Case Studies

Crossrail: Durward Stair Shaft by Waldeck Consulting


From BIM Journal. Click Here to Read Issue 3

From BIM Journal Issue 03 – here

Project Overview:

The Durward Stair Shaft project involved the integrated design, coordination, detailing, manufacture and erection of pre-cast concrete external and internal cladding panels to the new Durward stair shaft to the Whitechapel Crossrail project.

The cladding panels took the form of 125mm & 150mm thick pre-cast concrete panels supported both vertically and laterally by the main structural steelwork frame.

Our Solution:

With an experienced and energetic design team establishing a reputation for delivering innovative designs across a vast range of projects, Waldeck provided consultancy services for Crossrail’s Durward Stair Shaft project.

Waldeck provided the design and detailing of the specialist structures developing an innovative pre-cast concrete panel and fixing system which both addressed and mitigated the many transportation, handling and erection constraints faced on the project.

From the outset, the Waldeck project team utilised their in-house suite of specialist 3D design and visualisation tools to develop a panel system which maximised the potential for modularisation, benefiting the manufacture process whilst also ensuring that each panel could be individually assessed and coordinated with the main structure. The complexity of the main structure presented many challenges for the project team, with internal areas of the structure such as new staircases, escalators and lifts for passengers to access the platforms in the new Crossrail station all receiving the cladding panel facades.

The adoption of 3D design tools allowed the Waldeck project team to design, detail and implement innovative fixing solutions to areas of the structure where tolerance adherence was a limiting factor. The fixing solutions were analysed against the panel specifics, where our team identified the centre of gravity point within each unit through automated 3D analysis routines, from this we were able to optimally place fixings and lifting systems to suit.

In order to meet the particular project requirements, the Waldeck project team also made use of their specialist in-house software toolsets and technical expertise to incorporate the Crossrail project native Microstation DGN 3D Model files to facilitate the creation of a federated BIM model of the project. By overcoming the interoperability issues created by multiple authoring tools in this manner, our project team were able to function akin to a project where open BIM standards facilitated information exchange, collaboration and coordination.

The secure project Common Data Environment (CDE) was utilised to facilitate the collaboration management processes as outlined in BS 1192:2007+A2:2016 and provided the project teams with a single source of truth for the project information ensuring all stakeholders had access to the latest information at all times, an absolute must for the effective delivery of a complex BIM project.

The Federated BIM allowed the team to visualise and interrogate the intricate and highly complex overall structure which comprised of multiple floor levels, linking to the London underground system. 3D clash detection and coordination reviews were regularly undertaken by the Waldeck project team to ensure our designs and solutions remained in-line with the remainder of the evolving structure, this proved vital where our teams were able to liaise and coordinate with project stakeholders to resolve issues during the design stage prior to them becoming an issue on site at the construction stage.

An added challenge to this particular project was a pattern to be cast into the face of the majority of panels which visually formed and represented the sound wave generated from a bell when viewed across the completed façade. This requirement exasperated the modularisation constraints and was especially complex to incorporate around the corners of the building due to the unique shape of the project. The Waldeck in-house project team demonstrated further innovation to resolve those issues, creating bespoke jointing details and parameter based modularisation methods which enabled the team to maximise standardisation from a panel geometry viewpoint whilst still accommodating the complex individual panel pattern constraints, this is something which would have been virtually impossible and hugely time / resource intensive without the use of BIM.

The Waldeck team derived further BIM based benefits and advantages, with the seamless linking and integration of reinforcement, fixing and unit schedules which totally eliminated double handling of information and ensured item pick lists for the manufacture / fabrication team were always current and in-line with the latest project design.

From BIM Journal Issue 03 – here

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