Grafted Growth by Jared Moore

GRAFTEDGROWTH Grow. Cook. Eat.

Grafted Growth

Grow.Cook.Eat. A proposal for a vertical farm in Charleston South Carolina. The design studio worked with Clemson University’s Institute of Applied Ecology. The Institute received EPA funding to develop a design - feasibility study to build a “vertical farm” in downtown Charleston. ARCH 893 - Comprehensive Studio, Fall 2011 Dan Harding, Bernhard Sill, Ulrike Heine Designers: Jared Moore jjmoore@clemson.edu Chris Wilkins chris@chriswilkins.com

We would like to give a very special thanks to the following: to the EPA, for their support of the studio. to Dr. Gene Eidson, for his knowledge and help in understanding how a vertical farm should work. to our professors Dan Harding, Bernhard Sill, and Ulrike Heine, for their collaborative input on the design and technical aspects of the project.

ABSTRACT: Have you ever wondered how many miles your meal has traveled before making it to your mouth? Most foods have traveled hundreds or thousands of miles to make it from farm to table. Oil powers this travel. Oil also produces the fertilizers used for industrial scale food production and powers the tractors and irrigation pumps. In the United States, 400 gallons of oil equivalents are expended annually to feed each American (as of data provided in 1994)1. In addition to depleting fossil fuels, modern agriculture is also using soil and water supplies faster than they can be replenished. As global oil supplies become more scarce, the cost of our modern industrial food system will become increasingly unaffordable. Simply put, the way we are eating is unsustainable. The Vertical Farm is a conceptual design for a new method of food production. One that is not only sustainable in terms of oil, water, and soil use, but also provides more affordable, better tasting and healthier food. Farming, traditionally done in fields in the Midwest, will happen inside of hermetically-sealed grow rooms sited amidst the high-rise buildings of populous urban centers. Locally grown food will reduce oil consumed in transportation, while hydroponic and aeroponic growing methods will provide year-round food production with no impact to soil supplies and very efficient use of water and nutrients.

students, faculty, and professionals to engage the community members of Charleston, SC through a series of design charrettes. The aim was to understand not only the economic feasibility of urban farming, but also how a local culture can be grafted together with new methods of food production and culinary preparation to create an empowered and cohesive local food community with a sense of social justice. This semester-long collaboration between disciplines uncovered a richness of ideas that we don’t usually witness in the architectural design studio. The comprehensive requirements of the studio required a rigorous exploration of design details, such as using sustainable construction methods and materials – employed in the adaptive reuse of an existing vacant warehouse – and the integration of energy-efficient heating and cooling systems with real-time sensor networks for environmental optimization. For this architecture to succeed, the farming process had to be integral to the building systems just as the city’s culture is integral to its food. Working with scientists, engineers, and organic farmers we learned more than just architecture – we began to design the future of food. The vertical farm is where we will grow, cook and eat together.

As part of an EPA funded research project, graduate architecture students from Clemson University worked in inter-disciplinary teams of

1. Eating Fossil Fuels, Dale Allen Pfeiffer, From the Wilderness Press, 2004. http://www.fromthewilderness.com/free/ww3/100303_eating_oil.html

Community Design Charrette 1

The first charrette for the Charleston Vertical Farm Design Feasibility Study was held on September 16th in Charleston. The purpose of the first charrette was to select one property in downtown Charleston to focus the design feasibility study on. Three properties were initially selected to be discussed during the charrette and a participant invitee list that represented a substantial profile of the community of Charleston was developed and invitations sent out. Graduate students from the Clemson University School of Architecture developed introductory presentations for the charrette participants that detailed vertical farming and the need for community outreach and service of this type in Charleston.

Community Design Charrette 2

The second charrette for the Charleston Vertical Farm Design Feasibility Study was held on October 14th in Charleston. The purpose of the second charrette was to focus on a vision for the Vertical Farm building by reviewing and openly discussing numerous building design strategies for the Port City Paper site. Participants were charged with examining specific design schemes while providing meaningful, critical, and insightful feedback via a typical S. W. O. T. analysis (strengths, weaknesses, opportunities, and threats). The charrette shared a similar structure as the first event to capitalize on the diverse group of community members that had been invited.

Public Gallery and Exhibition

The final public presentation was held in December of 2011 as a public exhibition of the work and research completed during the semester. The exhibition was held in the Grow Food Carolina building, a company that focuses on supplying locally grown produce. The studio designed and constructed the exhibition panels that were used to display the presentation boards and physical models.

Food Location Map

The design process began by mapping out major areas in Charleston where food could be bought. This also included examining major food productions areas within the state.

Grocery & Markets Food Lion

Piggly Wiggly

Harris Teeter

The Vegetable Bin

Bull Street Market

Queen Street Grocery

J & W Grocery

President Market

time by vehicle

time by walking

1 2 8

3 4 5

context zone 1

This zone features both residential and commercial program. The only other food resource is in this zone.

context zone 2

This zone features a large amount of residentail program and undeveloped land. It is also the first zone to include interstate I-26.

context zone 3

surrounding green space

This map shows the existing green space within the surrounding context of the site. A major goal for the vertical farm is to influence and teach the community on how to make and manange their own urban gardens.

transportation + food resources

The main transportation networks for the vertical farm site include I-26 as a major connection to the rest of the state, and Huger Street as a main connection to downtown Charleston.

Zone 3 features many residential structures as well as two of the restaurants within the surrouding context of the vertical farm site.

context zone 4

This zone is mainly made up of residential program. The zone makes a concept of a vertical ideal for its current location.

Crime Rate

The surrounding neighborhood has a very high crime rate, one of the highest in the city. Security is a major priority for the project. The project also attempts to create spaces and activities that would help unite the community and begin to decrease the crime rate.

Charleston BAR

The Charleston Board of Architecture Review will have to approve any scheme before the project can move to construction. The design focuses on preserving as much of the existing as possible, and uses materials that are similar to other structures found in the Charleston area. The design needs to be an icon in the city, but also respect the historical qualities of Charleston.

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Height Restriction

According to the local Charleston zoning regulations a building in this area could not exceed a maximum height of 50â&#x20AC;&#x2122;.

10 Food Desert

Almost half of the surrounding population lives in what is called a food desert. A food desert is any area in the industrialized world where healthful, affordable food is difficult to obtain. It can be measured by how far a residence is located from an adequate food source, grocery store or food market. If the residence is more than 1 mile away then they are considered to live in a food desert.

Distance to Nearest Farm

Since Charleston is an urban coastal city itâ&#x20AC;&#x2122;s not hard to figure out that the nearest farm is quite far from the city. The introduction of a vertical farm into the city would greatly shorten this distance and reduce the amount of energy used to transport food from farms into the city. This would also reduce the amount of CO2 released into the atmosphere.

Quality of Existing Food Markets

The current condition of the food supply available to the local community is poor. Interviews reveal that the local food suppliers lack a variety of food selection and have little availability of certain foods.

Use of Existing Warehouse

A key part for the design was the use of an existing warehouse that currently occupied the site. This was required by the EPA.

King Street

The projects front elevation is located on King Street; a major connection to high population areas in Charleston.

King Street

SITE

Vacant Lots

Directly behind the site were two vacant lots. The two lots were added to the site, and allowed for a large community garden.

Port City Paper Warehouse

The grant from the EPA specified that the new vertical farm had to use an existing structure. The first design charrette presented three different sites to community members and by the end of this charrette the Port City Paper site was chosen. The challenge for the design and site use was as follows: 01. Provide a design scheme that meets the production needs of a vertical farm within the constraints of the program and existing building envelope on the site in downtown Charleston. This requires at least 3 floors of the building are dedicated to production only farming.

Port City Paper - Interior

02. Balance the aspects of a new production-oriented building with the needs of the surrounding community. Port City Paper Warehouse from King Street

Port City Paper - Loading Zone

Sun Studies

N 30

300

60 6:12

20:31

19:26

09 15

240

7:03

18 12

7:18

17:18

120 15

210

150

Daylight

APRIL

14 NOON

12 NOON

2 0

JANUARY

2 JAN

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330

Because our farming program uses the roof and south faรงade, we analyzed how the sun travels across the site. From our sun studies we found that there are no major shadows cast on the new structure from the surrounding buildings. We also researched how many hours of daylight Charleston receives during the year to determine how much light we should expect to get for growing our plants.

Summer Seasonal Wind Rose

For the ground level we employ a cross ventilation cooling strategy. Initially we research how cross ventilation could cool the farming program spaces, but after our research we determined that the farming spaces must be hermetically sealed from the exterior to prevent contamination. The wind rose was used to determine the direction of major winds during the hottest months of the year. After our research we decided to place small transom operable windows on the ground level south faรงade that can be manually opened by the occupants. The north faรงade also received the same treatment in the clearstory, but instead of being manually controlled it relies on sensors to determine when to open.

3:00 pm

Relative Humidity 100 90

ANNUAL (M): 86%

80 70 60

ANNUAL (A): 56%

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NORTH 15% 20

340

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10:00 am

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FEB

MAR

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MAY

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JUL

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DEC

12%

315

45 9%

Climate Data: Temperature

8.9-11.1

290

5.0-8.9

3.3-5.0 1.0-3.3 <1.30

WEST

EAST

110

250

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135

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10 200

160 SOUTH

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C U LT U R E Grafting

Our design strategy uses the concept of grafting, and examines how to graft the new vertical farm with the existing structure. The project explores the concept of grafting in structural issues, form and massing studies, as well as how the farm grafts with the existing community. The new vertical farm is dependent on the existing roots of the community, and in order for the project to succeed there must be a strong connection with the surrounding community.

Design Concept + Goals

A major design focus for our project is to integrate the vertical farm within the local community, and for the building to serve as a community center. The public program of the project is centered on the idea of â&#x20AC;&#x153;Grow. Cook. Eat.â&#x20AC;? This concept deals with the building providing a space for members of the community to come and learn how to grow food in their own gardens, then how to cook the food they grow, and finally provide a space for them to enjoy their hard work. This concept will also promote a healthier lifestyle.

Connection to Neighborhood

To continue with one of our major design goals of connecting the building to the community our first design move was to provide a connection path through the site. This allows for members of the neighborhood to travel through the building to get to Food Lion, and other areas surrounding the site. This also allows for the community to constantly see what is taking place in the farm, and allows for a high level of transparency.

Location of Farming Program

When trying to determine the location of the vertical farm program we wanted to use areas with the most natural sunlight. Because of this we chose to locate the major farm program spaces on the roof and on the south faĂ§ade of the building. This allows for plants growing in these regions to receive the maximum amount of natural light. There is also farming program located in the warehouse and the growing racks have been equipped with grow lights.

ET TRE GS KIN

Public Garden

A public garden is located directly off King Street and serves as a method to draw people into the building. The garden is maintained by the vertical farm staff and volunteers but is totally free and available to the public. The garden also serves as the first phase of urban gardens that will one day continue north along King Street. Since the garden is located across from a public library it will also serve as a teaching tool for students on the importance of urban farming.

Cafe

A café is also located off of King Street. The café will draw attention to the building and encourage people to enter the building and learn about vertical farming. The café is a “dirt-to-table” café, meaning that all of the food sold from the café comes from the vertical farm. The interior portion of the café features a bar and seating.

Distribution

The location of the distribution area is determined by the existing roll up doors and ease of access from the road. The distribution area is located directly under all of the farming levels. A large service elevator allows for easy transportation of produce from farm levels to the ground level. This area of the building also houses major mechanical units such as two water pumps, a switchgear room, and HVAC units.

Community Garden

The two vacant lots located directly behind the warehouse have been converted into one large community garden space. The concept for the garden is to engage the surrounding neighborhood and allow them a place where they can grow their own food. The grow.cook.eat. concept will allow members of the community to learn how to grow certain foods and how to maintain a garden. They will also be able to learn how to cook different meals with the food they grow.

N First Floor Plan

Non Farming Sq. Ft.: Total Farming Sq. Ft.: Total Sq. Ft.:

1. 2. 3. 4. 5. 6. 7. 8.

13,419 522 13,941

Daily Market Dirt-to-Table Kitchen Dirt-to-Table Cafe Cooking Classroom Distribution Water Pump Room Switchgear Room Elevator Mechanical Room

6985 sq. ft. 257 sq. ft. 835 sq. ft. 113 sq. ft. 522 sq. ft. 300 sq. ft. 184 sq. ft. 178 sq. ft.

9. 10. 11. 12.

Rain Water Collection Cistern Outdoor Eating Area / Garden Transformer + Generator HVAC Mechanical Room

155 sq. ft. 1730 sq. ft. 305 sq. ft. 130 sq. ft.

OPEN TO BELOW

N Second Floor Plan

Non Farming Sq. Ft.: Total Farming Sq. Ft.: Total Sq. Ft.:

1. 2. 3. 4. 5. 6. 7. 8.

16 2,220 6,758 8,958

Office Reception Vertical Farm Administration Farming Directorâ&#x20AC;&#x2122;s Office Conference Room Telecommunications Room Balcony Farming - Germination Lab Space

195 sq. ft. 673 sq. ft. 181 sq. ft. 200 sq. ft. 176 sq. ft. 451 sq. ft. 3194 sq. ft. 127 sq. ft.

9. HVAC Mechanical Room 10. South Facade Farming - Level 1 11. Air Lock

195 sq. ft. 3437 sq. ft. 190 sq. ft.

N Third Floor Plan

Non Farming Sq. Ft.: Total Farming Sq. Ft.: Total Sq. Ft.:

1. 2. 3. 4. 5. 6. 7. 8.

389 12,535 12,924

Farming Production Unit - A Native Farming Production Outdoor Growing Area Lab Space Farming Production Unit - B South Facade Farming Level - 2 HVAC Mechanical Room Air Lock

2360 sq. ft. 1223 sq. ft. 1837 sq. ft. 113 sq. ft. 3565 sq. ft. 3437 sq. ft. 243 sq. ft. 146 sq. ft.

N Fourth Floor Plan

Non Farming Sq. Ft.: Total Farming Sq. Ft.: Total Sq. Ft.:

1. 2. 3. 4. 5. 6. 7. 8.

18 1222 16,633 17,855

Farming Production Unit - A Farming Production Unit - B Farming Production Unit - C Farming Production Unit - D Farming Production Unit - E Lab Space South Facade Farming - Level 3 HVAC Mechanical Room

3208 sq. ft. 1640 sq. ft. 3340 sq. ft. 2220 sq. ft. 2518 sq. ft. 270 sq. ft. 3437 sq. ft. 786 sq. ft.

Section: A

Section: B

North Side Elevation

South Side Elevation

Front Elevation

Rear Elevation

Hydroponic Farming System

Aeroponic Farming System

The vertical farm also employs the use of aeroponic systems. Aeroponics is a method of growing plants in an air or mist environment without using soil. Aeroponics is different from hydroponics due to the fact that the aeroponic system uses no growing medium. Aeroponic systems are extremely efficient and sustainable, and like the hydroponic system, can produce stable and high yields. NASA has also experiemented with this system as a means of producing food during space travel.

The vertical farm produces a variety of foods using a hydroponic system. Hydroponics is a method of growing plants using mineral nutrient solutions in water without soil. The wate used in our hydroponic systems is completely recycled, which greatly reduces the amount of water used to grow plants. This system allows for the control of nutrition levels, easier control of pests, and is a stable system which produces high yields.

Basil

Dill

Spinach

Broccoli

Celery

Lettuce

Greenbeans

Okra

Cucumbers

Beets

Carrots

Corn

Onions

Tomatoes

Peppers

Farming Equipment:

Aero Tower Number of Racks: Rack Floor Area: Total Floor Area:

113 25 sq. ft. 1625 sq. ft.

Plants per rack level: Plants per full rack:

218 1200

Total Plant Growth: 135,600 Approx. 13.56 acres

Aero Tower

Aero Tower Water Supply

Section

Farming Equipment:

Flat Aero Rack Number of Racks: Rack Floor Area: Total Floor Area:

82 50 sq. ft. 3500 sq. ft.

Plants per rack level: Plants per full rack:

300 1200

Total Plant Growth: Approx. 9.8 acres

98,400

Flat Aero Rack

Total Farm Production: Approx. 23.4 acres

234,000 Plants

Flat Aero Rack Water Supply

Section

Structural System

For our structural concept we continued with the idea of grafting and we examined how our new structure could be grafted with and take advantage of the existing structure. We began by removing east and west brick facades, and then added two concrete cores to replace the sheer. We chose to keep all of the brick and cmu walls of both the north and south facades, and our new â&#x20AC;&#x153;treeâ&#x20AC;? columns graft onto the existing columns with custom steel connections joints. Our ETFE panel system is supported by large LVL beams.

Vertical Loads

Longitudinal Horizontal Loads

Transversal Horizontal Loads

25 1. Removal of existing east and west walls and bow trusses

2. Addition of cores for sheer

3. Addition of vertical columns

4. Grafted connections

5. Columns for roof support

6. Second floor primary structure

7. Addition of LVL roof structure

8. Third floor primary structure

9. Fourth floor primary structure

10. Grid structure for ETFE Panels

ETFE Panel System

For our envelope system we chose to use a triple layered ETFE panel. The tripled layered ETFE provides the necessary insulation requirements for the space while also providing a low tech shading devise to deal with the harsh summer temperatures. The ETFE shading system consists of a checkerboard pattern that is printed onto the top outer layer, while the middle layer is printed with the negative image of the top layer.

ETFE Panel Open

ETFE Panel Closed

Metal Grate Floor System

For the south façade of our vertical farm we chose to use a metal grate floor system. The system is easy to assemble and light weight. The grates allow for the maximum amount of natural light to penetrate each level and reach plants on the first and second levels. The grates also allow for a natural circulation of air from the HVAC system. Air is supplied at every level and because hot air rises there is only the need for one return duct system at the top level.

1” Welded Steel Grating with 1-3/16” spacing Steel Mounting Brackets 18k6 Open - web Joist Tapered I-Beam

ETFE Panel 2’ x 8” LVL 8” Dia. Steel Column

18k6 Open - Web Joist

DETAIL 01 Mullion Flashing Steel Connection Plate Reinforced Concrete Slab Metal Decking Hexagonal Castellated Beam Web Cleat Structural Connection Joint Continuous Bearing Angle Insulation Flashing

2’ Deep Hexagonal Castellated Beam

02 Grafted Steel Connection Joint

Flashing Existing CMU Existing Concrete Column

Existing Concrete Column

27 DETAIL 02 Existing Concrete Column 8” Dia. Steel Column 1” Steel Base Plate 1/2” Epoxy Bolt 3” Finished Slab Vapor Barrier Leveling Nuts Nonshrinking Grout Existing Foundation

03 North Side Wall Section

DETAIL 03

2’ x 8” LVL Bolts Welded Connection

DETAIL 04 8” Dia. Steel Column Steel I-Beam Welded Connection Steel Connection Plate

2’ deep hexagonal castellated beam Welded Connection

DETAIL 05 8” Dia. Steel Column Existing Conc. Column 2’ deep hexagonal castellated beam Web Cleat Concrete Slab Metal Decking Insulation Alucobond ACM Panel

South Side Wall Section

DETAIL 06

Skin Fabrication

The roof and southern faรงade were designed as an integrated environmental control system. The ETFE bubble system needs only a lightweight structure for support, but requirs an infrastructure of pressurized air supply hoses to maintain inflation. A mass-customized, aluminum mullion system has been designed to invisibly house the air supply system, along with an integrated rainwater collection system. Parametric modeling has been used to translate a single NURBS surface into several thousand unique cut-patterns. Mullions would be produced off-site, cut from aluminum sheets using a CNC water jet, and folded using brake forming. This prefabrication process will be more efficient and have a higher quality output than traditional on-site construction and could be applied to multiple projects. The structural grid is based on the Zollinger roof system, which is ideal for doubly-curved

Rainwater Collection

The mullion system has an integrated rain gutter which collects water into a series of cisterns on the uppermost level. Locating these cisterns higher than the water supply points allows for gravity-powered irrigation. Overflow is routed downwards for use in the ground-level, community garden.

ETFE Panel Clamp Integrated Gutter Debris Filter Pipe Fitting

Air Hose to ETFE Air Supply Hose Water Tube Water Collection Pipe

Integrated Skin System

Aluminum mullions house an air supply system for the ETFE bubbles, rainwater collection hoses, electrical wiring, and a real-time sensor network for environmental control. Systems can be accessed for maintenance via removable panels, and can be replaced completely without disturbing the structure.

Building Circulatory System

Air, water, electricity and data are passed between the skin and the structure via junction points where the Zollinger-based mullion system meets a structural system of CNC-fabricated, laminated veneer lumber (LVL).

HVAC: VAV Systems

For our HVAC system we chose to use multiple single-packaged VAV units. Each of the farming areas much have a separate HVAC system due to the risk of contamination. By supplying each farming zone with their own HVAC system the room has the highest amount of efficiency in temperature control. This also reduces the size of each unit since it only supplies air to small individual zones. The fresh air intakes and exhausts are located on the roof. The ground floor relies on a separate intake and exhaust system. The intakes and exhausts on the roof are located inside one of the 8’x8’ squares from the roof grid.

Switchgear Room + Transformer

For the electrical component of our building we have located outdoor space for a transformer, and back- up generator. The dimensions required for the pad-mounted transformer has been roughly sized to about 8’x8’. The switchgear room has been located in the distribution area on the ground floor. Along with the switchgear room we have located a 175 sq. ft. telecommunications room within the administration area of the building. This room will house any major electrical equipment and technology for the vertical farm.

Water Pumps

The building features two major water pumps. One pump, the domestic water pump, is dedicated to supplying potable water throughout the building, while the second pump is solely for the buildings sprinkler system. Because each farming zone has its own mechanical room we have also decided to add a small water pump to each farm zone. Because the pumps only have to supply water horizontally for one floor the individual pumps are much smaller. However, it’s important to note that these pumps would be primarily used as a back-up in case the major pump failed or was under repair.

EXHAUST FRESH AIR INTAKE

FRESH AIR INTAKE

Second Floor Mechanical Plan

FRESH AIR INTAKE

Ground Floor Mechanical Plan

Third Floor Mechanical Plan

Fourth Floor Mechanical Plan