Terrasol is a terra cotta fabricated façade module that exemplifies qualities of sun pattern reaction on the material surfaces. One discussion that took place during our final review was the implication of the seam when the module transitions in the horizontal direction. The seam that is created in a sequence consists of a quality that can potentially further exemplify the sun-ray/terra cotta relationship.

Another discussion that took place was the relationship between the terra cotta module in context with conventional materials such as a brick masonry system. We had brief moments of that representation in renderings, but a further exploration of the relationship between the module and other materials can be an interesting venture.

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Our panels will be manufactured using the Ram Press. As listed in the diagram above, the panels will be produced from a top and bottom mold that gives the panels their front and back profile. Below is a closer axon view of these crafted molds:

The revised module consists of changes with interior as well as the webbing detail. The previously designed curve on the interior has been replaces with a stagnant wall that is 3/4″ in width. The interior stagnant wall is parallel to the front surface. The webbing consists of a webbing pattern of 9 channels with a .5″ tapered inner wall thickness.

A monarch clipping system has been implemted to the module. The design consists of two aluminum clips, one attached to the TC module, the other attached to the material of installation, and is nailed by stainless steel bolts. The above module consists of MF375 monarch clips with .5″ in length and is placed in 4 vantage points across the module. It then slides into two secondary clips that are attached to the vantage point of installation.

Detail Drawing of the monarch clips and their function.

This drawing consists of three different iterations of the module being changed to accommodate the clipping system. The first iteration is the same we’ve implemented above, where the clip is .5″ in length and there is no change to the module. In the second iteration, the interior perimeter of the module is extended inward creating a thick interior wall where the clip changes to a 1.5″ length with the bolts aligned in the horizontal direction. The third iteration changes to the thickness consistent with the 3/4″ thickness with the front wall, while the clipping remains the same.

The monarch clip acting in a continuous wall segmentation.

Our revised hanging system is targeted around a vertical sliding sytem. This concept incorperates a system of pre-fabricated steel beams that have a notch cut down the length of them. This allows the TC panel to slide into them with the introduction of T-shaped gliders located on the back of the panel in line with the structural webbing. The panels are then supported by a steel dowel that intersects the beams but rests under a rounded nothch on the TC glider. This allows for the panels to hang on the beam at desired locations.

The panels can be lifted by two workers on either side and then placed into the steel beams. As they slide the panel down the steel track they are then set in place with the introduction of the steel dowel. All edges on are now tappered to allow easier Ram Press manufacturing. All edges have also been fillet in order to prevent any weak corner spots in the panel.

Each module represents a lighting/heating pattern that is generated by the movement of the Sun throughout the day. Due to the modules complex geometry, it causes different visual lighting and shading reactions throughout the day. The timeline represents January 1st, from 9:00Am-5:00Pm. The sun generates different patterns of light reflecting from the TC surface which in turn generates more heated surfaces than others. This proposition is not only generate different lighting patterns visually, but also creates various heating and cooling throughout the module.

Visual representations of the Terra Cotta module installed on site (Senior Design Competition: Home Theater). The installations include vertical implementations of the design that visually react to different sun patterns and create visual depth.

Our desired hanging system will consist of vertical steel beams in which our panels are aligned and bolted to. We will do this through the introduction of drilled holes in the terracotta as well as angled steel braces. Our intention in the hang each panel on these steel beams and then fasten them to that beam at these anchor points located at the corners of the panel.

Here you can see the dimensions of the panel and its revised webbing. We have redesigned the webbing to have less compartments. This drawing also shows how the panels will be places one above the other.

These detail drawings show the construction method for two different iterations of our wall design. The top detail shows the construction of a vertically continuous wall. This design would consist of panels continuing vertically, being stacked onto one another. In the second detail, the panels are shown to be adjacent to one another. This detail highlights the construction of a wall that would have the panels spanning horizontally, neighboring one another.

A schematic representation of the Terra Cotta module installed on-site on a façade in contrast with varying material. In previous iterations, the module was represented in a continuous array horizontally. In this iteration, it is continuous vertically and contrasted horizontally with glass and brick masonry.

Time Lapse of Sun Path.

A ram press process for the fabrication of our prototype would be most efficient. Press molds would be formed to accommodate the fabrication of the façade terra cotta design as well as a mold creating the webbing for the interior.

The clay would be packed into the ‘A’ mold, while mold ‘B’ would be pressed into the clay to create the webbing. The mold would be hydraulically pressed to create the desired form. The ‘B’ mold also accommodates for the curve that is generated in the terra cotta. The air forces water in the plaster die to the surface, releasing the clay from the bottom of the mold.