The main aspects of the Corn-Crete House system are the use of space, material efficiency and relationship to site. The way space is shaped influences human behaviour. According to a research paper done by KAYVAN MADANI NEJAD in 2007 the curvilinearity of interior design directly affects the way people feel inside them. It concluded that the more curvilinear a space is the more comfortable, safe, relaxed and friendly it feels. My project builds upon this argument. Research also shows that the concrete industry is a major environment pollutant. Cement is the most damaging ingredient. I am proposing a new system which will be using less concrete & less cement thanks to: 1) corn residues partially replacing aggregate making the structure lighter and more porous 2) casting around inflatables resulting in curvilinear architecture suitable for compression which requires less tensile strength.
Gum Arabic is a natural adhesive grown on the Senegalia Senegal tree. This tree grows in 6 years and only requires 100-200ml of water a year, this is a tree which has evolved to survive in the desert.
How can a third world country like Sudan can use a natural adhesive to act as a binder? How can we use the natural terrain as a framework for creating complex and controllable design?
Below the images illustrate how the construction process works.
I have designed a time-based construction programme. It begins with a setting out plan where string is used to determine where an industrial hoover (which usually transfers sand) sucks out sand and it is spewed out elsewhere. When my mix has been added to these cone shape voids the hoovering process is repeated but this time a thick layer of the Gum Arabic, Clay and Sand mix. The mixture is then lightly misted with salt water which causes the Gum Arabic to act as the binder. The Desert’s scorching sun then does the rest to solidify the material. Excavation around the land enables a structure which stands upright.
After exploring this method myself I discovered some interesting variations depending on whether I suck the sand first or pour it
I explored these forms digitally.
If you are wondering how I got to this point, well I will jump back to the beginning.
It started in Kew Gardens London, where I chose to study a plant and look into the early stages of bio-mimicry. I chose to study the Lotus Pod (Nelumbo Nucifera) found in Asia.
I wanted to find consistency between the holes of the flowers. Therefore I purchased 40 flower heads and begun experiments to study the arrangement of holes and the parameters within the plant. After experimenting I discovered that flower heads sized between 50-60mm have a gradient like effect where the largest hole is 3.5 times larger than the smallest. I therefore used Frei Ottos sand draining technique to explore what forms can be achieved with the arrangement of holes being that of the Lotus Pod.
After designing and building a smart box I began a matrix study.
I then Explored the parameters of each of these and found out that this sand grain drains at 30 degrees.
From this point I went on to look at how to solidify sand in its current form and that is when I discovered the properties of the Gum Arabic and began to explore. I had began to mix the mixture with sand and clay.
I then explored a site based on where Gum Arabic is produced and where sand and clay is in abundance. Therefore leaving me with Al-Fashir Sudan.
I then Explored the construction techniques using the gravity. Using the terrain as a natural formwork which can be moulded.
I then continued to design a construction process which requires less labour and would achieve high quality design attributes. Which is where I began with the hoovering process.
So that’s it we have finished the parametric models for Shipwreck and Fractal Cult and that’s how they look:
Shipwreck’s parametric model on Grasshopper by Chris Ingram and Arthur Mamou-Mani
Fractal Cult’s parametric model Grasshopper by Dan Dodds
So what do these weird drawings produce? Well have a look at the shipwreck – All of it can vary, from the amount of ribs to their depth – Last thing to do: unfold everything for fabrication.
After a long day of work with Chris Ingram, Dan Dodds and Thanasis Korras yesterday, we have nearly finished 3D modelling the two projects. The Fractal Cult was redrawn using rules defined by the hinge connection suggested by Ramboll. There are 5 different types of piece that make up each of the four fractal cults. Extracts from the rules as specified by Dan Dodds and Thanasis Korras:
The Acute angles on all triangles all have bolt holes with an offset of 32mm
The Obstuse angles all have bolt holes with an offset of 22mm
For each Fractal Cult pods:
12x  Large AAO [Acute,Actute,Obtuse]      : Side length 1241mm
18x  Medium AOO [Acute,Obtuse,Obtuse] : Side length 608mm
9x    Medium AAO [Acute,Actute,Obtuse]  : Side length 591mm
54x  Small AOO [Acute,Obtuse,Obtuse]     : Side length 283mm
108x Small AAO [Acute,Actute,Obtuse]Â Â Â Â Â Â Â :Â Side length 266mm
See iimages below:
View of the 3D model of Fractal Cult
Offset Ply Model on Grasshopper by Dan Dodds
CNC Layout for Quote – Fractal Cult – Dan Dodds
Hinge specification defining the rules for the parametric model
The Module being repeated for the 3d model with hinges by Thanasis Korras
View of the hinges in the module by Thanasis Korras
Hinged model of triangle by Thanasis Korras
Hinged model of triangle by Thanasis Korras
The Shipwreck now has more support on the ground which will help with the cantilever. The supports being more pronounced, we used this as an opportunity to create a bench. We are planning to finish the fabrication files this afternoon. We are still missing some notches, thickness as well as labelling and unrolling all the pieces.
Shipwreck ribs and spines
Shipwreck ribs and spines
Shipwreck ribs and spines
Shipwreck ribs and spines
Shipwreck – Work in Progress – Aerial View – Showing the new bench
Hello! Couple technical updates on our Burning Man Projects for the team, donators and potential collaborators:
We have developed the structure, geometry and details of the two projects with the help of Ramboll Computational Design (RCD). See drawings and analysis below.
We have signed the contract with Burning Man and received the first grant payment 20 of us are signed in to go.
We have sent our first fabrication files to get an initial quote on CNC milling all the pieces on 2440mm x 1220mm exterior grade plywood sheets of 9mm (for Fractal Cult) and 3mm (For Shipwreck). Our hope is to collect the pieces on the 19th August.
We will start small models to test the new structures
The Shipwreck now has a parametric model which outputs all the cutting profiles.
Please help us continue the work, even £10 helps – Donate Now –
You can also comment on this page to make suggestions on the fabrication – We need more quotes for the CNC and/or Laser cutting job in the U.S. West Coast (Los Angeles, San Francisco, Las Vegas, Sacramento, Fresno, Reno preferably) . We also need quotes for the scaffolding structure.
Stephen Melville of Ramboll RCD sketch for the Shipwreck structure
Shipwreck – Looking at different Versions with Parametric model
Shipwreck – Looking at different Versions with Parametric model
Shipwerck – Low View
ShipWreck View from above
Current Profiles for Shipwreck
Current Laser cut Profiles for Fractal Cult
Hinged Connection for Fractal Cult by Thanasis Korras with Ramboll
Ramboll’s suggestion for Fractal Cult’s Scafolding structure
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