Ross Myren - Cylindrical Cork System (speculative)

For this project, we were tasked to 'speculate as to new forms of architectural assembly and construction that maximize the unique potential of this material. To do so means going beyond material substitution, to creative design projections that rework historic and invent new tectonic configurations.'

Where each group worked with a different bio-based material, Amanda and I explored the opportunities of cork as a building system that strays away from its conventional use.

We began this project with a deep investigation into cork; understanding at a microscopic level the very biological makeup that drives its own innovation as a circular, recyclable, and fully biodegradable building material.

With our precedent research as a jumping off point, we began to sketch out our ideas for how we could utilize the cylindrical form to create a self supporting structure, and how to secure it vertically in compression between the framed ground floor and the roof. We thought of wrapping the structure with steel cables (much like a wine barrel or water tank) to prevent it from buckling outwards.

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All images, drawings, and models made by myself unless otherwise specified!

Scroll to bottom for a detailed walkthrough of the design.

based on our research, I drew & annotated this full lifecycle diagram that follows our Curved Cork Block from its inception to its end of life.

For our partial wall section, which we modeled at ⅜” = 1’, we used part of a thin sheet of rolled cork w/ adhesive backing (to cut and form the individual cork blocks), found/collected screws (to represent the helical piles), a thin piece of plywood (to represent the ground plane), tiny pins left-over from a previous project (not to represent an actual material, but to hold the cork in place), silver thread & wire (to represent steel tension cables), and tacky glue (purchased, only used on the model framing). All materials were sourced from the reuse shelves in the studio or from the street unless otherwise noted!

some initial concept sketches illustrating how we could use a timber frame & steel cables to hold the blocks together without adhesives.

Ease of assembly; with one custom block that is repeated & designed to be carried & installed by a single person!

Starting from the foundation, we knew immediately that we did not want to use any concrete or other cementitious materials which have high embodied carbon values and would not be easily removed at the structure's end of life. We proposed using helical piles - essentially large hollow steel tubes that screw & anchor into the ground. Though there is a carbon impact associated with the fabrication of these piles, they can be uninstalled and reused.

These piles would bolt into the floor framing that would be raised above grade, which would be constructed out of dimensional lumber that is milled on-site within a sustainably managed forest. As seen in the drawings/sketches, this framework takes a bit of inspiration from the radial structure of snowflakes; as it was, at first, difficult to imagine how we would resolve a cylindrical form into a rectilinear framing plan. Atop the framing would sit sawn boards, which would distribute the load of the outer walls more evenly. From there, a circular cork floor would be installed with an extruded ring around the perimeter onto which the cork blocks we designed would notch.

We designed this curved cork block such that it would notch not only into those adjacent to it, but also those above and below it. In doing so, we were able to assemble the model using copies of the same exact module by just rotating each ‘ring’ of blocks about the central vertical axis - much like how one would lay a cylindrical masonry wall.

Through our life cycle assessment research, we found that expanded cork agglomerate could be autoclaved under different pressure levels to create different densities; where less-dense is better insulating because more air is trapped in the cork itself, but consequently is also more fragile. With an R-value ranging from R-3.4 to R-4, we realized that the 18” thick block we need for stability & structural integrity could exist in itself as a complete ~R-60 wall system, on the low end! This justified using the less-insulating higher-density cork that would withstand wear-and-tear both internally and externally.

The cork block cylindrical system is continuous through the first and second level, meeting the roof that mirrors the same framing dimensionally as the base. This allows us to bolt & secure steel cables that tie the roof and base members together in tension on the exterior and interior of the structure, compressing the cork wall in between (think Swiss Sound Box, Zumthor).

The roof sits on top, and while it is framed with wood we wanted to test and imagine cork roof panels that are sloped and similarly interlocked to ensure tightness. At the peak, we imagine using a reclaimed skylight that would further compress the structure and help resolve it into the ground.

Detailed wall sections drawn by Amanda Park, based on a digital model by Ross Myren.