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Parametric Development of Variable Roof Structures with Central Supports

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Article  in  Nexus Network Journal · August 2013

DOI: 10.1007/s00004-013-0153-9

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Parametric Development of Variable Roof
Structures with Central Supports (Tulips)

Rodrigo García Alvarado, Arturo Lyon

Gottlieb, Patricio Cendoya & Pedro
Salcedo

Nexus Network Journal

Architecture and Mathematics

ISSN 1590-5896

Nexus Netw J
DOI 10.1007/s00004-013-0153-9

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 Author's personal copy
Rodrigo García Research
Alvarado* Parametric Development of Variable
*Corresponding author
Roof Structures with Central
Universidad del Bío-Bío
Avda. Collao 1202 Supports (Tulips)
Concepción, Chile
Presented at Nexus 2012: Relationships Between
rgarcia@ubiobio.cl
Architecture and Mathematics, Milan, 11-14 June 2012
Arturo Lyon Gottlieb Abstract. This work describes the exploration of a
Pontificia Universidad Catolica de parametric system to generate variable designs of low-cost
Chile roof units with central support (called “tulips”). The
El Comendador 1916 units aim to cover out-door areas and are composed of
Santiago, Chile commercial wood struts, digitally manufactured plates
alyon@uc.cl and a fabric cover to enable mass production and
variations according to different structural, functional
Patricio Cendoya and climatic conditions. The development has combined
Universidad de Concepción topological analysis, genetic algorithms, parametric
Victor Lamas 1290 programming and digital fabrication to produce models
Concepción, Chile and full-scale prototypes. This process suggests an
pcendoya@udec.cl approach to rationalizing design through mathematical
analysis and digital implementation that supports flexible
Pedro Salcedo and quick elaboration. That example illustrates new
Universidad de Concepción methods of architectural design with early integration of
Victor Lamas 1290 technical studies and industrial production.
Concepción, Chile Keywords: parametric design, genetic algorithm, digital
psalcedo@udec.cl fabrication, topological optimization, roofs, structures

1 Introduction
Due to the diverse conditions and complexity of today’s buildings, architectural
design usually develops unique solutions for each commission, thus generating long and
burdensome processes for each specific project. However, new design, analysis and
fabrication technologies make it possible to establish work strategies for groups of
building parts [Kieran and Timberlake 2004], and some experiences have demonstrated
the possibility of applying these capacities to produce variable construction components
[Stacey 2004; Gramazio and Kohler 2008; Meredith et al. 2008; Figueiredo and Duarte
2009], such as the usually sophisticated elements of large-scale building projects, to
absorb the cost of the advanced technologies used. This paper presents an exploration of
the potential of these systems to generate a variety of low-cost roofing modules with
central supports (called “tulips”) to cover outdoor places. It develops a parametric
programming for roofing units with digitally fabricated timber plates, regular struts, and
a covering fabric. The system is aimed at large-scale production of solutions that can be
adapted to suit different structural, functional and climatic conditions.
The development first involved the use of topology optimization software to
determine the general shape of the roofed module. This was then interpreted as a
structure of struts and plate connectors. Next, analyses of functionality and daylighting
were then carried out for different structural designs, which were studied in parallel to
assess their load-bearing capacities. In this way, numerical tables were obtained, listing
the angles of the upper and lower struts in different conditions, which were integrated

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DOI 10.1007/s00004-013-0153-9
© 2013 Kim Williams Books, Turin
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with genetic algorithms to determine more appropriate solutions. This procedure was
implemented in a parametric design system with two strategies of genetic algorithm (an
installed component and open programming) to compare their results with different
population regulations and mutations. The parametric elaboration of the construction
design is then developed, generating a visualization of the different modules with
mapping of the connecting boards and design of the covering fabric for digital
fabrication. The execution stage involves the assembly of the timber struts with
manufactured plates, smaller pieces and the corresponding fabric. The process deals with
analysis, design and general planning as well as the creation of physical models and full-
scale prototypes.

Fig. 1. Alternative designs of the units. Rendering: authors

2 Design and analysis
The shape of the units initially came about through an analysis with structural
topology optimization, using CALFEM, ANSYS and TOPOPT software in a collective
exercise with students. A one-day collaborative workshop with architecture, civil
engineering and computer science students from different universities was developed in
order to explore design possibilities. After that, some students then went on to carry out
further specific tests of specific alternatives. The structural topology optimization method
enables the definition of the most resistant configuration for a quantified space through
finite element analysis with continuous isotropic materials [Bensoe and Sigmund 2003;
Allaire 2004; Huang and Xie 2010]. In this case a covering area per module was defined
with a central support area at the base, which was translated into volumetric and planar
section discretization. This data was processed by commercial software with optimisation
functions or independent experimental programmes to compare processes and results.
Iterations were carried out with different densities and penalization values, generating
maximum resistance silhouettes which were then converted into spline profiles in CAD
software either by direct drawing or archive conversion. These layouts were prepared for
cutting with digital fabrication on scale models, using laser cutters on 3mm MDF sheets
with pieces of fabric and in some cases with the incorporation of struts. Different

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assembly strategies were developed, mostly concerning the connections between plates.
The models were reviewed according to the architectural configurations generated,
functional capacities (maximum coverage, efficient use of the base), structural solution
and use of materials.

Fig. 2. Structural topological analysis. Computer visualization: authors

Fig. 3. Examples of collaborative workshop to explore initial possibilities. Photo: authors

Some architecture students then continued the work, drawing up the construction
strategy, replicating the profile with steam-bent timber pieces to create a large-scale
prototype that including fabric, floor and fastening connectors on minor struts.
Engineering students also carried out subsequent analyses to determine the structural
development area and the underlying free space, identifying the main layouts that could
be interpreted with industrialized elements to facilitate large-scale execution. The
capacities of different materials and construction elements were reviewed, and a general
shape was established and interpreted in construction terms with commercialized timber
struts.

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Fig. 4. Schematic design of the roof units (tulips). Renderings: authors

In this way the overall design for the subsequent development stages was defined by
the standard lengths of the commercial timber struts with a radial distribution, forming a
pyramidal base and a six-faced polyhedron above as the roof covering, both shapes
converging to a point of union. This structural unit (called “tulip”) creates a stable
central support with the minimum of three elements and an extensive roof covering
made up of six similar elements forming a hexagon, facilitating the relationship between
the base and the roof, as well as the combination between modules to obtain extensive
coverings. The length of commercially available struts allows for a roof covering of about
30 square meters per module with a base that occupies some 3 to 5 square meters using
very low cost and easy to assemble elements for the surface area covered. The horizontal
relationship between the struts is kept constant (120° for the base and 60° at the roof
covering) in order to maintain a regular load distribution. However, the vertical angles
can vary at both the base and cover to adapt to different topographies and functions at
the base, or environmental conditions such as solar radiation, wind or rainfall at the roof
level. The relationship between base and roof can also vary (if the roof plane is inclined
on one side this must be compensated by lower supporting struts). To this end, structural
resistance studies were carried out with different angle conformations, first with regular
(symmetrical) variations in the roof cover and base and then with irregular
(asymmetrical) variations.
Some functional and environmental analyses were also undertaken at the initial
design stage. First, the total horizontal surface covered was examined according to the
different angles of the upper structure excluding the horizontal surface area occupied by
the base in order to determine useable surface area and functional possibilities (as well as
rainfall protection and accumulation, according climate data). Secondly, the sun angle
was simulated for the site latitude at different times of the day and periods of the year. A
summary of sun shading was then calculated for the summer equinox between 12:00 and
18:00, as the occupation period requiring the greatest sun protection. This generated
different shade amounts according to coverage angles of the struts (with greater shading
achieved with an asymmetrical layout), resulting in tables for shading and surface area
covered. In the differing angles of asymmetric coverings, modifications in the angles were
related to changes in the base pyramid necessary to maintain stability and the consequent
reduction in useable ground space. Likewise, a numerical table was drawn up showing
global resistance according to roof inclination angles and wind directions according to
structural calculations. This series of tables was fed into in a genetic algorithm to select
appropriate designs according to sun and wind orientation. Tables or values regarding the
topographic variations of the site or the relationships between units for the connecting
pieces (since any inclined unit must connect with the adjacent one to form a continuous
roof) or other specific variations in the project can also be incorporated. However, in this
present study the application was assessed according to the aforementioned functional,
environmental and structural tables which provided relevant and partially contradictory

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values (since the highest useable area and structural resistance coincided with symmetrical
configurations but better environmental conditions arose from more asymmetrical
designs). Genetic algorithm analysis makes it possible to find suitable solutions (though
not necessarily the optimum ones) to complex problems with multiple requirements.
This is achieved by generating sets of possibilities (populations), reviewing some of these
(individuals) in relation to a function of features and producing a number of mutations
following rules similar to those of genetic growth [Goldberg 1998]. The technique has
already been applied in some architectural problems, demonstrating the application of
this technique to find more proper design alternatives [Nahra and Terzidis 2006; Marin
et al. 2008; Papapavlou and Turner 2009].

Fig. 5. Genetic algorithm with Galapagos (top) and Visual Basic (bottom). Screen shot: authors
For the genetic algorithm analysis a basic layout was implemented in Grasshopper’s
parametric programming within Rhinoceros three-dimensional modelling software using
the Galapagos component, as well as a specific utility developed in Visual Basic in order
to compare results [Namoncura and Vásquez 2011]. In both cases variations in upper
and lower strut angles of the basic structure were established with an optimization

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formula using the data tables sequentially, starting with random values generation and a
determined solar/wind orientation. The Galapagos component has the advantage of
enabling modifications to be visualized since it shows all the angle alternatives evaluated
as well as a graph of the progression of evaluations and convergence with function,
although crossing patterns cannot be modified. Visualization was not implemented in the
programming developed, but rather alterations of populations and mutations could be
defined. A significant difference was noticed in the results between software, with the
Galapagos component presenting a high level of convergence in each generation, hence
requiring many populations and generations to test more optimal alternatives that
became progressively more similar. In contrast, the programming developed with Visual
Basic achieved more optimal results with a smaller number of populations in each
generation (and hence less time and computing resources were needed) while finding a
greater variety of solutions. This was mainly the result of a greater variety of strut crossing
patterns, thus creating mutations for a broader range of configuration possibilities, as
shown in other similar experiences [De la Barrera 2010]. This is relevant architecturally
speaking, since more diverse but sufficiently optimal possibilities can arise, combining
configurations or making them compatible with other non-quantifiable requirements
(circulation, views, etc.).

Fig. 6. Parametric programming (top) and models developed (bottom). Renderings: authors
Subsequently, based on the general layout, the complete parametric design of each
structure unit (tulip) was created. This started with the main timber struts, defining
volumes for the different pieces according to the structural calculations and developing
the connector plates by means of intersection operations and define connections between
pieces, according the thicknesses of commercial boards. A final visualization process was
included in the programming to permit further elaboration (integrating structure with
general modeling of the surroundings to obtain renderings of the places covered). In a
further programming sequence the plate profiles were developed in preparation for the
cutting process by digital manufacturing (and also the distribution routines in
commercial boards were calculated). The fabric also has a programmed design process,
based on the disposition of the points of support in each upper piece (the lower pieces are
always fixed to the base ring). Variations in fabric development were mainly related to
the asymmetry or extensions of the pieces. In each case an unfolding process is used to

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establish cutting lines with overlaps required for the edges and unions, thus favoring a
radial layout for the final assembly on-site. Regular construction detail plans were used
for the concrete foundations, minor connectors and special pieces as well as a list of
materials per unit. These data completed the documentation used for the production and
installation.

Fig. 7. Programming of fabric cover. Renderings: authors

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Fig. 8. Arrangements of units. Rendering: authors

3 Fabrication
The construction of the tulips involves standardized supporting elements and
components created by digital fabrication procedures, which are easily modifiable with
parametric design [Seely 2004]. The supporting struts are made of natural re-forested
timber pieces commercialized at low cost throughout the country (about $5-$10 US per
piece), although the quality is irregular (in terms of moisture content and knots, which
can lead to subsequent deformations or reduced loading-bearing capacities). However, a
visual selection can be used to adequately identify such problems without a major
increase in costs. These timber pieces are sold in different rectangular sections measured
in inches with a general length of 3.20m due to the limits imposed by commercial sawing
machines. The ends of these timber pieces must be refinished since they may need to be
regularized and perforated and, in the case of the main struts (of the central pyramid),
also slimmed along their sides to reduce their weight at the far end (and hence provide a
larger and lower base). Generally, three main struts are used, then a further six upper
ones for the roof and six lower ones for upper stress at mid-height of the covering
structure. If the design includes an extension to the bases or roof cover due to special
topographic or environmental conditions, then more struts may be used or longer pieces
of timber sourced (available to purchase, though usually in a smaller selection of
thicknesses). The timber struts are cut with hand-held electric saws using aids also made
by manufactured plates where the pieces and saw are placed in slots to hold the timber in
place and direct the saw cuts according to the required angles and lengths of the design.

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Fig. 9. Constructive details of execution. Image: authors

Sheets of structural plywood may also be used for the manufactured plates (made of
thin laminas of timber from native hardwood trees glued together to form a thicker sheet
with high stress resistance), with profiles defined by the parametric design and cut with a
CNC router machine. An optimization routine is used to determine distribution in the
board, particularly when a large number must be cut. These make up the central node
with two horizontal plates and six vertical ones to bear the upper struts and receive the
lower ones, with various securing methods for different angles. An intermediary bracing
plate can further strengthen the configuration (and also serve to carry or channel the
accumulation of rainwater on the roof) as well as a base plate to guide initial assembly
(removed once construction is complete). Other plates can also be added for additional
functions, particularly regarding the central pyramid (seats, tables, space divisions, etc.).
Diverse minor metal parts are also included but attempts have been made to minimize
and simplify these by using simple connectors readily available from any supplier,
including nuts and bolts and folded metal bands.

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There are different options for the roofing material depending on the function and
maintenance care involved. These vary mainly in terms of their technical quality and
cost. They range from simple linen to highly resistant and durable fabrics, such as
Précontraint® 402 from Ferrari with a tear resistance of 250/250daN/5cm (according to
ISO 1421) and a weight of 490g/m2, requiring a design process (dimensioning) in
accordance with the lengths of commercially available fabric for layout, cuts and seams
(or heat sealed edges). This includes the use of barrette and wire-reinforced edges.
Prefabricated concrete cubes can also be used for the foundations on site and to
compensate for lower loads, bolted to the struts of the pyramid.

Fig. 10. Prototypes built. Photos: authors

Therefore, for the elaboration of each module, parametric design is used to define the
main struts (verifying if regular commercial or special lengths are needed) and determine
the necessary accessories and bases (which do not usually vary per unit). After this the
layout of the plates and roofing fabric is obtained, taking into account specific variations.
The layouts of the different modules are then grouped together into a whole (or a series
of parts to be constructed) to make the best use of materials, optimizing use of timber
boards and roofing fabric lengths. Following this, the cutting of plates and fabric is
programmed and carried out with regular-sized CNC machines. The base plate to guide
assembly and a labeling system for the pieces in each module are included.
Installation starts out from a determined ground level and reference point, where the
base plate is positioned, thus enabling the concrete bases and supports for the main struts
to be put in place. The pyramid is then assembled on its side with its intermediate plate
and upper node, then lifted and placed onto the concrete bases. The upper struts and ties
(already braced) are then built on with the use of scaffolding and lastly the roof fabric is
added and a final coat of sealant applied.
4 Conclusion
This experience in working on a centrally-supported variable roof module has led to
the development of a complete production strategy, including design, planning and
creation of models and prototypes using advanced digital resources. Final fabrication,
installation and widespread use are still needed in order to fully prove the potential of
this approach, enhanced by the expected adaptability and low cost per unit.
Topology optimization techniques were applied to explore structural configurations
that were then interpreted with industrialized elements, in a novel design strategy. An

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analysis of geometric alternatives was developed according to functional, environmental
and structural factors through the use of genetic algorithms, thus identifying the
incidence of population regulations and mutations in the variety of resulting solutions.
Parametric programming for the main configuration of the design was devised, including
the connector plates and fabric cover, thus demonstrating the geometric relationship
between the components and variations visualized and determining the automatic
fabrication of design layouts. Digitally fabricated scale models were also created with a
laser cutter and real size prototypes produced with CNC routers, combining commercial
timber struts, manufactured plates and textile, as well as other minor pieces. A procedure
was established for execution and verification of aspects of construction, use, spatial
conformation and appearance.
This initiative to date has permitted the testing of diverse advanced design and
fabrication technologies, aimed at creating variable units that are both economic and fast
to produce. It has served to identify diverse conditions through the use of numerical
ranges and analysis procedures to define optimum characteristics in different situations
while also integrating regular design and construction processes. Although this proposal
has yet to be built on a mass scale and distributed in order to fully refine the processes
involved, it points to a combined strategy of design rationalization with mathematical
studies and digital implementation that could lead to large-scale and efficient
development. This example suggests new methods of architectural production with the
early integration of technical analysis and industrialized production with the potential to
contribute to a wide variety of construction possibilities.

Fig.11. Model of of a group of tulips. Rendering: authors

Acknowledgments
Research project Fondecyt 1100374, students Omar Rivera, Eduardo Saez and Manuel
Vasquez.
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About the authors

Rodrigo García Alvarado has a Ph.D. in Architecture from U. Politécnica de Catalunya, Spain
(2005), Ms. Sc. in Information Technologies for Architecture from U. Politécnica de Madrid
Spain, (1994); and Bch. in Architecture from Pontificia Universidad Católica de Chile (1989). He
has been visiting scholar in U. Kaiserslautern, Germany; U. Houston, USA; Strathclyde U., UK;
and Bauhaus-Weimar Universitat, Germany; as well as visiting teacher in U. Guadalajara, Mexico;
Unisinos, Brazil; and U. Catolica de Cordoba, Argentina. He is full-time scholar in Universidad del
Bio-Bio, Concepcion, Chile, since 1994, former Head of Dept. in Architectural Design and
Theory, Head of Diploma in Computer-Aided Design and Head of Master of Arts in Design
Teaching, currently Head of Ph.D. in Architecture and Urbanism. He is devoted to teaching
architectural studio and design courses, and to research architectural teaching and digital media,
building technology, housing and contemporary architecture. He has directed several research
projects funded by national and foreign agencies, international cooperation programs and arts
developments. He has published around forty scientific papers and presentations in international
conferences. He is a registered architect in Chile and he has designed around thirty houses and a
dozen public buildings, schools and health establishments. His main contribution has been the use
of digital media in architectural design and building management, renovation of design teaching
and architectural research.
Arturo Lyon is an architect who graduated from the Pontifical Catholic University of Chile in
2004 and Master in Architecture from the Design Research Lab of the Architectural Association in

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London in 2007. After graduating worked at Zaha Hadid Architects, London, during 2007 and
2008, involved in the conceptual and schematic design of various projects in China, Dubai and
Singapore. Currently is an assistant professor at the Catholic University of Chile where he has
developed interdisciplinary research in areas of technology, design and architecture. He has taught
workshops on the generative design and digital fabrication in different institutions in Europe and
Latin America, including the Landscape Urbanism and the Design Research Lab of the
Architectural Association in London. In 2009 founded LyonBosch Architects office that has been
dedicated to experimental development projects at multiple scales including furniture design,
mounts exhibitions, street art installations, single-family housing projects, tourism asset conversion,
landscape architecture and studies territorial.
Patricio Cendoya Hernández was born in Punta Arenas, Chile (1963). He holds the title pf Civil
Engineer (1986) from the University of Concepción (Chile) as well as a PhD (1996) from de
Polytechnic University of Catalonia (Spain). He is presently an Associate Professor of Civil
Engineering at the University of Concepción, Chile, where he has worked for the past 23 years. He
has worked as researcher at the University of Concepción (1990-1992, 1997-2013) and at the
International Center for Numerical Methods in Engineering (CIMNE), Barcelona (Spain) (1992-
1996). He has published papers in international scientific journals and has publications in
conference proceedings, technical report and instruction monographs. He has been the project
leader and member of the research team in many projects, funded by the public and private sectors.
His main research interests are in the fields of the numerical methods in engineering and applied
sciences, with particular emphasis on the finite element methods in structural mechanics.
Pedro Salcedo Lagos is an Associate Professor at the Department of Research and Educational
Informatics, Universidad de Concepción, Concepción. Chile. He obtained his PhD in Artificial
Intelligence from UNED, Spain, and his Msc degrees in Computer Sciences from Universidad de
Concepción (UdeC), Concepción, Chile. His research interests into Artificial Intelligence, Science
Education, e-Learning. He has participated and directed several research projects funded by
national and foreign, mainly on artificial intelligence applications in architecture, engineering and
education.

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