2016 NCSU Summer Design Build: NCMA by Vivian Chiang

NCSU Design-Build 2016 NCMA Discovery Pavillion

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College of Design Architecture Randall Lanou Erik Mehlman, AIA Ellen Cassilly, AIA Scott Metheny Joel Lubell

Vivian Chiang Jeromy Clements Bryan Davis Daniel Floyd Jake Heffington Matthew Hirsch Gitisadat Kazerooni Mo Kuan Lin Rhian Lord

Sarah Lower Scott Nelson Gabby Seider Eli Simaan Jennifer Smith Kristen Warring Emily Wood Zhen Chao Zhang

Special Thanks To... FINANCIAL DONORS:

Cecilia Moe Kimes Family Chiang Family Mary Hart-Paul Church Interiors Audio Video Rosa Kirkman David W. Martin Sara Queen Eileen Beccone Warring Family

COMPANIES & INDIVIDUALS WHO PROVIDED DONATED MATERIALS/SERVICES: AA Concrete A.G. Zalal, Afghan Roofing Ahern Rentals Barnhill Contracting Co. BuildSense Courtney Evans, Tactile Diane Thompson, Stewart Inc. HB Wentz Associates Highland Lumber John Deere Landscape Supply KCI NCSU College of Design Materials Lab NCSU Landscape Department North American Bocker Roofing Steve & Jenene Davis

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CONTENTS

Project Overview Site Visit + Design Process Construction Documents Site Preparation Footings Concrete Walls Steel Framing Roof Shed Shed Interior + Door Landscape Completion + Team

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01 Size: 802 sf

Budget: $25,000

Engineer: Diane Thompson, PE

Location: North Carolina Museum of Art

PROJECT OVERVIEW

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The Design Build Studio at NC State University’s College of Design is a cherished tradition among architecture students. This year seventeen students had the opportunity to return to the North Carolina Museum of Art (NCMA), home of the 2012 Design Build Project known as The Turning Point.

This year’s project was unique due to its location in the Museum’s 164 acre Sculpture Park and as part of the 17 acre expansion begun in November 2015. Rather than leasing out part of its Reclaimed Wood, Steel Columns and Framing, Glulam land, NCMA recently decided to reconfigure that land to create a new entrance to the Museum Beam, Corrugated Roofing and allow for a different social experience framed around experiences and social engagements throughout the Museum Campus. Materials: Concrete Foundation, Charred

As part of the renovation NCMA is creating a new grove called the Discovery Garden. This new zone is adjacent to the parking and is geared towards kids and families. The museum hopes to create a space that fosters education and is filled with fruited trees and instruments. It is within in this setting that the Design Build Studio was invited to design a project.

Within this unique setting, the Museum had specific project expectations as well as educational aspects that needed to be fulfilled. The request was for the students to design and build a garden shed and small outdoor classroom that would be beautiful, structurally expressive, functional, safe, accessible, young family-friendly, and durable. The Museum was was also interested in a rainwater collection feature, both for watering plants and for exemplifying how how water drains and is collected.

SITE VISIT + DESIGN PROCESS

SITE VISIT

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Before beginning the design phase, the students and professors first visited previous Design Build Projects and analyzed their successes and failures. Additionally, the class as a whole visited the site and discussed potential locations of the project as well as which aspects of the Museum Park the project should relate to. Following the site visit, the students individually participated in an intense, four hour modeling design charette. The many models built by the seventeen students were then pooled together and analyzed by the client and outside reviewers. These models were then grouped into four families with similar schematic concepts. After another week of focused design with input and direction from the professors, the client and another team of reviewers selected the â&#x20AC;&#x153;Canopyâ&#x20AC;? scheme with major revisions requested.

The parti that the client settled on was a wall along the path that led to the shed and a canopy overhead to tied the project together. Gabion walls, stacked masonry, and clad framed walls were all discussed before finally settling on poured concrete walls that spoke to the 2012 Design Build project: The Turning Point. As far as siding, the team quickly began to experiment with charred wood and gravitated towards it due to its UV, rot, bug, and weather resistant properties, its 80 year lifespan, and the possibility of reusing the board-form from the concrete for the siding.

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DESIGN PROCESS

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Scheme one out of four - Portal

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Scheme two out of four - Tortoise

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Scheme three out of four - Canopy

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Scheme four out of four - Frames

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CONSTRUCTION DOCUMENTS Several students worked to develop a set of Construction Documents and Shop Drawings using CAD and SketchUp. These students worked closely with the project’s structural engineer, Diane Thompson, early on in the project to make design decisions. Diane quickly gave feedback on sizing structural members and allowed the students to see how their design decisions began to have structural implications that required specific resolutions.

With the decision to use a mixture of concrete, steel, and wood for the structural members, the students also undertook the design of the various connections. Of the five columns, two were posts imbedded within the shed walls and the rest were steel pipes, one of which was partially imbedded in the concrete wall. The main diagonal beam was a 48’ built up glue-laminated member. The four girders were steel wide flanges that supported wood joists that also tied into the glulam. The connections were designed by the students based on what could be later fabricated at the Materials Lab at NCSU’s College of Design.

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SITE PREPARATIONS In order to begin construction, a great deal of preparation had to take place on the site. The future discovery grove was a dense, overgrown site. A great deal of maintenance took place concurrently with the summer build since many trees had to be taken down due to infestations or ivy overgrowth. Once the site was cleared and raked, some rough grading with the aid of an excavator also took place. The site had a slight slope of 1:10 so some of the site was dug out and some was filled in order to create a level space for the project.

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FOOTINGS From early on in the project, the process to create footings was fraught with mishaps. Due to errors with marking the locations, the two strip footings were incorrectly placed and had to be dug out larger. Our footing pour was subsequently delayed due to difficulties with scheduling the rebar delivery.

In the intervening days we received rain daily. This misfortune was amplified due to water runoff from an adjacent construction site at a higher elevation. Light sprinkling was enough to flood our footings and on the first downpour a group of students had to quickly drive out to the museum and practice some on site water management (aka, desperate canal digging). The site crew quickly became experienced at bailing water out of the footings and cleaning out the sludge. Eventually the rebar was delivered and a crew worked quickly to cut and assemble the cages at the site. When the day to pour concrete finally came, the mishaps continued. One buggy ran out of gas mid route and another buggy slipped on the soggy ground and fell into rebar. Given the inherent time constraint of the concrete pour, this became an unexpected all hands on deck day when all students pitched in to help pull the fallen buggy out of the rebar, bend the rebar back into place as much as possible, keep concrete in the marooned buggy wet, and finish pouring the remaining concrete in the truck.

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CONCRETE WALLS After considering myriad options for the tectonic and material expression of the walls, the team settled on board formed concrete walls. The board form was composed of 2x6 boards with staggered joints to emphasize the length of the wall. These decisions allowed us to use reclaimed wood which was used again for the siding. The formwork for the 36 foot walls was assembled at the College of Design, then joined into four panels per side that were carefully labeled, transported to the site, and carefully reassembled at the site. Although heavy and cumbersome to lift, a dedicated team worked hard to position and finish the the formwork quickly yet carefully. In contrast to the first concrete pour, the crew worked as an effective and well practiced team. The pump trunk rental also went a long way helping easily empty the two concrete trucks into the walls with plenty of time left over to vibrate the concrete wall and create a smooth finish on the top of the walls.

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STEEL FRAMING Due to the many steel elements in the structure, a great deal of steel fabrication took place both in the College of Designâ&#x20AC;&#x2122;s Materials Lab and on site. A team fabricated 86 clip angles for the joist-to-glulam connections, 66 shear tabs for the joist-towide flange connections, and 42 tabs for the joist-to fascia-connection. Each of these tabs were predrilled for the lag screws, primed and painted in preparation for installation. The connections between the columns and beams were custom designed pin connections and also fabricated in the Materials Lab. Shaped plates were welded onto the columns and two plates were bolted onto the end of each wide flange. Custom brackets were also designed and fabricated onto the top of the bifurcated steel column to cradle the end of the end of the glulam.

Once all of the columns were set, the glulam and wide flange beams were all lifted using an extended boom forklift driven by a skilled classmate and carefully leveled. The connection between the shaped plates and the wide flange beams was designed to be adaptable which allowed the plates to be bolted and field welded once the beam was in position, rather than relying on very tight tolerances.

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ROOF Each of the 2x10 joists was roughly cut to a unique length to create the butterfly roof, manually lifted up, and then carefully clamped and bolted to the glulam. The joists were then squared and aligned. Next, a string line was run along the edge of the roof and the tapered ends were cut to exact length.

Blocking was then installed every twenty four inches on center to help keep the joists straight and as a tertiary system to support the roofing which spanned in the same direction of the joists. The gutter was also custom fabricated in the Materials Lab and fitted onto the glulam in the space supported by the joists and blocking.

After the blocking and gutter were installed, the fascia angles were lifted onto the edge of the roof. The angle served to not only provide support to the cantilevered joists but also to protect the end grain of the joists. Shear tabs were welded to hold the cantilevered joists up, and the rest of the joists were drilled and the angle was screwed in place. The final step was to install the corrugated roofing, which was screwed into the blocking and the fascia angles. A metal circular saw was used to neatly trim the edge of the roofing along the angles. Once the roof was completely secured, a final pass ensured that all accidental holes were plugged and that no leaks would occur.

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SHED While the joists were cut and the roofing installed, another group of students worked on framing and cladding the shed. The walls were traditionally framed with 2x6 stud framing and sheathed with plywood. Once the walls were correctly positioned, the base plates were drilled through the concrete and anchored. The siding was reclaimed wood, much of it previously used as the board form for the concrete walls. The team made the decision to use charred wood due to its UV, rot, bug, and weather resistant properties and its 80 year lifespan. Over the course of many, many days a group worked in rotation to char all of the siding using a torch and then sealed it.

The charred siding was installed as a weather barrier onto furring strips. The corner condition was resolved using a custom detail with steel angles. The siding stopped at the angle and then reappeared on the next side. This allowed for some flexibility since the reclaimed wood varied largely in width while also using a similar language to the roof.

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SHED INTERIOR + DOOR The door frame and door were also fabricated using the same steel language as the corners of the siding. The front of the door was designed for the siding to neatly sit in and for the siding to run seamlessly with the shed siding. The handle and locking mechanism were all organized to fit within the space of one board. On the interior of the door, a tubed frame provided structural stability to the door and acted as the pivot. Once installed, the door was a perfect fit that pivoted smoothly within its frame.

Although initially planning to sheath the interior with OSB, the team eventually decided to express the stud framing and custom build shelving to fit into the stud framing. The supports and shelving were built from 1x4 reclaimed lumber. Using a datum line from the header above the doorway, shelving was installed along the north, east, and west walls. The west wall was designed for hanging tools, such as shovels or rakes. The north wall has two sets of shelving that are located about head-height. This way, there is an area for storing wheelbarrows and other equipment along that wall. The east wall also has two sets of shelving that align with the two on the north wall, as well as a work counter that has a depth of 20â&#x20AC;?.

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LANDSCAPE The landscape design and implementation was a collaboration between the students and NCMA. A group worked closely with the Museum to select plants for the rain garden and to design drainage for the project that aligned with the planned drainage for the Discovery Garden. Along with the initial grading and site preparation, the landscape ground also dug out channels above and along side the project as well as the large bioswale for the rain garden and stormwater management. The bioswale was designed to provide a route for the water draining off the roof and down to the Discovery Gardenâ&#x20AC;&#x2122;s natural drainage. Large river rocks of various sizes were used to line the bioswale. A massive two ton boulder was donated by one of the parents and installed beneath the gutter to serve as a splash surface during rainfall. Several splash tests were done in order to optimally position the boulder. Underneath the roof the ground was finished with Chapel Hill gravel which the Museum used for the Discovery Gardenâ&#x20AC;&#x2122;s paths. The gravel was compacted to provide a firm walking surface that was ADA compliant.

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COMPLETION + TEAM With the project quickly coming to an end, and group of students touched up all the paint on the steel, re-primed and painted any portions ground down for welding. The students also re-sanded the glulam and joists to remove chalk lines, pencil marks, and sooty hand prints. Mulch was also spread throughout the site to help prevent erosion and to prep the site for the Museum, who would be completing the sitework and providing the plants.

The project was finally completed on Monday, August 1st, three days after the end of the class. Though hectic in towards its final days, the project was nevertheless a herculean effort from the students that provided an incomparable learning experience. The following photos were taken throughout the 10-weeks up until project completion.

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