Complex Steel Structures

STRUCTURE OF THE BOOK This proposal for a text on Complex Steel Structures comes immediately following the completion of Diagrid Structures and as I am analyzing the materials collected to date for Architecturally Exposed Structural Steel. Diagrid Structures and Architecturally Exposed Structural Steel were designed to build upon chapters and ideas introduced in Understanding Steel Design, my first book with Birkhäuser on the basis of the suitability for the additional volumes to present materials that were beyond the capacity of the original book. In completing Diagrid Structures and in collecting materials for AESS it has become clear to me that I already have too much detailed information that can possibly be addressed in these volumes. The specific nature of the detailed materials seems to suggest a subsequent volume that addresses the particular topic of the handling of complexity in the design, fabrication and construction of contemporary steel structures.

This volume addresses the handling of complexity in the design, fabrication and construction of contemporary steel structures through innovative techniques that are predominantly digitally based.

Alvin Toffler (author of Future Shock 1965): “The more advanced the technology, the cheaper it is to introduce variation in output. We can safely predict, therefore, that when the construction industry catches up with manufacture in technological sophistication, gas stations, airports and hotels, as well as supermarkets, will stop looking as if they had been poured from the same mold. Uniformity will give way to diversity.”

Marshall McLuhan: “When automated electronic production reaches full potential, it will be just as cheap to turn out a million differing objects as a million exact duplicates. The only limits on production and consumption will be the human imagination.”

We have at last arrived at this time in architecture. Steel architecture has specifically evolved as a manifestation of our ability to create irregular, often asymmetrical, complex forms.

So, what are complex steel structures, how do they feed into this state of existence and why do architects need to be exposed to the details of this subject?

Canadian Museum of Human Rights (2014) Antoine Predock Architect

1. Introduction Image: Walters Inc.

THE EVOLUTION OF COMPLEXITY IN ARCHITECTURAL DESIGN

ACHIEVING ECONOMY THROUGH PREFABRICATION

Complexity in architecture, engineering and construction is constantly increasing due to our present ability to design, calculate and fabricate an increasing range of geometric shapes. Where traditional 20th century architectural design was forced to reasonably limit form-based architectural expression to engineering-based design – resulting in buildings and structures that could be largely be reduced to 2D force systems – the 21st century has stepped beyond those boundaries. Digital design software has permeated architectural education as well as the profession. The innovative advances in steel design and fabrication systems required to reach this level have only come about in the last 10 years. Even from the time of the construction of Swiss Re to Capital Gate, a period of perhaps 8 years, the profession has seen remarkable changes.

Although the supposition might be that all is possible through digital fabrication, there are limits based on prefabrication, digital techniques and material-based limitations – much of which relates to budget and available fabrication technology. In preparing the material for Diagrid Structures it had been my intention to create a specific chapter on the importance of Building Information Modeling to the design of these complex systems. Given the limitations of the length of the text, this subject was largely omitted. The intention of this book is to provide a detailed look at processes and innovative techniques that manage to be true to complex intentions through design, management and having an excellent understanding of these processes and limitations.

THE ROLE OF DIGITAL DESIGN Significant changes in the form of architecture can be directly traced to advances in computing systems for drawing, structural analysis and detailing. The orthogonal, determinate structures of the 20th century (typified by the work of Mies van der Rohe for instance) have given way to steel structures that boast to having no two elements alike. This has created challenges in the project flow and has questioned the previous relationships amongst the team members. Higher levels of expertise are required in order to ensure success on these geometrically challenging projects. Innovation is required to translate 3D architectural models into realizable steel structures. Where the architectural community is adapting their practices to include a BIM based workflow, steel fabricators are using their own specialty software. It is critical that architects are familiar with the processes and the workflow, from design through to construction, to maintain their control and credibility as primary team members.

Where numerous texts have already been published on the role of BIM in the practice of architecture, the approach has predominantly been viewed from the design point of view as the lead.

This does not necessarily truly acknowledge how digital software has actually changed the process of design as it does not look closely at the realities of the fabrication and erection of buildings. Software has served to enable designers to create great varieties of non-orthogonal buildings, and this has required a range of inventions, innovation and responses in construction. The presentation of this subject through the examination of complex steel structures will assist in creating a better understanding of the potential and limitations in this process.

Complex Steel Structures: Non-Orthogonal Geometries in Building with Steel is far more focused on the innovative processes that are now required to ensure highly successful projects whose geometries lie outside regularity and include: curved geometries, chaotic geometries, poly diagrids and lattice grids. Part of this is the constant need to reference the digital 3D models as orthographic drawings are really useless for other than permitting. Complex structures need a different approach to create meaningful and useful drawing sets and complex steel structures are rapidly being developed due to significant advances in this segment of design.

COMPLEXITY IN CONSTRUCTION PROCESSES Not all of the complexity arising in contemporary projects is digital or design-based. Complexity also impacts the way that buildings are constructed. The book will also look at the logistics of construction where the nature of what is being constructed is beyond traditional methods.

This will form an underlying thread to the proposed Project Profiles and will be examined in the second part of the book on a case by case basis. Projects will showcase innovative techniques that are required in order to realize many new challenges in construction and erection.

PROJECTS AND COMPLEX TYPOLOGIES: The book is divided into two aspects. The first aspect will introduce the ideas behind the relationship between steel structures, complexity, innovation and digital processes. This section will be supported by references to a wide range of International projects. The second aspect will highlight a number of detailed case studies where more detailed information is available. The case studies will be of varying lengths to permit some to be integrated into the more general chapters, thereby reserving a few more significant ones to constitute the latter half of the book (similar to the layout of Diagrid Structures).

As many of the projects in this book will be very recent, a number of projects will also be introduced that predated the extreme influence of digital methods and innovative techniques to highlight some of the new possibilities of these methods. It is also anticipated that projects will be included that may only come to knowledge in the next 18 months of preparation and writing, with the intention of ensuring that the book is very current. This would include a range of European projects as it is noted that these need to be expanded.

COMPLEX STEEL STRUCTURES: Non Orthogonal Geometries in Building with Steel

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Construction Processes Handling the Steel Transportation Issues Sequencing of Lifts Limiting Shoring Accessing the Steel for operations Safety issues

Terri Meyer Boake January 2017

PART TWO: PROJECT PROFILES

PREFACE

These will be arranged in a specific sequence that will be determined by the nature of the detailed information that I will be able to provide so that if read in sequence there will be a more natural buildup of information and topics. The profiles would be expected to range from 4 to 10 pages as a function of material available. Consider this an initial list that will be expanded (or projects removed) as determined during the workflow of writing the book. Many of the projects incorporate multiple aspects, making them truly “complex” so will not fall neatly into one category.

PART ONE: COMPLEXITY, PROCESSES AND INNOVATION

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TABLE OF CONTENTS FOREWORD

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Introduction The Evolution to Complexity in Structural Steel Design How Complexity Changes the Nature of Architectural Design and Construction Emergent Innovation in Non-Orthogonal Design Strategies

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The Digital Revolution Building Information Modeling Translating Architectural Design to Structural Design Managing the Flow of Information (communication) Cloud based advantages The importance of Interoperability

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Managing Complexity General discussion about: Repetitive geometries to achieve the appearance of complexity Chaotic geometries that are essentially devoid of repetition Incorporating curvature Layering to achieve complexity The invention of the node (this has been a very critical change in method!)

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Fabricating the Steel Software Systems for Steel Detailing Interactions with the Fabricator to Achieve a Better Product Issues with AESS versus Standard Structural Steel Nodes: Fabricated versus Cast Splices: Design issues, transportation, discreet, hidden

Terri Boake – COMPLEX STEEL STRUCTURES

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In Detail Introduction, Working with Software and Construction Processes: Introduction to this section: Union Station, Toronto, Canada – Zeidler Partnership a. Modular b. construction logistics Queen Richmond Center West, Toronto, Canada - &Co Architects a. Castings b. asymmetrical loading c. construction logistics South Beijing Railway Station, Beijing – Arup w/ TFP Architects a. Modular b. construction logistics Transbay Transit Center, San Francisco, USA – Pelli Clarke Pelli a. Castings b. Extreme size c. Curvature of light wells New York City Transportation Hub, NYC – Calatrava a. high amount of custom work and brake forming

Curved Geometries: 1. Introduction to this section 2. Orient Station, Lisboa, Portugal – Santiago Calatrava a. Curved, complex, trusses, cantilevers b. modular (1998 so an early example of doing this sort of architecture without benefit of advanced digital assistance).

3. Reichstag Dome – Foster + Partners a. Curved geometries b. Modularity c. high level AESS

Terri Boake – COMPLEX STEEL STRUCTURES

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4. Barajas Airport, Madrid, Spain – Rogers Stirk Harbour and Partners a. Curved b. Modular c. eccentric loading d. high level AESS 5. Valencia Science Complex – Santiago Calatrava a. Angled structures, curved, asymmetric loading, complex cladding, moving parts 6. AAMI Park Stadium, Melbourne – Arup w/ Cox Architects and Planners a. Curved geometries b. modular geometries 7. Sage Theater, Newcastle – Foster + Partners a. Curved geometries b. Modularity c. high level AESS 8. Phoenix New Media Center, Beijing – BIAD a. Highly 3D Curved geometries b. asymmetrical loading 8.

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Chaotic Geometries, Asymmetrical Loading: Introduction to chaotic Royal Ontario Museum, Toronto, Canada – Daniel Libeskind a. Diagrid b. Asymmetrical c. chaotic Canadian Museum for Human Rights, Winnipeg, Canada – Antoine Predock Architect a. Diagrid b. asymmetrical, chaotic Bird’s Nest Stadium, Beijing, China – Herzog & deMeuron with Ai WeiWei a. Chaotic b. asymmetrical, diagrid Federation Square, Melbourne – Bates, Smart Architects a. Chaotic geometries, b. asymmetrical loading Kurilpa Bridge, Brisbane – Arup w/ Cox Rayner Architects a. Chaotic geometries, b. asymmetrical loading, c. construction logistics, d. tensegrity e. high level AESS One Manhattan West, New York City a. Nodes b. Highly eccentric loading c. Lifting large members Dalian Convention Center, Dalian, China – Coop Himmelblau a. Asymmetrical b. chaotic

Terri Boake – COMPLEX STEEL STRUCTURES

Diagonal geometries: 1. Introduction to this section 2. World Financial Center Entry Pavilion, New York City – Pelli Clarke Pelli Architects a. Diagrid, curved, asymmetrical, construction logistics 3. King’s Cross Station, London – John McFarlane and Partners with Arup a. Lattice grid, castings 4. Marina Bay Greenhouses, Singapore a. Lattice Grid, curved arch support systems 5. Ottawa Convention Center, Ottawa – Brisbin Brook Beynon Architects a. Example of curved system for wall with innovative component connections for rotation alignment 6. Seattle Public Library, Seattle – OMA a. Example of early planar system and discreet connections 7. BMW Museum – Coop Himmelblau a. Chaotic geometries b. diagrid, lattice grid c. curved geometries d. asymmetrical loading 8. CCTV, Beijing, Arup w/OMA a. Diagrid, asymmetrical loading, extreme construction logistics 9. Beijing Poly Diamond Lantern – SOM a. Diagrid, modular geometries 10. Tokyo Skytree, Nikken Sekkei b. diagonal geometries 11. Torre Reforma, Mexico City, Arup c. Diagonal steel frame on one side of tower

Other projects to include but not profile: Guangzhou Opera House, Zaha Hadid : lattice Cooper Union School of Architecture, Morphosis: similar to structure in BMW Museum Guggenheim Museum, Gehry, Bilbao EMP, Gehry, Seattle (important as one of the first major CATIA projects) UAE Pavilion, Foster Lattice roof over Smithsonian, Foster, Washington, DC Parasol, Spain (wood but steel joints and good for lattices

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Terri Boake – COMPLEX STEEL STRUCTURES

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PART ONE: COMPLEXITY & PROCESSES

COMPLEXITY, INNOVATION & PROCESSES It is evident through the examination of many of the projects that have been the subjects of my research investigation that the practice of design and construction has been enabled and propelled by digital design. This area of research looks quite closely at the importance of the development of Building Information Modeling systems for steel structures. Significant changes in the form of architecture can be directly traced to advances in computing systems for drawing, structural analysis and detailing. The rectilinear, determinate structures of the 20th century (typified by the work of Mies van der Rohe for instance) has given way to steel structures that boast to having no two (elements, nodes, angles‌) alike. This type of steel construction also often excludes modularity as can be found in High Tech architecture. This has created challenges in the project flow and has questioned the previous relationships amongst the team members. Higher levels of expertise are required in order to ensure success on these geometrically challenging projects.

This chapter will specifically look at the current trends in digital software and their impact in facilitating complex steel structures.

- Building Information Modeling - Translating Architectural Design to Structural Design - Managing the Flow of Information

World Financial Center

South Railway Station

Queen Richmond West Center, Toronto (2014) &Co Architects

2. Software Systems & Complex Projects Image: Walters Inc.

Image: Arup

FABRICATING THE STEEL This chapter will go into detail regarding the specific fabrication characteristics and issues that become more particular to highly complex steel structures. These sorts of projects tend to require specialized equipment in the shop to assist with fabricating the steel that may require the elements to be lifted or turned to provide, for instance, welding access.

Some projects may also require pre-assembly in the shop in order to ensure fit and minimize “surprises� on the job site.

- Software Systems for Steel Detailing - Interactions with the Fabricator to Achieve a Better Product - Issues with AESS versus Standard Structural Steel - Manipulating the Steel

QRCW Node model

QRCW cast node, still red hot

Queen Richmond Center West, Toronto (2014) &Co Architects

3. Fabricating the Steel Image: CastConnex

Image: CastConnex

Image: CastConnex

ERECTION CONSIDERATIONS This chapter will go into detail regarding the erection issues that must be addressed when constructing highly complex steel structures. A much higher level of care in handling is essential in order to ensure that the surface of the steel does not get unduly damaged during construction.

Surface damage will have to be repaired or it will translate through to the final finish. Many of these projects might be described as extremely large puzzles, so even sorting and arranging the elements for lifting will not be straightforward. There is a high level of innovating thinking required to realize many of these steel structures.

Erection Considerations: - Handling the Steel - Transportation Issues - Sequencing of Lifts - Site Constraints - Erection Issues - Sequencing the Lifts

Threading in a support at the ROM

World Financial Center Entry Pavilion (2013) Pelli Clarke Pelli Architects

4. Erection, issues with the unique

A night lift at QWRC

PART TWO: PROJECT PROFILES

Within the general topic of Complex Steel Structures there can be identified several types, each requiring a different approach or methodology of design.

Curved geometries: Curves have always been difficult to draw and construct. Irregular curves exacerbate design and construction issues and are only now possible to more easily incorporate into designs in steel. The subject of “how to bend or curve� was address in Understanding Steel Design. I have several new case studies that take the issue of curvature to new limits that I will include. The field of parametric modeling is included in this type.

Chaotic geometries: Chaotic and angular geometries require advanced engineering design to solve issues of loading and digital fabrication models to have any understanding of connection design – particularly when such buildings tend to avoid repetition and symmetry. Where we may have seen chaotic geometries associated with Deconstructivism during the 20th century, chaotic or irregular geometries have become more mainstream and architects need to better understand how these are best constructed.

Poly Diagrid Structures: Although this volume has just been released I have some very new information on a diagrid structure under construction in Beijing that can be used to establish the inclusion of this type without repeating material. Digital models are indispensable in the creation of this building type.

Lattice Grids: These are growing in popularity and have design requirements that also fall well outside of more standard framed buildings.

Within these larger categories are situated additional innovations that serve either to simplify or complicate the design project.

Modular geometries: Many buildings are being constructed who use modular design and prefabrication to benefit the project. This is accompanied by the use of new digital software for fabrication. The complexity of the project and its construction/erection can be reduced through the application of modular design.

Union Station, Toronto (2014) Zeidler Partnership Image: Walters Inc.

Castings: This exploration will look at projects that include large custom castings that are intentionally unique to projects. The basic information on cast steel was included in Understanding Steel Design. This section will look at some new projects and examine particular issues of the use, installation, potential and incorporation of these large castings. Castings are able to simplify complex connections but also bring to bear important considerations that change the construction process and workflow.

Asymmetrical loading: Twentieth century modern architecture tended to use symmetrical loading as the basis for simplified structural design. Many new projects understand that they need not be limited to this regularity as software and fabrication methods have developed that allow for much variation.

These will be arranged in a specific sequence that will be determined by the nature of the detailed information that I will be able to provide so that if read in sequence there will be a more natural build-up of information and topics. The profiles would be expected to range from 4 to 10 pages as a function of material available. Consider this an initial list that may be expanded or projects removed as determined during the workflow of writing the book. I am not prepared to commit to their sequence at this time, but have included a list of their typological fit. Their ordering will have to be fine-tuned to fit the flow of reading as the text progresses.

In Detail Introduction, Working with Software and Construction Processes: • Union Station, Toronto, Canada – Zeidler Partnership

o Modular, construction logistics • Queen Richmond Center West, Toronto, Canada - &Co Architects

o Castings, asymmetrical loading, construction logistics • South Beijing Railway Station, Beijing – Arup w/ TFP Architects

o Modular, construction logistics Curved Geometries: • Phoenix New Media Center, Beijing – BIAD

o Curved geometries, asymmetrical loading • Galaxy Soho, Beijing – Zaha Hadid Architects

o Curved geometries, cladding issues • AAMI Park Stadium, Melbourne – Arup w/ Cox Architects and Planners

o Curved geometries, modular geometries • BMW Museum – Coop Himmelblau

o Chaotic geometries, diagrid, lattice grid, curved geometries, asymmetrical loading • Reichstag Dome – Foster + Partners

o Curved geometries, modularity, high level AESS • Sage Theater, Newcastle – Foster + Partners

o Curved geometries, modularity, high level AESS • Orient Station, Lisboa, Portugal – Santiago Calatrava

o Curved, complex, trusses, cantilevers, modular (1998 so an early example of doing this sort of architecture without benefit of advanced digital assistance).

• Barajas Airport, Madrid, Spain – Rogers Stirk Harbour and Partners

o Curved, modular, eccentric loading, high level AESS • Valencia Science Complex – Santiago Calatrava

o Angled structures, curved, asymmetric loading, complex cladding, moving parts

Chaotic Geometries: • Kurilpa Bridge, Brisbane – Arup w/ Cox Rayner Architects

o Chaotic geometries, asymmetrical loading, construction logistics, tensegrity • Federation Square, Melbourne – Bates, Smart Architects

o Chaotic geometries, asymmetrical loading • Canadian Museum for Human Rights, Winnipeg, Canada – Antoine Predock Architect

o Diagrid, curved, asymmetrical, chaotic • Royal Ontario Museum, Toronto, Canada – Daniel Libeskind

o Diagrid, chaotic, asymmetrical • Dalian Convention Center, Dalian, China - Coop Himmelblau

o Chaotic, asymmetrical • Bird’s Nest Stadium, Beijing, China - Herzog & deMeuron with Ai WeiWei

o Chaotic, asymmetrical, diagrid Poly Diagrids: • World Financial Center Entry Pavilion, New York City – Pelli Clarke Pelli Architects

o Diagrid, curved, asymmetrical, construction logistics • Beijing Poly Diamond Lantern – SOM

o Diagrid, modular geometries • CCTV, Beijing, Arup w/ OMA

o Diagrid, asymmetrical loading, extreme construction logistics Lattice Grids: • King’s Cross Station, London – John McFarlane and Partners with Arup

o Lattice grid, castings • Louvre Museum, Abu Dhabi – Ateliers Jean Nouvel

o Lattice grid, modularity, curvature • UAE Pavilion, Abu Dhabi – Foster + Partners

o Lattice grid, curvature Several of the other projects have lattice grids as components as well. This project is predominantly a lattice grid roof.

The underlying topic of constructability and the coordination of the structure with cladding systems will be addressed for each project as a function of the availability of information and documentation.

The organization of the spreads following are not in any particular order. In the book they will be arranged to suit the larger categories. As many of the projects include multiple complex aspects, the organization will flow based upon the developed sequence, availability of information and the emphasis on particular areas of conceren established project-by-project.

PROJECT PROFILE: WORLD FINANCIAL CENTER ENTRY PAVILION I have had the pleasure of documenting this project from its fabrication through to completion. I made several trips to the fabrication shop during the creation of the baskets. Saw their test preassembly and was on site in New York to watch the erection of the first sections. I made another visit 3 months later to document the completed structure with finish welding in process, and yet again in September 2013 to photograph the project about 2 weeks prior to the public opening.

I have access to all of the digital drawings as well as numerous stories to convey about putting together such a complicated structure.

Aspects of the connections and AESS choices will be addressed in Architecturally Exposed Structural Steel as this project is presently the cover for the book. It is the sheer amount of detailed information that I have on this project, amongst others, that made me decide to undertake a book and writing approach that would make it suitable to highlight the project in a great amount of detail. It will permit the reader a more comprehensive understanding and appreciation of the work and timeline of such projects.

Lifting the first basket

Making things fit

PROJECT PROFILE World Financial Center Pavilion, New York (2013) Pelli Clarke Pelli Architects

PROJECT PROFILE: CANADIAN MUSEUM FOR HUMAN RIGHTS This project will show the use of digital models in the creation of a highly complex steel structure that had to satisfy roles of AESS, glazing support, concealed structure and masonry support.

It includes large sections of curved tubular steel as well.

I had the opportunity to visit the site to take the included construction photos and have a trip coming this winter to take photos of the completed building as the exhibits are being installed.

The final piece is quite spectacular in terms of its form generation. I am hoping here to also tell the story about the work of Predock, who starts with clay models to look at form, and how these inspire and must be transformed to create the final building.

I already have quite a bit of information from the lead structural engineer on the project who seems keen on telling the story.

View in May 2011 during construction

Digital Tekla model of the structure

PROJECT PROFILE Canadian Museum for Human Rights (2014) Antoine Predock Architect

Image: Walters Inc.

PROJECT PROFILE: UNION STATION The new departures and arrivals hall for Union Station uses custom AESS and fritted glass to create a modern look for the historic building. This project will serve to introduce the role of digital models in terms of the Tekla Structures models, as they feed into sequencing of work.

This project, although limited in size, had to be sequenced and timed to permit the full operation of a train station in a large city. The case study will look then at sequencing of the work and timing as well as the selection of the structural systems, spans and typologies that permit this to happen.

A view up into the atrium of the first completed bay

Tekla model identifying the various elements

PROJECT PROFILE Union Station, Toronto (2014) Zeidler Partnership

Image: Walters Inc.

PROJECT PROFILE: QUEEN RICHMOND CENTER WEST I have had the pleasure of tracking this project from the fabrication stages through the erection.

The atrium space should be enclosed and painted by the timing of the work on this book. The project involves the use of three 31,000 pound steel castings that form the load transfer point for three “delta frames� that are used to support a multi-storey building over a large atrium space.

As this project has been done by Walters Inc. and CastConnex, two local firms with which I have a very good rappore, the documentation on this project will be extremely complete.

I was in attendance for a significant portion of the erection and so have highly detailed process images to share that should be of great interest to the readers and provide an abnormally up close view of the work.

The topic of castings was introduced in Understanding Steel Design and this provides an opportunity to elaborate on that information through this detailed project. The incorporation of castings (especially of this size) adds significant complexity to a project.

Lifting an upper leg portion onto a node casting

PROJECT PROFILE Queen Richmond Center West (2014) &Co Architects

A view up the legs during fabrication

PROJECT PROFILE: ROYAL ONTARIO MUSEUM Although the construction of the Royal Ontario Museum was covered in depth in Understanding Steel Design, and also included in Diagrid Structures, I feel it deserves another very specific look at the way it dealt with its complexity in terms of the communication process and digital drawings. It will be one of the oldest projects in the book, and was constructed when Tekla Structures was fairly new and fabricators and engineers were only beginning to use such software.

The digital images played a huge role in this project, even from the point of view of producing the architectural set of permit drawings as drawings such as orthographic elevations were pretty meaningless beyond that legal use as nothing was in plane.

I have a large amount of material on this project and can fairly easily create something that looks fresh by carefully examining what has been used before. It is also my intention that the drawings and images in these studies be larger than was possible in Understanding Steel Design, so will be able to bring forth a new look to the project.

Aerial view of the project during cladding operations

PROJECT PROFILE Royal Ontario Museum (2006) Studio Libeskind

Ironworker leading a piece of steel

PROJECT PROFILE: KINGS CROSS STATION The new atrium for Kings Cross Station in London, although very clean and simple in its appearance, is actually a very complex steel structure in that it makes use of varied curved sections to create a steel lattice that is supported by solid castings. The engineering was done by Arup and I have access to some detailed information on the design, fabrication and construction of the project.

Completed project photos were taken by me during a visit in February 2013.

Some of the AESS aspects with respect to its detailing and connections will be introduced in Architecturally Exposed Structural Steel to initiate some interest in the project.

Digital model of the steel for the structure

PROJECT PROFILE Kings Cross Station, London (2013) John McFarlane and Partners w/ Arup

Image: Arup

A view up the columns to the steel lattice

PROJECT PROFILE: DIAMOND LANTERN This is the latest diagrid building and was introduced at the very end of Diagrid Structures. I was able to have a complete construction tour when I went to Beijing in December 2013 and so have quite complete construction images as the project, although fully erected, was showing full stages of finishing including the installation of the curtain wall, fire protection and bare steel. I also had an interview with the engineer who provided me with all of his progress photos and an engineering drawing set. SOM is very keen to have this project published as well, so it should give a very full set of detailed information on the nature of complex steel through the construction of a diagrid building that is different from any of those addressed in Diagrid Structures. Thereby to extend the content of that volume into this one.

This project also serves to speak about the very different methods of steel construction that have emerged in China - the use of concrete filled steel tubes. This construction method is almost never used in North America and Europe as it is very labor intensive and requires a lot of site welding. Its use is spreading to the Middle East who also has access to inexpensive labor.

Close view of the tubular steel diagrid

PROJECT PROFILE Diamond Lantern, Beijing (2014) SOM Architects

Installing the curtain wall

PROJECT PROFILE: PHOENIX NEW MEDIA CENTER I had the opportunity to visit this project in December 2013 when it was nearing completion.

It is touted as being “the most parametric building in China� by its designers. Its owners are the rival company to CCTV and in creating this building were looking to create a project that could compete with the CCTV Building by OMA. Although the project is indeed smaller, it is extremely energetic and is making use of a very unique steel structure that has obviously presented challenges in design, fabrication and construction.

I intend to approach the designers for additional details through some contacts I made at Tsinghua University when I was invited to present a lecture there in December 2013. There is certainly very little available at present online about this project, which should make it very interesting for the readers. Although I was only able to obtain close to finished shots during my visit, i am hopeful that the designers will be keen to publish this work.

Interior view of the courtyard of the donut shaped complex

PROJECT PROFILE Phoenix New Media Center, Beijing (2014) BIAD Architects

The exit ramp from the theaters spirals down through the lobby space

PROJECT PROFILE: CCTV The discussion of CCTV will build upon previous coverage of this very famous project in my previous titles, Understanding Steel Design and Diagrid Structures. There are numerous aspects of the complex nature of this structure that can be looked at, but the one that is likely the most interesting is the large cantilevered portion of the building. In particular the very intense analysis that had to happen in order to ensure that the two projecting portions would actually be able to be connected.

This was the focus of Rem Koolhaas’ talk when he received the CTBUH Award for the Best Tall Building of 2013.

I have visited the building on several occasions, have significant technical information from Arup and will approach OMA for access to additional material that I saw presented at the CTBUH Awards in Chicago in November 2013.

As it is taking a very long time for the building to be complete, and the public gallery portion is not yet open, it is my hope to be able to access this part of the project to obtain my own interior photos and experience to be able to include this in the book.

Bridging the Gap Where the two cantilevered sections meet

A complex steel structure with many section types and shapes each taking a special role

PROJECT PROFILE CCTV, Beijing (2013) OMA

Image: Arup

Image: Arup

PROJECT PROFILE: GALAXY SOHO This project highlights the issues faced with cladding a steel structure that is created out of highly complex curved volumes, within the fabrication framework of a country such as China.

In China there is some very good fabrication and detaiiing, and also some that is not very good.

The designers of this building had to figure out the simplification of the number of panel types to allow for fabrication. I had the pleasure of hearing a talk by one of the Hadid partners on the project, and it should be an interesting story to tell. One that can benefit the potential reader in understanding how to go about taking complex curves and translate them into a built project. Of all of the aspects of complex design that have been generated by advanced design software, compound curves present designers with the most challenges.

Exterior view

PROJECT PROFILE Galaxy Soho, Beijing (2013) Zaha Hadid

View to lattice roof on atrium

PROJECT PROFILE: SOUTH RAILWAY STATION Railway stations have long been signficant users of exposed steel. The inclusion of this project complements Union Station and Kings Cross Station, showing how such structures are handled in North America, the UK and China. TFP is responsible for a large number of projects in China and Hong Kong. I have a good range of finished photos of this project from my visit in 2011 and information and drawings from Arup that make a good start on this case study. The project incorporates a number of structural types and sections as well as a range of details for their connection types.

Connection detail at one of the main A type supports

PROJECT PROFILE South Railway Station, Beijing (2008) TFP Architects /w Arup

Image: Arup

A view through the train shed

PROJECT PROFILE: AAMI PARK STADIUM This project is interesting in the way it resolves a very complex shape into prefabricated elements and a standardized method of assembly. I had the opportunity to visit the project in November 2012 and take exterior photos. I have obtained quite a range of construction process photos and digital images from Arup already.

Typical connection between major components

Digital model of the structure

PROJECT PROFILE AAMI Park Stadium, Melbourne (2012) Cox Architects and Planners w/ Arup

Image: Arup

PROJECT PROFILE: KURILPA BRIDGE I had the opportunity to visit and document this most amazing bridge in November 2012. I am excited to do further research into its fabrication and particularly its erection as it is quite unique in the world in being the only true tensegrity structure of this scale. I am hopeful that the Architects will be interested in promoting their project as although I have numerous high quality finished images, I have yet to undertake the procurement of the more technical information. I am confident that it will make for very interesting reading.

Detail of one of the end connections of the horizontal compression members

PROJECT PROFILE Kurilpa Bridge, Brisbane (2011) Cox Rayner Architects w/ Arup

Detail of the connections

PROJECT PROFILE: FEDERATION SQUARE I visited this project in November 2012 and was struck by its energy that excuded from its very chaotic looking structure. As a public space in the center of Melbourne, a city that is simply overflowing with extremely interesting architecture, it was highly successful. I am looking forward to exploring this project in more detail to add a more International flavor to the set of studies.

From the perspective of AESS, the project makes some excellent choices in the combination of a galvanized coating with a very technical looking set of connections. These will be introduced in Architecturally Exposed Structural Steel and the project expanded in this book in terms of the design sequence and fabrication. New Zealand has a very active steel industry. It is also a high seismic zone, which should add some interesting issues to the discussion of complexity.

Exterior view showing coordination with cladding system

PROJECT PROFILE Federation Square, Melbourne (2012) Bates Smart Architects

Rugged steel detailing with galvanized coating system to accentuate the technical

PROJECT PROFILE: BMW MUSEUM I visited this project very briefly in March 2012 and plan to revisit to obtain more detailed images of the lattice structure and glazing systems.

The work of Coop Himmelblau needs to be included in this text as they were one of the original contributors to the Deconstructivist movement, and the current digital technologies seem to have truly liberated them to take this idea to great heights.

Interior view showing display space and curvilinear ramp forms.

PROJECT PROFILE BMW Museum, Munich (2012) Coop Himmelblau

Interior view. Much of the steel is concealed save for the glazing support system.

PROJECT PROFILE: REICHSTAG DOME This project is the second oldest proposed to include in the book and also is useful to set the stage for the type of curved applications that were being incorporated into architecture towards the end of the 1990s and before the more widespread use of digital software such as Tekla Structures or Bentley Systems. We will have seen the use of this sort of software in the Diagrid Structures book in London City Hall and subsequently Swiss Re. This project showcases a very high level of AESS detailing and uses quite regular curved geometry. It will be useful to compare this to the work of Foster at the Sage Gateshead Theater.

Exterior view showing coordination with cladding system

Rugged steel detailing with galvanized coating system to accentuate the technical

PROJECT PROFILE Reichstag Dome, Berlin (1999) Foster + Partners

PROJECT PROFILE: SAGE GATESHEAD THEATER I visited this project in March 2012. Although somewhat early in the timeframe insofar as digital tools can be considered, the project is quite good in the way that it creates multiple curved forms through rather straightforward means. The structure is very clear in the way that the curved forms are broken down into manageable elements that can be simply bolted together. The project will provide a useful contrast to the more complex curved forms that do require high levels of fabrication and engineering that would make curves quite inaccessible for various projects.

Exterior view showing undulating curved forms

PROJECT PROFILE Sage Gateshead Theater, Newcastle (2004) Foster + Partners

PROJECT PROFILE: ORIENT STATION I visited this project in July 2013. This will be the “oldest� project to be included in the book, with a construction date that aligns with the 1998 Olympics in Lisboa. Because the project predates significant advances in digital tools, it allows us to see the transformation of complex steel design from one that seemed very much reserved to high profile architects such as Calatrava, to an approach that is to be seen on a much wider range of projects - directly as a result of the accessibility of digital tools. I will contrast this project with his recent Valencia City of Science to demonstrate the liberating nature of current methods.

This project is good as it has four discrete building elements: pedestrian bridges, canopy, train shed and bus station. It also includes a massive reinforced concrete structure at its center which is useful in demonstrating the use of materials to achieve varied aesthetics.

View towards main entrance with pedestrian bridges to either side, main canopy in front and train shed covering behind.

PROJECT PROFILE Orient Station, Lisboa (1998) Santiago Calatrava

PROJECT PROFILE: BARAJAS AIRPORT I visited this project in July 2013 and have a very complete set of images of all parts of the terminal. The project showcases eccentric loads through the sloped columns, curved steel in the roof, fine variations in detailing the connections throughout the different parts of the terminal.

From the perspective of AESS detailing, it is a good project to show how the architectural aesthetic is achieved through the larger moves of the overall form and primary structure, and that constructability has been achieved in the use of pretty straightforward connection details.

View over the baggage claim area

PROJECT PROFILE Barajas Airport, Madrid (2010) Rogers Stirk Harbour and Partners

Many of the connections are quite simple and make use of bolts and pins vs welding.

PROJECT PROFILE: CITY OF SCIENCE I visited this project in July 2013. The project is one of Calatrava’s most recent and likely the most controversial due to its cost overruns and the degradation of the Opera House component. As there are multiple buildings on the site, I would prefer to focus on the museum, round theater and galleria as these seem to be functioning quite well and are incredibly striking pieces. The project is a good contrast to his Orient Station in Lisboa, which I am also planning to include, as it shows the difference in his design style pre and post digital. Orient is far more regular and the Valencia project includes a wider range of geometries and eccentricities.

This project also showcases a wide range of AESS issues and connections. I have a wealth of close up images from which to draw.

View through the steel grid of the exterior garden

PROJECT PROFILE City of Science, Valencia (2012) Santiago Calatrava

The Y shaped steel supports are crafted from plate steel.

PROJECT PROFILE: DALIAN CONVENTION CENTER I visited this site in October 2011. While unable to obtain a construction tour, it is easy to understand the extreme complexity of this project. I would hope to supplement my own images with those from the architect to be able to present a fuller understanding of the project as it incorporates multiple aspects: chaos, modularity, custom fabrication, curves, asymmetrical loading

Overall view of the project

PROJECT PROFILE Dalian Convention Center, China (2013) Coop Himmelblau

Closer detail showing a multitude of systems

PROJECT PROFILE: BIRD’S NEST STADIUM I visited this site in October 2009. Truly this project in particular brought the reality of the possibilities of complex steel structural systems to the public eye through its high profile role in the Beijing Olympics. What is intriguing about the building is the underlying regularity in the structural system that evades perception for most views. The project will be useful in demonstrating how modularity can be used in quite secretive ways to create quite the opposite impression.

The project made immense use of digital tools in its creation.

Overall view of the project

PROJECT PROFILE Bird’s Nest Stadium, China (2008) Herzog & de Meuron

PROJECT PROFILE: LOUVRE, MUSEUM ISLANDI visited this site in October 2009. Truly The Louvre Museum on Museum Island in Abu Dhabi, UAE is the first of the suite of star architect projects to advance. Construction has commenced and a portion of the building is complete.

The mockups of the roof lattice and wall system are on site. Although this project will not be complete by the time of publication, it will be very useful to include as it makes use of many of the approaches discussed in the book and will ensure that the book is including extremely up to date projects.

The project makes immense use of digital tools in its creation.

Mockup of the stainless steel roof lattice

PROJECT PROFILE Louvre, Museum Island, Abu Dhabi (2016) Atelier Jean Nouvel

Mockup of the double facade screen system

PROJECT PROFILE: UAE PAVILION SHANGHAI EXPO This pavilion for the Shanghai Expo 2010 was one of the few that was designed to be dismantled and reused in its home country. The project uses a lattice grid for the structural system. The roof is designed as undulating curves to mimic the sand dunes that are so characteristic of the UAE landscape. It is the versatility of the lattice grid system that makes this type of highly irregular curved surface possible.

Project relocated to Abu Dhabi

PROJECT PROFILE UAE Pavilion, Shanghai Expo, China (2010) Foster + Partners

Lattice support structure expressed in the cladding