Terminal 3

Fraport AG

Summary

The ceiling of the "marketplace" is an architectural work of art weighing over 21 tons and consisting of around 3,000 individually bent aluminium tubes and three funnel-shaped design elements. The shiny anodized tubes add up to a total length of over 20,000 meters and were cut, bent and installed on site over a length of 94 meters and a width of 22.5 meters.

Services

Parametric planning, production, delivery, assembly (industrial climbers via partner companies)

Project manager

Christian Nochta, Peter Greskamp (Konstrukteur)

Client

Fraport AG

Year

2023

Innovative construction method for an icon at Frankfurt Airport

In 2022, Arnold was commissioned by Fraport AG to create an extraordinary 3D curved ceiling above the marketplace of the new Terminal 3 at Frankfurt Airport.

The vision of the LAVA architects presented us with special challenges:

  • The processing of around 3,000 individually bent and bright anodized aluminium tubes with a total length of over 20,000 meters.
  • The construction and erection of a supporting and substructure for secure fastening.
  • The construction and installation of three imposing, nine-metre-high design elements (drops), each weighing 4.5 tons, which direct the natural light from above onto the marketplace in a targeted manner

Instead of a traditional approach, in which each tube would have been individually planned in three dimensions, formed, anodized and then transported at great expense, our team opted for an innovative, resource-saving solution with fewer transports, lower CO2 emissions and more efficient project implementation: bending on site.

Bending at the scene of the event

To avoid transportation routes, we moved the production of the pipe elements directly to the airport. By transporting the pipes in a straight state, the transport volume was greatly reduced.

Using a specially developed free-form bending machine, we were able to shape the tubes, which were up to six meters long and already gloss-anodized, on site with a perfect fit.

Thanks to a special planning method in which a digital overall model is created (see parametric planning), the bending data for each individual tube was transferred directly to the bending machine. The actual bending process took less than 60 seconds per tube.

After a quality check, the Arnold team confidently handed the pipes over to the industrial climbers from Arnold's partner Gears. Due to the assembly at lofty heights, no elaborate safety scaffolding was required and there was therefore no disruption to other trades on site. 

Floats spectacularly, safely and firmly -
Ceiling sculpture at Frankfurt Airport

Parametrically planned - a sensible investment

Particularly for complex construction projects with many variables, we recommend not drawing each component individually in 2D, but instead creating all components digitally in an overall parametric model and linking them together.

Although planning takes a little more time at the beginning, this saves us considerable time and costs as the project progresses. This is because we can see every change, no matter how small, immediately and quickly calculate the effects on all other parameters. In comparison, manual corrections would be very time-consuming and almost impossible to achieve. 
 

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Drops transport the light

In addition to the substructure and the tubular ceiling, our team also planned and manufactured three funnel-shaped light-steering elements. For these, 1,700 triangular aluminum sheets, each of which is a different size, were precisely riveted together. From the top, they appear large-scale, while towards the bottom they become increasingly delicate and filigree.

The 1.5 millimetre thick sheets were painted dark on the outside of the funnels after anodizing.

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