MATERIAL STUDY: STEEL

RESEACH

PRECEDENTS

MODEL DEVELOPMENT

SPECIAL THANKS

STRUCTURAL MATERIALS RESEARCH CATALOGUE STUDIO 703

CONTRIBUTORS ARCHITECTURAL DESIGN STUDIO 4
ARCH 3501
Phil Hoffmann and David Ladewig COLLEGE OF ARCHITECTURE
TEXAS TECH UNIVERSITY - FALL 2008

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 STEEL USES TODAY

Steel was first used in the creation of long spanning bridges and railroad tracks across the world.
It has quickly become one of the most popular structural elements in the construction of tall build-
ings and skyscapers due to its incredible compressive and tensile strength. Steel consists almost
entirely of iron, with just a hint of carbon in its composition. Because of this, steel weighs less than
iron, even though they have many of the same components.

Steel has quickly broken away from its common use of purely structural strength as its beauty has
been discovered. Today steel is used throughout the world to not only strengthen structures, but to
also give them distinct visual forms and characteristics. Steel can be bent, curved, and twisted to
create amazing architectural components. Steel can be used to span long areas to open up large
interior spaces. Steel can be used to create window walls as it can carry much larger loads than
most other materials. It seems as we continue to try new things with materials, we will continue to
see new ideas used in different ways.

Right: an aerial perspective of Incheon

International Airport located 30 minutes
away from Seoul, the capital of South
Korea. Below: Munich Airport Terminal

Right: an interior perspective of Beijing

International Airport located in Beijing,
China.

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 STEEL JOINTS AND CONNECTIONS
As with any material, the integrity of the entire structure relies on the connections. If the connections of a structure fail, the building
will fall. Therefore, the connections are perhaps the most important part of construction.

There are many ways to connect steel beams to one another, and they are some of the most sound ways to build a structural
skeleton. The most typical method is welding, which uses direct heat to melt metal pieces into one another. This is a very common
connection method used in steel construction everywhere.

Another way for steel to be connected is by the use of plates and bolts. Plates must be welded in place to use, but when used in
conjunction with bolts, they only add more strength to the connections. With a welded corner supported even more by thick bolts
holding it in place, it would take a great amount of stress to bust it apart. This is why most failures in steel buildings come from
bending and buckling in the columns and beams themselves.

Right: David is looking through a book we Last is soldering, a common method used to connect smaller pieces together. Though it may not be as strong as welding, it is a
checked out for the best picture to convey very simple, accurate, and clean way to combine many types of metal pieces.
our idea about the airport.

Right: David is looking through a book we

checked out for the best picture to convey
our idea about the airport.

Right: A display of all the study models

we have worked on thusfar. We started
by working with simple triangular truss
systems and worked up to a portion of
Stansted Airport.

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 STEEL SPANNING AND LOAD BEARING
Every type of material has its limits, and the structural integrity of all buildings rely on a material’s
bearing capacity and spanning ability.

The chart to the left shows the effective spans in meters of steel for multiple different sizes. Today,
steel is perhaps the strongest steel that can span the longest distances without failure. This is the
reason why structures like airports and buildings that need to be unsupported over long distances
are constructed using steel.

Though it may be relatively expensive, steel spanning requires much less material than most oth-
ers, including wood, concrete, and masonry. The incredible compressive and tensile stability that
steel has makes structures much safer for human use.

Below: New River Gorge Bridge

Right: A chart that describes the specific

lengths that specific steel types can span
and the maximum loads that those steel
types can bear.

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PRECEDENTS: STEEL
INCHEON

BEIJING

MUNICH

SHENZHEN

STANSTED

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 INCHEON INTERNATIONAL AIRPORT

Incheon International Airport was one of our top building choices when we were looking into the
material study of steel. Incheon is located just outside of Seoul, South Korea and remains the
largest and most interactive airport in the country today.

The steel lattices that make up the roof system in the picture below is perhaps the most beautiful
part of the building. The strength of the steel allows for windows to flood the entire interior corridor
with light. With the great spanning abilities of steel, the interior space has little problem accepting
this light.

Exposed steel has only recently become a commonly used idea. Modern airport architecture has
been a leading building type in popularizing this technique. Incheon Airport uses exposed steel
throughout its structure to show how the elements of strength and beauty can work together to
create attractive architecture.

Right: An interior perspective of the ceiling.

The scale of the people in the photograph
show how large the huge steel trusses are
that keep the building standing. Below: Incheon Airport Terminal

Right: The complex steel lattice that creates

the long arched corridor remains
structurally strong but capable of allowing
the sun to infiltrate just about every section
of the room.

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 BEIJING INTERNATIONAL AIRPORT
Beijing International Airport is a fairly new building that is made almost entirely of steel. It is very
unique in its design that utilizes gigantic spans that open up spaces throughout the terminal.

The high ceilings and natually entering light at Beijing Airport give onlookers a feeling of freedom,
no matter where they go. The composition of steel throughout the building clearly proves that steel
can be used not only for strength, but for beauty as well.

Beijing Airport is a perfect example of how steel is used for light. Because of its strength, it takes
little steel to create the structural skeleton, allowing for glass windows, which have a very low
bearing capacity, to fill in the open spaces.

Right: The large circular spans that cover

the airport terminal show the incredible
strength of steel while maintaining the
natural light than is allowed to enter. Below: Beijing Airport Terminal

Right: A perspective from the interior of

Terminal 3 at Beijing Airport.

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 MUNICH INTERNATIONAL AIRPORT
Munich International Airport utilizes the same steel structural system as Incheon. The large central
membrane consists of a steel lattice that allows natural light to flow in freely without sacrificing
structural support.

The terminal shown below acts as a tent, since the covering is still exposed to the exterior. Al-
though the area is enclosed, onlookers don’t have the feeling because of the long spans and high
columns that make up the roof.

Steel is perhaps the only material that could make a structure like this stand without failure.

Right: A great example showing the long

distance that the steel spans to create the
wide open interior space. Below: Munich Airport Roof

Right: An overall perspective of Munich

Airport from afar. Very easy to see how
massive the scale of the lattice and spans
are.

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 SHENZHEN INTERNATIONAL AIRPORT
Shenzhen International Airport is located in Shenzhen, China and is a minor airport compared to
the others throughout China.

The most interesting thing about Shenzhen Airport is its repeated use of the popular triangulated
truss system. The shape helps to balance the loads that bear down on it to eventually carry the
loads down to the ground. Just about all of the skeleton is exposed so onlookers can see first
hand what parts make the building stand up.

Not many buildings of this span distance are possible without steel. The gigantic room that houses
all people who interact in the airport is spread wide open due to the strength of the steel that
houses it.

Right: The repetetive column system of the

terminal is a great example of the way steel
is used in exposed construction. Below: Shenzhen Airport Terminal

Right: The curved truss system on the

interior of the building uses the typical
triangulated truss system because of its
attractive look and structural strength.

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 STANSTED INTERNATIONAL AIRPORT
We chose Stansted International Airport because of the unique canopy design Norman Foster
utilized to create a roofing system.

The four columns that protrude from the ground carry the load from the dome lattice above it. At-
tached to the pyramid above this section are cables that span outward toward the corners of the
canopy itself. This system gives onlookers the idea that the diagonal beams are supported solely
by these cables, which actually act to pull the dome in to prevent failure and keep the roofing
structure stable.

The Jesus Bolt is the name for the connection atop the pyramid where all four cables are attached.
A large single bolt straight down the middle holds the welded cable rods in place. It is nicknamed
the “Jesus Bolt” because if this bolt is removed from its position, the entire lattice would fail.

Right: Shown is a good example of the

scale of the structure, particularly the size
of the “Jesus Bolt” that holds the canopy
and its pieces together. Below: Stansted Airport Terminal

Right: A detail of the “Jesus Bolt” from

below. As seen, the bolt slices through
the peak of the pyramid and holds all four
cables in their positions.

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MODELING: STEEL
SPORTS COMPLEX

SHENZHEN EXTERIOR TRUSS

SHENZHEN INTERIOR TRUSS

WELDING/SOLDERING

STANSTED TREE STUDY

STANSTED LATTICE

STANSTED JESUS BOLT DETAIL

STANSTED TREE DETAIL

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 STEEL SPAN STUDY MODEL
This is our very first preliminary study model of a simple sports complex. The goal was to learn a
bit more about how steel spans and how it is possible.

On the actual building, the thick steel beams curve from anchor point to anchor point and create a
giant semi-ellipse. The steel that spans perpendicular to these columns gives the structure of the
roof the added stability it needs to stay where it is.

To build this model, we curved some thin aluminum pipes to take the shape of the complex. Next
we used wire to line the inside of the roof, just as in the building itself. These thin strips of steel are
used to keep the roof sturdy and maintain its structure.

Right: A representation of the 3d sports

Because this was just a shape study, we used hot glue to put the model together. At this point, the
complex. The goal was to experiment with way steel connects was not yet important.
a steel span and solve how it is able to be
structuraly sound.

Right: An image showing how the arch

spans over a structure. (In this case the
wood block represents the interior space). Below: 3D Rendered Sports Complex

Right: A close up of the underside of the

span. The lattice consists of smaller rods
that frame the canopy.

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Right: A front view of a representation of the
exterior facade at Shenzhen Airport.
Right: A close up of the underside of the
roof truss system.
Right: A close up of hoiw the steel support
rods connect to the roof truss.
TRIANGULAR TRUSS SHAPE STUDY MODEL
Shenzhen International Airport was one of the first buildings where we found a very interesting
system. The triangulated truss is perhaps one of the most popular ways steel buildings are stabi-
lized. Therefore we had a good reason to model some.
One of the most interesting parts of the Shenzhen Airport is the huge cantilever that hangs over
the road. We felt that this would be the best part to model since we had some great photographs
of how it works and it is also a beautiful structure.
We put this model together with piano wire, thin aluminum pipes, and hot glue. These are probably
the best materials we can use for a simple study model of a steel system. Through this model, we
learned why triangulated truss systems are so popular.
The two top beams that rest just below the roof carry the load of the roof down to the multiple
thin strips just below it. These then carry the load down to the thicker beam, which holds all of
the weight at that point. Next, this beam carries the load down to the ground through the diagonal
columns located halfway down the beam.
Below: Shenzhen Airport Facade
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 TRIANGULAR TRUSS SOLDER STUDY MODEL
The goal of this model was to create a truss using solder for the connections and to make it strong
enough to span a long distance. This was our first experience with soldering, and it was quite a
task at first.

The roof is framed by a steel arched truss connected on either side to a load-bearing wall which
allows the truss to reach a great span. There are three main steel rods that frame the truss and
are connected by smaller rods whos purpose is to transfer loads.

While we were making this model, it was very difficult to heat the wire enough to get the solder
to melt into the joints we wanted it to. We left the soldering gun plugged in for almost four hours,
keeping the trigger pulled just about the entire time hoping it would heat the wire. To our dismay,
the soldering iron basically blew up in our hands as we were heating the wire, effectively ending
our attempts to get this truss finished using only solder.
Right: A represenation of a steel truss
spanning a distance.

Right: A ground level view of the steel truss

span. Below: Shenzhen Airport Roof Structure

Right: A close up of the soldered

connections in the steel truss.

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Right: A study of the process of welding. A
stick weld was used in this example.
Right: A study of connecting two plates by
the process of welding. A stick weld was
used in this example.
Right: A study of the process of soldering.
A soldering iron was used to connect the
rods in the truss together.
WELD AND SOLDER STUDIES
Because welding is the main connection method in steel construction we decided to learn the pro-
cess of welding. A stick welder was used to weld lines on a steel plate. The goal was to accomplish
a uniform weld across a 3” width. The technique is to move at a slow pace but quick enough that
the weld doesn’t burn through the material.
We also learned how to weld steel corners. A stick welder with copper wire was used to connect
the two plates. The technique is to hold the weld stick on the base for two parts and one part on
the top. This leaves a clean transition between the two plates.
We learned how to solder after buying a soldering iron from Home Depot. We heated the two rods
we were hoping to combine, and once they were hot enough, we applied the solder, which melted
into the joint. We tried to quickly cool the connection by blowing on it, and once it had a few sec-
onds to sit, the connection was solid.
Below: Stuttgart Airport Terminal
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 STANSTED AIRPORT TREE STUDY MODEL

The exterior facade of Stansted Airport in the United Kingdom by architect Norman Foster. The
18m x 18m roof is supported by a steel “tree”. The tree consists of four pillars that are connected
horizontally by smaller diameter steel. Four steel rods from all corners extend out and hold the
base frame for the roof.

The roof is held in tension by four steel cables at all corners which is connected to what is known
as the “Jesus Bolt”. This connection holds the roof in compression. If it were to fail, the roof would
collapse; thus you would be praying for its survival.

The goal was to experience how the tree is constructed and why each connection is important.
Our main focus was to identify how the architect was able to accomplish each connection accu-
Right: A representation of the “tree” rately while maintaining the structural integrity of the building.
structure.

Right: A compositional image of the “tree”

structure next to its origin. Below: Stansted Airport Facade

Right: A close up of the main connections in

the “heart” of the tree.

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 STANSTED AIRPORT LATTICE SHAPE MODEL

The lattice system of the roof at Stansted airport is not as significant structurally as the tree itself.
However, Norman Foster clearly found a way to use steel to improve the overall look of the interior
areas.

The lattice acts as a dome that sits on top of each tree system at the airport. Because of the great
strength of steel, Foster only had to use a few very thin strips to keep it structurally sound. The
small oculus at the peak of each dome allows natural light to enter the airport freely. This is just
another example of how steel can open up possibilities in a building.

The pieces on this model were laser cut to ensure accuracy of measurments and scale. The
model is a great representation of the way the steel works on the lattice at Stansted.

Right: A represenation of the structure of

the roof lattice. Below: Stansted Airport Interior

Right: A side view of the roof lattice. Notice

how the minimal amount of framing allows
for a large open interior.

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 STANSTED AIRPORT JESUS BOLT DETAIL
Stansted Airport is a unique airport in the way it was designed and constructed. Instead of using
typical load bearing vertical walls, the tree holds up the roof system.

The “Jesus Bolt” is located at the very top of the triangular prism that comes to a point just above
the base columns of each tree. It is bolted straight down into this point, and has four cables sys-
tems that come out from in that hold up the diagonal columns and the roof.

The term “Jesus Bolt” is used in this building because it “saves” the structure. If the bolt is re-
moved from the top of ANY of the tree systems used in the airport, the entire structure will fail. It
is the main component that holds the cables in place and preventing the large diagonal columns
from plummeting to the ground.

The “Jesus Bolt” may be very small, but it is clearly the most important component in the structural
stability of Stansted Airport.

Right: A perspective of the “Jesus Bolt.” Below: “Jesus Bolt” detail

Right: A detail of the top of the “Jesus Bolt”

and connections.

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 STANSTED: TREE CORNER DETAIL
The tree system at Stansted Airport is only successful when all parts of the structure work together
to keep the building standing. Behind the Jesus Bolt, the hinged corner is the most important
structural element to the building.

The cables that come out of the center bolt are meant to pull the long diagonal columns inward.
These columns then hold up the lattice of the roof and keep the dome in compression. This model
was made operational with a removable bolt and hinged joint to show how important the connec-
tions of the trees at Stansted Airport are.

The diagonal columns are similar to cantilevers and would not stand the way they do without the
cables to pull them in. This is why the operation of each of these gigantic columns is so important
to the integrity of the building.

The copper pipes were soldered together using a torch, providing a very sound connection. The
wood pieces that were laser cut to create accurate hinges were glued to the copper corner using
epoxy, which is probably the only way they could be connected. Just as in the actual building, the
connection of this hinge to the corner is very important, as the entire structure would collapse due
to dependency on all the parts working together.

Right: A top perspective of the corner detail

Stansted model.
Scale 1/2”:1’ Below: Stansted Tree Perspective

Right: A detail of the corner showing how

the model was put together. The solder
bonded the copper together and epoxy was
used to bond the wood hinge to the copper.
Scale 1/2”:1’

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 SPECIALTHANKS
RESEARCH
New Transport Architecture
by Will Jones

Stansted: Norman Foster and the

Architecture of Flight
by Kenneth Powell

Global Architecture: Transportation

by Yukio Futagawa

The Modern Terminal

by Brian Edwards

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