Season Tse//Project 5.5//Articulated Ceiling

ATA Design Project The Articulated Ceiling

Module AR6022 February 2016

Material- Steel Group 13

Alborz Bathaei Jordan Cottage Gustaf Hedberg Laurence Misick James Rogers Season Tse

Contents

Precedents

1

Grid Development

3

Idea Development

5

Light Experiments

7

Colour Options

9

1:100 Worms Eye Isometric

11

1:100 Reflected Ceiling Plan

13

1:100 Long Section

13

1:50 Short Section

14

1:20 & 1:10 Detail Sections

15

Material Palette

17

1:2 Junction Detail Option 1

19

1:2 Junction Detail Option 2

21

1:100 Steel Components

23

1:50 Steel Components

25

Sequence of Assembly

27

Detail Assembly

29

Construction Design Management

31

Weight Calculations

32

Renderings

33

1:25 Model

37

The Making off

41

1:10 Model

43

Post Crit Reflection

49

6

7

1

RCA Sackler

Latapie House

By Haworth Tompkins

By Lacaton and Vassal

The RCA Sackler Building by Haworth Tompkins is a conversion of a single storey factory to provide painting studios for the Royal College of Art. The new steel structure and sawtooth shaped roof sit atop the existing brick building. The roof is glazed to the north side, giving indirect natural light to the 7m high studio spaces. This was considered a useful precedent as it gave an example of a design which was tailored to provide a particular lighting condition.

Precedents

Latapie House by Lacaton & Vassal is a family home built using inexpensive materials to achieve a simple, efficient and versatile volume. The frame is clad in two materials: opaque fibre cement sheets to the street facade and transparent polycarbonate to the other.

The use of the contrasting transparencies of material in this building was relevant to our project in our attempts to achieve a particular quality of diffuse light entering the room through the articulated ceiling.

2

Hunstanton School

Johnroeluna

By Smithsons

By Isabel Ramseier

Hunstanton School by the Smithsons uses an external steel frame to express the method of construction. The exposed steel frame was made up of standard steel sections and welded on site to reduce material consumption, achieving a structure of high material efficiency. The steelwork is all black, creating a consistent and simple material palette which can be read throughout the building, emphasising the industrial quality of the exposed material.

Johnroeluna by Isabel Ramseier is a student project from a Diploma unit at ETH Zurich. This precedent was relevant to our project in creating a strong visual expression of the structural form. The consistent use of one colour across the steel members makes for an easily readable structural grid. The apparent weightlessness of the space frame is an attribute of this project aligned with our intentions to create a light and efficient frame.

3

Grid Development

4

From studying the proportions of the 15m x 8m theoretical room that our articulated celing. We developed a grid that allow for void spaces in the articulated ceiling that related to the anthropomorphic human scale. This void space will be a 2m x 2.5m cube that allows for someone to fit in the space and this has implications to the construction method of possibly welding the steel which could be done at ground scale and therefore be both cost efficient and safe.

5

Sketch Idea 1 The first option discussed was a space frame punctuated with a series of roof lights. The room would be lit by a combination of artificial lighting on the underside of the steel frame and natural light from the roof lights. It was discussed as to whether the depth and position of the opening would be consistent throughout or of a more varied pattern, providing different lighting conditions across the room. The opacity and treatment of the glazing was also considered at this stage. The tapered section of the roof light would conceal the services behind an opaque cladding. This option achieved a good material efficiency yet was less well resolved in its aesthetic merits and simplicity of form.

Idea Development

Sketch Idea 2 This option considered an alternative shape of steel frame and the accompanying materials. A series of arched steel trusses were experimented with spanning both the long and short sections of the room. The frequency and size of the arched steels was also explored.

This option was not pursued as the material efficiency of both the steel frame and accompanying material was deemed excessive given the size of the spans which were to be achieved. The quality of natural light that could be achieved with this method was also questioned.

6

Sketch Idea 3 The option which was decided upon and developed consisted of a space frame with polycarbonate surround. Corrugated steel sheets were fixed to the verticals of the space frame and translucent polycarbonate sheets to the diagonals. The artificial lighting and services were placed in the space between the polycarbonate and corrugated steel. Diffuse natural light would enter from both the sides and top of the polycarbonate surround, creating a subtle natural lighting condition within the room. These design decisions were then developed in greater detail and progressed beyond the initial sketch ideas.

7

Light Experiments

8

A few quick model experiments tested the difference between the vertical elements being solid or translucent. As we wanted the natural and artificial light to reflect off the corrugated steel to pick up its tactile qualities the decision based from this experiment was for the polycarbonate to be at an angle to allow for a more efficient direction of artificial light, and for the corrugated steel to be vertical.

9

When I first made a grid, I happened to be thinking of the innocence of trees, and then a grid came into my mind and I thought it represented innocence, and I still do, and so I painted it and then I was satisfied. I thought, ‘This is my vision.’ Agnes Martin

Colour Options

10

RAL 9010

A series of test renders were made to consider the colour options of the material components. Tests were made with a variety of colour options, testing whether the frame should be contrasting in colour to the accompanying materials. The decision was taken to move away from the distinct expression of the space frame and move towards a more subtle colour palette. A simple palette of white and light greys unifies the articulated ceiling as a whole, yet the component materials are subtly distinct from one another through their textural differences. Ral 9010 was the selected colour for the steel.

11

N

1:100 Worms Eye Isometric

12

N

The worms eye isometric shows the difference in the south and north views. The axis of the space is based on the corrugated sheets being visible when facing the north direction and reflecting the southern light.

The polycarbonate is then visible when looking north. This was with the original intention of the space being used as a gallery space however this is an articulated ceiling that can work in a flexible range of spaces.

13

1:100 Reflected Ceiling Plan 1:100 Long Section 1:50 Short Section

14

When considering the materials that will diffuse both artificial and natural light in the space we looked at different types of translucent glass and plastics and we found that polycarbonate would be the most cost efficient product on the market and light in weight. We were aware of the carbon footprint that plastic has over glass but we decided its advantages of cost efficiency and being lightweight. We decided to select this material as it had a close relationship with our other chosen materials. Aesthetically, this material would have a close relation to the corrugated steel cladding and also the colour of the steel.

15

8

7

5

6

1 2 3

4

Legend

1:20 & 1:10 Detail Sections

1. Aluminium connectors 2. Screw fixing 3, EPDM Rubber gasket seals 4. 50mm single layer cellular polycarbonate 5. 10mm polyycarbonate 6. Sliding Connectors 7. Services 8. Corrugated Steel 9. Protective lid 10. Pressure Slab 11. Plastic flanges

16

A B

DETAIL A

DETAIL B

C

DETAIL C

17

Polycarbonate Panels

Corrugated Steel Panels

40 x 40 mm Steel Square Hollow Section

Material Palette

18

Polycarbonate Pros + -Simple installation methods -Lightweight -Easy to transport -Low labour costs -Light diffusing qualities Cons -Easily damaged -Highly sensitive to abrasive cleaners, alkaline cleaning products and solvents -High processing temperatures used in the manufacturing process have a negative environmental impact -Manufacturing process uses phosgene which is known for its ill effects on human health

Corrugated steel Pros + -Relatively cheap material -Easy to transport -Panels can be removed to access services behind -Ease of maintenance - damaged panels can be easily replaced -Fixed in place on site -Powder coated off site -Lightweight -Can be cut to length in manufacture process Cons -Easily damaged -Large sheets can be difficult to manoeuvre manually on site -Acousitc qualities are not preferered due to sound verberation

Steel Sections Pros + -HSS is widely available in the UK -Steel can be recycled -The uniform shape of HSS makes it easy to fabricate.

-Same elements are used repeatedly throughout the structure.

-Less weight-per-metre, reduced weight means additional savings in erection and transporting costs.

-HSS has greater strength-to-weight ratios and high resistance to torsional loading than an I beam -Less surface area than open sections allows for reduced clean up and painting.

-High quality surface finish and corrosion resistance.

-Easier to weld, no preheating or post-heating is required.

Cons -Requires manually handled during prefabrication.

-The material has very little thermal qualities

19

1:2 Junction Detail Option 1

20

The first option we explored was the sleeve joint. This was a detail that featured a repeated node which the steels could then fix into and be bolted. The pre fabricated sleeve joint allowed the whole steel structure to be coated in a fire retardant paint after welding and then finished in a powder coated paint RAL 9010 in advance.

21

1:2 Junction Detail Option 2

22

The second option and chosen detail was the electric welded joint. Based from feedback in the crit we decided that there was an unnecesary complexity to option 1 which wasn’t needed and added further cost implications to the project, more weight to the total structure. This option is simpler and more elegant. From consulting with Richard Newark who works in the Cass metal workshop, we developed this method for joining as the welding is easily achievable and doesn’t require a high degree of specialised skill.

23

1:100 Steel Components

24

25

A1

A2

B1

B2

B3

1:50 Steel Components

26

2 x B1 6 x B2 3 x B3

x2

2 x B1 6 x B2

x6

2 x B1 6 x B2 4 x B3

x 2

2 x A1 2 x A2

x 28

27

1. Manufacture of components

5. Fixing of sheet components

Sequence of Assembly

2. Partial assembly of components

6. Crane required to lift strucutre in place

28

3. Delivery of structure

4. Electric welding of components

After re-visions and talking whit Chris Hosegood about different options of assembly, he suggested that the most beneficial method was to prefabricate as much as possible. The advantages was that the most precise work would be done under controlled circumstances. With this in mind and the maximum length of the box section pieces 7.5m, the least amount of site welds and the sizes of standard truck of the most rational seem to be to construct the space frame into four pieces for them then to be site welded into one piece. This particular option was concluded to be the best method after we explored other different configurations tested against the chosen parameters.

7. Exterior panelling fixed

29

1. Space frame

6. Fix metal profile

Detail Assembly

2. Fix hinge to frame

7. Polycarbonate panel

3. Corrugated Steel Panel

8. Rotate and fix in place

30

4. Bolt in place

5. Insert and fix ventilation pipe

9. Place polycarbonate panels

10. Fix panels for weather protection

31

Weight of load (kg)

Load weight/ frequency graph for liftin operations

One lift every (lifts per hour)

Load weight for team handling operations

The framework for the articulated ceiling is all set at 2000mm in height so as to allow anthropomorphic reach of the construction crew to be utilized without any additional equipment. Therefore reducing additional risk of working at height or in compromising positions/situations. The prefabricated elements are all constructed off site at ground level further reducing hazards by working in a controlled environment. The steel framework follows a set repetitive pattern with simple welding joints to reduce complexity further reducing risk.

The frame is constructed in four large components that fit to a standardized truck bed so minimal risk is incurred in transportation to site. Once at site the frame is placed at ground level and welded together with the lowest amount of welds possible. Painting and sealing of the frame can then be carried out again at ground level.

Corrugate steel sheeting will be then fixed to the frame with the first fix of services installed in the recesses. The services and utilities are to be installed to the upmost completion to reduce any extra installation at height. Polycarbonate sheeting is then to be placed onto the hinge fixings. Once the installation of services and cladding are finished the entire frame is to be craned into position. This is the most dangerous part of the construction process so maximum amount of care and attention must be applied here. The final fixing and connecting of the frame and services will then be carried out at height again with a greater deal of danger than the earlier stages of fabrication. All equipment and safety measures must be implemented to reduce risk for this stage.

Construction Design Management

32

Component (HxWxD)

Individual Component (lin m)

No. of Components

Total Component (lin Indivdual Component Total Component (Kg) m) (Kg)

Steel SHS (40x40x4mm) A1 (Diagonal) A2 (Horizontal)

2.14 1.99

56 56

119.84 111.44

9.54 8.88

534.49 497.02

B1 (Horizontal) B2 (Diagonal) B3 (Vertical)

7.52 2.28 1.92

20 60 14

150.40 136.80 26.88

33.54 10.17 8.56

670.78 610.13 119.88

Total

545.36

Corrugated Steel Sheet

Individual Component (m2)

Sheet (2000x600x203mm)

Polycarbonate Envelope

1.33

Individual Component (m2)

Internal (2120x1250x10mm) External (2000x1250x55mm)

Fixings / Misc

No. of Components

70

No. of Components

2.65 2.50

Indivdual Component (Kg)

Piano Hinges (1000x30mm) Hook Bolt Fixings (M8x80+washer)

Total Component (m2) 93.10

Total Component (m2)

42 106

111.30 265.00

Total

376.30

2432.31

Indivdual Component Total Component (Kg) (Kg/m2) 5.120

Indivdual Component Total Component (Kg) (Kg/m2) 4.51 12.50

Total Component (Kg)

48 280

96.00 10.00

Total Weight

A1

B2

189.42 1325.00 1514.42

No. of Components

2.00 0.04

358.40

4411.12

B3

A2 B1

All the materials are sourced from standard sized materials that can be bought from suppliers without any specific alterations or specifications. From the sheet and supplied lengths there will be an amount of wasted or overcut material. The Steel hollow section frame will have a 15%, the corrugated steel sheet 10% and polycarbonate sheet 5% respectively.

However using cut to length material would be able to significantly reduce these figures whilst increasing cost.

Weight Calculations

40

41

42

43

44

45

41

The Making of

42

The construction of our 1:10 partial model is similar to the processes and techniques that would be required to manufacture in reality.

First, two jigs are made to layout the repetitive truss + truss connector elements to create pieces to the same dimensions and tolerances.

Once completed, checked and cleaned the steel framework is welded in the reusable jigs.

After each truss elements completion the frames were arranged and fully welded to create the complete ceiling frame. In reality the frame would be created in four separate parts to ease transportation.

The steel framework was then cleaned, primed and powder coated using a charged spray gun.

However the full scale element would be brush painted on site with several layers of intumescent and gloss paint. Once painted the corrugate sheet steel and polycarbonate panels could be fixed then allowing the installation of services.

54

55

49

By working efficiently and effectively as a group we were able to realise a set design thesis early on in the design process.

Because of this we could put more of our efforts into resolving the details, service integration and communication of the project through various scales of models, drawings and visuals.

The critique was valuable to us as group to listen to the tutors and to understand the issues in our design that we had possibly overlooked. It was a chance to reflect on what we had done to see if we made the right decisions along the different stages of the design process.

The most important critique that we received was in relation the sleeve joint system we had developed. The criticism pointed out by Colin Wharry was an issue that we overlooked and this was that the complicated sleeve joint we had developed and built at a 1:2 scale worked only as a stand alone piece. In reality with the added complexity of different elements needing to come together at different angles, it was not possible for us to repeat this system across the entire structure as the steel components needed to both enter into the sleeve joint horizontally and at an angle simultaneously.

In contrast to this criticism and a view that one of our critiques Robert Mull believed, was that there is no harm in welding these elements together. This was an option that we began with and excluded in favour of the more technical sleeve joint. The bolted joint would allow for the steel to be powder coated off site and allows for easier disassembly of the ceiling. However this method also has the disadvantage of the added complexity, more material weight and cost implications.

In proceeding with resolving this joint we decided as a group that the welding option was the most appropriate, and in the end would have a greater benefit of being more cost efficient as there are less steel elements. We felt that by initially proceeding with the technically challenging junction, it would be more interesting although we realised at the end that this could be over complicated and in the end sometimes simplicity in resolution is the right choice.

Another comment of the project was that our truss would structurally more efficient if it was upside down and should be based on the principles of the Warren Truss. When we initially explored the concept of the final chosen option, we wanted the connections of the bottom of the triangles to connect on the corners of the square grid that we initially set up. This meant that could design the articulated ceiling to include the void space in the grid layout. Although the strength of the traditional Warren Truss would be more efficient we have stuck to the original intention of making full use of the angled polycarbonate panels.

This research has been valuable to explore the tectonics and design of a steel articulated ceiling. Our personal ethos from the beginning was always focused on the principles of affordability, material efficiency, replicable construction, low skill labour, safe assemblage and integration of services. By interrogating this element of architecture in this methods, we have challenged our own preconceptions of what a ceiling is and should be.

The ceiling used to be decorative, a symbolic plane, a place invested with intense iconography, Now, it has become an entire factory of equipment that enables us to exist, a space so deep that it begins to compete with the architecture. It is a domain over which architects have lost all control, a zone surrendered to other professions. - Rem Koolhaas

Post Crit Reflection

50

A special thank you to our critique panel

David Grandorge Robert Mull Colin Wharry

and to the the workshop staff

Chris Hosegood Richard Newark