Construction Manual for Polymers +

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1 Construction Manual for Polymers + Membranes Materials semi-finished products form-finding design Edition Knippers CREMERS GABLER LIENHARD

2 Authors Jan Knippers, Prof. Dr.-Ing. Institute of Building Structures & Structural Design (itke) Faculty of Architecture & Urban Planning, University of Stuttgart Jan Cremers, Prof. Dr.-Ing. Architect Faculty of Architecture & Design Hochschule für Technik Stuttgart Markus Gabler, Dipl.-Ing. Institute of Building Structures & Structural Design (itke) Faculty of Architecture & Urban Planning, University of Stuttgart Julian Lienhard, Dipl.-Ing. Institute of Building Structures & Structural Design (itke) Faculty of Architecture & Urban Planning, University of Stuttgart Assistants: Sabrina Brenner, Cristiana Cerqueira, Charlotte Eller, Manfred Hammer, Dipl.-Ing.; Petra Heim, Dipl.-Ing.; Carina Kleinecke, Peter Meschendörfer, Elena Vlasceanu Specialist articles: Joost Hartwig, Dipl.-Ing.; Martin Zeumer, Dipl.-Ing. (Environmental impact of polymers) Field of Study Design & Energy-Efficient Construction, Department of Architecture, Technische Universität Darmstadt Carmen Köhler, Dipl.-Ing. (Natural fibre-reinforced polymers and biopolymers) Institute of Building Structures & Structural Design (itke), Faculty of Architecture & Urban Planning, University of Stuttgart Consultants: Christina Härter, Dipl.-Ing. (Polymers) Institute of Polymer Technology (IKT), University of Stuttgart Andreas Kaufmann, MEng (Complex building envelopes); Philip Leistner, Dr.-Ing. (Building physics and energy aspects) Fraunhofer Institute for Building Physics (IBP), Stuttgart/Holzkirchen Alexander Michalski, Dr.-Ing. (Loadbearing structure and form) Chair of Structural Analysis, Technische Universität Munich Mauricio Soto, MA Arch. (Building with textile membranes) studio LD Jürgen Troitzsch, Dr. rer. nat. (Building physics and energy aspects) Fire & Environment Protection Service, Wiesbaden Editorial services Editors: Judith Faltermeier, Dipl.-Ing. Architect; Cornelia Hellstern, Dipl.-Ing.; Jana Rackwitz, Dipl.-Ing.; Eva Schönbrunner, Dipl.-Ing. Editorial assistants: Carola Jacob-Ritz, MA; Cosima Strobl, Dipl.-Ing. Architect; Peter Popp, Dipl.-Ing. Drawings: Dejanira Ornelas Bitterer, Dipl.-Ing.; Ralph Donhauser, Dipl.-Ing.; Michael Folkmer, Dipl.-Ing.; Marion Griese, Dipl.-Ing.; Daniel Hajduk, Dipl.-Ing.; Martin Hämmel, Dipl.-Ing.; Emese Köszegi, Dipl.-Ing.; Nicola Kollmann, Dipl.-Ing. Architect; Simon Kramer, Dipl.-Ing.; Elisabeth Krammer, Dipl.-Ing. Translation into English: Gerd H. Söffker, Philip Thrift, Hannover Proofreading: James Roderick O Donovan, B. Arch., Vienna (A) Production & layout: Simone Soesters Reproduction: Repro Härtl OHG, Munich Printing & binding: Aumüller Druck, Regensburg Bibliographic information published by the German National Library. The German National Library lists this publication in the Deutsche Nationalbibliografie; detailed bibliographic data are available on the Internet at This work is subject to copyright. All rights reserved, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, recitation, reuse of illustrations and tables, broadcasting, reproduction on microfilm or in other ways and storage in data processing systems. Reproduction of any part of this work in individual cases, too, is only permitted within the limits of the provisions of the valid edition of the copyright law. A charge will be levied. Infringements will be subject to the penalty clauses of the copyright law. This book is also available in a German language edition (ISBN ) Publisher: Institut für internationale Architektur-Dokumentation GmbH & Co. KG, Munich English translation of the 1st German edition Birkhäuser GmbH PO Box 133, 4010 Basel, Switzerland Printed on acid-free paper produced from chlorine-free pulp. TCF ISBN: (hardcover) ISBN: (softcover)

3 Contents Preface 6 Part A Polymers and membranes in architecture The discovery and development of polymers 10 The dream of the polymer house 12 Development of tensile surface structures 16 Structures with transparent and translucent envelopes 21 Potential, trends and challenges 24 Part B Materials 1 Polymers 30 2 Fibres 48 3 Adhesives and coatings 54 4 Natural fibre-reinforced polymers and biopolymers 60 Part C Semi-finished products 1 Primary products 68 2 Fibre-reinforced polymers 76 3 Semi-finished polymer products 82 4 Foil 94 5 Textile membranes Building physics and energy aspects Environmental impact of polymers 124 Part E Building with polymers and membranes 1 Building with semi-finished polymer products Building with free-form polymers Building with foil Building with textile membranes Complex building envelopes 212 Part F Case studies Examples 1 to Part G Appendix Statutory instruments, directives, standards 286 Bibliography 287 Authors 289 Picture credits 290 Abbreviations for polymers 292 Index 292 Index of names 295 Part D Planning and form-finding 1 Loadbearing structure and form Detailed design aspects 150 5

4 Part A Polymers and membranes in architecture The discovery and development of polymers 10 From alchemy to chemistry 10 Polymer chemistry and industrial production 11 Polymers in furniture and industrial design 11 The spread of polymers 12 The dream of the polymer house 12 First buildings of glass fibre-reinforced polymer (GFRP) 13 The polymer module for the house of tomorrow 13 Plastic houses as an expression of visionary ideas 14 Building with polymers and the first oil crisis 14 Room modules made from polymers industrial prefabrication and batch production 14 Polymers today 15 Development of tensile surface structures 16 The lightweight tensile surface structures of Frei Otto 16 Pneumatic structures 17 Cable nets and membrane roofs for sports stadiums 19 Tensile surface structures in contemporary architecture 20 Materials in membrane architecture from natural to synthetic fibre fabrics and polymer foil 20 Structures with transparent and translucent envelopes 21 Potential, trends and challenges 24 Applications and potential 24 Trends and developments 25 Challenges 27 Fig. A Mobile membrane pavilion, Stuttgart (D), 2006, Julian Leinhard 9

5 Part B Materials 1 Polymers 30 Classification of polymers 30 Production of polymers 31 Fillers and additives 32 Properties of polymers 34 Thermoplastics 40 Elastomers 44 Thermosets 46 2 Fibres 48 Properties and applications 48 Inorganic fibres 50 Polymer fibres 51 Natural fibres 53 Metal fibres 53 3 Adhesives and coatings 54 Adhesives 54 Coatings 57 4 Natural fibre-reinforced polymers and biopolymers 60 Natural fibre-reinforced polymers 60 Natural fibres 61 Biopolymers 62 Natural fibre-reinforced biopolymers 64 A vision of the future of building 65 Fig. B Translucent facade panel made from glass fibrereinforced polymer 29

6 Part C Semi-finished products 1 Primary products 68 Preparing the polymer 68 Textiles 69 Core materials 72 2 Fibre-reinforced polymers 76 Constituents 76 Properties of fibre-reinforced polymers 77 Production 78 3 Semi-finished polymer products 82 Sections 82 Planar products 85 Moulded items 91 Special semi-finished products for engineering applications 92 4 Foil 94 Production of foil 94 Semi-finished products and forms of supply 96 Keders 99 5 Textile membranes 100 Requirements profile for membrane materials 100 Coatings 100 Semi-finished products and forms of supply 103 Mechanical properties 105 Fabrication 106 Webbing belts Building physics and energy aspects 108 Thermal insulation characteristics 108 Light and heat radiation characteristics 113 Moisture characteristics 117 Sound insulation and room acoustics 117 Reaction to fire and fire protection 119 Further characteristics 121 Polymers in the active use of renewable energies Environmental impact of polymers 124 Life cycle assessment 124 The influence of the LCA in the life cycle of a polymer 128 Fig. C Temporary terminal building, Vienna (A), 2005, Itten + Brechbühl, Baumschlager Eberle P.ARC 67

7 Part D Planning and form-finding 1 Loadbearing structure and form 134 Structural systems 134 Geometry of lightweight surface structures 136 Tensile surface structures Detailed design aspects 150 Calculations 150 Testing and approval 154 Quality control and industrial safety 156 Fig. D Close-up view of soap bubbles 133

8 Part E Building with poly mers and membranes 1 Building with semi-finished polymer products 160 Means of connection 161 Sections 165 Sheets 168 Moulded items Building with free-form polymers 174 Unreinforced polymers 174 Fibre-reinforced polymers 176 Mouldmaking Building with foil 188 Cushion lay-up and form 188 Details 190 Air supplies for pneumatic structures 192 Safety of cushion structures 194 Mechanically prestressed foil 194 Cable net support systems Building with textile membranes 196 Elements of the construction 197 Seams 198 Linear supports 201 Edges 202 Corner details 206 High and low points Complex building envelopes 212 The envelope design brief 212 Special aspects of foil and membrane designs 214 Combinations of polymer and glass 222 Fig. E Roof covering to a shopping centre in the form of air-filled ETFE cushions, Amadora (P), 2009, Promontorio Architects 159

9 Part F Case studies 01 Baar-Baarenfels, facade design and interior fitting-out, Vienna (A) Marco Serra, reception pavilion, Basel (CH) Foster + Partners, The Walbrook office and retail development, London (UK) Takeshi Hosaka, private house, Minamituru-gunn (J) Atelier Architecture King Kong, Seeko o Hotel, Bordeaux (F) Pfeifer Roser Kuhn, private house, Müllheim (D) Squire & Partners, flagship store and company headquarters, London (UK) Selgas Cano, office pavilion, Madrid (E) KHR arkitekter, company headquarters, Middelfart (DK) Deffner Voitländer, house and office, Dachau (D) Zaha Hadid Architects, Mobile Art Chanel Contemporary Art Container raumlaborberlin, Mobile Action Space Jabornegg & Pálffy, bank, Bratislava (SK) Promontorio Architetcts, shopping centre, Amadora (P) L35/Ganz & Muller Architectes Associés/GM2A Architectes, leisure centre, Neydens (F) Herzog + Partner, training centre for mountain rescue service, Gaißach (D) SBA Architekten, roof over circulation zone at EXPO 2010, Shanghai (CN) hg merz architekten museumsgestalter, memorial, Sachsenhausen (D) von Gerkan, Marg & Partner, Olympic stadium, Berlin (D) Foster + Partners, refurbishment and conversion of main railway station, Dresden (D) Murphy/Jahn, passenger terminal complex, Suvarnabhumi International Airport, Bangkok (T) Behnisch Architekten, canopy over Forum, Old Spinning Mill, Kolbermoor (D) Nikolai Kugel Architekten, open-air theatre, Josefsburg Arena, Kufstein (A) 282 Fig. F Manually laminated GFRP panels, Mobile Art Chanel Contemporary Art Container, Zaha Hadid Architects 225

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