Smart Paper Factory

SMART PAPER FACTORY Gleaning paper cellulose to create a post-industrial smart paper factory in Maastricht where design, exhibition and production are intertwined

Zilin Zhou 5238927 Urban Architecture Graduation Studio 2021-2022 Delft University of Technology Department of Architecture

WHAT TO GLEAN?

1

MAASTRICHT From Industrial City to Smart City

SAPPI PAPER FACTORY Rebirth of Industry

PAPER CELLULOSE Catalyst for Architecture and Design

Urban scale

Architectural scale

Material scale

2

MAASTRICHT From Industrial City to Smart City Urban scale

3

Sphinx Belvédère Industrial heritage preservation Started in 2008

Sappi Paper Factory in operation

What's the tomorrow?

Céramique Urban renewal over heritage in the 1980s

"Without a past, no today and no tomorrow" (Belvédère Maastricht, [brochure)

ENCI Closure of the Netherland\s oldest cement factory in 2020

"Limburg 1839-1939. Van ploeg tot afbouwhamer"

4

MIGRANT CITY Diversity in Maastricht 5

An interdisciplinary site of research

Researcher Monuments Commodity transportation

Transport

Museum

Good Student Tourist

Worker Artist & Designer

Shop

Market

LBB culture freezone

Creative industry

From selling goods to service and knowledge production

GLEAN AGENT Interaction Activates the City 6

Sappi island Maas

Sphinxkwartier

Bassin

LBB

Frontenpark

City center

7

GLEAN MATERIAL Nature, landscape, buildings, machines, etc.

8

GLEAN MATERIAL Bassin 9

Clarifier

Tank

Storage

1986

1986

Tank

PM6 Rolling Lead

Maas water cleaning

PM6 Coating

Tank

PM6 Machine hall 1961

PM6 Sheet Finishing Expedition

Cellar off coater PM6 Finishing room

Sheet Finishing Power Plant 1979

1999

1961 1961

Cellulose Storage

Cellulose Storage 1962

Storage/Machine Maintenance

Energy Plant

1935

1951

Warehouse 1926

PM-5

PM-1 PM-4

Storage

1920

PM-1/4

Storage

Affuitenloods/Storage

10

PM-5

Pump

1827

GLEAN MATERIAL Time and history

1966

Office/Laboratory Office

1920

Warehouse/Archive

1883

1920

1920

GLEAN MATERIAL Factory space 11

ct

a mp

co se

loo

URBAN STRATEGY Reconnect 12

Demolish

URBAN STRATEGY Reconnect 13

New

URBAN STRATEGY Reconnect 14

URBAN STRATEGY Reconnect 15

16

17

18

0m

New Old

Green Water

19

10m

20m

50m

0m

New Old

Green Water

20

10m

20m

50m

0m

New Old

Green Water

21

10m

20m

50m

SAPPI PAPER FACTORY Rebirth of Industry Architectural scale

22

SAPPI PAPER FACTORY Machine space and leftover space 23

Paper machine

Paper cellulose

Structure

Form WHAT TO GLEAN? 24

1968 Teepee paper dress

2014 Semi-transparent paper / stlandsutstillingen

2011 paper furniture pavilion / Shigeru Ban

2008 Paper Chair / Mario Stadelmann

2006 Sculptural Cardboard / ball nogues studio

1968 Aalto exhibition / Shigeru Ban

2018 Paper pulp / Beer Holthuis

Honeycomb Wall / ECOCELL fastbuilding system

Furniture

Space Plan

Skin

Structure

1995 Paper log house / Shigeru Ban

1995 Paper house / Shigeru Ban

2019 Barjeel Installation / Miskavi Architecture Studio

2013 IE Paper pavilion / Shigeru Ban

2009 Cardboard pavilion / Cambridge University

2010 Paper composite / Finland pavilion Shanghai EXPO

2007 Digital Origami / CHRIS BOSSE

2001 Veneer Grid roof house / Shigeru Ban

GLEANING PAPER AS CATALTST Attract multiple agents 25

2014 paper tube wall / Perkins + Wills

2016 Wallpapering acoustic insulation / Dear Human

2003 Paper Dome in Amsterdam

2007 Paper composite / Shigeru Ban

2007 Papercut / dARCH studio

Paper cellulose insulation / ECOCELL

2011 Cardboard Column / Michael Hansmeyer

2006 paper cardboard / NOGUES STUDIO

THE POTENTIAL OF PAPER Origami 26

THE POTENTIAL OF PAPER Cast paper 27

THE POTENTIAL OF PAPER Regular structure 28

THE POTENTIAL OF PAPER Spatial experience 29

THE POTENTIAL OF PAPER Spatial experience 30

DESIGN PHASE Form 31

DESIGN PHASE Flexible space 32

DESIGN PHASE Curved folding roof 33

DESIGN PHASE Return to human scale 34

DESIGN PHASE Return to human scale 35

Old

Renovation New

36

0m

10m

20m

30m

Old

Renovation New

37

0m

10m

20m

30m

FACTORY MUSEUM

SPORTS CENTER

COMMUNITY CENTER

WORKSHOP

MANUFACTURING

ENTRANCE EXHIBITION

SHOP

ART STUDIO

HOSTEL

TEST GROUND

RESIDENTIAL

Old

Renovation New

38

0m

10m

20m

30m

Old

Renovation New

39

0m

10m

20m

30m

0m

40

10m

20m

0m

41

10m

20m

PAPER CELLULOSE Catalyst for Architecture and Design Material scale

42

Paper cellulose

Paper honeycomb

Paper cardboard

Wood Pallet

Load-bearing ceilings and walls

Foundation

Insulation layer

Load-bearing ceilings and walls

biodegradability and recycled nature the R-value 3.2 to 3.8 per inch with fire retardant (Boric acid) accept high humidity levels

the direction of force is perpendicular to the surface of the paperboard

Secondary processing

Insulation layer

lightweight 30-90kg/m3

WHAT TO GLEAN? 43

Entire load-bearing structure of the buildings Span 6m ceiling elements with three honeycombs of 65 mm thickness each have a total height of 27.5 cm and enable a span of up to 6.00 m

Water and fire retardant coated with mineral cement

ECO Solar Houses (ECOCELL)

CASE STUDY Paper honeycomb 44

Entire load-bearing structure of the buildings through rolling cardboard Thickness 24 layers of cardboard Water and fire retardant

Wikkel House

coated with a protective film and a shell of wooden slats

Life expectancy 50 years

CASE STUDY Paper cardboard 45

Two-layered wood panel folding structures All four panels can be joined directly along folded edges, the double tenons also serving as spacers between the two layers and absorbing shear forces.

Wikkel House

Span 16-20m CLT Plate thickness 45mm Hollow interspace 210mm

CASE STUDY Glue-free double layered folded plate 46

Tensile strength MD(machine direction) 15-45MPa CD(cross-machine direction) 0.3-0.5MD

l

r rol

e Pap

Compression strength MD(machine direction) 0.3-0.5Tensile strength CD(cross-machine direction) 0.3-0.5MD

CD

Anisotropic

MD

Structural Safety When facing compression, there's no significant plastic deformation before breaking. So, paper load with maximum force can still carry some forces.

Co

rru

ga

ted

pa

pe

rbo

ard

Paper cardboard is stronger in tension than in compression. co

mp

res

sio

ten

n

sio

n

compression tension

Structural rigidity balance

Building structure

Each layer of cardboard is oriented perpendicular to adjacent layers to achieve better structural rigidity in both directions.

Cardboard is used as a tensile structure, mainly as the internal load-bearing structure of the envelope, and the external is CLT panel, forming a double-layer structure.

Cross laminated cardboard

Cardboard as tensile structure CARDBOARD PERFORMANCE 47

Optimal moisture content

Ignition temperature of paper 230oC

5%-7%

If moisture level is exceeded, strength is reduced by 10% for every 1% increase in moisture content

thiicker cardboard is similar to timber in the flammability performance.

Waterproof Method

Fireproof Method

- a layer of waterproof liner - cover pvc sheet (not environmentally friendly) - paraffin to impregnate paper (applied by Shigeru Ban) - polyurethane liquid or polyurethane film (transparent) - polyethylene (coated layer can be inside / internal impregnation of fibres) - cement

- cover with intumesscent coating - coated with flame retardant in either solid or liquid form (kiilto) - double-sided spraying Hydroflam (class M1)

Waterproof

Fireproof

CARDBOARD PERFORMANCE 48

Cross laminated cardboard

Composite board

Composite Panel

(Cross laminated cardboard+honeycomb core)

(Cross laminated cardboard+cellulose insulation)

Vertical structural elements

Paper tube

Tube truss

Composite board

Cross laminated cardboard

Horizontal structural elements

(Cross laminated cardboard+honeycomb core)

STRUCTURAL ELEMENT 49

CONNECTION tongue-and-groove system 50

45mm cross laminated timber panels 210mm paper honeycomb 100mm cross laminated paper cardboard

CONNECTION tongue-and-groove system - wall 51

CONNECTION tongue-and-groove system - floor 52

Compsite loadbearing panel (cross laminated cardboard + honeycomb core) - 10mm flooring tiles - waterproof layer - 45mm 3 layer CLT Panel - 210mm 4 layer honeycomb paper layer with heating system - 100mm cross laminated paper cardboard - 5mm film solid waterproof polycarbonate sheet

Compsite loadbearing panel (cross laminated cardboard + honeycomb core) - 5mm film solid waterproof polycarbonate sheet - 45mm 3 layer CLT Panel - 210mm paper cellulose insulation layer - 100mm cross laminated paper cardboard - 5mm film solid waterproof polycarbonate sheet

CONNECTION tongue-and-groove system - floor 53

0mm

100mm

300mm

500mm

CONNECTION tongue-and-groove system - roof 54

Compsite loadbearing panel (cross laminated cardboard + cellulose insulation) - 10mm polycarbonate roofing sheet - 220mm ventilated air cavity with purlins - waterproof layer - 45mm 3 layer CLT Panel - 210mm paper cellulose insulation layer with purlins - 100mm cross laminated paper cardboard - 5mm waterproof polycarbonate film

- Motorized solar shade

- Glulam Beam (structural beam)

CONNECTION tongue-and-groove system - roof 55

- 5mm film solid waterproof polycarbonate sheet - 45mm 3 layer CLT Panel - 210mm paper cellulose insulation layer - 100mm cross laminated paper cardboard - 5mm film solid waterproof polycarbonate sheet

0mm

100mm

300mm

500mm

STRUCTURAL SCHEME Beams supporting the roof 56

STRUCTURAL SCHEME 57

58

0m

1m

2m

3m

ASSEMBLE PROCESS 59

ASSEMBLE PROCESS 60

ASSEMBLE PROCESS 61

ASSEMBLE PROCESS 62

ASSEMBLE PROCESS 63

ASSEMBLE PROCESS 64

ASSEMBLE PROCESS 65

ASSEMBLE PROCESS 66

ASSEMBLE PROCESS 67

ASSEMBLE PROCESS 68

ASSEMBLE PROCESS 69

ASSEMBLE PROCESS 70

ASSEMBLE PROCESS 71

ASSEMBLE PROCESS 72

ASSEMBLE PROCESS 73

ASSEMBLE PROCESS 74

75

0m

1m

2m

3m

76

0m

1m

2m

3m

77

78

DOUBLE FACADE 79

0m

1m

2m

3m

- 10mm polycarbonate roofing sheet - 220mm ventilated air cavity with purlins - waterproof layer - 45mm 3 layer CLT Panel - 210mm ventilated air cavity with purlins - 100mm cross laminated paper cardboard - 5mm film solid waterproof polycarbonate sheet

- Roofing batten

- Optional vent hole for ventilation

- Soffit vent (air flows along underside of roof) - Box gutter - Gutter boards - Varying depth packers to create gall - Waterproof layer - 45mm 3 layer CLT Panel with inserted

- Laminated glass louvre blade

- Hydraulically operated arm to operate louvres

- Hinge

Open louvres - Glulam beam (facade structure)

80

0mm

100mm

300mm

500mm

Exhaust air

Supply air

DOUBLE FACADE Open 81

External air curtain / summer shading

Internal air curtain / winter air buffer

DOUBLE FACADE Close 82

RAISED FOUNDATION 83

0m

1m

2m

3m

- 10mm flooring tiles - waterproof layer - 165mm honeycomb paper as insulation layer with heating system - 150mm glulam panel - 100mmx150mm wood beam

- Angle steel to fix loadbearing wall

- 210mmx260mm glulam wood beam - metal bracket

- Hexagon Thread Bolts - Concrete foundation

RAISED FOUNDATION 84

0mm

100mm

300mm

500mm

ROOF DRAINAGE AND VENTILATION 85

0m

1m

2m

3m

- Exhausted air exits ridge vent

- Wind baggles (limit infiltration of windblown rain and snow) - Roofing batten

ROOF DRAINAGE AND VENTILATION 86

0mm

100mm

300mm

500mm

- Prefab valley gutter - Gutter boards - Varying depth packers to create gall - Waterproof layer

- Roofing batten

- Glulam Beam (structural beam)

ROOF DRAINAGE AND VENTILATION 87

0mm

100mm

300mm

500mm

Mec

hani

MECHANICAL VENTILATION 88

cal r

oom

Paper honeycomb thickness: 65mm for underfloor heating

MECHANICAL HEATING 89

SPACE & STORY

DESIGN TOOL

NEXT PHASE & REFLECTION 90