12
SMITHFIELD VILLAGE . REDEVELOPMENT OF THE OLD JAMESON DISTILLERY SITE VINCENT BARRETI BSc (Eng),MSq DIC' MI StructE, MIEI' CEng CIARAN KENNEDY BSc (Eng),Dip Eng, MIEI BARRETT MAHONY CONSULTING ENGINEERS Presented to a meeting of the Structures and Construction Section of the IEI at The lnstitution, 22 Clyde Road, on Wednesday 3rd February 1999 at 8.00pm. Synopsis This 295,000 sq. ft development includes a museum,a theme hotel, bar and theatre,shops, restaurants, apartments and underground carparking. A panoramic lift on the largestchimney on the site will give views at 50m above the SmithfieldPlaza. The paper describes this exceptionally diverse and complex developmentfrom inception to completion.

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Page 1: BMCE Civil & Structural Engineering Consultants ...bmce.ie/wp-content/downloads/smithfield_village-vb-ck.pdfWorld War l, lrish independence and American prohibition further decimated

SMITHFIELD VILLAGE . REDEVELOPMENT OFTHE OLD JAMESON DISTILLERY SITE

VINCENT BARRETI BSc (Eng), MSq DIC' MI StructE, MIEI' CEngCIARAN KENNEDY BSc (Eng), Dip Eng, MIEIBARRETT MAHONY CONSULTING ENGINEERS

Presented to a meeting of the Structures and Construction Section of the IEI at The lnstitution, 22 Clyde Road,on Wednesday 3rd February 1999 at 8.00pm.

Synopsis

This 295,000 sq. ft development includes a museum, a theme hotel, bar and theatre, shops, restaurants, apartmentsand underground carparking. A panoramic lift on the largest chimney on the site will give views at 50m abovethe SmithfieldPlaza. The paper describes this exceptionally diverse and complex development from inception tocompletion.

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INTRODUCTION

The site for the Smithfietd Viilagedevelopment is located on the Easternside of the Smithfield plaza. lt iscontained within the block bounded bvSmithfield Plaza, Friary Avenue, BowStreet and New Church Street. ltcomprises the complete block except forthe corner on the South Western endwhich is occupied by the Children,sCourt. The site measures approximately85m x 125m.

In 1995 Architects A & D Wejcherl andBarrett Mahony Consulting Engineerswere appointed by Heritage PropertiesLtd, the Developers for the proposedredevelopment, and a planningapplication was lodged in July / August1995. The project commenced on site inDecember 1995 and is scheduled forcompletion by April 1999.

SITE HISTORY

-ameson's Disti l lery was founded in 1780at Smithfield and the site functioned as adisti l lery from that t ime unti l i t closed inthe early 1970's. The disti l lery togetherwith the local fruit and produce marketsensured Smithfield was a thriving areathroughout the last century and much ofthis century. Indeed the commercialhistory of the area is closely allied to thefortunes of the lrish Whiskey Industry.

The four big Dublin Disti l lers of the time,John Jameson and John Power, Will iamJameson, George Roe consideredthemselves the elite of the whiskevmakers in lreland, and lrish Whiskey waiconsidered a quality product abroad. Upto the '1 870's these firms grew andprospered and enjoyed a large exporttrade. Up to that time Scotch malts camefrom various highland disti l leries and. 3re very varied and unpredictable and: sUCh were no competition for the welldeveloped lrish Whiskey Industry.Essentially lr lsh Whiskey being disti l ledthree times in pot sti l ls was considered asuperior product.

An lrish Civil Servant called AeneasCoffey patented "The Coffey Stilt" circa1947. ln the 1860's Coffey Sti i ls direcflyled to the development of Scotch blendedWhiskeys which ultimately served toprovide the real competition for the lrishDisti l lers. The development of f inerScotch whisky by this process consideredby The lrish as "lnstant Whiskey" led tothe erosion of the export market. Worldevents in the early part of this century i.e.World War l, lr ish independence andAmerican prohibit ion further decimatedthe export business. The home marketprospered however and Jamesonscontinued to operate out of Smithfielduntil they closed the Disti l lery in the early70's and rationalised their production toMidleton Co Cork.

The site at Smithfield changed hands anumber of t imes subsequenfly andindeed was split up in the early 90's.Heritage Properties reassembled the sitebetween 1993 and 1995.

Continuity with the sites i l lustrious historywas copper fastened via the inclusion ofan lrish Whiskey Museum and retentionof many of the features which werespecific to the disti l lery business.

ARCHAEOLOGY

All of the existing buildings on the sitewere constructed during the life of thedistillery. The site is within the area ofpotential archaeological interest andtherefore an assessment was carried outat any early stage by ConsultantArchaeologist Ms Judith Carroll. 17substantial trials and trench excavationswere carried out and revealed nothino ofmajor archaeological significance. In'theareas that were densely covered withbuildings because of the mass andnature of the buildings on the site and theloads that they imposed on the ground,substantial foundations were providedand as such no archaeological f inds wereanticipated in these areas.

DEVELOPMENT

In 1994 Barrett Mahony ConsultingEngineers carried out an init ial appraisalof the site. Practically all of the site wasbuilt upon with lanes and yards betweenmulti storey brick and stone buildings.During slte visits between 1994 andJanuary 1995 the rate of deterioration ofthe existing buildings on the site wasdramatic. A series of f ires by vandalsetc. decimated some of the less rubustfeatures on the site.

The inception of the developmentpredated the current properly boom andthe historic area regeneration plan(Harp). The prospect of a tight railtravell ing through the area was sti l l adistant aspiration. Indeed for the 15months prior to this planning applicationbeing lodged there were no applicationslodged in the Smithfield area, and in theprevious 8 years a total of only twoplanning applications had been lodged inthe Smithfield area and these were smallalterations within the lrish Disti l lers HeadOffice building located immediately to thesouth of this site. Currently the area isone of the most active in the citv from aplanning application standpoint.

LISTED BUILDINGS

The '1895 large chimney, the Smithfietdwall and the stone warehouse at BowStreet / Friary Avenue corner wereamong the l ist 2 elements of the site.The old stone walls on the periphery ofthe site were also considered ofsubstantial merit. By '1 995 the kiln roofsand many of the brick surrounds to the

old stills were either very severelydamaged or in many cases haddisintegrated entirely. Many dangerousbuilding notices had been served on thebuilding and indeed the Bow Street wallhad been lowered to render it safebecause the timber floors behind hadbeen burnt.

REUSE OF OLD BUILDINGS

Figurel shows the typical old bondedwarehouse type construction. Cast ironcolumns and wrought iron of mild steelbeams and timber planks.

Figure 1. Existing Construction

The integration of new and old involvedthe development of an understanding ofthe existing buildings, their form and theirfunction. A visit to the Public RecordsOffice unearthed a vast hoard of processdrawings, design drawings and layoutdrawings of the Distil lery. Figure 2 showsan old process layout of the Distillerycirca 1930.

Figure 2. Old process layoutThe development of such disti l leries tookplace in somewhat an ad-hoc mannerand the locations of the various

C

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processes would bear this assumptionout.

THE IRISH WHISKEY MAKINGPROCESS

The lrish whiskey making process isbriefly outlined:

1. Mal t ing

Barely is soaked in water andallowed to germinate naturally. Thegermination is then halted and thebarley dried.

2. Mi l l ing

The milled barley and malt is thentaken to and mixed with water in"mash tuns" (very large circulartanks).

3. Mashing

The liquid in the "mash tuns" iscalled "wort" a sugary l iquid.

4. Fermentation

The worts is then pumped from the"mash tuns" to the washbacks wereit meets with liquid yeast and isallowed to ferment

5. Disti l lation

A triple disti l lation process in coppersti l ls was employed in the lrishwhiskey tradition.

6. Maturation

The distilled produce is stored in oakport and sherry casks. This is whatgives it its distinctive colour.

This process would suggest that fromgrain intake, the next process is themalting with the associated kilns, thenthe mill ing and onto the "mash tuns" andsubsequently washbacks onto the sti l lsare after this the bonded warehouse. lfone looks at the layout shown in Figure 2,one would have expected the "mashtuns" to be located where the washbacksare and vice a versa.

Nevertheless the use of these old brickstructures and stone structures on thesite varied but in most instances involvedcarrying exceptionally heavy loads suchas the foundations for the washbacks orwash tuns taking say 30,000 gallon tanksetc. The loads on existing walls werelarge with such tanks often being 6-7mhigh and several floors of grain storageor bonded warehouse above. Some oldwalls were calculated to be imposing upto 600 kN/m2 on their foundations withdead load alone.

SITE INVESTIGATION

Two boreholes were carried out on thesite initlally. These revealed relativelyconsistent ground conditions i.e. 2.5m -3m of rubble / fill overlying a clay graveloverlying a l imestone rock at depths upto 8m.

The 17 trenches which were dug for theArchaeologist gave a more reasonablespread throughout the site and theseverified the consistency of theloadbearing dense gravel layer. Thegravel gave N counts of between 40 and70. Allowable bearing pressures of250kN/m'? to 350kN/m, pending on thewidth of the foundation were assumed.The advantages of the dense gravelswere the free draining capabil ity i.e. inextremely wet conditions the groundunderfoot dried almost instantly andbanks exposed proved stable over theduration of the contract.

SITE ACCESS AND BUILDABILITY

Access to the site was restricted to theNorth Western end and demolit ionproceeded from that corner. lt alsobecame apparent early on that thebuilding should be built from thediagonally opposite corner and to "backout" of the site so to speak. ln order tofacilitate access to the South Easterncorner it became apparent earlier on thatnot all buildings in that corner couldeasily be maintained. The mash tunfoundations and the brick l iningstructures for the copper stills wereretained as a major feature which theArchitect developed the WhiskeyMuseum around. Apart from its impacton the skyline the tower building was oflittle merit. lt was effectively demolishedand rebuilt so that reasonableconstruction access was facilitated.Figure 3 shows the retained elements ofthe site. lt can be seen from this figurethat the development of the SouthEastern corner of the site became acrit ical item as did the demolit ion to getaccess to this corner of the site.

TEMPORARY WORKS

The temporary works / demolitionpacKage was prepared for tender inAugust 1995. ln as much as possible,supports to facade walls were kept

outside the site to provide unhinderedspace for construction activity within.External retention systems were adoptedfor Bow Street and Friary Avenue.Figures 4 and 5 show sections at relevantlocations. Verticalig surveys revealedthe existing walls to be reasonably plumband the design loads for the retentionsystems were assumed as follows:Figure 4. Fagade Retention Friary Ave.

Figure 5. Retention Bow Street

lndividual wail ing design load - 2Tzo/o ofthe total wall design load above thewailing level. Frame load - 17,% of thetotal dead load plus the wind load.Where possible return walls were utiliseduntil such time as permanent structurecould be constructed to provide lateralrestraint to the walls. See Figure 6relating to the Bow Street, Church Streetcorner.Figure 6. Bow Street / Church Street

Kentledge was provided by concretepipes filled with earth.

The old trusses over the "mash tuns" ,,,what is now the exhibit ion space of themuseum were supported by a simpleframe with a concrete base to providekentledge.

SCHEME DEVELOPMENT

Many of the features of the old distilleryhave been retained, imitated ordeveloped in the new development. Thef-l

nine storey tower house which housedthe grain conveyer machinery togetherwith three chimneys have beenmaintained as dominant skvline features.

hr

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Kiln roofs have been reflected in theturret aspect of the roof design.Internally brick surrounds to copper stil ls,blacksmith trusses, the retention of oldstone walls and brick walls all serve toreflect the sites former usaoe.

ACCOMMODATION

The development currently includes

220 Aoartments.79 Bed Hotel35,000 sq. ft. Museum including Theatreand Bar7,500 sq. ft. Leisure Centre3,000 sq. ft. Offices32,000 sq. ft. Commercial/ RetailRecording Studio132 Space Underground CarparkTwo through laneways3,000 sq. ft. Balconies13,000 sq. ft. Open Spaces and Terraces3,000 sq. ft Courtyard

Approximately 80% of the apartments aren'.'vided with their own balconv or

q 9 E .

COST EFFECTIVE STRUCTURE

The plan format was developed by theArchitect and retains many of the oldfacade features of the distillery site.Large circular courtyards were providedin the Northern half of the site. TheSouthern half of the site design wasdictated substantially by the requirementto retain the existing buildings.Apartments are generally located abovefirst and second floor. lt is the contentionof the Authors that the most effectiveconstruction for such cellular typebuildings as apartments is loadbearingmasonry and precast concrete floors.This form of construction is consideredappropriate both from a cost stand pointbut also from the ooint of view ofurilisation of the elements of structure

have to be there to providecohpartmentalisation.

Commercial and other activities aremostly located at ground floor level.These in effect warranted transferstructures to be located at either first flooror in the case of the museum building atsecond floor. An underground carpark inthe Northern half of the site warranted in-situ concrete construction. This in-situconcrete frame construction was carriedgenerally to transfer level where theloadbearing masonry and precastconcrete carried the various floors abovethis level. Curved facades above transferlevel were generally facilitated byproviding curved in-situ concrete edgebeams with in-situ infill to the facetedprecast slab.

SITE LAYOUT

The site was naturally divided in two byDuck Lane. The Northern part of the siteNorth of Duck Lane comprised threelarge blocks, namely ABC as set out onFigure 7. The hotel building locatedSouth of Duck Lane between Duck Laneand Jameson Lane is Block D.

sr/lTt_lF'f LDFigure 7. Site Layout

South of Jameson Lane The lrishWhiskey Museum is located within theold walls of the disti l lery at this corner.This area was further subdivided intoBlock E which comprised the multi storeyapartments over the basement, ground,first f loor and Block F which comprisedthe Museum Exhibition space and thestone warehouse building.

The hotel building is located south ofDuck Lane facing the Smithfield Plazabetween Duck Lane and the Children'sCourt. The Recording Studio is annexedto the Hotel Block (Block H). Table 1summaries the overall accommodationwithin each of the blocks.

FLOOR AREA CERTIFICATES

ln order to consider the building as newbuild for the purpose of obtaining floorarea certificates for the apartment it wasessential that the new structure did notrely for either vertical support or stabilityon old walls. lt was also a requirementthat if the old walls were at sometimeremoved "as if this could ever happen"that the inner leaf would comply with thebuilding regulations. ln any event from astructural standpoint the new structurewas independent.

ln the stone building (redeveloped asoffices and part of the Museum) iheexisting walls were used as support forthe new structure.

EXPANSION JOINTS

Figure 7 also shows the location of themain expansion jolnts within thedevelooment.

Buildings within these expansion l ineswere treated as entities in themselves. lnmany cases indeed these expansionjoints were defined by the extent of theusage type i.e. basement carpark l ine,museum etc.

CARPARKING

Given the ambitious nature of the planlayout overhead, the rationalisation of thecarparking space became a demandingproject in itself in the early stages of thedevelopment. Carparking and carparknumbers inevitably would be a trade offagainst what's a practical structure tosupport the overhead layout. Certainareas of the plan (for an effectivecarparking layout) became difficult touti l ise and counter productive and itbecame apparent that the area underBlock A for instance and the rampentrances were not viable as qualitycarparking spaces. Early discussion withDublin Corporation's Building ControlSection resulted in the adoption of aconcrete carpark base surface.

lzU

a

xO&:)r(j

BOW STRTIT

Block No. Floors Type

A

B

D

E

F

L:

L.l

5 / 6 FloorsoverBasement4 l7 FloorsoverBasement6 i 7 FloorsoverBasement4 / 5 Floors

6 i 7 Floors

'1 / 2 StoreyMuseumSpace6 StoreyoverBasement3 StoreyDome

New Build

New Build withinOld Stone Wall

New Build

New Build

New Build withOld RetainedStone WallsRefurbishment

New Build withOld Brick Walls

New Build

T a b l e l - S i t e L a y o u t

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kN/nr. lmposod Load

2.56 Imposed1 56 Partitions

--77-Altemativ€D6ad Load kN/m" lmposed Load

150 H.C. Uni l 4.1

Ground Floor/ Ofiice€ & ShoosD6ad Load kN,h, lmposed Load

AoaatmentaDoad Load

200 H.C Llnil65 SqeedFini6hes

200 1.1.C. unitb5 SCtOedFinishes

CourtvardDead Load

300 H.C. Unit

120mm Screed50 Sand100 Block Paving

ROOFSRoot GardenDead Loed

200 H.C. Unit95mm Screed30 Asphalt80 lnsulat ion50 Pea Gravel200 Soil50 M!lching

3.0

kN/m'

kN/m'

5 01 . 0

----

kN/m'

HA

kN/df

'1.5

kNlflf

2 01 0

2.56 Imposed1.56 Paf i t ions0.504.6

kN/rn: lmpos€d Load

3.55 BS 5400 BridgeLOAO

2.760.901 . 8 09 0

kN/nf lmpossd Load

2 5 62.240.700 1 00.903.600.201 0 . 3 1 5

DESIGN PARAMETERS

Design loadings are set out in Table 2.

Table 2. Design Loadings

TRADITIONAL TECHNIQUES

As with most old buildings many of thesestone buildings were built and maintainedwith l ime throughout and materials suchas l imewash work well andsympathetically with them. A basiclimewash was used for many of the oldstone walls which were left exposed as inthe Museum building. The use ofmodern consolidants was tested on manyof the old brick l ining structures to thecopper stills. However it was found thatthe old l ime mortar techniques were moreappropriate to the restoration of theselocally.

The reuse of old cast iron columns forstructural purposes was an aspiration atthe outset of scheme development.However, given the scale of thedevelopments overhead and the extent ofdilapidation of the existing structure itbecame impossible to extensively reusethese except in some nominal capacity inthe Museum space.

The steel trusses in the Museum roof aretermed "blacksmiths trusses" and arecopied in their detail from those whichhad existed in the old Smithfield shedlocated along the Smithfield elevation,

CONSTRUCTION

The various blocks are outl ined here inthe order in which they were constructedon site.

BLOCK EF

Block EF is situated at the South Eastcorner of the site and was the first blockto begin construction in June ' l 996. Thenew structure was buil i within theconfines of the existing stone walls andaccommodates the lrish Disti l lersWhiskey Museum at Basement, groundand first f loors and 36 apartments above.Extensive reuse has been made of wallsand features remaining from theDisti l lery.

Block EF Apartment Buildinq Structure

lsolated and combined pad foundationsrest on dense gravels with a designallowable bearing pressure of 250 kN/mr.Typically 400 square RC columnssupport 660 x 465 O/A deep beams atground and first f loors and 665 O/A deeptransfer beams at second. 200 deeoprecast hollow core units with 65mmstructural screed are used throughout.

At second floor level a loadbearingmasonry structure carries on fromtransfer. 215 wide walls are typically 20Nat second and third reducing to 10N atfourth and fifth to roof garden at sixthfloor level. Vertical ties are providedthroughout at appropriate centres fromtransfer level and anchored into the sixthfloor roof structure. Columns andtransfer beams are designed as keyelements to withstand accidentaloamage.

r r ' i , : l ' . ' - - : r : t i ; ;

I i j F F i : . - 1 ,

Retained Facade

The existing stone walls averageapproximately 650mm in width and havebeen retained along Bow Street and NewChurch Street. Floor levels have beenarranged to suit previous window opeswhich where necessary have beenslightly modified using brick and / orstone salvaged from earlier demolit ionelsewhere on site. Alterations involvedthe use of l ime based moftarssympathetic to the earlier construction.The new building and existing wall aretreated as independent structures but forlateral restraint offered to the retainedl a a a A ^I q u a u c .

Underpinning was carried out in standardfashion to the level of the newfoundations. From the onset of theproject the view was taken, consideringthe good ground conditions, thatdifferential settlement would be minor -the majority of which would beexperienced before constructionfinalised.

Walls were restrained at each floor levelby tying back to the underside of newprecast concrete floors. Threaded barswere chemically anchored into stoneworkand connected to mild steel angles.Further to tests by suppliers M12threaded bars where selected andembedded 200mm into stone at 1.2mcentres around the perimeter. Thesegave a SWL in direct tension of c.15kNwhich is well in excess of 2.5olo of the**., -- -.

I . : , - .

: t e .

+'fe nfr

Figure 8 Block EF plan

l t ,

J l i # i r J. " r . . . i - I

;li I' ' t : : .1-: .

j

t i , = . ' o ,ii

J : J

,&

5 - - r T ;' 1 - .

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verticaf load {2.5o/o x 300 = 4.5kN).Bolted connections were made only afterthe building had reached sixth floor leveland most of the expected differentialsettlement experienced.

Nonetheless, elongated holes on thevertical leg of all restraint angles wereprovided to accommodate any furtherseftlement, Repalr work has been caniedout to caping stones and a fungicidialtreatment applied to arrest the growth ofvegetation. The existing wall finishes toiorm a parapet to the fourth floor terracelevel.

New floor screeds were poured right upto the intemal wall face. Soundinsulation, preventing the travel ofairbome sound through micro crackslong the wall face was incorporated into

-<he perimeter drylining using fibrousinsulating material. lnsulating.apartments from air borne soundemanating from the Whiskey Museum,Theme Bars and Function Rooms is bymeans of proprietary acoustic ceiling.

Diamond Cantilever Features

A striking feature on both Bow Street andNew Church Street elevations are thecantilever oriel windows. Projecting 2mfrom the new structure. The triangular RCslabs, 265 deep and tapering to 125, arevertically aligned and cantilever over thepavement below from second floorupwards. Stone walls have beencurtailed and trimmed with either stone orbrick to allow these features protrude.The exteriors are clad with a glass andaluminium cladding system which is incontrast to the older stonework.

These "diamond cantilevers" are toppedoff with pyramid towers at sixth floor rooflevel whlch serve as a second level to thefifth floor duplex units. The unusuallyshaped pyramid towers are influenced bythe earlier mentioned kilns which existedon site. Essentially these towers consistof 127 x 76UB portal frames arranged inpairs in each direction. Considering thedifficult location the frames weredesigned for ease of erection. Each ofthe eight legs are connected to a rigidbox at higher level providing compressionand tension rings which allow the fullmoment capacity of rafier members to berealised. Secondary rafters arepositioned at corners carrying trimmedcleader rails and define the pyramidsshape. Overhead the 60 x 60 RSA boxframe lorms the turrets which housewater supply tanks for the apartmentswithin the pyramid.

At the foot of the pyramids 215x300 highupstand beams are cast on the roof slab.Reinforcement is lapped with the meshscreed to resist wind uplifi forces and inaddition threaded bars are dropped downthrough joints between precast unitswhere mild steel plate and bolt

connections are made. These beams,orientated at 45", extend out over the lineof fifth floor apartments and increase to800 deep as they pass over 215 x 1000RC piers and cantilever on to meet andform the final corner oi the pyramid base.

Figure 9. Steel Towers

The L shaped portal base plates tosteelwork and have plates arranged toallow bolts act in shear rather than directtension alone when resisting wind uplift.

Towers are protected against lightning byearthing back to foundations via the RCstructure.

Museum Receotion Area

Adjacent to the new apartment buildingthe original copper still and vat house isnow refurbished as the Museumreception area.

Reception Floor

Old brick "mash tun" foundationsconsisting of concentric circular wallshave been maintained and lie below thenew reception floor. The floor consists ofsteel beams supported off short stubcolumns on 450 square pad foundations.

Crane access was restricted within thisarea due to the elements of olderstructure being retained overhead. "Tee"beam and block flooring were chosen forits handleability. Sections of floor wereomitted to allow visitors view the featuresbelow.

Vats

and 6m in diameter have been carefullyrestored. These vats were previouslylined with copper and exposed to intenseheat for many years. Where necessary,stainless steel rods have been used inFigure 9. Steel Towers

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conjunction with repointing wofk tostabilise loose sections of brick.

At approximately mid height in the mostWestern vat a new floor was required toallow tour circulation. A 200 deep RCsfab is supported by 12 no. 450 x 200keys which were broken into the wall at30" intervals around the perimeter. Thesecond vat which was in considerablybetter repair now houses a lift fromground to first floor level. The support tothis feature lift consists of an open framecomprising of 100 SHS braced with aseries of lighter CHS members. Theframe is further stabilised and horizontaldeflections minimised by surrounding theshaft with an RC spiral stairs which tiestogether the whole assembly includingthe vat walls.

Existing Timber Truss

Two large timber lattice truss arecomposed of two separate trussesarranged side by side comprised of 300square top and bottom booms. Brokeninto two spans, the truss travels the fulllength of the reception area.

Vandalism and various fires had causedextensive damage. Originally this trusscarried grain storage over the "mashtuns" below, far more demanding than itspresent day requirement to support selfweight and a relatively light newmezzanine structure. No strengtheningwork was required.The truss was held in place by temporaryworks during demolition as previouslydiscussed and built into the new structureas work progressed.

New Museum, Roof

Where Block GH is now located thereoriginally existed a large warehousebuilding covered with very attractive

---

wrought and cast iron A-frame trusses.The new roof over the reception wasmodelled on this and consists mainly ofmild steel angle sections, flat plates andsolid rods as ties. In total 3 bays of trusswere used and supported off variouselements including the vat house wall,existing steel plate girder, new steelbeam and the perimeter wall of the newapartment building.

The irregular shape in plan and thenumber of objects which were to beavoided below including brick vats andlarge museum pieces, (such as copperstills which were installed prior to theroof), complicated the structuralarrangement.

Internally the roof is finished with timberwhich is coated with intumescent varnishand slated externally.

Audio Visual Room

The audio visual presentation room is astarting point to tours around theWhiskey Museum and accommodates200 people seated in a crescent fashion.

The stepped seating platforms weredesigned to act as plenum for the supplyof fresh air. For this reason honeycombwall construction supports 240 x 44timbers at 400 centres and 12mmplywood decking between. Holes havebeen cut under each seat to provide anevenly distributed air supply.

Jameson Court Entrance Canopv

Covering the main Museum entrance inJameson Court this external canopyconsists of galvanised steel plate rolledto present a curve which supports the

('l

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gently inclined glazing. This steel plate isin turn supported at each end off verticalRSC's which travel from concrete footingup to the roof parapet. Mid span, thecurved plate is supported by 12mmdiameter tie rods inclined at 45" andagain connected to the vertical channels.The RSC's are restrained at parapet levelby connecting back through the Museumwall to the new steel trusses behind.

Stone Buildinq

Considered as part of Block EF, thestone building is shared between theWhiskey Museum, Music Centre,Smithfield Hotel and a separate officesuite. Originally the building served asstorage space for granular materials andfinal products destined for duty freemarkets. The building is roofed by a castiron tank which held close to 4 ft. ofwater, which served not only as a watersupply to the production facilities aroundthe Disti l lery but also as a means ofmaintaining a cool temperature in thee+ores below.

The cast iron roof remains not only as aroof and feature but as plant storagespace for the many new facilities - whenfull this tank supported approximately 12kNim'? SWL. The tank was constructedwith individual 4 foot square cast ironpanels bolted together and sits on a gridof primary and secondary girders.Occasional panels have now beenremoved to provide access to plantspace from a new stairs below.

A common problem encounteredelsewhere on the site was also present atthe foot of the stone building. The manybrick service trenches, drainage andsmoke ducts which ran throughout thedisti l lery lay close to foundations. In thisparticular instance they were found to bevery low.

; first stage in restoring this buildingWds to underpin the stone foundations toa level so as not to be affected by voidsor proposed foundations and wherenecessary infill ducts with lean mixconcrete.

Maintaining the roof tank restricted craneaccess and hindered installation of thestructure below. For this reason asystem of 203 UC beams supportingblock and plank flooring was chosen.Block and plank floors, 250 O/A deep aresupported off the bottom flange of UCsections and this minimises the structuraldepth. Although considered an internalenvironment, any steelwork which entersinto or bears onto the existing stone wallsis coated with 2 layers of bitumen paint inaddition to standard specification Endplanks are supported by angles withvertical leg orientated upwards andmechanically fixed with anchors at 400centres. Reinforcement is welded toprovide a positive tie between the slab

and wall. Structural topping wasdelivered via concrete pumpThroughout construction the tank servedas a lateral restraint at eaves level.

A new structure was installed at ground,first, and second floor levels andopportunity was taken to reuse existing650 deep steel beams at third floor level.New opes were broken and lintelsprovided, typically l ight UC sections havebeen arranged parallel and gap betweeninfi l led using brick and / or stone material.

All steelwork is protected for t hour firerating either by encasing or, whereintended to remain exposed, by coatingwith intumescent paint.

BLOCK D

Block D Accommodates 43 apartmentsand provides 500m2 retail space atground floor level. Located on theEastern side of the site, apartments areaccessed from Bow Street. One side ofthe retail units opens out onto DuckLane, a reconstruction of a lanewaywhich previously ran through theDistillery. The other side which is curvedin plan forms the boundary to JamesonCourt, the newly formed courtyard areaserving the Museum reception. Anoticeable feature in this block is theretained chimney, the second largest onsite,

lated 18'13 AD.

Block D is the most irregularly shapedstructure within the development. Fix x-xshows the more regular rectangularportion which is present from basementlevel to sixth floor roof garden behind theretained facade on Bow Street.Sweeping towards the centre of the sitethe Western leg of Block D is curved onall sides. commencing at ground levelrather than basement, the structure forthis portion steps in progressively at eachfloor level up to fifth.

Structure

RC isolated pad foundations support 400diameter circular columns which in turnsupport the transfer structure at first floor.The irregular compartment layout abovedid not lend itself very well to a typicaltransfer beam system, an alternativesolution consisting of a 300 deep RC slabacting as a "transfer plate" was chosen.

Curved beams have been detailed with astraight inside face with varying l inks totake up the curve. This allowed detail ingthe beam as straight thereby avoidingtorsional complications.

Loadbearinq Masonry

Again 20N blocks support the precastfloor units at each level which reduce to10N from fourth floor. Vertical ties havebeen provided as per Block EF details.

Curved External Leaf Blockwork

Built with a radius of 12m along JamesonCourt, the perimeter edge beams werecast within shuttering faceted in 1.2mlengths. Continuous stainless steelrelieving angles are provided at third floorlevel and supplied in 1.2m lengths andmechanically fixed to the edge of theperimeter beams allowing the externalleaf of block work to be constructed tobear on the angle, ensur ing a min imumsupport of 80mm at all t imes.

Balconies

Balconies which overlook Jameson Courtare essentially t imber platformssupported off 4 storey vertical towersmade up of SHS and angle members.Vertically independent of Block D mainstructure, the towers are tied back forlateral restraint.

Expansion Joints

Along the southern l ine of Duck Lane andfor the full extent of the site an expansionjoint separates the North and South endof the site from foundation level andabove. Precast slabs on Duck Lane bearat one end on neoprene strips whichaccommodate small horizontalmovement and reduce any inducedstresses.Roof Tower & Diamond Cantilever

Roof tower and diamond cantileverfollows the same principles as thoseused in Block EF.

External Terrace Walkwavs

Access to apartments on the curvedportion of Block D is offered via externalwalkways which overlook Duck Lane. RCslabs are supported of galvanised steelcircular hollow sections. Servicesfeeding to these same apartments arehung from the underside of terraces.Terraces lead to the alternative fireescape route by the existing chimney.

Ch imnev (1813 )

The second largest chimney on site anddated 1813 was, despite some superficialdefects found to be in good condition.Signs of previous repair work wereevident including repointing andcircumferential steel straps. Towering at

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Figure 10. Block D Plan

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33m the chimney projects 10m aboveBlock D roof level.

Excavations for Block D foundationsrevealed the brick chimney was built off amass stone / rubble plinth extendingbelow the level of the new foundations.The underground carpark below BlockABC which extends as far as Duck Lanemeant much excavation in the immediatevicinity of the chimney foundations. Thecondition of the stone / rubble causedconcern and it was encased in concreteon a piecemeal basis to allow work toproceed. The chimney when consideredas free standing from foundation levelhad a factor of safety against overturningof 10 and mobil ised a bearing pressure of700kN/m'?.

Earlier proposals to provide an escaperoute from the external terracesmentioned above included steel stairsaround the outer oerimeter of thechimney spirall ing down to Duck Lane.Considering the irregular wall surface andpotential fabrication difficulties resulting,but more importantly realising thepossible benefit of providing an effective"wrap" around the chimney, an RC spiralstairs was chosen. The stairs, 175mmwaist and 200 deep landings, is t ied backto the building at each floor level.

BLOCK ABC

Block ABC comprises 139 apartmentsand 2,000m' retail space at ground floorlevel. Towards the front a sculpturegallery occupies a double floor heightexhibit ion space opening up ontosculpture court, the semi circularcourtyard onto Smithfield plaza whichforms the main village entrance. Atseventh floor level the double storeytower features overlooking Bow Streetand Friary Avenue are the highestresidential units on the develooment.The basement provides for l iZ carparking spaces and is accessed by aseparate entrance and exit ramp fromBow Street.

Structure

Structural scheme is similar to otherblocks with RC frame at lower levelssupporting the transfer system at 1st floorfrom where loadbearing masonrycontinues. Again, throughout each level,steps in plan and external terraces calledfor numerous transfers

Towers

At higher levels transfer structure supportthe legs of the large tower structures 8msquare in plan. Slightly different to thosediscussed in Block EF these consist of 4no. 400 diameter RC circular columns uoto 7th floor level which are framed withRC beams. Anchored to the RC beam

the steel portals rise 6m and are cappedwith glazed turret pieces.

Garden Area

The rectangular court area bounded byblocks A & B was designed to provideaccess for emergency services, includingfire tenders, through the Bow Streetpedestrian entrance. 400 deep precastunits span 10m and were designed forparameters as specified in BS 5400Bridge Design - HA Loading. A 5mdiameter opening is covered with a metalgri l le and contributes to the carparkventilation below.

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Figure 11. ABC Plan

Car Park Ramp

Car park exit and entry ramps both havedouble curvature in plan to sweep aroundthe structure. 200 deep in-situ slabs aresupported off 300 wide x 1000 high sidewalls which act as beams. The exit rampwas la id at 1:10 and entrance at 1 :9.

Raised Courtvard

A central courtyard in Block C is formedat second floor level over the sculpturegallery exhibit ion space. 200 deepprecast units span 7m and in addition togarden finishes, support steel SHS legsof the veranda which provides access toapartments at 3rd and 4th floor levels.

Pfatforms consist of 125 x 64 RSCspanning between SHS uprights andsupport 125 deep RC slab spanning onto215 walls. Additional restraint is providedby casting in M16 galvanised threadedbars passed through the vertical web ofchannell at 600 centres.

A sacrafical column approach was usedin the terrace slab design. Any onecolumn could be removed withoutaffecting the slab structure, therebyreducing the need for expensive fireprotection on external columns.

Perimeter Walls / Claddinq

The existing red brick wall further downSmithfield in front of Block GH has beenrecreated in front of Block C for theSmithfield elevation and around theFriary Avenue corner. Towards theeastern end of Friary Avenue theMalthouse walls have all been retainedexcept for the gable ends. Walls havebeen extended by up to two storeys usingtraditional technioues.

Fronting onto Smithfield Plaza, thesculpture court forms the main entranceto the development. Standing at fivestoreys tall this curved elevation is cladpredominately with glass.

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BLOCK GH

Block GH was the last block to beginconstruction. Accommodating a 79 suitehotel, theme bar and restaurant, musiccentre with exhibit ion space andauditorium. This block l ies at the southeastern corner of the site behind anexisting red brick wall leading ont.Smithfield Plaza. Block GH can b.separated into several distinct areas:

Hotel - which occupies the full frontelevation from sculpture court toboundary.

Music Centre - circular drum structurewith conical roof between the hotel andJameson Court.

Stone Building - as previously discussed.

Conservatory Area - glazed infi l l l inkingthe stone building, music centre andhotel.

Hotel Structure

For the more regular rectangular area,isolated pad foundations carry 400diameter circular columns supporting 600overall deep transfer beams at first floorlevel.

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-he existing wall has delermined.-domewhat the new floor levels, and in

order to maximise floor to ceiling heightsa thin floor plate was required. '100 deepsuper wide slabs with 'l 00 structuraltopping spanning 7.5m have been used.Slab changes to 250 deep in-situ flat slabconstruction over by the irregular andcurved sections by the main entranceand sculpture court where head roomwas not such an issue.

Above the first floor transfer level thestruciure changes to 215 wide loadbearing block work. At each level thefloor plates described at first have beenrepeated.

3rd floor level aligns closely with the topof the existing brick wall, a terrace isiniroduced here as the structure stepsback approximately 2m continuing up to5th floor level oenthouse suites.

A full height atrium is featured in the hotelentrance lobby where voids in the flatslab above align to a glass octagon rooflighi at sixth floor roof level.

Half Barrel Roof

Above the 5th floor penthouse theloadbearing block work and vertical tiesfrom below finish off in a 215 wide bandbeam above which additional blockworkiorms the curved roof contours. Steppedblockwork supports galvanised steelpurlins and curved insulated sandwichpanels. The purlins are strapped downvia galvanised steel straps anchored toRC band beams to resist possible upliftforces due to positive pressure actingthrough the large patio doors which leadonto terrace balconies.

Existinq Brick Walls

The existing red brick wall facing ontoSmithfield plaza dates back to 1895.Once the perimeter wall of a newersection of the distillery it has beenmaintained but altered by cutting fullheight vertical slots to allow generalaccess and light penetrate. Thismodified wall forms the basis for thatrecreated on the Block "C" Smithfieldelevation. Bounding the Eastern side, asecond wall with impressive arches andcircular openings has been retained.

The curved wall onto sculpture court isclad with glazing to mirror that on theBlock "C" side.

At basement levels the theme bar andrestaurant have been stepped to form anintermediate "lower ground" level runningparallel to the brick wall. This negatesthe need to underpin allowing a loadspread of 1:2" The 275 deep RC slab atbasement level has been designed to BS8102 as Grade 2 Basement using Type BConstruction (structural integralprotection).

At higher levels restraining angles areused to tie walls back to the newstructure in a manner similar to thatdescribed in Block E/F.

Music Centre Structure

The Music Centre drum is approximately26m in diameter and offers musicperformance, recording facilities and

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exhibition space at basement, groundand 1stfloor.

Once again pad foundations support 400diameter RC columns carrying 600 deepRC beams at ground and 1st floor. 300deep superwide slab floors spanning upto 10m are used throughout. Slabs areessentially 100 thick precast with 100void formers and 100 structural topping.On the periphery 215 block walls, curvedin plan support slabs cut at a suitableskew, in-situ topping or small infill in-situslabs define the final shape.

The solid peripheral walls are consideredto be inherently stiff and brace thestructure.

Conical Roof

At 1st floor level the RC structureterminates and a steel portal framecontinues. The conical portal frameconsists of 406 x 140 UB raftersananged radially at 45' and slopingapproximately 17", intermediatesecondary rafters break ihe span ofroofing deck at lower levels. 406 x 178UB stanchions (8 no.) are fixed to theslab directly over RC column heads.

Figure 13. Section Through GH

The future use of the auditorium calledfor the use of an acoustically insulatedroof. Many options were consideredincluding an RC shell, The finalconstruction consisted of a metal deck.12mm ply, 25 pyrock sound insulatingboard, 50mm polystyrene, 30 pyrock androofing membrane.

Eight rafters are connected to acompression block at apex consisting ofa CHS containing circular plates weldedin place. For purposes of design theconnection is considered to act as a pin.

At eaves level 203 UC's trim the metaldeck forming an octagon in plan - theoutstanding curved areas were then

infilled with 200 deep concrete slabsreinforced ts form a tie beam around theroof and further stabilise the structure.

Audio visual equipment, camgras andlighting gear are all hung from raftersinside.

The Music Centre connects directly withthe ground and second floor of the stonebuilding. Existing windows have beenopened out and where required new opescreated. Connections to higher levelsare made via stairs which curve aroundthe perimeter of the Music Centre drum.The RC stairs with 200 deep waist havebeen designed for long spans combinedwith torsional effects.

Conservatory Area - Structure

The basement level courgard formedbetween the site boundary, Hotel, MusicCentre and the stone building remainsclear for full height.

This area has been covered with asloping glass roof 15m above thebasement level at the stone buildingreducing to 5m at the hotel end. 3 No.800 deep steel lattice trusses comprisedol 120 x 80 and 60 x 40 RHS's span the12m length. Trusses are braced usingstainless steel cables and turn bucklecomponents. Above this 80 x 40RHSpurlins span from truss to truss and inonto the Music Centre wall. The steppedflashing detail along this curved wallprovides a dry cavity below the roof levelwithin the conservatory. Any steelworkwhich bears on neighbouring walls arecontained within this dry environment.

Finally the glazing mullion system is fixedand a walk-in gutter at the lower valley

Service Interaction

Much of the plant space required for thehotel was located remotely - within theold cast iron tank above the stonebuilding, this reduced the number ofstructural implications associated withproviding large items of plant at roof levelincluding concerns regards noise andvibration control. and increased thenumber of penthouse suites. To theexterior of the stone building 900diameter stainless steel ducts groupedtogether form a route for services fromroof level down.

Within the Hotel veftical service shaftshave been arranged so as to minimise

horizontal service runs which vvasimportant particularly within the areaoccupied by hotel suites where floor toceiling heights were critical and theunderside of supenride precast slabswere to form the final finish.

CHIMNEY

Built in 1895, the largest chimney on sitestands at 42m above ground level has aconstant internal shaft diameter of 9ft{2.74m) and external diameter ot '14 ft(4.27m).

Constructed with red brick, cut granite isused at intermediate level and inconjunction with cast iron plate at the toprim.

Proposal

The proposal has been to provide a glasspanoramic lift serving a two storey glassviewing platform located on top of thechimney. The platform is accessed atthe lower viewing level and visitors ca,.take a spiral stairs up a further flight.*Spiral stairs returns down through theshaft to provide an emergency escaperoute,

lnspection

A visual inspection of the chimney wascarried out by examining the internal andexternal brick faces from a cagesuspended off one of 3 site tower cranes.Brick and mortar were found to be ingood condition for a structure exposed toelements for over a century. Cast ironcapping pieces at the rim had conodedand signs of damage by vegetation wereevident.

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Structure

To enhance the chimneys strength andprovide additional resistance againstwind moment, axial load and torsionaleffects generated by the new structure a125mm thick sprayed reinforced concretelining has been proposed. This l iningshall effectively form a stiff 2.74mdiameter pipe with a 125 wall thickness,suitably reinforced the l ining shalltransmit the torsional and bendingstresses induced by wind on theasymmetric structure down through thechimneys to a level where verticalprecompression increases capacity.

Figure 14. Chimney Schematic

The planned sequence of construction isas follows:

1. Central spine ('193 CHS) is insertedthrough central shaft, and 3mm steeldurbar plate spiral stair treadsattached and anchored into brickwall. Horizontal going of treads stopshort of wall to allow sprayedconcrete l ining pass later.

2. At the Southern side, 533 x 19'1 UB'sand 203 UC's are erected verticallyand carry the lift support and railassemblies. lntermediate horizontalframes provide lateral restraint in two

directions, frames are connected tothe chimney wall with M25 dividagthreaded bars passed through thefull wall thickness to a MS plate andbolt connection on the internalsurface,

Reinforcement placed on the internalvertical surface and steel threadscovered with protective membrane.Sprayed concrete l ining is appliedworking upwards and finished withtimber float to provide a smoothersurface.

At the top rim the cast iron cappingpieces and damaged masonry areremoved, a new reinforced concretecapping piece is then formed usingthe refurbished cast iron plates aspermanent formwork.

The two storey viewing platform iserected at ground level, lifted intoplace, and connected to the RClining and the external steelframe.

Finally l i ft installation and finishesare fitted.

This remains the last element ofstructural work to be completed. Theinternal stairs is at this stage in place.The walls wil l hopefully be concertedwithin the coming weeks with completionexpected within 2-3 months.

The project has been an adventure. lthas l ifted the area in general and worksplanned for ihe near future by variousbodies in the Smithfield area are nowvery numerous. When this projectstarted it was the vision, determination.and ambition of the developer whichenthused the whole team. We thank allthose involved with what was an excitinoand rewarding project.

DESIGN TEAM

Developer:Heritage Properties

Architect:A & D Wejchert

M & E :Delap & Waller

Fi re Consul tant :Michael Slattery Associates

Archaeologist :Judith Carroll

Hote l F i t Out :Event

References

Public Records Library

lrish Whiskey - A 1000 Year Tradition -O' Brien Press by M Magee 1998

Temporary WorksFagade RetentionMahony '1996.

- The Design ofSystems by Brian

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