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Project Details

Fabric 1

TensoSky® ETFE Film
Producer/Manufacturer: Nowofol GmbH
Primary Use: Main Fabric

Engineer Name 1
Thorton Tomasetti (EOR) & Birdair, Inc. (Delegated Design)

Engineer Company 1
Thorton Tomasetti (EOR) & Birdair, Inc. (Delegated Design)

Design Name
Gensler

Design Company
Gensler

Architect Name
Gensler

Architect Company
Gensler

Fabrication Name
Birdair, Inc.

Fabrication Company
Birdair, Inc.

Subcontractor Name
Birdair, Inc.

Subcontractor Company
Birdair, Inc.

Graphics Name
Hueck

Graphics Company
Hueck

Project Manager Name
Birdair, Inc.

Project Manager Company
Birdair, Inc.

Installation Name
Birdair, Inc.

Installation Company
Birdair, Inc.

Please describe the project specifications

Through a collaborative, iterative design-assist process with the project team, the client selected ETFE film for its transparent lighting advantages to change the dynamic look of the building. Our project scope included design, engineering, fabrication and installation of the signature single-layer ETFE membrane with a customized frit print pattern, associated clamping hardware and the structural steel arched framing system featuring a tapered projection weighing a total of 105 tons. This intricate framework required meticulous coordination to ensure seamless integration with the building’s striking design and the iconic branding.

To meet logistical demands, all steel components were designed to fit into 40-foot cargo containers for transport from fabrication facilities overseas. On-site, the assembly required detailed planning for lifts involving both tower and mobile cranes as well as innovative techniques to distribute weight across the green roof’s restricted load capacity.

Some of the challenges and precision required on the project included that the final lifting be done with one crane, but we needed two cranes to rotate the pieces vertically and get them into place, which made it a critical lift. We had to start with the second steel truss in and stabilize back to the building, so the pieces didn’t rotate horizontally to the left or right. Another significant challenge our construction team faced involved the company's signature logo on the front of the building, as certain parts of the structure were inaccessible with typical man lifts or boom lifts. Ultimately, a beam system was designed to distribute load across the green roof.
We spent a great deal of time working with the engineers to design a way to distribute the weight of the machines to get the boom lifts on the roof. Creating access for the ETFE film and steel installation was certainly a challenge.

The entire façade project was completed ahead of schedule, with our site superintendents, on-site crew of 10-12 local ironworkers and rope technicians working between May and August 2024. Despite challenges like strong wind conditions and the complexity of the site and structure, our focus on design-build excellence and meticulous execution resulted in an architectural feature that redefines Under Armour’s corporate aesthetic and functional appeal. We have to think outside the box, and you have to make the design buildable.

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