Resolving Complexity

Complex designs specifying architectural masonry can easily involve a hundred different shapes with many in small quantities. Modeling can be helpful in several ways to reduce problems associated with complicated design elements. The new Miami Science Museum, currently under construction, provides an example of implementing the state of the art in masonry BIM tools to control the cost and the aesthetic of architectural masonry. Third-party BIM masonry modeling allowed the architect, manufacturer, and other trades to collaborate on some very specific details that would otherwise have been left to chance in the field. The architectural team of the visually striking, three-story, 250,000-square-foot Miami Science Museum, specified more than 17,000 masonry units in their world class design. The architecture of the museum was characterized by highly unusual angles in the glazed block structure, and designers did not want to sacrifice the integrity of their design by improper bonding or unnecessary field cutting and needed to assess the effects of small changes in the masonry profile on other systems in this high-profile project. As a result, a separately prepared masonry model was pulled into to the full BIM project, for a comprehensive living picture of all building systems—concrete, piping, electrical, etc. Clash detection was performed, and the BIM model accommodated changes in the masonry environment to resolve issues and promote trouble-free installation. “The masonry scope for the Frost Museum of Science project includes an exposed glazed masonry unit installation on two buildings, which both span five levels in height, with custom angled/shaped units and multiple transitions from full units to veneers, and back—all of which needed to be coordinated with the adjacent and supporting structure. For Suffolk and Formrite Construction, incorporating the masonry scope of work into the BIM coordination process was a must,” says Alan Barroso, assistant project manager for Suffolk.

Modeling can be enormously helpful in the design stage and on some projects, custom analytical tools may prove more useful than BIM. Such was the case with a particularly challenging masonry layout for the Museum at Prairiefire in Overland Park, Kansas. Verner Johnson Inc. designed the building using a complex blend of stone veneer products that did not lend itself to standard BIM masonry modeling techniques. The intent was to create a gradient of color and texture moving vertically up the wall. To accomplish this effect over the 46-foot-high cavity wall, 32 separate horizontal zones were established each containing a unique mix of material, color and texture with variable blends. Five colors of Cordova Stone (formerly Prairie Stone) and four colors of natural limestone in two different textures were used to compose the blend with each band varying proportions of product. In addition to the variation of product and color, unit height varied and unit lengths were randomly mixed. As is apparent in the model of one of two structures, the veneer envelope was also uniquely shaped. All these variables converged to present a very challenging modeling proposition.

Due to the number of variables and the desire for a random effect in the distribution of stone lengths, it was not realistic to create an exact stone model with individual unit placement. While it was possible to build such a model, the drawings and order produced by such a model would be far to constraining to use for construction. Instead, a custom modeling approach was devised that enabled flexibility in the unit placement while preserving the accuracy of unit counts to produce an accurate order. This also allowed the mason, D&D Masonry of Kansas City, Missouri, the freedom to blend the product in an efficient way with proper proportions for each band coming directly from the model. This hybrid modeling solution preserved the integrity of the order, was specific enough to yield useful data for each band, yet freed the masons to practice their craft in a cost-effective manner, a situation that underscores the current paradigm of using the latest technology to facilitate the ancient craft of masonry.

Another interesting aspect of this project was the timing of the modeling. Analytical modeling was deployed privately prior to bid by the winning contractor, which allowed for an accurate bidding process as well as early interaction with the architect to manage the complexity of the design from the standpoint of cost. The ability to have an accurate picture of cost as well as a basic strategy for construction provided very useful feedback for budgeting and the impact of design changes to the stone. The information generated from the model provided a basis for controlling costs by adapting the masonry materials and layout while still preserving the design intent. The Museum at Prairiefire illustrates how the use of BIM masonry modeling techniques can help preserve a complex masonry design through the bidding and construction process to make creative designs affordable and buildable realities.

The Cost of Inaccurate Orders

Any architect that has kept track of how much it costs to miss a masonry order, can attest to the fact that dollars mount up quickly. Architectural masonry does not come cheap and it does not take too much extra block at the end of a job to drain profits. Working with architectural masonry can be extremely complex, requiring considerable time to scrutinize the accuracy of plans. An efficient BIM modeling process sets out a blueprint that can be checked against a visual reference for every block in the building—3D drawings can be quickly reviewed to confirm accuracy. Trouble spots can be sorted out, and orders placed more quickly, which translates to on-site deliveries of block sooner than with conventional efforts. Bonding pattern and locations of field cuts can be reviewed prior to installation, assuring greater confidence in the final placement. These services are currently available and have proven to be a very effective means of eliminating such costs.

What Architects Can Do Today

Modeling technology for architectural masonry is rapidly evolving. A few programs currently exist, and the industry is quickly moving toward BIM for Masonry. Based on the proven effectiveness of these models it behooves architects to keep abreast of what is happening and to continue to educate themselves on developing possibilities and what various manufacturers have to offer. It is important to note that it is not necessary to wait to land a BIM job. There is no need to put off realizing the benefits of a modeling system until expert status has been achieved. Modeling technologies can simply be written into the specifications for a project, which can ensure that installers are working with proper orders and provide installation drawings or models for review.

Toward the Future of Masonry

Masonry has been used for more than 10,000 years from pyramids to domes to arches and walls. Designers have specified architectural masonry for centuries, and throughout it has always been—and will always be—an excellent choice to bring distinction to the built environment through a range of colors, textures, patterns, and shapes. Granted, there are challenges with using architectural masonry products—complex geometries, large numbers of diverse units, different bond patterns, the constructability of such details as corbels and quoins, etc. Yet current modeling technology is having a dramatic impact on reducing these challenges and the technology is improving every day. Architects can help themselves by requiring modeling services in the design phase—an action that will greatly increase chances of success with architectural masonry.

Tom Cuneio is a mechanical engineer who developed CAD BLOX 10 years ago to provide a reliable modeling method for complex masonry projects.

Oldcastle® Architectural is the leading North American manufacturer of concrete masonry, lawn, garden, and paving products and a regional leader in clay brick. The group also produces packaged cement mixes, lightweight aggregates, bagged decorative stone, and lime and concrete rooftiles. Oldcastle Architectural operates across 35 states and 2 Canadian provinces. www.Belgardcommercial.com