Posts tagged with "Concrete":

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This concrete screen wall was inspired by the proportions of camera lenses

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The Fort Worth Camera building, a new photography studio and retail space, is surrounded by notable concrete neighbors, the Modern Art Museum of Fort Worth by Tadao Ando and the Kimball Art Museum by Louis Kahn. Ibanez Shaw Architecture responded with its own concrete novelty inspired by the building’s program.
 
  • Facade Manufacturer Tim Pulliam Concrete (concrete sub-contractor/installer) Fort Construction (general contractor), PPG (low e Solarban)
  • Architects Ibanez Shaw Architecture
  • Facade Installer Tim Pulliam Concrete (concrete sub-contractor/installer), Fort Construction (general contractor, steel glass system fabricator), United Glass (glazing)
  • Facade Consultants HnH (structural engineer), W.J. Simpson Co. (concrete shop drawings)
  • Location Fort Worth, Texas
  • Date of Completion 2017
  • System Tilt-up site-cast concrete panels, steel plate window enclosure
  • Products PPG low e Solarban glass, site cast concrete panels by Tim Pullium Concrete
The primary facade is a site-cast concrete panel system which used tilt-up construction with steel anchors cast into the wall. The concrete wraps the perimeter of the building and transitions into an aperture screen on its most prominent street frontage. Ibanez Shaw decided upon concrete as the best material because security was a major concern for the client. The concrete provided protection at the street level and all the glazing on the building was either elevated above ground or made too small for a human to fit through. The seven standard aperture settings of a camera lens inspired the design of the concrete feature wall. The shape and proportions of the apertures were directly translated from these lenses and then modified to make them into standard-size openings. The formwork for the wall was made by gluing wood blocks together, which were then vacuum formed into fiberglass. The array of 25 fiberglass shapes were filled with grout and then cast around to create the screen wall. Because each hole is conical in shape, the aperture wall faces toward the interior and allows light and views into the courtyard. Across the courtyard from the concrete screen is a glass wall that allows views into the studio spaces. There was some initial concern about how the concrete would turn out. Bart Shaw, principal of Ibanez Shaw Architecture, told AN that with concrete, “you never know what’s going to come out. This big perforated concrete wall is going to sit across from the museum district, and when they lifted it out of the formwork it was pretty incredible.” The fiberglass formwork gave each aperture a smooth finish and release which contributed to the aesthetic of the wall. Aside from the concrete aperture wall, there is another distinguishable feature to the facade: a large window with a yellow steel enclosure. This glazing fronts a children's area on the interior and creates a framed window nook that faces the adjacent residential neighborhood. It is also the only glazing on the north facade of the building. The rest of the glazing fills the east and west facades.
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Morphosis Architects created a cloud-like facade using reinforced fiber modules

  • Architects Morphosis
  • Facade Contractors/Suppliers POSCO (Steel Curtain Wall), ALU EnC (Aluminum Curtain Wall), Korea Carbon (GFRP), Korea Tech-Wall (GFRC), Han Glass (Glass), Steel Life (Interior Liner)
  • Facade Consultants Arup, FACO
  • Location Seoul, South Korea
  • Date of Completion 2018
  • System Brise-soleil system on the main, west-facing facade
  • Products Fiber reinforced polymer (FRP) using one of Kolon’s own high-tech fabrics, Aramid
Magok is an emerging techno-industrial hub located on the outskirts of South Korea’s capital, Seoul. In 2013, The Kolon Group—a multinational corporation and leading Korean textile manufacturer—approached Morphosis Architects for a new consolidated headquarters within the district. The goal? A wholly unique design capable of housing the conglomerate’s diverse divisions while showcasing its array of manufactured products.

After half a decade of design and construction, the 820,000-square-foot Kolon One & Only Tower opened on August 23, 2018.

The project follows Founding Principal Thom Mayne’s preference for hyper-engineered, non-traditional forms. Sloped planes and yawning fissures wave across the facade and interior.

Carbon fiber–reinforced concrete piers, rising at acute and obtuse angles, are the primary compressive support for the structure.

The atrium is a vast space measuring approximately 140 feet tall and 330 feet long and provides inward and outward views. Dubbed “The Grand Stair” by the design team, the centrally-placed path of movement is meant to serve as a quasi-public space and a facilitator of vertical and horizontal circulation. Morphosis has lined the entire height of the atrium with 400 fiber-reinforced translucent polymer panels measuring 30 feet wide. Produced by Kolon, the panels are fastened to the interior structure by stainless steel armatures.

The west-facing facade has a dramatic inflection that defines the structure’s exterior. Morphosis describes the main facade as “an interconnected array of sunshades that form a monolithic outer skin, analogous to woven fabric.” The woven embellishment—featuring the Kolon-produced Aramid, a reinforced fiber with a greater tensile strength than iron—was designed parametrically to balance the interior’s need for outward vistas and shading requirements. Stan Su, director of enclosure design at Morphosis, views the sprawling sunscreen as carrying a “cloud-like plasticity in form while maintaining a remarkably high tensile strength.”

Each knot of “woven fabric” is fastened to the curtainwall with traditional stainless steel brackets that cut through exterior joints to the steel mullions that ring the structure.

While the western elevation is the primary face of the development, the facility was designed holistically. Stan Su states that “the pared-back embellishment of the three other elevations is a response to their interior functions; lab and office blocks comprise what can be considered the rear of the building.” The curtain wall wrapping these elevations largely consists of Han Glass’s low-iron glass and ALU EnC produced aluminum cladding, a measure to match the clear view and visibility requirements of the client.

In a bid to secure LEED Gold Certification, Morphosis added a number of sustainable and environmentally-friendly interventions; Kolon One & Only Tower is decked with a green roof, solar photovoltaic panels, and geothermal heating and cooling mechanisms. Additionally, Morphosis reduced concrete use by 30 percent through a bubble deck slab system which uses plastic balls as a form of reinforcement. Further projects by Morphosis Architects will be discussed during Facades+ LA October 25-26.
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SHoP Architects adds aluminum luster to Nassau Coliseum

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  • Facade Manufacturer Alucobond; Sobotec Ltd.
  • Architects SHoP, Gensler
  • Facade Installer Crown Corr; Hunt Construction Group (general contractor)
  • Facade Consultants SHoP Architects
  • Location Uniondale, NY
  • Date of Completion 2017
  • System Aluminum screen
  • Products Alucobond® PLUS naturAL Brushed
Originally opened in 1972, the old Nassau Veterans Memorial Coliseum on New York's Long Island was given a facelift and interior renovation by SHoP and Gensler respectively in 2015.  SHoP’s team relied on the concrete massing of the 1970s structure to shape a new facade composed of over 4,700 brushed aluminum fins that wrap the building in broad sweeping curves. The project, which benefitted from a rigorous digitally-conceived workflow, delivered the new undulating facade geometry by precisely varying each of the fins in profile and dimension. Two primary fin shapes are designed from one sheet of aluminum composite material (ACM), minimizing waste while highlighting SHoP’s commitment to a design process that is tightly integrated with fabrication and assembly processes. John Cerone, associate principal at SHoP, told AN that one of the successes of the project is the new facade's reflective effects that pick up on colors of the surrounding landscape. This is especially evident during sporting events where crowds wearing the home team’s colors reflect onto the facade. The project in many ways mirrors SHoP's success with Barclays Center over five years ago—same client, same building type, similar design process. When asked what, in this project, arose as a surprise or a challenge to the design team working on Nassau, Cerone candidly said, "Nothing!" He elaborated, "As we continue these projects, it's a continuous iteration: We recycle process. I don't think this industry does enough of that." "Don't ignore fabrication constraints and input from contractors," Cerone said. The fins are planar and negotiate a ruled digital surface, which was informed by early feedback from fabricators and contractors. "An intelligence builds from doing other projects like this. While the componentry and hardware differ, the actual process of how you structure the model and develop methods of automation improves with experience." The architects cite simple definitions which they adopted and advanced from prior projects which help to automate the generation of parts for geometrically complex assemblies. "This to us was a proof. It's a great testament to not being surprised by the process," Cerone said. The design process for SHoP was initiated with a laser scan of the existing arena, resulting in a highly detailed topographic mesh surface that became the base geometry for forthcoming design and fabrication models. The framework of the new skin was designed as a long-span space frame, springing off massive existing concrete piers that were, in the words of Cerone, impressively over-structured. The resulting structural subframe was assembled on the plaza level of the stadium and craned into place. Only 32 “mega-panels” were required. "Facades are the closest you can get to manufacturing in architecture," Cerone said, "but we are looking towards using this process throughout the building. How can it inform the superstructure and the interior? We are working to scale this process up."
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This experimental concrete roof is half the weight of its peers

A research team led by Jamin Dillenburger, an assistant professor at ETH Zurich, has recently produced and installed a concrete ceiling shaped by 3D-printed sand formwork. Dubbed the “Smart Slab,” the 1000 square-foot ceiling is significantly lighter and thinner than comparable concrete ceilings. The concrete slab is a component of ETH Zurich’s ongoing DFAB House project. The DFAB House is a load-bearing timber module prefabricated by robots. According to ETH Zurich, Dillenburger’s research group “developed a new software to fabricate the formwork elements, which is able to record and coordinate all parameters relevant to production.” In effect, the design of the ceiling is the product of the team-created software rather than analog design or planning. Following the design and digital testing phase of structural elements, the fabrication data was exported for the creation of 11 pallet-sized, 3D-printed sand formworks. After fabrication, each segment was cleared of sand particles and prepared for concrete spraying. The spray consisted of several layers of glass-fiber reinforced concrete. At its thinnest point, the concrete shell is less than one inch thick. After hardening for two weeks, the 11 concrete segments were joined to create the approximately 15-ton floor plate. While the underbelly’s contours were formed by 3D-printed sand casts, the ribbed grid above was shaped by CNC laser-cut timber formwork. The load-bearing ribs, resulting from timber formwork, were outfitted with a series of tubes for the insertion of steel cables both horizontally and vertically. These post-tensioned ribs carry the principal load of the “Smart Slab.” In placing the principal load above the concrete shell, the research team was able to insert complex geometric features below. The “Smart Slab” is not ETH Zurich’s first execution of an ultrathin concrete unit. Earlier this year, the university fabricated an undulating, two-inch thick roofing unit for a new live-work space in Zurich.
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How the Rio Grande came to separate the U.S. and Mexico

This article is the fourth in a series that originally appeared in AN's July/August 2018 issue which focuses exclusively on Texas and was guest edited by AGENCY. The rest of the essays will be released in the coming days and examine architecture and practice across the southern border of the United States. In the border metropolis of El Paso-Ciudad Juárez, the power relations of international negotiation are not only performed through the apparatus of control over the movement of bodies, but are also embodied in a concrete architecture that exposes the calculus of separation and asymmetrical infrastructural development between the two countries. In the borderland, the control of water—as territory, commodity, and reproductive agent—produces its physical spaces. While the shared waters of the river and the underground aquifers contribute to the reproductive capacity of land within the desert climate, the infrastructures of water supply and sanitation are material evidence of the socio-spatial injustices and imbalances that structure and reproduce social relations within the border cities. Negotiation The geopolitical history of the river as a border and of the partitioning of its waters is inscribed within the built environment as a thick constructed zone. The international border between the United States and Mexico was defined by the 1848 and 1884 Treaties, which delineated that the border follow the Rio Grande (Rio Bravo del Norte) from El Paso to the Gulf of Mexico. This rendered the border an unstable condition, as its line needed to be redefined by the International Boundary Commission each time floods caused the river to relocate. A treaty in 1933 attempted to “fix” the river by engineering it into a constructed channel. However, this location left several hundred acres of disputed Mexican territory to the north of the river—the result of a violent change in course in 1864. The 1963 Chamizal Agreement relocated the river and the international boundary once again, moving the Rio Grande back to its 1852 survey location. In this highly publicized moment of international diplomacy, the disputed land was “returned” to Mexico, and a new channel was constructed to reroute the Rio Grande north so that both river and international border aligned. The division between the two countries was now emphasized, further asserted by the open lands of the former riverbed on the Juárez side and a new elevated border highway on the U.S. side of the channel. Management The colonization of the U.S. would not have been possible without the massive campaign of dam projects in the early 20th century that commodified the waters of the West and irrigated the farms and settlements of homesteaders. Four dams manage and distribute the Rio Grande waters in the El Paso-Juárez region: Elephant Butte, Caballo, American Diversion, and the International Diversion Dam. Water is distributed according to the 1944 Water Treaty, drawn up when the population of Juárez was less than one-tenth its current size. In 1965, the binational Border Industrialization Program enabled maquiladoras, foreign-owned manufacturing plants, to be located within Mexico’s border zones, and to move materials and products with reduced tariffs and trade barriers. This propelled an influx of new residents who arrived to work in the Juárez border zone maquilas. The treaty, which retains the majority of the river water in the U.S., has not been revised since and contains no provisions for sharing the rapidly depleting Mesilla and Hueco Bolson aquifer waters, which traverse the binational region underground. The division of the river water produces politically charged urban spaces. The U.S. Franklin Canal materializes as a physical barrier within the U.S. border zone, flowing deeply and rapidly in a concrete channel alongside the Rio Grande. In Juárez, the diverted water flows along the Acequia Madre, which takes a diagonal course, traversing some of the city’s main public spaces. This once green irrigation channel and common space is now largely neglected and has deteriorated into a toxic line of sewage and trash. Biopolitics Water is not only scarce in the desert city of Juárez—it is also dangerous. The paper worlds of politics materialize as realities on the ground and in the tissues of bodies. Due to the explosive population growth of Juárez, large portions of the city have been rapidly and often informally constructed, typically without proper municipal sewage or drinking water services. The residents of these informal settlements, known as colonias, rely primarily on truck-supplied water, which has a much higher likelihood of being contaminated and results in high rates of water-borne diseases. Only about a third of the city’s sewage is actually treated.  Some colonias have additionally encroached on the city’s drainage gullies and arroyos, putting residents at further risk during flash flood events. In July 2010, the United Nations General Assembly “explicitly recognized the right to clean drinking water and sanitation as essential to the realization of all human rights.” If this mandate is taken seriously by the binational region of El Paso-Ciudad Juárez, new treaties and agreements will need to be negotiated that address not only the scarcity and distribution of its shared waters, but also the shared responsibility of water rights to citizens on both sides of the border. What remains to be seen is not only what shape these take in terms of political agreements, but also how they will reshape the physical urban spaces of the paired cities.
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Thinness pavilion stretches concrete to its limits

Syracuse-based APTUM Architecture has designed and fabricated Thinness, an ultra-light concrete pavilion in collaboration with international concrete manufacturer Cemex Global R&D. Concrete is one of the most ubiquitous construction materials in the world. Its advantages are many: it's easy to produce, is remarkably strong, and can take on a variety of forms. It does, however, have one rather weighty constraint: it's heavy. Thinness is an experiment in using contemporary and historical casting methods to create novel forms that stretch concrete to its thinnest and lightest proportions while maintaining structural integrity. The installation uses its shape and a proprietary concrete mix that includes glass beads for aggregate and steel fibers to create a freestanding structure with walls that are only three-quarters-of-an-inch thick. The perforated pavilion, a collection of 12 exterior columns arranged around four central light wells, was designed to be modular and scalable. The columns taper at the base and expand as they rise, vaulting to form a ring of arches. Although the installation is ten feet tall and ten feet long on each side, each column weighs only 200 pounds. Architects Julie Larsen, Assoc. AIA, and Roger Hubeli, founding partners of APTUM and professors at Syracuse University, sought to explore “thinness” and the role of volume in architecture. In collaboration with the research and development department at Cemex, based near Monterrey, Mexico, the team was able to develop a fiber-reinforced concrete mixture that would evenly distribute around the form’s sharp corners without clumping and weakening the structure. Grasshopper was used to map the stress across each column, and the perforations were made smaller or eliminated in the most heavily stressed areas to help distribute the load more evenly. The team ran through different pattern iterations looking for the correct balance between load-bearing ability, aesthetics, and amount of void before settling on the final grid. The columns were cast using the lost-wax technique. First, a silicon mold was cut using a water jet, and then braced in a steel enclosure to protect against bowing as the concrete cured. Wax was then poured into the mold to form a freestanding column; the silicon formwork was then removed, and concrete was poured over the wax. Once the concrete was fully cured, the wax was melted and the process was repeated for the remaining components. Thinness is just the first step in what Aptum sees as a collaborative, interdisciplinary future between academia and concrete manufacturers. In the future, APTUM wants to scale up the technology behind Thinness to encompass structural elements and has released a rendering of a speculative skyscraper made from the same components. Thinness was recognized with a citation in the AIA’s 12th Annual R+D Awards this year. The project was also on display at the Designing Material Innovation exhibition presented by the California College of the Arts earlier this year. Design Firm: Aptum Architecture, Syracuse, N.Y., Roger Hubeli, Julie Larsen, Assoc. AIA (project team) Industry Partner: Cemex Global R&D, Davide Zampini, Alexandre Guerini, Jeremy Esser, Matthew Meyers (project team) Fabricator: Cemex Global R&D Structural Engineer: Sinéad Mac Namar Research Assistants: Sean Morgan, Ethan Schafer
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Sculptural concrete canopies cool a San Antonio public park

As implied by its name, Confluence Park overlooks the meeting of San Pedro Creek and the San Antonio River in San Antonio, Texas. Located about three miles south of downtown, the park acts as a gateway for the historic Mission Reach section of the San Antonio River. The $13.7 million project includes an education center and extensive landscaping that illustrates the diverse biomes of Texas. But what most visitors will remember about the 3.5-acre park are the nearly 30-foot-tall concrete petals that emerge from the ground to form a sprawling overhead canopy. Twenty-two of these sculptural panels are clustered together to form a single, large, open-air pavilion. Another six are paired together to form three smaller gathering areas. In addition to providing relief from the South Texas sun, these panels are shaped so that when it rains, they channel water into an integrated system of rainwater collection, filtration, and dispersal. All of this reinforces the stated mission of the park, which is to act as a destination for recreation while teaching important lessons about environmental science and sustainability. To that end, the design team sought to create a composition of architectural and landscape elements that used the same kind of logic found in nature. Ball-Nogues Studio, a Los Angeles–based design practice, established the park’s conceptual master plan. From there, the design was developed in close collaboration with the landscape architect Rialto Studio, Lake|Flato Architects, and Matsys, a San Francisco–based design practice that specializes in the development of new approaches to architectural design and fabrication. That particular skill set was critical in the development of the park’s concrete. Given the structural gymnastics involved, the project’s structural engineer, Architectural Engineers Collaborative (AEC), became an integral part of the design team as well. Although petals of steel, fabric, and wood were all considered during the design process, concrete was ultimately selected for its durability and permanence. Even though the majority of funding for the project came from private donations, Confluence Park functions as a public park, and so vandalism and long-term resiliency were key considerations. Despite the apparent complexity of the assembled petals, the design only required three unique petal shapes. These three forms were refined digitally using Grasshopper and Rhino. The resulting computer files were then provided to Kreysler & Associates and fed to their large 5-axis CNC router at their factory in California. The resulting Styrofoam “positives” were then used to manufacture the fiberglass “negatives” that were shipped to San Antonio to be used as formwork for the petals. Each of the park’s 28 petals was cast on-site but not in place. Given their complex geometry, a portion of the petal had to be exposed during the pour. This resulted in two contrasting concrete textures: a smooth finish where the concrete was poured into the fiberglass form, and a broom finish where the concrete was left exposed. As with many other aspects of the project, a custom solution was required here, too. A special eight-inch broom was used to apply the finish consistently to the petal’s curved form and to emulate the flow of water down the petals. After the concrete had cured for several days, the petals were lifted into their final positions. As with any tilt-up concrete structure, this was the moment when the highest stresses would be placed upon the petals. Adding to the complexity of the erection process was the fact that the petals had to be assembled in pairs: neighboring petals were joined to one another with two steel pin connections to form a determinant structure. The result of all this effort is a unique landmark on the south side of San Antonio. Despite the weight of the concrete petals—individual petals weigh between 15 and 20 tons each—the resulting structure feels remarkably light. The space between individual petals contributes to this feeling of weightlessness, while acrylic lenses embedded in the concrete add a bit of playfulness to the overall composition. In addition to illustrating the possibilities of contemporary concrete construction, Confluence Park demonstrates what is possible when a highly collaborative interdisciplinary design team works with an educated client to create something truly unique. It is only fitting that a park built to celebrate the confluence of diverse bodies of water be created by a confluence of diverse design professionals. Pavilion Design Matsys Landscape Architect Rialto Studio Structural Engineer Architectural Eng. Collaborative MEP CNG Engineering, PLLC Lighting Designer Mazzetti Energy Consultants Positive Energy Waterproofing Consultant Acton Partners This article originally appeared in the July/August issue of Texas Architect magazine.
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As mass timber’s popularity grows, the concrete industry goes on the offensive

Is wood dangerous? It’s one of the oldest, most sustainable building materials (if harvested correctly) and recent advances in cross-laminated timber (CLT) have made it possible to build taller, multifamily timber buildings, but local building codes are just beginning to catch up. Sure, any Girl Scout knows that you can’t start a fire without it, but it’s generally considered kosher: CLT boosters say that if contractors know how to work with the material, timber is just as safe as steel. Despite their widespread use, concrete industry groups strenuously object to the use of “combustible materials” in construction. One industry group has launched an email campaign to ostensibly make members of the AEC industry aware of (non–fire-treated) wood’s shortcomings. These emails are part of an ongoing battle between the wood, concrete and steel industries, a conflict which seems to have escalated in concert with the growing popularity of CLT and the introduction of the timber innovation act, which would provide government support to the development of mass timber technology. With ominous subject lines like “Georgia Bill Would Leave Savannah Exposed to Hurricane Threat” and “Flames Quickly Consume Combustible Denver Apartment Complex Under Construction,” the emails seem to sow doubt about the durability and safety of timber buildings. The five-story, 84-unit Denver building detailed in the latter missive was under construction when it was engulfed by fire. “Combustible materials have no place in mid-rise housing projects, regardless of whether they’re under construction or fully operational,” said Kevin Lawlor, spokesperson for Build with Strength, which initiated the campaign, in the email. “These buildings are effectively tinderboxes on steroids, and when a fire breaks out, they’re incredibly difficult to extinguish.” Build with Strength is a partnership convened by the National Ready Mixed Concrete Association. As their names suggest, both groups are unabashedly pro-noncombustible materials, concrete and steel included. Reached by phone, Lawlor said Build with Strength doesn’t have a beef with wood—it just wants to fulfill its mission of educating the AEC industry on the benefits of ready-mixed concrete and its use in low- to mid-rise buildings. Its members include architects, engineers, steel and concrete interests, political leaders, and even religious organizations. “It’s not a materials fight,” Lawlor said. “The goal is to promote safer construction in three- to seven-story buildings. The notices are not specifically designed to go out and attack any particular industry.”
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Experiments with fabric form concrete on view at NYIT

Romantic notions would have us imagine finished sculptural forms as trapped within raw, unhammered rock until the artist who divines their truth liberates them. Isamu Noguchi had a more nuanced understanding of how sculpture might emerge from stone. He saw the final work as the result of a dialogue between subject and object, with the outcome contingent on their chance meeting. Happenstance, as stone was sometimes to Noguchi, was the medium of his friend and occasional collaborator John Cage. Known for setting up frameworks to embrace unintended occurrences, Cage’s work put forward incidental manifestations within parameters he set up as the finished outcome. Naomi Frangos, professor and curator of Inhabiting Surface, an exhibit at the New York Institute of Technology (NYIT), had the student authors of the exhibited works study Noguchi’s sculptures as part of a collaborative project with professor Rennie Tang. As a visitor to the exhibition, familiar traces of Noguchi’s dialogue was apparent in their work. While spending time with artifacts of the process by which they were made, Cage’s chance became palpable. Yet what made the long trip to this remote show in Long Island worthwhile were the ways that these architectural experiments went beyond the work of canonic thinkers to stir the more nebulous topic of specific human bodies that architecture usually neglects. Casting any material is usually done using rigid formwork that sets up stable negative spaces that will produce the same outcome over and over again. Frangos, however, directed students to sew flexible, woven, plastic fabric into sacks of their own design to restrain the concrete while it was still in fluid form. Scaffolding made of the same rebar usually inside the formwork was installed around the flaccid sewn bags and served as restraints to influence the final form as the liquid concrete engorged them. Lime slumped over steel, concrete hardened against plastic to make it appear forever wet. Fabric removed, the shapes that emerged evoked Noguchi chats, yet this time he might have been speaking with a younger stone still plump with baby fat. With Frangos’ technique in the students’ hands, a direction for spatial production opened up to the same uncanny collapse of the distinction between building and body sought by Aziz + Cucher's mole-ridden interiors, festooned with follicles, or more directly akin to Andrew Kudless’ P-Wall. Displayed alongside the sculptural objects were the flayed formwork skins themselves. Like the Shroud of Turin, efflorescent traces of the casting’s seepage furthered a sense of how imperfect human bodies might find their way into how architecture is made. Inhabiting Surface’s greatest promise was the hint toward an architectural future that might become through the process of play, discovery, and openness to the unintended that Frangos and Tang encouraged. As these young practitioners set the agenda for the way buildings are to be made, their next experiments will move up in scale from the sculptural to the inhabitable. In a couple of decades, it is my hope to walk in to a building designed by one of these young people that makes me feel at home in the same time-based body that will certainly have sagged by then as well. Inhabiting Surface, Studies in Variable Formwork Design New York Institute of Technology, Center Gallery, Education Hall, Old Westbury Northern Boulevard, New York February 26–April 2, 2018
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Ultrathin concrete roof to cap a net-positive energy rooftop apartment

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A full-scale prototype of the design was the culmination of a four-year research project by ETH Zürich, and now the thin-shell integrated system's concrete roof is under construction. The razor-thin assembly, built over the course of six months, tapers to an impressive one-inch thickness at the perimeter, averaging two inches thick across its more than 1,700 square feet of surface area. The ongoing project, sponsored by ETH Zürich, NCCR Digital Fabrication, and Holcim Schweiz, will lead to the completion of a rooftop apartment unit called HiLo, which will offer live-work space for guest faculty of Empa, the Swiss Federal Laboratories for Materials Science and Technology.  
  • Facade Manufacturer Jakob (cables); Bruno Lehmann (rods and cable-net components); Blumer Lehmann (timber); Dafotech (steel supports + plates); Bieri (fabric cutting + sewing)
  • Architects supermanoeuvre; Bollinger+Grohmann
  • Facade Installer Marti (general contractor); Bürgin Creations (concrete); Holcim Schweiz (concrete development); Doka (scaffolding)
  • Facade Consultants ETH Zürich (Block Research Group, Mathematical and Physical Geodesy, Automatic Control Laboratory)
  • Location Zürich & Dübendorf, Switzerland
  • Date of Completion 2017-18
  • System thin shell concrete with integrated systems
  • Products custom assembly of concrete, steel cable net, polymer textile formwork, heating and cooling coils, insulation, and thin-film photovoltaic cells
The rooftop structure rises about 24 feet high, encompassing 1,300 square feet. Innovations in thin-shell building techniques were explored by the Block Research Group, led by Professor Block and senior researcher Dr. Tom Van Mele, together with the architecture office supermanoeuvre. The team purposefully avoided wasteful non-reusable formwork, opting instead to develop a net of steel cables stretched into a reusable scaffolding structure. The cable net supported a polymer textile that forms the shell surface. According to ETH Zurich press release, “this not only enabled the researchers to save a great deal on material for construction, they were also able to provide a solution to efficiently realise completely new kinds of design.” The construction technique leaves the interior floor area below the roof relatively unobstructed, allowing interior construction work to proceed concurrently. Altogether, this method is expected to condense construction to eight to ten weeks. Block Research Group and NCCR Digital Fabrication were able to digitally model dynamic forces wet concrete applies to the lightweight cable net and textile formwork, so that the overall geometry and structuring of the surface can be calibrated to produce an accurate result. This level of optimization is perhaps most evident in the capacity of the reusable formwork system to hold around 25 times its own weight (20 tons of wet concrete will eventually load onto the formwork).
Experts from Bürgin Creations and Marti sprayed the concrete using a method developed specifically for this purpose, ensuring that the textile could withstand the pressure at all times. Together with Holcim Schweiz, the scientists determined the correct concrete mix, which had to be fluid enough to be sprayed and vibrated yet viscous enough to not flow off the fabric shuttering, even in the vertical spots. The innovative concrete structure offers more than a new method for constructing concrete shell structures: it’s aim is to be an intelligent, lightweight energy-producing system. This is achieved by careful assembly of multiple layers of building systems. Two layers of concrete sandwich together insulation, heating and cooling coils, while thin-film photovoltaic cells wrap the exterior surface. The residential unit, enclosed by this roof system, and an adaptive solar-shaded facade, is expected to generate more energy than it consumes.  “We’ve shown that it’s possible to build an exciting thin concrete shell structure using a lightweight, flexible formwork, thus demonstrating that complex concrete structures can be formed without wasting large amounts of material for their construction” said Block in a press release. Because we developed the system and built the prototype step by step with our partners from industry, we now know that our approach will work at the NEST construction site.” You can view progress at the Dübendorf, Switzerland construction site via live webcam, accessed here.
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New map pays tribute to concrete and Brutalist buildings across New York City

Blue Crow Media, a publishing group that publishes architectural guides for cities worldwide, just released a map glorifying concrete structures across New York City—titled, appropriately, Concrete New York. Among the structures highlighted by the map, many will be familiar to AN's readers. Eero Saarinen's TWA Terminal at JFK airport, currently being renovated into a 505-room hotel, is listed, as is the Marcel Breuer–designed granite and concrete monolith now home to the Met Breuer. Perhaps less visited is Breuer's Begrisch Hall on the Bronx Community College campus or I.M. Pei's Silver Towers at NYU. Concrete infrastructure also gets its due: the Cleft Ridge Span at Prospect Park (completed in 1872) is featured as well as the more recent Dattner Architects and WXY Studio-designed Spring Street Salt Shed (completed in 2015). In Greenwich Village, New Yorkers will recognize New Orleans architect Albert Ledner's Curran/O'Toole Building, unmistakable with its double cantilevered, scallop-edged facade, formerly serving as St. Vincent's Hospital (a landmark institution for victims of the HIV/AIDS crisis). The guide also points out historic works by Paul Rudolph, Frank Lloyd Wright, Edward Durell Stone, and many others. The map was edited by Allison Meier, a Brooklyn-based writer. The next guide will look at the use of concrete in Tokyo, and will be available next month. Previous maps by Blue Crow Media have examined modernism in Berlin and Belgrade, art deco in London, and constructivism in Moscow, although Brutalism remains their favorite topic to date, with maps on the subject for Boston, London, Paris, Sydney, and Washington, D.C.
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MARS Pavilion experiments with robotic construction

How do two young designers get to participate in an invite-only robotics conference in Palm Springs, California, organized by Amazon CEO Jeff Bezos? First, you have to be creative; second, you have to get your work online, and finally, you have to be lucky. Joseph Sarafian and Ron Culver, AIA were classmates at the University of California, Los Angeles (UCLA) Graduate School of Architecture and Urban Design in Greg Lynn’s studio. They were exploring how to use digital design to create unique components that could be fabricated using state-of-the-art industrial robotics, the kind of robots that build cars. They developed a system that allowed the designers to go directly from a digital image to physical reality. Their prototype eventually found its way onto the internet. Then, according to Sarafian, “We got an email from Amazon’s team out of the blue, after seeing our robotic concrete research 'Fabric Forms’ on blogs and websites.” They were invited to attend what Amazon calls their MARS Conference (Machine learning, Automation, Robotics, Space exploration). Like a private TED Conference, the MARS Conference brings together business leaders, academics and others pushing the envelope of technology.  

The resulting MARS Pavilion prototype—including an exhibition and video of the design process—is currently on view at the A+D Architecture and Design Museum in the Los Angeles Arts District.  The pavilion will be up through Saturday, October 7 and has been sponsored by CTS Cement and Helix Steel.

Besides acquiring The Washington Post and Whole Foods, Jeff Bezos owns Blue Origin, a space exploration company that is intended to compete with Elon Musk’s SpaceX. The Blue Origin company motto is “Gradatim Ferociter,” Latin for “Step by Step, Ferociously.” This motto might also apply to the work of Sarafian and Culver. The MARS Pavilion by their firm Form Found Design (FFD) is the first robotically-cast concrete pavilion in the world. While it is intriguing to look at, what is more important than its image is its method of design and construction. The MARS Pavilion consists of 70 unique, robotically-cast “wishbone” shaped components that are all bolted together with an identical steel connection detail.  Using the robotic precision of large ABB industrial robots, they achieved a tolerance of 1/16 inch. This is extraordinary in concrete construction, where the usual level of tolerance is ¼ inch—It’s an improvement of 400%. All the MARS Pavilion forms are derived from concrete’s most inherent quality, compression. Walter P. Moore performed a structural engineering analysis and recommended one-inch "Helix Steel" twisted fibers for reinforcement rather than traditional re-bar. This provides greater flexibility. The goal is to allow for the precision fabrication of a wide range of design components at low cost. Ron Culver described their approach as “a true digital workflow where previously unbuildable complex geometry is now feasible.” In downtown Los Angeles, for example, Diller Scofidio + Renfro designed the Broad Museum proposing many unique concrete forms. Due to cost constraints, the design had to be simplified so that only the oculus (a curved opening at the front of the building) survived the value engineering and cost-cutting process. FFD believe their approach will allow design variation in concrete with no additional cost. FFD envisions many future applications including creating economical housing solutions for developing nations. Sarafian explained, “We are interested in exploring this fabrication technique to create an easy-to-assemble housing prototype for developing countries.” The MARS Pavilion installation is on view through October 7th at the A+D Architecture and Design Museum, 900 E 4th St, Los Angeles, CA 90013, tickets are available for the closing reception here. You can follow Follow their FFD's work on Instagram @formfound_design