DESIGN / FABRICATION / INSTALLATION BRIEF
The Kina building at Green School New Zealand was conceived as a groundbreaking educational facility, designed to embody sustainable and innovative principles. The client’s vision was for a building that would integrate biophilic design with neuroarchitecture, enhancing both cognitive function and emotional well-being. The challenge was to create a structure that not only supported Green School’s commitment to holistic education and environmental stewardship but also reflected a deep connection to nature.
In addressing the design brief, Fabric Structures focused on several key aspects. The project demanded the use of cutting-edge fabric materials that would contribute to both the aesthetic and functional goals of the building.
These materials needed to be durable and weather-resistant, while also aligning with eco-friendly practices. Our approach involved selecting high-performance fabric membranes that would enhance the building’s energy efficiency and overall sustainability.
Integrating these materials required careful consideration of structural performance. The fabric membrane had to work harmoniously with the building’s framework, ensuring it provided both acoustic benefits and thermal comfort. In terms of aesthetics, the design was inspired by Aotearoa’s coastal sea urchin, and our task was to translate this natural form into the building’s fabric elements. This meant creating structures that mirrored the textures and shapes of the sea urchin, reinforcing the biophilic design intent and adding a layer of visual intrigue.
Sustainability was a core focus throughout the project. We prioritized materials and fabrication methods that minimized environmental impact, ensuring that our contribution to the building’s design was aligned with its overall sustainability goals.
STRUCTURAL SYSTEMS
The structural system of the Kina building at Green School New Zealand is a testament to innovative design and engineering, integrating advanced fabric membrane technology with a supportive framework. Fabric Structures played a pivotal role in crafting the fabric membrane, ensuring it met both aesthetic and functional requirements.
The building’s design features a sophisticated network of fabric that is supported by an intricate framework of 24 curved structural members. The Enviroclad roof membrane was selected for its durability and performance, aligning with the building’s environmental goals while also enhancing its visual appeal. The flexible nature of the fabric posed unique challenges in accommodating various design loadings, including wind and possible snow loads. The design required meticulous calculations to ensure the membrane could withstand dynamic and static forces without compromising structural integrity.
The geometric form of the Kina building presented both aesthetic and structural challenges. Translating this natural form into the building’s design involved advanced computational techniques and physical modelling. We used Building Information Modelling (BIM) to communicate complex 3D forms to our engineers for the best accuracy and tolerances. The final shape of the fabric membrane was developed through a process of iterative design and analysis. This included early conceptual designs, structural performance assessments, and geometric optimisations to ensure that the visual impact of the building did not compromise its stability.
The method of arriving at the final solution involved a thorough design process. Initial concepts were developed to reflect the biophilic and neuroarchitectural goals of the project. These concepts were then subjected to detailed structural analysis to evaluate how the fabric membrane would perform under various load conditions. Geometric forms were refined through computational tools, and physical prototypes were tested to validate the design and performance.
MATERIALS
For the Kina building at Green School New Zealand, Fabric Structures carefully selected materials that would not only fulfill the structural and functional requirements but also align with the project's sustainability goals. The building prominently features a sophisticated network of fabric panels, engineered to create the final Enviroclad roof membrane.
The primary fabric used for the membrane was Hiraoka HG102 HT. This choice was driven by the fabric's excellent light transmittance, durability, and suitability for the environmental conditions at the site. Hiraoka HG102 HT is known for its ability to balance natural light and shade, providing around 10-12% light transmittance while withstanding various weather elements, including UV radiation, wind, and rain. These properties were essential in ensuring the longevity and reliability of the membrane, contributing to the building’s overall sustainability and performance.
The decision to use Hiraoka HG102 HT was also influenced by its high quality and the support provided by the supplier. The fabric's performance characteristics, including its ability to maintain structural integrity under dynamic and static loads, made it an ideal choice for the complex and innovative design of the Kina building. The supplier’s expertise and the fabric’s proven track record in similar applications reinforced the decision, ensuring that the membrane would meet the aesthetic and functional needs of the project.
The fabric is designed with a focus on sustainability. Hiraoka is committed to producing environmentally friendly fabrics, and the HG102 HT is designed to be durable while minimizing environmental impact throughout its lifecycle. Additionally, the production process involves environmentally conscious practices, optimized to reduce waste and energy consumption. This aligns with broader goals of sustainable building practices by lowering the overall environmental footprint. Using a fabric and supplier with a focus on green and sustainable building practices was crucial to ensure that our part of the Kina’s construction aligned with the school’s desire for the structure to be built on foundations that connect to the United Nations Sustainable Development Goals. These considerations remained at the forefront when managing indoor quality, energy, logistics, land use, emissions, and innovation in the build. This approach inspired many of the techniques, materials, and systems used within the Kina.
With a commitment to sustainability, Green School set a challenge to divert 70% of all construction waste from landfill for this project, which was proudly achieved. Through the thermal and acoustic insulation provided by the Hiraoka HG102 HT and a highly energy-efficient hydronic heating and ventilation system, the Kina aims to consume a minimal amount of electrical energy over its lifespan while offering premium learning conditions to its young occupants.
FABRICATION
In the construction of the Green School Kina building, Fabric Structures employed advanced fabrication techniques and equipment to ensure the precise implementation of the fabric membranes. Our approach was meticulous, reflecting the high standards required for this innovative project.
The fabrication process began with detailed digital modelling and simulations to accurately translate the design concepts into physical forms. Using Building Information Modelling (BIM), we developed precise 3D representations of the fabric panels and their integration with the building’s structural framework. This digital approach allowed us to assess and refine the geometric complexities of the design, ensuring that all components would fit together seamlessly.
Specialised cutting equipment was used to handle the fabric for its durability and flexibility. The fabric panels were cut using automated cutting machines which ensured that each piece met the stringent tolerance requirements of the project. This precision was crucial for maintaining the structural integrity and aesthetic alignment of the fabric membranes.
Once cut, the fabric panels underwent welding and stitching processes. Advanced high-frequency welding techniques was employed to join the fabric panels. This method was chosen for its ability to create strong, durable seams that could withstand the various environmental stresses to which the building would be subjected.
The level of tolerances required for the Kina building was exceptionally high. Given the complex geometry and the need for perfect alignment with the structural framework, every aspect of the fabrication process had to be executed with meticulous care. The fabric panels were designed to fit within very tight tolerances, which necessitated a combination of advanced fabrication techniques and rigorous quality control measures. Each panel was tested for accuracy and fitted to ensure that the final installation met the exact specifications laid out in the design.
Throughout the fabrication and installation process, we utilised advanced quality assurance methods, including dimensional checks and structural integrity tests, to ensure that the fabric membranes would perform optimally. The integration of the fabric into the building was a complex process that required careful coordination between our fabrication team and the installation crew to achieve the desired outcome.
COLLABORATION, CONSTRUCTION AND MAINTENANCE
In the development of the Kina, Fabric Structures adopted a collaborative approach that was integral to the project's success. Our collaboration with various stakeholders, including architects, additional engineers, and the construction team, was vital in ensuring the seamless integration of the fabric membranes into the overall design of the building.
From the outset, we engaged in detailed consultations with the project's architects and structural engineers to understand the design requirements and constraints. This early collaboration allowed us to provide input on the feasibility of incorporating the Hiroka fabric into the building’s innovative design. By sharing our expertise in fabric engineering, we were able to influence the design to accommodate the unique properties of the fabric, such as its flexibility and durability.
Throughout the construction phase, our team worked closely with the installation contractors to ensure that the fabric membranes were installed accurately. We provided detailed installation guidelines and conducted on-site inspections to oversee the installation process. This hands-on involvement helped address any issues that arose and ensured that the fabric was installed according to the precise specifications required for the project.
The method of construction for the Kina building involved several key stages. The fabrication of the fabric panels was completed using advanced automated cutting machines, which allowed for high precision and accuracy. Once fabricated, the panels were assembled and prepared for installation. During installation, the panels were meticulously fitted onto the building's structural framework, ensuring that each piece was aligned perfectly with the design.
As part of our commitment to the building’s long-term performance, we also developed a comprehensive planned maintenance program for the fabric membrane. This program was designed to ensure the ongoing durability and functionality of the fabric over time. It suggested regular inspections to assess the condition of the fabric and identify any signs of wear or damage. The maintenance program also outlines procedures for cleaning and minor repairs to address any issues promptly and prevent potential problems from escalating, as well as ensuring the upkeep of the fabric aligns with the suppliers warranties.
Our planned maintenance program emphasizes proactive care. By addressing these concerns early, we help to extend the life of the fabric and maintain its performance. Additionally, we provide guidance on how to handle and treat the fabric to ensure that it remains in optimal condition throughout its lifespan.
COSTS
The Kina building at Green School New Zealand involved a complex and detailed process with various cost components associated with its design, fabrication, and construction.
In the early stages, which include engineering, design, and consent, approximately 14% of the overall budget was allocated. This phase covered the conceptual and detailed design work, including obtaining necessary approvals and ensuring the design met all regulatory requirements.
Preliminary and general costs, along with project management, accounted for about 9% of the budget. This portion encompassed initial project setup, administrative costs, and the management of the entire construction process to ensure smooth execution.
The largest share of the budget, approximately 38%, was dedicated to steel supply, fabrication, bracing, and installation. This significant portion reflects the critical role of structural steel in supporting the building and the extensive work required to fabricate and install the steel components.
Fabric supply and fabrication made up 13.5% of the budget. This includes the cost of the HG102 HT and the fabrication processes involved in preparing the fabric panels for installation.
The installation of the fabric membranes accounted for 22% of the overall budget. This phase involved the careful fitting and securing of the fabric panels onto the building’s structural framework, ensuring that they met both aesthetic and performance criteria.
EXTRA DOCUMENT - PDF Drawing
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