dead distiller kennedys

SMITHFIELD VILLAGE . REDEVELOPMENT OF
THE OLD JAMESON DISTILLERY SITE
VINCENT BARRETI BSc (Eng),MSq DIC' MI StructE, MIEI' CEng
CIARAN KENNEDY BSc (Eng),Dip Eng, MIEI
BARRETT MAHONY CONSULTING ENGINEERS
Presentedto a meeting of the Structuresand Construction Section of the IEI at The lnstitution, 22 Clyde Road,
on Wednesday3rd February 1999 at 8.00pm.
Synopsis
This 295,000 sq. ft developmentincludes a museum,a theme hotel, bar and theatre,shops,restaurants,apartments
and undergroundcarparking. A panoramic lift on the largestchimney on the site will give views at 50m above
the SmithfieldPlaza. The paper describesthis exceptionally diverse and complex developmentfrom inception to
completion.
INTRODUCTION
The site for the Smithfietd Viilage
development is located on the Eastern
side of the Smithfield plaza. lt is
containedwithin the block bounded bv
Smithfield Plaza, Friary Avenue, Bow
Street and New Church Street. lt
comprises the complete block except for
the corner on the South Western end
which is occupied by the Children,s
Court. The site measuresapproximately
8 5 mx 1 2 5 m .
The site at Smithfieldchanged hands a
number of times subsequenfly and
indeed was split up in the early 90's.
Heritage Propertiesreassembledthe site
between1993and 1995.
old stills were either very severely
damaged or in many cases had
disintegratedentirely. Many dangerous
buildingnoticeshad been served on the
buildingand indeed the Bow Street wall
had been lowered to render it safe
because the timber floors behind had
been burnt.
Continuitywith the sites illustrioushistory
was copper fastened via the inclusion of
an lrish Whiskey Museum and retention
of many of the features which were R E U S EO F O L D B U I L D I N G S
specificto the distillerybusiness.
Figurel shows the typical old bonded
ARCHAEOLOGY
warehouse type construction. Cast iron
columns and wrought iron of mild steel
In 1995 Architects A & D Wejcherl and All of the existing buildingson the site beams and timberplanks.
Barrett Mahony Consulting Engineers were constructed during the life of the
were appointed by Heritage Properties distillery. The site is within the area of
Ltd, the Developers for the proposed potential archaeological interest and
redevelopment, and
planning therefore an assessmentwas carried out
a
applicationwas lodged in July / August at any early stage by Consultant
1995. The projectcommencedon site in Archaeologist Ms Judith Carroll. 17
December 1995 and is scheduled for substantialtrials and trench excavations
completionby April 1999.
were carried out and revealed nothino of
major archaeological
significance.In'the
SITE HISTORY
areas that were densely covered with
buildings because of the mass and
-ameson's Distillerywas foundedin 1780 natureof the buildingson the site and the
at Smithfieldand the site functionedas a loads that they imposed on the ground,
distilleryfrom that time until it closed in substantial foundations were provided
the early 1970's. The distillerytogether and as such no archaeological
finds were
with the local fruit and produce markets anticipatedin these areas.
ensured Smithfieldwas a thriving area
throughoutthe last centuryand much of DEVELOPMENT
this century. Indeed the commercial
history of the area is closely allied to the In 1994 Barrett Mahony Consulting
fortunes of the lrish Whiskey Industry.
Engineerscarriedout an initialappraisal Figure
1. Existing
Construction
of the site. Practicallyall of the site was
The four big Dublin Distillersof the time, built upon with lanes and yards between
of new and old involved
John Jameson and John Power,William multi storey brick and stone buildings. The integration
the
development
of an understanding
of
Jameson, George Roe considered During slte visits between 1994 and
buildings,
theirformandtheir
themselves the elite of the whiskev January1995 the rate of deteriorationof the existing
function. A visit to the PublicRecords
makersin lreland,and lrish Whiskeywai
the existing buildings on the site was
a vast hoardof process
considereda quality productabroad. Up dramatic. A series of fires by vandals Officeunearthed
'1
drawings,
design
drawingsand layout
to the 870's these firms grew and etc. decimated some of the less rubust
drawings
of the Distillery.
Figure2 shows
prospered and enjoyed a large export features on the site.
process
an
old
layout
of
the Distillery
trade. Up to that time Scotch malts came
from various highland distilleries and The inception of the development circa1930.
. 3re
very varied and unpredictableand predated the current properly boom and
: sUChwere no competitionfor the well the historic area regeneration plan
developed lrish Whiskey Industry. (Harp). The prospect of a tight rail
Essentiallylrlsh Whiskey being distilled travellingthrough the area was still a
three times in pot stillswas considereda distant aspiration. Indeed for the 15
superiorproduct.
months prior to this planningapplication
being lodged there were no applications
An lrish Civil Servant called Aeneas lodged in the Smithfieldarea, and in the
Coffey patented "The Coffey Stilt" circa previous 8 years a total of only two
1947. ln the 1860's CoffeyStiilsdirecfly planningapplicationshad been lodgedin
led to the developmentof Scotch blended the Smithfieldarea and these were small
C
Whiskeys which ultimately served to alterationswithin the lrish DistillersHead
provide the real competitionfor the lrish Officebuildinglocatedimmediatelyto the
Distillers. The development of finer south of this site. Currentlythe area is
Scotchwhiskyby this processconsidered one of the most active in the citv from a
by The lrish as "lnstantWhiskey" led to planningapplicationstandpoint.
the erosion of the export market. World
events in the early part of this century i.e. L I S T E DB U I L D I N G S
World War l, lrish independenceand
American prohibitionfurther decimated The '1895large chimney,the Smithfietd
the export business. The home market wall and the stone warehouse at Bow
prospered however and Jamesons Street / Friary Avenue
corner were Figure 2. Old processlayout
continued to operate out of Smithfield among the list 2 elements of the site.
The developmentof such distilleriestook
untilthey closedthe Distilleryin the early The old stone walls on the periphery
of place in somewhat an ad-hoc manner
70's and rationalisedtheir productionto the site were also considered of
and the locations of the various
MidletonCo Cork.
substantialmerit. By '1995 the kiln roofs
and many of the brick surroundsto the
processeswould bear this assumption Two boreholes were carried out on the
out.
site initlally. These revealed relatively
consistentground conditionsi.e. 2.5m THE IRISHWHISKEYMAKING
3m of rubble / fill overlying a clay gravel
PROCESS
overlyinga limestonerock at depths up
to 8m.
The lrish whiskey making process is
brieflyoutlined:
The 17 trencheswhich were dug for the
Archaeologist gave a more reasonable
1. Malting
spread throughout the site and these
verified the
consistency of
the
Barely is soaked in water and loadbearingdense gravel layer. The
allowedto germinatenaturally. The gravel gave N counts of between 40 and
germinationis then halted and the 70.
Allowable bearing pressures of
barleydried.
250kN/m'?to 350kN/m, pending on the
2. Milling
width of the foundationwere assumed.
The advantages of the dense gravels
The milled barley and malt is then were the free draining capabilityi.e. in
taken to and mixed with water in extremely wet conditions the ground
"mash tuns" (very large circular underfoot dried almost instantly and
tanks).
banks exposed proved stable over the
durationof the contract.
3. Mashing
SITEACCESSAND BUILDABILITY
The liquid in the "mash tuns" is
called"wort"a sugaryliquid.
Access to the site was restricted to the
North Western end and demolition
4. Fermentation
proceeded from that corner. lt also
became apparent early on that the
The worts is then pumped from the building should be built from the
"mash tuns" to the washbacks were diagonallyoppositecorner and to "back
it meets with liquid yeast and is out" of the site so to speak. ln order to
allowedto ferment
facilitate access to the South Eastern
corner it became apparent earlier on that
5.
Distillation
not all buildings in that corner could
easily be maintained. The mash tun
A triple distillationprocessin copper foundations and the brick lining
stills was employed in the lrish structures for the copper stills were
whiskeytradition.
retained as a major feature which the
Architect developed the
Whiskey
6. Maturation
Museum around. Apart from its impact
on the skylinethe tower buildingwas of
The distilledproduce is stored in oak little merit. lt was effectivelydemolished
port and sherry casks. This is what and
rebuilt so
that reasonable
gives it its distinctivecolour.
construction access was facilitated.
Figure 3 shows the retained elements of
This process would suggest that from the site. lt can be seen from this figure
grain intake, the next process is the that the development of the South
malting with the associatedkilns, then Eastern corner of the site became a
the millingand onto the "mash tuns" and criticalitem as did the demolitionto get
subsequentlywashbacks onto the stills accessto this corner of the site.
are after this the bonded warehouse. lf
one looksat the layoutshownin Figure2,
one would have expected the "mash
tuns" to be located where the washbacks
are and vice a versa.
Neverthelessthe use of these old brick
structures and stone structures on the
site varied but in most instancesinvolved
carrying exceptionallyheavy loads such
as the foundationsfor the washbacksor
wash tuns takingsay 30,000gallontanks
etc. The loads on existing walls were
large with such tanks often being 6-7m
high and several floors of grain storage
or bonded warehouseabove. Some old
walls were calculatedto be imposingup
to 600 kN/m2 on their foundationswith
dead load alone.
SITE INVESTIGATION
hr
outsidethe site to provideunhindered
spacefor construction
activitywithin.
Externalretentionsystemswere adopted
for Bow Street and Friary Avenue.
Figures4 and5 showsectionsat relevant
locations. Verticalig surveys revealed
the existing
plumb
wallsto be reasonably
and the design loads for the retention
systemswereassumedas follows:
Figure4. FagadeRetentionFriaryAve.
Figure 5. RetentionBow Street
lndividualwailing design load - 2Tzo/o
of
the total wall design load above the
wailing level. Frame load - 17,% of the
total dead load plus the wind load.
Where possible return walls were utilised
until such time as permanentstructure
could be constructed to provide lateral
restraint to the walls. See Figure 6
relatingto the Bow Street, Church Street
corner.
Figure6. Bow Street/ Church Street
Kentledge was provided by concrete
pipes filled with earth.
The old trusses over the "mash tuns" ,,,
what is now the exhibitionspace of the
museum were supported by a simple
frame with a concrete base to provide
kentledge.
SCHEMEDEVELOPMENT
Many of the features of the old distillery
have been retained, imitated or
developedin the new development. The
f-l
TEMPORARY
WORKS
The temporary works / demolition nine storey tower house which housed
pacKagewas prepared for tender in the grain conveyermachinerytogether
August1995. ln as much as possible, with three chimneys have been
supports to facade walls were kept maintained
as dominant
skvlinefeatures.
Kiln roofs have been reflectedin the
turret aspect of the roof design.
Internally
bricksurrounds
to copperstills,
blacksmith
trusses,the retentionof old
stonewalls and brickwallsall serveto
reflectthe sitesformerusaoe.
ACCOMMODATION
Thedevelopment
currently
includes
SITELAYOUT
FLOOR AREA CERTIFICATES
The sitewas naturallydividedin two by
DuckLane.The Northernpartof the site
North of Duck Lane comprisedthree
largeblocks,namelyABC as set out on
Figure7. The hotel buildinglocated
Southof DuckLanebetweenDuckLane
andJamesonLaneis BlockD.
ln order to considerthe buildingas new
build for the purpose of obtainingfloor
area certificatesfor the apartment it was
essential that the new structure did not
rely for either vertical support or stability
on old walls. lt was also a requirement
that if the old walls were at sometime
removed "as if this could ever happen"
that the inner leaf would comply with the
buildingregulations.ln any event from a
structural standpointthe new structure
was independent.
BOW STRTIT
220Aoartments.
79 BedHotel
l
35,000sq. ft. Museumincluding
Theatre Uz
andBar
7,500sq.ft. LeisureCentre
3,000sq. ft. Offices
32,000sq.ft. Commercial/
Retail
Recording
Studio
132SpaceUnderground
Carpark
Twothroughlaneways
3,000sq.ft. Balconies
sr/lTt_lF'f
LD
13,000sq.ft. OpenSpacesandTerraces Figure7. Site Layout
3,000sq.ft Courtyard
Approximately
80%of the apartments
are
n'.'vided with their own balconv or
q9E.
COSTEFFECTIVE
STRUCTURE
a
x
&
O
:)
r
(j
South of Jameson Lane The lrish
Whiskey Museum is located within the
old walls of the distilleryat this corner.
This area was further subdivided into
Block E which comprisedthe multi storey
apartmentsover the basement,ground,
first floor and Block F which comprised
the Museum Exhibitionspace and the
stonewarehousebuilding.
The plan format was developedby the
Architectand retains many of the old
facade features of the distillery site.
Large circularcourtyardswere provided The hotel building is located south of
in the Northernhalf of the site. The Duck Lane facing the SmithfieldPlaza
Southernhalf of the site design was between Duck Lane and the Children's
dictatedsubstantially
by the requirement Court. The RecordingStudio is annexed
to retain the existing buildings. to the Hotel Block (Block H). Table 1
Apartmentsare generallylocatedabove summaries the overall accommodation
firstand secondfloor. lt is the contention withineach of the blocks.
of the Authors that the most effective
constructionfor such cellular type
buildingsas apartmentsis loadbearing B l o c k No. Floors
Type
masonry and precast concrete floors.
This form of constructionis considered
appropriatebothfrom a cost standpoint
A
5 / 6 Floors New Build
but also from the ooint of view of
over
urilisationof the elementsof structure
Basement
have to be there to provide
B
4 l7 Floors New Buildwithin
cohpartmentalisation.
over
Old StoneWall
Basement
Commercialand other activitiesare
6 i 7 Floors New Build
mostly located at ground floor level.
over
These in effect warranted transfer
Basement
structures
to be locatedat eitherfirstfloor
D
4 / 5 Floors New Build
or in the caseof the museumbuildingat
secondfloor. An underground
carparkin
E
6 i 7 Floors New Buildwith
the Northernhalfof the sitewarrantedinOld Retained
situ concreteconstruction.This in-situ
StoneWalls
'1/ 2 Storey Refurbishment
concreteframe construction
was carried
F
generallyto transfer level where the
Museum
loadbearing masonry and precast
Space
concretecarriedthe variousfloorsabove
L:
6 Storey
New Buildwith
this level. Curvedfacadesabovetransfer
over
Old BrickWalls
level were generally facilitated by
Basement
providingcurved in-situ concreteedge
L.l
3 Storey
New Build
beams with in-situ infill to the faceted
Dome
precastslab.
Tablel-SiteLayout
ln the stone building (redevelopedas
offices and part of the Museum) ihe
existingwalls were used as support for
the new structure.
EXPANSIONJOINTS
Figure 7 also shows the locationof the
main expansion jolnts within the
develooment.
Buildings within these expansion lines
were treated as entities in themselves. ln
many cases indeed these expansion
joints were defined by the extent of the
usage type i.e. basement carpark line,
museumetc.
CARPARKING
Given the ambitious nature of the plan
layoutoverhead,the rationalisation
of the
carparkingspace became a demanding
project in itself in the early stages of the
development. Carparking and carpark
numbers inevitablywould be a trade off
against what's a practical structure to
support the overhead layout. Certain
areas of the plan (for an effective
carparking layout) became difficult to
utilise and counter productive and it
became apparent that the area under
Block A for instance and the ramp
entrances were not viable as quality
carparkingspaces. Early discussionwith
Dublin Corporation's Building Control
Section resulted in the adoption of a
concrete carpark base surface.
DESIGNPARAMETERS
Aoaatmenta
Doad Load
200 H.C Llnil
65 Sqeed
Fini6hes
Altemativ€
D6ad Load
150 H.C.Unil
kN/nr.
2.56
1 56
Courtvard
Dead Load
kNlflf
20
10
Imposed
Partitions
--77kN/m"
3.0
lmposed Load
kN/m'
lmposed Load
kN/m'
4.1
Ground Floor/ Ofiice€ & Shoos
D6ad Load
kN,h,
200 1.1.C.
unit
b5 SCtOed
Finishes
lmposod Load
2.56
1.56
0.50
4.6
Imposed
Pafitions
----
50
1.0
kN/rn:
lmpos€d Load
kN/m'
300 H.C. Unit
3.55
BS 5400 Bridge
LOAO
HA
120mmScreed
50 Sand
100 BlockPaving
2.76
0.90
1.80
90
BLOCKEF
RetainedFacade
Block EF is situated at the South East
cornerof the site and was the first block
to begin constructionin June 'l996. The
new structure was buili within the
confinesof the existingstone walls and
accommodates the
lrish Distillers
Whiskey Museum at Basement,ground
and firstfloors and 36 apartmentsabove.
Extensivereuse has been made of walls
and features remaining from the
Distillery.
The existingstonewallsaverage
approximately650mm in width and have
been retainedalong Bow Street and New
Church Street. Floor levels have been
arranged to suit previous window opes
which where necessary have been
slightly modified using brick and / or
stone salvaged from earlier demolition
elsewhereon site. Alterationsinvolved
the use of lime based moftars
sympatheticto the earlier construction.
The new building and existingwall are
treated as independentstructures but for
lateral restraint offered to the retained
BlockEF ApartmentBuildinqStructure
lsolated and combined pad foundations
rest on dense gravels with a design
allowablebearingpressureof 250 kN/mr.
Typically 400 square RC columns
support 660 x 465 O/A deep beams at
groundand first floors and 665 O/A deep
transfer beams at second. 200 deeo
precast hollow core units with 65mm
structuralscreedare usedthroughout.
l aq au aa A
u c^ .
I
Underpinning
was carriedout in standard
fashion to the level of the new
foundations. From the onset of the
kN/nf
lmpossd Load
kN/df
project the view was taken, considering
'1.5
200 H.C. Unit
256
95mm Screed
2.24
the good ground conditions, that
30 Asphalt
0.70
differentialsettlementwould be minor 80 lnsulation
010
50 Pea Gravel
0.90
the majority of which would be
200 Soil
3.60
50 M!lching
0.20
experienced
before
construction
10.3
1 5
At second floor level a loadbearing finalised.
masonry structure carries on from
transfer.215 wide walls are typically20N Walls were restrainedat each floor level
Designloadingsare set out in Table2.
at second and third reducingto 10N at by tying back to the underside of new
fourth and fifth to roof garden at sixth precast concrete floors. Threaded bars
Table 2. DesignLoadings
floor level. Vertical ties are provided were chemicallyanchored into stonework
throughout at appropriatecentres from and connected to mild steel angles.
TRADITIONALTECHNIQUES
transfer level and anchored into the sixth Further to tests by suppliers M12
floor roof structure. Columns and threaded bars where selected and
As with most old buildingsmany of these transfer beams are
designed as key embedded 200mm into stone at 1.2m
stone buildingswere builtand maintained elements
withstand accidental centres around the perimeter. These
to
with lime throughoutand materialssuch oamage.
gave a SWL in direct tension of c.15kN
as
limewash work
well
and
which is well in excessof 2.5oloof the
sympatheticallywith them. A basic
jFFi
i
I
: . - 1 , I**., --. : -.
limewash was used for many of the old
,-.
stone walls which were left exposed as in
the Museum building. The use of
modernconsolidants
was testedon many
of the old brick lining structuresto the
copper stills. However it was found that
the old lime mortartechniqueswere more
appropriate to the restoration of these
locally.
ROOFS
Root Garden
Dead Loed
r r '
i
, : l ' . '
-
- : r : t
i ; ;
The reuse of old cast iron columns for
structural purposes was an aspiration at
the outset of scheme development.
However, given the scale of the
developmentsoverheadand the extent of
dilapidationof the existing structure it
became impossibleto extensively reuse
these exceptin some nominalcapacityin
the Museumspace.
The steel trusses in the Museum roof are
termed "blacksmiths trusses" and are
copied in their detail from those which
had existed in the old Smithfield shed
locatedalongthe Smithfieldelevation,
5
- -rT;
'
lt,
1-.
J li#i rJ
ti,=
,&
J:J
CONSTRUCTION
:t
The various blocks are outlined here in
the order in which they were constructed
on site.
+'fe
Figure8 Block EF plan
nfr
e.
i
i
.'o ,
. "r...i;li I
' 't::.1-:.
j
I
connections are made. These beams,
orientatedat 45", extend out over the line
of fifth floor apartments and increase to
800 deep as they pass over 215 x 1000
RC piers and cantileveron to meet and
form the final corneroi the pyramidbase.
Figure9. Steel Towers
The L shaped portal base plates to
steelwork and have plates arranged to
allow bolts act in shear rather than direct
tensionalone when resistingwind uplift.
Towersare protectedagainstlightningby
earthing back to foundationsvia the RC
structure.
Museum ReceotionArea
Adjacent to the new apartment building
the original copper still and vat house is
now refurbished as the Museum
receptionarea.
ReceptionFloor
verticaf load {2.5o/ox 300 = 4.5kN).
Boltedconnectionswere madeonly after
the buildinghad reachedsixth floor level
and most of the expected differential
settlementexperienced.
Nonetheless,elongated holes on the
verticalleg of all restraintangleswere
provided to accommodateany further
seftlement,Repalrwork has beencanied
out to capingstonesand a fungicidial
treatmentappliedto arrestthe growthof
vegetation.The existingwall finishesto
iorm a parapetto the fourthfloor terrace
level.
New floor screedswere pouredright up
to the intemal wall face. Sound
insulation, preventing the travel of
airbome sound through micro cracks
longthe wall face was incorporated
into
-<he perimeter drylining using fibrous
insulating
material.
lnsulating.
apartments from air borne sound
emanatingfrom the WhiskeyMuseum,
ThemeBars and FunctionRoomsis by
meansof proprietary
acousticceiling.
Figure9. SteelTowers
DiamondCantilever
Features
A strikingfeatureon bothBowStreetand
New Church Street elevationsare the
cantileverorielwindows. Projecting2m
fromthe newstructure.
Thetriangular
RC
slabs,265 deepandtaperingto 125,are
verticallyalignedand cantileveroverthe
pavement below from second floor
upwards. Stone walls have been
curtailed
andtrimmedwitheitherstoneor
brick to allow these features protrude.
The exteriorsare clad with a glassand
aluminiumcladdingsystemwhich is in
contrastto the olderstonework.
Old brick "mash tun" foundations
consisting of concentric circular walls
have been maintainedand lie below the
new reception floor. The floor consists of
steel beams supported off short stub
columnson 450 square pad foundations.
Crane access was restricted within this
area due to the elements of older
structure being retained overhead. "Tee"
beam and block flooring were chosen for
its handleability.Sections of floor were
omitted to allow visitors view the features
below.
Vats
These"diamondcantilevers"
are topped
off with pyramidtowersat sixthfloor roof
levelwhlchserveas a secondlevelto the
fifth floor duplex units. The unusually
shapedpyramidtowersare influenced
by
the earliermentionedkilnswhichexisted
on site. Essentially
thesetowersconsist
of 127x 76UBportalframesarrangedin
pairsin each direction.Considering
the
difficult location the frames were
designedfor ease of erection. Eachof
the eight legs are connectedto a rigid
boxat higherlevelproviding
compression
and tensionrings which allow the full
momentcapacityof rafiermembersto be
realised.
Secondary rafters are
positionedat cornerscarryingtrimmed
cleader rails and define the pyramids
shape. Overheadthe 60 x 60 RSA box
frame lorms the turrets which house
water supplytanks for the apartments
withinthe pyramid.
At the foot of the pyramids215x300high
upstandbeamsare caston the roofslab.
Reinforcement
is lappedwith the mesh
screedto resistwind uplifi forces and in
additionthreadedbarsare droppeddown
through joints between precast units
where mild steel plate and bolt
and 6m in diameterhavebeencarefully
restored. These vats were previously
linedwith copperand exposedto intense
heatfor manyyears. Where necessary,
stainlesssteel rods have been used in
conjunctionwith repointing wofk to
stabiliseloosesectionsof brick.
At approximately
mid heightin the most
Westernvat a new floorwas requiredto
allowtour circulation.A 200 deep RC
sfab is supportedby 12 no. 450 x 200
keyswhichwere brokeninto the wall at
30" intervalsaroundthe perimeter.The
secondvat which was in considerably
better repair now houses a lift from
groundto firstfloorlevel. Thesupportto
thisfeaturelift consistsof an openframe
comprisingof 100 SHS bracedwith a
series of lighter CHS members.The
frameis furtherstabilisedand horizontal
minimisedby surrounding
the
deflections
shaftwith an RC spiralstairswhichties
togetherthe whole assemblyincluding
thevatwalls.
ExistingTimberTruss
Two large timber lattice truss are
composed of two separate trusses
arrangedside by side comprisedof 300
squaretop and bottombooms. Broken
into two spans,the trusstravelsthe full
lengthof the reception
area.
Vandalismand variousfires had caused
extensivedamage.Originallythis truss
carried grain storage over the "mash
thanits
tuns"below,far moredemanding
presentday requirement
to supportself
weight and a relatively light new
mezzaninestructure. No strengthening
workwas required.
Thetrusswas heldin placeby temporary
works during demolitionas previously
discussed
and builtintothe newstructure
as workprogressed.
--
wroughtand cast iron A-frametrusses.
The new roof over the receptionwas
modelledon this and consistsmainlyof
mild steelanglesections,flat platesand
solidrodsas ties. In total3 baysof truss
were used and supportedoff various
elementsincludingthe vat house wall,
existing steel plate girder, new steel
beamand the perimeterwall of the new
apartment
building.
AudioVisualRoom
room is a
The audiovisualpresentation
starting point to tours around the
Whiskey Museum and accommodates
200peopleseatedin a crescentfashion.
The stepped seating platformswere
designedto act as plenumfor the supply
of freshair. Forthisreasonhoneycomb
wall constructionsupports 240 x 44
The irregularshape in plan and the timbers at 400 centres and 12mm
number of objects which were to be plywooddeckingbetween.Holes have
avoidedbelowincludingbrick vats and beencut undereach seat to providean
air supply.
large museumpieces,(such as copper evenlydistributed
stills which were installedprior to the
Canopv
CourtEntrance
roof), complicated the structural Jameson
NewMuseum,
Roof
arrangement.
Coveringthe mainMuseumentrancein
Where Block GH is now locatedthere Internally
the roof is finishedwith timber Jameson Court this external canopy
originallyexisted a large warehouse whichis coatedwith intumescent
varnish consistsof galvanisedsteel plate rolled
buildingcoveredwithveryattractive
andslatedexternally.
to presenta curve which supportsthe
('l
gentlyinclinedglazing. This steel plate is
in turn supported at each end off vertical
RSC's which travel from concrete footing
up to the roof parapet. Mid span, the
curved plate is supported by 12mm
diameter tie rods inclined at 45" and
again connectedto the verticalchannels.
The RSC's are restrainedat parapet level
by connectingback throughthe Museum
wall to the new steel trusses behind.
Stone Buildinq
Considered as part of Block EF, the
stone building is shared between the
Whiskey Museum, Music Centre,
Smithfield Hotel and a separate office
suite. Originallythe building served as
storagespace for granularmaterialsand
final products destined for duty free
markets. The buildingis roofed by a cast
iron tank which held close to 4 ft. of
water, which served not only as a water
supply to the productionfacilities around
the Distillerybut also as a means of
maintaininga cool temperature in the
e+oresbelow.
The cast iron roof remainsnot only as a
roof and feature but as plant storage
space for the many new facilities - when
full this tank supportedapproximately12
kNim'?SWL. The tank was constructed
with individual 4 foot square cast iron
panels bolted together and sits on a grid
of primary and secondary girders.
Occasional panels have now been
removed to provide access to plant
space from a new stairs below.
and wall.
Structural topping was
delivered
via
concrete
pump
Throughoutconstructionthe tank served
as a lateral restraintat eaves level.
A new structurewas installedat ground,
first, and second floor levels and
opportunity was taken to reuse existing
650 deep steel beams at third floor level.
New opes were broken and lintels
provided,typicallylight UC sectionshave
been arrangedparalleland gap between
infilledusing brickand / or stonematerial.
All steelwork is protected for t hour fire
rating either by encasing or, where
intendedto remain exposed, by coating
with intumescentpaint.
Curved beams have been detailedwith a
straightinside face with varying links to
take up the curve. This alloweddetailing
the beam as straight thereby avoiding
torsionalcomplications.
LoadbearinqMasonry
Again 20N blocks support the precast
floor units at each level which reduce to
10N from fourth floor. Vertical ties have
been providedas per Block EF details.
Curved ExternalLeaf Blockwork
Builtwith a radiusof 12m along Jameson
Court, the perimeter edge beams were
cast within shuttering faceted in 1.2m
lengths.
Continuous stainless steel
BLOCK D
relievinganglesare providedat thirdfloor
level and supplied in 1.2m lengthsand
Block D Accommodates43 apartments mechanically fixed to the edge of the
and provides 500m2 retail space at perimeter beams allowing the external
ground floor level. Located on the leaf of block work to be constructed to
Eastern side of the site, apartments are b e a r o n t h e a n g l e ,e n s u r i n ga m i n i m u m
accessed from Bow Street. One side of supportof 80mm at all times.
the retail units opens out onto Duck
Lane, a reconstruction of a laneway Balconies
which previously ran through the
Distillery. The other side which is curved Balconieswhich overlookJamesonCourt
in plan forms the boundaryto Jameson are
platforms
essentially timber
Court, the newly formed courtyard area supported off 4 storey vertical towers
serving the Museum reception. A
made up of SHS and angle members.
noticeablefeature in this block is the Verticallyindependentof Block D main
retainedchimney,the second largeston structure, the towers are tied back for
site,
18'13
AD.
lateral restraint.
lated
A
common problem encountered
elsewhereon the site was also present at
the foot of the stone building. The many
brick service trenches, drainage and
smoke ducts which ran throughoutthe
distillerylay close to foundations. In this
particularinstancethey were found to be F i g u r e1 0 . B l o c kD P l a n
very low.
; first stage in restoring this building
Wdsto underpinthe stone foundationsto
a level so as not to be affected by voids
or proposed foundations and where
necessary infill ducts with lean mix
concrete.
ExpansionJoints
Along the southernline of Duck Lane and
for the full extentof the site an expansion
joint separatesthe North and South end
of the site from foundation level and
above. Precastslabs on Duck Lane bear
at one end on neoprene strips which
accommodate
small
horizontal
movement and reduce any induced
stresses.
Roof Tower & DiamondCantilever
BlockD is the most irregularly
shaped
structurewithinthe development.Fix x-x Roof tower and diamond cantilever
shows the more regular rectangular follows the same principles as those
portionwhich is presentfrom basement used in Block EF.
levelto sixthfloorroofgardenbehindthe
retained facade on Bow Street. ExternalTerrace Walkwavs
Sweepingtowardsthe centreof the site
Maintainingthe roof tank restrictedcrane the Westernleg of BlockD is curvedon Access to apartments on the curved
access and hindered installationof the all sides. commencing
at groundlevel portion of Block D is offered via external
structure below. For this reason a rather than basement,the structurefor walkwayswhich overlookDuck Lane. RC
system of 203 UC beams supporting this portionstepsin progressively
at each slabs are supported of galvanised steel
block and plank flooring was chosen. floorlevelup to fifth.
circular hollow sections.
Services
Block and plankfloors,250 O/A deep are
supported off the bottom flange of UC
sectionsand this minimisesthe structural
depth. Although consideredan internal
environment,any steelwork which enters
into or bears onto the existingstone walls
is coated with 2 layers of bitumen paint in
addition to standard specification End
planks are supported by angles with
vertical leg orientated upwards and
mechanically fixed with anchors at 400
centres. Reinforcement is welded to
provide a positive tie between the slab
Structure
RC isolatedpadfoundations
support400
diametercircularcolumnswhichin turn
supportthe transferstructureat firstfloor.
The irregularcompartment
layoutabove
did not lend itself very well to a typical
transfer beam system, an alternative
solutionconsisting
of a 300deepRCslab
actingas a "transferplate"waschosen.
feeding to these same apartments are
hung from the underside of terraces.
Terraces lead to the alternative fire
escaperoute by the existingchimney.
C h i m n e v( 1 8 1 3 )
The second largestchimney on site and
dated 1813was, despitesome superficial
defects found to be in good condition.
Signs of previous repair work were
evident including repointing and
circumferentialsteel straps. Towering at
I
33m the chimney projects 10m above
Block D roof level.
Excavations for Block D foundations
revealedthe brick chimneywas built off a
mass stone / rubble plinth extending
below the level of the new foundations.
The undergroundcarpark below Block
ABC which extendsas far as Duck Lane
meant much excavationin the immediate
vicinityof the chimneyfoundations. The
condition of the stone / rubble caused
concern and it was encased in concrete
on a piecemealbasis to allow work to
proceed. The chimneywhen considered
as free standing from foundation level
had a factor of safety against overturning
of 10 and mobiliseda bearingpressureof
700kN/m'?.
Earlier proposalsto provide an escape
route from the external terraces
mentioned above included steel stairs
around the outer oerimeter of the
chimney spirallingdown to Duck Lane.
Consideringthe irregularwall surfaceand
potential fabrication difficulties resulting,
but more importantly realising the
possible benefit of providing an effective
"wrap"aroundthe chimney,an RC spiral
stairs was chosen. The stairs, 175mm
waist and 200 deep landings,is tied back
to the buildingat eachfloor level.
the steel portalsrise 6m and are capped
with glazed turret pieces.
PerimeterWalls / Claddinq
The existingred brick wall further down
Smithfieldin front of Block GH has been
recreated in front of Block C for the
The rectangularcourt area bounded by Smithfield elevation and around the
blocks A & B was designedto provide Friary Avenue corner. Towards the
accessfor emergencyservices,including eastern end of Friary Avenue the
fire tenders, through the Bow Street Malthousewalls have all been retained
pedestrianentrance. 400 deep precast except for the gable ends. Walls have
units span 10m and were designedfor been extendedby up to two storeys using
parameters as specified in BS 5400 traditionaltechnioues.
Bridge Design - HA Loading. A 5m
diameteropeningis coveredwith a metal Fronting onto Smithfield Plaza, the
grille and contributes to the carpark sculpturecourt forms the main entrance
ventilationbelow.
to the development. Standing at five
storeys tall this curved elevation is clad
predominately
with glass.
GardenArea
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BLOCK ABC
Block ABC comprises 139 apartments
and 2,000m' retailspace at ground floor
level. Towards the front a sculpture
gallery occupies a double floor height
exhibition space opening up onto
sculpture court, the semi circular
courtyard onto Smithfield plaza which
forms the main village entrance. At
seventh floor level the double storey
tower features overlooking Bow Street
and Friary Avenue are the highest
residential units on the develooment.
The basement provides for liZ car
parking spaces and is accessed by a
separate entrance and exit ramp from
Bow Street.
Structure
Structural scheme is similar to other
blocks with RC frame at lower levels
supportingthe transfersystem at 1st floor
from where loadbearing masonry
continues. Again, throughouteach level,
steps in plan and externalterraces called
for numeroustransfers
Towers
At higher levels transferstructuresupport
the legs of the large tower structures8m
square in plan. Slightly different to those
discussedin Block EF these consistof 4
no. 400 diameterRC circularcolumnsuo
to 7th floor level which are framed with
RC beams. Anchoredto the RC beam
F i g u r e1 1 . A B C P l a n
Car Park Ramp
Car park exit and entry ramps both have
doublecurvaturein plan to sweeparound
the structure. 200 deep in-situ slabs are
supportedoff 300 wide x 1000 high side
wallswhich act as beams. The exit ramp
w a s l a i da t 1 : 1 0a n d e n t r a n c ea t 1: 9 .
Raised Courtvard
A central courtyard in Block C is formed
at second floor level over the sculpture
gallery exhibition space.
200 deep
precastunits span 7m and in additionto
garden finishes,support steel SHS legs
of the veranda which provides access to
apartmentsat 3rd and 4th floor levels.
BLOCK GH
Block GH was the last block to begin
construction.Accommodatinga 79 suite
hotel, theme bar and restaurant,music
centre with exhibition space and
auditorium. This block lies at the south
eastern corner of the site behind an
existing red brick wall leading ont.
Smithfield Plaza. Block GH can b.
separatedinto several distinct areas:
Hotel - which occupies the full front
elevation from sculpture court to
boundary.
Music Centre - circular drum structure
with conical roof between the hotel and
JamesonCourt.
Pfatforms consist of 125 x 64 RSC
spanning between SHS uprights and
support125 deep RC slab spanningonto
215 walls. Additionalrestraintis provided
by casting in M16 galvanisedthreaded
bars passed through the vertical web of
channellat 600 centres.
ConservatoryArea - glazed infill linking
the stone building, music centre and
hotel.
A sacraficalcolumn approachwas used
in the terrace slab design. Any one
column could be removed without
affecting the slab structure, thereby
reducing the need for expensive fire
protectionon externalcolumns.
For the more regular rectangulararea,
isolated pad foundations carry 400
diametercircularcolumnssupporting600
overall deep transfer beams at first floor
level.
Stone Building- as previouslydiscussed.
Hotel Structure
A full heightatriumis featuredin the hotel
entrance lobby where voids in the flat
slab above align to a glass octagon roof
lighi at sixth floor roof level.
Half BarrelRoof
Above the 5th floor penthouse the
loadbearingblock work and vertical ties
from below finish off in a 215 wide band
beam above which additional blockwork
iorms the curved roof contours. Stepped
blockwork supports galvanised steel
purlins and curved insulated sandwich
panels. The purlins are strapped down
via galvanised steel straps anchored to
RC band beams to resist possible uplift
forces due to positive pressure acting
throughthe large patio doors which lead
onto terracebalconies.
+
ExistinqBrick Walls
-he existing wall has delermined
.-domewhat the new floor levels, and in
order to maximisefloor to ceiling heights
'100
a thin floor plate was required.
deep
'l 00 structural
super wide slabs with
toppingspanning7.5m have been used.
Slab changesto 250 deep in-situflat slab
construction over by the irregular and
curved sections by the main entrance
and sculpture court where head room
was not such an issue.
Above the first floor transfer level the
struciure changes to 215 wide load
bearing block work. At each level the
floor plates described at first have been
repeated.
3rd floor level aligns closely with the top
of the existing brick wall, a terrace is
iniroduced here as the structure steps
back approximately2m continuingup to
5th floor level oenthousesuites.
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The existing red brick wall facing onto
Smithfield plaza dates back to 1895.
Once the perimeter wall of a newer
section of the distillery it has been
maintained but altered by cutting full
height vertical slots to allow general
This
access and light penetrate.
modified wall forms the basis for that
recreated on the Block "C" Smithfield
elevation. Boundingthe Eastern side, a
second wall with impressivearches and
circularopeningshas been retained.
The curved wall onto sculpture court is
clad with glazing to mirror that on the
Block "C" side.
At basement levels the theme bar and
restauranthave been steppedto form an
intermediate"lower ground" level running
parallel to the brick wall. This negates
the need to underpin allowing a load
spreadof 1:2" The 275 deep RC slab at
basementlevel has been designedto BS
8102 as Grade2 BasementusingType B
(structural
Construction
integral
protection).
At higher levels restrainingangles are
used to tie walls back to the new
structure in a manner similar to that
describedin Block E/F.
Music CentreStructure
The Music Centre drum is approximately
26m in diameter and offers music
performance, recording facilities and
exhibition space at basement, ground
and 1stfloor.
infilled with 200 deep concrete slabs horizontal service runs which vvas
reinforcedts form a tie beamaroundthe importantparticularlywithin the area
roofandfurtherstabilisethe structure.
occupiedby hotel suites where floor to
ceiling heights were critical and the
Audio visual equipment,camgrasand undersideof supenrideprecast slabs
lightinggear are all hung from rafters wereto formthefinalfinish.
inside.
CHIMNEY
The MusicCentreconnectsdirectlywith
the groundand secondfloorof the stone Builtin 1895,the largestchimneyon site
building. Existingwindowshave been standsat 42m abovegroundlevel has a
openedoutandwhererequirednewopes constant internal shaft diameter of 9ft
created. Connectionsto higher levels {2.74m)and externaldiameterot '14ft
are madevia stairswhichcurvearound (4.27m).
the perimeterof the MusicCentredrum.
Onceagainpadfoundations
support400 The RC stairswith 200 deep waist have Constructedwith red brick,cut graniteis
diameterRC columnscarrying600 deep beendesignedfor long spanscombined used at intermediatelevel and in
conjunctionwith cast iron plateat the top
RC beamsat groundand 1st floor. 300 withtorsionaleffects.
rim.
deep superwideslab floorsspanningup
Area- Structure
to 10m are usedthroughout.Slabsare Conservatory
Proposal
essentially100 thick precastwith 100
void formersand 100 structuraltopping. The basementlevel courgard formed
On the periphery
215 blockwalls,curved betweenthe site boundary,Hotel,Music The proposalhas beento providea glass
in plan supportslabs cut at a suitable Centreand the stone buildingremains panoramiclift servinga two storeyglass
viewingplatformlocatedon top of the
skew,in-situtoppingor smallinfillin-situ clearfor fullheight.
chimney. The platformis accessedat
slabsdefinethefinalshape.
This area has been covered with a the lower viewinglevel and visitorsca,.
Thesolidperipheral
wallsare considered sloping glass roof 15m above the take a spiral stairs up a furtherflight.*
to be inherently stiff and brace the basementlevel at the stone building Spiral stairs returnsdown throughthe
reducingto 5m at the hotelend. 3 No. shaft to provide an emergencyescape
structure.
800 deep steel latticetrussescomprised route,
ol 120x 80 and 60 x 40 RHS'sspanthe
ConicalRoof
12m length. Trussesare bracedusing
At 1st floor level the RC structure stainlesssteel cables and turn buckle
terminates and a steel portal frame components.Above this 80 x 40RHS
continues. The conical portal frame purlinsspan from truss to truss and in
consists of 406 x 140 UB rafters ontothe MusicCentrewall. The stepped
ananged radially at 45' and sloping flashingdetail along this curved wall
approximately 17",
intermediate providesa dry cavitybelowthe roof level
secondary rafters break ihe span of within the conservatory.Any steelwork
walls are
roofingdeck at lower levels. 406 x 178 which bears on neighbouring
withinthisdryenvironment.
UB stanchions(8 no.) are fixed to the contained
slabdirectlyoverRC columnheads.
Finallytheglazingmullionsystemis fixed
and
a walk-ingutterat the lowervalley
-
Figure13. SectionThroughGH
The future use of the auditoriumcalled
for the use of an acousticallyinsulated
roof. Many options were considered
including an RC shell, The final
constructionconsistedof a metal deck.
12mm ply, 25 pyrock sound insulating
board,50mm polystyrene,
30 pyrockand
roofingmembrane.
ServiceInteraction
Muchof the plantspacerequiredfor the
hotel was locatedremotely- within the
old cast iron tank above the stone
building,this reducedthe number of
structuralimplicationsassociatedwith
providing
largeitemsof plantat rooflevel
includingconcernsregards noise and
Eight rafters are connected to a vibration control. and increased the
compressionblock at apex consistingof numberof penthousesuites. To the
a CHS containingcircularplateswelded exterior of the stone building 900
in place. For purposesof design the diameterstainlesssteel ducts grouped
connectionis consideredto act as a pin.
togetherform a route for servicesfrom
roofleveldown.
At eaves level 203 UC's trim the metal
deck formingan octagonin plan - the Withinthe Hotel vefticalserviceshafts
outstanding curved areas were then have been arrangedso as to minimise
lnspection
A visualinspectionof the chimneywas
carriedout by examining
the internaland
external brick faces from a cage
suspendedoff one of 3 sitetowercranes.
Brick and mortarwere found to be in
goodconditionfor a structureexposedto
elementsfor over a century. Cast iron
cappingpiecesat the rim had conoded
and signsof damageby vegetation
were
evident.
l0
Structure
directions,frames are connectedto TemporaryWorks - The Design of
the chimney wall with M25 dividag Fagade RetentionSystems by Brian
'1996.
threaded bars passed through the Mahony
full wall thicknessto a MS plate and
bolt connection on the internal
surface,
To enhance the chimneys strength and
provide additional resistance against
wind moment, axial load and torsional
effects generated by the new structure a
125mm thick sprayed reinforcedconcrete
lining has been proposed. This lining
shall effectively form a stiff 2.74m
diameterpipe with a 125 wall thickness,
suitably reinforced the lining shall
transmit the torsional and bending
stresses induced by wind on the
asymmetric structure down through the
chimneys to a level where vertical
precompressionincreasescapacity.
placedon the internal
Reinforcement
vertical surface and steel threads
covered with protective membrane.
Sprayed concrete lining is applied
working upwards and finished with
timber float to provide a smoother
surface.
At the top rim the cast iron capping
pieces and damaged masonry are
removed, a new reinforcedconcrete
capping piece is then formed using
the refurbished cast iron plates as
permanentformwork.
4.
The two storey viewing platform is
erected at ground level, lifted into
place, and connected to the RC
liningand the externalsteelframe.
Finally lift installationand finishes
are fitted.
This remains the last element of
structural work to be completed. The
internalstairs is at this stage in place.
The walls will hopefully be concerted
withinthe comingweeks with completion
expectedwithin 2-3 months.
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The project has been an adventure. lt
has liftedthe area in generaland works
planned for ihe near future by various
bodies in the Smithfieldarea are now
very numerous.
When this project
started it was the vision, determination.
and ambition of the developer which
enthusedthe whole team. We thank all
those involvedwith what was an excitino
and rewardingproject.
DESIGNTEAM
'-'-,:5--*-
Developer:
HeritageProperties
Architect:
A & D Wejchert
Figure14. ChimneySchematic
The plannedsequenceof constructionis
as follows:
1.
2.
Centralspine ('193CHS) is inserted
throughcentralshaft,and 3mm steel
durbar plate spiral stair treads
attached and anchored into brick
wall. Horizontalgoing of treadsstop
short of wall to allow sprayed
concreteliningpass later.
At the Southernside, 533 x 19'1UB's
and 203 UC's are erected vertically
and carry the lift support and rail
assemblies. lntermediatehorizontal
frames providelateralrestraintin two
M&E:
Delap& Waller
F i r eC o n s u l t a n t :
Michael SlatteryAssociates
Archaeologist:
JudithCarroll
H o t e lF i t O u t :
Event
References
PublicRecordsLibrary
lrish Whiskey - A 1000 Year TraditionO' Brien Press by M Magee 1998
l 1