CU Jan-Feb 2020

CASEstudy
©Steve McCurry / Magnum Photos
Distilling the essence of design
Thomas Mahon of Bimorph Digital Engineering explains the use of GenerativeComponents to
calculate the mathematics behind The Macallan Distillery's distinctive and complex roof
It's a fascinating concept that owners of
wineries and distilleries, build splendid
structures to house their produce whilst it
matures in the vats, casks and gleaming
copper distillation devices. Take for example
the winery designed by Frank Gehry in
Elciego, Spain, One can only assume that
the patience required as each vintage
matures is bolstered by contemplation
amidst some iconic piece of architecture.
On the other hand, visitors want to see as
much of the manufacturing process as
possible - and one needs to encourage
profligacy from them by the opulence and
magnificence of a grand design.
I learnt about just such a dramatic and
inspiring project in Scotland at Bentley's
recent GenerativeComponents Symposium
in London, where Thomas Mahon,
founding Director of Bimorph Digital
Engineering, gave a presentation on the
parametric design process that aided in the
development of The Macallan Distillery roof
structure project.
The new Macallan Distillery building was a
Rogers Stirk Harbour + Partners project for
the Macallan Distillery, which has been in
existence since 1824 when they produced
their first single malt whiskey. Set in the
beautiful rolling scenery of the Easter
Elchies estate, the aim was to provide a
building that had a minimum visible impact
on the landscape, yet allowed visitors to
see all elements of the whiskey production
process in a dramatic environment - a
contrast between the engineering manmade
forms of the industrial production
and the surrounding countryside.
The distillery consists of a substructure
package of earthworks, waterproofing and
concrete retaining structures using a grey
aggregate mix and dark grey cement using
local pulverized fuel ash, to match local
stone. This was complemented by a
superstructure designed to fit in yet appear
man-made, and a gently undulating roof
which was quite different and separate to
the main structure, 'sailing' above it and
freeing it from restraining ground pressures
and loads.
THE MACALLAN DISTILLERY ROOF
The roof structure is in two principle parts, a
primary tubular steel support frame and
undulating domes and valleys for the
timber grid shell. The primary steel frame is
laced through the centre of the timber
beam structure and helps to resist the
torsional forces. The timber domes act in
compression and the interconnecting
valleys are hung between the domes. All of
the roof beams are straight and all of the
cassettes are flat double skinned panels,
providing a facetted appearance to the
engineered landscape.
Despite the highly repetitive and rotational
roof geometry the finished structure is
constructed from over 380 thousand
components. The beams are a composite
of glulam and laminated veneered lumbar
(LVL) and steel reinforced in certain key
locations. All of the timber beams are
vertical with a constant expressed depth of
750mm which allows for considered and
neat interfaces with internal partitions as
well as the solid and glazed façade.
FAÇADE AND GLAZING
Running the full length of the eastern and
southern elevations of the building is full
height double glazing composed of 3m
wide structurally bonded double-glazed
panels, supported from the base and
restrained at the head with a flexible
movement joint. The interface between the
main glazed façade and associated downstand
roof beam is a key and important
interface. Running the full length of the
building, the façade undulates between
2.6m and 5m in height. The interface at
roof level incorporates a flexible movement
detail which needs to accommodate the
vertical and lateral range of movements of
the roof structure, to remain engaged to the
roof and support its lateral movement
whilst maintaining the performance of its
thermal and weathering envelope.
GREEN ROOF AND COVERINGS
On top of the timber roof structure is a
layered roof buildup of circa 300mm in
depth - 150mm of vapour barrier, thermal
insulation and waterproofing and then a
further 150mm of green living roof. The
insulation actually protects the irrigated roof
from the warming and drying effects of the
distillation process.
The architectural structural grid of the
timber provides a network of aluminum
channels, contributing to the engineered
aesthetic but also acting as a servicing
zone that crosses the entire roof, lightning
protection, irrigation runs, fall restraint lines
and power for actuated vents to the visitor
centre rooflights.
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January/February 2020