Reshaping of Barclays Center Arena Made Possible By Collaboration, Digital Tools

Developer Gambles on Modular High-Rise for Atlantic Yards Sports Village — Crews work on the 85-ft cantilever for the arena�s entrance canopy, added after the structural-steel and foundation packages had been released. Thanks to shared BIM, the structural engineer was able to quickly add the extra steel to the base-building structure and the steel fabricator was able to adjust the mill order.

Photo by Julie Jira / SHoP Construction

After SHoP Architects finalized the flocking pattern, SHoP Construction developed initial panel prototypes in the model. Then, it used CATIA to "unfold" the 12,000 panels of different shapes and sizes, followed by SigmaNEST's CAD/CAM fabrication and cutting software to nest panels based on the installation schedule.

Using CATIA, SHoP Construction then developed a workflow that allowed for the automatic generation of the 12,000 fabrication tickets. Each ticket has an automatically populated chart containing bending information for each panel.

SHoP also developed tickets for the rails that support the panels. Using the model, SHoP coordinated the fabricator's steel-panel support system that connects panels to the base-building enclosure.

Panels have been delivered to the site grouped into megapanels. SHoP also provided a megapanel sequencing model. Color-coded elements are automatically linked to Hunt's project schedule.

In its shop, ASI developed a 60-day pre-weathering patina line, which produces rust. The 3,000-panel-capacity line has racks that resemble a dry cleaner's line.

SHoP had learned that ASI was developing an electronic tracking system for each panel, using plastic tags with bar codes. Jumping off that, SHoP Construction generated a virtual tracking application using a custom iPhone interface to provide real-time updates to the remote building team as panels were fabricated.

On the factory floor, using the iPhone's camera, workers would scan tags as panels went through each weathering stage: water-jetting, surface preparation, bending, dipping and rinsing, and hanging.

"We don't know of any other tracking system that uploads to the model and provides a visual interface," says Mallie.

Mallie considers the app a prototype, for it was used only before ASI shut down. He says there is a "strong possibility" a similar app may be adapted for SHoP's second Ratner project: a 32-story Atlantic Yards residential tower overlooking the arena. That is, if Ratner's modular high-rise scheme, not yet a slam dunk, goes forward.

Nadine M. Post, ENR's editor-at-large for buildings, is an award-winning journalist with 45 years of experience covering trends, issues, innovations, controversies and challenging projects. Post has written about many industry giants, including 10 ENR Award of Excellence winners. And she has covered disasters, failures and attacks, including the 1993 bombing and the 2001 destruction of the World Trade Center. Project stories include the redevelopment of the World Trade Center; the 828-meter-tall Burj Khalifa; Los Angeles’ Disney Concert Hall; and Seattle's Bullitt Center and Rainier Square Tower. In 1985, Post wrote McGraw-Hill's book Restoring the Statue of Liberty (1986) for the restoration’s architects—Richard S. Hayden and Thierry W. Despont.

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