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Novum Structures | USA, China, Germany, India, Singapore,Novum Structures Turkey, UAE, | www.novumstructures.comUnited Kingdom, South Africa
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Grid Shell Structures on Freeform Surfaces
Company Introduction Novum Structures - Design & Build Specialty Contractor for Architectural Steel, Cable, Glass & Membrane Structures
Wrigley’s R&D Center Chicago, USA Dali Museum St. Petersburg, USA Tours Shopping Mall, France
Seattle Airport, USA Yueda 889 Shopping Mall Shanghai, China Old Castle Dresden, Germany
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Company Introduction Novum Structures International Network Novum Structures is a Design & Build Specialty Contractor for Architectural Steel, Cable, Glass & Membrane Structures
Holding Company: Diss, UK Sangerhausen, Germany Menomonee Falls, WI Farnham, UK Wurzburg, Germany Chicago, IL Istanbul, Turkey San Francisco, CA Beijing, China Dallas, TX Sarasota, FL Dubai UAE
Bangalore, India
Singapore
Selection of Novum Component Systems for Building Structures & Envelopes
KK-System BB-System BK-System FF-System CCG-System ECG-System AFP-System SSM-System
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Content
1. Contemporary Architectural Styles 2. Typology of Freeform Surfaces 3. Grid Geometry 4. Grid Shell Node Types 5. Novum FF-System 6. Process Case Study – Salvador Dali Museum 7. Other Freeform Projects
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Contemporary Architectural Styles High-Tech Architecture
Nicholas Grimshaw: Eden Project, , UK Foster & Partners: City Hall, London, UK
DP Architects: Esplanade Theaters on the Bay, Singapore Foster & Partner: Swiss Re, London, UK Kessler & Partner : K21 Duesseldorf, DE
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Contemporary Architectural Styles Blobitecture / Blob Architecture
The US architect and philosopher Greg Lynn is credited with coining this phrase, claiming that the name comes from a software feature that creates Binary Large Objects
Foster & Partner: The Sage, Gateshead, UK HOK: Salvador Dali Museum, St. Petersburg, FL, USA
The Jerde Partnership: Zlote Tarazy, Warsaw, Poland Studio Fuksas: New Fair, Milan, Italy Foster & Partners: British Museum, London, UK
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Contemporary Architectural Styles Deconstructivism
Frank O. Gehry : Walt Disney Concert Hall, LA, US
Frank O. Gehry :Dancing Houses, Prague, CZ
Frank O. Gehry : Gehry Tower, Hannover, DE Coop Himmelb(l)au: BMW World, München, DE
Novum Structures | www.novumstructures.com
7 5/2/2018
Grid Shell Structures on Freeform Surfaces
Content
1. Contemporary Architectural Styles 2. Typology of Freeform Surfaces 3. Grid Geometry 4. Grid Shell Node Types 5. Novum FF-System 6. Process Case Study – Salvador Dali Museum 7. Other Freeform Projects
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Typology of Freeform Surfaces Surface Classification Chart Freeform Surfaces
Structurally Structurally Optimized Non-Optimized
Scale Minimal Translation Surface Surface
Hanging Scale Form Revolution Surface
Ruled Surface
NURBS Surface
NURBS = Non-Uniform Rational B-Spline
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Typology of Freeform Surfaces Minimal Surface
• Doubly-curved anticlastic surfaces produced by experimental or numerical form-finding process • Application mainly for cable nets and tension or membrane structures
Fentress & Bradburn: SeaTac Airport Seattle, US Execution: Novum
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Typology of Freeform Surfaces Hanging Form
• Doubly curved surfaces produced by experimental or numerical form-finding process • Application mainly for predominantly gravity loaded shell structures
Frei Otto: Multihalle Mannheim, DE
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Typology of Freeform Surfaces Scale Translation Surface
• Facetted surface produced by a parallel translation and simultaneous scaling (dilation) of a generating polygon (generatrix) along a polygonal guideline (directrix) • Application mainly for glass structures with planar quadrilateral facets
Centric Stretched Curve Profile Curve Profile
Gerkan Marg & Partner: Main Railway Station Berlin, DE Engineer: Schlaich Bergerman Execution: Mero GmbH & Co.KG
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Typology of Freeform Surfaces Scale Revolution Surface
• Facetted surface produced by a rotation and simultaneous scaling (dilatation) of a generating polygon (generatrix) about an axis of rotation • Cylinder, sphere, cone and torus surfaces are widely used basic revolution surfaces with an analytically determined generatrix • Application mainly for glass structures with planar quadrilateral facets
Hadi Simaan & Partner: Aspire Tower Doha, Qatar Engineer: Arup
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Typology of Freeform Surfaces Ruled Surface
Restaurant auf der Zugspitze, DE Erick van Egeraat: Alphen City Hall, NL Execution: Oktatube International BV
• Practically important ruled surfaces: > Hyperbolic Paraboloid / Hypar surfaces > Hyperboloid surfaces • Hyperbolic Paraboloid surfaces are produced by translating a generating line (generatrix) along two skewed guide lines and parallel to a directing plane • Hyperboloid surfaces are produced by rotating a generating line skewed to the axis of rotation (each hyperboloid can be generated with two different generating lines)
Coop Himmelb(l)au: BMW World München, DE Vladimir Shuchov: Lipezk Tower 1896, RU Execution: Josef Gartner GmbH
Novum Structures | www.novumstructures.com
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Typology of Freeform Surfaces NURBS Surface
• NURBS surfaces (Non-Uniform-Rational-B-Spline) are analytically defined, double-curved surface areas controlled through the vertices of control polyhedrons • By manipulating the control polyhedrons, the surface Studio Fuksas : curvature at any location can be diversely influenced New Fair Milan, IT (rubber band effect) Execution: Mero GmbH & Co.KG • By combining multiple NURBS surface areas (patches) while maintaining the surface continuity along all area interfaces, it is possible to model any arbitrary technically or naturally occurring surface!
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Content
1. Contemporary Architectural Styles 2. Typology of Freeform Surfaces 3. Grid Geometry 4. Grid Shell Node Types 5. Novum FF-System 6. Process Case Study – Salvador Dali Museum 7. Other Freeform Projects
Novum Structures | www.novumstructures.com
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Grid Geometry Grid Generation Methods
Grid Generation
Projection Method Parcellation Method
• Projection of a regular grid pattern from a datum plane on to the freeform surface • Typically requires manual grid correction of surface areas with increased curvature or inclination to the datum plane
• Boundary lines get subdivided into portions of similar length, thus creating “orthogonal” auxiliary grid on surface • Final grid is tied into this auxiliary grid
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Grid Geometry Grid Generation Methods
Grid Generation
Projection Method Parcellation Method
Resulting grid is usually evenly spaced and balanced Grid along boundaries is unproblematic Planar grid projection is not considering boundary Resulting grid can appear slighly more irregular, lines, thus frequently creating problematic grid zones although this strongly depends on the perspective along boundaries of the viewer
Grid created with planar projection Grid created with surface partitioning
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Grid Geometry Elements of Grid Shell Structures
Node
Node Node
Node
Connectivity of Elements of Grid Shell Structures
Novum Structures | www.novumstructures.com
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Grid Geometry Element Orientation
Element orientation vectors are generated as follows: 1. Determination of all grid panels (panel finding) 2. Determination of normal vectors for all panels (panel vector) 3. Node vectors are determined by averaging the panel vectors of all panels adjacent to a node 4. Member vectors are determined by either: a) averaging the panel vectors of the 2 panels adjacent to a member b) averaging the node vectors of the 2 nodes adjacent to a member, both projected into the member cross section plane (thus minimizing twist at both nodes)
Node Vector
Panel Vector
Member Vector
Panel Vector
Member Vector
Node Vector
Novum Structures | www.novumstructures.com
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Grid Geometry Element Connectivity Angles
Element Connectivity Angles
Node Angles Member Angles
Vertical Angle V Horizontal Angle U Twist Angle W Panel Folding Angle F
F
V is the azimuth angle between the U is the polar angle between adjacent W is the angle between a member F is the angle between the 2 panel node vector and a member axis in the member axes in the polar coordinate vector and a node vector projected vectors projected into the member polar coordinate sytem of a node sytem of a node into the member cross section plane cross section plane
Novum Structures | www.novumstructures.com
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Grid Geometry Element Connectivity Angles – Vertical Angle
• Vertical angles primarily depend on local curvature parameter 1/R of the surface at this node: 1 – smaller curvature > vertical angle is close to 90° > smaller V1 (difference to 90°) 2 – larger curvature > vertical angle significantly deviates from 90° > larger V2 (difference to 90°)
Color plot of the vertical angles for a grid
Vertical angle at a real node
V
Novum Structures | www.novumstructures.com
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Geometry of Truss Elements Element Connectivity Angles – Horizontal Angle
• Horizontal angles primarily depend on the grid topology: 1 – quadrilateral grid > four way node > larger horizontal angle U1 2 – triangular grid > six way node > smaller horizontal angle U2
Color plot of the horizontal angles for a grid
Horizontal angle at a real node
U
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Geometry of Truss Elements Element Connectivity Angles – Twist Angle
• Twist angles primarily depend on local curvature parameter 1/R of the surface at this node and on the orientation of the member to the principal curvature directions: 1 – Larger deviation from principal curvature direction G1 > larger twist angle W1 2 – Smaller deviation from principal curvature direction G2 > smaller twist angle W2
Color plot of the twist angles for a grid
Twist angle at a real node • Twist angle is zero if member axis is parallel to principal curvature direction!
W
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Grid Geometry Element Connectivity Angles – Panel Folding Angle
• Panel folding angles primarily depend on local curvature parameter 1/R of the surface at this node:
Color plot of the panel folding angles for a grid
F (>0) F (<0)
Novum Structures | www.novumstructures.com
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Content
1. Contemporary Architectural Styles 2. Typology of Freeform Surfaces 3. Grid Geometry 4. Grid Shell Node Types 5. Novum FF-System 6. Process Case Study – Salvador Dali Museum 7. Other Freeform Projects
Novum Structures | www.novumstructures.com
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Grid Shell Node Types Grid Shell Node Design Requirements
• The local structural behaviour of arbitrary, single layer freeform structures is widely varying: - flat areas require significant bending capacity of members and node connections - shell-like areas require high axial load capacity of members and node connections • The local element connectivity angles of arbitrary freeform structures are widely varying as well: - node design must allow for geometric adaptability to varying vertical, horizontal, twist angles • This combination of structural and geometrical requirements make the grid shell node the key grid shell element for structural integrity, visual appearance, accuracy and cost of a freeform structure
Novum Structures | www.novumstructures.com
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Grid Shell Node Types Splice Plate Nodes Grid Shell Nodes
Single Layer Grid Shell Double Layer Grid Shell
Splice Plate Nodes End Face Nodes Spatial Nodes
Cross Plate Star Lug Disc Plate Cylinder Lug Node Node Node Node CP SL DP CL
Cross Chord Plate Node CCP
Novum Structures | www.novumstructures.com
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Grid Shell Node Types Geometric Adaptability: Connectivity Angles Loading Capacity Cross Plate Node CP Horizontal U Vertical V Twist W Axial Force Flexure CP + + O + O
•Suited for optimised grid shell structures with predominantly axial member forces
Gerkan Marg & Partner: Museum für Hamburgische Geschichte, Hamburg, DE Engineer: Schlaich Bergermann & Partner
Novum Structures | www.novumstructures.com
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Grid Shell Node Types Geometric Adaptability: Connectivity Angles Loading Capacity Alternative Cross Plate Node CP alt Horizontal U Vertical V Twist W Axial Force Flexure CP alt + + O ++ +
•Suited for optimised grid shell structures with predominantly axial member forces
Gerkan Marg & Partner: Bahnhof Spandau, Berlin, DE Engineer: Schlaich Bergermann & Partner, Project Execution: Mero GmbH & Co.KG
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Grid Shell Node Types Geometric Adaptability: Connectivity Angles Loading Capacity Cross Chord Plate CCP Horizontal U Vertical V Twist W Axial Force Flexure CCP + ++ O ++ ++
•Suited for special twist-free grid shell structures on arbitrary freeform surfaces
Gerkan Marg & Partner: Hauptbahnhof Berlin, DE Engineer: Schlaich Bergermann & Partner, Project Execution: Mero GmbH & Co.KG
Novum Structures | www.novumstructures.com
31 5/2/2018
Stabwerke auf Freiformflächen
Grid Shell Node Types Geometric Adaptability: Connectivity Angles Loading Capacity Star Lug Node SL Horizontal U Vertical V Twist W Axial Force Flexure SL ++ ++ ++ ++ ++
•Suited for all grid shell structures on arbitrary freeform surfaces, but very expensive
Frank O. Gehry & Associates: DZ-Bank, Berlin, DE Engineer: Schlaich Bergermann & Partner, Project Execution: Josef Gartner GmbH
Novum Structures | www.novumstructures.com
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Grid Shell Node Types Geometric Adaptability: Connectivity Angles Loading Capacity Disc Plate Node DP Horizontal U Vertical V Twist W Axial Force Flexure DP ++ + + ++ ++
•Suited for optimised grid shell structures with predominantly axial member forces
J. Gribl: Flusspferdehaus Zoologischer Garten, Berlin, DE Engineer: Schlaich Bergermann & Partner, Project Execution: Helmut Fischer GmbH
Novum Structures | www.novumstructures.com
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Grid Shell Node Types Geometric Adaptability: Connectivity Angles Loading Capacity Cylinder Lug Node CL Horizontal U Vertical V Twist W Axial Force Flexure CL ++ ++ ++ ++ ++
•Suited for all grid shell structures on arbitrary freeform surfaces
Shigeru Ban:Theater Dome Leideschenrijn, NL Project Execution: Octatube International BV
Novum Structures | www.novumstructures.com
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Grid Shell Node Types End Face Nodes Grid Shell Nodes
Single Layer Grid Shell Double Layer Grid Shell
Splice Plate Nodes End Face Nodes Spatial Nodes
Block Dish Star Block Cross Chord Node Node Node Node B D SB CC
Double Block Double Dish Star Block Pole Star Chord Node Node Node Node DB DD SP SC
Novum Structures | www.novumstructures.com
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Grid Shell Node Types Geometric Adaptability: Connectivity Angles Loading Capacity Block Node B Horizontal U Vertical V Twist W Axial Force Flexure B +++ +++ +++ ++ ++
• Very well suited for all grid shell structures on arbitrary freeform surfaces
HOK Chicago: Wrigley Global R&D Center, Chicago, US Project Execution: Novum Structures LLC
Novum Structures | www.novumstructures.com
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Grid Shell Node Types Geometric Adaptability: Connectivity Angles Loading Capacity Double Block Node DB Horizontal U Vertical V Twist W Axial Force Flexure DB +++ +++ +++ ++ ++
• Very well suited for all grid shell structures on arbitrary freeform surfaces
HOK Architects: Salvador Dali Museum, St. Petersburg, FL, USA Project Execution: Novum Structures LLC
Novum Structures | www.novumstructures.com
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Klassifizierung der Stabwerksknoten Geometric Adaptability: Connectivity Angles Loading Capacity Dish Node D Horizontal U Vertical V Twist W Axial Force Flexure D ++ ++ ++ ++ +
• Well suited for optimised grid shell structures with predominantly axial member forces
RTKL Spain: Principe Pio Train Station, Madrid, ES Engineer: Schlaich Bergermann & Partner, Project Execution: Mero GmbH & Co.KG
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Grid Shell Node Types Geometric Adaptability: Connectivity Angles Loading Capacity Double Dish Node DD Horizontal U Vertical V Twist W Axial Force Flexure DD ++ +++ + ++ ++
• Well suited for all grid shell structures on arbitrary freeform surfaces
Massimiliano Fuksas : Nuovo Fiera Milano, IT Project Execution: Mero GmbH & Co.KG
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Grid Shell Node Types Geometric Adaptability: Connectivity Angles Loading Capacity Star Block Node SB Horizontal U Vertical V Twist W Axial Force Flexure SB +++ +++ + +++ +++
• Well suited for all grid shell structures on arbitrary freeform surfaces
Foster & Partner: British Museum, Courtyard, London, UK Project Execution: Waagner-Biro Stahlbau AG
Novum Structures | www.novumstructures.com
40 5/2/2018
Grid Shell Structures on Freeform Surfaces
Grid Shell Node Types Geometric Adaptability: Connectivity Angles Loading Capacity Star Block Pole Node SP Horizontal U Vertical V Twist W Axial Force Flexure SP +++ +++ ++ +++ +++
• Very well suited for all grid shell structures on arbitrary freeform surfaces
Epstein Chicago: Zlote Tarazy Shopping Mall, Warschau, PL Project Execution: Waagner-Biro Stahlbau AG
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Grid Shell Node Types Geometric Adaptability: Connectivity Angles Loading Capacity Cross Chor Node CC Horizontal U Vertical V Twist W Axial Force Flexure CC + + O +++ +++
• Suited for special twist-free grid shell structures on arbitrary freeform surfaces
I. M. Pei: Deutsches Historisches Museum, Schlüterhof, Berlin, DE Engineer: Schlaich Bergermann & Partner, Project Execution: Mero GmbH & Co.KG
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Grid Shell Node Types Geometric Adaptability: Connectivity Angles Loading Capacity Star Chord Node SC Horizontal U Vertical V Twist W Axial Force Flexure SC ++ +++ ++ ++ ++
•Well suited for all grid shell structures on arbitrary freeform surfaces, but expensive
Michael Gabellini: Westfield White City Shopping Mall, London, UK Project Execution: Seele GmbH
Novum Structures | www.novumstructures.com
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Grid Shell Node Types Spatial Nodes Grid Shell Nodes
Single Layer Grid Shell Double Layer Grid Shell
Splice Plate Nodes End Face Nodes Spatial Nodes
Spherical Half Sphere Block Goblet Node Node Node S HS G
Novum Structures | www.novumstructures.com
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Grid Shell Node Types Spherical Node S
BDP Building Design Partnership: Glasgow Science Center, 3D Cinema, Glasgow, UK Project Execution: Mero GmbH & Co.KG
Novum Structures | www.novumstructures.com
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Grid Shell Node Types Half Sphere Node HS
Friedmutter Group: Harrah’s Casino Atlantic City, US Project Execution: Novum Structures LLC
Novum Structures | www.novumstructures.com
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Grid Shell Node Types Goblet Node G
DP Architects: Esplanade Theaters on the Bay, Singapore Project Execution: Mero GmbH & Co.KG
Novum Structures | www.novumstructures.com
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Content
1. Contemporary Architectural Styles 2. Typology of Freeform Surfaces 3. Grid Geometry 4. Grid Shell Node Types 5. Novum FF-System 6. Process Case Study – Salvador Dali Museum 7. Other Freeform Projects
Novum Structures | www.novumstructures.com
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Novum FF-System System Description
• The Novum FF-system is a proprietary end face node connection consisting of: - 2 forged steel discs of S355 or C45 material, with individually machined faces as required by the grid geometry - each machined face has a threaded hole for a grade 10.9 bolt M24 or M27 - precision cast steel adapters of steel GS-20Mn5V, with top & bottom faces which can have an offset to each other, with corresponding bolt holes, welded to ends of straight cut RHS members, typically ASTM A500 grade C 6”x3”, 8”x3” or 10”x3” or EN 10219 grade S355 150x80, 200x80 or 250x80 - concealed & pretensioned socket head bolts M24 or M27, fixing the adapters to the 2 node discs • The structural behaviour of these bolted node connections is semi-rigid and has to be adequately considered in the structural model - typically as a rotational spring stiffness at the end of each grid shell member
Novum Structures | www.novumstructures.com
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Novum FF-System Bending Capacity & Stiffness Tests of Node Connection
In order to establish the bending stiffness and verify the connection capacity of various combinations of FF-system components, series of methodical 4-point bending tests have been realized
140
120
100
） 80
kN
（ 60 Load RHS 250x80 S355 with adapter FFA1036-0-26 and M24-10.9 bolts 40
20 Displacement1 Displacement2 (M24 bolts) Displacement3 0 0 10 20 30 40 50 60 70 Displacement（ mm） Test Failure Ram Load, Bending Moment, # Mode at Failure at Failure 1 Bolt 127 kN 76.8 kNm 2 Bolt 128 kN 77.4 kNm 3 Bolt 129 kN 78.0 kNm
Novum Structures | www.novumstructures.com
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Novum FF-System Finite Element Analysis of Node Connection
• In order to verify those 4-point bending tests of FF-system components, series of finite element analysis of the test specimen have been performed
• Semi-rigid connection behaviour is a combined effect of the bolted connection stiffness and reduced bending stiffness in the mounting hole zone
• The observed mid span deflections of the FE models were only 80% of the average measured values, apparently due to small initial settlements of the real test specimen under loads
• This ratio is being used to calibrate FE models of FF-system node connections in any structural analysis
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Novum FF-System Calculation of Node Connection Capacity Initial parameters: it 0 , n it N , my it My , mz it Mz • The varying bending moment capacity of the bolted node orig orig orig
connection in dependency of the axial connection force is it it it it mz it my it n typically determined using an iterative numerical calculation Strain parameters: , , o z E Jz y E Jy E A method assuming planarity of member end section [Space Structures 5, Telford Publ. 2002, p. 759-773] > Compression stress in the connection profile / Element force & moments • > Tensile stress in the bolts / Bolt force & moments Calculation results shown below performed for 3 limit states > Internal connection force & moments : N
YE Stress distribution it = it + 1 All deviations 0 ? • Results from methodical 4-point bending tests are S determined ! conservatively close to the failure limit bending moment N it1 it it it1 Oit it it1 it it n n N , my my My , mz mz Mz
(M24 bolts)
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Novum FF-System Structure Design – Global Buckling Analysis • In addition to local member buckling and capacity checks, a global buckling analysis is conducted to ensure structural integrity of the grid shell frame.
• To account for imperfections due to fabrication and installation tolerances, an “imperfect geometry” model is generated and analyzed according to all appropriate load cases and combinations.
• The imperfect geometry is generated by deforming the structure to the node locations of critical buckling modes.
• The magnitude of the maximum nodal shift is scaled to an imperfection tolerance, which is generally derived from DIN 18800-2.
Novum Structures | www.novumstructures.com
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Novum FF-System Structure Design – Global Buckling Example
Halstenbek Sports Hall, “Knikei”
Novum Structures | www.novumstructures.com
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Grid Shell Structures on Freeform Surfaces
Novum FF-System Design and Fabrication Data
• Freeform grid shell structures in general (except for small projects) cannot be modelled, drawn and fabricated using conventional methods due to time, cost, manpower, reliability, accuracy and quality constraints
• Instead, the design process must be automated by using interconnected parametric component models for all nodes, members & glazing units. Novum is using proprietary software (GSD) for this purpose, which is linking standard Finite Element Analysis software with AutoCAD, Excel and CAM software for CNC machining. The initial parameters for these models have to be established after the grid geometry has been generated and the structural analysis has been done.
• Then, as a substitute of conventional drawing sets, only relevant data and very few parametric drawings are needed to design and fabricate all grid shell components. This process will be illustrated more detailled in a process case study later on.
Novum Structures | www.novumstructures.com
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Novum FF-System Node Fabrication
Typical fabrication procedure:
• CAD model data transfer into CNC software & check • CNC machining and marking • Quality control • Electroplating & painting • Crating and shipment
Novum Structures | www.novumstructures.com
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Novum FF-System Member Fabrication
Typical fabrication procedure:
• CAD model data transfer into parametric drawings & check • Automated profile length and mounting hole cutting • Quality control • Hot dip galvanizing & painting • Wrapping, crating and shipment
• Parametric drawing data transfer & check • Length and hole cutting • Adapter welding • Painting • Crating and shipment
Novum Structures | www.novumstructures.com
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Novum FF-System Installation
Typical installation procedure:
• Calibration of proprietary bolt pretensioning devices using Skidmore-Wilhelm units • Preassembly of “node fans”, single nodes with several members attached, on multiple ground stations • Lifting & mounting of “node fans” as extensions of already installed grid shell structure • Final bolt pretensioning • Glazing installation & caulking
Novum Structures | www.novumstructures.com
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Novum FF-System Installation
Novum Structures | www.novumstructures.com
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Content
1. Contemporary Architectural Styles 2. Typology of Freeform Surfaces 3. Grid Geometry 4. Grid Shell Node Types 5. Novum FF-System 6. Process Case Study – Salvador Dali Museum 7. Other Freeform Projects
Novum Structures | www.novumstructures.com
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Process Case Study – Salvador Dali Museum Architectural Concept
Salvador Dali Museum St. Petersburg, FL, USA: “Enigma” Architectural design by Yann Weymouth from Hellmuth Obata & Kassabaum, Inc. (HOK) “Igloo”
Artwork protection concept against hurricane floods w/o evacuation
Novum Structures | www.novumstructures.com
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Process Case Study – Salvador Dali Museum Grid Generation
Manual definition of intersecting Initial NURBS freeform surface planes for surface parcellation (Enigma)
Generated grid on freeform surface
Surface parcellation generates a dimensionally controlled reference pattern on the surface for various grids while maintaining control of surface edges (thus avoiding sliver facets)
Novum Structures | www.novumstructures.com
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Process Case Study – Salvador Dali Museum Grid Visualization
Final grid of Enigma and Igloo
Novum Structures | www.novumstructures.com
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Process Case Study – Salvador Dali Museum Structural Design & Glazing System Impact Testing
• Design component & cladding wind pressure per wind tunnel test results: ±100 psf (± 4.79 kN/m2) • Florida Building Code requires rigorous testing of glazing systems: - water penetration tests as per ASTM E 331 & AAMA 501.1 - structural tests as per ASTM E 330 for 200% design wind load - small / large missile impact tests & subsequent pressure cycling as per ASTM E 1886 and E 1996 (above / below 30 ft or 9.1 m)
Novum Structures | www.novumstructures.com
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Process Case Study – Salvador Dali Museum Building Interface Coordination
Geometric & structural coordination of support nodes including tolerance prediction
Novum Structures | www.novumstructures.com
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Process Case Study – Salvador Dali Museum Parametric Component Modelling – System Line Wireframe
The final structural model contains all information about member profile & bolt dimensions. Information about node types & dimensions needs to be added. Novum’s grid shell design software GSD is importing this information & connecting it with the grid shell system database.
Structural model of the Igloo in RStab System line wireframe model of the Igloo in AutoCAD generated by GSD
Novum Structures | www.novumstructures.com
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Process Case Study – Salvador Dali Museum Parametric Component Modelling with GSD – Element Orientation Vectors
GSD is now performing an automated panel search for all selected members of the generated wireframe in Autocad. Then GSD is establishing the element orientation vectors for panels, nodes and members as presented earlier.
Panels on the system line wireframe model in AutoCAD generated by GSD Close-up of panels with panel , node and member vectors
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Novum FF-System Parametric Component Modelling with GSD – Glazing Joint Wireframe
With all element orientation vectors determined, GSD is generating a glazing joint wireframe model on a predefined stand-off distance to the system line wireframe. The intersection points of glazing joints are always located on the node vectors.
Glazing joint wireframe model in AutoCAD generated by GSD Close-up of glazing joint wireframe model (yellow color)
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Process Case Study – Salvador Dali Museum Parametric Component Modelling with GSD – 3D CAD Model of Nodes & Members
Using all initially established component parameters on basis of the grid shell system database, GSD is then generating a full 3D CAD model of all grid shell nodes and members. Simultaneously the corresponding node and member fabrication data is being determined.
3D CAD model of nodes and members in AutoCAD generated by GSD Close-up of 3D CAD model of nodes and members
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Process Case Study – Salvador Dali Museum Parametric Component Modelling with GSD – 3D CAD Model of Glazing Units
With the earlier established glazing joint wireframe, GSD is now generating a full 3D CAD model of all glazing units. Simultaneously the corresponding glazing fabrication data is being determined.
3D CAD model of glazing units in AutoCAD generated by GSD Close-up of 3D CAD model of glazing units
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Process Case Study – Salvador Dali Museum Parametric Component Modelling with GSD – 3D Assembly Plan
In order to enable the correct installation of the grid shell structure, GSD is finally establishing a 3D assembly plan with orientation marks for all grid shell nodes, members and glazing units.
3D assembly plan in AutoCAD generated by GSD Close-up of 3D assembly plan with element orientation marks
Novum Structures | www.novumstructures.com
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Process Case Study – Salvador Dali Museum Fabrication Data Output – Nodes and Glazing Units
Fabrication data for nodes and glazing units is being generated in comprehensive Excel spreadsheets.
Node fabrication list generated by GSD Glazing unit frabrication list generated by GSD
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Process Case Study – Salvador Dali Museum Fabrication Data Output – Members
Fabrication data for members is being generated in comprehensive Excel spreadsheets.
Member fabrication list generated by GSD
Novum Structures | www.novumstructures.com
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Process Case Study – Salvador Dali Museum Detail Coordination & Approval Drawings
The comprehensive 3D CAD model generated by GSD is naturally the basis for all detail coordination & approval drawings as well as for all manually made fabrication drawings of components having an interface to the building or to other functional elements like doors, smoke vents, signage etc.
Novum Structures | www.novumstructures.com
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Process Case Study – Salvador Dali Museum Installation
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Process Case Study – Salvador Dali Museum Completed Project
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Process Case Study – Salvador Dali Museum Completed Project
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Process Case Study – Salvador Dali Museum Completed Project
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Process Case Study – Salvador Dali Museum Completed Project
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Content
1. Contemporary Architectural Styles 2. Typology of Freeform Surfaces 3. Grid Geometry 4. Grid Shell Node Types 5. Novum FF-System 6. Process Case Study – Salvador Dali Museum 7. Other Freeform Projects
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Other Freeform Projects Ottawa Convention Center
OCC Ottawa Convention Center, Ontario, Canada
Architect: Brisbin Brook Beynon Architects (BBB)
Grid generation & visualization
Novum Structures | www.novumstructures.com
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Other Freeform Projects Ottawa Congress Center
Novum Structures | www.novumstructures.com
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Other Freeform Projects Ottawa Congress Center
Novum Structures | www.novumstructures.com
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Other Freeform Projects Ottawa Congress Center
Novum Structures | www.novumstructures.com
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Other Freeform Projects UAE Pavilion at the Shanghai EXPO 2010
Pavilion shape is resembling sand dunes, natural formations typical for UAE deserts like Rub Al Khali
Pavilion has almost circular footprint with a diameter of about 65 m, height of the southern dune - 20 m, height of northern dunes - 18 m
Pavilion was disassembled after the EXPO 2010 and moved to Saadiyat Island, Abu Dhabi, UAE
Picture: Foster + Partner
UAE EXPO Pavilion, Shanghai, China
Architect: Foster + Partner Grid generation
Novum Structures | www.novumstructures.com
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Other Freeform Projects UAE Pavilion at the Shanghai EXPO 2010
Novum Structures | www.novumstructures.com
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Other Freeform Projects UAE Pavilion at the Shanghai EXPO 2010
Novum Structures | www.novumstructures.com
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Other Freeform Projects Lord & Taylor Yonkers
Lord & Taylor Yonkers, NY, USA
Architect: Giorgio Borusso Design
Novum Structures | www.novumstructures.com
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Other Freeform Projects Lord & Taylor Yonkers
Novum Structures | www.novumstructures.com
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Other Freeform Projects Lord & Taylor Yonkers
Novum Structures | www.novumstructures.com
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Other Freeform Projects Yueda 889 Square Shanghai
Yueda 889 Square, Shanghai, China
Architect: Callison Architecture
Novum Structures | www.novumstructures.com
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Other Freeform Projects Yueda 889 Square Shanghai
Novum Structures | www.novumstructures.com
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Other Freeform Projects Yueda 889 Square Shanghai
Novum Structures | www.novumstructures.com
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Other Freeform Projects Yueda 889 Square Shanghai
Novum Structures | www.novumstructures.com
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Thank you! [email protected]
Novum Structures | USA, China, GermanyNovum, India, StructuresSingapore, Turkey| www.novumstructures.com, UAE, United Kingdom
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