Canopy of Doors — Daniel Gehr

The Canopy serves as a low-tech continuation the digitally fabricated self-scaffolding Project RE_Entry marquee structure to illustrate the range of design and construction tool capabilities of Project RE_ paired with the narrative of reclaimed material from the Construction Junction retail floor becoming value-added products of the Project RE_ workshop. The primary structure is built from dimension lumber and aluminum angle. Over 90 reclaimed hollow core doors flow through the structure - attached with strips of reclaimed hardwood flooring

The Canopy undulates above the threshold between the two pavilions of Project RE_ and leads from the entry marquee on the Construction Junction retail floor to the Project RE_ workshop.

This is sheet from the permit drawing set.

Takeoff drawing calling out every piece and joint type by it's label. It was used as a visual aid during construction.

Working out the most efficient assembly with two teams of two workers, one UDBS student and one apprentice of Trade Insitute of Pittsburgh.

Working through scaffolding plank needs.

Inventory processing of reclaimed hollow core doors to be retrofitted and in the Canopy.

Manipulating the door panels properly oriented in natural light on a 1 1/2" = 1'-0" scale model.

Variation of indirect natural light on 1 1/2" = 1'-0" scale model.

3/4" = 1'-0' scale model

Building physical models was key to choreographing the hollow core door panel the aesthetic and the natural and artificial lighting qualities. Scaling up in physical models brought nuanced moments which make for special experiences underneath the Canopy.

Final full-scale mock-up built atop the corner mock-up of a pavilion.

Testing assembly of joints using different jigs and tolerances.

Early scaffolding plank iterations playing of Project RE_Entry scaffolding plank design.

Final scaffolding plank underside handhold is made from drilling two holes.

Testing scaffolding plank lifting from the side ergonomics.

Full-scale mock-ups worked through ergonomic conditions including installing the door panels, using the scaffolding planks, and iterating jigs to aid in assembling the aluminum angle joints. The final full-scale mock-up flushed out details between the Canopy structure and the two pavilions and was the last test of its structural integrity.

Takeoff drawing noting hardware quantities.

These edges were cut with a cutoff wheel.

I spent around 200 hours in 2 weeks milling. Fortunately I had a lot fun because the old Bridgeport mill is a beautiful machine.

Apprentices of Trade Institute of Pittsburgh have the tools in the Project RE_ workshop to cut and mill aluminum. Aluminum angle was used to join the primary structure together and this maintains consistency with the Project RE_Entry structure.

The detail of attaching the hollow core door panels to the primary structure underwent numerous iterations. Using reclaimed pegboard hooks was a viable option and these are some images of one set of many iterations manipulating this material.

The final detail uses reclaimed hardwood flooring and a simplified bending procedure of the pegboard hooks.