Posts tagged with "Cast Aluminum":

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City of Dreams winner will turn 300,000 aluminum cans into Governors Island Pavilion

After sifting through over 100 design proposals, the team of juries for the seventh annual City of Dreams Pavilion competition has selected Cast & Place by Team Aesop as the design for this year’s Governors Island Pavilion. The competition, sponsored by art non-profit FIGMENT, AIANY Emerging New York Architects (ENYA), and Structural Engineers Association of New York, asks designers to focus on the environmental and economic impacts of their designs and promote sustainable thinking. Cast & Place experiments with materiality and fabrication, testing to see if architecture could be constructed entirely from recycled materials. The team’s material pallet consists of 300,000 aluminum cans (the number of cans used in New York City in one hour, according to their Kickstarter), five tons of pure clay sourced from glacial deposits in Queens, and recycled wood. The pavilion will consist of two shade structures built from aluminum panels cast in cracked clay and will be surrounded by reflecting pools made from the clay formworks. The pools will be soaked by summer rain and then left to dry and crack in the heat, giving the audience a glimpse of the fabrication method for the panels. The process to create the panels is fairly simple: create molds from the reclaimed wood, fill them with clay, let the clay dry out and crack, and then fill the cracks with molten aluminum from melted-down cans. The canyons of clay become rivers of aluminum that connect to form one cohesive lightweight panel. The panels can then be joined and erected. When the pavilion is no longer in use, the panels can then be turned into benches furniture for the project’s supporters. So far the team has been able to cast small prototypes of the panels and has been working on methods of drying the clay to create enough cracks for a fully-formed panel. They have also been experimenting with their furnace to find the best method of melting down cans and casting the aluminum. As they continue to work toward a full-scale prototype, the project is waiting for approval from the city and for funding (via donations and sponsorships). According to their Kickstarter page, the project will require $30,000 to be feasible and the deadline for fundraising is March 27, 2017. If you are interested in learning more about the pavilion or wish to contribute to the pavilion’s construction, visit the project’s Kickstarter page here. Save Save Save Save
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Freelon Adjaye Bond / Smithgroup’s Crowning Achievement on the National Mall

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The Smithsonian National Museum of African American History and Culture (NMAAHC), scheduled to open to the public tomorrow, is capping off a nearly decade-long highly publicized planning and construction process. The 400,000-square-foot building is notable for securing the last developable site on the National Mall, and will be the nation’s primary home for exhibiting and celebrating African-American achievements in art, history, and culture. While 60 percent of the structure sits below grade, the remaining 40 percent rises 85 feet above grade and is wrapped in an arresting daylight-filtering screen referred to as a corona. The three-tiered, inverted form merges African and American historical references, drawing from Yoruban caryatids and the Washington Monument. The corona’s pattern was developed by digitizing traditional shapes the team found in historic ornate ironwork from Charleston and New Orleans. The project is the result of a collaboration among Adjaye Associates, who functioned as the lead designer, Freelon Group (now Perkins+Will), who covered the interior design scope above grade, Davis Brody Bond, who covered the interior design scope below grade, and SmithGroupJJR, who was responsible for the entire enclosure of the building from the foundations to the roof, and from curb to curb. With four architects and numerous consultant teams on board, the NMAAHC’s design process was fast and highly collaborative. The client and representatives of each of the firms attended workshops and presentations at project milestones. Work on the facade design process proceeded with a smaller team coordinated by Adjaye Associates, who held regular meetings at its New York City office. For federally funded projects, three initial concepts must be presented before narrowing down to one final scheme. Only 14 months was allotted for the time between a final concept submissions to the delivery of bid documents. Areta Pawlynsky, partner at Heintges & Associates, the consulting firm for facade engineering, said this timeframe was pressing, but ultimately benefitted the project: "This was incredibly demanding, but in a way, easier to keep the momentum going to work through all of these design decisions.” Throughout this process, Pawlynsky said, adhering to the competition-winning design vision was what drove the design development process. "The most challenging part of the project was making sure the facades remained true to the competition." She continued, "When we look back at the competition entry images and the verbal description, we are very proud the building's envelope was able to remain true throughout its development. That doesn't always happen."
  • Facade Contractor Enclos / Northstar
  • Architects Freelon Adjaye Bond / Smithgroup (The Freelon Group, Adjaye Associates, Davis Brody Bond, SmithGroup JJR)
  • Construction Manager Clark / Smoot / Russell, a joint venture
  • Facade Consultants Heintges & Associates; Guy Nordenson & Associates with Robert Silman Associates (structural engineering); Fisher Marantz Stone (lighting consultant); WSP Flack & Kurtz (Mechanical Engineer)
  • Location Washington, D.C.
  • Date of Completion 2016
  • Facade Construction Systems Hung AESS truss and framing system with structurally glazed curtain wall units installed onto AESS from interior (corona framing & enclosure); cast aluminum with custom artisan 5 coat PVDF coated panels on AESS carrier frames (corona screen); bent laminated glass clerestory (oculous); Metal panel rainscreen; Various other structurally glazed curtain walls
With full height atriums on each of the museum’s four sides, the exterior envelope was conceptualized as an “inside-out” assembly, providing clear spans of glass to the interior. Guy Nordenson & Associates developed the primary structural system—a series of three horizontal trusses that wrap the building, giving the facade its signature tiered form. Construction detailing of the envelope was carried out through a design assist package awarded to a joint venture between Enclos and Northstar, who developed a cost-saving strategy to integrate vertical trusses within the curtain wall assembly. Heintges & Associates then engineered and developed technical options for systems that attached to this structure, including the screen panels and unitized glass panels. Adjaye Associates’ decorative screen pattern was digitally manipulated—scaling up and down to produce four densities ranging from 65 to 95 percent opacity in response to key views of the surrounding monuments, and to solar orientation. Selective openings in the corona screen provide “lenses” looking outward to key views of the Washington Monument, Lincoln Memorial, Jefferson Memorial, White House, and U.S. Capitol. The material selection process for the corona screen began with solid cast bronze, which was deemed too heavy with a variation that—over time—would cause undesirable performative and maintenance issues. The design team settled on a cast aluminum due to the material’s track record as a reliable cladding. A unique five-coat application of PVDF produced variation and depth to the bronze coloration of the panels. The corona screen was assembled on-site from shop-fabricated steel plate carrier frames containing 13 cast aluminum panels each. A staggered paneling running across the facade required selective panels to be installed in the field. These “stitch panels” bridge the gaps between adjacent carrier frames, helping to conceal any visual clues to the pre-fabricated frame assembly. The design team consulted with Fisher Marantz Stone on a subtle lighting scheme to incorporate backlit panels that bounce light off frit glazed walls to produce a glowing facade at night. These details and lighting effects were scrutinized through numerous design studies and mockups, and by regulatory agencies to ensure the lighting of monuments at night would remain balanced. Hal Davis, senior vice president at SmithGroupJJR, said the building envelope design was “quite unusual.” Asked if there were any technical challenges associated with designing a curtainwall system with an inside-out weather line, Davis replied, “of course!” He explained that an off-the-shelf-system couldn’t simply be installed backward: "It’s a different approach and it did take quite a bit of effort. We worked with Enclos and Heinges and David Adjaye to get it right and to make sure we were going to maintain the integrity of the design, the tightness and the insulation quality of the system, preventing condensation. For this, we had to develop very subtle heating elements that would eliminate moisture.” Pawlynsky concluded, "I think the real story of success here is the collaboration, including the contractors, Enclos and Northstar, and CM Clark. There was a strong commitment to executing this facade in the appropriate way, and it extended across the board."
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DDG reinterprets cast iron facades of Soho

“We’re always interested in the intersection between old-fashioned hand craft, and modern machined factory production.”

Located in the Soho Cast Iron Historic district, XOCO325 (pronounced sho/co) is a 9-story, 24-unit condo development. Named after the Catalan word for chocolate, the project involves the renovation of a former Tootsie chocolate factory, and a new structure cloaked in a custom cast aluminum screen. The condos range in size from just over 1,000 sq. ft. to nearly 5,000 sq. ft. and are connected by a central courtyard. The design, development, and construction of the project has all been coordinated by New York-based office DDG who specializes in inclusive project delivery. Peter Guthrie, Chief Creative Officer and Head of Design & Construction of DDG, says from very early on, this “one-stop-shop” approach to development was rooted in the idea of embracing unique material qualities in construction. “At 41 Bond Street – one of our first projects – we were hand carving bluestone pieces on site. One of the ideas we had early on was that by doing this ourselves in house, and controlling everything throughout the process, we could bring back an element of craft that other companies couldn’t afford to do.” The most prominent feature of XOCO325 is a custom cast aluminum screen, carefully developed through an extensive survey of the cast iron district, where roughly 250 cast iron buildings reside. Through this study, the project team began to understand the cast iron facade as an industrialized “kit of parts” approach to architecture where design and construction rely heavily on series of componentry made available through pattern books. Inspiration also came from contemporary catalogs such as McMaster-Carr’s online website, which Guthrie labels as a “bible of industrial parts.” The catalog includes everything from bolts and screws to street lamp posts and furniture.
  • Facade Manufacturer Walla Walla Foundry
  • Architects DDG Partners
  • Facade Installer DDG Partners
  • Facade Consultants DDG Partners
  • Location New York, NY
  • Date of Completion 2016
  • System curtain wall with aluminum screen
  • Products cast aluminum in custom composite formwork, curtainwall system, cast in place concrete sitework
DDG adopted this attitude of mass-produced componentry in their digitally developed forms, arriving at a proportioning system and bay spacing reminiscent of historical buildings in the area. “We’re always interested in the intersection between old-fashioned hand craft, and modern machined factory production,” says Guthrie. “There was an angle here we wanted to explore. Aluminum was light and, in the end, more affordable than replicating cast iron.” The project team developed a repetitive spandrel and column shape, working with a foundry to develop reusable composite forms with a weathered burlap texture. When prototyping versions of the system, the project team prioritized formal adjustments to the massing such as curvature and shadow lines to emphasize a sense of depth found on facades of historic buildings in the district. By “delaminating” the building enclosure system from the cast aluminum screen, a two-foot gap was established allowing the residential units to have a full span curtain wall glazing, while still maintaining some level of security and privacy. “That was our way of getting both: making a modern building without compromising on psychological stability and privacy.” This configuration is celebrated by the project team as having a “robust stability.” Within this space, balconies occupy the courtyard facing units, while a custom planter system comprised of pockets cast into the screen and a series of cables, is incorporated onto the primary street facade. The project is beginning sales, with an anticipated completion in 2016.