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Chanel_Mobile_Art_Fabrication_019

Photo_Admin — Tue, 13 May 2008 18:20:43 +0100

by: Photo_Admin

Description: Two completely finished FRP panels. This whole manufacturing process from start (CNC Data Processing) to finish (Apply top coat paint) was developed inhouse by Stage One especially for Chanel. In total approx 400 panels were made using this process.

1 comment

Chanel_Mobile_Art_Fabrication_018

Photo_Admin — Tue, 13 May 2008 18:20:33 +0100

by: Photo_Admin

Description: When the panel has been filled and sanded a primer coat is applied. This is then baked in an oven before the top white pearlescent finish is applied.

Chanel_Mobile_Art_Fabrication_017

Photo_Admin — Tue, 13 May 2008 18:20:24 +0100

by: Photo_Admin

Description: Stage One installed a custom spray mix & application system. This ensured that the white pearlescent paint finish remained the same for every panel.

Chanel_Mobile_Art_Fabrication_016

Photo_Admin — Tue, 13 May 2008 18:20:15 +0100

by: Photo_Admin

Description: This panel has now been 'broken out' from its mould, and has been filled and then sanded. This process ensures that the panel is exceptionally smooth. The white pearlescent paint finish is very unforgiving and so every imperfection in the panel must be removed.

Chanel_Mobile_Art_Fabrication_015

Photo_Admin — Tue, 13 May 2008 18:20:06 +0100

by: Photo_Admin

Description: The black paint is a fire inhibitor used for all interior panels. This panel is now ready for 'breaking out' where it is removed from its foam mould. You can also see the CNC formers. These were slotted into the foam mould to ensure that overall dimensions remained within tolerance.

Chanel_Mobile_Art_Fabrication_014

Photo_Admin — Tue, 13 May 2008 18:19:57 +0100

by: Photo_Admin

Description: You can clearly see the fibre layers in this picture. You also start to get an understanding of how labour intensive the process of manufacturing the panels was.

Chanel_Mobile_Art_Fabrication_013

Photo_Admin — Tue, 13 May 2008 18:19:48 +0100

by: Photo_Admin

Description: Resin is sprayed onto layers of fibre polymer to build up the FRP (Fibre Reinforced Polymer) panels.

Chanel_Mobile_Art_Fabrication_012

Photo_Admin — Tue, 13 May 2008 18:19:39 +0100

by: Photo_Admin

Description: Resin is sprayed onto layers of fibre polymer to build up the FRP (Fibre Reinforced Polymer) panels.

Chanel_Mobile_Art_Fabrication_011

Photo_Admin — Tue, 13 May 2008 18:19:30 +0100

by: Photo_Admin

Description: A partially machined foam block. You can see how the CNC machine head has removed a large quantity of the material with a large cutting head. This is then automatically changed to a finer head to get the smooth finish required for the final panels.

Chanel_Mobile_Art_Fabrication_010

Photo_Admin — Tue, 13 May 2008 18:18:27 +0100

by: Photo_Admin

Description: The 3d surface data was taken from the Architects Rhino Models and then processed by Stage One into CNC data. This process included adding CNC paths for plywood formers, splitting some of the larger panels into separate blocks. The large blocks of foam were then machined by the Stage One 5 Axis CNC machine.

Chanel_Mobile_Art_Fabrication_009

Photo_Admin — Tue, 13 May 2008 18:18:18 +0100

by: Photo_Admin

Description: Sections of Terrace Deck finished and curing. Note the slot in the middle of the deck where custom lighting units will be added. These will be covered with safety glass.

Chanel_Mobile_Art_Fabrication_008

Photo_Admin — Tue, 13 May 2008 18:18:08 +0100

by: Photo_Admin

Description: The Terrace Deck surface required many samples and tests from Stage One before this method was agreed. Small dark grey coloured rubber chips were mixed with specialist resin and then laid onto a wooden deck. The rubber chips were contained in an aluminium angle fascia. The wooden deck was attached to a heavy steel sub frame. The use of rubber chips allowed the decks to be laid level, but also drain in wet weather.

Chanel_Mobile_Art_Fabrication_007

Photo_Admin — Tue, 13 May 2008 18:17:58 +0100

by: Photo_Admin

Description: This is a mock up of the stretched fabric inner walls and ceiling produced by Architen Landrell in Chepstow. The stretch fabric panels were assembled with seamed bungy cord along their edges. These bungy cords were then pushed into slots machined into the edges of CNC plywood formers. All profiles for the formers were taken directly from the architects Rhino CAD model.

Chanel_Mobile_Art_Fabrication_006

Photo_Admin — Tue, 13 May 2008 18:17:49 +0100

by: Photo_Admin

Description: A fabricator from Sheetfabs completes work on the sub-deck. The minimal amount of welding and fabrication work done on a site is a great testament to the accuracy of Sheetfabs and Steel Monkeys build processes.

Chanel_Mobile_Art_Fabrication_005

Photo_Admin — Tue, 13 May 2008 18:17:43 +0100

by: Photo_Admin

Description: A roof radial beam prior to final clean up and painting. Note the 40mm thick steel cleat on the end of this beam, and the other cleats attached for the braces and lighting track hangers.

Chanel_Mobile_Art_Fabrication_004

Photo_Admin — Tue, 13 May 2008 18:17:36 +0100

by: Photo_Admin

Description: Piles of precut steel plate lie in Sheetfabs fabrication yard, awaiting final assembly and welding. Each plate is different and required meticulous attention to detail to ensure that each beam was assembled with the correct number of cleats in the right position.

Chanel_Mobile_Art_Fabrication_003

Photo_Admin — Tue, 13 May 2008 18:17:31 +0100

by: Photo_Admin

Description: Structural radial wall beams lie in Sheetfabs fabrication yard. Each structural beam was made into an 'I' profile using separate 10mm plasma profiled steel plate. The massive challenge undertaken by Sheetfabs was to ensure that in the welding of these beams, the heat didn't distort them. Massive temporary jigs clamped the beams during welding. Each and every roof and wall beam was different. This was not a job where mass production techniques could be applied. Checking dimensions was very difficult due to the profiles of each beam coming directly from the architects Rhino model. These profiles were all NURBS (Non Uniform Rational B-Splines) meaning that there were no true radiuses.

Chanel_Mobile_Art_Fabrication_002

Photo_Admin — Tue, 13 May 2008 18:17:24 +0100

by: Photo_Admin

Description: The Courtyard Gutter (made by Brilliant Stages) is assembled, using the structural steelwork (made by Steel Monkey) in primer red. The gutters are made from 3mm thick steel plate. This is thicker then usual to allow for the crew to walk in them safely. The ETFE Panel frames are bolted into machined blocks in the gutter which are supported from fin plates attached to the main structural steel. This required a massive design coordination effort to ensure that each component fitted.

Chanel_Mobile_Art_Fabrication_001

Photo_Admin — Tue, 13 May 2008 18:17:18 +0100

by: Photo_Admin

Description: The first courtyard leg is assembled in Steel Monkeys fabrication yard. Note the use of small temporary steel members to ensure the leg remains within tolerance when welded.

Chanel_Mobile_Art_Packaging_and_Transport_029

Photo_Admin — Tue, 13 May 2008 18:16:09 +0100

by: Photo_Admin

Description: The whole Pavilion, Ticket office and Scenography fits into 64 shipping containers; 14 x 40' open tops, 1 x 20' standard, 17 x 40' standard, 32 x 40' high cubes. Here a 40' high cube shipping container is loaded with the main exhibition scenography. Each piece of scenography is carefully packed to ensure it can't move during heavy seas.

1 comment

Chanel_Mobile_Art_Packaging_and_Transport_028

Photo_Admin — Tue, 13 May 2008 18:16:00 +0100

by: Photo_Admin

Description: Container lifting chains are taken with the tour to ensure that safe and rated rigging hardware is always used when moving containers.

Chanel_Mobile_Art_Packaging_and_Transport_027

Photo_Admin — Tue, 13 May 2008 18:15:50 +0100

by: Photo_Admin

Description: These low profile loading pallets, fit exactly into a 20' Shipping container. They are fitted with solid steel wheels on their base. This allows cargo to be loaded safely onto them with access from all four sides and the top. With the pallet loaded, it can be pushed into a 20' container using a forklift. This removes the risk of crew getting crushed in containers during loading.

Chanel_Mobile_Art_Packaging_and_Transport_026

Photo_Admin — Tue, 13 May 2008 18:15:39 +0100

by: Photo_Admin

Description: A box of speed thread bolts used to attach the 24mm thick plywood down onto the decking system.

Chanel_Mobile_Art_Packaging_and_Transport_025

Photo_Admin — Tue, 13 May 2008 18:15:30 +0100

by: Photo_Admin

Description: One box of many BZP (Bright Zinc Plated) pins used to connect the structural steel together. Pins are preferred for touring situations due to the speed of assembly over bolts.

Chanel_Mobile_Art_Packaging_and_Transport_024

Photo_Admin — Tue, 13 May 2008 18:15:21 +0100

by: Photo_Admin

Description: A steel structural roof beam with aluminium 'shot gun' extrusion attached to the top. The aluminium extrusion was custom supplied by Architen Landrell. It features a slot down the middle which acted as a water drain, and also matched the 25mm width used for the main FRP wall panels.

Chanel_Mobile_Art_Packaging_and_Transport_023

Photo_Admin — Tue, 13 May 2008 18:15:12 +0100

by: Photo_Admin

Description: A pallet of FRP brackets in the foreground, with a stillage containing roof beams in the background.

Chanel_Mobile_Art_Packaging_and_Transport_022

Photo_Admin — Tue, 13 May 2008 18:15:05 +0100

by: Photo_Admin

Description: One 40' trailer loaded with one stillage of roof beams. Each stillage and beam was designed so that it could fit into a 40' shipping container.

Chanel_Mobile_Art_Packaging_and_Transport_021

Photo_Admin — Tue, 13 May 2008 18:15:00 +0100

by: Photo_Admin

Description: One 40' trailer loaded with two stillages of roof beams. Each stillage and beam was designed so that it could fit into a 40' shipping container.

Chanel_Mobile_Art_Packaging_and_Transport_020

Photo_Admin — Tue, 13 May 2008 18:14:40 +0100

by: Photo_Admin

Description: Structural roof beams with aluminium 'shot gun' extrusion attached to the top. The aluminium extrusion was custom supplied by Architen Landrell. It features a slot down the middle which acted as a water drain, and also matched the 25mm width used for the main FRP wall panels.

Chanel_Mobile_Art_Packaging_and_Transport_019

Photo_Admin — Tue, 13 May 2008 18:14:31 +0100

by: Photo_Admin

Description: Decking components packed into stillages. All of these beams are based on common Kwikform components which allow for fast assembly on site. These components supported the main floor deck of the pavilion to a level height of 650mm.

Chanel_Mobile_Art_Packaging_and_Transport_018

Photo_Admin — Tue, 13 May 2008 18:14:22 +0100

by: Photo_Admin

Description: Decking components packed into stillages. Note how the stillages stack to use the full height of the shipping containers.

Chanel_Mobile_Art_Packaging_and_Transport_017

Photo_Admin — Tue, 13 May 2008 18:14:13 +0100

by: Photo_Admin

Description: Braces stacked into a stillage.

Chanel_Mobile_Art_Packaging_and_Transport_016

Photo_Admin — Tue, 13 May 2008 18:14:04 +0100

by: Photo_Admin

Description: All braces are labelled using a profile cut steel plate. Paint is sometimes used for labelling, but over the duration of the tour, could have been scratched off. In this case the 'W' stands for wall, the '02' stands for the radial number, and the 'B' stands for the height position within the radial. The crew know quickly where each brace belongs in the building. There were a total of 582 braces used in the pavilion. Each brace was a different length with many requiring different end cleats welded at different angles.

Chanel_Mobile_Art_Packaging_and_Transport_015

Photo_Admin — Tue, 13 May 2008 18:13:54 +0100

by: Photo_Admin

Description: A stillage containing the full set of rigging required to lift the Courtyard Ring Beam. Each steel wire rope is a slightly different length. The coloured plates line up temporarily with cleats in the Courtyard Ring Beam. This ensures that the Courtyard Ring Beam is lifted level.

Chanel_Mobile_Art_Packaging_and_Transport_014

Photo_Admin — Tue, 13 May 2008 18:13:45 +0100

by: Photo_Admin

Description: Scenography from all over the world arrived in Yorkshire for final assembly and inspection before packaging and being sent to Hong Kong.

Chanel_Mobile_Art_Packaging_and_Transport_013

Photo_Admin — Tue, 13 May 2008 18:13:36 +0100

by: Photo_Admin

Description: Stacks of empty stillages in storage beside the Star Ferry Car Park in Hong Kong. The grey pallets are from the FRP Stillages but with vertical tube extensions removed allowing them to be 'flat packed'. Each FRP stillage measured 6.0m long x 2.39m wide.

Chanel_Mobile_Art_Packaging_and_Transport_012

Photo_Admin — Tue, 13 May 2008 18:13:26 +0100

by: Photo_Admin

Description: The FRP Panels were travelled in custom pallets made by Stage One. The vertical black tubes could be removed to allow the pallets to be 'flat packed' for storage.

Chanel_Mobile_Art_Packaging_and_Transport_011

Photo_Admin — Tue, 13 May 2008 18:13:17 +0100

by: Photo_Admin

Description: The beam stillages were designed to allow them to be lifted by crane or forklift.

Chanel_Mobile_Art_Packaging_and_Transport_010

Photo_Admin — Tue, 13 May 2008 18:12:34 +0100

by: Photo_Admin

Description: Structural wall beams are strapped into their stillages to ensure they couldn't move during transit.

Chanel_Mobile_Art_Packaging_and_Transport_009

Photo_Admin — Tue, 13 May 2008 18:12:25 +0100

by: Photo_Admin

Description: A gaggle of wall beams lie in their custom designed stillage.

Chanel_Mobile_Art_Packaging_and_Transport_008

Photo_Admin — Tue, 13 May 2008 18:12:15 +0100

by: Photo_Admin

Description: Drainage pipe coiled into stacking stillage.

Chanel_Mobile_Art_Packaging_and_Transport_007

Photo_Admin — Tue, 13 May 2008 18:12:06 +0100

by: Photo_Admin

Description: A row of Makita rattle guns fixed into the tool container.

Chanel_Mobile_Art_Packaging_and_Transport_006

Photo_Admin — Tue, 13 May 2008 18:11:56 +0100

by: Photo_Admin

Description: A row of manual chain blocks and rigging hang in the tool container.

Chanel_Mobile_Art_Packaging_and_Transport_005

Photo_Admin — Tue, 13 May 2008 18:11:47 +0100

by: Photo_Admin

Description: A 10' sea container was fitted out as a tool container for the crew. This allowed all tools, valuable components and spares to be safely stored on site.

Chanel_Mobile_Art_Packaging_and_Transport_004

Photo_Admin — Tue, 13 May 2008 18:11:34 +0100

by: Photo_Admin

Description: Scott Buchanan (ES Projects Technical Logistics Coordinator) kept a constant eye on the overall height of all freight and stillages during the design and build process. Look at the gap between the top of this stillage of Courtyard Legs and the ceiling of the plane and you'll know he did a great job.

Chanel_Mobile_Art_Packaging_and_Transport_003

Photo_Admin — Tue, 13 May 2008 18:11:22 +0100

by: Photo_Admin

Description: Internal view of one of the Cathay Pacific Boeing 747F-200 Cargo Planes.

Chanel_Mobile_Art_Packaging_and_Transport_002

Photo_Admin — Tue, 13 May 2008 18:11:10 +0100

by: Photo_Admin

Description: A Cathay Pacific Boeing 747F-200 Cargo plane loading with freight through the nose. The flight routing was: Manchester to Dubai, and then on to its final destination in Hong Kong.

Chanel_Mobile_Art_Packaging_and_Transport_001

Photo_Admin — Tue, 13 May 2008 18:10:57 +0100

by: Photo_Admin

Description: The tight design & build schedule meant that some freight had to be flown to Hong Kong to ensure the Pavilion opened on time. Four Boeing 747F-200 Cargo Planes were chartered by specialist logistics company Rock-It Cargo from Cathay Pacific Cargo. Each flight carried an average payload of 94,000kg. The aircraft are nose loadable.

Chanel_Mobile_Art_Ticket_Office_011

Photo_Admin — Tue, 13 May 2008 18:08:48 +0100

by: Photo_Admin

Description: The completed Ticket Office.

Chanel_Mobile_Art_Ticket_Office_010

Photo_Admin — Tue, 13 May 2008 18:08:31 +0100

by: Photo_Admin

Description: A view along the 'tail' of the Ticket Office. The 'tail' was made entirely from FRP wall and roof panels.