TERRI MEYER BOAKE

Architecturally
Exposed
Structural
Steel
Specifications, Connec tions, Details
 CONTENTS
The preparation of this book was kindly supported by the
World Steel Association.

9 FOREWORD by Dr. Edwin Basson, 35 AESS 4 – Showcase Elements

This book is now Director General, 37 AESS C – Custom Elements

available for purchase!

World Steel Association 40 Mixed Categories
GRAPHIC DESIGN, LAYOUT AND TYPOGRAPHY
11 PREFACE
Reinhard Steger, Christian Schärmer, Deborah van Mourik
Proxi, Barcelona
Available through 43 CHAPTER 3
EDITOR FOR THE PUBLISHER
Andreas Müller, Berlin
Amazon and other 13 CHAPTER 1
CHARAC TERISTICS
online retailers. THE BASIS OF
LIBRARY OF CONGRESS
CATALOGING-IN-PUBLICATION DATA ARCHITEC TURALLY 43

46
AESS 1 – Basic Elements
AESS 2 – Feature Elements with
EXPOSED
A CIP catalog record for this book has been
applied for at the Library of Congress. a View Distance > 6m/20ft

BIBLIOGRAPHIC INFORMATION PUBLISHED BY THE

STRUC TURAL STEEL 50 AESS 3 – Feature Elements with
a View Distance ≤ 6m/20ft
DEUTSCHE NATIONALBIBLIOTHEK
54 AESS 4 – Showcase Elements
The Deutsche Nationalbibliothek lists this publication in the Deutsche 13 What is AESS?
59 AESS C – Custom Elements
Nationalbibliografie; detailed bibliographic data are available in the 16 The Evolution of Architecturally
Internet at http://dnb.dnb.de. 59 Using the System
Exposed Structural Steel
60 AESS CATEGORY MATRIX
17 From Structural Rationalism to
This work is subject to copyright. All rights are reserved, whether the
whole or part of the material is concerned, specifically the rights of High Tech
translation, reprinting, re-use of illustrations, recitation, broadcasting, 18 Initial Developments in High
63 CHAPTER 4
reproduction on microfilms or in other ways, and storage in databases.
Tech Detailing
For any kind of use, permission of the copyright owner must be obtained.
20 Primary Factors of Influence that EREC TION
This publication is also available as an
e-book pdf (ISBN 978-3-03821-483-0) and 22
Define AESS
Communication Issues between
CONSIDERATIONS
EPUB (978-3-03821-446-5). Architect, Engineer and Fabricator
63 Transforming an Architectural
23 The Role of BIM and Detailing
© 2015 Birkhäuser Verlag GmbH, Basel Idea into Prefabricated AESS
Software
P.O. Box 44, 4009 Basel, Switzerland Elements
Part of Walter De Gruyter GmbH, Berlin/Munich/Boston
64 Shop versus Site Fabrication
65 The Impact of Transport Issues
Printed on acid-free paper produced from
chlorine-free pulp. TCF ∞ 25 CHAPTER 2 on Design

Printed in Germany THE CATEGORY 66

67
Site Constraints
Care in Handling

ISBN 978-3-03821-574-5
SYSTEM 69 Sequencing, Lifting, Access
and Safety
26 To Grind or Not to Grind? 71 Erecting the Steel
987 65 4 32 1 27 Standard Structural Steel 73 Combining AESS with Other
www.birkhauser.com
27 AESS 1 – Basic Elements Systems
30 AESS 2 – Feature Elements with
As a rule, this book does not make reference to existing patents, a View Distance > 6m/20ft
registered designs, trademarks etc. If such reference has been omitted, 32 AESS 3 – Feature Elements with
this does not signify that the product or the product name is not a View Distance ≤ 6m/20ft
protected. The great number of different materials and products mentioned
in this book made it impossible to carry out an investigation into the
possible existence of trademark protection in every case. Accordingly,
as a rule, the text makes no use of trademark symbols such as ®
or TM.
 BUILDING PROFILES

75 CHAPTER 5 117 CHAPTER 7 41 PORTO INTERNATIONAL AIRPORT 155 BALTIC CENTRE FOR CONTEMPORARY 167 ARGANZUELA BRIDGE

COATINGS & CONNEC TIONS Porto, Portugal

ICQ with WS Atkins
ART Gateshead, England
Ellis Williams Architects
Madrid, Spain
Dominique Perrault
PROTEC TION 117 Definitions
Architecture with MC2 Estudio
83 WESTGATE PEDESTRIAN AND CYCLE 158 SYDNEY OPERA HOUSE de Ingeniería, S.L.
118 Connection Design Checklist
76 Surface Preparation BRIDGE Auckland, New Zealand Sydney, Australia
120 Shop versus Site Fabrication
78 Paint Systems Jasmax architects, Aurecon Jørn Utzon and Ove Arup 168 ORIENTE STATION
121 Connection Mock-ups and
78 Primers Consulting Engineers and HEB Lisbon, Portugal
Visual Samples
79 Shop versus Site-applied Construction 159 AMGEN HELIX BRIDGE Santiago Calatrava
122 Bolted Connections
Coatings Seattle, WA, USA
124 Welded Connections
79 Corrosion Protection: 86 STRATFORD TOWN CENTRE LINK Johnson Architecture and KPFF 169 PEACE BRIDGE
130 Pin Connections
Galvanization, Metallization, London, England Consulting Engineers Calgary, AB, Canada
Stainless Steel, Weathering Steel Knight Architects with Buro Happold Santiago Calatrava
89 Fire Protection Systems: 160 CANOE BRIDGE
139 CHAPTER 8
Intumescent Coatings, Sprayed 87 THE GLASS BRIDGE Vancouver, BC, Canada 170 GATESHEAD MILLENNIUM BRIDGE
Fire-resistive Materials (SFRM), SPECIALIZED Perth, Australia PWL Partnership Landscape Newcastle, England
Concrete-filled Steel Tubes
CONNEC TIONS Donaldson + Warn; Capital House
Engineers; artists David Jones,
Architects Wilkinson Eyre Architects
with Gifford
Kevin Draper and Richard Walley; 161 VIADUCT EVENTS CENTER
139 Making Connections Less Visible
97 CHAPTER 6 John Holland Constructions Auckland, New Zealand 171 PEDRO AND INÊS BRIDGE
140 Hidden Connections
MEMBER CHOICES 142 Discreet Connections
115 ONTARIO COLLEGE OF ART AND DESIGN
Moller Architects Coimbra, Portugal
Cecil Balmond
147 Cast Connections
Toronto, ON, Canada 162 THE SHARD OBSERVATION LEVEL
97 The Texture of an AESS Project
Will Alsop Architect London, England 172 ABC MUSEUM
98 Choosing a Member Type
Renzo Piano Building Workshop Madrid, Spain
98 Hot-rolled Steel Sections 157 CHAPTER 9
134 BARAJAS AIRPORT TERMINAL 4 and WSP Aranguren + Gallegos
102 Tubular or Hollow Structural
Sections (HSS): Round Hollow
CUSTOM Madrid, Spain Arquitectos

Structural Sections, Square or FABRICATION Rogers Stirk Harbour + Partners 163 THE NEW YORK TIMES BUILDING
New York City, NY, USA 173 ST. JOHN AMBULANCE
Rectangular Hollow Structural
137 NEO BANKSIDE HOUSING Renzo Piano Building Workshop, HEADQUARTERS
Sections 158 Building Profiles
London, England FXFOWLE Architects and Edmonton, AB, Canada
108 Elliptical Hollow Sections (EHS)
Rogers Stirk Harbour + Partners Thornton Thomasetti Manasc Isaac Architects
110 Custom-fabricated Sections
113 Tapered Tubes or Cones
APPENDIX 152 BRISBANE INTERNATIONAL 164 NATIONAL ARCHIVES OF CANADA 174 BOSTON SOCIETY OF ARCHITECTS
178 Selected Bibliographic AIRPORT Brisbane, Australia Gatineau, QC, Canada STAIR Boston, MA, USA
References Richards and Spence with Arkhefield Blouin IKOY & Associés Höweler + Yoon Architecture
179 Notes
179 Illustration Credits 153 RENOVATION OF OLYMPIASTADION 165 CANNON STREET STATION AND 175 CAIXA FORUM
180 Subject Index BERLIN Berlin, Germany OFFICE BUILDING Madrid, Spain
182 Index of Buildings Architekten von Gerkan, London, England Herzog & de Meuron
183 Index of Persons and Firms Marg und Partner Foggo Associates
184 About the Author
154 REGENT PALACE HOTEL 166 PUENTE DE LUZ
London, England Toronto, ON, Canada
Dixon Jones Architects Francisco Gazitua
 FOREWORD
The World Steel Association (worldsteel) is proud to be the exclusive sponsor of Archi-
tecturally Exposed Structural Steel: Specifications, Connections, Details. Construction is
one of the most important steel-using industries, globally accounting for more than 50%
of world steel use. Buildings – from houses to car parks to schools to skyscrapers – rely
on steel for their strength and durability. In addition to structural frameworks, steel is
also used on many other parts of buildings, including roofs and cladding for exterior walls.

Steel continues to be at the root of advances in architecture and construction. The use
of exposed steel in buildings brings the design benefits and dynamic potential of steel
to the public eye. Its stiffness allows steel to span greater distances and provides more
design freedom than other materials. Steel’s superior strength-to-weight ratio makes it
possible for the structure to bear high loads using less material. Architecturally Exposed
Structural Steel (AESS) plays a significant role also in the design of contemporary
pedestrian bridges that elevates their role in the urban realm to that of art.

Sustainable steel is at the core of a green economy. Reusing or recycling building com-
ponents is key to the sustainability of a structure’s end-of-life as it is the most economic
and ecological solution. The global recovery rates for steel construction applications stand
at 85%, making it a good choice for building structures. The exposure of steel leads to a
reduction of materials that would otherwise be used to conceal the structural systems,
while at the same time creating stimulating architecture.

Steel is safe, innovative and progressive. Industry surveys consistently demonstrate that
steel is the safest construction material. Steel offers the highest strength-to-weight
ratio of any building material. Because of its strength and durability, steel structures are
designed to withstand natural disasters. It is also impervious to attacks from termites or
fungi, does not rot or split and is highly fire-resistant. The steel industry globally spends
more than €12 billion annually on improving the manufacturing processes, new product
developments and future breakthrough technologies.

Steel is a key driver of the world’s economy. The industry directly employs more than
two million people worldwide, with a further two million contractors and four million
people in supporting industries. In 2013, the steel industry had a turnover of more than
$900 billion, yielding over $100 billion in tax.

Steel plays a fundamental role in the development of modern societies and is an ideal
material to help meet the societies’ growing needs for buildings and infrastructures in
a sustainable way. Its intrinsic properties such as its strength, versatility, durability and
100% recyclability allow improved environmental performance across the entire life
cycle of buildings.

The AESS Category System of design presented in this book acknowledges the impor-
The Munich Airport Center tance of the role of proper connection design and erection strategies, and communication
in Munich, Germany, designed between the fabricator, engineer and architect, as central to ensuring safety on the site.
by Helmut Jahn and completed
in 1999, showcases high-level
detailing in Architecturally Dr. Edwin Basson
Exposed Structural Steel. Director General, World Steel Association

8 9
 PREFACE
ACKNOWLEDGMENTS I have found great joy and inspiration in the detailed study of
This publication has been made possible through Architecturally Exposed Structural Steel (AESS) that has ensued
the generous support of worldsteel. Worldsteel from the research and writing I undertook for my first book Under-
was also the sponsor of Diagrid Structures: Systems,
standing Steel Design: An Architectural Design Manual, published
Connections, Details.
by Birkhäuser in 2011. Where Understanding Steel Design looked
My early interest in steel must be credited to inspira- more holistically at the potential in the informed use of steel in
tion from the High Tech works of Foster, Rogers,
architectural projects, Architecturally Exposed Structural Steel
Piano and Grimshaw as well as Santiago Calatrava.
My appreciation of the importance of the details of these looks more specifically at an approach to properly designing steel
connections as elements of industrial design was inspired for exposure. Such exposure demands that architects become
by my former colleague at the University of Waterloo
more engaged in the detailed design of steel systems, and with
School of Architecture, Ron Keenberg of IKOY Architects.
Much of my energy and understanding of Architectur- that, understand better the varying approaches to connection
ally Exposed Structural Steel comes through my involve- design, fabrication and finishing and how these impact the entire
ment with the Canadian Institute of Steel Construction
project in significant ways.
in the development of the methodology that is expanded
upon in this book. I owe so much to the large number of
steel professionals involved in this development. Particu- The category approach to specifying and detailing AESS that
lar thanks go to Mike Gilmor, Rob Third and Suja John.
is presented in this book is derived from substantial work done
Also core to the CISC AESS committee work, my under-
standing and experience of steel would be nowhere with- in conjunction with the Canadian Institute of Steel Construc-
out the assistance of Sylvie Boulanger, Walter Koppelaar tion (CISC) between 2005 and 2011. The development of this
and Tim Verhey. Sylvie is my engineering counterpart and
system by CISC was intended to create better communications
has willingly shared so much knowledge and insight with
me. Sylvie traveled with me to Australia and New Zealand within projects in order to make the incorporation of AESS more
in conjunction with expanding the Category System to straightforward by standardizing some of the core fabrication and
Australasia. Walter has always encouraged me and allowed
detailing practices, thereby allowing the team to focus on the
me into his fabrication shop, and provided access to
numerous job sites and high-quality projects. Without “real questions”. The method has subsequently been adopted in
these detailed first-hand experiences of construction in New Zealand and Australia and I am working with a large team
process, my expertise would not have progressed beyond
in association with the American Institute of Steel Construction
that of a standard instructor and my image bank would
be substantially poorer. Tim Verhey was always willing to (AISC) to create a unified approach to AESS practices additionally
provide me with very detailed technical clarifications, between the USA and Canada.
many of which are included in this book.
Thank you to Alistair Fussell of Steel Construction
New Zealand and David Ryan of the Australian Steel Insti- The photos included in this book were predominantly taken by
tute for hosting Sylvie and me and providing access to myself during building visits. As the design of AESS strongly
some excellent steel projects, many of which are included
focuses on the details of finished steel, it was essential that the
in this book.
Thanks as well to my editor Andreas Müller for his derivation of the Category System be done through first-hand
expertise, input and support and to Reinhard Steger and experience, as it is the best means to validate the characteristics of
his team for their loving attention to the graphic layout
projects. Certain project images taken during fabrication processes
of this book.
Lastly to my family for the continued support of and where I was unable to be present, have been sourced from the team
pride in my publication endeavors. members. These are credited at the back of this book.

Ronald Reagan National Airport in Washington, DC, USA,

designed by Pelli Clarke Pelli Architects, demonstrates the
possibilities of AESS using a highly angular aesthetic. Here
the curves are faceted. Much of the high-level steel makes
use of simple structural shapes. A combination of remedi-
ated welded connections is mixed with exposed bolting.
The extensive use of natural light successfully animates the
technical appearance of the steel.

10 11
 Penny Lane (2012)
Gibbs Gage Architects

Preface
STRUCTURE OF THE BOOK
Architecturally Exposed Structural Steel (AESS) is seeing increased and widespread use around the world. AESS is steel
that is a purposefully expressed part of the architectural design of a building and subject to normal views by pedestrians or
occupants of a building. It must simultaneously satisfy aesthetic and structural requirements, hence placing itself strategi-
cally to include architecture and engineering. Its use was derived from High Tech Architecture and has come to be part of
the mainstream of the use of steel in architectural design. Because it is clearly visible, AESS is subject to closer tolerances
than standard steel that is hidden from view, and therefore requires special consideration during the design phase of a proj-
ect. AESS requires a much higher level of communication between the architect, engineer and fabricator in order to select
details that are appropriate to the finish, fire protection system and class of the structure.

There are clear advantages to the use of AESS:

- the exposed steel can be an expressive part of the architecture of the building in addition to providing structural support
- when steel is exposed it often obviates the need for other finishes, such as gypsum board
- exposed systems when they reduce the requirement for other finish materials can reduce the carbon costs and environ-
mental footprint of the building
- many of the types of steel systems that are used in AESS, such as tension, lattice and other specialty glazing support sys-
tems, create architectural interest in the project

The architectural challenge in AESS lies in details and connections.

Also, AESS is greatly concerned with and affected by the choice of finish and detailing. The current thinking recognizes
that the type (expense) of detailing needs to be warranted by proximity to view as well as building function. There is no
economic sense in overworking details that will not be able to be “seen”. For these reasons, the book will tend to focus on
these issues through the use of many close-up photographs, photos being more useful than drawings or diagrams in this
context, in order that the reader can really “see” the nature of the connection and level/type of finish.

The book will be structured in two parts.

The first half of the book will create a comprehensive understanding of the differentiated categories of AESS and how these
are impacted by the selection of steel shapes, connection detailing, fabrication methods, erection and finishing. The second
half of the book will focus on applications in AESS, to include some recent projects selected from around the world to be
very geographically inclusive as well as to emphasize the global nature of AESS. The projects will include some innovative
tension structures, exposed structural systems and pedestrian bridges. There will be a focus on the design of the connec-
tions rather than a focus on the creation of the overall systems.
 Milwaukee Art Museum (2001)
Santiago Calatrava

1. Introduction
INTRODUCTION

The first chapter of the book will provide a general introduction to Architecturally Exposed Structural Steel to establish the
basis for the balance of the text. Most importantly this will look at the difference between the use of regular carbon steel in
a concealed fashion and highlight the potential in the architectural use of steel in an exposed and expressed fashion.

Sub headings will include:

- What is AESS?
- The Evolution of Architecturally Exposed Structural Steel
- Primary Factors of Influence that Define AESS
- Communication Issues between Architect, Engineer and Fabricator
- The Role of BIM and Detailing Software

AESS for atriums and skylights AESS for pedestrian bridges Specialty AESS applications
 PART ONE:
UNDERSTANDING AESS DESIGN

The Sage Gateshead (2004)

Foster and Partners

2. Categories of AESS
CATEGORIES OF AESS

This chapter will set out the Category System for classifying Architecturally Exposed Structural Steel. This system
originated in the United States (developed by AISC), was further detailed and clarified by the Canadian Institute
of Steel Construction, and has been adapted and adopted by Australia and New Zealand.

There is a very clear link between the design goals of the system and the creation of an economy in use through
effective communication. Particularly with areas of depression in the Global economy, this method strives to put
effort and expense where it will be most valuable.

Sections will include:

- The Categories Approach

- Standard Structural Steel as the base mode
- AESS 1 - Basic Elements
- AESS 2 - Feature Elements (view distance > 6 meters)
- AESS 3 - Feature Elements (view distance ≤ 6 meters)
- AESS 4 - Showcase Elements
- AESS C - Custom Elements
- Mixed Categories

The example projects used in Part One: Understanding AESS Design will be intentionally varied in terms
of size, application and “fame”. The intention is to showcase the possible variety of applications, including some
very exquisite ones that might not be very well known. The reader should find a rich set of examples in this book
that they can use for inspiration and detailing ideas.

Ottawa International Airport Gaylord Resort, Dallas Bus Shelter using galvanized
 Winter Garden - World Financial Center (2012)
César Pelli and Associates

3. Characteristics of Fabrication
CHARACTERISTICS OF FABRICATION

This chapter will go into detail regarding the specific fabrication characteristics that should follow each of the
AESS Categories described in the preceding chapter. There is a prescribed additive sequence, from the most basic
steel in the AESS1 Category, up to the highest level AESS 4 steel.

Characteristics of Fabrication as Related to the Categories

- Surface Preparation Requirements
- Cutting and Edge Finishing
- Welding vs Bolting
- Tolerances

And finally:
- To Grind or not to Grind, that is the Expensive Question

Cutting Techniques To grind, or not? Revealing welds for effect!

 Winter Garden - World Financial Center (2012)
César Pelli and Associates

4. Erection Considerations
ERECTION CONSIDERATIONS

This chapter will go into detail regarding the erection issues that must be addressed when constructing with
AESS. A much higher level of care in handling is essential in order to ensure that the surface of the steel does not
get unduly damaged during construction. Surface damage will have to be repaired or it will translate through to
the final finish.

Erection Considerations:
- Handling the Steel
- Transportation Issues
- Sequencing of Lifts
- Site Constraints
- Erection Issues

Shanghai Tower Truss erection, Australia Padded slings to protect

 Pedestrian Bridge, Vancouver (2011)

5. Coatings and Finishes

COATINGS AND FINISHES

This chapter will go into detail regarding the impact of finish and coatings on the detailed design of AESS struc-
tures. Finish must be known at the outset of the project.

Topics will include:

- General Issues
- interior vs. exterior applications
- finish vs. corrosion protection
- Surface Preparation
- Painting and Primers
- Shop versus Site Painting
- Intumescent Coatings
- Galvanizing
- Weathering and Color Selection (when white may not be right)

As a good deal of AESS is being used in exterior applications, the issue of detailing for corrosion protection and
maintenance will be stressed. Poor finishes on projects can result in bad public relations and it is in the architect’s
best interest to design with maintenance in mind.

EMP - Gehry Wembley Stadium - Foster Guangzhou Stadium

 PART TWO:
AESS APPLICATIONS

Residential Complex, London (2011)

6. Designing Connections
DESIGNING CONNECTIONS

This chapter will go into detail regarding the design of connections. Connections are a key aspect of the architec-
tural flavor of the project and unlike Standard Structural Steel, cannot be left to the discretion of the consulting
engineer. Architects do however need to understand how the loads are transferred through the connections as
well as the issues that will be addressed regarding member selection and connection methods.

Topics addressed will include:

- General Issues
- Connection Mock-Ups
- Which Type of Connection Should I Choose?
- Bolted Connections
- Welded Connections
- Tubular Steel (RHS/CHS)
- Elliptical Sections (EHS)
- Cast Connections

The intent of this chapter is to include a very large selection of close up detail photos of buildings rather than
looking at overall projects. The images are intended to be large enough in format to be very informative and
revealing.

The idea behind this chapter is to show that there are many different choices that can be made regarding connec-
tion design.

Feature Stair - Boston Society of

Architects Ottawa Airport Seattle Museum of Flight
 Poly Plaza, Beijing (2007)
SOM Architects

7. Tensile Systems
ELEMENTS AND CONNECTIONS FOR TENSILE SYSTEMS

This chapter will go into detail regarding the design of connections that are used in tensile systems. This will
include tensile applications for buildings as well as for glazing support systems.

Topics addressed will include:

- Tension specific connectors

- Structural supports with tension
- Canopies and cantilevers
- Hybrid tension and compression systems
- Supporting glazing with tension

The chapter will highlight projects but focus more on the methodology and design of the tension systems as they
follow the AESS guidelines and method of detailing.

Shanghai Tower - atrium suspen-

sion system Hanging pods, Shanghai Wisconsin Museum of Art
 Cannon Street Station, London (2012)
Foggo Associates

8. Long Spans and Cantilevers

ELEMENTS AND CONNECTIONS FOR LONG SPANS AND CANTILEVERS

This chapter will go into detail regarding the design of connections that are used in a wide variety of AESS appli-
catons, including long spans, cantilevers, trusses and other projects not captured in “tensile systems” and “pedes-
trian bridges”.

These applications would include atriums, large interior spaces, sports facilities, canopies and other complex
building applications.

The focus will be on connections and providing the reader with close up examples of multiple ways of approach-
ing detailing - again reflecting on the Category approach in order to allow for proficiency in selecting methods
that are aesthetically pleasing but also economically viable.

Many of the projects that will be used in this chapter were created by “other than star architects”. Where build-
ings by Foster, Rogers and Calatrava will be included, these are normally fairly high end buildings with large
budgets. The idea of the book is to demonstrate that much can be achieved with less expensive detailing.

Connections discussion will look at issues related to the choice to bolt or weld the steel and the approaches that
are possible to reduce site related erection issues through connection design.

Wembley Stadium Penny Lane Abilities Center

 Pedestrian Bridge, Toronto (2012)

9. Pedestrian Bridges
ELEMENTS AND CONNECTIONS FOR PEDESTRIAN BRIDGES

This chapter will go into detail regarding the design of connections that are used in a wide variety of AESS ap-
plicatons of pedestrian bridges. Small bridge projects have seen a huge uptake by architects. These present the
potential for additional work for architects given the similarity of scale to other building related long span types
(previous chapter). The AESS connections for these are in some instances unique to bridge issues, so need to
be addressed, and in other cases, easily transferred to other project types. Detailing for corrosion resistance is
important. The bridge projects will be sourced from a mix of well known projects to lesser known ones that use
exemplary details, again to illustrate the different approaches to design that can be used for economical reasons.

Rolling Bridge, Paddington Basin Peace Bridge, Calgary Aviation Museum, Seattle

Gateshead Millennium Bridge,

Newcastle Pedestrian Bridge, Canary Wharf Highway overpass, Vancouver