design research for sustainable, adaptive reuse of industrial structures

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DESIGN RESEARCH FOR SUSTAINABLE, ADAPTIVE REUSE OF INDUSTRIAL STRUCTURES Three Case Studies

RUDI STOUFFS

Published by the Centre of Advanced Studies in Architecture (CASA) Department of Architecture School of Design and Environment National University of Singapore 4 Architecture Drive Singapore 117566 Tel: +65 65163452 Fax: +65 67793078 Design Research for Sustainable, Adaptive Reuse of Industrial Structures: Three Case Studies ISBN: 978-981-11-1129-7 Date of Publication: December 2016 Printed by First Printers Pte Ltd © CASA, Centre of Advanced Studies in Architecture Department of Architecture School of Design and Environment National University of Singapore © Rudi Stouffs/Individual Contributors Sponsor NUS-JTC i3 Centre All rights reserved; no part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise without prior written permission of the publisher. The publisher does not warrant or assume any legal responsibility for the publication’s contents. All opinions expressed in the book are of the authors and do not necessarily reflect those of the National University of Singapore. 2

ACKNOWLEDGE­ MENT

While many helping hands have made this book possible, my strongest gratitude goes to my thesis students Baey Yan Ling, William Chuo and Ong Kai Liang, whose thesis projects provided the main material for this book. All three whole-heartedly took it upon themselves in their thesis project to explore and address through design research the issue of adaptive reuse of an industrial building—each a different building and from a different angle—and develop innovative prototypical designs. I’m also sincerely thankful to Wu Yi’An Annie, Bek Tai Keng and Alvin Tan Pak Wei, and my PhD student Liu Yuezhong, who supervised them, for extending these design studies with energy analyses. These analyses enhance the studies presented, but also give some insight into the energy consumption of industrial buildings in Singapore. For the editorial work on the book, I received invaluable assistance from Baey Yan Ling, Tulika Agrawal and Prasanjeet Biswas. Baey Yan Ling additionally provided the image for the cover. My sincere gratitude goes to them as well. This book would not have been possible without the financial contribution of the NUS-JTC i3 Centre, for which I am the Centre and its Directors extremely grateful. The support of the Department of Architecture and the School of Design and Environment at the National University of Singapore was also indispensible for the success of this endeavour, and I extend my gratitude to the Department, its Head and Deputy Head (Research), and the School.

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8 Introduction 14

Regem: Regenerate, Retrofit, a Ramp-up Factory

66

An Industrial Urban Interface

124

A Community Factory: Making Connections

164 Conclusion

INTRODUCTION ADAPTIVE REUSE OF INDUSTRIAL STRUCTURES

This book presents the results from design research conducted at the Department of Architecture, National University of Singapore, targeting sustainable, adaptive reuse of industrial structures in Singapore. The design research took place in a Master of Architecture, Techniques and Tectonics, Final Design Project studio and resulted in three case studies of adaptive reuse of industrial buildings, taking into account social, economic, ecological and historical factors, including user requirements, environmental sustainability, urban design, building materials and construction. All three studies emphasised land-use optimisation, mixed-use development and preservation of industrial heritage, while exploring building performance and sustainability. The three studies respectively focus on regenerative design, closing loops within an industrial urban interface, and the design of a community factory. The three studies target three different existing industrial buildings, all three from the portfolio of JTC Corporation (JTC). JTC is Singapore’s largest industrial developer and lead government agency to spearhead the planning, promotion and development of Singapore’s industrial landscape.1 Two of the selected buildings are flatted factories, that is, multi-storey, multi-tenanted developments with common facilities such as passenger and cargo lifts, loading bays and car parking. “JTC’s flatted factories are designed for clean and light businesses that require functionality, production flexibility and space utility.” 2 Flatted factories were introduced in Singapore with the start of its industrialisation programme in the 1960s.3 Flatted factories are not as popular anymore as they once were and older factories are slowly becoming obsolete, as traditional manufacturing industries are now in a decline and higher skilled manufacturing processes require different types of spaces and facilities. An additional problem is that the Gross Plot Ratio (GPR) for the sites is commonly much lower than what is currently allowed in the Urban Redevelopment Authority (URA) master plan. As a result, 9

there is a strong incentive to demolish the buildings and to replace them with newer factory types with higher GPRs. At the same time, both sites are located near—across from—residential neighbourhoods and their land use is restricted to clean industry, light industry, warehouse, public utilities, telecommunication uses and other public installations, with additional constraints applying. Considering these restrictions and a general aversion of people living in sight of industry, demolishing and building new, larger factories may not be the only or best solution. Additionally, there exists a demand for low-rental industrial or semi-industrial spaces, for example, for start-ups, the creative industry and makers, offering arguments for the adaptive reuse of these buildings. Both flatted factories were presented to the students by JTC as buildings ripe for adaptive reuse targeting a new group of tenants with low-rental premises while at the same time increasing the sites’ GPR. The third study is an outlier in this respect as it concerns a ramp-up factory. The ramp-up factory is a newer, multi-storey factory type that generally boasts larger spans, higher floors and larger floor loads. Additionally, “every factory unit enjoys ground floor convenience via the vehicular ramp that is able to accommodate 45-foot container trucks.” 4 Each unit also has its own dedicated loading bay and car parking. Ramp-up factories are suitable for a range of industrial activities, including logistics. As such, ramp-up factories are far from obsolete, but the particular factory under consideration is nearly adjacent to a 40ha site slated for residential development, and locked in between a river and a large water reservoir. As such, it is assumed within this study that the building site will also lose its industrial land use or at least be upgraded to a more restrictive land use. With approval from JTC, this study considers the adaptive reuse of the ramp-up factory as a vertically integrated town centre for this new residential development as well as existing residential areas within about a 2km radius, a distance quite comparable to other residential towns in Singapore, such as Ang Mo Kio. Admittedly, though, it would fail in a comparison of the number of residents, due to the presence of the river and the water reservoir within the immediate vicinity. Baey Yan Ling presents Regem: Regenerate, Retrofit, a Rampup Factory, an adaptive reuse study of a ramp-up factory building at Penjuru Lane, considering a regenerative design approach. Regenerative design is based on an eco-centric worldview, which posits humans as actors in a greater network of the social ecological system. It emphasises a systems thinking approach to design based on flows and on the knowledge that discrete 10

entities are embedded in a larger, more complex system. Rege­ ne­rative design advocates a pattern-based approach to design, which seeks to impact the network through understanding patterns that occur in the system to cause a ripple effect in the system, rather than dictating changes. Regenerative design aims to achieve net positive outcomes, and considers place, with its ecological, cultural and economic connotations as a cornerstone of design. William Chuo presents An Industrial Urban Interface, a sustainable reuse study of a flatted factory building at Chia Ping Road, considering a closing loops approach. Closing loops recognises that industrial waste can become part of a closed loop cycle that takes this waste as resource to provide materials and components for makers, which in turn provide products for the consumers and the community. In addition, the shift towards sustainability begins with the education of the public, which is as important as the sustainable business practices themselves. Ong Kai Liang presents A Community Factory: Making Connections, an adaptive reuse study of a flatted factory building at Kolam Ayer, exploring a combined public-industrial typology. The study attempts to make explicit connections in the form of integrated spaces between two distinct typologies, the public and the industrial, at the boundary between an industrial and a residential zone. The study extends beyond the flatted factory building incorporating in the site also two rows of terraced factories located behind the flatted factory. Terraced factories are low-rise, single storey factories that are suitable for small businesses requiring ground-floor access. Terraced factories generally have a limited lifespan. The ones in question are due for demolition after serving for over thirty years. The methodology adopted includes the collection of relevant site data to inform the design process; the development of an urban design proposal for the site emphasising land-use optimisation, mixed-use development and preservation of industrial heritage; the consideration of various performance aspects through analysis and simulation, such as structural and daylighting aspects, to inform the investigation and the design exploration process; and, finally, the development of prototypical integrated design solutions, taking into account social, economic, ecological and historical factors, and building materials and construction. In addition to the three design studies, PhD candidate Liu Yuezhong led an energy analysis of the three buildings, both for the existing building and the redesigned building. A comparison of the energy performance before and after is included, although 11

such a comparison has limited value considering both the increase in GPR and the changes in programme. The energy analyses include both the total annual energy consumption and the annual Energy Use Intensity (EUI). EUI is a unit of measurement that describes a building’s energy use relative to its size.5 A building’s EUI is calculated by taking the total energy consumed in one year (measured in kWh) and dividing it by the total floor area of the building. EUI is a useful measure to understand a building’s energy performance with respect to design targets and benchmarks. Energy use intensity is further distinguished by source energy, site energy, end use and utility use. Source energy represents the total amount of raw fuel that is required to operate the building. It incorporates all transmission, delivery and production losses, thereby enabling a complete assessment of energy efficiency in a building. Site energy is the amount of heat and electricity consumed by a building as reflected in a utility bill.5 In terms of environmental impacts, source energy is the most important factor, however, when considering energy efficiency measures, it is important to know which end use consumes the most energy. In this study, it is assumed that district cooling is used for HVAC. District cooling has a conversion factor from source energy to site energy of about 1.056, thus indicating a loss of slightly more than 5%. However, electricity—as used for equipment and lighting—has a conversion factor of about 3.167, thus indicating a loss of over 68%. In addition, BCA offers a listing of (anonymised) annual building energy performance data for commercial buildings in Singapore (data from 2015)6, from which average EUIs can be extracted by building type (Table 1). Commercial building type

Energy Use Intensity

Hotel

275.5 kWh/m2/year

Mixed development

277.3 kWh/m2/year

Office building

233.3 kWh/m2/year

Retail building

370.1 kWh/m2/year

Table 1: Average EUI by commercial building type in Singapore.6 The energy analyses are performed for both the original Typical Meteorological Year (TMY) and an improved TMY. The latter is based on more recent weather data and also takes into account the Urban Heat Island (UHI) effect. Singapore, being situated near the equator, has a typical tropical climate, with abundant rainfall, high and uniform temperatures, and high 12

humidity all year round. Many of its climate variables, such as temperature and relative humidity, do not show large monthto-month variations. However, at the same time, Singapore, as many other cities in the world, suffers from the Urban Heat Island phenomenon. The UHI effect means that an urban area is significantly warmer than its rural surroundings due to the influence of the built environment. The currently available weather dataset used in building simulation software mainly comes from weather stations located at airports or in areas with relatively low urban influence. Therefore, without considering the UHI impact, the current TMY data for evaluating thermal and energy performance of buildings located in Singapore will not be accurate. Neglecting the influence of the neighbouring environment on a building’s energy performance may under­ estimate the average energy consumption of the building.7 In order to test the impact of historical weather data, on the one hand, and more recent weather data with UHI effect, on the other hand, the energy analyses makes use of two sets of weather data, the original TMY and an improved TMY.8

1

http://www.jtc.gov.sg/about-jtc/Pages/default.aspx

2

http://www.jtc.gov.sg/industrial-land-and-space/pages/flatted-factories.aspx

3

https://thelongnwindingroad.wordpress.com/tag/history-of-flatted-factories-in-

4

http://www.sembawangenc.com/landmark-projects-gallery/stack-factories

5

http://sustainabilityworkshop.autodesk.com/

singapore/

6

https://data.gov.sg/dataset/anonymised-building-energy-performance-data

7

Wong, N.H., Steve K.J, Nedyomukti I.S., Yixing C., Norwin H., Haripriya S., Yamini V.M.: 2011, Evaluation of the impact of the surrounding urban morphology on building energy consumption, Solar Energy 85, 57–71.

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Liu, Y.Z., Stouffs, R., Tablada, A., Wong, N.H., and Zhang, J.: 2016, Development of micro-scale weather data on building energy consumption in Singapore, Fourth International Conference on Counter measures to Urban Heat Island (IC2UHI) (eds., N.H. Wong and S.K. Jusuf ), SUB02_FP-0021, 12 pp, School of Design and Environment, National university of Singapore.

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REGEM REGENERATE, RETROFIT, A RAMP-UP FACTORY

BAEY YAN LING FINAL DESIGN PROJECT 2015-16 TUTOR : PROF. RUDI STOUFFS ENERGY ANALYSES ONLY : WU YI’AN ANNIE, LIU YUEZHONG

ABSTRACT This thesis is fundamentally a critique on sustainable models in Singapore. It is a counterproposal to the demolition of one of Singapore’s largest ramp-up factories, one that is designated for demolition in the next master plan. The proposal is to retrofit the building in a regenerative manner that creates positive social, economic and environmental effects that go beyond the boundaries of the building. Singapore’s current model for sustainable buildings is based on the application of technologies and the collection of points, which is problematic for numerous reasons. Namely, this quantitative approach is an oversimplification, resulting in an inability to understand the holistic system in which buildings are to be considered within the systems that they are embedded in. This leads, instead, to a piecemeal approach to creating a

truly sustainable building. This approach also reinforces existing ‘flawed best practices’ rather than innovating and creating a net positive effect. The value of this thesis is its critique on this current way of thinking about sustainable. To be sustainable, is to create positive ripple effects in the multiple systems and to recognise the value of retrofitting. Named Regem, a pun on regenerative and a gem, the project proposes to retrofit a to-be-demolished factory as the new town centre of a new residential area. Using this typology as a case study, one that is potentially phased away in the future, the thesis is a prototype of sorts that can be replicated to other rampup factories in the area. The method of thinking implemented in this thesis, on the other hand, can be used on any project, retrofitted or newly built.

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Preservation of Industrial Heritage

Introduction Green spaces for humans and animals to the current barren space

CULTURAL HERITAGE

Active Participation

CO2 Removal & Oxygen creation Increased Water Security

Pneumatic Waste Sorting System

retrofit

Central Parking

Park spaces Grey Water Processing for Neighbouring Industries

New Type of HDB estate

Organic Waste Collection

Rain Water Harvesting

ENVIRONMENT Algae Desalination

Primary, Secondary & Junior College Education & Public Participation

Algae Animal Feed Producion

SOCIAL

ECONOMIC Export Potental

New hub for Algae Related Research

Research & Development of Algae Desalination

Car & Roads Free

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Shops & Amendities

Bus and LRT Stations

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Increased Convenience for Residents

Centralised Cooling

Synopsis of the program

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Objectives Social impacts In the future 33,000 people will live in the surrounding neigh­ bourhood. A town centre brings much needed accessibility and amenities into this neighbourhood. This includes a bus interchange, shops and a library, in the first phase. The provision of 4,600 car parking spaces utilising the existing ramp and structural loading prevents the building of empty car parking shells, essentially dead spaces. At the same time, this allows for a new type of living in the area, creating a car free zone for the next 500m, corresponding to a comfortable walking distance of 10 min. The iconic ramp of the ramp-up factory transforms into a park on the upper floors, connecting the activities and green strips on both sides of the building, and allowing for people to enjoy the unique spatial experience. Education Regem is also a space to educate people about the new method of desalination and electricity production. Through their daily interactions within the space, as they go about their daily life, they will learn through experience. Educational institutes and polyclinics will be added in the second phase. Phasing allows for the retrofitting to progress at a rate suited for the needs of the community.

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Site model indicating impact on site; grey threads link to other ramp-up factories in the area

Description Text Goes Here

Environmental and economic impacts The creation of a positive environmental effect comes in the form of material preservation and the development of an algae desalination plant. Algae desalination is chosen as method of desalination as it only requires sunlight to desalinate water and has many positive by-products, such as, biofuel that can supply on average 50% of the population needs and a potential output comparable to 4 Tuas desalination plants. Offering experimentation with algae integrated building design, the building provides opportunities for research and development in this field. Algae produced are dried. This bio fuel is subsequently used to power the centralised district cooling. Algae biofuel research can synergise with the greater petrochemical industry already present in the area.

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Overview of Jurong industrial area

Projected development of Jurong industrial area (Government)

Projected development of Jurong industrial area (Self )

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Location of ramp-up factories

Impact of change if ramp-up factories were to sell food and amenities

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Location of ramp-up factories with projected development

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Analyses Pandan Reservoir area Understanding the progression types of the industries present in the area and how these industries may transform or move out in the coming years as more pressing residential needs arise for the same space is crucial. This allows the study to be more focused on retrofitting a building that has actual potential for demolition, rather than a hypothesised one.

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Manufacturing & Engineering

Stage 1: manufacturing and engineering industries move out Ramp-up factoriesLogistic industries Logistic industries

Stage 2: logistic industries move out Petrochemical industries

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Stage 3: shipyards and petrochemical industries are likely to stay

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Surrounding area of 24 Penjuru Road The site identified is in the northeast segment of the Pandan Reservoir district. In the 2015 URA master plan, the site has been rezoned to become a mainly residential district. In the proposed masterplan, the ramp-up factory is no longer industrial, but instead a civic area, while the southern part of the site is a commercial space that can be focused on algae related research and development.

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Residential

Manufacturing & Engineering

Small car or tech workshops

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Current site (left); 2015 URA masterplan (middle); Proposed masterplan (right)

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Floor loading: 20-25 KN/m2 Floor to floor height: 9m Column spacing: 11.4m Driveway width: 12m Building depth: 119m and 99m Total floor area per floor: 51182m2 Total floor area: 255 910m2 Building height: 5 storeys Year of construction: 1990s Building structure: Reinforced concrete Building envelope: Concrete Roof: Corrugated metal Summary of Features of 24 Penjuru Lane (Source: JTC; N. Gomes, 2015, Reuse or tabula rasa? An investigation on the future of ramp-up factories in Jurong West, M.Arch. dissertation, NUS)

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Material Analysis

Corrugated Metal Roo

Corrugated metal roof not applicable for second life

Not applicable for second life

Concrete columns 523 1.1 x 1.1m columns 29.1 km3 of concrete preserved

Concrete columns

523 1.1x1.1x m columns 29.1 Km3 concrete preserved

Concrete facade will be preserved in certain areas

Concrete Facade

Will be preserved in certain portion

Concrete Floor Plates

Concrete floor plates 65.9 Gm3 of concrete preserved

65.9Gm3 concrete preserved

Glass facade of office will be preserved or reused in new development

Glass Facade of Office

Will be preserved or reused in new development

Material analysis of 24 Penjuru Road

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Daylight factor Daylight factor is the ratio of the light level inside a structure to the light level outside the structure. It is defined as: DF = (Ei / Eo) x 100% with levels of 2-5% being the optimal range. The variations in daylight factor are extremely sharp. Large areas near to the openings are overexposed (a band of approximately 20 to 25 m). A small strip of approximately 5 m is in the optimal range. A majority of the building is extremely dark and falls below 2% daylight factor. This is attributed to the deep plan with no external openings on the north, east and west facades.

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Daylight factor analysis on western wing of building

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Annual Energy Consumption (kWh) for a typical floor (original Typical Meteorological Year)

Annual Energy Use Intensity (kWh/m2) for a typical floor (original Typical Meteorological Year)

Annual Energy Consumption (kWh) for a typical floor (improved Typical Meteorological Year)

Annual Energy Use Intensity (kWh/m2) for a typical floor (improved Typical Meteorological Year)

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Energy flow for the entire building (original Typical Meteorological Year)

Energy flow for the entire building (improved Typical Meteorological Year)

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Aerial perspective of Regem

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Material recovered 65.9 Gm3 of concrete can be potentially preserved

Historical and cultural significance Preservation of the largest ramp-up factory, a prominent urban feature of the area; a testament to the industrial history of the area

Imagable town centre The iconic roofscape and ramp allows users to remember the space for both its functionality and unique spatial experience

Increased accessibility With the introduction of a bus interchange, public transportation in the area has never been better

46

Car free living 4,600 lots created

Green areas Without cars, a new type of neighbourhood arises, one that is car free.; this allows for green spaces to be created between all buildings

Desalination With the capacity of 4 Tuas desalination plants, the treated water is able to cater for the needs of people well beyond the neighbourhood

Algae and electricity production The average electricity consumption of 50% of the 33,000 residents needs will be met

Net positive effects of Regem

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Conceptual model

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Upwards view of internal atrium

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Night view from Padan Reservoir

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Physical model

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Physical model

Sectional models

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Annual Energy Consumption (kWh) for a typical floor (original Typical Meteorological Year)

Annual Energy Use Intensity (kWh/m2) for a typical floor (original Typical Meteorological Year)

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Annual Energy Consumption (kWh) for a typical floor (improved Typical Meteorological Year)

Annual Energy Use Intensity (kWh/m2) for a typical floor (improved Typical Meteorological Year)

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Energy flow for the entire building (original Typical Meteorological Year)

Energy flow for the entire building (improved Typical Meteorological Year)

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Comparison of building area of existing and redesigned building

Comparison of building Energy Use Intensity of existing and redesigned building

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Feedback from JTC Clarify the function of the ramp. The bottom 2 floors are for vehicle circulation and parking and the top 2 floors are for human circulation. The top 2 floors act as a connection between both sides of the building; it is also a recreational park. What is the reason for the huge space for the library? The intent is for all surrounding schools to utilise the library. It also provides for a larger public space amidst the other commercial spaces for the public to utilise. A significant amount of the designated library space is actually void space; the large courtyard allows for natural light to enter and improve the interior lighting conditions and comfort. How does the town centre connect to the neighbouring community? The activity strip/plaza on the ground floor with a row of small commercial stores and market spaces makes the building more welcoming for people when they arrive at the bus interchange and taxi drop-off point. Prepare the site plan to show the linkages and connections of the activities/pedestrian flow to the neighbourhood residential areas. Emphasize the integration with the community as a town centre. The design looks like it was designed in isolation. What is the algae roof used for? It is used to produce biofuel. The design proposal includes a research centre. Existing uses for algae are as an ingredient for cosmetics, animal feed, plastics and pharmaceuticals. Are the algae produced on the roof transported out to other relevant sectors? The entire bottom floor (300m2) is designated for the M&E for processing of the algae into biofuel. This area is buffered by the car parking spaces. Basic testbeds for further processing of algae into biofuel are provided for within the building. Explain how the facade works. Water will be drawn up. The wires and plumbing are concealed within the structural components. Spaces are designated for the service pumps. Is the building naturally ventilated? Given Singapore’s weather, most customers would prefer air conditioning. Only the activity strips, the ground floor and the car parking are naturally ventilated. The rest of the mall is air-conditioned. Is there any residential function within the building? No. Are there any existing commercial sectors in the neighbouring estates? There are only small stores, hawker centres and food courts scattered throughout the area. The proposed idea is that as more ramp-up factories become phased out in the future, the design idea can be replicated for these factories. Due to their size, ramp-up factories are suitable and have the most 64

potential as town centres as they can hold many activities. What is the GFA? 500,000m2 (10 floors). As the building is developed in phases, there is a need to rethink how the activities and development are phased. How does the building support the activities when the development is phased? The program would have to be changed accordingly to the developmental phases to be sustainable. Clarify the structure. The existing structural columns as well as the extended structural columns for the roof will support the building.

65

AN INDUSTRIAL URBAN INTERFACE

WILLIAM CHUO FINAL DESIGN PROJECT 2015-16 TUTOR : PROF. RUDI STOUFFS ENERGY ANALYSES ONLY : WU YI’AN ANNIE, ALVIN TAN PAK WEI, LIU YUEZHONG

ABSTRACT This final design project attempts to uncover the potential merits of adaptive reuse of a specific industrial building that has been considered obsolete. In general, industrial buildings that are relatively new (around 20 years old) have little or no architectural merit, which makes adaptive reuse not a very compelling option for redevelopment. As such, despite the fact that adaptive reuse often proves to be more environmentally sustainable, total rebuilding is usually favoured. While there is a positive gain by adapting and reusing any existing building (e.g., lower carbon emissions for the same footprint), design interventions that adopt adaptive reuse strategies are more often than not devised for old buildings with cultural or historical significance and with an emphasis on conservation guidelines. The evaluation of the architectural

merits of such buildings is usually restricted to existing conservation codes. Such guidelines and codes do not exist for the evaluation of most industrial buildings. As such, cost implications and the evaluation of structural integrity of the existing building takes precedence in the context of adaptive reuse. This thesis focuses on these and other issues of sustainable adaptive reuse in industrial architecture.

View from site (industrial)

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Site plan (Source: OneMap)

View from site (residential)

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Northeastern facade

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Northeastern elevation

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Exterior steel staircase

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Southeastern elevation

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New Steel Staircase Up

Proposed 2hr fire rated material (vernaculise) below staircase,landing and all structure support

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CONTRACTOR TO PROVIDE CENTRIFUGUAL FAN 2500 CMH (FM) & W/P ISOLATOR FROM MSB

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1st storey plan

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375 CMH (F.M.) 235 CMH (N.M.)

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Typical floor plan for levels 2-6

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Main programs

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Objectives The building’s adaptive reuse is envisioned to start off with the main anchor tenant, the clean Material Recovery Facility (MRF), which provides the main income and resources stream in support of the growing makers movement. This synergy will foster and attract new start-up companies that share similar visions to set up within the estate. In close proximity to the Clean Tech Industrial Park and industrial zones, SMEs and Green Tech Manufacturing will also find it feasible to take up tenancy within the complex. The architectural intervention must look beyond MRF needs, and encompass all other potential future tenants. Social awareness elements are introduced into the programme via the Recycling Resource Centre, the Visitor Centre and the Resource Market Place to encourage interactions between the public and building tenants. Overall design proposal The fundamental approach to the design is to minimise changes to the existing structure. The existing structural void area presents the optimal opportunity to house the bulk of the MRF conveyor belt and sorting system in which multiple streams can be stacked on top of one another. Equipment allocated within this zone includes sorting machines—applying both gravitational and optical methods. Internal circulation and access pathways are integrated as one system to service the MRF core and tenants. The secondary intervention is to house all the heavy machinery for MRF processing within the west block of the existing building. These machines include the shredder, crusher and cleaning equipment, which require manual supervision. These spaces are housed at levels 3, 4 and 5 so as to free up the premium ground spaces for public interaction. For the tenanted spaces, predetermined areas with double volume spaces are stacked with lower live load spaces located above. This reduces the need to add structural reinforcement to the existing structure. A new access way and driveway are created to provide different circulation routes for different kinds of tenants: the MRF tenant has a dedicated recycling route, factories are served with a loading and unloading driveway, while makers and visitors are provided with their own entrance. Finally, the external components of the MRF, such as the tipping floor and baling station, are located in a faux basement located below the elevated park. The hierarchy of space allocation is based on the needs of 77

each tenant, such as MRF, manufacturing, SMEs, start-ups and finally makers (occupying the residual, though interconnected areas). The makers community, as a symbiotic component of the programme, will have the opportunity to share resources with both the industry tenants and the MRF. They also have the opportunity for knowledge-based interaction in many common spaces within the building.

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Diagram explaining flow of material processing

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Site plan with existing building

Existing structure

BUILDING TYPE ISSUES • • • •



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Max unit size 715 sqm, min 146 sqm Ground floor height 3.18m, insufficient Lack of ameneties Column grid at 6m x 5.1m, inadequate for the new industry demand Floor to floor height 3.18m, inadequate for the new industry purposes No hoist or loading lift provision Designed for single tenant

CHIA PING SITE ANALYSIS (EXTG.) Site Area

12,585,00 sqm

Extg. Planning Data Summary Industry GFA Other Total GFA Plot Ratio Per floor GFA

sqm

19.892.62 716.31 20,608.93 1.64 2944.13

Floor Nos

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Industry GFA Other Total GFA New Plot Ratio New GFA

19.892.62 1321.52 21,214.14 2.5 31462.50

Site details

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Site within URA masterplan

Site within 1 km radius

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LEGEND Accessible green space Inaccessible/private green space Developed building Industrial zone Residential zone Park connector MRT/LRT network

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Site greenery plan

The building site is located at the edge of the Taman Jurong Industrial Zone, which is adjacent to the upcoming Jurong Lakeside Residential District. The industrial buildings within this zone currently house a combination of light and medium industries, with greater emphasis on light industries. The extension of the East West MRT line (with Pioneer station, and Joo Koon station on International Road) and the proposed Jurong Region MRT Line will greatly enhance the accessibility of the region. There are a number of parks within the region but these have limited connection with Jurong Lake and Tengeh Reservoir at either end of International Road. To address the need for an urban interface between the industrial zone and residential zone, this thesis includes the urban context beyond the 1km radius of the subject site to encompass the 7 km length of International Road. The proposed building will be the ‘Seed’ that will transform not just its immediate vicinity, but the Taman Jurong Industrial Zone as well, into a sustainable, green-tech-based industrial area.

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Proposed urban strategy Phase 1: With the main ‘Seed’ building established, a similar typology of buildings can be developed through adaptive reuse along major junctions of the Green-Tech Corridor. These junctions or ‘intermediate nodes’ will each serve different aspects of waste-to-resource management, depending on the nature of the existing industrial waste potential within its 1km radius. Green-tech industries will move in to exploit these resources from these new waste-to-resource platforms. Phase 2: Secondary nodes are expanded along the vertical axis, which incorporate waste collection points that support the intermediate nodes along the Green-Tech Corridor. Phase 3: The secondary nodes in turn create new networks of green-tech industries and continue to establish an ecosystem.

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Phase 1: Interface

Phase 2: Nodes

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Phase 3: Networks

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Type of factories within 1km radius

Type of industry

Number of Factories

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Food

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Metal

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Wood

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Electronics

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Pharmaceutical

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Logistic

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Service

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10 Breakdown of each industry

Type of Waste

Tonnes per Day

Plastic

25.51

Metal

45.93

Wood

10.80

Paper

36.33

E-waste

1.00

Textile Leather

4.66 Summary of waste generated within 1km radius per day

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Residential waste volume (kg per capita) per day

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Industrial waste volume (ton per square km) per type and day

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MODEL EXTG. STRUCTURAL

ANALYZE EXTG. STRUCTURAL MODEL

ESTABLISH ARCHITECTURE PROGRAMME

PRELIMINARY MASSING MODEL

PRELIMINARY STRUCTURAL MODEL

STRUCTURAL MODEL ANALYSIS INCORORATING EXTG STRUCTURE

GENERATE POSSIBLE SOLUTION

EVALUATE BASED ON SUSTAINABLE CRITERIAS

Proposed workflow for structural analysis

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Structural analysis for existing building

Structural analysis with building variations

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Baseline simulation: plot ratio 1.68

Permutations

Plot ratio 2.5

Plot ratio 3.5

Reduction of floor plate by 50%

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Plot ratio 5.0

Plot ratio 3.5

Reduction of floor plate by 75%

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Annual Energy Consumption (kWh) for a typical floor (original Typical Meteorological Year)

Annual Energy Use Intensity (kWh/m2) for a typical floor (original Typical Meteorological Year)

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Annual Energy Consumption (kWh) for a typical floor (improved Typical Meteorological Year)

Annual Energy Use Intensity (kWh/m2) for a typical floor (improved Typical Meteorological Year)

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Energy flow for the entire building (original Typical Meteorological Year)

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Energy flow for the entire building (improved Typical Meteorological Year)

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Makers’ lobby + studio, MRF core from International Road

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Ground floor plan

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Second floor plan

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Longitudinal section

Longitudinal Section

Physical model

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MRF spatial organisation

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Physical model

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Overall strategy

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View of elevated park + MRF core + makers studios, from Corporation Road

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Structural strategy

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View of external MRF system, tipping floor

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Transverse sectional perspective

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Close-up of physical model

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Annual Energy Consumption (kWh) for a typical floor (original Typical Meteorological Year)

Annual Energy Use Intensity (kWh/m2) for a typical floor (original Typical Meteorological Year)

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Energy flow with respect to entire building (original Typical Meteorological Year)

Annual Energy Use Intensity (kWh/m2) for a typical floor (improved Typical Meteorological Year)

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Energy flow for the entire building (original Typical Meteorological Year)

Energy flow for the entire building (improved Typical Meteorological Year)

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Comparison of building area of existing and redesigned building

Comparison of building Energy Use Intensity of existing and redesigned building

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Feedback from JTC Is the elevated park open for public access? Yes. Why is the block (with glass windows) exposed? The block facing the residential area is a public and visitor centre. The interaction between the visitors and the centre happens in this space. Note that only level 3 is the visitor centre; the upper levels are offices for the start-up companies and SMEs. Using techniques such as removing alternate floor slabs, the floor to ceiling height could be increased to about 6-7m, which would allow for rental space. The ultimate aim is to create a mixed-use development. Although the building mainly has an industrial function, the design aims to house corporations, light industries, heavy industries, the MRF and also the makers. Is the waste management limited to plastics only? The initial intent was a holistic material waste recovery system. The recovery system can be tailored to the specifics of the site and surrounding area as the system flow for many material recovery systems are very similar. Looking at the site context, plastic is the most predominant waste; therefore the design is focused on plastics. As for other locations with different predominant waste output, the system can easily be adapted. Based on statistics, plastic recycling has decreased by 1% so focusing on plastics is the preferred choice. Is there any difference in the GFA/plot ratio after removing the slabs? Only alternate slabs are removed. The plot ratio is only 2.1 as the plot ratio was not the main driving point. The design has been addressed in a logical and sustainable manner. Are all the processed wastes used by the makers or will they be exported out? Due to the large amount of plastic waste received, only a small percentage of the recovered material will be used by the makers, most of the recovered materials will be sold as a resource by the material recovery tenants. For the sorting and processing of the waste materials, are there any key infrastructures to be installed in the building? No, it is dependent on capital investments. The sorting process is equipment driven; there are high-tech machines that use lasers to sort multiple objects or simple systems using gravitation with a machine and conveyor belt system. The sorting process occurs in the main (middle) spine including manual sorting of certain items such as PVC. Further processing (crushing and recovery) will occur in the other block (heavy industrial area). What are the red elements in the model? The red elements are playful interpretations that create interaction between the makers and the public. It aims to create a concept of factory-in-apark in order to appeal to the public (residents) to draw them 122

to the site. The participation of the public as well as the makers is important in the scheme, without them the scheme would just be a material recovery site. It would be a better idea to create a synergy between the various parties—the people recycling the materials, the makers who will utilise the recycled materials to create new products and the consumers. This would then create more vibrancy in the system. The original intent was to create a closed loop, self-sustaining system. The plaza area is proposed to be a market space for the makers to sell their products. However, the amount of plastic waste is too large. In a 1km radius, the amount of plastic waste amounts to 25 tonnes a day using NEA calculation, as well as a rough estimation of plastic wastes from the industrial area. The percentage that would be used by the makers—conversion into 3D printing materials—would only be about 10-15%. Effectively only 2/3 of the waste material will be recovered; even so, the volume will still be too big for the makers to use. Therefore, most of the recovered materials will have to be sold. How can the elevated park integrate into the park connector? The park would act as a node within an area that has few, scattered green spaces and the Jurong Lake. The idea is that the park would be a green-tech corridor connecting to the Tengeh reservoir area. The design hopes to be replicable to the other industrial buildings for adaptive reuse within the bigger context. As the design is still mainly industrial, there could be possible noise and smell, how would these issues be addressed considering the space is open for the public. Firstly on the smell, instead of a holistic approach where wet, organic wastes are also included, the idea is to focus on a clean material recovery, thus there would not be an issue of smell. Next on noise, the layout of the building is such that the office areas are separated from the heavy industrial zones. The middle spine acts as a separation between the corporates and the heavy industries. There was no thorough consideration on noise and acoustics within a stronger focus on spatial arrangements. What is the retail quantum, the amount of retail space? The idea is to let the makers grow organically. The makers start off from the spine. The spaces are designed with a modular system where there is potential for the makers to expand when needed. There are also more spaces on the rooftop, the spine as well as the ground for expansion when market demands increase.

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A COMMUNITY FACTORY MAKING CONNECTIONS

ONG KAI LIANG FINAL DESIGN PROJECT 2015-16 TUTOR : PROF. RUDI STOUFFS ENERGY ANALYSES ONLY : BEK TAI KENG, WU YI’AN ANNIE, LIU YUEZHONG

ABSTRACT This thesis explores the opportunities of a public-industrial typology located at this unique site at the boundary between an industrial zone and a residential zone. A new relation is explored here, the opportunity of community involvement in the industrial sector in the form of integrated spaces between two distinct typologies, the public and the industrial. The site at Kolam Ayer industrial estate has many terraced factories that are due for demolition after serving for 30 plus years. What can be done on this site other than continue to build larger factories? This thesis rethinks the future of manufacturing in Singapore.

Built in the 1980s, Kolam Ayer industrial estate was developed based on the economic needs of Singapore at the time, establishing manufacturing as the biggest economic sector surpassing trade. 35 years later, these factories’ leases have ended and they now stand to face demolition for bigger projects. Traditional manufacturing industries are now in a decline; over the years the industry has shifted towards higher skilled manufacturing processes that require different types of space and facilities. Now that these old factories must find a new life or be demolished to make way for new ones, it’s perhaps time to consider the aspect of social values in industrialisation. This thesis aims to create a new ecosystem of makerspaces that would suit the needs of current Singapore.

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Site plan

View from Aljunied Road (Source: JTC)

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View from Aljunied Road (Source: JTC)

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First floor plan

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Interior views

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Diagram about the players in a maker’s ecosystem

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Objectives In today’s society, Singapore needs to find itself a new competitive edge to distinguish itself from the competitors. Besides adding value for multinational companies, we need to grow our local enterprises and, fortunately, there is an increasing number of Singaporeans creating start-ups, due to government incentives and schemes to help them financially and provide guidance. More Singaporeans have the option to try out what they want to do with their lives; it is a luxury of a first world society to have the opportunity to explore interests and passion freely. The mentality of Singaporeans are shifting, we are taking more risk despite the “kiasi” attitude, which is still prevalent in our society today. However, we still need to be braver in taking risk to startup and innovate. We have the right infrastructure in Singapore to create an ideal place for people to start their businesses and now all we need are the local entrepreneurs. Makerspace is the ideal program for this site as it has both the aspect of the public and the industrial. In essence, the concept of makerspace is beyond a workshop with some tools, it embodies the idea of sharing, community, education, innovation and risk taking which is crucial for fostering local entrepreneurs in Singapore. As much as this thesis is about the future of Singapore’s economy, it is also about the society. The social aspect of the makerspace builds relations between friends, families and future business partners. The architecture lies between the negotiation of different groups of public and industrial domains interacting thereby creating a new working/ shopping/learning experience.

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Aerial perspective view of site

Key characteristics The site is located at the corner of an industrial zone (Kolam Ayer industrial estate) and opposite a residential zone. It is easily accessible from public transport with 2 major bus stops in the area within close proximity to the site. The site is located next to a main artery road (Aljunied Road), which suggests high visibility from car drivers. Car parks are only available within the residential area and users may have to walk some distance before reaching the site hence making it slightly inaccessible for car owners. Although located right by a park connector and the Pelton canal, the area lacks recreational space. 134

Context within the park connector network

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Public transportation within 500m radius

Institutions within the area

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Recreational spaces within the area

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Vehicular access to the site

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Annual Energy Consumption (kWh) for a typical floor (original Typical Meteorological Year)

Annual Energy Use Intensity (kWh/m2) for a typical floor (original Typical Meteorological Year)

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Annual Energy Consumption (kWh) for a typical floor (improved Typical Meteorological Year)

Annual Energy Use Intensity (kWh/m2) for a typical floor (improved Typical Meteorological Year)

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Energy flow for the entire building (original Typical Meteorological Year)

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Energy flow for the entire building (improved Typical Meteorological Year)

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Axonometric drawing

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Overall ground floor plan

View of event space from park connector route

View of internal courtyard and elevated streets

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Sectional perspective

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Physical model

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Close-up of physical model

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Floor plan of level 1 (commercial sector)

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Close-up of physical model

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Different programme types

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Adaptive reuse of existing factory

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Interior views of makerspace

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Physical model

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Annual Energy Consumption (kWh) for a typical floor (original Typical Meteorological Year)

Annual Energy Use Intensity (kWh/m2) for a typical floor (original Typical Meteorological Year)

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Annual Energy Consumption (kWh) for a typical floor (improved Typical Meteorological Year)

Annual Energy Use Intensity (kWh/m2) for a typical floor (improved Typical Meteorological Year)

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Energy flow for the entire building (original Typical Meteorological Year)

Energy flow for the entire building (improved Typical Meteorological Year)

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Comparison of building area of existing and redesigned building

Comparison of building Energy Use Intensity of existing and redesigned building

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Feedback from JTC Are there any carparks? Only some carparks are provided at the back as well as along the road. The site is very accessible; it is along the park connector and there are 2 MRT stations and 2 bus stops nearby. The neighbouring HDB carparks can also be utilised. Is the elevated walkway purely for connection purposes? No, it is not only for circulation purposes. It is more of an exploratory path similar to that of a park. The idea is to bring the public space to the ground level as the site is connected to the park connector. Each individual factory is connected to the ground by the elevated walkway, providing accessibility. The elevated walkway also provides opportunities for rooftop spaces. For example, for F&B services, the rooftop can be an alfresco dining area. If the ground floor is already well connected, is there a need for the large network of elevated corridors? The elevated corridors provide an additional domain at a higher level to create an intricate network. Users can also see what is happening downstairs; this adds vibrancy to the space. There are different movements across the space and this could induce people to go up to the higher level factory units. Regarding the construction sequence—intervening on the existing typology. There were no thorough considerations regarding the construction. There is a large gap in between the existing terraced factories of 12m. Demolition can easily be done as the gap would be large enough to accommodate the piles. However the issue is on how to produce the structures above. There was criticism on the scheme that the piles were too close to the existing building. However, there are existing cases building similarly close to existing buildings, therefore, the scheme could hold potential. Is the design a phased development? Most of the tenants have moved out and the factories are due for demolition. The proposal is to demolish some to create the axes and add additional blocks to increase the plot ratio. The existing plot ratio was 0.9 and the current allowance is 2.6. The proposed structure will add up to about 2.5. Although it is not fully maximised, there is potential to increase to 2.6. What is the designated commercial space per floor? The distributions of the various sized offices are of similar percentages to encourage interactions within the different groups. The sizes of big offices are 1250m2, medium ones are 1100m2 and the smallest ones are 1050m2 per level. This amounts to 7655m2 of office spaces per floor. The common outdoor spaces make up 57%, which includes walking spaces, meeting rooms, lecture rooms and work spots. Retail and workshop areas are about 17000m2 for 162

3 levels. The total area is about 63000m2. How many units can the structure house? There are 45 small offices, 11 medium offices and 5 big offices per level. Is there a loading and unloading space? The driveway to each unit serves as loading and unloading space. What is the reason for the size? Initially, the plot ratio was the consideration. However the idea was to prove that the scheme is scalable and replicable for all the low-rise terraced industrial buildings. What is the intention of the particular shape and orientation? The shape was created such that there is a visibility of the new intervention to draw crowds into the building.

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CONCLUSION

This book presents design research targeting sustainable, adaptive reuse of industrial structures in Singapore. The three student projects illustrated in this book each redesign a different industrial building and with a different focus, respectively, regenerative design as a town centre, closing loops within an industrial urban interface, and the design of a community factory. At the same time, all three case studies take into account social, economic, ecological and historical factors, including user requirements, land-use optimisation, environmental sustainability, and preservation of industrial heritage, next to building construction. Reflecting on the Singapore context, the three studies share specific characteristics. Firstly, adaptive reuse of these industrial buildings is not mainly prescribed from a heritage value point of view but, rather, from an economic and sustainability point of view. Secondly, except for one, these buildings are locked into an industrial zone and thus must retain their (light) industrial function. At the same time, they are located near—across from— residential neighbourhoods and thus the industrial-residential interface requires special attention. Thirdly, Gross Plot Ratio allowances for these sites are an important design target from an economic point of view; one that is not commonly maximised in the existing building due to planning allowances changing over time. Building upon an analysis of relevant site data, each design study proposes an urban design for the site emphasising land-use optimisation, mixed-use development and preservation of industrial heritage. Informed by analysis and simulation of varying performance aspects, each study leads to a prototypical integrated design solution. Finally, energy analyses for both the existing buildings and the redesigned buildings, considering micro-scale weather data with Urban Heat Island effect, offers some, if limited, insights into energy consumption of industrial buildings in Singapore. 165

CREDITS

BOOK DESIGN : BAEY YAN LING, TULIKA AGRAWAL, PRASANJEET BISWAS COVER PAGE IMAGE : BAEY YAN LING SPONSOR : NUS-JTC I3 CENTRE

Regem: Regenerate, Retrofit, a Ramp-up Factory Design: Baey Yan Ling Tutor : Rudi Stouffs Final Design Project, Master of Architecture, 2015-2016

An Industrial Urban Interface Design: William Chuo Tutor : Rudi Stouffs Final Design Project, Master of Architecture, 2015-2016 A Community Factory: Making Connections Design: Ong Kai Liang Tutor : Rudi Stouffs Final Design Project, Master of Architecture, 2015-2016 Energy Analyses Liu Yuezhong, Wu Yi’An Annie, Bek Tai Keng, Alvin Tan Pak Wei 167