ar ati and Challenges Benjamin Bear Technical Director Moinharat Facade Technology Dut, United Arab Emirates Keywords 1=Structural Silicone Glazing = Free: Farm ol-lending 2 Single Corner Cold-ending ‘Warp = Enginserng Stress BFE Streze Abstract Freeform cold-bent structural scone glazed facades open the door toa new world al options for cos allective two-way curves and free-form ‘he primary and secondary seal structural facades, The design of sllcanee is however a challenge ae ne design ‘standards are avaliable; even mast of the major silicone suppliers curren do nat nave ear design guidelines fr free-form cold-bent structural siicone glazed facades. Following upon the previous Class Performance Days paper by the author with focus on the “single corer cald-benzng” [1 this paper focusses onthe “ree farm shape (-vending" ana presents anew design concept forthe structural slicane design In edition, various graphs are shows to provide ‘theoretical background on facade panelisation options, various eolé-bending geometries le.g spherical, anticlastic and cancave/eemve fee form|, pst-cold-bending glass edge relation and siicone str models or dileren sald tendingledge warp mates Introduction era series of realise projects, the so ‘alles “Single Corner Cold Bending” process [Figure 02) eecame established within the facade industry to provide bller architectural appearance compared tothe Fish Scale principle [Figure 0]. Taking the next step the coid-tending process, the frst facade Using the new "Free-Form Gald-Bencing process s curently being installed in Dubai iFigure 08), Comparing tothe paneisation ‘options Fish Seale outwards, cenre-point and inwards] andthe option Single Corner Celd-Bending’ as explained in Figure 0, the Free-Form Cald-Bending option provides the best approximation toa perfect curved facade = however with the downside af high complexity GBB, oro otass Performance Days 2017 Free-Form Shape Cold-Bent Structural Silicone Glazed Facades - Design Concept ee | | I / Figure 01: Camearison of Fish Scale and Cold-Bending panelisation options Figure 02: Single corner cold-benaing “structural scone glazed fagades, Credit Libanais, Beat In the structural slione design When considering the structural slicone ign and guidance fra stress based design, both cold-bending processes mentioned above are not covered by national or internal ddes'gn codes or standards ~ showing the need fr in-dosth research and ds between industry experts. Whilst the single corner eold-bending racess was scuseed bythe author in provious publication (0) [02 300 Figure 03: Free-form shape c structural silicone glazed facades Ipartaliphot bent glass ie used) including» gropesal fora design cones, tie paper focusses an a new structural silicone design cance for free-form shape cla bent facades. Ths design concept uses a stress approach "FE Stress Finite Element Stress) vs. “Enginecring Stress", in which a FE analysis wih hyperelastic material constitutive meeelling implemented fo reference project [Figure 03igure 04; Principle overview of the most common cold-bending geometries op, Single Corner Cold-Bending vs. Free-Form Cold-Bending Figure Ot provides an overview of pica cold-banding geometries. The single corner calbening i the most common geometry bing reslised on various projects over the last approximately 10 years. Here, the aluminum framing members are near and the glaze Is produced flat, Al other colé tending geometries including spherical conven, spherical concave, antilasi free-form, convex reesarm and concave / convex ree form are based on curved framing members Tre amount of warp at each corner (P,P, Ps and Py), al centre ofthe edges [P,P Pu and alana tne relation between the ware data (% to Pl defines the cold-bending geometry. Mast coid-bending geometries have an inwards ‘and outwards mode as shown in Figure 8, ‘Swopping in between these two modes can be done by exchanging the ware value of the corner paints [Ps Ps, Ps andr] wth the warp values of he cates of ages ints Py, i, Peand Pl The choice between mwards or outwards mode is ueualy dictates by the postion ofthe framing members, typically located onthe buling’s nse Cold-Bent Structural Silicone Glazed Facades - Silicone Shear Stresses. ‘he cold-bending process and resulting curvature causes shear ceformations between the varius layers af the facade panel azsemely, The shear deformation net Constant and varies over the wath ang height othe panel. maxmmum values can be expacied at the points of greatest shear deflections and are defined by tne angle of rotalin g. Figure 06 provides system sketches inciating edge ware fn edge rotation forthe two Xe locations otner and mid-edge New Figure 05: Invards and outwards bending option fr spherical concave cold-bending te cola-bencing Figure 06: Comparison of e09e warp and edge rotation due -301- GPD lass Performance Days 2017 OR,Besides the permanent tensile farces in the siretural silicone, the edge rotation angle ane resulting permanent shear deformation is one ofthe key problems when designing cla- bent structural scone glazed facades. This agelies to bath structural scone seals Figure 0): 1 Primary Seal between the (GU inner glass pane and aluminum frame 8] Secondary seal - between ISU inner and outer glass pane As per andthe corresponding European Technical Aproval ETAS fr typical two part structural slicones, the allowable long term silicone stress is only 10 af the allowable short erm slione sites ina afore reduce the silcone primary seal shear _iresses for single corner cole-bent facade and ist use forthe Crit Libanais project in Beirut], the author developed the method “Workshop Cold-Bending & Site Re-Bending™ A comparison ofthe 149 cold-bensing options ‘or single corer cald-bending is sted below ‘A Option A- Site cld- bending ‘The glass panel and the raming members are produced flat the structural slicone between glass panel and traming members is plied in the workshop, Once the siicones cued, the Rat fagade panel is transported to site and forced into the cold bent geometry during instalation to the building’ sat edges. 3] Option B - Workshop cole re-bending ‘The glass ganal and te framing members are produced flat, While stil inthe workshop, the glass panel and the framing memoers are forced into the col6-bent geometry using a bending rack Then the structural sifcone between glass and {raming member's applied. Once the sligone is eyed, the cold ent fagade panels transported to site inthe bending rack, The iting and installation of the panel requires he pane’ release rom the bending rac, fr tis temporary condition ‘he panel wil partly dearm back from the cold-bent geometry and silicone shear stresses increase for that moment. The panel fixing to the building’ slab edges wil require these recold-bending. Aer thal process the installations fished andthe licane shear slrecees are ack ta the poet- colé-bending normal evel Figure 07 compares the corner shear Getormasions and provides an overview table ‘or the singe corner cold-bending ations ‘and 8, aswell as forthe mode free-form cold-bending. AS mentioned above, the single corner eals-bending oplionB resulsin ower shear stresses inthe primary seal Due tothe pre-cured framing members used for fee ing and ste Figure 97. Single corner and free-form cold-bending - Mullan, glass and silicone details with shear deformation form col bending a similar effect with ower shear stresses inthe primary sea is achieved, It srl be noted that forall options, the shear stresses inthe secondary sea between inner and outer glass panel are not reduced as the Insulating glass production is usvaly before facade panel assembly and cold-bending An insulating glass unit preston with pplication ol the secondary sal sirulurat silicanepest-cald- bending might be technically feasible, would however require further research andi does net form part ofthis paper. Free-Form Cold-Bent Structural Silicone Glazed Facades - Silicone Tensile Stresses Astor the allowable slicone shear sress fio the tense straze for long term leads can be assumed te 10% of short term allowable stress. Que othe elastic colg-bending process andthe glass trying to bend back ints origina at positon, permanent (long terml tensile stresses act inthe scone The dstribtion of the permanent silicone tensile stresses doponds on the cld bending geometry and the method of stress analysis: hand calculations ar Finite Element IF] anayss,Referng othe cutput of computational FE analysis and stress peaks often encountered inthe results graphs, the ‘valuation requires substantial expertise and engineering judgement. The stress peaks are ‘ten localized in small areas and might be “cutout” to aeid an overly conservative design considering that these smal overstressed reas wil result ina localizes higher ‘longation which shal be no grablem forthe overall system, The concept of camer ‘cut-out Gg 2 IB GPD Glass Performance Days 2017 -302-Figure 08: i e0-form cod-benaing al srass peaks was presented for single ing in al strass modelswith actual Figure 98 compares and free-form shape cola-be Free-Form Cold-Bent Structural Silicone Glazed Facade - Project Example bai Figure 03). The curved facades use th hotsbent glaze and cold-bent glass; the ent glass is used for areas with voture wh have been exceeded. Figure 09 shows the pr cald- bending satus withthe open goo corner wargl between glass and (rame. Figures 10 and 1! show photos taken after cold-tending ry sel structural silicone Engineering Approach for the Structural Silicone Design Concept Currently no international eo vers he srueluals leone design of cl nt structural slicons glaze systems. the structural slicone design dels is given in Sa i], whare Figure 09: Free-torm cold-bent structural silicone glazed uniize ane before glass cald-bending process, gap showing the comer warp 10, Free-form cog-ben tus 22d fgade panel ges and conver shart edges Figure during glass ing process, cance publication FE] Stresses vs emphasize the importance of deriving com en bath stresses [also ents the concept of True see tem This poper is based on an engineering 2. Initial simplified assessment ofthe structural seo seats suming at ols and at raring cl tg EAS 0025 Unsupported tem Ths algae Sleoccomelyeolaiioerstaionl B.Sc upand arabe FE modelo silt 0 Oni st edt seat) tested ye tk Systems ? iyan hes to assace the ne supplier as [European Technical Aaproval. This mo oder a sets 28 validation m conversion tween the tru Finite ment (FE| Stress derive crodels, ana the Engineer Free-fom cold-bent structural red univzed fagade pane during cave long edge rom the FE he allowable design imi stress states in he ETA tthe sine supplier. €. Set up and analyse a FE-Model for each Iree-for shape coldbent gloss panel 1 strvlurat models ineluge 49 volume laments ofthe structural slicane and ail eads in rmie.g cold 303 GPD Glass Performance Days 2017 RRenna shor term oad fg nd ae = pressure and suction E te D. Assessment of the FE-Stress results st and emerson fon FES to “Enanerng See reelt aren ving theallwance sess appraach spr Local tess peaks right aceon ng the comer cute method explained in fo a = H-Test Model to Derive Conversion Factor “Engineering Stress” to “Finite Element Stress” Figure 12: H-test specimen FE model to derive conversion factor “Engineering Stress” to "FE Stress The H-test model FE analysis shall use identical boundary canitions as the aberatory tested H-tast specimen as perl thesteet plate being 0 men wath, 80 mm ength, mem thickness and the slcone being 12 mm width 12mm height 89 mm length (Figure 1), These imensions are in ine with ETAG figures (4. me af Stresses and strains are derive fr ths model ca land compared withthe actual es results This H-test FE model [Figure 12] shall use the Figure 12: -lst specimen FE result for normal lenie stress, load case 8& N, course mesh same setting analysis software Mare Me 12, setting, FE mesh density etc asthe FE" Yimwen on I) tenors modest the complete glass panetsteng sme ct rld-ben igure 2,21 Al FE models is oe shelilements forthe glass panes,volume fos = clement forthe structural siicoe sealants Sas cS andthe Neo-Hook material model othe ee cs Fe i i L jae setup to dere the conversion factors for atypical 14 Nimo silicone stress imi las per sieone supplies. Figure 14: H-test specimen FE model result for equivalent von Mises Stress, lead case 86 N, course mesh ETA anda silicone overstess of 10 Nm? Yama wn wa [as the engineer’ judgement See data below [ug " “Lead case tN terse ead to derive ie a orversion factor far 0.14 N/mm silicane oes co Face oad on uper ste plate in a 4/1 mm 50mm = 0042 Nine am a Nominal tension stress in silicone fred or {40/112 mmx $0 mm = 0.120 Nl? oe te t «Ltd ease 0 Nera cere oir L conversion factor fr 1.0 Nin silane stress: Figure 15; H/-tet specimen FEresul or euiralent on Mises Stress for oad case 600 Face load on ste plat: course mesh 20 le mm x50 mm = 0.3 Nine? Nominal tension srzein scene 800/112 mmx 50 m= 1,0 Nin? + Load case 4 lequialent 00.14 Ninn? dens tess type sed and other terns Engiwering Sess): 389 “herlore, he above conversion factor varies The FE resus are shown'n Figure 13t0 15. Laadease400Nlequlentto 1.0 Ninn? from the factor shan nother publiations Taking he Von Wises tess ouput ofthe Engineering Sess); 382 {8.Rshall also be notes that used the case 66 Nand 600 N models, the fling Firat Pringle Stress, whereas the above anersion acters “Engineering Sress to The above factor of 52 and 239 depends _calelalins use the Van Mises Stress Finite Element Sress” can be drive. an the FE stare, calculation ode, mesh Gg - 304 - 3B GPD Glass Performance Days 2017 30.Both stresses can be used and the diflerence ors FE Siress to Engineorng Stes inte cnarsontacrssamesinegeea [> Pie 1 : Figure 16). i. FE Mesh Density i Theatore Tet models igure 12 tluse | 1s 1 FrunllfEmehansiparieasine |B 8 — = Sunmoiesotoecaleegacspones | Ey a Tego Ths isimporont asthe comerson | faowrengaeerngsiesoiresvesstiom | Easy ‘the H-Test model will be used for actual é {Beatin The mesh dens fe Test ao models above might be seen as course and nol dense enough. This hanover should have no ellect asthe same mech density is used or tne complete laser ie, Spee panals[Figurs 21], nevertheless camparsson ‘aleulations with higher FE mesh densities ‘wore carried out When comparing the Van Mises stresses ofthe H-Test mode with ‘course mesh (Figure 131015) andthe Van ‘the actus calcula Figure 16 Conversion Factors for Von-Mises and Frist 1ONimm2 Engineering Siress rincple Stress at 14 Nini? and Mises steses ofthe Het made with ne omen ~ andra ine mesh Figure 1713, the bro dierencein marimum Van Mises siessis ae [ftroen tallow: Bees «Standard meshdansiy cou 25¢Ninm? [Esa «ine mesh dens soem lemme + Exrafinemesh density, 492Nime ftom To keep the computing time within reasonable J‘ \imits, the actual models of the complete glass ee anes use the standard mesh Ashe W-Tet | SS ‘mode fr caleltion af the conversion factor i. ees the same mesh densi th standard sey < ‘mesh wil nt ead to sgntficant dilerenes in Senne the stress results andis therefore acceptable. Figure 17. H-test specimen FE result or equivalent von Mises Stress fo toad case 600, fnemesh Full Scale FE Models of Free-Form Cold-Bent Structural Silicone Glazed Panels a= o The FE models arebuitintwo stages; frst the (ST structural sealant wih an es bet ee irre defections under al oad cases) nd ee second he planar at} msuating glass unt, omen FE contac elements are placed Between he [Rta insulting glass unt and rca sealant ee The madeling and analysis process invhes mae the owing steps ae 1 Set upf teal pre-ol-bending sve rade with cure raring and planar fat) e™=o" glas [Figure 20) Generate the FE mesh Figure 21 wth mesh deny as por Hest a mode! used to derive the conversion factor “Engineering Stress" to Finite Element Seress 2. The intial model with planar insulating glass is loaded atthe edges, the lacs is “elormed unt the edges getin contact vith he structural zealant geometry (bent silean, Figure 2, Figure 18: #-test specimen FE result or equiralent von Mises Stress for load case 600.N,¢ ine mesh ive sections through silicone) ~ 305 - Gg 305 SPD Glass Performance Days 2017 SIP‘The cantact elements ae closed andwill Hamm cae be “glued” forthe other stops. This step ansiers thatthe primary structural hee silicone applied after cld-bending ofthe] Tee alas, se alto the statin and able see {lalorireelrmesisbensing snownn fe Figure 07 [os 4. The edge loads required to achieve contact «gts? telween the slicane and the cured frame [™E are deleted Allglass elastic co-pending |“ toads are now ranslered via thestrucurst 2" silicone; preven he glass ohow back S7~—. init rigina at ara! geomet le 4 Lad the mode withthe climatic ads mee lisochronic pressure in cavity) based an a air pressure[hPal temperature change Figure 19 Hts specimen FE result for equialet von Mises Stress or lod case 600 N inaircaviy(Clandthehelgh aiference exrafine mesh il between glass manuactrer nd sie loco, 5. Add the wind toads 7 foi The process aloud application atthe edges non during stp is teratve, the load amountand mm Lead spacing must varied up tothe stats of continuous cela between he scene and framing tal acaions. Some FE programs alow outed output plots fr contac checks Figure 23) ws Evaluation of FE Analysis Stress Outputs Figure 20: Example of ull scale FE model a pre-cold-bending stage, overall view FE analysis srs outputs or the following load cass lier tod and oad combinations item 5 shal te checkas i evaluate campliance to allowable stress its 1 Bead eae = Long term iad 2. Post-cold-bendng eaa-bensing forces released - Lang term lead 4. Climate eas lisoehroic pressure summer or wie] - Lang ttm las 4 Win ea pressure or suction» Shar erm u& toad 5. Combinations of the above lod cases ‘Figure 2: Ful scale FE made at pre-cola-bonaing stage, deta including wind oa case ~ Combination of tong and short term eas kom rafers to oad combinations inlusing short and longterm loads. Here the results ‘evalation is further complicated by the fiferent stress its for longterm loads and shor erm loads, where he ses iis for long term oads is usualy 1/10 ofthe lint ‘or shart term loads Due tothe nature ofthe cold-bending process retlectag in the step uring FE analysis, the shor term load case 4 [ind load) can only be ru in conjunction vith the tng term oad case 2 [old-bending as Ioeesrdaned osc tedngl Forts oe u lead combination, the FE software provides jst See stress plo "merging' the stress resus figure 22 Full scale FE model at post-cld-bending stage, detail with defection plot ‘or the longterm ans shert erm load case, ‘an “manual overlay ofthe shart and long Gg - 306 - 3B GPD Glass Performance Days 2017 306term stress data foreach FE mesh nodal point canbe done, honover this complex and time ‘onsuming method might not be preferred. Further research wil be requted to assess the best way howto easily evaluate these load ‘combinalion, Looking atthe overall strass plot fr one glass panel, the svluation of FE results can diferente between “Overall, “Peak and "Non-Peak” areas, For peak aeas, the concept of euting out stress peaks Figure G8) ‘an be used to awid-an overly conservative {esign. The definition of extent of corner cut-out requires engineering judgement and ‘experience, as a local silicone overstress val be allowed. he eae af he secondary sealant, acting asthe edge seal of insulating glass unt te oeal ovrstress might lead toa localy reduced ai tightness ofthe edge Seal Atypical corner area with sess peaks is shown in Figuee 24, Here, he concep of cormer cut-out as showin in Figure 25 non peak plotl and in Figure 26 leas to a str reduction of approx. 25%, Further information an the topic of ong fem performance of cold bent insulating glass units can be found in, ‘though no deta information on strese limits is prow ‘Summary To achieve aflush and capless cuter glass appearance, many complex gesmetry cold bent fade projects use structural silicone glazing system ta hol the glass panels in place. While his is archtecturalya preferred and ideal sation, the facade engineering and structural designers faced withthe problem of long orm tensile and shear foes on ‘the structural scone, caused by the glass intending lo reverse the elastic glass cld ending process and forming back to ts inal “at pasion, This effete unique to cold-tent ‘acades ana diferent o not kent glaze facades, vere the glaee benaing process causes 3 permanent [non-lastcl curvature ofthe glass Besides the presentation of various graphs for ‘the mast common cold-bending geometries and 3 recommendation lor workshop col tending ang site re-2ending te reduce structural scone grimary seal shear stresses 4 new design concept for he structural sllcane design af ree-form cola-bent structural silicone lazed panels is presented inthis pager To push this new design concept ‘oan agred standara within cold-bent facade specialists and silicone suppliers he author welcomes feedback and technical comments Figure 22: Fl scale FE made, contact check of primary seal structural silicon frame (yellow 1° fll contact, ive: 0- ne cantact) tetas ce iy stress} for lad case | Figure 24: FE analysis stress plt of primary seal Man Mi showing local stress peaks Steen I Figure 25. FE analysis stress plot of primary seal Nan Mises stresI for load case 1 excluding corner cut-out areas as 3 a . F i Figure 26: FE analyse strece plot of primary seal an Mises stresl for load ca corner cut-out areas - 307 - Gg 307 SPD Glass Performance Days 2017 SIPAcknowledgements ‘The autnor kindy acknowledges Prof Or-Ing Era Schedelor [University of Applied Sciences Ostwestfalen-Lippo, Germany] and ner engineering les for ther support in earying ‘ut the hyperelatic Neo-Hackean material model analysis wth MSC Mare Mentat 12, (0) Beer 8 Structural icone Saied Cld ent, Glass High ise Projets Experience Leading aa New Design Conep, ass Performance Days, 213 (2) Beer B. Complex Geometry Facases~ Invodcing New Desgn Concept or Coa-Bert lass las Pectrmance Days. 2012 1) Datsou, £6, arene M The estan response a eos ben manele glans lates during the bending process, Engineering Sucre 117 (aora ss, 2016 [u)EOTAI2O1}, E186 000 Guta tor Europoan “eehnieslApproal lorSivlurl Sea. 3% Sang Xs (50K, Eaton November 199,21 amendment May 2012 Ig) Descamps,?, Kimber. J. Bout, \aneerechon > Sutra Slain: Design Under high aincload, 68 Waguane Summer 2016 sue (i) Wonderecken, P, PomerPoint Post aring on FeAsnatsieDow Corning. 206 (1) Besser K Berges WJ Bae, A, ona UD, Mavuek A Mason D Rubi K: Dura of (eid inslatng bass Uns, Journal of AST Intrnstonl Vit, Nad, 2012 fs e Gg ~ 308 - 3B GPD Glass Performance Days 2017 308