Sustainability and Service Life of Curtain Walls

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1 Thalia Anastasia Kakolyri _ P5 presentation Stick and unitised system for short-term and long-term use in curtain walls Mentors: Dipl.ing. Tillmann Klein Dr.ir. Fred Veer

2 v world s middle 60% consume 21.9% world s poorest 20% consume 1.5% world s richest 20% consume 76.6% (Heesbeen 2010) References Heesbeen, C. (2010). Materializing the life cycle of the facade. MSc, Tu Delft, Delft University of Technology. 2

3 + 1.8% billion tons of resource extraction in 2020, globally metal ores fossil energy carriers biomass 12 non-metallic minerals tonnes / capita (Foundation 2014) References Foundation, E. M. (2014). Towards the Circular Economy - Economic and business rationale for an accelerated transition, Ellen Macarthur Foundation. 3

4 v service life 0-2 years production storage transport construction x years operation demolition/ disassembly Product category business volume Introduction Growth Maturity Decline time 4

5 service life Product category business volume 0-2 years production storage transport construction x years operation $ demolition/ disassembly $ $ Introduction Growth Maturity Decline time 5

6 v Design - decision making How long do you want your product to live? Cost Time Disturbance etc Program of maintenance Non-/durable materials Level of connectivity RELIABILITY 6

7 Design - decision making Program of maintenance How long do you want your product to live? Non-/durable materials RELIABILITY Cost Time Disturbance etc Level of connectivity repair recycle refurbish reuse materials manufacturing parts manufacturer product manufacturer service provider user collection 7

8 v Problem statement Proportion between materialisation and operation of a construction must be in balance for a sustainable life cycle Low energy buildings have already reduced the operational energy demands Minimise environmental impact of materialisation Rethink the role of product s expected life span Starting point: curtain walls (widely used in office and commercial buildings) Design phase Decision making Sustainability & Environmental Impact 8

9 Problem statement Proportion between materialisation and operation of a construction must be in balance for a sustainable life cycle Low energy buildings have already reduced the operational energy demands Minimise environmental impact of materialisation Rethink the role of product s expected life span Starting point: curtain walls (widely used in office and commercial buildings) Product s service life Design phase Decision making Sustainability & Environmental Impact Materialisation Operation 9

10 v Research question - How long should a curtain wall live to have minimum environmental impact? - Does stick or unitised curtain wall provide the most sustainable materialisation and service life? (Watts 2013) (Knaack, Auer et al. 2014) References Watts, A. (2013). Modern Construction Handbook. Berlin, Ambra. Knaack, U., T. Auer, M. Bilow and T. Klein (2014). Façades; Principles of Construction. Basel, Switzerland, Birkhäuser. 10

11 Research question - How long should a curtain wall live to have minimum environmental impact? - Does stick or unitised curtain wall provide the most sustainable materialisation and service life? $ Embodied energy CO 2 emissions Time Cost End-of-life 11

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13 Gap between designer and manufacturer References Boothroyd, G., P. Dewhurst and W. Knight (1994). Product design for manufacture and assembly. New York, Dekker. 13

14 v INITIAL DESIGN 14

15 AFTER DESIGN FOR DIS-/ASSEMBLY 15

16 v Press fitting Living hinge Snap fit 16

17 Snap fit 17

18 v Irreversible snap-fit Snap fit 18

19 Reversible snap-fit Snap fit 19

20 v Reversible snap-fit Snap fit 20

21 Reversible snap-fit Snap fit 21

22 v Reversible snap-fit Snap fit 22

23 10 steps to disassemble Phoneblocks 23

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25 Architectural design 25

26 v Architectural design Visual comfort 26

27 Architectural design Visual comfort Thermal insulation 27

28 v Architectural design Visual comfort Thermal insulation Ventilation 28

29 Architectural design Visual comfort Thermal insulation Ventilation Protection from weather conditions 29

30 v Architectural design Visual comfort Thermal insulation Ventilation Protection from weather conditions Structural integrity 30

31 Curtain wall systems 31

32 v Stick curtain wall Curtain wall systems Unitised facade 32

33 Stick curtain wall Curtain wall systems 33

34 v Stick curtain wall Curtain wall systems 34

35 Stick curtain wall Curtain wall systems 35

36 v Curtain wall systems Unitised facade 36

37 Curtain wall systems Unitised facade 37

38 v Curtain wall systems Unitised facade 38

39 Design for easy dis-/assembly 39

40 v Design for easy dis-/assembly 40

41 Design for easy dis-/assembly 41

42 v Design for easy dis-/assembly 42

43 Design for easy dis-/assembly 43

44 v Life span of materials 70+ years (Aluminium) 30years (EPDM gasket) 30years (Glass unit) 30years (PE foam) 30years (EPDM gasket) 44

45 Life span of materials 70+ years (Aluminium) 30years (EPDM gaskets) 30years (Glass unit) 30years (PE foam) 30years (EPDM gaskets) 45

46 v Façade s service life 30 years 60 years 120 years 46

47 Façade s service life % Primary cost Environmental impact + Flexibility 30 years 60 years 120 years service life 47

48 v Façade s service life % Primary cost Environmental impact + Flexibility 30 years 60 years 120 years service life 48

49 Mechanical, Maritime and Materials Engineering Faculty (3mE) Use educational => regular changes Design 4 modular wings connected ~100m 2 49

50 v Typical Dutch construction (brick facade - insulation - concrete wall) 50

51 Scenarios of service life 15 years service life 51

52 v Scenarios of service life replace only the facade building serv.life = 60 years 15 years service life 52

53 Scenarios of service life replace only the facade building serv.life = 60 years 15 years service life take apart the complete building building serv.life = 15 years 53

54 v Scenarios of service life replace only the facade building serv.life = 60 years 15 years service life take apart the complete building building serv.life = 15 years 60 years service life 54

55 Scenarios of service life replace only the facade building serv.life = 60 years 15 years service life take apart the complete building building serv.life = 15 years 60 years service life refurbish once after 30 years building serv.life = 60 years 55

56 v Span of 60 years in total No material losses during disassembly and transportation to recycling shredder Highest percentages of material recovery through recycling Values acquired: average data (CES Edupack 2014) Façade s performance: efficient Only triple glazing is evaluated for the long-term scenario Feasibility, experience, current equipment considered for the redesign 56

57 Detailing 15 years service life 60 years service life 57

58 v Detailing Stick curtain wall 15 years service life 60 years service life 58

59 Detailing Stick curtain wall 15 years service life reduced tolerance for adjustments in glazing 60 years service life 59

60 v Detailing Stick curtain wall 15 years service life 60 years service life 60

61 Detailing Stick curtain wall 15 years service life 60 years service life cover cap reversible connection 61

62 v Detailing Stick curtain wall 15 years service life 60 years service life replace with Nylon polyamide 62

63 Detailing Stick curtain wall 15 years service life 60 years service life 63

64 v Detailing Unitised facade 15 years service life 60 years service life 64

65 Energy evaluation Primary Embodied Energy + Refurbishment/Replacement Embodied Energy + End-of-life Energy = Total Embodied Energy of evaluated energy (Refurbishment E.E = x % recycling E.E. + y % primary E.E.) 2.8m 4m *Respectively for the CO 2 emissions. Evaluated elements for primary energy 65

66 v Energy evaluation Embodied energy & CO 2 emissions 66

67 Energy evaluation Stick curtain wall Embodied energy & CO 2 emissions Unitised facade 67

68 v Energy evaluation 15 years service life Stick curtain wall Embodied energy & CO 2 emissions 60 years service life 15 years service life Unitised facade 60 years service life 68

69 Energy evaluation 15 years service life Embodied energy & CO 2 emissions Stick curtain wall Unitised facade 60 years service life 15 years service life 60 years service life Outcome Stick Vs Unitised 69

70 v Energy evaluation 15 years service life Stick curtain wall Embodied energy & CO 2 emissions 60 years service life 15 years service life Unitised facade 60 years service life Outcome Stick Vs Unitised Short Vs Long-term 70

71 Comparison of Results Glazing: double Refurbishments: 2 Emb.Energy (MJ) CO 2 emissions (kg) Emb.Energy (MJ) CO 2 emissions (kg) STICK UNITISED 71

72 v Comparison of Results Glazing: double Refurbishments: 2 Emb.Energy (MJ) CO 2 emissions (kg) Emb.Energy (MJ) CO 2 emissions (kg) % + 27% STICK UNITISED 72

73 Comparison of Results Glazing: triple Refurbishments: 2 Emb.Energy (MJ) CO 2 emissions (kg) Emb.Energy (MJ) CO 2 emissions (kg) STICK UNITISED 73

74 v Comparison of Results Glazing: triple Refurbishments: 2 Emb.Energy (MJ) CO 2 emissions (kg) Emb.Energy (MJ) CO 2 emissions (kg) -15% % STICK UNITISED 74

75 Comparison of Results Glazing: triple Refurbishments: 2 Emb.Energy (MJ) CO 2 emissions (kg) UNITISED STICK 75

76 v Comparison of Results Glazing: triple Refurbishments: 2 Emb.Energy (MJ) CO 2 emissions (kg) UNITISED STICK 76

77 Comparison of Results Glazing: triple Refurbishments: 2 Emb.Energy (MJ) CO 2 emissions (kg) % UNITISED STICK 77

78 v Comparison of Results Glazing: triple Refurbishments: 2 Emb.Energy (MJ) CO 2 emissions (kg) % UNITISED STICK 78

79 Comparison of Results Glazing: triple Refurbishments: 2 Emb.Energy (MJ) CO 2 emissions (kg) UNITISED STICK 79

80 v Cost - Time Primary Cost Facade system / Pri ma r y co st ( ) Double glazing Triple glazing Stick 15 years Service Life Stick 60 years Service Life Unitised

81 Cost - Time Primary Cost Facade system / Pri ma r y co st ( ) Double glazing Triple glazing Stick 15 years Service Life Stick 60 years Service Life Unitised Time of labour (hours) STICK UNITISED IN FACTORY ON SITE 81

82 v Cost - Time Primary Cost Facade system / Pri ma r y co st ( ) Double glazing Triple glazing Stick 15 years Service Life Stick 60 years Service Life Unitised TIME = MONEY UNITISED + 40 h in factory h on site Time of labour (hours) - 90 h in total IN FACTORY less labour better conditions better quality less expenses STICK UNITISED ON SITE 82

83 Design matters... 83

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88 v Both stick and unitised facade have approximately the same environmental impact 88

89 Both stick and unitised facade have approximately the same environmental impact Unitised system provides better working conditions and saves a lot of time and expenses Stick system requires more time and costs and daily transportation, as most of the work is done on site 89

90 v Both stick and unitised facade have approximately the same environmental impact Unitised system provides better working conditions and saves a lot of time and expenses Stick system requires more time and costs and daily transportation, as most of the work is done on site Advantage of element facade 90

91 Both stick and unitised facade have approximately the same environmental impact Unitised system provides better working conditions and saves a lot of time and expenses Stick system requires more time and costs and daily transportation, as most of the work is done on site Advantage of element facade Long-term service life should be applied on façades, and refurbish when needed (currently not applied) 91

92 Thank you for your attention! Questions?