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Old October 30th, 2005, 12:09 AM   #381
weill
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nice, im glad to see this finish....
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Old October 31st, 2005, 09:14 PM   #382
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Engineering News Record

Manhattan High-Rise Is Chock Full Of Jarring Juxtapositions:

October 31, 2005






It’s an expanded home for the Hearst Corp. media family, not the Hearst family itself. But the Manhattan job may as well be called Hearst Castle East. The builders of the 46-story office building–a restoration, an adaptive reuse and a modern steel tower rolled into one–are as obsessed with quality and detail as was William Randolph Hearst, when he built his extravagant California estate in the early 1900s.

The Hearst Building leaves no room for error and has "no forgiveness," says Ted Totten, president of Cives Steel Co.’s Northern Division. The fabricator, based in Gouverneur, N.Y., furnished and erected the job’s 12,000 tons of structural steel, under a $38-million contract.

Design architect, Foster & Partners, London, wanted the modern tower to appear to float over the six-story, 1928 landmark–to separate the old and new. This forced the general contractor to "approach the project as two separate entities," says Scott Borland, one of three project managers for Turner Construction Co. The New York City builder holds a $252-million guaranteed-maximum-price contract for the core and shell of the 856,000-sq-ft development.

Even with the demands, at 95% completion of the core and shell, the job is on time and under budget, says Borland. And there are no claims, he adds.

Hearst has gone to extremes to consolidate 2,000 employees from 10 locations, and provide a "nurturing, secure" and sustainably correct environment. The owner expects the office building to be the first in New York City to earn a gold rating from the U.S. Green Building Council’s LEED program for sustainability. And after the terrorist attacks on the World Trade Center, Hearst beefed up the structure. This included filling "box" megacolumns and superdiagonals with concrete and encasing the steel core in concrete. The curtain wall system also is built to perform better under certain blast conditions.

Work consisted of first gutting the six-story landmark–Hearst’s headquarters since 1928–and then adapting it to function as a hollowed-out lobby-atrium. Concurrently, construction proceeded on the new tower, 160 x 120-ft in plan, that rises from within the 200-ft-square base.

The tower boldly expresses its perimeter structure–a diagonal grid pattern of steel, clad in stainless steel. The tower corners "slice" in and out, creating a stack of eight-story, open-mouth "bird beaks." The main entrance, on the east side, leads into a lobby that will contain an $8-million water feature. Sources say the water feature costs more than the plumbing to cool and dehumidify the entire building.

Slicing through the tall water feature are escalators to a third-floor atrium, an open space with ceilings as high as 80 ft that will contain, among other things, Hearst’s indoor "piazza." The volume of the lobby-atrium is 1.7 million cu ft.

A clerestory wraps the base of the tower, from floor seven to 10, just above the atrium skylight. The core is offset to the west wall, which abuts a high-rise.

The typical office floor, and the "diagrid," begin at the tenth level. The diagrid is a triangulated system of horizontal rows of steel A-frames. It has no vertical members. A rarity, the diagrid interconnects all four faces of the tower, creating a highly efficient tube structure, says Ahmad Rahimian, president of the project’s local structural engineer, WSP Cantor Seinuk.

The intersections, every four stories, of the 57-ft-long legs of the "A"s with horizontal beams form nodes, set on a 40-ft module, that redirect member forces. Architecturally, nodes could not be larger than the cross dimension of the diagrid elements. Gusset plates, though more economical, would have violated the architecture, says the engineer. The architect of record is Adamson Associates, Toronto.

At the "jaw" of each beak, diagrid nodes, typically planar, are three dimensional. To develop the more-complex jaw node, the engineer rejected high-tech methods and built a balsa wood model.

The 10,000-ton diagrid, made of wide flange rolled sections, weighs 20% less than a conventional moment frame, says Rahimian. But its inherent stiffness makes it tougher to build, he adds.

The diagrid transfers loads at the tenth floor into 12, expressed perimeter megacolumns, unbraced for 85 ft. Megacolumns continue to foundations. Eight, 90-ft-long superdiagonals slope in from third-floor megacolumn nodes to column lines at the tenth floor. Superdiagonals carry load and also stabilize the core wall.

A horizontal truss system in the third floor braces the landmark facade, provides diaphragm action for megacolumns and superdiagonals and accommodates the lobby-atrium opening. Tubular steel framing at the seventh floor supports skylight panels and provides lateral bracing for the landmark facade.

On the mechanical side, the building is designed to use 25% less energy than a building that meets minimum requirements of prevailing codes, for a projected savings of 2 million kW hours of electricity per year. Hearst claims the building will reduce stormwater runoff by 30%, through roof rainwater harvesting. The water will be used for landscaping and in cooling tower water makeup. Total water conservation is projected at 1.7 million gallons annually.

The water feature will help cool and dehumidify lobby-atrium air in the summer and humidify the space in winter. "We took an aesthetic feature, and at little cost, integrated it into the mechanical system to maintain comfort and reduce operating costs," says Gary Pomerantz, a senior vice president of the consulting engineer, Flack + Kurtz, New York City.

The lobby-atrium uses radiant heating and cooling, with polyethylene tubing in the topping slab. Office space exhaust air is used to condition the lobby-atrium, which will reclaim energy and minimizes use of outside air.

There was concern about the facade, currently exposed on the interior, and freeze-thaw cycles. To prevent this, the engineer designed a wall-heating system.

For sustainable construction, the team has diverted, to date, 2,419 tons or 84% of waste from landfills, says Hearst. Ventilation systems are protected from dust and materials from moisture damage. The building will be flushed with outside air prior to occupancy in April.

Turner’s Borland calls the base-building work "the first most challenging aspect" of a very challenging job. "The lower six floors account for 40% of the cost of the core and shell," he says.

Workers from LJC Dismantling Corp., Elmont, N.Y., kicked off a 32-month construction schedule in June 2003, with a multistage "surgical" demolition. Crews left the landmark’s perimeter interior bay to help support the facade until new wall framing and third and seventh floor framing were erected.

In March 2004, workers from Cornell & Co., Woodbury, N.J., began steel erection. Thanks to the tight interface between the diagrid and the unitized curtain wall panels, "there was lots of opportunity but no room for error during steel fabrication and erection," says Totten.

It wasn’t just the tower that was demanding. Cives spent months developing skylight frame connections that would satisfy the high design load to resist blast and yet meet aesthetics. In many locations, bolted connections were hidden inside the frame’s steel tubes.

The ends of megacolumns and diagrid columns were milled to less than 1/16 in. Measuring tapes only go down to 1/16 in. "This job was off the charts," says Totten, admitting that it was not profitable.

Connections were developed to allow tenth-floor framing to be perfectly level and at the correct elevation so the diagrid above would interface with the curtain wall. Cives had to mill the diagrid node plates on all sides, instead of two, because a 10-in.-thick plate can actually measure 10 3/4 in. Surveyors frequently checked the x, y, z coordinates for elevation and plumbness, and maintained diagrid nodes to within 1/2 in. of the theoretical.

Cornell broke the building into two sections, one below and the other above the diagrid. "It took four months to get to the tenth floor," says Kevin Ducey, Cornell’s project manager.

The third floor became a platform for construction of megacolumns and superdiagonals. Superdiagonals, too heavy to ship in one piece, were assembled and welded on site. Two cranes picked each one.

The significant challenge at the tenth floor was the installation, on two falsework towers, of the beam supporting the superdiagonals. Compared with the lower levels, the diagrid was like production work, says Ducey. But because it was "very carefully" stick built, it took longer. Cornell built a floor every four days, instead of the more typical three.

Because of the tight interface between the diagrid and the curtain wall, "we ended up buying the steel and the curtain wall roughly at the same time," says Bruce Phillips, manager for Hearst’s local developer, Tishman Speyer. Curtain-wall bidders had to develop conceptual plans.

The curtain-wall supplier provided the window panels and the stainless steel cladding for the diagrid and other expressed framing. Every unitized glass panel is independent to absorb the building’s movement, according to Carlo Eisner de Eisenhof, senior project manager for Permasteelisa Cladding Technologies, Windsor, Conn. Of 3,200 glass panels, 625 are "special." Many of these are in the bird’s beak. Thirty-six of the largest panels, 15 ft tall and 12 ft wide, required a special frame for shipping at an angle.

The curtain-wall system included 600 brackets welded to diagrid steel at Cives’ plant. That reduced the depth of the panel by 4 to 5 in., allowing Permasteelisa to fit one extra panel in each shipping crate.

To make sure brackets were properly located, steel-detailer Mountain Enterprises, Sharpsburg, Md., shared its 3D model with Permasteelisa. "We coordinated so that anchors would not run into bolt heads," says Totten.

For the curtain wall, Permasteelisa did three visual mockups, four performance mockups and a blast test. It ranks the Hearst Building as its second-most difficult job and most expensive, at $126 per sq ft.

For Hearst, which is trying to attract and retain talent at its communications empire, the effort is likely worth the investment.
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Old October 31st, 2005, 09:32 PM   #383
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wow nice diagrams! thanks Talb!
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Old October 31st, 2005, 09:59 PM   #384
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The atrium of this tower must be great!
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Old October 31st, 2005, 10:03 PM   #385
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Stunning.

Congrats New York - you've got a beauty,
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Old November 1st, 2005, 08:46 AM   #386
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Mgnificent. But as its short, I think it might be dwarft by the many skyscrapers. Therefore wont have much impact.
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Old November 2nd, 2005, 09:23 PM   #387
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What it looks from the newly-opened GE Bldg observatory.

Originally posted by NYguy on SSP
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Old November 3rd, 2005, 05:11 AM   #388
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Wow this tower looks great
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Old November 3rd, 2005, 05:55 AM   #389
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yes it is
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Old November 3rd, 2005, 06:30 AM   #390
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Such a beautiful building, pity it isnt taller
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Old November 3rd, 2005, 10:40 PM   #391
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Quote:
Originally Posted by SJM
Such a beautiful building, pity it isnt taller
Indeed. It does look rather swamped in the NY skyline. Still, it looks fantastic from street level.
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Old November 4th, 2005, 02:27 AM   #392
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Looks really amazing and elegant!!!
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Old November 14th, 2005, 04:47 AM   #393
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as of today! November 13, 2005

not so small at street level!

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Old November 14th, 2005, 04:49 AM   #394
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Looks like it's missing a few windows.
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Old November 14th, 2005, 06:24 AM   #395
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When it the grand openning scheduled? It will be nice to see it without the elevator shaft on the outside.
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Old November 14th, 2005, 08:30 AM   #396
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Interesting geometry. It would be somewhat challenging to clean the inward facade on the side of the tower.
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Old November 14th, 2005, 10:00 AM   #397
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It's good to add more cool and modern buildings in NYC.
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Old November 14th, 2005, 12:00 PM   #398
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OMG would i ever want that in my city.
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Old November 14th, 2005, 12:24 PM   #399
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Great picture!
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Old November 14th, 2005, 05:44 PM   #400
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Thanks Carlos, for that great photo!
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