Scalable Disruptors

Inhaltsverzeichnis

1. Frontmatter

2. Area A: Realising Circular Design

   1. Frontmatter

   2. A Taxonomy of Techniques and Tools for Rubble

      Design and Fabrication Concepts for (Re)use of Mixed Mineral Construction and Demolition Waste Maria Wyller, Hana Svatoš-Ražnjević, Eva Schad, Achim Menges

      Abstract

      The research presented in this paper investigates how traditional design and fabrication methods can be adapted to mixed mineral construction and demolition waste through computational design and digital fabrication. Forty-seven historical and contemporary masonry techniques associated with rubble were surveyed and analyzed, and a representative selection was explored in physical prototypes with brick and concrete rubble: (i) brickwork, (ii) drystone, (iii) slipform masonry, (iv) block casting and (v) gabion construction. These were evaluated based on the range of inclusion of rubble types, complexity of the adaptation in the terms of design, fabrication and assembly. The results outline two main approaches based on material handling: (I) high data and low tolerance placement methods, where the individual characteristics of the object play an important role, and (II) low data and high tolerance pouring methods, where the behavior of the material as a bulk is of importance. The paper provides an overview of suitable design and construction concepts for unprocessed rubble of different materials, sizes, and geometries and asks what affordances digital technologies can provide to make rubble a competitive digital building material for sustainable architecture.

   3. Structural Concrete Rubble Arrangements

      A Framework for Upcycling Demolition Waste into Slender Masonry Walls for Buildings Maxence Grangeot, Qianqing Wang, Katrin Beyer, Corentin Fivet, Stefana Parascho

      Abstract

      Reused concrete rubble is a challenging material to design and construct with despite its potential for diverging waste from landfilling and energy-intensive recycling. We propose a design to construction framework that leverages a camera and computationally cheap tools for making stable and space-efficient irregular masonry building walls from concrete waste. Large flat concrete rubble pieces are stacked vertically on their thin faces in single-leaf masonry walls. Lifting operations compose the basis of the framework’s construction planning and can be realised with any hoisting equipment. The framework also considers limited storage of construction sites. We use raster-based digital scanning and stacking methods chosen for their robustness and scalability. They provide stable and slender design options, minimising embodied energy through optimisation of void and masonry stability. The pattern regularity of the resulting single-leaf masonry designs is geometrically benchmarked against historic single-leaf masonry examples. Further informed by a compression load test, the results highlight a load-bearing capacity for buildings.

   4. VRoxel

      Immersive Design Environment for Digital Materials Jan Philipp Drude, Hendrik Wiese, Chun-Te Lee, Youssef Daadoush, Tatjana Sabljo, Mirco Becker

      Abstract

      Circular construction scenarios aim for comprehensive reuse of building elements. Only maximal reuse can help to reduce the sourcing of raw materials and eliminate energy consuming manufacturing and recycling processes. This requires the replacement of traditional construction techniques with technologies using materials and products that are designed for disassembly and reassembly. Two main strategies aim for maximal reuse. 1. Modularisation towards standardised kits of parts and 2. Discretisation towards small generic building blocks. Discretisation, a LEGO-like approach, was scientifically introduced as so-called digital materials (DM) at MIT’s Center for Bits and Atoms (CBA) in the 2000s [1]. While developed in an engineering context, DMs have also been picked up in architectural research [2‐4]. Considered a discrete form of additive manufacturing (AM), a recent CBA paper has shown how DMs can be automatically assembled on an architectural scale through hierarchic robotic systems [5].

      Current design systems (CAAD, BIM, parametric) are not fit for handling millions of elements, necessary for DM design on an architectural scale. A novel design environment for DMs should offer adequate design strategies, considering architectural objects such as walls and columns as large assemblies of building blocks. To fill this gap, we propose VRoxel, an immersive design environment for discrete assemblies in virtual reality (VR), capable of designing intuitively with millions of building blocks. The paper presents the underlying design paradigm and the software architecture of VRoxel. It illustrates its use in the context of academic design studios, workshops, and a demonstrator, thereby introducing the H-Block DM.

   5. Shaping Structures from Reclaimed Elements A Computational Framework for Stock-Constrained Design of Static Equilibrium

      Jonas Warmuth, Pierluigi D’Acunto, Corentin Fivet

      Abstract

      The reuse of reclaimed structural elements in new structures can be an effective way to lower their embodied carbon. However, integrating this approach into existing design workflows without affecting design freedom is challenging because designing with a predetermined inventory of structural elements highly affects the resulting design. Therefore, this paper presents a new framework aimed at facilitating the design and exploration of reticular structures incorporating reclaimed bar elements. The approach bridges constraint-based form-finding and stock-based assignment optimization, leading to a flexible and feedback-driven design tool. Comprising three key steps – i.e., layout, geometry, and assignment optimization – the framework enables the generation of structures that align with the characteristics of available stock elements while preserving design flexibility. Key feature is the geometry optimization, introducing a form-finding engine based on a proximity function and constraint projections. This expands the scope of stock-constrained design from a mere assignment task to a broad framework for exploring diverse forms within the vast solution space of structures that integrate reused materials.

   6. Place the Waste: Designing with Reclaimed Concrete

      Raitis Pekuss, Mariana Popescu

      Abstract

      Recognising the high rate of structurally sound concrete discarded as demolition waste, this study suggests a novel workflow for designing funicular structures using reclaimed concrete. The workflow is centred around a Voussoir Stacking Algorithm, created using COMPAS, which stacks quadrilateral voussoirs on a funicular thrust surface. Three design principles underpin the algorithm. First, opposing voussoir faces are aligned parallel to the force flow. In contrast, the remaining pair, which represents the load-transferring faces, is aligned perpendicular to it to prevent sliding failure. Second, the thrust surface is confined within the middle third of the voussoir to avoid the formation of hinges and cracks. Third, voussoirs are cut into hexagonal shapes, and staggering is ensured among neighbouring voussoirs to create an interlocking geometry. To validate the algorithm, 12 structures were made using different stocks, deployment strategies, and thrust surfaces. Since trimming the concrete elements is permitted by the algorithm, it was measured that, on average, 47% of the volume per voussoir is retained in the final structure. Finally, suggestions are made to improve the retained volume by expanding the criteria used to select the voussoir of best-fit to include distance-to-staggering, a local radius of curvature, and the surrounding voussoir dimensions.

   7. Bayesian Inference for Modelling Uncertainty in Non-standard Building Systems

      Fabian Kannenberg, Marta Gil Pérez, Tim Schneider, Steffen Staab, Jan Knippers, Achim Menges

      Abstract

      This paper introduces a Bayesian inference approach tailored for modelling uncertainty in non-standard building systems. The proposed framework is exemplified through a case study on coreless filament winding, offering insights into the interplay between probabilistic modelling and structural design. By integrating heterogeneous data sources encompassing fabrication parameters, geometry, material properties, and structural response metrics, the proposed methodology offers a comprehensive solution for quantifying uncertainty in novel construction processes. Through probabilistic graphical models and Bayesian inference techniques, this research contributes to advancing the understanding and management of uncertainty in the co-design of non-standard building systems, facilitating informed decision-making for architects and engineers.

   8. Integrating Naturally Grown Timber in Sandwich Timber Panels

      Kevin Moreno Gata, Felix Amtsberg, Sheldon William Stephens, Achim Menges, Martin Trautz

      Abstract

      The use of irregularly grown timber elements in construction may be challenging due to standardized cross-section requirements and the prevalence of common timber construction methods. Trees, shaped by environmental factors, develop unique material properties and irregular growth patterns. These irregularities, particularly in broad-leaf trees, often result in significant fritter away, with up to 50% of felled trees not being used in construction. Previous applications of non-uniform, naturally grown timber have focused on the geometric diversity, proposing unique, singular structures that remain largely within the academic realm. This paper introduces a practical method for incorporating naturally grown timber into flat structures like ceilings or walls. Timber elements are integrated into sandwich panels through a methodology involving geometric analysis to determine the timber's flatness, using image-based modelling for direct forest documentation. These elements enhance panel structural efficiency by aligning them with force and stress directions found through static load-case analysis. An example demonstrates this approach with a self-supporting elliptical sandwich panel for a canopy supported by V-shaped supports. The construction method incorporates 55mm planed timber and two 16mm thick three-ply panels, each placed individually due to the natural curvature of the timber. Augmented reality headsets guide precise assembly. This study highlights the potential to improve sustainability in timber construction by revaluing unused elements.

   9. Constructing with Discarded Wood

      Niels Martin Larsen, Anders Kruse Aagaard, Peder Lyngesen Kjærvik, Matthias Klith Harðarson

      Abstract

      Throughout history, irregular tree parts and excess wood have been used for their unique properties or because of a lack of straight wood. Thus, natural tree growth has been embedded in building culture.

      This paper presents a design and fabrication workflow for an outdoor structure – the public outdoor learning space Tingstedet – to be realised in the fall of 2024. The structure is built from two types of waste wood: discarded crooked oak logs and offcuts from window frame production. The presented method builds from the author’s previous research into 3D scanning technology, custom digital workflows, and robotic fabrication [1]. The paper focuses on how the research can be developed and applied to work in a real-life building and construction context with craftsmen, developers, municipalities, and planning permission. In previous research, the authors developed a generalised workflow for engaging irregular logs [1]. The method described in this paper proposes a workflow where crooked tree trunks are cut into live-edge curved slabs before digital registration and subsequent manufacturing. The workflow includes camera-based registration and a processing setup assisted by projection mapping. The workflow can allow a relatively effective design-to-production and assembly process.

      The development and realisation of the project Tingstedet will reveal knowledge of the potential and implications of building with curved wood and waste wood. The project rethinks and optimises previously developed workflows to engage the building industry in the realisation process, thereby investigating the viability of the methods on a larger scale.

   10. Computationally Integrated Embodied Carbon Performance Tools for Structural Design Stages

       Carlo Fusari, Chiara Bariviera, Douraya Kessaria, Duncan Walters, Jun Wen Loo, Mark Skepasts, Miriam Dall’lgna

       Abstract

       In today’s context of climate emergency, designers play a crucial role in mitigating the emissions associated with the construction industry. This responsibility weighs even more heavily on structural engineers given that structures are estimated to contribute up to 65% of a building’s upfront embodied carbon. The challenge remains in being able to monitor embodied carbon through the design evolution and being able to provide effective feedback to steer decision making towards low-carbon solutions. Existing tools on the market often lack parametric and customization capabilities, robust user interfaces for clear communications of results, and seamless interoperability between design environments. The process detailed in this paper showcases a streamlined approach to embodied carbon calculations by enhancing design software capabilities, such as Rhino/Grasshopper and Revit, with the Smart Massing Tool (SMT) and the ECO2 tool, respectively. The SMT facilitates early-stage analysis allowing for quick exploration and comparison of design options while the ECO2 tool enables detailed embodied carbon calculations drawing data directly from BIM models. The development of the tools represents a significant step towards integrating sustainability considerations into structural design processes, empowering engineers to design low carbon buildings.

   11. Web-Based Material Database for Circular Design

       Ian Law, Keng Chia Chang, Beril Önalan, Dominik Reisach, Simon Griffioen, Arabelle de Saussure, Benjamin Dillenburger, Catherine De Wolf

       Abstract

       In circular construction, sourcing reclaimed materials for design projects is often hindered by inconsistent data formats and lack of 3D data integration. This study addresses these barriers by proposing a digital workflow to streamline information flow between 3D architectural models and circular materials. Our approach includes three key elements: a PostgreSQL database integrated into the CAD environment for easy querying of reclaimed materials, an automated 3D model generation system using image-segmentation and depth-estimation models with OpenCV and META Segment Anything Model, and an intuitive user-interface within 3D CAD software.

       The workflow detects and segments elements like windows and doors from image data, performs perspective transformations, and converts the data into JSON format for 3D model generation in CAD software to reduce manual modeling effort. It also includes a database for standardized material data and an intuitive user interface integrated into 3D modeling software to provide architects real-time access to circular materials. The interface features cost calculations, greenhouse gas emissions visualizations, and summary tools, ensuring digital models correlate with physical materials.

       This user-friendly approach simplifies incorporating reclaimed materials into designs, paving the way for future investigations into more complex shapes and materials. This integration significantly enhances efficiency for designers and architects during the design stage. Overall, in this research, we aim to showcase a more user-friendly approach to simplify the use of reclaimed materials. The proposed workflow enables architects and designers to efficiently and effectively incorporate reclaimed materials with detailed characteristics into their designs. Future work will expand the database to include diverse material types, such as structural components, and address the challenges of photo-based 3D model generation for more complex geometric shapes.

   12. Kit-of-Parts Equilateral Constant Normal Curvature (ECNC) Gridshell

       Haotian Man, Zongshuai Wan, Davide Pellis, Eike Schling

       Abstract

       This paper investigates the design and construction of doubly-curved equilateral constant normal curvature (ECNC) gridshell structures with straight, flat, and repetitive building components. Using kit-of-parts with identical shape and size, enables standardized prefabrication. These components are connected to form a collapsible scissor-hinge grid, which can be deployed onsite to create freeform gridshells. The structure is then converted into a stable triangulated grid using diagonal elements. The angles of connections between the kit-of-parts can be adjusted to accommodate different constant normal curvature values and facilitate positive and negatively curved design shapes. This approach allows for the reuse of the same repetitive components in multiple designs and life cycles, promoting a sustainable, circular building system for energy conservation and carbon reduction.

   13. Modular Metal Nodes for Timber Space Frames

       Lukas Kirschnick, Jan Willmann, Jürgen Ruth

       Abstract

       This research explores a new approach toward sustainable timber construction by utilizing leftover timber for space frame structures, and, as such, introducing digitally designed and fabricated modular metal nodes as connectors. With timber construction on the rise in Europe, the potential for future timber shortages looms, necessitating a more effective and efficient use of available wood resources, and, ultimately, characterizing systemic building processes that capitalize on leftover timber. In this light, one important key is to develop modular connectors that are suitable to non-standard material systems and are architecturally lean. Hence, these elements must be geometrically generic while allowing an optimal architectural and structural performance. Of particular concern is therefore the design, development and fabrication of metal node connectors optimized for round timber elements, with two variants explored: one involving individualized topology optimized nodes produced via “lost foam casting”, and another utilizing the same fabrication technique but with a modular approach to allow for efficient assembly, mechanical adaption and serial production. The paper discusses 1) research parameters, 2) the iterative design and fabrication process, and 3) presents an 1:1 architectural prototype. Overall, it highlights the potential of using leftover timber in digital design and building construction, reshaping sustainable timber practices and architecture’s constructive repertoire.

   14. Data-Driven Reuse of Waste Wood

       Jens Pedersen, Jon Krähling Engholt, Ander Kruse Aagaard, Niels Martin Larsen

       Abstract

       This paper presents an industrial research collaboration, addressing how discarded lumber from a cutting process can be used in construction. The process cuts lumber is into sizes, based on digital visual information, and high-quality elements are used in products for the furniture or window industry. Such a process results in otherwise discarded off-cut lumber in either a good or bad qualities. The process is driven by data, which if leveraged through our proposed design method, could distribute good/bad material where needed in wooden beams for construction. The design system creates a data stream, intended to inform a machine that cuts finger joints and glues small lumber pieces into continuous linear members. As a result, the research describes the current facilities of the industry partner while detailing how the method could be implemented within their facilities. Furthermore, the method is evaluated through a series of digital design proposals, where the ease of implementation, visual correlation to the intended design and material performance are evaluation criterias.