‍Widespread Child Illiteracy and Educational Barriers:

In Madagascar, about 45% of children are not in school due to economic hardship, resource scarcity, and inadequate infrastructure, reflecting a broader crisis in sub-Saharan Africa with 34 million children out of school.

Impact of Natural Disasters:

The country faces the highest frequency of cyclones in Africa, with significant damage to educational infrastructure, highlighting the inadequacy of traditional construction methods in ensuring safe learning environments.

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‍Logistical and Climatic Challenges in Remote Areas:

Difficulties in material transportation, scarcity of skilled labor, and cyclone vulnerabilities necessitate innovative construction methods for durable and quickly deployable educational facilities.

Need for a Paradigm Shift in Education Infrastructure:

Madagascar requires  a transition to building techniques that are resilient against its unique challenges to provide every child the opportunity for a quality education in a safe environment.

‍What We Did:

The proposed plan for the Prototype 3D printed pilot hut for Thinking Huts reflects the innovative use of 3D printing technology to create educational spaces in Madagascar’s rural regions. The structure's hexagonal design is not only aesthetically pleasing but also aligns with the project's focus on efficiency and community space. The compact yet functional layout suggests a mindful approach to utilizing space effectively for educational purposes, potentially offering a transformative solution to educational infrastructure challenges in the region

General Layout:

The plan shows a hexagonal structure, aptly chosen for its efficient use of space and materials. Each side of the hexagon measures 10185mm x 910 mm (approximately 33’-5” x 29’-10”). The hexagon's corners have additional cut-out areas for windows and an entrance. The interior space, has an area of 66 m2 or approximately 712 SF (square feet). There are 4 planters that flank all the corners of the foundation, each of which is 3D concrete printed into a unique shape that helps define the space as the prototype classroom might be deployed in rural areas sometimes as a single unit. The planter has an integral wood bench that allows the students to sit outside in small groups for outdoor learning or activities. The planters would be filled with local flora and fauna and will most likely be used to grow vegetables.

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‍Foundation:

Spans 12040mm by 12040mm, providing a robust base for the classroom. Its core is a concrete slab on grade, reinforced with an integrated network of 8mm transverse and 10mm longitudinal steel rebars, ensuring strength and stability with a density of 350kg/m3. Placed on the native clay soil, the foundation begins with a compacted soil base, enhancing load-bearing capacity and forming a resistant barrier to water ingress. A gravel course above this compacted layer serves as a critical capillary break, preventing groundwater from wicking upwards. A 6-mil polyethylene moisture barrier is then placed over the gravel to rigorously protect the slab from moisture. The subsequent sand layer functions to regulate the concrete's hydration, ensuring a smooth curing process, essential for mitigating cracks and structural weaknesses. The outer grade beam, measuring 200mm in width and 600mm in height, and an internal beam of 380mm by 600mm, trace the hexagon's perimeter, effectively distributing the structural load.

Wall Thickness and Height:

In designing the walls for the 3D-printed classroom, we focus on structural integrity, thermal efficiency, and durability. The walls are constructed using the COBOD’s BOD2 3D printer and stand at a max printing height of 11 feet, with an overall thickness of 7”, meticulously crafted for both strength and insulation. The construction features a dual-layer of 3D-printed concrete, each 2” thick with a layer height of 3/4", encompassing a 3-inch air cavity designed for blown-in insulation, aiming for an R-value of 15. 3D printed walls are considered to be a very high-performance wall system as they significantly reduces thermal bridging, bolstering the classroom's energy efficiency.

The masonry ties embedded within the wall fortify the connection between the layers, ensuring structural cohesiveness. Above the doors and windows, a 5mm thick metal span plate is strategically placed, functioning as a lintel to bear loads over the openings and providing a reliable shelf for the 3D printer to continue extruding concrete. For durability and reflectivity, the 3DCP walls are coated with an elastomeric white paint. This specialized coating serves multiple purposes: it protects the concrete from the elements as it hardens into a flexible, watertight covering, bridges minor surface cracks preventing water ingress, and due to its reflective nature, it significantly reduces solar heat gain, keeping the interior of the classroom cooler and more comfortable in Madagascar's sunny climate.

Drawing on the advanced properties of Holcim's TectorPrint concrete mix design, the walls possess an estimated compressive strength of 4,250 psi and an estimated shear strength of 320 psi, exceeding the structural resilience of the typical single wythe brick masonry construction used on the island. The thoughtful design encapsulates the confluence of technology and material science, ensuring the classroom stands resilient against the demands of its harsh stormy environment.