CHAPTER TITLE Bartlett Design Research Folios
Tim Lucas Kew House
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TIM LUCAS
KEW HOUSE
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BARTLETT DESIGN RESEARCH FOLIOS
Tim Lucas Kew House
CONTENTS
1 (previous) View of street frontage of house shortly after completion. 2 View of the steel gabled roof surrounded by the neighbouring houses.
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Project Details
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Statement about the Research Content and Process
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Introduction
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Aims and Objectives
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Questions
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Context
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Methodology
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Dissemination
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Project Highlights
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Bibliography
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Related Publications
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TIM LUCAS
KEW HOUSE
Project Details Author
Tim Lucas
Title
Kew House Structural Envelope
Output Type
Building
Function
Residential
Location
Kew, London Borough of Richmond upon Thames
Practical Completion
April 2015
Budget
£1.2 million
Area
370 m2
Architect
Piercy & Company
Structural Engineer
Lucas realised this project through his structural engineering practice Price & Myers LLP, where he is a Partner
Services Consultant
Arup
Clients and Project Managers
Tim and Jo Lucas
Main Contractors
Tim and Jo Lucas
Groundworks and Basement
Estbury Basements Ltd
Steel Frame, Metal Façade Commercial Systems International Ltd and Glazing Joinery and Fitout
Sam Lucas
Approved Building Control Inspector
Adrian Thomas Building Control
Research Assistants
Thais Espersen, Thomas Impiglia, Zipporah Ong, Thomas Parker, David Shanks, Nadia Stollen-Wikborg
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PROJECT DETAILS
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3 View of the site and lorry delivery method.
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TIM LUCAS
KEW HOUSE
Statement about the Research Content and Process Description
Methodology
Kew House is a single family house, constructed using research-based design, fabrication and assembly techniques. The building envelope is a prefabricated structural weathering steel shell, built over a large basement that was used as an onsite drawing and fabrication workshop.
1. Close collaboration between the author/client/structural engineer and the architect; 2. Analysis of site-specific and logistical constraints that promote the case for prefabrication; 3. Use of computational design software to create a ‘digital twin’ of the physical building;
Questions
1. How does digital fabrication open up possibilities for self-build housing?
4. Iterative design and fabrication through drawing, model making, factory trials, assembly trials and the development of large-scale templates.
2. How can a building be formed from fewer multifunctional components to reduce material waste, and simplify and accelerate construction?
Dissemination
3. How can factory manufacture of a sheet metal building fabric enable new approaches to architectural design, prefabrication technology, transportation logistics and assembly?
Kew House was discussed in a paper in the Institute of Structural Engineers’ journal Structures. It was the subject of five lectures to academic institutions and professional architecture and engineering practices, and has been reviewed in national and international press (The Sunday Times, Evening Standard and The Wall Street Journal, etc.) The project has been the subject of three documentaries, including Grand Designs House of the Year.
4. How can the use of a structural steel envelope be reconciled with thermalperformance requirements?
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STATEMENT ABOUT THE RESEARCH CONTENT AND PROCESS
Project Highlights
Kew House has won ten design awards and commendations, including IStructE Award, Community or Residential Structures (2014); Blueprint Award, Best Non-Public Project (2014); RIBA National Award (2015) and RIBA Regional Award (2015). The project contributed to Lucas receiving the IABSE Milne Medal (2015), awarded to an individual engineer for excellence in structural design, both in the overall concept and in the attention to detail in their work.
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TIM LUCAS
KEW HOUSE
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STATEMENT ABOUT THE RESEARCH CONTENT AND PROCESS
4 Street elevation.
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TIM LUCAS
KEW HOUSE
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STATEMENT ABOUT THE RESEARCH CONTENT AND PROCESS
5 Cross section of house though glazed link.
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KEW HOUSE
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STATEMENT ABOUT THE RESEARCH CONTENT AND PROCESS
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6 Cross-section digital study model of Kew House.
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KEW HOUSE
Introduction Kew House is an experimental project that promotes housing innovation through design-led research exploring a kit-of-parts approach, structural façades, prefabrication and how digital fabrication opens up the possibilities for self-build. Constructed on a tightly constrained site in a conservation area in Kew, South West London, the project was developed by and for the author, Tim Lucas, and his family. Lucas was the client, structural engineer, project manager and contractor. A significant element of the brief and the resulting architecture was to build the house around a central courtyard. The design was conceived so that the house was presented as two buildings, joined by a glazed circulation link. This strategy breaks up the visual mass of the house, whilst acknowledging the scale and character of the surrounding houses with their layered gabled-roof forms (1-6).
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INTRODUCTION
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7 View from the courtyard, showing the south side of the building and the glazed link façade.
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KEW HOUSE
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INTRODUCTION
8 Internal courtyard with staircase leading to the basement.
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9 Glazed link and steel staircase.
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KEW HOUSE
The research focuses on two prefabricated weathering steel (ASTM – Corten B) structures, made in a factory using automated technology and assembled onsite behind retained nineteenth-century brick walls. Weathering steel was chosen for the external envelope based on its surface patina, which would blend in with the colour and texture of the surrounding brick buildings, and the lack of maintenance required on the areas that would face the surrounding properties. The weathering steel superstructure was designed as a self-supporting shell that acts as both cladding and structural building envelope for the roof and internally facing walls (10). Constructing from within the site boundary became a key factor in the prefabrication, given that the outer edge of the building would be largely set against the perimeter with no available access from neighbouring gardens. Part of the research examined how to construct it offsite and lift it into place from within the confines of the site and adjacent street (3).
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INTRODUCTION
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10 Brick gable wall of original stable building against weathering steel shell of new house.
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11 Southerly roof shell against surrounding residential gardens. 12 Early physical model of the design proposal.
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KEW HOUSE
Aims and Objectives
Questions
1. Test novel construction and material quality for a single family house within the vernacular of the local conservation area;
1. What is an appropriate choice of construction method for the challenge of self-build housing with limited site access? What are the advantages of digital sheet-metal prefabrication?
2. Develop and promote housing innovation through design research into a kit-of-parts approach and the self-build possibilities emerging from digital fabrication;
2. How can a kit-of-parts building method be formed using fewer multifunctional components to reduce material waste and simplify and accelerate construction?
3. Experiment with building construction that is driven by technical innovation for structural metal shells and offsite prefabrication using automated material forming techniques;
3. Can factory manufacture of a sheet metal building fabric enable new approaches to prefabrication, transportation logistics and assembly that go beyond established building techniques? What lessons can be learned from the disciplines of vehicle manufacture and ship building?
4. Research how a prefabricated structural shell can perform multiple functions: a contextual response to architectural and planning requirements; a self-supporting building envelope; unified waterproof wall and roof cladding; and a unitised building that can be fabricated, transported and installed from within the confines of a constrained London building site.
4. Can a structural steel shell make a distinctive contribution to its setting, as well as create an optimised water and air-tight building envelope that includes the roof? Ultimately, can it perform the functions of three systems – structural, visual and environmental – in one unified and efficient envelope component? How can this unified building component function when responding to the thermal requirements of the envelope, alongside structurally holding its form?
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AIMS AND OBJECTIVES / QUESTIONS
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13 Digital study model of a ‘typical’ roof module in its first position for fabrication. 14 View of all stiffeners and skin panels in the 3D-modelling environment.
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TIM LUCAS
KEW HOUSE
Context
modular building of chassis, fuselages, ship hulls and train carriages is common. The structural shell of these objects is closely aligned to the finished form. They are effectively self-supporting shells in the form demanded by their function. The idea of a structural shell is well understood and used in the automotive and similar industries, for example in rolling stock production. The number and size of modules that vessels and vehicles are subdivided into is mainly dependent on the constraints of transportation logistics. Units that work within the size constraints imposed by road or rail transport can be fabricated as one whole. Subdivision is necessary when the size of the project is larger than applicable transportation limits. Transport logistics would also prove crucial in determining the size of Kew House’s roof panels.
This research project uses an interdisciplinary knowledge base centred on manufacturing techniques, and employs practices from other industries. By doing so, it consciously seeks to address current difficulties in the building construction industry. These difficulties were clearly identified in the most recent review of the UK construction labour model, produced in 2016. The Farmer Review of the UK Construction Labour Model identifies critical symptoms of failure and poor performance in the UK construction industry, including: low productivity; low predictability in workforce size and demographic; structural fragmentation; lack of research, development and investment in innovation; and poor industry image. Traditional construction is acknowledged by Farmer as too site-based and reliant on the assembly of small components, such as bricks, timber joists and other elements, in a messy environment rather than the controlled setting of a factory as in other industries. There is a range of alternatives to this model, from the volumetric construction of prefabricated pod-type elements to the use of large cross-laminated timber panels. Many of these are, however, factory-based versions of conventional building-construction systems. Kew House differs from conventional building-envelope construction, which is typically detailed by a build-up of rainscreen elements, waterproofing, structure, insulation, vapour-control layers and internal finishes (15). The structural shell used in the constuction of Kew House allows for a simple, prefabricated sandwiched panelling system. The choice of Kew House’s structural shell emerged from research into modular manufacturing that extended beyond architecture. An analysis of metal production methods in other industries showed that
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CONTEXT
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15 Typical domestic house construction. 16 Module of a ship, HMS Prince of Wales, in transit.
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TIM LUCAS
KEW HOUSE
Methodology
The Site as Factory
A basement space was initially created to allow the site to become a factory in its own right, with space to store, prototype and fabricate components of the building. This workshop space was handed over to the author who moved in with main contractor duties and drawing and fabrication responsibilities (18).
1. Interdisciplinary exchange between structural engineering and architecture, aiming to experiment with prefabrication technologies whilst delivering an outstanding housing design; 2. Analysis of site-specific and logistical constraints that promote the case for prefabrication; 3. Use of computational design software to create a ‘digital twin’ of the physical building; 4. Iterative design and fabrication through drawing, model making, factory trials, assembly trials and the development of large-scale templates.
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17 Composite plan and section model in laminated layers of laser-cut card. 18 Basement space following construction and handover.
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METHODOLOGY
Digital Design
The structural design work was based on a detailed 3D-fabrication digital model of the whole steel skin, which evolved over many iterations. The author’s structural design was drawn in exquisite detail, followed by offsite Computer Numerical Control (CNC) machining. Each cut line was generally within 1 mm of its intended position, and as each panel was welded to its neighbour the dimensional tolerance was absorbed by the weld line (19–20).
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19 View of early-stage design model with basic sheet sizes established. 20 View of the same model following design development.
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TIM LUCAS
KEW HOUSE
Sheet Layout
Stiffener Design
Firstly, the layout of the sheets that compose the building envelope, including window openings and other architectural features, was established. Joint positions were defined by features such as the edges of gutter lines and openings. Constrained by standard sizes, the dimensions and proportion of the panels was carefully considered, as these were critical in reducing wastage of raw material. Favourable dimensions, such as half a sheet width, were chosen where possible to optimise the number of panels that could be taken out of a single sheet. This empirical process of choosing panel sizes provided a layout that worked within maximum sheet sizes and offered functional joint positions. To optimise the layout as much as possible, web-based nesting service, mynesting.com, was used to establish the most efficient placement of panels on the parent sheets. This gave the required number of sheets to fabricate the planar envelope of the house with optimal use of the parent material (21).
A network of tertiary, secondary and primary stiffening ribs are welded onto the inner surface of the steel panels to structure the roof. Their design was closely related to the panel design, with stiffening ribs required to support the edges of panels and also provide an overall load path to the supporting structure. The edge stiffeners created a portal frame structure that allowed threaded bars and bolts to be used to maintain the correct spacing between the prefabricated units (22–4).
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22 Secondary stiffener concept sketch. 21 Nesting layout of panels on 2.5 × 1.25-m steel sheets.
23 Primary and tertiary stiffener concept sketch.
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METHODOLOGY
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KEW HOUSE
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METHODOLOGY
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24 Network of stiffeners that underlie the surface metal panels.
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Transportation Strategy
The question of how to subdivide the volume of the roof shells for transportation and erection was central in the research process. A logistics study was carried out to identify the maximum possible height based on existing truck bed and bridge heights. This work identified that units up to 3,950 mm could be transported. This was lower than the overall height of the roof units, so an approach where the units would be transported at right angles to their final orientation was adopted. Reorienting the units during fabrication and erection enabled a simplified methodology: the diagonal surface of the roof was taken as the horizontal base; the skin panels were then set out in their correct arrangement and spaced on the flat floor of the factory; and a network of stiffeners was finally welded onto the surface without a need for temporary jigs (25–6).
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25 Completed module with all skin panels, stiffeners and internal structural parts. 26 Portal frame structure at the edge of a partially assembled roof shell.
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METHODOLOGY
Assembly and Erection Trials
Manipulating units gave an early indication of the durability of the prefabricated volumetric shells. Each component was reoriented several times during production with no adverse effect on the fabric of the shells. A number of erection trials were carried out to devise an optimal solution for the transportation and assembly of the shell units. After some unsuccessful lift trials with magnetic blocks, the decision was taken to weld steel tabs to the outer surface of the units. This meant they could be fixed to each module and moved for trial, transportation and final erection onsite. Significant time was spent carrying out two trial erections of the roof shells in the factory in Hull and the Shepperton yard where the units were stored. A full assembly of both roof shells was made in Hull, whilst in Shepperton, a test lift was carried out to tip them from their rotated transport position to their final orientation (27–9).
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27 Unsuccessful lifting trial with magnetic blocks. 28 Test assembly in Hull of north wing of Kew House. 29 (overleaf) Assembly hall with volumetric shells in final stages of production.
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Templates
The use of a physical component to dictate the formation was necessary for allowing the prefabricated elements to be dropped into place in the correct position. Full-scale rectangular templates were, therefore, devised with a twin use. Firstly, the templates facilitated trial assemblies. For this, they were mounted on short struts to allow the roof shells to overhang the sides of the supporting slab. Fixing studs were installed on the template to allow the units to be lowered down onto them. Their second use was as onsite templates installed on the supporting steel and concrete table structures (30).
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30 Lowering a roof module onto the floor template. 31 View of the inside of the integrated gutter with painted finish.
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METHODOLOGY
Rotating Shells
The logistical challenge of rotating the shells was primarily explored using models. In order to better understand the constraints of the site, study models were made in cardboard and were suspended by string to show how the units behaved. This established that, in addition to the main support from the crane hook, secondary points of restraint were required to change the orientation of the shells during erection. These points of restraint were provided by strapping parts of the shells to fixed points on the existing supporting structure (32–3).
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32 Stage two: Model showing unit being lifted and rotated onto the bed of the large lorry. 33 Stage three: Unit rotated on the roof slab.
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METHODOLOGY
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34 Temporary bolted connections to establish fit-up distances required for welding. 35 View of primary, secondary and tertiary stiffeners and skin panels following painting.
36 Detail sketch showing façade and supporting structure interface.
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KEW HOUSE
3D Point Cloud
The perforated weathering steel cladding used in this project is an inventive sandwich panel system with insulation bonded to its underside, and gutters and chimneys formed in the same material. A key detail was the internal timber skeleton that was isolated from the cold external shell. This structure was made from CNC-cut plywood which was reinforced at areas of high stress by carbon fibre tape. The design model of the plywood framework was carefully coordinated with the model of the external shell and a 3D point cloud scan taken onsite to ensure that each component fitted within the building envelope. The precision of the scan data enabled production of the timber components to dimensional accuracies within 2 mm. Following this, two layers of thermal insulation foam were applied and a layer of vapour-resistant chipboard was installed.
37 Digital model of internal lining structure. 38 View of digital 3D scan overlaid onto the timber lining structure model.
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METHODOLOGY
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39 Roof shells in fabrication at CSI factory, Hull.
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40 Ian Chapman, a fabricator from CSI, welding the garage box to the main façade structure.
METHODOLOGY
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41 Internal view of south shell under construction in Hull. 42 Prefabricated roof shells being lifted and placed onto the site with a truck-mounted crane.
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43 Kew House finished and in use.
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Dissemination
Project Highlights
Since its completion in 2014, Kew House has been reviewed extensively in the press, including Architects’ Journal (2015), Financial Times (2015), The Guardian (2015) and The Sunday Times (2015), and has been the subject of three documentaries: Grand Designs House of the Year (2015), Place Invaders (2016) and Kew House in London (2016). Lucas has been invited to give lectures on the project’s unique design and prefabrication methods, including at: · Newcastle University (2016) · Business in a Day, London (2015) · The Institution of Structural Engineers, London (2015) · University of Westminster, London (2013)
Kew House realised one of the first adaptations of construction technology from industries such as vehicle manufacture and ship building, where the form of the hull, fuselage or chassis performs multiple functions. This is in stark contrast to conventional building construction technology based on traditional modes of practice, where separate systems of structural frameworks, cladding and finishes are installed in sequence by specialised contractors. Issues inherent to this approach include defects from one trade to another, aggregated tolerances leading to larger than necessary façade build-ups and interface problems between different systems and trades. The Kew House structural envelope overcomes these problems and succeeds in its aim to innovate in terms of building efficiency, economy and aesthetic outcome. The project has won ten design awards and commendations: · Civic Trust Awards, Regional Finalist (2015) · RIBA House of the Year, shortlisted (2015) · RIBA National Award (2015) · RIBA Regional Award (2015) · Surface Design Award (2015) · BD Architect of the Year, One-off House Award (2014) · Blueprint Award, Best Non-Public Project (2014) · FX Design Award, UK Project (2014) · IStructE Award, Community or Residential Structures (2014) · Structural Steel Design Awards, Special Merit Commendation (2014)
Both Tim and Jo Lucas shared their innovative approach to building Kew House as part of the TedxStPeterPort series in 2015. They reflected on the process of being closely involved with the design, planning, fabrication and construction of their home from start to finish. Lucas expanded on how he ‘threw the engineering and contracting rulebook out of the window’ and reflected on the ups and downs of his unusually varied role – that of client, engineer and main contractor – in ‘Kew House, London – Engineering and Building a Home from First Principles’, which was published in Structures in 2016 (see pp. 53–60).
Kew House contributed to Lucas receiving the IABSE Milne Medal (2015), awarded to an individual engineer for excellence in structural design, both in the overall concept and in the attention to detail in their work.
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DISSEMINATION / PROJECT HIGHLIGHTS / BIBLIOGRAPHY
Bibliography Farmer, M. (2016). The Farmer Review of the UK Construction Labour Model. www.constructionleadershipcouncil.co.uk/ wp-content/uploads/2016/10/FarmerReview.pdf
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44 Perforated steel gable.
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Related Publications by the Researchers Lucas, T. (2016). ‘Kew House, London – Engineering and Building a Home from First Principles’. Structures – the Research Journal of The Institution of Structural Engineers. May. pp. 12–9.
Related Writings by Others BBC News (2015). ‘RIBA Reveals its Favourite UK Buildings of 2015’. BBC News. Bloomfield, R. (2014). ‘A London Family Steels Home’. The Wall Street Journal. 20 June. n.p. Cheeran, B. (2015). ‘RIBA Awards 2015: House’. Architects’ Journal. Frearson, A. (2014). ‘Weathered Steel Sits Alongside Ageing Brickwork at Kew House by Piercy & Company’. Dezeen. 16 April Graham, H. (2015). ‘Slide Rules’. The Sunday Times. 20 September. pp. 42–3. Gray, K. (2016). ‘See Inside Richmond’s Grand Designs Home’. Evening Standard. 25 August. Ideal Home (2016). ‘From Derelict Garages to £4 Million Home – Step Inside Kew House, as Featured on Grand Designs’. Ideal Home. Jennings, P. (2011). ‘Boldly Discreet’. World Architecture News. 2 March. Mark, L. (2014). ‘Piercy & Co Completes Cor-ten Steel-Clad Home’. Architects’ Journal. Miles, P. (2015). ‘The UK’s Best Designed Home? RIBA’s Manser Medal Seeks the Answer’. Financial Times. 23 July. Murphy, D. (2014). ‘Kew House by Piercy & Co’. ICON. 9 July.
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RELATED PUBLICATIONS
Stathaki, E. (2015). ‘Stiff Competition: Two More Nominees in the Running for RIBA House of the Year’. Wallpaper. 11 November. Stockley, P. (2014). ‘Kew's Twin Peaks is a House Full of Surprises’. Evening Standard. 8 October. pp. 28–9. The Guardian (2015). ‘New Kids on the Block: RIBA's AwardWinning Buildings – In Pictures’. The Guardian. 18 June. Vlassis, L. T. (2014). ‘Kew House by Piercy & Company in London’. Wallpaper. 10 April. Wang, L. (2015). ‘Gorgeous Modern Kew House is Clad in Prefab Weathering Steel’. Inhabitat. 14 July.
Printed article
Online article (clickable link)
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KEW HOUSE
Image Credits
Bartlett Design Research Folios
All images © Tim Lucas, unless otherwise stated.
ISSN 2753-9822
Photo: Jack Hobhouse © Piercy & Company 13–4, 19–24, 36–8 © Price & Myers 15 PA Images / Alamy. Photo: Ben Birchall 16 Image: BAE Systems 27 Photo: Maarten Kleinhout 31–3 Photo: David Shanks 1–2, 7–11, 17, 43
© 2022 The Bartlett School of Architecture. All rights reserved.
4–5, 39–42, 44
Text © the authors Founder of the series and lead editor: Yeoryia Manolopoulou Edited by Yeoryia Manolopoulou, Barbara Penner, Phoebe Adler Picture researcher: Sarah Bell Additional project management: Srijana Gurung Graphic design and typesetting: Objectif Every effort has been made to trace the copyright holders of the material reproduced in this publication. If there have been any omissions, we will be pleased to make appropriate acknowledgement in revised editions.
CHAPTER TITLE
C
TIM LUCAS
BARTLETT DESIGN RESEARCH FOLIOS
KEW HOUSE
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