Issue 1 2020 The Arup Journal Contents

4 Cityringen Metro, Copenhagen, Denmark An expansion to the Danish capital’s metro system using passenger-centred design Tony Evans, Katrine Falbe-Hansen, Neil Martini, Nille Juul-Sorensen, Mohammad Tabarra, Kristian Winther

16 Claridge’s Hotel, London, UK A luxury hotel gains five new storeys underground, with no disruption to guests Alice Blair, Sarah Glover, Dinesh Patel, Andy Pye

24 Beijing Daxing International Airport, Beijing, China Passenger experience and fire safety are at the heart of this busy airport Robert Feteanu, Ming Li, Fangzhou Su, Kelvin Wong, Vala Yu

30 Samuel De Champlain Bridge Corridor Project, Montreal, Canada A novel design and procurement process was used to deliver this critical infrastructure project Douglas Balmer, Jo Balmer, Matt Carter

38 Guoco Tower, Singapore Constructing two geometrically complex towers as part of a vibrant new development in Singapore Dion Anandityo, Jason Tan

44 Macallan Distillery, Scotland, UK A working distillery and visitor centre that blends in with and respects the local environment Jim Deegan, Susan Deeny, Paul Edwards, Adam Jaworski, Stuart Jordan, Bob Lang, Alistair Murray

Beijing Daxing International Airport, Beijing, China: Hufton + Crow

2 1/2020 | The Arup Journal 3 CITYRINGEN METRO | COPENHAGEN, DENMARK

The Cityringen metro line, consisting of (JV) partners COWI and SYSTRA to act as fire and life safety, lighting and construction 16km of twin-bore tunnels and 17 new multidisciplinary technical adviser for this planning. During the design and construction underground stations, provides a design and build contract. It was the city’s phase, the JV team acted as Metroselskabet’s 24-minute loop around Copenhagen’s city largest construction project in more than 400 technical adviser, assisting the company centre, interchanging with the existing years. Working on the design and procurement with the tender evaluation, detailed design metro, mainline services and buses. strategy for the contract, the JV provided check, testing and commissioning, and Cityringen runs 24/7 and seeks to engineering, architectural and advisory construction management. encourage residents out of their cars and services, including civil and structural design, onto an environmentally friendly form of risk assessment, cost estimates, and project Arup led the architectural design for all transit. It is a key part of the city’s plan to and programme management. Arup was also stages of the project, taking a user-centric become carbon neutral by 2025. Cityringen responsible for the reference design safety approach at every step. This has resulted in opened in September 2019; 85% of case on the project. spacious, light-filled stations with distinctive Copenhagen residents are now less than a internal façades that echo the locality above 10-minute walk from a train station. For the concept and reference design, the stations. Arup (as part of the JV) provided a range In 2007, Metroselskabet, Copenhagen’s metro of services, including geotechnics, structural Passenger-centred design company, appointed Arup with joint venture engineering, tunnelling, tunnel ventilation, The original Copenhagen metro lines opened between 2002 and 2007 and were successful from the start. Building on this, the JV’s design for Cityringen focused on Cityringen enhancing the traveller experience by putting the emphasis on passenger comfort Metro lines 1 and 2 throughout the journey. The metro is a fully automated, high-frequency, driverless system. The stations do not have ticket Enhancing barriers, and staff are available on concourses, platforms and trains to assist customers during their journey. Every the metro station has two lifts that take passengers from the platform directly to street level, making the metro fully accessible for all. experience Tunnel depth has been minimised at station locations, thereby reducing passengers’ Copenhagen’s Cityringen metro 1: The Cityringen line, line expands the city’s existing which opened in September 2019, aims award-winning underground to encourage more citizens to use this system, making it even easier environmentally friendly to travel around the capital form of transport 2: Cityringen Authors Tony Evans, Katrine Falbe- (represented on the map by a yellow line) Hansen, Neil Martini, Nille Juul- adds a third line to Sorensen, Mohammad Tabarra Copenhagen’s extremely popular and Kristian Winther existing metro system 1. 2.

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3: The stations have 3: The stations have been designed to be been designed to be relatively shallow in depth where possible, shallow in depth, giving clear sight lines between street and giving clear sight lines platform level between street and 4 & 5: Each station’s surroundings have platform level influenced their design. At Marmorkirken 4: Each station’s Station, the limestone cladding is a nod to the surroundings have marble church above influenced their design. At Marmorkirken Station, the limestone cladding is a nod to the marble church above For example, in Marmorkirken Station the fossil-embedded, sand-coloured Swedish limestone cladding is a reference to the 19th-century marble church above. In Trianglen, mirrored glass panels have been used to reflect and multiply the colours worn by sports fans flocking to the adjacent national stadium, contributing to the lively pre-game atmosphere. Grey and yellow bricks are used in Nørrebros Runddel to 3. complement the yellow brick wall around 6. 7. the churchyard located above the station. travel time on escalators and lifts. As security and physical comfort, while also Modular design developed further, with the skylights also 6: A 5.5m module is used for commuters enter the majority of the stations, optimising passenger flows. Cityringen interchanges with the existing The architectural approach across all 17 acting as emergency air vents, thereby finishes to match the module of the shallow depth helps them to see all the M1 and M2 metro lines at two locations stations was to use a ‘kit-of-parts’ design. reducing the reliance on mechanical smoke the passenger screen doors on way down to platform level; and, conversely, Station identity (Kongens Nytorv Station and Frederiksberg This led to a cost-effective, rational design ventilation systems and the need for further each platform at platform level they can see the exit above. By incorporating ideas and motifs inspired Station) and the commuter/regional train at and modular construction system. Future- in-station equipment rooms. 7: Skylights provide natural These clear lines of sight help people to by each station’s surroundings, Arup’s three locations (København H/Copenhagen proofing the stations was an important design light at platform level easily navigate through the metro. Based on architectural design approach – using Central Station, Østerport Station and driver for Arup’s materials and lighting The lighting design is fully integrated with 8: The skylights’ distinctive extensive pedestrian modelling work, Arup sculptural wall panels and cladding on the Nørrebro Station). Grey natural stone was specialists. They sought high-quality the architecture and uses the feature glass pyramids appear developed the concept for station layouts, the internal façades – draws each chosen for both Kongens Nytorv and long-life fittings and durable self-finished ‘origami ceilings’ as reflectors, throughout Copenhagen new line’s visual identity and signage for neighbourhood’s identity into each station, Frederiksberg Stations, as grey cladding is surfaces, such as terracotta tiles and granite complemented by bespoke LED lighting that effective wayfinding. Static signs are making the metro a natural continuation of used inside the existing metro stations, while platforms, to provide high-impact solutions helps avoid glare. The origami geometry combined with dynamic displays and the surrounding area. It also helps with red ceramic panels are used at the three rail with low maintenance costs. was designed using 3D simulations and 1:1 interactive travel panels to generate a sense of inferred wayfinding. transit stations, as the urban trains are red. mock-up testing of luminaires and Where possible, fittings and finishes, such as the wall cladding, were specified in 5.5m modules. This matches the module of the passenger screen doors used on each platform to separate passengers from the tracks, with the repetition of this module at all stations reinforcing the identity of the new metro line.

Bringing light underground Metro passengers can navigate from the street to the platform without feeling as though they are venturing underground. To achieve this, most of the 17 new stations feature skylights. These provide bright natural daylight at platform level, to help bring the outside in and improve energy efficiency within each station.

For the first phase of Copenhagen’s metro, completed in 2002, Arup contributed to the design of the distinctive glass pyramids and skylights. For Cityringen, this was 4. 5. 8.

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9: The ‘origami ceilings’ act architectural finishes. A detailed 1:25 scale of the residual train-induced piston airflow as reflectors for the daylight architectural station model was created in and is always in the direction of train travel. spilling in from the skylights which the intensity of the daylight could be This was made possible by the short (39m) 10: To minimise disruption, tested in relation to the station space. three-car trains used on the line – for short stations were built trains, the passenger risk exposure and underneath pre-existing Design integration therefore the emergency ventilation parks and squares where Each station has an approximate footprint direction is far less dependent on the possible of 64m x 20m and a 45m platform length. location of fire on a train. The fully 11: Four TBMs had to In order to minimise their impact on traffic, automatic, driverless system allows fast tunnel through challenging utilities and properties during construction, reaction times, with minimum human ground when constructing stations were placed under existing parks interaction required during emergencies. Cityringen and squares wherever possible. This has 12: Arup used advanced allowed new landscaped plazas to be A mode table of all possible ‘what if’ modelling techniques to created above many stations, providing scenarios, assisted by heat and smoke analyse fire and smoke civic spaces for the surrounding community sensors in the tunnels and on board the behaviour in the stations and tunnels and simple, welcoming entrances and trains, guides the control centre operator forecourts for passengers. to arrive at the correct emergency response swiftly. The compact, driverless metro trains allowed the JV team of engineers, designers Construction and transport consultants to design smaller A major metro extension represents long- platforms, helping to shrink the overall term disruption to any city, but Arup’s footprint of the stations. This meant careful programme management, together 9. with Metroselskabet’s intensive stakeholder management, ensured shopowners, residents 11. and visitors could go about their daily lives with minimum disruption during the eight demolition was kept to a minimum, with just more likely, rubbish-bin fire scenario years of construction. two buildings demolished for the new metro replaced the more traditional, and larger, line. The life of the city was able to continue baggage fire scenario in the design of Embedding 17 new stations within a fairly undisrupted throughout construction. station ventilation systems. historical city was a delicate engineering design task. It was critical that the impact on Ventilation A simple emergency tunnel ventilation and heritage structures was minimised. At Arup’s work on the fire and life safety risk evacuation strategy was adopted, where the Marmorkirken, the station is 36m below strategy and the tunnel ventilation during the default ventilation direction takes advantage ground and is carefully located in a narrow concept design phase helped to reduce the number of intermediate escape shafts from 17 to three, significantly improving the visual and physical impact on the city, as well as reducing costs and disruption due to construction.

The ventilation design consisted of a single tunnel ventilation fan plant and single- pressure draft relief shafts at each station. The modular station design continued with the civil coordination of over-track ventilation ducts with the station structure. This was repeated along the metro line, where a single tunnel opening and multiple grille over-track openings were connected to the single ventilation plant via dampers.

Advanced modelling techniques were used to simulate all operating scenarios. A subway environment simulation software program was used for the 1D analysis of the tunnel network, with computational fluid dynamics used for the 3D analysis of fire and smoke behaviour in complex station geometries. A smaller, but statistically 10. 12.

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13: At Gammel Strand, the adjacent waterway was kept open during construction by placing the worksite on a platform above the canal 14: The abundance of natural light means using Cityringen does not feel like being underground

During construction, groundwater was managed by a comprehensive re-infiltration system implemented and monitored closely, as groundwater is extracted for drinking in Copenhagen. Re-infiltration also ensured that the large number of historical buildings that are founded on wooden piles were not adversely affected by dewatering.

In order to track building settlements unrelated to Cityringen, and for the seasonal fluctuations of heave and settlement in the ground to be recorded, initial baseline monitoring was carried out by Metroselskabet from 2009 onwards (three years before the contract was signed with the contractor) on a number of 13. buildings along the Cityringen alignment. Furthermore, building condition surveys corridor adjacent to the 19th-century marble further working space at ground level, relaunched to complete the drive from of hundreds of buildings along the metro church’s foundations. helping to limit the extent of the worksites Nørrebroparken shaft to Øster Søgade route were carried out both before and and thereby reducing disruption to the shaft in challenging soft and mixed after construction. At Gammel Strand, the station was partly local community. ground conditions. built under the canal. The waterway was Arup’s reference design for the new metro kept open for tourist boats during Four earth pressure balance type tunnel Monitoring took into account the sensitivity of existing construction, with the worksite placed on a boring machines (TBMs) were used to Implementation of an exhaustive risk buildings and set out the framework for the platform above the canal, allowing boats to construct the twin tunnels (of 4.9m internal management programme to monitor and design and build contractor to carry out the pass beneath. diameter) to depths of between 20m and minimise damage to third-party assets works. During the design and construction 35m. Two TBMs bored the first parallel and continuous monitoring of the ground, phases, Arup was responsible for reviewing The stations were generally constructed at a drive, constructing the twin tunnels from structures, groundwater, noise and vibration and following up on the contractor’s depth of approximately 19m below ground the Nørrebroparken shaft to a shaft at was critical to successful completion of building damage assessments, including at using cut-and-cover box structures. All bar Sønder Boulevard. This drive was the project. Marmorkirken Station, the Magasin du Nord one of the stations used a semi-bottom-up predominantly through good quality hard department store building, and tunnel method. In this method, the retaining walls ground beneath residential areas. These The Cityringen station footprints have crossings under and above surface railways and roof slab were constructed first, before TBMs were then moved and relaunched for been inserted into the existing urban fabric, and existing underground metro tunnels. excavating to the base level. Temporary their second drive from Øster Søgade shaft meaning that some station retaining walls Alert and alarm values from the damage props were placed between the station walls to København H, passing through the heart are only 1.5m from existing buildings, assessments informed the monitoring plans prior to the installation of the permanent of the city close beneath many sensitive including the foundations of the 260-year- and the emergency plans. floor slabs. Building the lid of the station heritage structures. At the same time, two old ‘Marble Church’. The new line first reduced the level of noise during the other TBMs bored, in twin tunnel formation, connects with three existing railway Detailed monitoring by both the contractor excavation and construction of the lower from the Control and Maintenance Centre stations and two metro stations, so it was and Metroselskabet took place during the levels below the roof slabs. It also minimised at Otto Buses Vej, underneath the main rail also critical that the existing transport works to confirm the assumptions for the settlement of the neighbouring buildings. corridor into Copenhagen to the shaft at network was not compromised during design models, and to record the impact In addition, the roof slabs offered Sønder Boulevard. They were then construction works. of the construction works on existing 14.

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15: The TBM passed very close to A further design challenge to tunnelling the shallow foundations of the below Magasin du Nord was the complexity Magasin du Nord department store of the department store’s structural system. 16: Kongens Nytorv Station was one It consists of multiple interconnected of the most challenging locations, buildings constructed at different times, with with mixed ground conditions, and different materials, on a range of foundation nearby metro lines and shallow types. In addition, in 2000, the building’s building foundations basement was lowered by approximately 1m to accommodate an additional shop floor and provide access from the original Kongens Nytorv metro station. There was a possibility that micro-piles used in that construction were still in place, with a risk that the TBM could hit these as it passed below the building.

To reduce the building’s predicted settlement, and the risk of encountering the micro-piles, the contractor proposed lowering the new Kongens Nytorv Station and the Cityringen tunnel alignment to within 1.5m of the existing metro tunnels. 15. 17. A detailed analysis of the effect of the TBM passage on the existing metro structures and infrastructure. More than data acquired. All site managers and The settlement data and TBM parameters on the existing metro tunnels with a clearance of lifts, increased the excavation required and tunnels was conducted to determine the 22,000 monitoring stations provided 200,000 relevant members of the contractor’s the database helped the contractor to tunnel in only 1.5m, before diving, with very limited would have led to higher costs. potential implications. The results showed readings every day. Automated monitoring technical department, including TBM difficult soil conditions. Monitoring data clearance, beneath the shallow foundations of that the deflections and stress levels in the occurred at variable frequency but often took technical staff, had full access to the acquired during the project allowed for several heritage buildings, including the The contractor performed a detailed existing metro tunnels were negligible and place every 30 seconds when tunnelling was monitoring database and had specific duties design optimisation and helped to avoid flagship Magasin du Nord department store. assessment at Kongens Nytorv, involving could be accommodated by the tunnel close to the monitoring points. Monitoring and roles regarding monitoring. A dedicated unnecessarily costly and disruptive mitigation the analysis of a fully coupled 3D structure. After crossing the tunnels, the data fed into an extensive, real-time database. emergency action plan was continuously measures in the centre of Copenhagen by The risk of settlement and associated geotechnical and structural model, with the TBMs dived down at the maximum updated and in use during construction, with allowing the contractor to precisely predict damage to buildings and utilities in this area advancement of the two TBMs modelled allowable gradient (6%) to clear the Both the contractor and client had dedicated precise procedures detailed in case any the volume loss from TBM boring. would have been lessened if a deeper ring by ring in order to identify all possible underside of the Magasin du Nord teams to manage the extensive quantity of threshold values were exceeded. Cityringen station was constructed, with the settlement scenarios. The initial analysis foundations and any micro-piles that Protecting heritage buildings TBMs passing beneath the existing metro predicted that damage to the buildings may still have been in place. The contractor was required to carry out the and through good soil conditions. However, would be at unacceptable levels, so works on the project without causing this option would have significantly additional mitigation measures needed The contractor used both preventative Existing M1 & M2 Metro Lines significant damage to third-party assets. increased passenger time on escalators and to be put in place. and corrective measures to mitigate the Acceptable limits for typical building damage were outlined within the contract – damage should be limited to category 1 according to the classification in BRE Digest 251, which defines damage as “fine cracks which can be treated easily using Zone with the highest risk Cityringen normal decoration. Damage generally of settlement restricted to internal wall finishes; cracks rarely visible in external brickwork. Typical crack widths up to 1mm”. Category 2 damage, where serviceability would be Kongens Nytorv Cityringen Station affected – requiring external repointing of brickwork and doors/windows needing repair – with crack widths up to 5mm, was not acceptable. Historical building archives were used to provide information for the assessment of building damage. 17: The driverless metro trains run every three minutes at peak times, and every Kongens Nytorv Existing Station Kongens Nytorv was one of the project’s five minutes during the rest of the day most challenging locations. In this area, the 18: The Øster Søgade shaft was used to TBMs had to break out of the new station at launch the TBMs and to incorporate Kongens Nytorv, tunnel through shallow, soft bifurcation structures for the metro ground in mixed-face conditions, pass above extension to Nordhavn 16. 18.

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risk of damage to the buildings at Kongens Transport network expansion bifurcation chamber was a tapered (in plan) Nytorv. The preventative measures included Arup is continuing to work on expanding reinforced concrete shaft with stacked track lowering the tunnel alignment as described Copenhagen’s transport network to the north bifurcation on the two lower structural levels, above, filling disused underfloor heating and south of the city. The Nordhavn branch 15m and 26m below ground level, and with a conduits with lean concrete and using of Cityringen, with two new stations, will technical level housing equipment and plant localised jet grouting to underpin sensitive create a transport hub for the docklands rooms approximately 7m below ground level. foundations. Corrective measures included redevelopment north of the city centre and an extensive compensation grouting array opened in March 2020. To the south-west, For the larger crossover caverns where and the preparation for emergency Arup is working on the detailed design of the tunnels branch off towards Nordhavn and dewatering if required in order to allow five-station underground extension to the Sydhavn, Arup designed a novel, lightweight access to the TBM face. A comprehensive Sydhavn district. This is set for completion in fire board panel system, supported by a steel liquid levelling monitoring system was 2024, as part of the regeneration of the city’s frame for the over-track exhaust duct in the installed in the basements and ground floors south harbour area. To ready the transport ceiling. This replaced the heavy and of the buildings most at risk of settlement, network for these new elements, two cumbersome fire-rated metal sheet work, 3D prisms and levelling bolts were installed bifurcation structures were incorporated traditionally used in other metros, saving time on building façades and an automatic 3D during Cityringen’s construction. This and cost on the construction programme. monitoring system was installed inside required modification to the already planned the existing metro tunnels to detect Øster Søgade shaft and the introduction of a Cityringen opened in September 2019. tunnel convergence. new shaft at Havneholmen. Trains run every three minutes in the peak morning and evening commutes, and wait The compensation grouting array consisted The changes to the Øster Søgade shaft saw times are less than five minutes during the of 45 horizontal tube-a-manchettes ranging the introduction of two additional tunnel rest of the day. The line is forecast to from 15m to more than 40m in length, with interfaces to the western edge of the shaft. transport up to 120 million passengers a grout valves every 0.5m. Where the liquid This was a complex project, as the worksite year, with 85% of all Copenhagen residents levelling systems indicated a localised was also a tunnel construction service site for now within 600m of a metro or train station. foundation movement, the array enabled a the TBMs creating the eastern part of The new line is a fantastic example of direct and immediate response with grout, Cityringen between Øster Søgade and elegant, efficient and intuitive rail design, quickly re-establishing the foundation København H. The design for the centred on delivering an effortless and 20. stability. A maximum settlement of just modification to the shaft minimised the enjoyable travel experience for 1.2mm was measured during the passage of disruption to the Cityringen works and Copenhagen’s citizens and visitors, and the first TBM, and a maximum value of maximised future flexibility for the addition building on the strengths of the city’s Authors Project credits Kasper Kramer, Ben Kreukniet, Sachin Kumar, 0.8mm for the second, proving that the hard of the Nordhavn branch to the metro network. existing system. It proves that the Tony Evans was seconded into Metroselskabet’s Client Metroselskabet I/S Maciej Kupczyk, Tatjana Lampe, Eduardo work by Metroselskabet, the designers and Crucially, the design also minimised any architecture of rail systems can contribute construction management team as Technical Design and build contractor Copenhagen Landete Mata, Jens Larsen, David Leal, Yu-Chen the contractor had paid off. The best solution unnecessary change that might impose greatly to a city’s identity, with a sustainable Manager during the project. He is an Associate Metro Team (Salini-Impregilo, Tecnimont Lee, Chris Lees, David Loosemore, Helle Lyng possible had been achieved for the station at additional cost or disruption on the design that can be maintained cost- Director in Arup’s Midlands Campus in the UK. and Seli) Svensson, Steve Macklin, Guy Macleod, Enrico Manganelli, Neil Martini, Stuart McClymont, this location. surrounding area. The Havneholmen effectively, long into the future. Joint venture partners COWI, SYSTRA Katrine Falbe-Hansen was seconded into Acoustics, architecture, civil engineering, Jonathan McKiernan, Charles Milloy, Phil Morley, Metroselskabet and was responsible for building construction management, electrical Sabine Moser, Trent Murrihy, Omid Nakhaei, Paul assessment coordination and third-party issues engineering, façade engineering, fire Newton, Anders Nohr, Alberto Palma, Dinesh for Cityringen. She is a senior civil and structural engineering, geotechnics, lighting design, Patel, Aitana Paya Perez, Giuseppe Pelagalli, engineer and is based in the Copenhagen office. materials science, mechanical engineering, Francesco Petrella, Saskia Polster, Gregory pedestrian modelling, programme and project Quinn, Dirk Regenspurger, Mhairi Riddet, Derek Neil Martini was the Project Manager. He was management, structural engineering and Roberts, Nina Rutz, Prakash Sabapathy, Russell seconded into Metroselskabet as the tunnel tunnel design Arup: Yakup Akkas, Jarrod Alston, Saltmarsh, Sheela Sankaram, Cornelius design manager during the project. He is an Ambrogio Angotzi, Giulio Antonutto-Foi, Eva Schneider, Nazaneen Shafaie, Ruth Shilston, Associate in the Copenhagen office. Arquero, Mo Attia, Enrica Barzaghi, Andrés Siegrid Siderius, Derek Smyth, Jamie Stern- Bascones, John Batchelor, Charles Betts, Johan Gottfried, Colin Stewart, Igor Stipac, Louise Nille Juul-Sorensen was the lead architect on Beudeker, Joanna Bielecka, Paola Blasi, Andre Stroud, Julia Summers, Matt Sykes, Sebastian the project. He was also previously responsible Blokker, Tamas Bodri, Lucio Boscolo Mezzopan, Szafarczyk, Mohammad Tabarra, Rachel Taylor, for the design of Copenhagen’s M1 and M2 Brendan Bradley, Nicholas Bruce, Edel Casserly, Nick Troth, Rogier van der Heide, Alexandra van metro lines. He is Arup’s global leader for Tim Chan, Man-Yiu Cheuk, Francisco Cortes- Tintelen, Jeroen Verwer, Ida Villumsen, Marie architecture and a Principal in the Toronto office Franco, Piotr Czapko, Andy Davidson, Fred West Henriksen, David Whittles, Heather Wilson, (he was formerly based in Copenhagen). Deacon, Tim Dixon, Jim Dunne, David Eborall, Kristian Winther, Kevin Womack, Anna Wudzka, Anna-Maria Ejrup, Matthew Evans, Tony Evans, Jan Wurm, Clara Yeung, Pietro Zanetti, Mohammad Tabarra was responsible for Katrine Falbe-Hansen, Andrej Fojkar, Pernille Gertraud Zwiens. the tunnel and station ventilation design on Fournais, Jens Frederiksen, Jens Fugl, Salome the project. He is Arup’s global tunnel ventilation Galjaard, Mads Gandil, Valentina Gastaldi, Tim Image credits lead and an Associate Director in the London office. Goeckel, Rene Guenther, Na’amah Hagiladi, 1, 3, 4, 6–10, 14, 17, 20: Rasmus Hjortshøj – 19: Compensation grouting was used Stuart Hall, Diana Hare, Ali Hariri, Alexis COAST to prevent the risk of excessive building Kristian Winther was responsible for design Harrison, Chris Harvey, Des Hendrick, Michael 2, 5, 11, 12, 16, 19: Arup movement and coordination of the main concept for the Hess, Daniel Hof, Tom Honnywill, Andrew 13, 18: Dragør Luftfoto/Metroselskabet I/S 20: Cityringen opened in September 2019; station architecture. He is an Associate in the Jenkins, Aslak Jensen, Inge Jensen, Nille 15: Arup/Metroselskabet I/S some 85% of Copenhagen residents are Copenhagen office. Juul-Sorensen, Tomasz Kasprus, Areti Kavoura, now within 600m of a metro or train station 19.

14 1/2020 | The Arup Journal 15 CLARIDGE’S HOTEL | LONDON, UK

Digging deep Creating a five-level basement below a fully operational five-star hotel in London’s Mayfair

Authors Alice Blair, Sarah Glover, Dinesh Patel and Andy Pye

The owners of Claridge’s, a five-star The project was put on hold following the hotel in the heart of London’s exclusive 2008 global financial crisis. When the client Mayfair district, wanted to enhance the revisited the idea in late 2015, they had even services offered to their guests and more ambitious plans – they now wanted to increase capacity. To do so, they needed develop a five-level basement. Having to expand the hotel. Planning reasons successfully collaborated on projects meant they could not increase the height previously, Arup and the design and build of the building, so an alternative solution contractor, McGee, worked together on a was needed. Could a modern extension methodology to excavate and construct the be created by excavating below the basement using mining techniques. building – without disrupting the hotel services or disturbing the guests? This was a uniquely challenging project, as it required the design and construction of a In 2007, when the Maybourne Hotel Group 22m-deep basement and 30m-deep foundations initially proposed extending Claridge’s by beneath a 90-year-old concrete raft slab constructing two basement levels below the founded on material that was difficult to safely Grade II-listed building, they were advised excavate. Adding to the complexity, in order to that the hotel could not remain open during avoid disruption to hotel guests, all the works. But closing Claridge’s temporarily construction materials, machinery and was not acceptable to the owners. A closure excavated spoil needed to pass through a single of any kind would jeopardise client loyalty – 2m x 2m window to the rear of the hotel. The the hotel has long boasted an impressive construction operation was performed from a guestlist that includes Hollywood celebrities, single 7m2 room, which was the only available rock stars and royalty. The owners required a space that the client could afford to give to the solution in which facilities could be upgraded construction team; later, a second room was while the hotel remained fully operational. provided at the front of the building.

1: The five-storey basement was constructed under the 1920s Art Deco section of the hotel 2: All the machinery and excavated materials passed through a single window to the rear of the hotel 1. 2.

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The design team developed a solution that excavation electrically operated to minimise involved coring through the existing noise, vibration and possible pollution. F basement raft slab in a single 2m x 2m location, and from there constructing This work required close collaboration horizontal tunnels (more than 400m in total) between Arup, McGee and temporary works E under the slab to below each of the designer RKD, with Arup carrying out 61 columns requiring support, with four extensive analysis of the existing building additional columns supported on new transfer foundations to understand the load path from D structures. Vertical shafts 1.8m in diameter the building and determine its response were then hand-dug beneath each of the through all phases of the work. Movement

C columns. These needed support to depths of had to be limited, as excessive displacements 30m in order to form caisson foundations. A would have had serious consequences for the five-storey reinforced concrete column was structure, sensitive listed heritage features

B built within each shaft up to the underside of and – most importantly – the hotel occupants. the existing raft to provide vertical support to A rigorous regime of movement monitoring A.1 the superstructure above. Once complete, the and control was put in place during basement area was excavated around the new construction. Buildability drove the design; A columns to create the basement space. All the work needed to be methodically planned,

1.2 3

12 10 11

8 7 3 5 6 9 2 4 25,000m of excavated material was removed as construction was taking place in such a

4.2 1.1

7.1

2.1 4.1

1 through the one window at the rear of the confined space and with access to the building, with all equipment used in the construction site so limited. 3. Raft slab investigation 3: More than 400m of horizontal tunnels were Claridge’s first opened in 1856 and, before the 6. constructed in total basement extension began, it was made up of 4: The shafts were hand-dug, with temporary steel two buildings – a Victorian-era seven-storey response to the movements from the crack pattern and associated concrete liners installed by the miners building constructed in the 1890s and an Art proposed construction methodology. deflections at rupture. This combined analysis 5: Basement level one was excavated directly Deco building at the east of the site dating confirmed that the slab behaviour would below the 1920s raft slab from the 1920s. The Victorian building was An 800mm x 800mm section was cored remain acceptable, provided any deflections 6: 3D model showing the foundations and constructed with load-bearing masonry walls out to investigate the slab’s concrete caused by excavation underneath were columns, along with the first basement level founded on an unreinforced mass concrete strength and reinforcement quantity. This carefully controlled. slab, making it unsuitable to excavate under. section was lightly reinforced, matching minimum code requirements at the time of its Challenging ground conditions The Art Deco section consists of a nine- construction. As access restrictions prevented While the raft slab was being examined, a Pioneering solution storey steel frame with heavy perimeter investigations elsewhere, it was not possible significant geotechnical issue was being The client’s aim was to create 5,500m2 of load-bearing walls founded on a 50m x to confirm whether any other areas of the raft investigated, one that had the potential to stop extra space. The upper two floors of the 25m x 1.1m deep concrete slab. With careful had more reinforcement than this sample. the project. Claridge’s is located in the former basement were earmarked for a range of new construction of a new supporting foundation course of the River Tyburn, and initial site offerings for hotel guests, including a gym, system, this load-bearing raft slab could be Using only the minimum 1920s code investigations suggested that the raft was a spa and two swimming pools. The three converted into a suspended slab, thereby reinforcement as a conservative estimate, founded on combination sand and gravel lower levels were to be used for back-of- allowing the basement to be excavated below Arup carried out extensive analysis of the raft material. After further analysis, it was house facilities and plant. By moving some of 4. the slab. In order for this plan to be feasible, strength to inform the design and understand determined that the raft slab was bearing on the staff areas into the basement, this freed up it was crucial to understand how the slab the construction-related movements that the an alluvial clay silt deposit of varying depth space at lower ground floor level, which could would behave at all stages of construction. building would experience. Deflections and (up to 2m) on layers of gravel above London then be used for luxury retail units instead. settlements were analysed with soil-structure Clay. In situ, the alluvial layer has high- Relocating the roof-level mechanical and Arup needed to quantify the strength of the 2D and 3D finite element (FE) analyses. The bearing pressure, but it is very sensitive to electrical plant areas to the basement would slab and determine the density of staged geotechnical analysis modelled the moisture. The stability of this soil layer create the space for 40 new rooms, including reinforcement within it to ensure it could various activities across the complete during excavation was a huge safety concern, penthouse accommodation on the top floor. span over the tunnelling works and safely construction sequence to predict the load as once disturbed and in contact with water it transfer loads both during the tunnelling distribution in the slab, along with ground turns into a paste-like consistency, making it Arup’s geotechnical, structural and advanced operations and when the new columns were settlement and heave. impossible to tunnel safely through and technology engineering teams worked closely in place. There was limited information on risking excessive building settlements. with McGee to minimise the significant ground the slab – one of the only sources was a A separate 3D FE analysis investigated and structural risks inherent in constructing a November 1931 article on construction of inelastic cracked behaviour of the raft and A solution needed to be found to prevent this basement under a heritage building. They the Art Deco wing in The Builder magazine, failure mechanisms, using a Continuous sensitive soft layer from turning into liquid initially spent six months carrying out site which noted the overall quantity of Surface Cap Model for the concrete material during the mining operation. Options trials, material tests, and geotechnical and reinforcement, as well as the difficult soil model that included each element of considered included ground freezing and structural analysis to demonstrate that the conditions. The slab is an early example of reinforcement. Hand calculations and grouting. However, ground freezing would proposed basement construction methodology the use of a reinforced raft. As it did not meet non-linear FE analysis were also carried out, have required extensive additional access was workable. There was no precedent for modern codes of practice, one of the major with Arup’s Advanced Digital Engineering within the hotel, and there was also the such an ambitious project. challenges was understanding the raft’s team modelling the concrete to analyse the potential that this method would cause soil 5.

18 1/2020 | The Arup Journal 19 A1 A B C D E F G H I J K L M N

Notes:

1. Caissons on grid A1 removed subject to design of appropriate transfer structures at B1 level.

1 1 1.1 1.2 2 2.1 3 4 4.1 4.2 5 6 7 7.1 8 9 10 12 13 2. Caissons at F4, F5.5, F6 and F7 loading based on option to construct F5.5. No F6 Caisson required. 07/03/2017 16:48:41 07/03/2017 3. Caisson design based on WSP loading plans version P2 issued 29.02.2016 and superstructure loads issued 11.05.2016. 0.96° 840 610 4326 3275 1325 1935 1265 4600 3700 1280 4020 4200 7950 2000 2200 4. Design of caissons on gridline A assume bells extend beyond the party wall line.

5. Setting out of all caissons TBC. In Abeyance 6. For caisson schedule refer to drawing CH-AR-XXX- S-0001. 2

F F F 0 F F F F .5 F F F .1 2 3 4 5 -7 -8 -9 -1 F 1 - - - - P P P P -1 - P P P P C C C P P C C C C C C C 4720

3 E 0 E E 1 -7 -8 - E E E E E E E P P E P -1 -2 -3 -4 -5 -6 C C -9 C P P P P P P P C C C C C C C 4640

D D D D 0 4 D 6 -7 -8 -1 D 1 - P P D P 1 D D . D P 9 D - -2 -3 -4 -5 C C C - C P P P P P P C C C C C C 4440

C C C 0 C 6 7 -1 C C .1 C - - C C P C 1 2 C 4 P P 8 9 - - -3 - -5 C C - - C 5 P P P P P P P C C C C C C C 4600

B 0 B -1 B B B .2 B B B B P 1 3 4 4 6 .1 8 9 C - - - - - 7 - - P B P P P P - P P B C -2 C C C C P C C P C C 6 2200 A1

C1 07/03/17 DT AB AB

A A 3300 0 Construction .1 A A 1 A A -7 -8 -9 - A 2 -6 P P P P A A A 4 . P C P4 26/08/16 DT AB SG .1 .1 3 - -4 C C C A 1 2 - P P C -1 - - P C CLARIDGE’S HOTEL LONDON, UK P P P C C Preliminary Issue - Caisson B6, A & F | C C C A Updated 7 P3 09/08/16 DT AB SG Preliminary Issue P2 08/06/16 DT AB SG Preliminary Issue A B C D E F G H J K L M N 0 p A1 CL CL P1 01/06/16 DT AB SG Preliminary Issue 7: 152 UC steelwork sections were used to frame 1 Existing <7 �basement Rev Date By Chkd Appd the tunnels on all sides. Excavation was carried out raft slab <7 SSL -6.100m SSL -6.100m <7 Caisson Pile G.A in small sections to minimise distortion on the slab <7 8 1 <7 1 : 100 <7 2 8: Some 61 of the building’s columns required varies s lab B5 Slab varies B5 Slab B5 support, while four other columns were supported 152x152x23 UC 1600 x 1600 x 1200dp R.C 1600 x 1600 x 1200dp R.C pad to be constructed with pad to be constructed with 13 Fitzroy Street 10mm thick column column. London W1T 4BQ on new transfer structures Tel +44(0)20 7636 1531 Fax +44(0)20 7580 3924 stiffener plate 1807 www.arup.com 3 9: A 2m x 2m shaft was cut from the access room Client Harjacks 15/10 (40mm closed Macrete 2440 McGee Group Holdings LTD. to allow tunnelling to begin height, 10mm max travel) __ ...lo. 2 M24 Macrete 2440 Dry pack 0, jacks to be removed once Smoothbore Rings ><"' bolts 9 smoothbore rings concrete packing in place ...lo. 0, 4 ><"' w"' Grouted around Grouted around C annulus annulus Project Title () Claridge's Basement 0 0 .....00 5

...lo. 610 typ.

>< ...lo. 200mm x 50mm x Drawing Title

0, t oe ( v aries) to construct a 1.2m-wide x 1.8m-deep water "' 500mm long precast 4mm thick steel plate 125x75 C24 10 concrete plank with Caisson Foundation 6 timber noggin cut-off beam 25m in length. In a ‘hit and C A142 reinforcement a bove General Arrangement () between frames miss’ underpin method, a trench was b ell 610 typ. excavated in front of the raft, within the Scale at A1 Height of Internal 2440 Internal 2440 As indicated 7 Role lightwells in the pavement outside the hotel. 3D View - Caisson Pile Structural 7. 152x152x23 UC Shaft diameter (2700) Shaft Dia. (Varies) 2 Suitability This trench was then filled with concrete to Bell diameter at toe (varies) Construction expansion that could damage the structure. flowing back into the site. On the west side of form the cut-off. Three vacuum dewatering 11 Arup Job No Rev 8 245269 C1 Semi-dry bed Grouting would not work due to the high the site, existing sheet piles used during the wells were sunk on the south side of the Typical Internal Caisson Detail Without Bell Name fines content of the soil. The solution, construction of the Art Deco section of the hotel, with another two sunk to the north. Typical internal caisson detail with bell CH-AR-DGA-094-S-2094

10. 11. Do not scale © Arup designed in conjunction with WJ building already prevented water from Once the dewatering process was complete, 9 Groundwater, was to dewater the alluvial entering, and on the east side adjacent it was safe to excavate in the alluvial layer. layer using vacuum wells. This method buildings had either underpinning or secant passages mined from the main tunnels to 15 experienced miners, mostly from Donegal, This allowed shafts to be sunk from both sucked out the water to provide increased soil piles providing a similar cut-off. Tunnels 10 locations below the steel columns supporting using hand-held pneumatic spades. sides of the site, with 1,800m of vertical strength and stiffness, with the wells initially To allow the tunnel construction to the hotel. The size of the tunnel was a balance shafts excavated in total.

2 Client Job Title Drawing Title Scale atA1 placed in the single 7m room to the south. A new secant pile wall was installed to the commence, a 2m x 2m vertical shaft was cut between being large enough for the miners to Shafts and caisson foundations 1 :25 ARUP Discipline No default available Job No Drawing Status south, but on the north side a different through the basement slab from the safely work in, but also small enough to Vertical shafts, 1.8m in diameter, were When the steel-ringedNo default available shafts reached to below 50 Arup, Ringsend Road Drawing No Issue Dublin, D04 T6X0 By Chkd Appd www.arup.ie Section A-A However, the dewatering could only take place solution was required. This area is not easily construction access room. Three main 2m x ensure the raft above was adequately Issue I Date I I constructedTel +353(0)1 233 4455 Fax +353(0)1 668 3169 below the 61 building columns the lowest basement level, 22m beneath the © following the installation of perimeter cut-off accessible, as it is below a busy road and the 2m tunnels were initially built midway Do not scalesupported while maintaining a load path that needed support, with a reinforced raft, they were enlargedArup to form a caisson walls, which would prevent groundwater from hotel’s ballroom entrance. The solution was between the main column grids, with shorter through the tunnels into the ground below. concrete collar used to frame the top of each foundation 2.7m in diameter. At the bottom, shaft. Miners worked 24 hours a day across the caisson sizes were further increased up to The tunnels were hand-dug in 500mm two 12-hour shifts. Three separate teams a maximum diameter of 4.6m to provide a sections, with 152 UC steelwork sections used worked on a shaft each, with no two wide base for the foundation, at a depth of up to frame the tunnel on all sides. The steel was adjacent shafts excavated at the same time, to 30m in places below the raft. Each caisson light enough to be put into position, bolted in order to minimise any raft disturbance. was inspected by McGee and Arup staff prior and assembled on site. The frames were Two miners hand-dug each shaft using to concreting, as it was essential the shaft placed at 500mm centres, with steel plates pneumatic spades and, as they excavated, dimension was correct and that the bottom of inserted between the side frames and the voids installed 1m-deep temporary steel liners the base was founded in the London Clay grouted behind to control movement. The top manufactured specifically for the project. layer. The concrete caisson rings were then of each frame was jacked and dry packed To speed up construction, a second access filled with unreinforced concrete up to the against the underside of the raft to minimise point through the raft was constructed. underside of the new basement level five. raft settlement. Carrying out the excavation in such small sections meant any imposed distortion on the existing slab was reduced. The tunnelling was carried out by a team of

10: Section showing the supporting steelwork in the tunnel 11: Beneath the lowest basement level, the shafts were enlarged to form 2.7m diameter caisson foundations 12: Some 30m below the raft, under the most heavily loaded columns, the foundations were widened to 4.6m in diameter 8. 9. 12.

20 1/2020 | The Arup Journal 21 CLARIDGE’S HOTEL | LONDON, UK A1 A B C D E F G H I J K L M N

Notes: Existing column centre-point 1. This drawing is to be read in conjunction with all Assumed line of existing raft above relevant design reports, specifications, architectural and services drawings, specialist sub-contractor’s 1 4 4.1 drawings including approved builders work drawings and other contract documents.

Avoiding having to1600dp fix x 600mmreinforcement 1325 17:09:34 25/05/2017 all carried out at night, with the excavated 16: Two service shafts B prevented any delayTransfer that beam might have causedCL Transfer beam 2. For general notes drawing refer to drawing material removed in wheelbarrows through were constructed A A1 A A1 B CH-AR-DGE-XXX-S-0100. softening of the base of the foundation. 3. For internal and perimeter column head details the hotel corridors. The 4m diameter vertical under the hotel’s 3300 2200 3300 2200 Assumed step in 6 refer to drawings CH-AR-DDE-XXX-S-4401 and soffit of existing CH-AR-DDE-XXX-S-4411. Victorian wing to 4554 raft above shafts were built first, with the 3m diameter 4. For caisson pile information refer to drawing provide building Concrete columns 1200 horizontal tunnels then constructed from the C C C CH-AR-SCH-XXX-S-0001. C C C L L L services routes to L L L 335 265 335 265 Reinforced concrete pads (each measuring 5. For lining wall tolerances refer to General basement to reach the shafts. These shafts, 2 1.6m x 1.6m, and 1.2m in depth) were Arrangement drawings. tunnels and connection chambers were as the basement

constructed on top of the concrete300 infilled logistically challenging as the main basement. 17: Claridge’s Existing neighbouring building caissons. Internal columns 600mm in remained fully 65

300 operational +16.070 m (Indicative) diameter were then built to the underside of Movement monitoring and control

1200 throughout the Existing neighbouring building the raft from inside the 1.8m diameter shafts. During construction, extensive movement Profile A 300 basement extension, This column diameter was the largest that391 monitoring of the building took place. 3 Existing 600Ø contiguous with guests barely neighbouring piles Assumed top of column A constructed to suit higher could be accommodated within300 the shafts Monitoring mechanisms were installed to noticing the works raft soffit level

Profile B Void TBC SSL +10.400 m while still allowing safe access for assess movement of the existing raft and the taking place

Level B1 J52d J52g construction. The column reinforcement was building overall. Real-time movement beneath them F F FJ87a

600 made up of 2m lengths with coupler monitoring was put in place on all columns, Profile A 1600dp x 600mm Transfer beam. Beam connections, making the reinforcement easier inclinometers were placed internally on all TOC to suit adit frame 400mm min. R.C and safer to handle and reducing rebar 13. retaining walls, and precise level studs and 4 lining wall congestion in the column. The couplers were 3D targets were positioned externally. Liquid +5.900 m +5.850 m 600 SSL +5.750 m Assumed location of placed at waist height to enable the columnsexisting incontiguous this piles manner freed up space in the basement level was fully excavated, it created levelling sensors enabled movements to be Level B2 Existing 600Ø contiguous neighbouring piles 600Ø R.C column 17. 300 Profile B

550 reinforcement to be fixed more readily. excavated basement at each column location. space to construct a 750mm diameter, displayed in the site office in real time. 3 A4 - Profile A Self-compacting C60/75N concrete 1 : 20 was used Using a 1.2m diameter column also provided 19m-deep contiguous pile wall around the 600Ø R.C column Assumed +3.000 m SSL +10.400 min each column, ensuring good quality sufficient space during construction for basement perimeter. A modified electrically The hydraulic fluid-filled flat jacks at the top extensive technical knowledge, skills and Level B1 4 4.1 Authors Profile C +1.750 m +1.700 m concrete in zones of congested reinforcement workers to fix the column reinforcement powered piling rig was used for this work to of the columns allowed for the control of raft experience to overcome the significant 5 600 600 SSL +1.600 m 1325 Alice Blair led the structural design delivery Level B3 400mm min. R.C and avoiding the need to use a vibrating from within the steel reinforcement cage. avoid diesel fumes and reduce noise. The rest movements (ground settlement and heave) challenges in creating a five-storey basement 1200 lining wall 1200Ø nominal diameter on the project. She is an Associate in the 300 550 poker to compact the concrete in the small of the basement was excavated and built and for adjusting the distribution of loads below this Grade II-listed building. for R.C detailing 335 265 335 265 London office. access shafts. Steel shutters were used for the All the columns were cast to the underside of using traditional top-down construction, with going into the new columns. The

formwork to provide a high-quality concrete the existing300 raft. The column heads were cast each basement level taking two months to measurement systems allowed for the actual With construction taking place beneath an 300 Sarah Glover was the Project Manager. She -2.100 m -2.150 m

600 SSL -2.250 m 2 A4 - Detailed Column Section finish, with the added advantage that they with twin hydraulic jacks installed on top of excavate and construct. loads from the superstructure to be operational hotel, in such confined space is a geotechnical engineer and Associate Level B4 1 : 50 0 0 300 6 could be reused across the site during 9 them and beneath the raft. These were to determined. These confirmed that the actual and with such limited site access, the Director in the London office. 300 s 550 iu

1200 d a 691 construction. To prevent buckling,R temporary engage the column, so they could take the Service shafts below Victorian wing building loads were within design tolerance. design process was governed by what 1600 x 1600 x 1200dp R.C 65 pad to be constructed with struts were used to stabilise900 the columns in superstructure load from above and control Two service tunnels were constructed At the end of construction, the hydraulic could be practically and safely built. Dinesh Patel was the Project Director. He is column. the 22m-deep shaft until the basement floors raft movement. A underneath the Victorian section of the hotel fluid was replaced with cement grout, Each element of construction required a geotechnical engineer and Director in the 900 SSL -6.100 m London office. Level B5 were built. Void TBC to provide building services routes into the locking the building into its final position. meticulous planning. The £37m basement 5 4.2 4.1 4 The tunnelling works, shaft excavation and basement, along with a lift and stair core. The works were delivered on budget, four Andy Pye was lead structural engineer on the 7 1265 1935 1325 The columns at the edge of the building form construction of the columns took 18 months. new access core serves the first three Building the impossible basement months ahead of programme and carried project. He is an Associate Director in the part of the retaining wall and are subjected to Once all the columns were built and basement levels, providing a shorter route for The successful completion of this project out while the hotel remained fully A B London office. -4 -4 P P C2 25/05/17 DT AB AB C C eccentric loads from above. These columns preloaded, the tunnel steelwork could be hotel guests and staff into the new facilities. would not have been possible without close operational at all times, with guests +16.070 m (Indicative) Revised as Clouded are 1.2m in diameter and located to one side carefully dismantled and the ground beneathC1 30/01/17TheDT tunnelsAB wereAB built to provide services collaboration between McGee, Arup and oblivious to the feat of engineering that -11.500 m -11.500 m Project credits +15.400 m (Indicative) Infill void as of the 1.8m-wide shafts. Offsetting the edge the existingAssumed location raft of removed. When the first Construction Issueaccess to the lowest level. These works were RKD, which collectively drew on their was going on below their feet. Client Maybourne Hotel Group required to suit existing contiguous piles Rev Date By Chkd Appd Toe -12.800 m Toe -12.800 m step in soffit Norman McKibbin – Director of Construction 8 Design and build contractor McGee 13: Twin hydraulic Jim Mackey – Project Director jacks sit atop each Awards Temporary works designer RKD Consultant A4 - Full Height Column Section column, to transfer the Profile A 1 13 Fitzroy Street 1 : 100 1800Ø construction Geotechnical engineering, tunnelling, shaft (indicative) London W1T 4BQ 1600dp x 600mm 1600dp x 600mm Telload +44(0)20 and7636 1531 helpFax +44(0)20 control 7580 3924 Council on Tall Buildings and Transfer beam. Beam Transfer beam. Beam 4 4.1 www.arup.com hydrogeology, structural engineering and TOC to suit adit frame TOC to suit adit frame raft movement 1325 Client Urban Habitat Profile A 1200Ø nominal diameter BIM Arup: Paul Bailie, Samila Bandara, Alice for R.C. detailing McGee14: The Group edge Holdings columns LTD. Geotechnical Engineering Award of Blair, Chris Brewis, Tristan Ferguson, Orlando 9 form part of the Excellence (2020) Gibbons, Rupert Gibson, Sarah Glover, retaining wall Rosemary Judd, Marialina Klokidi, Doreen Profile B Project Title Concrete Society Awards 2019 Lu, Frank O’Leary, Dinesh Patel, Anton Pillai, Profile B 15: The internal columns Claridge's Basement Highly Commended Barrie Porter, Andy Pye, Darryl Tanner, Bryen 300 measured 600mm in

SSL +10.400 m 300 diameter – the largest Vieira Commins, Dunshun Yang. Level B1 Ground Engineering Awards 2019 0 possible size that would 90 50 7 Drawing Title us 10 di ø Editor’s Choice 50 a still allow safe Image credits 7 1200 R Column Sections and Details

691 ø Column A4, B4 and Adjacent 1, 6, 11, 14, 15: Arup

900 construction access 6 Transfer Beam Section Transfer Beam UK project with a geotechnical value over 1 : 50 2, 8, 9, 13, 16, 17: Paul Carstairs/Arup A £3 million: Highly Commended Scale at A1 3: McGee As indicated 4, 12: Nick Carter Role Structural British Geotechnical Association 5, 7: Daniel Imade/Arup Suitability Construction Fleming Award (2018) 10: RKD Consultant 11 Arup Job No Rev 3D View - A4 Transfer Beam 245269 C2 Name 14. CH-AR-DSE-XXX-S-4554 15. 16.

Do not scale © Arup 22 1/2020 | The Arup Journal 23 BEIJING DAXING INTERNATIONAL AIRPORT | BEIJING, CHINA

Taking flight Beijing Daxing is the largest airport in the world and acts as a new gateway for the Chinese capital

Authors Robert Feteanu, Ming Li, Fangzhou Su, Kelvin Wong and Vala Yu

The spectacular starfish-shaped Beijing Fire safety design Daxing International Airport is one of the The airport’s vast size, the high footfall and biggest single-structure terminals in the the terminal’s flowing interconnected form world, measuring 1.2km from end to end. present a significant number of design Covering more than 700,000m2, it is the challenges, particularly in relation to the fire largest airport (in terms of size) globally. strategy. At the heart of the airport, there is a It opened in September 2019 and single 500,000m2 central space, spanning currently handles 300 take-offs and from the fourth floor to two levels below landings an hour and 42 million ground – this is one of the largest unseparated passengers per year. This will eventually fire compartments in the world. grow to 100 million passengers annually. The eight-platform transportation hub below Working closely with Beijing Institute of the airport makes travel to and from the Architectural Design, Arup designed a terminal convenient for passengers, but from number of innovative solutions for this a fire safety point of view adds further project. The firm provided fire engineering, complexity, as the space for emergency passenger and logistics simulations and discharge of occupants to the outside is structural peer review services. This work has limited. Arup took the lead in providing the resulted in significant material and cost fire safety design solutions and coordinating savings, and carbon emission reduction. with the various clients, operators and Successfully integrating the ground approval authorities in order that a consistent transportation centre with the terminal fire design, agreed on by all stakeholders, was building, for instance, has helped to save at approved. The firm overcame these least 1.6 million hours for nearly 30 million challenges by deploying an innovative passengers every year. performance-based fire design strategy.

1: The transportation hub beneath the airport provides access to high-speed rail, intercity trains and the airport express 2: The airport is arranged around a large central space and measures 1.2km from end to end

1. 2.

24 1/2020 | The Arup Journal 25 BEIJING DAXING INTERNATIONAL AIRPORT | BEIJING, CHINA

There were four main aspects to this strategy: 3: Depending on diluted by the sheer volume of the atrium 6: The building’s • means of escape; the location of a fire, space and then removed through the vents. design means that • smoke extraction; there are various smoke is directed • interface with the railways; and egress stairs and Arup conducted simulations to ensure the upwards; the huge exit strategies central atrium space • fire protection for the roof. design was optimised for smoke extraction 4: The airport is at the airport’s heart and that people would be able to escape. allows smoke to be Means of escape divided into six These tested what would happen if some smoke control zones diluted naturally Arup divided the airport’s public space into vents failed to open or if smoke rose high 5: Arup used several 7: MassMotion helped 30 zones, each spanning between 2,000m² into the ceiling, stratified, spread out, or to size and locate the and 48,000m². Rather than a conventional techniques to prevent lost its drifting power because of the heat. fire from spreading vertical circulation solution of zones separated by solid walls, a from one zone to The results of these simulations were then elements such as lifts mix of flexible shutters and doors were used another, including fire used to refine the placement of vents and and escalators so that the spread of fire and smoke could be separation boards and other measures. Arup also developed contained and safe spaces created without passive vents in the augmented reality tools to visualise the affecting passenger circulation during normal roof and downstands smoke simulation. operational times. The higher risk areas with high fire load were, however, constructed for Interface with the railways full fire containment. These were limited to a Below the airport terminal is the 80,000m² maximum area of 2,000m² and equipped with underground transportation hub for high- two-hour fire-rated construction elements and speed rail, intercity trains and the airport 1.5-hour fire-rated floors. express to Beijing city. There are three underground stations, eight platforms and In the event of a fire, people can leave the 16 tracks for five railway lines. The platforms 6. zone where there is an immediate threat and are located on basement level two and the take shelter in a safe space nearby. The concourses on basement level one. roof trusses within a 6m to 9m distance above The detailed passenger flow outputs from the decision can then be taken to either evacuate the floor needed to be fire protected. The simulation tools enabled Arup to demonstrate occupants further if the fire escalates or allow Arup liaised with both the railway and airport majority of the roof structure did not require the effects of suggested design modifications them to return to the area if it is safe to do so. 3. authorities to develop a strategy. Normally, additional protection, as its height meant that at a stage in the project when they were fire safety plans in such cases are developed it would be sufficiently far from any ground- relatively inexpensive to implement. There are 11 escape staircases in the large Smoke extraction activity resumes. Arup needed to consider separately, but given the interdependency level fire. This finding led to a cost saving of central area; these shorten the escape distance The second element of the fire safety strategy comfort and operational continuity as a major between the two in this case, that approach several million renminbi. Every aspect of the airport has been designed to the building perimeter. Arup provided was smoke extraction. This is vital to part of its strategy. was not practical. around passenger experience, which includes different exit strategies for the central zone minimise the risk to building occupants and Terminal simulation and analysis the provision of passenger processing based on the fire location. If a fire is detected reduce potential damage to the building. The terminal was divided into six smoke Arup developed a proposal that was accepted Beijing Daxing is expected to handle up facilities and sizing of corridors to prevent on the ground floor, for example, the egress China’s building codes assume much smaller control zones – the central zone and five by the airport and railway approval to 72 million passengers by 2025. Arup excessive passenger congestion. Passenger stairs in the central area will be closed and rooms than those present in Beijing Daxing. piers. Downstands were installed within authorities as well as the national fire expert used a series of simulation tools that processing facilities include boarding gates, occupants on other floors in the building will Because of the airport’s vast open space, the perforated ceilings to prevent smoke review meetings. The firm proposed using combined airport schedules and passenger aircraft stands, check-in counters, bag drop be directed by smart signage towards egress smoke could potentially fill a larger area spreading from one zone to another, so the transportation interchange hall that flow data to optimise the airport’s design areas, security checkpoints, passenger stairs along the building perimeter. Should a without being obstructed. The smoke that if a fire occurs in one pier, the other connects the railway areas and the terminal so that it can accommodate both the current holdrooms, inbound and outbound border fire be detected on other floors, then all stairs extraction is directed at both helping people four can remain operational. To extract as a main circulation space. This hall is and expected number of passengers. This was control, bag reclaim and washrooms. are made available to allow rapid evacuation escape and preventing smoke spreading and smoke from the building, Arup made full designed as a safe area. It has features such as the first time an airport in China was fully of people close to the fire. Arup performed affecting other areas of the building. It is rare use of the roof, incorporating passive vents an opening towards the roof, sufficient means simulated before construction and also the Passenger flows were particularly simulations for both scenarios to make sure that an airport needs to be fully evacuated between its metal and glass elements. of escape to the outdoors and no high fire first project on which Arup integrated these complicated. Most international airports they were acceptable and in order to gain the during a fire; more often, the fire is localised, The building was designed so that smoke load use, such as retail areas or fuel storage. two types of data and two different software have departure and arrival areas split across approval of the expert panel. people move away from it and normal is directed upwards; that way, it can be This significantly reduces the required packages, Simio and Oasys MassMotion. different floors, but Beijing Daxing takes number of egress stairs directly extending this even further, with domestic and from the concourse level to the ground. It international flights occupying separate also means that during an evacuation, floors. The main passenger flow therefore passengers can remain in a familiar, spans over four floor slabs. In addition, a comfortable environment. separate check-in and security screening area in the basement is planned; this will Fire-proofing the roof serve flights at the proposed satellite building, Finally, the fire safety engineers had to which will be located away from the main consider the large-scale steel-framed roof terminal. All passenger flows needed to be structure. Under China’s building code, steel connected to the roadways and the ground structures need to be protected by fire-proof transportation centre. This meant that the paint to make sure they achieve the required analysis had to incorporate a complex set level of fire resistance. Arup’s performance- of vertical circulation demands spanning based model looked at the worst-case fire six floors in order to identify potential scenarios and analysed their impact on the bottlenecks at different times of the day roof structure. The results showed that only based on flight arrivals and departures. 4. 5. 7.

26 1/2020 | The Arup Journal 27 BEIJING DAXING INTERNATIONAL AIRPORT | BEIJING, CHINA

8: Arup optimised the The simulation was based on the flight A total of 420 load combinations were 11: A simulation model truss pattern scheme schedule. It followed every passenger’s considered and 38 different cross-section was used to predict used in the complex movement through the airport’s facilities to sizes were employed in the superstructure. every passenger’s roof structure using identify shortfalls or over-provision. The Through its review, Arup determined that movement around the several analysis tools detailed simulation model, built in Simio 3D, about 1% of the steel members had exceeded airport and optimise design accordingly 9: In order to reduce helped decision-makers and stakeholders to their limits for deflection and required the roof’s weight, Arup visualise the airport’s future performance. strengthening. More than 90% of the members 12: Ultimately, the recommended that The passenger congestion model built in had a stress ratio of less than 0.5. The team airport is expected to some of the spherical handle 100 million joints on the longer MassMotion informed the design, particularly proposed various optimisation strategies to passengers annually spans be replaced by with regard to the sizing of critical corridors. improve the roof truss patterns and reduce tubular joints It helped to avoid the creation of geometric structural depth and member sizing. 10: The roof is a chokepoints, as well as inform the size and continuously flowing location of vertical circulation elements such The radius of many of the compression steel dynamic shape as lifts and escalators. members was reduced, as they were already well below the slenderness ratio limit set by Trolley simulations were also carried out to the expert review panel. For circular hollow analyse the management of passenger trolleys sections that had slenderness ratios close to the 11. both air-side (beyond security) and land-side. 120 limit but with excessive margin in A Simio model was used to demonstrate how their strength and stiffness, their thickness trolleys circulated from land-side car park to was reduced to minimise self-weight. These curb to check-in, and from arrival piers to strategies were most effective in the reclaim carousels at air-side. The model concourse wings; they achieved a allowed Arup to indicate the minimum trolley 40% steel reduction in the north-west wing. numbers in each storage area and to advise the client on how many operational staff Single horizontal braces in the roof truss were would be needed and on the timing of trolley replaced with higher tension cross-braces so collection throughout the day. This helped the that their sizes could be safely reduced. This airport operator to optimise work procedures led to a 70% reduction in bracing steel. In and reduce unnecessary trolley purchases. addition, the original scheme used a large number of spherical joints, with diameters Engineering the complex roof structure ranging from 300mm to 900mm. Using finite One of the most important aspects of this element analysis, Arup recommended that for 8. 9. project was the engineering of the roof, larger spans some of the spherical joints be designed by Zaha Hadid Architects. The roof replaced by tubular joints to reduce the covers a 350,000m² area and is a continuously structure’s weight. flowing dynamic shape supported by giant C-shaped columns. It has more than 170,000 A new gateway for China steel members. Arup’s role was to carry out a Beijing Daxing International Airport opened peer review and value-engineering exercise on 25 September 2019, with its first on the hyperboloid steel grid structure. This commercial flight landing the following day. work was done when the construction The project is a new gateway for the capital drawings were almost finished, with a tight and China as a whole, paving the way for the timescale to carry out the analysis. country’s continuing economic growth. 12. Arup set up a computer model to analyse the structure within a week and completed the Authors Vala Yu worked on the fire engineering Karen Lai, Abby Li, Ming Li, Kevin Liu, Ling-Tao evaluation and optimisation in three months, Robert Feteanu led the passenger simulation and elements of the project. She is an Associate Liu, Peng Liu, Shirley Liu, Vincent Liu, Mingchun in order to meet the deadline for the analysis aspects of the project. He is an Associate in the Beijing office. Luo, Daley Mikalson, Aarshabh Misra, Fan Qi, Bert steelwork tendering schedule. Principal in the Toronto office. Su, Fangzhou Su, Wei Sun, Yong-Shan Wan, Jolin Project credits Wang, Ryan Wang, Shiny Wang, Kelvin Wong, Arup used a wide range of analysis tools, Ming Li was the Project Manager on the Clients Beijing New Airport Construction Michael Wu, Emily Yang, Young Yang, Flora Yao, including GSA, Sap2000, Strand 7 and structural peer review. He is an Associate in Headquarters, Beijing Institute of Architectural Kim Yong, Vala Yu, Jin-Ai Zhang, Leo Zhang, LS-DYNA to carry out the elastic analysis, the Beijing office. Design (BIAD) Cong-Ming Zhong. connection FEM analysis and non-linear Joint venture partners ADP Ingeniérie, Zaha analysis. Arup’s extensive experience in Fangzhou Su worked on the passenger Hadid Architects, BIAD, China Airport Image credits simulation and analysis aspects of the project. Construction Co Ltd 1, 3–5, 8, 9: Arup long-span steel structure and structural He is a senior analyst in the Toronto office. Fire engineering, structural design peer review 2, 6, 7, 11: Hufton + Crow optimisation tools enabled the firm to develop and optimisation, and passenger and logistics 10: Zhou Ruogu Architecture Photography alternative designs. These resulted in a saving Kelvin Wong was the Project Manager for the fire simulation and analysis services Arup: Najim 12: Xinhua News Agency of more than 4,000 tonnes of steel (with the engineering design. He is an Associate in the Afzalzada, Jing Chen, Emo Chiou, Robert value of around RMB54 million) and a large Shenzhen office. Feteanu, Jian-Yun Han, Clement Ho, Rita Ho, reduction in carbon emissions. 10.

28 1/2020 | The Arup Journal 29 SAMUEL DE CHAMPLAIN BRIDGE CORRIDOR PROJECT | MONTREAL, CANADA

1: Stretching 3.4km, the bridge crosses the Saint Lawrence River and the international shipping channel, which links the Atlantic Ocean to the Great Lakes

In June 2019, Montreal celebrated the opening of the 3.4km Samuel De Bridging Champlain Bridge, one of the largest and busiest bridges in North America. Crossing the Saint Lawrence River and its international shipping channel, it is a the gap vital thoroughfare for both goods and Arup’s expertise meant an people, accommodating in excess of 50 million crossings and facilitating essential piece of CAD$20 billion (around £12 billion) of infrastructure was delivered trade every year. Built through a public- private partnership (PPP) between two and a half years earlier the Government of Canada (via Infrastructure Canada) and the Signature than originally planned and on the Saint Lawrence Group, it is a within the project budget landmark structure forming a gateway to the city of Montreal. Authors Douglas Balmer, Jo Balmer The construction of the bridge was part of the and Matt Carter CAD$4.24 billion New Bridge for the Saint Lawrence Corridor Project, a major urban highway improvement project in the Montreal metropolitan area and one of the largest infrastructure schemes in North America. The project also encompassed the construction of the 500m Île des Sœurs Bridge and the renewal of 8.5km of highway; there is a dedicated public transport corridor incorporated, as well as an enhanced network of pedestrian and cycling paths throughout the corridor. 1.

30 1/2020 | The Arup Journal 31 SAMUEL DE CHAMPLAIN BRIDGE CORRIDOR PROJECT | MONTREAL, CANADA

Arup’s challenge was to define and enable consulting services. The firm also provided architecture for Montreal. Arup led an procurement of a durable yet architecturally expertise in programme and project integrated team of engineers and architects pleasing new bridge before the ageing management; asset management; acoustics, (Danish architects Dissing+Weitling and local original Champlain Bridge reached the end of aviation, lighting, operational and architects Provencher_Roy) to deliver this. its useful life. Drawing on its global maintenance requirements; economic and The design comprises three corridors, with the knowledge of PPP procurement on major cost estimating; and procurement advice. bridge’s cable-stay span supported by a 160m infrastructure projects, Arup provided Arup’s streamlining of the procurement tower in the shape of a tuning fork, flanked by comprehensive technical advisory services, process was crucial to the successful an elegant harp of cables. and engineering and procurement strategies completion of the project. to the Government of Canada. The total length of the bridge is 3.4km from The need for a new bridge the west to the east abutment, with a Transport linchpin In Canada, infrastructure is generally the navigation clearance to 38.5m above the The Samuel De Champlain Bridge crosses domain of provincial governments, but Seaway channel. The vertical alignment of the St Lawrence River on a broadly east–west certain international or critical assets are the western approach smoothly rises over the alignment and connects the City of Montreal managed by the federal government. The width of the river. This option was considered with the municipality of Brossard on the Champlain Bridge is one such asset due to its to be preferable from both an aesthetic and south shore. It has an asymmetrical cable- strategic value. It crosses the Saint Lawrence operational perspective, and was a change stayed main span of 240m, supported by a Seaway international shipping channel that from the older bridge, which had a relatively single, elegant 160m pronged tower, with links the Atlantic Ocean to the Great Lakes, low and flat section over the majority of the elevated approaches on either side. Gradual connects Quebec and Ontario to the United river before starting an abrupt, steep gradient horizontal and vertical curves along the States, and links to three major highways to climb over the Seaway channel. length of the structure provide an ever- (Autoroutes 10, 15 and 20). changing view for everyone who crosses over From the beginning of the process, the or passes by the bridge. The resulting bridge Arup’s initial appointment in 2012 was to provincial government stated its aspiration to is visually spectacular and built for the long help develop the business case for this bridge eventually replace the planned bus services term. It has been designed so that it can adapt for the Canadian government. The existing that crossed the bridge with a light rail to the changing transport needs of the region bridge required significant structural system. However, there was no specific and has a lifespan of 125 years – significantly strengthening and ongoing maintenance costs 3. timeline for this plan, so the three decks were longer than the 75-year period normally owing to its exposure to extreme winter created with this eventual transition in mind. required of such infrastructure in Canada. weather and a harsh schedule of de-icing forward to the procurement stage. The The idea was that, at least initially, the two salts. These had led to irreversible corrosion, government had already spent hundreds of outer decks would be used as highways, Arup was selected to be the owner’s engineer, which was further compounded by large millions of dollars to keep the old bridge while the central one would be reserved for providing Infrastructure Canada with full increases in traffic using the route. operational, so Arup had the foresight to bus transit. When the shift to a rail system engineering and coordination services for the develop two timelines for the project; one began, the plan was for buses to use a bridge. These included civil, structural, Arup was tasked with developing a range of where it would progress in a business-as- temporary reserved bus lane on each of the bridge, geotechnical, highway, mechanical technically viable bridge options in order to usual scenario, aiming for completion in highway decks, while a light rail corridor and electrical engineering, as well as security, understand the costs and practicalities for 2021; and an accelerated schedule taking into would be built down the middle deck. fire, threat mitigation, life and sustainability each bridge scheme, before taking the project account the deteriorating condition of the existing bridge so that the new bridge could Connecting communities be opened by the end of 2018. The abutments on either side of the bridge serve four primary functions: providing Through a two-stage screening process, a long vertical and lateral supports for the east and list of bridge options was reduced to three west approach structures; retaining the preferred alternatives. Based on Arup’s adjacent embankments that support the recommendation, one of these was selected as roadway; housing the mechanical and the base case design for carrying out more electrical equipment necessary for bridge detailed cost estimates and quantitative risk operation and maintenance; and providing analyses to determine the viability of the architecturally novel features at the entrance project, the procurement method and the and exit points of the bridge. required budget. During the summer of 2013, when it became apparent that ongoing During the development of the business case, 2: The original maintenance problems on the existing bridge the west abutment was set to be located to the Champlain Bridge were more acute than anticipated, Arup was west of Boulevard René Lévesque, a road that was opened in 1962 asked to move ahead with the accelerated passes beneath the bridge close to the shore. 3: Arup’s initial timeline and was awarded a contract to get the However, a subsequent study indicated that a appointment was to new structure to market as quickly as possible. preferable placement for the abutment was on help develop a business the east side of this road, next to the river. case for the new bridge An aesthetically pleasing design Although this required a small amount of 4: The 240m main As well as being a strategic section of the reclamation in the river, it had the major span is supported region’s transport infrastructure, the bridge advantage of providing maximum flexibility by a 160m-tall was required to be a landmark piece of for the future construction and urban pronged tower 2. 4.

32 1/2020 | The Arup Journal 33 SAMUEL DE CHAMPLAIN BRIDGE CORRIDOR PROJECT | MONTREAL, CANADA

5: The design process included a programme legitimately declare that “what you see is of architectural reviews with a panel of local what you will get”. engineering, architectural, urban planning and heritage professional bodies Because the definition design integrated all 6: Longevity has been built into the design by the constraints included in the technical using stainless steel and concrete requirements, while still allowing flexibility 7: The width of the highway decks was increased in terms of materials and methods of to accommodate bus lanes construction, the bidding proponents were 8: The bridge is made up of three separate able to save significant time in elaborating box girders their proposal. 9: Built for the long term, the bridge has a lifespan of 125 years Accelerated programme Shortly after the project team completed the business case for the new bridge, it became apparent that the condition of the existing bridge that served the route was rapidly deteriorating. Despite the costly repairs and maintenance that had already been 8. implemented on the 1960s structure (and others that were planned), the bridge was during the harsh winter months, which programme of architectural reviews with an deemed to be living on borrowed time. led to the Minister of Infrastructure and Architectural Quality Review Panel (AQRP) Arup’s team recommended and implemented Communities being able to declare that that consisted of representatives from the strategies to accelerate the preliminary the multi-purpose path would be open local engineering, architectural, urban design and procurement process. Arup year-round. planning and heritage professional bodies, produced the procurement documentation in and the City of Montreal. Animations and eight months, enabling the PPP project to Defining moment renderings of the bridge were produced in reach financial close in June 2015. The Arup’s considerable experience in designing 3D, which helped to respond to any bridge was then constructed in a mere 48 long-span bridges (including the Queensferry concerns and explain how the project would months. This was two and a half years less Crossing in Scotland and the Oresund Bridge improve the built environment in a than the original timeframe, while remaining that links Malmo in Sweden with sustainable way. For example, belvederes within the government’s original budget. Copenhagen in Denmark) meant the team were incorporated into the elevated bridge had the expertise to ensure that architectural design on the north corridor. Along with a Arup drew on lessons from its past projects, 5. 6. aspirations were mandated through contract viewing platform below the bridge, these including the Tappan Zee Bridge in New documentation. The approach required the provided vantage points for the public. York, to bring the project rapidly to market, integration of a transit station if the bridge was use of a ‘definition design’ within the PPP compressing the procurement preparation converted to carry light rail on the central procurement process, a first for the North This AQRP consultation process meant that period. The firm refined the reference design, deck. The abutment placement also had the America market. the design was developed with the amending as appropriate to accommodate the benefit of shortening the length of the main cooperation of local stakeholders, with the outcomes from stakeholder consultations, and bridge by approximately 70m, so this was the The definition design that Arup developed finalised architectural design received well also to incorporate Arup’s own assessments option that was ultimately selected. To allay clarified the intentions in terms of aesthetics, by the public. It also permitted the Minister on how to improve the lives of those who concerns regarding views to the river, the span ensuring that all bidders would consider the of Infrastructure and Communities to lived and worked close to the highway and of the bridge that was required over Boulevard technical and visual dimensions of the design announce the design of the bridge, and bridge corridor. The reference design served René Lévesque was significantly increased to when submitting their bids, thus safeguarding maintain as many sightlines as possible. the bridge’s architectural integrity through to the final stages of the project. In order to As Arup further defined the scheme, it arrive at a definition design, it was necessary proposed that the spans be increased for the to first generate a preliminary design for the sections carrying the reconstructed highway bridge that was compatible with both the over local roads, to both help reconnect architectural vision and all other project communities and provide space for pedestrian constraints. Then, critical dimensions and and cycle paths, thus promoting active tolerance allowances were identified to form transportation. To further enhance the the definition design requirements, which community connections, a 3.5m-wide ensured that the design was preserved during multi-purpose path was constructed on the the procurement and construction process by north side of the new Samuel De Champlain mandating certain geometric elements in the Bridge to provide a direct pedestrian and project requirements. cycling connection over the St Lawrence Seaway and River. As the project progressed, Given the prominence of the new bridge, Arup undertook studies to assess the viability and the public interest, this design was not of keeping the link open as much as possible developed in isolation but included a 7. 9.

34 1/2020 | The Arup Journal 35 SAMUEL DE CHAMPLAIN BRIDGE CORRIDOR PROJECT | MONTREAL, CANADA

10: To support the three separate box girders, a W-shaped system of supports was used 11: The bridge was constructed in just 48 months 12: Arup drew on lessons from its past projects, including the Tappan Zee Bridge in New York, to bring the project rapidly to market

11. 12.

Longevity was built into the design by the use across the bridge. This means that buses will the area, and the viewing points mean that the of robust materials, including stainless steel not run along the middle deck, so the bridge is a tourist attraction in its own right. and concrete; modifications to standard foresight to increase the width of the highway Arup has also completely redesigned an concrete mix specifications; and requirements decks to accommodate temporary bus lanes is interchange that bisected two parts of the city. for protection against ice abrasion as well as a already benefiting road and bus users. In addition, in several nearby areas, roads comprehensive structural-health monitoring have been reconfigured to make them greener, system. Arup prescribed such measures in the The provision of this new and more efficient cleaner and quieter, enhancing community design that went to tender, to ensure the public transit system has advantages for the connections and promoting physical activity. 10. design-build contractor included these local environment and improves accessibility important features in its construction. for the local population. The combined All this was made possible by the client and to help define the project’s technical working to stricter standards than officially cyclists per year use the cycle path on the dike, pedestrian and cyclist pathway provides an project team always keeping in mind the twin requirements, and thus inform the cost and required (aiming for a 125-year lifespan and the platform offers an excellent vantage Since the original design was devised, the invaluable alternative form of transportation, focus of improving the lives of the local schedule estimates. It was used to rather than the legally mandated 75), point from below the bridge of the sculptural provincial government has decided to go which is proving particularly useful for the populace and creating an iconic new demonstrate that the design was technically emphasis was placed upon adopting tried piers supporting the deck, the bridge’s curved ahead with constructing the light rail scheme previously poorly connected communities in landmark in Montreal. viable and achievable within the proposed and tested solutions that would help to alignment and the river habitat. budget and timeframe. achieve the required design life. Either side of the bridge, the highway and The main objective was to open the new Realising the vision four interchanges have been reconstructed. Authors Design build contractor Signature on the Saint Maria Mingallon-Villajos, Kelvin Moneypenny, bridge as soon as possible, without To support the three separate box girders, Arup consulted, assessed and documented in Douglas Balmer was the Project Director. He is Lawrence Construction Omar Moussa Shehata, Guillermo Munoz-Cobo compromising the safety and security of Arup proposed a W-shaped system of the PPP contract the requirements that an Associate Principal in the Montreal office. Infrastructure design, bridge, civil and Cique, Dimitrios Niarchos, Ryan Nolan, Louise workers or the quality of work. For some of supports, almost with the appearance of needed to be met. For example, the presence geotechnical engineering Arup: Aidan Archer, O’Neill, Chuck Ormsby, David Orta, Ralph the most important aspects, especially those fingers supporting the highway and central of a major sewer alongside Highway 15 Jo Balmer was the Project Manager. She is an Andrew Armstrong, Mahsa Azad, Stephen Otrembiak, Mariona Pahisa, Nicolas Pawlonka, relating to durability and the need to achieve public transport decks, all supported on two required detailed analysis and optioneering Associate in the Montreal office. Baldrey, Douglas Balmer, Jo Balmer, Pouya Adrian Pena-Iguaran, Francisco Perez, Paolo a 125-year design life, the specifications sloping piers. There are 37 W-shaped frames to improve the eventual solution. Owned by Banibayat, Abeera Batool, Maxime Bellefeuille, Perugini, Lana Potapova, David Pratt, Audrey developed by Arup were more prescriptive in total, each weighing approximately 450 the City of Montreal, it provides drainage Matt Carter was the bridges lead on the project. Ken Bontius, Clifford Bouchereau, Jean-Claude Provost, Louise Ann Quevillon, Isabelle Raymond, than usual. For example, they stated that tonnes and measuring 51.2m x 11.4m x 3.3m. for about a third of the city. Due to its He is a Principal in the New York office. Bourque, Matt Carter, Mei Cheong, Sarah Mark Roche, Léonard Roussel, Francisco Rueda, stainless steel reinforcement, rather than These were installed on 74 separate pier location and limited construction records, it Cholloux, Pierre-Louis Cons, Anthony Cortez, Laurent Rus, Marina Saez, Dan Saville, Lauren regular steel, should be used in critical areas, footings of approximately 11m x 11m x 2m, was not possible to fully inspect and assess Project credits Sebastien Cote, Margaret Cowie, Gary Crisp, Scammell, Nicole Scanlon, Juanma Serrano, Will so the bridge was more likely to realise the each weighing between 600 and 1,000 tonnes. the sewer’s condition before construction of Client 2012–14 Transport Canada Sebastian Cumpatescu, Ankit Desai, Joseph Sims, Jelena Sisko, Jordy Tang Hon Yue, Daniel durability criteria. This also took away the Of these, 38 footings were prefabricated on the bridge commenced. Part of the challenge 2014–20 Infrastructure Canada and Public Digerness, Bob Donker, Chris Donovan, Jelena Tarantino, Graham Thomas, Assumption Uber, potential for protracted approval discussions site and 36 were constructed in situ. was to develop a process that would not Services and Procurement Canada Durovic, Juan Echague, Casey Eckersley, Monica Valls Marquez, Carmen Venegas Perez, during the delivery phase. have an impact on the sewer. The design- Architects Dissing+Weitling Architecture and Georges El Chammas, Corey Fan, Adam Finkin, Yannick Vintila, Jeff Walter, Nicole Washington, The tower supporting the cable-stay main build contractor adopted a solution similar Provencher_Roy + Associés Architectes Inc. Matthieu Galland, Ahmed Ghazi, Javier Gonzalez, Paul Wilson, Christopher Wong, Roger Wood. The bridge’s durability was a key concern. bridge span comprises two tapered concrete to that foreseen in the Reference Design, Traffic modeller Loctrans Inc. Steven Gresk, Eric Guerra, Dawn Harrison, A layered approached was adopted, working legs connected by a tapered concrete cross which used polystyrene (lightweight fill) Road and environmental design services Sylvana Hochet, Martin Hooton, Vicki Hope, Image credits on the principle that if something was beam. This tower was constructed adjacent to embankments to minimise the imposed load Groupe S.M. International Inc. Aidan Hopkins, Evan Hughes, Sayed Kadiri, Tim 1, 3: Infrastructure Canada © Her Majesty the important, it needed to be specified in the the seaway dike that frames the navigation on the sewer during construction. ITS and tolling IBI Group Kaiser, Gerard Keogh, Amjad Khan, Martin Landry, Queen in Right of Canada contract. If there was the possibility that one channel. A berm, at the base of the tower, was Electrical and lighting Roche Ltd, Rebecca Lasry-Legault, Anthony Lefour, Diana 2, 4–8, 10, 11: Arup form of protection could fail, due to issues added to aid construction and retained as a Looking to the future Consulting Group Lubniewski, Bill Maddex, Sanjeev Malhotra, Bryan 9, 12: HELIMOB with design, construction or maintenance, a permanent feature to serve as a maintenance The bridge opened in June 2019, saving two Private partner Consortium Signature on the Marsh, Peter Matusewitch, Keith McCall, Colin secondary measure provided an additional and work platform for the bridge and to and a half years on the original schedule, Saint Lawrence Group McCreath, Andrew McNulty, Omar Metwally, layer of protection. Given that the team was provide a viewing platform. About 200,000 while staying within the planned budget.

36 1/2020 | The Arup Journal 37 GUOCO TOWER | SINGAPORE

1: Guoco Tower consists of two towers that offer residential, hotel, office and retail space 2: An urban park in front of the building provides a green public space in the heart of this humid city 3: At 290m, the 64-storey tower is the tallest building in Singapore

2.

Guoco Tower is a 156,000m² mixed-use round and provide relief from the often development consisting of premium office, stifling heat of the city. residential, hotel and retail space. Named An oasis after its occupant and owner, property Further ensuring that the development will developer GuocoLand, it sits at the heart attract people, the centre connects directly to of a neighbourhood that is swiftly being the Tanjong Pagar Mass Rapid Transit (MRT) in the city transformed into Singapore’s next metro station via three basement levels, business and lifestyle hub. Working in which are 18m deep in total. This proximity The construction of these conjunction with US architectural to an integral piece of urban infrastructure geometrically complex practice Skidmore, Owings & Merrill, created challenges for the design and Arup was responsible for civil, structural construction of the scheme. The Guoco towers was achieved at and façade engineering, and sustainable Tower site is also surrounded by small roads, great speed and with building design. historical shophouses and buildings with shallow foundations, further adding to the minimal disruption to the The development comprises two towers; the complexity of the construction process. taller, at 290m, is the tallest building in surrounding area Singapore. It is linked to the smaller 105m tower by a podium that offers 10m column- Authors Dion Anandityo and Jason Tan free, ceiling-to-floor views across the area.

Part of the brief for Guoco Tower was that the development should attract people, becoming a vibrant centre of activity amid Singapore’s central business district. In order to provide an area the public could enjoy, a 14,000m² urban park was created in the space in front of the buildings. This is a rare patch of shaded outdoor public space in hot and humid Singapore, where recreational areas generally tend to be indoors and air- conditioned. Amid this lush greenery is a 15m-high canopy that creates a sheltered ‘city room’. This can host activities all year 1. 3.

38 1/2020 | The Arup Journal 39 GUOCO TOWER | SINGAPORE

To create the open space within the podium At the transfer floor on level 39, where the construction site, which as a result that links the two towers, Vierendeel steel Awards the tower changes from office to residential was safer and experienced less noise, dust frames are used from levels two to five, use, an innovative 1.3m-thick transfer and vibration. spanning 26.4m. Transfer beam structures Council on Tall Buildings and composite steel and concrete floor plate was are located within 2.5m-deep reinforced Urban Habitat created directly below the columns in the In order to reduce the number of temporary concrete at level seven of the hotel tower, Urban Habitat – Single-Site Scale – 2019 residential levels. This was to circumvent supports needed for the erection of the floor Award of Excellence transferring weight to the composite the difficulties of installing falsework and structures in the office levels of the taller columns below. FIABI Singapore Property Awards 2019 scaffolding at such a height, and with such tower, steel decks forming concrete ribbed Mixed-Use Development Category (Winner) heavy loads involved, and to reduce the slabs were adopted. These steel decks spanned To allow for the angular shifts in the shape amount of labour involved in construction. up to 8m across the post tensioned of the 64-storey tower, outward-sloping Land Transport Excellence Awards 2019 This floor plate acted as temporary (PT) beams as ribbed slab formwork, southern perimeter columns have been Best Design for Land Transport Integration formwork, doing away with the need supported in turn by temporary supports at the installed from level one and inward-sloping Award (Winner) for propping. PT beams. The permanent structure was northern columns have been put in place The Institution of Structural Engineers formed after pouring concrete over the deck, from level 26. The horizontal ‘kick-out’ Singapore Structural Awards 2018 Speeding up the construction process with the steel profiled sheet serving as forces where the sloping columns change Supreme Award for Structural Engineering Constructing a building in the middle of permanent formwork. direction at level six – as well as on the floors Excellence Singapore’s central business district adjacent just above and below these transition points Tall or Slender Structures category (Winner) to an operational metro system meant that The engineering team and the contractor, – are resisted by steel floor beams that act as speed was essential. Arup was charged with Samsung C&T Corporation, spent a lot of time tying structures, as well as by steel connectors Association of Consulting finding engineering solutions that could planning the project to ensure it ran efficiently. that direct loads to the core walls through the Engineers Singapore contract the construction process to fit The team studied all possible site access, steel columns and beams at level six. At level Design Excellence Award 2018 (Winner) within the tight project timeline. Essential storage space and cranage capacity available 39, additional stability is supplied by transfer Building and Construction Authority to this was the adoption of a top-down before deciding how the segments would be beams acting with perimeter belt trusses. Design and Engineering Safety Excellence basement construction process, which fabricated. Wherever possible, bolted These transfer loads from the walls/columns Award 2018 (Winner) meant that the superstructure could be connections were used for floor beams, in of the residential section of the taller tower to BIM Award 2015 (Gold) constructed at the same time as the basement order to maintain an efficient construction and the office floors below. levels. To enhance productivity at basement installation process. This efficiency was further 4. 5. level, steel was used for the basement and extended with the use of automated cutting and podium construction. welding machines for the built-up concrete and Geometrical complexity structural integrity. Crucial to this was steel sections. The two towers are connected by a public- creating lateral stability via a central core The construction process was refined to be facing six-storey podium at their base. The wall made up of cast-in-place reinforced as fast and efficient as possible. Materials The benefits of steel 64-storey tower contains office space on its concrete, into which large steel plates with were procured three months ahead of The use of steel, rather than reinforced lower 37 levels and a mechanical floor at enormous shear studs were embedded at the schedule. The cutting and drilling of concrete, on the basement and podium level 38, with residential space taking up points of greatest tension. At level one, segments was carried out with the utmost levels was also essential to speeding up the floors 39 to 64. At the western end of the site, reinforced concrete beams transfer horizontal precision to ensure that each component was programme. This was an unconventional the 21-storey 105m tower contains a six-star forces to the core wall in the basement. To fabricated accurately and was easily move – the building was one of the first hotel from levels 5 to 20, with a mechanical provide further stability, reinforced concrete identifiable throughout the fabrication hybrid concrete and steel structures to be built floor on the top level. links and coupling beams are located above process. The components that were made of in Singapore. Even though steel is more doorways and corridors, and additional shear 100% steel were fabricated off-site, where expensive than reinforced concrete, the The structure is characterised by its elegant walls have been installed around stairways quality could be best controlled. Off-site benefits of expediting the process by using form – two tapered towers with angular shifts and mechanical rooms, as well as passenger construction also meant less overall the material were deemed to be worth the at several levels that create intriguing dips and service elevators. disruption to the neighbourhood around extra cost. and turns. The scale and unusual shape 7. resulted in significant engineering challenges, 7: Steel plates with as these angular changes create opposing shear studs were forces at different levels that had to be embedded at key accounted for in both the design of the tension points buildings and the construction process. At 8: The towers are level six, for example, the tallest tower slopes located in a crowded on its southern side, and the floorplate is area containing many reduced dramatically above level 39, with adjacent structures weight shifting to the northern side. The 4: The two towers are linked by a podium and differing soil result was that this tower was predisposed to level. The taller tower offers office space up to complexities lean southwards at its base, while the level 37, and residential space from level 39 9: At level 39 of counterweight from the higher levels would and above the taller tower, a move it towards the north. 5: To create lateral stability, the central core transfer raft plate was wall was made of cast-in-place reinforced installed to act as Working with the architect, Arup’s task was concrete with embedded steel plates temporary framework to take this ambitious vision and develop the 6: The tapered towers have angular shifts that design without compromising the building’s create opposing forces 6. 8. 9.

40 1/2020 | The Arup Journal 41 GUOCO TOWER | SINGAPORE

10: Speed was soil and existing adjacent structures, 3D essential in the modelling was used to study the effect of construction of the excavation and long-term settlement of the towers, which are structure itself. located in a busy area of central Singapore The 3D models were used to analyse the 11: A 15m-high phasing of the project to better control the canopy in front of wall deflections of the MRT station. Arup Guoco Tower provides a cool, worked with the contractor to phase the shaded ‘city room’ construction so that the basement levels doubled as supports to the retaining walls, Authors thereby meaning there was minimal Dion Anandityo leads the sustainability team 12. 13. disruption to the station’s usual operations. in the Singapore office. These analyses also informed the approach to the design; for example, the decision to wood in the building is Forest Stewardship building services systems is estimated to Jason Tan was the Project Manager and one keep the building’s base slab at the same Council certified, and recycled steel and contribute to 31% energy savings compared of two Professional Engineers responsible to 10. level as the existing raft foundation of the concrete were used as far as possible. The with similar buildings. Studies of thermal the local authority for the design and overall MRT station. This also translated into a 30% use of steel in particular was crucial to comfort criteria informed the design of the project supervision. He is an Associate saving on creating piled raft foundations and meeting environmental goals, as it produces canopy, including its glass roof. The PV Principal in the Singapore office. a reduction in the number of piles required. less dust, noise and carbon emissions during panels on its surface allow soft light to filter The main tower is founded on a 4m-thick construction than other options, and can be through while capturing the energy from Project credits Client GuocoLand Group raft supported on 1.8m-diameter bored piles, reused and recycled. the sun. Architect Skidmore, Owings & Merrill LLP extending approximately 40m below the (SOM) in association with architects 61 base of the raft. Photovoltaic (PV) panels have been placed A blueprint for sustainably Main contractor Samsung C&T Corporation on the rooftops and the canopy in the public constructed buildings Steel fabricator TTJ Design & Engineering A sustainable high-rise plaza. Placing them in this latter space was Since its completion, Guoco Tower has won Civil, structural and façade engineering Guoco Tower has been awarded Green Mark challenging, because of the dual need to several awards for its design, engineering and sustainable building design Arup: Platinum rating and a LEED Platinum create shade for people and maximise the and innovative use of materials. The Ivy Abo, Alexander Agung, Liyana Ahmad, certification for its office and commercial amount of sunlight received by the PV apartments at the top of the skyscraper have Joseph Amores, Dion Anandityo, Christine spaces, as well as a Green Mark GoldPlus for panels. Arup carried out thermal modelling become among the most highly coveted Ang, Serene Ang, Christopher Anoso, Eddra its residential elements. It is one of very few to ensure the plaza space was designed in slices of real estate in the city. Perhaps most Ardentiana, Jenny Austin, Sandar Aye, Renuga Chandra, Wei Cheng, Henry Chia, buildings in Singapore to achieve such high such a way that it was both sheltered by crucially, the building is at the forefront of Wah Kam Chia, Dominic Chong, Shiao Teng standards of environmental sustainability. Guoco Tower and also well ventilated, sustainable construction and engineering Chow, Russell Cole, Shane Collins, Majal This was achieved through a combination of meaning it is comfortable to use year-round. and will act as a model for future mixed-use Dag, Gino De Castro, Feng Gao, Gladys energy- and water-saving strategies, as well The use of PV panels and energy-efficient developments across the region and beyond. Goh, Liana Hamzah, Eric He, Subash as the provision of ample public green space. Kathiresan, Min Kyi Myo, Lukki Lam, Phuong Le, Jia Le Ngai, Wong Lei Lei, Keithson Liew, One of the most innovative aspects of the 12: Rainwater Jia Yuan Lim, Lip Boon Lim, Julius project’s sustainability plan relates to water harvesting facilities on Limanjaya, Siaw Ling Hiew, Bee Choo Lloyd, conservation. Owing to rainwater harvesting the rooftop assist with Geena Loke, Sin Ching Low, Kimberly Lu, 11. facilities on its rooftops and water storage reducing stormwater Farong Luo, Tim Lyon, Nur Farah Mazlan, run-off Wing Sze Mo, Jon Morgan, Mitchell Mulvey, facilities in the building’s basement, there is 13: PV panels have Daniel Mulyawan, Scott Munro, Sabariah Steel floor frames and composite slabs on the Accommodating the MRT station almost zero stormwater run-off when it Norman, Nilo Ola, Azri Omar, Jimmy Pang, basement levels and podium meant that Guoco Tower is located immediately rains. This recycled water is used to irrigate been installed on the plaza canopy Sam Peart, Sujesh Piillay, Jason Poon, temporary formwork and scaffolding were adjacent to an MRT station that is supported the greenery that surrounds the building and Ronilo Portugal, Virgilio Quinones, Nizar 14: Guoco Tower not required. Due to the lighter self-weight of by raft foundations. As such, one of the for flushing the lavatories, which means the Abdul Rahim, Jerr Ricafort, Ei Sandar, Jamie connects directly the steel structure, compared with the biggest challenges was to control the building’s water usage is half that of a Scott-Toms, Heng Seng Lee, Daniel to the Tanjong Simmonds, Benjamin Sitler, Seng Siong Soh, concrete structure, five additional upper movement of the MRT structures, as well as conventional building that meets current Pagar MRT station floors were constructed during the top-down of the two other buildings founded on local environmental codes. Vilia Soelaeman, David Sum, Evi Susanti, construction of the basement and podium shallow foundations less than 20m away Richard Tai, Elaine Tan, Jason Tan, Rohan levels – this would not have been possible in from the development. For the residential areas, natural ventilation Tariq, Jee Wei Tay, Andra Thedy, Shi An Ting, Mart Umali, Dino Van Deijzen, Leo Waible, a fully reinforced concrete structure. As a is provided through operable windows. Berlina Winata, Kah Chou Wong, Wendy Wu, result of this strategy, the structures were Arup undertook careful mapping and 3D Fresh air is delivered to the interior office Xiaofeng Wu, Joelle Xiong, Wesley Yeo, Jing completed two months earlier than scheduled. modelling of the movements of the two spaces at a rate that is 30% higher than a Zhang, Ning Zhang, Xiangjing Zhang, buildings to understand the impact that conventional office building. This is Dianfeng Zhao, Steel’s lightness meant the components could excavation works and their long-term complemented by shading on the façade that Zhi Qin Zhou. be easily transported to the site. In general, settlement would have on these existing controls the amount of sun that reaches construction with steelwork is much faster structures. It began by using 2D analysis to inside the building and heats it up. Image credits compared with other materials, because steel size the wall elements and predict ground 1, 2, 11–14: Ying Yi Photography allows for a more efficient and safe movement behind the new basement Materials were also chosen with 3–10: Arup sequencing of a construction programme. structures. Due to the complexities of the sustainability in mind. For example, all the 14.

42 1/2020 | The Arup Journal 43 MACALLAN DISTILLERY | SCOTLAND, UK

The new Macallan Distillery and Visitor increasing demand for Macallan Scotch Experience is located in the Easter Elchies whisky. It also wanted a welcoming building Building to match the spirit of the estate in the Scottish Highlands, where it for those looking to explore the whisky- is set into the landscape so that it blends making process and its heritage – whisky in with its surroundings. The building’s has been distilled in the Spey Valley double-curved grass-covered roof is one since 1824. Scottish Highlands of the largest timber grid-shell roofs in the world. Arup provided traffic and transportation A state-of-the-art distillery and visitor centre created to meet advice and documentation in support of the growing demand for Macallan Scotch whisky Working in collaboration with architects planning application for the facility. The Rogers Stirk Harbour + Partners (RSHP) on distillery is located in a designated Area of Authors Jim Deegan, Susan Deeny, Paul Edwards, Adam Jaworski, Stuart Jordan, Bob Lang and Alistair Murray the £140m project from concept through to Great Landscape Value, meaning that it must completion, Arup carried out the structural, not disrupt the character of the surrounding building services, fire, acoustic and civil area. Arup assisted with the environmental engineering design, along with providing and ecological aspects of the building’s environmental and transportation advice for design and construction. This included the new facility. technical support for the variation in the surface water abstraction and discharge The client wanted a contemporary distillery licences associated with the distillery. that would showcase the production of The nearby River Spey is an important Macallan whisky and also be of the highest fishery habitat, and is also a source of quality and craftsmanship, reflecting the water for production and cooling in the company’s values. In addition, they wanted whisky-making process. Arup carried it to respect the surrounding countryside. out analytical modelling and technical Arup’s multidisciplinary approach has assessment, developing monitoring and resulted in a 15,000m2 building that meets mitigation measures to ensure compliance this vision while also mitigating the fire with the EU Water Framework Directive risks inherent in the distilling process. regulatory requirements.

Distilling the building design The process of whisky distilling is presented In its design brief, the client required a in the facility in a highly coordinated space. state-of-the-art facility in order to meet Arup’s building services engineers worked closely with the architect; the main contractor, Robertson Construction Group; and the process engineers, Forsyths, 1: The new Macallan Distillery and Visitor Experience to ensure the striking roof form and soffits are showcases the production of Macallan whisky clear of any visible services and to control the 2: The curved timber grid shell allows the roof to ventilation so that potentially flammable flow over each still house in the distillery using a ethanol vapours produced in the distilling lightweight structure process are removed quickly and safely.

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44 1/2020 | The Arup Journal 45 MACALLAN DISTILLERY | SCOTLAND, UK

Grid shell roof The distillery roof consists of five domes that reflect the rolling hills of the Spey countryside. The tallest dome encloses the main entrance and the Visitor Experience centre, where an exhibition and gallery introduces visitors to Macallan and its history. The four other domes enclose the mash house (where hot water is added to the dried malt grist as part of the distilling process) and three still houses (where the spirit is heated and distilled prior to casking).

The building is dug into the sloping contours of the site, reducing the above-ground footprint of the distillery and meaning that views across the countryside are not disrupted by its presence. Although the domed roof mirrors the adjacent sloping 8. 9. hillsides, the architectural vision was not for 3. the distillery to disappear completely into beams. The steel sections are typically are 200mm wide and 750mm deep, with connection but are not frequent or large the landscape but for it to be clear that it was 16mm thick, but where required, in some 930mm-deep beams used in the area with enough to engage the cassettes as a a man-made, yet fully integrated, part of the isolated locations around connections, this the highest loads. The beams consist of a diaphragm. In the higher loaded areas, environment. The roof has a network of thickness increases to 40mm. An additional glulam core with laminated veneer lumber 930mm-deep beams extend up into the aluminium channels that provide a service perimeter frame that is of similar (LVL) boards glued to each side. depth of the cassette and ensure that the zone for lightning protection, rainwater construction to the typical internal frames bottoms of all the timber beams are located run-off, safety fall restraint systems and runs continuously along the glass façade of The top ‘skin’ of the roof structure consists in the same plane. At these locations, the power to serve vents in the roof lights. the building. Overall, 216 tonnes of of 200mm-thick prefabricated hollow timber cassettes connect to the timber beams by steelwork were used in the roof. cassettes. These are made up of a 9mm-thick means of small steel shear connectors fixed The complex shape of the roof was top layer, 75mm x 200mm softwood joists to the side of the timber beams running rationalised by using a repetitive form. Timber elements and a 21mm-thick LVL soffit. They are around the perimeter of the cassettes. There are three main components to the roof The timber beams are set out in a 3m x 3m triangular in shape, with two cassettes filling structure: steel portal frames, timber beams grid on plan. The actual distance between one panel of the beam grillage. The construction required the timber and 4. 5. and timber cassettes. The steel portal frames beams varies depending on the slope of the steelwork to be erected to very tight support the timber beams, with the timber roof, with the maximum distance being The cassettes are independent components tolerances in the demanding climate of cassettes spanning between the beams to 3.7m where the roof slope is 35°. The timber and are not designed to be relied upon to north-east Scotland. The roof construction form the roof deck. The timber grid shell beams form a two-way spanning structure. provide any diaphragm action between started in March 2016 and the 13,620m² allows the roof to ‘flow’ over each still The geometry of the timber frame adds elements. Approximately 85% of the timber roof was completed within six house using a lightweight structure. Four of stiffness and reduces stresses by causing timber cassettes simply sit on top of the months using 1,800 individual timber the domes are identical in shape, 11.5m tall the timber to transfer loads largely through timber beams that support them. Screws beams, 20 installers and two cranes that and 36m in diameter. arching rather than bending. The roof beams inserted from above provide a robust carried out 4,245 lifts.

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The roof is separated from the ground and 14:15:56 1 walls, meaning it supports vertical load only. 16/02/2015 Timber roof cassette joined to primary timber Timber roof cassette with OSB top Each dome contains one standalone four-sided beam with proprietary shear connection skin and LVL/PLY bottom skin. 2 75x200 C24 noggin steel portal frame supported on concrete (Cut at 45° for section) 150x200 C24 noggin (cut at 45° Centreline buttresses. At roof level, the frame is of timber for section) Top of deck 3 octagonal on plan and is supported at the eight 3: The grid shell roof 6. consists of steel portal corners by V-shaped columns that meet the 75x200 C24 noggin Top of timber (Cut at 45° for section) frames that support timber 4 ground at four locations in each dome zone. beams and cassettes The portal frames support the timber roof

4: A repetitive form was 5 Angle varies elements by providing a vertical load path Top of used to create the roof’s deck 220

Angle complex shape back to the ground and tying together the varies Hybrid timber beam. 6 timber domes so that they can resist any Top of Glulam core (GL32c) with 5: The roof domes timber LVL sides. Structurally 8: The visitor centre and the distillery have horizontal load potentially caused by glued together have been designed to been brought together safely under one roof reflect the surrounding 7 arching action within the roof. In order that rolling hills they can efficiently resist both horizontal 9: At the steepest angle, the roof slopes 35˚ Secondary timber beam 6 & 7: 3D models and vertical forces, the steel frames are joined to primary timber 10: The timber beams have a glulam core and 8 beam with proprietary showing the steel and made from circular hollow sections that pass shear and axial connection laminated veneer lumber boards on each side timber roof elements directly through the centre of the timber 11: Model mapping the roof axial forces 7. 9 10. 11.

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14 ss e 15 ogr 0 /2 15 Pr /02 3 Notes: Client Job Title Key Plan g in 1 Scale at A0 1. For setting out information refer to steel frame elevations on Arup drawing series AST-D000-04000 The Macallan Distillery As indicated 2. For timber beam cross-sectional dimensions, refer to detail on drawing AST-D000-04205-D-xx Scotland Roof - Timber Details in Discipline 3. For General Notes please see Drawing Number AST-D000-00090-X-XX Sheet 5 STRUCTURAL Job No Drawing Status 13 Fitzroy Street London W1T 4BQ Tel +44 (0)20 7636 1531 Fax +44 (0)20 7580 3924 229222 DRAFT www.arup.com Drawing No Issue Issue Date By Chkd Appd Draw AST-D000-04205-D-XX Do not scale © Arup MACALLAN DISTILLERY | SCOTLAND, UK

12: The smoke-detection system was tested 14: The transparent fire wall (shown behind the on-site to ensure its efficacy copper stills) separates the distillery and visitor 13: Due to the potentially flammable ethanol centre while retaining the welcoming and open vapours produced in the distillation process, the feel of the building distillery has a comprehensive fire-detection and 15: Any potentially flammable liquid spillage is action plan immediately expelled from the building 16: The green roof contains a service zone that provides lightning protection, safety fall restraint systems and power

Fire engineering Arup’s Fire Engineering team were crucial in shaping the building’s design, bringing innovative solutions to the project in of the foul and surface water, effluent and addition to their considerable knowledge of cooling networks, communications, local building regulations and the Scottish electrical, steam, whisky and process water approvals environment. Typically, a supply networks. building’s design and construction fire safety is achieved by following prescriptive rules. 12. The building’s buried nature meant that The unique architectural design of the external drainage networks were up to 12m Macallan Distillery required a bespoke below ground, with specialist access approach that demanded the subtle construction to separate the two, but this well as heat and flame detectors. An ethanol manholes designed to provide safe access. integration of fire safety concepts with all would have compromised the vision of gas detection system was deployed at low Effluent from the distillation process is very aspects of the building design. having a strong visual connection between level. This kept the roof clear of detection aggressive (it has both high and low pH both parts of the facility. equipment and allowed maintenance of the levels), highly flammable and potentially 14. By using an integrated design coordinated system to take place at a low level rather very hot. Coupled with the installation with civil engineering elements, Arup’s fire Arup’s solution was to develop a than at height. Combined with heat and depths, pipe material selection required strategy avoids the need for sprinklers and transparent fire wall, which was a first for a flame detectors at an elevated level, these extensive investigation with support from other equipment such as heavy fire curtains. distillery. The fully glazed partition, 10m alternative types of detection ensure reliable Arup’s Advanced Technology and Research This required careful detailing with RSHP tall and 40m long, separates the visitor detection while minimising false alarms that team, resulting in specification of a and the structural engineering team to centre and distillery, with steel cantilevers would interrupt the distilling process. specialist plastic product. The effluent ensure that the roof remained isolated keeping the glazed wall structurally drainage system is connected to the on-site structurally. A third-party reviewer worked independent of the timber roof. In a fire Reviewing the process safety risk assessment treatment plant via a balancing tank where on behalf of the regulatory authority to situation, a bespoke drenching system is with the client, it was noted that any spillage aeration and filtration are used to remove review these elements of work, with deployed along the two-hour fire rated from one of the vessels needed to be dealt harmful pollutants. The waste is then discussions with the local fire service glazed wall. This creates a continuous film with quickly to reduce the risk of an combined with the cooling water network framing the design outcomes. of water over the glazing surface to prevent escalating fire. Arup designed the floor so that and discharged into the river. it from shattering. A full-scale fire test was it slopes towards high-capacity effluent ring The distillery has an explosive gas carried out on a 5m-tall sample of the wall drains that are linked to large underground Rainwater collected from the green roof is atmosphere classification due to the nature to verify the design and demonstrate to the tanks. Any spillage that is potential fuel for a stored in buried tanks and used to irrigate of the gases produced in the distilling project team and the approving authority fire can be evacuated from the building safely the roof during dry weather. A sustainable process. As such, it was a complex challenge the system performance. and quickly (up to 12,000 litres in less than drainage system has been put in place in to bring the visitor centre and the distillery 60 seconds) from both a fire and an order to protect the River Spey. Swales are together safely under one roof. Each The fire detection strategy also minimised environmental perspective. 15. used with flow restriction to attenuate initial presents a risk to the other. The typical the visual impact on the roof. The system rainwater discharge peaks. They also solution would have been to provide heavy uses a combination of aspirating detectors as In the event of an emergency within the encourage the settlement of suspended distillery, the effluent is purged into the particles before the water flows into pipes effluent drainage system and, should the beneath the steeply sloped farmland to emergency continue, escapes via a high-level energy dissipation structures, prior to outlet into a specially lined effluent holding discharging into a grassed retention pond away from the distillery. This pond is pond. This pond encourages the depositing capable of storing the combined contents of of remaining suspended solids (and provides the whisky process and any spent emergency a variety of natural habitats) before firefighting water. The overall design of the discharging at a controlled rate into the river. spillage evacuation system was a key factor in the building gaining permission to host visitors Building services within the process hall. Working closely with the process engineering designers, Arup provided the Civil engineering building services design for the distillery. Arup’s civil engineering design for the Distilling is an energy-intensive process. distillery also included the external sections Waste heat from distillation is recovered and 13. 16.

48 1/2020 | The Arup Journal 49 MACALLAN DISTILLERY | SCOTLAND, UK

This repeated wall pattern meant that the reinforcement cages could be prefabricated and lifted into position, allowing faster and safer working practices. The relative thinness of the wall panels reduced the effects of shrinkage on the long lengths of wall, aiding waterproofing, as this allowed the basement box to be constructed without joints. Early age shrinkage was controlled by leaving out one 3m-wide wall panel every 50m. This also benefited the contractor, as it could use these openings for working access into the basement zone during construction.

The steel-frame section of the roof is supported on concrete buttresses. These 8m-tall structures are the main stability elements of the building. Each pier is formed of two shear walls in the east–west orientation, and a moment frame and shear 17. 18. wall in the north–south direction. The shear walls receive the thrust coming down from 17: Development of the timber roof was carried used as the primary source of heating in the hot air; this also prevents dispelled process the roof and transfer it, via their out in conjunction with timber contractor Wiehag building through an underfloor heating gases from recirculating back into the foundations, to the ground. These buttresses 18: The reinforced concrete air circulation ducts system, and for domestic hot water in the structure. As the expelled air contains are tied together across the east–west axis also act as structural ties as part of the building’s visitor centre. concentrations of ethanol vapour, the zone of the building by the reinforced concrete 19. stability system just above the roof is classified as an ATEX ties below the floor slab that also act as the 19: The award-winning distillery blends into its Steam power is used as the main energy Zone 1. The lightning-protection finials on air circulation duct. was carried out in conjunction with analysis model from that before developing surroundings while utilising state-of-the-art source for the distillery. This is supplied by the roof are raised above this zone. Austrian timber contractor Wiehag. Arup the fabrication geometry. technology the Speyside Combined Heat and Power 3D design and Wiehag shared geometry and load plant, which is located 2km away and is A small air handling unit (AHU) is used to The design team worked on the project in a cases in 3D, with all of the models checked Working collaboratively, the project team fuelled by sustainable low-grade harvested condition the Cave Privée cellar space in digital 3D environment. Coordination was independently so that they were aligned. has created a graceful award-winning Awards wood and draff – a biomass by-product the visitor centre. Here, 300 wooden casks critical for the successful delivery of such a Arup’s structural analysis model was industrial building that does not 2019 from the distillation process. Two 10MW of maturing whisky are stored. The complex building design. Development of coordinated geometrically with the compromise the original concept, and World Architecture Festival Awards gas-fired boilers provide a back-up during temperature is ideally kept at 12°C with a the design and detailing of the timber roof architect, with Wiehag developing its final respects the surrounding environment. Completed Building Production, Energy any planned maintenance downtime. relative humidity of 70% by mixing a & Recycling portion of outside air with return air and The process ventilation has been re-humidifying to adiabatically cool the RIAS Award engineered to dilute and remove potentially space. Low ambient temperatures allow Authors Paul Edwards, Chris Eliades, Angus Elliott, Sam Doolan Best Building in Scotland Award flammable ethanol vapours. This is critical, these conditions to be maintained most of Jim Deegan worked on the mechanical Alistair Murray was the Project Director for Frith-Salem, Jonas Fuchs, Rob Gilbert, Mark Special Category Award – Wood for Good/ as parts of the building have potentially the year. It is accepted that some upward aspects of the project. He is a senior engineer the fire engineering design. He is the leader of Heath, Iain Herriott, Nicky Hilton, Afser Hussain, Scottish Forestry Commission for the Best explosive environments. The air drift will occur in the summer months. The in the London office. Arup’s fire engineering team in the UK and a Adam Jaworski, Lidia Johnson, Stuart Jordan, Use of Timber management system draws in air from a visitor centre does not require mechanical Director in the Glasgow office. Nikolaos Karamitsos, Mike Kong, Bob Lang, Andrew Lawrence, Rhodri Lea, Mark Lindsay, trench along the building’s east side, with cooling. The main AHU for this part of the Susan Deeny led the fire engineering design. She is an Associate in the Edinburgh office. Project credits Tyler Little, Rena Maguire, Gavin Maloney, RICS Scotland fans circulating the air throughout the facility has a heat recovery wheel, with the Client Macallan Distillers Ltd Mei-Yee Man Oram, Carlo Marras, Grant Martin, Design Through Innovation Award building. An example of the coordinated operation running with 50% fresh air and Paul Edwards was the lead structural engineer Architect Rogers Stirk Harbour + Partners Fraser Maxwell, David McAllister, Matthew design of the building is the 1m-wide x 50% recirculated air. and Project Manager. He is an Associate in the Landscape architect Gillespies McCullough, Danny McVee, Paul Morrison, Structural Steel Design Awards 1.6m-deep concrete floor ducts that are London office. Lighting consultant Speirs + Major Alistair Murray, Tom Parker, Dan Pook, Hugh Merit Award used for air circulation. These also act as a Concrete elements Main contractor Robertson Construction Group Quail, Morgan Rhodes, Eduardo Rico, Adriana structural tie for the building between the A 180m-long, 54m-wide basement structure Adam Jaworski worked on the electrical Process contractor Forsyths Salgado Perez, Vera Sarioglu, George Scott, 2018 buttresses that support the roof above. forms the distillery’s main operating floor. aspects of the project. He is an Associate in Project manager and quantity surveyor Andrew Sedgwick, Piotr Skowron, Clem Structural Timber Awards The excavation works for the building took the London office. Equals Consulting Smoothy, Giulia Strallo, Katarzyna Tekieli, Con Engineer of the Year and Winner of Winners The air circulation reduces the risk of place in an open cut without the need for Civil, structural, fire, geotechnical engineering, Therrios, Steven Thomas, Peter Toth, William Tung, Denis Venkov, Khyati Vinod, Colin Winant. accumulation of gas around the equipment any temporary sheet pile foundations for Stuart Jordan led the civil engineering design building services, transportation planning and on the project. He is a senior engineer in the ecological advice Arup: Scottish Design Awards and helps to moderate the temperature in the most of the retaining wall construction. The London office. Matt Adams, Rodney Arnedo, Will Arnold, Endrit Image credits Leisure/Culture Building or Project space. The air up to 3m above floor level is main 300mm-thick, 10m-high retaining Badallaj, Rick Benjamin, Tim Brosnahan, Celine 1, 8: Mark Power/Magnum Photos changed six times per hour. Above 3m, walls were built free-standing and Bob Lang was the Project Director. He is a Cannam, Ian Carradice, Stuart Chambers, Tom 2, 3, 6, 7, 10–13, 15, 16, 18: Arup Wood Awards rising heat from the plant dilutes the ethanol backfilled at a later date. The walls are former Director and is currently a consultant Clack, Andrew Cole, Ricardo Costa, Jim Deegan, 4: RSHP Structural Award vapour. Positive pressure is maintained supported at regular 3m centres by 300mm- with Arup. Susan Deeny, Tarun Devlia, Gordon Diamond, 5, 9, 14, 17, 19: John Paul Photography within the building by the escaping ambient thick counterforts.

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1. Cityringen Metro, Copenhagen, Denmark: Rasmus Hjortshøj – COAST; 2. Claridge’s Hotel, London, UK: Nick Carter; 3. Beijing Daxing International Airport, Beijing, China: Hufton + Crow; 4. Samuel De Champlain Bridge Corridor Project, Montreal, Canada: Arup; 5. Guoco Tower, Singapore: Ying Yi Photography; 6. Macallan Distillery, Scotland, UK: John Paul Photography. Front cover image: Cityringen Metro, Copenhagen, Denmark: Rasmus Hjortshøj – COAST.

The Arup Journal Printed by Geoff Neal Group Vol.55 No.1 (1/2020) Produced on FSC paper Editor: Macdara Ferris and printed with vegetable- Designer: Wardour based inks. Email: [email protected]

Published by Arup 13 Fitzroy Street London W1T 4BQ, UK. Tel: +44 (0)20 7636 1531 All articles ©Arup 2020

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