Professional Documents
Culture Documents
ARCHITECTURE IN CARDBOARD
Research in Architectural Engineering Series
Volume 7
ISSN 1873-6033
IOS Press
© 2008 IOS Press and the authors.
All rights reserved. No part of this book may be reproduced, stored in a retrieval system or
transmitted, in any form or by any means, without prior permission from the publisher.
Published and distributed by IOS Press under the imprint Delft University Press
Legal Notice
The publisher is not responsible for the use which might be made of the following informa-
tion
ISBN
978-1-58603-820-5
Editors
Mick Eekhout, Fons Verheijen, Ronald Visser
Preface
The paper and cardboard industry, just like the building
industry, is a long-established business sector with considerable
knowledge and experience. Apart from the honeycomb door
and paper-based round column formwork, there are few
contacts between the two industries. But architects have
made many attempts, further back in the past and also more
recently, to use cardboard as a building material.
~ 1930 – paper house, USA
~ 1970 – temporary accommodation, TU Delft
~ 1980 – two temporary theatres, Apeldoorn
~ 1990 – temporary accommodation Japan, Shigeru Ban
~ 2000 – Japanese pavilion, Hanover, Shigeru Ban
v
The Department of Building Technology at the Faculty of
Architecture at TU Delft plans to study and develop cardboard
as a potential building material on a broad, systematic and
where possible comprehensive basis. The guiding research
question here is:
Paper Leaves 49
Peter Gentenaar
A House of Cardboard 69
Elise van Dooren & Taco van Iersel
Epilogue 165
Mick Eekhout
Abstract
1
development and design of new materials, new techniques
and their applications in architecture. The current cardboard
research group is composed of:
• PhD student Julia Schönwälder
µ0HFKDQLFDO3URSHUWLHVRI&DUGERDUG¶
• PhD student Maria den Boom
µ&DUGERDUG3DUWLWLRQLQJ:DOOV¶
• PhD student Taco van Iersel
µ$SSOLFDWLRQ'HVLJQV&DUGERDUG&DEOH'XFW¶
• Staff member Elise van Dooren for co-ordination
and integration;
• In 2006 a research fellow from Washington State
university, architect Robert Barnstone, has been
invited to spend his sabbatical in the cardboard
research group.
0,&.((.+287 3
between the proposals of Ban and Eekhout. The engineering
took 2 weeks and the production and assembly took a further
some 4 weeks. For future possibilities the developed project
system ought to be developed to become a commercial
(marketable) system with more general applications.
0,&.((.+287 5
OZ School Material
Bouw Platform DDi
DSD
Speerpunt Delft
Bouw Scientific
Tillman
Design
Klein
Thimo Complex
2006
Ebbert Processes
post-doc vacancy
Walter
Karel
Façades Reinhardt Hein
Lockefeer
Vollers Hasselbach
Complex Doeksen
Daan
Design
Rietbergen
Stefanos
&
Shore BLOBs Anestasiou Engineering
Shahnoori (Bath)
Wim
GRP Poelman
Structures 2006
Martijn vacancy Joris Martin
Veltkamp Molenaar Smit
Jordan Chair
Brandt Constructions Research
Jeroen Kunça
Geurts Saher
Product
Development
ZAPPI Architectural
Dave
van
Eijnsbergen
Zappi Engineering
design 2006
Pablo vacancy
vd Lugt Elise
Sannie
van Robert
Verwey And
Andreas
dr
Vögler Dooren Barnstone
Huib
Plomp
KNAW Ties
Rijcken
Rijck
Concept marketing
2006
vacancy
House
Elise
van Robert Cardboard
Wind Dooren Barnstone Ype Maria Taco
Cuperus Domotica
Erik vacancy 2006 den van
Vreeden- Boon Iersel
burg
vacancy vacancy Cardboard
1 2 Maria Taco
MKB den van
Boon Iersel
Julia
Schönwälder
Julia
Schönwälder
Glass
industry
NWO vacancy
Composites
industry Façades STW Ring of PhD students
industry
Satelite Orbit
Research Arenas
0,&.((.+287 7
x Cardboard for Constructional purposes, where
the element or component has a stand alone
function of minor structural nature (wind loading
as a outside wall) and major cladding nature of
separating spaces
x Cardboard for Temporary Buildings, where
cardboard has both a structural and a constructional
use (example the Apeldoorn theatre designed by
architect Hans Ruijssenaars)
x Cardboard for Emergency Housing Purposes
in combinations of structural and constructional use,
with assistance of other materials like plastic foil;
(Many examples in the work of Shigeru Ban)
x Cardboard for Interior Purposes, to be applied
in cupboards, kitchens furniture (examples Ikea
products)
x Cardboard for Furniture Purposes, to be
worked out on the Faculty of Industrial Design
Engineering of TU Delft, rather than Architecture
x Cardboard for Installation Purposes, where the
packaging practically could be deformed to become
GXFWVH[DPSOHV7DFRYDQ,HUVHODQG7KH;;RI¿FH
by Jouke Post)
x Cardboard for secondary purposes in
structures like honeycomb sandwich cores, tubular
FRUHVRIUHLQIRUFHGFRQFUHWHÀRRUDQGFDUGERDUG
castings for concrete columns
next pages:
,Q)LJWKHOD\RXWRIWKH¿UVWSKDVHµ&RQFHSW'HVLJQ¶LV
given as an illustration of the above given description. In
my opinion it is unavoidable in order to attain ambitious
targets to work systematically as an engineer. This route
unavoidably leads to a planned and time consuming
enterprise. This approach is called a deductive approach.
Reference is made to the dissertation of Mieke Oostra
„Componentontwerpen, de rol van de architect in
productinnovatie“3. I would rather call this approach the
engineers approach.
0,&.((.+287 13
involved show an absence of cautious product development.
The pavilion is also the result of the massive support by the
cardboard industry to sponsor the cardboard necessary for Fig. 10. Concept Phase of Mick
the building of the pavilion. (HNKRXW¶V2UJDQRJUDP
of Product Development
0,&.((.+287 15
them, will be involved in all three major phases, of the earlier
mentioned 6 main stages of Fig. 1. The industry shall not
expect to consume easily prefabricated cardboard knowledge:
LWWDNHVPXFKHIIRUWWRGHYHORSDQHZ¿HOGRIH[SHUWLVHDQG
the support and time of many. The university cannot develop
new technology without the practical remarks of the current
industry, but never in absence of creative future-directed
marketing.
0,&.((.+287 17
29. Design large scale pre-fabricated emergency
housing with minimal transport volume
30. Design structural skeleton systems with tubular
elements and cast cardboard nodes
31. Design interior partitioning systems with
cardboard for do-it-yourself use
32. Design one-off structural systems with
honeycomb core for 3D blob surfaces
33. Design cardboard chalets for use in private
gardens
34. Design self-build partitioning walls for
spontaneous accommodation of home guests
35. Design cardboard outdoor storage spaces, to be
VXVSHQGHGIURPEDOFRQLHVRIÀDWV
36. Design summer house units for temporary use;
'HVLJQHDVLO\GHPRXQWDEOHRI¿FHSDUWLWLRQLQJ
with printing surfaces and acoustic absorbing
qualities
38. Design structurally independent indoor
partitioning system for museum purposes
39. Design Student housing for fast expanding
needs
'HVLJQURRIWRSH[WHQVLRQRIÀDWURRIVXVLQJ
cardboard constructions and structures
41. Design Concept Houses with load carrying walls
DQGÀRRUV
References
1 Wim Poelman, Technology diffusion in product design: towards
an integration of technology diffusion in the design process, S.l:
S.n, Delft, 2005, ISBN 9051550235
2 Mick Eekhout, POPO, Delft University Press, Delft 1996, ISBN
9040716315
3 Mieke Oostra “Componentontwerpen, de rol van de architect in
SURGXFWLQQRYDWLH´(GLWRU(EXURQ'HOIW,6%1
4 Matilda McQuaid, Shigeru Ban, Phaidon, London, 2003, ISBN
0714841943
5 Mick Eekhout, Ontwerpmethodologie 28 en 29 mei 1998, TU
Delft Faculteit der Bouwkunde, Delft, 1998, ISBN 9052692556
0,&.((.+287 19
This page intentionally left blank
Cardboard in Architecture. M. Eekhout et al. (Eds.). IOS Press, 2008.
© 2008 The authors and IOS Press. All rights reserved.
Abstract
1. Introduction
Materials – we want to know everything about them.
Where they come from, how you work with them,
how far you can push them, what else you can make
from them.1
21
a cardboard box; foldable, lighter, easy to discard of and
recyclable after use.
,Q$G.LOHQ5R.RVWHUGHVLJQHGDFRPSOHWHRI¿FHLQWHULRU
using cardboard5. The explicit demand was an interior which
would give a soul to the somewhat boring space. By gluing
cardboard in several layers on top of each other, walls with
an exceptional texture were created, which moreover had a
positive affect on the sound inside the room.
Fig. 1.,QWHULRURIWKHRI¿FHRI
Scherpontwerp, a graphic
design company in
Eindhoven.
2. Projects
2.1. Shigeru Ban
Shigeru Ban placed cardboard tubes in circular shapes behind
a (semi) transparent façade in his Paper House and Paper
Church (1995), thus creating beautiful spaces, each with their
own character, in a show of light. His designs intertwine two
WUDGLWLRQV -DSDQHVH VLPSOLFLW\ DQG WKH RSHQ ÀXLG VSDFH RI
modern architecture. These and other projects, were he used
cardboard tubes in construction, like Library of a poet (1991)
and the Japan Pavillion at the Expo in Hannover (2000) are
YHU\ZHOOGRFXPHQWHGLQWKHERRNµ6KLJHUX%DQ¶6
5XG\8\WHQKDDNGHVLJQHGDÀRDWLQJWKHDWUHRQWZRSRQWRRQV
in the Apeldoorn canal. The load bearing structure was to be
made from steel, with beams and cables. The roof and some
of the side-wings were to be made from cardboard elements.
The elements in the roof were coated with polyethylene
to ensure water-resistance. Inside the side-wings they are
uncoated.
2.5. Barn
In the nineteen seventies and eighties research was being
done into the development of cheap cattle barns. The aim
LV WR PDNH WKH EDUQV¶ WHFKQLFDO OLIHVSDQ HTXDO WR WKH VKRUW
economical writing off term. Different materials were tested
amongst which corrugated cardboard. With triangular
cardboard beams large spans are achieved and the demanded
insulation values are met. The cattle barn remained standing
for a couple of years.
2.6. Cardboardschool
Cottrell and Vermeulen in cooperation with bureau Happold
designed an after school child care connected to a school
in England14,15 :HVWERURXJK SULPDU\ 6FKRRO 8.
2002). The central idea for the design of the extension was
the folding of paper. Furthermore the aim was to use as
much recyclable and recycled material as possible. At the
end of its 20 year lifespan all the materials used (cardboard,
wood, natural rubber tiles) are to be recycled. Before actually
building the extension, a scale model of 6 x 2.4 metres was
EXLOW7KHNQRZOHGJHDFTXLUHGIURPWKLVPRGHOVLPSOL¿HGWKH
design. One of the major changes was the application of
wooden edges on the entirely cardboard panels. To protect
the cardboard from water during the actual build, a temporary
scaffolding structure covered in plastic was erected.
2.7. Multished
On the occasion of the opening of a paper recycling company
in Duiven (2002), a temporary extension was designed and
EXLOWDFDUGERDUGSDUW\WHQWWKH³0XOWLVKHG´HUHFWHGIURP
cardboard tubes, honeycell and solid cardboard.14 7KH ¿UH
UHVLVWDQFH SURYHG WR EH VXI¿FLHQW LQ FDVH RI D WHPSRUDU\
structure, because the solid cardboard plates meet the
demands of fire-class 4 (non-housing structures). The
extension is built up from a skeleton of cardboard tubes with
honeycell plates laminated with solid cardboard between the
tubes. With a minimal addition of cellophane and a small
amount of PE foil, water resistance of the tubes and the plates
was achieved. In order to also waterproof the end grain, black
tape was used in all connections.
3. Products
3.1. Ventilation duct
7KH;;DUFKLWHFWVRI¿FHLQ'HOIWE\-RXNH3RVW16, was based on
the thought, that when the economical lifespan of a building
does not coincide with the technical lifespan, the latter should
DGDSWLWVHOIWRWKH¿UVW7KLVOLIHVSDQZDVVHWRQ\HDUV7KH
materials were chosen in such a way, that they could be re-
used or returned to nature. Part of this concept is the use of
cardboard tubes as ventilation ducts.
3.3. Cable-duct
The cardboard cable-duct by Taco van Iersel18 is an example
RIDSUHIRUPHGÀDWSODWHZKLFKFDQEHIROGHGDWWKHZRUNVLWH
and placed into brackets. The predecessor of this cable-duct
in the design process was the semi-round tube. However, the
IROGDEOHSODWHLVPXFKPRUHHI¿FLHQWEHFDXVHLWUHTXLUHVOHVV
space during transport.
Fig. 9.³7KH:DOO´DORQJVLGHWKH
A2 highway near Utrecht.
7KHZDOOKDVEHHQVXEPLWWHGWRPDQ\WHVWV¿UHFRPSUHVVLRQ
tension) and experiments (Sandbag swinging test). On
some points the wall reached a surprisingly high score, but
sometimes improvement of the wall is necessary. Some of the
growing pains can be deduced from the way of production.
7KHSDQHOVZHUHDVVHPEOHGE\KDQG7KLVKDVJUHDWLQÀXHQFH
on the total quality of the wall. For many applications the wall
in its current shape is satisfying, but optimisation will improve
the chances for cardboard as a partition.
4. Study projects
It is clear that cardboard is a relatively new material in
the building industry and not a lot of data is known yet.
We need research on a broad basis, as well as in depth
research, meaning: research in a designing, synthesizing
way and research in a specialized way (e.g. research into the
mechanical properties and moisture-resistance of cardboard)
5. Conclusion
5.1. Fascination
There is a lot of enthusiasm. Architects, researchers and
students feel challenged by an unknown material (in their
area of expertise).
5.2. Temporality/Lifespan
Looking at all the realised projects up till now, the amount
of temporary projects stand out. This must be inherent to
the material. Packages have a relatively short lifespan. After
having been used for a few times, boxes will have been torn or
become wet and should be discarded. Formulated differently:
FDUGERDUGLVD¿UPPDWHULDOEXWHVSHFLDOO\FRQVLGHULQJVKRUW
periods of time. When used for longer periods it becomes a
vulnerable material.
5.3. Recycling
Environmentally, cardboard seems to get high scores. Further
research will have to acknowledge this. One of the aspects in
such research are the additives which can be added during the
production process. During this process this additive could be
many natural materials, such as clay, chalk and starch. After
the production process many different kinds of paint, coating
DQGIRLOPDNHFDUGERDUGZDWHUUHVLVWDQWDQG¿UHUHWDUGDQW
Also the types of glue used to glue the different layers of
paper together, could play an important role. In a number of
cases the quality of the cardboard improves, like the moisture
resistance, but at the same time the ability to recycle the
5.4. Economy
Cardboard is a relatively cheap material. This means that there
is a reasonable margin for experimenting and working the
material, so that products and applications can be marketed
reasonably positively considering its price.
5.5. Humidity
Next to some clearly positive properties, there are also a
few properties, which are without a doubt, a nuisance when
cardboard is being used as building material. The behaviour
when in contact with moist is a perfect example.
5.6. Knowledge
Up till now different projects have been designed or built
using cardboard and cardboard has been applied inside
buildings. However, most of the knowledge is bound to the
VSHFL¿FSURMHFWDQGQRWDORWRIH[FKDQJHWDNHVSODFH0RUH
general information is only accessible through the book by
Mathilda McQuaid about Shigeru Ban6 and on the website of
the cardboard school.15
5.7. Development
Cardboard has been used as a building material a few times,
and some cardboard products have been designed and
produced. Most of the time, it is not really clear why a product
did not make it on to the market. It seems that most of the
committed parties abandon the project when the product is
EHLQJGHYHORSHGWHFKQLFDOO\DQGWKHSURFHVVRIFHUWL¿FDWLRQ
KDVWRVWDUW,WPLJKWEHZRUWKZKLOHWU\LQJWR¿QGRXWZK\WKH
process stagnated. Does it happen because the viability of the
product is limited or because there is a lack of perseverance
and the right type of people.
5.8. Future
Experiments with cardboard as a building-material are being
conducted worldwide. The many practical examples seem to
support the search for a broader application of the material.
Cardboard is not expected to replace current building materials.
When there is a place for paper and cardboard in architecture
and as a building material, then it will be for its own content,
LQUHODWLRQWRWKHVSHFL¿FSURSHUWLHVRIWKHPDWHULDO
6FLHQWL¿FFXULRVLW\DQGWKHQHZQHVVRIDPDWHULDOVWLPXODWH
researchers, students and architects to think further than
traditional materials and solutions. The different appearances
(tubes, honeycell, solid and 3D) and the characteristic
properties of cardboard, like folding, sliding together, printing,
lightness and temporality are an inspiration and starting point
in the research into the possibilities.
References
1 Brower, Mallory, Ohlman, Experimental eco design, architecture/
fashion/product. Rotovision, 2005, ISBN 2-88046-817-5
2 Therese Weber, die Sprache des Papiers, eine 2000-jahrige
Geschichte, Verlag Haupt, ISBN 3-258-06793-7
3 http://www.powerhousemuseum.com/collection
4 http://www.stange-design.com
5 BN/DeStem van 9 juli 2005 op: www.besin.nl
6 Mathilda Mc Quaid, Shigeru Ban, Phaidon, 2003, ISBN 0-7148-
4194-3
7 Prof.dr.ir.Mick Eekhout, Het ontwikkelen van de kartonnen
IJburgkoepel, in: kartonnage, Rumoer 30, sept 2003, jaargang
9, Periodiek voor de bouwtechnoloog, uitgave van Bout,
praktijkvereniging Bouwtechnologie faculteit Bouwkunde, TU
Delft. ISSN 1567-7699
8 Taco van Iersel, report interview Paul Rohlfs
9 http://www.rsdevelopments.nl
10 http://www.housesofthefuture.com.au
11 T.Verstegen, Rudy Uytenhaak, 010 Publishers, 1996, ISBN 90-
6450-241-2
$.RRLVWUD'RRVMHGRRVJURWHGRRVIHHVWWKHDWHU%RXZZHUHOG
nr. 13 (25 juni 1993)
13 Taco van Iersel, Feesten in kartondoos, detail in architectuur,
maart 2003
14 Andrew Cripps, Cardboard as a construction material: a case
study, Building Research & Information (may-june 2004)
15 Buro Happold en Cotrell & Vermeulen, Constructing a prototype
cardboard building, on www.cardboardschool.co.uk
.ORPSHQ3RVWOHYHQVGXXUJHEUXLNVGXXU;;HHQJHERXZ
als prototype van een nieuw mileiuconcept, Stuurgroep
Paper Leaves
Peter Gentenaar
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WR,WLVIRUFHGWREHÀDWDQGWKHSDSHULQGXVWU\XVHVORWVRI
HQHUJ\GU\LQJLWVSDSHUVÀDW
$WULDQJOHPDGHZLWKEDPERRULEVDQGEOHDFKHGÀD[SXOSZDV
DFRPSOHWHO\ÀDWVKDSHZKHQLWZDVOD\LQJZHWRQP\VFUHHQ
After drying you see that a triangle keeps its shape, because
as architects know, triangles are stiff and are great to build
railroad bridges with.
49
OHVVWKHVDPHZD\EXWZLWKGLIIHUHQWSODQW¿EHUV
,¶PDQDUWLVWVRPHRQHZKRSOD\VDURXQGSURIHVVLRQDOO\ZLWK
a background in sculpture, painting and printmaking, etchings
and lithography. I recently spent a year at the California
College for Arts & Crafts in Oakland where I was getting my
Master of Fine Arts (MFA). I made engravings on thick sheets
of Plexiglass (polymethyl methacrylate). The plexiglass had
air bubbles in them and the factory had dumped them on the
campus.
50 PAPER LEAVES
I built mixers, sheet formers and presses and with those I
made huge relief prints.
What I mean is, until that time I had been using industrial
cellulose halfstuff which I mixed with water in a 200l mixer.
,WVHSDUDWHGWKH¿EHUVIURPHDFKRWKHUEXWQRWKLQJPRUH
Great amounts of wood glue were added to give the paper
some coherence. The paper I made was felty and thick. I put
big coloured sheets of this paper on top of each other and
built great coloured layered multi sheets, which took ages to
press dry. Once it was dry I sawed the sheets into shapes with
DEDQGVDZ,QWKHHQGLWZDVRQO\DJORUL¿HGVRUWRISDSLHU
mâché, nothing more.
7KH +ROODQGHU IURP WKH .13 ODE ZDV DQ 8PSKHUVWRQ W\SH
built by Voight in Germany 1954. Working with it I found
RXW DERXW ¿EUH OHQJWK ¿EULOODWLRQ RYHU EHDWLQJ DQG DOO WKH
different paper types that come from these pulps. In short I
learned what all papermakers know, that paper is really made
in the Hollander. The machine was impressive, high speed
water cooled and a motor of 7 brake horsepower, and all I
did was beat cotton linters. After some years I became more
GDULQJZLWKWKHEHDWHUDQGERXJKWP\VHOIDIHZEDOHVRIÀD[
ZDVWHLQ=HHODQG,EHDWWKLVYHU\WRXJKDQGZRRG\¿EUHVR
PXFKWKDWLWWXUQHGJROG$W¿UVW,ZDVDPD]HGODWHU,UHDOL]HG
that it was the bronze of the knives and bedplate wearing of
RQWKH¿EUHV7KHSDSHUEHFDPHFULVS\MXPS\DQGLPSRVVLEOH
WRGU\ÀDW7KHZRRGWKDW,ODLGRQWRSRILWWRNHHSLWÀDWVWXFN
to it sometimes and on other places the paper pulled away
from under it and in those places the paper curled up wildly.
7KRVHZHUHWKH¿UVWWLPHV,QRWLFHGDZD\WRSOD\ZLWKGU\LQJ
paper. At the time the paper product I was making probably
was a failure because of this curling. Make something of your
failures was the motto and it still is. Putting sticks in paper
pulp and letting them dry up together became a great way to
work. The paper in itself became my tool of expression, it was
PETER GENTENAAR 51
not only a carrier for other media but it became the subject
RIWKHVWRU\3OD\LQJZLWKORQJEHDWHQ¿EUHVQH[WWRYHU\VKRUW
beaten ones and seeing how both dried up and effected
HDFKRWKHU%XLOGLQJWKHWKLQIUDPHV¿QGLQJWKHULJKWNLQGRI
bamboo. Finding the relation between beating times, beater
adjustments and the shrinkage of the pulp gives you a control
over part of your matter, While in other later stages of your
work, during the drying, nature really takes its own course and
leaves you standing in the side line.
But all this comes at great risk, if the paper is too wet it will fall
of the bamboo frames. You want to take this risk because the
shrinking will be all the more baroque and unexpected when
you dare to take the paper of the screen as wet as possible.
The more water there is to evaporate the more movement
the shrinking will make. The process gives every form its own
tension. To enlarge the forms to three or four meters raises
the drama caused by the drying process.
52 PAPER LEAVES
to be placed outside on both sides of a bridge in Capelle aan
den IJssel.
After casting the plaster is taken off the bronze and the three
pieces are welded back together to one big sculpture. I spend
a month bringing up the patina and polishing the bronze
so that a result of gold skin with blue ribs through it was
reached.
Fig. 4. Tabakswolken
Tobacco Clouds
1230 x 120 x 45 cm
PETER GENTENAAR 53
Fig. 5. Two paper sculptures
cast in bronze on
a bridge near the
Fascinatio district,
Capelle a/d IJssel, 2005
7KH ORQJ ¿EUHV VSXQ DURXQG WKH D[OH DQG RQFH WKH\ GULHG
54 PAPER LEAVES
up prevented the machine from starting. It was very hard to
reach the axle and clean it, because it was an Umpherston
type machine, with a completely enclosed water/pulp canal.
So time after time I had to take the machine apart what made
me very familiar with the way it was built.
7KH¿UVW+ROODQGHU,GHVLJQHGZDVEXLOWLQDPDFKLQHIDFWRU\
in The Hague. In the design I had mounted the knives roll on
a moving arm so it could bounce over lumps and knots in the
ORQJ¿EUHDOVR,JDYHLWDFRXQWHUEDODQFHZLWKZHLJKWVRQ
LWWRUHJXODWHWKHZHLJKWLPSDFWRIWKHUROORQWKH¿EHUVDQG
combined it with a more traditional open arena shaped tub. In
the new machine all the parts, like bedplate and axle are easy
to reach and clean. I took the new machine home and placed
it next to the old one and found out that my new creation was
very unpractical and had a too weak electro motor. So I kept
using the old Hollander. One day a stainless steel nut from the
QHZ+ROODQGHUIHOOLQWRDEXFNHWIXOORIVRDNLQJ¿EUHV:KHQ
I threw this bucket full into the old machine all the bronze
knives of the ground plate broke loose and I was forced to
continue pulp making with my own new and very unpractical
beater. I improved it, gave it a stronger electro motor but it still
GLGQRWZDQWWREHDWÀD[RUKHPS,GHVLJQHGDQHZLPSURYHG
machine and found a better machine and tool factory who
built a beautiful good working Hollander. When I could sell this
Fig. 6. Venus Hollander I quickly did, improved the design further and had 3
Ø 110 x 200 cm machines built which all sold within a year. This brought on a
whole new development. Clients who bought a Hollander also
wanted a paper press and a drying box, which I designed and
had made also. Over a 100 paper making machines, mostly
the Hollanders are sold to places like a university in South
.RUHDDQGWKH6&$IDFWRULHVLQ6ZHGHQ
Fig. 7. Blauwe Sigaar The coloured pulp is the colour and the carrier or the substrate
µ%OXH&LJDU¶ in one. Her pulp palette gives her much more choice in colour
Ø 90 x 320 cm and texture than normal paint would. A red pigmented hemp
PETER GENTENAAR 55
¿EUHZKLFKKDVEHHQSLJPHQWHGLQWKH+ROODQGHUZLOOEHGHHS
red, through and through, comparable with dyed textiles.
7KHGLIIHUHQW¿EUHVDOOWDNHWKHSLJPHQWVLQDGLIIHUHQWZD\
also depending on how long they have been in the Hollander.
'LIIHUHQWSODQW¿EUHVDOVRUHÀHFWWKHOLJKWGLIIHUHQWO\KDYHD
different surface and a different texture. It is the richest and
most natural material to paint with I know. A great deal off the
VXEMHFWPDWWHURI3DW¶VSDLQWLQJVFRPHVIURPKHUSKRWRJUDSKV
which she makes in our garden.
PETER GENTENAAR 57
This page intentionally left blank
Cardboard in Architecture. M. Eekhout et al. (Eds.). IOS Press, 2008.
© 2008 The authors and IOS Press. All rights reserved.
Abstract
1. Background
In 2000, the Faculty of Architecture started a research project
around the material cardboard. Main goal is to establish
cardboard as real building material. Cardboard is almost 90%
renewable, relatively cheap and can, just because of these
aspects, be used shameless. In the past, some temporary
constructions were built, using cardboard. Well known
examples in The Netherlands are two temporarily theatres
in Apeldoorn, built because of the celebration event of “1200
\HDUV$SHOGRRUQ´8\WHQKDDN1,2 and Ruijssenaars3, 1992) and
more recently the Paper Dome in Utrecht4 (Octatube, 2003).
One step in the ongoing cardboard research project is the
GHVLJQDQGEXLOGLQJRIDFDUGERDUGSDYLOLRQVHH¿JXUH%RWK
GHVLJQDQGEXLOGLQJSURFHVVRIWKLVSDYLOLRQFDQEHGH¿QHGDV
³DQHGXFDWLRQDOH[SHULPHQWDOH[HUFLVH´$KXJHVORJDQRQD
billboard claims the setting of the pavilion project: “Starting
SRLQW RI UHVHDUFK´ VHH ¿JXUH 7KLV SDSHU GHDOV ZLWK WKH
problems encountered during the building of the cardboard
pavilion.
59
Fig. 1. The card board pavilion,
an overview
2. Architectural design
2.1. Architectural concept
The design of the cardboard pavilion is made by students
working on their MSc in Architecture. An important goal
for the design concept, was that the pavilion could act as
an exhibition in itself: what possibilities offers cardboard as
D EXLOGLQJ PDWHULDO" 0RUHRYHU WKH SDYLOLRQ KDG WR KDYH D
spacious character from an architectural point of view.
.((69$1.5$1(1%85*(/,6(9$1'225(1$1')5('9((5 61
a brief description is given below:
The boxes are glued together and a top surface layer is applied.
Because of the top layer, a rigid construction arises. Further Fig. 5. 4-point bending tests on
LQIRUPDWLRQFDQEHIRXQGLQ³&DUGERDUG$UFKLWHFWXUH´5. a reinforced card board
beam
3. Building technology
3.1 Mechanical tests
In general, the mechanical behaviour and the failure behaviour
of cardboard in an architectural engineering setting were not
well understood yet. For safety reasons, mechanical properties
and failure behaviour of the different cardboard elements used,
HJZDOOVVWDLUDQGÀRRUKDGWREHGHWHUPLQHG&DUGERDUG
beam specimen in different compositions are made and tested
to get an indication of the reliability of structural components,
VHH¿JXUH5HVXOWVDUHXVHGWRGHWHUPLQHIRUH[DPSOHORDG
FDUU\LQJFDSDFLW\DQGSRVVLEOHVSDQRIWKHÀRRUDUHD7KUHH
more advanced series of tests were conducted to characterize
Fig. 6b. Impregnation of the the mechanical behaviour of the (soon commercial) Bee Wall.
stairs wall 7KH¿UVWVHULHVFRPSUHVVLRQDQGEHQGLQJWHVWVDUHPDGHRQ
small sections of the wall. In a second series impact tests
DUHSHUIRUPHGVHH¿JXUH,QWKHWKLUGVHULHVDIRXUSRLQW
bending test is made on a whole wall element.6
.((69$1.5$1(1%85*(/,6(9$1'225(1$1')5('9((5 63
to the burning process. During burning, a layer of carbon is
formed, protecting the underlying material from burning. Flame
resistance of both solid board and treated open cell structure
of honeycomb board can be marked as moderate7. For this
reason only the visible open cell structure is impregnated with
DFKHPLFDOÀDPHUHWDUGDQWVHH¿JXUHE
7KH ¿QDO WKLFNQHVV RI WKH ÀRRU LV FP ZLWK VSDQV RI
PHWHUV7KHXSSHUSDUWRIWKHÀRRUKDVEHHQ¿QLVKHGZLWK
a top layer of solid board in order to protect the underlying
honeycomb from intrusion.
3.5. Use
After building, the pavilion in used as part of the exhibition on
the 2-days symposium. During „service life“, no considerable
problems appeared, except some problems with the weak top
layer of the rungs. The rungs were covered with multiplex
plates in order to protect them from damage. After a short life
cycle of three weeks, the pavilion was demolished and offered
for recycling.
4. Conclusions
We have faced a number of technical, engineering problems
during the design and building process of the cardboard
pavilion. In some cases, these problems can be marked as
VSHFL¿FWRFDUGERDUGUHODWHG7KHPRVWUHPDUNDEOHSUREOHPV
are described below. Moreover, some possible solutions are
provided.
.((69$1.5$1(1%85*(/,6(9$1'225(1$1')5('9((5 65
EHQGLQJVWLIIQHVV7KLVVSHFL¿FFRPELQDWLRQORZGHQVLW\DQG
low bending stiffness, leads to a problem. A soft push on
the balustrade on the terrace on 3 meters height resulted
in movement of the entire construction with considerable
DPSOLWXGH DV LOOXVWUDWHG LQ ¿JXUH D %HFDXVH RI WKLV WKH
decision was made not to build higher than 3.40 meter.
4.2 Deformation
A second problem is the permanent deformation introduced
during manufacture. The cardboard elements are glued
together using adhesive. The adhesive diffuses into the
paperboard, as a result of which the paperboard softens and
loses its original form. After drying, this deformation becomes
permanent.
$VLPSOHVROXWLRQFDQEHIRXQGLQ¿[LQJWKHHOHPHQWVXQWLO
WKHJOXHKDVGULHG+RZHYHULQVRPHFDVHVLWLVGLI¿FXOWWR¿[
glue and dry large elements at the same time, for example the
¿QLVKLQJWRSOD\HURIWKH7DFRZDOO
4.5. Adhesive
General problem, in a mechanical sense, is the joint between
Fig. 9.'HODPLDWLRQRIWKHÀRRU different parts of cardboard. Failure caused by delamination is
RIWHQREVHUYHGVHH¿JXUH0XFKUHVHDUFKKDVWREHGRQH
LQWKLV¿HOG
5. References
1 T. Verstegen, Rudy Uytenhaak, 010 Publishers, isbn 90-6450-
241-2, Amsterdam, 1996
2 http://www.uytenhaak.nl
3 http://www.architectengroep.nl/hansruijssenaars
4 http://www.octatube.nl
5 E. Van Dooren and T. Van Iersel, Cardboard architecture,
drukkerij Groen, Leiden, The Netherlands, 2006
6 M. Veldhuizen, Mechanical tests on the Bee Wall, (in Dutch),
Delft, december 2005
)$9HHUDQG&YDQ.UDQHQEXUJ9HUJHOLMNLQJYDQGH
brandwerendheid van het Bee Wall binnenwandsysteem met
verschillende afwerkingen, (in Dutch), Delft, december 2005
.((69$1.5$1(1%85*(/,6(9$1'225(1$1')5('9((5 67
This page intentionally left blank
Cardboard in Architecture. M. Eekhout et al. (Eds.). IOS Press, 2008.
© 2008 The authors and IOS Press. All rights reserved.
A House of Cardboard
Abstract
,VDKRXVHPDGHRIFDUGERDUGIHDVLEOH":K\ZRXOG\RXZDQWWR
XVHDFDUGERDUGKRXVH",QRUGHUWRJLYHD±WHPSRUDU\±DQVZHU
a few thoughts have been written down.
69
1. Designing a cardboard house?
When asked why he climbed Mount Everest (1959) Sir Hillary
DQVZHUHG³%HFDXVHLWLVWKHUH´$FRPHGLDQRQFHVSRNHRI
a house where, because of sounds, everything was knitted:
knitted china, knitted doors, etc.
,VWKHIROGRIFDUGERDUGHTXLYDOHQWWRWKHKLQJH",I\RXIROG
open a cardboard door, how long will the fold last during
QRUPDOXVH"2UFDQWKHGRRUVLPSO\EHDUHPRYDEOHFDUGERDUG
SDQHO"%HFDXVHFDUGERDUGLVDOLJKWDQGWHPSRUDOPDWHULDODQG
seems therefore to be appropriate to be applied as movable
parts in a building. Is this example another way of thinking
DERXWWKLQJVZHFRPPRQO\DFFHSW"2UFDQWKHQDWXUHRIWKH
material cardboard change the way we think about building
DQGDUFKLWHFWXUH"
Fig. 1.&DUGERDUGER[DVµD
KRPH¶
70 A HOUSE OF CARDBOARD
Paper and cardboard are being used in the building industry on
very small scale. Cardboard (side) products are the ventilation
ducts in the XX building by Jouke Post (1995, Delft)1 and the
formwork tubes for concrete columns. Cardboard is the bearer
RIGXFWVLQDÀRRUKHDWLQJV\VWHP2. Wooden doors often have
D¿OOLQJRIKRQH\FHOOFDUGERDUGDQGLQVXODWLRQFDQEHDFKLHYHG
with cellulose plates3,4. Building paper (paper with asphalt) is
used in constructions as a protective layer for resisting water.
%HIRUHEHLQJLQÀXHQFHGE\:HVWHUQDUFKLWHFWXUHDQGFXOWXUH
the Japanese build in wood and paper. Or maybe better: the
Japanese built in wood. Because in fact paper is a derivative
of wood. Shigeru Ban, nowadays a well known architect,
Fig. 2. Projects by Shigeru Ban VRPHWLPHVXVHVWKHWHUPµHYROYHGZRRG¶IRUFDUGERDUG5.
72 A HOUSE OF CARDBOARD
designing space. New techniques in digital image printing,
printable electronic circuits and 3D-cutting computer programs
(Papercura) could lead to interesting options beyond the
possitbilities of traditional wallpaper.
74 A HOUSE OF CARDBOARD
Fig. 3. Structural test of a From a building perspective there are two important divisions:
honeycomb cardboard construction and separation. From a construction perspective,
panel GLIIHUHQWSDUWVZLOOEHGLVFXVVHGIRXQGDWLRQÀRRUVDQGURRIV
columns and plate constructions. Special shapes are those
where vertical and horizontal constructions meet. Connections
will also be discussed.
2.1. Foundation
Depending on the type of ground we build on and the degree
of temporality of the building, we will have to choose a type
of foundation. Principally there are two possibilities: a heavy
IRXQGDWLRQRUDIRXQGDWLRQZKLFKOHDYHVQRWUDFHDWDOOµOLNH
DWUDYHOOHU¶:KHUHFDUDYDQVOHDYHYLUWXDOO\QRWUDFHZHRIWHQ
do need a sturdy foundation. The most common material
for foundations is concrete. Even when using a wooden
skeleton as a construction, the foundation is often made from
concrete.
)RUPZRUNFDQEHXVHGDVDQHQYHORSHEXWDOVRDVDQµLQVHUW¶
The formwork thereby keeps the material from reaching
that point. In a case-study in Amsterdam13 (not executed)
cardboard was the answer to a very tricky formwork problem.
7KHIDFWWKDWQRFHUWL¿FDWHVDQGJXDUDQWHHVIRUFDUGERDUGDVD
formwork material were available stopped it from being used.
In the past formwork tubes have been used as inserts in cast
ÀRRUVPRQRWXEH9DQ$QWZHUSHQ7KHURXQGWXELQJUHGXFHG
the amount of concrete used and thereby the weight of the
ÀRRU$WWKHPRPHQWWKHGHPDQGIRUWKHVHW\SHVRIIRUPZRUN
is low, most probably because the reduction in weight is also
DFKLHYHGE\SUHIDEKROORZFRUHÀRRUV
7RJHWD¿UVWLPSUHVVLRQRIWKHGLPHQVLRQVRIDÀRRUSDFNDJH
and beams we use rules of thumb. For traditional building
PDWHULDOVWKHUDWLRKHLJKWVSDQRIDÀRRUHOHPHQWRUEHDP
vary from 1/10 to 1/30, depending on the material used and
WKHSUR¿OHXVHGVHFWLRQ0RVWFRPPRQLVWKHUDWLR7KH
76 A HOUSE OF CARDBOARD
rule of thumb of 1/10 is only used for relatively transparent
steel trusses.
5RRIVGLVWLQJXLVKWKHPVHOYHVVWUXFWXUDO\IURPÀRRUVEHFDXVH
their dimensions are much more favourable following the
lighter load. Shigeru Ban used a cardboard roof construction
LQ KLV FKLOGUHQ¶V PXVHXP LQ -DSDQ5 Beams of honeycell
cardboard (60 cm x 1 m and 60 cm x 3 m) from a triangular
VWUXFWXUH(YHU\WKUHHPHWHUVZH¿QGDFROXPQ7KHMRLQWVDUH
made of aluminium.
8QWLOOUHFHQWO\FDUGERDUGKDVEHHQXVHGYHU\OLWWOHLQÀRRUV,Q
the pavilion built in January 2006 at the faculty of Architecture,
TU Delft, honeycell panels were glued together making a
ODUJHGLPHQVLRQHGÀRRU7REHDEOHWRVXVWDLQFRQFHQWUDWHG
ORDGVWKHÀRRUZDVVXSSOLHGZLWKDIHZOD\HUVOLQHUVRIVROLG
cardboard. Creep (elongation progressing with time) and
the type of glue as well as the manual production process
presented a reasonable problem.
Experiences with the ratio height / span for now point in the
direction of 1/10. A relatively large amount of material for the
span.
5RXQGFROXPQVGRQRWDOZD\V¿WWKHEXLOGLQJLQGXVWU\ZLWK
its predominantly orthogonal shapes. The joints are especially
GLI¿FXOWWRGHVLJQ,Q-DSDQVTXDUHFROXPQVDUHDYDLODEOHEXW
the disadvantage is they are vulnerable to buckling.
78 A HOUSE OF CARDBOARD
at aspects like dimensional stability, building order and load
GHÀHFWLRQ
80 A HOUSE OF CARDBOARD
materials and building systems, but for now the conclusion
that structure in cardboard is only applicable in special
situations, like emergency housing, or because it is cheap,
EHDXWLIXORUHFRORJLFDOVHHPVMXVWL¿HG
2.5. Connections
A distinctive characteristic for the building industry is the
manner of connecting. Connections are mainly constructive
DQGRUIRUZDWHUSURR¿QJLQWKHLUXVH
82 A HOUSE OF CARDBOARD
contact with water, it loses its strength and disintegrates to
pulp. Therefore it is not a very logical choice to use cardboard
as a water repelling layer. And if we do decide to do so, we will
have to pay a lot of attention to this aspect.
0HDVXUHVWRPDNHFDUGERDUGZDWHUUHVLVWDQWDUHLQFRQÀLFW
with the potential of paper recyclabililty. The paper and
cardboard industry points out that a small percentage of these
types of cardboard in the pulp-phase are not a limitation for
the recycling process.
84 A HOUSE OF CARDBOARD
its warmth just as fast, whereas a building with a heavy
construction will temporarily store the warmth (accumulation).
Wooden constructions are an example of a lightweight
construction and stone-like materials are often used for
ZDUPWKDFFXPXODWLQJµKHDY\FRQVWUXFWLRQV¶
)LUHUHVLVWDQFHDW¿UVWVHHPVWREHDQXQDFKLHYDEOHDVSHFW
of paper and cardboard. Paper is an excellent fuel. But some
FDVHVKDYHVKRZQWKH¿UHUHVLVWDQFHRIFDUGERDUGWREHEHWWHU
WKDQ ¿UVW DVVXPHG $ OD\HU RI VROLG FDUGERDUG UHDFWV LQ D
VLPLODUZD\WR¿UHDVZRRGPLJKW7KHPDWHULDOIRUPVDOD\HU
of coal and thereby protects itself.
86 A HOUSE OF CARDBOARD
A possible solution might be found in using (some light form
of) reinforcement inside the cardboard walls.
,WKDVSUREDEO\DOZD\VEHHQWKLVZD\ORRNLQJDW0DUF/DPSH¶V
FRQFOXVLRQLQ³7KHJUHDWHVWSRZHULVWKHSRZHURIDWWUDFWLRQ´
88 A HOUSE OF CARDBOARD
“Structure was and still is, that much may be assumed proven
E\WKLVSXEOLFDWLRQIRUDUFKLWHFWV¿UVWO\DVRXUFHRISRVVLELOLWLHV
a way of escaping from everyday reality, and only secondly a
given which has to be solved while working out demands such
DVVWUHQJWKVWLIIQHVVVWDELOLW\DQGGXUDELOLW\´25.
4.2. Characteristics
Cardboard has advantages with regard to traditional building
materials:
1. Low weight, lightweight materials have advantages
in many aspects of the building industry (transport,
reducing the need for human or mechanical energy)
2. Foldable/printable, in the world of packaging
folding and printing is essential when applying
cardboard. Considering as a building element, these
advantages are less obvious
3. Recycling, the ecological advantage is large. The
UDZPDWHULDOLVLQ¿QLWHFHOOXORVH¿EUHDQGWKHF\FOH
RIROGSDSHUKDVDQHI¿FLHQF\RI+RZHYHUWKH
energy intensive recycling process does increase its
impact on the environment
4. Mass production, the bulk production has all the
(dis-)advantages of the production process. The
OLTXLGDQGµUROOLQJ¶SKDVHSXOSDQGUROOSUHVVLQJ
give us excellent opportunities to guide the
properties of the material.
5. Low price, the raw material is very cheap. This
means that we have a margin, by working the
SURGXFWWRDFKLHYHDFRVWHI¿FLHQWSURGXFWRU
building part.
90 A HOUSE OF CARDBOARD
Also the physical properties are largely unknown. Regarding
sound and warmth the different kinds of cardboard seem to
behave neutrally, with one or two exceptions like cellulose
board, which has excellent warmth-isolating properties and
honeycomb plates and work well as sound-deadening devices.
We all know the moisture sensitivity of cardboard and it can
therefore often only be used with a protective layer.
5HVHDUFKLQWRWKHPDWHULDOSURSHUWLHVLVQHFHVVDU\WR¿QGWKH
connection with the building industry. Not only do we need
to research the characteristics, but we also need to establish
classes and properties within a set spectrum, in order to set
QRUPVDQGEHJLQFHUWL¿FDWLRQ7KHH[LVWLQJSDSHUDQGFDUGERDUG
assortment has originated from a long tradition of developing
packages. In the development and production of cardboard this
market has been the basis. Improvements in the product and
the production process are pointed at the functional demands
of the package relative to its price. To apply cardboard in the
building industry means we must improve it, and yet learn
from the knowledge gained in the packaging industry. Precisely
that is why it is so important to search globally for different
NLQGVRISDSHUDQGFDUGERDUGZH¿QGWKDWFDUGERDUGWXEHV
from Germany and Japan are better suited for constructive
applications, because these tubes are made from cardboard
ZLWKDKLJKSHUFHQWDJHRIYLUJLQ¿EUH
92 A HOUSE OF CARDBOARD
2. next to recycling, the presence of one or more of
the afore mentioned characteristics in the new
product is essential: lightweight, foldable and
printable, machine produced and low price.
4.6. Context
Not just technical properties play a role in the development
of new applications for cardboard, also the social and cultural
context is of importance. Two examples will illustrate this.
Cardboard seems to be a suitable material for application in
temporary housing, because of its relatively short technical
lifespan27,28 and its advantages (lightweight, cheap, foldable
and thereby easy to transport).
References
.ORPSHQ3RVWOHYHQVGXXUJHEUXLNVGXXU;;HHQJHERXZ
als prototype van een nieuw milieuconcept, Stuurgroep
Experimenten Volkshuisvesting, Rotterdam, 1999, ISBN 90 5239
153 X
&KULVWRSK0DULD5DYHVORRW,QGXVWULHHOÀH[LEHOHQGHPRQWDEHO
vloerverwarmen, Gezond Bouwen & wonen, 2001-2
3 http://www.warmteplan.nl
4 Christoph Maria Ravesloot, Elastische isolatieplaat van gebruikt
papier, Gezond Bouwen & wonen, 2001-2
5 Mathilda Mc Quaid, Shigeru Ban, Phaidon, 2003, ISBN 0-7148-
94
Cardboard in Architecture. M. Eekhout et al. (Eds.). IOS Press, 2008.
© 2008 The authors and IOS Press. All rights reserved.
Abstract
Cardboard and paper products have been used for decades in the
¿HOGVRILQWHULRUDQGSURGXFWGHVLJQDQGWKHSDFNDJLQJLQGXVWU\
But cardboard has not been used widely in architectural design,
building technology and structural engineering and construction,
GHVSLWHLWVSRWHQWLDODGYDQWDJHVRIÀH[LELOLW\ORZPDWHULDOFRVW
ready availability and good environmental credentials.
95
1. Cardboard product range
No cardboard products specifically manufactured and
designed for the construction industry are currently available.
Structural projects using cardboard products generally use
standard cardboard or paper products from the packaging
LQGXVWU\KHQFHLWLVXVHIXOWREULHÀ\VXPPDULVHWKHVWUXFWXUDO
and construction qualities of these products.
1.1. Tubes
Tubes are manufactured by rolling multiple layers of spirally
wound paper plies over a spindle. The layers are glued
together by starch or PVA. The tube wall thickness depends
on the number of plies but can range up to 16mm. Tube
diameters up to 600mm are commonly available. The inner
and outer layer of the tube walls can be made from different
paper than the interior build up, to give a treated, coloured or
stronger paper on the surface. The tube length is not limited
by the manufacture process, but by transportation.
1.2. Panels
Cardboard panels are manufactured by laminating sheets of
paper or cardboard onto an interior honeycomb structure. The
honeycomb boards are made by sandwiching a honeycomb
structure between sheets of paper. The honeycomb structure
itself is manufactured by gluing multiple sheets of paper
together and pulling them apart or by gluing two halves of
moulded honeycomb panels together, made by pressing paper
pulp into a honeycomb mould.
Panels are generally between 1.2m and 1.5m wide and 2.4m
to 3.6m long. The size of the sheets is determined by the size
of the lamination press used in the manufacturing process.
The thickness and build up varies from single layer sheets of
1mm thick to 65mm thick sheets of honeycomb board. Sheets
can be laminated or mechanically bonded together to achieve
thicker sections. Sheets can be curved and easily cut into
any shape, either by hand or by state of the art CNC cutting
processes. It is possible to laminate different types of paper
onto both sides of the sheets to achieve differing interior and
exterior surfaces. It is also possible to laminate non paper
1.3. Sections
A number of L and T shaped and rectangular hollow sections
are available in cardboard. They are generally single layer
elements with wall thicknesses up to 4mm. cardboard sections
are manufactured as connection and stiffening elements for
furniture products or packaging. While they are not commonly
used in any of the example projects described it is possible to
use them similarly to small size steel sections to build up larger
sections or connect tubes or panels.
2.1. Columns
Axial loaded columns can be designed using tubes or build
up hollow sections. Load bearing columns are generally of a
large diameter and the ratio between the tube wall thickness
and the diameter is high, hence tubes tend to fail in local
buckling. Overall buckling of the tubes is less likely due to
the low slenderness ratio of the sections. The critical areas
when designing column are the load transfer points. The loads
should be spread over the entire tube circumference to avoid
stress concentrations and local creep.
2.2. Beams
Beams can be designed in using sheets of honeycomb
cardboard or sections. Due to the low ultimate strength of
cardboard elements the beam sections will appear deep and
2.3. Walls
Flat panels or rows of tubes sandwiched between panels
can be used for the design of walls. The walls can either be
load bearing or self supporting stability elements. walls can
either be designed entirely in cardboard or more commonly
as cardboard elements mounted onto a primary timber frame.
In both cases the stiffness of the wall and its performance
under lateral loads are critical. The stiffness can be enhanced
by utilising stiffeners, cross walls or the design of the wall as
a folded plate. If the panels are mounted onto timber frames
the cardboard becomes primarily a cladding material and the
board a stability element.
3. Design parameters
As a result of the projects described within this paper a number
of tentative design parameters for cardboard have been
HVWDEOLVKHG7KHVHSDUDPHWHUVDUHEDVHGRQSURMHFWVSHFL¿F
tests and particular products and can be divided into material
properties and connection parameters. However as there are
no generally agreed structural requirements and standards for
the use of cardboard in construction, it is essential that these
parameters are reassessed and re-evaluated prior to each
project.
The following values might be used for the design with 20mm
thick honeycomb sheets:
Design tensile/compressive
strength taking account of 0.6 N/mm2
creep effects
4. Connection design
Secondly the design parameters vary greatly with time and the
environmental conditions. Hence, any permanent cardboard
project requires a far more wide reaching analysis than a
temporary one and might rely on assumptions which can not
be tested prior to the construction. This partially explains why
the majority of the cardboard project carried out so far have
7KHLQLWLDOGHÀHFWLRQLVVWURQJO\LQÀXHQFHGE\WKHPRLVWXUH
content of the cardboard at the start of construction.
&RPPRQO\FDUGERDUGGHOLYHUHGWRVLWHLVVWLOO³JUHHQ´DQGLW
VWLOOVKULQNVVLJQL¿FDQWO\GXULQJWKH¿UVWPRQWKRIFRQVWUXFWLRQ
and building usage, especially if the building is relatively dry
and heated.
6.5. Fire
It is a known fact that card and paper burn. They can be a key
¿UHORDGLQVRPHEXLOGLQJVLI¿UHPDQDJHPHQWLVQRWWKRURXJKO\
considered and applied. What has been established through
ad-hoc tests carried out during the design and material
development of the Locla Zone and Westborough School is:-
• Thick card chars like timber: the end os a 12mm
walled cardboard tube was exposed to a 1000oC
ÀDPH7KHEHKDYLRXURIWKHWXEHZDVVLPLODUWRWKDW
of timber in that the material charred, protecting
LWVHOIIURPIXUWKHUGHWHULRUDWLRQE\WKHÀDPH
• Untreated 5mm card nearly achieves a rating of
&ODVV2VXUIDFHRIÀDPH
• With treatment using a clear product typically used
on timber this rating is achieved. Alternatively over-
cladding with a protective board is a solution.
6.6. Cost
Cardboard as a raw material is relatively inexpensive. However,
recycling can only be achieved by a manufacturing process that
is highly repetitive and standardised, hence recycled cardboard
is only economically available in a number of basic shapes. As
long as standard elements are used cardboard presents an
economic material, especially for complex structures. The
additional cost of cardboard structures lies primarily in the
H[WHQGHGGHVLJQWLPHFRVWVIRUVSHFL¿FPDWHULDOUHVHDUFKDQG
testing and the use of specialist labour.
7. Case Studies
The next pages describe 7 projects in which Buro Happold
was involved:
In a project partly funded by the Department of A prototype bay was erected to test the
the Environment Transport and Regions (DETR) ease of manufacture and erection of the
Buro Happold engineers headed a team to panels. The prototype erection proved
construct a building for Westborough Primary important in the development of the
School, Westcliffe on Sea, Essex, which uses scheme. In particular, panel junctions
cardboard components wherever possible. FRXOG EH UH¿QHG DQG VLPSOL¿HG DLGLQJ
the manufacturing time and the ease
The projects main objective was to produce a of erection. This prototype construction
building which was 90% recyclable at the end of provided us with a building which could be
its life and which is almost entirely constructed created from a number of panels simply
from recycled materials. In addition we had screwed together on site along their
the aspiration of producing a product which edges.
could be made available to the construction
industry fo ruse in other buildings. The new
building, intended for use as an after school
club, is actually used by the school pre, post
and during school hours. In order to realise the
project, we teamed up with an architectural
practice, Cottrell and Vermeulen, paper and
board manufacturers; Paper Marc Ltd, Essex
7XEH :LQGLQJV /WG 4XLQWRQ DQG .DLQHV /WG
and, at the time of construction, a building
contractor, CG Franklin Ltd.
The Japanese Pavilion was built for the Hanover it is both low energy and easily reusable.
:RUOG¶V)DLULQDQGUHPDLQHGLQSODFHIRU
seven month. The theme of the exhibition The design and modelling of the of this
³GHVLJQ IRU SODQHWDU\ FRQWLQXDQFH´ UHTXLUHG structure was part of an intense design
pavilions to be designed to demonstrate HIIRUWZKLFKLQFOXGHGIRUP¿QGLQJH[HUFLVH
reduced use of resources and CO2 emissions. and the construction of physical models, in
The architect Shigeru Ban, working with Buro order to determine the project geometry
Happold, designed a pavilion hall formed as well as the possible buckling failure
from cardboard tubes and clad in a paper modes. Rigidity is aided by wood arches
membrane. at regular intervals. Steel struts at the
ends were incorporated into the grid at
7KHEXLOGLQJZDVFRQFHLYHGDVDÀH[LEOHJULG the insistence of the German checking
shell structure that would be assembled and authorities, although analysis indicated
laid lat on the ground, and then lifted and that these were not needed.
formed into place by a protruding scaffolding
V\VWHPWKDWZRXOGJLYHLWWKHD¿QDOJHRPHWU\ Detailing the structure involved the
7KLV¿QDOVKDSHZDV¿[DWHGE\DVWLIIERUGHU resolution of some key connections.
element at its perimeter edge. The overall These are the cross points between the
dimension of the hall is 75m by 35m with a rise two tubes, the connection of the tubes to
of up to 15.5m. the ground plane and the connection of
the tubes to the cladding as well as to the
The main tubes consisted of 120mm diameter, wood ladders. The connection solutions
22mm thick paper tubes. The tubes were are similar to the ones designed for the
formed of three glued spiral card tapes of MoMA Arch, described later in this article.
an exact moisture content and structural
strength. Their design was based on material The hall was stabilised laterally by rigid
properties established in tests by the University end walls and longitudinally by the shells
of Dortmund with a partial factor of safety tubular shape structural supported by
approach similar to the European codes for metal cable cross bracing.
timber structures. The tubes were lashed
WRJHWKHUDWWKHLUFURVVLQJSRLQWVE\¿UHUHVLVWDQW The hall was totally recycled by the end of
plastic straps. its seven month life.
Architect Daniel Libeskind was awarded the of cardboard panels needed to form the
Hiroshima peace prize in 2001. Following modules. The fabrication of these panels
this, four large scale (1:5) building models was achieved by CNC cutting all panels
of recent projects by studio Libeskind formed from templates supplied by the architects.
the centrepiece of an exhibition that started in
the Hiroshima Museum of Contemporary Arts The models where analysed using by
in July 2002and moved to the ICC Museum in LPSRVLQJVLPSOL¿HGVWUXWDQGWLHV\VWHPV
Tokyo at the end o 2002. The models where onto the units and hand calculations. This
approximately 30m in plan and up to 10m in approach gave a clear understanding of
height. The second exhibition in Tokyo was D GH¿QHG ORDG SDWK ZLWKLQ WKH FRPSOH[
not part of the original design brief, but it was layering of units formed from plane
decided to design the exhibition as a travelling panels. The models where analysed for
show, such that any interest arising from strength and stability only. Creep and
WKH ¿UVW VKRZ FRXOG EH UHVSRQGHG WR ZLWK ORQJWHUPGHÀHFWLRQZKHUHQRWDQDO\VHG
remounting the exhibition. because of the temporary nature of the
project, but creep issues where addressed
The design time was extremely tight, with by detailing each model as a highly
one month for the entire design from the redundant system.
concept to the detailing stage and one
month for manufacture and a week for on The project showed how cardboard
site construction. In addition the scale of the could be used effectively to respond
proposed models required a light construction to a number specific site issues, ie
material to avoid excessive loads onto the access and manhandling restrictions,
museum floors. Hence it was decided to speed of construction and design,
design all models entirely using cardboard and ease of maintenance and local repairs,
paper fabricated into a modular box system of demountability, minimum weight of the
20mm honeycomb cardboard sheets, glued overall structure. In addition the project
and jointed together. The joint – a cardboard responded well to the Japanese tradition
angle glued and screwed to the inside of the and knowledge of using paper products
cardboard facing boards- carries the forces and in construction. Hence the construction of
the screws are for positioning only. The glued the complex shapes was easily understood
connection form a structurally rigid unit which by the fabricators, once the design had
could be transported into the exhibition areas been demonstrated with a full scale
and bolted to the adjacent units. mock up module. This mock up module
was constructed by the design team to
The maximum size of the units was determined test the connection detail and stiffening
by the largest access door into the exhibition requirements.
hall. Small access doors in one face of the
allowed them to be bolted together and give
access into the inside of the large models. The
modules itself where all of different shape and
size and hence there was an enourmous variety
The exhibition investigated the use of working The design and construction period for
models in the design process. The models the entire exhibition consisted of only 7
DUH KRXVHG LQ D VWUXFWXUH FRPSRVHG RI ¿YH weeks, and again cardboard was chosen
layers of cardboard panels, stacked to form to rapidly and easily respond to a complex
walls which loosely follow the outline of the geometric layout. All cardboard sheets
exhibition space. the panels change height and were pre-cut and delivered to site and
fold in different directions to the ones above the entire exhibition constructed in two
DQGEHORZWKH\DUHDOOÀDWEXWQRWJHQHUDOO\ days. The use of cardboard also allowed
vertical. The folded arrangement creates steps HDV\PRGL¿FDWLRQVRQVLWHWRUHVSRQGWKH
and shelves on which the designers models are existing structure, which had, due to time
positioned. and cost constraints, only been surveyed
very basically during the design phase.
The overall stability of the structure is achieved The budget for the exhibition design and
by the folding geometry of the walls and by construction was just above £ 10.000
overlapping the panels, so that, for example, and due to the cheapness of cardboard
folded portion of an upper panel is triangulated base material, the majority of the budget
with the straight portion of the panel below could be spent on the labour, design and
it and vice versa. Using this stacking system ¿QLVKHV
the shelves can easily cantilever into the room
or draw back into the space behind. The
cardboard used was 30mm thick honeycomb
panels, faced both sides with an aluminium foil
WRJLYHUHVLVWDQFHDJDLQVWWKHVSUHDGRIÀDPHV
WKH\KDYHDWKLQZKLWHSDSHU¿QLVK
This temporary structure was erected as part vertical elements were inserted and the
of a retrospective of art and architecture of grid shell elements added. The diagonal
the 20th century at the Museum of Modern truss cables were inserted into the truss
Art in New York City. It is made up by 200mm and then the top chord was attached
diameter cardboard tube sections with a wall in order to complete the truss. Once
WKLFNQHVVRIPP7KHWXEHVGH¿QHWKHWRS assembled and painted with waterproof
and bottom chord of 600mm deep paper tube coating the structure was cut into eight
arches. These arches span approx. 24m and are half arch slices in order to be able to
linked transversally by a paper tube gridshell transport it to the museum. Adjacent to
of 150mm diameter tubes with a 25mm wall the museum site the pieces were partially
thickness. Cable stiffening ties are located connected together, lifted into place and
under the arch and attached to the bottom then attached to the receiving support
chord. The overall size of the structure is 24 points.
x 24 m and it was installed over the summer
season for a period of 90 days.
This 4000m2 temporary exhibition hall is the museum departs for other countries
intended for a travelling venue that will (expected to include France, China and the
highlight the work of a contemporary artist. Vatican State), the tubes will be recycled,
The hall is approximately 20m wide by 200m DVLW¶VOHVVH[SHQVLYHWREX\QHZRQHVWKDQ
long. It is constructed of materials typical LW LV WR VKLS WKHP ³,W¶V D WUDQVSRUWDEOH
used in temporary structures including fabric, PXVHXPZKHUHZHGRQ¶WKDYHWRWUDQVSRUW
scaffolding, cribbing and the containers used WKHEXLOGLQJPDWHULDO´
to ship them.
1. Introduction
Cardboard in the building industry means the enlargement of
the share of renewable raw materials in the building industry.
Considering that this industry is one of the most polluting
sectors, the use of ecologically sound materials is desirable.
2. Surrounding
The proper functioning of a partition system depends on
the materials properties and how far the design meets the
markets demands. The demands are a multitude of conditions
asked from a building product: the surrounding factors. An
analysis of these factors gives an insight in the conditions,
traps and success factors, a partition must meet.
7KHWHFKQLFDOVSHFL¿FDWLRQVDUHLQÀXHQFHGE\WKUHHFDWHJRULHV
RIVXUURXQGLQJIDFWRUV¿JXUHD
1. legislation and rules
2. user demands
3. economical factors (market)
119
semi-
permanent
architect
new
development
use
transport
professional
do housing
hallmark it
yourself
user commercial renovation
building
event
project
(de)montage technical market building
specifications retail
legislation
&
factories safety
rules
act hallmark
environment building
regulations national
environment
plan
health
safety
utility
energy
3. Economical factors
Each segment of the market (housing, utility building, amd
project building) have their own user characteristics, size and
tradition. Different existing building systems have taken their
place in a segment of the market.
geometry product/brand
Stucloper
1 hollow wall system Metalstud
case study 1
Tako-dozen
2 stacking systems Xella, Gibo
case study 2
Bee-wand
3 panel systems Faay, Verwol
case study 3
5.1. Case-study 1
Type of wall hollow wall system
Material - core whitewood
- liner laminate of PE, aluminium foil and paper
OLTXLGSDFNDJLQJFDUGERDUGRUVWXFFRÀRRU
Connections glue and stitches
5.1.1. Sub-conclusion
7KHORZFRVWSULFHRIFDUGERDUGZLWKLWVUHÀHFWLQJSURSHUWLHV
shows that it technically might be a replacement for mineral
wool. Cardboard can also compete with glass wool concerning
cost-price per square metre. The work-intensive assembly
of the many cardboard layers makes the system as a whole
economically unviable to replace traditional systems (metal
stud).
Fig. 4. Curve of compression
5.2. Case study 2 strength according to
Type of wall stacking wall 0F.HH
Type of cardboard FRUUXJDWHGFDUGERDUGFÀXWHPP
Connections timber glue or starch glue
5.2.1. Sub-conclusion
The staking system of glued cardboard boxes shows a direct
translation of masonry. However, technically the system is
not capable of replacing solid blocks directly. The hollowness
of the wall gives it a weight advantage, but the mechanical
properties are not parallel to solid blocks. The building speed
might be high, but the use of glue requires many handlings
and long drying time. A critical remark is the fact that it mimics
traditional masonry in detail. A stacking system without
adding a third element (glue), would produce a smarter and
faster building system.
5.3. Case-study 3
Type of wall panel system
Type of cardboard
- liner solid cardboard
- core honeycell cardboard
Connections tongue and groove system with a
strip of honeycell cardboard
5.3.1. Sub-conclusion
The panel system has a high building speed and remains
under 25 kg through the use of honeycell cardboard. The dry
assembly offers possibilities for reuse and recycling. When
WKHF\FOHLVUHVWRUHGE\WDNLQJEDFNWKHSURGXFWD¿QDQFLDO
advantage is created for the user in the demolition phase. This
6. Sound
Sound insulation takes place in the shape of absorption,
UHÀHFWLRQDQGWKURXJKPDVV7KHODWWHULVWKHPRVWLPSRUWDQW
but also the missing factor when using cardboard. Corrugated
cardboard and honeycell cardboard are lightweight paper
constructions. One possibility of overcoming the lack of mass
is disconnection. In hollow partition systems this can easily
be realised by assembling the posts disconnected. With panel
V\VWHPVWKLVLVDPRUHGLI¿FXOWWDVNLWLVDRQHHOHPHQWSDQHO
Adding mass is being restricted by government rules. A panel
can weigh a maximum of 25 kg.
8. Conclusion
To appoint decisive factors in the landscape of surrounding
factors which will guarantee a successful product is very hard
WRGHWHUPLQH2QVRPHOHYHOVLWLVSRVVLEOHWRGH¿QHVXFFHVV
factors and factors that act as a brake.
$FWLQJDVDEUDNH¿UVWRIDOOLVWKHIDFWRURILQGXVWULDOSURGXFWLRQ
The paper and cardboard industry consists of a long chain of
different paper and cardboard producing companies. The
basis of this industry is built on large volumes (quantity) The
development of a cardboard suitable for the building industry
µEXLOGLQJFDUGERDUG¶ZLOOEHDKDUGWUDMHFWRU\$QDSSOLFDWLRQ
with a large sale volume connects to the current nature of
the industry. The introduction of a new building material is
characterised by a project-basis and small-scale.
weight cardboard
weight wood
exhaustion cardboard
exhaustion wood
emissions cardboard
emissions wood
recycling cardboard
recycling wood
disassembly cardboard
disassembly wood
waste cardboard
waste wood
Table 2. Positive and negative effect of the partition materials per m2 wall
Literature
1 Rapportage IFD Haalbaarheidsstudie, project nummer 04019,
.HQQLVFHQWUXP3DSLHUHQ.DUWRQ$UQKHP
2 Compression Strenght Formula for Corrugated Boxes,
5&0F.HH-:*DQGHU-5:DFKXWD
3 Wijziging Beleidsregels arbeidsomstandighedenwetgeving, nr.02
48717. Convenant Sociale Zaken en Werkgelegenheid. M.Rutte,
5,-0.XLSHUV
4 Indicatieve LCA berekening kartonnen binnenwand, H. van Ewijk
,9$0.HQQLVFHQWUXPSDSLHUHQ.DUWRQ$UQKHP
6WXFORSHUDOVZDUPWHUHÀHFWLHIROLH,ULVGH.LHYLHW,Q6LWX
Architecten, Den Haag. http://216.154.208.139:8080/recyclicity/
designers/index.jsp
6 Isover Benelux, www.isover.nl, januari 2006
((7.LHPUDSSRUW6HQWHU1RYHPSURMQU
(LQGUDSSRUWDJH%RXZHQPHW.DUWRQMXQL
Abstract
131
packaging and personal hygiene. Most of the mechanical
properties required for structural usage are generally not
determined for paper or board. Particular little research on
long-term behaviour is documented, given that creep is a big
issue for cardboard constructions.
Material Structural
Testing Design
Mechanical
Behaviour
of
Cardboard
Computational
Modelling
Fig. 2. Domains of PhD research
From the table it can be seen that most of the properties can
be derived from one single tensile test, if no more experimental
data is available. However, as the relations are still rather
vague and depend on the single paper it is always advisable
WRGRDFRPSOHWHWHVWVHULHVIRUPRUHVSHFL¿FLQIRUPDWLRQ
7KHFHOOXORVH¿EUHVPDNHFDUGERDUGK\JURVFRSLF7KDWPHDQV
the moisture content of cardboard is related to the ambient
5.1. Beam 1
For the construction of beam 1 only solid board was used. The
VWUXFWXUHZDVDGRXEOH,SUR¿OHZKLFKZDV¿OOHGZLWKD]LJ]DJ
slat to prevent buckling of the web. The solid board was glued
WRJHWKHU ZLWK ZRRG JOXH 7KH FRQQHFWLRQ EHWZHHQ ÀDQJH
and web was performed by toothing and glue. The overall
dimension of the section was 25x30 cm.
This beam could bear a maximum force of 6000 N. The top Fig. 4. Test setup for the four
ÀDQJHVKRZHGODUJHORFDOGHIRUPDWLRQDWWKHORDGWUDQVPLVVLRQ point bending test of the
SRLQWV 7KLV ZDV EHFDXVH WKH OD\HUV LQ WKH ÀDQJHV ZHUH cardboard beams
5.2. Beam 2
This construction was also built of solid board. The main
VWUXFWXUHZDVDGRXEOH,EHDPZHUHWKHÀDQJHVDQGWKHZHEV
consisted of several sheets glued together with wood glue.
7KHWRSÀDQJHFRXQWHGOD\HUVRIERDUGDQGWKHERWWRP
one 8 layers. The web was designed with 5 layers. The two
webs were stiffened by a triangle construction to prevent
HDUO\EXFNOLQJ7KHÀDQJHVDQGWKHZHEZHUHFRQQHFWHGE\
toothing without any additional glue. The overall dimension of
this beam was 30x15 cm.
5.3. Beam 3
The main material of this beam was honeycomb board. The
beam had different cross-sections in side (Picture 11) and
middle part (Picture 12). In the compression zone of the beam
KRQH\FRPE ERDUGV ZHUH SODFHG YHUWLFDO LQ RUGHU WR EHQH¿W
from the high compression strength of honeycomb structures.
Around the honeycomb structure solid board was glued in a
box shape. The bottom, the tensile zone, of the beam was
strengthened by extra layers of solid board. This beam was
designed to be smaller than the previous beam and had an
overall dimension of 25x15 cm.
5.4. Beam 4
As all the previous beams failed in the compression zone, a
beam was design with a tube in the upper part of the beam
as a compressive reinforcement. The rest of the construction
resembled beam 3 to have a clear comparison for the effect of
compressive reinforcement.
The maximum load of this beam was 600 kg. As expected the
beam could bear more compressive stress and started to crack
Fig. 14-19. Cross-section (side in the tension zone. After reaching the maximum strength the
PLGGOH¿HOGDQG crack mouth opened very fast and the beam immediately lost
failure of beam 3. strength. The load deformation response of this beam was
5HJDUGLQJWKHGHÀHFWLRQRIWKHEHDPVDOOEHDPVZHUHQRW
very stiff and showed high deformations. These were due to
local buckling and deformation, but also because the basic
PDWHULDOGLGQRWKDYHDVLJQL¿FDQWVWLIIQHVVVHHWHVWUHVXOWV
own test, Table 2). A stiffer beam can be obtained with a
higher modulus of elasticity of the basic material and higher
moment of inertia of the cross-section.
Fig. 23. Load-deformation curve of beam 1. Fig. 24. Load-deformation curve of beam 2.
Fig. 25. Load-deformation curve of beam 3. Fig. 26. Load-deformation curve of beam 4.
References
1 Verhoef, M. Paper Buildings – Onderzoek naar de mogelijkheden
van karton als bouwmateriaal. Graduate project, Building
Technology, Faculty of Architecture, TU Delft, The Netherlands,
2002
9DQ,HUVHO7.DUWRQQHQ:RRQKXLV*UDGXDWHSURMHFW%XLOGLQJ
Technology, Faculty of Architecture, TU Delft, The Netherlands,
2002.
3 Den Boon, M., Studie naar honingraat panelen van karton.
Graduate project, Building Technology, Faculty of Architecture,
TU Delft, The Netherlands, 2003.
4 Eekhout M., Cardboard: Technical Research and Developments
DW78'HOIW"""
5 Schönwälder J., Rots J.G., Veer F.A., Determination and
Modelling of Cardboard as a Building Material, Proceedings, 5th
International PhD Symposium in Civil Engineering, Delft, The
Netherlands, 2004.
6 Schönwälder J., Veer F.A., Rapid determination of creep
properties of paperboard using staircase loading tests,
Proceedings, Progress in Paper Physics Seminar, Trondheim,
2004.
9HHU)$6FK|QZlOGHU-+HLGZHLOHU$.XLSHUV17KHFUHHS
fatigue interaction in solid paper, Proceedings, 15th European
Confernce of Fracture (ECF15), Stockholm, 2004.
146
Cardboard in Architecture. M. Eekhout et al. (Eds.). IOS Press, 2008.
© 2008 The authors and IOS Press. All rights reserved.
Mick Eekhout
Abstract
:KDWVLJQL¿HVGHVLJQDWWKH)DFXOW\RI$UFKLWHFWXUHDQGPRUH
147
VSHFL¿FLQWKH0DVWHUV%XLOGLQJ7HFKQRORJ\":KDWH[DFWO\LV
GHVLJQ"$SUHFLVHDQGFRPSUHKHQVLYHGH¿QLWLRQLVQRZKHUH
to be found. So let us considers design from different points
of view:
x Functional: The goal of design at the faculty of
Architecture is a material solution by inventing an
Fig. 1. The position of the
architectural composition for a posed architectural
problem. designer is located
x Composition: Design is composing parts into between the composer
a larger whole (artefact). Architectural design and the inventor
is composing elements and components into a
material artefact. Depending on the three levels this
could be: city planning, a building or components of
the building.
x Artistic: Design is creating an original spatial
composition. The material and immaterial means
are usually familiar; the position of matter in space
transforms a building into a piece of applied art.
x Technical: Design is inventing and ingeniously
developing new material elements, components,
systems and products for city planning/architecture/
building technology and the integration of those
parts into an artefact.
x Process: Design is the process of analysis,
synthesis and development starting with a problem
statement and ending in a material solution.
x Philosophical: Design is seeking an optimal
compromise between ambiguous demands and
desires.
x Economical: Design is seeking a balance
between demand, formulated in many wishes and
requirements and supply of a possible technical
H[HFXWLRQZLWKWKHUHTXLUHG¿QDQFLDOPHDQV
(YHUVLQFHP\¿UVWGD\DWWKH)DFXOW\RI$UFKLWHFWXUH,KDYH
been interested in design as a collection of activities with a
path-breaking result. Novelty is at top of the list. Not only
IRU\RXUVHOIZKLFKLVTXLWHFRPPRQZKHQ\RX¶UHDVWXGHQW
0,&.((.+287 149
Fig. 2.7KH¿YH*53URRIVRIWKH
Yitzhak Rabin Center, Tel
Aviv, Israel
$NDGHPLHYDQ:HWHQVFKDSSHQ¶5R\DO1HWKHUODQGV$FDGHP\
RI$UWV 6FLHQFHV,ZLOO¿UVWVXEVWDQWLDWHVFLHQWL¿FGHVLJQWR
subsequently gain understanding for design as a process of
composing.
But there are also architects who see it as their job to design,
research and develop the means (elements, components,
systems, products) with which they shape their buildings
according to their design. The interest of these architects is
both focusing on innovation in architecture and in technology.
They are focused on both the development of material means
to build, as composing a surprising artefact into a building.
These designers position themselves both at the producers-
side as the consumer-side of technology. Think of British
high-tech architects, Renzo Piano and Santiago Calatrava for
example. In the past decade Piano and Calatrava received
Fig. 6.µ7ULSSHQKXLV¶LQ an honorary doctorate at the TU Delft and were therefore
Amsterdam, where acknowledged for their professional quality in Delft.
the Royal Netherlands
Academy of Arts &
Sciences is housed.
0,&.((.+287 151
2. Inventing and composing in cardboard
This lengthy introduction was necessary in order to
comprehend the backgrounds of the designers of the
cardboard IJburg dome: Shigeru Ban and Mick Eekhout. Both
of them are used to invent and compose: to research and
design, research by design and design by research.
0,&.((.+287 153
³(VLVWQLFKWV1HXHVGDV:LVVHQYHUJHKW´EXWRQO\DIWHUWZR
years this seemed rather fast.
7KH¿QDOGHVLJQSURFHVVWKDWIROORZHGWKHGHVLJQRI6KLJHUX
Ban, was executed at Octatube under my strict supervision.
7KH LQLWLDO GLYLVLRQV RI %DQ¶V GRPH ZHUH EDVHG RQ D
Fig. 16.&ORVHXSVRID¿UVW frequecy subdivision. Because I have designed over 30
detail using bolted domes worldwide – all in steel and aluminium – I know what
connections before repetition factors mean. Consequently I proposed to reduce
tensile testing the frequency from 16 to 8, or even 6. The number of tubes
could be reduced to a quarter or even less. Ban, however,
seemed to be in love with cardboard: the more the better. This
was opposed to my minimalist principles including the cost
HI¿FLHQF\%XW-HDQHWWHYDQGHU6WHHQKRQRXUHGWKHRULJLQDO
design despite the fact that costs would increase if the dome
would be realized in its original design.
0,&.((.+287 155
nodes on 5 elevated tetrahedron-shaped supports.
4. Cardboard Engineering
By e-mail several discussions arose between cardboard lover
Ban and metal-tiger Eekhout about several aspects of the
design, including the design of the node. Twenty years ago
I developed a useful node for an aluminium dome in Jeddah
that was covered with a double membrane and transparent
insulation. With the help of this node it was possible to
FRQQHFWWKHEDUVDQGWKHWHQWPHPEUDQHWKDWFRXOGEH¿[HG
DQGVWUHVVHG%DQNHSWVWUHVVLQJDZRRG¿OOHGQRGHSUREDEO\
due to a Japanese tradition. The next design of the dome Fig. 17. Cardboard pressure test
was based on a compromise: Ban determined the geometry ZLWKWKHµ6RQRFRWXEHV¶
with a relatively short tube-length (a 10-frequent dome) and
Eekhout determined the detailing.
The detail existed out of a steel head on both ends of the tube
ZLWKDÀDWSURWXEHUDQWWDEWR¿[LWWRWKHQRGHV&RQQHFWLRQ
tests proved the weakness of cardboard at the transverse
screws and bolts. In Hannover Ban did not use screws because
the tubes crossed each other. Because the IJburgdome is
composed out of different shorter tubes and not continuous
WXEHVWKHJHRPHWU\LVGH¿QHGE\WKHQRGHV
Just like metal space structures the devilish idea arose: “Why
would you shorten a factory-produced tube of 6 meters to
OHW¶V VD\ PHWHUV WR HYHQWXDOO\ FRPH EDFN WR DJDLQ"´
Of course the answer is: utilising continuous tubes eventually
results in tubes that have to cross each other. The structural Fig. 18. Result of pressure test
engineers prefer an axial connection. Nonetheless, the design ZLWKWKHµ6RQRFRWXEHV¶
ZRXOGKDYHJDLQHGDEHWWHUFRVWHI¿FLHQF\<HW%DQYHWRHGWKLV (Fmax: 154kN)
SURSRVDODJDLQ,QWKH¿QDOEXGJHWWKHFRVWVIRUVWHHOZHUH
WLPHVKLJKHUWKDQIRUFDUGERDUG%DQ¶V+DQQRYHUSDYLOLRQKDG
continuous tubes, but the tubes were only loaded to a tension
of 25% compared to the IJburgdome. The limitations of the
current state of technology concerning the use of cardboard in
construction are notably increased because of this.
7KHGH¿FLWZDV¼,QDWHOHSKRQHFRQYHUVDWLRQZKLOH
driving to Belgium, I proposed to split the shortage in three
(Group van der Steen, Municipality of Utrecht and Octatube).
This created three risk-bearing parties that all had a clear
arranged risk. The following Monday it was decided to start
production immediately.
Fig. 21. Close-up of the
Octatube nodes used in 6. Final Detailing
Jeddah
The last test concerning the type of connection between the
tube ends and the heads of the node showed that bolted
connections, screws and steel pins – all based on the principle
RI VKHDU IRUFH ± ZRUN KLJKO\ LQHI¿FLHQW ZKHQ DSSOLHG WR
cardboard. Using glue is also out of the issue since it will only
connect the inner layer of paper and will therefore easily lead
to collapse. This is exactly the same for threaded connections.
Dot-shaped connections should be avoided in these kind of
cardboard constructions with high loads.
2QHRI2FWDWXEH¶VVWUXFWXUDOHQJLQHHUV/XLV:HEHULQWURGXFHG
the idea to apply a steel tensile rod within the cardboard tubes.
Pressure is locked up in between two steel head-plates. The
tensile rod deals with tension. In the factory the two galvanized
steel heads were twisted in two right-threaded props with a
10mm stainless steel thread and manually pre-stressed. True
and high pre-tension cannot be applied: it would not work
considering the sensitivity for creep of cardboard.
0,&.((.+287 157
connection in the star-shaped node can be adjusted in height
in this arrangement. The edges of the dome consist of steel
,3(SUR¿OHVWKDWDUHIROGHGVLGHZD\VEXWWKHKHDUWRIWKH
body is placed in the axial plane of the dome bars. The IPE-
SUR¿OHKDVVWHHOWDEVRQWKHRXWHUVKHOOWRWHQVHWKHPHPEUDQH
that is placed over the tubes; protecting the cardboard form
WKHZDWHU7KH¿YHIROGHGHGJHSUR¿OHVDUHWREHSODFHGRQ
tetrahedrons: stabile corner columns with outward and side-
way supports. All steel tubes are bolted down with steel plates
on the concrete foundation slabs.
0,&.((.+287 159
9. Humidity
Already during the research it was clear that next to creep,
UHODWLYHKXPLGLW\DOVRLQÀXHQFHGWKHVWUHQJWKRIWKHFDUGERDUG
tubes. Therefore we decided to seal off the tube ends with a
OD\HURIYDUQLVK%XWZKDWLVWKHLQÀXHQFHRIUDLQ",ILWUDLQV
during the assembly, water could drip towards the tube ends
and eventually get sucked inwards. A capillary effect between
the steel shaft and the cardboard is not very unlikely either. Fig. 25. Assembly of the dome:
a covering sail to keep
7KH¿UVWZHHNRIWKHDVVHPEO\LWZDVEHDXWLIXOGU\ZHDWKHU the bars as dry as
but the second week was very uncertain: rain and hard wind possible.
gusts. There was virtually no other choice than wrapping every
LQGLYLGXDOWXEHZLWKSDFNDJHIRLORUFRYHULQJWKH¿QLVKHGSDUW
of the dome with a covering sail. We chose for the last option,
EXWLWVHHPHGOLNHFRYHULQJWKH¿QLVKHGSDUWVWRRNDVORQJDV
assembling the nodes and the bars. However, the result was
D GRPH ZLWK GU\ EDUV $QG WKH ¿QLVK LV FHUWDLQO\ WKDW RI D
cardboard dome.
Fig. 26. Assembly of the dome:
0,&.((.+287 161
Fig. 31-33. Build-up of the
cardboard dome on
IJburg, Amsterdam.
References
1 Mick Eekhout, Inleiding tot de ontwerpmethodologie,
Symposium Ontwerpmethodologie TU Delft 28 mei 1998, TU
Delft, 1998, ISBN 90-5269-255-6
2 Octatube Space Structures, Research Report for the Cardboard
Dome in IJburg, internal publication, Delft, 2003
3 Matilda McQuaid, Shigeru Ban, Phaidon, London, 2003, ISBN 0-
7148-4194-3
%XFNPLQVWHU)XOOHU&ULWLFDO3DWK*ULI¿Q/RQGRQRULJLQDOO\
published in 1981), ISBN 0-3121-7491-8
0,&.((.+287 163
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Cardboard in Architecture. M. Eekhout et al. (Eds.). IOS Press, 2008.
© 2008 The authors and IOS Press. All rights reserved.
Epilogue
165
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Cardboard in Architecture. M. Eekhout et al. (Eds.). IOS Press, 2008.
© 2008 The authors and IOS Press. All rights reserved.
Author Details
Mick Eekhout
Chair of Product Development / Nestor Research Building Technology
Delft University of Technology, Faculty of Architecture, The Netherlands
Director Octatube Space Structures BV, Delft, The Netherlands
a.c.j.m.eekhout@tudelft.nl/m.eekhout@octatube.nl
Fons Verheijen
Chair of Architectural Engineering, Delft University of Technology,
Faculty of Architecture, The Netherlands
'LUHFWRU99.+$UFKLWHFWHQ/HLGHQ7KH1HWKHUODQGV
a.p.j.m.verheijen@tudelft.nl
Peter Gentenaar
Graphic designer, sculptor, paper artist
gentor@hetnet.nl
Fred Veer
Delft University of Technology, Faculty of Architecture, The Netherlands
f.a.veer@tudelft.nl
Helen Gribbon
$VVRFLDWH'LUHFWRULQ%XUR+DSSROG¶V0DQFKHVWHURI¿FH8QLWHG.LQJGRP
helen.gribbon@burrohappold.com
Florian Foerster
)UHHODQFH6HQLRU6WUXFWXUDO(QJLQHHULQ%XUR+DSSROGV%HUOLQRI¿FH*HUPDQ\
ÀRULDQIRHUVWHU#EXURKDSSROGFRP
167