Modularity in Flex: Controlled Deformation and Versatility of Elastic Formworks

Taubman College of Architecture and Urban Planning University of Michigan

Concrete Labor_Circularity: Student Work Master of Architecture Thesis Studio

Professors:

Tsz Yan Ng & Wes McGee

Student Work:

Michael DiBenedetto (M. Arch ‘24) , Gabriel Maisonet (M. Arch ‘24)

Student Work is the intellectual property of the authors and contributors to this thesis project and is part of ongoing research at Taubman College’s FABLab. Please contact Michael DiBenedetto, Gabriel Maisonet, Tsz Yan Ng, Wes McGee, or Taubman College of Architecture and Urban Planning to learn more about this project research.

Weareinterestedindevelopingarainscreenfacade system made up of modular precast wall components. We are working to refine a casting method that employs reusable and reconfigurable formworks that can produce various surface geometries out of a single mold. Modularity in Flex aims to reduce the waste and expenses seen in conventionalprecastpanelcustomization.

PRECEDENT STUDIES

Alan Chandler (2015) Fabric formwork –prototype to typology, The Journal of Architecture, 20:3, 420-429, DOI:

https://doi.org/10.1080/13602365.2015.10 42904

“P_Wall (2013)” - fiber reinforced thin-shell precast concrete panels mounted on steel frame - Andrew Kudless (Matsys) and Concreteworks, 2013. Located in FRAC Centre, Orleans, France. Fabricated by Concreteworks, Oakland, California.

“Responsive Gravity Casting”glass-fiber reinforced concrete ceiling tiles - Alicia Morris and Julia Hunt; Concrete Labor_Circularity, Fall 2018 with professor Tsz Yan Ng at Taubman College of Architecture and Urban Planning, Ann Arbor, Michigan.

West, M. (2016). “The Fabric Formwork Book: Methods for Building New Architectural and Structural Forms in Concrete” (1st ed.). Routledge. pp. 183

Flexible Formwork Studies

Woven Polyethylene GeoTex Fabric

Membrane Material Properties

GeoTextile

● Woven Polypropylene fabric

● High permeability (perm rating: 4)

● Stretches only in one-dimension

Tyvek / House-wrap

● Woven Polyethylene fabric

● Low permeability

● Same stretch characteristics

Deformation

on “the bias”

● Woven PE or PP textile stretch characteristics

● High durability, will not propagate tears

● Stretch-axis influenced by weave of fabric threads

Pinching Frame

Geotextile / Woven House-wrap / flexible formwork

Base Frame with PVC Pipes

Concrete pour

Surface Finish

Wrinkling - woven PP textile a non-stretchable membrane

Colorization- from permeability of membrane

Why switch membranes?

● Poor surface finish

● Undesired wrinkles

● Uneven surface color

● Limited configurations with formwork

● Casting surface provides limited stretching capabilities

● Difficulty in exploring design options such as apertures

Membrane Development

● Vytaflex 10, 20

● Super-Stretchable Abrasion-Resistant Natural Rubber

Membrane Development

Woven PE Textiles

● Water and Air Resistant

● No stretch value (wrinkles)

● Poor surface finish

Urethane Rubber Sheet

● Vytaflex 20 (3/8", 3/16” sheets)

● SHORE-A 20

● Stretch multiplies as membr gets thinner

Natural Rubber Sheet

● Super-Stretchable Abrasion-Resistant Natural Rubber (1/16” sheets)

● SHORE-A 40

● Impermeable

Resulting Parameters

● Rubber as flexible casting surface

● Robotically-bent rods and foam acting as impactos to provide undulating qualities and apertures

Matrix of Inquiry

Self-Weight of Concrete

● application would require thinness, leads to apertures and inquiry of how to control casting an aperture

● leads to development of foampactos and correlated 3d printed parts

How flexible formwork studies informed design process

DESIGN APPLICATIONS

Panel Design and Configuration

Panels in Use

Attachment System

…andwiththis,weaimtopresentaviableoptionfor accessible precast construction methods where formwork costs and waste can be cut down substantially. Meanwhile, still retaining the essential creative elements that come with increased formal variability, makingthisanattractiveoptionforsmallto midsize projects that want to include the natural beautyofconcretewhilebeingsmarteraboutwaste andtheircarbonfootprints.