[DAB510-Design] Materiality

Shigeru Ban's use of cardboard tubing as a structure really intrigued me as I had never seen this done before. After some research, some basic knowledge about its use became apparent:

  • Firstly, it must be weatherproofed. This is done simply by coating the tubes in clear polyurethane to water- and fireproof them. The additional benefit of this is that it restricts contraction and expansion in areas with high humidity, making it usable in sub-tropical climates like Brisbane.
  • Secondly, the joining of the tubes: This would have to be achieved with a strengthening component that would prevent the tubes from deflecting. Shigeru Ban's method is to use a wooden block with a cylindrical bit inserted into the tube. This cylinder would need to fit snugly, and then bolted in on multiple sides. I noticed that they weren't secured with one bolt all the way through the diameter, and this is due to this method weakening the structural integrity of the circle. Ban had previously used a hexagonal section but found the circular insertion would allow greater purchase for the parts.


Image source: http://clarewashington.files.wordpress.com/2012/12/paper-dome_cover.jpg?w=640&h=392&crop=1
Cardboard Tube Pavilion by UNSW students
Source: http://inhabitat.com/sydney-architecture-students-build-pavilion-from-2000-recycled-cardboard-tubes/cardboard-tube-pavilion-12/

  • I had also found a design by UNSW students using cardboard rolls, but their form of structural stability was in the form of sheets of ply in which the rolls sat. I think this design would be more suited for taking heavier loads, but would be ill-suited aesthetically and practically with my proposal.

  • Insulation was used inside many of Ban's projects but is not needed in mine as it is an open space. It could help to regulate the internal temperature to minimise contraction/expansion but the polyurethane should be enough considering it was used in snowy conditions as well.
  • The diameter and thickness of the tubes also was also considered. A high thickness to diameter ratio means that it would be stronger and able to transfer loads vertically without buckling. Obviously a greater diameter would allow for increased length in the rolls, and this was noted in Ban's use of the material in Paper Dome, where shorter spans for the peak of the dome were smaller in diameter compared to the longer and wider tubes used to transfer the loads down.
    In my design, the only loads the tubes would carry would be the canvas roll at the top of the sail, and the roofing structure. For this reason, I have used two rolls to span the distance connecting the work surface to the top roll: the join in between also accommodating a connection to the roofing structure. As the vertical load of the top sail canvas is distributed in two ways, the supporting tubing running up from the concrete projection would not need to be split in to smaller lengths given that it is of sufficient thickness. This said though, the tubing holding the roof would need to be significantly thicker.
     
  • The tubing also means I can run LED lights with the cabling hidden inside for a clean finish.


  • Weaving of the canvas allows for a soft lighting which I've incorporated into the roof. Tubes running perpendicular add strength and they are finished with a corrugated polycarbonate sheeting in clear green. Again, this is a reference to the sheds but also allows for light to penetrate and create a soft lighting effect as above.


For the workspaces, the use of precast concrete will achieve the desired form. I initially wanted to use environmentally friendly materials, but to get the form I wanted from using crates and pallets for instance would have been very difficult. A major lesson this taught me was that in prefabrication, it is oftentimes quicker to produce something with a higher standard of quality than it is to repurpose found objects. Because my design is essentially a workspace replicated 6 times, the precast concrete would be the easiest and quickest option, and I guess this is what readings suggested was the advantage compared to regular on-site construction. However the downside of this is the obvious cost, both financially and environmentally.

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