A SYSTEM APPROACH TO PLASTIC HOUSE DESIGN
Case Study: Green Bay, Taiwan
by
Ze-Yi Hsu
Bachelor of Science in Architecture
Cheng-Kung University, Tainan, Taiwan
June 1982
SUBMITTED TO THE DEPARTMENT OF ARCHITECTURE
IN PARTIAL FULFILMENT OF THE REQUIREMENTS OF THE DEGREE
MASTER OF SCIENCE IN ARCHITECTURE STUDIES AT THE
MASSACHUSETTS INSTITUTE OF TECHNOLOGY
June 1985
©Ze-Yi
Hsu 1985
The
author hereby grants to M.I.T.
permission to reproduce and to distribute publicly copies
of
this thesis document in whole or in part.
Signature of
the author
Ze-Yi Hsu
Department of Architecture
May 8, 1985
Certified
by
Eric Dluhosch
Associate Professor of Building Technology
Thesis Supervisior
I
/A
Accepted by
Juilan Beinart
Departmental Committee
for Graduate Students
MASSACHUSETTS
OF TECHNOLOGY
INSTITUE
tg
t
JUN 0 3 1985
L1DPARE>
A SYSTEM APPROACH TO PLASTIC HOUSE DESIGN
Case Study: Green Bay, Taiwan
BY
Ze-Yi Hsu
Submitted to the Department of Architecture on May 8, 1985
in Partial fulfillment of the requirements for the Degree of
Master of Science in Architecture Studies.
Abstract
Since
the building industry is getting more and
more
sophisticated in today's world,
many new technologies
lead
us
to many new possibilities for producing houses which
we
never
would
have thought of producing in the
past.
New
technology for a designer implies the use of new rules.
As
a designer
wants to use a new technology in
a
meaningful
way,
information which is useful to an engineer
might
not
be directly useful to an architect.
To say it clearly, two
things are important for a designer to do before he starts a
design:
1. He
must understand not only the technology
itself,
but
also
the implications of it
for
design form.
2. He
must organize the technical information
which he can use to evaluate the design.
in a way
Thus,
following
this
format,
my reason
for
choosing
plastic houses the object of this study is because there are
many new
implications and
much new design information
of
the
plastic technology for us to understand;
For
example,
plastic
houses
may be
transported
to
areas
that
are
difficult to reach by any other means of transportation than
helicopters.
This may lead to a very interesting approach
toward the relationship between technology and architectural
design.
Thesis Supervisor: Eric Dluhosch
Title: Associate Professor of Building Technology
2
ACNOWLEDGEMENTS
I wish to express my deepest appreciation to my
thesis
supervisor, Prof. Eric Dluhosch, for his advice and guidance
throughout the course of the thesis.
Thanks are also due to
Prof.
Albert
Dietz
and Prof.
Waclaw Zalewski
for
their
professional advice and guidance.
greatly
are
many people in Taiwan to whom I am
There
indebted
for
the help they provided in the
completion
of
this thesis.
I am especially grateful to Mr. James Chao of
the
China
General
Plastic
Co.,
Mr.
Sui
of
the
Tico
Development
Co.,
who provided much
valuable
information
regarding recent applications of plastic houses in Taiwan.
And
last,
to my father and mother,
for their love and
solid support during my studies abroad.
3
-----------------------
ABSTRACT
CONTENTS----------------------------
..............................................
ACKNOWLEDGEMENTS
CHAPTER 1.
1.1
CHAPTER
2
......................................
INTRODUCTION
3
...............................
Background of
the
Development of
Plastic House
....
............
6.....
Recent Trends ....
.......
1.3
Study Objective
.........
0
1.4
Approach Method
............
INVESTIGATION
OF
BU I LD ING
THE PLASTIC HOUSE
2.1
2.2
CHAPTER 3.
the
7
1.2
2.
7
9
0..
12
13
MATER IALS
.
FOR
.... 0
16
Identify the Ingre dients of Building
Materials for the Plastic House...........
16
2.1.1
2.1.2
16
20
GRP (Glass Fiber Reinforced Plastic)
Foam Plastic ......................
Identify the Physical Properties of the
Building Materials .......................
21
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
21
23
24
25
25
Mechanical Properties ..............
Thermal Conductivity ...............
Thermal Expansion and Contraction ..
Fire Resistance.....................
Durability..........................
CLASSIFICATION OF EXISTING SYSTEMS
3.1
Saddle Surfaces
3.2
Domes
.........
27
..........................
30
....................................
4
35
3.3
Synclastic Curves
........................
41
3.4
Pneumatic Structures .....................
46
3.5
Tubes ....................................
48
3.6
Rigid Frames
54
CHAPTER 4.
.............................
CLASSIFICATION OF EXISTING TECHNOLOGIES
....
58
Production Methods .......................
59
Hand Lay-Up .......................
Spray-Up ..........................
Filament Winding ..................
Inflatable Dome ...................
59
63
65
70
4.2
Erection and Transportation Methods .......
75
4.3
Subsystems
..............
77
4.4
Joints and Connections
...................
82
4.5
Reinforcement ............................
86
................
88
......................
90
..........................
91
......................
92
.................
93
Shapes ........................
94
4.1
4.1.1
4.1.2
4.1.3
4.1.4
CHAPTER 5.
(Bathroom Units)
DESIGN CONTEXT INTRODUCTION
5.1
Natural Environment
5.2
Technical
5.3
Planning Objectives
CHAPTER 6.
Level
EVALUATION OF ALTERNATIVES
6.1
Structural
6.2
Production Methods
6.3
Erection and Transportation Methods
.......................
95
96
CHAPTER 7.
BUILDING SYSTEM DESIGN
7.1
.....................
97
System Description
...................
98
7.1.1
Basic Unit
...................
98
7.1.2
Basic Components
.............
98
7.1.3
Joints .......................
99
7.1.4
Partitions
...................
99
7.1.5
Envelope Systems .............
98
7.1.6
Electrical
7.1.7
Bathrooms
7.1.8
Production and Transportation
7.1.9
Erection Process
7.1.10
Design Morphologies
Distribution
......
....................
100
100
.............
101
..........
101
CONCLUSION
............................................
BIBLIOGRAPHY
.....................................
6
100
..........
121
125
CHAPTER 1.
1.1
INTRODUCTION
Background
The
house
of
first
the Development of
real
in Germany
plastics structure was
(Fig.
1),
in 1955.
house was based upon the growth of a
that
the
house consists of
with cooking area,
lonel
Schein's
shown at the Paris Exhibition of
1956 but designed and constructed
the
the Plastic House
The concept
of
snail's shell,
so
a basic circular
living
sanitary block and warm-air
space
heater,
to
which a number of bedroom units may be attached at will.
As
the
shell
grows to accommodate the snail,
grows to accommodate the family.
for
its
time,
e.g.,
the successful
elements of clip-on heating,
above
all
features
the
a
The
reconsideration
bathroom
F ig1.
after
the
lonel
core
of the
doors,
and
were
the
house a truly worthy foundation
the Future
was designed by Hamilton and Goody,
years
house
planning was advanced
evolution of plastics in architecture.
The Monsanto House of
this
moulded sculptural
most revolutionary
which made the
so
Schein's
Fig. 2
7
(Fig.
(Ref.
2)
14,
pp. 44)
in the
and built in 1957,
house.
This
is
Fig. 3
for
U.S.A
two
still
the best known plastic structure in the world.
probably
(glass fiber
brilliantly engineered. GRP
was without doubt,
It
honeycomb
cores
cantilevered from a concrete core with windows in the
flank
plastic)
reinforced
of
each arm --
shells with multiple
a demonstration of
of
after
the Monsanto house,
3)
the first British shell
British
development section of the
(Eastern Region).
in
together
GRP
a
of
variety
mould.
ways
to
meet
The first structure was
Thameshaven Junction in Essex in
subsequently
design.
This
1961 and over
including
produced
different
pp. 50)
8
Ionel
all
on
assembled
a
at
three hundred
variations
is probably the most successful
yet to go into production since
14,
Railways
Three shells were designed which could be
of 0.3cm GRP and a 2cm core of expanded phenolic,
were
structure
these were constructed of an inner and outer skin
functions,
female
years
Two
was designed by a group working in the architects'
and
research
put
conditions.
the most difficult stress
some
(Fig.
how plastics can overcome
on
the
GRP structure
Schein's house.
(Ref.
1.2
Recent Trends
Basically, two areas are suggested for the potential
of
plastics
1.
in housing module design:
Portable
Housing
Modules
exploration industry:
The
expanding
particularly
as
oil
and
mineral
(Fig. 4)
in the areas of
personnel
for the
industrial development of Southeast Asia,
created a substantial
use
use
oil
and mineral
exploration, has
need for portable housing modules
living quarters
in
remote
for
exploration
areas, construction site offices and accommodations on offshore
production, etc.
Until
recently
conventional
mounted
on
wood
Singapore,
was
with
felt,
due
skids.
and
In 1974,
panel
Sail
of
construction,
Craft
managed fiberglass fabrication
Ltd.,
an
firm
in
it
would resolve many of the shortcomings associated
construction.
panels
4
The
use
of
fiber glass/foam
would eliminate the maintenance
to the rotting of
Fig.
plywood
units
designed a fiberglass portable module which,
wooden
sandwich
frame and
steel
American-owned
these needs have been met by
the structural
members and
Fig.
5
problems
attack
by
fiberglass
The
material.
t hereby
light,
helicopter
considerable
industrial design and would
2.
f lexib i lity in
be
extremely
to
well
fiberglass
and
structural
an attractive and modern
provide
(Ref. 22, pp.
finished a ppearance.
the
the use of
Final l y,
core
as
particularly
i tse 1f
lift operations.
per mit
would
lending
would also
unit
was
strength
foam
polyurethane
of
use
the
by
achieved
and
of rigidity
degree
high
A
termites.
3-7)
Second home:
Between
houses
houses.
the
One example
of
Inc.
Structures,
5)
marketed
an d
These
were or can be considered.
facilities,
After
trends
of
recreational
and medical
this
brief
offered as follows:
1.
Formability:
formed
into
review of
uses of
buildings,
(Ref.
the
severa l
3,
pp.
food
configurations.
10
service
1-3)
history
important
the material has no inherent shape,
its final
O'Domes
include primary homes for
and
recend
of
reasons
for plastic as a major building ma terial
be
Because
clinics.
plastic houses,
consideration
at
While promot ion has been directed
in 1971.
buildings,
pilot
the company began full-scale
the second home market, many other practical
exhibit
Tensile
by
After
Michigan.
Plymouth,
production and test marketing,
operations
(Fig.
is the O'Dome.
manufactured
are
O'Domes
for plastic
a market
there ex
for second homes,
complete
and
campers
for
market segment
it
can
must be
This makes possible
the use of efficient structural
shapes that use a minimum of
material
efficiency.
2.
for maximum structural
Strength,
Because
lightness,
of
their
plastics can be used
with a consequent
3.
toughness:
toughness
and
strength,
in thin sections,
leading
reinforced
to lightness
reduction in dead load.
Corrosion resistance:
Environments that corrode metal
or rot wood,
have no effect upon reinforced plastics.
12)
11
(Ref.
frequently
19, pp.
10-
1.3
Study Objective
The
objective
implications
technology
system
optimal
type
of
for
of
a
this
new
plastic
thesis
is
technology
houses)
(matrix house shell
(the
for
for
to
a
explore
the
manufacturing
specific
building
living) and to find
an
design process for designing this kind of house
by
incorporating the new technology productively and correctly.
To achieve the objectives listed above, the emphasis of
thesis
1.
this
is on the following three aspects:
The
implications on the form of
the house design by
using plastic as a building material.
2.
The
framework
technical
which can be used
to
information on plastics and
organize
to
the
evaluate
building system design.
3.
A building system design of a plastic house for Green
Bay, Taiwan,
is used to test the framework.
By using this approach, a prototype
design can be generated in a rational
12
industrialized house
and systematic way.
1.4
Approach Method
The
System Approach has been used as the study
seven
Basically,
different stages of
questions
addressed
be
the
in
the study and the research steps will
built around these questions.
the six
will
method.
be
These seven questions respond
chapters of my thesis, and the research steps follow
the subdivision for each chapter.
Question
1:
This question has
What is the study objective?
already been answered on the previous pages.
Question
2:
system
What
are the implications in building
design, based on the physical properties of this
material?
Step
2.1:
Identify the ingredients of
(i.e., plastic).
Step
2.2:
Identify the physical
Question
3:
the material
properties of plastics.
How
to
classify
the
system
architectural point of view?
from
the
Step
3.1:
Identify
the
classification
hyperbolic paraboloid curves.
Step
3.2:
Identify the classification criteria for domes.
For
the
purpose of this
thesis,
defined as "a process which is used
a
set
overall
of
the
criteria
System
Approach
is
in viewing a problem
as
interrelated parts which work together
objectives of the whole".
13
for
(Ref. 5,
pp. 57)
for
the
for
criteria
Step
3.3:
t-he
classification
Identify
synclastic shapes.
Step
3.4:
Identify the classification criteria for
pneumatic structure.
Step
3.5:
Identify the classification criteria for
shapes.
Step
3.6:
the classification criteria for
Identify
frame structures.
Question
4:
tube
rigid
How to classify the existing technologies
to produce existing systems?
criteria
used
for
Step
4.1:
the
classification
Identify
production methods.
Step
4.2:
Identify the classification cri teria for erection
and transportation methods.
Step
4.3:
Identify the classification criteria for
units.
bathroom
Step
4.4:
Identify the classification criteria for
methods.
jointing
Step
4.5:
classification
the
Identify
reinforcement methods.
Question
5:
criteria
Bay
the
context of Green
What
is
building system design?
5.1:
Identify the natural
Step
5.2:
Identify
context.
Step
5.3:
Identify the planning objectives of
Question
6:
for
environment of Green Bay.
Step
the
for
technical
level
of
the
design
the developer.
How to find the most approprate system for GREEN
BAY?
14
Step
6-1:
Evaluate the structural shape alternatives.
Step
6-2:
Evaluate the production method alternatives.
Step
6-3:
Evaluate the
alternati ves.
Question
7:
erection
What is the physical
evaluation?
15
and
transportation
design based on the
FOR THE
MATERIALS
OF BUILDING
INVESTIGATION
2.
CHAPTER
PLASTIC HOUSE
Identify the
2.1
for
Ingredients of Building Material
the Plastic House
be
can
GRP
materials
of
idea
(Glass Fiber Reinforced Plastic)
GRP
2.1.1
classified as one of
strength,
combination
high
to the fiber;
modulus composite.
this results
in a
of
the
in which
the
The aim
is to produce a two-phase material
primary phase, which determines stiffness and
of
particles of
high aspect ratio
(fiber),
and bonded by a weak secondary phase
is in the form
dispersed
is well
(matrix).
requirements of the fibers in a
The desirable functional
fiber
(plastic
the composite is to use the plastic flow
load
basic
The
in the fiber/matrix composite groups.
resin) to transfer the
high
important
most
the
reinforced composite are:
1. The
fiber should have a high modulus of
elasticity
in order to give efficient reinforcement.
2.
The fiber should have a high ultimate strength.
The matrix
is required to fulfil
the following
functions:
1. To
bind
surfaces
together
from
the fibers
damage
fabrication.
16
during
and
protect
handling
and
their
2.
To
transfer
stress to the fibers efficiently
adhesion and/or friction.
Thus,
the physical
(Ref. 7,
ingredients of
by
pp. 27-29)
GRP can be
classified
into the follows:
1. The plastic resin function as the matrix
part:
Plastic consists essentially of two elements,
hydrogen.
which has
The carbon possesses
the
combining
having
materials
unsatisfied
valency.
temperature
Plastics
and
from
units
under
suitable
catalytic action.
simpler units
The
is called
plastics are known as high polymers.
Although
many
the
hundreds,
groups:
are
organic
they
can be broadly
conditions
"building
of
up"
polymerization
of
and
(Fig. 7)
number of- individual
plastics
runs
classified
into
into
two
thermoplastic plastics and thermosetting plastics.
Thermoplastics consist of
are not
chain
groups of atoms
with very high molecular weights constructed from
repeating
plastics
(Fig. 6)
to satisfy any of these valencies by
with other carbon groups or other
an
simpler
ability
four valencies
carbon and
interconnected.
is
linear polymer molecules which
The chemical
extremely strong,
but the forces
between adjacent chains are weak.
carbon
valency bond along the
Because of
of
attraction
their
carbon
-CFig.
6
Fig.
17
7 Polymerization
be
may
thermoplastics
structure,
chain
unconnected
repeatedly softened and hardened by heating and cooling
respectively.
in a
Thermosetting plastics are
once, and then harden irreversibly;
liquid or plastic stage
reaction
this chemical
is known as polyaddition, polymerization or curing, and on
completion of this reaction the material
softened
cannot be
structure.
or made plastic again without change of molecular
they are
Because of their cross-linked molecular structure,
more resistant to heat, chemicals and solvents than
thermoplastics are. Among all
polyester
resins,
and epoxy are
plastics
7, pp 27-30)
manufactured
are
reinforced
the
for
industry by the rapid drawing of melting glass from
furnace continuously.
an electrically heated
to
used
glass function as the fiber part:
fibers
Glass
the commonest materials
(Ref.
as the matrix part of GRP.
2. The fiber
the thermosetting plastics
of
the glass
its fabric shape,
following three
a. Chopped
According
fiber is classified
groups:
strands
into 50 mm
continuous
are
lengths.
these fibers
strands
Due to the method of
not
chopped
dispersing
in the matrix, the distribution is
generally very uneven and consequently the
are
into the
usually
manufactured
with
laminates
this form of
reinforcement.
b.
Chopped strand mats are manufactured from chopped
strands and probably represent the most important form
1S
of
glass fiber reinforcement
strands are bonded
The glass
dimensional
together
manner with a resinous
has
laminate
resulting
for building components.
in a random, two
binder
the
and
good
exceptionally
interlaminar cohesion and impact strength.
c.
Woven rovings are used in mouldings and
produce high directional
strength characteristics.
cloth
roving
Bidirectional
laminates to
have
laminates
high
strength properties in two directions at right angles
which can be used
each other,
to
with chopped
mats to
strand
give
in
conjunction
and
bulk
extra
strength to laminates.
Of
the two major components of
composites,
glass
fiber
is
stronger than the resin matrix.
properties
upon
the
of
considerably
stiffer
The mechanical
a composite are therefore highly
content and properties of
upon the arrangement of
(Ref. 7,
glass reinforced plastics
the fibers
pp. 30-34)
19
the
and end use
dependent
reinforcement
in the matrix.
and
and
Foam Plastic
2.1.2
Rigid foams are two phase
a solid phase plastic;
formulations and this causes
increase
of
small
their original
cells.
agent
the materials
volume many times by the
Like solid plastics,
and
they share the advantages and
the
foam plastics used
polyurethane
excellent
resistance,
in the
solid
geometry and gas phase
can be varied to modify their products.
composition
foams
materials,.
limitations of the
in addition, the density, cell
construction
Among
industry,
foam is the most important one because of
low thermal
low
insitu foaming.
conductivity,
vapour
(Ref. 7,
good high
permeability and
pp. 89-94)
to
formation
rigid plastics
be thermoplastics or thermosetting plastics
all
chemical
to
to expand and
can
phase;
plastics
and utility of the foam.
produced by adding a blowing
are
They
in most cases the solid
only a minor property
represent
in
a gas dispersed
systems of
the
its
temperature
property
of
2.2
Identify the Physical Properties of
the Building
Material
By
using
plastics as
understanding
in
of some of
a
building
material,
their basic attributes is
determining whether or not to employ plastics
application.
strength,
stiffness,
resistance,
given
Among
the most
thermal
and durability.
here,
but
the
important for
response,
an
helpful
in a given
buildings
are
permeability, fire
A detailed description is not
properties
of
most
importance
in
building are briefly treated.
2.2.1
Mechanical
Properties
There are two major requirements when designing
structural
components:
1. The deformation under
prescribed functional
load must be within the
and aesthetic considerations.
2. Fracture or rupture should not take place within
their scheduled
To
satisfy
these
life time.
requirements
it is necessary
information on two particular mechanical
properties,
stiffness
and
discussion
mechanical
characteristics will
strength.
Therefore, a
to
have
namely
of
the
largely revolve around these
two properties.
The
for
strength of plastics varies from a very high
reinforced
plastics.
plastics to
low
Generally speaking,
for
some
GRP and
flexible
some unidirectional
laminates are among the strongest of most of
21
soft,
value
the commercial
materials,
Strength
especially
is
bending.
not the
Fig. 8
strength
of
on
a
same
gives
plastics.
in
strength-to-weight
tension,
approximate
Compression
basis.
compression,
ranges
and
of
bending
and
tensile
strength
usually run higher.
to
As
Fig. 9
that
laminates
wood.
even
lie well
stiffest
the
reinforced
in
find
plastics
an d
below other building materials
except for
problem for
the use of
factor presents a major
This
plastics
we can
the stiffness factor of plastic,
in construction.
There
are
basic ways
two
to
overcome
stiffnes s
the
problem.
1.
Sandwich construction:
Sandwiches are composites
different
materials
stiffness
with
insulation,
In sandwiches
stiff,
8
are
combined
give
strength
minimum weight and thickness combined
and
with
plus the necessary resistance to wear and tear.
as employed
strong,
in buildings,
two
relatively hard,
thin facings are bonded to a thick
core
of
C-,
0
0
to
layers of distinctly
me."U0-
z
in which
1 oJ
-3~
M
t
-p
0
0
0c
0
0~
U)
Fig. S
IS -
0
Z
-3
a)
0l:
0
U)
0
0
r=4
-1
Fig. 9
-3
M2
relatively
The
light, weaker,
facings
and usually
less
provide the resistance to
taking up the shear and
stiff
material.
bending,
the
stabilizing the thin facing
core
against
buckling, and the geometry of the combination providing high
overall
of
stiffness.
structure
(Ref. 7,
2.
implies a high production cost of
structures
such as domes,
strength properties of
Thus,
then derived
the
the material
the required
of which
rigidity of
the
they
are
structure is
from its shape rather than from the material.
The structural
of
is primarily a
the structure and thus depend on
function of the geometry of
of.
and folded
shells,
sytems show convincingly that stiffness
made
the material.
structure:
Surface
the
the use of this kind
pp. 68-70)
Surface
plate
Generally speaking,
shapes of
plastic may be placed under one
three following geometric forms:
a.
Folding plates
b.
Synclastic and anticlastic shells
c.
Domes
Among these three categories, folding plates are generally
used
for
large
synclastic,
span
structures
anticlastic
shells
significantly toward small
(Ref. 7,
2.2.2
or
and
roof
systems,
domes
only
contribute
house module designs.
pp. 75)
Thermal
Conductivity
Compared with metals,
plastics are
heat
insulators.
Most
solid, unmodified plastics have a
wood
but
lower than that of
Conductivity of
filled,
glass,
laminated,
depends upon the nature of the
Among
all
up
or
the density,
the
lower
concrete.
(Fig.
10)
materials,
insulator available.
the thermal
low,
than
and reinforced plastics
foams depends upon density.
the density becomes too
the
higher
of the plastics and other building
conductivity of
if
brick,
additive.
foam plastics are the best heat
lower
conductivity
Thermal
In general,
the
conductivity,
the cell
size
but
increases to
point where appreciable convection currents may be
in the cells, and conductivity rises.
2.2.3
Thermal
The
extent
of
is
building
materials.
than
pp.
120)
Expansion and Contraction
plastics
thermal
(Ref. 7,
set
thermal
appreciably
expansion
and
larger than that
(Fig.
11)
contraction
of
many
other
Reinforced plastic has
expansion coefficient close to wood but still
other building materials.
Allowances
in design
therefore be made for these dimensional changes,
of
a
higher
must
either by
z~,*4-D
CdJU
P-44
Co
(D
CCd
ILI
a,
4
r_4
M
0
Fig. 10
Z
4-
Nf)
3
Fig. 11
accommodating
folded surface
curved or
(Ref.
4,
2.2.4
them in the shape of
or by providing expansion joints.
pp. 67-68)
Fire Resistance
inherently combustible,
large volumes of
they will
decompose or burn when in
plastics may give off
nitrogen
are
in
the
present
given off during fire.
gases
To
china
also be
they will
in the plastic,
present
smoke.
the heaviest
fluorine,
constituents such as chlorine,
the
and some of
carbon monoxide and smoke,
flammable
produce
may
plastics
Besides, some
contact with fire.
least
are
plastic materials are organic in nature and
Because
If
the component by using
solve this problem,
and asbestos
clay,
retardancy
to
fillers
such as
calcium carbonate,
greater
this,
Aside from
plastics.
flame
of
impart varying degrees
fire
penetration resistance can be achieved by the use of a cheap
fire-resistant
plasterboard.
inner
such
linings
Alternatively a sandwich
with a fire resistant core material.
2.2.5
and
or
laminate can be used
pp. 72-74)
(Ref. 4,
Durability
Durability
to
asbestos
as
lack of
for plastics
information, since it
the aesthetic
important
is often difficult to assess due
for
the
property
is a relatively new material
of
performance of
quantify.
25
plastics,
which
durability,
is
is
hard
very
to
In
component may change significantly due to weathering,
plastic
and
responsible for changes
particularly
permeability
the exposed
of
the
last controls the
the
oxygen and the escape of
of
penetration
factors
humidity and
the
surface;
sunlight,
Other
degredation are temperature,
influencing
is
in appearance
component.
ultraviolet
its
significant
The most
product aesthetically unacceptable.
the
render
to
in some cases may be sufficient
this
factor
a
of
the exposed surfaces
of
appearance
general,
of
products
degradation.
and
Fillers
and durability of
appearance
surfaces of
Besides,
impact
a
have
plastics.
on
on
effect
major
The use
additives may aggravate yellowing of
retardant
decline
pigments
of
the
the
flame
exposed
the plastic.
the mechanical
especially
weathering,
strength
which
plastics may also
properties of
tensile
to
sensitive
are
strength
and
surface
deteriorations.
Two important factors upon which the durability and
weathering performance of a plastic composites
1.
The
choice of
matrix of
resins
for
the gel
the composite i.e.,
depend are:
coat and
for
the
an appropriate type of
reinforcement must be used.
2.
The provision of the
control
required
level
of
quality
to ensure a suitable production environment,
correct fabrication procedures and
for the resin.
(Ref. 4, pp. 74-75)
adequate
curing
CHAPTER 3.
In
CLASSIFICATION OF EXISTING SYSTEMS
this
chapter,
investigated
surfaces,
tubes,
and
several
classified into
synclastic curves,
rigid
theory.
frames.),
These
alternatives
category
six
systems
six categories
domes,
according to
categories will
be
carefully
principles,
orthodox
be
(Saddle
structural
be used as the
defined,
to
are
pneumatic structures,
for the system design in Chapter
will
structural
existing
Seven.
according
followed
design
by
a
Each
to
its
design
evaluation.
The
classification
criteria for
the evaluation can
be
divided into two parts:
1. From the viewpoint of their exterior shapes:
a. Whether
The
systems
the system is easy to expand vertically:
objective
to
is to check the vertical
section
of
the
see whether the units can be stacked easily
to
expand vertically.
b. Whether
The
systems
the system is easy to
objective
to
is to check
expand horizontally:
the boundary
see whether we can combine
shape
of
the units easily
the
to
expand horizontally.
c. Whether
Basically,
groups;
shape
a
the system is
the
group
structurally sound:
six categories
can be divided into
which takes advantage of
(saddle surfaces,
synclastic curves, domes,
structures) and a group which does not
The
objective
of this
the
two
structural
pneumatic
(tubes, rigid frames),
criterion is to identify these
two
groups.
2.
From the
viewpoint
of their
Having
examined
the
we
futher
viewpoint,
their
viewpoint of
of
will
shapes:
systems from
an
exterior
shape
f rom
evaluate the systems
interior shapes. The basic three
the
criteria
such an evaluat ion are the following:
rectangular
The
combine
claddi ng systems:
objective is
the
with
and
rectangular
standard doors
dome
infill
frame
rigid
be
wi 11
b.
as
to
being
to
in corpora te
with
and windows, whereas the boundary shape for a
more
wi 11
to
difficult
combine
This situation will
standard
with
lead to an increase
since non-s tandardized products
for
have to be used.
Whether the system is capab le to accommodate regular
easily:
partiti on systems
The
to
the bounda ry shape
close
normally
very easy
is
thus
system' s cost,
the clad ding
For example,
is
such
cladding
system of the
systems
cladding elemen ts.
the
the system is easy
to check whether
windows an d so on.
doors,
of
system is easy to combine with a regular
Whether the
a.
of
interior
object ive
incorpor ate
is
to
st andardized
system.
For
vertical
secti on,
elements
have
increasing the
most
of
either
check
two
by
whether it
four
system s
the
a
of
the
this
system.
into
have
ceiling
to be produced to solve
production cost
partition
which
dropped
easy
is
a
or
to
the
curved
special
problem
thus
c.
space is used efficiently:
Whether the interior
This
(1).
item can be examined from
The
or
vertical
built-in
furniture
needed,
the perimeter of the house may be
around
interior
Otherwise
curved
avoiding
by
arrangement,
furniture
the
by
may be wasted
space
cost.
production
the
increase
will
this
if a
For example,
horizontal
mold-in or
special
section,
and
curved
a
has
system
furniture.
regular
can
system
is to check whether the
objective
accommodate
two different viewpoints:
interfaces.
(2).
section of
vertical
space
is
vertical
low
too
section of
lower
always
dome
is
objective
The
the system where
for
the exterior
than that of
system.
This
For
use.
interior
the
example,
of
can
the
be
shape
solved
but
the
requires
that extra reinforcement will be
the edge of
the changed part.
29
the
is
perimeter
changing
for
a
the center part for the
problem
integrity
is
there
to check whether
by
this
needed
3.1
Saddle Surfaces
the saddle surfaces:
1. Formation of
formation of the
The
a
identical
of
family
saddle surfaces can be described as
parabolas which
in two mutually opposed directions.
Structural behaviour:
When
buckling
downward
parabolas
applied.
(Ref.
3.
of
system of
force
In
other.
downward
4. Case study:
This
fire
core.
load
is
is transferred
a
of
suspension
of
the
along
the
reinforce
the
the tensile force
rib system is
the
the
the
by
Each edge has to resist the
of one axis and
general,
(Ref.
system.
the
of
(Fig. 14)
the downward parabolas to
direction
upward
the
pp. 231-232)
the upward parabolas.
thrusting
be resisted by
to keep the shape stable when a
loading of a saddle surface
system
arch
the
surface,
strength
compressive
the
Structural considerations:
The
a
18,
saddle
the
The tensile strength of
resist
will
(Ref. 18, pp. 230)
This deflection will
upward parabolas.
parabolas
upwards.
arch
increase of the curvature of
deflection causes the
the downward parabolas.
the
and
(Fig. 13)
is applied to
load
a
inverted
is saddle-shaped. The saddle is curved
The resulting surface
2.
are
two other parabolas that
between
suspended
(Fig. 12)
parabolas
applied
to
18, pp. 232-233)
My-My system
(Fig. 17,18)
system is basically a sandwich construction with
retardant polyester resin skin and a urethane
Along the doward direction of
30
foam
the parabolas, a folded
pattern
system
is
molded
in the surface of
the rear part
of
the
to reinforce the system against bukling.
The system is produced as a completed finished box
mold-in
furniture
along
the
bathroom
the
attached to
the main
system
outside.
contains
(Ref.
a
of
related to the
Because of the difficulties
partitions,
perimeter
is
living
built as
unit.
31
system.
of
installation
a
Thus,
living unit with service
10, pp. 23-25)
the
with
separate
the
unit,
complete
units
located
I
Fig. 12
Fig. 15
Fig.
16
Fig. 13
Fig.
17.
Fig.
Fig. 14
Evaluation
18
(Exterior Shape):
Advantages:
1. Structurally sound because of
the double curvature.
(Fig.
Disadvantages:
1. The basic unit
plan
2.
is hard to exp and horizontally because the
is usually a hyperbolic
The basic unit
is hard
irregular vertical
shape.
(Fig.
15)
to exp and vertically because of its
section.
(Fig.
18)
16)
Fig.
19
Fig. 20
Fig. 21
Evaluation (Irrterior
Shape):
Advantages:
1. There is no vertical
(Fig.
section too
low for human use.
21)
Disadvantages:
1. The boundary shape has to be adjusted to accommodate
standardized cladding systems.
2. It
is hard to install
complicated
shape.
(Fig. 19)
interior partitions because of the
Service spaces,
such as toilets or
Xitchens are
always
connect with the
3.
Special
around
built-in
conceived as
living spaces.
separate
units
(Fig. 20)
or mould-in furniture has to
the perimeter of
which
be
used
the system to make the use of
interior space more efficient.
(Fig. 21)
the
Domes
3.2
1. Formation of
formati on
The
of
rotation
to
the
(Fig.
of a hemisphere.
act
like
to
and
amount
to deform will
similar,
adjacent,
line of
zone
to form a solid c ap,
the
horizontal
their
on
the
The
same
of
When continuity is
action of the shell
inwards,
thrust against
in which all
the forces are
an annular band,
individual tendencies
meridional
the
sides,
pressure.
a
The elements on the upper zone
felt.
together horizontally a nd form
restrains
has
arch
depending
strips.
the hemisphere, which ten d to sag
tied
tend to
characteristic of any number
arch-li ke
to make itself
the
Imagine a narrow strip cut
restored, however, the three -dimensional
each other
biggest
il lustrate
to
deflection
be
is
pp. 213)
sag at the cro wn and bulge at the
tendency
of
section
the
which has
This n arrow semicircular
of
semi-
a
In i solation this strip will
direction
the
23)
deviation of the arch from t he
begins
to
horizontal
use the hemisphere
an arch.
tendency
as
vertical section of a
(Ref. 18,
action of doubly curved shel ls.
out
The
the parallel
Structural behaviour:
propose
descr ibed
shape close
axis.
is call ed the equator.
diameter
We
(or a
the meridian,
par allel,
the
called
2.
a semi-circle
called
is
(Fig. 22)
the domes can be
of
around a vertical
circle)
dome
the domes:
stresses
stresses tensile.
35
are
(Ref.
to
bulge.
compressive
18, pp. 214-215)
In
and
which
this
the
3.
resistance can be
buckling
The
seldom used since ribs will
is
A
to increase
parallels
along
the
resist
the thrusting force.
4.
O'Dome
Case study:
triangular panel
(Fig. 25,
of fiberglass
In erection,
core.
(Ref.
interior space.
the
to
strength
the annular
18, pp.
part
upper
in the
215)
26)
prefabricated component of the
basic
The
disturb
ring is usually used
compression
ribs
adding
raised by
the meridians and parallels. This method
the direction of
along
(Fig. 24)
considerations:
Structural
skin and a cellular
a
is
O'Dome
urethane
these panels, plus 6 other major
18 of
components, are assembled, interlocked, and cabled together,
structure
with
height of
2.85m.
a
form
to
down
bolted
then
and
a 0.8 kg
into
it
The
through
and
the panel
base of
which it
dome
ellipsoid
an
interior
density urethane foam
fire retardent polyester bonded
sandwiched by skins of
fiberglass.
super
7.5m diameter base
The basic panel contains
core
a
has a steel
is bolted to a
molded
bar
wooden
deck
or
a concrete slab'.
The
panels come out of production flat and are
that way to the building site.
into
at
and
their final
the top,
curved
Onsite
shape, connected
the panels are
bent
to an aluminum ring
interlocked at their tongued and grooved edges,
further secured by a tensioned aircraft cable
through the panel
The
shipped
threaded
cores.
assembled O'Dome
provides about 53
36
square meter of
unobstructed
interior
addition to the wall
space.
panels,
Six other
components,
provide for a doorway, sliding
glass
door, and a skylight with acrylic glazing.
(Ref.
12,
pp. 45-47)
37
in
Evaluation
(Exterior Shape):
Advantages:
1.
The basic
unit
is
structurally
sound because of
the double
curve.
Disadvantages:
1. The basic unit
is hard to expand horizontally.
(Fig.
25,
Fig. 27)
2.
The basic unit
is
hard to expand vertically.
(Fig.
26,
28)
00C
Fig.
0)00)
29
Fig. 30
CC
U
Fig.
31
Fig.
32
Evaluation
(Interior Shape):
Disadvantages:
1.
It
is
the
with
either
cladding
2.
It
is
to incorporate standardized
hard
boundary shape.
disturbing
the
elements.
hard
to
cladding
elements
The problem can be solved
curved
form
or
using
by
special
(Fig. 29)
incorporate
standardized
two
by
four
partition elements
3.
It
into the system.
(Fig. 30)
is difficult to accommodate regular furniture
the system's perimeter
There are two solutions
.
along
to this
problem:
The
a.
is
shape
Built-in
or
mold-in furniture can be
perimeter part of
4.
There is
part
of
solutions
regular
accommodate
to
(Fig. 31)
furnitures.
b.
adjusted
the system.
used
in
the
(Fig. 31)
inefficient interior space near the perimeter
the
system
too low to
to this problem:
The shape has to be adjusted to make
b.
An elliptical
in section
ceiling height.
40
are
two
(Fig. 32)
a.
shape
There
use.
the space usable.
is used
to
increase
the
Synclastic Curves
3. 3
1. Formation of
Synclastic
The formation of the
curve perpendi cu lar to
2.
The
of
form
the
(Ref. 18,
it.
Structural be haviour:
the cylindrical
curved
in
both the
wi th
stiffness
result
the
the
pp. 220)
is
The
shape.
longtitudinal
a
shell of
shallow
and parallel directions.
3.
edge
of this
thrusting force of
the
Compression
curve to
(Ref.
4.
(Re f.
Structural considerations:
The
strength alon g
dome with compressiv e
rings
pp.
Case study:
Viewed
is
natural
edge
the
structural
to
is close
its
a
meridian
pp. 221)
(Fig. 35)
shape has to be reinf orced
to
resist
the ar
can be used
increase the annular
18,
18,
to
T he
pa rt of the shell
a
transverse
and
loading being transferr ed
center
the
of
as
surface
increased
arch from the arch system alo ng both axes.
behaviour
downard
synclastic shape can be regarded
of
directions,
semi-
(Fig. 34)
transformation
twice,
or
to these) along another
close
sh apes
or
circles,
synclastic curve
(parabolas
discr ib ed as a downard curve
be
the
of
category
the
to
belong
curves
translational st ell.
can
(Fig. 33)
synclastic curves:
the
in the upper p art
strength of the
of
the
sha pe.
223)
Poly-Pod System
from the top,
with
sides of equal
sits
on a
central
(Fig. 38, 39)
the pod is
length and
cylindrical
LL1
tri-angular
rounded corners.
base connected to
in
shape
Each
the
pod
ground
and
through which the utilities
Each
assembled
into
a
variety of room
length of
varying the
shapes of
triangular
the
of
enter.
the
shapes
may
be
sizes;
by
pods
and
the support column they can be adapted
to many surface typographies.
As more pods are added together,
The smallest unit is composed of three pods with
and rigid.
the
columns
stability
become
they become more stable
in a tripod placement providing
The total dwelling
in any direction.
like a
good
lateral
unit
can
adding elements and subtracting
living thing,
them as the demand dictates.
42
(Ref. 21,
pp. 5-9)
Evaluation (Exterior Shape):
Advantages:
1. The basic unit
is easy
to expand horizontally.
2.
The basic unit
is easy
to expand vertically.
3.
The basic unit is
curvature.
(Fig. 37)
structurally sound because of
(Fig. 39)
43
(Fig. 36)
the double
Fig. 40
Fig.
41
Fig.
42
Evaluation (Interior Shape):
Advantages:
1. The boundary shape is very easy to adjust to accommodate
standardised cladding elements. (Fig. 40)
2. Built-in furniture is not necessary.
(Fig. 42)
3. There
is
no inefficient space in the
where
is
too
vertical
(Fig. 42)
low to use,
section
since the
vertical
section
curvature
can be controlled to a
moderate
of
the
degree.
Disadvantages:
1. The system
partition
is hard to
elements.
combine with standard two by
Either a dropped ceiling or
ceiling elements have to be used.
45
(Fig. 41)
four
special
3.4
Pneumatic Structures
1. Formation of pneumatic structures:
Pneumatic
shapes
of
structure
the
are
membrane
one of
structure
the
most
important
A
pneumatic
group.
is formed when a membrane has been filled with air
in order to
support exterior pressure.
2. Structural
The
structures
(Fig. 43)
behaviour:
loading of the
(Ref. 13,
pp. 5)
(Fig. 44)
structure
is resisted by the
interior
air pressure and the- membrane stress caused by this pressure
has
of
a positive relationship with the diameter of
the structure.
3. Structural
A cable is
(Ref. 13,
considerations:
curvature
pp. 6)
(Fig. 45)
generally used
to change the structure
into a
form with smaller curvature to decrease the membrane stress.
(Ref.
4.
13,
pp.
7)
Case study: Xanadu System
The
basis
spraying
large
of construction of the Xanadu system
of polyurethane
hemispheric
balloons
(Fig. 48, 49)
foam
insulation on the
balloons.
are removed,
Doors and windows are
The
then formed
dome has no
inside
of
cures,
of solid
the
insulation.
into place.
to construct;
super structure.
paint.
coating product.
The sphere
to the elements.
sun which could damage the
sunscreen
foam
the
plumbing
and
wires are sprayed into place during construction.
strong and resistant
the
the
leaving a shell
Xanadu took about six weeks
electrical
After
is
The
interior
(Ref. 26,
pp.
shape
Ultraviolet
is
very
rays from
foam are blocked out with
is protected with
10-11)
a
a
fire-
The significance of
system
design
this kind of
is
mainly
a
structure on building
result
of
its
production
method.
Thus,
discussed
in the production method part of chapter 4.
the
comments
47
for
this
part
will
be
3. 5
Tubes
1. Formation of the
The
formation
translation
of
2.
Structural
The
of
a
perpendicular to
the tubes
it.
is
(Ref.
p p.
18,
line
s traight
a
shell
from
the
c yl Inder,
the
be understood by imagining
can
In the direction of
like small
to points A an d B.
loads
the
(Fig. 51 )
the flat elements between f olds act
transferring the
as
225)
replaced with a folded plate.
span
descr ibed
along
a shape derive d
action of a cylindrical
it
can be
enclosed curv e
behaviour:
tube
(Fig. 50)
tubes:
the
beams,
(Fig. 51)However
they are capable of
since they are continuous at the
fold s,
resisting
they mutually restrain each
other's
shear.
tendency to deform and t hus
capacity of the
3.
Structural
The
shape
transverse
these
Accordingly,
structure as a wh ole.
considerations:
of
the
and
transmitting shear.
4.
Case study:
equal
thickness
The materials for
panels
polyurethane
must
shell
pp.
be
means
GRP
capable
of
228)
skins of 0.3
thickness of 15
to
(Fig. 54)
foam core,
reinforced
0.6cm plate
0.35cm
it
and
a
to 23cm.
the endwalls consist of
with
of
between
is a monocoque sandwich structure.
polyurethane foam with a
sandwich
the
Filament Winding Housing System
The system shell
has
preserved by
The connection
18,
pp. 227)
(Ref. 18,
each end.
(Ref.
carrying
52)
structure is
stiffeners at
stiffeners
(Fig.
the
increase
plastic
glass,
2.54cm
skins
and
thick
and
a
aluminum
operating
sash
end exterior doors.
These components
are
attached to the
shell
gasket,
is both mechanically fastened and bonded
which
by using a structural
neoprene
zipper
to
the shell.
The reinforced vinyl-faced gypsum wallboard
as
the
interior partition material
shell
with
a
floor
flat,
light
integral
open steel
on-site
factory.
gasket.
To keep the
supported on a
reinforced plastic units
heating,
for the housing unit is
assembly, and all
system is
the
frame.
complete with wiring,
Piping
zipper
with the system.
a 1.6cm plywood floor
The bathrooms are molded
are
which is attached to
mechanically fastened butyl
Doors and frames are
is selected
internal
Site
bottom part of the shell.
to be
and internal
located
in
which
plumbing.
the
floor
connections are to be made
in the
connections are made
(Ref.
49
16,
pp.
12-15)
through
the
Evaluation
If
(Exterior Shape):
the vertical
section in the
long axis
is close to a
rectangular shape:
Advantages:
1. The system
is easy to expand horizontally.
2.
is easy to expand vertically.
The system
(Fig. 53)
(Fig. 54))
Disadvantages:
1.
The
system does not have the
double curved shape.
50
structural
advantage of
a
If the
vertical
section
in the
long axis
is close
to a circular
shape:
Advantages:
1.
The system
axis.
is easy to expand horizontally along its
long
(Fig. 55)
Disadvantages:
1. The system is hard to expand vertically.
2.
The
system does not have the structural
double curved shape.
51
(Fig. 56)
advantage of
a
Evaluation
If
(Interior Shape):
the vertical
close
section in the
to a rectangular
long axis of
the system
is
shape:
Advantages:
1. The boundary shape can easily accommodate standardized
cladding elements.
(Fig. 58)
2.
Built-in or mould-in furniture
3.
There
is no inefficient
is not needed.
interior
space
in the
(Fig. 61)
system.
(Fig. 63)
Disadvantages:
1. The
system
does
not
partition elements.
If
accomodate
Special
easily
ceiling and
are needed.
(Fig. 59)
the vertical
section of the system
standardized
floor
elements
is close to a circle:
Disadvantages:
1. There
is
inefficient
section where
2.
It
is hard
along
3.
It
in
is too
interior
low to use.
to incorporate
the boundary shape.
is hard
the
space
in
the
vertical
(Fig. 62)
stanardized cladding elements
(Fig. 57)
to incorporate standardized partition elements
system.
Special
ceiling and floor
elements
are
needed.
4.
Built-in
or
perimeter
of the system.
mold-in
furniture is
(Fig. 60)
needed
along
the
3.6
1.
Rigid Frames
Formation of
The
most
the rigid frames:
simple
structure system where
post.
and
lintel,
18,
the total
pp.
When a
rigid
system
behaviour:
vertical
connection
deflection
is
post
and
lintel
simply supported
is called a
by the
the
post
rigid frame system.
(Fig. 65)
load is applied, the
forces
the post to
lintel
move
is resisted by the horizontal
sags and the
outward.
This
thrusting force of
post base which forces the post bottom to move back
its original
lintel
(Ref.
3.
lintel
is a
139-141)
Structural
the
the
system
When rigid connections are used to connect
(Ref.
2.
frame
(Fig. 64)
position.
bend
18,
142-143)
Structural
resist
the
and a bending moment occurs.
pp.
Ties
At this time, both the post and
to
considerations:
are
(Fig. 66)
usually used to connect
the thrusting force,
the post
which causes the
bottoms
to
post bottom to
move outward.
4.
Case study: Sprayed Plastics Housing Units
The
monocoque
construction was spray fabricated
female mould using chopped
fiber strands,
and a urethane foam core.
The system
system along
The
plaster
encased
its
longitudinal
was
wallboard
fastened to steel
the
a
facings
is reinforced by a rib
conventionally
finished
studs,
inner sandwich surface.
54
polyester
in
direction.
interior
to
(Fig. 67)
(Ref.
with
1.3cm
which were foam
17,
pp. 23)
Evaluation
(Exterior Shape):
Advantages:
1. The basic unit
2.
The basic unit
is easy to expand horizontally.
is easy to expand vertically.
(Fig. 67)
(Fig. 68)
Disadvantages:
1. Structurally, this
because
it
does
is a very bad example of using plastic
not take advantage
construction
has
of
the
to
be
shape.
Sandwich
increases
the material's cost radically.
structural
used
which
partition
Fig.
71
Fig.
T1
Advantages:
1.
(Interior
The system
There
standardized boundary
(Fig. 71)
easily combines with standardized two by
partition elements.
3.
Fig. 74
Shape)
The system easily accommodates
elements.
2.
73
T=.Fig.
72
is
four
(Fig. 72)
no need for built-in or mould-in
furnitu re.
(Fig. 73)
4.
There
is n 0
the system
inefficient space
(Fig. 74)
in the vertical
section of
Other Possibilities:
This
is a
system usually used for
large span structures.
Fig. 75
A
structure of
this kind of
system is a space grid
by other
plastic
kinds of
made
material,
is only used as
the
1cladding.
Fig. 76
The structure of
this system
is a wooden frame.
Plastic
is only used as cladding
which does not resist
major
loads.
Fig. 77
Note:
Structurally, these are not reasonable
plastic house design.
57
solutions for
CHAPTER 4.
CLASSIFICATION OF EXISTING TECHNOLOGIES
This
to
chapter will
produce
and erect plastic houses into
(production
methods,
subsystems,
joints,
include
classify existing technologies
both
implications
system design.
categories
erection and transportation
reinforcement).
critical
or
five
problems of
influences of
The
methods,
discussion
the technology
these problems
used
on
and
will
the
building
Production Methods
4.1
Hand Lay-Up Method
4.1.1
1. Production method:
be
is used,
this technique only one mould
In
either male or female,
A suitable
generally made of GRP.
this
and from
78),
(Fig.
is prepared
pattern
master
and this may
GRP
moulds may readily be made.
then allowed to dry before
agent is applied to the moul
resin rich area,
is applied to the
called gel
ty of
also determines the surface
After
of
coat
glass
the gel
the product.
tacky but firm,
coat has b
it
is brushed
resin
an d the first
posi tion and
reinforcement is plac
with brush and roller.(Fig. 79)
The
Subsequent
precut to the correct size.
reinfo
rcement
the composi te is reached.
2.
Critical
technical
liberal
of
la yer
conso 1 idated
fabric,
layers
of
in
wh ich
is
re sin and
the required th ickness
are then appl ied until
of
a
glass fiber ma y be
form of chopped strand mat or woven
the
mould.
surf ace of the prod uct and
is used to protec
layer
This
1ayer of
operation, a
this
is undertaken.
lay-up
any
release
a
components,
the GRP
bonding of
prevent
To
(Ref. 7,
pp. 25-27)
points:
a. Curing shrinkage:
A
and
GRP may shrink by 0.1 to 0.4 percent
since
pattern and
there
are two moulding
processes
the finished product, the net
59
during
curing,
between
the
shrinkage may be
as
much as 0.8 percent.
from
on
The manufacturer
experience how much to allow for
the shape of
the unit,
gradually
shrinkage,
the resin,
and
the
learns
depending
temperature
change expected.
b.
Demolding:
Although
moulds
it is clearly desirable to design
it is
sections
for
simple
possible to develop "split moulds" with movable
to
achieve return angles
for the
convenience
of
demolding.
c. Mould width:
If
the
up
the mould
fabricator cannot get to all
an even coating of
The
the mould
parts of
theoretically
For
to
be
easily,
inf in ite,
d. Gel
coat o perati on:
Great
care
an
The
gel-coat is
if
while at
say 2m width.
but
is
and
even
too
rolling
out.
limited to 4 or 6
meter
for
transportation.
tilted to allow
the
(Fig. 80)
s kill
i s needed
s hould
in this
operation
to
bubbles
or
be carefully controlled:
thin it will
impact resistance
reach
could
coat ing wi thout trapping air
thick ness
the
Length
moulds may be
the coating is too thick
reduced
to lay-
han dl ing on site and size
fabricator easier acces s.
dirt.
the areas in order
is one where the operator can
more complex shapes ,
produce
shape,
glass-fiber and resin,
panel width
ideal
subject
in
ensurin g good compaction and ease of
same time
all
is too large or too complicated
if the
not give enough protectio n; but
,
crazing, cracking, as w ell
in use
60
,
is
likely
to occur.
as
e.
Catalyst control:
Manufacturers
catalyst used:
must
also
control
excessive catalyst will
chemical
(the
resulting
in cracking and crazing;
will
and
produce insufficient curing.
low
workshop
temperatures
laminates which perform badly.
61
while
heat)
off
inadequate catalyst
Cutting catalyst
will
the
cause the mixture to
reaction produced gives
overheat
of
the quantity
produce
levels,
inferior
(Ref. 25, pp. 509-517)
oller
mould
Fig.
Fig. 79
Fig. 78
80
Tools and Equipment:
Implications:
1. Master pattern mold (ususal
-ly made by wood).(Fig. 78)
1.
Labour intensive
production method.
2.
Slow production rate.
3.
Limitation on the
2.
Brush and roller.(Fig. 79)
Critical Technical
1. Mould width
Problems:
(workability).
2.
Gel coat operation
control).
3.
Curing
4.
Additives
control.
5.
Ghost effects
control).
(thickness
4.
Quality control is based
on experienced workers.
shrinkage control.
and catalyst
(appearance
Advantages:
1. Low capital
2.
Freedom of
investment.
the product
shape.
disadvantages:
1. Quality control
2.
product
size.
(Fig. 80)
is
based on skilled
Slow production rate.
62
labour.
4.1.2. Spray-Up
Method
1. Production method:
roving
fiber
is fed continuously through a chopping
unit,
resin matrix
fiber
operator
glass
(Fig.
to control
the thickness of the
and
composite
glass/resin ratio.
pp. 28-29)
(Ref. 7,
Critical
technical
points:
Thickness control:
The technique requires greater skill
up
The
is then consolidated with rollers.
to maintain a consistent
a.
the
to
technique requires considerable skill on the part of
82) The
2.
81)
in conjunct-ion with a resin jet.(Fig.
mould
the
glass
spray-up
resulting chopped strands are projected on
the
and
intensive than the
labour
operation,
During the
lay-up method.
hand
less
spray-up technique is
The
method
thickness
on
of
the
the
part of
the
than the hand
operator
control
to
composite and to maintain
lay-
a
the
consistent
glass/resin ratio.
b.
Other
method.
considerations are the same as
(Ref. 25,
63
pp. 702-704)
in the
hand
lay-up
Fig. 83
Fig. 82
Fig. 81
-----------------------------------------------------------Equipment
and Tools:
1.
Spraying gun.(Fig.
2.
Same as hand
Critical
Implications:
81)
1.
lay-up method.
2.
Technical
Labour intensive
production method.
Slow production rate.
(faster than hand lay-up)
Problems:
1.
Thickness control. (more
critical
than in hand layup method)
3.
Experienced
needed.
2.
The same as
method-
4.
Limitation on the size
of the components.
in
hand
lay-up
workers
are
----------------------------------------------------
Advantages:
1.
Low capital
2.
Freedom
investment.
of product shape.
Disadvantages:
1.
Quality is
2.
Can not
3.
Limitation
more
satisfy
difficult
mass
to control
than
markets.
on product size.
64
(Fig.
83)
in
hand
lay-up method.
4.1.3
Filament Winding
1. Production method:
First,
joining
the
steel
mandrel
together the vertical
is assembled
Then,
rotating
hoop
the
bearing
its
four sides.
wraps are applied around the
mandrel
on a turntable
and using a sending
which advances
the field
by
plates which are hinged at the
corners and at the center of each of
84)
in
(Fig.
mandrel
supported
by
an
by
air
tower with an elevator carriage
the roving up and down the mandrel.
(Fig. 85)
Second,
oriented
preassembled core sections with
glass-filament
against
the
outher
inner
shell
Third,
to
a
with
skins are applied to
hoop wrap.
the
Following this,
hoop wraps are wound around
attached to the mandrel.
longitudinally
the core
lamps
located around the shell
and
from the
filament-wound tube by using jackscrews
side section of
expanded
winding
(Ref.
sections
is
moved
are
cured
inside
the
(Fig. 87)
Finally, when curing is complete, the mandrel
each
final
(Fig. 86)
curing area where the composite materials
mandrel.
the
the complete structure with the mandrel
heat
mandrel
to
its
table ready
16,
pp.
12)
the mandrel.
winding position,
The mandrel
and
is
to
removed
retract
is cleaned,
returned
to start spinning the next unit.
to
the
2.
Critical
a.
technical
points:
Demolding:
In the production of
structures,
tension
the
typical
mandrel
inside
is usually restrained by
the finished shell
destroyed to be removed.
designed
large-scale filament wound
and
filament
therefore
must
be
To solve this problem, a specially
mandrel with flexible extending
jackscrews has
to
be produced which increases the production costs.
b.
Corner
A
structural
indicates
corners
and
stiffness:
analysis
of the
of the tube to provide for
bending
stress at these
the
difficulty
is to provide for
Aerojet-General
Research
the
construction
(one of
Project of
16,
pp.
inner
involves
shell
system
a possible need for greater stiffness at the four
complicates
Ref.
proposed
transfer of
points.
This
process.
between the
most
the winding of the
the sponsors of
serious
inner
the Plastic
the University of Michigan,
helical-wound
skin.
Housing
1968,
5) has already developed a process
insertion of a
shear
consideration
The
and outer skins together at the
the
high
see
for tying
corners,
which
filament
coil
two skins.
c. The winding force:
During the production process of filament wound housing,
a problem was discovered which is characteristic of
winding
operations
Depending
mandrel
on
added
as
filament's
applied
tension,
to
rectangular
66
sections.
each revolution
approximately 10 kg/cm of
force,
filament
of
the
compressing
the
mandrel
certain
amount
filaments
it to
and threatening
of
conform
deform.
tension is necessary to insure that
to the
rectangular
sections
cylindrical
surfaces.
mandrel
require
Thus,
surface.
greater
slightly
16, pp. 23-27)
In
a
the
general,
than
do
curved corners
are
tension
required when rectangular sections are used.
(Ref.
Furthermore,
I)
Fig. 85
Fig. 84
Fig.
Fig. 86
Tools
and Equipment:
87
Implications:
1.
Steel mandrel (includes
extended jackscrew ).
(Fig. 84)
1. High capital
2.
Winding
2.
High production rate.
3.
Elevator carriage.(Fig. 86)
4.
Curing area with heat
(Fig. 87)
3.
Excellent quality control.
4.
A convex tube-like form
is preferred.
5.
Sophisticated industrial
capacity is needed.
Critical
tower.(Fig. 85)
technical
lamps.
problems:
1. The mandrel has to maintain
sufficient filament tension.
2.
The mandrel
investment.
has to be reused .
Advantages:
1. Good quality control.
2.
High production rate.
Disadvantages:
1. High capital
investment.
2.
Limitation on the product shape.
3.
High-tech environment is needed.
69
4.1.4
Inflatable Dome
1. Production method:
First, the ground
levelled and a shallow trench about
is
rods and
Then,
10cm deep for the foundation is prepared.
segments for anchorage to stabilize the pneumatic form
steel
are assembled.
Second,
(Fig. 94)
the
and connected with a pump and control
then inflated.
The form
system.
fiberglass
Subsequently,
88)
(Fig.
rods
steel
pneumatic form is fixed on the
is
forms
for openings and electric installations are affixed.
a inner
Third,
connection
their
Following this,
Fourth,
the
foam is applied. Then cables and
layer of
insulation
a thermal
outer
are
circuits
to the
layer of
foam
layer
89)
(Fig.
made.
is cast.
sun
is applied and a
foam may be applied.
screen paint to protect the
Finally, the pneumatic form is deflated and the anchoring
are unscrewed.
segments
applied
2.
the
interior finishing
is
in a conventional manner.
Critical
technical
(Ref.
Deformation caused by
A
drastic change in the shape of
on
part is
the
pp. 31)
loading:
a.
sprayed
6,
points:
caused by the weight of
will
form is then removed from
this,
After
structure.
completed
The
the
foam.
lower part of
loaded with the foam,
the pneumatic form
For example,
the form and then
swelling,
which
increases the diameter of the
70
if foam is
the
the upper portion of
sink, causing a swelling to appear below.
is
upper
the form
This
lower part of
the form, may cause the concrete to crack and collapse.
also
as
to be of high quality and strength to resist
stress.
The
in
proportional
relationship between the
temperature;
that
of
also a rise
the
Deformat ion
inter
ior pressure, and vice versa.
caused
pressure,
pressure
cooling,
a
the
enough
air
press ure droF s,
can
be
pressure control
maintaine d
systems,
until
released
if,
more air
at
a
is pumped
required
constant
The full
weight of
acts at the bottom of
the
desi red
the
because of
leakage or
into
level.
level.
the
T hus
Air
currently available, are designed
for heavy work-load, but their sensitivity
c. Li fting force:
increasing
thereby
up,
simi la rly,
be
If the
in the form as required.
is
is
valve which increases or
form to b ui ld up the pressur e to its
pressure
may
changes
temperature
by
heat s
fo rm
is reached;
t he
temperature there
with a rise of
decreases t he amount of air
in
interior pressure and
is,
avoided by u sing a security control
with
direct
a
exists
be
inflated
When the
there
stable,
is
will
form
pneumatic
the
temperature changes.
form
the
of
shape
and
size
affected by normal
air
(Fig. 90)
Deformation caused by temperature:
b.
air
membrane used
the
increases the membrane stress. Thus,
the form has
this
pressure
interior air
But increasing
interior air pressure.
increasing
by
diminish
the swelling will
of
size
The
is
low.
(Fig. 91)
the interior
pressure of the envelope
the form, creating a
71
lifting force
which tends to uproot the rim of
to
force
This
foundation.
the
of a conventional
counter-weight
the form from its anchorage
is much
than
greater
the
therefore,
foundation and
the foundation may be pulled away from the ground.
problem can be
This
system of steel
a
system
wheel
bicycle
forces,
of
pressure
(Fig. 94)
radially like
arranged
and which are
therefore, are
a
the spokes of
raised above the
ground.
The
thus transferred to a circumferential
ring which may be of
(Ref. 6,
a
form by
the bottom of the form rests on
i.e.,
rods,
rods,
solved by supporting the
pp. 24-29)
72
lighly reinforced
concrete.
Fig.
Fig. 88
Fig.
Fig.
89
Fig.
Fig. 92
91
Tools and Equipment:
Implications:
1. Spraying
1.
gun and air pumps
2.
Pressure control
3.
Support system for the bottom
of the ballon formwork
(Fig. 93)
4.
Anchoring system (Fig. 92)
Critical
Low capital
Technical Problems
2.
Lifting force on the form
due to the air pressure.
3.
Thickness control.
:
3.
Experienced workers or
equipment may be hard
to find since the
technology is relatively
new.
1. No production stage in the factory at all.
insulation.
intensive.
2. Equipment may be expensive
since the technology is
new.
Advantages:
Good
93
system
1. Deformation of the formwork
due to temperature changes.
2.
90
Disadvantages:
1. New technology, high risk of construction
74
failure.
4.2
Erection and Transportation Methods
Fig. 94
Fig.
95
Fig.
Advantages:
Method
1:
On site erection (inflatable form)
2.
No production time in
factory is needed.
3.
No need for
1.
2.
the
transportation.
2:
The
system
(Fig. 95)
97
Easy to transport.
The system
(Fig. 94)
1.
Influenced by the
Weather.
2.
Skilled
find.
3.
Low erection rate.
is erected and
Transportation and erection
of the components can be
operated manually.
Method 3:
(Fig. 96)
Fig.
Disadvantages:
1. Cheap formwork.
Method
panels
96
labour
transported
1. Joints has
on site.
2.
is
as
hard to
flat
to be provided
If the system is a double
curved form, special
equipment is needed
to bend the panels.
is erected and transported as curved panel
1. The components can be erected
and transported manually.
1. Hard to transport
critical).
(not
2.
Joints have to be
provided on site.
Method 4: The system is erected and transported as a box
(Fig. 97)
1.
Increasing erection rate.
1. Expensive erection
equipments are needed.
2.
Quality control
than above.
2.
is better
76
Hard to transport.
4.3
Subsystems:
(Bathroom Units)
Bathroom units used for the plastic house can be divided
into the following six
1.
groups:
comp on en ts:
Individual
(Fig.
show er ,d toilet,
The tub,
98)
and sink are manufactured as
discrete products an d attached to built-up walls and floors.
Coordinating these a ctivities with each other and with overa ll
building schedule
2.
re quires very careful
Combined compon en ts:
coordination.
(Fig. 99)
The combined-c om ponent approach joins elements which are
related
by
funct io n
t0 achieve visual
installation and
Typically,
molded
water
these
e lements
inlet spout,
toil et
walls
to
plumbing
integration of the space.
countertop,
back
sinks
splash,
and
water tank integrated
enclosures:
into
the vanity.
(Fig. 100)
enclosur es are formed by adding factory-produced
the
completely
simplify
shower and bathtub combinations, as well
Components with p artial
Partial
to
include single and double
in one piec e with the
as vanity and
3.
or proximity physically
tub/ shower to create an
waterpro of
and
has few
enclosure
seal
joints.
that
is
Often,
runs can b e surface-mounted and hidden by the
GRP
wa lls.
4.
Lower
half enclosure:
Since practically all
occur below
tub,
the Im
floor, and
(Fig.
101)
the wet activities
level
side wal ls
in the bathroom
designs that mold sink,
toilet,
in one piece are also available.
77
5.
Total
enclosure:
With the
of
(Fig.
total-enclosure concept,
completing a room.
at
102)
In the first,
there are two methods
the unit
is assembled
the point of manufacture and shipped as a fully packaged
box,
from
which is plugged into
the outside.
the box.
large
the unit
which are moved
space and assembled on-site.
through
standard
around
Construction may then continue
In the second,
parts,
the basic structure and hooked up
door widths,
into the designated
bathroom
If the parts are sized to fit
they can
required by the building sequence.
78
is molded as a number of
be
(Ref. 9,
installed
pp. 4-9)
as
Fig.
981
Fig.
99
Fig.
100
Fig.
101
Fig. 102
Advantages:
Individual
Disadvantages:
Components:
(Fig. 98)
1.
Style and color variation
permitted by volume market.
1. Multiple on-site joints t hat
may leak and trap dirt.
2.
Relative ease of
manufacturing.
2.
Need for several trades t 0
complete an installation.
3.
Small size for easy shipping
and handling.
3.
Susceptibility to handlin g
damage and pilferage.
Combined Components:
(Fig. 99)
1. Fewer detailed parts for
simplified installation and
manufacturing.
1. Requirement for some crit ical
on-site jointing.
2.
Fewer on-site joints.
2. Need for several
trades.
3.
Visual integration of
function.
Partial
Enclosures:
related
3.
construc tion
Susceptibility to handling
damage and pilferage.
(Fig. 100)
1. Elimination of many on-site
joints.
.
1. Handling and shipping
problems due to large size of
pieces.
2.
Fewer building trades
required.
2.
3.
Factory finishes used in
high-moisture areas.
3. Need for close dimensional
control of rough carpentry.
Lower-Half Enclosures:
(Fig.
Susceptibility to damage by
remaining trades during
construction.
101)
1. Elimination of almost all
joints in wet area.
1. Susceptibility to damage
during remaining finishing.
2.
2. Shipping and handling
Factory finishes in all wet
problems due to large size.
areas other than upper half of
shower.
3.
Minimized pilferage
to large size.
loss due
80
3.
Need for close dimensional
control of rough carpentry.
Total
enclosures:
(Fig. 102)
1. Factory assembling and
engineering of all joints.
1. Difficulty in varying
standardized design style,
color, and materials.
2.
Factory finishes on all
surfaces.
2.
Shipping and handling
problems due to large shell
sizes.
3.
No on-site trades required
to work within the shell.
3.
Higher material
81
unit cost.
4.4
Joints and Connections
1. Open-drained
These
joints:
joints
were
concrete,
and work
in
in the edges
grooves
at
the
back
(Fig.
103)
developed
on
for
use
with
precast
the basis of a baffle strip
of the panel
with an airseal
They may be
of the panel.
used
located
located
with
GRP,
subject to a few important factors:
a.
Control
b. Control
form of
of
the panel
edge.
detailed profiling including rounding of
of
corners:
to be jointed must be
Profiling of each panel
rather than around a profiled timber
mould,
2.
Preformed strips:
The
formed against a
insertion.
(Fig. 104)
can be simplified
open-drained joints
preformed strip joints.
into straight
The most frequent problem with GRP
is the tendency for
the seal
joint
time.
is sometimes aggravated by the
in
slight
taper
This problem
on the edge (for demoulding) and
glossy surface caused by the residual
preformed
Sealants:
Detailing
with
a
requires
by
release agent.
strip joints are generally used only when
are made by bolting through
3.
to slide out
the
cladding
a
very
Thus,
fixings
the flange.
(Fig. 105)
of
panel
gun-applied
a
of
high
edges
mastic
quality
is simplest with joints sealed
or
sealant
sealant
and.
but
this
method
careful
joint
preparation.
A
single seal
should not be relied upon as a primary
82
where the consequence of
seal
joint
result
in
seals
water
penetration
consist
can
of
into
a second
could
sealant failure
the
line
Ba ck-up
building.
of
or
sealant,
a
preformed strip, with a drained space between.
4.
Gasket:
When
(window
(Fig. 106)
panels
are
to be
sealed
together
frames etc) are to be fitted into
may be used.
The
or
panels,
fit tings
ga skets
important aspects affecting the produ ction
of GRP panels are:
The flange on the GRP must be thickened to the
a.
size
as
the glass/metal
fittings on the other side of
same
the
gasket.
b.
The GRP flange thickness must be more constant
than
is normally obtained by hand consolidation and the back face
must
be
weather
smoother than the normal
seal.
(Ref.
15,
pp.
741-745)
83
finish to obtain
a
good
Fig.
Fig. 104
103
GRP
metal/glass.
grp
Fig.
Fig. 105
Disadvantages:
Advantages:
Method
1:
(Fig. 103)
1. Good water
achieved.
2.
106
proofing can be
1.
Separate mould is needed
to produce the flange
part of the panel.
Long term durability.
Method 2:
(Fig. 104)
1. Easier to produce than
open-drained joints.
Method 3:
1. The seal i s tend t 0
slide
out of the j oint
bolting
in time.
through fl anges is
preferred.
(Fig. 105)
1. Easy and cheap to erect.
1. Great care is needed to
eliminate t he tensile or
compressive stress on the
sealant.
Method 4:
(Fig. 106)
1. Easy to assemble and change
components.
85
1. The thickness of the
flange of the panel has
to be consistent .
4.5
Reinforcement
Single skin construction can be
ribs
on the back of
the panel.
the ribs determine the overall
stiffened by a system of
The depth and
position of
stiffness obtained.
There are two methods which are generally used for
reinforcement:
1.
Polyurethane
commonly used as
also
can
panel.(Fig.
2.
ribs
skins
to
different
may
be
rib forming means.
be
pre-moulded
and
GRP "top hat"
laminated
are
sections
into
the
107)
Timber
are
foam and cardboard or paper tubes
and metal
sometimes
stiffen
coefficients
necessary
to
sections of similar profile to
laminated
these
them,
of
ensure
rather than rely on adhesion.
86
into
expansion
a
the
back
materials
to
GRP
mechanical
(Fig. 108)
of
(Ref.
key
15,
GRP
GRP
have
and
to
it
GRP
PP.621)
timber
foam
Fig.
Fig. 108
107
Disadvantages:
Advantages:
---------------------------------------------------------------------Method 1: Foam or paperboard
(Fig. 107)
is used as the
reinforcement.
1. Lower stiffness
Method 2.
1. Low cost.
than
2. No incompatibility problems
between GRP and the reinforcement.
---------------------------------------------------------------------Method 2: Metal
(Fig. 108)
1.
or timber section
is used as
the
reinforcement
1. Differential thermal
movement between GRP and the
rib may occur.
(In general, timber is
since it has
preferred
similar thermal coefficient
as GRP,)
High stiffness can be
achieved.
87
CHAPTER 5.
The
design
DESIGN CONTEXT INTRODUCTION
is
a 7500 square meter
called Green Bay;
side of Taipei,
located on the northeast
site
during rush hours.
sea-side
Taiwan.
The
about 40 minutes drive
site is penetrated by Kin-Ken road,
from Taipei
house
the plastic
design context being chosen for
(Fig. 109) Green Bay has been
planned as a resort development project, which, according to
ULI's
4),
of
(the Urban Land
Institute) definition
(Ref.
20,
pp.
is a short term destination which provides an assortment
recreational
entertainment
services.
building material
important
system
for
lodging, dining, and
Plastic will
be used as the major
the facilities of
characteristics
design
as
as well
activities,
are
which
identified
this chapter.
88
this
relate
to
project.
the
The
building
in the following sections
of
EAST
SEA
GREEN BAY
M.
SIN TEI
I
Q
railvway
driveway
Fig.
109
89
5.1
Natural
1. Coast
2.
Environment
length:
Topography:
2.3km.
15 degree steep level
on the hill-side site, flat on
the sea-side site.
3.
Area:
7500 square meter.
4.
Soil:
Red clay, rock base,
5.
Temperature:
6. Wind:
7.
Typhoon
Rainfall:
(Ref.
good bearing capacity.
22.3 degree C.
is possible.
2102.7mm/ average.
24, pp. 3-5)
90
5.2
Technical
1. No crane
Level
or expensive construction equipment is expected to
be used.
2.
Labour
3.
Skilled
cost is cheaper
labour
than machine cost in TAIWAN.
for GRP construction is available.
(transferred from the boat industry.)
4.
A
factory based on hand
(no temperature control
5.
lay-up technology
is available.
facility.)
Transportation is by pick-up truck
with a
ton to one ton and a cargo bed
loading capacity
size
of
0.5
2m.
(5 minutes drive from factory to site.)
91
of
1.8m
by
5.3
Planning Objectives
1. Function:
Resort/residential community
definition of the URBAN LAND
20,
(Ref.
2.
300
(based on the
INSTITUTE of U.S.A).
pp. 4)
plastic house units are needed to be built as
second vacation homes.
3.
Support
4.
Target
facilities:
income group:
Motel,
shop,
pavilion, others.
US $ 2000/month, middle-high income
group.
92
EVALUATION OF ALTERNATIVES
6.
CHAPTER
catalogs for
The
established
system
design
which
been
has
in Chapter 3 and Chapter 4 can be separated
into
following:
the
shapes.
1. Structural
2.
Production methods
3.
Erection and transportation methods
4.
Subsystems
5. Joints
(bathroom units).
and connections.
6. Reinforcement.
Each item presents
alternatives
the
that
(chapter 5),
2,
3,
on
the
information
and on e
designer
of
the
an Alpha-Beta table has been built for
to choose the best alternatives
for the explanation of
and
alternatives,
has to be chosen by the
Based
range.
several
6 will be
(see Ref.
the Alpha-Beta method).
w ithin
co ntext
ite ms
93
1,
1, pp. 21-25
Items 4,
only used as a design reference and will
be evaluated by the Alpha-Beta method.
of
5,
not
Structural Shapes:
-----------------------------------------------------------------------
6.1
EXISTING CONDITIONS:
DESIGN CRITERIA:(=C)
1. The construction of the
system should be reasonably
cheap.
C-1.
Efficient structural
should be used.
shape
is a entertainment C-2. The form of the system
should be as attractive
as possible.
2.
The project
center.
3
More than one
buiding type is needed.
C-3. The units of the system
can be combined into many
variations easily.
4.
There are many different
family sizes to accommndate.
C-4. The system should be
able to expand and
contract easily.
5.
The shelter is the main part
to be built by plastic.
C-5. The system should be easy
to combine with other
systems.
---------------------------------------------------------------Alternatives:(=A)
A-2.
A-1.
Saddle Surfaces
A-4.
Pneumatic Structures
A-3.
Domes
A-5.
Tubes
Synclastic Shapes
Rigid Frames
A-6.
----------------------------------------------
Alpha-Beta
Model:
----------------------------------------------
A Value
A-1
A-2
Beta-Value
A-4
A-3
9
9
7
7
6
9
8
7
6
6
8
8
9
9
7
A-5
A-6
7
8
7
7
7
6
7
6
9
9
----------------------------------------------
22.5
20
20
20
17.5
C-1
C-2
C-3
C-4
C-5
7
9
9
7
7
----------------------------------------------
100
Sum
----------------------------------------------
According
it
is
to the table,
A-3 has a total
the best alternative for
94
this
score of
project.
8.2 shows
Production Methods:
6.2
DESIGN CRITERIA:(=C)
EXI STING CONDITIONS:
1. The system is used for
project only.
this
C-1.
Low capital
investment.
C-2. Production flexibility.
2.
The essence of the GREEN BAY
PROJECT is a sea side resort,
the variation of the building
type is very important.
3.
C-3. Qulity control depends on
A factory which is based on
labour's skill.
the hand lay-up method exists
,workers are transfered from a
GRP boat facility to this factc ry.
4.
Labour cost is cheaper than
machine cost in TAIWAN.
C-4. Labour
intensive.
5. Unstable climate condition.
C-5. Reduce
site.
the working time on
6.
critical
no
is
There
pressure on scheduling for
the completion date.
C-6. Production
requirement
critical.
rate
is not
Alternatives:(=A)
A-2. Spray-Up
lay-up
A-3. Filament Winding
A-1.
Hand
A-4.
Inflatable Dome
------------------------------------------------------------------
Alpha-Beta Table:
C-1
C-2
C-3
C-4
C-5
C-6
Sum
A Value
19
19
17
17
15
13
A-1
9
9
9
9
8
6
A-2
8
9
8
9
8
6
A-3
6
6
6
6
9
9
A-4
7
8
6
9
6
7
100
According to the table, A-1 has a total
that
score of
it is the best alternative for this project.
95
9.4 reveals
6.3
Erection add Transportation Methods:
DESIGN CRITERIA:(=C)
EXISTING CONDITIONS:
1. No expensive equipment
used.
to be
expected
C-1.
is
2.
Labour cost is cheaper than
machine cost in TAIWAN.
3.
Unstable climate condition.
4.
No critical
schedule pressure
5. 5 minutes drive to site from
the existing factory.
Labour intensive erection
transportation methods
and
should be used.
C-2. Reduce erection time
on site.
C-3. Production rate
requirement is not
critical.
C-4. Ease of transportatio n
is not critical.
Alternatives: (=A)
1. Total
4.
2.
on-site erection
Flat panel
3.
Curved panel
Box
Alpha-Beta Table:
A-value
A-1
Beta
A-2
Value
A-4
A-3
C-1
C-2
C-3
C-4
29
27
22
22
8
5
8
9
9
7
7
8
9
8
7
7
SUM
100
According to
shows that
the
table, A-3 has
6
9
9
5
the highest score of 8.85
it is the best alternative of
96
this project.
CHAPTER 7.
BUILDING SYSTEM DESIGN
According to the outcomes of
critical
several
design
the evaluation
principles
have
(chapter 6),
emerged
as
follows:
1.
Synclastic shape should be used.
2.
Hand
lay-up method should be used.
3.
The
house unit should be erected and transported
as
curved panels.
Based
on
these
principles,
a building
developed
pertaining to the above principles,
the
time satisfying the requirements of
same
function.
97
should
be
while
at
site and
us e
System Description
7.1
Basic Unit
7.1.1
110)
curved shelter made up of
double
dimension of
the
panels,
a
3.6m
wide
identical
1.8m
wide
is
the plastic house
of
unit
basic
The
(Fig.
four
the basic units and the panels is
determined by the following two considerations:
1. Design flexibility:
is used as the dimension of
3.6m
the unit width because
great flexibility for unit subdivision.
it allows
2. Transportability:
Large panels are preferred for
house,
large panels can save construction time,
since
sould be
the size of the panel
the
of
width
to a range that
limited
requirements
panels
since this
as
1.8m is used
transportation problems.
cause
not
the prefabricated plastic
can
size
but
will
the
fulfill
both
GRP
with
listed above.
7.1.2 Basic Components
1. Panels:
The
(Fig. 111)
panels are made by layers of
plywood reinforcement around
the
panel
where 2.5cm
constrution
is 1.775m
is used for
and
erected
The exact width of
its nominal
is used for the tolerance at
and the cap weights 35kg.
transported
its edges.
instead of
lay-up
hand
the caps.
width
1.8m,
the joints. Similar
The panel
weights
Thus, both components
easily by
of
man power.
60kg
can be
(The
unit
applied for this caculation is 8kg/square meter
weight
3mm-4mm thickness GRP
2.
Other components:
Components
for
laminates.)
(Fig. 112)
are
D,E,F
used
where E
points of the panels,
to
modify
is used
the
connection
the
accommodate
to
partition system and D is used to accommodate exterior walls
D,
and windows.
E and F are made of extruded PVC which is
ordered from the outside manufacturer. The compression
C)
(conponent
ordered
of aluminum is also
made
ring
from
an
outside manufacturer.
(Fig. 113)
Joints
7.1.3
The
are connected indirectly by
panels
components D,
E, or F
a
for
both tolerence
distribution.
An additional
a
place
accomodation
strip of
rubber
further protection for the joints and
7.1.4
Partitions
Gypsum
used
for
component
within
by
the
F
and
the
provide
electrical
is provided as
is also designed to
expansion.
(Fig. 114)
dry wall
accommodated
of
These components
in between.
accommodate tolerance and thermal
providing
is used as the partition system
either components E or F.
partitions
is used
between
in the ceiling
two
level
to
Component E
basic
for the
units
be
is
and
partition
the basic unit, where E provides an easy subdivision
the space without using special
99
partition components.
7.1.5 Envelope System:
The
cladding GRP panels are reinforced by
backed
Both
(Fig. 115)
up
by
cardboard to
form a flat
plywood
interior
the cladding panels and the exterior door
and
surface.
and
window
system are accommodated by components D.
7.1.6
Electrical Distribution:(Fig. 116)
Electrical
wiring
is put within components E or F which
provide a perfect passage for
7.1.7
Bathrooms:
the utility system.
(Fig. 117, Fig.
118)
Two kinds of prefabricated bathroom are
two
different
standard type
house
types of unit
plywood
to
enclosure
one
for
(Fig. 118) The
the
first type is a
height enclosure bathroom which is reinforced
around
joined
design;
(Fig. 117) and one for a more elaborate design
type with built-in furniture.
lower half
produced for
its upper perimeter, where
the basic unit.
The second one
bathroom type where
the GRP wall
the bathroom
is
a
by
is
partial
is reinforced by
plywood strips and backed up by cardboard to achieve a
flat
surface.
7.1.8
Production and Transportation:
The panel
for
the
quality.
is produced
workers
in a tilt mold which allows access
to the panel easily,
Because
characteristics
(Fig. 119)
of
of
the
toughness
the material,
100
to
panels
ensure
and
can
product
plasticity
be
stacked
together
7.1.9
to make transportation easier
Erection Process:
First,
a
the
in large volume.
(Fig. 120)
site is cleaned and concrete is poured to get
flat surface to place the plastic shelter on.
designed
plates are fastened to the
steel
accommodation
position
of
components D and E.
for adjustment during panel
Second,
panels are jointed
Specially
for
ground
A template is
the
put
in
erection.
to components D and E and the
outside strips are provided.
Third,
bathroom
the caps are connected to the basic unit, and the
unit
is moved
into the house shell
and
joined with
the basic unit.
Finally,
the
finish items are moved
cladding
interior
7.1.10
panels
are
provided
as
a
combining
units,
121
types
of
different
vacation
houses
One
is designed
conventional
income
different income
incorporate
regular
Fig.
121
provided
groups.
furniture
in
Type
and
plans
and
122 shows
the
Type Two is designed
for
shows the
possible
arrangements of Type One and Fig.
morphological
small
interior partition arrangements for middle-high
people.
furniture
to
or
basic
For the Green Bay
basic types of design have been
price ranges for
and
to 126)
restaurants can be built by these units.
two
then
method.
the different catalog items of the
different
Project,
unit,
protection
finishes are applied by convensional
Design Morphologies:(Fig.
By
into the basic
range of Type One.
101
luxury
interior arrangements, using
specially designed built-
in furniture.
The target
123
124 show the plan types and
this
and Fig.
type,
while
interior design of
All
houses.
the
All
Fig.
125
Fig.
morphologies
is an isometric
showing
of
the
the unit.
designs
of
income group is high-income.
listed above are
these house types
for
single
can be combined
family
together
to form courtyard multi-family housing types which are shown
in Fig.
126.
Beyond that,
building
individual
types for other
or pavilions.
panels can be combined to
functions, such as
Possible plans for
102
small
form
restaurants
these are shown in Fig.
127.
jj
Ap~k
o.
ELEVAT ION
PLAN
103
j,10~
U~.
"41
.0-I
ELEVATION (component A)
I/
PLAN
1~
ITIZII~
TT
I
*1~
.PLAN
(component B)
ELEVATION
od
SECTION A-A
SECTION B-B
SECTION C-C SECTION D-D
Fi g111 BASIC COMPONENTS I
104
component B
c omponent
C
extruded pvc
component E
p
component D
-1
4 component E
component D
-component FI
IS H
Fig. 112
component G
ocomponent 'F
105
CMPONENTS
2
L
I
30
1.
plywo
4
SECTTON A-A
HORIZONTAL SECTION OF A-A
ood
compi
ring
SECTION B-
4
SECTION C-C
'a
S
I
-
4j
~ ~-
m
r
w
SECTION D-D
g.113 JOINTS
106
II
II
II
horizontal)
SECTION A-A
SECTION A-A
B
SECTION C-C
SECT
Fig2.'1SthCTIN
PARTITIONS
c
107
D-D
-
J1~
7
e*4
Example of the exterior panel distribution
El
E2
r
U
M
I-I
II-I
I-I
I-I
14t
E 3
E4
E5
E6
E7
Fig.1115
ENVELO PES
108
Fi 9.116
ELECTRICAL
DISTRIBUTION
109
It
1±
component A
LOi
3
30
Fig. 117
BATHROOM 1
110
i
a t?
/ p
r
IC
GPGRP
GRP
gypsum boa rd
-
gypsumboard
P LAN
ELEVATION
,TION A-A
Fig118 BATHROOM 2
111
tilt
mold
mold can be tilted f'or operation
panels can be packed together for
transportation
Fig. 119
PRODUCTION $ TRANSPORTATION
112
Step 3
Fig. 120
ERECTION
PROCESS
Step 4
113
DR: dining room
LR: living room
KIT: kitchen
BR: bedroom
MBR: main bedroom
BATH: bathroom
A2
A 1
Fig. 121
PLAN TYPES I
A3
114
1. BASIC TYPES
Al
A3
A2
2. VARIATIONS
r'r
L .L
Ji
A6
A5
A4
Fig. 122
MORPH OLOGY1
L JL .JL .JL J
A7
3.
SUNSHADING TYPES
r -
A J LZ
A8
,i ,
r
c
JA
A0
AlI
A9
115
B4
B2
B1.
Fig. 123
LR
PLAN TYPES 2
DR
B3
116
1. BASIC TYPES
rB
B~4
B13
B2
B.
2. VARIATIONS
C
~
Cl
t
B6
B9
3.
B8
Fig. 124
MORPHOLOGY2
U
k
SUNSHADING TYPES
"ir i
r cm
co
I:D
B10
J
)
B7
%r Na
r
%,
JS
L
B5
1
L
LJ
r
r
L
r
J(33
:3 V
)rq-
ir
%B12
-I$11
l
117
Fig125.
INTERIOR ISOMETRIC
118
IULTI-FAMILY
TYPES
1*
~-
r
a
.
JL
r
4. jL
L
r
it-
rS
L
ir
ir
4.
.L
L4
r-
L.
r
.3
a'
JL.
L.
J3
.3
e.
L3
r
r
L.
'C
'p
JL
L.
.3
.~'.
JL
a'
ra
L
JL
-i r
wr
t.C
.
.1
'S
-tr V
'.
K
L S
J
L
JI
n'~ rt
r
L.
L~
4.
J1
J
,
i rr
.3
L4. L )
r
L
L
,
r
Ir
r
'.
r'
L(
JL
ONS
V-1
Ta
ORPHOLOGY 3
119
r'
r
0.
J
L
J
4.
I
r
L 3.4..J.
-1 r)
'
SMALL RESTAURANT
PAVILION
i
bm
=
2
Fig,126 OTHER POSSIBILITIES
120
Conclusion:
By using plastic as a building material
design,
easy
and
aside from the advantages of
transportation,
advantages
which
the
might
material
for
house module
easy forming
suggests several
be worthwhile to
explore
and
other
in
the
into
the
future, especially from a cost saving viewpoint:
1. Reduction of
Many
design
structural
For
insulating
installed
panel
features
plastic panel
requirements.
applied,
finishing time:
in
can be
to
incorporated
satisfy many diverse
example,
a
finished
material added,
functional
surface
can
be
interior studs can be
a single operation during the molding of
at a much lower cost than if done separately
the
in
the
field.
2.
Reduction on construction cost:
Because
reinforced plastics are
conventional
construction
lighter
materials,
with
employed.
Also, because of the relatively
panels,
the
time
required
to
enclose
than
erection
lifting capacity requirements
greaterly reduced and fewer
3.
weight
small
machinery
low
in
can
be
large size of
the
a
building
is
joints have to be sealed.
Energy saving:
With
fuel
costs rising and with
that the energy problem is a
contributes
to
a
up
term
For example,
of an aluminum grid core
121
awareness
phenomenon,
certain degree to help
cooling and illumination.
made
long
increasing
reduce
plastic
heating,
panel wall
(or a polyurethane
systems
core)
with
translucent
fiber
glass
reinforced
bonded to both sides can produce a
composites
thus
cooling load of
However,
can
offer,
1. Fire
house modules.
barries which have
of
Some of
this kind of
and
and
public
to be overcome before
technology
resistance to fire,
officials
are
myth are mixed
be
fully
plastics.
increasingly
This perception needs
is true
smoke during fire.
obscures vision,
combustion of plastics.
conceptions
Whether
large quantities of
both
and
in
black
inducing panic
To alleviate this
a marked
increase
research-intensive
the fire
toxic
toxic or not, such smoke easily
fire-retardant resins and additives
applications,
the
to be corrected and qualified.
making escape difficult and
shown
about
that many plastics evolve dense
that can result in disaster.
has
smoke
Even some professionals believe
gases.
it
in
since building
becoming
in popular
burning plastics give off
pushed
can
the
the most important consideration
that all
plastics
including
not only about fire hazards but also about
fire behaviour of
use. of
and
14, pp. 123-125)
disadvantages
gas generated as a by product of
However,
heating
problem:
concerned
Fact
Such
these are:
building applications is
and
(Ref.
there are also several
In the near future,
codes
U-value.
may significantly reduce the
potential
explored.
low
panels
in spite of the many advantages a plastic house
psychological
full
very
plastic
retardant
122
in
in
reinforced
fire-sensitive
programs
and
problem, the
are
being
smoke-represent
from being satisfactorily resolved.
far
2.
Durability:
Durability under various exposure
around and
are
efforts and practical
plastics
if
solutions,
to exper ience a major expansion in building.
Methods of
long term behaviour of plastics,
especially
predicting
the
out-doors,
the
basis of
short-time tests are
reliable, es pecially in the absence of
utilize any new material,
reliable
3.
User's ps ychological
Finally,
probably
including plastics,
most
the
Most
prefer
"house"
of
as
plastic
coatings,
semistructural
beyond
however,
tend
to
which satisfy their
image
of
applications of
adhesives,
application
the range of
built
house.
plastics such
as
furnitures,
or
sealants and
such as cladding panels
this
to
well
inherently stiff as
represented by a conventionally
Although nonstructural
most
reinforced plastic
the house buyers,
conservative designs,
of
geodesic designs
Both the modular shell and
efficient shapes that are
user's
the
shapes
the unusual
advantage of the formability of
strong.
is
a
for
problem
critical
developer,
to
resistance
plastic houses.
provide
in the absence
resistance:
house
plastic
psychological
take
long-time experience in
performance.
of
potential
totally
not
users are understandably reluctant to
Potential
use.
actual
are
existing
conditions,
in buildings is another major problem calling for
concentrated
as
and
highly complex,
the subject is still
However,
areas.
thesis) have proven to
(which
be
a
great success, the drawbacks mentioned above prevent plastic
With
own adaptability for certain functions.
housing
recreational
for
difficult
the
careful
properties
amount
by
conditions
functions where a small
of
but with
site
the
easy
as
its
adaptability
oil
exploration
Thus, plastic house modules may not adapt to all
industry.
kinds
Module was approved for
Housing
Portable
the
such
construction
sandwich
"exotic"
With its
market successfully.
lightness,
and
forming
its
penetrate
did
such as Xanadu
structure
foam
shape,
its
must keep in mind that any technology has
we
However,
market.
housing
from penetrating the major
modules
house
of
house shell
can be
used,
design based on appropriate applications of
of
potential
plastics,
for
this
waiting for us to explore.
124
there still
kind of
is
an
structure
enormous
which
is
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