MERCEDES-BENZ STADIUM – DESIGN AND … Presentation_SEAOG.pdf · MERCEDES-BENZ STADIUM – DESIGN...

M E RC E D E S - B E N Z S TA D I U M – D E S I G N A N D C O N S T R U C T I O N

Structural Engineers

Association of Georgia

05/10/2017

B U R O H A P P O L D

LO C A L K N O W L E D G E + G LO B A L E X P E RT I S E

Buro Happold

ORIGINS OF BURO HAPPOLD: FREI OTTO + TED HAPPOLD

BEGINNING OF ROOFS THAT TRANSFORM

� The New Stadium Project for the Atlanta Falcons will seat 75,000 fans and will feature a

roof opening that will provide flexibility in hosting a wide variety of events in the

stadium.

� Eight unique roof petals can open in less than eight minutes, creating a “camera lens-

like” effect that exposes the inside of the facility to the open air on game and event

days.

� Another first of its kind is the nearly five-stories tall 360-degree HD video halo board

that will not only be the largest video board in the NFL, but in the world.

PROJECT OVERVIEW

� Attraction for Atlanta

� Unique Design

� Roof Innovation

� Draw on World-Class Events

and Entertainment

INITIAL DESIGN GOALS

� Owner: Georgia World Congress Center Authority� Developer: Atlanta Falcons� Architect: HOK (Kansas City)� TVS, GVSA, SBS (Atlanta)� Contractor: Holder, Hunt, Russell, Moody, a Joint Venture� Structural: BuroHappold Engineering (Superstructure)

Sykes Consulting, Inc (Foundations, Precast)HOK (Halo Steel)

� Mechanization: Uni-Systems� MEP: WSP� Steel Fabricator: Canam Group� Steel Erector: Derr-Isbell Construction (Roof)

Superior Rigging (Facade)� Connection Consultants: Ferrell Engineers, MBJ� Use: NFL, MLS, NCAA Sports, Entertainment Events� Size: Approximately 2.0M square feet & 75,000 seats

PROJECT DETAILS

NEW STADIUM – SITE LOCATION

SIZE COMPARISON

SIZE COMPARISON

� 100% Schematic Design October 7, 2013

� Ground Breaking May 19, 2014

� 100% Design Development June 18, 2014

� Construction Documents - Concrete August 15, 2014

� Mill Order – Roof Steel (65 ksi) July 27, 2014

� Mill Order – Roof Steel September 2, 2014

� Mill Order – Façade Steel October 17, 2014

� Construction Documents – Roof Steel December 1, 2014

� Construction Documents – Architecture April 8, 2015

� Construction Documents – MEP April 8, 2015

� Opening August 2017

MILESTONES

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F A L C O N S S T A D I U M B R E A K D O W N

Foundation

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F A L C O N S S T A D I U M B R E A K D O W N

Bowl Structure

Foundation

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F A L C O N S S T A D I U M B R E A K D O W N

Bowl Seating

Bowl Structure

Foundation

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F A L C O N S S T A D I U M B R E A K D O W N

Bowl Seating

Bowl Structure

Foundation

Façade

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F A L C O N S S T A D I U M B R E A K D O W N

Roof Structure

Bowl Seating

Bowl Structure

Foundation

Façade

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F A L C O N S S T A D I U M S T R U C T U R E

COPYRIGHT © 1976-2015 BUROHAPPOLD ENGINEERING. ALL RIGHTS RESERVED

F A L C O N S S T A D I U M

S K I N

Foundations

PROJECT CASE STUDY

For Structural Engineers Association of Georgia (SEAOG)

By Martin Kigudde, PE

In Collaboration with BuroHappold Engineering and HOK

May 10, 2017

Mercedes Benz Stadium

May 10, 2017

� Structural Engineering Consulting Firm

� Established in 2001

� Headquarters in Atlanta, GA

� Satellite Office in Savannah, GA

� Aviation, Sports, K-12, Higher Education,

Commercial, Residential.

Charles Drew High SchoolMetropolitan ChurchGainesville State

FISERV Office Building Metropolitan Library Lucas Oil Stadium

Hartsfield Jackson International Airport

Consolidated Rental Car Facility (CONRAC)

The New World of Coca-Cola

Atlanta

Savannah

Mercedes Benz Stadium

May 10, 2017

National Work

21 States

International Work

Abu Dhabi

Anguilla

Mercedes Benz Stadium

May 10, 2017

� Stadium is the new home of the Atlanta Falcons and Atlanta United FC.

� Scheduled to open in the fall of 2017.

� Foundation design started Mid-2013.

� Architects: HOK, tvsdesign, SBS, and GVSA.

� Structural Engineer Super-structure: Buro Happold Consulting Engineers

� Structural Engineer Halo: HOK Structural

� Structural Engineer: Sykes Consulting, Inc. EOR for:

� Foundations, retaining walls, and slab-on-grade.

� CMU walls.

� Precast seating and framing at lower bowl.

� Concession lids.

� Sponsorship Suites.

� Civil Engineer: Kimley-Horn and Associates, Long Engineering, Skyline Eng.

� Geotechnical Engineer: Langan Engineering and Environmental Services.

� Weekly BIM Collaboration between team members.

Project Introduction:

Mercedes Benz Stadium

May 10, 2017

� Site located south of the current Georgia Dome and

bounded by:

� Northside Drive.

� Mangum Street.

� MLK Jr. Drive.

� Stadium construction required relocation of:

� MLK Jr. Drive and Mangum Street.

� Friendship Baptist Church.

� Mount Vernon Baptist Church.

� MARTA East-west line tunnel runs adjacent and to the

north of the site.

� Vibration considerations for the tunnel.

� Construction load surcharge limits.

� 5’-0” horizontal easement to tunnel walls

� Field Elevation at 1018’-0”

� Georgia Dome Field Level at 980’ (plaza 1011.6”)

Project Site:

Mercedes Benz Stadium

May 10, 2017

� Foundation designed based on loads from Buro’s SAP analysis

models.

� 5 foundations types due to varying sub-surface conditions.

� Deep foundations for cast-in-place concrete bowl.

� Drilled Piers (66” to 78” diameter.)

� 18” diameter augercast-in-place piles (220-T & 150-T)

� Shallow foundations for precast inner bowl.

� Shallow foundations on existing soils

� Shallow foundations on Geopiers.

� 8" SOG Approx. 460,000 GSF (not including the playing field).

� Playing field was designed by specialty field designer, FTE, Inc.

� Quantities:

� 1900+ augercast piles

� 220+ Drilled piers

� 11,000+ CY of concrete in footings and pilecaps

� Deep Foundation Testing:

� 1 Full scale Statnamic test.

� 1 O-cell test to determine capacity.

� 2 Full scale auger cast pile tests.

Foundation Design:

Mercedes Benz Stadium

May 10, 2017

� 19-mega columns support the main roof trusses.

� 8-Mat foundations support the mega column clusters.

� Mat foundations were designed using SAFE 3D-Finite

elements design software.

� Foundation reaction loads from Buro Happold’s SAP

model.

Mega Column Foundations:

Mercedes Benz Stadium

May 10, 2017

� Mat foundations 7’-0” to 12’-0” thick high-strength concrete.

� Mat foundations supported on drilled piers and piles.

� Longitudinal and shear reinforcement required in the mats.

� Mass concrete considerations:

� Crushed ice and cooling the coarse aggregate with chilled water.

� Surface thermal insulation boards and curing blankets.

� Temps monitored using thermal couples.

Mat Foundations:

Mat Foundation rebar Mat Foundation rebar Insulation boards at Mat Foundation

Mat Foundation at South-East Quad (MCC02)(221 -18” diameter piles)

Mercedes Benz Stadium

May 10, 2017

Foundation Design:

Mega Column Mat MCC05(7’-6” thick; 11-72” Piers)

� Mat Foundation design using SAFE software.

� IBC 2012

� Longitudinal and shear reinf.

� Individual piles and drilled piers designed

using Enercalc software.

� Drilled Pier Capacities: 2800 kips – 8300 kips

� Spread footings designed using Enercalc

software.

� Column pilecaps designed using Window’s

based proprietary pilecap design software

� Concrete Strength:

� Spread Footings = 4000 psi

� Augercast Piles = 4000-6000 psi

grout

� Pilecaps = 6000 psi

� Drilled Piers = 6000 psi

� Mat Foundations = 7000-8500 psi

Mega Column Mat MCC08(7’-6” thick; 16-72” Piers)

Mercedes Benz Stadium

May 10, 2017

� Aggressive schedule; fast-track project.

� Foundation installation began while super-structure design still

progressing.

� Drill and epoxy for CMU wall dowels.

� Drilled pier rock sockets (5’-0” to 18’-0”).

� Failed O-cell drilled pier load test required redesign.

� Existing unforeseen deep foundations from previously demolished

structures.

� Handling long pile/pier rebar cages.

� Rebar congestion in mat foundation.

� Damaged foundation dowels.

Foundation Challenges:

Handling long rebar cages

Rebar congestion Damaged pile dowels

Mercedes Benz Stadium

May 10, 2017

� Auger-cast pile contractor: Berkel & Company Contractors, Inc.

� Drilled pier contractor: ABE Geotechnical Contractors.

� Geopier contractor: Hayward Baker.

� Shallow foundation contractor: Precision Concrete.

� Concrete Supplier: Argos

� Foundation construction started in June 2014.

Foundation Construction:

Installation of 1st pile on project Auger-cast pile rebar cages Drilled pier rebar cages

Mercedes Benz Stadium

May 10, 2017

Foundation Construction:

Geopiers at shallow

foundations

Tops of auger-cast piles Pilecap rebar and column dowels

Mercedes Benz Stadium

May 10, 2017

� Hydrotherapy pools

� Drink rails.

� Goal post foundations.

� Broadcasting booths.

� Elevator pits.

� Escalator pits.

� Ramps.

Special Features at Field Level:

Escalator pit walls Elevator pit walls

Mercedes Benz Stadium

May 10, 2017

� Inner bowl is all precast structure:

� Columns

� Vomitory walls

� Raker beams

� Seats

� Precast seating on cast-in-place rakers at concourse levels

outside inner bowl.

� Standard double and triple units

� Metromont is the precast contractor.

� Total NFL seating capacity is 70,148.

Precast Seats:

Mercedes Benz Stadium

May 10, 2017

Precast Seating:

Mercedes Benz Stadium

May 10, 2017

Concession Lids:� At Concourse levels.

� Roofs over the concessions and bathrooms.

� Steel beams, joists, and metal deck.

� Supported by CMU walls and cast-in-place rakers.

� Fit out of Corporate sponsorship suites.

� Suites at Concourse levels.

� Structural steel and cold-formed framing.

� Misc. Framing for banners and TV monitors.

� ATT, Equifax, Anheuser Busch, American Family.

Sponsorship Suites:

Concrete Bowl

CONCRETE BOWL

Top of Seating

Upper Mezz

Upper Concourse

Upper Suite

Concourse 2

Low Suite

Concourse 1

Admin 2

Admin 1

RAKERS

MEGA COLUMNS

Mega Column Section

MEGA COLUMNS

MEGA COLUMNS

Mega Column Cap Details

CHALLENGES

Irregular Geometry

Fast Track Schedule

CONSTRUCTION - OCT 2014

CONSTRUCTION – MAR 2015

CONSTRUCTION – OCT 2015

CONSTRUCTION

CONSTRUCTION – MEGA COLUMN

CONSTRUCTION – RAKER

CONSTRUCTION – RAKER

CONSTRUCTION – FORM SAVERS

CONSTRUCTION – FIN COLUMN

CONSTRUCTION – FIN COLUMN

CONSTRUCTION – EXPANSION JOINT

CONSTRUCTION - RAMP

CONSTRUCTION – PRECAST TUB

CONSTRUCTION - CRANE

Facade Structure

FAÇADE STRUCTURE

Diagonal Truss System

Diagrid System

DESIGN EVOLUTION

FAÇADE STRUCTURE

Rhino

FAÇADE STRUCTURE

SAP2000

FAÇADE STRUCTURE

FAÇADE STRUCTURE

FAÇADE STRUCTURE

FAÇADE STRUCTURE

Façade at East Window

FAÇADE STRUCTURE

Façade at East Window

Façade at East Window

CONSTRUCTION PHOTOS

Fixed Roof

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R O O F S T R U C T U R E

EARLY PHASES

FIXED ROOF STRUCTURE

� 4 Primary Trusses

� Rotated 46 deg

� Supports Video Halo

� Supports Downward Rail

FIXED ROOF STRUCTURE

� Frames Octagon Opening

� Supports Video Halo

� Supports Downward Rail

FIXED ROOF STRUCTURE

� Parallel to A & B Trusses

� Supports Upward Rails

FIXED ROOF STRUCTURE

� Petals run on A, B, & C Trusses

� Downward rails on A & B Trusses

� Upward rails on C Trusses

COPYRIGHT © 1976-2014 BUROHAPPOLD ENGINEERING. ALL RIGHTS RESERVED

A N A LY S I S M O D E L

• 25,856 Members• 13,033 Joints• 157 Load Patterns• 2100 Load Combinations

BIM

3D MODEL – AS DELIVERABLE

� Tekla Model was the deliverable for Steel

� Contractor can rely on the model for Steel information

� PDFs still required for:• General Notes, Specs, Typical Details

Someday this will be the standard of care

STEEL DELIVERY PROCESS

REVIEW SUBMITTALS IN 3D

SUMBITTAL ARE LISTED HERE

STATUS OF ASSEMBLY HERE.

BENEFITS OF MODEL REVIEW

• More accurate review

• Better coordination with other trades

• Faster review

• Green!!!

� Review Process in 3D

� Better coordination with other trades

3D SUBMITTAL REVIEW

APPROVAL STAMPING

COMMENTS ON THE PDF

REPORT OF REVIEW STATUS

ERECTION DRAWINGS

GEOMETRY REVIEW IN 2DA

... PUT IN CONTEXT WITH 3D

IDENTIFY CONNECTIONS BETWEEN

SUBMITTALS

REVIEW REPETITIVE ASSEMBLIES

CONNECTION

CONSTRUCTION PHOTOS

CONSTRUCTION PHOTOS

CONSTRUCTION PHOTOS

TRUSS PICK

Video Halo Structure

MERCEDES BENZ STADIUMHALO SUPPORT STRUCTURE

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Rich Saunders, P.E., S.E.Associate | Senior Project Structural Engineer HOK

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Revit Model of Primary Roof

Structure (Buro Happold)

AutoCAD layout of Video

Screen (Daktronics)

Primary Roof Truss

Displacements, Stiffnesses

(Buro Happold)

Grasshopper Script

Structural Analysis Model

(Oasys GSA)

Geometry For Revit

Model

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Roof Petals

RETRACTABLE ROOFS

Stadium Roof Opening Time

AT&T Stadium Dallas, Texas

12 Minutes

NRG StadiumHouston, Texas

10 Minutes

Lucas Oil StadiumDallas, Texas

12 Minutes

University of Phoenix StadiumPhoenix, Arizona

12 Minutes

Mercedes-Benz StadiumAtlanta, Georgia

8 Minutes

ROOF STRUCTURE

1

23

1

3

2

PETAL ROOF STRUCTURE

OPERABLE ROOF STRUCTURE

ETFE Framing

3D Axonometric: ETFE Framing

OPERABLE ROOF STRUCTURE

Button Framing

3D Axonometric: Button Framing

PETAL SUPPORT TRUSSES

OPERABLE ROOF STRUCTURE

OPERABLE ROOF STRUCTURE

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Q U E S T I O N S ?