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Mercedes-Benz Stadium – Design and Construction

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Mercedes-Benz Stadium – Design and Construction MERCEDES-BENZ STADIUM – DESIGN AND CONSTRUCTION Structural Engineers Association of Georgia 05/10/2017 BUROHAPPOLD LOCAL KNOWLEDGE + GLOBAL EXPERTISE ORIGINS OF BURO HAPPOLD: FREI OTTO + TED HAPPOLD BEGINNING OF ROOFS THAT TRANSFORM Buro Happold PROJECT OVERVIEW ° The New Stadium Project for the Atlanta Falcons will seat 75,000 fans and will feature a roof opening that will provide flexibility in hosting a wide variety of events in the stadium. ° Eight unique roof petals can open in less than eight minutes, creating a “camera lens- like” effect that exposes the inside of the facility to the open air on game and event days. ° Another first of its kind is the nearly five-stories tall 360-degree HD video halo board that will not only be the largest video board in the NFL, but in the world. INITIAL DESIGN GOALS ° Attraction for Atlanta ° Unique Design ° Roof Innovation ° Draw on World-Class Events and Entertainment PROJECT DETAILS ° Owner: Georgia World Congress Center Authority ° Developer: Atlanta Falcons ° Architect: HOK (Kansas City) ° TVS, GVSA, SBS (Atlanta) ° Contractor: Holder, Hunt, Russell, Moody, a Joint Venture ° Structural: BuroHappold Engineering (Superstructure) Sykes Consulting, Inc (Foundations, Precast) HOK (Halo Steel) ° Mechanization: Uni-Systems ° MEP: WSP ° Steel Fabricator: Canam Group ° Steel Erector: Derr-Isbell Construction (Roof) Superior Rigging (Facade) ° Connection Consultants: Ferrell Engineers, MBJ ° Use: NFL, MLS, NCAA Sports, Entertainment Events ° Size: Approximately 2.0M square feet & 75,000 seats NEW STADIUM – SITE LOCATION SIZE COMPARISON SIZE COMPARISON MILESTONES ° 100% Schematic Design October 7, 2013 ° Ground Breaking May 19, 2014 ° 100% Design Development June 18, 2014 ° Construction Documents - Concrete August 15, 2014 ° Mill Order – Roof Steel (65 ksi) July 27, 2014 ° Mill Order – Roof Steel September 2, 2014 ° Mill Order – Façade Steel October 17, 2014 ° Construction Documents – Roof Steel December 1, 2014 ° Construction Documents – Architecture April 8, 2015 ° Construction Documents – MEP April 8, 2015 ° Opening August 2017 FALCONS STADIUM BREAKDOWN Foundation COPYRIGHT © 1976-2015 BUROHAPPOLD ENGINEERING. ALL RIGHTS RESERVED FALCONS STADIUM BREAKDOWN Bowl Structure Foundation COPYRIGHT © 1976-2015 BUROHAPPOLD ENGINEERING. ALL RIGHTS RESERVED FALCONS STADIUM BREAKDOWN Bowl Seating Bowl Structure Foundation COPYRIGHT © 1976-2015 BUROHAPPOLD ENGINEERING. ALL RIGHTS RESERVED FALCONS STADIUM BREAKDOWN Façade Bowl Seating Bowl Structure Foundation COPYRIGHT © 1976-2015 BUROHAPPOLD ENGINEERING. ALL RIGHTS RESERVED FALCONS STADIUM BREAKDOWN Roof Structure Façade Bowl Seating Bowl Structure Foundation COPYRIGHT © 1976-2015 BUROHAPPOLD ENGINEERING. ALL RIGHTS RESERVED FALCONS STADIUM STRUCTURE COPYRIGHT © 1976-2015 BUROHAPPOLD ENGINEERING. ALL RIGHTS RESERVED FALCONS STADIUM S K I N COPYRIGHT © 1976-2015 BUROHAPPOLD ENGINEERING. ALL RIGHTS RESERVED Foundations PROJECT CASE STUDY For Structural Engineers Association of Georgia (SEAOG) By Martin Kigudde, PE In Collaboration with BuroHappold Engineering and HOK May 10, 2017 Mercedes Benz Stadium Structural Engineering Consulting Firm Established in 2001 Gainesville State Metropolitan Church Charles Drew High School Headquarters in Atlanta, GA Satellite Office in Savannah, GA Aviation, Sports, K-12, Higher Education, Commercial, Residential. FISERV Office Building Metropolitan Library Lucas Oil Stadium Atlanta Savannah Hartsfield Jackson International Airport The New World of Coca-Cola Consolidated Rental Car Facility (CONRAC ) May 10, 2017 Mercedes Benz Stadium National Work 21 States International Work Abu Dhabi Anguilla May 10, 2017 Mercedes Benz Stadium Project Introduction : Stadium is the new home of the Atlanta Falcons and Atlanta United FC. Scheduled to open in the fall of 2017. Foundation design started Mid-2013. Architects: HOK, tvsdesign, SBS, and GVSA. Structural Engineer Super-structure: Buro Happold Consulting Engineers Structural Engineer Halo: HOK Structural Structural Engineer : Sykes Consulting, Inc. EOR for: ° Foundations, retaining walls, and slab-on-grade. ° CMU walls. ° Precast seating and framing at lower bowl. ° Concession lids. ° Sponsorship Suites. Civil Engineer: Kimley-Horn and Associates, Long Engineering, Skyline Eng. Geotechnical Engineer: Langan Engineering and Environmental Services. Weekly BIM Collaboration between team members. May 10, 2017 Mercedes Benz Stadium Project Site : Site located south of the current Georgia Dome and bounded by: ° Northside Drive. ° Mangum Street. ° MLK Jr. Drive. Stadium construction required relocation of: ° MLK Jr. Drive and Mangum Street. ° Friendship Baptist Church. ° Mount Vernon Baptist Church. MARTA East-west line tunnel runs adjacent and to the north of the site. ° Vibration considerations for the tunnel. ° Construction load surcharge limits. ° 5’-0” horizontal easement to tunnel walls Field Elevation at 1018’-0” Georgia Dome Field Level at 980’ (plaza 1011.6”) May 10, 2017 Mercedes Benz Stadium Foundation Design : Foundation designed based on loads from Buro’s SAP analysis models. 5 foundations types due to varying sub-surface conditions. Deep foundations for cast-in-place concrete bowl. ° Drilled Piers (66” to 78” diameter.) ° 18” diameter augercast-in-place piles (220-T & 150-T) Shallow foundations for precast inner bowl. ° Shallow foundations on existing soils ° Shallow foundations on Geopiers. 8" SOG Approx. 460,000 GSF (not including the playing field). Playing field was designed by specialty field designer, FTE, Inc. Quantities: ° 1900+ augercast piles ° 220+ Drilled piers ° 11,000+ CY of concrete in footings and pilecaps Deep Foundation Testing: ° 1 Full scale Statnamic test. ° 1 O-cell test to determine capacity. ° 2 Full scale auger cast pile tests. May 10, 2017 Mercedes Benz Stadium Mega Column Foundations : 19-mega columns support the main roof trusses. 8-Mat foundations support the mega column clusters. Mat foundations were designed using SAFE 3D-Finite elements design software. Foundation reaction loads from Buro Happold’s SAP model. May 10, 2017 Mercedes Benz Stadium Mat Foundations : Mat foundations 7’-0” to 12’-0” thick high-strength concrete. Mat foundations supported on drilled piers and piles. Longitudinal and shear reinforcement required in the mats. Mass concrete considerations: ° Crushed ice and cooling the coarse aggregate with chilled water. ° Surface thermal insulation boards and curing blankets. ° Temps monitored using thermal couples. Mat Foundation at South-East Quad (MCC02) (221 -18” diameter piles) Mat Foundation rebar Mat Foundation rebar Insulation boards at Mat Foundation May 10, 2017 Mercedes Benz Stadium Foundation Design : Mat Foundation design using SAFE software. ° IBC 2012 ° Longitudinal and shear reinf. Individual piles and drilled piers designed using Enercalc software. Drilled Pier Capacities: 2800 kips – 8300 kips Spread footings designed using Enercalc software. Column pilecaps designed using Window’s based proprietary pilecap design software Concrete Strength: ° Spread Footings = 4000 psi ° Augercast Piles = 4000-6000 psi grout Mega Column Mat MCC05 Mega Column Mat MCC08 ° Pilecaps = 6000 psi (7’-6” thick; 11-72” Piers) (7’-6” thick; 16-72” Piers) ° Drilled Piers = 6000 psi ° Mat Foundations = 7000-8500 psi May 10, 2017 Mercedes Benz Stadium Foundation Challenges : Aggressive schedule; fast-track project. ° Foundation installation began while super-structure design still progressing. ° Drill and epoxy for CMU wall dowels. Drilled pier rock sockets (5’-0” to 18’-0”). Failed O-cell drilled pier load test required redesign. Handling long rebar cages Existing unforeseen deep foundations from previously demolished structures. Handling long pile/pier rebar cages. Rebar congestion in mat foundation. Damaged foundation dowels. Rebar congestion Damaged pile dowels May 10, 2017 Mercedes Benz Stadium Foundation Construction : Auger-cast pile contractor: Berkel & Company Contractors, Inc. Drilled pier contractor: ABE Geotechnical Contractors. Geopier contractor: Hayward Baker. Shallow foundation contractor: Precision Concrete. Concrete Supplier: Argos Foundation construction started in June 2014. Installation of 1 st pile on project Auger-cast pile rebar cages Drilled pier rebar cages May 10, 2017 Mercedes Benz Stadium Foundation Construction : Geopiers at shallow Tops of auger-cast piles Pilecap rebar and column dowels foundations May 10, 2017 Mercedes Benz Stadium Special Features at Field Level : Hydrotherapy pools Drink rails. Goal post foundations. Broadcasting booths. Elevator pits. Escalator pits. Ramps. Escalator pit walls Elevator pit walls May 10, 2017 Mercedes Benz Stadium Precast Seats : Inner bowl is all precast structure: ° Columns ° Vomitory walls ° Raker beams ° Seats Precast seating on cast-in-place rakers at concourse levels outside inner bowl. Standard double and triple units Metromont is the precast contractor. Total NFL seating capacity is 70,148. May 10, 2017 Mercedes Benz Stadium Precast Seating : May 10, 2017 Mercedes Benz Stadium Concession Lids : At Concourse levels. Roofs over the concessions and bathrooms. Steel beams, joists, and metal deck. Supported by CMU walls and cast-in-place rakers. Sponsorship Suites: Fit out of Corporate sponsorship suites. Suites at Concourse levels. Structural steel and cold-formed framing. Misc. Framing for banners and TV monitors. ATT, Equifax, Anheuser Busch, American Family. May 10, 2017 Concrete Bowl
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