The design of the Barclays Center achieves a striking balance between iconic form and performance. A major component of the arena's design is its intricate pre-weathered steel and glass enclosure.

To execute this design, SC was engaged by the facade contractor to ensure the architectural gesture of the pre-weathered steel 'latticework' was accurately reproduced in the built form. Through implementation of an integrated direct-to-fabrication process, SC facilitated the manufacturing, assembly and sequenced delivery of 900 unitized mega-panels containing 12,000 uniquely sized pre-weathered steel latticework panels.

Upon receipt of SHoP Architects' initial global surface geometry for the exterior facade design, SC began analysis of the pre-weathered steel 'Latticework System' and performed automated quantity take-off extractions during the initial design stage. This operation included population of the “Design-Cost Matrix” which contained multiple combinative groupings of macro level pre-weathered steel zones of the exterior cladding. Through this exercise, the owner was provided with quantity and cost breakdowns for each iteration of the exterior form by which informed decisions could be made regarding design relative to cost.

With global surfaces in order, the surface model was then imported into the parametric design platform, CATIA V5, to generate and manage the Latticework System. Parametric criteria included panel count, size, weight, spacing between panels and finalized form. With openings between panels accounted for, the final pattern developed for the Latticework System, a.k.a. 'the flocking pattern', amounted to 85% of the global surface area of the façade, and consisted of 12,000 uniquely sized pre-weathered steel panels.

SC developed 3D panel prototypes or "document templates" which were utilized to inform unfolding sequences for each of the 12,000 uniquely sized pre-weathered steel panels into their flattened states. SC utilized SigmaNest to nest and prescribe the coil width for the A5888 raw material order. This process improved the material yield by +/-10% over original assumptions by the fabricator. SC's scripted CATIA workflow allowed for automatic generation of “fabrication tickets” which were then utilized to guide CNC production. Each fabrication ticket included an automatically populated chart containing bend information for forming each latticework panel.

SC provided a 4D construction sequencing model of the facade and structural steel components, which enabled the project team to make informed decisions in real-time as related to the installation of the unitized mega-panel assemblies. Each assembly included the pre-weathered steel latticework components which were pre-assembled with curtain-wall enclosure units, varying in size from 10' in width by 20' to 50' in height. To ensure proper sequencing and installation, SC used NavisWorks to create the 4D construction sequencing model which was referenced on a daily basis by all parties to make decisions affecting planning and design.

During the detailed design stage, SC generated a custom iPhone interface utilized to track fabrication, pre-weathering
and installation of the pre-weathered steel latticework system components. Each panel was digitally tagged with a unique bar code and scanned with the iPhone camera. SC's iPhone app allowed for panels to be ‘tagged’ with one of five corresponding manufacturing processes: Waterjet, Surface Prep, Form, Dip and Rinse, and Hang. The app automatically updated the project database and building information model, providing online accessibility – thus providing real-time updates to project
stakeholders as panels were produced and installed on the building.

The SC team managed assembly and logistics coordination for the facade installation by providing on-site VDC support for the facade fabricator and installer. This direct support system enabled the team to maintain interaction with the facade components as they were installed, ensuring proper fit and achievement of original design intent. SC coordinated the alignment of the pre-weathered steel facade and facilitated the coordination of special support, rigging and anchorage systems. These systems included layout and installation procedures for facade anchor install, scaffolding design and erection sequencing in conjunction with lifting and transport mechanisms.

On-site modeling services were also provided to support, crane setting, rig design, multi-system clash detection, install sequencing and QA/QC component inspections. Smartboard technology was also integrated into field operation procedures to allow for the installers to directly interact with the virtual model.

In parallel with VDC support, SC also managed survey information by importing/exporting coordinate data through a "total station" surveying system and 3D laser scanning. This allowed the team to analyze as-built conditions and predict steel movement to ensure proper layout and installation of facade panels.