MASS PRODUCED BUILDING SYSTEM FOR UNSKILLED LABOR

By:

Angelo Petrozzelli, Boston Architectural Center,

Certificate of Architecture, 1966

A THESIS SUBMITTED IN PARTIAL FULFILLMENT

OF THE REQUIREMENT FOR THE

DEGREE OF MASTER OF ARCHITECTURE

AT THE MASSACHUSETTS INSTITUTE OF TECHNOLOGY

June 1972

Department of Architecture, May 12, 1972

esis Superv 6r

Chairmnan, Depar aent Oominittee OnGrad e Students

Rotch

JUN 27 1972

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405 Saratoga StreetEast Boston, Massachusetts 02128

May 12, 1972

Dean William PorterSchool of Architecture and. PlanningMassachusetts Institute of Technology77 Massachusetts AvenueCambridge, Massachusetts

Dear Dean Porter:

In partial fulfillment of the requirements for the degree ofMaster in Architecture, I hereby submit this thesis entitled."Mass Prod.uced. Build ing System For Unskilled. Labor".

Respectfully yours,

Angelo Petrozzelli

Enclosure

ABST RACT

A Strategy For Developing A Mass Produced Building System ForUnskilled Labor

by Angelo Petrozzelli

Submitted. to the Department of Architecture on May 12, 1972 inpartial fulfillment of the requirements for the Degree ofMaster of Architecture.

It should. be noted that this thesis is a continuation of an.earlier submission by the office of Imre and Anthony Halasz,Inc. and. various other participants. This submission was partof the H.U.D. Operation Breakthrough Program RFP No. H-55-69.

The reason for selecting the development of a mass producedbuild.ing system for unskilled. labor is my reaction to presentlyavailable housing systems that by their size and. complexitycreate a physical and human strait jacket Ill suited. to userparticipation in any stage of its development or existence.This thesis prepares the ground. work for a building systemsympathetic to this need and applicable in the immediatefuture at minimal cost.

It is the hope that this thesis will stimulate a research pro-gram to d.evelop a full-scale model to test and. improve thesystem.

The illustrations shown in the text deal with housing, butthe system is not limited to this use. It seems to adaptwell to other building types with similar clearance and spanrequirements.

Thesis Supervisor: John SteffianAssociate Professor of Architecture

iI

ACKNOWLEDGEMENTS

I wish to express my deepest gratitud.e to Professor John

Steff ian and Professor Waclaw Zalewski for their unselfish

participation during this study for my graduate work, and I

wish to include in my thanks the many faculty members and staff

of the Department of Architecture.

I wish to thank my associates within the staff of the archi-

tectural office of Imre and Anthony Halasz, Inc. especially

Imre and. Anthony Halasz for giving me the opportunity to com-

plete my work at the institute and for their contributions to

my academic enrichment. I also wish to thank them for the

personal relationship which has developed not only during this

experience, but also within the last five years since I have

known them.

My gratitude extends to Mr. Frank Ransome of the Wheeling Steel

Corporation, and Mr. Kenneth Sisson of American Architectural

Iron, for help in obtaining the structural members and universal

connection development.

Finally, my deepest gratitude to the members of my immediate

family, especially my parents, for understanding and unfailing

support over the number of years it has taken me to complete my

education. Without their support I do not know what I would have

done. I also wish to thank my personal friends who have

encouraged me to continue with my studies.

III

TABLE OF CONTENTS

TITLE PAGE

ABSTRACT 11

ACKNOWLEDGEMENTS 111

TABLE OF CONTENTS iv

PART 1: GOALS AND DESCRIPTION OF THE SYSTEM

a. General

b. Architectural

c. Structural

d. Interior Work

e. Mechanical, Electrical

f. Foundations

PART 2: SYSTEM ADAPTABILITY 10

a. Housing Types and Scope

b. Climatic Areas

c. Geology and. Soils

d. Site Topography

e. Site Size

f. Site Situations

g. Changes

h. Regional Application

PART 3: SYSTEMS COMPONENTS 15(Introduction of system as related. to housing)

iv

PART 4: MODULAR STUDIES (System Applications) 33

a. General Site Matrix

b. Diagrammatic Layout of Housing Matrix

PART 5: DIAGRAMMATIC EXAMPLES OF HOUSING TYPES 39

a. Row House using a 20'-0" Matrix

b. Row House using a 32'-0" Matrix

c. Townhouse

PART 6: PHOTOGRAPHS OF MODEL 75

PART 7: BIBLIOGRAPHY 80

PART 8: MECHANICAL SYSTEM DIAGRAMS 63

V

GOALS AND DESCRIPTION

OF THE SYSTEM~ -l1-

A. BUILDING SYSTEM CONCEPT

1. GOALS AND DESCRIPTION OF THE SYSTEM

a. General

The basic rationale underlying the concept of this

proposed building system-is that the system should

not only fulfill the needs for shelter but also

should. become a source of employment, primarily for

the unskilled of our society. The essential feature

of this system is simplicity, based on the following

objectives and solutions.

1. Participation by the unskilled or semi-skilled

members of society, who would be able to

erect, and maintain the system with minimal

training and. supervision.

ii. Minimal capital investment for production and

construction so as to allow immediate applica-

tion in any volume, anywhere and throughout

the country.

iii. The use of available commercial products in

order to minimize new building components. A

few of the system components may be especially

fabricated., but the parts will be standard.

It is hoped that these components will be

stocked in local outlets.

-2-

iv. Shop fabrications should be done with minimum

investment on the part of the supplier. Fab-

rication of some of the components may be

accomplished on the site at first in order to

keep investment to a minimum.

V. The components shall be of a size and weight

that can be handled. manually by two people.

This will result in modest spans and small

components. Small component size will allow

greater individual freedom for different

assemblies and will allow the system to be

adapted to a wide variety of needs.

vi. Simple mechanically fastened joints are

intended for the entire system without using

special equipment and skilled. labor.

vii. A universal joint is proposed. at all inter-

sections of structural members.

viii. The system will expand or contract in every

direction due to the use of the universal

joint. Change and. growth can occur without

disruption of the finished spaces already

occupied..

viiii. The system will take advantage of readily

available components from other systems that

are practical and usable.

-3-

x. High standards of quality, low cost, easy

adaptability to individual preferences, com-

bined with the consumer's possible involve-

ment in the production and marketing process,

should assure his acceptance and identifica-

tion with the housing product.

Following this logic the system consists of a

series of independent structural frames with

replaceable infill panels that constitute all

finished surfaces. Prefabricated mechanical units

will form an integral part of the system.

b. Architectural

The architectural character of the system.

i. Additivity

One of the chief dangers generated by pre-

fabricated and preassembled. industrial systems

is that they often eliminate flexibility.

This system, both in the relationships of its

components to each other and in the components

themselves, is based on the principle of

additive flexibility. The resulting environ-

ment, be it an individual house or a complex

settlement, can be molded. and. articulated

according to specific need.s and human desires

rather than forced. into an imposing precon-

ceived industrial strait jacket.

11. Component Parts

The principle of additivity is maintained by

the relatively small size of the basic floor

and wall panels between the structural frames.

Since the assembly of the components is

designed for the utmost simplicity, the

number of joints does not adversely in-

fluence cost. However, by virtue of modest

spans, small components, and. great individual

freedom of different assemblies the system

can adapt itself to a wide variety of needs.

Old. systems based on large component parts

often offended. our sense of human dignity

by limiting additive modulation. The selec-

tion of the smallest component parts, readily

available through the regular channels of

the construction industry has its advantages

not only in cost, easy handling, self-help,

etc., but chiefly in that the small compon-

ent parts enable the user to contribute to

the form of his environment, exercise choice

and initiative, and. thus restore his pride in

his place of living because he can adapt the

system to his specific needs and requirements.

-5-

ii1. Diversity

Since the system consists of relatively small

components and. a very large degree of addi-

tive flexibility, it can adapt itself to

different housing densities, site conditions,

and. individual needs. Since the wall panels

are designed for additive flexibility, they

can adapt to different climatic conditions,

as well as various zoning and building code

requirements.

The main test of every contemporary system

is its behaviors in terms of change and

growth. The proposal allows change and

growth on different levels.

It can most easily expand. in every direction

by virtue of the universal joint.

It permits the alteration of the standards

of housing units themselves, even in higher

d.ensities, by exchanging components without

interfering with the rest of the units.

Since the proposal d.oes not concern itself

with a building as a product, but with an

additive process it will change itself through

field experience, demand., research and human

ingenuity.

-6-

The ease of assembly implies the ease of

dismounting. Change and growth demands

addition as well as removal of parts in

relation to the whole, without disruption.

c. Structural

1. Low-rise Construction

The basic structure consists of a light

gauge metal frames and infill panels that

form all finished surfaces.

A prefabricated "universal" joint piece,

which is placed at every intersection be-

tween frame members, allows simple attach-

ment of column and. beam units. No element

exceeds 150 pound.s in weight. All frame

connections in the field are by high tensile

bolts. Details are such that while all the

frame parts will be prefabricated in a shop,

all assembly will be handled. by unskilled

labor, without any hoisting equipment.

All panels, for floors, exterior and interior

walls and. partitions, are of standard manufac-

ture and are set into the frames by simple

connections. The use of advanced. fastening

devices is contemplated to assure easy, rapid

and safe assembly. Fairly large tolerances

O-7-

are employed to avoid the need for exacting

precision.

The frame structure is designed to withstand

all vertical loading and the effects of wind.

or earthquake forces.

ii. High-rise Construction

The system is adaptable to any building

height with the provision that it becomes a

subsystem in a megastructure whenever it ex-

ceeds four stories. In such a case a basic

concrete frame, consisting of columns, core

walls and. floor slabs at four-story intervals

will be constructed. The structure serves as

a four-hour fire barrier, both in vertical

and. horizontal planes, in addition to its

load bearing function. The low-rise light

gauge steel frames and infill panels will

be plugged into the megastructure, with pro-

visions for fire protection.

While the megastructure will demand skilled.

labor, all the infill structure will be

manufactured and. assembled exactly as the

low-rise units.

d. Interior Work

Prefabricated assemblies of stairs, cabinets,

-8-

partitions and closets are introduced into the

system, at a wide variety of possible modular

applications, allowing any pattern of growth and.

change,

e. Mechanical, Electrical

The general approach, here as well as in the struc-

ture, is based on the following premises:

i. Simple mechanical installation by unskilled

labor.

ii. Individual control of the mechanical system

in each dwelling and independence from

occupants of other units.

iii. Possibility to change, remove or upgrade the

mechanical installations.

A suggested outline specification has been developed

for some housing units investigated. These are

included in the Appendix.

f. Foundations

The system is designed to be supported at discrete

points, the cases of the frames. As such, it is

applicable to practically any soil condition. The

flexibility of the steel frames and the tolerances

between infill panels make the system relatively

insensitive to minor differential settlements of

the supports.

-9-

SYSTEM ADAPTABILITY-10-

2. SYSTEM ADAPTABILITY

a. Housing Types and Scope

The proposed system will allow maximum freedom of

choice and degree of self-participation at densities

up to 15 units per acre. At these densities the

capacity for growth and change can be employed to

a very large extent. Simple family detached or

attached homes can expand in all directions in

small or large increments by the use of building

components (stair, mechanical unit) and by use of

columns, universal joints and panels.

The limit of the proposal serving as a primary

system is in the range of 40 dwelling units/acre.

The accompanying illustration assumes the following

restraints:

100% parking

on-grade parking

limited walking distance from car to units

walk-up with maximum two flights of stairs

emergency and service traffic only within

the residential matrix

no more than four stories (possible duplex

on top)

Residential densities higher than 40 u/a will

adapt the proposed components as infill or

-11-

secondary systems. These densities will change

the rationale of parking relationships and circu-

lation considerations in general.

The attached. site application addresses itself

to the upper limits of the system in terms of

its residential densities as demonstrated in the

general site matrix. This type of site utiliza-

tion is a long neglected. prototype for urban

housing.

The well known later d.ay prototypes in the lower

and upper extremes of urban residential densities

did. not fulfill the aspirations and promises of

their urbanistic conception. Not only did they

stereotype their architectural presence but a non-

compromising social segregation followed.. The

careful study and revitalization of middle density

housing is most timely and necessary. The proposed

system is best suited. to such middle density appli-

cations while still effective in all other types

of residential development.

b. Climatic Areas

No restriction.

Steel frame is designed to resist any specified hori-

zontal and vertical load. Infill construction is

such that any insulation value is attained by using

an appropriate insulating blanket.

-12-

c. Geology and. Soils

The system is usable on soils with poor natural

drainage and unstable soils, d.ue to the relative

flexibility of the structure which is capable of

adjusting to differential settlements without

excessive stress. All infill panels allow minor

distortion without damage to them.

d. Site Topography

At sloping sites footings with piers of adjustable

length will allow the use of the system both in

the same form as on flat sites as well as with

the introduction of partial lower levels.

e. Site Size

The system is adaptable to any site size.

f. Site Situations

The basic concept of the system, its simplicity

in the use of unskilled. labor and finished light

materials that are available anywhere, renders it

applicable to any site situation and. basically

independent of local labor and material supplies.

The presence of existing or removable structures

d.oes not restrict the applicability of the system,

g. Changes

All components are removable or can be added on,

as desired.. Thus the standard. of surface finishes,

cabinets, etc. can be improved at any time by

simple exchange of panels. Expansion and re-

arrangement are handled. similarly. In many cases

the frame may be erected. at the time of construc-

tion, to serve as porch or terrace, and. later en-

closed by snapping the finished panels into the

frames.

h. Regional Applications

No restriction.

-14-

SYSTEM COMPONENTS-15-

PREFABRICATEDFLOOR PANEL

-'7

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BEAMS

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TYPE: B

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ELEVATION OF UNIVERSAL CONNECTOR: TYPE A

I2GA.JOISTHANGER

COLUMN

SLEEVE

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COLUMN

JOIST HANGER

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PLAN OF UNIVERSAL CONNECTOR: TYPE A0 1 2

I

;D

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SECTION AT TYPICAL INTERIOR JOINT

6-COLUMN

0 1 2id"LJ."""""

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PLAN OF TYPICAL INTERIOR JOINT0 1 2W"6.rmm7

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BUILDINGPAPERPREFABRICATED

t-R PANEL

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PLAN OF TYPICAL INTERIOR JOINT

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PLANS OF UNIVERSAL CANTILEVER CONNECTOR JOINT TYPE: B

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L 2SIDE ELEVATION-TYPE B CONNECTOR END ELEVATION 0 1 2

EXANSION

MINIMUM UNIT 2 1 BEDROOM UNIT

SELECTIVESEXPANSION

VERTICAL3 3 BEDROOM UNIT 4

3 BEDROOM UNITADAPTED TO SLOPING SITE

STRUCTURAL ADAPTABILITY

1

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FLOOR PLANS %A

SYSTEM APPLICATION-.33-

0O

Proposed system primary

Max. possibility for self-help

Adaptability and change And

growth for each Living Unit

Proposed System Primary

Establishes a Range of

possibilities for self-help,Adaptability and change and

growth for each Living Unit

Proposed System subsystem of

'Structural Matrix. Limited

possibility for self-help-Adaptability and change and

growth,for each living unit

1-2 stories .detached

1-3 stories attached

3-4 stories attached

High Density4;r0

Construction Cost ($/L.U.)

Environmental Cost (S/L.U.)

- -.-.--I -o -

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SYSTEM APPLICATION DIAGRAM

r__

SYSTEM APPLICATION DIAGRAM

This diagram is a generalized illustration of the relationship

between cost and type of housing development. Housing is

divided into three categories in terms of number of living units

per acre. These categories and. the implications of the pro-

posed structural system for each category have already been

discussed.

The solid-line curve in the diagram represents the relation-

ship between construction cost and density of housing. The

dashed-line curve represents the relationship between environ-

mental cost and intensity of land use, i.e., the environmental

factors, or costs, necessary to develop a socially and economi-

cally successful community. The underlying assumption is that

the success of a housing development depends not only on the

comforts provided by the living unit itself, but also on the

services available to the community. These services range from

utilities, open spaces, parks and recreation areas, schools,

shopping centers, community centers, transportation networks,

etc. to more abstract benefits which determine the quality of

socio-economic life. Based on past experience with housing

types and community development, it is assumed that the cost

per living unit of these supporting services decreases as the

intensity of land use, hence the sharing of facilities by larger

numbers of living units, increases.

-35-

However, this relationship is not directly proportional. The

diagram indicates that the benefits of increasing land use

intensity grow in smaller increments as increasingly high

densities are reached.

These considerations led to the selection of the 15-40 living

units per acre density as the area of intensive study; (the

shaded area in diagram). This type of housing was selected

because it represents the low to medium range in terms of

construction cost and promises better environmental benefits

with increasing land. use intensity.

The 15-40 living units per acre d.ensity was selected for

intensive study because it appears to be more economical

in terms of construction cost and of environmental cost, and

also offers a desirable range of possibilities for self-help,

adaptability, and change and. growth for each living unit.

The proposed construction system may be used to develop a

wide range of site plans at a density of 15-40 living units

per acre. The "General Site Matrix" and the "Diagrammatic

Layout of Housing Matrix" illustrates a possible application

of this system.

-36-

LiLLLIfltI LLLLLL ~LIfl~114~41ILi~i1i~1

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- _ _- _ _.- -- ..-.. _ _ - -- ix - jL

167Com Com CO 0

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f tel sh

el sch.j1K~-~It

GENERAL SITE MATRIX

POSSIBLE CENTRALPEDESTRIAN ROUTE

TO COMMUNITY FACILITIES

PARKINGFEEDERROAD

PARKING

PEDESTRIAN

OCCASIONALSERVICE ACCESS

PLANTEDSPACES

BETWEEN

BUILDINGS

THIS DIMENSIONEXPANDS WITHINCREASE INHOUSING UNITS

THIS DIMENSION IS DETERMINEDBY QPTIMUM WALKING DISTANCE

THIS DiMENSIONEXPANDS WITHINCREASE INHOUSING UNItS

DIAGRAMMATIC LAYOUT OF HOUSING MATRIX

PARKINGFEEDERROAD

DIAGRAMATIC EXAMPLES OF HOUSING

TYPES: 20'-O"MODULE UNITS-39-

IB

V EXP

(.EXPI-

POSSIBLE FAMILY GROUPINGS20' UNIT MATRIX

-7

i~~1

IB B IB 2B 3B

3B2B IBE

EFFICIENCY APARTMENT ,

ONE BEDROOM APARTMENT

~TWO BEDROOM APARTMENT

THREE BEDROOM APARTMENT

CLOSET

[SHADED AREAS INDICATE POTENTIAL

EFABRICATED COMPONENTS

LEGEND

E

1B

2B

3B

C

io

.8/1-9

.9

.9 ,~I

--

-~-.

-~-

-

--

-. -.

--

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-I-074

I-=0

119IZ

V1,9i

04

U.

E&1B FLOOR PLANS

,7(C4

'0sk -

I-0..J

2B&3B FLOOR PLANS

2B -Jt V

I B

E

SECTION 3 STORY

3B

2B

IB

E

SECTION -4 STOR Y

DIAGRAMATIC EXAMPLES OF HOUSING

TYPES: 32a-O''-MODULE UNITS-48.

SPACE STANDARDS

It is suggested that another method. of reducing costs in

housing units is by examining present-day space standards.

Significant savings in low-cost housing can be achieved by

a reasonable reduction in these standards. The following

plans are based on English space standards currently

recommended as minimum standards.

IB 2B

EXP EXP

--

L1

E E IB IB IB 2B

EXP EXP

POSSIBLE FAMILY GROUPINGS32' UNIT MATRIX

L

E 3BEIB

60412@ 6 B' 6ON

-440

4

STRUCTURAL LAYOUT

6,4z121T1

1---tas

LIV.-DIN. LIV.-DIN -SL.

K K

BR. STOR.

1B&E FLOOR PLANS

I 2

STRUCTURAL LAYOUT

44'I,

4'

t4

4

C~4

4,

c~4

-4 -.4

--- iv-~7C

4'

1B&2B FLOOR PLANS

E&3B FLOOR PLANS

2B-IB -

IB-28

E-IBCINSO

SECTION 3 STORY

E-3B

IB-2B

IB-E

E

SECTION 4 STORY

DIAGRAMATIC EXAMPLES

TYPES:

OF HOUSING

TOWNHOUSE MODULE UNITS-58-

1ST FL.

SECTION

ii-

2 ND FL.

2B

1ST FL.

SECTION

2 NDFL.

2B

1ST FL.

SECTION 3B

2 ND FL .

1STFL. 2 ND FL.

SECTION 3B

APPENDIX 1

MECHANICAL SYSTEMS DEVELOPED

FOR ILLUSTRATED HOUSE TYPES

HEATING

PLUMBINGELECTRICAL

PLUMBING

The basic design of plumbing is in accordance with the

"Recommended Minimum Requirements For Plumbing" (Hoover

Report) as published by the United States Department of

Commerce. Consequently, all sanitary piping is not only

inexpensive, but, as can be observed by inspection of the

drawings, also lends itself in its simplicity to installa-

tion by unskilled labor. In single family isolated units,

and where there is no incentive towards inclusion of hot

water, individual hot water heaters are installed in each

unit. Hot water heaters may be gas or electric as dictated

by fuel and energy costs at each specific location. Where

rent inclusion of hot water is permitted in multiple

occupancy units, further economies can be realized by pro-

viding one hot water heater per building in lieu of one

hot water heater per dwelling unit. Piping materials can be

ferrous, nonferrous metal, or synthetic as indicated at each

location by availability, adaptability, acceptance, and cost.

HEATING AND VENTILATION

Heating of each apartment is accomplished by a warm air

furnace located in each unit and discharging directly into

a ceiling plenum. The plenum is fabricated under the general

construction, thus avoiding sheet metal work. The system can

utilize fossil fuel or electricity as a source of heat as

dictated by economic analysis at each location. The system

requires no skilled labor to assemble in the field. Techni-

cians are required only during initial firing where fossil

fuels are incorporated. and. not at all where electric heat is

utilized. Each apartment will have its own thermostatic control.

Interior bathrooms are exhausted. through shafts constructed. in

the general construction and topped by wind-driven turbine

exhausters. Interior stairways are also similarly ventilated.

bymeans of wind-driven turbines at the top of the staircase.

Both.avoid expensive wiring, fans, and. maintenance. Accordingly,

installation of the heating system consists primarily of

setting a single factory assembled warm air heating unit in

place. Sheet metal duct work is almost non-existent. The

heating system lends itself readily to rent inclusion of hot

water or to individual metering as may be desired. It also

lend-s itself to future installation of mechanical cooling.

-65-

ELECTRICAL

All wiring conforms to the requirements of the National

Electrical Code. Individual fuse boxes in each apartment

permit convenient servicing of the system by each tenant

as well as individual or master metering of electrical

consumption. Cooking can be electric or gas. Branch

wiring is inexpensive aluminum not metallic sheathed cable.

Telephone system can be readily prewired in the construction.

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PHOTOGRAPHS OF MODELS-75-

I

e- -- - - -

-BIBLIOGRAPHY-80-

BIBLIOGRAPHY

Thomas Schmid/Carlo Testa, SystemsBuild.ing--An International

Survey of Methods, Frederick A. Praeger Publishing Company, 1969.

"Aesthetics and. Technology of Preassembly", Progressive

Architecture, October 1964.

"Metals Review", Progressive Architecture, October 1969.

Don Raney and Suzanne Stephens, "Operation Breakthrough--Opera-

tion P/R", Progressive Architecture, Pagesl20-137, April 1970.

Wells and Koetter, "Modular Housing System", Progressive

Architecture, Pages 86-87, January 1971.

Helmot E. Schultz, "Structure for Change and Growth", The

Architectural Forum, Pages 60-63, March 1971.

Special Issue on Build.ing Subsystems, Building Design and

Construction, September 1971.

"Building Systems", Engineering New Record, McGraw-Hill Pub-

lishing Company, October 22, 1970.

"Housing Systems Propoposals For Operation Breakthrough",

U.S. Department of Housing and. Urban Development, U. S. Govern-

ment Printing Office, December 1970.

"Modular Assembly (The Art of Design with Standardized. Parts)",

Progressive Architecture, November 1957.N ~0*

"Britain's Clasp System", The Architectural Forum, Pages 116-

123, November 1961.

"Unskilled Mass Production of Housing Proposed For Type B

Contract", submitted. in response to RFP #H-55-69 for Operation

Breakthrough H.U.D. Proposal prepared. by Imre and. Anthony

Halasz, Inc. and various other participants.

"Wheeling Steel Framing", catalogue of structural framing by

Wheeling Corrugating Company.

Stressed Skin Panels, catalogue of plywood components by

Plywood Fabricator Services, Inc.

Strong Tie Connector, Structural Design and Load Values,

Simpson Company.

-82-