Solar decathlon house research

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Lee Finnerty;300128299

Construction:321Assignment One: Solar Decathlon House Research Paper

Methods and Analysis of underlying principles of Prefabrication systems to be incorporated in the Solar Decathlon House 2010

Lee Finnerty: 300128299

Introduction 3

Solar Decathlon house 4

Case Study backgrounds and systems used. 4

Temporary Prefabrication: Detachable Twist-Locks. 4

Portable exhibition building: 5

HUF Haus - Established 1912 6

Home Delivery - Museum of Modern Art Exhibition [20 July - 20 October 2008]. 7

Joint Connections - My analysis of the details 8

Prefabrication systems underlying case study designs: 8

-Twist-Locks 8

Cast aluminium joints: 9

Onsite Wall System Connection 9

Solar Decathlon house Systems: Synthesis 11

Modularisation/Transportability 11

Timber Canopy 12

Wall Systems 13

Final Synthesis 13

Wall System: 13

Floor System: 14

Timber Canopy: 14

Conclusion 15

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Introduction

“The nature of prefabricated architecture means it exploits the opportunities of contemporary materials and techniques in relationship with traditional or conventional systems” [Kronenberg, p.24]

The New Zealand team building the Solar Decathlon house First Light need to incorporate a prefabricated system into their house to increase ease of assembly and disassembly. However this may require more than fitting prefabricated joinery into the existing design. This research paper will analyses existing examples and apply that knowledge to the solar decathlon house to discover what is required to incorporate a prefab system keeping to the following statements and questions. Does a prefabricated system have to be incorporated into a building during the design stage to be effective, or can it be initiated into into an existing design? To provide information for this topic four case studies were chosen that utilize a prefab system to be analysed for application to the Solar house. This raises the question of what particular aspects of the case studies render the prefabricated connection system effectual, and can the hierarchy of structure and cladding be altered to create a more efficient and unique prefabricated system? Theoretically the aim is to reveal the underlying ideas of the incorporation of a prefab system into each of the case studies projects, the ideals will in practice provide direction for the application of a prefab system in the Solar Decathlon house.

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Solar Decathlon house The Solar Decathlon house has a variety of systems that can be separated into individual modules to be addressed in terms of connectivity. This mini research paper will address the connection details of three physical systems in the house: The wall system, timber canopy and the floor and foundation systems, as well discuss the transportability and demount-ability. The case studies have been selected to help develop a system of prefabrication for each module in the house, this will then be used to determine whether such a system must be incorporated in the design stage or can be initiated into the existing design.

Case Study backgrounds and systems used.

Figure 1: Front view of the entrance to Shigeru Banʼs Nomadic Museum. Illustration sourced from: <http://www.flickr.com/photos/paolomazzoleni/248929123/sizes/o/in/photostream/>

Temporary Prefabrication: Detachable Twist-Locks. Photographer Gregory Colbert went to Japanese architect Shigeru Ban to build him a traveling cathedral in order to display his photos to the public, the building had to evolve just like Colberts art exhibited within. Ban then designed the shipping container and paper-tube Nomadic Museum [shown above in figure 2], the form of which reflects its temporary nature by adapting a prefabricated system. In relation to the Solar Decathlon house, the prefabrication used has to reflect how the house is inhabited. Although the house itself is temporary it will be used as a permanent structure, yet it still has to be disassembled and assembled somewhere and maintain the surface appearance of a permanent residence. Some of the temporary sites of the Nomadic Museum had different dimensions which required the building to adapt to its settings, Shigeru Ban reconfigured the structure to fit into the new dimensions. “This evolving and adaptive nature will, no doubt, become one of the projects defining qualities as it travels the world” [Broome, p.110]. The connection systems used in Shigeru Banʼs 2005 Nomadic Museum are taken along with the exhibition.

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Figure 2: Renzo Pianoʼs IBM Traveling Pavilion in 1984 with the Museum of Natural History, London in the backdrop. Illustration sourced from <http://arquitecturamashistoria.blogspot.com/2007/11/delicias-renzo-piano-y-el-pabelln.html>

Portable exhibition building: The Traveling Pavilion uses a joint system combining traditional and new materials with an easily demountable design. IBM commissioned Renzo Piano Building Workshop to design a traveling exhibition building in 1984, it set out to convince the “Luddites” that computers could become an everyday tool and show the public what is on offer [Hannay, p.24]. Piano’s Pavilion was scheduled to be constructed and deconstructed several times over its journey around Europe and this aspect was taken into design consideration. Special joint connections were designed to limit the amount wear on the wooden elements of the structure, this also meant less repair was needed after assembly and disassembly [Hannay, p.26]. In Hannay’s 1984 article [documenting the setting up of the Pavilion in London] he describes the polycarbonate prisms making up the ‘cladding’ aspect of the pavilion which have been heat-formed from a single sheet1 [p.24]. This project was chosen for analysis on timber canopy used in the Solar House, the Pavilion overcame the issue of wear on wooden elements during dismantling. Specific detailing between materials was an underlying idea behind the design intent of pavilion, this particular aspect made the prefabricated system efficient, given its context.

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1 The prisms create a flowing simple building because forces normally taken up in visually messy metal lattices cross-bracing have been dispersed through this modern translucent material [Hannay, p.24].

Figure 3: Showhome for HUF Haus Germany, Standard homes are all post and beam with the choice of two colours only, black or white. Illustration sourced from HUF HAUS home website <http://www.huf-haus.com/en/portfolio.html>

HUF Haus - Established 1912 HUF Haus is a German prefabricated house manufacturer, their houses are built in their custom factory in Germany and shipped across northern Europe to a number of clients [HUF HAUS]. The system used in the design of the HUF houses is based around factory prefabrication, however their method differs from the postwar prefab2. The house components are all assembled in one factory and can be shipped to a number of countries in Europe, they are prefabricated so HUF Haus workers can travel over to set the building up quickly and return to Germany [HUF HAUS]. The HUF approach to this is ideal for the Solar Decathlon house where the team will have to travel overseas to set the house up because the team the builds and manufactures the components of the Solar House are also assembling it in America.

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2 The ʻsemiʼ successful postwar project built over 150,000 houses that were to last 10 years but ended up being used for the next half century [Glancey]. The object of this prefabrication was to build as many houses as possible that could be assembled by any builder, the HUF Haus provides its own team of German builders to assemble their houses efficiently and properly.

Figure 4: The left image is the House For New Orleans in a computer render of construction in progress. The right image is the System3 house showing all elements possible in the design. Both illustrations sourced from MoMA Home Delivery progress blogs [Bergdoll]. <http://www.momahomedelivery.org/>

Home Delivery - Museum of Modern Art Exhibition [20 July - 20 October 2008].From 20th July to 20th October 2008 the Museum of Modern Art held an exhibition to design, build and deliver a prefabricated house, five architects took part and the following are two studies. -Larry Sass; Single Prefabrication System: uses a system of fabrication where each part is not unique and fits together like a jigsaw puzzle - A “system” of prefabricated joinery where one piece can have several applications. Similarly to the post war prefab Larry Sass designed a house for people who had lost theirs, it could be assembled by anyone and was made entirely from “interlocking parts with no fasteners or screws or mechanised attachment (figure 5).” [Bergdoll] “Itʼs very hard for people to understand that you can draw a little attachment and it can have the same strength as a screw” says Larry Sass in his video blog “in fact it is stronger than a screw because you have parts completely interlocking other parts” [Bergdoll]. -Oskar Leo Kaufmann + Albert RÜF; System3 is the outcome of years of research by Oskar Leo Kaufmann on the question of: “How small can you live, how much space do you need to live” [Bergdoll]. Changing the hierarchy of spaces around to create a unit which can be self contained or a building block in a larger structure3.

Figure 5: This is a detail from the house for New Orleans and shows how the contact points between components is maximised so fasteners are not needed. illustration sourced from MoMA Home Delivery progress blogs [Bergdoll]. <http://www.momahomedelivery.org/>

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3 Within each unit there is a service space and a naked space. The service space which comprises of the kitchen, bathroom, electricity, and heating, is located in the centre. The naked space is the of the area within.

Joint Connections - My analysis of the details

Each project researched embraces the prefabricated nature of its design, rejecting the conventional concealing of such conjunction points. The following section details the analysis of the joints used in the projects which define them as a prefabricated building, while keeping in mind the context of the project they came from.

Prefabrication systems underlying case study designs:

-Twist-Locks The connection system for the shipping containers is a slightly modified version of what is already used to keep them down on ships [figure 6], twist-locks in the corners which Ban has modified slightly for added structural strength. The containers were rented and fixed by twist-locks. “That is how you do it when you transport them, you do it with every truck4” [Bauwelt]. Ban’s adaption of this conventional shipping system to the application of a museum continues his reputation for architectural alchemy in the recycling of the most humble of materials5 [Bowring, p.106]. In Kronenbergʼs book he covers the Nomadic Museum in Portable Architecture, he suggest transporting only the key components using Banʼs exhibition building as an example. “It is not always necessary to move all the components of a building when it is rebuilt in another location” [p.35]. If Solar Decathlon house parts were standard they could be sourced overseas and the connection systems could be adapted into them.

Figure 6: The above illustration was taken from Bowring [p.110] and shows how Ban did not alter the existing container, only add his modified connection system to secure the structure.

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4 Phone conversation between German Bauwelt reporter and member of Shigeru Banʼs firm that worked on the Nomadic Museum. The Bauwelt reporter claimed the containers were welded then asks how they could possibly be twist-locked, the firm member explains itʼs very conventional.

5 The purpose for this was to not overpower the art with the building, once you are inside the building fades away and you are left with a space containing art [Broome, p.110].

Cast aluminium joints: In the pavilion Renzo used beech wood for the ribs and polycarbonate pyramids for the roof. The detailing of the connections was specifically designed to allow for rapid assembly and disassembly [figure 7], therefore he used cast aluminium which wears better than wood when being bolted and unbolted6 [Lisnovsky]. The particular details also highlights the combining of traditional and contemporary materials to show the fusion of past and present working together. The Solar house has a similar underlying cause, to bring the quintessential New Zealand bach into the 21st Century The aluminium joint splices into the wood and is glued in place [Ziyang], the fasteners do not contact the wooden elements but the splicing means load is transfered through the wooden members. This method allows the beech to perform its job while opening up possibilities for repeated assembly which would otherwise be difficult. The Solar House has many such connections in the ʻTimber Canopyʼ system, a material that wears better fitted between the meeting joints of delicate materials would improve disassembly and highlight the house practicability.

Figure 7: This detail shows the connection between the beech wood ribs, the Aluminium is the only part that is in contact with any other element in the building and the aluminium is glued and spliced into the wood to minimise any corrosion of the wood.

Onsite Wall System Connection As noted in the above paragraph, the connection elements have to protect the brittle materials at their conjunctions. In standard HUF Haus construction two wall frames are pulled together very tight and between the two frames is a rubber seal that makes the connection waterproof, the panel opposite the rubber seal has a groove running down it to enclose the sealing so the beams sit flush. The process of this detail can be seen in figures connection. The prefabrication systems used in the HUF houses have been incorporated into the building elements at the design stage. During construction of the frames holes are drilled through the beams on the ends of the walls which are to be connected with other frames, these holes are filled with a metal jacket which a screw will go into and pull the two walls together. The metal jacket protects the beam so the bolts do not wear away the wood.

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6 Joints which combine the contemporary prisms with traditional wooden features have been designed so that they can be easily disassembled, the twist-locks and cast aluminium bolts also highlight the prefabricated nature by revealing junctions between the structure and cladding [Hannay, p.25].

Once onsite the frames are winched into position ready to be fitted together, when they are roughly alined the builders use a tool to pull the panels together so the seal sits tightly into the groove7 on the adjacent panel. Further up the panel a tool is used to screw together the two panels using the holes filled with the metal jackets, these are again pulled tight and the two frames are secure. This method means that the bolt does not come into contact with the wood and would lessen the wear and tear caused if the house was ever to be disassembled. This method will work well for the Solar Decathlon house if the hierarchy between structure and cladding is altered.

Figure 8: These three illustrations show how the the wall panels are pulled together onsite with the rubber seal on the beam to the left side. Illustrations sourced from still shots of Grand Designs Episode documenting the construction of a HUF Haus: Grand Designs S04E02 - Customised German Kit House: Surrey <http://www.channel4.com/4homes/on-tv/grand-designs/episode-guides/walton-huf-haus-revisited-08-06-04_p_1.html>

These is some issues here with how the structure relates to the cladding, and the play between them as structure acts as cladding and cladding performs like structure. In the HUF Haus projects the structure becomes part of the cladding, while in the IBM Traveling Pavilion the cladding [the polycarbonate prisms which also act as the structure] is separated from the structure. These aspects in both of the case studies have been incorporated at the design stage and comprise the character of the building

Temporary Solutions The MoMA exhibition buildings were designed to have a surface look of a permanent residence while remaining as temporary as possible, most structures were assembled within one day [Gonchar, p.138]. This is the underlying principle for the fast assembly of the System3 and New Orleans house, the lack of fasteners in certain areas of the house could mean more effort can be concentrated on the structure rather than the surface. Furniture and kitchen cupboards were kit set joined in each of these projects [Figure 9], although both System3 and House for New Orleansuse different prefab system the furniture in each was assembled solely from interlocking parts [Gonchar, p.24].

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7 Due to New Zealandʼs high UV levels rubber can deterorate quickly, as seen in car tyres that are left sitting, Therefore an exposed rubber seal would deteriorate and the seal between the two walls would weaken. The groove which would enclose the gap would ideally protect it from direct UV contact.

Figure 9: One of the tables made like a kit-set similar to the house in System3, this was purely for surface appearance and to “reduce onsite assembly to an absolute minimum” [Gonchar, p.144]. Illustration sourced from still of video walkthrough of System3, [Bergdoll] < http://momahomedelivery.org/index.php/>.

Solar Decathlon house Systems: Synthesis

The Solar Decathlon house has a variety of systems that can be separated into individual modules to be addressed in terms of connectivity. The analysis of the above case studies has provided insight into the methods of joinery used the underlying principles that led to a particular method being used. The synthesis section looks at whether this can address the questions of hierarchy of structure and cladding and what kinds of prefabricated systems render a project successful.

Modularisation/Transportability The nomadic museum was designed specifically to create an atmosphere reminiscent of a temple space to portray the tranquility of the photos it contained, its design, although temporary, responds to the way people interact with the objects contained within8 [Kristal]. This union is important for a starting definition of First Light in relation to prefab because prefabricated design inevitably evokes recollection of Britainʼs postwar prefab housing project [Glancey], defining how the space is to be used and choosing the prefab system should be done in conjunction. The prefabricated nature of the building cannot be concealed behind the cladding and remain efficient, as has been analysed from the case studies selected for this research. Junctions between the materials on the First Light house have to be highlighted. In highlighting the details that have hither to remained a late addition to the design the Solar Decathlon team can relate more to how the bach is used. First Light should approach the design as a prefabricated bach that can change and evolve with its inhabitants, this can be achieved by accentuating junctions. “The nature of this [Prefabricated] architecture means it can take place at prominent locations and prestigious sites, albeit temporarily” [Kronenberg, p.24]. Piano used this technique to great effect when he set up the Traveling Pavilion in a central London park in figure 2.

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8 Webbʼs description shows a union between the space and the contents: “From the dark void emerge still and moving sepia-toned images of Colbertʼs peaceable kingdom, an idealised world of picturesque natives, cavorting with wild beast” [p.52].

Timber Canopy The proposed assembly method states that the timber canopy will be entirely flat-packed, the design schematic also shows that the supporting poles are separated from the structural elements of the roof. The method of connection between these two elements is initially specified as bolts through the wooden beams and columns, this would however create a lot of wear on the wood as bolts are being continuously being passed through the wood. From analysis of the case study on Renzo Piano the proposal is to use a similar fastener where the supporting columns meet the rafters on the roof. The joinery for this detail is shown in figure 11 where the bracket has been sketched up to show how the connection between two timber elements can be finished.

Figure 10: This illustration is a possible draft for a joint process to be used in the manufacture of the timber canopy specified in First Light.

Figure 11: This illustration shows the aluminium brackets spliced into the beech. Illustration sourced from <http://arquitecturamashistoria.blogspot.com/2007/11/delicias-renzo-piano-y-el-pabelln.html>

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Wall Systems In the design schematic the Solar Decathlon team propose assembling each wall as a panel including insulation and cladding, once they are on site they are ready for rapid assembly. Many problems can arise in joining already clad walls, using conventional nails or screws are inadequate for quick assembly because there would be inconsistencies where the modules fit together. The HUF company have thought about this and incorporated new ideas into the design and manufacture of their walls [HUF HAUS], instead of fixing the cladding to the structure they have fixed it between the beams. The beams are joined together and sealed watertight using the methods observed above, this crucial change in the hierarchy of wall layers means the structure becomes part of the cladding.

Floor to wall connection and temporary foundation The foundations for the house have to be adequate to support the house while not leaving a mark on the site. The foundations also have to be able to be easily and quickly removed. In the System3 house the foundations act as a plinth for the structure to sit upon. The floor structure has connection points for each pedestal. The grooves for these pedestals which enclose them and connect them to the house are also used as the connection points for the crane to lift the structure up out of the container it is shipped in.

Final Synthesis

Wall System:

As stated in the analysis of the HUF Haus the optimum design is to shift the structure and cladding positions to make the structure part of the cladding to allow for minimal assembly. The implication to this however is to create an exposed structure building but this is necessary to create a structure that can be transported overseas and be set up onsite in minimal time. Each of the case studies used as an example for methods in the Solar house expose the structure as part of the prefab method, System3 even combines the structure and cladding in a single wall panel. Methods from HUF Haus assembly could be applied directly to the Solar house if the construction of the wall panels was altered according to these proposed principles.

Timber Canopy:

Each project in the case studies has been designed with the intent to become a transportable structure, temporarily to transport it to site or a permanent traveling building with no end to itʼs journey. Although many of the prefab system discussed can be adapted for use in the First Light project, they must be adapted into the design well before the construction stage. The First Light takes a quintessential New Zealand Bach into the 21st Century, traditional or conventional methods may not apply to every aspect. Using a design similar to figure 10 may give the bach a very un-New Zealand look by mixing traditional wood materials with cast aluminium demountable brackets.

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Floor System:

Figure 12: This Illustration shows how the proposed method of foundation assembly specified in figures foundation by the Solar Team have been used in a real project. Illustration sourced from still of video walkthrough of System3, [Bergdoll] < http://momahomedelivery.org/index.php/>.

In the Design schematic put forth by the First Light team they proposed to set the house on temporary foundation pedestals on which the house will rest. Figure 12 shows how the pedestals are laid out for temporary foundations The principle behind this idea was to minimise material as well as assembly time, therefore the points on the floor panel that go into the pedestals are also the points used to transport and winch the panel into place. This method should be used in the Solar house for ease of transport also, parts of the house are going to be transported by flat-rack so the connection points which will sit on the temporary foundations can also be used to secure the units to the racks as they are going to be transported.

Wall System:

As stated in the analysis of the HUF Haus the optimum design is to change the structure and cladding positions to make the structure part of the cladding to allow for minimal assembly. The implication to this however is to create an exposed structure building but this is necessary to create a structure that can be transported overseas and be set up onsite in minimal time. Each of the case studies used as an example for methods in the Solar house expose the structure as part of the prefab method, System3 even combines the structure and cladding in a single wall panel. Methods from HUF Haus assembly could be applied directly to the Solar house if the construction of the wall panels was altered according to these proposed principles.

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Conclusion

The researched projects that to keep to a unified design incorporated prefabrication methods into the design at an early stage, as in Shigeru Banʼs Nomadic Museum, the prefab element defined the entire structure. The projects, although each very unique, contained similar approaches to prefabricated design not in the physical joints but in the principles beneath them. Each project altered the hierarchy of structure and cladding to expose the structure as the cladding, this particular aspect rendered each design efficient in terms of prefabrication. The underlying principles behind a lot of the projects was transportability relating to the clients needs and specifications, whether they wished to express that the future and past can work together or the need to be set up quickly in another country so workers can return to their families. The Solar Decathlon team need to relate their preferred prefab method to the fact that it is a competition house and surface look may overcome other aspects in the face of time constraints.

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BibliographyBooks

Kronenberg, Robert. Portable Architecture: Design and Technology. Germany: Architectural Press, 2008

Journals

Bowring, Jacky. “Ashes and Snow”. Architecture New Zealand, Sept-Oct.5 (2005): 110, 112

Broome, Beth. “A traveling museum transports urban visitors”. Architectural Record, 193.5 (2005): 109-110

Erleben, Kunst. “Nomadic Museum in New York”. Deutsche Bauzeitung, 139.11 (2005): 28-32

Gans, Deborah. “Home Delivery: Fabricating the Modern Dwelling”. Journal of Architectural Education, 62.3 (2009): 85-86

Gonchar, Joann. “Some Assembly Required”. Architectural Record, 196.9 (2008): 138-147

Hannay, Patrick. “Piano Forte/.” Architectʼs Journal, 180.43 (1984): 24-27

Hood, Sallie., and Ron Sakal. “Home Delivery, Museum of Modern Art (Spring 2008)”. Design Issues, 25.3 (2009): 102-107

Kelly, Karen. “Sustainable materials build a Nomadic Museum”. Business, 27.3 (2005): 25

Loh, Adeline. “Container Architecture Goes Places.” ISH. 2008. 11 Aug. 2010

Webb, Michael. “Traveling Museum, Santa Monica, USA”. Architectural Review, 219.1311 (2006): 48-53

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Online Articles

Cameron, Kristi., Pedersen, Martin C., and Stephen Zacks. “Public-Interest Architecture”. Metropolis. 2008. 3 Aug. 2010<http://www.metropolismag.com/story/20081015/public-interest-architecture>

Campbell, Scott. “The house that Larry built: MIT architect Sass puts up a prefab at MoMA”. MIT News. 2008. 10 Aug. 2010<http://web.mit.edu/newsoffice/2008/arch-sass-0703.html>

Glancey, Jonathan. “Prefab sproutings”. Guardian. 2005. 15 Aug. 2010<http://www.guardian.co.uk/artanddesign/2005/aug/31/architecture>

Kristal, Marc. “Banʼs Roaming Cathedral”. Metropolis. 2005. 3 Aug. 2010<http://www.metropolismag.com/story/20050516/bans-roaming-cathedral>

Quale, John. “The Promise of Prefab”. Metropolis. 2008. 1 Aug. 2010<http://www.metropolismag.com/story/20081015/the-promise-of-prefab>

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Websites

Bergdoll, Barry., and Peter Christensen. HOME DELIVERY: Fabricating the Modern Dwelling. July 20—October 20, 2008. <http://momahomedelivery.org/index.php/>

Colbert, Gregory, Ashes and Snow. <http://www.ashesandsnow.org/>

Grand Designs: German Kit Home - Surrey.<http://www.channel4.com/4homes/on-tv/grand-designs/episode-guides/walton-HUF-haus-revisited-08-06-04_p_1.html>

HUF HAUS. “HUF Haus: Das Original - Seit 1912”. 2010<http://www.HUF-haus.com/en/home.html>

Kullman Buildings Corp. “Kullman Offsite Construction”. 2010. 12 Aug. 2010<http://www.kullman.com/index.html>

“Kullman Design Manual”. 2010. 12 Aug. 2010<http://www.kullman.com/catalogs/designmanual/index.htm>

Lisnovsky, Martin. “Delicias: Renzo Piano y el Pabellón Itinerante IBM 1982-1986”. 7 November 2007.<http://arquitecturamashistoria.blogspot.com/2007/11/delicias-renzo-piano-y-el-pabelln.html>

Ziyang Poh. “IBM Traveling Pavilion by Renzo Piano”. 16 November 2009. <http://ziyangpoharchitecture.blogspot.com/2009/11/ibm-pavilion.html>

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Videos

Grand Designs S04E02 - Customised German Kit House: Surrey<http://www.channel4.com/4homes/on-tv/grand-designs/episode-guides/walton-huf-haus-revisited-08-06-04_p_1.html> /

Larry Sass Overview of House for New Orleans<http://www.youtube.com/watch?v=82_6cH6JXHU> /<http://momahomedelivery.org/index.php/>

Home Delivery Walkthrough: SYSTEM3.<http://www.youtube.com/watch?v=iTtLQu5yAJk> /<http://momahomedelivery.org/index.php/>

Home Delivery: Fabricating the Modern Dwelling, now on view at MoMA.<http://www.youtube.com/watch?v=DApR17dyh50&NR=1> /<http://momahomedelivery.org/index.php/>

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Solar decathlon house research

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