Modularity in Flex: Controlled Deformation and Versatility of Elastic Formworks

University of Michigan Taubman College of Architecture and Urban Planning Master of Architecture Thesis Studio Concrete Labor_Circularity: Student Work 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 1 learn more about this project research.

We are interested in developing a rainscreen facade 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 conventional precast panel customization.

2

PRECEDENT STUDIES

3

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

4

P_Wall (2013) Slide

“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.

5

“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.

6

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

7

8

Flexible Formwork Studies

9

Woven Polyethylene GeoTex Fabric

10

Membrane Material Properties

GeoTextile

Tyvek / House-wrap

●

Woven Polypropylene fabric

●

Woven Polyethylene fabric

●

High permeability (perm rating: 4)

●

Low permeability (perm rating: 12)

●

Stretches only in one-dimension

●

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

11

12

Concrete pour

Pinching Frame

Geotextile / Woven House-wrap / flexible formwork

Base Frame with PVC Pipes

13

GeoTextile Panel

Tyvek / Housewrap Panel Michael DiBenedetto + Gabriel Maisonet-Santiago | Concrete Labor -Circularity 14 | ARCH 662

Surface Finish

Wrinkling - woven PP textile a non-stretchable membrane

Colorization- from permeability of membrane 15

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

Buckling 16

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

Natural Rubber Sheet ●

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

●

Vytaflex 20 (3/8", 3/16” sheets)

●

SHORE-A 20

●

SHORE-A 40

●

Stretch multiplies as membrane

●

Impermeable

sheets)

gets thinner 18

Cast 1

Cast 2

Cast 3

Cast 4

Cast 5

VytaFlex 20

VytaFlex20

VytaFlex20

Natural Rubber

Natural Rubber

3/8“

3/16”

3/16”

1/16”

1/16”

19

Resulting Parameters ● Rubber as flexible casting surface ● Robotically-bent rods and foam acting as impactos to provide undulating qualities and apertures

20

Matrix of Inquiry

22

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

23

How flexible formwork studies informed design process

24

25

26

27

28

29

30

31

32

DESIGN APPLICATIONS

33

Panel Design and Configuration ● Panels hung on curtain wall ● Variability of applications depending on presence of apertures

34

Panels in Use

35

Attachment System

36

… and with this, we aim to present a viable option for 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, making this an attractive option for small to midsize projects that want to include the natural beauty of concrete while being smarter about waste and their carbon footprints.

37

THANK YOU