Friday, March 23, 2012

Bill & Melinda Gates Foundation featured in Architectural Record


Sean Airhart/NBBJ

The Bill & Melinda Gates Foundation is this month’s office building study by Architectural Record. The article calls the recently completed headquarters campus for the world’s largest charitable organization “well-dressed corporate architecture” whose “aggressive daylighting [is] made possible by narrow buildings that keep all workstations within 30 feet of sunlight.” This exposure to natural daylighting was a key contributor to the campus’ LEED Platinum rating from the U.S. Green Building Council.

Enclos participated as a consultant to the design team before being awarded a design/build contract for the project’s facade work. The project features over 300,000 square feet of custom unitized curtainwall and a cable wall at the museum podium, located at the north office building. A custom glass connection system for the vertical cable-supported wall was developed for this project, and is an example of one of many systems developed by the Enclos design team in response to project specific requirements. All facade systems have been designed to demanding performance and security specifications, including stringent blast requirements.

 

You can see the entire Architectural Record article and accompanying slideshow here, and read more about the Seattle Family Foundation Campus here.



 


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Thursday, March 22, 2012

Concept to Fabrication: A Grasshopper Driven, Doubly-Curved, Cable-Net Structure


Handling complex forms with the goal of automating parts generation can be challenging to say the least. The application of parametric tools — such as software company Rhino’s parametric modeling plug-in “Grasshopper” — eases these challenges and allows for a streamlined information exchange between architects, general contractors and specialty subcontractors alike.

In this AIA/CES registered course case study, a doubly-curved shell clad by perforated metal panels comes to life through a sequence of automatic form generation from nothing but known node coordinates. By using these 1100+ coordinates, each with an X, Y and Z component, Enclos was able to automate the generation of a cable-net geometry and extract accurate cable lengths. Beyond estimating cable lengths, this model served as a study of fabrication and installation means and methods, structural analysis to predict the elongation of cable lengths when subject to loading, and to automatically generate fabrication drawings for the 952 unique rhomboid and triangular perforated metal panels that wrap the net geometry.

Enclos’ Concept to Fabrication: A Grasshopper Driven, Doubly-Curved, Cable-Net Structure AIA:CES certified course meets today’s emerging design complexities by identifying and comparing:

  • The application of parametric tools within the context of the facade subcontractor
  • The advantages/disadvantages of parametric tools within the project delivery process
  • The role of database exchange in the construction of complex geometries
  • Case study examples

About the presenter:

Jeffrey Vaglio, PE, Assoc. AIA, LEED AP [BD+C], is a Design Engineer at the Advanced Technology Studio of Enclos. His project ex­perience includes a slew of specialty facade structures, ranging from cable nets (Seattle Family Foundation Headquarters) to point-supported systems (L.A. Live Tower & Residences), skylights (300 New Jersey Avenue) to double-skins (Loyola University Chicago: Information Commons). Vaglio is currently a Ph.D. Candidate at the University of Southern California School of Architecture.

 

Additional AIA/CES registered courses by Enclos include:

 

To schedule an AIA/CES presentation, please send your request to .(JavaScript must be enabled to view this email address) or call 888.234.2966.

Enclos_AIA_Concept_to_Fabrication.pdf


 


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Tuesday, February 28, 2012

The Architect’s Newspaper features Pomona facility


Enclos’ Pomona, California assembly factory.


The Architect’s Newspaper published a spotlight yesterday on stateside manufacturing plants, with their focus on Southern California facilities in particular. The article challenges the notion that all architectural products originate overseas, and makes the claim that local markets can provide a higher-skilled workforce, decrease in shipping costs, and quicker project turnarounds.

Enclos’ Pomona, California assembly factory is shown extensively throughout the article. The Southern California facility has assembled cladding material for numerous west coast projects over the years, most recently the New San Diego United States Courthouse, McCarran International Airport: Terminal 3, and L.A. Live Tower & Residences. These three projects combine to include just under one million square feet of facade, each delivered with accelerated schedules and just-in-time delivery strategies by the Pomona facility.

“It’s not uncommon for people to ship parts to China, where they’re assembled and then shipped all the way back,” says Mic Patterson, director of strategic development for Enclos, in the article. “It’s crazy.”

To combat this “craziness,” Enclos also operates a fabrication plant in Ephrata, Pennsylvania, and second manufacturing plant in Harrisburg, Pennsylvania. With established facilities on both coasts, Enclos is able to provided the optimum quality assurance, decrease in shipping costs, and quicker turnarounds that the article suggests on a nationwide level.

A step-by-step visual walkthrough of Enclos’ manufacturing process can be seen in part one of our online facade series, Modular Prefab: The Manufacture of Unitized Curtainwall Systems.

The Architect’s Newspaper article can be read in its entirety here.



 


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Friday, February 17, 2012

Recap | Collaboration: the Facades and Digital Fabrication Conference


Image courtesy of The Architect's Newspaper/Erik Verboon.


Collaboration, the Facades and Digital Fabrication Conference, concluded yesterday with an impressive lineup of speakers and more than 250 professionals and students attending the event at the McGraw-Hill Auditorium in New York. The Architect’s Newspaper and Ornamental Metal Institute of New York sponsored event explored diverse aspects of advanced facade technology.

Mic Patterson, director of strategic development at the Advanced Technology Studio of Enclos, took to the podium at 11AM and delivered a presentation on facade retrofit for tall curtainwall buildings. The presentation focused on the looming need for retrofit in this building type, and its relevance in achieving energy efficiency and carbon reduction goals in the building sector. Current retrofit practices were explored within the context of sustainability, including a critical assessment of facade performance, durability, reuse and recycling. Amongst Patterson’s concerns is the fact that architectural glass, with its applications of films and coatings, is not recyclable — a fact unrecognized by many in the industry. Patterson also pointed out the mismatch in life cycle between the building structure and facade. Insulated glass units, for example, have a life expectancy of twenty to twenty-five years, far less than the average 75-year lifespan of commercial buildings. In spite of this fact, buildings have not been designed to accommodate future retrofit requirements, and this is equally true of new buildings as it is of the old buildings currently in need of retrofit.

Demonstrating these points were photographs of the current facade retrofit underway by Enclos for the Jacob K. Javits Convention Center in New York City, as part of a half billion-dollar renovation of the facility. The building was completed in the mid 1980s, but the original has experienced significant deterioration in the glass and facade system. Side-by-side photographs of the new facade and old systems dramatically evidence the difference. The latest photo documentation of the Javits retrofit can be seen here.

In recent news, Governor Andrew M. Cuomo recently proposed tearing down the remodeled Javits facility and building a new convention center in neighboring Queens (you can read his proposal here). Coincidentally, Patterson remarked upon the sustainability challenge presented by today’s throwaway culture, where facade systems — and even entire buildings — are routinely subject to demolition with little consideration given to repurposing and reuse.

The conference concluded with keynote speaker Patrick Schumacher of Zaha Hadid Architects. Schumacher presented an overview of his firm’s visually stunning portfolio. Other presentations addressed aspects of digital design practice and new fabrication processes as dominant themes.

A full conference recap is available on AN’s website here. The event concludes today with workshops focused on conceptual design and the application of cutting edge digital technologies.



 


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Monday, February 13, 2012

Modular Prefab: The Installation of Unitized Curtainwall Systems


Modular Prefab: The Installation of Unitized Curtainwall Systems is the second feature in Enclos’ online facade series. Part One, Modular Prefab: The Manufacture of Unitized Curtainwall Systems, can be viewed here.

There is simply no way to over-emphasize the role of the building site in the construction process. It is certainly one of the most challenging playing fields in all of industry. While the modular prefabricated systems discussed in Part One of this series are interesting in themselves, the reason for their effectiveness in construction is as a response to conditions imposed by the building site. The vagaries of weather, the omnipresent dirt and dust, the congestion of multiple trades competing for access, and increasingly dense urban locations all combine to render the jobsite as the dominant consideration in building construction.

This dominance of the building site has important implications for the rest of the building process. While a facade designer might be tempted to disregard the installation component as not particularly relevant to his or her design problems at hand, this would be a serious and potentially costly mistake. It is imperative that facade systems be designed to facilitate field installation. Anticipating fabrication and installation requirements is fundamental to optimal systems design. This involves pinpointing the fabrication and installation requirements essential for consideration as early in the design process as possible. At Enclos. we refer to this as “constructability review” — continuous budgeting and constructability review are services we provide as part of our design development work process (most effectively applied under a design-assist project delivery strategy, and providing an optimum environment for design decision-making). In fact, we typically involve field operations personnel to assist in developing preliminary installation planning as part of our pre-sale effort. The ability to speak to the requirements of installation and site planning during proposal development is pivotal to selecting the appropriate facade contractor, and has been a predominant consideration in the award of many of our past projects.

Furthermore, innovation in building construction is not limited to design, and cost saving is not limited to value engineering exercises. Depending on location, the cost of field labor can approach $100 per hour, and the total field labor cost for facade systems installation can easily amount to 25-30% of a facade program’s total contract value in some regions of the domestic marketplace. Strategies that minimize field labor and speed the installation process can provide a significant competitive advantage by reducing first costs for the owner-developer. This is a key advantage provided by unitized curtainwall systems. Fabrication of the unitized modules under factory-controlled conditions — and the quality improvements that result therefrom — is another significant advantage. Novel strategies involving material handling and unit setting can also favorably impact cost and schedule. Consequently, innovation in installation method can be equally as important, and often result in cost savings and system design innovations.

For example, Enclos pioneered the use of the double-span modular unit, thereby enclosing two floors with a single unit (see image 24). This strategy cuts material handling nearly in half. Other installation innovations may also include rigging, or the manner in which the units are prepared and secured for lifting and positioning. Enclos has implemented a technique for hoisting multiple units with a single lift, a strategy that saves considerable time on projects where units are being lifted from the ground to the upper stories of a skyscraper (see image 25). Combining these two techniques can offer significant timesavings that result in schedule acceleration.

 

Installation Planning

The very first steps of the installation process involve installation planning, including considerations ranging from unit sequencing to material handling and site logistics. Equipment needs are determined. Staging/hoisting areas, material delivery routing and other project specific requirements are also assessed. Field safety is also a paramount consideration that commences in unison with the initial installation planning. A project-specific safety plan is prepared following a site review to determine requirements for fall protection systems, overhead protection, and other site-specific hazards.

Unit production in manufacturing is coordinated with installation schedules to determine a material delivery program. A number of units are typically stacked and packaged together in what is called a “bunk.” Installation typically commences at lower floors and follows the construction progress of the building upward, floor-by-floor. The curtainwall units interlock, so a progressive sequence of installation is required. The modular curtainwall units are actually bunked in the sequence that they will be installed on the building, either stacked flat such that the topmost unit is the first in the sequence with the lower units following progressively, or stacked on edge, which may provide slightly more latitude in unit positioning within the bunk. Entranceways, storefronts, podiums, and other ground floor facade systems are typically installed near the end of the installation phase.

Staging requirements vary widely between projects but include such considerations as accessibility, routing, permits, weight and height restrictions, loading dock availability, and rigging/hoist requirements, with each playing a significant role in the overall scheduling and budgetary successes of a project. Additional considerations may include security and on-site versus off-site storage requirements.

 

Site Preparation and Anchor Installation

Initial on-site activities involve preparing the site for the installation of the facade systems. This work can vary significantly between projects, but typically includes such things as the installation of overhead and fall-protection systems, the protection of work or materials of adjacent trades, the securing of storage areas, and the clearing and setup of staging areas. The fundamental activity, however, is the installation of the anchor assemblies that will secure the curtainwall units to the building. The development of the anchor assembly is an early system design activity. They are typically located on the top or face of the floor slabs. A precise survey is conducted to mark the anchor locations at the building interface, followed by installation crews installing the anchors on the slab or other building structure. Anchors are occasionally required to be embedded in the slab, making it necessary for them to be positioned before the slabs are poured.

 

Unit Setting Methods

There are several basic approaches to getting the modular curtainwall units into position and secured to the building. This is referred to as “unit setting.” The basic difference between the methods is where the units are located prior to setting: either inside or outside of the building. If the units are set from the outside they are typically lifted from a staging area on the ground adjacent to the building. A ground crew rigs a crane to the appropriate unit and directs the crane operator in lifting the unit from its bunk. A ground-based or tower crane can then be used to hoist the unit into position, where a setting crew inside of the building awaits to guide the unit into place and secure it to the preinstalled anchors.

Ground-based cranes have limited reach, which restricts their use in tall buildings. Positioning ground cranes on a constrained building site can also present a major logistical challenge. Alternatively, a tower crane is a common site on most major construction sites. This crane type is typically built up progressively along with the building structure, thus being always above the work and able to service the building at any level. The tower crane can be used to pick units from the ground and place them at any location on the building facade. There is typically only a single tower crane (sometimes a back-to-back pair) used on a high-rise building, and is in high demand by the prime contractor and multiple trade contractors. The use of the tower crane by the facade contractor is often not an option because of inadequate availability. Tower cranes are also expensive to rent and operate. Another drawback of the exterior unit setting method is the amount of time required to lift the materials from the ground and into position, particularly at the higher elevations. The cycle time in hoisting units from the ground to the 50th story and returning the rig back to the ground involves many minutes, during some of which the ground crew and setting crew are inevitably idle. Creative rigging can provide for hoisting multiple units in a single lift to minimize hoisting time.

Another method involves unit-setting operations from within the building. This requires that the bunked units be strategically distributed within the building, and thus becomes an important material handling consideration. Units are bunked in a manner to facilitate this, and can often be delivered to the appropriate location using the project’s material lifts or cranes. An advantage is that many units are being handled together until they are in close proximity to where they will be installed, thus minimizing material handling. The lifting crew in this case works from a floor elevation above the level on which units are being set. A portable floor crane or similar equipment is used to lower a hook to the setting crew. The required units have been previously delivered to the setting area. The setting crew rigs the unit to the crane and directs the lifting crew in hoisting the unit as it is swung outside the building and positioned for installation. A variation of this method uses a hoist fixed to a monorail track running horizontally around the perimeter of the building. Units can then be lifted from a common position within the building and traverse the monorail system around the building to the required setting location. Units set from within the building are limited to single-span systems.

In any case, the actual setting of the unit involves fitting it to adjacent units, typically below and to one side. The horizontal stack joint (described in Part One) between upper and lower units is mated. The split vertical mullions of the adjacent units are snapped together. Particular attention is given to assure full engagement and the correct sealing of gaskets. Finally, the unit is secured to the preinstalled anchors, fixing it in place. The crane is cut loose and sent to fetch the next unit. The installed unit is subsequently inspected for elevation and alignment, and adjusted as required. Limited wet sealant and trim operations may follow depending upon the curtainwall system design. Later, firesafing is installed between the curtainwall unit and the face of floor slab, and interior finishes are applied according to project requirements.

The selection of a setting method for each particular project is a function of a complex set of variables, ranging from building design and location, site conditions, code requirements, and available equipment.

 

Advanced Facade Technology

The increasing complexity of facade systems also impacts their installation. This generic narrative of curtainwall installation method assumes a simple, basic system type. In reality, the systems frequently and increasingly incorporate significant geometric complexity, a novel use of materials, and incorporate other systems ranging from lighting and signage to shading and power generating systems (i.e., photovoltaic systems). Automation is now frequently encountered in the building facade, as facade systems and components are integrated through a building management system (BMS). Shading systems and electrical lighting can be linked through sensors and controllers to provide optimum efficiency. As these new technologies emerge, the zone of the building facade grows from a few inches to feet or yards in depth. Designs can also include maintenance or circulation space within the facade system, again increasing depth. The assurance of fit and function with respect to these complex integrated systems often becomes an additional responsibility of the facade design-builder. Facade commissioning by a third-party specialist is often a requirement with advanced facade designs. Regardless, we regard it as an important final step of our work to assure that the facade system is functioning as intended throughout.

 

Summary

Site operations are a core strength of Enclos. We develop a custom, comprehensive installation strategy finely tuned to specific project requirements for each new project we undertake. Constructability review begins early in the design phase — more often than not before we are actually awarded a project — with facade systems designed to facilitate fabrication and installation, and thereby producing optimum economy. Our strategic pairing of lean manufacturing with just-in-time delivery minimizes the impact of the facade system installation on the building site in regards to both site storage and staging requirements; each a vital consideration for the increasingly dense, urban jobsites common today. The unitized curtainwall systems described above effectively accelerate installation schedules and maximize system quality. Each project presents unique challenges with respect to the building site, and our expertise in early installation planning and site logistics is but one of the capabilities that separates Enclos from our competition.



 


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