickness analysis, topological optimisation, and agent behavior.

+

Rammed Clay and Algae

Thickness Analysis - Clay + Algae Mapping

173

Material Architecture Lab | Materials Research | UCL 174

DESIGN APPLICATION Hakka Housing - Interior

175

Material Architecture Lab | Materials Research | UCL 176

Chapter 7

ECOVILLAGE SITE - China Algae Harvesting Coast

- Huang’bi’ao, Xiangshan, Ningbo

+ Xuwen Algae Company + Collaboration Proposal

- Existing Land Use - Site Photo

- Eco Village Lifestyle Transition

- Site Drawings

- User Journey

177

Material Architecture Lab | Materials Research | UCL 178

ALGAE HARVESTING China

Harvesting Coast

[SITE] - Ningbo, Zhejiang Hangzhou Bay

Zhoushan Islands Beilun Port

Hebei Beijing Qingdao Jiangsu

Yellow Sea

+ Fujian

+

Zhejiang 浙江省

East China Sea

Ningbo

宁波市

+

Chosen Site Major Locations Algae Harvesting Coast

179

Material Architecture Lab | Materials Research | UCL 180

SITE

Huang’bi’ao, Xiangshan, Ningbo, China 121°48’ 25.6392’’ E`

+

29°33’ 6.7608’’ N Xiangshan

Algae land farming in Xiangshan

象山县

+

Chosen Site Algae Harvesting Coast

181

Post harvest, drying algae in Xiangshan Material Architecture Lab | Materials Research | UCL 182

SITE

Huang’ bi’ ao, Xiangshan, Ningbo, China

Algae cleaning / processing in the laboratory

+ [Production + Supply] Xuwen Algae Company

[Eco-village Site] Baiyucun, Xiangshan

高泥村

白屿村

+

Chosen Site

Further processing to create algae used as water filter

Major Locations 500 km 183

Material Architecture Lab | Materials Research | UCL 184

SITE

Xuwen Algae Company We propose to collaborate with a neighbouring company within close proximity to our village to supply the algae we need to construct our ecovillage. Xuwen’s new water filtering algae has no other use after it is used as a filter.

We propose to utilize this unusable algae as our primary construction material.

Combination of existing species

Processing / manufacturing

utilizing excess algae in design

Reintegration into ocean

Water pollution filtration

Excess unusable algae

Eco village construction

processing + usage of new algae species 185

Material Architecture Lab | Materials Research | UCL 186

CONCEPT

Transition - Eco Village Lifestyle

URBAN

187

TO

RURAL

Material Architecture Lab | Materials Research | UCL 188

SITE

Huang’ bi’ ao, Xiangshan, Ningbo, China Existing Land Use

Road Factory Housing 405 acres

Cultivated Land

417 acres

Forest

N

200 km 189

Aquaculture Farming

Sea Material Architecture Lab | Materials Research | UCL 190

SITE

Existing Conditions - Tide

Tide up in Baiyu Village

191

Tide down in Baiyu Village

Material Architecture Lab | Materials Research | UCL192

SITE

Huang’ bi’ ao, Xiangshan, Ningbo, China Existing Landscape Use

Living

TIDE UP

Aquaculture Farming

TIDE DOWN Tidal Flat

N

200 m 193

Sea Material Architecture Lab | Materials Research | UCL 194

SITE

Huang’ bi’ ao, Xiangshan, Ningbo, China Section

Forest

Cultivated Land

Living

Aquaculture Farming

Tidal Flat

Sea

100 m

195

Material Architecture Lab | Materials Research | UCL 196

SITE

Huang’ bi’ ao, Xiangshan, Ningbo, China Site Photo

197

Material Architecture Lab | Materials Research | UCL 198

SITE

Huang’ bi’ ao, Xiangshan, Ningbo, China Site Photo

199

Material Architecture Lab | Materials Research | UCL 200

USER JOURNEY Eco Village Program

WARM - UP

PROGRAM Program 1 - Tide Down

Welcome - Transition

WARM - DOWN

Program 2 - Tide Up

Tool - Prep

Boat Travel

Drying Algae

Cooking

Wild Harvest

Aquafarming

Making Seasoning

Having Feast

Making Material

Viewing Scenery

Washing Algae 201

ALGAE PROCESSING

Material Architecture Lab | Materials Research | UCL 202

Chapter 8

ECOVILLAGE DESIGN - Approach

- Component Distribution

- Topological Optimisation

- Interlocking Aggregation System - Component Tests

- Final Design

203

Material Architecture Lab | Materials Research | UCL 204

APPROACH

Ecovillage Overview The final approach to the design of our ecovillage is informed by all of the experiments and explorations we previously detailed. Our Ecovillage will be situated on the existing aquaculture farming area of Huang’bi’ao, where the high tide meets the landscape. The overall arrangement of the structures of the Ecovillage mirror that of a humble village. The program of the Ecovillage is reflected in the design of the units, housing the activities of aquafarming, processing algae, and communal gatherings.

The design of the units will use a combination of the topological optimisation approach with the interlocking component system. The topological optimisation serves as a system of placement and mapping for the algae and clay components, while the interlocking components act as the main construction system.

Design Approach

+

Eco Village User Journey

205

+

Topological Optimisation

Interlocking Component System

Material Architecture Lab | Materials Research | UCL 206

COMPONENT DISTRIBUTION Component Density Composition

The final design of the multifunctional dwelling units populating the ecovillage will be constructed out of interlocking clay and algae components. These components vary in density, the least dense being the algae box component completely comprised of algae, to the most dense being a component comprised of 90% clay and 10% algae.

Least Dense Component

100%

207

Algae

Densest Component

70%

Algae

50%

Algae

10%

Algae

30%

Clay

50%

Clay

90%

Clay

Material Architecture Lab | Materials Research | UCL 208

COMPONENT DISTRIBUTION Topological Optimisation

Applying a generative design approach, the main load bearing elements of our unit will be populated by our densest component. The areas outside of the load bearing elements will be comprised of less dense components.

This system dictates and maps the different components on our geometry.

Generative Design Process

3D Load

3D Load

Starting Wall Volume

Starting Wall Volume

3D Support

3D Support

10%

Algae

90%

Clay

50%

Algae

50%

Clay

100%

1

2

3

Set Load and Volume Limits

Volume Generation

Component Distribution Most Support Required

209

Medium Support Required

Algae

Least Support Required

Material Architecture Lab | Materials Research | UCL 210

COMPONENT DISTRIBUTION

Generative Design Process - Wall Generation Simulation

3D Load component

3D Support component

Stress

0

1.25

Best iteration : 30 / 100

211

2.5

Step 0 / 100

Step 10 / 100

Step 30 / 100

Step 50 / 100

Step 70 / 100

Material Architecture Lab | Materials Research | UCL 212

TOPOLOGICAL OPTIMISATION Interlocking Aggregation System

1

2

3

Load Bearing Foundation

Secondary Load Bearing Foundation

Window / Screen Elements

Most Support Required

Medium Support Required

+

213

Least Support Required

+

+

Material Architecture Lab | Materials Research | UCL 214

COMPONENT TEST 1 Housing Typology 1 Volume 1

Component Set A

100%

Algae

Component Set A - Volume 1 340 sqm / 2 Floors

215

50%

Algae

50%

Clay

10%

Algae

90%

Clay

Material Architecture Lab | Materials Research | UCL 216

COMPONENT TEST 1 Housing Typology 2 Volume 1

Component Set B

100%

Algae

Component Set B - Volume 1 340 sqm / 2 Floors

217

50%

Algae

50%

Clay

70%

Algae

10%

Algae

30%

Clay

90%

Clay Material Architecture Lab | Materials Research | UCL 218

COMPONENT TEST 1 Housing Typology 3 Volume 1

Component Set C

100%

Algae

Component Set C - Volume 1 340 sqm / 2 Floors

219

50%

Algae

50%

Clay

70%

Algae

10%

Algae

30%

Clay

90%

Clay

Material Architecture Lab | Materials Research | UCL 220

COMPONENT TEST 2 Housing Typology 4

Volume 2 Generation Process

Component Set D

100%

Component Set D - Volume 2 230 sqm / 3 Floors 221

Algae

50%

Algae

50%

Clay

10%

Algae

90%

Clay

Material Architecture Lab | Materials Research | UCL 222

COMPONENT TEST 3 Housing Typology 5 Volume 3

Component Set B

100%

Algae

Component Set B - Volume 4 258 sqm / 3 Floors

223

50%

Algae

50%

Clay

70%

Algae

10%

Algae

30%

Clay

90%

Clay Material Architecture Lab | Materials Research | UCL 224

COMPONENT TEST 4 Housing Typology 6 Volume 4

Component Set C

100%

Algae

Component Set C - Volume 4 194 sqm / 3 Floors

225

50%

Algae

50%

Clay

70%

Algae

10%

Algae

30%

Clay

90%

Clay Material Architecture Lab | Materials Research | UCL 226

FINAL DESIGN Plan

N

100 m 227

Material Architecture Lab | Materials Research | UCL 228

FINAL DESIGN Exterior Render

229

Material Architecture Lab | Materials Research | UCL 230

FINAL DESIGN Exterior Render

231

Material Architecture Lab | Materials Research | UCL 232

FINAL DESIGN Interior Render

233

Material Architecture Lab | Materials Research | UCL 234

FINAL DESIGN Interior Render

235

Material Architecture Lab | Materials Research | UCL 236

FINAL DESIGN Interior Render

237

Material Architecture Lab | Materials Research | UCL 238

algae anatomy Bryan Law | Dinel Mao | Jie Song Material Architecture Lab | RC 5/6