1863_Kallari

Entered into: South America Challenge

Overview

team

Kallari Craft Association Competition Narrative

Our goal is to collaborate with the Kallari Association and help them achieve
economic and artistic success. We bring a unique blend of experts and
experienced resources to the Kallari cooperative to assist in solving the myriad of
issues they may face in expanding their chocolate and craft market as well as
developing a community center and tourist attraction. Given our experience in
chocolate manufacturing, production facility planning and construction, we
realize that the Kallari Chocolate makers have their own preferred methods and
equipment that will ultimately guide us both as designers as well as resource
asset managers. Our team includes not only the traditional planning experts of
architects, Landscape architects, LEED and environmental sustainability
specialists, civil engineers, micro-hydroelectric systems operators, computer
technology and internet professionals, but also marketing and branding
development experts embedded in our business plan team (see Supplemental
Business Plan Submission), project management consultants, and nongovernment
organization (NGO) representatives experienced in bridging cultural
and international gaps both in Ecuador and world wide. Our hope is that our
synergistic efforts have yielded a project of greater cohesiveness and ultimate
feasibility than would otherwise have been developed, and that we are further
able to capitalize on collaborative efforts directly with the Kallari Craft Association
and other volunteers. This belief in collaboration and the desire to help the
Kallari Association achieve their dreams is the foundation of our team and our
proposal for the project.

The narrative is organized into the following major sections; General
Architectural and Planning Concepts, Program Assumptions and Descriptions,
Sustainable Development Strategies, and Computer and Internet Technology

General Architectural and Planning Concepts

The site plan is developed to work with the existing topography and significant
slopes, facilitating vehicular access while celebrating the path of water and views
of the majestic river valley. The entry point to the site serves as the gateway for
public visitors to the chocolate factory and craft retail sales area. It also opens to
an adjacent plaza serving the association Learning Center, where the Kallari can
gather throughout the week for various community activities, meetings, classes,
conferences, etc. This single entry allows a general access control point both for
potential entrance fee collection as well as direct access to the chocolate retail
area on a visitors way in and out. The rest of the retail area itself cascades down
a terraced plaza of Kallari craft booths northward to the larger community
gathering spaces and buildings, the Cafe, and the Botanical Garden, with private
community and residential buildings nestled into the southern portion of the site.

The overall concept is developed around sustainability as an integral aspect of
the community, with one of the most visible example being site water collection
and use along with celebration of living roofs over the largest structure of the
factory and admin building, limiting runoff into the river and minimizing visual
impact on the site. This announces to visitors that the Kallari Association and
community center itself is focused on environmental stewardship at this site as
they are with their cacao farms. Water is exposed along the terraces and plazas,
and is envisioned to be used as grey water for various functions (see
Sustainability Strategies). The layout allows the easiest site access and exit
scheme, with the driveway and major construction parallel to the slope, with
buried retaining wall structures to aid in temperature control and minimize
exposed surface grading. We envision a center of lively community activities,
varying and evolving as the community grows, enhanced by the intersection of
craft plaza and pathway, community and visitor. Simultaneously, we realized
that there are also areas where privacy from the more public activities is
desirable which is achieved through site location and relative grade changes.

Major materials used include gabion rockery retaining walls which incorporates
site collected rocks in either steel or bamboo cage material to form retaining
walls, regionally harvested Guadua Timber Bamboo structural posts and site
assembled trusses, thatch roof, plaster and bamboo solid wall panels, bamboo
and grass matte moveable panels, and locally made textile/tent roofs.
Conditioned spaces are limited as required, with natural light and ventilation
maximized through application of skylights, borrowed light, and translucent tent
roofing. The vast majority of materials could be locally or Kallari made and
assembled, with limited readily available corrugated steel roof and connectors.
We also envision the compound will likely be built in phases, growing and
expanding with the community needs over generations. All major structural
elements have been conceived around locally available materials and familiar
methods. While some of the longer span trusses will require some engineering
oversight, they are repetitive and scalable in nature and application.

There are essentially three (3) building types, identified by roof form, which
create a language for the community center structures with a vocabulary of
materials and methods associated. These are 1) living roof, 2) thatch, and 3)
tent textile/fabric. The sloped site suggests and requires retaining structures in
some locations, which is achieved through Gabion wall technology, using
galvanized steel caging where below grade, and bamboo caging where above
grade and protected. The gabion walls are plaster finished where conditioned
space and insect control are required and left natural to allow ventilation
wherever appropriate. Structures such at the Factory, Administration Building
and Learning Center require varying degrees of conditioning and security, and
thus are built of either the long span flat roof trussed living roof, or thatch roof,
with thin plastered bamboo wall panels. These structures are traditional forms,
with modern improvements to facilitate security and conditioning. We also
recognize a need to provide flexibility for immediate use as well as long term
growth. Given the mild climate, many of the gathering spaces may need only sun
and rain shelter, and while thatch structures do provide this, they are relatively
heavy and limit natural light. Our proposal recommends these structures be
natural (bee) waxed textile/fabric tents over scalable site-built bamboo truss
systems. The textiles could easily be made and maintained by the Kallari
craftspeople, thus fostering continued self-reliance, keeping ongoing
maintenance costs under control while providing work for the Kallari
tradespeople themselves.

As we reviewed and conceived of the various functions of the facility compound,
we drew upon our South American cultural heritage within our own architectural
firm (Bolivia and Peru), but also from NGO representatives historically active in
Ecuador and interested in the Kallari Association project, as well as international
chocolate grower and industry representatives who currently work with the
Kallari. Our proposal diverges from the program on occasion, as our
understanding of it became informed by our investigations and information
gathered when we were unable to get direct responses. We see these as options
and opportunities to capitalize on flexibility and multi-use relationships within the
program that may not have been fully explored or considered. In the final
program analysis, these aspects may or may not prove valuable, but we thought
them worthy of consideration. One such divergence occurs around the café,
which we envision serving not only families of visitors out for their weekend “dia
de campo” (day in the country), but also with the kitchen serving as the other
community center activities.

Program Assumptions and Descriptions

Factory

Building type and material is living roof over long span bamboo trusses,
plastered gabion walls and bamboo panels. We have enhanced the factory
process and production line with optional and additional equipment as well as
temperature, humidity and particulate control measures. Factory optimization
and cleanliness is paramount to consistent product quality and protection of
finished goods. Simple tried and true methods can foster clean production
environments, such as exhaust/fan pressurization control, screened natural
ventilation and borrowed light, production path flow, and proper door swing
orientation to support pressurization. Conditioning as needed could be provided
via the micro hydro-electric heat pump or direct water transfer cooling (see
Sustainability Strategies).

Exhaust and intake fans can be can be run by direct solar convection (alternate
blades painted black & white) or may be on the solar/hydroelectric power
system. It is important to allow flexibility so the system can be properly
balanced to allow roasters and cyclones to function properly. Factory flow and
temperature control for both products and people needs to be considered, along
with limiting cross path contamination. Our proposal varies somewhat from
program information given, based on ‘assumed/projected’ methods and
equipment, but will need to be verified with the Kallari Chocolate maker’s
preferred methods and practices. While the above are simple techniques, they
are just a few examples of the real world food and chocolate production
knowledge and expertise we look forward to sharing with the Kallari Association.

Factory rooms and equipment:

Administration Building

Building type and material is living roof over long span bamboo trusses,
plastered gabion walls and bamboo panels. Attributes include:

Learning Center

Building type and material is thatch roof over bamboo truss/framing with both
bamboo and plastered bamboo fixed and operable panels. Attributes include:

Gallery

Building type and material is thatch roof over bamboo truss/framing with both
bamboo and plastered bamboo fixed and operable panels. Attributes include:

Retail

Building type and material is fabric/textile tent structure over bamboo trusses.

Attributes include:

Building type and material is fabric/textile tent structure over bamboo trusses
with living roof and plastered panels. Attributes include:

Residences

Building type and material is thatch roof over bamboo framing with both bamboo
and plastered bamboo fixed and operable panels. Attributes include:

Hand Craft Market

Building type and material is fabric/textile tent structure over bamboo framing.
Attributes include:

Botanical Garden & Greenhouse

Attributes include:

Computer Kiosk

The platform is conceived as a portable satellite learning center made on a
readily available truck/trailer platform. Attributes include:

Sustainable Development Strategies

Successful sustainable design requires a holistic approach to building and site.
As in nature, the relationships that exist between location and users may be
challenges or utilized for mutual benefit. It is known that working against
natural conditions requires more of everything: energy, materials and building
systems. Informed by nature, we intend these structures to interact with the site
as organisms rather than machines. Challenged to integrate with the local
geography and climate, we considered foremost the pristine environment and
biodiversity of the Napo Province. With an average rainfall of 2 meters,
abundant water is just one of the many unique site features. The Amazon
rainforest is a complex balance of relationships that must be preserved for the
ecosystem to survive. These relationships are sensitive to human activity;
however people have been living in the rainforest for centuries. Studying the
traditional architecture of the Kichwa culture, we recognized their construction
traditions are inherently sustainable. These building practices have evolved in
response to their environment and available resources. The Kitchwa construction
traditions will be enhanced with modern amenities as needed for chocolate
production and information technology. By expanding upon familiar methods,
local labor may be used to construct, operate and maintain the facility over time.
Both the community and rainforest will benefit from employing multiple
sustainable strategies for the Kallari Association facility.

Major Building Strategies Employed

While comprehensive, our sustainable strategies for this facility focus on 4 main
themes of efficiency; building materials, site strategies, water and energy. With
LEED™ Gold certification in mind, a variety sustainable materials and methods
have been selected for the construction of the Kallari facility. This facility has
been designed to LEED V2.2 New Construction standards. The majority of
credits pursued may be achieved by tangible strategies. Several additional credits
would require additional analysis, calibration/verification of building systems and
thermal comfort, and monitoring by third party consultants. These services
would likely be required in order to achieve the equivalent of 39 credits required
for LEED Gold certification. These services ideally would be donated by qualified
consultants.

The majority of the building materials proposed for the Kallari facility are familiar
and native to the region including regionally harvested Guadua Timber Bamboo.
Requiring little transportation and manufacturing, these local materials are
common to traditional construction and inherently sustainable. Examples are
woven and bamboo panels and thatch roof; rapidly renewable materials and
forms common to the Napo Province. After reviewing the specific needs of the
Kallari Association, several unique qualities of space requirements were
identified. For example, the chocolate factory requires large enclosed tall indoor
spaces to accommodate equipment. Larger spaces require longer roof spans.
Several modifications to traditional bamboo connections were required to provide
long spans using a minimal amount of structure. In another variation, we
propose a bamboo lath and plaster wall construction. These updated yet simple
bamboo construction details ensure that local labor may be used for construction
and long-term maintenance. Applying modified construction methods to other
buildings on the site allow for innovative roof expressions; iconic gestures in
sustainable design. To strengthen the destination experience, we incorporated
the use of lightweight tent structures. Versatile yet simply constructed from
bamboo and wax-treated fabric/textile, these structures are proposed for several
public areas. These lively spaces offer flexibility, natural light and ventilation
using environmentally-friendly yet durable materials made by the Kallari Craft
Association members. Another subtle departure from traditional Kichwa
construction is the use of Gabion “rock cage” walls. Essentially rocks enclosed a
wire box; these durable modules are used to integrate the buildings with the
natural geography. Gabions are proposed to be used for both earthwork and
building applications filled with native rock material removed during necessary
clearing of the actual site.

Not all building materials can be local or rapidly renewable. Wherever possible,
we intend to employ recycled content and/or salvaged materials in lieu of “off
the shelf” products. Spanning a wide spectrum, this class of materials includes
fiberboard, steel and local salvaged materials. The use of wood and bamboo
products from certified forest stewardship suppliers that support sustainable
forestry practices are another responsible option. Recycled, reclaimed or FSC
type certified alternatives all minimize the impact of using raw or finite natural
resources.

To address the many characteristics of a rainforest site, we propose the use of
various low-impact strategies which cooperate with the natural geography. The
primary site challenges are the steep-sloped rainforest habitat and an abundance
of water. In response, our stepped/linear plan bends with the contours and
engages the site through terraces and retaining walls. Conforming to the natural
grade and contours, the profile of buildings and landscape are minimized, both
visually and physically. Site terracing minimizes unnecessary cut/fill earthwork
and helps to control runoff and erosion. With 2 meters or more of annual
rainfall, water is abundant most of the year. To address water surplus and use,
various water strategies must be employed including:

On a sloped site abutting a river, controlling soil erosion is imperative.
Construction site boundaries and temporary erosion techniques minimize the
disruption to the native ecosystems during construction. Restoring all disturbed
native vegetation maintains the local habitat and further reduces erosion. Using
strategically placed native shade trees will offer erosion control while aiding
heating and cooling of buildings.

Considering the Kallari Association’s remote location, concerns about energy
consumption and supply are justified. To rely solely upon grid power would be a
mistake. Several forms of free, clean energy are available to the Kallari facility.
Redundant power sources must be employed to guarantee operations continue
regardless of the grid. By first reducing the energy consumption, we begin to
solve the energy challenges. We intend to use flexible structures and passive
strategies wherever possible. Through these energy-saving measures, we
greatly decrease the power demands. These measures include: Thermal mass
heating and cooling, operable wall panels for ventilation and day lighting, deep
eaves for shade, gravity-fed plumbing, living roofs, locally produced recycled
shredded textile/cotton insulation, compact fluorescent and LED lighting, highefficiency
on-site-powered HVAC equipment, low-albedo roof and paving
materials to reduce heat gain and landscaping oriented to provide shade. With
these measures in place, we can predict the power consumption for normal
operations and design our systems for maximum efficiency. To estimate the size
of this system, we performed a few preliminary calculations. The anticipated
load for the factory is as follows:

Anticipated Chocolate Factory Electrical Loads

Average DC Load	Volts	Amps	Watts	Hrs./Day	WH/Day
Granite stone chocolate grinder	24	40.0	960	8.0	7,680
Inverter (for AC loads)	24	19.0	456	11.0	5,016
Chocolate temper kettle	24	43.0	1,032	4.0	4,128
19 DC CF lights	24	10.5	252	10.0	2,520
2 Vent fans	24	5.0	30	24.0	3,600
Cocoa bean winnower	24	33.3	799	0.8	599
Cocoa butter press	24	4.0	96	2.0	192
Mold cooling tunnel	24	5.0	48	4.0	960
Cocoa bean roaster	12	5.0	60	2.0	120
Chocolate mold vibrator	12	1.5	18	3.0	54
Total 24,869 WH (full load)

After benefiting from the energy-saving measures, the factory will account for
the largest portion of the electrical demand. Assuming the rest of the facility
uses an additional 10% over the factory load, a rough estimate of required peak
kilowatt hour demand is 27.3 kWH. This estimate assumes the unlikely scenario
that all facility electrical equipment is operating at the same time. A reasonable
operational factor of 80% yields an estimated demand of 21.9kWH. To meet this
demand, on-site energy will be provided by multiple sources apart from grid
power. Some strategies operate at peak efficiency during specific seasons, some
only during the day. An example of such is solar power. With a $20,000 USD
budget available for solar electric, this system will likely provide only a fraction of
the total electricity needed for the facility. This budget will approximately afford
a high quality 2 kW system. Ideally, additional solar equipment would be
donated to the facility. Mounting the panels high on rotating poles, the panel
direction may be adjusted for maximum efficiency. Elevating the solar array of
the ground makes theft more difficult. The sun’s rays may also be used to heat
hot water. We propose to harness this free energy using efficient evacuatedtube
units for preheating water. Additional heating can be added with electric
tankless water heaters. Cold water will be available from the buried collection
tank, naturally chilled.

A more cost effective and productive system of low speed, low-impact microhydroelectric
power generation is proposed to harness additional free energy.
After careful consideration, a system has been selected that minimizes the
impact to the river ecosystem. Based upon the photos of the river, this quantity
may be generated through low-impact hydroelectric equipment. We propose to
cantilever two side-by side Gorlov Helical Turbine systems at a suitable portion of
the river. A proven low-impact system, it affords quiet and efficient hydroelectric
power generation on-site. University of Michigan studies have verified the small
pressure zone formed by the blade motion causes fish to swim around the
turbine, similar to a rock in current. They can be installed with light weight
locally built suspension frames limiting impact on rive bank and bottom surfaces.
The blades spin at less than 100rpm (3/4 second per 3’ diameter revolution)
virtually eliminating risk of impact damage to aquatic life. Very affordable, two
(2) helical turbines and associated switch gear equipment, heat pump, and
battery banks would cost approximately $20,000 USD. This price is equivalent to
the solar budget and could be substituted in its place. The installed turbine cost
is approximately under $5,000 USD and could be phased for cost control.

(See Kallari supplemental text for flow chart of the micro-hydroelectric
generation and distribution system)

Generating in DCV is preferred, starting with one turbine/generator unit, and as
the site and development expands adding more as required. Generating in DCV
avoids complexities associated with ACV power including synchronizing the
power waves of multiple generators. From the generators the line voltage flows
to a load control center that will primarily power the DC panel, secondarily
charge the DC battery bank, and tertiary dump to the cooling system. The
batteries act as back-up to the DC panel, in case the turbines/generators need to
be taken off line for service. From the DC panel all DC equipment motors are
powered, as well as DC lighting, DC outlets, Heating equipment, heat pump(s),
compressors and an inverter to produce AC voltage. The AC voltage is fed
through a panel to power the remaining AC motors and auxiliary 110v outlets.
The reason for providing both DC and AC power for motors and/or appliances
are is that certain equipment/motors are not available in DC.

(See Kallari supplemental text for flow chart of the micro-hydroelectric
generation and distribution system)

The electricity generated from solar and/or low-impact hydroelectric will be tied
to a central battery bank. Excess power, generated 24hrs a day 7 days a week,
by the micro-hydroelectric plant could power a heat pump for heating, cooling
and humidity control as well as hot water for facilities and equipment. Surplus
power may be potentially sold through net metering or other means. The local
power grid and on-site Biodiesel generators are proposed as emergency backup
power sources.

The Kallari Association facility has been designed to LEED New Construction
standards with the intent to achieve the equivalent of LEED Gold certification. By
using LEED as a framework for design, we have applied many sustainable
strategies to the facility, serving both people and environment. Among the many
purposes, we propose that the facility also serve as an interpretive center for
sustainable design. Very few facilities on the planet could serve as a powerful
example of the nexus of community, business and environment. Placing simple
placards at each feature, visitors could take some of this consciousness home
with them.

Internet and Computer Technology

After careful consideration of various options for the computer technology,
communications, and internet connectivity, our experts recommend the Kallari
focus on their primary chocolate production business to avoid operational pitfalls
and distraction from the primary goals. While Information Technology is
important it can be a distracting and energy intensive. Initially all web based
content would more appropriately be hosted and maintained by a service
company with a 24/7 capability and reliable broadband connection to the
Internet.

Web access for education needs to be accessible virtually on demand. The
notion of a mobile technology facility creates an inherent conflict in that the
information is taken away in the computer itself, unlike the “bookmobile” model
which leaves the information behind. We suggest the mobile facilities be viewed
as assets for trained staff who visit the outlying sites. If Internet access is
desired in remote locations satellite access is probably the only viable network
option, though cost and complexity need to be considered. Vehicle or generator
power is likely to be required.

The primary form of computers should be notebooks. They consume less power,
can be moved to the place of need, and can be more easily secured from theft.
The exception would be the primary computer in the business area of the
factory. Its role would be as a server to back up vital information from the
portables, control access to the network connection, and host the business
system of the factory.

Simple lead-acid storage batteries are the energy storage medium of choice due
to their universal availability, longevity, and simplicity. Recharging systems are
simple and can be installed in fixed locations powered by grid, hydro, and solar
power generation systems. Portable PCs can be powered/recharged via simple
inverters and/or regulators.

We suggest considering the IT equipment as the base of a pyramid of
capabilities. A good foundation of reliable equipment, simple software, and
trained staff is required to avoid the system ending up unused or in need of
minor repairs in a closet. Simplicity should be the guiding principle.

(See Kallari supplemental text for a diagram of recommended approach to
computer and internet technology development that allows the Kallari to grow
into greater and ongoing responsibility)

(See Kallari supplemental text for a diagram describing the key relationships
between technology, responsibility and skill advancement within the community)

Location

Cuyuja, Napo

Ecuador

Project Updates

South America Challenge

Name: South America Challenge
Host: AMD Open Architecture Challenge
Type: Public
Registration Deadline: 02/29/2008
Submission Deadline: 02/29/2008
Entry Fee: $$30: $0 for Dev. Nat.
Award: 1/3rd share of entry fees
Contact: Kallari Association
Status: Voting Period

The competition entry ID for this project is 1863.

Additional South America Challenge Links

Interested in hosting your competition on Worldchanging? Contact Us and tell us about your competition!

1863_Kallari

Location

South America Challenge

Worldchanging Competition Undefined Block

Who's online

Online users

Footer Menu