A ProtoType Foundry: A Technical Requisite

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- A TECHNICAL REQUISITE - [-7 ] -

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A ProtoType Foundry

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Jonathan Harker 0808005

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A ProtoType Foundry Jonathan Harker A Technical Requisite

TABLE OF CONTENTS

INTRODUCTION A Systematic Approach

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Birmingham: CIty of a Thousand Trades, Workshop to the World

5

TECTONIC CONCEPT AND LANGUAGE Tectonic Concept

6

Robustness

7

The Typographic Kit of Parts

8

Materiality Precedents

10

Casting Concept

11

Materials Board

13

PROCESS Tectonic Process Storyboard

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Panel Ties and Stitching

18

Couplers and Rebar

21

Specifying Concrete

22

Curing

23

Event Application

24

Legacy Alteration

25

DETAILING Working from Tilt-Up Slab Principles

26

Foundations

27

Tying back into In-situ Spanning Slab Integrated Lighting

28

Roofing and Parapet

29

Difficulties in Site Specific Construction

30

PERFORMANCE

3

Generating U-Value

31

Ventilation Strategy

32

Fire Strategy

34

Heating and Cooling

36

Economic Proforma

37

A SYSTEMATIC APPROACH

This thesis shall consider the design of a systematic approach to pre-fabricated component construction that can be adopted as a commercial means of exhibiting.

The nature of the spectacle of the understood ‘fair’ shall be appraised by plugging this architectural prototype EXPO model into former process driven industrial quarters. This is done whilst valuing that a constant presence in the architecture of exhibition design is the commercial drive to identify with products and processes through the treatment of built surface.

Permanence

[+]

[EXPO 2026?]

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A ProtoType Foundry Jonathan Harker A Technical Requisite

BIRMINGHAM: CITY OF A THOUSAND TRADES, WORKSHOP TO THE WORLD.

Digbeth is an intensely industrial

The Duddeston viaduct is a

region of Birmingham and was chosen as a

blue brick elevated structure built in the

model urban situation for a manufacturing

mid 19th century with the intention of

focused reappraisal of the exhibition model.

linking the Great Western Rail line from

A site in central Digbeth mediates frequent

Oxford into Birmingham Moor Street

footfall between the proposed Curzon Street

with the London line from the time (of

high-speed rail terminal and planned

which the final stages form the route for

national scale sport facilities adjacent to

the new HS2 line. The opening of Snow

Birmingham City.

Hill station midway through construction however deemed this infrastructure link

Although characteristically defined

unrequired and it stands today with its

by the industrial architectural typologies,

fragmented terminus dotted across the

elevated rail infrastructure and arterial canal

meeting of the grand union canal and

system through the area, there is anonymity

the carved out junctions of industrial

about the processes and nature of the

Digbeth. This structure stands today as

industry that lies behind the Eastside of this

a monument to the modesty of the brick

trade city. These are broader traits of very

as a modular building component which

similar industrial urban fabrics, which have

shaped the masonry industrial fabric

also given birth to social bodies and

across the area.

entertainment venues further north along the second phase of high speed rail plans.

5

Tectonic Strateg

Masonry construstion with large spanning steel trusses

TECTONIC CONCEPT

Symmetrical or north light oriented industrial pitched roof typology Surface as sheild. Covert to programme

ONE ESTABLISHED MODULAR TYPOLOGY THAT SERVES AND FABRICATES ANOTHER

The typical industrial warehouse

or ‘shed’ typology consists of modular masonry construction with a steel column, beam and truss system supporting a corrugated metal roof usually with north light glazing. Tectonic Strategy

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ion with large spanning

Tectonic Strategy

rth light oriented industrial ogy

Covert to programme

This thesis aims to propose a

new modular prototype system of Tilt-up slab component concrete core and sheer wall construction

construction for the means of

ion with large spanning

commercial exhibiting. The system shall

comprise rth light oriented industrial ogy

Facade glazing allows lighting. As well as intricate filligree roof support

of pre-fabricated reinforced

Allows permeable surface. Overt to programme

concrete load bearing modules which

Covert to programme

are stitched together as well as into cast In-situ spanning slabs.

Tilt-up slab component concrete core and sheer wall construction Facade glazing allows lighting. As well as intricate filligree roof support

The prototype system shall play off and

Allows permeable surface. Overt to programme

work with both the iconography left over from previous industrial revolutions, as well as within the existing understood typologies.

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A ProtoType Foundry Jonathan Harker A Technical Requisite

ROBUSTNESS

A key element of this technical

requisite is the understanding of the connections between the components and ties into other types of structure, so that the proposal as a summation of parts works as an inherent structure with robustness and not merely a set of individual elements.

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THE TYPOGRAPHIC KIT OF PARTS

The thesis looks to what a

contemporary exposition model can learn from the largely obsolesced cases that have documented previous industrial revolutions. Much of the legacy and iconography lies away from the architecture, in the efforts to create identity through the graphic approach and stylistic branding of what is foremost little more than a six month showcase.

These key historic events are now perhaps more fondly referenced by the work of a typeface foundry and poster campaign rather than the fallen iconography of the architecture. The design process has largely worked with a pragmatic approach to the universal graphic setting out of typeface to inform both the macro and micro scales of the built construct. The prototype system treats pre-fabricated components as if they are characters, which are then given context within the process driven narrative of the industrial.

MINIMAL CHARACTERS MAXIMUM PERMUTATIONS

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A ProtoType Foundry Jonathan Harker A Technical Requisite

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MATERIALITY PRECEDENTS

NOTTINGHAM CONTEMPORARY Caruso St John The facade is clad in lace-patterned, precast concrete, inspired by the regular and repeated surfaces of the surrounding industrial warehouses.

HERMAN MILLER CHEROKEE OPERATIONS Mack Scogin Merrill Elam Architects

Materials include a concrete tilt-up structural wall system; steel columns, trusses, bar joints and deck at the roof; and concrete slab on grade floors.

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A ProtoType Foundry Jonathan Harker A Technical Requisite

CASTING CONCEPT The traditional setting out of letterpress block characters within a confined tray has informed the detailed envelope aesthetic of the component system.

This relieved composition of surfaces shall be demonstrated by fabricating planes of sheet cut aluminium which are the stacked and arranged to display the graphic aesthetic of a universal set of typographic guides which can generate any permutation of characters.

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SHEET WORKING ALUMINIUM The formwork for the pre-cast concrete skins will be made by configuring a set of sheet cut aluminium panels based on the typographic setting out guides.

These are arranged and repeated in trays and draws directly on the concept of arranging letterpress blocks.

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A ProtoType Foundry Jonathan Harker A Technical Requisite

Rolled Steel Sections of Window Mullions and Transoms

Toughened 12mm Double Glazed Unit

Rigid Foam core Insulation

4mm built up aluminium sheet formwork

Fly Ash Aggregate Concrete Panel Skin set with superplasticiser

Foil Insulation Casing

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TECTONIC PROCESS STORYBOARD

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A ProtoType Foundry Jonathan Harker A Technical Requisite

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A ProtoType Foundry Jonathan Harker A Technical Requisite

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240

18

40

120

A ProtoType Foundry Jonathan Harker A Technical Requisite

240

310

120

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PANEL TIES AND STITCHING

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19.5

Module horizontal ties are based on Anstar ASL Steel bracket locking system which is inherently tied into the Rebar structure.

290

The system effectively is comprised of

19.5

150

a bolt and socket which interlock in an

50

immovable connection which aids to achieve the level of robustness required for this type of pre-cast component sys-

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335

20

71

tem.

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The tie drawings are dimensioned for the locking mechanism to be concealed between the two precast skins as shown

305

20

35

45

230

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in the tectonic process storyboard.

55 100

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ASSEMBLY

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A ProtoType Foundry Jonathan Harker A Technical Requisite

COUPLERS AND REBAR

Couplers integrated into the panel construction will allow them to be easily lifted into place as temporary threaded inlets for lifting can be located from the reinforcement cage. These would then be craned by screwing a corresponding threaded bracket to suspend the load and manoeuvre into place.

PRECAST COMPOSITE COMPONENT SYSTEM

TECTONIC SYSTEM IN CONTEXT DETAIL 1 : 50

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SPECIFYING CONCRETE Using a concrete mix with fine Fly ash particles as an aggregate reduces the cement content whilst also giving a comparative sustainable edge over other concrete products as the fly-ash is merely a waste product of the blast furnace.

The minute particles create a ball bearing effect that creates a very fluid mix when filling the formwork that rushes to the finest cavities.

This also contributes to this specification of concrete being self-levelling. This would save expenditure on vibration tables and is appropriate for the over plan fine detail application within the building programme.

Less water is required in the mix with the

Foundations

inclusion of a super-plasticiser. Less water equals

5000mm deep Pile foundations 850mm Concrete pile cap with extruded base plate for base component to be resin anchored and in-situ cast into position

a stronger mix that is required in load bearing instances under compression. Better

600mm Concrete ground beam

performance at resisting weathering, wind loads

250mm Compacted Core for levelling

and freeze/ thaw cycles.

Vapour barrier

Self levelling can reduce finishing time by up to 75% which would mean less labour costs.1

DETAIL SECTION

La Farge are a specialist concrete reinforcement and superplasticiser provider. Their ‘Agilia’ product uses plasticisers to reduce water content.

It also imilinates the need for additional vibration. The concrete specification mix would list this super-plasticiser

ELEVATION [ NW ] 1Petricone, Pina. Concrete ideas: Material to shape a city (Thames and Hudson, London, 2012) p.22

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A ProtoType Foundry Jonathan Harker A Technical Requisite

CURING

The Pre-cast components will require 28 days of curing to attain the required strength, this is of importance due to the load bearing requirement on the vertical components. They will be cured within the industrial masonry fabrication warehouse which can be temperature controlled to the required extent. The fabrication process and factory floor can be viewed as an industrial attraction and each modular piece waiting to have a structural role can be utilised as ground level display surface and to define / break up open ‘shed’ spaces to aid wayfinding.

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EVENT APPLICATION

The nature of the casting of the envelope with a universal system for constructing typography is rooted in a commercial application during exposition events.

The concrete casting will provide a physical set of guidelines to give identity to the panel during for the duration of the ‘fair’ Simple painted and transferred applications (such as 3M ScotCal Vinyl Film) will be a common interpretation however the setting out rules provide opportunity for more innovative approaches just as obscured projections or using the system to produce supergraphics at a macro scale of motif across multiple panels or whole facades.

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A ProtoType Foundry Jonathan Harker A Technical Requisite

LEGACY ALTERATION

After the duration of the events spaces the temporary graphic painted application will be removed using one of two processes.

If the removal of material required is very fine then a focused high pressure water jet can be use to take off the surface layer of paint and concrete particles.

If the desired effect is to abstract the original casting and tone down the aesthetic to blend with the industrial working fabric then a grip-blasting process would be used, stripping back the material and removing the fine cast detail. This would obscure the original function but could create favourably unexpected results . It is envisaged that the legacy of such a system would employ both techniques to maintain the fine detail of the typographic casting but also mellow and wear elements of the structure into its surrounding industry.

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DETAILING THE COMPOSITION OF THE SYSTEM WORKING FROM TILT-UP SLAB PRINCIPLES With the tilt-up method concrete elements such as walls and structural supports, are formed horizontally on a concrete slab; usually the building floor, but sometimes a temporary concrete casting surface near the building footprint. After the concrete has cured, the elements are “tilted” to vertical position with a crane and braced into position until the remaining building structural components (roofs, intermediate floors and walls) are secured.

Concrete elements can also be formed at factories away from the building site.

Tilt-up differs from prefabrication, as all elements are constructed on the job site.

This eliminates the size limitation imposed by transporting elements from a factory to the project site.1 2

1 Woodland Construction Co. 2010 2 Collins, J (2002). “Tilt-up dominates Australian construction” London Concrete Society 36 (3)

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A ProtoType Foundry Jonathan Harker A Technical Requisite

TYING BACK INTO IN-SITU SPANNING SLAB Grouted Stitching – In-situ to Pre-cast Junction Threaded Rebar protrudes 350mm and acts as a coupler which is then deformed and tied back into threaded inlets on the spanning slab reinforcement cage.

Modules would be craned by screwing a corresponding threaded bracket to suspend the load and manoeuvre into place.

340mm deep In-situ cast one-way spanning slab Slab cast at junction against 120mm rigid foam insulated block slotted between modules 9.5mm diameter (No.3 grade) Reinforcing stirrups tie Rebar grid Vapour Barrier 70mm of screed and under floor heating and cooling system.

Polished internal finish

FOUNDATIONS Contiguous driven pile foundations to a depth of 5000mm are required for three storey applications of the component system in this location due to the close proximity of the adjacent Grand Union Canal and geological uncertainties.

5000mm deep Pile foundations 850mm Concrete pile cap with extruded base plate for base component to be resin anchored and In-situ cast into position 600mm Concrete ground beam 250mm Compacted Core for levelling Vapour barrier Ground Beams tie back the forces (rotary moment) received at the special instance tilted corner panels from the pile caps.

1 : 20 27

SPANNING AND SIZING MEMBERS

The design allows for a maximum oneway span of 10200mm in the spanning In-situ concrete slab.

The required depth for this maximum span has therefore been calculated and specified at 340mm.

Length / 30 based on a one end continuous end condition of slab with an intermediate grade of reinforcement (No. 3 19mm or 40 ksi tensile stress capacity)1 10200 / 30 = 340mm Post tensioning in the spanning slabs also allows for minimising the amount of reinforcement required.

INTEGRATED LIGHTING The pre-cast modular panel design allows for 200mm at the top edge of each panel to recess floodlighting in order to illuminate the base line of typographic detail on the above panel. The lights are housed within a turn and tiltable casing, with steel sheet metal protection with a powder coated finish. The recessing allows a reflective plate to be flush with the base of the cavity anchoring out to reflect light above. The plate is mirrored on the inward facet and finished with dark grey 3M Scotch Cal vinyl acrylic transfer on the facade face.

1 : 20 1 Ambrose and Tripeny, Building Structures: Third Edition (Wiley, New Jersey, 2012) p.222 Material in Building Code Requirements for Structural Concrete (AC1 318-08)

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A ProtoType Foundry Jonathan Harker A Technical Requisite

ROOFING AND PARAPET INSTANCES

In instances where the composition of the highest storey modules are not capped within standing modules to add aesthetic roofscaping they are subtly finished and protected with the small parapet. The material detailing of these roofing slab to parapet junctions is listed below are demonstrated opposite; 2mm aluminium flashing Duplex Board with vapour barrier Silicon seal with compressible filler 60mm Insulation Wooden batten to seal cavity 50mm Thermabate cavity closer on roof facing edge Ties to Concrete Up-stand butted against In-situ cast spanning slab Vapour Barrier

1 : 10 29

DIFFICULTIES IN SITE SPECIFIC IMPLEMENTATION

Due to the proximity of the adjacent historic Duddleston viaduct to the built works several key technical processes must employed.

A specialist compact pile driver will be required to get to within 1500mm of exisitng masonry structures. So not to disturb their groundworks, in a few instances the pile caps and cast ground beams will required a cantilever in order to achieve sitting the precast components close against existing masonry construction.

The post tensioning in the In-situ cast spanning slab will have to in some instances be applied from a dead anchorage point in one direction due to restricted access.

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A ProtoType Foundry Jonathan Harker A Technical Requisite

COMPOSITE PRE-CAST MODULE Outer Skin – 100mm Concrete panel pre-cast against built - up sheet cut aluminium sections in 4mm intervals Concrete reinforced with 19mm diameter (No.6 grade) Reinforcement bars spaced at 300mm intervals Damp Proof Membrane (Damp proof course running horizontally where In-situ slab meets pre-cast panels and rigid insulating block) 120mm Rockwool fibrous insulation in cavity between concrete skins

U­Value Calculator 19mm Rebar ties and spaces concrete

Thermal transmittance (U­value) according to BS EN ISO 6946 2007

Project

skins

Inner Skin – 100mm reinforced Concrete pre-cast panel (cast smooth or with relieved system as internal finish)

Reference

Modules are horizontally tied by Anstar

ASL Steel bracket locking system which Building Type is inherently tied into the Rebar structure

External Wall

Element Type: Perimeter (m):

Area (m2):

Max U­Value U = 1/RT = 0.28 W/m2K

GENERATING THE U-VALUE OF A MODULAR PRECAST COMPONENT P/A = N/A

Thermal Cond.

(W/m2K)

Material

%

Thickness (mm)

Resistance (m2K/W)

Internal Surface ( Rsi )

0.1300

Reinforced concrete 2% steel Glass fibre/Wool batt Reinforced concrete 2% steel

2.50 0.035 2.50

100 100 100

External Surface ( Rse )

Total thickness: Total resistance: U­Value (uncorrected): Total ΔU: U­Value (corrected):

100 120 100

0.0400 3.4286 0.0400

0.0400

mm

RT = Rsi+R+Rse =

320.0 3.679

U = 1/RT =

0.272

W/m2K

0.272

W/m2K

m2K/W

0.000 U = 1/RT+ ΔU =

31

Disclaimer: Please be aware that you use this U Value calculator entirely at your own risk.

No responsibility for the accuracy of this data or any outcome due its use is accepted by ChangePlan Ltd or any of the parties involved in creating or

VENTILATION STRATEGY The ventilation strategy for the building

Ventilation Rate

will be a hybrid solution calling on both natural and mechanical ventilation.

The ventilation air change rate for theatres and exhibition spaces is given in

Due to the programme of

the CIBSE guide Table B2.3 as 6-10 air

public spaces taking large visiting

changes per hour.

capacity crowds ventilation

This is total air supply rate.

rate and

changing the circulating air is of integral importance to the successful operating

The amount of fresh air supplied per oc-

and comfort of the environment.

cupant is specified in Table B2.2 as

8 litres per second per person for

Large rooms such as lecture

rooms; theatres, conference rooms,

non-smoking areas. These two figures

exhibition halls, auditoria and halls for

can determine the air flow rates in the

public gatherings need careful designing

ventilation system.

for ventilation or air conditioning.

Two of the most important design criteria

Ventilation rate (m3/h)

=

are:

Air Change Rate (/h)

x

- The ventilation rate.

Room Volume (m3)

- The distribution of air in the space.

MECHANICAL

HYBRID

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A ProtoType Foundry Jonathan Harker A Technical Requisite

USING CORES FOR STACK EFFECT VENTILATION

The naturally ventilated concrete cores are capped with a permeable composition of layered glazing and CNC cut aluminium profiles which provide a breathable roofing skin. Warm arm convects through the ground floor from the entrances

and

apertures

and

rises

through the channelled core. It dissipates and convects out from the core openings on each floor before passing through the natural roofing ventilation. The convection imbalance in pressure then draws cool air in again at the base of the design and the buoyancy of heating the rising air is repeated in the ‘stack effect’.

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FIRE STRATEGY

[ 1 ] Means of escape and alarming [ 2 ] Inhibiting the spread of fire across the internal linings [ 3 ] Adequate fire resistance of the structure to maintain stability and compartmentalisation [ 4 ] Prevention of fire spread between buildings [ 5 ] Adequate provision for Fire service access up to a through buildings; fire fighting facilities.

- GROUND FLOOR 25m

Maximum travel distance to closest

exit from two emergency egress strategies

25m

23m

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A ProtoType Foundry Jonathan Harker A Technical Requisite

- 1st FLOOR -

14m

Maximum travel distance to closest

exit from two emergency egress strategies

14m

11m

- 2nd FLOOR -

15m

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Maximum travel distance

HEATING AND COOLING

Some areas of the programme will have the requirement to have underfloor cooling as well as heating due to the nature of their inhabitation. For example the Printworks production floor will have heavy machinery running for extensive periods of time, massively contributing to the internal gains. This paired with the large crowds of visitors concentrated with a potentially uneven distribution,

UNDERFLOOR HEATING

demonstrate why a dual system such as those offered by companies such as

Timoleon of underfloor heating and cooling would be favourable for this project.

UNDERFLOOR COOLING

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Practice Management and Economics MArch 2

A ProtoType Foundry Jonathan Harker A Technical Requisite

Economics Oral Examination

ECONOMICS PROFORMA

Executive Summary Your Name:

Jonathan Harker

Studio:

Economy

Principal Building Function (s)

Exhibition Spaces, Printworks and Fabrication in sheet metalworking and precast concrete components

Site Location

Digbeth, Birmingham

Promoter/Client:

Recognised as a specialist exposition by the BIE (Bureau International des Expositions). Must have a precise character to its theme. One of two forms of acknowledgement, rather than a registered event (also known as a World Expo) Commercial Promoter - Google ‘Exhibit’ or similar online platform promoting letting of commercial units through a recognised exposition.

Business Birmingham, Millennium Point, Birmingham City University Google ‘Exhibit’

Principal Funding Sources

Payback through commercially lettable modular units through online platform and trade in prefrabricated building systems.

A secondary level structure of corporate sponsorship

Brief statement of how scheme represents value for the promoter

The appraisal of the EXPO model utilises existing industrial character, iconography and warehouse typology spaces rather than new vast capital investments. Transport Infrastructure links will be in place due to the close proximity to HS2 hub at Curzon Street.

The scheme is proposing the pioneering of a prototype exhibiting system, which can generate revenue when used within other urban conditions and events.

The scheme aims to give architectural manifestation to an online platform promoter requiring easily replicable identity within the built environment.

Proposed Gross Internal Floor Area

Net to gross ratio:

(New Build) 4950m2

(New Build) 1 : 1.22

Estimated Costs (State sources) The source of estimated costing is SPON’S Architect’s and Builder’s Price Book 2012 unless stated.

Zone/Function

Approx £m

Exhibition Centres

2

2

Area (m )

Total (£)

1300

4950

6,435,000

Excavation and disposal off site

22

1877

41,294

Specialist excavation and machinery for use amongst existing structure

52

400

20,800

Fully Piled Foundations in poor ground (adjacent to Grand

230

1877

431,710

(SPONS Guide Estimation per 2 m building type) Preparatory works and Substructure

37

Union Canal) Ground Beams

(Linear Metre) 140

(Linear Metre) 243

34,020

Demolition

62

410

25,420 700,000

Restoration (Based on Restoration works to Accrington Viaduct, March 2013)

Superstructure (by precedent) Precast Concrete Panel Structure and envelope construction

540

4950

(Generated from precedent conversion from $ and taking into account inflation since 2000)

(Based on Herman Miller Cherokee Plant, Tilt up Concrete Slab Construction Precedent)

Roofing

2,673,000

94

1250

117,500

75mm thick lightweight screed roof covering and vapour barrier

18

1250

22,500

Existing Fabrication Warehouse Roof Replacement

35

3900 (Flattened Pitch)

136,500

Existing Printworks Warehouse Roof Replacement

37

2430 (Flattened Pitch)

89,910

Roofscaping and Landscaping

(29 + 40) 69

2015

139,000

Industrial Printworks category A fit out (developers)

450

373

167,850

Industrial Printworks category A fit out (tenants)

300

373

111,900

Component Fabrication Warehouse category A fitout

475

1025

487,000

245

(75 x 16) 1200

294,000

53,000 (total)

x3

106,000

44,360 (total)

x2

88,720

Concrete Flat Roofing Reinforced Spanning Slab (no coverings or finishes)

(Generated from online quote calculator for project spec from Accord steel cladding)

Interior Finish and Fit out

Flexible Exhibition System Fit out Modular Exhibition System (Based on POD Exhibition systems – Arena 4 Kit E) Lift Shafts Glazed shaft 3 x 6 person carriage. 2 x Heavy industrial goods lift.

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A ProtoType Foundry Jonathan Harker A Technical Requisite

Fire Strategy

8

4950

39,600

Sprinkler system

15

145 + 1296

21,615

(Metal casting foundry and Print house production floor)

(SPONS Mechanical and Electrical 2011)

Mechanical Ventilation

200

1441

288,200

Toilets and Sanitation

52

160

8,320

Interior Artificial Lighting

18

4950

89,100

Underfloor Heating and Cooling

30

5323

159,690

Smoke detection

AC and extraction in industrial process spaces. Heat recovery due to air change requirements

Total Estimated Cost:

6,293,649

Estimated Superstructure Costs by Modular Component Type of Component

Approx ÂŁ per component

Number of Instances

Standard Component

Fine aggregate highly specified concrete mix with polypropylene fibrous additive and super-plasticiser.

Component Modular design

116 per m

3

53,424

144

131,328

3

3.2m per component 371

2

912 (16m )

4000mm x 4000m Reinforced concrete double skin with insulation and DPM

Additional Labour and Formwork costs (Base rate)

144

848 (53 x 16)

Economy of Scale through re-use

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First 9 panels

848

9

7,632

Up to 27 Panels

645

18

11,610

Up to 180 Panels

110

117

12,870

81

37,584

81

202,500

460

9

4,140

350

18

6,300

60

54

3,240

140

144

20,160

Special Component

Fine aggregate highly specified concrete mix with polypropylene fibrous additive and super-plasticiser.

Special Component used in vertex instance.

Requires curvature in formwork and sloping up to 15 degrees

Additional Labour and Formwork costs (Base rate)

116 per m

3

3

4m per component 464

2

2500 (20m )

460 (23 x 20)

Economy of Scale through re-use First 9 panels Up to 27 Panels Up to 90 Panels

Exterior Component Floodlighting (Standard Panels)

Total Estimated Cost for Modular Vertical Components: Element

Approx £m

In-Situ One-way PostTensioned spanning slab Formwork –Galvanised steel support struts and shuttering

2

2

490,788

Area (m )

Total (£)

107

4950

529,650

33

4950

163,350

Total Estimated Cost for In-situ cast Spanning Slabs: Total Estimated Cost for Concrete Superstructure based on Modular Components:

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693,000 1,183,788

A ProtoType Foundry Jonathan Harker A Technical Requisite

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Costly Elements

Cheap Elements

Fabrication of the CNC sheet cut aluminium formwork

Reproduction of modular building system and ability to achieve an economy of scale.

Site Specific construction, specialist processes and machinery required eg. Smaller scale pile driver and one way post tensioning due to proximity to existing structures.

Crane hire and access points

Uniform material finishes with few additives.

Reuse of formwork.

Specified concrete is self levelling and can save on costs for labour, vibration tables etc.

Creation of image value

Complex joints and connecting systems between components, however they are uniform and so achieve an economy of scale.

Revenue Earning Capacity

Significant Operating/Lifecycle costs

Envelope Skin sold for event duration as commercially lettable area. Commercial draw and image value of being part of an architectural prototype system is as valuable as the occupation of 2 multiples of 16m envelope area.

Concrete structure can entail significant maintenance costs after first 20 years such as cracking, shrinkage and expansion through freeze thaw cycles.

Exposition gains turnover from taking an exhibitors fee from the product sales made by companies.

Spaces will be rented out to the specific smaller industries; metal casting foundry, graphic design and typeface foundry and printworks.

Process to allocate legacy use to exhibition spaces.

Potentially high overheads that will need to be taken on by a long-term tenant. Idea is that the architectural identity becomes the language of the online platform promoter who adopt the EXPO space as their operations centre whilst valuing and supporting the industry and ‘making’ aspects of the programme, metal casting foundry, print house, fabrication and typeface foundry.

The industrial landscape chosen at the centre of Digbeth works at a model urban, left-over industrial fabric for which this prototype system can be applied and sold elsewhere.

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