Case Study – Civil Infrastructure: The WMATA Awnings
Posted: April 2024
ABOUT THE CLIENT
Steel Fab Enterprises, a major steel fabricator & erector subcontractor, won a bid for phase IV of the long-running subway awning project for the Washington Metro Area Transit Authority (WMATA).
Upon winning the contract, the company needed a fabricator who not only had ample space in a dedicated stainless bay for the project but also had the creativity and capabilities to fabricate a complex, functional work of art.
The selected partner would need to be able to produce something that could withstand the elements, protect their infrastructure, and keep equipment maintenance and replacements to a minimum.
The Problem
For several decades, WMATA’s escalators were open to the elements. That led to increased downtime, maintenance, and replacement costs. Without functional escalators, passengers were left unprotected from the weather.
The constant breakdowns of the sensitive and necessary civil infrastructure prompted WMATA to host a contest in the late 1990s. Contest entrants submitted designs and plans for beautiful, functional awnings that would not only protect the subway and passengers, but also add to the area’s aesthetic charm.
The contest winner, Lourie Architects, LLC, delivered a bold and creative design for stainless steel awnings with glass panels nestled in smooth grids. Designed as a hyperbolic paraboloid, this fantastic, futuristic canopy reinvented typical angular civil infrastructure, combining form and function to create a beautiful, protective piece of art and protection.
This project faced many challenges from the start, some caused by the nature of the civil construction projects.
Domestically produced steel was required for the job, and the base materials were more challenging to get than more common sizes and shapes. Tools and capabilities at the needed scale were not readily available, either.
Adding to the complexities, the scale of the canopies was immense. Each of the brilliant stainless steel canopies was to measure 26 1/2 feet wide and 65 feet from the front to back.
But the complexities and challenges did not end there. The canopies were designed to provide a dynamic look, finished with complex longitudinal curved edges and ends, with each square tube flowing to the next and meeting at the radius.
These curved square tubes then needed to be connected at the top to create grids where the glass panes were placed to protect the escalators and passengers from the elements.
Bringing this design to life meant that SWF Industrial’s team had to think outside the box, meticulously plan each step of the project, and maximize the design’s capabilities through value engineering and constructability reviews.
The Solution
To ensure the final product not only met but exceeded the client’s expectations, SWF Industrial had to create processes, and sometimes even tools, that could handle fabricating the large scale canopies. The main girders required a 360-foot radius, and the eyebrow ends needed to be curved in two directions, presenting many challenges.
Unphased by the challenges, SWF’s team jumped into action, taking on and successfully executing the massive project.
To date, this is SWF’s largest stainless steel build. Due to its size and unique design, the canopies are beyond the capabilities of most fabricators. So, the first step was to reimagine the drawings to maximize compatibility with SWF’s internal processes, and streamline the in-house fabrication to provide the best results for the final product.
Fueled by SWF’s culture of Character, Commitment, and Creativity, the team was able to effectively problem solve, grow their skill sets, and expand SWF’s capabilities. As a result, the fabrication of the first canopy is complete, with the futuristic, functional design brought to life. Upon completion, the canopy will ship to WMATA to take its place among the iconic structures and landmarks in the Washington, D.C. area.
SWF Industrial exceeded the client’s expectations and again proved that you never allow the size of a project to intimidate you. Take the opportunity, apply character, and provide results that overcome every challenge and expectation.
SWF Industrial: Making A Difference
Over the last forty years, SWF Industrial’s dedication to character, commitment, and creativity has enabled us to be the reliable, innovative partner that our customers count on when they are pursuing their largest goals.
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