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REBAR REVIVAL RESEARCH MANUAL Georgia Institute of Technology School of Architecture Material Diversion 2021 Annie/ Yining Chen Instructor: Debora Mesa Molina Special thanks to: RenQing Song-Office Director of Liming Resources Recovery Jian Zhu- Director of Shanghai Jiading Jiaxi West Fan Co., Ltd. & all the workers during the construction progress

LIMING RESOURCES RECOVERY Field Trip, Resources Gather and Selection, Collaboration Visiting the Resource Company to browse through the recycling progress and products could be very inspiring to the use of material, and understanding the ultimate goal of the industry could promote an ideal project built for this environmental friendly space.

• • • • • • •

Construction Waste Resource Utilization Plant Landfill Expansion Projects Landfill Gas Power Project Leachate Treatment Center Organic Matter Treatment Center Recycling Exhibition Center Resources Recycling Center (Incineration plant)

Location Pudong District, HaoJiang Rd. No. 259, Shanghai, China. Introduction The rapid advancement of urbanization and dramatic rise of urban population lead to drastic increment of the output of municipal solid waste. Nowadays, the waste of the nation has exceeded 250 million tons, with an average annual compound growth rate of 2.1%. Therefore these garbage are exigencies to be treated quickly and effectively in order to prevent the garbage siege phenomenon, and serious air, water and soil pollution. As a representative of the industry, the company dedicates to reuse all the accessible sources to protect the urban environment. Recycling Industry Includes Construction Waste Resource Utilization Plant Landfill Expansion Projects Landfill Gas Power Project Leachate Treatment Center Organic Matter Treatment Center Recycling Exhibition Center Resources Recycling Center (Incineration plant)

Brochure of Liming Resources Recycling

Plastic Bottles Sculpture (Recycling Exhibition Center)

Field Trip Note on Jan. 26 This trip aims to gain a comprehensive understanding of the catagories, concept, methodology and future blueprint of reutilization and protection of the resources in Shanghai. The browse of the resources and the recycling progress could concrete and inspire the selection of the potential material for future production. The place for material searching will mainly happen inside of the Construction Waste Resource Utilization Plant. Another task during this field trip is to propose a collaborate project to the manager of the industry. The negotiation will focus on the material provision, tansportation, aesthetic and functional expectation, submission date, installation method. 3

Resources Recycling Center (Incineration plant) & Recycling Exhibition Center- Jan. 26 Field Trip Model of the incineration plant

Incineration plant (partial)

The Recycling Center and the Exhibition Center are integrated into one area inside of the industry. The first floor of the exhibition center mainly shows different waste recycling systems, for example the catering pretreatment system, kitchen waste pretreatment system, anaerobic treatment system, biogas pretreatment and storage system, sewage treatment system, crude oil extraction system and deodorization system. All the models are displayed in the lobby and the some systems are partially revealed by the glass window between the cabins of the recycling center and the showroom of the exhibition center. In my consideration an essential and fascinating portion of the system is the incineration plant where most of the organic solid waste get processed. The produced heat, gas and residues are transformed into electricity power, oil, and fertilizer etc.

Electricity power for Internet Through observing this diagram introducing the recycling system of the company, the incineration plant is the key link of this recycling process.

Refrigeration

Monitor room of the incineration plant

Hot Water

Steam

Heat Extract Oil Organic Mateter Treatment

Electricity power for the Industry

Marsh gas

Landfill gas Marsh gas power generation

Landfill

Leachate & Sodium filtered water The water filtered from the leachate could be reused.

Samples of Products from the Recycling Process Inspiration Hunting These samples give clues about some final results of the recycling process. The industry is doing studies on the further utilization of these prouducts to optimize the recycle progress. Among these final products, I am mostly interested in their research on reproducing biochar and biogas residue as crop fertilizer. This is a virtuous circle- the food waste could promote the growth of new food. This circle could relieve the pressure of the rising popultion and food demand in Shanghai.

Ash and Cured product No further utilization.

Slag and Slag brick Slag gets compressed in the molds and clot into bricks. This could be a potential substitute for normal bricks. Biochar- Biochar is charcoal that is produced by pyrolysis of biomass in the absence of oxygen; it is used as a soil ameliorant for both carbon sequestration and soil health benefits. Biochar is a stable solid that is rich in carbon and can endure in soil for thousands of years.

Biogas residue pellet- Residues from the biogas process are a relatively new type of organic fertiliser with composition varying with origin of the raw material fed into the biogas process.

Histogram from Liming Resources Effects of Biogas Residue and Biochar on Plant Height and Root Length of Sijiqing (Grass)

Biochar and Biogas Residue Experimentation on Grass by Liming Resources

Plant Height: cm Root Length: cm

1. 2. 3. 4. 5. 6.

Control Group Biogas Residue 400g/m^2 Biogas Residue 600g/m^2 Biogas Residue 800g/m^2 Biogas Residue 300g/m^2 + Biochar 300g/ m^2 Biochar 600g/ m^2

Basic conclusions of biogas residue and biochar crop planting experiments: (1) Biogas residue or biochar can promote the growth of lawn (2) The amount of biogas residue added is positively correlated with the growth of the lawn (3) Comparing the experimental groups (group 3, group 5, and group 6) that all added 600g/m2 fertilizer, it can be observed that the lawn growth of group 3 (600g/m2 biogas residue) is slightly better than that of group 5 (300g/m2 biogas residue+ 300g/m2 biochar), and the growth of the two groups of grass was significantly better than group 6 (600g/m2 biochar)

Overview The project was officially launched in July 2019. Based on the systematic analysis of the nutrient composition, and pollution characteristics of the biogas residue from the anaerobic fermentation of food waste in the region, the ability of partial biogas residue being carbonized and used as a biochar base fertilizer was analyzed. The agricultural safety of biogas residue, the effect of biochar and carbon-based fertilizer on improving the fertility of farmland soil were studied. Introduction • The main research content includes: • Analysis of the characteristics of food waste • Analysis of the nutrient content of the biogas residue • Evaluation of agricultural feasibility • Research on the carbonization of biogas residue and the functionalized environmental pollution restoration material • Research and application of the key technology of the biogas residue seedling substrate, • Research on the key technology of biogas residue fertilizer test with field application. So far, the research team has completed the analysis of the characteristics of food waste, the nutrient content analysis of the biogas residue, the preparation of biogas residue and biochar, and the experiment of biogas residue and biochar crop planting.

After reading about the experiment and the field trip, sketches were made to speculate on the sequence of building the test field and some possible researchers’ body movement on the field. From all the observations and investigations, I thought about developing an educational, functional and inspiring project for the research lab, in order to celebrate the profound and revolutionary research, and I told the principal of the industry about this idea. During the communication, he required an appealing, sculptural, and monumental piece for the Exhibition Center, whence visitors get more interested in the magic of recycling. Furthermore, the principal was willing to provide any materials from the recycling plants for the project production. 7

Construction Waste Resource Utilization Plant Material Hunting- Jan. 26 Field Trip

The piled up construction waste will be transported by the tractor to the preliminary screening place and classified into construction waste and decoration waste.

A huge filter with many transfer belts sorts the waste according to size and category,

Larger pieces of decoration materials are piled up in another space, waiting to be sorted/destroyed/reused

The sorted stones remains are transported by trucks to a place specializing in processing debris.

Metal wastes were piled up in the factory, I was attracted by the shiny ductile aluminum foil, and on the other hand, the huge stiff rebar piece. These two materials were opposite to each other. The aluminum foil could be deformed into any desired shape; whereas rebar coulld be made into some kind of sturdy structure by hinging and welding. This collaborative project with Shanghai Liming Resources Recovery Co. Ltd, focuses on recycling methods of constructive and domestic waste in Shanghai. Eventually, with the research data and documentaries of the research process, these dumped materials are reformed and reconstructed into an interesting lab for future experimentation on reproducing fertilizer from the residue of incinerated domestic waste.

Different materials are collected during the field trip and brought back for further explorations. For each of these materials, there are some initial ideas. The thoughts about debris and random rebars are excluded due to the cocerns about feasibility

Material Sample Collection & Model Experimentation Aluminum Foil

Debris (Filtered by size)

Rebar Mesh (Funtioned as machine sieve)

Random rebars, iron rods, and other metals

Process: by folding and molding, the aluminum foil pieces were made into standardized shapes. Then I cut the pieces at certain points, hinged them on each other, and used solid gum to glue them down. Advantage of the material: super dutile, it could be disassembled and reformed anyhow. Moreover, the relfectiveand shiny quality of the material produce shimmering light effect. Disadvantage of the material: extremely breakable and due to the flexibility of the material, it will be very hard to blow the model up later into a 1:1 human scale. Therefore this material was excluded later. Light Exploration During Daytime

Light Exploration During Nighttime

Aluminum Foil Model Experimentation

7 21.11

17.01

19.51

16.12

33.84

19.70

23.05

42.92

21.79

21.11

Size: 80 in* 80 in

Process: the mesh wire was a substitute for the rebar mesh in this experiement. After measuring the size of the rebar mesh in the reality, the model of one piece of mesh was scaled down proportionally. Then the piece was cut into a kit of parts. With these smaller pieces, I hinged them on each other and fixed them down by using super glue. Advantage of the material: this material cannot be easily deformed and it replicates the shape of rebar finely and it is very easy to play with this firm material. Disadvantage of the material: it is very hard to use super glue to stick all the meshes together because the limited contact area of each piece. Furthermore, it lacks the weaving quality of the original mesh.

Rebar Model Experimentation I

Process: The second phase to improve this model was to add white resin to fix the meshes with super glue so the model could be more stable than the previous one. Also human figures are integrated with the model. Advantage of the resin: this material is very flexible and easy to reform when it is heated by 80°C water, and it becomes very stable and firm after it cools down. Also it gives clear hints about the edge for welding. Disadvantage of the resin: the resin has strong ropiness, so it is hard to control the amount of resin attached to the meshes. Circulation Explorations on Model 1

Circulation Explorations on Model 2

Rebar Model Experimentation II13

Mind Mapping for Design and Construction

Individual

Group On site rebars cutting

Design

Manufacturer ( Shanghai Jiading Jiaxi West Fan Co., Ltd.)

Welding

Installation of other materials Purchase for materials (Acrylics)

The Client (Liming Resources)

Final installation on site

Rebar Cutting on Site Oxyacetylene Metal Cutting- Mar.16

Confirm cutting size on site

Two process gasses Oxygen (O2) and Acetylene (C2H2) were mixed in the oxygen-acetylene torch. Both gases werestored in separate compressed gas cylinders. The two gas hoses transported the gases to the torch. The gases were mixed at the correct proportions and ignited, the hot flame’s temperature was up to 630WF. The reaction near the tip is as follows: C2H2 + O2 -> 2CO + H2 Gas valves on the torch let me adjust precisely the volume flow of the gasses. With the help of an additional oxygen blast trigger, additional oxygen was released through the nozzle. The additional O2 reacted with the metal to produce iron oxide and process heat. The reaction far away from the tip is as follows: 4CO+2H2 +3O2 -> 4CO2 + 2H2O The cutting torch was used to heat the metal to start this process. The process heat of the burning metal was used to continue the cutting process.

Oxygen (O2)

Acetylene (C2H2)

IDEAS ABOUT REBAR REUSING

The idea of converting rebars into an artistic pavillion/ pergola is later adapted in the Liming Resource’s case.

Distortion of Rebar Pieces and Prototyping 21.11

17.01

19.51

16.12

33.84

19.70

23.05

42.92

21.79

21.11

Selected pieces from the kit of parts The pieces of rebars could be distorted into a variety of angles. Therefore I chose four sizes from the cut pieces, and catagorized them into four groups which are pulled/squeezed into 0, 10, 20 and 30 degrees. Each of them could function as horizontal elements in the shelves, tables and chairs. The rest of the pieces could function as supports or other decorations. The aim of the design was to cosume all the rebar pieces. 18

0°

10°

20°

30°

10°

30°

20°

TYPE A: This is the smallest size of all. This size is appropriate for individual usage.

10°

20°

30°

10°

TYPE B: This type is long and skiny. This size is appropriate be be used as shelves and benches. This type could be used by multiple users.

30°

20°

10° 20° 30°

20°

10°

30°

TYPE C: This type is slightly wider than TYPE B. This size is appropriate be be used as shelves, table or benches. This type could be used by multiple users.

10° 20°

30°

10°

30°

20°

TYPE D: This type is in a medium size. This size is appropriate be be used as shelves, table or benches. This type could be used by one or multiple users.

10°

20°

30°

Shelves Prototyping

0°

Unit: inch

10°

20°

30°

28.91

41.36

58.84

Type A

Type B

Side View

Type C

Type D Front View 20

Tables/ Chairs Prototyping

Unit: inch (sorted by height- the highest to the lowest)

0°

10°

20°

30°

22.51

Type D

20.20

Type C

16.61

Type A

16.59

Type B

Configuration Design- Preliminary

Doodles of Initial Thoughts

Key words: rebars, pavillion, minimalistic, entertaining, environmental friendly. The project was planned to be constructed in Shanghai Jiading Jiaxi West Fan Co., Ltd. The idea initiated from a paper board model. One piece of paper board represented one piece of rebar. In a minimalistic manner, the space was constructed with vertical walls, then partial walls got tilted to create a more dramatic and entertaining experience. More wasted rebars (14mm in diameter) in the factory were found and they became the framing for the pavillion.

Shape Evolution-the figure indicates the final shape of the pavillion.

53°

Isometric View- The rebars are cut and then composed together. (Before)

Isometric View- The rebars are cut and then composed together. (After)

Configuration Design- Framing 23

Isometric View- Rebars are welded to the frame, most of them gather at the lower level in order to guarantee the upstanding of the frame.

Isometric View- The acrylic pieces are installed on the frame, the color of the piece are pieces are determined by the available products.

Configuration Design- Paneling 24

Configuration Design- Details & Final

Rebars are installed to the frames by electrowelding.

Steel slots, which are used to hold the acylic panels, are installed by gas shielded welding.

Primary Rendered View A quick exported view with human figure gives a sense of scale of the pavillion.

Drawing with Annotated Length of Rebars Unit: mm

This drawing mainly helps the constructors during the process of construction. The diagonal measurements of the two pieces help the workers to confirm and accuracy of cutting each time a rebar rod is cut. Minor errors happen due to the loss of material in the progress of cutting and welding.

Supplement to the Configuration Design 26

Functional Division & Shelves/Chairs Installation Formation Progress: Rebars

Panels

Perspective View (Side for Planting)

Crops/Plants

The sculptural screen divides the space into two therefore the two sides of the pavillion are assigned with different functions. One side is zoned for the shelves for planting and the other side installs chairs for sitting. The transparency of acrylics and permeability of rebar meshes enables the interaction between the two spaces. Chair Type: Type A 0°, Type C 10° Shelf Type: Type A 0°, Type B 10°

Perspective View (Side for Sitting)

Steel reinforcing bars are produced from molten steel, by forming it into large rectangular billets and then running it through a series of dies, which shape the steel into reinforcing bars. During the forming process, deformations are formed in the surface of the bars that are used to help in transferring loads between the concrete and the reinforcing steel. It is necessary to splice concrete reinforcing bars in all but the most simple concrete structures. In the past, splicing was done by overlapping the bars from 20 to 40 diameters and wiring them together and relying on the surrounding concrete to transmit the load from one bar to the other. This method is wasteful of the steel and is sometimes impractical. An example of this occurs when splices must be made in heavily reinforced columns. The close spacing of the bars makes lap splicing particularly difficult and often requires a larger column diameter to provide sufficient concrete between bars and covering the bars.

Research About Properties of Rebars Before Practice 28

Construction and Fabrication Manufacture in Shanghai Jiading Jiaxi West Fan Co., Ltd.

Frame Construction by Welding- Rebar rods are measured and cut, then welded into a whole.

Protection Notice- Face guard and glasses/goggles are required in the process of welding.

Welded rebars in progress- after the welding is done, the whole piece is held straight up as a screen.

Progress of Rebar Meshes Welding to the Rebar Frame (Electrowelding) This step is done while the piece is laid flatly on the ground due to the concern of safety- large amount of sparks and flames are produced in the progress.

Steel Slots Welding & Installation of Acrylic Panels (Gas Shielded Welding) This step is done while the piece is standing straight-up. Ladder is required during the installation of the pieces at higher levels.

FURTHER THOUGHTS Visionary Scenarios & Future Application for Rebar Revival

Most recycling companys like Liming Resources are far away from the city center following NIMBY “not in my backyard”, Therefore this monument, depending on the size of available materials, could be scaled up or down to function as a substation far away from the company’s exhibition center. This new architectural prototype is where people could get educated about garbage classification and recycling at the place they live. The construction of this project could happen in any place. It could be built in the city center as a public gallery. Or it coulld be built in suburban area as a monumental structure, an evidence which represents the human intrusion to the nature in this prosper industrialized era.

Scaled Up- Urban Recycling Monument Daylight Time Due to an increment of urban reconstructions, more wasted constructive materials like rebars will be abandoned. The sculptural piece could be constructed on water-close to the riverbank, or along the coast, in order to celebrate the rebloom of the material in the our daily life. LED light tubes are attached to the framing. The recovered rebars accompany with the revival of city- both old and new materials are included and utilized.

Scaled Up- Urban Recycling Monument Night Time When the night comes, the city is still wide awake. The lights on the rebar monument and the city lights are twinkling in the darkness. With great lighting, the monument functions as a lighthouse gallery which introduces the magic of recycling to the citizens. The lights are on from early morning to late night. The celebration of the old material on water in the city is always on.

Reference

https://www.eng-tips.com/viewthread.cfm?qid=455695

https://www.totalmateria.com/page.aspx?ID=CheckArticle&site=kts&NM=189

https://www.bnproducts.com/blog/physical-properties-you-should-consider-when-us ing-rebar/ https://compare-bear.com/oxy-acetylene-cutting-torch/#how-does-oxy-acetylene-cutting-work