An Eye-Catching Penthouse Roof | Composites Manufacturing Journal


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Modeled on the angular wings of an F-117 Nighthawk fighter jet, a roof comprised of composite sandwich panels soars atop a lounge and deck above the penthouse of a Sydney, Australia, residence. Half roof, half sculpture, the construction, which was designed by Australian architect Richard Goodwin, isn’t merely eye-catching. It additionally reduces the constructing’s carbon footprint by channeling rainwater into floor degree tanks.
The roof options 1200 g quadriaxial E-glass/KINETIX epoxy skins with a 60 mm finish grain balsa core (150 kg/m3) fabricated by ATL Composites of Queensland, Australia.

“The fabrication concerned an inner metal skeleton, very similar to an plane wing spar association, with the composite panels forming the structural shell,” says ATL CEO Lorraine Duckworth. She provides that the design provided one of the simplest ways to convey Goodwin’s design to life – particularly a 17.5-meter-long cantilevered part.

“The challenges of weight, power and stiffness related to a cantilevered roof of this dimension made it a pure for composites,” she says. “With its distinctive form and related masses, it couldn’t be achieved with regular metal fabrication.” The balsa additionally gives wonderful hearth efficiency, in addition to sound and thermal insulation.

The roof options ATL’s DuFLEX® panels, which can be found in prefabricated kits. The corporate used scorching compression molding to fabricate the three.6 x 1.2-meter panels. Duckworth says this methodology will increase E-fiber quantity, producing panels with 62% E-glass fiber quantity by weight. It additionally saves time and assets. The panels have been completed with peel ply to guard the laminate.

“Time-consuming laminating, coring and vacuum bagging steps usually required to manufacture high-performance composites are prevented,” Duckworth says. “And materials waste, labor and tooling prices are additionally significantly diminished.”

As soon as cured, the roof panels have been reduce into the required part shapes utilizing a CNC router. Every pre-cut half remained connected to the panels with one or two small tabs to make sure they remained safe throughout transport to Azzura Marine in Sydney. As soon as there, the small tabs have been reduce, and the person roof elements have been eliminated and joined to the underlying stainless-steel body.



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