RUTHERFORD REGIONAL SCIENCE AND

CASE STUDY NO 3
INNOVATION CENTRE, UNIVERSITY OF CANTERBURY
SEPTEMBER 2017

STEEL : BUILT TO LAST THE FACTS

The $216 million Rutherford Regional Science and Innovation Centre (RRSIC) will be
the cornerstone of the University of Canterbury’s Science Precinct. The state-of-the- • Six-storey building
art facilities will be a focal point for the University’s science and innovation network • 25,000m2 gross floor area
and foster collaborative teaching, learning and research. • BRB seismic technology is a
visible architectural feature
The RRSIC project is two buildings, the first of which is being built by Fletcher • $216 million budget for
Construction and is a 25,000m2 seismically engineered steel structure that includes the entire Science Precinct
specialist teaching and research laboratories for physics, astronomy, chemistry, upgrade, which includes
geology, geography and biological sciences. two buildings
• 31,000 bolts
The development is part of a $1.2 billion capital works programme that is progressively
transforming the University campus with state-of-the-art teaching, learning and • 1,643kg, weight of heaviest
research facilities. A further $1.2 billion in developments out to 2045 has been baseplate
identified in a recently released Campus Master Plan. • 8,525kg, weight of U frame
• 967kg, weight of heaviest
The design team describes the first building of the RRSIC project as a “collegial effort”. HD bolt assembly
The team’s attitude was to solve issues together, which was central to overcoming the
many challenges the job threw at them.

...
OWNER: THE UNIVERSITY OF CANTERBURY STRUCTURAL ENGINEER: BECA ARCHITECT: JASMAX
BUILDER: FLETCHER CONSTRUCTION STRUCTURAL STEEL FABRICATORS: D&H STEEL, AUCKLAND; JOHN JONES STEEL, CHRISTCHURCH
 RUTHERFORD REGIONAL SCIENCE AND INNOVATION CENTRE, UNIVERSITY OF CANTERBURY

“WORKING CLOSELY WITH THE LOCAL FABRICATOR WE WERE Structural steel fitted perfectly with the desire to
incorporate buckling restrained braces (BRBs) as
ABLE TO ADJUST DETAILS TO INCORPORATE BUILDABILITY the main lateral-resisting system for the building.
AND OFFER SAVINGS TO THE CLIENT. DRIVING DOWN This seismic engineering technology enables
buildings with this technology to operate soon
THE ROAD TO BRAINSTORM A BETTER WAY IS FAR MORE after post-earthquake inspections are completed.
PRODUCTIVE THAN NUMEROUS PHONE CALLS, EMAILS AND If damaged, BRBs can be easily removed and
replaced.
SKETCHES WITH PARTIES THAT ARE NOT FAMILIAR WITH
...
CONSTRUCTION PRACTICES IN NEW ZEALAND.”
– ANDRE KIRSTEIN, TECHNICAL DIRECTOR - STRUCTURAL ENGINEERING, BECA

ENGINEERING complexity. Fortunately, steel is relatively design methodology with a structural peer
forgiving and allows simple modification as reviewer and the local territorial authority
During the concept design phase a number of required on site. allowed agreement on design principles
structural solutions were considered. Other throughout the design process.
than the foundations and floor slabs, the Most important, perhaps, is that structural
entire structure is fabricated steel and is the steel fitted perfectly with the desire to The use of BRBs enabled the team to design
main material in both the gravity and seismic incorporate buckling restrained braces (BRBs) a structure that limits lateral movement,
members. as the main lateral-resisting system for the giving the façade greater protection from
building. This seismic engineering technology earthquakes than specified in the Building
Structural steel was chosen due to its ability enables buildings with this technology Code. BRBs also provided a very cost-
to deliver on a range of key design points: it to operate soon after post-earthquake effective façade system as it could be
is cost efficient; allows large open spaces in inspections are completed. If damaged, BRBs fabricated with simplified waterproofing
line with modern teaching environments; has can be easily removed and replaced. details to joints, and without the need
sufficient strength and stiffness to minimise for complex movement details or support
total building deflections and inter-storey BRBs perform consistently in both systems.
drifts; and offers a flexible and adaptable compression and tension. A flat plate, which
framing system, particularly salient given the passes through the centre of the brace, is A stiff building does, however, pose other
extensive building services. enclosed in concrete and then sheathed in challenges. The impact of this approach
steel. The outer steel casing prevents the was that the large over-strength forces had
A building of this nature needs to almost internal steel core from buckling. As the to be absorbed in the foundation raft design.
be designed around the services rather than building moves during an earthquake, it Coordinating column hold-down bolts and
trying to fit the services into the building. The yields the piece of flat steel inside the brace, holding them in position while also feeding
steel members can accommodate numerous which absorbs the energy of the quake. The the foundation reinforcing around the bolts
and large penetrations that perfectly fit the concrete case retains the plate and stops it is a common challenge on projects. But
building services ducts and pipes without from seriously deforming. when you have a 1.5m-deep foundation raft,
forcing higher floor-to-floor dimensions. numerous layers of closely spaced 32mm-
Currently, the New Zealand Building Code diameter bars and need to install 64mm-
Design changes during construction are does not include specific design provision or diameter holding down bolts, it requires
inevitable with the number of end users guidance for BRBs, so US design guidance was some thought. Working closely with the
in an educational building of this size and adapted for use here. Early agreement on the contractor the issue was eventually resolved
 RUTHERFORD REGIONAL SCIENCE AND INNOVATION CENTRE, UNIVERSITY OF CANTERBURY

The structural steel provided a quick, lightweight

and clean framework from which other elements
“THE PRECISION THAT STEEL OFFERED THIS PROJECT WAS
could hang. What’s more, the steel is integral to PIVOTAL TO ITS SUCCESS – THE STRUCTURE WENT TOGETHER
the building’s architecture and aesthetic, both VERY WELL. DIFFERENT FABRICATORS WORKED TOGETHER
internally and externally.
ON THIS JOB TO ENSURE QUALITY AND EFFICIENCY – THE
...
DELIVERY AND QUALITY WAS SEAMLESS. SUCH A HIGH-
QUALITY OUTCOME WOULD BE DIFFICULT TO OBTAIN FROM
AN OVERSEAS SUPPLIER.”
– CHRIS BOSS, ASSOCIATE PRINCIPAL, JASMAX

by installing specially designed steel ‘tables’ plates, up to 150mm. Working with the the building’s architecture and aesthetic,
that formed a template to support the bolts, fabricator the engineer was able to source both internally and externally. For example,
shear key anchors and reinforcing. higher grade steel allowing for thinner plates structural steel rods are used to support
to be used. In addition, some circular hollow a glass balustrade, and the façade design
Prefabricated steel formwork, which looked section columns required wall thicknesses follows the diagonal bracing system of the
look like inverted tables, was placed within of up to 32mm. Again working with the BRBs – glimpses of the structure can be seen
the foundation to which the hold-down fabricator, the engineer rationalised the at different points through the glazing.
bolts were fixed and the reinforcement was column design such that very little waste was
threaded through. It allowed the contractor incurred. Working with offshore fabricators While the braces look the same, they are
to hold all of the components in place with would not offer this service easily and waste exposed to different loads throughout the
precision while the concrete was poured. would have been seen as just part of the cost. building. The south end is the heaviest part
of the structure. At this point the braces use
Structural steel’s light weight reduced the stronger pins rather than bolts to hold them
impact on the design of the foundation ARCHITECTURE in place.
raft. The ground underneath one building
in particular has very soft layers. The design The building’s architecture is a symbol of The mechanical services in the RRSIC are
team’s solution was to ‘float’ the building on its cultural and aspirational context. The massive and it was crucial to get this aspect
top of the stiffer upper soils. The heavier the ‘tree of knowledge’ design begins with the underway as early as possible to ensure
building, the further the load must be spread atrium, which serves as a wayfinder and the project was completed on time. The
to limit settlement to a level that the building encourages movement up through the levels structural steel solution offered phenomenal
can accommodate. The steel made it easier to of the building, from the undergraduate accuracy and early access for the multiple
distribute those loads over a small area. spaces below to the post-graduate areas trades. Importantly, the material also allowed
above. The stairs evoke the spider webs of deeper ceiling voids and castellated beams to
Another feature of the project was an existing Ruahinematamorari that the Maori mythical accommodate the services.
underground service tunnel. The tunnel hero Tawhaki used to climb to the heavens on
couldn’t be moved without disrupting all his search for knowledge. The building has also been designed with
services to the entire university. As such the environmental sustainability in mind, with
engineers had to incorporate the tunnel into During construction, the structural steel a specific focus on limiting energy use,
the design of the raft. provided a quick, lightweight and clean maximising access to natural light and
framework from which other elements could ventilation, and reusing existing materials
The design required the supply of very thick hang. What’s more, the steel is integral to wherever possible.
 RUTHERFORD REGIONAL SCIENCE AND INNOVATION CENTRE, UNIVERSITY OF CANTERBURY

“MEETING THE PROGRAMME IS EVERYTHING. OUR HIGHLY The fabricator coordinated the detailed design
phases with the builder as a way of managing
AUTOMATED TECHNOLOGY MEANS THINGS ARE MUCH the limitations inherent in a compact site. The
MORE PREDICTABLE. WE CAN PLAN TO A HIGH LEVEL building was constructed in two vertical phases:
up to level four, then a second jump up to the
OF DETAIL, GIVING CONSULTANTS AND BUILDERS FULL top-most level.
CONFIDENCE IN THE PROGRAMME.” ...
- WAYNE CARSON, GENERAL MANAGER, D&H STEEL

FABRICATION tolerance and buildability risks for the builder bolts for the foundations were massive.
were significantly reduced. Typically a manual process, for this project
Joint venture partners D&H Steel and John the bolts had to be craned into place as the
Jones Steel supplied and installed the The fabrication processes use highly advanced complete assembly weighed over a tonne.
structural steel for the project. D&H Steel machines. Half of the components are By working closely with the builder in the
looked after the high productivity, easy-to- produced using automated CNC technology. planning stages, the fabricator identified a
transport components from its Auckland base, It allows precise and rapid repetition of the way of making the assembly simpler and
while John Jones Steel managed the more elements compared with manual operations. also suggested an alternative baseplate shear
difficult, “big and ugly” elements as they were connection detail, shaving $300k off the cost
close to the construction site. The nature of the project, as both a science in the process.
and an architectural building, meant there was
considerable complexity. There were multiple The six-storey high, 600mm-diameter columns
In addition, D&H Steel was tasked with the
services to be accommodated including air, provided some challenges. There are a large
design and supply of the BRBs. D&H Steel is the
water, data, gas and air conditioning. Also, number of attachments inside the column
exclusive New Zealand agent for US company
much of the structural steel is exposed so a along its length, as well as reinforcing steel. To
Star Seismic, one of only three companies
high level of architectural coordination was manage the attachments the fabricator cut the
internationally offering the BRB solution. Star
required – the finish and the alignment must columns into sections then welded them back
Seismic developed the design and D&H Steel
be precise to create the desired aesthetic. together in the workshop. Getting them from
manufactured the BRBs on the ground in New
Zealand. the workshop to the site was a logistical feat.
The fabricator, engineer, builder and architect Having John Jones Steel’s workshop on the
worked together closely. There was ongoing ground near the site was a real advantage to
As the fabricator responsible for both, D&H dialogue and information was shared via 3D
Steel seamlessly coordinated the BRBs and the the programme.
building information modelling (BIM). The
structural steel. There is a series of intricate fabricators worked from the architect’s model,
connections between these elements – up to which saved considerable effort when it came The fabricator coordinated the detailed design
30 for each BRB, of which there are 120 reaching to the secondary steel. BIM replaced traditional phases with the builder as a way of managing
diagonally from the floor to the ceiling. shop drawing from a set-out perspective – the limitations inherent in a compact site.
bracket placement, for example. The 3D model The building was constructed in two vertical
BRBs are essentially highly specialised shock went straight to the CNC machine so the final phases: up to level four, then a second jump
absorbers – the piece in the core is the magic. product was precise and without human error. up to the top-most level. The fabricator
Having the same fabricator for the structural sequenced production of the steel structure
steel and the BRBs meant the fabrication As part of the seismic design, the hold-down to sync with the construction phases.