XSHELL
PAPER SHELL MADE OF CELL UNIT
ELECTIVE COURSE, FALL '19, CORNELL UNIVERSITY
IN COLLABORATION WITH YU SUN, MENGYI YAN, AND JUNSIK OH
XSHELL
PAPER SHELL MADE OF CELL UNIT
ELECTIVE COURSE, FALL '19, CORNELL UNIVERSITY
IN COLLABORATION WITH YU SUN, MENGYI YAN, AND JUNSIK OH
This project explores the simplest way of constructing a doubly-curved shell structure - by setting the fabrication method based on planar manufacture, which can be achieved by CNC Routers or laser machines and using sheet materials like chipboard. The cellular unit was mapped and unrolled to planar folding and cutting lines, fabricated through tens of recycling chipboards within 2mm thickness. The whole fabricating process including cutting, folding, and assembling took only 5 days and 3 group members to complete the construction of this human-scale installation on the 3rd floor of Sibley Hall.
This project explores the simplest way of constructing a doubly-curved shell structure - by setting the fabrication method based on planar manufacture, which can be achieved by CNC Routers or laser machines and using sheet materials like chipboard. The cellular unit was mapped and unrolled to planar folding and cutting lines, fabricated through tens of recycling chipboards within 2mm thickness. The whole fabricating process including cutting, folding, and assembling took only 5 days and 3 group members to complete the construction of this human-scale installation on the 3rd floor of Sibley Hall.
ZOLLINGER VAULTS
ROOF DESIGN FOR THE WEST BUND VENUE B
INTERNSHIP PROJECT, FALL '18, FAB-UNION TECHNOLOGY
IN COLLABORATION WITH AND OFFICE FOR STRUCTURAL DESIGN
SITE: SHANGHAI, CHINA
PROJECT SUPERVISOR: ALEX HAN AND PHILIP F. YUAN
Located next to the vibrant waterfront of Xuhui Riverside in the heart of Shanghai, the project demonstrates the latest advancement of BIM and other construction technologies, highlighted by the two digital prefabricated timber vaulted roofs above the garden spaces.
Photography @Tian Fangfang
Size of the rooftop
Through algorithms, the form is slightly arched and the force is evenly distributed. The overall arch is balanced by the lateral arrangement of the steel trusses and is further reinforced at the three corners.
Initial structural form finding
Optimized structural form finding
Structural solution for further development. Courtesy @AND Office
Bar elements to maintain balance. Courtesy @AND Office
The design of the column also provides integrity for the lightweight vault space. To achieve the sense of lightness, the columned is designed to be hexagons with variable cross-sections, weakening the volumetric feeling visually as well as providing high bending stiffness structurally.
Diagrams of the supporting columns
Visual effect of the supporting colunmn
After the decision on the general structural system, we began the deep investigation on tectonic and details. The motif for 'fast and convenience determines that we need to use small segments to connect the roof instead of large-spanning timbers. Based on the research on previous case studies, we decided to use the Zollinger roof (or Lamella roof) as the construction system. Such a system deploys cross members to achieve reciprocal structure at the expense of rigidity on several joints. We optimize the tectonics based on decreasing the usage of CLT(to reduce the budget), easing the difficulty of labors(accelerating the construction time), and improving the rigidity at each connection node(to enhance the mechanics). Every single beam can be optimally materialized during gluing.
Sketches for the roof tectonics
Model decomposition for the roof tectonics
The installation process only requires 3-4 labors, which has significantly improved the construction efficiency on site. All beam heads are optimized in a parametric manner and such data is then used to guide the digital fabrication for milling and boring. The joints feature a standardized hollow aluminum structure that further reduces roof weight while facilitating prefabrication and on-site construction.
Relationship between structural members
Integral model in the end
On-site construction for the 2000 square meter timber shell only took 29 days. From the side, the ceiling is slightly above the main conference space, which results a better ventilation on ground level. The top is covered by polycarbonate corrugated board. Light is filtered through several layers and sprinkled in the gardens.
Pictures during construction process
