Low-tech Pre-fabricated Structural Building System
Concept/Intent:
The development of a low-tech pre-fabricated structural building system comprised of entirely recyclable materials: cardboard and high-density polystyrene foam, with an alternative of a fabric membrane for greater permanency and waterproofing. This system allows for variation of form and adaptation to different site conditions with a consistent method of assembly. The two independent materials can be easily separated, readapted, extended or dismantled recycled or reused as requirements for dwelling transformation change.
Component Materiality:
- Laser-cut heave-duty cardboard bracing structure
- Waterproof glues with a catalytic releasw
- High-density structural polystyrene foam
- Compressible foam rod (to eliminate need for sealant)
- Weatherproof fabric membrane, i.e. sailcloth or Teflon (alternative)
System Advantages & Process:
The proposed system has the potential to produce a variety of structurally enclosed spaces and/or building appendages - flat wall, ceiling, floor system, dome, and barrel vault - free of supplementary structural supports. Geometrically based on a space-frame structural logic but modularized into insulated composite panels, the system can range in scale of assembly from a small autonomous dwelling to a broader spanning surface. As components are added, the system actually gets stronger as it grows larger. Designed in very low-tech manner simple enough for homeowners to assemble on-site, the proposed enclosure system has great potential to lower the net cost of construction compared with standard construction procedures.
While traditional SIP [Structurally Insulated Panel] panels composed of plywood and foam adhered over the entire surface are difficult to separate and recycle, this externally braced panelized structure provides for enclosure, which minimizes surface contact and makes separation/disassembly of materials for reuse or recycling easier. Structural and thermal performances of the foam wall are maintained as flexibility and variation are increased.
The basic bracing structure can be sequentially erected very quickly: pre-fabricated laser-cut cardboard bracing is folded along seams; waterproof glue (with a catalytic release) is applied to lower ridges of the bracing; hexagonal/triangular lightweight foam panels are then adhered; compressible foam rod is inserted between panels to eliminate the need for sealant; sequence is repeated. The polystyrene panels are positioned in specified patterns relative to the cardboard bracing providing for necessary or desired openings (windows, doors) through this fragmented growth system.