3.

0Overseas Case Study: Eden Project, Cornwall

General Information
Building: Multiple Greenhouse Complex
Location: Cornwall, United Kingdom
Size: 23,000 square metre
Construction time: 2 ½ years
Completion: March 2001
Cost: then £86 million
Design team:
Architect: Nicholas Grimshaw
Structural Engineer: Anthony Hunt and Associates
Main Contractor: McAlpine Joint Venture
Structural Background
Space frame: Double layer geodesic dome
Total surface: 39.54 m2
Total steel weight: 700 tonnes
Shapes: 625 hexagons, 16 pentagons & 190 triangles
Hexagon diameter: 5 – 11 metres
Column free area: Warm Temperature Biome (WTB): 15590m2
Humid Tropics Biome (HTB): 6540m2
Nodes: 4,000 numbers
Members: 7,545 numbers

3.1 Structural
Idea 1: Arches and purlins.

Disadvantage:
1. High steel weight
2. Small glass elements blocks sunlight
3. Difficult to fit to varying natural
surface of clay pit

Idea 2: Single layered dome with hexagonal

geometry

Disadvantage:
1. Not economical
2. Deformation too large

Final idea: Geodesic double layer space frame

dome

Advantage:
1. Column free space
2. Maximum sunlight intake
3. Geodesic structure able to conform to
expanding and contracting of clayey soil
As said by Tony Hunt, the appointed structural engineer, the first challenge was the nature of the ground;
clayey quarry. In early design stage, the land and foundation line on this 600 year-old China clay-pit was
constantly shifting due to the ongoing mining process.

Figure 11: Soap bubbles

Architect Nicholas Grimshaw, inspired by series of soap bubbles, came up with this indigenous hex-
tri-hex structure. Bubbles adjust to the surface they land on and when two or more series of bubbled
connects, the line of join is always perpendicular.

Figure 12: Sphere scheme roof

Using that concept, build in a sphere and embedded on ground, the sphere can be ‘cut’ depending on
the ground level. This enables changes of either moving up or down from the sphere scheme.
 3.2 Geodesic double layer space frame dome

Figure 13 & 14: Construction before & after

Geodesic dome is a spherical space frame, transferring loads to its support from a network of linear
elements arranged in spherical dome. Though the whole structure resembles a semi-sphere, the entire
structure is built from straight planes with straight edges. Loads are transferred to support points by axial
forces; tension and compression.

Figure 15 & 16: Interior & exterior of Hex-Tri-Hex net

The structural network are of two concentric spherical networks, with a certain radius difference
between them. Diagonal struts are connected, creating a double layer three-dimensional load carrying
network. This hex-tri-hex dome is reliant on two layers, outer skin is a hexagonal, some pentagonal
framework (Hex- Net) and inner layer are made of triangular and hexagonal grid (-Tri- Hex Net).
Hexagonal

Figure 17: Hexagonal framework

Hexagonal domes divides their struts into:

a. Large, strong struts that forms the hexagonal shells and provides primary weight-bearing support for
dome
b. Narrow, lighter truss that provides stability for dome

Reasons for using hexagonal framework comparing to conventional triangular framework:

1. Thickness
Eden Project significant exterior is of thin geodesic dome. Converting a conventional triangular
geodesic dome to a hexagonal dome reduce about two third of struts, maintaining same volume.

2. Big domes
Domes of larger span with higher strength to weight ratio can be built as it uses strong weight-
bearing outer connectors and lighter inner stabilising connectors.

3. Strength
Evenly distributed strength across surface of hexagonal domes as triangular domes concentrates
more at hubs

4. Smooth surface
Triangular domes presents challenges when roofing of smooth surfaces due to its corners
 3.3 Nodes & Tubes

Top chord connections:

a. Rigid connection for three circular hollow sections (CHS) tubes of 193mm diameter
b. Hinged connection for diagonal struts to bottom chord
c. Top exposed surface is even with tubes, enabling cladding over it

MERO NK-Bowl node:

a. Made of cast iron (GGG40) and galvanized for corrosion protection
b. Weight about 80kg
c. Diameter of 400mm

Top chord beams:

a. CHS tube diameter of 193.7mm
b. Ends are cut rectangular and fixed to nodes
c. High pre-stressed bolts (M27 & M36) used to connect beams to bowl nodes
d. Bolt M16 fix beam in right position & transfer torsional moments
Bottom chord & diagonals:
a. CHS tube diameter between 76.1mm and 168.3mm
b. Buckling length limited to 180

3.4 Construction Technology

Erection method

The most basic hexagonal structure is not stable. It is stiff but difficult to support until they are all in place.
Step 1: Setting the Guinness World Book of Records, a birdcage scaffolding of 60 metres high and 125
metres across was set up for erection as temporary support.

Step 2: Hexagons were put together on ground and then lifted up by mobile crane and tower cranes on larger
domes in the HTB, starting from dome A of HTB to dome H of WTB.

Step 3: Bolting of hexagon structure.

Step 4: Scaffolding removed after erection.

4.0 Local Case Study: Shah Alam Sports Complex, Selangor

General Information
Location: Shah Alam, Selangor, Malaysia
Size: 155,000 square feet
Capacity: 80,000 people
Construction cost: RM480 million
Construction begin: 1st January 1990
Construction time: 4 years
Design Team
Owner: State Government of Selangor
Architect: Hijjaz Kasturi Associates Sdn.Bhd, German firms of Weidleplan and Consulting GmbH, and
Schlaich, Bergermann and Partners
Structural Background
Space frame: USSP Unistrut space frame roof
Arc length: 284m
Cantilevered from the back: 69m
Shape: Crescent shape (generated from cut section of circular cylinder)
Type of tube: Cold-form high strength structural tubing
Tubes: Local buckling of tubes
Column buckling of tubes
Nodes: 5556
Members: 21550
 4.1 Structural

Unistrut Space Frame Roof

Unistrut is a series of threaded road and metal channel used to form a ceiling-mounted support structure for
anything, to injectors, to overhead system components.

Unistrut Features
It consists of a large chamfer in nut ease starting of bolt. A special shaped in turned edges and tapered,
serrated grooves produce strong vice-like grip between channel and nut.

4.2 Double Layer Barrel Vault

The stadium constructed of two graceful arches, each measuring 284m, making it one of the longest
free-standing arches in the world, enclosing 70% of interior. A double layer barrel vault space frame is
utilized but incorporated with a triple layer at the front arc to preserve an arch action for effective load
distribution.
Support

Each of the two space-frames is supported in the back by prestressed concrete cantilever beams at 16
locations, and each side is supported by a prestressed concrete buttress at 8 locations. Stiffness and
maximum reactions at supports were established a priori, and space-frame design has to satisfy these
requirements.

4.3 Connectors

Each module consists of cold-formed steel tubes bolted into spherical steel nodes to form a
rectangle-base pyramid. Cross sections of cold-form high strength structural tubing are tapered towards the
nodes using a truncated cone interface elements welded to the tubes. Cones provide for the transfer of forces
from tubes to the connections, and reduce the sizes of the otherwise large nodes. A hexagonal bearing
element "sleeve" is used between the cone and the node with a pin penetrating through the bolt and sleeve to
allow for turning the bolt to engage into the node. The tube-cones assembly is galvanized before inserting
the bolts into the tubes.
 4.4 Construction Technology
Erection

Space-frame is being constructed by strips extending between the back support and the front arch of
the frame. Each strip is secured between two adjacent supports to insure its relative position. Strips are
supported by temporary shoring towers between the supports and the front arch of space-frame. Each tower
is equipped with a screw-jack to fine-tune the relative position of space-frame and to enable cambering the
frame by its dead load deflection. Strips are tied together as they are extended towards the front arch of the
frame. This is to preserve the arch action of the frame which provides a self-supporting mechanism.
5.0 Reference

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Khaldoun Mhaimeed (1992, October 20). Shah Alam Sports Complex Design and Construction of

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http://scholarsmine.mst.edu/cgi/viewcontent.cgi?article=1684&context=isccss

Limited, H. A. (2015, October 15). Erection Methods for Space Structures. Retrieved November 27,
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