Materials Liz

Materials are being repositioned in architecture back into elements that need to be understood by having physical contact with its materiality. As architects take a step back from the digital space and into the worlds of materials; the growing question among practices and universities is can material development be harnessed into a design-led practice?

The research proposes a new methodology that puts an architect at the helm of a material development process and will critically document this process so that others may follow and asks fundamental questions of an architect’s role in the material development process.

Hypothesis:

If an architect is placed in the navigating seat in a material development, will the different expertise create a material that is;

• Designed to meet the end users need (architects have been trained to think about building with regards to end users and put them at the heart of designs) • Commercially viable (architects are normally the people specifying products for projects and have a sense of what sells in the market place) • Aesthetically orientated (Having an architect from the start of the process, will create a product that is aesthetically positioned from day one)

Research Question:

What happens when an architect is put into the world of material development? With this research question in mind the next stage was to get into the concrete labs at QUB. The current concrete lab at QUB is mostly used to date to support civil engineering research. To start the process, it meant learning how the procedure of acquiring lab time, health and safety requirements, equipment and mix calculations work in the lab. The challenge was an architect becoming comfortable in the concrete lab with regards to both the equipment, the processes, language and general engineering culture.

The project is to develop a sustainable façade/component made from concrete that uses waste streams and act as a biotope for plants, microbes and microorganism’s.

Dr Rory Doherty is an academic who applies chemistry, geophysics and microbiology to environmental problems to produce viable engineering solutions. Rory’s interests are: The Circular Economy, Reuse & Recovery of Hazardous & Valuable Materials, Restoration of Peatlands, Sustainable Remediation of Pollution, Identification and apportionment of Potentially Toxic Elements. The Circular Economy is based around good design of products that can be reused and upcycled into a second, third, fourth life. Rory’s area of interest is how to regain value from materials that are often costly and difficult to manage – hazardous wastes .

Dr Sree Nanukuttan has worked extensively in the concrete industry; within his own PhD he developed a concrete test instrument that is now commercialised and marketed by Amphora NDT Ltd. He went on to specialise in service life modeling of concrete structures and now works on the management of built infrastructures. This involves condition assessment and management of bridges, piers, culverts and also developing a management strategy for new structures in extreme environments. The same principle is also applied to buildings to improve the energy efficiency and reduce carbon footprint. Sree also specialises in the durability of structures, whole life management and concrete technology/production process.

Professor Ruth Morrow is recognised as an innovator in her approach to material development. In 2005 she cofounded Tactility Factory, which is a collaborative material practice, built to commercialise the patented technology they had developed around concrete and textiles. The collaboration is between Trish Belford, a renowned textile designer and researcher, and Ruth Morrow, architect and academic. Their working relationship stems from a mutual interest and respect for each other’s discipline, but they quickly decided on the utopian challenge of making hard things soft as a means to bring purpose and focus to their collaborative practice. The ambition of the project also draws on a long-term engagement with inclusive design and feminist critiques of the built environment that Ruth, as an architect has previously been involved in.

A key part of the context of this project is also the team involved in driving it forward – their interests and expertise. The team consists of Elizabeth Gilligan (PhD Student), Professor Ruth Morrow (Architect), Dr Sree Nanukuttan (Civil Engineer) and Dr Rory Doherty (Environmental Engineering).

Me: AKA Liz

Elizabeth Gilligan first developed a fascination for materials in architecture during the final year of her architecture degree. After graduation she entered the field of materials research at a world-leading architecture firm that taught her the importance of materials in design. It exposed her to all parts of the design process from different perspectives working with architects, engineers, product designers, urban planners, acoustic specialists and manufacturers. Drawing on her own experience of architecture and design, she was able to apply her knowledge to the field of materials and in turn opened a dialogue to question why architects/designers are not involved in material development; this is a question that is starting to arise in the industry itself. This led to her pursuing a PhD in the field of materials and architecture.  In parallel to her PhD, Elizabeth has successfully become part of the innovation academy which is a cross-school program (Trinity college Dublin and Queen’s University Belfast) that teaches entrepreneurial and innovation. This program has significant relevance for the research as the skills taught in this program are directly transferable to the PhD; marketing, finance and demographics.  

PU Foam Closed/ PU Foam open

Context:

675,000 Tons of Polyurethane foam is put into landfill in the UK each year

PU Foam comes from many different sources: Furniture, Bedding, Insulation, Packaging, Automotive components, Manufacturing, Pharmaceutical and Construction

Recycling of PU foam is done in two primary ways: mechanical recycling, in which the material is reused in it current form and chemical recycling that takes the material back to its various chemical constituents

There has been some previous test in concrete mixes, which have shown potential for using PU foam for lightweight concrete. It has also been researched for thermal insulation in concrete.

Properties:  

light weight, flexible, sound absorption and heat retention.

Based on Properties what can this do?

• Fiber reinforcement • Acoustic properties • Light weight concrete • High flexural strength

To what extent can it meet the projects aims?

To create an architectural façade system that will be made from a low carbon based concrete and use a waste stream that can act as a carbon sink to be used as a habitat for the growth of plants/ microbe / microorganisms.

• Permeability   • Large surface area for carbonation • Growth on Façade   • All of this will need to be tested

Chicken Feathers

Context:

Nearly 1.5 million tons of chicken feathers are plucked each year in the UK with the majority of these being sent to landfill. Chicken feathers wasted in the process of food production have increased landfill waste and are adding to our landfill strains. Chicken feathers have unique structure and properties not found in any natural or synthetic fibres. Although feathers as such cannot be processed as the protein fibres wool and silk due to the complex structure of the feathers, the secondary structures of feathers i.e. the barbs have the structure and properties that make them suitable for use as natural protein(69) fibres. The low density, excellent compressibility and resiliency, ability to dampen sound, warmth retention and distinctive morphological structure of feather barbs make them unique fibres. For example, the density chicken feathers is about 0.8 g/cm3 compared to about 1.5 g/cm3 for cellulose fibres and about 1.3 g/cm3 for wool.

There has been some previous test in concrete mixes, which have shown potential for using chicken feathers as a fibre reinforcement, for light weight concrete, a concrete mix that offer high flexural strength.

Properties:

light weight, compressibility, sound absorption and heat retention.

Based on Properties what can this do?

• Fiber reinforcement • Acoustic properties • Light weight concrete • High flexural strength

To what extent can it meet the projects aims?

To create an architectural façade system that will be made from a low carbon based concrete and use a waste stream that can act as a carbon sink to be used as a habitat for the growth of plants/ microbe / microorganisms.

• Permeability   • Large surface area for carbonation • Growth on Façade   • All of this will need to be tested

Eggshell waste

Context:

At home, eggshells can easily be composted or sprinkled on flowerbeds as a slug deterrent or soil enhancer. But for industrial egg producers, shells have to be disposed of in landfill because the waste egg attached to them rots quickly, causing a smelly by-product. Eggshell is made of calcium carbonate, like chalk, with a hardwearing, crystalline structure. Each year approximately 11.4 Million tons of eggshell waste produced globally with 90 % of that going straight into landfill. There has been some previous test in concrete mixes, which have shown potential for using eggshells as a lightweight aggregate replacement. It has also been researched as a cement replacement.

Properties:

Lightweight, high in calcium/protein and porous.

Based on Properties what can this do?

• Light weight concrete • Growth medium/fertilizer • Moisture retention

To what extent can it meet the projects aims?

To create an architectural façade system that will be made from a low carbon based concrete and use a waste stream that can act as a carbon sink to be used as a habitat for the growth of plants/ microbe / microorganisms.

• Permeability   • Large surface area for carbonation • Growth on Façade   • All of this will need to be tested

Synthetic carpet/ Natural Carpet/ Carpet Underlay

Context:

Floor finishes are a significant element of a building and contribute around 12% towards a buildings environmental impact. Carpets are the predominant floor covering used in both domestic and commercial settings accounting for 58% of the floor finishing market in the UK. 400,000 Tonnes of carpet are sent to landfill each year in the uk. The benefits of using the carpet underlay waste that I have found is that it is a virgin waste that is produced from off cuts so will have no contaminants. There has been some previous test in concrete mixes, which have shown potential for using carpet waste as reinforcement . Natural wool rich carpets have also been used in land restoration and use in growth medium/fertiliser .

Properties:

High Fibre concentration, reinforcement, thermal insulation, acoustic properties, growth medium/fertiliser and moisture retention.

Based on Properties what can this do?

• Recycled reinforcement • Thermal Insulation • Acoustic properties • Growth medium/fertilizer • Moisture retention

To what extent can it meet the projects aims?

To create an architectural façade system that will be made from a low carbon based concrete and use a waste stream that can act as a carbon sink to be used as a habitat for the growth of plants/ microbe / microorganisms.

• Permeability   • Large surface area for carbonation • Growth on Façade   • All of this will need to be tested

Paint Waste

Context: Latex paint is recyclable, but oil-based paint are considered household hazardous waste (HHW). There are two types of recycled paint: re-blended (also called consolidated paint) and re-processed (also called re-manufactured paint). Re-blended paint contains a much higher percentage of recycled paint than re-processed paint. Creating re-blended paint involves mixing several paints together, including various colors and sheens (glossy, eggshell, etc.). The paint is then filtered, packaged and distributed or sold. Re-processed paint results from mixing old paint with new paint and other new materials. The paint is then tested for quality, packaged and distributed or sold . In the UK each year 50 Million Litres of unused paint is sent to landfill. There has been some previous test in concrete mixes which have shown potential for using paint waste as an admixture, for improved workability, higher flexural strength, lower chloride ion penetrability, better resistance to de-icing salt surface scaling and can be more economic because they require less water-reducing and air-entraining admixtures.

Properties:

High polymer content, most white paints contain Titanium Dioxide (which can be used to purify air).

Based on Properties what can this do? • Improved workability, • Higher flexural strength, • Lower chloride ion penetrability, • Better resistance to de-icing salt surface

To what extent can it meet the projects aims?

To create an architectural façade system that will be made from a low carbon based concrete and use a waste stream that can act as a carbon sink to be used as a habitat for the growth of plants/ microbe / microorganisms.

• Permeability   • Large surface area for carbonation • Growth on Façade   • All of this will need to be tested

Wet Blue

Context: Wet blue production (so called because the semi-finished hide is given a chrome bath which imparts a bluish tint). This process involves removing unwanted substances (salt, flesh, hair, and grease) from a rawhide (by soaking in a bath of lime and sodium sulfide to dissolve hair and flesh), trimming it treating it to impart the desired grain and stretch, and finally soaking it in a chrome bath to prevent decomposition.  This step is far more polluting than finishing, generating 90% of the water pollution associated with leather tanning. Finishing – Finishing involves splitting, shaving and re-tanning the wet blue (this is where the Waste stream comes in from the splitting and shaving. Each year 1.2 Billion hide are produced globally. From 1000kg of Raw hides 850kg of wasted will be created and 40% of that waste come in the form of wet blue. It is currently disposed of as a hazardous waste due to the chromium used within the tanning. There has been no previous test in a concrete mix but I think it has real potential for making a highly nutritional concrete with a porous texture.

Properties:

Organic base, High in nitrogen/protein, high water absorption, Fibrous, course texture .

Based on Properties what can this do? • Nutrition for plant growth • Porous texture • Used as core to act as a moisture sink

To what extent can it meet the projects aims?

To create an architectural façade system that will be made from a low carbon based concrete and use a waste stream that can act as a carbon sink to be used as a habitat for the growth of plants/ microbe / microorganisms.

• Permeability   • Large surface area for carbonation • Growth on Façade   • All of this will need to be tested

P.S this has a highly chemical smell (probably the chromium) but is the greatest shade of blue.

Lycra: ( DUPONT)

Context:

Lycra is a registered brand name for a polyurethane-based synthetic fiber that’s also called spandex or elastane. The DuPont Company first developed Lycra in 1958 to replace latex rubber as a stretching agent in clothes. It’s also prized for its strength and durability. There has been no previous test in a concrete mix but I think it has real potential for making a lightweight flexible concrete.

Properties:

Lightweight, flexible, soft, rubbery, a rigid section that makes it tougher than rubber, UV resistant, good resistance to oxidizing agents and Sticks at 350-390F. Melts above 500F.

Based on Properties what can this do?

• Light weight concrete • Flexible concrete • Used as core to act as a moisture sink • Acoustic

To what extent can it meet the projects aims?

To create an architectural façade system that will be made from a low carbon based concrete and use a waste stream that can act as a carbon sink to be used as a habitat for the growth of plants/ microbe / microorganisms.

• Permeability   • Large surface area for carbonation • Growth on Façade   • All of this will need to be tested

P.S it also feels how I imagine it is to touch a cloud :)

Despite efforts made by many of us to Reduce, Reuse and Recycle, the fact is we’re generating more landfill trash now than ever before. Our waste is projected to nearly double globally over the next 15 years, this equates to 1.3 billion tons of landfill waste annually, which is projected to increase to 2.2 billion tons by 2025. Much of what is consider as waste can often be recycled, composted or reused in some other form, unfortunately there are still many items and materials that have no further economic or practical use. These truly are ‘waste’ and this is what interests me, finding a material or ‘waste stream” that has no other alternative but to go to landfill. How can this be used in concrete to create for example; a light weight flexible concrete.

The waste streams chosen for initial research are Lycra, wet blue, paint waste, Synthetic Carpet waste, Natural Carpet waste, Carpet Underlay, Egg shell, Chicken feathers, PU foam closed and PU foam opened.

This is the only post I will ever write that sounds like it could be diary entry (I promise).

I think that it is important to explain where I have come from and why my experiences are important to the work I do.

I also want to talk about PhD in a vague sense for anyone that is looking to embark on one.

I studied architecture at Plymouth University and loved the experience; it had its ups and downs, but for me the experience developed and pushed me as a designer. It made me think of questions that still intrigue me now and is also where I developed my fascination for materials.

 Jobs, Jobs, Jobs;

After university I took the standard route into architecture and got a job in London.

My first job was at an architectural firm that dealt with large urban developments and to be honest I hated it. Nothing about the firm used any of the skills I had learnt at university.

I left this job and went to another firm; this time a much smaller one, thinking that this experience would feed my hunger for architecture but this didn’t work and I carried on this trend of searching for a different firm.

I finally discovered that I was interested in the materials in architecture and how they relate culturally and physically. I hated the way materials were an afterthought in buildings and not a key design force.

I found a job that fitted this need and I was to become a materials researcher at an architectural firm which had the perfect balance of working on design and materials.

 How did the PhD happen?

The PhD is an interesting story, I was speaking to my tutor from university and he recommended that I speak with my now supervisor, I then  emailed her about doing a PhD.

At the time I was in fact applying to masters' courses for architecture and had been interviewed/accepted places.

However a week before I was meant to start the masters' course, I was offered the PhD. I flew over to Belfast to meet everyone and check it out, I knew this was where I needed to be and I accepted the place.

 PhD , PhD……….

I started the PhD a few weeks later after visiting Belfast for only the second time and it was crazy; I felt like they must have made a mistake, I shouldn’t be here it was typical imposter's syndrome.

It was also a kind of learning that I had never experienced before; it was so free and driven by me, which was exhilarating as well as being completely daunting.

There was no road map as I was in control of writing my own PhD question, which for a long time scared me, but I’m the kind of person that when they are worried, works to forget the guilt of not knowing where your going.