Location: Auckland
Product: Smarttray Custom made wave dome roofing
Medium: Copper
Surface: 980 sqm
Architect: Noel Lane
Architectural Metalformers Ltd created the "wave" dome for the Grand Atrium at the Auckland War Memorial Museum.
The undulating copper roof and matching gutter is a unique achievement for our team. Our research and craftsmanship of this dome will ensure the dome is a landmark for future generations.
The copper splayed dome tops a structure within the heritage building which is bold in concept and scale for transforming the iconic Auckland building where redevelopment began 12 years ago. The additions will provide an extra 8500m2 of space on seven levels.
Project specifics
Topping the entire structure is the copper and glass dome, transforming the southern aspect of the museum.
The suspended four storey building and roof structure were the most challenging aspects of the entire project along with height restrictions on the roof through the Resource Management Act.
Early input
Design issues were the subject of early discussions with Architectural Metalformers to expose critical elements of this unique re-development.
We engaged in preliminary, pre-tender talks with Mark Katterns, project director for Hawkins Construction, the main contractor. Noel Lane Architects' original drawing for the roof featured a shallow dome to the atrium which has been built within the central courtyard of the museum.
But what has evolved is a dome with far greater design and structural challenges for the coppersmiths and craftsmen from Architectural Metalformers - a "waved" copper dome with 1760 splayed panels, each with a different radius.
Most of the copper work was completed in February and March 2007 with 96 linear metres of copper full half round of guttering and 3 meter brass brackets, all measured individually, were also installed.
Breaking ground
In the intervening years (between initial talks and installation) Architectural Metalformers continued R & D and innovation.
We completed a spectacular splayed copper roof on a Waiheke residence with a similar style used on the new Vodafone building in Fanshawe Street.
It was eight years ago when Architectural Metalformers first received architect's plans for structures using copper in this way and their initial comment was that it would be "too difficult and not achievable".
But with excellent people in the team, who are good problem solvers, brought their technical expertise to the fore for these situations. This resulted in plenty of innovation and development and within two years many new techniques with copper had been mastered.
These include creation of hand held folders, pioneering development of a slip joint (a clasp that goes under and over the panels) and designing a special tool to make the stainless steel clips which for the museum job also had to be wind-rated and "do the job".
Creating the dome
With only 4 of the 1760 copper panels on the Grand Atrium dome being the same measurement, the scale and complex detailing of the dome was heavily reliant on a CAD software system offering 3D imaging.
The Architectural Metalformers team devised innovative solutions to configure every different radius required for each panel. Their expertise in technical drawing and maths plotted the entire project into the CAD system for a design that would meet the requirements of Hawkins Construction and the architectural team.
Eight of the copper panels were produced as a trial for the perfection required in laying and twisting the copper to ensure it looked concentric.
Logistical challenges
All of the copper panels were individually measured and folded at our factory.
They had to be numbered and catalogued so that the manufacture, packaging, transportation and installation ensured that each panel fitted exactly in its designated position.
Prior to placement of the copper, Enkamat® was installed (to promote noise absorption for the premier events centre) and waterproofing membrane was applied onto plywood so the entire 400 square metre area of the dome was sealed (all nail holes covered). This was before the copper panels were placed.
One of the greatest challenges for us was the need to produce quarter of the panels relying on the CAD system before they could actually access the roof and physically measure up. They had produced a design system for the panels but the physical reaffirmation of the dimensions was a bonus. The plan of attack was to install the copper sheeting in block panels leaving a bottom row and sections in-between to be in-filled later.
Eleven tons of copper was required for the Grand Atrium dome, 30% of it unseen in the seams and overlaps of the undulations, and all of it crafted in our in-house workshop.
Meticulous attention to detail, provision of product samples across the entire job and exhaustive hours of plotting on the CAD software has resulted in a dome the company is proud to call its own.
The dome is a unique project which will stand the test of time and Architectural Metalformers Ltd is very proud to hang their hat on it.
