Stephen Ying - openlab.citytech.cuny.edu · Stephen Ying Mohammad Alsharif Tasnuva Ahmed 05.7963.000 Concrete Design Specification Worksheet 300 Jay Street, Brooklyn, NY 11201 2

Stephen Ying Mohammad Alsharif Tasnuva Ahmed

05.7963.000

Concrete Design Specification Worksheet 300 Jay Street, Brooklyn, NY 11201

SECTION A – Cast Concrete Specifications & Procedure

PART 1- GENERAL

1.1 SUMMARY

A. Section Includes:

1. Concrete design (non-structural) applications and procedures :

a) formwork design

b) form lining design

c) mixing, pouring, and casting concrete mix

2. Considerations of design form analysis and influential precedents using Rhinoceros

3D NURBS modeling program.

3. Use of Universal X-660 laser cutter to produce form lining design

4. Supplementary components and accessories such as tools and name brand

products that were used or considered for the mixing and casting of concrete .

B. Related Requirements:

1. Section for design constraints and requirements

2. Section for laser cutting safety precautions and waste management & disposal

3. Section for concrete mixing and casting safety precautions and waste management & disposal

1.1 REFERENCES

A. Abbreviat ions and Acronyms:

1. X-660: X-660 L aser Cutting m achine


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2. CA-RS: Rapid Set Cement All - fast curing concrete mix

3. 2x4: 2 inch by 4 inch piece of wood

4. Plexi: 1/4 inch thick plexiglass

5. NURBS: Non-uniform rational B-spline modeling

6. Rhino 3D: Rhinoceros 3D NURBS Modeling software

B. Other tools and materials used:

1. Wood formwork duplex nails


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2. Standard hand-held claw hammer

3. Six sheets of 10 inch by 10 inch by 1/4 inch thick plywood

4. Vaseline as form lining release agent

5. 5/8 inch diameter marbles


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1.3 ADMINISTRATIVE REQUIREMENTS

A. Sustainable Materials: Mandatory use of materials non-toxic to the environment nor

to its handlers or any individuals within the vicinity of material use. Items used in the

work of this Sect ion that must follow these guidelines include but are not limited to:

1. non–toxic concrete mix that should NOT contain any possible hazardous admixtures, chemical compounds, or ingredients harmful to the health of its handlers and the

environment.

2. liquid chemicals, adhesives, sealants, paints, coatings, or tapes should NOT contain VOC's or other toxins;

3. materials used should be from recycled content and recyclable thereafter

B. Delegated Design Requirements :

1. Design Requirements: Fabricate and cast a design onto the 6 surfaces of or within the 9 inch x 9 inch x 9 inch concrete cube that:

a. has minimal deformations and warping on the surfaces of the concrete cube

b. has minimal air pocket gaps on the surfaces of the concrete

c. must be contained within the 9 inch x 9 inch x 9 inch size constraint

d. must follow these design guidelines:

1) no extrusions extending past the size constraint of the concrete cube

2) concrete cube must hold its structural integrity to NOT collapse on itself

1.4 SUBMITTALS

A. Informational Submittals:

1. Include a detailed list of all tools and programs used for the concrete design

fabricat ion and form cast ing with a step by step procedure explaining the

process.

2. Include a detailed list of all supplies each with a procedure to detail the concrete cast ing process.

1.5 QUALITY ASSURANCE

1. Quality Standard Requirements:

The resultant concrete mix ready for use will have:

a. minimal air bubbles within the mix

b. minimal concrete aggregates and clumping

c. smooth and fluid texture before pouring


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1.6 WARRANTY

A. Manufacturer's Warranty: All materials and products will be covered that protect the concrete fabricators during the warranty period against:

1. deterioration;

2. defective products, materials, and fabrications;

3. patent or latent defects of final product that may put it at risk of incipient or

catastrophic failure

B. Warranty Periods:

1. At least 6 months after Substantial Completion.

Remedy: If the concrete fabrication or any aspect of it defects within the specified warranty period, then the fabricator(s) shall replace as necessary.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Manufacturers: Provide products manufactured by one of the following:

1. Description: Rhinoceros 3D NURBS Modeling software developed by Robert McNeel & Associates

2. Products: Using the X-660 to fabricate the design on six sheets of plexi

3. Performance Requirements: Fabricated form lining design should not jeopardize the

concrete cube’s composition that will result in collapse.

1. Description: Concrete Wood Formwork

2. Products: Six sheets of 1 inc h thick by 10 inc h by 10 inch plywood held together by duplex

nails

3. Performance Requirements: Formwork box should be strong enough to withstand the weight of the concrete mix pushing against it as it ’s poured in

2.2 ACCESSORIES

A. Rhino 3D software – used to create the fabricated design intended for the surfaces on

the concrete cube

B. Adobe Photoshop software – used to recreate the desired images reflecting the design

concept as contrasted grayscale images to effectively implement into the Rhino 3D

software.

C. Autodesk AutoCAD software – used to laser cut the form liner of the concrete design

D. Wood formw ork duplex nails - re sponsible for binding t ogether the six sheets of plywood


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E. Hand held claw hammer – used to drive the duplex nails deep enough into the plywood

F. Vaseline – rele asing agent for effective removal of formwork and form liner fr om concrete

cube without dam age

G. 2 inch by 4 inch by 24 inch long wood plank – used to stir concrete mix until it reaches an acceptable texture

H. Duct tape – to keep the marbles locked in place within the plexi form liner

I. 5-gallon plast ic mixing bucket: holds the concrete mix and water while being mixed until

it’s ready to be poured directly from the bucket into the wooden formwork box

PART 3 – FABRICATION DESIGN

3.1 RHINO 3D MODELLING PROCEDURE

A. Open a new file and name it accordingly

B. Create a cube with 9 inch by 9 inch by 9 inch dimensions and use the “explode” command to explode it to 6 separate faces (each face will have its own design)

C. Select the Render Tools tab right below the command line -> select the bumpy orange ball icon labeled as Displacement

D. Select the surfaces you want to apply a design on -> Press Enter (Displacement will apply a desired image onto the selected surfaces and create impressions or extrusions

defined by black and white colors ONLY)

E. Click on New in the Displacement Settings pop up window -> Select the image you

want mapped out on the previously selected surfaces of the cube (you will need to adjust the color of the image before selecting it)

F. Download any images you feel would best represent your design concept. Bring them

into Adobe Photoshop.

G. In Photoshop, go to the Image tab at the top left -> Adjustments -> Hue/Saturation ->

Move the Saturation slider all the way to the left until image is in grayscale


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PART 4 – LASER CUTTING EXECUTION

3.2 EXAMINATION

A. With the fabricator present, examine sheets of plexi before laser cutting for:

1. warping, shrinkage, and other defects on the surface (this will cause uneven

surfaces on the concrete cube)

2. jagged edges that may create inaccurate dimensions

3. rough edges and surfaces

4. cracking (plexi may split into undesired pieces during or after laser cutting)

B. With the laser cutter supervisor present, be sure to:

1. Turn on the two air fans for the X-660 (the power switch of one fan is located at the bottom

of the X-660 and the other is a separate fan with a power switch on the back side.)

2. Clean the inside the laser cutter of any remaining material or debris from previous sessions.

3. Place staples accordingly to evenly support the plexi off the surface of the laser cutter.

4. Make sure the plexi can fit into the laser cutter’s 18 inch by 32 inch boundary and line it

straight along the inside of the ruler guidelines provided on X and Y axis.

C. Proceed with laser cutting ONLY after unsatisfactory conditions have been corrected.

3.3 LASER CUTTING PROCEDURE AND PREPARATION

CONCEPT

For our design we decided to place marbles in place of the black dots to map out the similar curved pattern. This was risky because this would create an almost entirely new effect from our design. The concentrat ion of so many black dots created a nice texture and a defined curvilinear form. We wanted to use marbles to add some transparency and glossiness to what would otherwise be a dull concrete block. The contrast was not only between the marble’s plastic material and the concrete but also between the green t inted color of the marble and the light

grayish color of the concrete.

EXECUTION

We created holes that were the same size as the marbles (5/8 inches in diameter) to place the

marbles inside and lock them in the desired pattern on each of the concrete cube’s surfaces. We wanted a continuation of the pattern throughout the entire cube by connecting together the curvilinear layout of marbles on all 6 surfaces of the cube.


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A. After import ing the dotted pattern image into AutoCAD and scaling the image into

a 9 inch by 9 inch square, we laid out 5/8 inch diameter circles to replicate the dotted pattern as best we could.

B. All the lines of the circles and boundary of the 9 inch and 9 inch bounding box were changed to Blue to indicate cutting for the laser cutter (blue reads as cutting through

the material, green is scoring to about halfway through the thickness of the material, and red is etching through about 1/4 of the material’s thickness.)

C. Load the file onto the desktop of the computer associated with the laser cutter.

D. Plot using the X-660 laser cutter as the printer -> Select OK for Plot Using Default Paper Size -> Uncheck all plot options on the right of the Plot Settings window.

E. Go to Properties tab next to the Printer/Plotter dropdown menu in the Plot Settings wndow -> Load -> Select the acrylic preset settings as the material type (this will tell

the laser cutter how much power and speed is needed to cut through the plexi) -> Select OK -> Select OK -> Apply to Layout.

F. Under What to Plot, change it to Layout and click Preview to make sure the viewport in paperspace is correctly aligned with the size of the cutting boundary of the laser cutter (18 inches length x 32 inches width).

G. Place the plexi right up against the top left inside corner of the ruler guidelines inside the laser cutter then close the cover. Make sure it is fully closed with no obstructions

under the cover.

H. Press OK for the Plot Settings in AutoCAD and press OK on the X-660.

PART 5 – CONCRETE CASTING EXECUTION

3.4 EXAMINATION

A. With the fabricator present, examine wooden formwork plywood sheets for:

1. warping, shrinkage, and other defects

5. splintered edges or chipped away areas

6. rough edges and surfaces

7. wood rot on the surface (some wood rot may be present inside the wood but not visible

until milled, in which case the entire piece of wood should be discarded)

3.5 CONCRETE CASTING PROCEDURE AND PREPARATON

A. Drop the marbles inside the laser cut plexi form liner and make sure each marble sits t ightly in each hole (some marbles may be smaller or bigger than the specified 5/8 inch diameter)


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B. Use duct tape to seal the side of the plexi form liner where the marbles are protruding out

less. The duct tape will keep the marbles locked in place and prevent them from falling out when placed into the formwork.


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C. Flip the form liner around after each marble is secured by the duct tape. Press down on a flat surface so the marbles will be pressed further into the duct tape and form liner. Do this for all six form liner designs for the concrete cube.

D. Cut around half the circumference of each marble taped with the duct tape to release air pockets and allow for a tighter connection between the duct tape, form liner, and marbles .


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E. Apply Vaseline on the surface without the duct tape as a release agent to easily separate the form liner from the cured concrete (this side is where the concrete will be in contact with the marbles and form liner when poured while the other side is untouched.)

F. Place the 10 inch by 10 inch pieces of plywood with an 3/4 inch offset from the edge on each surface (this will leave a 1/4 inch gap between the plywood formwork and the form liner for the marbles to protrude out of the concrete surface after pouring). Hammer in 3 duplex nails evenly separated between every two pieces of wood connected together (the nails will be driven from the surface of one wood face into the 1 inch thickness of a perpendicular sheet of wood.)


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G. Now place the form liners into the box, be sure to place each face of the cube with the right form liner design in the correct orientation.


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H. Pour the CA-RS mix and water into the 5-gallon bucket while mixing using the 2x4. The ratio we used was 4 to 1 (4 cups of concrete mix per 1 cup of water.) This created a malleable mix that wasn’t too dry to mix or too liquefied to cast.


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I. Continue mixing using the 2x4 until a smooth texture is obtaine d with minimal clumps in the mix.


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J. Once the mix is concrete mix is smooth, pour the concrete direct ly from the mixing bucket into the formwork. We needed about 50 pounds of concrete mix to fully fill up the 9 inch x 9 inch x 9 inch formwork.

3.6 CLEANING

A. Use detergent soap, baking powder, and chlorine (if necessary) on a damp cloth and wipe down working station. Rinse tools and accessories with water and detergent soap, baking powder, and chlorine (if necessary). Wash hands, face, and any other area of skin

thoroughly with bar or liquid soap that may have been exposed to the concrete while

mixing.

3.7 PROTECTION

A. Eye Protect ion - Protect against light ing flare from the laser of the laser cutter

1. Use eye visors, screens, or goggles to protect eyes from the strong intensity of light from the laser cutter.

B. Mouth and Nose Protect ion – Protection against airborne hazards and odors

1. Use a face mask covering both the nose and mouth while pouring and mixing the concrete mix. The mix is non-toxic but the face mask may prevent any possible allergic reactions to the concrete mix.

C. Skin Protection – Protect ion against harmful chemicals in concrete mix

1. Wear latex gloves as a precaution to protect skin from any agents in the concrete mix that may cause an allergic reaction.

END OF SECTION

Documents

Stephen Ying - openlab.citytech.cuny.edu · Stephen Ying Mohammad Alsharif Tasnuva Ahmed 05.7963.000 Concrete Design Specification Worksheet 300 Jay Street, Brooklyn, NY 11201 2