2016
ROBERT MARCALOW
DESIGN PORTFOLIO
ROBERT MARCALOW GOOD DESIGN IS PRACTICAL, EXECUTABLE AND BEAUTIFUL. My design work bridges the gap between the ROBERTMARCALOW.COM wildly imagined and the physically realized. I RMARCALOW@GMAIL.COM design what can be built, emphasizing innovative 413.824.9978 methods, iteration and experimentation. My projects implement complex digital tools but also lay knowledge and manual technology. Where they combine - the manually parametric - is my area of focus.
YEAR
2015
WORK/SCHOOL SELFEMPLOYED
ADJUNCT PROFESSOR: UMASS AMHERST
AIA SCHOOL MEDAL CERTIFICATE OF MERIT
INTERN: SITELAB ARCH.
PROJECT
MANUAL
BARN FOR TWO DONKEYS (BUILT)
2014 RA: CNC ROUTER RESEARCH @ UMASS
p.14
LIGHT SKIPPER LAMP
p.22
WMAIA SCHOLARSHIP
DIGITAL FABRICATION EXPERIMENTS p.26 NEW HAVEN BOATHOUSE
2013 2011 2010
p. 04
BARN FOR TWO DONKEYS
M.ARCH: UNIVERSITY OF MASSACHUSETTS, AMHERST
PARAMETRIC
p.32
AUTONOMY HOUSING SELF-EMPLOYED
BA: ENVIRONMENTAL DESIGN PITZER COLLEGE
p.38
1
BARN FOR TWO DONKEYS (BUILT)
GILL, MASSACHUSETTS TIMBER FRAME LIVESTOCK BARN
{built}
2016
This 2300 square-foot barn is the built realization and expansion of my graduate thesis project (p.13). A modern update on the traditional banked barn, the building folds the land and forms a functional, layered space. A durable heavy timber frame ensures multiple generations of use and re-purposing. Gabion retaining walls form outdoor space. A wood solar screen keeps spaces cool in summer.
04
structure roof ceiling accentuate site section
existing house and new barn
existing site
tear and fold
frame and gabion retaining walls
PERSONAL LANDMARK
This barn is the first large-scale design/build project I have undertaken. I designed all aspects, including (with consultation) the joinery, electrical system and foundation. I hired all external subcontractors and laborers, marked and cut the joints, and supervised assembly and construction. The barn is scheduled for completion early in the spring of 2016.
more seams
slab and retaining walls
PLANS
0
2
4
8
16
loft
HAY AND STORAGE
GABION RETAINING WALLS
ground
STALL
SHOP
WORKING
STALL
PADDOCK
BARN FOR TWO DONKEYS (BUILT)
06
ANIMALS
PORTICO
power wash to accent texture
deep grooves create relief
fasten to inside of standard formwork
BOARD FORMED CONCRETE
One prominent foundation knee-wall served as a canvas for material experimentation. Highly textured, board-marked concrete references and balances the board and batten siding above and brings intrigue to an otherwise blank surface..
LOCAL MATERIALS & MANUAL METHODS
The local white pine timber frame employs traditional joinery, shaped largely with hand tools. The heavy timbers ensure longevity and permit large spans, lending flexibility to the space.
BARN FOR TWO DONKEYS (BUILT)
08
JOINTS ash wedges ash pegs
stop-splayed wedged scarf
mortises and tenons in wall
ELEVATIONS
east
south
SECTION
metal roof polycarbonate clerestory
engineered trusses
board over batten siding
awning flaps
large picture windows
solar screen
2� pine flooring (100 psf)
custom post brackets
poured in place foundation
continuous slab floor precast concrete piers
0
2
BARN FOR TWO DONKEYS (BUILT)
4
10
8
16
solar screen wraps around building
north
DURABLE & FLEXIBLE
west
assembling a large scarf joint
BARN FOR TWO DONKEYS (BUILT)
12
EMERGES FROM THE LANDSCAPE
2 GILL, MA
BARN FOR TWO DONKEYS
{thesis} STORAGE/WORKING
ROOF SLOPE COLLECTS WATER & SHEDS SNOW
2013
SPACES FOR DONKEYS AND PEOPLE
PARAMETRIC ELEMENTS IN A STICK FRAME LIVESTOCK BARN
A parametric siting process locates a small livestock barn near a rural home through multiple runs in an optimization algorithm. The structure and skin use manual, low-tech construction methods to achieve parametrically designed form and function. The resulting tools and processes require no digital fabrication equipment, only standard carpentry tools.
14
TWIST TO COVER ENTRANCE
ANGLE ROOF TO MOVE AIR PAST HAY
BLEND SIDING TO VENTILATE HAYLOFT
the site
SITING
PARAMETRIC SITING ANALYSIS EVALUATES THOUSANDS OF SITING OPTIONS FOR A SET OF DEFINED PARAMETERS
STRUCTURE RATIONALIZE A WARPED ROOF SURFACE TO UTILIZE OFF-THESHELF ROOFING MATERIALS AND CREATE A PARAMETRIC JOBSITE CUTTING SYSTEM
SKIN
MANUAL FABRICATION SYSTEM FOR A PARAMETRIC OPEN SKIN SYSTEM TO VENTILATE HAYLOFT
SITING highest concentration
This design process explored the potential to use a mathematical approach to siting. A genetic solving algorithm in Grasshopper tested thousands of potential rectangular sites and optimized for three variables (below), eliminating those that did not match five constraints. Constraints and criteria were selectively removed in four distinct runs to look at more flexible options. All the runs were overlaid and the area with the highest concentration was selected for the final building site. CRITERIA
Run #1
Run #2
Run #3
Run #4 BARN FOR TWO DONKEYS
16
DISTANCE TO HOUSE > 50’
ORIENTED TO HOUSE AXIS
specified distance CRITERIA ELEVATION CHANGE > 3’
IN VIEWSHED
N-S ORIENTATION
IN ROAD
IN TREES
maximize slope IN HOUSE
viewshed
orient in line with house
HARD CONSTRAINTS
existing house
final siting at highest concentration from algorithm
site model
STRUCTURE
MAPPING PANEL DEFORMATIONS
The barn roof uses standard building materials to achieve a complex twisted form that directs air and rain, and covers the barn entrance. The final form was mapped in Grasshopper according to the limitations of the metal roofing panels so that no custom metal cuts are required. The angles for the birds-mouth cuts at the tops and bottoms of the rafters were mapped onto two rotating cut guides with customized stops to produce perfect markings. A carpenter sets the stops to the correct rafter number, lays the tool on the board and marks it, making the cuts using a standard circular saw. analyzing deformations in paper roof components
standing seam metal roof
unrolled
stock 4’x8’ sheathing folded
custom-cut rafters
BARN FOR TWO DONKEYS
18
intersection of spheres centered at adjacent corners defines bending path
warped surface shares topology with flat stock
COMPLEX SURFACE WITHOUT COMPLEX CUTS
rafter seat cut tool
rafter top cut tool
SKIN
The final project uses no digital fabrication methods at all, but produces a complex parametric surface with a simple set of straight cuts. A series of cut and bent strips of horizontal siding approximate a doubly curved surface, transitioning smoothly from 6� siding into 3� siding over an angled intersection. Each piece is ripped to a specified length then nailed up to the beginning of the rip. Blocks nailed to the studs push the cut end out as far as possible and receive nails from the outside. The resulting surface allows air to circulate into the hay loft in the barn. early concept model
sketch
A A
NO DIGITAL TOOLS REQUIRED, ONLY A LIST OF CUT LENGTHS
BARN FOR TWO DONKEYS
20
RIP LENGTHS: 67”, 69”, 71”, 72”, 72”, 71”, 70”, 68”, 66”, 63”, 59”, 55”, 51”, 46”, 41”, 36”, 32”, 28”, 24”, 21”, 18”, 15”, 12”, 9”
3” SIDING
MANUALLY PARAMETRIC
TRANSITION
6” SIDING
3
LIGHT SKIPPER LAMP
{thesis} surface roughness pools of light
2014
GENOMIC GENERATIVE FORMFINDING
CNC-ROUTED FOAM FORMWORK, PAPER, ROUTED WOODEN BASE
Light striking a textured surface at an oblique angle inspired this fully parametric lamp design. Parametric software endlessly adjusted three variables and tested for a set of fitness parameters. After 30,000 lamp iterations, 24 were offered for final selection. Fabrication utilized CNC-routed molds and a handforming process.
22
surface 50% lit
natural condition inspires concept
desired characteristics
BULB HEIGHT CIRCUMFERENCE & POSITION AT 5 HEIGHTS
SURFACE ROUGHNESS
# OF POOLS OF LIGHT
APPROACHING 50% LIT
BASE WIDTH
user-defined variables
SURFACE ROUGHNESS
finding the most fit individuals (in red) (Octopus for Grasshopper)
GENETIC ALGORITHMS
The user-defined variables of the lamp are adjusted at random and the resulting snapshots are evaluated for three characteristics by a genetic solver algorithm. The parameters of the best lamps are re-entered into the algorithm with slight variations, resulting in an increasingly ‘fit’ generation of lamps. Because there are three evaluation criteria, multiple lamps can be fit equivalents. The user must select the final design by intuition.
routing
forming
removing mold
BEST “GENES” PRESERVED
generation 1 lamps BEST FIT
gen. 2 gen. 3, 4, etc
controls A B C
LIGHT SKIPPER LAMP
24
final lamp
BEST FIT
E
GENOM
GENOME
GENOME
FULLY PARAMETRIC PROCESS
HAND FINISH
4
{built}
DIGITAL FABRICATION EXPERIMENTS
2013
LASER CUTTER AND CNC ROUTER FABRICATION FOAM, PAPER AND CEMENT FOLLIES
Five quick design and fabrication projects explored the 5 categories of digital fabrication as outlined in Lisa Iwamoto’s Digital Fabrications: CONTOUR TESSELLATE SECTION FORM FOLD The projects served only as subjects for material and process experimentation. All projects were modeled completely in Grasshopper for Rhino, then cut using digital fabrication tools and assembled.
26
light passing through a thin section of the contoured foam surface
RAPID FABRICATION FEEDBACK
CONTOUR
CNC router cutting curves respond to the slopes and shapes of the surface. • curves gather in steeps and spread vin flats • draws focus and detail to steep sections • resulting texture is dynamic • CNC-routed in foam
original surface
isocurves on surface
normals along isocurves
deflect curves proportionally to slope
final cutting curves for CNC manufacture
TESSELLATE
Small reciprocal frames interlock and approximate a larger surface. Each individual piece supports another in a rectangular structure. • frames are staggered so grid is continuous • approximates a bell-shaped surface • laser cut and assembled without adhesive
tiled rectangular pattern
DIGITAL FAB EXPERIMENTS
28
offset lines
...new threedimensional form
extend to intersect
transform original shape into a...
pattern applied
extrude from surface
notch and fabricate
no adhesive or fasteners
SECTION
Repeating cylinders intersect a freeform, tapered tower, creating curved, non-planar sections. • three ribs support petals • scores parallel to bending increase flexibility • laser cut from card stock
cylindrical sections are bent in place
original form
semi-cylindrical sections
intersection edges
resulting panels
support ribs
final structure
unrolled for fabrication
FORM
The faces of a geodesic dome are equilateral panels tapered toward the dome’s center - a perfect forming exercise! • angular exterior, round interior • openings vary by aspect • molded in foam cut on a CNC router • laser cut base resists outward thrust
rockite in CNC-routed form
geodesic dome DIGITAL FAB EXPERIMENTS
30
extruded to center
subtracting a sphere
resulting solid panels
openings vary by aspect
pieces placed into a solid form
final form with codes ready for fabrication
FOLD
Folding creates three-dimensional structure from flat stock. This project superimposed a Voronoi diagram onto a highly textured surface. • curved side accurately represents surface • angled side approximates surface • thickness relates to position • laser cut and assembled with adhesive
fold and fasten with tab
original surface
project voronoi pattern
offset vertices, connect with lines
solid digital model
unroll and manufacture
5
NEW HAVEN BOATHOUSE
NEW HAVEN, CT
{studio} DOWNTOWN NEW HAVEN
2013
BOATHOUSE, LOCKERS, EVENT SPACE, CLASSROOM, ADMINISTRATIVE FACILITIES
A large boating facility provides urban New Haven with long-deprived access to the waterfront, encouraging community involvement in rowing and sailing activities. Three blocky, sail-shaped masses overlap and create paths through the building onto docks, decks and terraces. Curving overhead beams allude to the curved early massing model ribs of a ship.
32
SITE
LONG ISLAND SOUND
locus map
sketches
COMMUNITY WATERFRONT ACCESS
The boathouse rests near Long Wharf, at one time a critical port. Isolated from downtown by a major interstate highway, the site is neglected and oddly serene. The boathouse provides a safe space by the water for those coming from the downtown in search of nature and exercise.
NEW HAVEN BOATHOUSE
34
CARVE OUT SPACE FOR COMMUNITY
models
section
LARGE SPACES AND DYNAMIC GEOMETRY Large glulam beams and Cross-Laminated Timber decking achieve a wide uninterrupted roof span in the event space. The tops of the bearing walls arch upwards, producing an expansive, subtly curved interior space that draws the eye forward toward views of the bay.
NEW HAVEN BOATHOUSE
36
PLANS
CATERING KITCHEN WOMEN MEN EVENT STORAGE
0
EVENT SPACE
ROOF PATIO AND TERRACES
KITCHEN
RECEPTION EXEC. OFFICE
MGR.
CLASS ROOM
second
MEN’S LOCKER ROOM
TRASH
MECH. WMN’S LOCKER ROOM
LONG WHARF DR.
RECEPTION WORKOUT/FLEX SPACE BOAT STORAGE
LOBBY
DOCKS
ground
8
16
32
64
6
AUTONOMY HOUSING
HOLYOKE, MA
{studio}
2013
AFFORDABLE HOUSING, LIVE/WORK STUDIOS, MAKER SPACE, COMMERCIAL SPACES
This mixed use affordable housing building rejects traditional mortgage models. Subsidized “Autonomy Blocks” create income for new owners through rental of an attached studio, offsetting mortgage costs. Arts and maker space facilities foster a lively atmosphere at the street level, drawing outside capital into a decayed urban core.
38
empty urban site was once a booming transit depot
HOME 1,2 or 3 bedroom unit
TOTAL SF OF PROGRAM
RAISE RESIDENTIAL
SPLIT TO CREATE COURTYARD
SHIFT UNITS & GLAZE PUBLIC SPACE
RAISE/LOWER FOR LIGHT IN ALLEY
INCOME rental sub-unit
VENTILATE
AUTONOMY THROUGH HOMEOWNERSHIP
MASSING IS MEANING
Faรงade and positioning indicate public and private space. Residential and administrative spaces occupy upper levels with more opaque faรงades, while public spaces are mostly glazed, providing sight-lines through the building.
solar tower (ventilation)
2-bedroom +studio units
envelope (internal) glazing
winter-garden (external) glazing
solar screen
3-bedroom +studio units
1-bedroom +studio units
live-work studio units
public space glazing
circulation
maker space
commercial and social spaces
AUTONOMY HOUSING
40
0
8
16
32
64
1 - LOBBY AND MAIL ROOM 2 - FAB-LAB LOBBY AND GALLERY 3 - MAKER SPACE 4 - MAKER SPACE RESTROOMS 5 - COMMERCIAL 6 - LIVE-WORK STUDIOS 7 - MECHANICAL
1 - Residences Lobby and Mailroom 2 - Fab-Lab Lobby and Gallery 3 - Fab-Lab 4 - Fab-Lab Restrooms 5 - Commercial 6 - Live-Work Studios 7 - Mechanical
(ALLEY)
8 - Apartments 9 - Studios 10 - Community Space 12 - Laundry 13 -
8 - APARTMENTS 9 - STUDIOS 10 - COMMUNITY SPACE 11 - OFFICES AND MEETING ROOMS 12 - LAUNDRY 13 - ROOF PATIO AND GARDEN
6
6
6
6
7
8
7
8
3
APPLETON ST.
PLANS
7 5
1
4
2
MAIN ST.
ground First Floor Plan 0
4
8
16
32
6
6
6
6
11
11
11
8
SECTION 0
4
8
16
5
Section A-A
8
9
second 32
Second Floor Plan 0
4
8
16
32
1 - Residences Lobby and Mailroom 2 - Fab-Lab Lobby and Gallery 3 - Fab-Lab 4 - Fab-Lab Restrooms 5 - Commercial 6 - Live-Work Studios 7 - Mechanical
13
8 9
8
9
8
9
8
third MAIN ST.
(ALLEY)
1 - Residences Lobby and Mailroom 2 - Fab-Lab Lobby and Gallery 3 - Fab-Lab
8 - Apartments 9 - Studios 10 - Community Space
8
BUILDING CAPITAL AND COMMUNITY
Commercial, arts and maker spaces on the street level draw traffic to the block at all hours of the day, creating a new focal point at the core of the city.
ELEVATIONS 0
8
16
32
1 - Residences Lobby and Mailroom 2 - Fab-Lab Lobby and Gallery 3 - Fab-Lab 4 - Fab-Lab Restrooms 5 - Commercial 6 - Live-Work Studios 7 - Mechanical
64
main st.
Main St. Elevation 0
4
8
16
32
alley
Alleyway Elevation 0
4
8
16
32
appleton st.
AUTONOMY HOUSING
42 Appleton St. Elevation
8 - Apartments 9 - Studios 10 - Community Space 12 - Laundry 13 -
solar tower
solar screens
PASSIVE COOLING AND VENTILATION
A tall solar tower with a perforated metal core creates a Venturi Effect, pulling air through the units and providing natural ventilation year-round. Solar screens on the southeast of the units provide midday shade in the summer. Glazing behind the screens enclose a winter garden.
MORE PROJECTS AND DRAWINGS AT ROBERTMARCALOW.COM
ROBERT MARCALOW robertmarcalow.com rmarcalow@gmail.com 413.824.9978