In June 2016, we started to work on an medium size aquaponics system ( 1m3 fish tank , 1 m2 of media bed, 3m2 of NFT) outside of the Green Fab Lab. We’ve been following a design proposed by the FAO using recycled materials such as IBC cuves, food barrels, etc.

This system is a small scale version of what could be an aquaponics farm on the rooftop of Barcelona. The idea behind, is to work with different growing techniques such as Media Bed, NFT and ZipGrow towers, to learn valuable lessons on aquaponics system operation, plant production, crop scheduling and pest management. We use it as a “training wheel” to make small mistakes, and feel more confident about going into full-scale production.

From April to October, the average temperature is between 16°C and 25°C which is optimum to grow our crops, maintain our nitrification bacterias and our fish happy. However, if we want to continue growing crops during the winter, we will need a Greenhouse.  

From the constraints associated to our field (i.e. not straight, rocky, wild and a very unstable corner) and the requirements of aquaponics, we didn’t find any commercial greenhouse fitting our needs, so we decided to Fab it !

With the help of Grégoire Duress ( Green Fab Lab Manager) and his architecture knowledge, the global shape of the greenhouse was designed. We ‘ve followed an inverted hyperbolic cosinus curve to answer the field constraint of 2,7 m wide base and the aquaponics needs of having a minimum height of 3 m. 

We used a 3-axis CNC Milling Machine ShopBot PRSalpha 96 48 to mill all the sandwich joints.

We assembled the arcs one by one. We first began by putting the transversal profiles through the holes of the joints. We then put the structure profiles in the joint and closed the two faces of the “sandwich” with vises. We then fixed the whole with 8 screws.

Repeating the operation for the 7 joints, we finally obtained our arc. We then covered the wood joints with waterproof paint twice to complete the process.

We assembled the arcs one by one. We first began by putting the transversal profiles through the holes of the joints. We then put the structure profiles in the joint and closed the two faces of the “sandwich” with vises. We then fixed the whole with 8 screws.

Repeating the operation for the 7 joints, we finally obtained our arc. We then covered the wood joints with waterproof paint twice to complete the process.

A first step has been to start digging trenches around the greenhouse (they will be useful later cf Construction – The Skin) to level the field and see what the dimensions of the greenhouse could be and remove the disturbing rocks in the ground. For this, we also had to move the already existing aquaponic system towards the centre of the future greenhouse.

We then used ropes to mark the limits of the greenhouse. We finally choose (depending on the field and on the aluminium profiles we had) a 9200 x 2700 mm greenhouse for a height of 3 meters. Such specific dimensions are not common in the Greenhouse market. This is the main reason we had to build our own greenhouse. It also fits the Self-Sufficiency philosophy of Can Valldaura, demonstrating how digital fabrication can help us make our own farming infrastructure.

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