ARCHITECTURE DEPARTMENT CHINESE UNIVERSITY OF HONG KONG

MASTER OF ARCHITECTURE PROGRAMME 2002-2003 DESIGN REPORT

THE COMPONENT BUILDING

WONG Sze Wai, Ada May 2003

Department of Architecture The Chinese University of Hong Kong

The Component Building Design Report

Foreground 1 Project Objectives 3 Research Study Different Types of Prefab Systems 4 Different Types of Structural Systems 14 Comparison of Traditional and Prefab Modular Systems 17 Different Types of Spatial Modules 18 Decomposition of a Building 19 Module Combinatory Possibilities 20 Design Program 21 Site Selection 22 Site Plan 23 Form Formation 24 Plans 25 Development of Basic Module 30 Prefab Components 31 Integration of Components 32 Spatial Varieties 33 Varieties of Units 36 Functions丨 Adaptabilities 37 Sectional Details 38 Modules Gonnection Details 39 Erection Sequence 41 Sketches 42 Images of Study Models 45 Annex Hotel Design 48

Ada Wong Sze Wai Master of Architecture

2002-2003 Graduation - May 2003

Foreground

Inspired by the recent prefab projects a n d with the exper ience during my year-out of conduc t ing a research of「elatea issues, I was interested in the prefab techniques a n d modular design.

A l t h o u g h normal ly r e g a r d e d as a p r o d u c t of t he industrial age, the prefabr icat ion of elements of domestic archi tecture is an extremely ancient activity. The world oldest-known printed archi tectural treatise, the Ying tsao fa shih from the Chinese Song Dynasty, systematically sets out the range of building elements necessary to build virtually all types of building.

Throughout the 195〇s and 60s systems of prefabr icat ing large-scale building elements for mass housing were d e v e l o p e d and utilized in an a t tempt to increase productivity a n d decrease construction time.

Despite the claims m a d e for the advan tages of system building, human beings and their physiological a n d psychological condit ions remained all i l l-defined construct. The lack of design variability was always seen as a big d isadvantage of system construction, but its economic viability has also been quest ioned. Buildings that are ab le to grow a n d adap t t〇

chang ing require a far greater technical 〇nd financial investment in the first p lace. In 1967, the proport ion of prefabr icat ion construction was less than 10 percent of the overall vo lume of building. Because of the relatively small product ion runs, therefore, it was never possible to ach ieve the desired cost savings.

The advent of CAD has brought dramat ic changes to product ion technology, making even small product ion series with individual forms and complex geometries viable today, and since the beginning of the 1990s, architects and engineers have shown a renewed interest in the concep t of system building. The need of forms of construction thot conserve natural resources and a renewed interest in fiexioility of use should lend fresh impetus to builaing sys‘ems.

Can v/e learn fnom the 60s in the questions of system oui la ing? With the m a n u f a c t u r i n g technology cjvailable today and in viev/ of the a e ^ a n d s r^iCde in the reaims of environmental ly frienaiy cons卜uction ana building ohysics, we can certainly ouilding tq a d v a n t a g e on the exper ience g a i n e d in these yea^s.

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Project Objectives

01 Constructional eff iciency -To promote wider use of precast construction -To enhance cost efficiency -To minimize site work and acce lera te on-site c〇n-struction -To achieve better quality product to the end-user -To provide safer constructional environment

02 Architectural Flexibility Diversity rather than repetition: -To create wide range of units by various combina-tions of components -To create varieties of spatial experiences: projec-tion, recession, suspension, cantilever, opened, closed areas

Adaptabil ity rather than specialization: Constructional adoptabil i ty -To adap t t〇 varieties of architecture: cantilever, suspension, low rise, high rise Functional adaptabil i ty -To adapt t〇 varieties of programs: residential, hotel, bridge etc. -To transform the units according to market de-mand

03 Environmental Sustalnablllty -To minimize construction waste generated -To recycle components

3

05 suspended cellular systems

cellular systems

04 s tacked cel lu lar systems

03 frame + cellular systems

4

panel systems

01 panel systems 02 frame + panel systems

Different Types of Prefab Systems

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01 Panel systems

Flat panels having the size of a wall section 〇「of entire walls serve as spatial partitioning and simultaneously as supporting structure. -Dependen t structure. Advantages -Maximize material efficiency-Disadvantages -To maintain the integrity of the skin, it should have a minimum of perforations which decrease planning flexibility.

02 Skeletal frame + panel systems

Spatial partitioning and supporting functions are assigned to two different groups of elements. The supporting functions are al lot ted to a skeletal frame, whose interstices are closed up with non-supporting panels. - I ndependen t structure Advantages -Since only the frame itself is load-bearing, any of the sides, top, or bot tom can be omit ted without af fect ing the structure. -Modules can be combined vertically 〇「horizontally which increase planning flexibility. Disadvantages -Frame is heavy, expensive.

Housing and Office Block, Germany

Locat ion: Kassel, G e r m a n y Building Type: Office and residential Arch i tec t : A lexander Reichel

To allow for maximum flexibility, the idea was to develop a 3D load-bearing structure that could be extended in all directions and would provide func-tionally neutral spaces. The openings between the structural elements could be filled with various wall panels, depending on the usage required. The building was divided into 3 different systems:

01 The l〇ad-bea「ing structure: reinforced concrete skeleton frame, filigree floors, filigree walls. 02 Timber framed elements: closed elements, ele-ments with large window strips, elements with small window strips, room-height glazing. 03 Cladding elements: c ladding to columns, beams and wall panels.

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Swiss Re Tower, London, UK Location: 30 St Mary Axe, the City, London, UK Building Type: Off ice building grade A Contract Period: 2001-2004 Contract Sum: i 130 million GBP, US$190 million Gross Floor Area: 46,000 m2, 500,000 sqft. Developer: Swiss Reinsurance Company Client's Representative: RWG Associates Architect: Foster and Partners Structural Engineer:〇ve Arup & Partners

The structure comprises approximately 10,000te of structural steelwork that forms the core and outer d iagonal gi ld (diaghd). The whole enve lope is glass c lad and the diagrid is internally enclosed in pressed aluminum panels.

7

03 Skeletal frame + cellular systems

Spatial partitioning and supporting functions are assigned to two different groups of elements. The supporting functions are al lot ted t〇 • skeletal frame, whose interstices are closed up with non-supporting cells. - I ndependen t structure. Advantages -Since only the frame itself is load-bearing, any of the sides, top, or bot tom can be omit ted without af fect ing the structure. -Modules can be combined vertically or horizontally which increase planning flexibility. Disadvantages -Frame is heavy, expensive.

Office Block, Germany Location: Fellbach, Germany Building Type: Office Architect: Dollmann and Partners (Stuttgart

The modules were fabr icated in the factory and were transported to the site and positioned. This off ice building provided a variety of spaces from group working areas to unit offices and conference rooms, using standard elements in readily avai lable materials and prefabricated modules f〇「confer-ence rooms and sanitary areas. The envelope of the building consisted of 2 closed and 2 glazed fa-cades.

Housing and commercial block, Germany Location: Rathenow, Germany Building Type: Commercia l and residential Architect: Klaus Sill and Jochen Keim

The load bearing structure consists of a precast concre te skeleton frame designed t〇 support 12 prefabr icated housing containers. These were assembled comp le te with sanitary and other. The cells were transported by road on • normal lorry and were hoisted into position by crane and p lugged into the service systems.

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03 Stacked Cellular systems The components of these systems consist of room sized cells, which serve both to enclose volumes and to carry loads. - D e p e n d e n t structure Disadvantages -Min imum openings should be introduced into the walls since it is the continuity of surface that gives the modules their extreme strength.

• • •

Habitat 67, Canada Location: Cite du Havre, Montreal, Canada Building Type: Residential Contract Period: 1964-1967 Contract Sum: $21 million Public Circulation Space: 165,000 sq.ft. Including circulation space 110,000 sq. ft., and parking space 55,000 sq. ft. Livable Space: 250,000 sq. ft., including 354 units, each unit being 19 ft x 38 ft externally. Architect: Moshe Safdie

Habitat 67 consisted of ] 58 houses made from 354 modular construction units. Recent fusions have reduced the number of houses to 150. The apart-ment sizes varied from a one-bedroom (600sqft) to a four-bedroom (ISOOsqft).

The units measured 1 1.7 m x 5.3 m x 3 m, and weighed 70 tons. They were assembled in a clus-tered geometry, with eight boxes piled on top of another. Vertical circulation was conduc ted through 3 elevator cores leading to horizontal pedestrian streets located on 4 floors of the com-plex. All parts of the building part icipated as 丨oad-carrying members. The units were connec ted to each other by post-tensioning, using high tension rods, cables, and welding, resulting in a continuous s 汁 ucture.

10

Murray Grove, London, UK Locat ion: London, UK Building Type: Residential Contract Period: Contract duration 27 weeks (02/ 1999 to 08/1999) excluding manufacture period for modules. Total c o m p l e t i o n t ime 44 weeks Contract Sum: Construction cost {J 2,335,000 and the average cost per unit i 77,800 Gross External Floor Area: 21 50 nn2 Architect: Cartwright-Pickard Main Contractor: Kajima

The 5-storey high residential building comprises 16 one-bedroom apartments assembled from two modules, a n d 1 4 t w o - b e d r o o m apa r tmen t s assem-b l e d f rom three modules. No add i t i ona l structural frame was provided.Each unit measured 8x3.2x3 metres.

04 Suspended cellular systems

The cells are suspended from a central core. - Independent structure.

NaKagin Capsule Tower, Japan Location: Ginza, Tokyo, Japan Building Type: Residential Contract Period: Design/Construction 1970-1972 Building Area: 429.51 m2 Total Floor Area: 3,091.23 m2 Architect: Kisho Kurokawa

This building was the world' s first capsule architec-ture built for actual use. The prefabr icated units were a t tached t〇 • concre te core with 4 high-tension bolts which m a d e the units de tachab le and replaceable. The building' s 1 1 and 13-storey provides single bedroom dwellings which some of them are used as studio. The capsule dimensions were 2.5 nn x 4 m x 2.5 m. The capsules were fabr icated •丨 the factory and fitted out including utilities, interior fittings etc., and w e r e a t t a c h e d to the c o n c r e t e towers. Each c a p -sule was a t t a c h e d to the shaft by 4 high-tension bolts and were independent ly cant i levered from the shaft so that any capsule may be easily re-moved without af fect ing the others. The form of the capsule was simple and the major structure was an al l -welded lightweight steel-truss box.

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Sony Tower, Japan Location: Minami-ku, Osaka-City, Osaka, Japan Building Type: Commercia l Contract Period: Design/Construction 1972-1976 Building Area: 466.75 m2 Total Floor Area: 3,940.62 m2 Architect: Kisho Kurokawa

The 72 meters building was designed as a showroom f〇「

Sony Electronics. It comprises 2 basement floors and 10 floors over ground. The vertical circulations were exposed to the streets providing large flexible space for the show-room. Along the outside of the central display space, the stairs, elevator, escalator, and toilet were capsulized. The cap-sules were the same size as those of the Nakagin Capsule Tower, but the exterior were made of stainless steel.

13

Different Types of Structural Systems

0] Dependent structure

02 Independent structure

4

01 Dependent structure

- T h e bot tom units support the units above. -Favorable for low-rise building.

Disadvantages -Non-economica l - to achieve an efficient material economy, addit ional fl〇〇「modules should be designed to carry less weight modules of different structural design minimizes the potential economy of mass production. -Non-f lexible for long range planning - non rep laceable modules as the lower modules cannot be removed without first removing those on top.

5

02 Independent structure

Modules are not interdependent f〇「structural support, but are instead stojcturally and physically independent . They therefore only need enough structural integrity to support themselves. Both skeletal frames and suspension systems have been proposed f〇「such structures.

Advantages -Flexible - modules can be prefabr icated using a variety of methods and materials (i.e. wood , steel, concrete, plastic, and so forth} as d ic ta ted by the economics of a particular project. -Flexible for long range planning - the removal of one or a number of modules without disturbing the basic structure of the building. The module, therefore, becomes an in terchangeable part. -Economica l - every module can be structurally identical, a favorable condit ion f〇「mass production.

Disadvantages -Unfavorable for low-rise as the cost of a structural frame might exceed costs when compa red with low rise appl icat ion of the dependen t structure.

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Comparison of Traditional and Prefab Modular Systems

Design Kng incc r i ng Site P repa ra t i on Cons t ruc t i on

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The entire unit is divided into a few large sections regardless of function.

Different functional「〇〇ms f〇「example the bedroom, the living room and the bathroom might be considered as a separate item.

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Different Types of Spatial Modules

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Program

Service apar tment was being selected as the testing program due to its modular and standardized characteristics. At the same time, varieties should be in t roduced into the program in order to meet individual interest. C o m p a r e d to the tradit ional apar tmen t program, service apar tment o f fered a much higher degree of flexibility bo th in terms of design a n d program. F〇「

the tradition•丨 apar tment , usually the end-users have their own right to ar range the internal layout. Whereas for the service apar tment , the m a n a g e m e n t has its right to transformed the units accord ing to market d e m a n d , thus the designer retains a higher deg ree of control t〇vv〇「ds the internal details say furniture design a n d ar rangement .

No. of storeys: 4 (ground floor f〇「commercial, upper floors f〇「residential) No. of units: 26 to 38 Total no. of modules: 254 Dimensions of Module: 6.3 m x 2.1 m x 3.425 m = 13.23 sq meter

Public facilities: Administrative of f ice Shops Gymnasium G a m e r〇〇m Children play area Internet r〇〇m Magazine room G〇门f6「6nc6「〇〇m Self-served laundry Cafe

10 Modules 12 Modules 8 Modules 6 Modules 3 Modules 3 Modules 3 Modules 6 Modules 3 Modules

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132.3 sq meter 158.76 sq meter 105.84 sq meter 79.38 sq meter 39.69 sq meter 39.69 sq meter 39.69 sq meter 79.38 sq meter 39.69 sq meter 132.3 sq meter

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21

Site Selection

site selection criteria 01 丨门 order to focus on the tectonics issues of the project, sites with simple site considered. 02 Apartment of luxury type was being planned, remote and quiet sites were Site location Hong Kong Gold Coast No.l Castle Peak Road, Castle Peak Bay, Kowloon, Hong Kong. Site characteristics Break water, linear shape and surrounded by water.

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Development of Basic Module The dimension of the units is 6.3 m x 2.1 m x 3.425 m

Scheme 01 - End wall structure The disadvantages of this configuration •「e that the whole module is too heavy. Also, the end wall hinders flexibilities in creat ing continuous and large spaces.

Scheme 02 - Column structure Column structure enhances flexibilities creating continuous and large spaces also helps「educing weight.

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the basic module are based on: 01 Transportation limitation - The module can be transDorted by a normal lorry. 02 Erection limitation 03 Production eff iciency - the module should be as large as possible t〇 be practical. 〇4 Flexibilities - column structure enhances flexibilities in creating continuous and large spaces. Also, the width: length = 1:3, which fosters fiexiDilities in combinat ion. 05 Construction ease - standardizing construction procedures. 06 Additional site work - minimizing addit ion elements and site works.

30

Prefab Components The design deve lopment of the components kit starts with the basic living module.

The dimensions of other components are based on the basic living module: The height, dep th and width of the furniture are accord ing to the module height, co lumn dep th and space betv/een columns respectively.

All components are prefabr icated, mass-produced and standardized. This not only accelerates the manufactur ing process but also enhances the s p e e d of e rec t ion . All c o m p o n e n t s a re d imens iona l coordinated, thus the in terchangeable ability allows a variety of forms to be c rea ted thus belying the limits of the manufactur ing process.

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Modules Connection Details All parts of the building part ic ipated as load-carrying members. The units were connec ted to each other by post-tensioning, using high tension rods, cables, and welding, resulting in a continuous structure. The benefits of the post-tensioning dry assembiy system include: 01 No in-situ concret ing is involved, therefore, erection is fast, simple and weather independent. 02 Environmental sustainable as:

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03 Adaptab le to varieties of architecture: low-rise high-rise suspension can-

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Erection Sequence

01 1F modules 05 vertical joints

02 horizontal joints 06 modules completed

03 2F modules 07 panels, furniture, staircase

04 horizontal jo ints 08 roof, bridge'

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Some Sketches

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Annex • Hotel Design A hotel design was first proposed as the testing program and the site of the existing Gold Coast Hotel was being selected. The complexity and the large scale of the hotel program would, nevertheless, hinder the study of the tectonics of spatial modules. Finally, the hotel program was simplified to the apar tment program.

Program Guestroom

Suites Mini-suite 50 sq meter Conference suite 65 sq meter Junior suite 65 sq meter Executive suite 90 sq meter Deluxe suite 90 sq meter

Double-double Mid-price 44 sq meter First class 46 sq meter Luxury 48 sq meter

King Mid-price 30 sq meter First class 33 sq meter Luxury 48 sq meter

Twin Mid-price 30 sq meter First class 33 sq meter Luxury 35 sq meter

Public Arec 1 Lobby 320 sq meter Food and beverage 900 sq meter Function areas 800 sq meter

Administration Front off ice 130 sq meter Executive offices 100 sq meter Sales and catering 100 sq meter Account ing 100 sq meter

Service Are ，a

Food preparation 480 sq meter Receiving / storage 260 sq meter Employee areas 390 sq meter Laundry / housekeeping 450 sq meter Engineering / mechanical 820 sq meter

Recreation Outdoor

Swimming pool and deck 225 sq meter Basketball

Indoor Game room 300 sq meter Gymnasium 300 sa meter

Hotel Design - Site Plan

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CAFETERIA NEW BEACH

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Hotel Design - Plans

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Hotel Design - Building Configuration

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hi(jh blocks with <ujspended frames and plug-in modules provide the potential for future growth

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Hotel Design - Modules Study

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