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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.

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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.