Knock it Down - Bring the bamboo home

1

Preface

For all of us who have been through and education in ‘Design’, the word means many different things. We understand its nature and its implications. We apply and we observe. We gather and we collate. We instill in and imbibe from myriad spaces of thought, culture, society and environment. We all feel a sense of belonging when we hear the word ‘design’. The beauty of it all lies in the fact that we all understand it differently. We define its purposes differently. It is almost as though we all constantly seek to find our own missions, once empowered to ‘think like designers’. Through two years of a study in Product Design I have learnt much. I have spent a lot of time trying to get to the bottom of it all, to define Product Design. Along the line, my notions have constantly undergone change. It has been an adventur-ous but steady ride. A fluctuating but enriching experience. This project is another such adventure. I no longer wish to define Product Design. I have instead developed an apatite for the mysteries it has to offer.During my study in Product Design, somewhere down the line I became acquainted with a new medium, one which took me by surprise and instantly filled my frame of vision. Being very intrigued by this medium, I dove right in and began taking a shot every opportunity I found. In the process I discovered amazing things and found a large scope for this medium. I took the unconventional way in, starting at the top and tumbling my way down to the basics. With this project, I started again, at the basics, with a fresh new angle. The attempt has been to find a new way up, learning as much as I possibly can along the way.

Acknowledgements

I would like to convey my gratitude to a number of people and parties, all of whom have contributed in some way or the other towards bringing this project home...

A special thank you to Sangaru Design Objects Pvt. ltd.Their involvement has been integral and key to the completion of this project

A heartfelt thank you to Jackson Poretta and the Green Chakra group for their undying enthusiasm and support. Jackie Bhai and the boys never fail to synergize and energize !

A special thank you to my review panel, Janak Mis-try, Bani Singh and Jackson Poretta for their con-stant guidance and support.

A big thank you to Prof. M. P. Ranjan and Susanth. C. S. at NID for their guidence.

A big thank you to Sudipto Dasgupta, Naga Nandini Dasgupta and Gopal Bengeri.Thank you all for your valuable feedback and ‘ever ready’ attitude.

I would specially like to thank David at the workshop or ‘in-novation station’ as he and I like to call it, for providing me with his full cooperation and taking interest in my work.

A big thank you is also due to Matthew at the workshop for constantly making himself available to us all.

Finally, I would like to thank the home team, my family, for their undying faith and unconditional support, and my fellow batch mates and friends for sharing their energy and occa-sionally boosting my ego!

Contents

Synopsis....................................................................................................................................1

Initiatives

Green Chakra..........................................................................................................................3

Bamboo - the material...........................................................................................................6

The Project

Introduction.............. ................................................................................................................................13

Methodology..............................................................................................................................................14

Concept 1 - Strip Arch..,........................................................................................................................19

Concept 2 - Knockables, Satackables and Bamboo.......................................................................47

Prototype production............................................................................................................54

Critique....................................................................................................................................89

Conclusion..............................................................................................................................91

Bibliography............................................................................................................................92

1

Synopsis

Towards the end of my two year study in Product Design, I got an opportunity to do a self initiated project. By this time, I had begun thinking about the field of natural building as an area of design. I decided to generate my project in the field of natural building. At this point I got in touch with Jackson Poretta and the Green Chakra group, who were working with natu-ral building techniques at the time. A large part of their activity was taking place at Drishya Kalika Kendra in Bayappanahalli, Bangalore. After some discussion, it was decided that I would come in and contribute a shelter structure to the Drishya campus. The designs I created incorporated bamboo as the prime material. This would be my first time working with bam-boo. The structure required multiple bamboo poles to be bent into similar curves. With no prior experience and too much research to process in the given time, we jumped right into an experimental exercise, mixing techniques and learning as we went along. It was here that I first felt an urge to learn more about bamboo.Following the Drishya project, I took up an internship at the Center for Bamboo Research, Auroville. During the course of the internship I worked on a real time project - designing public furniture for the Pondicherry marine drive, in Bamboo. I undertook design development and coordination of prototype production. Working with scant facilities and only a few hours of electricity a day, I ended up doing a lot of work manually and got real up close with the material. I was exposed to new techniques and methods using bamboo. It was here that I became acquainted with the issues and challenges related to bamboo, with relation to furniture production. I understood the qualities of the material; Qualities that make it unique and those that hold it back from full exploitation of its capabilities. I found myself asking - so what ? why not ? there must be a better way. It is here that I found my inspiration for this project. Following this I got in touch with many professionals with varied experience, gathered data, and jumped in!

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Green Chakra

Initiatives

Any design process must be as ‘inclusive’ as possible. Includ-ing multiple parties, within reason of course, increases the number of beneficiaries and adds collective synergy to any design process and here lies the true value of design as an exercise.I now had an opportunity to act upon this belief, by orient-ing my project such as to include more people, for whom this can be a valuable learning exercise.

The Green Chakra group :Jackson Poretta is a natural builder and an ecological artist who has undertaken the tutorship of six young men from Byappanhalli and Sanyasikunte, with a goal to train them in the field of natural building, in order to equip them with the knowledge to make a difference in their own homes and the skills to generate employability. Together they are“GreenChakra”.

All material experiments and basic prototyping for the Knock It Down project, would be carried out in collabora-tion with the Green Chakra group.This would be a new area of work for Green Chakra. It would be a valuable learning exercise for them and would help expand their workspace to include new production techniques with Bamboo. Simultaneously, it would serve the purpose of material tests and explorations for the Knock It Down project.

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bamboothe material

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About Bamboothe material

The culm consists of tissues which have vessels for carrying watery sap, conducting food solutions, and the thick walledfibres. The cells store starch and all cells are vertically oriented. All these together make up the fibrovascular bundles which run vertically in the internodes. The bundles are smaller, more in number and compact towards the periphery. Also, the maximum number of fibrovascular bundles is found towards the base of the culm. This is because as they ascend some of them pass into the branches and leaves at the nodes. There is no branching of the vessels or fibres along the internodes, resulting in weak transverse bonds. The fibres constitute 60 to 70 percent by weight of the bamboo, while the vessels make up about 15 percent.1 The transverse section of a culm shows a much higher concentration of fibres towards the periphery than the inner wall. Near the base of the culm, the outer one third portions contain the most fibres. The longest and most mature fibres are found between one-fourth to half the height of the culm. Above this the fibres tend to get smaller and less mature

the culm is usually hol-low, but in few species it is solid or has small

branchclum

node

Sheath or culm leaf

culm shoot or sprout

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of the whole culm, the top part is the strongest in compression, and bending strength in most cases

culm

internode

in the internode the shortest fibres are located near the nodes and the longest are in the centre of the internode

of the whole culm the central part of the culm is the strongest in tension

the lower part of the culm inspite of its largest diameter and wall thickness has the lowest mechanical characteristics of the whole culm.

the thickness of the wall culm decreases from the base to the top


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Bamboo culms are tall cylindrical stems which taper at the top with the maximum diameter at the base. They are usually hollow with few exceptional species. All culms are rhythmically divided by transverse walls at nodes which appear as a slight swelling on the surface of the cylinder. The parts between the nodes are called the internodes and the hollow space within is called the lumen. Branches and leaves grow out of the nodes, generally towards the upper part of the culm. Culms of different species of bamboo are characterized by varying physical properties . These are reflected in the variations in diameter of culm, height of culm, wall thickness of internodes, size of lumen, length of internodes, branching pattern, and so on. The most significant variation seems to lie in the shapes of the culm sheaths which are attached to the nodes till the culm attains maturity.

The nodes are swollen and more lignified than the internodes. The transverse membrane completely separates each internode. The vessels and fibres that are unconnected in the internodes pass through the transverse wall, cross connecting the wall of the culm.. The nodes, therefore, provide the only connection from one end of the culm to another. The slenderness ratio of bamboo culms is very high which could make the structure of the plant unstable. Nodes play an important role of the axial crack arrester. It prevents the cylinder from structural buckling and increases bamboo’s rigidity.

Diverse physical characteristics of bamboo culms of different species. (a) variation in diamter (b) variations in internode length

Variations in wall thickness in different species of bamboo

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The term ‘bamboo’ describes all tree or bush-like grasses having a durable woody or branched stem. The lignifying cell structure of the bamboo tissue and its technological properties are similar to the wood tissue. Bamboo may, therefore, also be termed ‘wood’. However, bamboo has the most rapid growth amongst all plants (up to 1.2m in 24hrs).1

Bamboo is extremely resistant to tensile stresses, has high resistance to bending and buckling stresses. It fails in shear before it fails in tension. The bottom portion of the culm is more resistant to shear due to its greater wall thickness. As far as size, lightness and strength are concerned, bamboo is one of nature’s extreme products. Other products, such as reed, cane, and rod timber, are practically its equal, since almost all them constitute light weight constructions.

All types of rods – in particular grasses (bamboo, reeds and straw) and straight - growing coniferous trees (fi r, spruce) are not only effective from a structural point of view, but also very economical. Effective transmission of forces over a particular length makes bamboo extremely inexpensive compared to other rods.

Young culms with high moisture content show a greater increase in strength when dried than older culms. The difference between old and new culms gradually diminishes by about 2 ½ years. The moisture content of bamboo causes it to behave like wood in relation to its compressive strength which almost doubles when the green culm is air-dried.

With regard to its mechanical/ technological properties bamboo is superior to constructional timber (softwood) and also to constructional steel in terms of the ratio of live load/ deadweight. Bamboo as a plant is a phenomenon; and possesses fascinating material properties. Because of the hard silicate layer of the outer surface, bamboo is highly resistant to chemical, insect and mechanical exposure.

cross - section(cm.sq.)

weight(kg)

failure at tensile load (kp.)

Steel St. 37 1 0.785 4

Wood 13.5 0.785 8

Bamboo 12 0.785 24

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The capacity of the bamboo wall to be split longitudinally within its segment results from the parallel orientation of the constituent fibres. In the nodes, however, these fi bres cross each other in all directions. These reinforcement nodes with their highly silicified diaphragms thus increase the resistance to splitting or bending. The bamboo tissue has no radial fibre orientation. This is why there is no increase in diameter above ground unlike timber structures. The whole section of bamboo becomes a single annual ring. From mechanics we know that, cylindrical tubes containing the same amount of material as a solid round bar has four times the rigidity of that bar.

A variety of sections or splits that are extracted from the culm, each to suit a specifi c purpose.

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the project

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knock it downBring the bamboo homeDiploma Project

Nishant Wazir

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Introductionscenario

Bamboo up till now...

Bamboo, a versatile grass, often referred to as ’won-der grass’, is found in most parts of India. For ages, this material has been used to meet day to day living needs, with diverse applications. Up till now, bam-boo handicrafts and products have existed in very niche-spaces of the urban market. Most people, be it, manufacturers or consumers, are not fully aware of the potential and versatility of this material. This limit’s the spectrum of possible applications relevant tothe urban scenario.

The Problem

In the urban scenario, bamboo products occupy segments largely in lifestyle product markets. The material has been well established as more than appropriate for the existing product range. However, for some time now, the furniture market has remained small, disproportionate to the potential held country wide, both in terms of material diversity and skill types.Few manufacturers enterprise bamboo products, as the market is small. This in turn leads to monopolis-tic market conditions.

As a result, the access points for purchase/exchange of these products are few, and highly specialized, predominantly – lifestyle brands, NGOs etc.So, in most cases, the product range is high-end, highly priced.Bamboo has the potential to cater to markets which are larger, wide-spread, economically viable and utility based.

The Opportunity

One of the most well established applications for bamboo is that of lifestyle products. Of this, furniture holds a very small segment. Bamboo furniture products are not accessible to most people, due the reasons stated above.Bamboo has now come into the limelight as a sustainable material resource, hence ‘the way forward’. The material is being more widely accepted across industries and markets. This is a growing sector where new technologies and market-ing methods are being researched, to cater to future industry and market conditions, while consumers are becoming more aware of ways in which bamboo can cater to their different lifestyles.What the industry needs now, is innovative production tech-niques and marketing methodologies, to expand the bamboo market, catering to all socio – economic levels.

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Knock it downproject methodology

The Approach

This project will work towards development of new production methods and process for bamboo furni-ture products.Increasing marketability – by incorporating modular-ity for ease of stocking and shipment/delivery, while keeping production costs to a minimum. This will enable manufacturer-consumer interaction to take place remotely through a select and order exchange channel.

Why Knock-down furniture

Knock-down furniture has certain key qualities that favour the goals set by this project :

A knock-down piece of furniture comes in parts. This means that different components are manufactured separately and eventually packaged together. This allows for production chains to flexible and optimized.

A knock-down piece of furniture is received in parts and as-sembled into full form by the user. This allows the end user to have some first hand tactile interaction with the material. This feature will help helps to instill a basic understanding of and awarness about the material used, accross a large user base.

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The Challenge

As versatile a material as bamboo is, it comes with its own set of challenges, arising from its unique characteristics. Traditionally used materials like wood and various metals are standardised to a large extent before being translated to furniture or other prod-ucts. This makes standardization easy, which in turn helps mass manufacture, organized and optimized production units and also helps reduce costs.

Unlike wood and metal, bamboo, as a raw material, is near impossible to standardize. It is safe to say that every single piece of bamboo is different from the other. This also depends, to a large extent, on the type or species of bamboo.Such irregularities have to be manually tackled, making the process time consuming and labour intensive. This also often results in wastage of material as not all pieces turn out to be suitable and have to be discarded.

A production process of this nature is labour intensive, with a considerable margin of material wastage. Hence we can deduce...1. Bamboo as a raw material is almost impossible to standardize. Standardization is the first step towards cost reduction. It is safe to say that every piece of bamboo is different from the other.

2. For the very same reason, easily 80% - 85% of the work has to be done manually, by skilled labour. With a process that is labour intensive and time intensive to this degree, costs are bound to be high.

For the reasons explained above, the profit margin for every bamboo product, furniture in this case, is high. Since the margins cannot be compromised much for the above reasons, the only way to allow lowering of profit margin per piece, is by producing in larger volumes, such that a even a smaller profit margin per piece will collectively bring in a reasonable amount.

The main questions :

1. To what extent can this material be standardized ? 2. How can this standardised avatar of the material be used to produce volumes?

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Bamboo splitting machine Bamboo knot removal machine

Bending bamboo splits by applying heat and pressure Bending bamboo splits by applying heat and pressure

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The Approach

1. Bring the material to a form that can be stan-dardised : The bamboo poles are converted into bamboo strips, by splitting and planing to achieve a standard width, thickness and length.

These process can be carried out mechanically, ma-chines do exist for this purpose.

2. The bamboo strips are bent (using heat) and laminated (using suitable adhesives), into the desir-able form. These forms are simplified and easy to replicate using identical steel Jigs.

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Knock it downinitial exploration

Knock down stool comprises 5 main pieces, assembled using bamboo pins or screws

Exploring ‘knock - down’ in general

Knock down bench comprises 5 main pieces, assembled using bamboo pins or screws

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Knock it downsplit arch concept

First set of sketches for the SPLIT ARCH concept

The split-arch concept incorporates two modules :

1. An arch like structure made from laminated bamboo splits2. A supporting structure, a truss-like frame on which to mount the arches

Several arches mounted in a row-like arrangement would form a seat.

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Knock it downwith the artisans

Furniture workshop at NID R&D, Bangalore : Joinery

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Knock it downwith the artisans

Furniture workshop at NID R&D, Bangalore : Joinery

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Splitting + bending

Knock it downmaterial tests

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Splitting + bending

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Splitting + bending


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Using rigidtsteel Jig

The steel Jigs evidently provide a well defined shape and form.The extra space between the two strips is cause by irregularity in level and volume at the nodal points. It turns out that the particular species of bamboo used here is not suitable for this process as it comes with many irregularities. The ideal species of bamboo to be used in order to get a good finish is the Balcooa species. Balcooa poles are almost completely straight with a regular surface and almost standard inter-nod-al lengths, as opposed to Bambos, which we are cur-rently using. However, Balcooa will have to sourced from Katlamara plantations in the north east. This is not feasible for the project at this stage as time does not allow it. Also, the material requirement is too small to place an order. For the purpose of prototyping for this project, we will be using Bambos itself. Carefully selected pieces, which are reasonably straight and consistent should do the job in terms of finish consistency.

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Variations

Variable assembly depending on the form and arrangement of the supporting frame and arch dimensions

Assembly of split arch stool

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The Problem : Stability

The above depictions assume stability of the arch structure. However, on close observation, one can see that at the junction of joining with the arch, the pole frame behaves like a pivot for the otherwise support-less arch to ‘rock’ or ‘sway‘. The arch is rendered unstable.

The next step will be to devise a better structure for the supporting frame, one which provides stability to the arch.

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Sketches



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Sketches



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Revised support frame

A small scale mock up.

A two piece support frame, where bamboo arches would be inserted between spacers to prevent ‘sway‘

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The Problem : consistency

This support frame relies on spacers to provide the structure with rigidity. This structure assumes that all the bamboo arches will be of exactly the same in terms of size, thickness and surface properties.

To achieve this level of precision and consistency in an irregular material like bamboo is not possible.

The next step will be to incorporate spacers as com-ponents providing rigidity, without requiring too high a level of precision or consistency.

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Revised support frame

Here the arches would snap into place onto the pole frame and would have split sections for spacers

A support frame using poles as well as splits

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The Problem : cumbersome assembly

This design reverts to the pole frame as seen in the first design. However, this pole frame incorporates two penetrating tie members instead of one (top right). This greatly reduces the ‘pivot‘ effect. This design also incorporates flat split bamboo sections as spacers (left), which would fit into grooves created along the edge of the arch.

This design has too many components assemble.There are too many detailed components. The ‘consistency‘ persists.

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Revised modules

Here the three arches are permanently fixed together, held by a flat bamboo split section

Arch module incorporating 3 arches clubbed together.

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The new module

This design addresses the basic problem that has been recurring through the previous designs i.e. stabilityThis design incorporates a revised arch module. Here, three arches are clubbed together as one mod-ule. The expansion that occurs in the base (x3)not only provides rigidity and stability, but also re-duces the impact and load borne by each arch when used as furniture to sit on.All designs from hereon will use the new (x3) three arch module.

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Revised (x3) design

Three arch module. Incorporates solid bamboo poles as tie members and hollow bamboo sections as spacers

Add-ons can be incorporated, e.g. arm rest, back rest. The add-ons would be fixed in place of spacers

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Though this design does incorporate the new add-on feature, the additional loops on the arches pose a problem regarding consistency.

The absence of a tie member between the two ‘arms‘ of the arches creates the possibility of the arms sliding/growing apart with repeated use, with the load and impact coming from above. This poses a problem with stability.

New features : add-onsThe Problem : consistency, stability

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Solid pole frame + (x3) arch module

One piece rigid pole frame

Arch arms are forced closer and pushed into frame from above. When released, the arms snap into place.

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The Problem : bulky components, tension in arches not contained

This design attempts a simplified approach - using fixed solid bamboo pole frames on which to mount the arch modules.The solid bamboo frame is too bulky. This defeats the purpose of knock down furniture, as it does not aid optimized utility of space.The arch arms experience a high ‘push and pull’ ten-sion between the top and bottom of the frame.After a point, the slightest shift or force from be-neath or sliding of arches on the top section may cause the arches to be launched off the frame.

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Solid pole and split frame + (x3) arch module

Support frame using solid bamboo poles as well as bent laminated bamboo splits


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The Problem : complex forms, tension in arched not contained

Though this design is aesthetically exciting, it uses very complex forms. These forms are possible to achieve using bamboo splits, but again demand too high a level of consistency. This will also be labour intensive.The arch arms experience a high ‘push and pull’ ten-sion between the top and bottom of the frame.After a point, the slightest shift or force from beneath or sliding of arches on the top section may cause the arches to be launched off the frame.

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Collapsible pole frame + (x3) arch module with locks

Collapsible solid bamboo pole frame with modified (x3) arch module, incorporating locks


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This design uses a collapsible X frame made using solid bamboo poles.This design uses a modified version of the (x3) arch module, incorporating solid bamboo pole sections as locks. The arches are force fitted from above. When released, the solid pole sections on the arch arms, find their place between the lower middle tie members of the X frame. This locking mechanism ensures that the arches will not be launched off the frame, unless forced manually, with the same action as applied when assembling.

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Collapsible pole frame + (x3) arch module with locks

Collapsible solid bamboo pole frame can be varied in length

Add-ons like a back rest can be installed using an additional lock

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Added feature : customization

This design also has a new provision for add-on features such as a back rest.The add on can be installed by manually force-fitting from the top. The bottom locks in using the same mechanism as the arch modules. An additional lock is installed on the top section of the X frame, running across the length, above the arch modules.

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The verdict

The ‘strip arch’ concept aimed at creating designs for knock down furniture which is modular in nature, to be assembled using a few simple steps. The ‘strip arch + support frame’ designs went through various stages, constantly tackling flaws and problem areas as they arose along the way. Eventually, the technical problems were all solved and the design was theoretically ‘working’. However, in the process, the design lost its simplicity and the desired aesthetics had been compromised to a large extent. Simplicity of assembly, form appeal and approachability of the design were key criteria to determine the feasibility of investing time, labour and funds in prototyping and production. Since it failed to sufficiently satisfy these criteria, it was decided that the ‘strip arch’ concept would not be taken forward to the prototyping stage.

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Knock it downknockables, stackables and bamboo

First set of sketches for the ‘knockable, stackables and bamboo’ concept

Knock - down Furniture : A piece of furniture which is received in parts (components) and assembled by the user. Once as-sembled, the final piece of furniture is permanently fixed. It is not necessarily “collapsible“. The furniture can be dismantled, with the use of a basic and common tool like a screwdriver. This concept emphasized on creating knock-down furniture using forms that are easy to integrate into an ‘assembly line’ type of production method.All finished components will be stackable - for ease of stocking and transportation.These components can come together in different configurations to form a complete piece of furniture which too will be stackable as a whole.The designs will incorporate modularity and scalability as integral qualities to aid expansive production and marketing meth-ods.

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Further exploring form

Stackable assembled furniture

Easy to replicate, stackable forms

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Further exploring form



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Finalized form



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Finalized form

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Finalized form

All details of joints and joiner depicted here are subject to change.While working with hands-on with the material, deci-sions will be taken regarding suitability of joinery.

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prototype production

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Knock it downprototype production

Treatment

Proper treatment of bamboo is essential for longevity of the material, making it immune to insects and fungus (the prime reasons for decay and short lifespan)The method of treatment used here involves soaking the bamboo poles / splits in a solution of water and boric acid for a period of 3 to 4 days.This process rids the bamboo of all sugar and lactose content, making it immune to fungus and insects such as termites and ants. After soaking, the bamboo must be naturally dried in the sun before it is ready for use.

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The Tools

Left to Right : The Dao, Chisels, Files, Hacksaw

Left to Right :LPG flame blower,G-Clamps

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Splitting

The splitting of bamboo poles and thinning of splits here is done manually using basic tools like the hatchet and the dao

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Bending

Bending of splits is done by applying heat and pressure simultaneously, along a profile with the help of jigs

Mild (MS) steel rings An MS ring held to plywood board using a screw

The Jigs :A modular system of JIgs has been used here. This includes steel rings of varying diameters and a board on which to arrange them

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Bending

Arranging MS rings to create Jig :

Selecting the right sized rings aginst full scale bend-ing profile

Arranging the MS rings in a configuration suitable to achieve the required curve

The steel rings are placed on top of a full scale drawing of the bending profile, and checked for selection of the correct sizes, suitable for achieving an accurate bend along the specific bending radius (as depicted in the profile)

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Bending

Bending along the Jigs

Applying heat while pulling the split to bend along the Jig

G-Clamps being used to hold the bent segment in place while it cools

The bamboo splits are bent by applying heat and pressure simultaneously, to key sections, along the layout of the Jig.G-clamps are used to hold bent section in place to avoid warping.Using this method of bending, several splits can be bent in to a similar profile using fixed Jigs, making replication easy.

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Smoothing

Cleaning charred skin :

Smoothing the inside surface using a file Removing the burnt skin using a dao

After bending, the surface of the split is cleaned and smoothened using simple tools like the file, the dao and the chicsel.This procedure can also be carried out on a rotating sanding machine.

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Lamination

Clubbing multiple splits together

Bent splits being held together after application of epoxy glue - Areldite

Bent splits being held together after application of epoxy glue - Areldite

The process of lamination involves the application of epoxy glue (e.g. areldite) and clamping the bent section together.After clamping, this assembly left undisturbed for a period long enough to allow the adhesive to dry.

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Bending + Lamination

Main profiles for lower section - each profile com-prises 3 laminated splits - these are stackable

Main profiles for seat and backrest - each profile comprises 3 laminated strips - these are stackable

This particular Design incorporates 3 laminated splits for each individual component (for strength and rigidity)The result of Bending and Lamination 3 splits each for all the profile is shown below :

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Bending + Lamination

Preparing profiles

Main profiles for lower section - each profile com-prises 3 laminated splits - these are stackable

Main profiles for seat and backrest - each profile comprises 3 laminated strips - these are stackable

This particular Design incorporates 3 laminated splits for each individual component (for strength and rigidity)The result of Bending and Lamination 3 splits each for all the profile is shown below :

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Assembly

Attaching tie members for lower section arches

Creating hole for insertion of bamboo pin Applying adhesive

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Assembly


Preparing bamboo pin for insertion Inserting bamboo pin (force fit)

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Assembly


Fully inserted bamboo pin Fully inserted bamboo pin

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Assembly

Inserting tie-members for lower section arches

Creating slots for insertion of tie member

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Assembly


Slot for insertion of tie member

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Assembly


Junction being held by G-Clamps while adhesive dries

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Creating half lap cuts in backrest profile

Attaching tie members for backrest profiles

Assembly


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Assembly


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Assembly


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Gluing backrest profiles to tie member


Assembly


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Joint reinforced with bamboo pin


Assembly


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Gluing backrest profiles to tie member


Assembly


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Checking measurements for spacingTemporary brace

Adjustments : spacing and alignment of backrest profiles

Assembly


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Assembly


Positioning external members for align-ment

Clamping after application of adhesive


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Assembly


Joint reinforced with bamboo pins


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Assembly

Adjustments : leveling

Leveling bottom end of backrest profiles

Leveling bottom end of backrest profiles


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Assembly

Adjustments : leveling

Positioning external member for align-ment

Joint reinforced with bamboo pin


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Assembly

Fixing screw inserts on bottom section frame

Screws with washers and inserts Screw insert to be embedded in tie member


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Assembly


Creating holes to embed inserts Applying adhesive to insert


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Inserting screw-insert into the tie members while screwing from the top, through the backrest tie member


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Final stage of smoothing using sandpaper and a handheld grinding machine

Final touches

Finishing

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Polishing

Final touches

Applying a coating of wax polish to lend a glossy texture, while maintaining the natural look


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The finished piece


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The finished piece


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Cost analysis


Raw material was sourced and sponsored by me

Bamboo Rs. 600

Bamboo procurement Rs. 800

Prototype production was carried out at Sangaru Design Objects Pvt. Ltd., Bangalore

Overheads:Gas, adhesive, electricity Rs. 1500

Labour:2 persons X Rs. 250/day X 10 days Rs. 5000

*As is evident from the difference in raw material cost and procurement cost, it is very important to have a good system in place for sourcing and procurement of material

*The adhesive used here is ‘Areldite’. This costs approximately Rs. 200 per 100gms. For a larger scale of production, cheaper alternatives can be used (epoxy glue of any kind)

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Aesthetics

Knock it downmy critique

Aesthetics seem to be nice on the whole

The chair appears to have good proportions

Tie members at the top and bottom ends of the seat-backrest seem to be obstructing an otherwise streamlined look

Some of the bamboo split ties members could per-haps be replaced with steel pipes. This would give the chair a more contemporary look.

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Ergonomics

Knock it downmy critique

The backrest should be more inclined, the current position is too up right. The current incline on the back rest is 10 degrees. This could be increased to 20 degrees. Alternately, 2 instead of 3 laminated splits could be used to create back rest profiles. This will allow some flex and actions in the back rest.

The seat is too short. The current seating depth is 36cm. This should be increased to 40/42cm.

The seating height too is a little bit more than it ide-ally should be. Perhaps 5cm lower would be more comfortable.

The seat is currently straight, at almost 180 degrees. A slight dip towards the back end of the seat will be more comfortable.

The tie member in front of the bottom section is hindering to the legs. Perhaps more rigid steel tie members along the profile could allow us to do away with the from tie member altogether.

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Reflections

Knock it downconclusion

The final concept - knockables, stackables and bamboo, has achieved the goals set by this project. This concept uses bamboo in an unconventional avatar, one that can be standardised to a large extent. This allows for mass production and cost control, which in turn enables the contemporary bamboo markets to expand. An increased market space for these products has a direct effect on craftsmen and artisan communities, providing them with more work and exposing them to a fresh approach to the material. From hereon, they now have an extended workspace to translate their deep understanding and experience of the material. In working first hand with artisans, I find that design intervention has a catalytic effect. Working with designers, constantly trying new approaches, craftsmen and artisans begin an exploratory phase themselves and knowingly or unknowingly begin to apply design thinking. Given their strong foundation in the use of the material, this enables them to think on fresh lines, evolving their traditions, perhaps even developing indigenous techniques and technology. All this contributes to the core mission of propagating the use of bamboo in a way that its is socially, economically and ecologically viable, profitable and progressive for all those involved.

This project has been carried out on a very small scale. The aim has been to set an example and showcase a few of the many possibilities bamboo offers the urban industry, markets and lifestyles. The up scaling of such production methods can have a strong impact on markets, livelihoods, traditions as well as the environment.The production of the the prototype for this project has been labour intensive as one single product prototype is not motive enough to encourage heavy investment in mechanized systems. However, most of the processes involved can be mechanized using existing technology.

Responsible material sourcing is as important , if not more, than design application. Bamboo is a highly sustainable resource with many environmental and ecological benefits. Using bamboo to replace other, less sustainable materials is a move for-ward, but plantation exercises are all important. If we do not invest time money and energy in plantation, proportionately to increase in applications, we will be back to naturally occurring forests for resources and all will be lost. As a designer, I have taken the position of a small catalyst. With this project, I hope to provide a look into what I see as a bright future with main streamed bamboo.

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Bibliography

Books

Bamboo- the gift of the gods - • Oscar Hidalgo - LopezBamboo and Cane crafts of Northeast India • -Ranjan, M P., Iyer Nilam, Pandya Ghanshyam,

Project documents

Lifestyle accessory in Bamboo - • Rajive Jassal PGDPD, NID Furniture Design for Tripura Bamboo Mission • - Garima Aggarwal PGDPD, NIDBamboo Product Development for Tripua Bam-• boo Mission - Andrea Noronha PGDPD, NIDBamboo Product Development & • Entrepreneurial Workshops - Outreach Programmes, Centre For Bamboo Initiatives, NID

Websites and blogs

http://sandeepsangaru.com/• http://www.idc.iitb.ac.in• http://www.ikea.com/• http://www.ipirti.gov.in• http://studioalaya.com/• http://www.ubfdb.org/• http://www.wondergrass.in/• http://wondergrass.blogspot.com/• http://design-for-india.blogspot.com/•

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Documents

Knock it Down - Bring the bamboo home