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Metal Fabricating in A New Millennium
Metal Fabricating in A New Millennium
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http://www.thefabricator.com/article/arcwelding/metal-fabricating-in-a-new-millennium
How metal fabricators elevated plate cutting, bending, welding, and finishing to an
art form to create Millennium Park's Cloud Gate
THE FABRICATOR MAY 2006
May 9, 2006
The forming and fabricating of the 925-foot BP Pedestrian Bridge located at the east section of Chicago's Millennium
Park, and the Jay Pritzker Pavilion is explored.
"What I wanted to do in Millennium Park is make something that would engage the Chicago skyline ... so that one
will see the clouds kind of floating in, with those very tall buildings reflected in the work. And then, since it is in the
form of a gate, the participant, the viewer, will be able to enter into this very deep chamber that does, in a way, the
same thing to one's reflection as the exterior of the piece is doing to the reflection of the city around."
World-renowned British artist Anish Kapoor, Cloud Gate sculptor
(Photo courtesy of Millennium Park Inc., Chicago.)
One could hardly guess by looking at the placid surface of the monumental stainless steel sculpture how much metal
and mettle are below its surface. Sealed within Cloud Gate are the storiesfive-plus years in the makingof more
than 100 metal fabricators, cutters, welders, finishers, engineers, technicians, ironworkers, erectors, and managers.
Achieving the requirements of the project would mine the two companies' artistic execution, ingenuity, mechanical
know-how, and fabrication savvy. They customized and even created equipment for the project.
Some of the project's challenges arose from its oddly curving shapean omphalus, or inverted belly buttonsome
from its sheer enormity. Constructing the sculpture at separate sites thousands of miles apart by two different
companies created transport and workstyle issues. Many of the processes that had to be done on-site were difficult
enough to achieve in a shop environment, much less in the field. Much of the difficulty arose simply because such a
structure had never been created before; therefore, there was no reference, no blueprint, no roadmap.
An Omphalus Is Born
Having in-depth experience creating shell structures, initially on ships and later on other art projects, PSI's Ethan Silva
was uniquely qualified for the shell structure fabrication task. Anish Kapoor asked the physics and art graduate to
provide a small-scale model.
"So I made a 2- by 3-meter sample, a very smoothly curved, polished piece, and he said, 'Oh, you did it, you're the
only one who did it,' because he had been looking for two years to find somebody to do this," Silva said.
The original plans were for PSI to fabricate and construct the sculpture completely, after which the entire piece would
be shipped south on the Pacific Ocean, through the Panama Canal, north up the Atlantic and down the St. Lawrence
Seaway to a port on Lake Michigan, where a specially designed conveyor system would transport it up to Millennium
Park, according to Millennium Park Inc. Executive Director Edward Uhlir. Time constraints and practicality forced
those plans to change. So the curved plates had to be braced for transport and trucked to Chicago, where MTH would
assemble the substructure and superstructure and join the plates to the superstructure.
Ultimately, the sculpture was to resemble liquid mercury, said to be the artist's inspiration.
"And so we basically worked on that project, making those parts, for about three years," Silva said. "It was a major
task. And a lot of that time was spent figuring out how to do it and working out the details; you know, just perfecting it.
Our approach, using computer technology and good old-fashioned metalworking techniques, was a combination of
blacksmithing and aerospace technology."
It was difficult to fabricate something very precisely that would be so large and heavy, he said. The largest plates
were, on average, 7 ft. wide and 11 ft. long and weighed as much as 1,500 pounds.
"Doing all the CAD work and just creating the actual construction drawings for the piece was actually a big project in
and of itself," Silva said. "We used computer technology to measure the plates and to accurately assess their shape
and curvature so they would all fit together correctly.
"We did computer modeling and then divided the piece up," Silva said. "I utilized my experience with shell structures
and I had ideas about how to divide up the shape to make the seam lines work so we would have optimum-quality
results."
Some plates were squared, some were pie-shaped. The closer they got to the sharp transitions, the more pie-shaped
they were, and the greater the radial transition. At the top, they were much flatter and larger.
Plasma cutting the 1/4- to 3/8-in.-thick 316L stainless steel plates themselves was tough enough, Silva said. "The real
challenge was to get the mammoth plates to the precise-enough curvature. And that was done by very accurately
forming and fabricating the rib-system framework for each plate. That way we could accurately define the shape of
each plate."
The plates were rolled on a three-dimensional roller that PSI designed and built specifically to roll these plates (see
Figure 1). "It is sort of a cousin to an English roller. We rolled them using techniques similar to fender-making," Silva
said. Each plate was curved by moving it back and forth on the roller, adjusting the pressure on the rolls until the plate
was within 0.01 in. of the required dimension. The high level of precision required made it difficult to form the plate
smoothly, he said.
Figure 1
Much of the equipment had to be designed or customized especially for Cloud
Gate. PSI designed and built a three-dimensional roller to roll the plates smoothly
and precisely. Each plate was curved by moving it back and forth on the roller,
adjusting the pressure on the rolls until the plate was within 0.01 inch of the
required dimension.(Photo courtesy of PSI, Oakland, Calif.)
Figure 2
The plates were grinded and
polished to a mirror finish
before they were shipped
and assembled. (Photo
courtesy of PSI, Oakland,
Calif.)
The welders then flux-core stitch-welded the curved plates onto the inner rib-system structures. "Flux-core is really a
wonderful way to create structural welds, I think, in stainless steel," Silva explained. "It gives you a great-quality weld
and it's very production-oriented and it has a good appearance."
The plates' entire surfaces were both hand-ground and machine-milled to trim them to the thousandths-of-an-inch
precision needed so that they would all fit together (see Figure 2). Precision measuring and laser scanning
equipment were used to check the dimensions. Finally, the plates were polished to a mirror finish and covered with a
protective film.
Before the plates were shipped from Oakland, approximately a third of the plates and the base and interior structure
were erected in a trial fit-up (see Figures 3and 4). Plate-hanging procedures were planned and some seam welding
done to a few of the small plates to combine them. "So we knew it was going to fit when we were putting it together in
Chicago," Silva said.
Figure 3
The superstructure to which the plates
would be attached started with O-shaped
rings and a pipe truss system. (Photo
courtesy of PSI, Oakland, Calif.)
Figure 4
A third of the plates, and the base and interior structure, were erected
in a trial fit-up in Oakland before being shipped to Chicago. The
erecting of the superstructure started with the "belly button." (Photo
courtesy of PSI, Oakland, Calif.)
Temperature, time, and truck vibration could have caused the rolled plates to relax. Not only were the rib grids
designed to add stiffness to the plates, they also were intended to retain the plate's shape while in transit.
So, with the reinforcing grid on the interior side, the plates were heat- treated and cooled to release the material
stresses. To further prevent damage in transit, cradles were made for each plate, and the cradles were loaded on
containers, about four at a time.
Then the containers were loaded into semis, about four at a time, and were sent to Chicago, along with PSI staff to
work with MTH's staff on the installation. One was a logistic person to coordinate shipping, and the other was a
technical field supervisor. He worked alongside MTH's crew on a daily basis as well as to help to develop new
techniques as needs arose. "He was certainly a very pivotal part of the process," said Silva.
On-site in Chicago
At first it was MTH Industries' mission to anchor the ethereal sculpture to the ground and install the superstructure,
and then also to weld the plates to it and perform the final grinding and polishing, with PSI providing technical
direction, said Lyle Hill, MTH president. Completion of the sculpture meant balancing the artistic with the practical;
theory with reality; time required with time scheduled.
Lou Cerny, vice president of engineering and the project manager for MTH, said what intrigued him about the project
was its uniqueness. "There are things that happened on this particular project that, to the best of our knowledge, have
never been done before, or really considered before," Cerny said.
But working on a first-of-its-kind required nimble, on-the-spot ingenuity to master unforeseeable challenges and
answer questions that arose as the job progressed:
How do you mount 128 car-sized stainless steel plates onto a permanent superstructure while handling them with kid
gloves? How do you weld the enormous curved bean without leaning on it? How do you penetrate the welds without
being able to weld from the inside? How do you achieve a perfect mirror finish on stainless steel welds in a field
environment? What happens if lightning strikes it?
Substructure
Cerny said the first indication that this would be an unusually difficult project was when building and installation began
on the 30,000-lb. steel substructure to support the sculpture.
Although the zinc-rich structural steel fabrications provided by PSI for assembling the substructure base were
relatively straightforward, the site for the substructure was halfway over a restaurant and halfway over a parking
garage, each at different elevations.
"So the substructure was kind of cantilevering, teetering over one point," Cerny said. "Where we were setting a lot of
this steel, including the beginning of the platework itself, we actually had to have a crane drive into a 5-foot-deep
hole."
Cerny said they used highly complex anchoring systems, including mechanical pretension systems, similar to the
types of things that are used in coal mining, and some chemical anchors. Once the steel substructure was set in
concrete, a superstructure had to be erected, to which the shell would be attached.
"We started installing the truss system with two large fabricated 304 stainless steel O-shaped ringsone at the north
end of this structure, and one at the south end," Cerny said (see Figure 3). The rings are held together with crisscrossing pipe trusses. The ring-core subframe is built in sections and field-bolted with welded reinforcements using
GMAW and stick welding.
"So there's this big superstructure that no one ever sees; it's strictly for structural framing," Cerny said.
In-process FabricatingOn-the-Fly
Despite best efforts to design, engineer, fabricate, and erect all the needed components for the project in Oakland,
this sculpture was unprecedented, and blazing new trails always comes with burrs and scratches. Too, meshing the
fabrication concepts of one company with those of another wasn't as simple as passing a baton. In addition, the
physical distance between sites created delivery delays that made some on-site fabrication logical.
"Though the assembly and welding procedures had been worked out in advance in Oakland, the actual field
conditions required adaptive ingenuity from everyone," said Silva. "And the union crew was truly great."
For the first several months, MTH's daily ritual was to determine what was needed for the day's work and how best to
fabricate some members needed to erect the subframe, as well as some of the struts, "shock absorbers," arms, pegs,
and pogo sticks needed to erect a temporary plate-hanging system, Hill said.
"It was a continual process, to design and fabricate on the run to keep things moving and get them out to the site
quickly. We spent an awful lot of time sorting out what we had, redesigning and re-engineering in some cases, and
then fabricating the needed parts.
"Literally, on Tuesday we'd have 10 pieces of something we had to have on- site Wednesday," Hill said. "There was a
lot of overtime, a lot of shop work done in the middle of the night."
"Probably about 75 percent of the plate-hanging assemblies were fabricated or modified in the field," Cerny said. "On
several occasions, we literally fabricated 24 hours a day. I would be at the shop until 2 or 3 in the morning, I'd go
home, take a shower, and pick up material at 5:30 in the morning, still wet."
Shell at Last
The temporary suspension system MTH used to assemble the shell was composed of springs, struts, and cables. All
the joints between the plates were bolted together temporarily. "So the whole structure was mechanically attached,
suspended from the inside, the 304 trusswork," Cerny said.
They started with the dome on the underside of the omphalus sculpturethe "belly button of the belly button." The
dome was suspended from the truss using a temporary four-point hanging spring support system composed of
hangers, cables, and springs. The springs provided "give-and-take" as more plates were added, Cerny said. Then the
springs were readjusted based on the weight each plate added to help balance the entire sculpture.
Each of the 168 plates had its own four-point hanging spring support system and so was individually supported as it
was put into place. "The idea was to not overstress any joint, because these were put together to a 0/0 clearance,"
Cerny said. "If one plate hit the plate below it, it could cause buckling and other problems."
Perfect Fit-up
As a testament to the accuracy of PSI's work, the fit-up was so good, the gaps were nearly nonexistent. "PSI did a
tremendous job of fabricating the plates," Cerny said. "I give them all of the credit for that, because in the end, it
actually fit. The fit-up was excellent, which to me was amazing. We're talking about, literally, thousandths of an inch.
The plates came together with a closed edge."
"When they were done fitting it up, many people thought it was finished," Silva said, not only because the seams were
tight, but also because the fully assembled Piece, with its highly polished, mirror finished plates, had emerged in its
role to reflect its surroundings. But the butt joint seams were visible, and liquid mercury does not have seams. Also,
the sculpture still had to be fully seam-welded to retain its structural integrity for all posterity, Silva said.
Completion of Cloud Gate had to be put on hold during the park's autumn 2004 grand opening, so the omphalus was
spot-GTAW, and that's how it stayed for months.
"You could see little brown spots, which were TIG spot welds all the way around the structure," Cerny said. "We
started putting the tent back up in January."
circumstances and modifying it to work, really," Cerny said. "The heads were modified, cut at certain angles, and
everything else was changed slightly. We did a lot of experimentation to get it to work, because it was all-position
welding within the same runmeaning it's right in front of you, vertically up, vertically down, and overhead. So you're
constantly adjusting your gas feed, your wire feed speed, how fast you're traveling It's something that the guys had to
develop as they were working with it. There is no book that tells you that, unfortunately."
"The nerve-racking thing for the welders, I think, was they knew if you screw up and blow holes, there's a lot of repair,"
Cerny said. "If you don't get full-penetration welds, you cut it back out. We were very fortunate; they did a very good
job, and they handled it pretty quickly. Essentially we did it in the time we said it would take, and at the level of quality
we were hoping for."
"Because this was a first-time project, a new process, and a new product, we wanted to err on the side of caution,"
Hill said. "For instance, we originally followed a recommendation as to how to preload the plates, as we refer to it. The
theory is you push out the two edges where these two planes meet, actually force the edges out high, or proud, as
they are welded into place, and then under heat, they shrink back. You would then grind the joint down into plane. You
never want to have a concave joint.
"Well, guys in the field pointed out that initial assumptions as to how the steel would react during welding were way
off. The shrinkage during the plasma welding technique ended up being almost nonexistent. So we were pushing
them out 0.0015 inch, and then they were standing 15 thousandths high. So we started pulling it back. There was a
certain amount of trial and error."
Once all the plates were fully in place and the exterior plate welding was completed, permanent weld-ups had to be
done on the inside.
Figure 5
Finishing and polishing Cloud Gate's welds to achieve a seamless appearance was one the toughest aspects of the
onsite erecting and assembly tasks. The 12-step process concluded with abrightening rouge likened to jeweler's
polish. (Photo courtesy of Jason Bartholme.)
and polishing, internally we had a little bit of a debate over whether or not we wanted to do it," Hill said. "We had
peers in the industryboth guys who fabricate only in-house and companies that do field fabrication and finishing
tell us, 'You're not going to be able to achieve a mirror finish after welding stainless steel. You will have discoloration or
a rough surface, most likely both.'
"We were in a tough situation because it's one of those projects that we had a fair amount to gain if it turned out well,
and a tremendous amount to lose if it didn't," Hill said. "I had a lot of sleepless nights during the course of the job."
The weld finishing was a 12-step process, explained Cerny, beginning with rough grinding the weld close to the
existing surface using 60-grit zirconium paper on a circular belt. To grind material out of the joint so it would blend with
the surrounding areas without gouging, all subsequent sanding was done with semiautomatic belt sanders with
wheels on them that would "ride" the material outside of the joint.
"The wheels had adjusting screws on them, and we would set the height or depth of the belt and keep adjusting them
until we got to the surrounding surface height and everything was blended to the same level of finish," Cerny said.
From there, the finishers used a special grade of 400-grit ceramic sandpaper, called a type CF-Trizact "It's
something you don't really see in our industry; it's usually for a surgical instrument. But it works very well on
stainless," Cerny said.
3M worked with them to develop some new belting systems to make the finish very bright before the final polishing
phase, he said.
"They allowed us to work on some that aren't on the market yet," Cerny said. "3M also came up with probably a
couple dozen sanding products, and we took it down to about six that worked for us, so most of this was done with a
belt machine and 3M products."
Park Jewelry
To achieve the gleaming, highly polished, reflective mirror finish, the finishers used a kind of jewelers' polish, a waxy
substance called a rouge. Three types of rouges contain three grades of abrasives.
"A lot of the rouges that are capable of taking the polish from a semifinished surface to a mirror finishwe call them
cutting rougesalso have a fair amount of abrasives in them, which means they literally cut the stainless. Our
problem was, they also added distortions, waves. So we only used the final 800-grit rouge, a lubricant, for brightening
and to remove the final scratches," Cerny said.
"Everyone will tell you that if you skip a step, you have to go back," Cerny added. "Because we had to do this on a coproduction basiswe had 24 or 25 people working at once just on the outsidewe had to make sure all the steps
were taken. We didn't polish a 3-foot square all the way to mirror and then move over. We would do a certain step on
large areas of the surface and then do the next step.
"But the targetand everybody's got crossed fingersis that when we get to the next step, everything goes OK."
"I think we reached the point where, OK, you're in it, and you've committed to it, so you're going to have to finish it."
"We decided to use straight sections and segment them to create the illusion of curvature," Zils said. "In other
words, there actually are no bent members in those ribbons," Zils said.
The framing sections are set up on a 9- by 10-ft. grid to form the rough curvature. The verticals are wide-flange
sections and the horizontals are square tubes, prefabricated in the shop in straight sections. The angle change
takes place at nodal points on the grid to follow the curvature, Zils said. "So when the stainless steel cladding was
attached, it actually had the exact curvature that Gehry was looking for."
The backup structure was prefabricated into segments which were trial-fitted and then brought to the site and
assembled into larger sections. Prefabricated aluminum backup panels were then mounted to the backup structure
with a bolted connection. Then the stainless steel "shingles" were attached mechanically with clips to the backup
panels. "So each one of the metal ribbons might have three or four prefabricated structural sections that were then
erected in pieces," Zils said.
BP Bridge
The other Frank Gehry-designed feature in Millennium Park is a 925-foot-long, sloping pedestrian bridge that
meanders seemingly aimlessly but that actually functions as a link to Grant Park and Lake Michigan as well as a
sound barrier for the pavilion. Other than its hardwood deck, it is entirely clad in stainless steel panels.
Zils said a major challenge was achieving Gehry's shape, configuration, and low-profile (1-to-20 ratio)
requirements. "We had to figure out a way to span over Columbus Drive, a major thoroughfare with a certain
portions of the bridge be assembled and mocked up in the shop so that the fabricator could then check all his
alignments before he shipped everything out here to the site," Zils said. "Doing these trial fit-ups in the shop was
crucial."
"The erecting that weekend literally went without a hitch," Zils said.
Acme Structural, 2101 N. Packer Road, Springfield, MO 65803 417-865-6691, fax 417-865-6289,
acmefab@acmefab.com, www.acmefab.com
Chicago Metal Rolled Products, 3715 S. Rockwell, Chicago, IL, 60632, 773-523-5757, fax 773-650-1439,
www.cmrp.com
Millennium Park, 20 N. Michigan Ave., Ste. 106, Chicago, IL 60602, 312-744-2053, fax 312-744-2036,
www.millenniumpark.org
MTH Industries, One MTH Plaza, Hillside, IL 60162, 708-498-1100, fax 708-498-1101, info@mthindustries.com,
www.mthindustries.com
Performance Structures, 499 Embarcadero, Oakland, CA 94606, ethan@performancestructures.com,
www.performancestructures.com
Radius Track Corp., 3530 88th Ave. N.E., Blaine, MN 55014, chuck@radiustrack.com, www.radiustrack.com
Skidmore, Owings & Merrill LLP, 224 S. Michigan Ave., Ste. 1000, Chicago, IL 60604, 866-296-2688, 312-554-9090,
fax 312-360-4545, somchicago@som.com
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