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F.E.W. structural prototypes: retrofitting residential buildings with ecological rooftop infrastructures

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... Inspired by the works of Fisac and Barredo, this research explores the potential of segmental ceramic hollow structures, as an alternative to reinforced concrete solutions, harnessing the potential offered by the combination of ceramic materials and robotic fabrication technologies to generate non-standard hollow structures that integrate ecological functions such as rainwater collection and heating and cooling systems, and combining their structural function with their potential activation as thermally active surfaces (Castellón et al. [6]). ...
... The research and development of this segmental ceramic hollow column is part of an ongoing research collaboration for the design and construction of ecological and collective urban infrastructures (Castellón et al. [6], Castellón [7]). As a result, the "Stem I" piece has been used for the construction of two previous installations: one exhibited at the Seoul Biennale of Architecture and Urbanism 2021 (Figure 8, left) and another one at POST Houston (USA) in 2023 (Figure 8, right). ...
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This paper presents the structural concepts and manufacturing methods implemented to produce segmental ceramic hollow columns for the design and construction of ecological urban infrastructures. The research objective is to harness the potential offered by ceramic materials and robotic manufacturing methods to produce hollow building components that combine structural and ecological functions endowed with elegant aesthetics. The proposal takes reference from the work developed in the 1960’s by the Spanish architect Miguel Fisac in collaboration with the civil engineer Ricardo Barredo. Together they invented and patented a series of posttensioned hollow concrete beams inspired by the morphology of animal bones. The resulting sectional beams, so-called “bones” by Fisac, integrated structural requirements with functional aspects such as water collection, thermal isolation, or solar protection. Following this conceptual approach, the proposed structural system is based on segmental posttensioned columns composed of hollow ceramic components. These components are produced by the combination of conventional extrusion manufacturing processes and subtractive manufacturing methods harnessing the potential offered by robotic technologies to generate non-standard hollow structures that incorporate ecological functions. In this regard, the proposed structural application works both as a column and a water collector integrating aspects of climatic control and water storage.
... Subsequently, the rainwater would be channeled through the hollow ceramic columns, from which it would be diverted to pipes below the elevated floor and collected into modular water tanks uniformly distributed within the elevated floor. The water management system as proposed would work to alleviate the effects of flooding and drought through storage as well as release and reduce runoff by capturing water and redirecting it into the tanks (Castellón, D'Acunto, Bertagna, López Cardozo 2021). Besides, the materiality of the modular ceramic columns, with their low thermal conductivity, could potentially provide energy-saving cooling benefits. ...
... Besides, the main functional aspect of this modular structure is the collection, treatment, and storage of stormwater and rainwater. Therefore, in addition to creating new spaces for communal use, it would offer the opportunity to reuse collected water for agricultural irrigation systems (Castellón, D'Acunto, Bertagna, López Cardozo 2021) as well as hydronic systems for heating and cooling. Accordingly, the project lends itself to operate as a prototypical flexible module with the potential to be deployed onto any pre-existing urban rooftop or public area. ...
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The ultimate purpose of this research is to propose new models of urban infrastructures and collective spaces for social interaction based on the integration of material, structural, and environmental systems. Accordingly, the prototypical installation presented in this paper works as a preliminary concept developed as result of a collaborative and interdisciplinary research approach conducted at Rice University and involving expertise in the fields of structural, civil and environmental engineering, materials science, music, and architecture. The project lends itself to operate as a prototypical flexible module with the potential to be deployed onto any pre-existing urban rooftop or public area. The modular system is comprised of hollow ceramic pieces acting as structural columns and water collectors, a modular ceramic floor elevated on pedestals, a lightweight space truss structure, and a waterproof membrane that captures and cleans rainwater through its expansive surface. Subsequently, the rainwater would be channeled through the hollow ceramic columns, from which it would be diverted to pipes below the elevated floor and collected into modular water tanks uniformly distributed within the elevated floor. The water management system as proposed would work to alleviate the effects of flooding and drought through storage as well as release and reduce runoff by capturing water and redirecting it into the tanks (Castellón, D'Acunto, Bertagna, López Cardozo 2021). Besides, the materiality of the modular ceramic columns, with their low thermal conductivity, could potentially provide energy-saving cooling benefits. The resulting prototype integrates structural and material strategies to optimize construction aspects related to transportation, assembly and disassembly of building components, as well as thermodynamic questions related to heat transfer and water cycles while helping to foster a sense of community and social interaction. This paper focuses on the description of the material processes implemented in the design and construction of the installation. The resulting prototype acts as a proof of concept for future developments of the project.
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