Bio-Based Materials

Tatu

An installation made of hempcrete blocks to highlight the potential of bio-based materials in architecture.

On the occasion of the second edition of Build - From High Tech to Low Tech, a fair held last September at Casa da Arquitectura in Porto, Park Associati was invited to design and build a pavilion to enhance the role that bio-based materials play in the future of architecture. The structure, entirely assembled dry and designed to be quickly disassembled, aimed to explore the structural and aesthetic potential of hempcrete and how a parametric approach can enhance the efficiency of the construction process in low-tech applications. Once dismantled, the blocks used to make the installation were shipped to the construction site of a private villa under construction outside Porto.

The design process and assembly

The pavilion reinterprets the vernacular style of the Pantescan garden, taking the form of a hemp brick semicircle that protects a single plant element, evocatively representing the biosphere. The project concept was entrusted to the Park Plus team and the Design Technology group within the studio. The latter was responsible for the overall geometric layout of the intervention. The installation had to be completed in just a few hours and entirely dry, necessitating the development of a parametrically designed installation method. The template used by workshop participants for self-construction was created in-house with a CNC mill and used on-site to "mathematically" control a process that, due to its inherently low-tech nature, would otherwise have compromised the final result of the work. The progressive rotation of the blocks, which achieves the desired armadillo skin effect envisioned by the designers (hence the name of the installation, "Tatu" – armadillo in Portuguese), was thus executed almost perfectly.

Circularity

Biobased materials encompass materials derived from renewable biological sources such as plants, wood, and organic waste, making them ecologically preferable to certain other materials. To assess their environmental impact and relevance in the context of a circular economy, tools like Life Cycle Assessment (LCA) play a pivotal role. LCA is a widely used technique that evaluates the environmental effects associated with each stage of a product’s life cycle, from raw material extraction and manufacturing to distribution, use, repair, and disposal.

In the pursuit of a circular economy, which strives to optimize resource value and lifespan while minimizing waste through material regeneration, it becomes crucial to develop tools that can measure the circular economy’s contributions. As the development and application of biobased materials are still relatively nascent, further research is necessary to determine their sustainability in comparison to existing materials and how they can offer options and opportunities for a more circular economy and society.

Materials

The introduction of new materials in construction, untested and without a history of durability, along with the recycling of materials not originally designed for construction purposes and the emergence of biobased materials, presents a significant challenge to the construction industry’s capacity for innovation. Moving from recycled materials to biobased materials and composites, the range of commercially available materials in construction continues to expand, opening opportunities for reuse, recycling, and repurposing. Materials such as sawdust, timber, clay, brick, mycelium, and kelp are now being explored. An inspiring example is the studio Emerging Objects, which explores innovative recipes for 3D printing using materials like coffee grounds, salt, tea, and rubber, even printing entire self-standing structures in the desert.

Choosing materials with high potential for circularity is a crucial step towards facilitating a circular design economy by ensuring their reusability.

Factors such as sourcing, production methods, and lifecycle considerations play a vital role in determining circular qualities. Biobased materials are currently at the center of discussions. The European Union defines biobased materials as derived from biomass, offering a broad framework for operation. However, it is important to note that being biobased does not automatically imply biodegradability or extended circular lifecycle, nor does it specify a fixed mixing ratio for composite materials. Material choices serve as a crucial first steppingstone when considering circularity in design and architecture.

Process

To achieve circularity in the construction industry, it is crucial to prioritize the maintenance and reuse of components. Repurposing components that are not traditionally associated with architecture can result in extraordinary and unpredictable material expressions.

Incorporating circularity and biobased materials into our design practice necessitates a shift in thinking, expanding from design thinking to system thinking and considering the lifecycle and cyclical flows of materials and components.

Process plays a vital role, emphasizing the relationship between biomaterials, components, design qualities, and fabrication, rather than solely focusing on style. To maximize circularity in projects, design and manufacturing must align material and component usage, treating different aspects in a unified and holistic manner.

Computation and digital fabrication offer valuable tools for optimizing efficiency, production, and performance, reducing material waste through the design of CNC-based workflows. Embracing emerging technologies requires adaptation from designers, tradesmen, and manufacturers, managing increased logistics, labor, and complexity.

This shift also necessitates expanding networks and fostering collaboration to overcome the current limitations in contact points and large-scale networks. It is important to acknowledge that designing for disassembly may require additional input, time, and labor. The industry, professionals, and clients must recognize these realities and their implications.

Engaging clients early in the process, even before specific projects are commissioned, is crucial. Initially, clients may be hesitant to accept a certain level of managed “unpredictability” in materials or components, but their commitment is essential to successfully navigate these processes.

Advantages of bio-based

The pressing issue of climate change and the depletion of finite resources has created an urgent imperative to seek viable alternatives to fossil-based raw materials. Bio-based raw materials provide a promising solution, facilitating a transition away from fossil fuels and supporting the development of a more sustainable society. A notable advantage of bio-based materials is their superior recyclability compared to their fossil-based counterparts. Additionally, their production processes, which leverage biologically derived methods such as enzymes, fermentation, and bio-catalysis, often result in higher process efficiency and may contribute to a reduced carbon footprint. Furthermore, bio-based materials have the potential to exhibit lower toxicity levels compared to traditional materials. They also possess unique properties, including biodegradability, which aligns with the principles of a circular economy and promotes environmental sustainability.

  • Renewable: Derived from renewable resources such as plants, crops, and organic waste. Bio-based materials can be sustainably produced, reducing our reliance on non-renewable resources.

  • Lower Carbon Footprint: The carbon dioxide released during the production of bio-based materials is typically offset by the carbon absorbed by the plants during their growth, making them carbon-neutral.

  • Recyclability: They can be easily broken down and processed into new products or composted, minimizing waste and supporting circular economy principles.

  • Reduced Environmental Impact: They may require less energy and water for production, emit fewer pollutants, and have a lower potential for toxic or hazardous effects.

  • Versatility and Performance: They can have desired characteristics such as strength, flexibility, thermal insulation, and fire resistance.

  • Economic Opportunities: It encourages innovation and investment in sustainable technologies, supporting economic growth while contributing to environmental goals.

A research by: Federico Bruno, Marco Ghezzi, Giorgia Ronco, Martha Serra, Simone Tolosano