Material Exploration

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A research-driven phase that deepens the investigation into the functionality and performance of selected materials.

Working alongside specialists, scientists, and engineers, the research team tests and refines material combinations for structural integrity, durability, and environmental responsiveness—seeking innovative applications in design, architecture, and sustainable production. This chapter offers comprehensive documentation of material mix ratios, workshop processes, and lab test results, forming a foundation for future development and application.

It is a chapter where possibility meets performance, mixing experimentation with actionable insight.

About

Site Matters

Intuitive Making

Discourse

Material Exploration

Manifestation

Spatial Adaptation

an index of Material Variation

The exploration began with a base mix of clay, charcoal powder, and water.

Test A

Establishing a baseline ratio between clay and charcoal powder.

A3 was selected as the base ratio for most subsequent variations.

Test B

Adjusting the liquid content and substituting water with vinegar.

Test C

Incorporating fibrous material to improve cohesion and reinforcement.

Test D

Adding biopolymer, nano-material, and natural binder to test structural strength.

Test E

Introducing mineral stabilizers to enhance binding performance.

Test R

Adjusting water content to transform the mixture into a renderable material.

constant: Methodology

Preparation of Materials

Clay

01 — The clay was sieved to remove large clumps and broken down into a powdery form.

02 — The sieved clay was further blended into a fine powder.

Charcoal Powder

01 — Charcoal chunks were crushed into smaller pieces, then blended using a machine.

02 — The resulting powder was sieved; larger particles were returned to the blender for further processing.

Material Measuring

A standard measuring cup was used for clay, charcoal powder, and liquids, all measured in milliliters (ml).

Biopolymers and nano materials such as chitosan and graphene were measured using a scale in grams (g).

Material Mixing

All materials were poured into a bucket and mixed thoroughly using a tossing and rolling method, without direct hand contact or pressing.

Formwork & Ramming Process

01 — A plywood formwork measuring 100 × 100 × 100 mm was held together using G-clamps. Two scoops of the material mix were placed into the formwork.

02 — A 100 × 100 mm plywood plate was placed on top of the material to serve as a press. A manual compaction rammer was then used to tamp the material 15 times to compress and compact it.

03 — The cover was removed, and steps 01 and 02 were repeated until the block reached a total height of 10 cm.

test: Impact Test

Model:

Automatic Compression Machine 2000kN Eco Smartz

Purpose:

To determine the compressive strength of concrete by gradually and uniformly applying a specific compressive load to the sample, with automated force control and data recording via a touchscreen display, thereby streamlining the testing process.

ASTM:

The test was conducted following American Society for Testing and Materials standard (ASTM C39).

Procedure:

1. Measure the dimensions of the sample to calculate its volume.

2. Weigh the sample using a digital scale.

3. Calculate the density by dividing the mass by the volume.

4. Turn on the compression testing machine.

5. Enter the sample’s weight, density, and aging time into the touchscreen interface.

6. Place the sample vertically at the center of the machine platen.

7. Press the start button to begin applying the compressive load.

8. Observe the increasing load on the display screen.

9. Stop the test when the load begins to decrease, indicating failure.

10. Carefully remove the cracked sample from the machine.

test: Microscope Test

Model:

Handheld Digital Microscope (Image Resolution 1920*1080; Focus range 15mm-40mm)

Purpose:

To examine and document the exterior surface morphology and interior microstructural features of concrete using an optical microscope, in order to identify visible defects, voids, aggregate distribution, and the cement matrix interface.

ASTM:

Not Applicable

Procedure:

Turn on the optical microscope and adjust the illumination settings.
Place the sample securely on the microscope stage.
Start with low magnification to observe the overall structure and locate key features.
Gradually increase magnification to focus on fine details such as cracks and pores.
Record observations of aggregate size, distribution, surface texture, and presence of voids or microcracks.
Clean the stage and microscope lens after completing the observations

test A:

Objective:

Establishing a baseline ratio between clay and charcoal powder.

The objective of Test A is to establish a baseline understanding of how varying charcoal content influences the material properties when mixed with clay. With three different clay-to-charcoal powder ratios this study aims to evaluate the effect of increasing charcoal content on workability, density, and overall performance.

Material:

Charcoal Content Variation

microscopic _ material density _ [ cracked surface ]

microscopic _ material density _ [ flat surface ]

impact test _ Automatic Compression Machine 2000kN Eco Smartz

100 x 100 x 100mm rammed cube

1500ml

500ml

300ml

3 : 1

clay

charcoal powder

water

clay : charcoal

clay

charcoal powder

water

clay : charcoal

1750ml

250ml

300ml

7 : 1

clay

charcoal powder

water

clay : charcoal

2000ml

0ml

300ml

1 : 0

test B:

Objective:

Adjusting the liquid content and substituting water with vinegar.

This test aims to observe how changes in the type and amount of liquid affect the mixture's consistency, binding behavior, and potential chemical interactions. The results will help determine the suitability of alternative liquid additives in the molding of the mixture.

Material:

Liquid Modifier Variation

microscopic _ material density _ [ cracked surface ]

microscopic _ material density _ [ flat surface ]

impact test _ Automatic Compression Machine 2000kN Eco Smartz

100 x 100 x 100mm rammed cube

1500ml

500ml

80ml

clay

charcoal powder

water

vigenar

clay

charcoal powder

water

vigenar

1500ml

500ml

200ml

0ml

clay

charcoal powder

water

vigenar

1500ml

500ml

300ml

0ml

test C:

Objective:

Incorporating fibrous material to improve cohesion and reinforcement.

To investigate the effects of incorporating fibrous materials—specifically coconut husk and sawdust—into the clay–charcoal mixture to enhance cohesion and structural reinforcement. By introducing natural fibers, the study aims to improve the material’s tensile strength, crack resistance, and overall integrity.

Material:

Fiber Reinforcement Variation

microscopic _ material density _ [ cracked surface ]

microscopic _ material density _ [ flat surface ]

impact test _ Automatic Compression Machine 2000kN Eco Smartz

100 x 100 x 100mm rammed cube

1500ml

500ml

300ml

150ml

12: 4 : 1

clay

charcoal powder

water

saw dust

clay : charcoal : dust

clay

charcoal powder

water

coconut fiber

clay : charcol : coconut

1500ml

500ml

300ml

125ml

12 : 4 : 1

clay

charcoal powder

water

fiber

1500ml

500ml

300ml

0ml

test D:

Objective:

Adding biopolymer, nano-material, and natural binder to test structural strength.

To evaluate the impact of advanced additives—such as biopolymers, nano-materials, and natural binders—on the structural strength and performance of the clay–charcoal composite. To find other natural alternative materials to replace cement like material enhancing properties of rammed block.

Material:

Bio Polymer/ Nano/ Natural Binder

microscopic _ material density _ [ cracked surface ]

microscopic _ material density _ [ flat surface ]

impact test _ Automatic Compression Machine 2000kN Eco Smartz

100 x 100 x 100mm rammed cube

1500ml

500ml

300ml

30ml

1.5%

clay

charcoal powder

water

graphene

clay

charcoal powder

water

chitosan

1500ml

500ml

300ml

30ml

1.5%

clay

charcoal powder

water

fiber

1500ml

500ml

300ml

0ml

test E:

Objective:

Introducing mineral stabilizers to enhance binding performance.

To evaluate the effectiveness of natural and chemical stabilisers in enhancing the durability, water resistance, and structural integrity of the clay–charcoal composite. By introducing stabilising agents such as lime, starch, or other binders, the test aims to reduce material degradation, shrinkage, and erosion over time.

Material:

Material Stabilisation

microscopic _ material density _ [ cracked surface ]

microscopic _ material density _ [ flat surface ]

impact test _ Automatic Compression Machine 2000kN Eco Smartz

100 x 100 x 100mm rammed cube

1500ml

500ml

300ml

150ml

10 : 3 : 1

clay

charcoal powder

water

cement

clay : charcoal : cement

clay

charcoal powder

water

hydrated lime

clay : charcoal : lime

1500ml

500ml

300ml

150ml

10 : 3 : 1

clay

charcoal powder

water

fiber

1500ml

500ml

300ml

0ml

test R + A:

Objective:

Adjusting water content to transform the mixture into a renderable material.

to adjust the water content of the clay–charcoal mixture to achieve a renderable consistency suitable for surface application. The aim is to identify the optimal amount of water that allows the mixture to remain cohesive while being easily spreadable, ensuring it adheres well to substrates without compromising its structural integrity or workability.

Material:

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Render of Charcoal Content

Variation

render (wet) _ mesh + sheer _ 100 x 100mm

R.A3

R.A1

render (wet) _ plywood _ 100 x 100mm

R.A2

300ml

100ml

180ml

3 : 1

clay

charcoal powder

water

clay : charcoal

clay

charcoal powder

water

clay : charcoal

350ml

50ml

210ml

7 : 1

clay

charcoal powder

water

300ml

100ml

180ml

test R + B:

Objective:

Adjusting water content to transform the mixture into a renderable material.

Material:

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Render of Liquid Modifier

Variation

render (wet) _ mesh + sheer _ 100 x 100mm

R.B2

R.A3

render (wet) _ plywood _ 100 x 100mm

R.B1

300ml

100ml

180ml

3 : 1

clay

charcoal powder

vingar

clay : charcoal

clay

charcoal powder

water

vingar

clay : charcoal

300ml

100ml

90ml

3 : 1

clay

charcoal powder

water

clay : charcoal

300ml

100ml

180ml

3 : 1

test R + C:

Objective:

Adjusting water content to transform the mixture into a renderable material.

Material:

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Render of Fiber Reinforcement Variation

render (wet) _ mesh + sheer _ 100 x 100mm

R.C2

R.A3

render (wet) _ plywood _ 100 x 100mm

R.C1

300ml

100ml

180ml

clay

charcoal powder

water

saw dust

clay

charcoal powder

water

coconut fiber

300ml

100ml

180ml

clay

charcoal powder

water

clay : charcoal

300ml

100ml

180ml

3 : 1

test R + D:

Objective:

Adjusting water content to transform the mixture into a renderable material.

Material:

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Render of Bio Polymer / Nano /

Natural Binder

render (wet) _ mesh + sheer _ 100 x 100mm

R.D2

R.A3

render (wet) _ plywood _ 100 x 100mm

R.D1

300ml

100ml

180ml

6ml

1.03%

clay

charcoal powder

water

graphene

clay

charcoal powder

water

chitosan

300ml

100ml

180ml

6ml

1.03%

clay

charcoal powder

water

clay : charcoal

300ml

100ml

180ml

3 : 1

test R + E:

Objective:

Introducing mineral stabilizers to enhance binding performance.

Material:

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Render of Material Stabilisation

render (wet) _ mesh + sheer _ 100 x 100mm

R.E2

R.A3

render (wet) _ plywood _ 100 x 100mm

R.E1

300ml

100ml

240ml

30ml

10 : 3 : 1

clay

charcoal powder

water

cement

clay : charcoal : cement

clay

charcoal powder

water

hydrated lime

clay : charcoal : lime

300ml

100ml

230ml

30ml

10 : 3 : 1

clay

charcoal powder

water

clay : charcoal

300ml

100ml

180ml

3 : 1