Innovations in Design and Fabrication Technology
Fabrication Rendering
The Catia coordination model contains the design model, consultant models, as well as as-built scans
The Grasshopper script allows the designers to apply the panel geometry onto the skin surface in the Rhino model and to control the scale of the panels through sliders
Basic geometric parameters common to all panels, as well shared fabrication and documentation elements, are all contained in the master Catia template
Basic geometric parameters common to all panels, as well shared fabrication and documentation elements, are all contained in the master Catia template
Basic geometric parameters common to all panels, as well shared fabrication and documentation elements, are all contained in the master Catia template
Once an elevation has been released for fabrication, the cut files and assembly drawings are sent to the shop for fabrication. The first step is to lay out the unfolded panels on the 48" x 120" sheets of anodized aluminum to both maximize yield and to keep a consistent grain direction across all panels. The panels are then laser cut and etched to include both the panel number and fold lines. The next step is to fold the panels which is all done manually on press brakes, with each panel requiring twelve to thirteen folds. Pins, stiffeners and sealant are then applied to finish each panel. MGM has developed an in-house software solution that allows them to track each panel from fabrication to shipping and to install. Each panel is given a bar code after fabrication has begun and is scanned at six stages of the process: cutting, bending, crating, shipping, receiving and installation. The user is prompted at each stage to conduct various QC operations and the data collected along the way helps MGM track efficiency and fine-tune the process as they go.
INSTALLATION
While the panels are being fabricated in the shop, the field team is working on-site to install the z-girts from which the panels will be hung. A series of control z-girts with the intersection point of four panels pre-etched into them are shot in with a robotic total station marking precise locations every two to three rows of panels so the installation team can ensure they are going up correctly. Standard z-girts are then filled in around the control girts, after which the entire assembly is water-tested one more time to ensure that there are no issues with unsealed penetrations.
Once the water testing of the substrate is signed off on, the installation of insulation and panels can begin. Work proceeds from the bottom up, with each panel being screwed to the z-girt and the next panel being connected to the next with a series of pins and receivers. Along the way, the panel tracking system will prompt the installers to conduct various QC checks every few panels, including checks of the water proofing, layout, panel quality, etc.
The final coordination of as-built conditions happens at the interface of the diamond panels and the ACM return panels, a lesson learned while constructing the mock-up. Once the diamond panels are laid out on an elevation, the edge conditions are scanned and surveyed (both points and point-cloud) and this information is fed back into the Catia model to finalize the geometry of the ACM return panels. The return legs of the ACM panels must align precisely with the edge formed by of the adjacent diamond panels which runs from straight to curved several times along its length, all while maintaining constant joint dimensions both between adjacent ACM panels and between ACM and diamond panels. ACM panels are then fabricated in the shop, a much more time-intensive process than fabricating a single diamond panel. Where the ACM turns from the vertical to horizontal at the top of the building, the ACM panels are semi-conical in shape and require hand-braking of the metal at half-degree increments every 1/16" of an inch, taking nearly twelve hours of fabrication time per panel. Once complete, the ACM panels are shipped to the site to finish the skin installation.
LESSONS-LEARNED
By no means has this process been perfect. At the time of writing, no panels have actually been installed on the building. Z-girts are being installed and panels are being fabricated for the first of the four elevations. The mock-up—after multiple panel installs, modifications and revisions—has been approved by the design team and met with favorable response, and the design and construction teams are optimistic that the project will ultimately be successful. It is beneficial, though, to point out a couple of lessons-learned to improve the process both moving forward on this project and also on future projects.
The benefits of having one point of truth on a project—a federated model that brings together all the 3D building information of the various team members—are numerous as we have seen. However, not all subcontractors rely on this 3D model and the sophisticated layout tools required for executing the design. There is still reluctance amongst certain trades to commit to this technology—be it resistance to change, cost for adopting technology, difficulty in training employees, etc. There have been occasions on this project where a subcontractor has not utilized the coordination model for their scope and proceeded with an attitude of “we’ll make it work.” Not to say that they have not been successful: their work meets project specifications and exhibits the necessary craft. However, it may not match what has been developed in the coordination model, and the general contractor and design team must take this into account as they move forward so they are not taken by surprise.
Another issue that requires careful coordination is the initial location of the project base point: the physical point in space which should be common to each model (despite the best efforts to have one federated model, there will often be multiple models early in a project with multiple model-specific base points). Early mis-coordination of this base point between subs resulted in errors in the construction of the mock-up, with the structural steel being out of alignment with the subsequent framing for the skin and curtain wall systems. Luckily, this is what mock-ups are for: to work through all the issues you will likely encounter during construction and to ensure there are processes in place to avoid these mistakes moving forward. In the end, these issues were resolved and the team is confident they will not resurface on the main building.
Ultimately, the design and execution of the skin system on the USOM would not have been possible without the use of the latest 3D BIM and parametric modeling software available, at least not within the budget and time-frame required. Through an iterative process of collaboration between the various team members, the design of the skin system evolved to a point where it could be efficiently fabricated and installed, despite there being thousands of unique panels arrayed over a complex surface. Moving forward, the architecture profession will continue to use the latest digital tools to push the limits of what is possible, but it is only with skilled designers and craftspeople behind the tools that these designs will ultimately be successful and stand the test of time.
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