Although the design is finalized according to digital measurement, field measuring is important taking into account of fabrication and installation inaccuracies. I used tape to mark down hole positions and distances and found it very useful and fast.
After field measurements were incorporated, full-scaled paper mockups were made to help directly visualize problematic moments
The tabs need to align with holes on the rib and the platform level; no warped, or in other words, doubly curved platforms!
There could be many tests…
Until the one that fits perfectly. The front lateral support is modified into a triangular shape to create a more elegant look.
Running parallel to the making of paper mockups was the production of prototypes with actual material, 20 Guage or 0.33 inch steel on the waterjet
The sample panel was folded by hand on a vise; Because of the stiffness of the material and conservative dash pattern, it was very hard to have a clean fold without any bulge, especially at corners. The radius at the folding line also caused misalignment of the rivet holes, necessitating an elongated hole for tolerance.
Folds will also be sequenced to avoid constant readjustment of angles.
Prototype installed; Even with one-sided support and no fasteners between panels, the corner was very sturdy. There will be several changes for the final panel:
1. Longer dashes and shorter spacing for ease of bending
2. square tabs than strip tabs for ease of aligning rivet holes
3. elongated rivet hole on the outside for tolerance of misalignment
Complete Fabrications: The New Normal 