The dome is an elliptical shaped octagon so all the sides are not equal. The unique shape of the dome created a set of challenges in the fabrication process and installation of the locking panels. At the base of the dome exists a 20 ounce copper inlay gutter that ties into the first row of flat locking plumb panels. The next 5 rows of flat locking panels pitch inward about 10 degrees creating some tapered panels. The following 6 rows of flat locking panels pitch inward about 60 degrees coming to a center point creating even more extensive tapered panels. One of the 8 sides has a dormer that rises above the peak creating more custom flat locking panels. All the valley, ridge cap, door, window, stock and tail flashing interlock with the flat locking panels creating several hand formed lock seams.

Once the dome was installed Brady Air added a 20 inch wide, 32 ounce copper skirt covering the turning ring at the base of the dome. The installation of the skirt was performed from a basket suspended from a crane. As per the specifications and details, very little solder was used throughout, relying on the location and direction of the locking seams for water proofing.

Brady Air Conditioning’s work began in May 2011 and was completed in December 2011. The 64-ton dome was placed on top of the windmill on September 12, 2011.

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Li Ka-Shing Center
UC Berkeley

The 210,000 square foot Li Ka-Shing Center for Biomedical and Health Sciences consists of 6 levels of research and teaching laboratories, as well as lecture halls and seminar facilities. It also provides highly specialized areas for instrumentation and containment spaces to handle viruses and stem cell cultures. Lean construction techniques and sustainable environment design features for energy efficiency were integrated throughout the project.

In the course of the project, over 3600 RFI’s and 211 supplemental instructions were issued. The magnitude of changes resulted in a 94% increase to the contract value, while only adding a few months to the project schedule. The project required over 70,000 sheet metal detailing, fabrication and installation hours to complete.

In order to incorporate the essential systems and amenities, intensive 3D coordination required multiple disciplines to handle the complex structural, mechanical, electrical, plumbing, fire protection and architectural systems. Total sign-off of the coordinated drawings mitigated nearly all trade conflicts and associated costs during the construction phase.

The unique and highly specialized facility required extensive air filtration systems resulting in uncommonly large ductwork and equipment. Many of the exhaust fans on the roof were in excess of 25’ tall and some of the ductwork was sized at 120” x 66”, large enough to drive a car through. Due to the nature of the systems, all of the ductwork required external reinforcement in lieu of internal stiffening. The sheer size and weight of the systems complicated all aspects of fabricating, mobilizing, handling and installation.

One of the largest challenges was the combination of a complex structural system with oversized equipment and duct, which required complete coordination between the entire team. Throughout the erection of the structural steel, AHU’s and fans had to be set within the structure on the lower levels. The roof ductwork and equipment was also set strategically with structural steel as the two were intertwined and could not be completed independent of each other.

A zero lot line and a highly secured perimeter with one entry and exit added complexity to site logistics and required extensive coordination between all trades. Additionally, the site location at the University of California, Berkeley provided unique demographic challenges and required vigilance from all personnel.

Despite all challenges, Control Air North’s collaboration with the other sub-trades, general contractor, owner, architect and engineers allowed for the successful incorporation of unique materials not to mention quality and craftsmanship for the state-of-the-art research science facility. The success of this project is a testament to the extensive coordination from the Control Air North detailing department. Lead detailer and 25 year sheet metal worker Mike Renslow considered The Li Ka-Shing Center his most inspirational project based on its unique complexity.