A Brick in the air

AI Quick Summary

The project aims to prototype a sustainable masonry element for non-load-bearing internal walls that can be easily disassembled and reused. An initial exemplar of the block will be designed through parametric modelling and will be produced. The block will be designed in a manner that their mechanical, shape, and ergonomic characteristics facilitate clean, quick, and safe disassembling activities by low-skilled workers, while also ensuring efficient storage and transportation. The project aims to prototype a masonry element (block) for non-load-bearing internal walls that can be easily disassembled and reused (Design for disassembly). An initial exemplar of the block will be designed through parametric modeling and will be manufactured through a production process that allows rapid fabrication of complex shapes (e.g., robotic fabrication, large scale 3D printing). The block and its associated construction system must guarantee not only conventional structural and physical performance, but also be designed in a manner that their mechanical, shape, and ergonomic characteristics facilitate clean, quick, and safe disassembling activities by low-skilled workers (individuals experiencing difficulties in receiving social assistance or reintroduction to work), while also ensuring efficient storage and transportation.The final goal is both to guarantee flexible use of spaces and partitions during a building lifecycle and to facilitate recovering and re-installation of the blocks at the building end-of-life. The material of the block must be locally available, recycled, biobased, and/or recyclable.What problem would you like to solve?From the experiences made through the studies about the reuse potential of elements in local public buildings carried out by the SUPSI 4RnD Circular Construction Hub, through "DeCO – Decostruzione degli edifici recenti" project, and through the continuous comparison with companies that deal with demolition and recycling, it has emerged that vertical partitions of existing buildings are not recovered for reuse but are demolished due to technical, practical, labor cost reasons and their low residual value. Furthermore, as far as we know, on the local market, there are no masonry blocks for internal walls designed in such a way as to facilitate dismantling and reuse. The main types of non-load-bearing internal partitions and the current obstacles that prevent their deconstruction and subsequent reuse are listed below:Lightweight dry vertical partitions (e.g., plasterboard and prefabricated timber panels): for reasons of time/labor costs and low residual value, they are demolished destructively although, in some cases, at least a sectioning or partial dismantling may be possible. Compliance with acoustic regulations requires the installation of tapes, insulation mats, and membranes that increase the complexity of dismantling and plastic waste, limiting the spread of movable walls. Furthermore, there is no structured supply chain at the local level for recycling timber and, especially, plasterboard.Wet vertical partitions (e.g., brickworks): for technical reasons, they are dismantled destructively because the bricks cannot be separated from the cement mortars as the latter have greater resistance than the brick blocks. The brick tiles are fragile and break with the application of lateral loads and, therefore, storage for reuse is difficult.In addition to the technical obstacles, there are issues concerning labor costs. When the labor cost for dismantling weighs more than the value of the material, recovery and, therefore, reuse are not carried out. That often happens when the dismantling processes require time and when the residual value of the element is low. As a result, companies that deal with reuse and dismantling are often part of/collaborating with associations in which work reintegration programs are activated, limiting labor costs. Furthermore, for the same reasons, there is a tendency to recover masonry elements with artistic or historical value but not those from conventional constructions.Consequently, the aim is therefore to identify the requirements and characteristics that a vertical partition block must have to meet not only basic performance but also the requirements of simple and fast disassembly (installation/application technology), effective storage (resistance to lateral forces and interlocking), ergonomics (how to facilitate manual operations), and simplicity of block production. It will also be necessary to determine the optimal constituent material among recycled, biobased, and/or recyclable materials (e.g., brick, raw clay, quarry waste, etc.) present locally. Once the performance characteristics to be guaranteed have been identified, the aim is to carry out a preliminary design of the standard block and prototype the first blocks, also hypothesizing the related construction packages. Once the ideal shape has been determined, it must be adapted to the industrial needs of mass production. Finally, a circular business model that involves social associations dealing with people in need's reintegration into the labor market will be defined. We will envisage strategies to train non-specialized workforces for deconstruction activities in a short time and to provide customers with disassembly and assembly services available not only at the construction and the end of life of the building but even during its use.Who will benefit from your solution and how?Potentially, the solution will have a significant impact on social, economic, and environmental sustainability. It could lead to benefits for various stakeholders of the Construction sector (customers, designers, operators ...) and create value and innovation.The ergonomics of the block and the ease of assembly/disassembly can have a social impact by making it possible to feed the reuse chain and create jobs in this area. People would be able to access work without the need for lengthy training programs, which are difficult for individuals in a state of social fragility.From an economic point of view, the block presents itself as a new innovative material that generates employment and the possibility of new businesses in the reuse chain, with potential positive implications, especially at a local level. The idea addresses the pioneering theme of Design for disassembly. The basic block will have to be scalable in large quantities. It could represent a systemic transition towards a circular construction sector.From an environmental point of view, the possibility of reusing the elements in blocks several times reduces greenhouse gas emissions for new elements production, allows the circularity of materials, and avoids waste generation. Furthermore, the adaptability of the underlying construction methodology will facilitate the creation of flexible interior areas that adhere to the tenets of a sustainable and circular built environment.Who are the existing persons/companies in your team and what is their role?Carlo Gambato, SUPSI – Hub 4RnD Circular construction hub _ Coordinator - operational direction, determination of requirements and performances.Leidy Guante Henriquez, SUPSI – Hub 4RnD Circular construction hub _ PhD candidate - determination of requirements and performances, valorization and academic contextualization.Aron Chiappini, Tiriuso Sagl _ Owner of a company that deals with the recovery of construction materials and elements for reuse from buildings before demolition and of the first Ticino's exchange platform for building components (ti-riuso.ch). He provides the team with expertise about the operational and ergonomic requirements of the block in relation to the experience gained through his deconstruction activities and by employing people for the benefit of social aid.Serena Cangiano and Marco Lurati, SUPSI – Fab Lab _ Digital fabrication for prototyping, Robotic fabrication, large scale 3D printing technologies.Deborah Briccola, SUPSI – IST _ Preliminary structural design of the block.How does your challenge have a positive impact on the planet (e.g., material reduction, CO2 emission reduction)? The challenge has a positive impact on the planet by reducing construction waste, which is the majority of waste by weight produced in Switzerland and Ticino, and by reducing CO2 emissions from construction since the reuse of a material avoids the respective emission for the production of a new comparable material.Has your idea been tested before?The idea is new and emerged following the research, services, and networking activities with local businesses and institutions of the HUB SUPSI 4RnD Circular construction hub.What are you planning on working on throughout the booster (e.g., developing the business model, building an initial prototype, material for prototyping, etc.)? What will you deliver at the end of the booster?During the booster, the activities concern the preliminary identification of the needs and performance requirements of the block. Subsequently, a preliminary structural design will be performed with the identification of the possible constituent materials. Then, we will outline a circular business model capable of supporting a resource-saving and sustainable use of the block. As a last phase, the creation of prototype blocks ready for subsequent phases of testing and product development is foreseen.What are you expecting from the booster (e.g., looking for specific partners, expert support, etc.)?We expect to reach a prototyping stage and a level of depth that will allow us to present the product idea to further research and industrial partners for further development.How will you attract the 3rd party funding (10% of the total funding amount)?By reaching the prototyping and consolidation phases of the idea, we will be able to contact industrial partners and/or evaluate accessing local/national financing systems for innovation and enterprise (e.g., local economic development funds).

Project Idea Metadata

Project Idea Name: A Brick in the air
Date: 9/18/2024 3:18:35 PM
Administrators:
- Leidy Guante Henriquez

Project Idea Description

The project aims to prototype a masonry element (block) for non-load-bearing internal walls that can be easily disassembled and reused (Design for disassembly). An initial exemplar of the block will be designed through parametric modeling and will be manufactured through a production process that allows rapid fabrication of complex shapes (e.g., robotic fabrication, large scale 3D printing). The block and its associated construction system must guarantee not only conventional structural and physical performance, but also be designed in a manner that their mechanical, shape, and ergonomic characteristics facilitate clean, quick, and safe disassembling activities by low-skilled workers (individuals experiencing difficulties in receiving social assistance or reintroduction to work), while also ensuring efficient storage and transportation.

The final goal is both to guarantee flexible use of spaces and partitions during a building lifecycle and to facilitate recovering and re-installation of the blocks at the building end-of-life. The material of the block must be locally available, recycled, biobased, and/or recyclable.

What problem would you like to solve?

From the experiences made through the studies about the reuse potential of elements in local public buildings carried out by the SUPSI 4RⁿD Circular Construction Hub, through "DeCO – Decostruzione degli edifici recenti" project, and through the continuous comparison with companies that deal with demolition and recycling, it has emerged that vertical partitions of existing buildings are not recovered for reuse but are demolished due to technical, practical, labor cost reasons and their low residual value. Furthermore, as far as we know, on the local market, there are no masonry blocks for internal walls designed in such a way as to facilitate dismantling and reuse. The main types of non-load-bearing internal partitions and the current obstacles that prevent their deconstruction and subsequent reuse are listed below:

Lightweight dry vertical partitions (e.g., plasterboard and prefabricated timber panels): for reasons of time/labor costs and low residual value, they are demolished destructively although, in some cases, at least a sectioning or partial dismantling may be possible. Compliance with acoustic regulations requires the installation of tapes, insulation mats, and membranes that increase the complexity of dismantling and plastic waste, limiting the spread of movable walls. Furthermore, there is no structured supply chain at the local level for recycling timber and, especially, plasterboard.
Wet vertical partitions (e.g., brickworks): for technical reasons, they are dismantled destructively because the bricks cannot be separated from the cement mortars as the latter have greater resistance than the brick blocks. The brick tiles are fragile and break with the application of lateral loads and, therefore, storage for reuse is difficult.

In addition to the technical obstacles, there are issues concerning labor costs. When the labor cost for dismantling weighs more than the value of the material, recovery and, therefore, reuse are not carried out. That often happens when the dismantling processes require time and when the residual value of the element is low. As a result, companies that deal with reuse and dismantling are often part of/collaborating with associations in which work reintegration programs are activated, limiting labor costs. Furthermore, for the same reasons, there is a tendency to recover masonry elements with artistic or historical value but not those from conventional constructions.

Consequently, the aim is therefore to identify the requirements and characteristics that a vertical partition block must have to meet not only basic performance but also the requirements of simple and fast disassembly (installation/application technology), effective storage (resistance to lateral forces and interlocking), ergonomics (how to facilitate manual operations), and simplicity of block production. It will also be necessary to determine the optimal constituent material among recycled, biobased, and/or recyclable materials (e.g., brick, raw clay, quarry waste, etc.) present locally. Once the performance characteristics to be guaranteed have been identified, the aim is to carry out a preliminary design of the standard block and prototype the first blocks, also hypothesizing the related construction packages. Once the ideal shape has been determined, it must be adapted to the industrial needs of mass production. Finally, a circular business model that involves social associations dealing with people in need's reintegration into the labor market will be defined. We will envisage strategies to train non-specialized workforces for deconstruction activities in a short time and to provide customers with disassembly and assembly services available not only at the construction and the end of life of the building but even during its use.

Who will benefit from your solution and how?

Potentially, the solution will have a significant impact on social, economic, and environmental sustainability. It could lead to benefits for various stakeholders of the Construction sector (customers, designers, operators ...) and create value and innovation.

The ergonomics of the block and the ease of assembly/disassembly can have a social impact by making it possible to feed the reuse chain and create jobs in this area. People would be able to access work without the need for lengthy training programs, which are difficult for individuals in a state of social fragility.

From an economic point of view, the block presents itself as a new innovative material that generates employment and the possibility of new businesses in the reuse chain, with potential positive implications, especially at a local level. The idea addresses the pioneering theme of Design for disassembly. The basic block will have to be scalable in large quantities. It could represent a systemic transition towards a circular construction sector.

From an environmental point of view, the possibility of reusing the elements in blocks several times reduces greenhouse gas emissions for new elements production, allows the circularity of materials, and avoids waste generation. Furthermore, the adaptability of the underlying construction methodology will facilitate the creation of flexible interior areas that adhere to the tenets of a sustainable and circular built environment.

Who are the existing persons/companies in your team and what is their role?

Carlo Gambato, SUPSI – Hub 4RⁿD Circular construction hub _ Coordinator - operational direction, determination of requirements and performances.
Leidy Guante Henriquez, SUPSI – Hub 4RⁿD Circular construction hub _ PhD candidate - determination of requirements and performances, valorization and academic contextualization.
Aron Chiappini, Tiriuso Sagl _ Owner of a company that deals with the recovery of construction materials and elements for reuse from buildings before demolition and of the first Ticino's exchange platform for building components (ti-riuso.ch). He provides the team with expertise about the operational and ergonomic requirements of the block in relation to the experience gained through his deconstruction activities and by employing people for the benefit of social aid.
Serena Cangiano and Marco Lurati, SUPSI – Fab Lab _ Digital fabrication for prototyping, Robotic fabrication, large scale 3D printing technologies.
Deborah Briccola, SUPSI – IST _ Preliminary structural design of the block.

How does your challenge have a positive impact on the planet (e.g., material reduction, CO2 emission reduction)?

The challenge has a positive impact on the planet by reducing construction waste, which is the majority of waste by weight produced in Switzerland and Ticino, and by reducing CO2 emissions from construction since the reuse of a material avoids the respective emission for the production of a new comparable material.

Has your idea been tested before?

The idea is new and emerged following the research, services, and networking activities with local businesses and institutions of the HUB SUPSI 4RⁿD Circular construction hub.

What are you planning on working on throughout the booster (e.g., developing the business model, building an initial prototype, material for prototyping, etc.)? What will you deliver at the end of the booster?

During the booster, the activities concern the preliminary identification of the needs and performance requirements of the block. Subsequently, a preliminary structural design will be performed with the identification of the possible constituent materials. Then, we will outline a circular business model capable of supporting a resource-saving and sustainable use of the block. As a last phase, the creation of prototype blocks ready for subsequent phases of testing and product development is foreseen.

What are you expecting from the booster (e.g., looking for specific partners, expert support, etc.)?

We expect to reach a prototyping stage and a level of depth that will allow us to present the product idea to further research and industrial partners for further development.

How will you attract the 3rd party funding (10% of the total funding amount)?

By reaching the prototyping and consolidation phases of the idea, we will be able to contact industrial partners and/or evaluate accessing local/national financing systems for innovation and enterprise (e.g., local economic development funds).