Fascinating Shape

An exhibition pavilion with a particularly impressive façade design has been created in Milan for the Expo 2015. The concept, based on a design of the renowned architect Daniel Libeskind, is a flowing organic shape which originates from a free-hand sketch. Shimmering vermillion stoneware tiles produced by Casalgrande Padana are used for the façade of the complete building. The glazed material with its shimmering metallic surface and the dynamic three-dimensional pattern emphasises the impact of the pavilion. The tiles were attached to the curved parametric building with an intelligent anchoring system. The undercut anchors by KEIL of Engelskirchen used for this made the secure and invisible installation possible. The pavilion which has been created is an impressive statement of the possibilities offered by technical detail solutions to modern architecture and façade design.

The Expo 2015, taking place in Milan until 31 October of this year, has the theme of “Feeding the Planet – Energy for Life”. A total of 155 nations participate in the world exhibition and leave visitors with a lasting impression with the individual and unusual architecture of their national pavilions. This year, the Chinese real estate company Vanke is represented with its own pavilion. The interior of the pavilion represents a traditional communal Chinese dining hall, a “Shitang” with its customs and utensils – and thus takes up the theme of the world exhibition.

4,200 ceramic tiles

The façade cladding of the Pavilion sets the tone. Specially designed 60 x 60 centimetre porcelain stoneware tiles are used for this. They are attached with the KEIL undercut system. The fixing points are not visible so that the special visual impact of the tiles is not adversely impacted. The mixture of clays, quartzes and feldspars used for the tiles in combination with a metallic glaze rich in oxides provide for a ceramic surface with dynamic effect. In addition, the tiles were given a fractal 3D pattern. As a result, the colour appearance of the pavilion changes – depending on incidence of light, time of day and viewing angle of the observer – from a deep red to shimmering gold. A total of 4,200 tiles are used for the scale-like skin of the building. The individual elements do not touch and thus create their own shadows.

Extraordinary façade construction

The flowing curved shape of the building demands a clever façade structure and the thought out installation of the individual elements. The supporting steel structure of the pavilion consists of portals and struts which lend shape to the complex geometry. Profile sheets were mounted horizontally with joint cement and provided with a secondary support layer. A cladding layer follows consisting of mineralised wood-fibre panels and graphite polystyrene panels covered with render protecting the building from air and water. However, the façade becomes complete only with the ceramic tiles. To attach them, steel squares are anchored to the structure of the pavilion and welded to round calendered steel rods. The latter surround the architectural shape and run parallel below each other. They form the base for the subsequent installation of the façade tiles.

Requirements for the installation of the façade panels

The façade cladding must follow the curved shape of the building and create a uniform organic impression. For this reason the ceramic tiles were fitted on the rear with metal plates and a system which enabled adjustment during installation. Thus an adjustment to the asymmetric shape was possible on site. Another aspect for the attachment of the tiles was safety: unexpected breakage of individual tiles or loading from wind gusts and other weather effects must not endanger the structure. In addition, the attachment had to be invisible so that the harmonic overall impression of the sinuous building was not impaired.

Anchor system for invisible attachment

The KEIL undercut technology is particularly suitable for these requirements: For the Vanke Pavilion in Milan, this intelligent system enables the invisible and, at the same time, very secure attachment of the façade cladding. The attachment points are on the rear of the tiles. A special drill bit produces the cylindrical hole as well as the conical undercut in one step. These form the basis for the attachment of the undercut anchor consisting of an anchor sleeve and a hex screw. When the screw is inserted, the anchor sleeve settles into the undercut hole with a positive fit and free from stress. The different diameters of hole and undercut ensure a secure hold – without loading the tile. Thus stress cracks are avoided. The tile can be cleanly attached to the support structure with the bracket situated between anchor sleeve and screw.

Approved system

In addition to the tiles used in Milan, other materials, too – such as natural stone, cast stone and glass fibre reinforced concrete – can also be attached with the KEIL undercut technology. The system has extensive building approvals – also at European level. Thus the manufacturers of façade material no longer have to obtain their own approvals. For the planner, this means the greatest possible selection of façade materials for the design and their attachment under defined conditions with clear performance parameters. The seismic safety of this technology has been tested up to magnitude 9.4 on the open-ended Richter scale. Characteristic values for wind suction loading are also available. Internationally, the attachment has proven itself under extreme weather conditions – in the cold of Novosibirsk and the heat of Kuwait.

Building with a striking character

With a height of twelve metres and a gross floor area of 740 square metres per floor, the Vanke Pavilion in Milan has a nett exhibition space of more than 900 square metres. Even from a distance, the curved building stands out clearly and acts as a magnet to visitors due to its innovative architecture. The organic shape mirrors the Chinese landscape with its mountains, rivers and hills and at the same time its scale-like surface recalls a dragon. The pavilion is an outstanding architectural example for innovative façade design and emphatically highlights the use of technical solutions. The sophisticated attachment technology by KEIL opens up many possibilities of designing a harmonious façade without visible attachment points.

 

 

 

 

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