lascaux caves building construction integration · 2019. 6. 19. · lascaux caves building...

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BUILDING CONSTRUCTION INTEGRATION MICHAEL KNOLL STUDIO LYNN WS17 LASCAUX CAVES BUILDING CONSTRUCTION INTEGRATION WS 2017, Studio Lynn, Michael Knoll Lascaux 4 Replica by Atelier des Fac- Similés du Périgord Building the casting module “The skill required to produce a replica involves mastering the latest technology and applying it to a true production chain.Once the dimensions have been established, the matrices are cut digitally into polystyrene blocks 01.” - AFSP Making the wall “Now modelling 02 comes into play to complete the sup- porting structure. Next our technicians spread elastomer 03 to take an impression, then produce resin casting moulds 04) that give the inverse of the shape to be cre- ated.” - AFSP Painting and installing the structure “Once the metal support structure 05 has been produced with millimetre precision, the resin shell 07 reproduces the wall, with the addition of a stone veil 06 our own, patented technique) which faithfully reproduces the mineral sur- face of the rock, onto which the coloured patinas and wall paints 08 are applied.” - AFSP

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Page 1: LASCAUX CAVES BUILDING CONSTRUCTION INTEGRATION · 2019. 6. 19. · LASCAUX CAVES BUILDING CONSTRUCTION INTEGRATION WS 2017, Studio Lynn, Michael Knoll Lascaux 4 Replica by Atelier

BUILDING CONSTRUCTION INTEGRATION MICHAEL KNOLL STUDIO LYNN WS17

LASCAUX CAVES BUILDING CONSTRUCTION INTEGRATIONWS 2017, Studio Lynn, Michael Knoll

Lascaux 4 Replica by Atelier des Fac- Similés du Périgord

Building the casting module“The skill required to produce a replica involves mastering the latest technology and applying it to a true production chain.Once the dimensions have been established, the matrices are cut digitally into polystyrene blocks 01.” - AFSP

Making the wall“Now modelling 02 comes into play to complete the sup-porting structure. Next our technicians spread elastomer 03 to take an impression, then produce resin casting moulds 04) that give the inverse of the shape to be cre-ated.” - AFSP

Painting and installing the structure“Once the metal support structure 05 has been produced with millimetre precision, the resin shell 07 reproduces the wall, with the addition of a stone veil 06 our own, patented technique) which faithfully reproduces the mineral sur-face of the rock, onto which the coloured patinas and wall paints 08 are applied.” - AFSP

Page 2: LASCAUX CAVES BUILDING CONSTRUCTION INTEGRATION · 2019. 6. 19. · LASCAUX CAVES BUILDING CONSTRUCTION INTEGRATION WS 2017, Studio Lynn, Michael Knoll Lascaux 4 Replica by Atelier

BUILDING CONSTRUCTION INTEGRATION MICHAEL KNOLL STUDIO LYNN WS17

Construction Strategies 3 ways of replicating caves as exterior walls

section of cave panelization of cave

3D printed blocks (Hansmeyer Cave)3d printed (laser sinter) sand blocks till max size of 4x2x1m

+ less layers and thin construction+ big heat storage+ 3d printed high efficient insulation- panels need to additionally be connected with beam angles- steel needs to be layed into the 3d panel during print process

This type of construction has the big advantage of having less layers then the others. While the 3d printed silicon sand panels produce a lot of mass (heat storage) the needed insulation can be also integrated in the 3d print. Recent studies have shown that a 3d printed insulation CAD design can produce highly efficient products and can be an alternative to insulations like vacuum and aerogel in the near future. In order to create a watertight hull that follows the rough form of the interior cave wall I decided to best build a roof construction with air ventilation. The wind paper is a protection layer for the fine structure of the printed insulation to not get damaged by the circulating wind over time. The needed substructure for this wind-circulation space will be fixed on a beam angle that gets integrated into the main structure while 3d printing. After fixing a solid formwork, epdm will seal the whole structure from exterior water. On top of that layer standard systems can be attached cladding the exterior facade.

Ech of the panels get stacked on each other and will be additionally fixed with already integrated steel plates. In order to be able to screw the panels together there will be a cutout on the corners that will be filled up with insulation after assembly.

DETAIL 1any exterior facadeairepdm sealing 1,0cmbattens 2,5cmsubstructure / air 10cmwind paper 3d printed silica sand porous 15cm3d printed silica sand 40cmpaint and patinas------------------------------------------------------------------------ 71cm

DETAIL D1 m. 1:10paint and patinas 0.5 cm3d printed silica sand 30-100 cm3d printed silica sand porous 15 cmwind paper 0.1 cmsubstructure / air 12 cmbattens 0.2 cmepdm sealing 0.5 cmsubstructure / air 18 cmclipped panel sheet 0.2 cm

DETAIL D2 m. 1:10open mesh floor 3.0 cmsubstructure / air 9.0 cmgravel 10 cmPE foil 0.1 cmreinforced concrete 35 cmfiberglass insulation 15 cmcleanliness layer 15 cmgravel 50 cm

neoprene support

air c

ircul

atio

n

air c

ircul

atio

n

mirror

wind paper

panel sheet brushed

substructure

air ci

rculat

ion

air ci

rculat

ion

air ci

rculat

ion

air ci

rculat

ion

DETAIL D3 m. 1:10paint and patinas 0.5 cm3d printed silica sand 30-100 cm3d printed silica sand porous 15 cmwind paper 0.1 cmsubstructure / air 12 cmbattens 0.2 cmepdm sealing 0.5 cmsubstructure / air 18 cmclipped panel sheet 0.2 cm

epdm sealing

high-tensile plaster

engaged end-plates

engaged end-plates screwed together

DETAIL D4 m. 1:10paint and patinas 0.5 cm3d printed silica sand 30-100 cm3d printed silica sand porous 15 cmwind paper 0.1 cmsubstructure / air 12 cmbattens 0.2 cmepdm sealing 0.5 cmsubstructure / air 18 cmclipped panel sheet 0.2 cm

air circ

ulation

air circ

ulation

air circulation

air circulation

wind paper

panel sheet brushed

substructureepdm sealing

engaged end-plates

D1

D3

D4

D2

wind papersubstructure

epdm sealingengaged end-plates

welded end-plates3d printed silica porous

3d printed silica sand

DETAIL M. 1:20

W S 2 0 1 7 S T U D I O L Y N NKNOLL MICHAEL 0817117BKI

DETAIL M. 1:20

DETAIL M. 1:20 SECTION M. 1:50

PANEL AXONOMETRY

DETAIL D1 m. 1:10paint and patinas 0.5 cm3d printed silica sand 30-100 cm3d printed silica sand porous 15 cmwind paper 0.1 cmsubstructure / air 12 cmbattens 0.2 cmepdm sealing 0.5 cmsubstructure / air 18 cmclipped panel sheet 0.2 cm

DETAIL D2 m. 1:10open mesh floor 3.0 cmsubstructure / air 9.0 cmgravel 10 cmPE foil 0.1 cmreinforced concrete 35 cmfiberglass insulation 15 cmcleanliness layer 15 cmgravel 50 cm

neoprene support

air c

ircul

atio

n

air c

ircul

atio

n

mirror

wind paper

panel sheet brushed

substructure

air ci

rculat

ion

air ci

rculat

ion

air ci

rculat

ion

air ci

rculat

ion

DETAIL D3 m. 1:10paint and patinas 0.5 cm3d printed silica sand 30-100 cm3d printed silica sand porous 15 cmwind paper 0.1 cmsubstructure / air 12 cmbattens 0.2 cmepdm sealing 0.5 cmsubstructure / air 18 cmclipped panel sheet 0.2 cm

epdm sealing

high-tensile plaster

engaged end-plates

engaged end-plates screwed together

DETAIL D4 m. 1:10paint and patinas 0.5 cm3d printed silica sand 30-100 cm3d printed silica sand porous 15 cmwind paper 0.1 cmsubstructure / air 12 cmbattens 0.2 cmepdm sealing 0.5 cmsubstructure / air 18 cmclipped panel sheet 0.2 cm

air circ

ulation

air circ

ulation

air circulation

air circulation

wind paper

panel sheet brushed

substructureepdm sealing

engaged end-plates

D1

D3

D4

D2

wind papersubstructure

epdm sealingengaged end-plates

welded end-plates3d printed silica porous

3d printed silica sand

DETAIL M. 1:20

W S 2 0 1 7 S T U D I O L Y N NKNOLL MICHAEL 0817117BKI

DETAIL M. 1:20

DETAIL M. 1:20 SECTION M. 1:50

PANEL AXONOMETRY

DETAIL D1 m. 1:10paint and patinas 0.5 cm3d printed silica sand 30-100 cm3d printed silica sand porous 15 cmwind paper 0.1 cmsubstructure / air 12 cmbattens 0.2 cmepdm sealing 0.5 cmsubstructure / air 18 cmclipped panel sheet 0.2 cm

DETAIL D2 m. 1:10open mesh floor 3.0 cmsubstructure / air 9.0 cmgravel 10 cmPE foil 0.1 cmreinforced concrete 35 cmfiberglass insulation 15 cmcleanliness layer 15 cmgravel 50 cm

neoprene support

air c

ircul

atio

n

air c

ircul

atio

n

mirror

wind paper

panel sheet brushed

substructure

air ci

rculat

ion

air ci

rculat

ion

air ci

rculat

ion

air ci

rculat

ion

DETAIL D3 m. 1:10paint and patinas 0.5 cm3d printed silica sand 30-100 cm3d printed silica sand porous 15 cmwind paper 0.1 cmsubstructure / air 12 cmbattens 0.2 cmepdm sealing 0.5 cmsubstructure / air 18 cmclipped panel sheet 0.2 cm

epdm sealing

high-tensile plaster

engaged end-plates

engaged end-plates screwed together

DETAIL D4 m. 1:10paint and patinas 0.5 cm3d printed silica sand 30-100 cm3d printed silica sand porous 15 cmwind paper 0.1 cmsubstructure / air 12 cmbattens 0.2 cmepdm sealing 0.5 cmsubstructure / air 18 cmclipped panel sheet 0.2 cm

air circ

ulation

air circ

ulation

air circulation

air circulation

wind paper

panel sheet brushed

substructureepdm sealing

engaged end-plates

D1

D3

D4

D2

wind papersubstructure

epdm sealingengaged end-plates

welded end-plates3d printed silica porous

3d printed silica sand

DETAIL M. 1:20

W S 2 0 1 7 S T U D I O L Y N NKNOLL MICHAEL 0817117BKI

DETAIL M. 1:20

DETAIL M. 1:20 SECTION M. 1:50

PANEL AXONOMETRY

connection of panels

Page 3: LASCAUX CAVES BUILDING CONSTRUCTION INTEGRATION · 2019. 6. 19. · LASCAUX CAVES BUILDING CONSTRUCTION INTEGRATION WS 2017, Studio Lynn, Michael Knoll Lascaux 4 Replica by Atelier

BUILDING CONSTRUCTION INTEGRATION MICHAEL KNOLL STUDIO LYNN WS17

DETAIL 2any exterior facadeairepdm sealing 1,0cmbattens 2,5cmsubstructure / air 10cmwind paper eps insulation 15cmOSB - steam brake 2,5cmbeam steel structure 35cmsubstructure with hidden fixation 15cm3d printed silica sand 8,0cmpaint and patinas------------------------------------------------------------------------ 82cm

DETAIL 3any exterior facadeairepdm sealing 1,0cmbattens 2,5cmsubstructure / air 10cmwind paper eps insulation 15cmreinfroced concrete 25cm3d printed silica sand panels 12cm(lost castingpaint and patinas------------------------------------------------------------------------ 64cm

3D panels attached on steel structure

+ lightweight structure+ relatively cheap+ easy panel construction+ panels can be changed- no heat strorage- many layers- gaps between panels

concrete and 3d print (as lost casting)

+ solid structure+ simple construction of facade layers+ 3d print additionally functions as lost casting+ thin structure- complicated casting of concrete shell

This last type of construction uses 3d printed panels both as interior facade and as lost casting for the main structure - reinforced con-crete. The biggest challenge of that construction is to not destroy the panels while using them as casting. Reinforcement that was put into the silicon sand panels while 3d printing can be attached on the exterior casting. This exterior casting needs to be fixed in position with a exterior structure, just for the building process. Once the concrete is hardened out and is permanently connected to the 3d pan-els it builds a perfect base for further layers. I would suggest like with the other two constructions to build a facade with air circulation.

Beside the big challenge of assembling the casting for this structure it would have advantages like a relatively thin struc-ture and being a perfect base for further construction layers. The reinforced concrete mass would additionally function as heat storage.

This second variation of construction uses 3d printed panels to clad the interior facade. The panels dont have additional load bearing function and are attached on a substructure with hidden fixation. This substructure is again mounted on a beam steel structure. A solid framework additionally stiffens out the steel structure and builds the base for further layers like insulation, air circulation and sealing. Optionally the space between the beams can be filled out with insulation to additionally save some space.

The big advantage of this structure is its cheap construction that’s relatively simple to build. On the other hand a uncoupled panelling in the interior has to have gaps between the panels. This gap further increases up to 1,5cm if panels should be changeable and make it unusable for a cave replica. Another disadvantage of that structure is that it is not massive and therefore does not store heat.

DETAIL 3d print as lost castingany exterior facadeairepdm sealing 1.0 cmbattens 2.5 cmsubstructure / air 10 cmwind paper 0.1 cmeps insulation 15 cmreinforced concrete 25 cm3d printed silica sand panels 12 cmpaint and patinas

air circulation

air circulation

DETAIL panels attached on steel structureany exterior facadeairepdm sealing 1.0 cmbattens 2.5 cmsubstructure / air 10 cmwind paper 0.1 cmeps insulation 15 cmOSB - steam brake 2.5 cmbeam steel structure 25 cmsubstructure w. hidden fixation 15 cm3d printed silica sand panels 8.0 cmpaint and patinas

DETAIL 3d print as lost castingany exterior facadeairepdm sealing 1.0 cmbattens 2.5 cmsubstructure / air 10 cmwind paper 0.1 cmeps insulation 15 cmreinforced concrete 25 cm3d printed silica sand panels 12 cmpaint and patinas

air circulation

air circulation

DETAIL panels attached on steel structureany exterior facadeairepdm sealing 1.0 cmbattens 2.5 cmsubstructure / air 10 cmwind paper 0.1 cmeps insulation 15 cmOSB - steam brake 2.5 cmbeam steel structure 25 cmsubstructure w. hidden fixation 15 cm3d printed silica sand panels 8.0 cmpaint and patinas