Issue 1 2018

The Arup Journal

 Contents
4 Harbour Area Treatment Scheme
Stage 2A, Hong Kong
Upgrading the sewage treatment works
that serve six million people
David Pickles, Fergal Whyte

14 V&A Grain Silo Complex,

Cape Town, South Africa
Transforming an abandoned silo complex into a
cultural hub
Francis Archer, Tessa Brunette

22 Francis Crick Institute, London, UK

A collaborative approach to a new
scientific research institute
Steve Berry, Andrew Harrison, Clodagh Ryan,
Richard Smith, Catherine Wells, Julie Wood

28 3D Housing 05, Milan, Italy

The first 3D-printed concrete house in the EU
pushes the boundaries of the technology
Guglielmo Carra, Luca Stabile

32 Downtown Line, Singapore

A technically challenging underground project
greatly benefits Singapore commuters
Charles Im, Gordon Lee, Michael McGowan

42 Bloomberg Center at Cornell Tech,

New York, USA
Designing a building with the aim
of achieving net-zero energy use
Fiona Cousins, Carl Mister, Tom Rice

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HARBOUR AREA TREATMENT SCHEME STAGE 2A | HONG KONG

Sewage treatment works

with a social impact
First held in 1906, the Cross Harbour in 1994 and was completed in 2001. The
Swim across Hong Kong’s iconic Victoria second stage, renamed the Harbour Area
Major upgrades to the sewage treatment works serving nearly six million Hong Harbour was one of the city’s most Treatment Scheme (HATS), led by Arup,
Kong residents have modernised and future-proofed the sewerage system, and celebrated sports events until it was started in 2007 and was commissioned in
halted in 1978 because the water was December 2015. The quality of this stretch
made Victoria Harbour suitable for swimming once again deemed unfit for swimming. of water has improved to the extent that in
2011 the beaches reopened and, last year,
Authors David Pickles and Fergal Whyte At the time, up to 2 million m3 of sewage, the authorities declared the water in the
with only a very minimal level of treatment, harbour clean enough to resume the Cross
was discharged straight into the harbour Harbour Swim along its original route.
every day, with serious consequences for
the water quality in the harbour. As well as In October 2017, against the backdrop of
the swimming race being stopped, nearby the city’s famous skyline, almost 3,000
sandy beaches, such as Hong Kong’s Gold people took part in the race, swimming from
Coast near Tuen Mun, had to be closed Tsim Sha Tsui Public Pier on the Kowloon
down to bathers. Peninsula to Wan Chai Golden Bauhinia
Square Public Pier on Hong Kong Island.
The upgrading of the city’s main sewage
treatment system was required to meet both Ambition
the existing and the future demands of The aim of the HATS was to collect
Hong Kong. The largest environmental sewage – previously discharged into
infrastructure project in the territory’s the Victoria Harbour with only minimal
history, the Strategic Sewage Disposal treatment – from both sides of the harbour
Scheme was proposed in the late 1980s. and channel it into a centralised sewage
The first stage of the scheme commenced treatment works on nearby Stonecutters

1: Stonecutters
Island Sewage
Treatment Works,
located in Victoria
Harbour
2: The annual Cross
Harbour Swim was
halted in 1978 owing
to the poor water
quality in the harbour
1. 2.

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HARBOUR AREA TREATMENT SCHEME STAGE 2A | HONG KONG

4: The Stonecutters Island site (shown in 2008) is

Kwai Chung located adjacent to two other Arup projects: the
Stonecutters Viaduct and Stonecutters Bridge
5: Plan of the upgraded SCISTW

Tsing Yi

to SCISTW. Following CEPT, the treated

sewage is disinfected by chlorination
and discharges into the harbour after
Northwest To Kwa Wan dechlorination. The residual sludge produced
Kowloon from the sewage treatment is dewatered and
moved to a sludge treatment facility by ship.
Outfall
system
Kwun Tong The opening up of the Hong Kong Gold
Coast beaches that had been closed owing
to poor water quality was made an initial
Central Tseung Kwan O priority. Arup ensured this could happen in
North Point 2011 by designing the advanced disinfection
package of works, showing the public
Shau Kei Wan the benefits of the HATS 2A project.
Wan Chai East Challenges
In addition to designing the complex system
Sandy Bay Chai Wan of sewage treatment works, Arup had to
ensure the construction programme allowed
4.
Cyberport

Wah Fu HATS Stage 1 sewage conveyance system

Aderdeen HATS Stage 2A sewage conveyance system
HATS Stage 1 preliminary treatment works
HATS Stage 2A preliminary treatment works
Ap Lei Chau
3.

Island. There it would be processed in built up over more than 20 years designing 3: As part of HATS 2A eight existing preliminary
one of the largest treatment facilities of water treatment plants in the UK. treatment works were upgraded and connected
its kind. Stage 1 of the project provided via new tunnels. The partially treated water is
treatment for about 75% of the sewage Awarded the contract in August 2007 by transferred to SCISTW via a tunnel running under
the harbour
from urban areas around the harbour, the Hong Kong Government’s Drainage
with an average dry weather flow (ADWF) Services Department, Arup’s commission
of 1.7 million m3 per day. included civil, mechanical, electrical,
geotechnical, tunnelling, hydraulic
Stage 2A was a commission to treat the modelling, process, environmental, control
remaining 25% of Hong Kong’s sewage, and automation engineering, as well as
bringing the treatment capacity up to a programme and project management. preliminary treatment works that carry
2.45 million m3 per day average and a out initial screening of the sewage were
4.1 million m3 per day peak flow. This Arup’s design included modelling the upgraded and connected via new tunnels
was achieved by taking all sewage from complete hydraulic system to optimise running along the western and northern
the Victoria Harbour area to the upgraded the waste water collection and conveyance coasts of Hong Kong Island.
Stonecutters Island Sewage Treatment Works across the harbour, as well as the upgrade
(SCISTW) for chemically enhanced primary of the treatment works on Stonecutters The overall treatment process when finally
treatment (CEPT) and disinfection. Island, including the design and construction commissioned collects sewage from around
of one of the world’s largest underground Victoria Harbour to be treated at the
Arup tendered for Stage 2A of the project on pumping stations. As part of the project, preliminary treatment works, removing
the basis of the firm’s extensive experience eight of the existing Hong Kong Island large solids, before travelling via tunnels
5.

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HARBOUR AREA TREATMENT SCHEME STAGE 2A | HONG KONG

10,000m3 wet wells 10,000m3 wet wells Kowloon and the north-east of Hong Kong
Island, as well as the proposed upgrades as
part of Stage 2A.
To CEPT tanks To CEPT tanks
To estimate the sewage flow through to the
year 2030, Arup used data that projected
Hong Kong’s population and employment
Pumps Pumps for the next two decades. A geographic
˜ 20m information systems model was built and
calibrated using that data and the records of
historic flows. The hydraulic model assessed
the velocity and head losses through the
tunnel, waste water levels at various drop
shafts, tunnel size and depth of the main
pumping station under average and peak
flow conditions.
˜ 40m The average flow during the dry months
was calculated at 2.5 million m3 per day
for 2030. Typically, combined sewage and
storm water sewerage systems are designed
Side for peak flows equivalent to three times the 7.
chamber dry weather flows. However, in Hong Kong,
Via interconnection Pumps Pumps wet weather comes in the form of short flash
From Hong Kong Island ˜ 55m diameter
tunnel to main storms rather than extensive periods of rain,
pumping station 1 with some of the storm water contained in
Plan Section overflows, locally known as nullahs. Arup
established that to collect and treat 99.5%
6. of the combined waste water, the peak flow
would be 1.7 times that of the dry season.

6: Plan and section of the pumping station, infrastructure and detailing how the When designing such facilities, a tunnel of This was the first time a computer-driven
which has a volume equivalent to 38 standard contractors should phase the construction. this shape (forming an inverted siphon) is hydraulic model of this size had been
swimming pools generally avoided because waste can settle used and it proved very successful in
Hydraulic system at the bottom. To ensure that did not happen, terms of accuracy and helping with cost
After the initial screening, the partially the tunnel was sized so that the waste water efficiency. Ultimately, despite the project’s
treated sewage drops down 120m through velocity was fast enough to exit from the complexities, the model was accurate
shafts at each treatment works, entering riser shaft at the Stonecutters Island end to within centimetres. This system
a tunnel that crosses below the harbour, without solids settling in the tunnel along minimised the tunnel diameter, ensuring
before coming up through a riser shaft into the way. The system also needed to cope there was enough velocity to avoid any
the project to proceed in stages to ensure the the pumping station on Stonecutters Island with large differences in flow rates between settlement within the tunnel and minimising
system could remain online at all times, as for treatment prior to discharge into the summer and winter months. With wet any overflow.
there could be no interruption to the operation harbour. Arup modelled the hydraulic weather in the summer, resulting in high
of Hong Kong’s existing sewerage systems. system for sewage transportation from flow rates of water, and dry winters resulting This design balanced the land requirement,
Hong Kong Island to Stonecutters Island in the opposite, Arup designed the system so capital and operation costs against the
Upgrading the existing extremely congested (with the tunnel design by others). that the velocity of flow stayed within hydraulic performance and environmental
facility on Stonecutters Island also presented acceptable parameters all year round, with compliance requirements. A minimum
8.
difficulties. In the 1990s, the island was The design challenge was to ensure the minimal overflow. These two constraints capital cost saving of HK$480 million
expanded through land reclamation, waste water could travel to Stonecutters meant the tunnel had to be narrow enough to (£42.5 million) was achieved.
connecting it to the mainland. Arup had Island through the tunnel without backing maintain a flow of sufficient velocity to keep interrupting the existing treatment works. 7: The Stonecutters Island main pumping station
to find a way of increasing the capacity up or overflowing at the preliminary works the tunnels clean during the drier months, Pumping station As the overall project manager for the work, is one of the largest in the world, at 55m in
of the sewage treatment works within the and without solids dropping to the bottom taking into account the inverted siphon, The pumping station at Stonecutters Island Arup developed a procurement strategy, diameter and 40m deep
existing site boundaries. of the tunnel floor. Typically, sewerage but wide enough to not overflow during the is one of the world’s largest for sewage which included space planning and a 8: There are eight main pumps in the pumping
works use gravity to keep the flow of waste wetter months. To establish the most treatment works. It is 55m in diameter and detailed construction programme. By station motor hall
Working closely with the client, Arup constant, with the treatment works located efficient and cost-effective diameter for the reaches 40m below ground. Above ground, gathering information from various
proposed a procurement strategy to suit the at a lower level than where the waste tunnel, Arup developed an extensive it is a 20m tall striking glass building contractors, Arup assessed the size of
capabilities of both local and international originates. In Hong Kong, however, this was hydraulic model of the complete system for complete with green roof. The scale of the the construction equipment that might be
design and build contractors. Detailed not possible: the tunnels had to be deep both existing and future treatment volumes pumping station to be constructed within brought to site, and determined the number
planning was required on the placement enough to go under the harbour and below in Hong Kong. This included modelling the the confines of the existing site presented a and size of pumps needed to maintain the
of various elements of the plant, designing the foundations of the buildings on the Stage 1 systems of 23.6km of underground considerable challenge, particularly as this 32m3/s flow, designing the space – and the
how they would fit with the existing shoreline of Hong Kong Island. tunnels, which collected sewage from work was required to take place without surrounding diaphragm wall – accordingly.

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HARBOUR AREA TREATMENT SCHEME STAGE 2A | HONG KONG

Original scheme Completed scheme

9. 14.

14: Chemical scrubbers and activated carbon

9: Arup’s solution for the effluent tunnel and model of the final system. This allowed the combining the effluent tunnel and filters for the deodourisation of the sludge
disinfection facility significantly reduced excavation to commence early ahead of conveyance system within the same 8.5m dewatering building
excavation and construction costs the awarding of the main contract, helping diameter, 90m deep, 880m long tunnel, with
15: All the primary sedimentation tanks were
to speed up the overall project programme. disinfection taking place along the tunnel. covered for odour control
It was constructed using drill and blast 15.
Effluent tunnel and disinfection facility techniques, advancing on two faces from
To minimise pollution levels in the drop and riser shafts. By disinfecting the
discharged water, Arup used a computational effluent in the tunnel, it eliminated the need reduced excavation and construction costs. of the pumping stations as and when the risk of water entering the TBM launching
fluid dynamic model to determine the to construct an above-ground chlorine It also released valuable space above ground maintenance is required on the other. The chamber. To minimise the potential flood risk,
A priority was given to the efficiency of the required contact time for the treatment contact tank (originally sized at 174m x for development. tunnel has a 3.9m internal diameter, is 250m a series of holes were drilled from the surface
pumps to minimise electricity consumption. chemicals. Arup also designed a cost-saving 34m x 14m and proposed to be located long and is at a depth of 30m. The tunnel to approximately 30m below ground level,
The detailed design for the diaphragm walls solution using the outfall tunnel as the close to a piled viaduct). This significantly The design for this aspect of the scheme was constructed using a slurry type tunnel with the ground chilled to -10°C for several
of the underground portion of the pumping chlorine contact tank. achieved a saving of 40% in lifecycle boring machine (TBM), supplemented weeks until the groundwater froze. The TBM
station was carried out early in the project, costs and significantly reduced the by a state-of-the-art specialist ground was launched through the frozen ground,
rather than as part of the main contract Originally, the proposal was for a environmental footprint. freezing technique for the TBM break-in preventing any flooding of the launch
works. The pump station was sized to ensure conventional arrangement for disinfection and break-out. chamber. This was a novel construction
it would be large enough to accommodate comprising a short effluent tunnel with a Other works method for Hong Kong at the time.
the equipment of any contractor. To prove large above-ground combined chlorine At SCISTW, Arup designed an The treatment works are located in an area
the concept, Arup developed the design contact tank and dechlorination facility with interconnecting tunnel between the existing that has a very high water table and is As part of the project, each of the
within a 3D digital model, with Hong Kong connection culverts. Instead, Arup and new main pumping stations. This allows adjacent to the sea. It was therefore essential preliminary treatment works on Hong Kong
University building a 1/15th physical scale developed a more efficient solution flexibility to divert flows through just one for measures to be put in place to minimise Island was upgraded to increase the capacity

10: The TBM, dubbed

‘Victoria’, in the factory
11 & 12: TBM being
lowered and assembled
prior to launch
13: Artificial ground
freezing for TBM
break-in/break-out

10. 11. 12. 13.

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HARBOUR AREA TREATMENT SCHEME STAGE 2A | HONG KONG

16: The Commissioning Control Centre facilitates

the management of the works, which serve
5.7 million people on both sides of Victoria
Harbour, processing 900 million m3 of sewage
each year

were carried out in line with contract

18.
conditions and local regulations, Arup put in
place a quality site supervision plan. A system
of regular inspections and audits ensured the
works progressed as planned. 17 & 18: The quality of the water in Victoria
Harbour has improved to such an extent that the
The team also developed an ethical beaches were reopened in 2011, and the Cross
code to provide guidance on acceptable Harbour Swim resumed in 2017
17.
business practice on the project. A training
programme, in the form of an e-learning
module, was developed for all staff to
16.
underline the importance attached to high discharged waste on the marine environment day, which makes it one of the largest CEPT project, delivering it on time and
standards in all business activities. were monitored by an independent plants in the world. The 10.6ha plant serves within budget. Since completion, Arup
of the pumps and initial treatment screens. possible, construction materials were inspector, with the results made public on 5.7 million people on both sides of Victoria has expanded its water business in East
Odour controls were added and, with the reduced and reused; for example, excavation Communications the project’s webpage. Harbour – equivalent to 70% of Hong Asia, using the HATS project – and its
works located close to the roadside and material such as completely decomposed The scale and significance of the project Kong’s population – processing 900 million innovative use of data and computer
some areas of housing, green roofs were granite was sent to active landfills as a meant that communicating its objectives, Future-proofing m3 of sewage per year. modelling on the project – as a reference
added to improve aesthetics. capping layer, and the excavated general fill benefits and progress to the public, as well With demographic shifts and the impact of to develop sewage treatment projects
materials were reused in other reclamation as district councils and government climate change, Hong Kong’s needs for Arup was able to draw on both local elsewhere in Hong Kong, as well as
Deodourisation projects in the area. departments, was crucial. The project team’s sewage treatment will change. To future- and international expertise to design in mainland China, Singapore and
A decentralised and compact deodourisation aim was to inform the public on the proof the project, Arup’s role included and manage this large-scale, complex the Philippines.
system was installed at SCISTW to treat the Arup designed the large sludge dewatering sustainability credentials of the project predictive work on flows and loads in the
odourous gases produced from the sewage system with large centrifuges, each where the efficient use of resources and treatment works. This entailed working
treatment works before discharge into the handling up to 150kg/hour and capable state-of-the-art technology helped improve with the Planning Department of the
atmosphere. All the existing and new of producing 1,200 tonnes of dry sludge the water quality in Victoria Harbour. This Government of the Hong Kong Special Authors Bernard Cheng, Anson Cheung, Eric Cheung,
primary sedimentation tanks, channels and cakes a day. The sludge cakes are delivered called for a comprehensive public relations Administrative Region to understand its David Pickles was Project Manager managing Carrie Chu, Daniel Chu, Corey Fan, Arlene
flow chambers were covered with fibreglass via two container vessels to a treatment strategy, including a 24-hour public hotline development plans for the next few the overall technical design on the project. He is Goode, Raymond Sy Guan, Gary Hung, Lewis
reinforced plastic covers. Foul air was facility for incineration to generate low- for the project, regular notifications to key decades, as well as looking at historical a Director in the Leeds office (formerly in Hong Hwoi, Jeff Ip, Mark Knowles, Anil Kumar, Andrew
Kong). Lai, David Lai, Gabriel Lai, King-Chak Lai,
extracted and conveyed through ducts carbon energy. Replacing the previous stakeholders, public community meetings, data, potential land use, industrial growth,
Antony Lau, Jak Lau, Michael Lau, Vicki Lau,
to biotrickling filters for treatment with transport by road, these vessels are the and presentations and visits to district projected population change and the impact Fergal Whyte was Project Director. He is a Lawrence Lee, Donald Leung, Rex Li, Ronald Li,
multistage chemical scrubbers, followed first diesel-electric propulsion container councillors and school communities. The of climate change with increased rainfall. Director in the Hong Kong office, a member of Yuvi Luo, Edwin Mak, Louis Mak, Wilson Mak,
by activated carbon filters. These works vessels in Hong Kong, using ultra-low- team also published project brochures, This work means the system is designed to the Arup Group Board and is the firm’s Director Nick Ng, Tin-Chi Ngai, David Pickles, Dora
all provide long-term improvements to sulphur diesel to generate electricity for newsletters and web content, and created be resilient until at least 2030. of Health, Safety and Wellbeing. Shum, Franki So, Monique So, James Sowden,
the air quality in the vicinity of the works. propulsion. They are connected to onshore videos and physical models. Arup designed Jeremy Sparrow, James Sze, Stanley Sze, Lara
power supplies when berthed, without a visitor centre in the new pumping The success of the HATS project has been Project credits Tang, Ted Tang, Paul Taylor, Simon Tsang, Iris
Sustainability using diesel and releasing zero emissions. station, to help with public outreach. The widely recognised, both by the government Client Drainage Services Department, Hong Tse, Simon Tso, Shanshan Wang, Fergal Whyte,
The new main pumping station achieved The vessels collectively reduce carbon positive media coverage of the project is a and the community in Hong Kong. It has Kong Government Billy Wong, Peter Wong, Jenny Yip, Simon Yu.
a Provisional Gold rating under BEAM emissions by 130 tonnes each year testament to the success of this public won local and international awards, including Civil, Mechanical, Electrical, Geotechnical,
Tunnelling, Hydraulic Modelling, Process, Image credits
Plus, the environmental assessment scheme compared with regular ships, equivalent relations strategy. the Global Water Awards, the British
Environmental, Control and Automation 1, 3, 4-7, 9-16: Arup
of the Hong Kong Green Building Council, to the carbon load absorbed by 6,000 Construction Industry Awards, the Tien Yow Engineering, Programme and Project 2: CY Yu/South China Morning Post
which considers energy use, indoor trees in a year. Also crucial to keeping the public informed Jeme Engineering Prize in China and the ICE Management Arup: Gamini Ananda, Bill Au, 8: Sun Fook Kong
environmental quality, materials, water use was demonstrating that the project was Edmund Hambly award for sustainability. Kitty Au, Robert Bates, Agnes Chan, Alan Chan, 17: Image under licence from Shutterstock
and innovation. Arup ensured the project Professional excellence complying with appropriate standards. Albert Chan, Chris Chan, Ivan Chan, Paul Chan, 18: Sam Tsang/South China Morning Post
itself was managed in a way that minimised To ensure the project achieved the highest of As such, the performance of the new The upgraded Stonecutters Island facility Sing-Wa Chan, Siu-Yuen Chan, Andy Chee,
adverse effects on the environment. Where professional standards and that the works disinfection facilities and the impact of the now has a capacity of 4.1 million m3 per

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V&A GRAIN SILO COMPLEX | CAPE TOWN, SOUTH AFRICA

A silo in form only

Advanced engineering transformed an abandoned 90-year-old grain
silo complex into a cultural hub and the jewel in the crown of Cape
Town’s bustling V&A Waterfront district
Authors Francis Archer and Tessa Brunette

1: The V&A Grain Silo

The V&A Grain Silo Complex houses Complex houses the Silo
The Silo Hotel and the Zeitz Museum of Hotel and Zeitz MOCAA
Contemporary Art Africa (Zeitz MOCAA).
2: The Grain Silo in
Zeitz MOCAA is a partnership between the its original form, when
Victoria & Alfred (V&A) Waterfront and the waterfront area was
Jochen Zeitz, whose collection of a centre for export
contemporary African art, on long-term
loan, forms part of the museum’s founding
collection. Overlooking the Atlantic Ocean
and Table Mountain, and adjacent to a
working harbour, the Grain Silo Complex
opened last year. Arup collaborated with
designers Heatherwick Studio on the
redevelopment, which has provided a focal
point for the area’s regeneration.
3

Spread over nine floors and 15,500m² (including 2.

the hotel), the £30m development includes 80
gallery spaces, a hotel, a rooftop sculpture garden
and restaurant, and hospitality spaces. From the of manual jacks to raise the formwork. By the tower ‘working house’ and a shorter ‘storage
outside, it is a behemoth of exposed concrete. turn of the century, South Africa’s grain export annexe’ block made up of 42 27m high tubular
A 57m high tower punctuated with a grid of market had declined and the advent of silos. Heatherwick Studio’s architectural vision
billowing faceted windows stands tall above a containerised shipping had made such large to create an atrium within the tightly packed
main, shorter block. Inside the main building, a storage facilities redundant. The building had silos by carving a grain-shaped void gives
30m tall atrium has been carved out of the 42 been left empty since 2001 and, over time, fell visitors the sense of being inside a giant
tightly packed 5.5m diameter concrete tubes that into disrepair. While the surrounding 123ha honeycomb, bringing light into the building
previously held grain. Daylight cascades into this V&A Waterfront industrial complex was while still retaining its original features.
cathedral-like void through the skylights above. redeveloped into a vibrant mixed-use district of
A specially commissioned artwork that is baked commercial, retail and leisure facilities, the silos In 2012, Arup was brought on board as
onto the skylights helps moderate the harsh sat quiet and unused, awaiting a design that multidisciplinary consultant by the client to
summer sun and creates a gentle lighting would do justice to the building’s historic and work closely with Heatherwick Studio to
transition between day and night. architectural significance. Technically, it would resolve the engineering challenges of the
have been simpler and cheaper to demolish the proposed refurbishment and confirm the
Decline and revival silo complex, and if the owners had not found a viability of the scheme. Staff from Arup offices
The original building was completed in the way to reuse the building, this might ultimately in South Africa, Botswana and London worked
1920s and was used for three-quarters of a have been its fate. collaboratively to develop the scheme at this
century to store maize, millet, sorghum and stage. The structural scheme was developed in
wheat that had travelled from inland South However, the client, V&A Waterfront, had an London before it was handed over to local
Africa to the coast for export, mainly to Europe. ambition for the project to instigate a cultural designers Sutherland Engineers for the detailed
It started life as the tallest structure in the revival in this neglected space and, with the silo design. Meanwhile, Arup’s façade team in
country and was quite a feat of engineering for complex the closest part of the district to the South Africa took the window design from
its time; for example, the concrete that formed city, create a stronger link and draw additional concept stage through to installation, providing
the silos was poured in a single continuous pour visitors to the V&A Waterfront. The original a prescriptive design to the fabricators to ensure
in a matter of days, using an ambitious system building comprises two elements: a grading the buildability of the signature windows.
1.

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V&A GRAIN SILO COMPLEX | CAPE TOWN, SOUTH AFRICA

3 & 4: Arup’s engineering solution for the carved-

It became apparent that by re-sleeving the complex glazing design. A series of pillow-like surface of a sphere proved unsatisfactory.
out concrete atrium design involved rationalising
the space into a portal frame structure by tying retained silo walls with a new inner skin of faceted windows was proposed, bulging out of Turning to a more principle-based approach,
together the silo bins above the void reinforced concrete, all of the structural the building where existing infill masonry could Arup established a series of geometric rules
challenges could be solved. be removed in between the structural grid of – horizontal and vertical planes meeting at the
concrete-encased steel; both along the top rim same focal point – intersected by a sphere to
A new 250mm layer was cast directly against of the storage annexe and upwards on all sides create the bulging pillow shape. The primary
the original concrete, which was used as a of the working house. The architectural concept constraint was to keep the whole length of each
one-sided shutter. In addition to holding in was inspired by the convex glass elements of of the main vertical and horizontal framing
place all the retained original walls, the lanterns, where glass is blown out of gaps in a members in one plane so that they could be
re-sleeved perimeter walls also supply the grid. These delicate elements would contrast made with flat steel bars that would intersect
vertical load path for the new gallery floor against the bulk of the concrete frame and neatly at the nodes in a way that made welding
slabs and act as shear walls resisting lateral refract the light as it entered the building. possible. Arup turned to parametric design
loads. Above the atrium the overflying using Grasshopper, a visual programming
re-sleeved cylinders were connected to each Arup had to find a way of realising these language for the Rhinoceros 3D computer-aided
other via reinforced shear keys through the elements in a pragmatic, cost-effective and design software. By programming a script using
retained original concrete, creating a spanning buildable manner. Working with Heatherwick the geometrical rules with an interface that gave
3.
portal structure. Studio, this process began by determining the the architects complete control to manipulate
optimum number of facets for each ‘pillow’ the projection of each node and the main joint
Arup’s solution allowed the architectural window. The greater the number of facets, the lines, each possible solution was already
design to be practically realised, while still more complicated the fabrication process. pre-tested for viability. This allowed a specific
retaining the building’s grandeur and Fewer facets would overly simplify the aesthetic geometry to be developed for each of the five
authenticity, and displaying the inner intent and lose the delicate yet industrial different window designs, but with the same
workings of the original building. appearance that was desired. The number settled patterns and overall constraints.
Arup also provided mechanical and public on was 56 facets as the optimum balance
health engineering services from concept Foundations between appearance, cost and buildability. This iterative parametric tool locked in the
through the detailed design stage and to project Prior to excavation there were plans to add necessary structural constraints for fabrication,
close-out, along with wind, security, and additional short piles down to the bedrock A parametric solution allowing for Heatherwick Studio to experiment
artificial and daylighting studies advice. under the new internal columns. However, Arup experimented with a range of methods to with multiple iterations, each of which had
during the excavation stage the original 3m conceptualise the windows. An initial attempt to effectively been pre-assessed for viability,
The storage annexe deep raft structure was found to be more project the architectural geometry onto the reducing the time and cost required to
Creating a functioning building out of a bundle robust than expected. This meant new
of concrete tubes presented a host of design foundations did not need to be built, offering
challenges. The existing structure gained its a significant cost saving.
strength and stiffness by being an integral set 5: Isometric view showing the carved-
of bundled tubes. The carved out atrium space, The working house out atrium and silo demolition
and the removal of all walls except the western The structural independence of the working
perimeter wall, left the remaining structure house tower from the storage annexe was
with no integrity and needing new structure to maintained in the redevelopment. With large
hold the original concrete in place. sections of the original perimeter walls that
supplied the stability for the tower removed,
In the western zone where new galleries were both at ground level and high up on the hotel
planned, new floor slabs were to be constructed floors, new stability cores were constructed
on new internal columns. However, the containing stairs and lifts.
perimeter edge of these slabs needed new
vertical support, as the original perimeter walls New floors were added in the lower rectilinear
had no spare capacity. To avoid constructing silos zone to form small gallery rooms. The
new internal shear walls, some of this perimeter floors on the upper steel portion of the building
zone needed to be braced with new structure to were strengthened to meet robustness criteria
provide lateral stability. of modern codes. In addition, some mezzanine
floors and a high level swimming pool slab
A variety of solutions were considered to were added.
overcome these design challenges. Initially
considered was a scheme with new columns Financial feasibility and construction sequence
and local shear walls around the perimeter, were central to this ambitious scheme and
along with new high level steelwork above the Arup worked closely on this with the
atrium to hang the original concrete. However, contractor, WBHO, and Sutherland Engineers,
this solution was discarded, as these elements who carried out the detailed structural design.
would be visually prominent and could be seen
as ‘crutches’ required to hold up a ‘broken’ Designing the pillow glazing
building. The design breakthrough came from While the structural issues were being resolved,
studying the original slip form construction. Arup’s façade team was working on the 5.
4.

16 1/2018 | The Arup Journal 17

V&A GRAIN SILO COMPLEX | CAPE TOWN, SOUTH AFRICA

The next step was to build the windows. In 10 & 11: The silo bins
contrast to the digitalised design process, the were topped with
manufacturing stage called for craft skills; skylight windows that
each element was to be cut and welded form the floor of the
rooftop sculpture
together by hand. Arup communicated the
garden. Bespoke
design intent to a high level of detail before
artwork made of ceramic
tender by using the 3D models produced frits was printed onto
through the parametric process. This allowed the glass. The pattern
the design intent model and the shop drawing controls light levels in
model to be reviewed and compared in a 3D the atrium and also acts
virtual environment, rather than using 2D as an anti-slip measure
drawings. This lessened the possibility of
errors. A local subcontractor, Mazor
Aluminium, came on board in 2015 to deliver
Arup’s prescriptive design.

Making the design a reality presented

numerous challenges. For one thing, each
window is three-dimensional rather than flat,
10.
6. so locating the nodes in the right place was an
exacting process, as was the sequence in
which each joint was welded to ensure the
loads were evenly distributed.

The steel sections were cut and welded at each

node. Flat bars were cut to length and
positioned on a jig, then welded together. Some
of the nodes had up to eight connecting bars.
7. Working with the subcontractor at its factory,
Arup devised a welding sequence that ensured
all welds could be accessed and welded after
complete the process. This allowed the the framing was tack welded together and the
window designs to be finalised with fabrication jig removed. Each node was then ground
drawings generated within a few hours. What smooth, before being filled out and smoothed
could have been a year-long process of back using an automotive body filler to ensure it
and forth ended up taking just two months to appeared like a continuous element rather than
design the five different types of window. a joint. The subcontractor had a specialist team
Analysis methods (including Feldmeier and responsible only for dressing and shaping each
finite element analysis) were used to determine of these nodes on all the windows.
the glass pane flexibility of the irregular 11.
triangular shapes within each window. Installation
Arup’s design incorporated a lifting bracket that
Fabrication allowed the 5m by 5m window units to be seismic activity and intense south-east winds which were an important element of the
The final window design comprised a frame installed with tight tolerances to the concrete in the summer. lighting control. These skylights form part of
9.
made of slender flat steel 500mm by 160mm openings. This bracket was temporarily bolted an external sculpture garden, supporting the
bars welded together at central nodes. Rather to the unit and was designed to ‘correct’ the The pillow windows are the most noticeable sculptures and live pedestrian loading.
than aluminium, steel was chosen for the frame, eccentric centre of gravity, allowing the unit to design within Arup’s façade engineering
allowing for very slender members to minimise be hoisted vertically, with the lifting cables scope, but the team also designed a number of The top layer of the multiple laminated glass
the frame’s visible bulk, while still maintaining positioned outside the concrete face. This varied and complex solutions for each glazed features artwork created specifically for this
6 & 7: Each pillow
strength and allowing for welded connections. significantly simplified the installation process, element within the building. project on glazing supplied by Saint-Gobain
window was handmade
in a sequence devised
which took just 30 minutes for each panel. France. The design helps control the bright,
by Arup and the Fifty-six small triangular insulated glass units Elsewhere, Arup undertook a series of qualitative hot South African sun, ensuring there is a
subcontractor to were structurally bonded to an aluminium Prior tests had shown that the concrete around desk studies to advise the design team on wind smooth transition between the levels of
ensure loads were glazing bar that was fixed to the steel frame. the columns where the windows were to be avoidance strategies in critical areas of the lighting during day and night, rather than
distributed evenly Double-glazing and high strength structural attached was too weak to fix into. A number of building, such as entrances and main pedestrian a ‘switch on the lights’ moment. Arup
8: Arup designed the silicone seals provide a high level of acoustic solutions were investigated; ultimately, the routes, and on ventilation arrangements and door conducted a 24-hour lighting analysis for
window lifting bracket so performance, and reduce the noise entering the team decided to strip the old structure back types suitable for these conditions. the project, considering daylight conditions
each window could be building from the working harbour outside. and install new concrete. The joints around in the building over the period of a year,
fitted to a tight tolerance These seals were sized specifically to take each window were detailed to allow for large Lighting then ran simulations to help devise an ideal
9: One of the account of the climatic pressure brought about sway movements, as the windows are stiff in The final element of the glazing was the percentage of ceramic frits for the skylights.
windows in situ by the small double-glazed triangular shapes. their own planes, and the area experiences skylights on top of the 5m diameter silo bins, These were rendered on the glass in artwork
8.

18 1/2018 | The Arup Journal 19

V&A GRAIN SILO COMPLEX | CAPE TOWN, SOUTH AFRICA

12: Zeitz MOCAA is now an internationally

celebrated cultural hub that attracts visitors The masterplan
from around the world

consumption and the building’s demand on

municipal infrastructure.

A low-velocity air displacement system

conditions each gallery by means of a raised
floor with grilles arranged around the perimeter.
The galleries make use of the thermal inertia
from the exposed concrete soffits to help
regulate the temperature and humidity in the
spaces, slowing the rate of change in the gallery
spaces as visitors pass through the exhibitions.

The heating and cooling is fed from the precinct- f Façades

wide district cooling system, which uses s Sustainability
seawater from the adjacent harbour as a heat m Mechanical
12.
source or sink as needed (see ‘The masterplan’ w Wet services
story, shown right). The heating temperatures for s Structural
created by Togo-born artist El Loko. They could be designed for lower peak conditions the gallery spaces were optimised to allow the * Full multi-
take the form of an anti-slip silk screen print, and the plant size reduced accordingly. central plant designers to maximise the efficiency disciplinary
resulting in an element that is both beautiful of the district plant heating and cooling cycles. services to
and functional. Except for the solar control glass, which was scheme design
imported from Europe as sheets, the materials Cultural landmark
13.
Sustainability for the façade were procured locally and local With the opening of Zeitz MOCAA and The
The cooling and heating requirements of the labour was used to fabricate each window, Silo Hotel, the V&A Waterfront has added The V&A Grain Silo Complex is perhaps the
glazed pillow windows were collaboratively extending the project’s sustainability beyond another destination to its existing portfolio that most significant building in the V&A
analysed between Arup’s façade and the building itself. draws people in from the city centre, Waterfront. Six new buildings were
mechanical teams using computational fluid encouraging them to spend a day in the area. developed to form the recently completed
dynamics. The design minimised solar heat The mechanical engineering design allowed The museum, the largest museum of Silo District, with the grain silo as its
gain and maintained natural light, while still precise environmental control within the contemporary African art in the world, is an centrepiece. Arup’s brief extended beyond
reducing peak energy loads compared with a museum, enabling loans from international art internationally significant cultural landmark the grain silo building to provide
flat façade. This equates to lower running costs institutions. Particular emphasis was placed on and a unique platform for artists from Africa sustainability consulting to the precinct as a
and energy use, as the mechanical systems energy-efficient design to reduce power and its diaspora. whole, as well as various consulting
services on each of the new buildings
including the underlying super-basement.
This continuity, and particularly the façade
and sustainability design of each building,
Authors Executive architects Van der Merwe Miszewski Khan, Jacob Knight, Adam Lane, Adam Ozinsky, 13: The V&A
Francis Archer was Arup’s lead structural Architects, Rick Brown & Associates Architects, Guillermo Martinez Pajares, Pine Pienaar, Martin was key to achieving the Green Star Waterfront district
engineer on the project during the scheme Jacobs Parker Radley, Gianluca Rapone, Rui Rodrigues, Rudolf sustainability standard across the board, and Arup’s role in
design phase and is an Associate Director in Electrical engineer Solution Station Le Roux, Vanesh Seganathirajah, Jolyon Smith, with two buildings achieving the highest its regeneration
the London office. Quantity surveyor MLC Surveyors Nic Smith, Con Strydom, Michael Stych, rating possible: a six-star as-built rating. 14: The cooling system
Project manager Mace Innocent Svodziwa, Calvin Taylor, Matilde Tellier, devised by Arup uses
Tessa Brunette was involved in the project from Main contractor WBHO Max Walker, Manja Van De Worp. This was primarily achieved by devising a seawater to cool the
concept stage as the overall design manager Façade, mechanical and wet services seawater cooling system, with cold water Grain Silo Complex
and led the façade design during the engineer Arup Image credits from the ocean drawn into a cooling plant 14.
construction stage. She is a Senior Façade Structural engineer Arup and Sutherland 1, 3, 4, 6-12, 14: Arup/Tessa Brunette
and through a heat exchanger, which is
Designer in the Cape Town office. Arup: John Abbott, Francis Archer, Rossouw Van 2: V&A Waterfront
used to chill the building interior through the the flexibility to be rolled out right across the
Der Bank, Willem Bosman, Michael Bradbury, Ian 5: Arup
Braithwaite, Charlotte Briggs, Tessa Brunette, 13: InfrastructurePhotos air-conditioning systems. This method was development. It was so successful that the
Project credits
Client V&A Waterfront, Cape Town, Ryan Collins, Gaye Dalton, Naeem Ebrahim, originally introduced on the first two plant was expanded to provide district-wide
South Africa Simon Gill, Terence Govender, Philip Guthrie, Ed buildings in the district, which were cooling, and the whole precinct is now cooled
Design architects Heatherwick Studio, London Hoare, Ben Jones, Darren Kent, Shaai-Qah completed in 2011, and was designed with by seawater.

20 1/2018 | The Arup Journal 21

FRANCIS CRICK INSTITUTE | LONDON, UK

Collaborative science The Francis Crick Institute is one of the

world’s leading biomedical discovery
institutes. Its research focuses on why
diseases develop and how they can be
prevented, diagnosed and treated.
The Francis Crick Institute is one of the largest biomedical facilities in The institute has brought 1,500 scientists,
Europe, created by bringing six of the UK’s top scientific institutes together researchers and support staff together into one
building where new ideas can be shared and
under one roof worked on in close collaboration. The vision
for the building was to encourage a step
Authors Steve Berry, Andrew Harrison, Clodagh Ryan, Richard Smith, Catherine Wells and Julie Wood
change from scientists working independently
and in isolation, to a spirit of collaboration
across teams and disciplines.

This collaborative ethos was integral to the

project management and design approach
taken by Arup in the delivery of the building’s
design and construction, to ensure that the
demanding technical requirements were met.
Arup’s involvement on the project began in
2003 with an appointment to assess existing
facilities, and continued with the evaluation of 2.
a number of potential sites as part of the site
selection process. Arup was appointed to carry vibration signatures were assessed and used
out the building services engineering design; as the baseline for compliance and mitigation
logistics; and elements of the fire and security measures. Background electromagnetic
consultancy services. Arup was additionally levels were also scrutinised in order to
appointed as the client’s project manager and minimise any potential interference with
contract administrator, from concept design the sensitive equipment and research planned
through contractor procurement and for the facility.
appointment to post-completion.
During the early stages of the project, part
Francis Crick Institute of the challenge was to help and support the
In 1953, molecular biologist Francis Crick, business case feasibility. The aim of the
working with James Watson and building on institute was to create an establishment that
research from Maurice Wilkins, identified the would not only further cement the UK’s
double-helical structure of DNA. This position as a leader in the field of biomedical
discovery earned the three scientists the Nobel research, but also underpin a vision of
Prize in Physiology or Medicine. ‘collaborative science’.

The Francis Crick Institute is dedicated to Fast-track programme

understanding the fundamental biology Arup’s Project Management team worked
underlying health and disease and is a closely with the client to manage the delivery
collaboration between six of the UK’s top of planning approvals. Arup set up and led
scientific institutes – the Medical Research the procurement strategy that allowed the
Council, Cancer Research UK, the Wellcome extensive basement construction – four levels
Trust, University College London, Imperial below ground – to begin as soon as practically
College London and King’s College London. possible after receiving planning consent. The
fast-track programme included a two-stage
Site selection package procurement process that allowed the
A key requirement for the new facility was contractor to commence constructing the 16m
that it be attractive to leading researchers. It deep basement as soon as planning consent
had to be located close to leading London was granted. A ‘top-down’ construction
hospitals, universities, existing medical process allowed the upper levels of the
institutions and transport links. building to be constructed in parallel with the
basement works.
1 & 2: The Francis In 2008, a site beside the British Library and
Crick Institute is a St Pancras Station was chosen. The location’s Stakeholder engagement
hub for research into compatibility was evaluated against a range Arup led the strategy for engagement with
health and disease of factors. Background acoustic levels and building stakeholders from concept design
1.

22 1/2018 | The Arup Journal 23

FRANCIS CRICK INSTITUTE | LONDON, UK

The interstitial floors accommodate the The services in the general laboratory areas
sizeable ventilation and air filtration plant, were designed to operate as a Containment
as well as other services required to support Level 2 area. Higher containment levels are
the basement laboratories. There is a main located in dedicated areas. The write-up/office
plant area in the basement, and two whole areas are located outside the laboratories.
floors of plant are located at the top of the
building. Large vertical distribution risers, Climate control in the general laboratories is
which run the height of the building, are handled by a variable air volume (VAV)
used to distribute services from the plant system. Within secondary laboratory areas,
areas to occupied floors. In addition, additional fan-coil units supplement the
horizontal primary routes for services VAV cooling.
connecting between risers at each floor level
were created in 1.5m deep ceiling void Since the laboratories can accept only very
spaces to facilitate distribution of services. limited, low levels of vibration transmitted
within the structure, all building services plant
Services were set to minimise the building’s and equipment that generate vibration were
energy consumption. Plant operation was isolated using a mixture of anti-vibration
optimised; a combined heat and power plant mountings, spring hangers and supports. The
was installed to generate electricity, steam and laboratory floors are designed to Vibration
hot water; and an extensive photovoltaic array Criteria-A (VC-A), with inertia slabs and local
(1,700m2) was integrated into the curved roof. 6. isolation tables set up in specific areas that
require higher controls (VC-D and VC-E).
The specialist operations taking place in the 6: Arup created a 3D building model crucial to
building required specific consideration for planning such a highly complex building, which The drainage from the highest level
3.
building functionality and performance. needed to accommodate specialist equipment and containment laboratory is linked to a
Laboratories containing sensitive equipment all the associated building services packaged effluent treatment plant located in
needed to have high vibration control, and 7 & 8: Plant was housed predominantly in the the basement. This prevents any
through to handover. To achieve this a from the user groups fed into the final design. that was extended to all appropriate research basement and two interstitial floors. Two further contaminants entering the drainage system.
governance structure was developed for This had significant benefit to the client in spaces in order to provide greater floors of plant were located at the top of the building
decision-making. There were 23 user groups, assurance that the final construction would adaptability for future use. Controls
each with a dedicated lead who fed into a meet user needs. The building has extensive controls and an
senior user group. Scientists and operational In addition to domestic hot and cold water, energy management system with some
staff were drawn from across the institutes to The mock-up also allowed the contractor to special provision was required for separate 25,000 points, sophisticated diurnal lighting
develop the user requirements and brief. Arup trial its construction methods. This was laboratory hot and cold water, reverse five substations within the institute (each of control, as well as environmental,
managed the contractor to develop a full-scale particularly useful for planning services osmosis water, softened water for specialist these have two associated transformers ventilation and fire controls. Emissions from
mock-up of a typical laboratory and office coordination and construction of the high- equipment and water to support aquatic life. apiece). Back-up generation is provided by air stacks carrying exhaust from laboratories
area. Constructed off-site during the design containment laboratories. Carbon dioxide, nitrogen and compressed three 2.5MVA generation sets located in the were numerically modelled. These exhausts
stage, they were fully fitted out with air are among the gases distributed from a roof plant area. These are designed to take come from fume cupboards, the biological
equipment and user groups were able to visit Building services design central source. the entire essential load of the building and research facilities and the high-containment
the mock-ups. This gave an appreciation as to The building’s form and function were are configured so that should a generator laboratories – as well as the flue discharges
how their new work area looked and how they shaped by the significant service Due to the nature of the research carried out go offline, load can be shed and distributed from dual fuel boilers, combined heat and
would work within the space, encouraging the requirements. The 82,000m² facility consists in the building, particular attention was given across the remaining generators. 7. power plant and standby generators.
scientists to provide feedback. It also of four basement levels, including two to ensure resilience and redundancy within
improved success levels of achieving user interstitial plant floors, and eight levels above the engineering systems. There are four Laboratory areas Discharges from the building had to be in
sign-off at completion. Different types of ground, which contain laboratory, plant, independent electrical feeds to the building The general laboratory areas consist of compliance with the Clean Air Act and local
laboratory furniture were tested and input support, administration and amenity areas. from a primary St Pancras substation, and primary, shared secondary, dedicated authority requirements regarding
secondary and write-up areas, with contamination levels at street-level receptor
adaptability built into the building services points. To ensure no discharges were returned
3: General cross- design to accommodate changing scientific into the building through the fresh air intakes,
section through the
programmes. Arup’s Project Management a dispersion model was developed. The
building showing
plant and laboratory
team devised and led an adaptability numerical analysis reviewed the stack
layout strategy that recorded for the client the discharge, flue dilation and concentration
building services system capacity, furniture levels, confirming that the discharge from the
4: A full-scale
laboratory mock-up
layouts and options for future change. The 32 large extract air stacks and thermal flues
created off-site for design for the laboratory areas was was compliant with emissions requirements.
user group testing adaptable, with standardised room layouts
5: A finished
that can be readily reconfigured as the Biological research facilities
laboratory in use sciences evolve. Connection points were The biological research facilities are located
by scientists installed above the ceilings with capacity for in the basement, along with most of the
additional power, data, gas and water high-containment laboratories. Although not
services to support future technologies. high-containment, the biological research
4. 5. 8.

24 1/2018 | The Arup Journal 25

FRANCIS CRICK INSTITUTE | LONDON, UK

facilities are still subject to considerable scope, also needed to be completed and Conclusion
scrutiny by the Home Office and various external approvals obtained from the Health Francis Crick’s Nobel Prize showed how
government agencies. These facilities have and Safety Executive, the Home Office and collaboration between disciplines can
significant ventilation requirements and were the local authority, to allow occupation. significantly aid scientific research. The
designed to be capable of achieving 20 air Arup developed a comprehensive handover Francis Crick Institute continues to foster
changes per hour. plan that set out detailed requirements to this collaborative spirit, both in terms of the
be achieved by the contractor prior to layout of the building, and in the way the
These facilities incorporate stringent odour practical completion, as well as the project team worked together to project
control and ventilation regimes. Odour interfaces with the client-supplied manage, design and build the institute. The
modelling was conducted using numerical and equipment and provisions for client project team’s collaboration has also reaped
empirical testing of facility waste and feed inspections, familiarisation and training. rewards: the institute has secured BREEAM
materials on exhaust streams. This was incorporated in the construction Excellent accreditation, a particularly
contract to minimise risk and allow a notable accolade given the nature and size
As the facility accommodates advanced successful handover. of this heavily serviced building.
scientific equipment, including electron
microscopes, temperature control was
required to within ±0.1°C over a period of one
hour while maintaining airflow at low Authors Anna Coppel, Marc Crompton, Tim Crow, James
velocity. This was achieved by designing a Steve Berry was the Project Manager and the Davison, Grzegorz Delikat, Jennifer Dimambro,
specialist three-stage air conditioning system. building service design team lead. He is an Vipul Dudhaiya, Ryan Dunne, Mike Durtnall, Sam
Associate Director in the London office. Dust, Adam East, Mike Ebsworth, Stuart Edwards,
Controlling costs Max Eyre, Bronwyn Field, Elizabeth Fletcher,
Richard Foster, Malcolm Fullard, Rafal Gawlowski,
Comprehensive value engineering studies Andrew Harrison was the Project Director for
Steve Gilchrist, Jerell Gill, Vullnet Gjakolli, Ben
were led by Arup, together with the the building services element of the project. He is
Glover, Artur Gorlovsky, Milan Graovac, Blair Gray,
contractor, Laing O’Rourke. These a Director in the London office and the firm’s
global science and industry business leader. Tony Greenfield, Ross Griffiths, Amaury Guillais,
demonstrated the value of a pre-assembled Shane Haines, Kori Hamilton, Andrew Harrison,
modular approach to much of the building Clodagh Ryan led the project management Naveed Hassan, Mike Hastings, Malcolm Heath,
services owing to the challenging construction services related to the building services. She is David Hewlett, Simon Humphreys, John Hunt, Jay
programme and constrained site. Arup worked an Associate Director in the London office. Hussain, Helen Jackson, Lucas Janssen, Richard
with the contractor to accommodate the Jeffs, Rishi Jobanputra, Chris John, Ian Johnson,
modular construction, factoring this into early Richard Smith was the lead mechanical Andrew Jones, Mario Kaiser, Pawel Karwat,
designs and reviewing proposals. engineer and is an Associate Director in the Joanna Kennedy, Peter Kinson, Simon Lee, David
London office. Lester, Mark Van Lith, Gareth Lloyd, Jenna Lobb,
Michael Lorimer, Jacek Madej, Andrew Marks,
Arup used a comprehensive 3D model, which Thomas Marr, Nazir Mawjee, Keith Mccall, Laura
was passed to the contractor to assist them. Catherine Wells was the Project Manager for
Mccann, Andrew McConachie, Ross Mills, Rayna
This was used for clash detection and routing, the overall project management and contract
Mistry, Kalpana Nepaul, Claudia Newsam, Pamela
administration element. She is an Associate
as well as to review how the services would be Nwaneri, Oliver O’Brien, Ed Oelman, Sebastian
Director in the London office.
installed – critical for such a heavily serviced Oleksiak, Alberto Padilla-Peinado, Jessica Parsley,
building. This information was tagged to assets Julie Wood was Project Director for the overall
Steve Pennington, James Perou, Charlotte Perry,
within the building and given to the client’s project management and contract administration
Hugh Pidduck, Mathura Ponnuthurai, Garry Porter,
Facility Management team at handover. element. She is a director in the London office
Anthony Proctor, Simon Rainsbury, Craig Reid,
Daniel Reid, Marcin Rerak, Charles Richardson,
and the firm’s global skills leader for programme
Kat Roberts, Michael Roberts, Alice Robertshaw,
9. The contractor incorporated more than 4,000 and project management.
Kathrine Rusling, Adam Russo, Clodagh Ryan,
pre-assembled building services modules, Stefan Sadokierski, Jodh Sahambi, Peter Samain,
along with a further 2,000+ prefabricated Project credits
Demetri Serghiou, Jamie Shantonas, Celia Smith,
sections of pipework, containment and Client Francis Crick (UK Centre for Medical Richard Smith, Thomas Smith, Michal Smolicki,
valve assemblies, within the building Research and Innovation) Yeside Sogunro, Andrew Somerville, John Steele,
services systems. Architects HoK/PLP and BMJ Hannah Stevenson, David Stoker, Jon Stokes,
Cost Consultant Turner and Townsend Jiaxi Sun, Glen Swinney, Joanna Tolloczko
Handover Structural Engineer AKT II Theodore, Mark Togher, Christopher Tolmie, Gary
The client’s objective was to start moving Main Contractor Laing O’Rourke Towens, Mutlu Ucuncu, Mike Underhay, Gregory
staff in and operate the facility immediately Project Manager and MEP Engineer Arup: Visscher, Gary Walker, Ricky Watcham, Oliver
Davar Abi-Zadeh, Michael Adams, Jim Aitken, Webber, Catherine Wells, Annabel West, David
following handover. Demonstrating correct
Christian Allison, Stuart Allison, Luke Bannar- West, Antaeus Wheatley, Will Whitby, Gordon
performance of building systems and Wills, Marcin Wojewski, Chris Wood, Julie Wood,
Martin, Alan Beadle, Steven Berry, Francesco
compliance of building construction with Biancelli, Martyn Biss, Nicolas Bittner, Stephanie Jeff Yuen, Eduard Van Zyl.
the client’s requirements was essential to Black, Dora Boese, Miroslaw Bogusz, Bartosz
achieve practical completion of a project Borowicz, Anita Bramfitt, Darren Briggs, Damian Image credits
9 & 10: The completed building enables that incorporates complex environmental Bronowski, Andrew Brooks, Nathan Bryce, Kevin 1, 2: Paul Carstairs
collaboration between scientists of different conditions and controls. Integration of the Burke, Kevin P Burke, Keith Butler, Lee Carter, 3, 4, 6: Arup
disciplines by encouraging interaction client’s specialist equipment, which was Greg Chandler, James Connell, Shane Cooney, 5, 7-10: Paul Grundy
in shared spaces installed outside the main contractor’s
10.

26 1/2018 | The Arup Journal 27

3D HOUSING 05 | MILAN, ITALY

Pushing the boundaries of 3D printing Every April, the global design industry
descends upon Milan for the world’s best
known design fair.
At the end of Salone del Mobile, the entire
structure was dismantled within five days,
packed up and moved to a permanent
location, leaving no trace of its short
In the lead up to the 2018 event, the existence on the Piazza Cesare Beccaria as
organisers of Salone del Mobile – the everyday life resumed in the city.
A project that started as a design fair challenge has the potential to furniture fair at the centre of Milan Design
speed up the progress of 3D-printed buildings in Europe and beyond Week – published a manifesto calling for The future of construction
designers to up their game when it came to Over the past few years, governments and
Authors Guglielmo Carra and Luca Stabile tackling the global challenge of sustainability. industry bodies around the world have
hailed off-site manufacturing as the future of
With this in mind, Arup worked with Italian construction. The large-scale fabrication of
practice CLS Architetti to create a temporary building components in factories ahead of
installation that went on to win the festival’s assembly on site has the potential to
Best Sustainability award, which celebrates revolutionise the way our built environment
the project that puts ethics and sustainability is produced by speeding up the construction
at the centre of design. What started as a plan process and improving quality. It also has
to build a wall using 3D printing for an the added benefit of a more controlled and
industrial building evolved into the first safe environment for workers than the
3D-printed concrete house constructed in the average building site.
EU, and one of the first in the world made
using a portable robot manipulator. The technology used to 3D-print concrete
buildings is still a step behind that of
3D Housing 05 – a 100m² structure with off-site construction, but it is arguably an
curved walls that enclose a living area, even more compelling commercial
bedroom, kitchen and bathroom – was built proposition, as it means the advantages of
on a busy square in Milan’s city centre in full industrial off-site production could be
public view. It took just 48 hours to create the brought to the construction site itself.
house’s 35 concrete modules, each 3.2m high, Greater flexibility in building shape is also
which were printed in 60 to 90 minutes. The possible, allowing more complex shapes
completed structure, which was assembled in and structures such as double curved walls.
two weeks, weighed about 50 tons, or 1,000kg Digital plans could be used to print modules
per linear metre of printed wall. in situ, pushing the speed and efficiency of

3.

1: Arup worked with CLS Architetti to create 3D

Housing 05
2 & 3: The robotic manipulator can move along
both horizontal and vertical planes to create
shapes that are hard to achieve using traditional
building methods
1. 2.

28 1/2018 | The Arup Journal 29

3D HOUSING 05 | MILAN, ITALY

4: Deformation analysis output under wind load

from the Rhinoceros 3D software used by Arup
Its flexibility and range mean it can move 7: After the design
horizontally as well as vertically to create fair, 3D Housing 05
shapes that are difficult – and therefore was rapidly dismantled,
expensive – to achieve with traditional leaving no trace in
techniques, at a speed of 200mm per second. the piazza
The robot can extend up to 4.5m, but with
some adjustment, it could go much higher,
potentially allowing buildings of several
storeys to be constructed.

Making it a reality
Europe is believed to have fallen behind other Building a temporary structure to
parts of the world in 3D-printed construction demonstrate a technology’s potential does not
because of its building regulations. With 3D of course necessarily translate to the real
Housing 05, the Arup team wanted to change world. The installation in Milan, as it was
that. More specifically, the aim was to temporary, was not required to meet some of
demonstrate to the public the technology’s the regulations and codes that would apply to
flexibility, speed and potential to build at a permanent building. In addition, the reality
4. scale, paving the way for its use in real-world is that 3D printing is currently not cheap.
projects in the near future.
The robot is priced at €349,000 and 3D
construction to its limits, as was the case with relative ease, either for use elsewhere Design and fabrication Housing 05 cost about €800/m2 to build,
with this project. or to recycle the basic material. Also, as Arup, collaborating with architects CLS costing €80,000 in total, excluding fit-out and
artificial intelligence technology develops, Architetti, provided structural engineering fixtures. This might be attractive to a client or
In such a scenario, every centimetre of several printing robots could work in and materials consulting services. While an architect looking to create a customised
material produced is used and placed exactly combination quickly and efficiently Arup had previously done research into the structure with complex and unusual shapes;
where needed without the requirement for without human intervention. potential of robotics in 3D concrete printing, for example, all the modules that made up 3D
formwork. This minimises materials, this was the first time the firm had used the Housing 05 were double-curved. However,
reduces waste and conserves energy. Using Today, there are still only a few examples of technology to create a real building. The this level of expense is not yet competitive
digital technology, the structure can be 3D-printed buildings erected directly on site. design process commenced in January 2018, compared with the cost of traditional methods
analysed and the design refined before it is At present, China is the furthest ahead in the leaving just 90 days to plan and complete the of construction. This means it is not yet
rendered in real life and without the risk of race to complete 3D-printed buildings of scheme. With no time for test runs, the team’s realistic to use the technology to build at scale
miscommunication or human error. several storeys. The designs for these tend to capability would be demonstrated for the first or in contexts such as refugee camps and
mimic those of traditional houses, with 90° time live on site, with no room for error. disaster zones, where temporary but cheap
Such structures, designed to the principles angles, rather than the complex shapes Arup buildings need to be quickly erected.
of the circular economy, can be dismantled helped create in Milan. Conscious of the risk, the Arup team spent
the months leading up to Milan Design This is partly because the process itself is 7.
Week conducting simulations to ensure that complex, with the flow of concrete needing
– at least in theory – the process was to be in sync with the robot’s printing speed.
5 & 6: 3D Housing 05 was built in Milan’s busy
Piazza Cesare Beccaria in just two weeks,
seamless. Arup used GSA, LS-DYNA® and The main expense is materials, which technology to design structures that withstand
Rhinoceros 3D software to develop the account for approximately 60% of the cost dynamic loads. Assessments are currently Authors
demonstrating the flexibility of this technology,
design, with the 3D model used on site of a 3D-printed structure. For the house in underway of the engineering and materials Guglielmo Carra was the Project Manager.
which can create distinctive shapes such as
He is a Senior Engineer in the Milan office
curved walls with ease during the construction process, all of which Milan, CyBe Construction provided a considerations, with a view to completing
and is Arup’s Europe Region Materials
helped visualise and resolve issues in concrete mix with performance set to meet such a project before the end of 2019. Skills Leader.
advance. Before starting on site, the team the robot’s features, therefore ensuring an
needed to consider factors such as the curing optimised result. To bring the cost down The widespread adoption of 3D printing Luca Stabile was the Project Director. He is
time of the concrete, the intricacies of substantially, different materials for 3D in construction will require a systemic a Director in the Milan office and is the
3D-printing unusual shapes, and the printing need to be investigated. Arup is change within the industry, rather than building practice leader for Arup in Italy.
reinforcement that would allow each panel exploring the possibility of reusing recycled just technology enhancements. Traditional
to be lifted out when the house was concrete, as well as experimenting with construction sites also need to adapt if Project credits
dismantled at the end of the design fair. natural materials – such as cellulose – and they are to become suitable and safe for Architect CLS Architetti
natural fibres, which would also mean rapid, factory-style production. Neither Contractor CyBe Construction
Structural engineer Arup: Guglielmo Carra,
What made the project possible in a busy materials could be sourced locally. The more is the regulatory environment nor the
Daniele Dozio, Eleonora Lai, Luca Stabile.
central Milan square was the use of a robotic buildings that are constructed in this way, supply chain currently designed to take
manipulator, mounted on a movable base and the cheaper the technology will become. into account the specific technologies and Image credits
caterpillar tracks, to fabricate the components processes required to build in this manner. 1, 5: Arup/Luca Orlandini
directly on the pavement of the square. While Following the success of this project, Arup Having completed this landmark project, 2-4, 7: Arup
most 3D printers are large, fixed devices aims to build the first permanent two-storey Arup is now leading efforts to transform 6: Arup/Giorgio Giunta
supported by heavy infrastructure, Dutch 3D-printed building in Europe. At present, the industry so that 3D-printed buildings
company CyBe Construction’s RC 3Dp is no such structures exist in Europe or the can go from being a niche today to
smaller and weighs just three tons. US because of the challenge of using this commonplace tomorrow.
5. 6.

30 1/2018 | The Arup Journal 31

DOWNTOWN LINE 3 PACKAGE A | SINGAPORE

1.

A new phase for transport in Singapore By 2030, the Singapore government aims
for 80% of households to be within a
10-minute walk of a metro station. A key
to the public. Downtown Line Stage 3
(DTL3) comprises 16 stations linked by
21km of tunnels. It connects the central
1: Bencoolen Station opened to the public
after completion in October 2017

part of the strategy for achieving this is business district with the eastern residential
a significant expansion of the city-state’s areas of Bedok and Tampines.
One of the most technically challenging underground projects ever undertaken in Singapore, the Mass Rapid Transit (MRT) system, a vital
part of its transport infrastructure that Arup’s involvement in the project began in
Downtown Line delivered more than just a new transport link is used by more than three million people 2008, when the firm undertook alignment
every day. design for the entire length of DTL3. A year
Authors Charles Im, Gordon Lee and Michael McGowan later, Arup was appointed to carry out the
In October 2017, the final phase of the latest full engineering design for Package A of
line to be added to the network was opened DTL3, through the historic districts of Fort

32 1/2018 | The Arup Journal 33

DOWNTOWN LINE 3 PACKAGE A | SINGAPORE

HDB Block 34

Cut and cover

tunnels

State Courts

3: The tunnels between

Chinatown and Fort
Canning stations had to
navigate a particularly
narrow corridor of
Botanic Gardens buildings, with cut
Geylang Bahru
and cover tunnel
Bendemeer methods used for
Upper Cross Street
Jalan Besar construction outside
Bencoolen Bugis the State Courts
Fort Canning 3.
Chinatown

Key
Arup worked on the early phases of the DTL up an in-depth understanding of the ease of access. This was vital because of
Stage 2, carrying out the reference design challenges involved in designing, building the built-up density of the corridor. For
Thomson-East Coast Line for the 10km stretch of tunnels and stations and operating such a mass transit system, example, the tunnels between Fort Canning
from Chinatown to Botanic Gardens. Arup and how these could be resolved. and Bencoolen stations were constrained
North South Line
was subsequently appointed to develop a by existing MRT lines, and passed directly
concept design for DTL Stage 3, including For the concept alignment study, Arup below a national monument, the National
2.
Circle Line station location and alignment within all developed a comprehensive horizontal Museum of Singapore. The tunnels had to
the existing under- and above-ground and vertical alignment of the tunnels, pass over the North East Line, with a 1.3m
infrastructure. This allowed Arup to build considering buildability, operations and clearance, then under the North South and
North East Line
Circle Lines, with clearances of 8.7m and
Canning, Bencoolen and Jalan Besar, and 2: Downtown Line set against the 3.2m respectively. The tunnels between
the neighbourhoods of Bendemeer and pre-existing MRT system and planned lines East West Line Fort Canning and Chinatown stations had to
Geylang Bahru. The scope included the pass through a very narrow corridor between
Downtown Line – Stage 1
design of a station in each of those five the State Courts and a public Housing and
locations, along with 5km of connecting Development Board (HDB) building,
Downtown Line – Stage 2
twin tunnels and associated escape shafts. requiring the tunnels to be in a stacked
configuration. At one point in this corridor,
Downtown Line – Stage 3
The line’s central location means it runs challenges, while maximising ridership the MRT tunnels had to be constructed a
under a dense, complex mix of modern and the benefits of a mass transit system for mere 640mm away from the foundations
and historic buildings, making it the city’s commuters and businesses. Arup carried of one structure.
deepest underground link. It also weaves out more than 1,000 building impact
under and over various existing subterranean assessments along the proposed route, environment. In doing so, it has set a Following this alignment design, Arup was
infrastructure, including telecommunications, with design solutions suggested and precedent for sustainability and innovation appointed, as part of a competitive tendering
fibre optics, power, traffic and street implemented to navigate the varied for future rail developments in the city-state. process, to carry out the full engineering
lighting cables; water and gas pipes; and design constraints, including developing station and tunnel design for DTL3 Package
three existing MRT lines. In addition to the concept for temporarily diverting the Alignment A, running from Chinatown to Geylang
those obstacles, the line drops below the Singapore River during construction. The latest addition to Singapore’s MRT Bahru. The scope of design work included
Singapore River and skirts arterial roads and system, the 42km Downtown Line is the infrastructure, alignment, geotechnics,
underground road tunnels. This combination Arup worked with Singapore’s Land longest underground and driverless rail tunnels, civil and structural engineering,
4: The alignment is
of design constraints made it one of the most Transport Authority (LTA) to develop line in Singapore and was designed to link acoustics, traffic impact assessment,
so fine between Fort
technically challenging underground safe, buildable designs that were not only the downtown district with commuters in the Canning and Chinatown
environmental impact assessment and
projects ever undertaken in Singapore. innovative but improved the overall north-western and central-eastern parts of stations that at one geographic information systems.
productivity of the construction works, the city. The line was developed in three point the tunnels pass
When Arup took on the project, it was while pushing the boundaries of ground stages. Stage 1 opened in 2013, Stage 2 in just 640mm from the During the preliminary design stage, studies
conscious of the need to tackle all these engineering methods in an urbanised 2015 and Stage 3 in 2017. foundations of a building were carried out to eliminate, minimise and
4.

34 1/2018 | The Arup Journal 35

DOWNTOWN LINE 3 PACKAGE A | SINGAPORE

6: As the deepest potential risk of debris left behind in the

station in Singapore, riverbed. If the tunnelling machines
Bencoolen sits encountered any remnants from these
below pre-existing activities during construction under the
MRT tunnel levels river, both the DTL3 construction works
and potentially the adjoining live railway
lines could have been flooded.

Arup developed a concept to negate this

risk: divert the river prior to the tunnelling
process. This facilitated the removal of any
obstructions in the riverbed, allowing for the
safe construction of the twin tunnels beneath
the riverbed, mitigating the possibility of a
catastrophic flooding event. The diversion
also allowed the river to remain fully
operational and navigable by rivercraft
during the three-year construction period.

To achieve this, a 42m wide, 7m deep

diversion channel, approximately 100m in
length, was built along the river’s west
bank. The river walls at either end of the
5. diversion canal were then demolished to
create the river’s new temporary route. An
5: Section showing the alignment design between
Fort Canning and Bencoolen stations, which
6. embankment was constructed across the
efficiently navigated the existing, densely packed river’s original course, allowing removal of
subterranean infrastructure system, but also managing the logistics of side of the river. The only feasible tunnel obstructions including timber beams,
the project, from finding space to allow alignment brought construction at this cabling and reinforced concrete debris
construction worksites to function, to location close to the Central Expressway within the DTL3 tunnel corridor. To further
manage the impact of station and tunnelling The overall aim was for the underground made the design more efficient, optimising ensuring minimal disruption to people (CTE) road tunnel and the potential that negate soil instability during tunnelling,
works on existing structures. Building type, works to be as shallow as possible, saving the construction process to make DTL3 living and working in the area. The critical some temporary ground anchors remained in which would increase risk of flooding, the
condition and heritage value were all construction cost as well as improving safer and quicker to build, with significant challenge was the design of the tunnels situ after its construction in the 1980s. soils through which the tunnels passed
considered when assessing the horizontal public access and passenger experience financial savings for the client. under the Singapore River between Fort beneath the river were stabilised and
and vertical rail alignment. In addition, when entering stations and inter-changing Canning Station, a shallow two-level In addition, over the city’s history, the area strengthened by grouting.
several investigations were carried out for between lines. By challenging past practices Diverting Singapore River underground station structure 17.5m below of the Singapore River close to the
key buildings and structures along the and rail geometry design requirements Arup’s role in DTL3 Package A involved ground level, and the existing Chinatown proposed Fort Canning Station had been Once the debris removal, grouting and
alignment to determine building foundations without compromising operations, Arup not only designing a future-proofed transit Station (part of DTL Stage 1), on the other a timber yard, which meant there was a tunnelling works were complete, the
where as-built information was not available
or the accuracy of records was in question.
This helped to minimise construction risk by
determining if they impeded the tunnel
boring construction. Arup carried out design
checks to ensure that where some piled
foundations were removed during
tunnelling, the buildings above would
remain stable.

A key design criterion was to minimise the

number of buildings requiring demolition,
as acquisition and demolition would add
substantially to the cost of the project.
Ultimately, only one building was
demolished, and Arup’s work meant that
a significant multi-storey building in the 7, 8 & 9: The Singapore
River diversion works,
downtown area could be retained intact,
showing the diversion
a significant saving for the client. Arup’s channel under
optimised alignment also reduced the construction (left and
number of buildings that DTL3 passed centre) and the diverted
directly under by more than 60% from the river during tunnel
original alignment. construction (far right)
7. 8. 9.

36 1/2018 | The Arup Journal 37

DOWNTOWN LINE 3 PACKAGE A | SINGAPORE

11: Tunnel boring machine access shaft at Fort

Canning Station
12: Arup demonstrated, using traffic simulations,
that even with Bencoolen Street closed during
DTL3 construction the surrounding roads could
accommodate the temporary arrangement
13: While closed for the station works, Bencoolen
Street was redeveloped to be ‘car-lite’, creating
better access for bikes and buses

Cripple siding

Running tunnel tracks

Fort Canning Station platform

Running tunnel tracks

Cripple siding

10. 11.

embankment and the temporary bridge were structure for the siding. This was a design 10: The cripple sidings for temporary train storage provided the necessary high level of wall The monitored ground and building roadside parking was removed at Waterloo
removed, and the diversion canal filled in, and operations first for Singapore. were placed within Fort Canning Station rather restraint against deflections and ground movements were within acceptable limits. Street, and Selegie Road, previously a
restoring the river to its original route. than along the tunnels, which significantly movements in this critical area. The one-way street, was made two-way.
Jalan Besar Station reduced costs station, measuring 170m long, 23m wide Bencoolen Station These adjustments ensured the extra traffic
Fort Canning Station The construction of the four-level Jalan and 35m deep, was constructed using At rail level, Bencoolen Station is 43m volumes along existing streets were
Located within a constrained site on the Besar Station was particularly challenging. top-down methods, further enhancing below ground, and is the deepest accommodated even with the closure of
north side of the Singapore River bank The station is immediately adjacent to movement control. underground station in Singapore. It Bencoolen Street.
between Liang Court and the CTE, this conservation shophouses that are founded required the temporary closure of a nearby
station extends towards the southern end in soft soils and required retention. The major street because of the complexity of Following completion of the works, a
of the historical Fort Canning Hill. Station proximity to these heritage buildings posed construction work required within the tight redesigned Bencoolen streetscape was
Entrance A is located next to the CTE significant space constraints for the works, construction programme. This station depth constructed with wider pavements, an
tunnel, with a minimum clearance of as well as prompting concerns that the deep was required to avoid the existing North all-day bus lane, dedicated cycle paths
approximately 5m. A robust design excavation (>30m) could cause damaging South Line and Circle Line tunnels and more bicycle parking. This ‘car-lite’
solution comprising propped diaphragm vibrations or movement to these buildings. immediately west of the station. The station streetscape is one of the first in Singapore.
walls and top-down construction methods comprises six levels and is 190m long.
was required to control movement of the During the design stage, Arup carried Critically, it is only 23m wide in order to fit Steel fibre reinforced concrete
sensitive CTE. An extensive impact out pre-construction inspections to establish within the streetscape corridor. The Arup Arup proposed the use of steel fibre
assessment was necessary to demonstrate the existing condition of all structures within team not only developed a system of reinforced concrete as permanent lining
that the effect of the main station 250m of the station excavation. This escalators and lifts that allowed rapid for a section of the bored tunnels of DTL3,
excavation works on the existing CTE determined if there were any pre-existing and seamless vertical transportation of a system not previously used for tunnels in
tunnel was acceptable. building defects and what type of passengers from the concourse to platform South-East Asia. The decision to use this
foundations were in place supporting the level, but also designed the interiors to method was made to reduce the need for
Fort Canning cripple sidings buildings. Building impact assessments make this journey memorable. labour to fix and place traditional steel
Arup designed the cripple siding, which were conducted to predict the potential reinforcement, saving time and costs during
is an extra track that is used to facilitate effects of the station work and show that During construction, Bencoolen Street lining fabrication, resulting in increased
withdrawal or storage of trains, to be located impacts were acceptable. was closed to traffic. Arup prepared a construction productivity. The use of fibres
within Fort Canning Station. Typically, microsimulation model of the road network in concrete also enhances durability and
cripple sidings are located along the tunnel Shophouses that required precautionary surrounding the site, incorporating all improves concrete performance under fire
length, but given the very tight site protection had propping systems installed junctions and other relevant infrastructure loads. Using less material is also more
constraints along DTL3, there was no for the façade and were monitored closely such as car parks and traffic exit points. This sustainable: a typical steel ratio for a tunnel
suitable site available between stations. during construction. allowed the traffic pattern to be simulated to in Singapore averages about 120kg/m³,
Arup’s solution to locate the cripple sidings ensure that the existing road network could compared with a steel fibre ratio of 30-40kg/
on each side of the Fort Canning Station The earth retaining and stabilising system carry the increase in traffic volumes with the m³. Arup developed the approach for testing
platforms made the station wider, but at the station comprised a combination temporary Bencoolen Street road closure. the material and its performance, as well as
ultimately saved significant construction of 1.2m and 0.8m thick diaphragm walls, proving the feasibility of using steel fibre
cost by removing the need to find additional crosswalls, ground improvement and The surrounding road network required concrete in underground construction in
land to construct a discrete cut and cover concrete walers. This retaining system a number of junction upgrades. In addition, Singapore. This required Arup to engage
12. 13.

38 1/2018 | The Arup Journal 39

DOWNTOWN LINE 3 PACKAGE A | SINGAPORE

14: BIM is now

mandated on all Authors Lee, Kah Peck Lee, Mandy Lee, Sazlynda
Singapore’s transit Charles Im was the Project Manager during Lee, Sean Lee, Sebastian Lee, Wong Lei Lei,
projects, a process construction. He is an Associate Principal in Anthony Leversedge, Siyu Li, Yangyang Li,
facilitated by the the Singapore office and the Geotechnical Hasta Lie, Keithson Liew, Daniel Lim, Deyuan
standards set on DTL3 Leader in Singapore. Lim, Jia Yuan Lim, Lip Boon Lim, William
Lim, Angie Lin, Chris Liu, Ashley Lloyd, Tom
15: Journey times for
Gordon Lee was the Deputy Project Manager Lok, Ragavendra Lokaranjan, Annabelle
the majority of people
during construction. He is an Associate in the Loke, Chunrong Lu, Steven Lucianto, Neville
using DTL3 have
Singapore office. Lui, Farong Luo, Xiangyue Luo, Malcolm
been reduced by up to
Lyon, Serene Mah, Noraziza Mahbob, Juan
10 minutes
Michael McGowan was the Project Director Maier, Swee Chiang Mak, Israel Maraddag,
16: At 43m below during construction and led the project Mukunthan Manickavasakar, Noel Manuel,
ground level, management element. He is a Principal in Haruko Masutani, Chandana Medagoda,
Bencoolen Station the Singapore Office leading Arup’s Michael McGowan, Wing Sze Mo, Zin Soe
is the deepest infrastructure business. Moe, Junaideen Sainulabdeen Mohamed,
in Singapore Daniel Mulyawan, Sudhakaran Nair, Andrew
17: Fort Canning Project credits Nelson, Betty Ng, Jia Le Ngai, Rain Nguyen
Station required careful Client Land Transport Authority of Singapore Pham, Rosella Obordo, Nurmarlia Omar,
design considerations Architect Aedas Pte Ltd Shahnaz Omar, Khine Khine Oo, Abner
due to its location Contractors: Paredes, Benjamin Pascua, Michael Dela
adjacent to the Central Fort Canning Station – GS Engineering & Pena, Brett Perez, Hai Pham, Alan Philp,
Expressway Tunnel Construction Corporation Luis Piek, Seng Tiok Poh, Jason Poon, Chris
Bencoolen Station – Sato Kogyo (S) Pte Ltd Pynn, William Quah, Virgilio Quinones, Nizar
Jalan Besar Station – Leighton John Holland Abdul Rahim, Hamed Rahimi, Ashish Raikwal,
Joint Venture Pablo Romero, Ken Roxas, Ali Sadeghi,
Bendemeer Station – Penta Ocean Norliah Sanusi, Wisnu Saputra, Jeyabalan
Construction Co Ltd Sathaiah, Dennis Seah, Sau Fong See, Kartini
14. 15. Geylang Bahru Station – China State Shabani, Xiao Shan, Nikki Shaw, Hongwei Shi,
Construction Engineering Corporation Limited Ming Simon, Ernesto Siochi, Sai Sivarajah,
Seng Siong Soh, Jeremy Su, Lifeng Su,
with the Building Control Authority and develop and use Building Information construction. Designing through BIM is now the eastern part of Singapore and the Full engineering design: Arup Leo Suhaendi, Kevin Suhartono, Arbaiyah
work collaboratively with the supply chain Models (BIM) for design. Arup led this mandated on all the city’s transit projects. downtown area. It is a key part of the Roel Abubo, Nur Liyana Ahmad, Michael Sulaiman, Barry Sullivan, Qian Sun, Podianko
to ensure the new material was approved drive. Using these digital methods of The standards of coordination and quality government’s transport strategy. Daily Alder, Lioni Alvarez, Victor Andrade, Pei Wen Surya, Sharifah Syed, Cheryl Tan, David
and adopted smoothly. collaborating and coordinating, through 3D set by DTL3 contributed to this process. weekday ridership on the DTL has grown Ang, Serene Ang, Anton Arceo, Jhunel Arroyo, Tan, Fook Aik Tan, Lawrence Tan, May Tan,
models containing every feature of each by more than 50%, from 300,000 to Harry Asilo, Camelia Badeo, Daniel Bali, Yoong Heng Tan, Yunyou Tan, Lim Mei Tang,
Digital modelling station and tunnel, meant that any clashes in Results 470,000, after the opening of DTL3. Warren Balitcha, Jomar Baquiran, Rolando Xin Ning Tang, Joo King Tay, Kelvin Teheri,
Bautista, Tim Bennett, Roger Blackwell, Tamas Kim Keong Teo, Handoko Tham, Lin Than,
DTL3 Package A was one of the first the design were identified and removed prior DTL3 opened towards the end of 2017, About 60% of journeys involving DTL3
Bodri, Nigel Casey, Kartigayen Poutelaye Nagadurai Thangavel, Vivian The, Andra Thedy,
construction projects in Singapore to to tender rather than during on-site offering a swifter commute between have been shortened by up to 10 minutes, Cavounder, Gary Cequena, Peggy Chan, Angelina Theng, Mart Umali, Henry Vong,
compared with previous travel routes, Ricky Chan, Naimet Cheema, Andrew Cheng, Ekarin Wattanasanticharoen, Kenny Wen,
while 20% of journeys are shortened by Joy Cheong, Alvin Cheung, Heidi Cheung, Gary Weston, Ryan Williams, Berlina Winata,
more than 10 minutes. Henry Chia, Lok Ching Choi, Fann Chong, Jin Ambrose Wong, Ling Chye Wong, Peter Wong,
Thai Chong, Ricky Chong, Ts Choong, Shiao Eddie Woods, Nelson Xiong, Da Xu, Jingfeng
The opening of DTL3 has brought people Teng Chow, Wai Fun Choy, Steve Colomb, Xu, Alan Yang, Kimm Ho Yap, David Yeung,
who live and work in the east closer to train Jonathan Constantinou, Argoon Chuang, Edwin You, Pippen Yung, Jie Zhang,
stations. Today, 64% of households across James Daish, Yang Dang, Christopher Daniel, Yimin Zhou.
Singapore are within a 10-minute walk of John Davies, Lauren Davis, Chris Deakin,
Sheryl Demesa, David Derige, Deirdre Devery, Image credits
a station, bringing the city-state closer to
Symur Diche, Lu Lu Din, Ronaldo Domingo, 7, 8, 9: Land Transport Authority
achieving the goal of 80% of households Ryan Edano, Hidayah Edward, Fendy Edy, Yu All other images: Arup
being within a 10-minute walk of a train Ting Fan, Shuhong Feng, Ting Yi Foo, Vivien
station by 2030. Foo, Arvin Francisco, Ezel Gabriana, Sacha
Gebbie, Mercy Guevarra, Xinrui Guo, Hasnita
Following the success of this project, Hashim, Kok Hui Heng, Andrew Henry, Ka
Arup has secured a number of other Fui Hiew, Siaw Ling Hiew, Arge Hipolito, Kent
rail projects in Singapore, including Ho, Sai Ho, Dongmei Hu, Hangyu Huang,
the Thomson-East Coast Line, where Sarah Huskie, Jamilah Hussain, Charles Im,
Arup is the designer of 14 stations Bradley Jackson, Gladys Jahja, Nur Hayati
Jamalludin, Rohani Jamalludin, Henry Jeens,
and nearly 20km of tunnels. Subsequently,
Jimmy Jiang, Damien Jolly, Subash Kathiresan,
Arup was engaged to develop the design Zahid Khan, Rachel Khoo, Nam-Jo Kim,
for the 50km long Cross Island Line. Yan Ru Kiu, Christofer Kristo, Siang Meng
Arup will continue playing a leading Kua, Ben Kwong, Francis Lai, Aishah Abdul
role in helping the Singapore government Latiff, Ching Lau, Vicki Lau, Alice Laung,
create one of the world’s best urban Phil Lazarus, Cheryl Lee, Faith Lee, Gordon
transport systems.
16. 17.

40 1/2018 | The Arup Journal 41

BLOOMBERG CENTER AT CORNELL TECH | ROOSEVELT ISLAND, NEW YORK CITY, USA

Capturing net-zero energy design

The Emma and Georgina Bloomberg Center, part of Cornell Tech’s new 12-acre
campus on New York City’s Roosevelt Island, combined energy demand reduction
with on-site generation to achieve the potential for net-zero energy operation
Authors Fiona Cousins, Carl Mister and Tom Rice

2.

1: Opened in The Bloomberg Center was the first production offsetting the building’s
September 2017, the academic building completed on Cornell consumption. Cornell Tech, a partnership
Bloomberg Center Tech’s new New York City campus. The between the Technion-Israel Institute of
was the first
building has the aspiration of net-zero Technology and Cornell University, won a
academic building
on Cornell Tech’s
energy use as part of the campus’s competition run by New York City to secure
new campus on broader sustainability programme the site for the development of a campus.
Roosevelt Island and has achieved the highest LEED
2: The Bloomberg
Platinum certification. Collaboration
Center (left) and Tata Cornell Tech was willing to change the typical
Innovation Center Through close collaboration with Cornell form and function of an academic building to
(right) under Tech and Morphosis Architects, Arup pushed promote collaboration and innovation and set
construction the boundaries of what could be achieved in new standards in building performance and
creating such a large-scale, low-carbon sustainability. Flexible spaces were designed
energy-efficient building. to encourage collaboration, and open-plan
offices were adopted.
Arup provided multidisciplinary services,
including: structural, mechanical, electrical, The culture of collaboration that the finished
plumbing and fire protection engineering; building needed to facilitate was also to be
acoustic and audio-visual consulting; found in the project team during the design
communications, façade and lighting/ process. Arup worked in partnership with
daylighting design; security; and Cornell Tech and Morphosis Architects
smart building consulting. In addition, with the aim of creating a net-zero building
Arup’s responsibilities included key that would serve as a model for future
sustainability services, LEED advice and development on the campus. This
net-zero-energy goal consulting for the collaboration was essential to meet the energy
160,000ft² (15,000m²) facility. efficiency goals, and Arup’s multidisciplinary
design philosophy helped with the delivery.
Roosevelt Island development
The new university campus is located on the Sustainability
two-mile-long Roosevelt Island in New York The aim was to create a building that is
City’s East River. The campus had its genesis low-carbon, energy-efficient, healthy and
in an initiative of the administration of then pleasant to be in. Throughout the design, Arup
New York City Mayor Michael Bloomberg to evaluated opportunities for reducing energy
promote the city as a hub for tech innovation. demand through internal load reductions; for
The development on Roosevelt Island example, through the use of low-energy
represented a great opportunity for the city, as workstations and lighting, energy recovery
large sites such as this do not become systems and design for reduced solar heat gain.
available very often.
To achieve this, the façade and roof canopy
The city focused on a net-zero-energy were used to limit solar heat gains, thereby
development, with on-site energy lowering the amount of energy needed within
1.

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BLOOMBERG CENTER AT CORNELL TECH | ROOSEVELT ISLAND, NEW YORK CITY, USA

3: Arup produced a 6: The building’s façade balances

Academic Building Energy Use Intensity full-building energy transparency and opaqueness to further
(kBtu/GSF/year electric) Total: 29.3 model to track minimise energy demand
progress towards 7: The east and west façade faces are formed of
achieving LEED small discs set at different angles, which together
Plug load 8.6 Platinum status create an overall image
4: LED lighting was
Lights 5.3
used throughout
Fans 2.9 the Center
Pumps 2.2 5: The rooftop to monitor and control the mechanical,
canopy is made up electrical and plumbing systems,
 round source
G of 1,465 PV panels helping to conserve energy by using
plant – heating 5.7 occupancy sensors.
 round source
G
plant – cooling 4.4 The building itself is set up as an object of
research and learning, with multiple data
 ooling tower
C collection points throughout the building
fan/pumps 0.2 systems. Energy and hot water usage,
occupancy and weather station data are all
collected. Ground-source energy, the PV
3. 4.
system, air-handling unit energy recovery,
chilled water and domestic water usage and
the building for cooling. The solar photovoltaic canopy supports 1,465 PV panels. Arup transparency (40%) and opaqueness (60%) rainwater harvesting are all monitored. This
(PV) roof canopy provides the building’s worked with the client and solar project to decrease energy demand. The system, data is available to Cornell Tech and other
6.
primary power on-site. The building was also developer Distributed Sun to review developed in conjunction with the internal researchers, and can be used as a teaching tool
designed in accordance with the LEED NC preliminary energy analysis and panel layout. efficient LED lighting scheme, ensures for smart buildings and other applications.
2009 rating system, and has achieved the adequate daylighting and maximises views is of a gorge in Ithaca – the home of the water – and most of its cooling. A modular
highest LEED Platinum certification. The panels are laid flat, rather than placed in across the East River towards Manhattan for main Cornell campus – and the western heat recovery ground-source heat pump is The integration of the building services in
the more traditional tilted style. For this the building’s occupants. It reduces solar façade image shows the Manhattan skyline. located in the central plant area. This the publicly accessible café needed to be
Arup tracked progress towards these goals project, where area is limited, it is a more heat gain within the building and maximises The metal panels are also iridescent and provides both hot and chilled water carefully managed because the ceiling and
by producing a full-building energy model cost effective and energy-efficient system. insulation. Exterior shading systems were appear to change colour when viewed from simultaneously. A ground-coupled heat tables are part of an art installation by artist
based on an electric energy consumption More panels can be fitted on the canopy, and located on the eastern façade to help balance different angles. exchanger serves as the primary heat source/ Michael Riedel, who has created a striking
rate of 30 kBtu/GSF/year, providing an with flat panels there is no additional daylight harvesting against cooling sink for the heat recovery chillers, with graphic inspired by Donald Knuth’s
improvement of 35.5% against ASHRAE supporting structure required, nor is there demands, and to minimise the mechanical Rainwater harvesting water used to transfer heat between the publication The Art of Computer
Appendix G energy baseline levels. any shading of adjacent panels as would be systems required along that perimeter. Initial efficiency measures for the building building and the ground. Programming. Arup’s design ensured the
the case with a sloping strategy. fixtures and operations reduced water mechanical and electrical services in the
All-electric building The metal panel cladding on the east and demands and subsequent waste water During the hotter summer months, when less café, including both the HVAC and fire
New York City has the stated goal of Building façade west façades includes a series of small discs discharge by 28%. A rainwater harvesting heat is required in the building, the rejected protection systems (which incorporated
reducing greenhouse gas emissions to 80% The façade plays an important part in the set at different angles, which form a system further reduces potable water usage heat gets pumped into the ground, while in
of the 1990 baseline by 2050. Much of these building’s passive energy design. It balances pixelated pattern. The eastern façade image and discharge into the public sewer. By winter this heat is drawn out and used for
carbon emission reductions will stem from capturing rainfall from the Center’s roof, the heating purposes. The closed-loop
power plants as coal and oil are phased out building supplies the bulk of all of its geothermal system consists of 80 boreholes
of electricity generation in New York State non-potable water demand. at 6m centres drilled 120m deep. The system
and replaced by solar and wind sources. provides 330 tonnes of cooling to the
This is collected and stored in a building through an active chilled beam
An important characteristic for Cornell Tech 40,000-gallon (150m3) retention tank under system. A supplementary cooling tower is
was therefore to have an all-electric building the campus plaza. The stored rainwater is used in periods when additional cooling is
ready to benefit from decarbonisation of the transferred via submersible pumps to a required. The tower supplements the heat
electricity grid. The heating and cooling are packaged treatment system. From there it is rejection system and is also used to avoid
provided primarily using electrical ground- distributed to the building’s non-potable overcharging the ground with excess heat.
source heat pumps, and the building electricity fixtures (such as toilets), used for irrigating
supplied predominantly by PV panels. the campus lawn and in the cooling tower Enthalpy wheels are used in the energy
through dedicated non-potable plumbing. recovery systems, recovering warm or cool
PV canopy A back-up system is in place to deal with air from exhaust streams to pre-heat or
The PV array on the Bloomberg Center’s prolonged spells without rain. pre-cool incoming air to the building
canopy provides on-site renewable energy as appropriate.
generation, as well as shading that reduces Ground source
the building’s cooling load in summertime. Ground-source heat pumps were installed to Building services
A campus-wide array of solar panels was warm and cool the building, exploiting the Building energy loads were analysed
developed, with PV panels placed both on the constant ground temperature of 57°F (14°C). thoroughly and allowances for lighting and
Bloomberg Center and the adjacent Tata This ground-source system provides all the computers were carefully planned. The
Innovation Center. The 40,000ft2 (3,750m²) building’s heating – including domestic hot Building Automation System (BAS) is used
5. 7.

44 1/2018 | The Arup Journal 45

BLOOMBERG CENTER AT CORNELL TECH | ROOSEVELT ISLAND, NEW YORK CITY, USA

8: Michael Riedel’s
sprinklers), satisfied code requirements and black and white
met both the architectural and artistic inkjet print graphic
requirements for the space. decorates the café
ceiling and tables
Structural design 9 & 10: The feature
The building has a single-level basement staircase is located
under part of its footprint and is founded on above the campus
footings bearing on rock (with rock anchors) plaza and forms
and mini-piles socketed into rock. These act the apex of the
against uplift from groundwater – a key building’s canopy
requirement, as in the event of flooding the support. Its central
resulting hydrostatic uplift pressure on the spine truss provides
structural support to
basement would exceed the building’s
the canopy
permanent weight.

The structural grid is typically 30ft by 30ft

(9.1m by 9.1m). The building’s superstructure
is a steel frame with a composite concrete
slab on a metal deck. The thickness of floor 9. 10.
slabs varies to suit loading requirements and
the mass required for some limited acoustic 8.
structure. This system is part of the system and is connected to the transverse damage and further highlighted the
and vibration control. To allow for future primary structural system providing and central spine trusses. A vertical truss resilience required by the campus.
flexibility, a minimum live load of 100psf gravity support to the stair edges and on the south end laterally connects the
(4.8kN/m²) is used across the majority of the scheme made up of a single storey-height building’s canopy and cantilevers out over façade. Similar to an outrigger system diagrid system and central column to To mitigate potential damage to equipment
floors. This allows office spaces to be truss is used between levels 2 and 3 at the the pedestrian route between the Bloomberg used in high-rise construction, the the main building. during a flood event, the main electrical
converted to classrooms without fixed north end of the building. The building Center and the neighbouring Tata Innovation exterior diagrid system also helps to switchroom and emergency and life
seating, or to assembly spaces, without overhang varies from approximately 30ft at Center building. brace the overall stair structure laterally Resilience safety power systems are located at roof
requiring any structural intervention. level 2 to 45ft at roof level. and transfer the lateral forces back into Roosevelt Island is in a vulnerable location level, along with the generator, while
A central spine truss oriented longitudinally the main building structure. for flooding, so resilience against flood the basement footprint and plant equipment
The steel columns of the structure extend Feature staircase along the stair axis extends up to the roof conditions and rising sea levels was a are minimised.
above roof level to support the solar panel A prominent staircase is a key component of canopy, providing the main structural Additional concealed trusses include critical design component. In October 2012,
canopy structure, above which is a grillage of the building’s eastern elevation. Located support. An outer, partially curved diagrid transverse trusses perpendicular to the only a few months after the design process The number of electrical panels installed
steel beams in one horizontal plane supported above the campus plaza and close to the truss system supports and provides central spine truss, and an edge truss that began, New York City was hit by Hurricane in the basement was kept to a minimum.
on steel columns. A cantilever structure main entrance, it forms the apex of the additional stiffness to the façade and vertically supports the perimeter diagrid Sandy. The flooding caused $70bn in Ground fault circuit interrupters were also
put in place so that in the event of a flood, or
if water infiltrates those circuits, they can be
Authors Chad Fusco, John Hand, Spencer Harris,
isolated without damaging the connected
11: 3D model Fiona Cousins was the Project Director. She is Andrew Heiser, Peter Ibragimov, David Jones, circuits or panels. Similarly, motors and
showing the an Arup Fellow based in the New York office. Deepak Kandra, Igor Kitagorsky, Marina Kremer, critical mechanical equipment were kept
structural frame. Ken Garmson, Leonie Van Ginkel, Alex above the flood line.
The steel columns Carl Mister was the lead electrical engineer. He Gorenstein, Tyler Gorton, Tom Grimard, Anne
extend above roof is an Associate Principal in the New York office. Guthrie, Matthew Lacey, Gary Lam, Dennis Continued work on campus
level to support the Lowenwirth, Filip Magda, Andrew Marchesin, Arup has continued its work on Cornell
PV canopy and Tom Rice was the Project Manager and lead Will Mason, Claudia Mazzocchetti, David Tech’s Roosevelt Island campus with
incorporate thermal structural engineer. He is an Associate Principal McNell, Anjali Mehrotra, Ashraf Metwally, Carl involvement in two further projects.
breaks to reduce in the New York office. Mister, Sarah Moore, Elvis Nunez, Allan Olson,
Working with Weiss/Manfredi Architecture,
cold bridging James Olson, Christian Paunon, Filip Popovic,
Project credits Eugene Prokofiev, Dylan Quan, Alvaro
Arup provided security, IT and AV
Client Cornell Tech Quinonez, Tom Rice, Ron Ronacher, Chris Rush, consulting services for the interior fit out of
Architect Morphosis Roberto Saldarriaga, Kirsten Salmins, Yet Sang, four floors within the Tata Innovation
Main Contractor Barr & Barr Adriana Sangeorzan, Katelyn Sapio, Joe Center. This building consists of classrooms,
Cost Estimator Dharam Consulting Saverino, John Scavelli, Jeff Schwane, Markus general and robotics laboratories, huddle
Geotechnical Engineer Mueser Rutledge Schulte, Juanma Serrano, Anatoliy Shleyger, rooms, studio and open office space, and
Acoustics, Façade, Fire Protection, Lighting Christopher Simon, Joe Solway, Daniel several large collaborative spaces.
MEP, Structural and Sustainability Engineer, Wilcoxon, David Wilts, Therese Worley.
IT/AV/Security, Smart Building Arup: Currently under construction, Arup is
Jonah Allaben, Chelsea Bajek, Daniel Brodkin, Image credits
also providing (in collaboration with
Beverly Brooks, Cillian Brown, Thomas 1, 6, 9: Iwan Bann
Bukovac, Aaron Burger, Foram Chaliawala, Dan 2: Cornell Tech
Snøhetta) acoustic, AV, IT and
Clifford, Fiona Cousins, Casey Curbow, Daniel 3, 5, 7, 10: Arup security consulting services on the Verizon
Dichiro, Zohaib Dar, David Easter, Ming Feng, 4, 8: Matthew Carbone Executive Education Center, a 40,000ft2
Adrian Finn, Vincent Fiorenza, Adam Foxwell, venue for executive programmes, academic
11.
conferences and workshops.

46 1/2018 | The Arup Journal 47

 1 2

3 4

5 6

1. Harbour Area Treatment Scheme, Hong Kong: Arup; 2. V&A Grain Silo Complex, Cape Town, South Africa: Arup/Tessa Brunette; 3. Francis Crick Institute, London,
UK: Paul Carstairs; 4. 3D Housing 05, Milan, Italy: Arup; 5. Singapore Downtown Line: Arup; 6. Bloomberg Center at Cornell Tech, New York, USA: Iwan Bann.
Front cover and inside cover images: V&A Grain Silo Complex, Cape Town, South Africa: Arup/Tessa Brunette.

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