The renovation of Intelhorce factory recovered a historical building of the textile industry of Málaga, preserving its inner space and its spectacular concrete structure. Energy efficiency led the design concept of the new façade formed by huge pleated GRC panels which flow lightly expressing the dynamic state of fabric.
项目概述 | GENERAL DESCRIPTION
The project consisted of rehabilitating Intelhorce, an important textile company of the past century located in Málaga, Spain, to become the new logistic center of Mayoral, one of the main children’s clothing companies around the world. For the main building renovation, the project preserves the inner space, repairing the main structure and includes the design of a new representative façade. Simultaneously, the rest of the industrial area is prepared for the future extension of the company.
▼旧纺织工厂转变为Mayoral童装公司的新物流中心，the old Intelhorce factory was renovated to become the new logistic center of Mayoral clothing company
Improving energy efficiency and reducing the CO2 footprint were at the foundation of the design concept. Therefore, the new façade was designed as a solar shading system made of GRC panels, the largest fabricated in Spain. Its design, inspired by a pleated piece of fabric, generates a functional envelope that reduces the direct solar radiation by 39%, becoming the new image of Mayoral.
▼新立面的设计灵感源于带有褶皱的面料，the design of the new facade was inspired by a pleated piece of fabric
理念、背景和策略 | CONCEPT / CONTEXT AND STRATEGY
When Intelhorce (1957-2004), a public textile company, went bankrupt, Mayoral acquired the complex (30 Has) to develop its new logistic center and as a reserve area for its future expansion. The rehabilitation of the main building, (Vázquez, Valdés. 1963) became the core of the project, and consisted of: 1. Recovering the structure; 2. Improving the energy efficiency of the building; 3. Designing a new skin that represents the textile company.
▼建筑内部的旧结构得到了保留和修复，the inner space and the original main structure was preserved and repaired
▼新的空间适应了物流中心的功能需要，the inner space is renovated to function as a new logistic center
▼空间细部，interior detailed view
The main challenge was creating a bioclimatic performative façade that represented a textile company. Therefore, we formulated our design strategy: creating a shading system using the concept of “fabric” as the leitmotif of the final form: a fabric that protects the building from the sun. The next challenge was the integration of the historic building with the new skin. Hence, we used the scale and proportions of the cross section of the existing structure as the base geometry of the panels. Finally, we had to come up with a low cost decorative solution for 10 Has for the expansion areas. So, we used different recycled materials to design a decorative pattern, based on a macro image of wool, as a kind of sustainable land art strategy.
▼新立面系统能够有效地保护建筑不受日晒干扰，the shading system protects the building from the sun
施工、材料和结构 | CONSTRUCTION / MATERIALS AND STRUCTURE
The whole project has been based on a sustainable approach. For the urbanization we used a microclimate strategy to reduce temperature close to ground level analyzing different scenarios by digital simulation. For the building, we used several bioclimatic strategies and through solar radiation analysis and CFD simulation, we explored different solar shading systems and natural ventilation strategies. The main materials used were concrete and steel for the structure, sandwich panels with a zinc cover for the roof, and the GRC stud-frame system panels for the façade. The main construction challenge was the manufacture of the 13.5 meters long GRC panels, because the maximum recommended length was 7.5 meters. The strategy was using the pleated geometry of the panels to increase its rigidity, increasing the thickness of the GRC layer and reinforcing the steel frame.
▼以螺柱框架支撑的GRC板面系统，GRC stud-frame system panels are used for the façade
▼屋顶处使用了镀锌的夹层板，the roof constitutes of sandwich panels with a zinc cover
The next challenge was the assembly on site of the panels in the correct inclination. Consequently, we had to use an aircraft industry tool to make it possible. Nowadays, these are the largest panels manufactured and assembled in Spain and probably in Europe.
▼褶皱的几何形状能够增加立面的刚度以及GRC板面的厚度，the strategy was using the pleated geometry of the panels to increase its rigidity, increasing the thickness of the GRC layer
▼设计示意图和生成过程，conceptual diagram-generation process
▼立面模块生成过程，definition process of the facade modules
▼立面日照分析图，study of solar radiation on the facade