With its complex geometry, the folded plate roof structure would traditionally require a costly custom form system of environmentally unfriendly materials. During pursuit of the project, Pepper proposed an alternate method using prefabricated frames of conventional 2x4 lumber erected on elevated flat decks constructed of traditional shoring, saving time and money. Over a 48-hour period, Tekla was used to model and convey this method to the team, which helped Nabholz Pepper Doyne win the project.
The real challenge came in using the design models as a reference locking the defining features, including peaks, valleys and edges, but then manipulating them within Tekla and 3DS Max to create a surface that could be formed by frames at regular 12" spacing with straight top chords to achieve the desired cost and schedule savings. To define a similar surface, over 1,245 unique wood frames varying in width, height and pitch were generated within Tekla. Several different plan alignments were tested to create a best fit to the original design surfaces.
This approach, as well as other processes implemented by our team, allowed more than 10,000 tons of waste to be successfully diverted from landfills and 87.7% of waste, including the trusses, to be reused or recycled. The project exceeded LEED goals for Building Product Disclosure Optimization credits, which contributed to the goal of LEED Silver certification.
“The 3D Tekla model played a crucial role during construction administration because it allowed all parties to confirm the rebar layout prior to submitting shop drawings. The coordination between the structural team and Pepper as the concrete detailer was so successful that over the course of all three roof placements, there was only one request for information (RFI) related to bar placement in the field."
Benjamin Sexton, P.E., S.E. Senior Project Engineer, Thornton Tomasetti
Overcoming challenges from the beginning... and even before