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burj Khalifa

office ceiling design TO fabrication


burj Khalifa

office ceiling design TO fabrication

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table of contents Introduction....................................................................................... 01 Table of Contents............................................................................. 02-03 Project Data........................................................................................ 04-05 Global Delivery.................................................................................. 06-07 Process................................................................................................. 08-09 previous Design.................................................................................. 10-11 Project STate...................................................................................... 12-13 design Intent...................................................................................... 14-15 Existing Installation....................................................................... 16-17 Prototypes and Sketches................................................................ 18-19 Surface AnAlysis................................................................................ 20-21 design drivers.................................................................................... 22-23 system drivers................................................................................... 24-25 completed surface model................................................................ 26-29 coordination drawings................................................................... 30-31 shipping and sequencing................................................................. 32-33 planking/paneling............................................................................ 34-35 Mockup.................................................................................................. 36-41 mockup approval............................................................................... 42-43 survey data and as-built conditions........................................... 44-51 veneer mapping.................................................................................. 52-55 System design..................................................................................... 56-59 detail capture and reuse................................................................ 60-63 fabrication jigs................................................................................. 64-65 detailing.............................................................................................. 66-67 completed panel model.................................................................... 68-69 Installation........................................................................................ 70-75 Completed ceiling.............................................................................. 76-87 project Credits.................................................................................. 88

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“An essential feature of the office lobby space is the free form ceiling made of wood and bridge system that connects the hotel space above to the upper level of the pavilion structure. This feature continues the organic nature of the project into the office environment much the same way as the curved walls do for the residential entrance and public spaces. This highly sculpted feature becomes a landmark feature that differentiates this pavilion from all others.” –Adrian Smith

burj Khalifa

office ceiling design TO fabrication

3


project data name Burj khalifa office ceiling Location Dubai, UAE Type Interior Size 541m3 of ceiling surface duration April 2009 – DECEMBER 2009 client emaar properties project manager turner main contractor samsung / besix / arabtec (Joint Venture) design architect skidmore owings & Merril (SOM) architect of record Hyder

4


5


Global Delivery

LOS ANGELES GEHRY TECHNOLOGIES (LA) AUTOMATION SUPPORT

SOM (CHI) DESIGN CHICAGO IMPERIAL WOODWORKING FABRICATION

GEHRY TECHNOLOGIES (NY) PROCESS + KNOWLEDGE ENGINEERING

NEW YORK PHILADELPHIA ICON INTEGRATED CONSTRUCTION DESIGN + FABRICATION ENGINEERING

6


PROJECT SITE INSTALLATION TEAM COORDINATION DUBAI

7


Process

DESIGN INTENT

KE DESIGN SURFACE PANELIZATION

SHIPPING & SEQUENCING

KE PANELIZATION

SURFACE & PLANK MODEL

KE PLANKING

PLANKING

FABRICATION MODEL

DETAILING

KE PANEL ASSEMBLY

SYSTEM DESIGN KE VENEER MAPPING

VENEER MAPPING 8


MATERIAL BENDING LIMITS

SURVEY DATA AS-BUILT

COORDINATION DRAWINGS

COORDINATION MODEL

COORDINATION

COMPLETION SHIPPING

FABRICATION

CNC TOOLPATHS

VENEER INVENTORY 9

ON-SITE ASSEMBLY


previous design

10


11


PROJECT STATE

state of building during re-design phase

12


existing documentation

13


DESIGN INTENT

14


taking design back to concept design

15


16


17


prototypes and sketches

18


19


surface analysis

20


21


DESIGN DRIVERS

BLEND wireframe

primary drivers

22


driver surface

BLEND SURFACEs

23


SYSTEM DRIVERS

Major Panel divisions

Completed Surface driver

24


COMPOSITE PLANKING/PANELS

Major planking Divisions

25


completed surface model

26


27


28


29


coordination drawings

3d and 2d contract deliverables

30


reflected ceiling plan

31


shipping and sequencing

fabrication sequence

panel types and re-use

32


panelization plan

33


planking/paneling

34


automated planking design tool 35


mockup

36


37


38


39


40


41


mockup approval

42


43


survey data and aS-Built conditions

44


45


46


47


48


49


50


51


veneer mapping

veneer Sorting worksheet

veneer options A-c

sorted veneers 52


Imperial Woodworking Co. 310 North Woodwork Lane Palatine, IL  60067

Veneer Aesthetic Layout Grid Imperial Project #9165 Burj Dubai

mapped veneers

1.1

1.2

1.3

3.5

3.6

1.1

X

X

X

2.1

2.2

X

X

X

4.6

4.7

1.2

X

X

X

X

X

X

1.3

X

X

X

X

X

X

X

X

4.6

X

X

4.7

X

X

2.1

X

X

2.2

X

X

3.1 3.2

3.1

3.2

X X

X

X

3.3

3.4

X

X

X

X

X

X

X X

3.4

3.3

X

3.5

X

X

X

X

X

X

3.6

X

X

X

X

X

X

3.7 4.1

3.7

4.1

4.3 4.4 4.5

5.1 6.1 7.1

veneer adjacency matrix

4.2

4.3

4.4

4.5

5.1

6.1

7.1

X X

4.2

53

10/6/2009

X X

X

X X

X

X X

X

X

X X X

veneer database


54


55


system design

capturing typical panel adaptability through details and sketches 56


57


58


59


detail capture and Reuse

60


61


2d output for CNC fabrication

interoperability across platforms 62


panel build geometry

typical panel assembly 63


fabrications jigs

64


65


detailing

66


67


completed panel model

68


69


70


71


72


73


74


75


76


77


78


79


80


81


82


83


84


85


86


87


project team Imperial woodworking co. 310 North Woodwork Lane Palatine, IL 60067 www.imperialwoodworking.com

Frank Huschitt Sr.............................Chairman Frank Huschitt III..............................President, Executive Project Management Frank Moceri.......................................Project Manager / Job Site Coordinator Matt Riemenschneider......................Engineering Manager Cesar Noriega.....................................CAD Draftsman Scott Sherby.......................................Shop Foreman Omar Bartomioli.................................Assembly Foreman Ted Piwowar.......................................Finishing Foreman Teofil Bradin......................................Veneer Lead John Howell........................................Veneer Layout Gary Lichtenberger...........................CNC Operator / Programmer Bob Dewitt..........................................Assembly Lead Vic Anguilo..........................................Assembly, Job Site Installation Tim Heinz..............................................Assembly, Job Site Installation Marcin Onak........................................Assembly, Job Site Installation Ralph Heppner....................................Job Site Installation Foreman

gehry technologies / New York 14 Wall Street 20th Floor New York, NY 10005 www.gt-global.com

James kotronis...................................managing director, US–Eastern REgion neil meredith......................................project lead deam demko..........................................project consultant victor keto..........................................Senior Automation consultant nicholas pisca....................................Senior Automation consultant timothy porter...................................project consultant david pysh............................................Senior project consultant christoper reinig...............................project consultant

icon Integrated Construction 508 Spruce Street Philadelphia, PA 19106 215 669 7900

Rick Herskovitz, RA............................owner

© IMAGES IMPERIAL WOODWORKING CO. Pages 16-18, 30, 38-41, 52, 58-59, 70-75 © IMAGES ICON INTEGRATED CONSTRUCTION Pages 15,16, 56-59, 66 © IMAGES skidmore, Owings & merrill Pages 10, 11, 13 © gehry technologies 2011 ISBN: 5-800053-326349 DESIGN BY NEIL MEREDITH Version: BRJ_08 | Output: February 3, 2011 11:19 AM 88


5 800053 326349

Burj Khalifa  

Office Ceiling Design to Fabrication

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