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J.D. O'Callaghan

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Novel Connections Designed for Reusability & Sustainability of Laminated Glass

Master thesis (2025) - M. Motedayen, J.D. O'Callaghan, M. Bilow
This research investigates the design and implementation of modular float glass systems that prioritize reusability and sustainability. The project addresses a significant gap in architectural practices involving glass by developing modular, demountable glass systems that can be disassembled and reused, challenging the traditional, single- use paradigm of glass in construction. Through a comprehensive review of existing glass systems and the exploration of novel connection designs, this master thesis aims to create a modular glass system as pavilion that exemplifies sustainability in architecture. The key focus is on innovating connections that allow for easy assembly and disassembly without compromising structural integrity or aesthetic values. Preliminary findings suggest this specific interlocking connection designs can enhance the life cycle and functionality of glass structures, thereby reducing their environmental impact. ...

Extending the Life Cycle of Primary Glass Structures

Master thesis (2025) - M.E. Venus, J.D. O'Callaghan, G. Mirra
The environmental impact of construction materials, particularly in structural applications, has become a pressing concern in the building industry. A key strategy to reduce this impact is the transition to a circular economy, in which reuse is considered the most effective way to extend the lifespan of a product or component (Platform CB’23, 2019).

Float glass has increasingly been used as a primary load-bearing material in recent decades, driven by the fascination of architects and engineers with its aesthetic and structural qualities (Rammig, 2022). This interest has contributed to significant advancements in its technical development (Giese et al., 2024). Nevertheless, despite the material’s inherent durability and its widespread use in both historic and modern contexts, the reuse potential of float glass remains largely underexplored.

This research explores how a reusable float glass system can be designed, enabled by spatial adaptability and modularity. By creating a practical system design, the study encourages designers and researchers to go beyond traditional recycling and consider other circular strategies. In doing so, it explores a potential pathway to extend the functional lifespan of structural glass, reducing waste, conserving resources, and limiting unnecessary energy use.

The study combines theoretical, computational, and experimental research methods. A literature review laid the groundwork for the conceptual design of structural elements and connections and identified key design principles for structural float glass. Using parametric design experimentation, various spatial configurations were explored based on a selected concept: bent laminated glass modules that dry-interlock, allowing for reconfiguration and straightforward assembly. This parametric exploration showed that a system based on two standardized bent float glass modules - each around one meter in length and with two variable heights of up to half a meter to reduce weight and allow manual handling - enables the creation of variable spans of several meters. This is achieved by interlocking the modules at both positive and negative angles and by varying the assembly sequence of the two standardized heights.

Based on these findings, a parametric tool was developed to generate compression-driven forms using the system. These forms are tailored to the span and shape requirements of a specific location, while optimizing both structural weight and ease of assembly.

In the final phase, structural analyses and laboratory testing demonstrated that the adaptable system, made from 2×6 mm fully toughened glass, is structurally feasible when loaded in compression via the slots. A single slot was experimentally shown to withstand at least 2.5 times the design load of 3 kN, accounting for a worst-case configuration of 70 stacked modules - corresponding to a maximum span of approximately 8 meters. If 2×5 mm heat-strengthened glass is to be used, additional testing will be required to verify its structural performance. ...

Integrated design for glass projects

Glass structures have been dominating in the architectural world for the past decades, unveiling the material’s structural potential. Advancements in glass manufacturing and post-processing techniques have not only led to innovative applications but also resulted in the development of unique glass products. Aluminosilicate glass exhibits superior strength and flexibility compared to the commonly used soda lime glass, due to its distinct composition and manufacturing process. This enables the production of ultra-thin glass with thicknesses as low as 25 μm, giving rise to the category of "thin glass" encompassing any glass below 2 mm in thickness.
Thin glass has found applications in industries such as automotive and electronics due to its unique properties, including optical clarity, scratch resistance, durability, flexibility, and reduced weight. In architecture, the evolving design vocabulary embraces complex geometries and the integration of curved panels, offering clear structures that provide exceptional optical clarity and blend seamlessly with their surroundings. Thus, thin glass holds potential for creating complex, lightweight, and transparent architectural structures.
This research addresses the limitations of thin glass in construction and explores optimal bending techniques to maximize its capabilities. The methodology comprises a literature review of the glass industry, design principles, and an in-depth study of thin glass properties. This study culminates in the establishment of design guidelines and a computational approach to assist the design process while using cold bent thin glass. After investigating the available and most used design and structural simulation software, the ones found more accurate are integrated in the process.
The findings highlight the successful development of a computational method that provides tools, design principles, and guidelines for working with single curved cold bent thin glass panels. Additionally, the research examines suitable connection types for thin glass projects and concludes with a proposal for a hinge clamp connection. A case study showcases the proposed workflow, leading to the creation of a prototype utilizing a 3d-printed based approach of the suggested connection design.
The conclusions emphasize the significance of the integrated computational design workflow and its implications for architectural design using thin glass. ...

Prototyping of a dynamic thin glass unit with a switchable thermal insulation

Master thesis (2023) - P.M. Ullmer, J.D. O'Callaghan, M. Bilow
Building energy regulations worldwide are increasingly advocating for better-insulated facades since improved insulation in facades can significantly reduce a building’s heating energy demand. However, research indicates that super-insulated buildings are already at risk of overheating due to high internal heat storage and low heat loss. In addition, over the past decades, the climatic trend demonstrated a significant rise in surface temperatures. As a result, well-insulated commercial buildings have become increasingly dependent on cooling.
On the other hand, approximately 85% of Europe’s glazing comprises single glazing and uncoated double glazing. This prevalence leads to high demand for heating and cooling energy. Therefore, there is an urgent need to enhance the insulation of these buildings’ glazing while maintaining the existing window frames.
A glass unit prototype with switchable insulation has been developed and assessed to address these issues. The findings of this thesis demonstrate that in mixed climate zones, the utilization of switchable insulation can lead to a reduction in total energy demand by as much as 33% compared to the use of present high-performance glazing technologies.
When advantageous, Inflatable Glazing can be activated on-demand or controlled by internal and external sensors. The heat transfer coefficient of the facade, known as the U-value, can be switched from a low insulating value to a high conducting value. During the cooling period, this technology can be employed to increase the heat flux of the glass unit, thereby enhancing heat dissipation. Conversely, Inflatable Glazing can provide excellent insulation and highly effective solar gain during the heating period.
This thesis investigates the potential of a switchable insulating glass unit for buildings in mixed and mild climate zones, where selecting the appropriate U-value can be complex. The focus is set on building and testing a fully transparent glass unit with a switchable U-value. The innovative material, thin glass, serves as the primary dynamic component due to its advantageous bending properties and strength. ...
Master thesis (2022) - C.J. Backer, J.D. O'Callaghan, M. Bilow
To reduce the heat loss in heritage buildings, this graduation research aims to explore what alternative solutions arise when thin glass is used to design an insulating glass panel that replaces the single glazing? To do so, six different designs are proposed. The first two are an IGU with thin glass and laminated thin glass. The third design is made with a hollow twin-wall sheet of PC and laminated to thin glass. The fourth and fifth proposal are laser cut PMMA connected to thin glass. While design four uses a honeycomb pattern, the fifth proposal experiments with a more freely design of cavities. The last proposal uses glass balls in the cavity of the IGU.

Based on the computer analysis, design 5 and 6 fail on the thermal properties and design 1 and two cannot handle the wind load. For design 1, 2, 3 and 4 prototypes are made but design 4 did not succeed during this research. The others were then tested on the U-value and the maximum force before breakage. This concluded that design 3 performed thermally as expected but design 1 and 2 performed worse, due to a flaw in the computer modelling. Converting the force to the maximum distributed load showed that all designs could handle the wind load. The materials were also tested on ageing due to UV rays. Only the polycarbonate changed significantly over ten years, but with an extra UV-coating, this is avoidable.

The aesthetic of the design 3 and 4 and the opinion of the public are tested with a survey. It can be said that the division between design 3 and 4 was fifty-fifty. If the other design had a better U-value, they did not switch. Depending on the function of the space behind it, people chose design 3 for more private spaces and design 4 for more public spaces. To show the final appearance and precision of the designs, a rendering and details are given. After this, a table is made to compare the designs based on stars which concludes that design 2 is the best alternative solution to replace single glazing in heritage buildings. ...
Master thesis (2022) - W.J. Lasonder, J.D. O'Callaghan, C. Noteboom, F. Messali, K. Haarhuis
Glass is a fascinating material that has also been used as a primary construction material in various remarkable buildings since the last century. Unfortunately, a lot of carbon dioxide is released during the production of glass because of the extreme heat required. The construction industry accounts for ten per cent of global CO2 emissions. If a focus in this sector is put on recycling, reducing and reusing, emissions can be drastically reduced because of less needed new building material. However, structural glass is currently hardly reused. A second challenge arises with existing demountable structures made of glass like the LocHal: these are not weatherproof, thus unsuitable as sheltered accommodation.

In response to the absence of adequate standardised structural glass building systems, this research project proposes a preliminary design for a modular, transportable art pavilion with an appropriate structural verification. The research question is therefore: ’How can glass be applied as load‐bearing material in temporary modular building units to realise easy‐to‐ (dis)assemble, transparent and transportable structures?’.

A case‐study is introduced to find an answer to the main research question. The fictive scenario is sketched to design a temporary art pavilion which stands for one to three months in a city centre in the Netherlands. After this period, the pavilion should be demounted and transported to the next destination. The information described here determines the boundary conditions for the design and calculations. The imaginary pavilion is 24 m in length, 10 m in width and 2.5 m in height. The inner walls in the pavilion are retained to create a natural walking path inside. On the short side of the pavilion, doors are inserted as an entrance and an exit. From the available literature, the transportability of the building elements and the requirement for thermal insulation appear to be important preconditions for the final design.

The design is based on four different types of prefabricated building elements: roof panels, wall panels, floor panels and base profiles. The roof panels are of 220 mm thick cross‐laminated timber (CLT), in length six or three metres and have a width of 2.5 m. The wall panels are of laminated glass, 2.5 m in height and come in two types. Insulated glass units (IGU’s) of 6 or 5 m long function as exterior walls. These consist of an outer sheet of 10 mm fully tempered glass, a 15 mm cavity of 90% argon gas and a triple laminated inner panel of 5.10.5 mm heat‐strengthened glass. The inner walls are of a composition of 5.10.5 mm heat‐strengthened glass. The glass is laminated with a SentryGlas® interlayer of 1.52 mm. CLT is also used for the floor panels, now with a thickness of 210 mm and lengths of 6 and 3 m. The base is defined by steel ’cap’ (RHSFB, lengths of 6 and 5 m) and ’hat’ (THQ, length of 4.25 m) profiles. Both profiles are 265 mm in height.

Roof connections, wall connections and base connections were designed and dimensioned, in total seven different types. The most innovative and structurally interesting joints are two wall connections. These connections consist of a so‐called ’coffee‐ cup‐hand’ system; titanium elements laminated 30 mm into the middle sheet of the wall panels. The wall panels are checked on maximum deflection and tensile stress, as well as the local tensile stress in the glass and in the SentryGlas® interlayer around the laminated titanium elements. All checks comply with the maximum allowable values described in the Eurocodes and in literature.

The conclusion is that the proposed design, with some enhancements to be made, satisfies the structural‐, building physics‐ and practical requirements as a transportable and a relative transparent building system for structural glass. With this building system, glass can be integrated as a load‐bearing material for designs of temporary structures.

Engineers who wish to apply this building system in practice are advised to first enhance the roof connections. For transportation means, the grid‐measurements should be decreased by 8% to fit the components in a regular container. For practice, it is also advised to deal with factors such as installations and drainage systems, which were not included in this study. Follow‐up research could focus on the adaptability of the building system when the building is used with a more permanent function. In addition, it is mechanically interesting to further investigate how the wall connections interact with each other in a 3D analysis and lab experiments. ...

Migration of social adaptation to climate change

The climate is changing and to deal with this climate change, adaptations have to be made to the way we live. This research focusses on a particular site in Rotterdam Zuid in terms of climate change. The research question is the following: How can both- social and hard infrastructure contribute to the creation of a climate proof, resilient community? This question will be answered in the form of a building. Starting with a research about the climate change that has to be dealt with in Rotterdam Zuid. As a group we defined a new vision for the area and we all designed one building that contributes to that vision. In this case solutions for climate change contribute to the vision. This research about the location determined the location of the intervention. After this a research is done into the subject social infrastructure, changing the habits of people from an individual mindset to a communal mindset. This can save lives during a disaster. This research determined the target groups and the function. The elderly and the children and the function should be a combination between an aid organization and a communal center. The Red Cross Social Center. Then a reference research started, different types of communal centers and red cross headquarters have been analysed to come up with a program bar for the project. Along with the program bar, different ambitions have been established in terms of function, site and design. Having all these guidelines set the massing could start. After trial and error the final massing has been established. A rectangular shaped building with a courtyard in the middle. The courtyard can be reached through a large (water)square which creates passages underneath the building. The large green roof is connected to the ground floor to make it accessible to the public to reach the second floor. The ground floor, second floor, third floor, and fourth floor contain public functions for people to establish this social connection, this social infrastructure. On the first floor the headquarters of the Dutch Red Cross is placed. This location and the design of the building will increase their visibility. The aim of the design was to create a building that deals with climate change in terms of hard- and social infrastructure. The hard infrastructure is achieved by various interventions. The social infrastructure is a more difficult topic, the building offers the ideal circumstances for people to create this social infrastructure themselves and create this resilient community. ...

An explorative study on their potential for architecture

Glass buildings seem to be as popular as ever (Louter, 2011) and glass shapes the appearance of contemporary architecture unlike any other building material (Wurm, 2007). Moreover, the demand for glass buildings is rising (Eskilson, 2018). As designers look to make the buildings as transparent as possible, the ambition is to execute structural elements out of glass too. Glass has always been perceived as luxurious and through history has been associated with knowledge, modernity, quality engineering and technological progression. Additionally, glass architecture has always been a signifier of public identity (Eskilson, 2018). These characteristics are still true for modern glass buildings, which is part of people’s fascination with them. In the foreseeable future, to be able to keep captivating people the ‘marvels’ for the average urban viewer should be greater and kept fresh. This is why more variety should be added to the architectural expression while the current characteristics of glass elements should be kept or even enhanced. Another reason for adding new elements to the toolkit is to simultaeniously keep up with building requirements like safety and sustainability. Combined this is why the toolkit for architectural glass needs to be expanded upon to be able to keep up with future building requirements and expectations. A structural element would be a promising addition to the current toolkit because of the already great variety of non-structural elements and the ambition to make more structures transparent. A section-active structural glass element would be a promising addition to the current toolkit because these structural elements are implemented especially often and there is a lack of variety here specifically. To design this section active structural glass element from extruded glass would be promising because the extrusion process allows for complex geometry beneficial to the aesthetic experience and also the structural performance. Another benefit of this process would be that the borosilicate glass used for this is much more fire resistant than the glass used for structural fins (O’Regan, 2015). The research question thus is: what is the potential of section-active extruded glass structural elements for architectural design? To answer this question a design vocabulary is set out in three different design aspects: system, section, and connection. After designing principle solutions the best option is chosen through assessments. The assessment of all parts of the design at all stages will be done following the same criteria. For the criteria a wide perspective was chosen that includes the entire cycle of the element’s lifetime: safety, structural performance, building sequence, sustainability, costs, and aesthetics. After assessments, it is decided on a system comprising of individual post-tensioned segments of elliptical shaped glass section with steel cast connections, bolted together on site. The system is designed as modular, re-usable and recyclable. This draft design is dimensioned through hand calculations and numerical simulations in finite element analysis software. To evaluate the potential of the dimensioned system for implementation in architecture, it is compared to the glass fin which is its only direct competitor. In order to offer a fair comparison the same façade is designed with both systems. The conclusion of this comparison is that the designed system has a promising potential for architectural implementation with regards to structural performance, safety, building sequence, sustainability, and aesthetics. Obviously additional physical testing is needed to affirm estimations and more research has to be done should it be developed to a market-ready product. The exact costs are unclear too as no equipment exists at this point to produce the extruded glass segments in the required dimensions. The tooling costs will be high but the material costs are low, making it especially viable when mass-produced as products with standard dimensions. Summarizing the comparison the first indications and explorations necessitate to think positively towards the possibilities of such an extruded system for architecture. ...