In the Shadow of a Skyscraper

In the Shadow of a Skyscraper

Clinging to the foot of the giant, multifunctional building, however, has its own very solid dimensions: two split-leveled 18-storey buildings in the top point of the Atrium reach a height of 78 meters. The floor area of the building is more than 40% of the sum of the squares of the entire complex. Futuristic architecture requires a significant amount of innovative design and technological solutions.

In August NTZMK began to manufacture some of the most dimensional designs for multifunctional building: series of 8 meter long trusses, each of which comes close to 20 tons.

The first of the obvious implementation difficulties for this frame is the combination of multiple brands of high strength steels in their design: local S440 and HiSTAR-460 beams, supplied from abroad 120 mm thick which is rare for building structures.

Why does the building with relatively small height need such strength? – explains the head of the design bureau D.A. Derbyshev. – The idea of architects and designers was to create inside the building huge free spaces, which will accommodate a Congress Hall, Sports Centre and an Education Centre. Therefore, half of the entire building would be “hanging in the air” relying only on a small number of constructional elements. The load generated is enormous for those elements.

Forming metal of such thickness, cutting, drilling holes are quite complicated tasks available for not each manufacturer. Framing rolls UBR-40, bending machine Verrina, automatic lines of gas and plasma cutting and drilling Gemini-364, TIPO-B254, “Comet”, gouging and milling machines, supplemented by the work of manual welders, only such a broad application of equipment and staff of pre-fabricated product shop makes it possible to manufacture these designs. The assembly and welding processes are also very technological.

– A necessary condition for manufacturing of these constructions is a very precise conformity of the product “at the exit” to the given geometrical parameters, – says engineer-technologist K. L. Bisharov. – All parts of the framework in this project are designed for installation with the use of high-strength bolts that invalidates the existence of gaps or offsets. Most tolerances do not exceed 2 mm, which is a very serious test dealing with building constructions. 

Control of flatness and convexity of components, metal templates developed specially for this project, a large number of temporary “tack welds” -these are not a complete list of technological solutions used to ensure the accuracy of the geometry of the farms.

The assembling is carried out in 11 steps with welding structural elements, milling the assembled parts, measuring of deviations using survey equipment. The final docking of framework parts is performed on the individually designed assembly stand. All welds are subjected to 100% ultrasonic control. All the results are filled in the map of measurements for each assembled mark transmitting all geometrical parameters of real constructions in virtual model of the object.

– By the 10-point scale, the complexity of manufacturing of this type of designs is well worth evaluation of 8-9 points, – concludes K.L. Bisharov. – But this is not the limit. Now we have already worked out the next series of designs for a multifunctional building “Lakhta”, demanding new decisions and that is not only equal to the complexity of these farms, but surpasses them.

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