We primarily used glass fiber but also carbon fiber in certain sections where there were deflection issues.” Approved by the Dubai Civil Defense, Notus Composites EPFR-609 prepreg, in combination with NE11-FR surface film, has passed NFPA 285, EN13051-1 and ASTM E1098 and E84 Class A fire requirements (see “Fire-retardant prepregs enable ...” and “Better, cheaper screening of FRP building materials”). “Each CNC machine had its own oven,” says Affan. Parametric design was used to develop the steel diagrid — a framework of 2,400 diagonally intersecting steel members — to which composite concrete floor slabs and 17,000 square meters of composite cladding are attached, the latter using 1 million square meters of multiaxial glass and carbon fiber-reinforced epoxy prepreg. On-site, you have to coordinate all of the people. “If you have FR resins, then you don’t need the parts that were previously metal.” Citing a Marriott hotel built this way and completed last year in New York City, Affan adds, “that building was steel and timber, but we can build it in composites.”. According to the designers, the building’s oval shape represents the fertile fields of the earth and the limitless imagination of the sky, and the empty space in the center denotes the unknown. Keeping in line with this vision. And not only has this boom led to an uptick in the number of expats making the emirate their home, it has also lured numerous investors to come be a part of this incredible growth story. In 1985, I worked as a student at NASA in California on damping of space station structures. “This was only possible with digital design and CNC machining.” This precision would also be needed to ensure that the script, which varied from one panel to the next, aligned precisely as the panels were installed so that the letters and words flowed correctly across the building’s exterior. “We also have unique technology that enables us to make large panels,” Affan adds, “up to 3 meters wide by 9 meters high, curved in both directions, which means fewer joints.”. One additional complexity, and innovation, is that the panels also integrated their own attachment system. The museum of the future either will be a collective work or will not exist. You are also dependent on the weather and work stoppages. The company’s résumé includes the complex, geometric aluminum screen/cladding for the King Abdullah Sports City Stadium (Jeddah, Saudi Arabia), the composite entrance canopy and 64 intricately-patterned glass and steel skylights for the Yas Mall (Abu Dhabi, UAE), the exterior composite roof for the Sidra Hospital (Doha, Qatar) and many other challenging projects. Instead, when each panel was ready, we immediately cured it to maintain as high a production flow as possible. Clad with stainless steel, each panel is a unique 3D shape and integrates molded-in Arabic calligraphy. Dubai, UAE - February 2020 : The Museum Of The Future is visionary cultural institution currently under construction in Construction of a modern museum of the future under construction opposite to … All four of Affan Innovative Structures’ CMS (Zogno, Italy) 5-axis CNC machines — the largest measuring 33 meters long by 13 meters high by 2.5 meters high — were needed to meet the museum’s demanding production rate. “There were not many companies who could do the work required for the exterior cladding,” notes Affan. “We managed the whole process together,” adds Affan. Formed in 2004 by Dr. Affan, the company provides complete turnkey solutions — from concept design to installation and building maintenance — gravitating toward very technical challenges. Thus, the molds were machined out of a polyurethane foam which could withstand that high temperature, which is more expensive. The leadership of Dubai realize that this can only be made a possibility by reskilling its existing workforce and extending its cooperation with global technology partners. The Museum of the Future currently being constructed in Dubai, United Arab Emirates (UAE), is one of the most complex structures ever built. Established in 1997, Advanced Fiberglass Industries (AFI) is a UAE based supplier and manufacturer of advanced composite components for architectural design, theming, transportation and the military markets. Dubai firm Affan Innovative Structures provided the composite design for the panels, as well as fabrication and support for installation. “The only other competitor proposed a normal curtain wall with aluminum or stainless steel panels on the outside.” Curtain walls, typically used in addition to a structural steel framework, are thin and made from aluminum frames that support glass, metal and/or thin stone exterior panels (see “The building envelope: FRP unitized facades”). “We did not bunch many panels together per cure cycle. One of the most challenging and unique building projects in the world, Dubai’s Museum of the Future is a true architectural experiment. “The stainless steel is adhesively bonded to each panel and then attached with mechanical fasteners, which is an art in itself,” says Affan. The Museum of the Future is a LEED Platinum accredited, torus-shaped building, currently under construction adjacent to the Emirates tower on Sheikh Zayed Road in Dubai. This agenda gave birth to the Dubai Future Foundation, which will oversee all the futuristic initiatives by the Dubai government. “We maintained a precisely spaced gap between panels and this was filled with a special gasket.” This gasket, soft enough to expand, yet rigid enough to withstand loading, provided sealing functionality while enabling the building’s aesthetic appearance. “Within each composite panel, there is a system of flat glass [panels] inside the Arabic script,” Affan explains. The Museum of the Future is a building with an … Each panel is adjusted via unique 3D “universal joint” to achieve smoothly aligned exterior facade. Not only would that have been extremely time consuming, it would have considerably escalated the costs as well. “This is the first time such a project has been undertaken,” says the company’s CEO, Dr. Amer Affan. Each panel is adjusted via a unique 3D “universal joint”. Conceived by Sheikh Mohammed as an incubator for innovation and invention, the Museum of the Future is considered to be one of the most advanced buildings in the world, a place where people can experience and research new technologies. “Especially in Dubai and the GCC (Gulf Cooperation Council), people want to try new ideas. It is slated to open its doors to the public, towards the end of 2019. Large components of the building will even … Prepreg layups are vacuum-bagged and cured in an oven for 6 hours at 120°C. The reason why building the façade proved to be so complex, is its unique hyperbolic paraboloid shape, where each panel has a non-repetitive shape. “At the edges, 24 plies form the cassette-like attachment geometry to connect to the building,” Affan explains. “If one [machine] was down for maintenance, we had the others running in parallel,” Affan explains. “Imagine how much time you will save when each module is already outfitted. … Glass fiber/epoxy prepreg is hand laid into the molds. Museum of the Future is located close to Emirates Towers on Sheikh Zayed Road in Dubai. Though types and geometries vary, cassettes typically enable a flat, rainproof exterior surface that is secured behind to the building’s load-bearing framework. But this has affected everyone, not just us.” And yet, Affan sees hope for the future and for the role composites will play in achieving the sustainability and innovation the world needs in construction. Even though we have experience and confidence in bonding, there could be no risk of a single hexagon coming apart during the lifetime of the building. “The metal was cut into small hexagons in order to drape over the 3D panels. The building consists of seven floors and characterized by the absence of … It is slated to open its doors to the public, towards the end of 2019. The exterior facade of the torus comprises 1,024 fire-retardant (FR) composite panels. Set to open its doors in 2020, the museum "embodies one of the pillars of the vision of HH Sheikh Mohammed bin Rashid Al … Dubai wants to be at the forefront of ground-breaking technology – it wants to be 10 years ahead of all the other global cities. Even with such automation, the company’s workforce of 250 employees, a total it had reached by 2015, were also necessary to deliver on production, averaging four panels per day. “Because we come from a structures background, we are able to combine many materials. The design, however, was not trivial, and had to meet a variety of structural and wind loads. Considering that the façade was 80 meters long and that there was a total of 225 panels, AFI would have had to make 225 unique moulds using traditional CNC machining techniques. In this transition, … “We finished this job just before the pandemic lockdown,” he says. Aside from this, the museum will also play host to conferences, fairs, talks and workshops. CNC machining of each mold took 12 to 72 hours and each of the 1,024 composite panels required its own mold. “We haven’t had a panel yet that has not fitted or has been the wrong shape or the word misspelt,” testified Buro Happold project manager Bauly in a BBC article by Elizabeth Bains.