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1 Hybrid City Challenge - Villa Mokum - [email protected] VILLA MOKUM mostly wood, some steel and a concrete base

VILLA MOKUM · VILLA MOKUMCOMPACT HOUSING Hybrid City Challenge - Villa Mokum - infoJaspermiddelberg.com Villa Mokum, by Kampman Architecten , is a mixed use block of 620 studio appartments,

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Page 1: VILLA MOKUM · VILLA MOKUMCOMPACT HOUSING Hybrid City Challenge - Villa Mokum - infoJaspermiddelberg.com Villa Mokum, by Kampman Architecten , is a mixed use block of 620 studio appartments,

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VILLA MOKUMmostly wood, some steel and a concrete base

Page 2: VILLA MOKUM · VILLA MOKUMCOMPACT HOUSING Hybrid City Challenge - Villa Mokum - infoJaspermiddelberg.com Villa Mokum, by Kampman Architecten , is a mixed use block of 620 studio appartments,

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CONTENTS

3 VILLA MOKUM

4 DESIGN GOALS

5 HYBRID STRUCTURE

6 2 STUDIOS IN 7 PARTS

7 PREFABRICATON

8 4 STUDIOS ON 2 TRUCKS

9 DIVIDED FLOOR SPAN

10 MODULE ASSEMBLY

11 CONSTRUCTION EASE

12 LATERAL BRACING

13 CONTINOUS INSULATION

14 DECOUPLED LAYERS

15 INSTALLATIONS

16 HOISTING

17 OFF-SITE & ON-SITE

18 EXTERIOR

21 DETAILS

Page 3: VILLA MOKUM · VILLA MOKUMCOMPACT HOUSING Hybrid City Challenge - Villa Mokum - infoJaspermiddelberg.com Villa Mokum, by Kampman Architecten , is a mixed use block of 620 studio appartments,

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VILLA MOKUMCOMPACT HOUSINGVilla Mokum, by Kampman Architecten, is a mixed use block of 620 studio appartments, commercial spaces at ground floor and an underground parking garage.

The building is, apart from the underground parking, made of prefabricated concrete elements, for the facade elements halved bricks were included with the concrete pouring.

I choose this building since brick seems not an obvious choice for wood construction but it’s a Dutch cultural staple and one of the best materials when it comes to durability and surface wear.

Also I believe there will be a growing demand for compact housing and Villa Mokum is a great example, combining efficient floorplans with light and open communal spaces.

Page 4: VILLA MOKUM · VILLA MOKUMCOMPACT HOUSING Hybrid City Challenge - Villa Mokum - infoJaspermiddelberg.com Villa Mokum, by Kampman Architecten , is a mixed use block of 620 studio appartments,

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DESIGN GOALSIf I would have to summarize the goals I had while starting to design a Hybrid Structure for Villa Mokum, using mostly Kerto in combination with concrete & steel, it would be:

Construction efficiencyMaterial efficiencySound perfomance

Page 5: VILLA MOKUM · VILLA MOKUMCOMPACT HOUSING Hybrid City Challenge - Villa Mokum - infoJaspermiddelberg.com Villa Mokum, by Kampman Architecten , is a mixed use block of 620 studio appartments,

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HYBRID STRUCTUREKERTO STUDIOS2 studios in 7 prefabricated parts, a combination of elements and modules, made of:

• Kerto Ripa floors

• Kerto S post & beam walls combined with steel strap bracing

• Steel consoles for concrete corridor floors.

CORRIDORS & COMMUNAL SPACE Concrete traffic floors supported by steel consoles attached to the kerto modules.

Steel fire escape on both ends.

Communal spaces made of steel frames with wood decking & siding.

CORE & BASEUnderground parking, ground floor commercial spaces and the central core made of concrete with the addition of a steel structure to support the 2x3750mm span of the Kerto studios.

Page 6: VILLA MOKUM · VILLA MOKUMCOMPACT HOUSING Hybrid City Challenge - Villa Mokum - infoJaspermiddelberg.com Villa Mokum, by Kampman Architecten , is a mixed use block of 620 studio appartments,

module / element edge

on-site fastening

DC

excluding tolerances

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2 STUDIOS IN 7 PARTS

WALL ELEMENTSKerto S internal post & beam structure with strap bracing, wrapped in continous rigid Rockwool insulation with a decoupled front/installation wall.

For the ‘Kerto studios’ I choose to combine prefabricated floor and wall elements with 2 modules; 7 parts for 2 studios. All elements and modules have grooves and edges from which the parts slot into each other and are fixed on-site from the interior.

FACADE MODULE

FLOOR ELEMENTS

WALL ELEMENTS

center wall

side wall

side wall

rest

BATHROOM MODULE

Kerto Q 2438 mm*

Kerto Q 2438 mm*

(Determined by the width of the continous wall insulation, page 13)

Kerto Q 2500mm

FLOOR ELEMENTS Kerto Ripa Box floor with a span of 7500mm divided on 3 supports for a minimal thickness 200mm.

At the underside of the floor a detached climate ceiling is placed.

MODULESThe corner modules have the same Kerto Ripa floor and a similar Kerto S Post & Beam structure.

The modules can be completely finished at the exterior.

Page 7: VILLA MOKUM · VILLA MOKUMCOMPACT HOUSING Hybrid City Challenge - Villa Mokum - infoJaspermiddelberg.com Villa Mokum, by Kampman Architecten , is a mixed use block of 620 studio appartments,

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SIZE MATTERSThe maximimum load allowed on a truck is a maximum of 18.75m in length with an extra 1m allowed at the back. The maximum width is 2.55 meter, the maximum total height is 4m. As exemption a maximum width of 3m and a total length of 27m is possible.

1 MODULEBeing able to completely finish the interior is a big plus with modular construction. But, while you also transport quit a bit of empty space, a load with a width of 3750mm is not allowed in Holland.

ELEMENTSFloor and wall elements are more compact but also require more onsite work, limits the degree of pre-finishing and increases the amount of onsite joints and seams.

MODULES VS ELEMENTSPrefabrication comes in 2 shapes, entire modules or elements, both have pros & cons:

MODULES + less onsite work + interior (completely) finished + neighbouring ceiling / floors can be

decoupled.

- higher, due to ‘double‘ floor + ceiling construction and connection points at corners.

- high transportation cost.

ELEMENTS + ‘flat pack’, efficient transportation. + easier to store.

- more onsite work. - more joints & seams.

PREFABRICATON3750

VOID

Page 8: VILLA MOKUM · VILLA MOKUMCOMPACT HOUSING Hybrid City Challenge - Villa Mokum - infoJaspermiddelberg.com Villa Mokum, by Kampman Architecten , is a mixed use block of 620 studio appartments,

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4 STUDIOS ON 2 TRUCKSThe current development of nitrogen policies in Holland affects both the building and especially the transpost industry.

4 studios will fit on 2 trucks with semi-dropdeck trailers.

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module / element edge

on-site fastening

DC

excluding tolerances

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DIVIDED FLOOR SPAN7500MM ON 3 SUPPORT POINTS The floor elements span 7500mm and are divided over 3 support points, a floor thickness of just 200mm is possible with, 2x KertoQ 25mm and only 3 Kerto S beams of 145mm divided over 2400mm.

HEIGHT & SOUNDPartly due to the limited height availablefrom floor to floor, 3000mm with a required ceiling height of 2600mm, only 400mm is possible for the floor thickness.

This floor already performs great on vibration but for further sound improvement I choose to completely decouple the climate ceiling.

The decoupled ceiling has a height of 140mm, the finished floor a total of 245mm. With a maximum floor deflection of 6,5 mm and a free gap of around 10-15 mm the floor and ceiling is a snug decoupled fit.

3 VS 2 SUPPORT POINTSAnother advantage of using 3 support points: a span of 7500mm on 3 support points improves the deflection by 16% compared to a span of 3750mm on 2 support points.

climate ceiling

Kerto Ripa Box floor

Page 10: VILLA MOKUM · VILLA MOKUMCOMPACT HOUSING Hybrid City Challenge - Villa Mokum - infoJaspermiddelberg.com Villa Mokum, by Kampman Architecten , is a mixed use block of 620 studio appartments,

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FLOOR & WALLThe ceiling is constructed first, on the underside of the floor elements. The element is then rotated to build the walls. The ceiling jois & flange made of Kerto S protects the ceiling during handling. On-site they are used to fasten the modules and elements together.

For the post & beam walls the floorelements are the working surface on which the wall parts can be assembled with the use of simple tooling.

AUTOMATION Actual framing automation requires advanced custom robotics and is not commonly in use (yet?).

Framing is mostly done by 1 or 2 persons with the use of assembly tables and hoists combined with CNC machines and maybe a loading system.

MODULE ASSEMBLY

module / element edge

on-site fastening

DB

excluding tolerances

s1

s2

s37500

2500

The wall parts are built on top of the floorelements.

ceiling joist climate

ceiling

climateceiling

ceiling joists along the outer edge

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FLOOR GUIDEThe posts are placed on the protruding edge of the bottom kerto Q sheet and fixed by screws along the height of the rim and floor joists. This connection provides a part of the lateral stiffness for the modules.

HALVE LAP - BUTT JOINTSThe two simplest joints, which can be cut by a basic 3 axes CNC machine. The halve lap joint secures the beam to the post, the buttjoint transfers vertical loads from beam to post.

floor e

dge

halve

lap

buttjoint

2 PERSON JOBThe floor elements, placed flush, form the working surface. The wall sub parts are compact and can be manually lifted into place by 1 or 2 persons.

Pre-cut CNC posts and beams with basic joints makes fastening a breeze. The protruding edge of the bottom Kerto Q sheet is the guide to place the posts on top.

The wall structure can be assembled by a team of 2 inexperienced carpenters using only basic tools, the cordless drill and a spiritlevel as the center pieces.

WORKING CONDITIONSThe maximum a person is allowed to lift in Holland is 23kg, depending on the frequency and circumstances this could go down to 12 kg.

CONSTRUCTION EASEkerto Q

kerto S

4x 23kg

92kg

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LATERAL BRACINGThe lateral bracing is a total of:1. Kerto S: bottom of post to floor rim

joist2. Kerto S: cross-diagonal fastening of

ceiling joists to wall beam along the entire perimiter.

3. Kerto Q: wall sheets of riser shaft, meterbox and along the facade posts.

4. Steel: diagonal strap brace & tensioners on kerto post-beam structure

5. Steel: framed studwall with solderded brace strips with corner sheets.

STRAP BRACESometimes called speed brace, available on a coil and quick to apply with nails and cut with pliers. Bracing strength is depended on amount of nails, in a standard studframe wall around 3kN/m per brace. Since the post & beams have more area to fix nails the bracing strength will be substantially higher.

The tensioners do not obstruct other layers, tensioning will bend the straps inwards and move in between the post and beam, the leftover screw thread can then be cut. The strapbrace is also a good backing for the continous and rigid insulation.

strap brace

Kerto S

Kerto Q

Console

Page 13: VILLA MOKUM · VILLA MOKUMCOMPACT HOUSING Hybrid City Challenge - Villa Mokum - infoJaspermiddelberg.com Villa Mokum, by Kampman Architecten , is a mixed use block of 620 studio appartments,

module / element edge

on-site fastening

DP2

excluding tolerances

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CONTINOUS INSULATIONRigid Rockwool is dense, an excellent soundproofing material and non combustible with a meltingpoint at approx. 1177°C.

Compared to insulation inbetween studs: by wrapping the post & beam structure in continous insulation the insulation becomes part of the fireproofing.

A standard available width is 2438mm (depending on manufacturer). Custom ceiling height is possible.

Large continous, ceiling height sheets will reduce the need for sealing and decrease flanking noise and installation time.

With an open ventilated structure and a vapor barrier, interior insulation is a viable option. The vapor barrier can be placed inbetween insulation layers, avoiding possible puncturing.

vapor barrier

ventilated through holes in grout

2373

2438

2438

Page 14: VILLA MOKUM · VILLA MOKUMCOMPACT HOUSING Hybrid City Challenge - Villa Mokum - infoJaspermiddelberg.com Villa Mokum, by Kampman Architecten , is a mixed use block of 620 studio appartments,

module / element edge

on-site fastening

DC

excluding tolerances

module / element edge

on-site fastening

DC

excluding tolerances

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DECOUPLED LAYERSContinous, dense layers, decoupling and the use of aircavities are among the most (cost) effective measures to improve sound insulation. With an aircavity backed with insulation, a deeper cavity will absorb lower frequencies better.

FRONT WALLWith continous rigid rockwool insulation fixed to the post and beams, a front wall of metal stud is placed against it. This can be done without the use of soundresilient clips since the insulation acts the same. An aircavity of 45 mm allows for standard socket boxes to fit. The ductwork is distributed along the top of the front wall and creates no punctures in layers, reducing flanking noise and makes installation easier. With continous insulation it will also act as fireproofing, reducing the amount of plasterboard needed.

po

st &

be

am +

air

cavi

ty

con

tin

ou

s in

sula

tio

n

airc

avit

y &

ele

ctri

cty

ceilingjoist CLIMATE CEILING

In similar fashion the climate ceiling is also decoupled with metal stud profiles of 125mm high that are fixed to the ceiling joist. In this way vibration and contactnoise from the floor will not be transfered to the ceiling.

(A suspended ceiling with wires will be hard to build since the ceiling will be installed with the floor element up side down. Also, this type of ceiling will still transfer vibrations to the ceiling.)

Page 15: VILLA MOKUM · VILLA MOKUMCOMPACT HOUSING Hybrid City Challenge - Villa Mokum - infoJaspermiddelberg.com Villa Mokum, by Kampman Architecten , is a mixed use block of 620 studio appartments,

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INSTALLATIONS

ELECTRICITYElectricity is placed in the side & center walls. The cabeling does not need to interupt any layers. Along the reversed top metalstud the cabling can be connected towards the meterbox.

During onsite assembly the elements and modules can be connected at the junctions.

VENTILATIONDuctwork for ventilation of the bathroom and kitchen can be installed in the decoupled ceiling.

junction

junction junction

( kitchen added on-site)

junction

meterbox riser

shaft

RISER SHAFTThe vertical ductwork can be pre-installed per module with connection sleeves at the bottom. On-site the riser shaft can be accessed from the exterior to connect the ductwork together, the connection sleeves also act as expansion points.

PLUMBINGThe toilet and shower is placed directly against the riser shaft avoiding any ductwork through beams. The top Kerto Q sheet requires one 40mm hole for the shower drain.

The bathroom front walls are slightly wider to include the plumbing for water and drains.

electricty

water

ventilation I changed the original bathroom design so it could fit on the bathroom module.The front wall makes installing ductwork more straightforward, it doesn’t interfere with the insulation. I also tried to avoid any ductwork through layers or the Kerto Ripa floors (except for the showerdrain)

socket box

water& drainducts

electricitydistributionin reversed metalstud

Page 16: VILLA MOKUM · VILLA MOKUMCOMPACT HOUSING Hybrid City Challenge - Villa Mokum - infoJaspermiddelberg.com Villa Mokum, by Kampman Architecten , is a mixed use block of 620 studio appartments,

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HOISTINGThe modules are hoisted along the posts, which are secured to the floor beams.

Into a threaded insert in top of the post a temporary swivel hoist is fixed for secure hoisting. The hoist needs to be placed on the inside, a fail system is not needed.

An advantage of the mirrorerd layout is that the center of gravity is in the middle ensuring levelled placement without the need for any balancing system.

HOISTING FROM FLOOR BEAMSThe bottom of the posts can be secured through the floor joist (green) and rim joists (yellow) and possibly vertically through the bottom Kerto Q sheet (red).

Page 17: VILLA MOKUM · VILLA MOKUMCOMPACT HOUSING Hybrid City Challenge - Villa Mokum - infoJaspermiddelberg.com Villa Mokum, by Kampman Architecten , is a mixed use block of 620 studio appartments,

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OFF-SITE & ON-SITERAINY DAYSIn the case of steel structure PPVC, the roof, which frequently consists of metal stud and exposed gypsum board and/or insulation, is often covered with plastics, in rainy conditions sometimes a roofing mebrane.

OPEN TOP MODULESThis is one of the drawbacks of constructing modules with an open top.

One idea, to limit the use of plastic foil wrap is a temporary and reusable roof, for onsite, transport and storage.

Something like aluminium profiles with overlapping polycarbonate on a slope, which can be easily fastened to the top of the post-beam structure?

Tricky one.

Page 18: VILLA MOKUM · VILLA MOKUMCOMPACT HOUSING Hybrid City Challenge - Villa Mokum - infoJaspermiddelberg.com Villa Mokum, by Kampman Architecten , is a mixed use block of 620 studio appartments,

module / element edge

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FACADE

excluding tolerances

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EXTERIORBRICK - WOOD - TRANSPARANTBrick has a sturdy character, gives a sense of massiveness and security to a building while wood construction evokes a sense of being lightweight. Used together they can create a contrast.

This is not the type of building to have exposed wood on the interior. But with the use of a translucent cladding the nature of the building can be revealed on the outside.

moisturethermal

Page 19: VILLA MOKUM · VILLA MOKUMCOMPACT HOUSING Hybrid City Challenge - Villa Mokum - infoJaspermiddelberg.com Villa Mokum, by Kampman Architecten , is a mixed use block of 620 studio appartments,

CostEffective

InstallationEase

DurableCO2 friendly

Circulair

Brick Slips

Cost Effective

InstallationEase

DurableCO2 friendly

Circulair

Wood

Cost Effective

InstallationEase

DurableCO2 friendly

Circulair

Glass panels

Cost Effective

InstallationEase

DurableCO2 friendly

Circulair

Translucent Plastics

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FACADE FRONT (R-value 4,6) t(mm)brick slips glued to cement fiber boar 32vapor barrierbatten 35post & beam, Kerto S (51x225-260) 51continous rigid rockwool insulation 100metalstud + insulation 45gypsum board 12,5

275,5

FACADE CORRIDOR (R-value 4,6) t(mm)cladding 25batten 40post & beam, Kerto S (51x225-260) 51continous rigid rockwool insulation 100vapor barriermetalstud + insulation 45gypsum board 12,5

273,5

WALL CENTER t(mm)gypsum board 12,5decoupled metalstud + electrical 45continous rigid rockwool insulation 40post & beam, Kerto S (63x235-260) 45continous rigid rockwool insulation 40decoupled metalstud + electrical 45gypsum board 12,5

240

WALL SIDE t(mm)gypsum board 12,5decoupled metalstud + electrical 45continous rigid rockwool insulation 40post & beam, Kerto S (51x225-260) 51continous rigid rockwool insulation 40decoupled metalstud + electrical 45gypsum board 12,5

246

FACADE FRONT (R-value 4,6) t(mm)brick slips glued to cement fiber boar 32vapor barrierbatten 35post & beam, Kerto S (51x225-260) 51continous rigid rockwool insulation 100metalstud + insulation 45gypsum board 12,5

275,5

FACADE CORRIDOR (R-value 4,6) t(mm)cladding 25batten 40post & beam, Kerto S (51x225-260) 51continous rigid rockwool insulation 100vapor barriermetalstud + insulation 45gypsum board 12,5

273,5

WALL CENTER t(mm)gypsum board 12,5decoupled metalstud + electrical 45continous rigid rockwool insulation 40post & beam, Kerto S (63x235-260) 45continous rigid rockwool insulation 40decoupled metalstud + electrical 45gypsum board 12,5

240

WALL SIDE t(mm)gypsum board 12,5decoupled metalstud + electrical 45continous rigid rockwool insulation 40post & beam, Kerto S (51x225-260) 51continous rigid rockwool insulation 40decoupled metalstud + electrical 45gypsum board 12,5

246

FLOOR t(mm)onsite floor finish 20onsite subflooring 20

Kerto Ripa BoxKerto Q 2400x25mm 25Kerto S 3x45x150mm + insulation 150Kerto Q 2400x25mm 25gypsum board 12,5

Decoupled Ceilingair cavity 7,5metalstud C125 125climate ceiling 15

400

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DETAILS• principal detailling, scale 1:5• excluding tolerances• only onsite fastening displayed

DP1

DADP2

DA

DC

PD4

DP3

DC

DB

DB

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DP1

excluding tolerances

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schematic

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DP2

excluding tolerances

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schematic

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module / element edge

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Page 28: VILLA MOKUM · VILLA MOKUMCOMPACT HOUSING Hybrid City Challenge - Villa Mokum - infoJaspermiddelberg.com Villa Mokum, by Kampman Architecten , is a mixed use block of 620 studio appartments,

module / element edge

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