"structure" 1. "what exactly is a “structure”? can you give examples? what other...
TRANSCRIPT
Structure1 What exactly IS a ldquostructurerdquo Can you give examples What other words come
to mind
2List questions you want answered today
3 Then add your Post itregs to designated papers on wall
Welcome to an IncreDIble Illinois
Structure WorkshopPlease check in 1230- 100 pm
Brainstorming One idea per Post itreg
What is a Structure
bull A structure is anything made up of a number of parts that are held together in a particular way and has a base or foundation
bull All structures give support or provide a framework You can find structures everywhere Bridges buildings chairs shoes plants spider webs tables and even your own body are all structures A structures shape size and what its made of depend on what the structure does and how strong it needs to be
bull Form and FunctionEvery structure has form and function Form and Function are interconnected
The shape (or form) of something affects its purpose (or function)
Something with a certain shape can have more than one purpose or function
bull Forces of Tension and CompressionEvery structure is affected by forces
The force of one structure can affect another
The affect can go back and forth with a push and pull force
Compression and Tension are examples of push and pull forces
Compression the state of a material pressed together or forced into less space
Tension a stress on a material made by the pull of forces extending outwards
Structures in the Real World
You can find inspiration all around you if you just look
6 Flags ndash Texas Giant
6 Flags ndash G Force
6 Flags ndash Bob Sled
6 Flags ndash Judge Roy Scream Roller Coaster
Construction Project ndash Masonry Scaffolding
DFW Airport ndash Tower Cranes used constructing new Terminal
Six Flags ndash The Titan
DFW Airport ndash Doppler Radar
Six Flags ndash Mister Freeze
Electrical Wire Transmission Tower
Six Flags Oil Derrick
DFW Airport - Scaffolding holding up concrete forms
BasicConcepts
ampDefinitions
Intro to teaching basic structure
bull Woodbull Jigsbull Forcesbull Gluebull Tools and More Toolsbull Construction Areabull This yearrsquos Challengebull The Duct Tape Challengebull Summary
Construction Area
A large open table where team can place building jigs weigh wood saw and cut materials assemble amp finish structures
Cover the table top (sheet of thick plastic or masonite)Make sure that work areas are kept well ventilated especially when teams are using glues with harmful vapors
Cutting Tools and Equipment
Helping teams learnabout wood characteristics
bull Wood
ndash Wood comes in a variety of dimensions (sticks and planks)
ndash Hobby stores carry balsa and basswood (basswood generally denser and heavier)
ndash USA Balsa and SIG has a large assortment of wood (wwwsigmfgcom) ndash Factors to consider
bull Weightbull Strengthbull Ease of use
Wood Hands on
bull Examine the wood forndash Texturendash Grainndash Smoothnessndash Kerf marks
bull How porous is itbull How easy does a stick bendbull How much does it weigh
Sanding Balsa Wood prior to sorting
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
What is a Structure
bull A structure is anything made up of a number of parts that are held together in a particular way and has a base or foundation
bull All structures give support or provide a framework You can find structures everywhere Bridges buildings chairs shoes plants spider webs tables and even your own body are all structures A structures shape size and what its made of depend on what the structure does and how strong it needs to be
bull Form and FunctionEvery structure has form and function Form and Function are interconnected
The shape (or form) of something affects its purpose (or function)
Something with a certain shape can have more than one purpose or function
bull Forces of Tension and CompressionEvery structure is affected by forces
The force of one structure can affect another
The affect can go back and forth with a push and pull force
Compression and Tension are examples of push and pull forces
Compression the state of a material pressed together or forced into less space
Tension a stress on a material made by the pull of forces extending outwards
Structures in the Real World
You can find inspiration all around you if you just look
6 Flags ndash Texas Giant
6 Flags ndash G Force
6 Flags ndash Bob Sled
6 Flags ndash Judge Roy Scream Roller Coaster
Construction Project ndash Masonry Scaffolding
DFW Airport ndash Tower Cranes used constructing new Terminal
Six Flags ndash The Titan
DFW Airport ndash Doppler Radar
Six Flags ndash Mister Freeze
Electrical Wire Transmission Tower
Six Flags Oil Derrick
DFW Airport - Scaffolding holding up concrete forms
BasicConcepts
ampDefinitions
Intro to teaching basic structure
bull Woodbull Jigsbull Forcesbull Gluebull Tools and More Toolsbull Construction Areabull This yearrsquos Challengebull The Duct Tape Challengebull Summary
Construction Area
A large open table where team can place building jigs weigh wood saw and cut materials assemble amp finish structures
Cover the table top (sheet of thick plastic or masonite)Make sure that work areas are kept well ventilated especially when teams are using glues with harmful vapors
Cutting Tools and Equipment
Helping teams learnabout wood characteristics
bull Wood
ndash Wood comes in a variety of dimensions (sticks and planks)
ndash Hobby stores carry balsa and basswood (basswood generally denser and heavier)
ndash USA Balsa and SIG has a large assortment of wood (wwwsigmfgcom) ndash Factors to consider
bull Weightbull Strengthbull Ease of use
Wood Hands on
bull Examine the wood forndash Texturendash Grainndash Smoothnessndash Kerf marks
bull How porous is itbull How easy does a stick bendbull How much does it weigh
Sanding Balsa Wood prior to sorting
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
bull Form and FunctionEvery structure has form and function Form and Function are interconnected
The shape (or form) of something affects its purpose (or function)
Something with a certain shape can have more than one purpose or function
bull Forces of Tension and CompressionEvery structure is affected by forces
The force of one structure can affect another
The affect can go back and forth with a push and pull force
Compression and Tension are examples of push and pull forces
Compression the state of a material pressed together or forced into less space
Tension a stress on a material made by the pull of forces extending outwards
Structures in the Real World
You can find inspiration all around you if you just look
6 Flags ndash Texas Giant
6 Flags ndash G Force
6 Flags ndash Bob Sled
6 Flags ndash Judge Roy Scream Roller Coaster
Construction Project ndash Masonry Scaffolding
DFW Airport ndash Tower Cranes used constructing new Terminal
Six Flags ndash The Titan
DFW Airport ndash Doppler Radar
Six Flags ndash Mister Freeze
Electrical Wire Transmission Tower
Six Flags Oil Derrick
DFW Airport - Scaffolding holding up concrete forms
BasicConcepts
ampDefinitions
Intro to teaching basic structure
bull Woodbull Jigsbull Forcesbull Gluebull Tools and More Toolsbull Construction Areabull This yearrsquos Challengebull The Duct Tape Challengebull Summary
Construction Area
A large open table where team can place building jigs weigh wood saw and cut materials assemble amp finish structures
Cover the table top (sheet of thick plastic or masonite)Make sure that work areas are kept well ventilated especially when teams are using glues with harmful vapors
Cutting Tools and Equipment
Helping teams learnabout wood characteristics
bull Wood
ndash Wood comes in a variety of dimensions (sticks and planks)
ndash Hobby stores carry balsa and basswood (basswood generally denser and heavier)
ndash USA Balsa and SIG has a large assortment of wood (wwwsigmfgcom) ndash Factors to consider
bull Weightbull Strengthbull Ease of use
Wood Hands on
bull Examine the wood forndash Texturendash Grainndash Smoothnessndash Kerf marks
bull How porous is itbull How easy does a stick bendbull How much does it weigh
Sanding Balsa Wood prior to sorting
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Structures in the Real World
You can find inspiration all around you if you just look
6 Flags ndash Texas Giant
6 Flags ndash G Force
6 Flags ndash Bob Sled
6 Flags ndash Judge Roy Scream Roller Coaster
Construction Project ndash Masonry Scaffolding
DFW Airport ndash Tower Cranes used constructing new Terminal
Six Flags ndash The Titan
DFW Airport ndash Doppler Radar
Six Flags ndash Mister Freeze
Electrical Wire Transmission Tower
Six Flags Oil Derrick
DFW Airport - Scaffolding holding up concrete forms
BasicConcepts
ampDefinitions
Intro to teaching basic structure
bull Woodbull Jigsbull Forcesbull Gluebull Tools and More Toolsbull Construction Areabull This yearrsquos Challengebull The Duct Tape Challengebull Summary
Construction Area
A large open table where team can place building jigs weigh wood saw and cut materials assemble amp finish structures
Cover the table top (sheet of thick plastic or masonite)Make sure that work areas are kept well ventilated especially when teams are using glues with harmful vapors
Cutting Tools and Equipment
Helping teams learnabout wood characteristics
bull Wood
ndash Wood comes in a variety of dimensions (sticks and planks)
ndash Hobby stores carry balsa and basswood (basswood generally denser and heavier)
ndash USA Balsa and SIG has a large assortment of wood (wwwsigmfgcom) ndash Factors to consider
bull Weightbull Strengthbull Ease of use
Wood Hands on
bull Examine the wood forndash Texturendash Grainndash Smoothnessndash Kerf marks
bull How porous is itbull How easy does a stick bendbull How much does it weigh
Sanding Balsa Wood prior to sorting
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
6 Flags ndash Texas Giant
6 Flags ndash G Force
6 Flags ndash Bob Sled
6 Flags ndash Judge Roy Scream Roller Coaster
Construction Project ndash Masonry Scaffolding
DFW Airport ndash Tower Cranes used constructing new Terminal
Six Flags ndash The Titan
DFW Airport ndash Doppler Radar
Six Flags ndash Mister Freeze
Electrical Wire Transmission Tower
Six Flags Oil Derrick
DFW Airport - Scaffolding holding up concrete forms
BasicConcepts
ampDefinitions
Intro to teaching basic structure
bull Woodbull Jigsbull Forcesbull Gluebull Tools and More Toolsbull Construction Areabull This yearrsquos Challengebull The Duct Tape Challengebull Summary
Construction Area
A large open table where team can place building jigs weigh wood saw and cut materials assemble amp finish structures
Cover the table top (sheet of thick plastic or masonite)Make sure that work areas are kept well ventilated especially when teams are using glues with harmful vapors
Cutting Tools and Equipment
Helping teams learnabout wood characteristics
bull Wood
ndash Wood comes in a variety of dimensions (sticks and planks)
ndash Hobby stores carry balsa and basswood (basswood generally denser and heavier)
ndash USA Balsa and SIG has a large assortment of wood (wwwsigmfgcom) ndash Factors to consider
bull Weightbull Strengthbull Ease of use
Wood Hands on
bull Examine the wood forndash Texturendash Grainndash Smoothnessndash Kerf marks
bull How porous is itbull How easy does a stick bendbull How much does it weigh
Sanding Balsa Wood prior to sorting
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
6 Flags ndash G Force
6 Flags ndash Bob Sled
6 Flags ndash Judge Roy Scream Roller Coaster
Construction Project ndash Masonry Scaffolding
DFW Airport ndash Tower Cranes used constructing new Terminal
Six Flags ndash The Titan
DFW Airport ndash Doppler Radar
Six Flags ndash Mister Freeze
Electrical Wire Transmission Tower
Six Flags Oil Derrick
DFW Airport - Scaffolding holding up concrete forms
BasicConcepts
ampDefinitions
Intro to teaching basic structure
bull Woodbull Jigsbull Forcesbull Gluebull Tools and More Toolsbull Construction Areabull This yearrsquos Challengebull The Duct Tape Challengebull Summary
Construction Area
A large open table where team can place building jigs weigh wood saw and cut materials assemble amp finish structures
Cover the table top (sheet of thick plastic or masonite)Make sure that work areas are kept well ventilated especially when teams are using glues with harmful vapors
Cutting Tools and Equipment
Helping teams learnabout wood characteristics
bull Wood
ndash Wood comes in a variety of dimensions (sticks and planks)
ndash Hobby stores carry balsa and basswood (basswood generally denser and heavier)
ndash USA Balsa and SIG has a large assortment of wood (wwwsigmfgcom) ndash Factors to consider
bull Weightbull Strengthbull Ease of use
Wood Hands on
bull Examine the wood forndash Texturendash Grainndash Smoothnessndash Kerf marks
bull How porous is itbull How easy does a stick bendbull How much does it weigh
Sanding Balsa Wood prior to sorting
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
6 Flags ndash Bob Sled
6 Flags ndash Judge Roy Scream Roller Coaster
Construction Project ndash Masonry Scaffolding
DFW Airport ndash Tower Cranes used constructing new Terminal
Six Flags ndash The Titan
DFW Airport ndash Doppler Radar
Six Flags ndash Mister Freeze
Electrical Wire Transmission Tower
Six Flags Oil Derrick
DFW Airport - Scaffolding holding up concrete forms
BasicConcepts
ampDefinitions
Intro to teaching basic structure
bull Woodbull Jigsbull Forcesbull Gluebull Tools and More Toolsbull Construction Areabull This yearrsquos Challengebull The Duct Tape Challengebull Summary
Construction Area
A large open table where team can place building jigs weigh wood saw and cut materials assemble amp finish structures
Cover the table top (sheet of thick plastic or masonite)Make sure that work areas are kept well ventilated especially when teams are using glues with harmful vapors
Cutting Tools and Equipment
Helping teams learnabout wood characteristics
bull Wood
ndash Wood comes in a variety of dimensions (sticks and planks)
ndash Hobby stores carry balsa and basswood (basswood generally denser and heavier)
ndash USA Balsa and SIG has a large assortment of wood (wwwsigmfgcom) ndash Factors to consider
bull Weightbull Strengthbull Ease of use
Wood Hands on
bull Examine the wood forndash Texturendash Grainndash Smoothnessndash Kerf marks
bull How porous is itbull How easy does a stick bendbull How much does it weigh
Sanding Balsa Wood prior to sorting
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
6 Flags ndash Judge Roy Scream Roller Coaster
Construction Project ndash Masonry Scaffolding
DFW Airport ndash Tower Cranes used constructing new Terminal
Six Flags ndash The Titan
DFW Airport ndash Doppler Radar
Six Flags ndash Mister Freeze
Electrical Wire Transmission Tower
Six Flags Oil Derrick
DFW Airport - Scaffolding holding up concrete forms
BasicConcepts
ampDefinitions
Intro to teaching basic structure
bull Woodbull Jigsbull Forcesbull Gluebull Tools and More Toolsbull Construction Areabull This yearrsquos Challengebull The Duct Tape Challengebull Summary
Construction Area
A large open table where team can place building jigs weigh wood saw and cut materials assemble amp finish structures
Cover the table top (sheet of thick plastic or masonite)Make sure that work areas are kept well ventilated especially when teams are using glues with harmful vapors
Cutting Tools and Equipment
Helping teams learnabout wood characteristics
bull Wood
ndash Wood comes in a variety of dimensions (sticks and planks)
ndash Hobby stores carry balsa and basswood (basswood generally denser and heavier)
ndash USA Balsa and SIG has a large assortment of wood (wwwsigmfgcom) ndash Factors to consider
bull Weightbull Strengthbull Ease of use
Wood Hands on
bull Examine the wood forndash Texturendash Grainndash Smoothnessndash Kerf marks
bull How porous is itbull How easy does a stick bendbull How much does it weigh
Sanding Balsa Wood prior to sorting
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Construction Project ndash Masonry Scaffolding
DFW Airport ndash Tower Cranes used constructing new Terminal
Six Flags ndash The Titan
DFW Airport ndash Doppler Radar
Six Flags ndash Mister Freeze
Electrical Wire Transmission Tower
Six Flags Oil Derrick
DFW Airport - Scaffolding holding up concrete forms
BasicConcepts
ampDefinitions
Intro to teaching basic structure
bull Woodbull Jigsbull Forcesbull Gluebull Tools and More Toolsbull Construction Areabull This yearrsquos Challengebull The Duct Tape Challengebull Summary
Construction Area
A large open table where team can place building jigs weigh wood saw and cut materials assemble amp finish structures
Cover the table top (sheet of thick plastic or masonite)Make sure that work areas are kept well ventilated especially when teams are using glues with harmful vapors
Cutting Tools and Equipment
Helping teams learnabout wood characteristics
bull Wood
ndash Wood comes in a variety of dimensions (sticks and planks)
ndash Hobby stores carry balsa and basswood (basswood generally denser and heavier)
ndash USA Balsa and SIG has a large assortment of wood (wwwsigmfgcom) ndash Factors to consider
bull Weightbull Strengthbull Ease of use
Wood Hands on
bull Examine the wood forndash Texturendash Grainndash Smoothnessndash Kerf marks
bull How porous is itbull How easy does a stick bendbull How much does it weigh
Sanding Balsa Wood prior to sorting
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
DFW Airport ndash Tower Cranes used constructing new Terminal
Six Flags ndash The Titan
DFW Airport ndash Doppler Radar
Six Flags ndash Mister Freeze
Electrical Wire Transmission Tower
Six Flags Oil Derrick
DFW Airport - Scaffolding holding up concrete forms
BasicConcepts
ampDefinitions
Intro to teaching basic structure
bull Woodbull Jigsbull Forcesbull Gluebull Tools and More Toolsbull Construction Areabull This yearrsquos Challengebull The Duct Tape Challengebull Summary
Construction Area
A large open table where team can place building jigs weigh wood saw and cut materials assemble amp finish structures
Cover the table top (sheet of thick plastic or masonite)Make sure that work areas are kept well ventilated especially when teams are using glues with harmful vapors
Cutting Tools and Equipment
Helping teams learnabout wood characteristics
bull Wood
ndash Wood comes in a variety of dimensions (sticks and planks)
ndash Hobby stores carry balsa and basswood (basswood generally denser and heavier)
ndash USA Balsa and SIG has a large assortment of wood (wwwsigmfgcom) ndash Factors to consider
bull Weightbull Strengthbull Ease of use
Wood Hands on
bull Examine the wood forndash Texturendash Grainndash Smoothnessndash Kerf marks
bull How porous is itbull How easy does a stick bendbull How much does it weigh
Sanding Balsa Wood prior to sorting
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Six Flags ndash The Titan
DFW Airport ndash Doppler Radar
Six Flags ndash Mister Freeze
Electrical Wire Transmission Tower
Six Flags Oil Derrick
DFW Airport - Scaffolding holding up concrete forms
BasicConcepts
ampDefinitions
Intro to teaching basic structure
bull Woodbull Jigsbull Forcesbull Gluebull Tools and More Toolsbull Construction Areabull This yearrsquos Challengebull The Duct Tape Challengebull Summary
Construction Area
A large open table where team can place building jigs weigh wood saw and cut materials assemble amp finish structures
Cover the table top (sheet of thick plastic or masonite)Make sure that work areas are kept well ventilated especially when teams are using glues with harmful vapors
Cutting Tools and Equipment
Helping teams learnabout wood characteristics
bull Wood
ndash Wood comes in a variety of dimensions (sticks and planks)
ndash Hobby stores carry balsa and basswood (basswood generally denser and heavier)
ndash USA Balsa and SIG has a large assortment of wood (wwwsigmfgcom) ndash Factors to consider
bull Weightbull Strengthbull Ease of use
Wood Hands on
bull Examine the wood forndash Texturendash Grainndash Smoothnessndash Kerf marks
bull How porous is itbull How easy does a stick bendbull How much does it weigh
Sanding Balsa Wood prior to sorting
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
DFW Airport ndash Doppler Radar
Six Flags ndash Mister Freeze
Electrical Wire Transmission Tower
Six Flags Oil Derrick
DFW Airport - Scaffolding holding up concrete forms
BasicConcepts
ampDefinitions
Intro to teaching basic structure
bull Woodbull Jigsbull Forcesbull Gluebull Tools and More Toolsbull Construction Areabull This yearrsquos Challengebull The Duct Tape Challengebull Summary
Construction Area
A large open table where team can place building jigs weigh wood saw and cut materials assemble amp finish structures
Cover the table top (sheet of thick plastic or masonite)Make sure that work areas are kept well ventilated especially when teams are using glues with harmful vapors
Cutting Tools and Equipment
Helping teams learnabout wood characteristics
bull Wood
ndash Wood comes in a variety of dimensions (sticks and planks)
ndash Hobby stores carry balsa and basswood (basswood generally denser and heavier)
ndash USA Balsa and SIG has a large assortment of wood (wwwsigmfgcom) ndash Factors to consider
bull Weightbull Strengthbull Ease of use
Wood Hands on
bull Examine the wood forndash Texturendash Grainndash Smoothnessndash Kerf marks
bull How porous is itbull How easy does a stick bendbull How much does it weigh
Sanding Balsa Wood prior to sorting
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Six Flags ndash Mister Freeze
Electrical Wire Transmission Tower
Six Flags Oil Derrick
DFW Airport - Scaffolding holding up concrete forms
BasicConcepts
ampDefinitions
Intro to teaching basic structure
bull Woodbull Jigsbull Forcesbull Gluebull Tools and More Toolsbull Construction Areabull This yearrsquos Challengebull The Duct Tape Challengebull Summary
Construction Area
A large open table where team can place building jigs weigh wood saw and cut materials assemble amp finish structures
Cover the table top (sheet of thick plastic or masonite)Make sure that work areas are kept well ventilated especially when teams are using glues with harmful vapors
Cutting Tools and Equipment
Helping teams learnabout wood characteristics
bull Wood
ndash Wood comes in a variety of dimensions (sticks and planks)
ndash Hobby stores carry balsa and basswood (basswood generally denser and heavier)
ndash USA Balsa and SIG has a large assortment of wood (wwwsigmfgcom) ndash Factors to consider
bull Weightbull Strengthbull Ease of use
Wood Hands on
bull Examine the wood forndash Texturendash Grainndash Smoothnessndash Kerf marks
bull How porous is itbull How easy does a stick bendbull How much does it weigh
Sanding Balsa Wood prior to sorting
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Electrical Wire Transmission Tower
Six Flags Oil Derrick
DFW Airport - Scaffolding holding up concrete forms
BasicConcepts
ampDefinitions
Intro to teaching basic structure
bull Woodbull Jigsbull Forcesbull Gluebull Tools and More Toolsbull Construction Areabull This yearrsquos Challengebull The Duct Tape Challengebull Summary
Construction Area
A large open table where team can place building jigs weigh wood saw and cut materials assemble amp finish structures
Cover the table top (sheet of thick plastic or masonite)Make sure that work areas are kept well ventilated especially when teams are using glues with harmful vapors
Cutting Tools and Equipment
Helping teams learnabout wood characteristics
bull Wood
ndash Wood comes in a variety of dimensions (sticks and planks)
ndash Hobby stores carry balsa and basswood (basswood generally denser and heavier)
ndash USA Balsa and SIG has a large assortment of wood (wwwsigmfgcom) ndash Factors to consider
bull Weightbull Strengthbull Ease of use
Wood Hands on
bull Examine the wood forndash Texturendash Grainndash Smoothnessndash Kerf marks
bull How porous is itbull How easy does a stick bendbull How much does it weigh
Sanding Balsa Wood prior to sorting
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Six Flags Oil Derrick
DFW Airport - Scaffolding holding up concrete forms
BasicConcepts
ampDefinitions
Intro to teaching basic structure
bull Woodbull Jigsbull Forcesbull Gluebull Tools and More Toolsbull Construction Areabull This yearrsquos Challengebull The Duct Tape Challengebull Summary
Construction Area
A large open table where team can place building jigs weigh wood saw and cut materials assemble amp finish structures
Cover the table top (sheet of thick plastic or masonite)Make sure that work areas are kept well ventilated especially when teams are using glues with harmful vapors
Cutting Tools and Equipment
Helping teams learnabout wood characteristics
bull Wood
ndash Wood comes in a variety of dimensions (sticks and planks)
ndash Hobby stores carry balsa and basswood (basswood generally denser and heavier)
ndash USA Balsa and SIG has a large assortment of wood (wwwsigmfgcom) ndash Factors to consider
bull Weightbull Strengthbull Ease of use
Wood Hands on
bull Examine the wood forndash Texturendash Grainndash Smoothnessndash Kerf marks
bull How porous is itbull How easy does a stick bendbull How much does it weigh
Sanding Balsa Wood prior to sorting
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
DFW Airport - Scaffolding holding up concrete forms
BasicConcepts
ampDefinitions
Intro to teaching basic structure
bull Woodbull Jigsbull Forcesbull Gluebull Tools and More Toolsbull Construction Areabull This yearrsquos Challengebull The Duct Tape Challengebull Summary
Construction Area
A large open table where team can place building jigs weigh wood saw and cut materials assemble amp finish structures
Cover the table top (sheet of thick plastic or masonite)Make sure that work areas are kept well ventilated especially when teams are using glues with harmful vapors
Cutting Tools and Equipment
Helping teams learnabout wood characteristics
bull Wood
ndash Wood comes in a variety of dimensions (sticks and planks)
ndash Hobby stores carry balsa and basswood (basswood generally denser and heavier)
ndash USA Balsa and SIG has a large assortment of wood (wwwsigmfgcom) ndash Factors to consider
bull Weightbull Strengthbull Ease of use
Wood Hands on
bull Examine the wood forndash Texturendash Grainndash Smoothnessndash Kerf marks
bull How porous is itbull How easy does a stick bendbull How much does it weigh
Sanding Balsa Wood prior to sorting
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
BasicConcepts
ampDefinitions
Intro to teaching basic structure
bull Woodbull Jigsbull Forcesbull Gluebull Tools and More Toolsbull Construction Areabull This yearrsquos Challengebull The Duct Tape Challengebull Summary
Construction Area
A large open table where team can place building jigs weigh wood saw and cut materials assemble amp finish structures
Cover the table top (sheet of thick plastic or masonite)Make sure that work areas are kept well ventilated especially when teams are using glues with harmful vapors
Cutting Tools and Equipment
Helping teams learnabout wood characteristics
bull Wood
ndash Wood comes in a variety of dimensions (sticks and planks)
ndash Hobby stores carry balsa and basswood (basswood generally denser and heavier)
ndash USA Balsa and SIG has a large assortment of wood (wwwsigmfgcom) ndash Factors to consider
bull Weightbull Strengthbull Ease of use
Wood Hands on
bull Examine the wood forndash Texturendash Grainndash Smoothnessndash Kerf marks
bull How porous is itbull How easy does a stick bendbull How much does it weigh
Sanding Balsa Wood prior to sorting
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Intro to teaching basic structure
bull Woodbull Jigsbull Forcesbull Gluebull Tools and More Toolsbull Construction Areabull This yearrsquos Challengebull The Duct Tape Challengebull Summary
Construction Area
A large open table where team can place building jigs weigh wood saw and cut materials assemble amp finish structures
Cover the table top (sheet of thick plastic or masonite)Make sure that work areas are kept well ventilated especially when teams are using glues with harmful vapors
Cutting Tools and Equipment
Helping teams learnabout wood characteristics
bull Wood
ndash Wood comes in a variety of dimensions (sticks and planks)
ndash Hobby stores carry balsa and basswood (basswood generally denser and heavier)
ndash USA Balsa and SIG has a large assortment of wood (wwwsigmfgcom) ndash Factors to consider
bull Weightbull Strengthbull Ease of use
Wood Hands on
bull Examine the wood forndash Texturendash Grainndash Smoothnessndash Kerf marks
bull How porous is itbull How easy does a stick bendbull How much does it weigh
Sanding Balsa Wood prior to sorting
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Construction Area
A large open table where team can place building jigs weigh wood saw and cut materials assemble amp finish structures
Cover the table top (sheet of thick plastic or masonite)Make sure that work areas are kept well ventilated especially when teams are using glues with harmful vapors
Cutting Tools and Equipment
Helping teams learnabout wood characteristics
bull Wood
ndash Wood comes in a variety of dimensions (sticks and planks)
ndash Hobby stores carry balsa and basswood (basswood generally denser and heavier)
ndash USA Balsa and SIG has a large assortment of wood (wwwsigmfgcom) ndash Factors to consider
bull Weightbull Strengthbull Ease of use
Wood Hands on
bull Examine the wood forndash Texturendash Grainndash Smoothnessndash Kerf marks
bull How porous is itbull How easy does a stick bendbull How much does it weigh
Sanding Balsa Wood prior to sorting
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Cutting Tools and Equipment
Helping teams learnabout wood characteristics
bull Wood
ndash Wood comes in a variety of dimensions (sticks and planks)
ndash Hobby stores carry balsa and basswood (basswood generally denser and heavier)
ndash USA Balsa and SIG has a large assortment of wood (wwwsigmfgcom) ndash Factors to consider
bull Weightbull Strengthbull Ease of use
Wood Hands on
bull Examine the wood forndash Texturendash Grainndash Smoothnessndash Kerf marks
bull How porous is itbull How easy does a stick bendbull How much does it weigh
Sanding Balsa Wood prior to sorting
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Helping teams learnabout wood characteristics
bull Wood
ndash Wood comes in a variety of dimensions (sticks and planks)
ndash Hobby stores carry balsa and basswood (basswood generally denser and heavier)
ndash USA Balsa and SIG has a large assortment of wood (wwwsigmfgcom) ndash Factors to consider
bull Weightbull Strengthbull Ease of use
Wood Hands on
bull Examine the wood forndash Texturendash Grainndash Smoothnessndash Kerf marks
bull How porous is itbull How easy does a stick bendbull How much does it weigh
Sanding Balsa Wood prior to sorting
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Wood Hands on
bull Examine the wood forndash Texturendash Grainndash Smoothnessndash Kerf marks
bull How porous is itbull How easy does a stick bendbull How much does it weigh
Sanding Balsa Wood prior to sorting
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Sanding Balsa Wood prior to sorting
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Comparison of woods
Species Wtlbscf
StiffnessStrength
BendingStrength
CompressionStrength
Balsa 8 72 70 75
Balsa 14 156 161 149
Spruce 28 230 260 289
Basswood
26 261 288 288
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Wood Characteristics
bull Anistropic means having properties that differ depending on direction
bull Wood has grain to it and will react differently depending on the grain
bull Consider how grain affects how wood reacts and build your structure with this in mind
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Moisture
bull Wood absorbs moisture from the air (especially balsa wood)
bull When weight is a consideration teams may want to consider ways to remove moisture from their structure
bull Many teams try to control the moisture absorption by the wood
bull Others try to remove moisture prior to weigh in
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Moisture
bull Teams may find that certain glues degrade when exposed to extreme heat(thus the structure is weaker after drying)
bull Teams should brainstorm quantify and test any techniques they consider for removing moisture from their structure
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
General Definitions
bull Structurebull Column bull Bracebull Memberbull Stress (Forces)
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Stress (Forces)that act on a structure
bull Compressionbull Tensionbull Shearbull Twisting Rotation
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Compression
Compression forces try to ldquocrushrdquo things
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Compression
Compression forces also try to buckle things
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Tension
Tension forces try to pull things apart
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Shear
Shear forces try to ldquobreak thingsrdquo
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Hands on
bull Take a 12rdquo piece of wood ndash Stand on its end and push down on it
You are putting the wood in compressionndash Now try to pull it apartndash Now lay it frac12 over the edge of your table
and press down on the outside piece
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
More DefinitionsConcepts
bull Buckling load ndash The amount of weight required to cause a
structure to failbull Critical Length
ndash The length where wood no longer bends but crushes
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Law of Squares (cont)
bull If I have a 12rdquo column and a 4rdquo column constructed from the same material the 4rdquo column will hold 9 times as much weight as the 12rdquo column
bull 4rdquo = 13 of 12rdquo So Invert 13 to get 3 and then square it to get 9
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Hands OnLaw of Squares
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Balsa Balsa Estimate Weight
Balsa Actual Weight
Weight Held Estimate
Weight Held Actual
36rdquo X X
18rdquo
12rdquo
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Demonstrations
The next few slides come from a computer program that allows a user to
build a structure on screen and then test the structure We are using screen shots form this program to demonstrate
a few of these concepts
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Simple 4 column 8rdquo tall structure with compression load
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Held 110 grams of weight
11074 grams
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Simple Tower ndash horizontal braces in middle
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Tested to failure 4 x 110 = 440 grams
44468 grams
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Columns are now braced twice (13 length)
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Tested to failure
89923 grams
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Not testing to failure
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Adding another force acting on the side of the structure (only 1 gram)
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Disaster strikes
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Correcting the problem
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
The Diagonal Braces kept the structure stable
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Bracing
bull Horizontal Bracingndash Typically ndash horizontal bracing is used to
resist buckling in a columnbull Diagonal Bracing
ndash Typically ndash diagonal bracing resists twisting in the structure (adds stability)
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
With compression force applied straight down ndash column held 3505 grams
3505 grams
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
4 x 35 = 140
14038 grams
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Total Column height is 12rdquo
14038 grams
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Total Column height is 12rdquo
14038 grams
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Cutting
bull Cut (donrsquot ldquosquashrdquo) the woodbull Cutting can damage cells at end of the
piecebull Think of ways to keep that from
happening
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Cut by rocking blade straight back and forth
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Helping teams learn about glue characteristics
bull Gluendash Expose team to many different types of
glue read directionsbull Hot gluebull Super glue
ndash CYANOACRYLATE (pronounced sigh-ano-ack-relate) adhesive specially formulated to meet the tough demands of building and flying model airplanes Available in three different viscosities Each viscosity has different application and cure characteristics
bull Wood glue (Gorilla glue)bull Epoxybull Carpenterrsquos wood glue (Elmerrsquos)
ndash Factors to considerbull Strengthbull Drying timebull Weightbull Ease of use
Provide Adequate Ventilation
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Airplane Glue
Gorilla Glue
Glass Surface to build on
Wood Glues
CA ldquoSuperrdquo Glues
Acetone
Extra CA Glue Tips
Old Razor - to clean glass
Pill bottles to clean CA Glue Tips
Glues
Contact Cement
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Glue Testing Device
bull Teams may want to construct testing devices to test the different types of glues
bull Plans for a device for testing glue strength are available at
httpwwwspecializedbalsacomstrength_test_instructionsphp
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Glue Safety Rules
bull No Horseplaybull Read and Follow Safety Instructionsbull If you canrsquot use it safely ndash donrsquot use itbull Donrsquot mix glues together bull If using CA Glue ndash keep Acetone on
hand
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Tools amp Safety
bull Tools such as saws X-acto knives and razors can be used to cut wood When any sharp tool is used sharp edges should always be directed away from flesh
bull Let team members experiment with cutting sawing and sanding wood with various tools Encourage them to explore any tool they think will allow them to build bettereasier
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Useful tools
bull X-acto fine tooth razor sawbull Plastic holder holding a single edge razor blade
bull small aluminum mitre box for razor saw
Other useful building itemsbull Flat tile or mirrorbull Building squarebull Emery boards sand paper
All tools should be readily available to consumers and of the teamrsquos own choosing
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
LevelStraight Edge
Levels are usually used to see if a surface is perfectly level (meaning it wonrsquot tilt up or down) They can also be used to draw a straight edge
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Other Useful Things to Have
bull Gram scale accurate to 01 gramsndash Permits weighing wood and completed
structuresndash Ohaus has a low-cost one (lt$90) but
you can probably borrow or get access to one (school lab workplace post office police station (ask for confiscated scales)
ndash Ebay frequently has ldquodealsrdquobull Hair Dryer
ndash Speeds up glue dryingndash Removes excess moisture from wood
(weight)
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
More Useful Things to Havebull Structure Tester
ndash TM or other parents are allowed to construct a tester for the team
ndash Instructions are available (httpwwwfarnorthdiorgTRAININGHow_to_build_testerdoc)
ndash Try borrowing a testerbull Weights
ndash Olympic style (2 inch hole)
flat metal weights
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Clear Plastic Ruler comes in handy when yoursquore cutting sticks of balsa wood When you mark the balsa wood make sure of three things One make sure that you have the edge of the ruler aligned with the edge of the stick Two make sure you mark the length with a single dot Otherwise if you mark it with a line it will be crooked for sure Three once yoursquove measured it be sure to measure it again There is an old woodworking saying ldquoMeasure twice cut oncerdquo Thatrsquos because it is a lot easier to fix a mistake before you make it than afterwards
Woodworking Basics
Measuring Tools
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Woodworking Basics
Measuring Tools
Top T square is used to put one piece of wood at a right angle to another
Bottom L Square
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Woodworking Basics
Measuring Tools
bull A combination square is used to mark a line lengthwise down the middle of a long piece of wood A combination square consists of two main parts The first part is a foot long metal ruler with a notch at the end to hold a pencil The second part is an adjustable steel bar that slides This lets you adjust where you want the mark to be
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Jigs
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Jig (template)
bull A gauge pattern or mold used as a guide to the form of a piece being made
bull Jigs can be 2 dimensional or 3 dimensional
bull It is not necessary to use a Jigbull A Jig helps you to build consistentlybull ANY jigs used by the team must be
BUILT by the team
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Sample materials that can be used to make templates
Aluminum Square Tube from hardware store
Plastic and brass square tube from Hobby store
Steel keystock from hardware store
1x1 from lumber yard
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Closeup of a Tester
bull Base alone
bull Loaded with structure presser board amp weights
Presser Boardsupported about 1rdquoabove
corner postsby
structure
The Presser Board amp weights are fully supported by structure
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Tester setup
Team Designed Structures
Floor surface
Metal Weights
Traditional Tester Supporting Blocks
Pressure Board
75rdquo to 9rdquo
2nd structure inside first structure
Top of red tape is 1rdquo below top of pole
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
More Hands on
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
The Duct Tape ChallengeFocus The Testing process for structure challenges
Architectural Design Structural Engineering Construction Teamwork
The Destination Where This Challenge Will Take You
bull One of the keys to building REALLY strong structures is to spend the time lsquofollowing through on the detailsrsquo Without doing so could turn a wonderfully constructed structure into a lsquoleaning tower of Pisardquo unless it is checked to be sure it is ldquoplumbrdquo
bull The process of placing weights on the structure is an area many first-time structure teams do not give sufficient attention
bull What happens if all the parts of the structure that have to carry ldquoloadrdquo do not actually contact the upper and lower surfaces of the tester What happens when the weights are placed on the structure Is there a way to anticipate those things and plan for them
bull This goal of this challenge is to help teams anticipate these questions and develop a team plan Teams that plan practice and brainstorm issues in advance will have a plan ndash and a contingency plans- so they donrsquot have to make ldquosnap decisionsrdquo at tournament that they might regret
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
bull Your team will
bull 1048720 Build and test a Structure made completely of Wood and Tape 1048720 bull Time Limit The team must complete the solution on site within one hour which will include weigh-in and testing of the
structure bull Team Materials Required Teams will provide their own duct tape and masking tapes and may prefer to bring a ruler for
their use The pre-cut balsa wood for the structure a ldquotemplaterdquo and ldquojigrdquo gram scale for weighing it testing device and Olympic weights will be provided by the Trainers
bull Roadmap for Success Teams must work together and plan a strategy in order to successfully solve this Challenge bull a Team will open kit and construct the structurebull b When complete they can raise their hand and let the Trainer know they are ready for ldquoweigh-inrdquo bull c The team will test the strength of their Structure by stacking weights on the Pressure Board of a Structure Tester while
the Structure rests on the Tester Basebull d The testing will result in an Official Weight Held Normally at each level of competition the Structures with the highest
Official Weight Held score will receive 160 points The score for all other teams in that Level would be based on the percentage of that Official Weight Held for that competition Level In this challenge the focus is not on the weight held but on how well the teams can place the weights on their structure so that it will hold as much weight as possible
bull Building the Structures Specificationsbull a A ldquolevel playing fieldrdquo has been ensured for all teams in regard to the design and the materials of the structure The
test here will be in how they construct and TEST the structure bull b Height of Structures Each Structure must have a minimum height of 75in (191cm) and a maximum height of 8 in
(219cm)bull c Weight of Structures The weight for Middle and Secondary team Structures may not exceed 40 grams The
weight for all other levels is unlimited but the teams will want to know what it is for their records and to note the efficiency of their structure
bull d The Structures are designed to support weights stacked on the Pressure Board of the Structure Tester bull e The Structures must have an opening running their entire height which can accept a circular column with an outside
diameter of 2in (51cm) The Structure must rest upon the Tester Base and fit over the Safety Pole The Structure must fit entirely on the Tester Base and may not touch any of the Safety Supports or the Safety Pole
bull f The Structures will be constructed using ONLY natural Wood and Tape- Duct tape and Masking Tape no other materials will be allowed The Balsa Wood included in the kit was not weighed in advance and has not been screened in any way Pieces were placed randomly in the kits
bull Laminates in the Structures Team may use duct tape as a laminate in this structure but should realize it will add to the weight of the finished product
bull Jig provided is a simple block of wood with L square
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Weight Placement
bull Practice practice practicebull Have a planbull Be prepared to modify your planbull What will happen when you mishandle a
weight bull How can you protect your fingers from
being pinched
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Analyzing
bull Analyze broken structure to determine what failed
bull Use safety shields and watch what happens ndash make notes
bull Analyze the video tapesbull Use a sports camerabull Incremental testing
Analyzing tested structures is the best way to discover where you can improve
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Design Considerations
bull Record pertinent information about every structurendash Glues usedndash Materials usedndash Weight and weight held
bull Donrsquot change too many variables between tests
Donrsquot change too many things at once
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Whatrsquos the Secret
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Thoughts onthe Tournament
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Tournament Day Considerations
bull How are your going to transport your structure safely to tournament
bull What supplies do you need for repairsbull What will you store your structures in
when you turn them over to the Appraisers
Tournament Day Thoughts
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
(continued)
bull Before tournament do your own mock check in with the structure ndash does it meet the challenge specifications
bull Do you think you need a spare structure
Tournament Day Thoughts
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
Closing Thoughts
bull Good structures look goodbull Keep it simplebull Keep in Levelbull Keep it Well-gluedbull Have Fun
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-
AcknowledgementsVictor Tom Bill Allen Pre-engineering Corp (pictures) Reggie Bunis
Ernie Chang
Special thanks to Charles Compton Arlington TX for creating the structure of this presentation and offering
suggestions corrections technicalexplanations and commentary
- Welcome to an IncreDIble Illinois Structure Workshop
- What is a Structure
- Slide 3
- Structures in the Real World
- Slide 5
- Slide 6
- Slide 7
- Slide 8
- Slide 9
- Slide 10
- Slide 11
- Slide 12
- Slide 13
- Slide 14
- Slide 15
- Slide 16
- Basic Concepts amp Definitions
- Slide 18
- Slide 19
- Slide 20
- Helping teams learn about wood characteristics
- Wood Hands on
- Slide 23
- Comparison of woods
- Wood Characteristics
- Moisture
- Moisture (2)
- General Definitions
- Stress (Forces) that act on a structure
- Compression
- Compression (2)
- Tension
- Shear
- Hands on
- More DefinitionsConcepts
- Law of Squares (cont)
- Hands On Law of Squares
- Slide 38
- Demonstrations
- Slide 40
- Slide 41
- Slide 42
- Slide 43
- Slide 44
- Slide 45
- Slide 46
- Slide 47
- Slide 48
- Slide 49
- Slide 50
- Bracing
- Slide 52
- Slide 53
- Slide 54
- Slide 55
- Cutting
- Slide 57
- Slide 58
- Helping teams learn about glue characteristics
- Slide 60
- Glue Testing Device
- Glue Safety Rules
- Tools amp Safety
- Slide 64
- LevelStraight Edge
- Other Useful Things to Have
- More Useful Things to Have
- Slide 68
- Slide 69
- Woodworking Basics Measuring Tools
- Jigs
- Jig (template)
- Slide 73
- Closeup of a Tester
- Tester setup
- More Hands on
- The Duct Tape Challenge
- Slide 78
- Weight Placement
- Analyzing
- Design Considerations
- Whatrsquos the Secret
- Thoughts on the Tournament
- Tournament Day Considerations
- (continued)
- Closing Thoughts
- Acknowledgements
-