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4/26/2018 1 Grid Shell Structures on Freeform Surfaces Novum Structures | USA, China, Germany, India, Singapore, Turkey, UAE, United Kingdom, South Africa Novum Structures | www.novumstructures.com Grid Shell Structures on Freeform Surfaces Company Introduction Novum Structures - Design & Build Specialty Contractor for Architectural Steel, Cable, Glass & Membrane Structures Seattle Airport, USA Dali Museum St. Petersburg, USA Tours Shopping Mall, France Wrigley’s R&D Center Chicago, USA Yueda 889 Shopping Mall Shanghai, China Old Castle Dresden, Germany Novum Structures | www.novumstructures.com Grid Shell Structures on Freeform Surfaces Company Introduction Novum Structures is a Design & Build Specialty Contractor for Architectural Steel, Cable, Glass & Membrane Structures Holding Company: Menomonee Falls, WI San Francisco, CA Sarasota, FL Chicago, IL Diss, UK Wurzburg, Germany Sangerhausen, Germany Beijing, China Istanbul, Turkey Farnham, UK Dallas, TX Bangalore, India Dubai UAE Singapore BB-System BK-System FF-System KK-System SSM-System AFP-System CCG-System ECG-System Selection of Novum Component Systems for Building Structures & Envelopes Novum Structures International Network

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Page 1: 4/26/2018… · Beijing, China Istanbul, Turkey Farnham, UK Dallas, TX Bangalore, India Dubai UAE Singapore KK- SystemBB-System BK -SystemFF CCG-System ECG-System AFP SSM-Selection

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1

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Novum Structures | USA, China, Germany, India, Singapore, Turkey, UAE, United Kingdom, South Africa

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Company IntroductionNovum Structures - Design & Build Specialty Contractor for Architectural Steel, Cable, Glass & Membrane Structures

Seattle Airport, USA

Dali Museum St. Petersburg, USA Tours Shopping Mall, FranceWrigley’s R&D Center Chicago, USA

Yueda 889 Shopping Mall Shanghai, China Old Castle Dresden, Germany

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Company Introduction

Novum Structures is a Design & Build Specialty Contractor for Architectural Steel, Cable, Glass & Membrane Structures

Holding Company:

Menomonee Falls, WI

San Francisco, CA

Sarasota, FL

Chicago, IL

Diss, UK

Wurzburg, Germany

Sangerhausen, Germany

Beijing, China

Istanbul, Turkey

Farnham, UK

Dallas, TX

Bangalore, India

Dubai UAE

Singapore

BB-System BK-System FF-SystemKK-System SSM-SystemAFP-SystemCCG-System ECG-System

Selection of Novum Component Systems for Building Structures & Envelopes

Novum Structures International Network

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Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Content

1. Contemporary Architectural Styles

2. Typology of Freeform Surfaces

3. Grid Geometry

4. Grid Shell Node Types

5. Novum FF-System

6. Process Case Study – Salvador Dali Museum

7. Other Freeform Projects

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Contemporary Architectural Styles

High-Tech Architecture

Nicholas Grimshaw: Eden Project, , UK

DP Architects: Esplanade Theaters on the Bay, Singapore Kessler & Partner : K21 Duesseldorf, DEFoster & Partner: Swiss Re, London, UK

Grid Shell Structures on Freeform Surfaces

Foster & Partners: City Hall, London, UK

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Contemporary Architectural Styles

Blobitecture / Blob Architecture

Foster & Partner: The Sage, Gateshead, UK

The Jerde Partnership: Zlote Tarazy, Warsaw, Poland Foster & Partners: British Museum, London, UK

Grid Shell Structures on Freeform Surfaces

HOK: Salvador Dali Museum, St. Petersburg, FL, USA

Studio Fuksas: New Fair, Milan, Italy

The US architect and philosopher Greg Lynn is credited with coining this phrase, claiming that the name comes from a software feature that creates Binary Large Objects

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Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Contemporary Architectural Styles

Deconstructivism

Frank O. Gehry : Walt Disney Concert Hall, LA, US

Coop Himmelb(l)au: BMW World, München, DEFrank O. Gehry : Gehry Tower, Hannover, DE

Frank O. Gehry :Dancing Houses, Prague, CZ

Grid Shell Structures on Freeform Surfaces

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Content

1. Contemporary Architectural Styles

2. Typology of Freeform Surfaces

3. Grid Geometry

4. Grid Shell Node Types

5. Novum FF-System

6. Process Case Study – Salvador Dali Museum

7. Other Freeform Projects

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Typology of Freeform Surfaces

Surface Classification Chart Freeform Surfaces

StructurallyOptimized

StructurallyNon-Optimized

MinimalSurface

HangingForm

ScaleTranslation

Surface

ScaleRevolution

Surface

RuledSurface

NURBSSurface

NURBS = Non-Uniform Rational B-Spline

Grid Shell Structures on Freeform Surfaces

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Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Typology of Freeform Surfaces

Minimal Surface

• Doubly-curved anticlastic surfaces produced by experimental or numerical form-finding process

• Application mainly for cable nets and tension or membrane structures

Fentress & Bradburn: SeaTac Airport Seattle, USExecution: Novum

Grid Shell Structures on Freeform Surfaces

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Typology of Freeform Surfaces

Hanging Form

• Doubly curved surfaces produced by experimental or numerical form-finding process

• Application mainly for predominantly gravity loaded shell structures

Frei Otto: MultihalleMannheim, DE

Grid Shell Structures on Freeform Surfaces

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Typology of Freeform Surfaces

Scale Translation Surface

Gerkan Marg & Partner:Main Railway Station Berlin, DEEngineer: Schlaich BergermanExecution: Mero GmbH & Co.KG

• Facetted surface produced by a parallel translation and simultaneous scaling (dilation) of a generating polygon (generatrix) along a polygonal guideline (directrix)

• Application mainly for glass structures with planar quadrilateral facets

Grid Shell Structures on Freeform Surfaces

Centric StretchedCurve Profile Curve Profile

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Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Typology of Freeform Surfaces

Scale Revolution Surface

• Facetted surface produced by a rotation and simultaneous scaling (dilatation) of a generating polygon (generatrix) about an axis of rotation

• Cylinder, sphere, cone and torus surfaces are widely used basic revolution surfaces with an analytically determined generatrix

• Application mainly for glass structures with planar quadrilateral facets

Hadi Simaan & Partner:Aspire Tower Doha, QatarEngineer: Arup

Grid Shell Structures on Freeform Surfaces

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Typology of Freeform Surfaces

Ruled Surface

Vladimir Shuchov: Lipezk Tower 1896, RU

Restaurant auf der Zugspitze, DE

Erick van Egeraat: Alphen City Hall, NL Execution: Oktatube International BV

• Practically important ruled surfaces: > Hyperbolic Paraboloid / Hypar surfaces > Hyperboloid surfaces

• Hyperbolic Paraboloid surfaces are produced by translating a generating line (generatrix) along two skewed guide lines and parallel to a directing plane

• Hyperboloid surfaces are produced by rotating a generating line skewed to the axis of rotation (each hyperboloid can be generated with two different generating lines)

Coop Himmelb(l)au: BMW World München, DEExecution: Josef Gartner GmbH

Grid Shell Structures on Freeform Surfaces

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Typology of Freeform Surfaces

NURBS Surface

• NURBS surfaces (Non-Uniform-Rational-B-Spline) are analytically defined, double-curved surface areas controlled through the vertices of control polyhedrons

• By manipulating the control polyhedrons, the surface curvature at any location can be diversely influenced (rubber band effect)

• By combining multiple NURBS surface areas (patches) while maintaining the surface continuity along all area interfaces, it is possible to model any arbitrary technically or naturally occurring surface!

Studio Fuksas : New Fair Milan, IT Execution: Mero GmbH & Co.KG

Grid Shell Structures on Freeform Surfaces

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Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Content

1. Contemporary Architectural Styles

2. Typology of Freeform Surfaces

3. Grid Geometry

4. Grid Shell Node Types

5. Novum FF-System

6. Process Case Study – Salvador Dali Museum

7. Other Freeform Projects

Novum Structures | www.novumstructures.com

• Projection of a regular grid patternfrom a datum plane on to the freeform surface

• Typically requires manual grid correctionof surface areas with increased curvatureor inclination to the datum plane

Grid Geometry

Grid Generation Methods

Grid Generation

Projection Method Parcellation Method

Grid Shell Structures on Freeform Surfaces

• Boundary lines get subdivided into portions of similar length, thus creating “orthogonal” auxiliary grid on surface

• Final grid is tied into this auxiliary grid

Novum Structures | www.novumstructures.com

Grid Geometry

Grid Generation Methods

Grid Generation

Projection Method Parcellation Method

Grid Shell Structures on Freeform Surfaces

Grid created with planar projection Grid created with surface partitioning

Grid along boundaries is unproblematic Resulting grid can appear slighly more irregular,

although this strongly depends on the perspective of the viewer

Resulting grid is usually evenly spaced and balanced Planar grid projection is not considering boundary

lines, thus frequently creating problematic grid zonesalong boundaries

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Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Grid Geometry

Elements of Grid Shell Structures

Node Node

Node

Node

Connectivity of Elements of Grid Shell Structures

Grid Shell Structures on Freeform Surfaces

Novum Structures | www.novumstructures.com

Node Vector

Panel Vector

Member Vector

Grid Geometry

Element Orientation

Node Vector

Panel Vector

Member Vector

Element orientation vectors are generated as follows:

1. Determination of all grid panels (panel finding)

2. Determination of normal vectors for all panels (panel vector)

3. Node vectors are determined by averaging the panel vectors of all panels adjacent to a node

4. Member vectors are determined by either: a) averaging the panel vectors of the 2 panels adjacent

to a memberb) averaging the node vectors of the 2 nodes adjacent

to a member, both projected into the member cross section plane (thus minimizing twist at both nodes)

Grid Shell Structures on Freeform Surfaces

Novum Structures | www.novumstructures.com

Grid Geometry

Element Connectivity Angles

Element Connectivity Angles

Node Angles Member Angles

Vertical Angle V Horizontal Angle U Twist Angle W

Panel Folding Angle F

F

Grid Shell Structures on Freeform Surfaces

V is the azimuth angle between the node vector and a member axis in the polar coordinate sytem of a node

U is the polar angle between adjacent member axes in the polar coordinate sytem of a node

W is the angle between a member vector and a node vector projected into the member cross section plane

F is the angle between the 2 panel vectors projected into the member cross section plane

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Novum Structures | www.novumstructures.com

Grid Geometry

Element Connectivity Angles – Vertical Angle

V

• Vertical angles primarily depend on local curvature parameter 1/R of the surface at this node:

1 – smaller curvature > vertical angle is close to 90° > smaller V1 (difference to 90°)2 – larger curvature > vertical angle significantly deviates from 90° > larger V2 (difference to 90°)

Color plot of the vertical angles for a grid

Grid Shell Structures on Freeform Surfaces

Vertical angle at a real node

Novum Structures | www.novumstructures.com

U

• Horizontal angles primarily depend on the grid topology:

1 – quadrilateral grid > four way node > larger horizontal angle U12 – triangular grid > six way node > smaller horizontal angle U2

Geometry of Truss Elements

Element Connectivity Angles – Horizontal Angle

Grid Shell Structures on Freeform Surfaces

Horizontal angle at a real node

Color plot of the horizontal angles for a grid

Novum Structures | www.novumstructures.com

W

• Twist angles primarily depend on local curvature parameter 1/R of the surface at this node and on the orientation of the member to the principal curvature directions:

1 – Larger deviation from principal curvature direction G1 > larger twist angle W12 – Smaller deviation from principal curvature direction G2 > smaller twist angle W2

• Twist angle is zero if member axis is parallel to principal curvature direction!

Grid Shell Structures on Freeform Surfaces

Geometry of Truss Elements

Element Connectivity Angles – Twist Angle

Twist angle at a real node

Color plot of the twist angles for a grid

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Novum Structures | www.novumstructures.com

Grid Geometry

Element Connectivity Angles – Panel Folding Angle

• Panel folding angles primarily depend on local curvature parameter 1/R of the surface at this node:

F (>0) F (<0)

Grid Shell Structures on Freeform Surfaces

Color plot of the panel folding angles for a grid

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Content

1. Contemporary Architectural Styles

2. Typology of Freeform Surfaces

3. Grid Geometry

4. Grid Shell Node Types

5. Novum FF-System

6. Process Case Study – Salvador Dali Museum

7. Other Freeform Projects

Novum Structures | www.novumstructures.com

Grid Shell Node Types

Grid Shell Node Design Requirements

Grid Shell Structures on Freeform Surfaces

• The local structural behaviour of arbitrary, single layer freeform structures is widely varying:- flat areas require significant bending capacity of members and node connections - shell-like areas require high axial load capacity of members and node connections

• The local element connectivity angles of arbitrary freeform structures are widely varying as well:- node design must allow for geometric adaptability to varying vertical, horizontal, twist angles

• This combination of structural and geometrical requirements make the grid shell node the key grid shell element for structural integrity, visual appearance, accuracy and cost of a freeform structure

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Novum Structures | www.novumstructures.com

Grid Shell Node Types

Splice Plate Nodes Grid Shell Nodes

Single Layer Grid Shell Double Layer Grid Shell

Splice Plate Nodes End Face Nodes

Cross Plate Node

CP

Cross Chord Plate Node

CCP

Star Lug Node

SL

Disc Plate Node

DP

Cylinder Lug Node

CL

Spatial Nodes

Grid Shell Structures on Freeform Surfaces

Novum Structures | www.novumstructures.com

Grid Shell Node Types

Cross Plate Node CPGeometric Adaptability: Connectivity Angles Loading Capacity

Horizontal U Vertical V Twist W Axial Force Flexure

CP + + O + O

•Suited for optimised grid shell structures with predominantly axial member forces

Gerkan Marg & Partner: Museum für Hamburgische Geschichte, Hamburg, DEEngineer: Schlaich Bergermann & Partner

Grid Shell Structures on Freeform Surfaces

Novum Structures | www.novumstructures.com

Grid Shell Node Types

Alternative Cross Plate Node CP altGeometric Adaptability: Connectivity Angles Loading Capacity

Horizontal U Vertical V Twist W Axial Force Flexure

CP alt + + O ++ +

•Suited for optimised grid shell structures with predominantly axial member forces

Gerkan Marg & Partner: Bahnhof Spandau, Berlin, DEEngineer: Schlaich Bergermann & Partner, Project Execution: Mero GmbH & Co.KG

Grid Shell Structures on Freeform Surfaces

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Novum Structures | www.novumstructures.com

Grid Shell Node Types

Cross Chord Plate CCPGeometric Adaptability: Connectivity Angles Loading Capacity

Horizontal U Vertical V Twist W Axial Force Flexure

CCP + ++ O ++ ++

•Suited for special twist-free grid shell structures on arbitrary freeform surfaces

Gerkan Marg & Partner: Hauptbahnhof Berlin, DEEngineer: Schlaich Bergermann & Partner, Project Execution: Mero GmbH & Co.KG

Grid Shell Structures on Freeform Surfaces

Novum Structures | www.novumstructures.com

Stabwerke auf Freiformflächen

Grid Shell Node Types

Star Lug Node SLGeometric Adaptability: Connectivity Angles Loading Capacity

Horizontal U Vertical V Twist W Axial Force Flexure

SL ++ ++ ++ ++ ++

•Suited for all grid shell structures on arbitrary freeform surfaces, but very expensive

Frank O. Gehry & Associates: DZ-Bank, Berlin, DEEngineer: Schlaich Bergermann & Partner, Project Execution: Josef Gartner GmbH

Novum Structures | www.novumstructures.com

Grid Shell Node Types

Disc Plate Node DPGeometric Adaptability: Connectivity Angles Loading Capacity

Horizontal U Vertical V Twist W Axial Force Flexure

DP ++ + + ++ ++

•Suited for optimised grid shell structures with predominantly axial member forces

J. Gribl: Flusspferdehaus Zoologischer Garten, Berlin, DEEngineer: Schlaich Bergermann & Partner, Project Execution: Helmut Fischer GmbH

Grid Shell Structures on Freeform Surfaces

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Novum Structures | www.novumstructures.com

Grid Shell Node Types

Cylinder Lug Node CLGeometric Adaptability: Connectivity Angles Loading Capacity

Horizontal U Vertical V Twist W Axial Force Flexure

CL ++ ++ ++ ++ ++

•Suited for all grid shell structures on arbitrary freeform surfaces

Shigeru Ban:Theater Dome Leideschenrijn, NLProject Execution: Octatube International BV

Grid Shell Structures on Freeform Surfaces

Novum Structures | www.novumstructures.com

Grid Shell Node Types

End Face Nodes Grid Shell Nodes

Single Layer Grid Shell Double Layer Grid Shell

Splice Plate Nodes End Face Nodes

Block Node

B

Double Block Node

DB

DishNode

D

Star BlockNode

SB

Cross Chord Node

CC

Star Block PoleNode

SP

Double DishNode

DD

Star ChordNode

SC

Spatial Nodes

Grid Shell Structures on Freeform Surfaces

Novum Structures | www.novumstructures.com

Grid Shell Node Types

Block Node BGeometric Adaptability: Connectivity Angles Loading Capacity

Horizontal U Vertical V Twist W Axial Force Flexure

B +++ +++ +++ ++ ++

• Very well suited for all grid shell structures on arbitrary freeform surfaces

HOK Chicago: Wrigley Global R&D Center, Chicago, USProject Execution: Novum Structures LLC

Grid Shell Structures on Freeform Surfaces

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Novum Structures | www.novumstructures.com

Grid Shell Node Types

Double Block Node DBGeometric Adaptability: Connectivity Angles Loading Capacity

Horizontal U Vertical V Twist W Axial Force Flexure

DB +++ +++ +++ ++ ++

• Very well suited for all grid shell structures on arbitrary freeform surfaces

HOK Architects: Salvador Dali Museum, St. Petersburg, FL, USAProject Execution: Novum Structures LLC

Grid Shell Structures on Freeform Surfaces

Novum Structures | www.novumstructures.com

Klassifizierung der Stabwerksknoten

Dish Node DGeometric Adaptability: Connectivity Angles Loading Capacity

Horizontal U Vertical V Twist W Axial Force Flexure

D ++ ++ ++ ++ +

• Well suited for optimised grid shell structures with predominantly axial member forces

RTKL Spain: Principe Pio Train Station, Madrid, ESEngineer: Schlaich Bergermann & Partner, Project Execution: Mero GmbH & Co.KG

Grid Shell Structures on Freeform Surfaces

Novum Structures | www.novumstructures.com

Grid Shell Node Types

Double Dish Node DDGeometric Adaptability: Connectivity Angles Loading Capacity

Horizontal U Vertical V Twist W Axial Force Flexure

DD ++ +++ + ++ ++

• Well suited for all grid shell structures on arbitrary freeform surfaces

Massimiliano Fuksas : Nuovo Fiera Milano, IT Project Execution: Mero GmbH & Co.KG

Grid Shell Structures on Freeform Surfaces

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Novum Structures | www.novumstructures.com

Grid Shell Node Types

Star Block Node SBGeometric Adaptability: Connectivity Angles Loading Capacity

Horizontal U Vertical V Twist W Axial Force Flexure

SB +++ +++ + +++ +++

• Well suited for all grid shell structures on arbitrary freeform surfaces

Foster & Partner: British Museum, Courtyard, London, UK Project Execution: Waagner-Biro Stahlbau AG

Grid Shell Structures on Freeform Surfaces

Novum Structures | www.novumstructures.com

Grid Shell Node Types

Star Block Pole Node SP

Epstein Chicago: Zlote Tarazy Shopping Mall, Warschau, PLProject Execution: Waagner-Biro Stahlbau AG

Geometric Adaptability: Connectivity Angles Loading Capacity

Horizontal U Vertical V Twist W Axial Force Flexure

SP +++ +++ ++ +++ +++

• Very well suited for all grid shell structures on arbitrary freeform surfaces

Grid Shell Structures on Freeform Surfaces

Novum Structures | www.novumstructures.com

Grid Shell Node Types

Cross Chor Node CCGeometric Adaptability: Connectivity Angles Loading Capacity

Horizontal U Vertical V Twist W Axial Force Flexure

CC + + O +++ +++

• Suited for special twist-free grid shell structures on arbitrary freeform surfaces

I. M. Pei: Deutsches Historisches Museum, Schlüterhof, Berlin, DEEngineer: Schlaich Bergermann & Partner, Project Execution: Mero GmbH & Co.KG

Grid Shell Structures on Freeform Surfaces

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Novum Structures | www.novumstructures.com

Grid Shell Node Types

Star Chord Node SCGeometric Adaptability: Connectivity Angles Loading Capacity

Horizontal U Vertical V Twist W Axial Force Flexure

SC ++ +++ ++ ++ ++

•Well suited for all grid shell structures on arbitrary freeform surfaces, but expensive

Michael Gabellini: Westfield White City Shopping Mall, London, UKProject Execution: Seele GmbH

Grid Shell Structures on Freeform Surfaces

Novum Structures | www.novumstructures.com

Grid Shell Node Types

Spatial Nodes Grid Shell Nodes

Single Layer Grid Shell Double Layer Grid Shell

Splice Plate Nodes End Face Nodes

Spherical Node

S

Half Sphere Block Node

HS

Goblet Node

G

Spatial Nodes

Grid Shell Structures on Freeform Surfaces

Novum Structures | www.novumstructures.com

Grid Shell Node Types

Spherical Node S

BDP Building Design Partnership: Glasgow Science Center, 3D Cinema, Glasgow, UKProject Execution: Mero GmbH & Co.KG

Grid Shell Structures on Freeform Surfaces

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Novum Structures | www.novumstructures.com

Grid Shell Node Types

Half Sphere Node HS

Friedmutter Group: Harrah’s Casino Atlantic City, USProject Execution: Novum Structures LLC

Grid Shell Structures on Freeform Surfaces

Novum Structures | www.novumstructures.com

Grid Shell Node Types

Goblet Node G

DP Architects: Esplanade Theaters on the Bay, SingaporeProject Execution: Mero GmbH & Co.KG

Grid Shell Structures on Freeform Surfaces

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Content

1. Contemporary Architectural Styles

2. Typology of Freeform Surfaces

3. Grid Geometry

4. Grid Shell Node Types

5. Novum FF-System

6. Process Case Study – Salvador Dali Museum

7. Other Freeform Projects

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Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Novum FF-System

System Description

• The Novum FF-system is a proprietary end face node connection consisting of: - 2 forged steel discs of S355 or C45 material, with individually machined faces as required by the grid geometry- each machined face has a threaded hole for a grade 10.9 bolt M24 or M27- precision cast steel adapters of steel GS-20Mn5V, with top & bottom faces

which can have an offset to each other, with corresponding bolt holes,welded to ends of straight cut RHS members, typically ASTM A500 grade C 6”x3”, 8”x3” or 10”x3” or EN 10219 grade S355 150x80, 200x80 or 250x80

- concealed & pretensioned socket head bolts M24 or M27, fixing the adapters to the 2 node discs

• The structural behaviour of these bolted node connections is semi-rigid andhas to be adequately considered in the structural model - typically as a rotational spring stiffness at the end of each grid shell member

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

In order to establish the bending stiffness and verify the connection capacity of various combinations of FF-system components, series of methodical 4-point bending tests have been realized

0 10 20 30 40 50 60 700

20

40

60

80

100

120

140

Displacement( mm)

Load(

kN)

Displacement1

Displacement2

Displacement3

Test

#

Failure

Mode

Ram Load,

at Failure

Bending Moment,

at Failure

1 Bolt 127 kN 76.8 kNm

2 Bolt 128 kN 77.4 kNm

3 Bolt 129 kN 78.0 kNm

(M24 bolts)

Novum FF-System

Bending Capacity & Stiffness Tests of Node Connection

RHS 250x80 S355 with adapter FFA1036-0-26 and M24-10.9 bolts

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

• In order to verify those 4-point bending tests of FF-system components, series of finite element analysis of the test specimen have been performed

• Semi-rigid connection behaviour is a combined effect of the bolted connection stiffness and reduced bending stiffness in the mounting hole zone

• The observed mid span deflections of the FE models were only 80% of the average measured values, apparently due to small initial settlements of the real test specimen under loads

• This ratio is being used to calibrate FE models of FF-system node connections in any structural analysis

Novum FF-System

Finite Element Analysis of Node Connection

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Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

• The varying bending moment capacity of the bolted node connection in dependency of the axial connection force is typically determined using an iterative numerical calculation method assuming planarity of member end section[Space Structures 5, Telford Publ. 2002, p. 759-773]

• Calculation results shown below performed for 3 limit states – elastic, plastic and failure limit – of RHS 250x80 S355 with adapter FFA1036-0-26 and M24-10.9 bolts

• Results from methodical 4-point bending tests are conservatively close to the failure limit bending moment

Initial parameters: orig

it

orig

it

orig

itMzmz,Mymy,Nn,0it

Strain parameters:AE

no,

JyE

my,

JzE

mzit

itit

ity

itit

z

itit1ititit1ititit1itMzmzmz,Mymymy,Nnn

> Compression stress in the connection profile / Element force & moments

> Tensile stress in the bolts / Bolt force & moments

> Internal connection force & moments : N<it>, My<it>, Mz<it>

> Deviations from given force & moments: N<it>, My<it>, Mz<it>

All deviations 0 ?it = it + 1Stress distribution

determined !

N

O

YE

S

(M24 bolts)

Novum FF-System

Calculation of Node Connection Capacity

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Novum FF-System

Structure Design – Global Buckling Analysis• In addition to local member buckling and capacity checks,

a global buckling analysis is conducted to ensure structural integrity of the grid shell frame.

• To account for imperfections due to fabrication and installation tolerances, an “imperfect geometry” model is generated and analyzed according to all appropriate load cases and combinations.

• The imperfect geometry is generated by deforming the structure to the node locations of critical buckling modes.

• The magnitude of the maximum nodal shift is scaled to an imperfection tolerance, which is generally derived from DIN 18800-2.

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Novum FF-System

Structure Design – Global Buckling Example

Halstenbek Sports Hall, “Knikei”

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Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

• Freeform grid shell structures in general (except for small projects) cannot be modelled, drawn and fabricated using conventional methods due to time, cost, manpower, reliability, accuracy and quality constraints

• Instead, the design process must be automated by using interconnected parametric component models for all nodes, members & glazing units. Novum is using proprietary software (GSD) for this purpose, which is linking standard Finite Element Analysis software with AutoCAD, Excel and CAM software for CNC machining. The initial parameters for these models have to be established after the grid geometry has been generated and the structural analysis has been done.

• Then, as a substitute of conventional drawing sets, only relevant data and very few parametric drawings are needed to design and fabricate all grid shell components. This process will be illustrated more detailled in a process case study later on.

Novum FF-System

Design and Fabrication Data

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Typical fabrication procedure:

• CAD model data transfer into CNC software & check

• CNC machining and marking• Quality control• Electroplating & painting• Crating and shipment

Novum FF-System

Node Fabrication

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

• Parametric drawing datatransfer & check

• Length and hole cutting • Adapter welding• Painting • Crating and shipment

Novum FF-System

Member Fabrication

Typical fabrication procedure:

• CAD model data transfer into parametric drawings & check

• Automated profile length and mounting hole cutting

• Quality control• Hot dip galvanizing & painting• Wrapping, crating and shipment

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Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Novum FF-System

Installation

Typical installation procedure:

• Calibration of proprietary bolt pretensioning devices using Skidmore-Wilhelm units

• Preassembly of “node fans”, single nodes with several members attached, on multiple ground stations

• Lifting & mounting of “node fans” as extensions of already installed grid shell structure

• Final bolt pretensioning • Glazing installation & caulking

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Novum FF-System

Installation

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Content

1. Contemporary Architectural Styles

2. Typology of Freeform Surfaces

3. Grid Geometry

4. Grid Shell Node Types

5. Novum FF-System

6. Process Case Study – Salvador Dali Museum

7. Other Freeform Projects

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Novum Structures | www.novumstructures.com

Process Case Study – Salvador Dali Museum

Architectural Concept

Grid Shell Structures on Freeform Surfaces

Salvador Dali Museum St. Petersburg, FL, USA:Architectural design by Yann Weymouth from Hellmuth Obata & Kassabaum, Inc. (HOK)

Artwork protection concept against hurricane floods w/o evacuation

“Igloo”

“Enigma”

Novum Structures | www.novumstructures.com

Surface parcellationgenerates a dimensionally controlled reference pattern on the surface for various grids while maintaining control of surface edges (thus avoiding sliver facets)

Manual definition of intersecting planes for surface parcellation Initial NURBS freeform surface

(Enigma)

Generated grid on freeform surface

Grid Shell Structures on Freeform Surfaces

Process Case Study – Salvador Dali Museum

Grid Generation

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Process Case Study – Salvador Dali Museum

Grid Visualization

Final grid of Enigma and Igloo

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Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Process Case Study – Salvador Dali Museum

Structural Design & Glazing System Impact Testing

• Design component & cladding wind pressure per wind tunnel test results: ±100 psf (± 4.79 kN/m2)

• Florida Building Code requires rigorous testing of glazing systems:- water penetration tests as per ASTM E 331 & AAMA 501.1- structural tests as per ASTM E 330 for 200% design wind load- small / large missile impact tests & subsequent pressure cycling

as per ASTM E 1886 and E 1996 (above / below 30 ft or 9.1 m)

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Process Case Study – Salvador Dali Museum

Building Interface Coordination

Geometric & structural coordination of support nodes including tolerance prediction

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Process Case Study – Salvador Dali Museum

Parametric Component Modelling – System Line Wireframe

The final structural model contains all information about member profile & bolt dimensions. Information about node types & dimensions needs to be added. Novum’s grid shell design software GSD is importing this information & connecting it with the grid shell system database.

Structural model of the Igloo in RStab System line wireframe model of the Igloo in AutoCAD generated by GSD

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Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Process Case Study – Salvador Dali Museum

Parametric Component Modelling with GSD – Element Orientation Vectors

GSD is now performing an automated panel search for all selected members of the generated wireframe in Autocad. Then GSD is establishing the element orientation vectors for panels, nodes and members as presented earlier.

Panels on the system line wireframe model in AutoCAD generated by GSD Close-up of panels with panel , node and member vectors

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Novum FF-System

Parametric Component Modelling with GSD – Glazing Joint Wireframe

With all element orientation vectors determined, GSD is generating a glazing joint wireframe model on a predefined stand-off distance to the system line wireframe. The intersection points of glazing joints are always located on the node vectors.

Glazing joint wireframe model in AutoCAD generated by GSD Close-up of glazing joint wireframe model (yellow color)

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Process Case Study – Salvador Dali Museum

Parametric Component Modelling with GSD – 3D CAD Model of Nodes & Members

Using all initially established component parameters on basis of the grid shell system database, GSD is then generating a full 3D CAD model ofall grid shell nodes and members. Simultaneously the corresponding node and member fabrication data is being determined.

3D CAD model of nodes and members in AutoCAD generated by GSD Close-up of 3D CAD model of nodes and members

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Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Process Case Study – Salvador Dali Museum

Parametric Component Modelling with GSD – 3D CAD Model of Glazing Units

With the earlier established glazing joint wireframe, GSD is now generating a full 3D CAD model of all glazing units. Simultaneously the corresponding glazing fabrication data is being determined.

3D CAD model of glazing units in AutoCAD generated by GSD Close-up of 3D CAD model of glazing units

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Process Case Study – Salvador Dali Museum

Parametric Component Modelling with GSD – 3D Assembly Plan

In order to enable the correct installation of the grid shell structure, GSD is finally establishing a 3D assembly plan with orientation marks for all grid shell nodes, members and glazing units.

3D assembly plan in AutoCAD generated by GSD Close-up of 3D assembly plan with element orientation marks

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Process Case Study – Salvador Dali Museum

Fabrication Data Output – Nodes and Glazing Units

Fabrication data for nodes and glazing units is being generated in comprehensive Excel spreadsheets.

Node fabrication list generated by GSD Glazing unit frabrication list generated by GSD

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Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Process Case Study – Salvador Dali Museum

Fabrication Data Output – Members

Fabrication data for members is being generated in comprehensive Excel spreadsheets.

Member fabrication list generated by GSD

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Process Case Study – Salvador Dali Museum

Detail Coordination & Approval Drawings

The comprehensive 3D CAD model generated by GSD is naturally the basis for all detail coordination & approval drawings as well as for all manually made fabrication drawings of components having an interface to the building or to other functional elementslike doors, smoke vents, signage etc.

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Process Case Study – Salvador Dali Museum

Installation

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Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Process Case Study – Salvador Dali Museum

Completed Project

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Process Case Study – Salvador Dali Museum

Completed Project

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Process Case Study – Salvador Dali Museum

Completed Project

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Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Process Case Study – Salvador Dali Museum

Completed Project

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Content

1. Contemporary Architectural Styles

2. Typology of Freeform Surfaces

3. Grid Geometry

4. Grid Shell Node Types

5. Novum FF-System

6. Process Case Study – Salvador Dali Museum

7. Other Freeform Projects

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Other Freeform Projects

Ottawa Convention Center

OCC Ottawa Convention Center, Ontario, Canada

Architect: Brisbin Brook Beynon Architects (BBB)

Grid generation & visualization

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Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Other Freeform Projects

Ottawa Congress Center

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Other Freeform Projects

Ottawa Congress Center

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Other Freeform Projects

Ottawa Congress Center

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Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Other Freeform Projects

UAE Pavilion at the Shanghai EXPO 2010Pavilion shape is resembling sand dunes, natural formations typical for UAE deserts like Rub Al Khali

Pavilion has almost circular footprint with a diameter of about 65 m, height of the southern dune - 20 m, height of northern dunes - 18 m

Pavilion was disassembled after the EXPO 2010 and moved to Saadiyat Island, Abu Dhabi, UAE

Picture: Foster + Partner

UAE EXPO Pavilion, Shanghai, China

Architect:Foster + Partner Grid generation

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Other Freeform Projects

UAE Pavilion at the Shanghai EXPO 2010

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Other Freeform Projects

UAE Pavilion at the Shanghai EXPO 2010

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Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Other Freeform Projects

Lord & Taylor Yonkers

Lord & Taylor Yonkers, NY, USA

Architect: Giorgio Borusso Design

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Other Freeform Projects

Lord & Taylor Yonkers

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Other Freeform Projects

Lord & Taylor Yonkers

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Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Other Freeform Projects

Yueda 889 Square Shanghai

Yueda 889 Square, Shanghai, China

Architect: Callison Architecture

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Other Freeform Projects

Yueda 889 Square Shanghai

Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Other Freeform Projects

Yueda 889 Square Shanghai

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Novum Structures | www.novumstructures.com

Grid Shell Structures on Freeform Surfaces

Other Freeform Projects

Yueda 889 Square Shanghai

Novum Structures | www.novumstructures.com

Thank you! [email protected]

Novum Structures | USA, China, Germany, India, Singapore, Turkey, UAE, United Kingdom