ARCHITEC TUR ALLY E XP OSE D S TRUC TUR AL S TE E L SPECIFICATIONS / CONNECTIONS / DETAILS AESS-18.indd 1 24/11/14 12:09 AESS-18.indd 2 24/11/14 12:09 TERRI MEYER BOAKE ARCHITEC TUR ALLY E XP OSE D S TRUC TUR AL S TE E L SPECIFICATIONS / CONNECTIONS / DETAILS BIRKHÄUSER / BASEL AESS-18.indd 3 24/11/14 12:09 The preparation of this book was kindly supported by the World Steel Association. GRAPHIC DESIGN, LAYOUT AND TYPOGRAPHY Reinhard Steger, Christian Schärmer, Deborah van Mourik Proxi, Barcelona EDITOR FOR THE PUBLISHER Andreas Müller, Berlin LIBRARY OF CONGRESS CATALOGING-IN-PUBLICATION DATA A CIP catalog record for this book has been applied for at the Library of Congress. BIBLIOGRAPHIC INFORMATION PUBLISHED BY THE DEUTSCHE NATIONALBIBLIOTHEK The Deutsche Nationalbibliothek lists this publication in the Deutsche Nationalbibliografie; detailed bibliographic data are available in the Internet at http://dnb.dnb.de. This work is subject to copyright. 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AESS-18.indd 4 24/11/14 12:09 CONTENTS 9 FOREWORD by Dr. Edwin Basson, 35 AESS 4 – Showcase Elements Director General, 37 AESS C – Custom Elements World Steel Association 40 Mixed Categories 11 PREFACE 43 CHAPTER 3 13 CHAPTER 1 CHARACTERISTICS THE BASIS OF ARCHITECTURALLY 43 AESS 1 – Basic Elements 46 AESS 2 – Feature Elements with EXPOSED a View Distance > 6m/20ft STRUCTURAL STEEL 50 AESS 3 – Feature Elements with a View Distance ≤ 6m/20ft 54 AESS 4 – Showcase Elements 13 What is AESS? 59 AESS C – Custom Elements 16 The Evolution of Architecturally 59 Using the System Exposed Structural Steel 60 AESS CATEGORY MATRIX 17 From Structural Rationalism to High Tech 18 Initial Developments in High 63 CHAPTER 4 Tech Detailing ERECTION 20 Primary Factors of Influence that Define AESS CONSIDERATIONS 22 Communication Issues between Architect, Engineer and Fabricator 63 Transforming an Architectural 23 The Role of BIM and Detailing Idea into Prefabricated AESS Software Elements 64 Shop versus Site Fabrication 65 The Impact of Transport Issues 25 CHAPTER 2 on Design THE CATEGORY 66 Site Constraints 67 Care in Handling SYSTEM 69 Sequencing, Lifting, Access and Safety 26 To Grind or Not to Grind? 71 Erecting the Steel 27 Standard Structural Steel 73 Combining AESS with Other 27 AESS 1 – Basic Elements Systems 30 AESS 2 – Feature Elements with a View Distance > 6m/20ft 32 AESS 3 – Feature Elements with a View Distance ≤ 6m/20ft AESS-18.indd 5 24/11/14 12:09 75 CHAPTER 5 117 CHAPTER 7 COATINGS & CONNECTIONS PROTECTION 117 Definitions 118 Connection Design Checklist 76 Surface Preparation 120 Shop versus Site Fabrication 78 Paint Systems 121 Connection Mock-ups and 78 Primers Visual Samples 79 Shop versus Site-applied 122 Bolted Connections Coatings 124 Welded Connections 79 Corrosion Protection: 130 Pin Connections Galvanization, Metallization, Stainless Steel, Weathering Steel 89 Fire Protection Systems: 139 CHAPTER 8 Intumescent Coatings, Sprayed SPECIALIZED Fire-resistive Materials (SFRM), Concrete-filled Steel Tubes CONNECTIONS 139 Making Connections Less Visible 97 CHAPTER 6 140 Hidden Connections MEMBER CHOICES 142 Discreet Connections 147 Cast Connections 97 The Texture of an AESS Project 98 Choosing a Member Type 98 Hot-rolled Steel Sections 157 CHAPTER 9 102 Tubular or Hollow Structural CUSTOM Sections (HSS): Round Hollow FABRICATION Structural Sections, Square or Rectangular Hollow Structural Sections 158 Building Profiles 108 Elliptical Hollow Sections (EHS) 110 Custom-fabricated Sections 113 Tapered Tubes or Cones APPENDIX 178 Selected Bibliographic References 179 Notes 179 Illustration Credits 180 Subject Index 182 Index of Buildings 183 Index of Persons and Firms 184 About the Author AESS-18.indd 6 24/11/14 12:09 BUILDING PROFILES 41 PORTO INTERNATIONAL AIRPORT 155 BALTIC CENTRE FOR CONTEMPORARY 167 ARGANZUELA BRIDGE Porto, Portugal ART Gateshead, England Madrid, Spain ICQ with WS Atkins Ellis Williams Architects Dominique Perrault Architecture with MC2 Estudio 83 WESTGATE PEDESTRIAN AND CYCLE 158 SYDNEY OPERA HOUSE de Ingeniería, S.L. BRIDGE Auckland, New Zealand Sydney, Australia Jasmax architects, Aurecon Jørn Utzon and Ove Arup 168 ORIENTE STATION Consulting Engineers and HEB Lisbon, Portugal Construction 159 AMGEN HELIX BRIDGE Santiago Calatrava Seattle, WA, USA 86 STRATFORD TOWN CENTRE LINK Johnson Architecture and KPFF 169 PEACE BRIDGE London, England Consulting Engineers Calgary, AB, Canada Knight Architects with Buro Happold Santiago Calatrava 160 CANOE BRIDGE 87 THE GLASS BRIDGE Vancouver, BC, Canada 170 GATESHEAD MILLENNIUM BRIDGE Perth, Australia PWL Partnership Landscape Newcastle, England Donaldson + Warn; Capital House Architects Wilkinson Eyre Architects Engineers; artists David Jones, with Gifford Kevin Draper and Richard Walley; 161 VIADUCT EVENTS CENTER John Holland Constructions Auckland, New Zealand 171 PEDRO AND INÊS BRIDGE Moller Architects Coimbra, Portugal 115 ONTARIO COLLEGE OF ART AND DESIGN Cecil Balmond Toronto, ON, Canada 162 THE SHARD OBSERVATION LEVEL Will Alsop Architect London, England 172 ABC MUSEUM Renzo Piano Building Workshop Madrid, Spain 134 BARAJAS AIRPORT TERMINAL 4 and WSP Aranguren + Gallegos Madrid, Spain Arquitectos Rogers Stirk Harbour + Partners 163 THE NEW YORK TIMES BUILDING New York City, NY, USA 173 ST. JOHN AMBULANCE 137 NEO BANKSIDE HOUSING Renzo Piano Building Workshop, HEADQUARTERS London, England FXFOWLE Architects and Edmonton, AB, Canada Rogers Stirk Harbour + Partners Thornton Thomasetti Manasc Isaac Architects 152 BRISBANE INTERNATIONAL 164 NATIONAL ARCHIVES OF CANADA 174 BOSTON SOCIETY OF ARCHITECTS AIRPORT Brisbane, Australia Gatineau, QC, Canada STAIR Boston, MA, USA Richards and Spence with Arkhefield Blouin IKOY & Associés Höweler + Yoon Architecture 153 RENOVATION OF OLYMPIASTADION 165 CANNON STREET STATION AND 175 CAIXA FORUM BERLIN Berlin, Germany OFFICE BUILDING Madrid, Spain Architekten von Gerkan, London, England Herzog & de Meuron Marg und Partner Foggo Associates 154 REGENT PALACE HOTEL 166 PUENTE DE LUZ London, England Toronto, ON, Canada Dixon Jones Architects Francisco Gazitua AESS-18.indd 7 24/11/14 12:09 8 AESS-18.indd 8 24/11/14 12:09 FOREWORD The World Steel Association (worldsteel) is proud to be the exclusive sponsor of Archi- tecturally Exposed Structural Steel: Specifications, Connections, Details. Construction is one of the most important steel-using industries, globally accounting for more than 50% of world steel use. Buildings – from houses to car parks to schools to skyscrapers – rely on steel for their strength and durability. In addition to structural frameworks, steel is also used on many other parts of buildings, including roofs and cladding for exterior walls. Steel continues to be at the root of advances in architecture and construction. The use of exposed steel in buildings brings the design benefits and dynamic potential of steel to the public eye. Its stiffness allows steel to span greater distances and provides more design freedom than other materials. Steel’s superior strength-to-weight ratio makes it possible for the structure to bear high loads using less material. Architecturally Exposed Structural Steel (AESS) plays a significant role also in the design of contemporary pedestrian bridges that elevates their role in the urban realm to that of art. Sustainable steel is at the core of a green economy. Reusing or recycling building com- ponents is key to the sustainability of a structure’s end-of-life as it is the most economic and ecological solution. The global recovery rates for steel construction applications stand at 85%, making it a good choice for building structures. The exposure of steel leads to a reduction of materials that would otherwise be used to conceal the structural systems, while at the same time creating stimulating architecture. Steel is safe, innovative and progressive. Industry surveys consistently demonstrate that steel is the safest construction material. Steel offers the highest strength-to-weight ratio of any building material. Because of its strength and durability, steel structures are designed to withstand natural disasters. It is also impervious to attacks from termites or fungi, does not rot or split and is highly fire-resistant. The steel industry globally spends more than €12 billion annually on improving the manufacturing processes, new product developments and future breakthrough technologies. Steel is a key driver of the world’s economy. The industry directly employs more than two million people worldwide, with a further two million contractors and four million people in supporting industries. In 2013, the steel industry had a turnover of more than $900 billion, yielding over $100 billion in tax. Steel plays a fundamental role in the development of modern societies and is an ideal material to help meet the societies’ growing needs for buildings and infrastructures in a sustainable way. Its intrinsic properties such as its strength, versatility, durability and 100% recyclability allow improved environmental performance across the entire life cycle of buildings. The AESS Category System of design presented in this book acknowledges the import- The Munich Airport Center ance of the role of proper connection design and erection strategies, and communication in Munich, Germany, designed between the fabricator, engineer and architect, as central to ensuring safety on the site. by Helmut Jahn and completed in 1999, showcases high-level detailing in Architecturally Dr. Edwin Basson Exposed Structural Steel. Director General, World Steel Association 9 AESS-18.indd 9 26/11/14 15:00