As architectural teams continue to push the limit of building design with ever more complex geometries, engineering and construction firms must develop clever solutions to execute these daring schemes on time and within budget.
During the course of several recent projects, engineers with Simpson Gumpertz & Heger (SGH) and fabricator CW Keller have created an integrated approach to model, design, and off-site fabricate formwork for complex concrete geometries. The process combines SGH’s expertise with concrete materials, construction, and analysis of intricate assemblies, with CW Keller’s advanced modeling and computer numerically controlled (CNC) fabrication capabilities, to create geometrically complex, prefabricated formwork systems.
“The combination of advanced CNC machining and emerging technologies in construction materials is pushing the bounds of what can be cost-effectively constructed in concrete,” says Matthew Johnson, Principal with SGH. Johnson says the two disciplines—structural engineering and formwork fabrication—work hand in hand since the fabrication model can serve as the basis of analysis models. As a result, “teams can assess many options early and rapidly,” he says.
On the team’s most recent project, the new Gulf Stream Tank at the Patricia and Phillip Frost Museum of Science in Miami (pictured above), the prefab process saved roughly nine weeks of the project schedule compared with conventional site-constructed formwork. The elevated tank structure is 125-foot-diameter, conical, cast-in-place concrete construction. It will hold more than 500,000 gallons of seawater, and will feature an acrylic oculus to offer museum visitors views into the tank from below.
Also on the Building Team: Grimshaw (architect), Baker Concrete Construction (concrete subcontractor), Peri (shoring contractor), and Skanska (GC).
Photo: CW Keller
Photo: CW Keller
Rendering: Grimshaw
Related Stories
Great Solutions | Aug 23, 2016
GBBN designers take on wellness research
In a new research paper, three healthcare specialists present factors that contribute to a psychological state that is receptive to healing.
Great Solutions | Aug 23, 2016
Visual energy model database demystifies net-zero design
Diamond Schmitt Architects’ ecoMetrics tool allows its designers to quickly analyze solutions based on models from 44 LEED-certified projects.
Great Solutions | Aug 23, 2016
Reusable infection control barriers ease hospital renovation
Clark Construction Group pilots the Edge Guard system on the Fair Oaks (Va.) Hospital reconstruction project.
Great Solutions | Aug 23, 2016
Novel construction approach speeds K-12 school projects
The Folia system uses pre-engineered components to deliver school buildings at 20% less cost.
Great Solutions | Aug 23, 2016
Mobile emergency room arrives just in time for Alabama hospital
The MED-1 Mobile Hospital Unit serves as a lower-cost solution during construction of new ED.
Great Solutions | Aug 23, 2016
Durable coffeemaker brings a bit of comfort to job sites
The CoffeeBoxx is lightweight rust proof, dust proof, water resistant, and ultra durable.
Great Solutions | Aug 23, 2016
Reclaimed wood paneling adds color to retail and hospitality projects
Colorburst panels are available in four stock options—Robin Egg Blue, Viridian Green, Haute Pink, and Cascade White—as well as custom colors.
Great Solutions | Aug 23, 2016
Biophilic pods beat the shade when it comes to outdoor cooling
The Xylem concept by CallisonRTKL regulates outdoor thermal comfort through shading, air movement, water circulation, and a vegetated roof.
Great Solutions | Aug 23, 2016
Mini-grant R&D program pays off in a big way for AE firm
Created through funding from Little’s LaceUp program, the Center for Building Performance has helped the design firm win 14 new jobs since its inception.
Great Solutions | Aug 23, 2016
At Beyer Blinder Belle everyone’s seeing RED
The firm’s R&D initiative inspires its designers to develop ideas that could positively disrupt the practice.