ARST 436 - Architecture II
The Barn at Long Lane
A monolithic, sculptural structure designed and built by Wesleyan's North Studio
Phase 1: Intial Design and Models
Week 1
This was our very first version of what the barn could look like, and we wanted to focus on light and transparency as the key elements of the building. With translucent carbon fiber paneling wrapped around the entirety of the structure, viewers were purvey to the inner mechanics and hardware of the barn.
Week 2
The following week we inherited our classmates' design, which focused on community and efficiency as the base of their design.
Week 3
The final week of design iterations we were given "the simple shed", a design centered around simplicity and elegance in form. This was a barn that would minimize costs and maximize efficiency, however the barn we were given was very bland and did not provide the architectural intrigue the class was designed around.
Our model was built using small dowels, balsa wood panels, paper, and cardboard. All dimensions are set to 1":1' scale. The foundation of our structure is based in a simple pole barn design, a sturdy and efficient method to construct a barn that can be built relatively quickly. As we were working on a tight schedule, any time we could save made a large impact on our ultimate ability to construct this barn by the conclusion of the semester.
While the design was solid, there were a few logistical issues. For starters, they had 3 sides of the building where there were doors. Having so many sides with openings created lots of irregularities in the building and a lot more work. We changed from having 1 set of double doors on each side to replacing a full wall with double doors, as well as increasing the height of the ceiling at the lowest point from 7' to 8'.
We came up with a few solutions to make the simple shed more interesting, all of which revolved around changing the orientation of the windows, their composition, and their size. We ultimately presented two designs, both clerestory windows but at different heights.
Phase 2: Final Design and Budget
Final Model
At the conclusion of the three week design period, 5 representatives from the barn came to hear a presentation about each design. Ultimately, we moved forward with the design my team had initially created, however modified with each group's own improvements. In this meeting we also presented budgets for each of the buildings, all coming in at around $19,000 - $23,000. This design was on the higher end of the budget spread, however we knew we could minimize costs by eliminating pre-produced parts such as doors and windows and making those ourselves.
Additionally, each member of the class was assigned a specific element of the model to design, and later build during the construction phase. I was tasked with designing the truss that would become an essential feature of The Barn. As our initial team's model was designed around the idea that half the building would be transparent, where 2 sides contained glass or carbon fiber paneling and the other walls would be available for storage shelves, the truss was intended to be a visual divider between the two sides. Furthermore, we wanted to minimize any horizontal support beams as this could potentially disrupt each sides distinct space. Hence, this self-built "space frame" had to span a insane 36' from the furthest posts, while also moving upwards in accordance with the slant of the roof, using metal tie rods to pull the truss into compression and provide the necessary lift for the building.
Phase 3: Construction
The MEga Truss
Given its nickname due to its sheer size and weight, the Mega Truss was my responsibility during this semester-long project. With the help of a structural engineer, we were able to calculate the exact loads taken on by the truss and therefore the necessary hardware and material needed to build it.
Left: first sketches of the truss lateral bracing system
Wood alone was not strong enough to support the entire structure; in order to span the diagonal of the barn we needed to attach several wood systems together via metal flitch plates. These plates would also serve as bracing points for the cross-lateral tie rods, with custom laser cut pieces that could fit through slots in the plates and exert tension on one another to pull the weight up and eventually hoist the truss into the air.
Right: spray-painting the metal flitch plates red
Over the course of 3 days, I led a team of 8 peers through the process of assembling, hoisting, and securing the truss in place. On the ground, we first drilled all the connection points, creating a series of 4 pre-bolted wood systems. Then, each ~200 lbs system was carefully lifted onto scaffolding and set in place. Working from one corner down to another, the individual wood systems were bolted together in the air, a task that had to be completed incredibly fast while also calling for extreme precision.
Left: 1/2 of the truss assembled in the air, supported by 2x4" wood "chopsticks"
After the wood and flitch plate component of the truss was installed, we moved onto attaching the lateral tie rods that were responsible for stabilizing the truss and contributing to pulling the entire system into compression. The tie rods were all set at different heights in correspondence to their respective metal flitch plate. The rod systems were actually composed of 2 metal rods, one left turn and one right turn, and a turn buckle in the middle. By having rods with opposing screw directions we were able to tighten the entire system using the turnbuckle. My partner and I systematically went through the entire truss, first tightening the rods spanning parallel underneath the wood system, and then moving onto the lateral rods.
Right: Lateral tie rods connected, about to be tightened
After tightening all of the lateral tie rods the truss was completely self supporting! All "chopstick" supports were removed, and final tough ups (sanding off notes, spray painting areas that got scratched off) were completed. Now, the entire structural frame of The Barn was done and our class could move forward with attaching cladding, windows, and doors.
Left: Finished structural frame
The Barn at Long Lane
