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604 Metal Monocoques – Moving Buildings Welded like Ships 2015 ¥ 6 ∂ 12–16 Steel monocoque as integral constructional element for column, ramp and roof light: “Twist” in the transit hall of Arnhem Station, 2015; architects: UNStudio 12 Three-dimensional model of “Twist” at assembly stage with auxiliary structures as temporary supports and working platforms 13 Prefabricated element of monocoque construction with temporary eyes for crane during unloading on site 14,16 The welded and coated monocoque structure constantly changes its appearance according to the position of the viewer – from a slender column to a spatially articulating wall slab. 15 Visualization 12 13 14 working sections that can be treated as individual units (ills. 7, 8). Monocoques are increasingly establishing themselves in sculptural engineering, too. The undulating roof over a Munich tram station by OX2 Architects, for example, a prizewinning design in plastic in the competition, was ultimately implemented by RPM in 2009 as a metal structure with prefabricated curved columns of thick steel sheeting (ill. 11). In London’s Olympia Park, Wilkinson Eyre conduct the loads from the 84-metrehigh cable-car masts into open cylinders welded together from helically curved steel sheets. The two-storey tubular bridge that links the two sections of the Yas Viceroy Hotel in Abu Dhabi is an integral part of the architecture. Designed by the architects Asymptote in the aesthetic of the yachts in the surrounding marina (ill. 19), the glazed network skin spans a Formula One racecourse. The special challenge here lay not only in the structural and formal aspects, but in the extremely ambitious time schedule: the construction had to be finished before the deadline for the first race, which could not be postponed. Only 45 weeks after the award of the contract, the entire bridge had been assembled on site. In view of its location immediately next to the sea, it was possible to deliver the upper half by ship as a single prefabricated element. Stainless-steel monocoque In the case of the Porsche Pavilion in the Autostadt Wolfsburg by Henn Architects and the building engineers schlaich bergermann and partners, the constraints lay not only in a tight schedule – only seven months for the planning and erection of a structure with a perfect surface quality. In addition to an optimum form, the planners adopted the target of the chairman of the supervisory board of the Volkswagen company at that time, Ferdinand Piëch, who always insisted on the thinnest possible joints and smallest clearances and was known by the nickname “jointing Ferdi”. For that reason, the initial structural concepts for a gridshell and panelled cladding were replaced by a jointless form of construction. For the design that was deemed suitable for execution – a variant form with a jointless CFRP outer skin – there were great reservations that the time remaining until the completion deadline was too tight. Under the circumstances, a monocoque structure in stainless steel proved to be the best solution (ills. 4, 5). The pavilion is divided into two user areas that are reflected in two different forms of construction. Spanned over the internal showroom is a quarter dome, consisting of longitudinal and cross-struts with a closed sheet-steel external surface. As a visible closure to the internal space, a separate three-dimensional inner shell was inserted in a dry form of construction. The showroom is separated from the utility and service spaces by a concrete slab. In front of this wall, the monocoque becomes a canopy roof visible from all sides and additionally lined on the underside with metal sheeting. In other words, the monocoque corresponds structurally to a curved single-span girder that is anchored in the ground at one end and that bears in the middle on the concrete wall. From here, it cantilevers out over a pool of water. Spatially, parts of the monocoque correspond to a membrane-like shell, while other parts form a plate structure. The short planning period was also made possible by the expertise of the test engineer who gave his approval within a short time. The structural optimization, using steel between 10 mm and a maximum of 25 mm thick, made it possible to cold-form the sheeting to implement the architects’ design. A decisive factor in meeting the deadline, despite the difficult assembly conditions, was the high degree of prefabrication. The construction period occurred during the winter months. In addition, site work was confined to the night-time: the canal leading to the Autostadt was frozen, so that the 51 prefabricated elements had to be delivered by road. Executing the monocoque entirely in stainless steel meant a price increase of approximately 15 per cent, but ultimately proved to be of distinct advantage. All maintenance in terms of corrosion protection was obviated – not only for the outer skin, but also internally. If the longitudinal and cross-bracing members had been executed in untreated or “black” steel, it would have been necessary to dimension the internal spaces more amply to provide access, so that the surfaces could be coated or retreated, or for paint to be removed. What is more, the “tip of the tongue” at the end of the roof could not have been designed so elegantly. In the internal exhibition area, a circulation of air occurs between the inner spatial skin and the load-bearing monocoque shell, warming the metal structure in winter. As a result, it was unnecessary to attach ungainly snow guards externally. The exceptional smoothness of the
∂ 2015 ¥ 6 Technology 605 15 surface for a monocoque construction consisting of 620 metal covering sheets was possible only with minimum tolerances and filigree working joints, with quality control at every stage of the work, with comprehensive inspection and the coordination of all welding processes. The stainless-steel sheeting was cut and shaped at the works in Groningen, then welded to create the construction elements in Stralsund in a hall that is completely separate from the normal steel construction department. This was done to avoid impurities and chemical corrosion. Working with stainless steel also calls for the utmost care, since scratches cannot be subsequently painted over. Integration into an overall design concept Monocoques are suited not only for isolated structures. They can be design objects that serve an overall spatial concept, whereby the distinction between monocoque and surrounding environment may become blurred to the point where it is no longer recognizable. What is probably the most complex constructional element in the world of building was assembled last year in the transit hall of Arnhem Station by UNStudio. After 20 years of planning and a step-bystep process of completion, the hall forms the closing piece to the development, creating a link between the railway and bus stations, an underground garage and a bicycle parking area. The complexity and dynamics of the scheme culminated in an integral load-bearing building component. Situated in the middle of the transit hall, it accommodates the most diverse functions – ramp, column support and roof light – lending them, in an almost playful manner, an organic sense of movement. This “Twist” monocoque, consisting of the largest possible prefabricated parts, to which the steel roof structure was to be connected quite simply, provided a realizable solution after the original concept for a reinforced concrete form of construction had proved abortive. Admittedly, a further year was to pass before the test engineers 16
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