Resolving Complex Geometries for Iconic Towers: Combining Unitized and Stick Built Curtain Wall Systems in High-Rise Designs

Presenter: Manan Raval, PE – Partner – Building Envelope/Facade Engineering, Hatfield Group Engineering

This session will explore curtain wall detailing, fabrication, testing, and installation oversight strategies for resolving complex geometries involved in iconic high-rise tower design that combine stick-built and unitized systems. It will begin with a general overview of the key differences between stick-built and unitized curtain wall systems, covering the pros and cons of both in terms of water and air barrier performance, schedule and cost efficiency, quality control, installation time, construction equipment and labor demands, and inspection requirements. It will also explore why, though unitized curtain wall systems are typically preferred for high-rise design, combining unitized and stick-built systems can yield better performance and aesthetic results, and how by rationalizing the facade design the systems can be combined effectively. It will also provide valuable insights into economical procurement options for curtain walls, as well as the structural performance of curtain walls and how various anchorage systems affect it. The presentation will also explore common pitfalls in curtain wall installation that threaten to compromise building performance and strategies to overcome these issues, which include installation errors, gasket and seal degradation, and sealant issues. The presentation will conclude with a discussion of a case study, Halo Tower in Newark, NJ, a high-design three-tower development that includes Newark’s tallest building. The tower gracefully combines unitized and stick-built curtain wall systems to achieve its complex geometries, which include distinctive facade slices, stepped terraces, inclined glass panels, and curved glass elements.

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