Raw Timber Pergola

The Project

In a collaboration between IAAC’s Robotics Lab and the Circular Factory the research project supported by Prospera has explored the challenges of a more sustainable construction for the Caribbean island of Roatan, Honduras. Here the tourism economy has driven an exploitation of resources and workforce beyond sustainable development, challenging the real estate sector for alternative approaches. Instead of using imported concrete and prefabricated metal, the research explored the potential of robotics & computation to make a contemporary structure  from local wood and craft practices. 

On Prospera grounds, the Circular Factory has established a state of the art Micro-Factory with the support of IAAC, that  demonstrates the possibility to make high-end architecture with local craftspeople and local wood, using accessible and flexible technologies such as robotic fabrication. To kickoff the new factory, a workshop with the Master students of IAAC (Barcelona, Spain) and USAP (San Pedro Sula, Honduras) was held to explore the potential of this microFactory to rethink architecture and construction details. The result after 1 year of research and 2 intensive weeks of production was the construction of a large-scale prototype that served as a pergola for the local staff on Prospera ground. 

The research involved three steps over one year : In a first step, different material streams, fabrication technology and construction products have been explored within the specific context of Roatan, taking in considerations requirements such as sustainable sourcing, productive fabrication, and assembly. In a second step a set of prototypes was produced and tested in a research lab using a mock-up system of robot and wood similar to the one to be found on the island. In a third step, a final prototype was built in-situ using a newly setup microfactory employing local crafts people together with robots. 

The final construction exhibits a structure made of laurel tree sourced on the island, with a focus on using forks and short sections usually discarded in wood manufacturing. The trees were scanned by drones to inform a computational design workflow that adapts the geometry and production workflow to reduce waste while increasing productivity. This flexible software stack was completed with a versatile fabrication setup using two robots on tracks combined with a custom holder and tracking system, permitting a quick and adaptive production process. The wood structure was then completed with a traditional  palapa roof system. This semi-automated workflow was supported by different workers, from expert carpenter to robot researcher, where adaptability and communication was key. The final outcome is a 5 m tall wood structure covering 20m2 for the local community to rest in the shadow.

Our Contribution

The project gained from the expertise of IAAC’s Robotics Lab in developing flexible and productive digital design and fabrication systems for the construction industry. After a consultancy phase with experts and researchers, the project then moved to an academic collaboration where faculty and students of IAAC’s Master in Robotics and Advanced Construction, and the Master in Advanced Architecture explored the new material and architectural possibilities offered by this unique micro-factory in roatan. The project reflects IAAC’s commitment to hands-on experimentation and its belief that the future of architecture lies in locally rooted, technologically empowered solutions.

Who is it for?

The pergola was designed for local workers and residents of the Prospera site in Roatán. Beyond its immediate use as a community structure, the project provides a blueprint for other Caribbean regions seeking low-carbon, high-quality building solutions that make use of native materials and local knowledge.