FENIX: impressive steel structure with 3D curved elements 

An impressive steel structure has risen in the port of Rotterdam: FENIX. A new museum that focuses, through art, on the theme of migration. The project, realized by CSM Steelstructures, includes 2,100 meters of curved tubes, reflective stainless steel, wooden finishes and double-curved glass panels, and presented many technical challenges. Through tight cooperation with all construction partners and the use of advanced BIM software such as Rhino, Grasshopper, Tekla Structures and Trimble Connect, the complex structure was realized step by step.

FENIX and the Tornado

The design is by MAD Architects, which came up with a striking Tornado construction, consisting of two spiral staircases that cross each other. These stairs symbolize the movement of migrants: meeting and parting. CSM Steelstructures began work on this complex steel structure in the middle of the early 1900s warehouse in 2019. It was not designed for such heavy and large structures. This required great attention to the integration of new and old elements.

Technical challenges

The Tornado structure, with its large spans, required innovative engineering. The architect wanted as few visible supports as possible, which increased the complexity. Working with IMD Consulting Engineers, CSM Steelstructures decided to use a space-frame structure, using 3-D curved tubes as the basis. "This enabled us to realize the large spans of the spiral staircases without compromising the stability of the structure," says project leader Andreas Vermeeren, working at CSM Steelstructures.  

Pointcloud connects old with new

To accurately map the existing building, a full pointcloud of the shed was created. This detailed digital representation of the existing concrete structure gave the team a realistic model of the space, which was essential for developing a workable 3D model for the new steel structure. "This technique allowed us to seamlessly plan and precisely match the integration of the new structure with the existing shed," said Robin Hurkmans, project engineer at CSM Steelstructures.

Unique materials and detailed workmanship

The steel structure is sheathed in reflective stainless steel, giving it a modern look, while inside the Tornado are wooden elements that reference Rotterdam's shipping history. The roof is covered with double-curved glass panels, a technically challenging choice due to the complexity of the geometry. These materials and finishes make the project not only architecturally , but also technically very impressive.

BIM-driven design 

The project team made extensive use of BIM technology, with Rhino, Grasshopper and Tekla Structures at its core. Parametric design with Grasshopper allowed the complexity and variability of the 3D structure to be modeled efficiently. The final model was uploaded into Tekla Structures, where it was further developed for production and assembly. "This working method ensured a perfect matching of the different materials and an error-free design," said Hurkmans. 

"Tekla Structures played a key role in aligning the models of all external construction partners and generating detailed production drawings and NC files," says Lisa Luys, project engineer at CSM Steelstructures. "This facilitated production and ensured that everything was delivered on time and to specification." On the construction site itself, Trimble Connect was used to visualize the 3D model and verify the correct dimensions. "Thanks to Trimble Connect, all the necessary data could be consulted directly on site, which greatly accelerated the assembly of the complex Tornado structure."

Clash-free integration

BIM was essential to FENIX's success. By modeling the project in 3D, the construction partners were able to identify and solve potential problems from the beginning. Hurkmans explains, "This type of project is impossible to execute efficiently without BIM technology. BIM works as a crucial tool to control everything from the right materials to the clash-free integration of different models."

Despite the complexity of the project, there was always trust and open communication. The rapport between the architects, engineers and builders made it possible to successfully realize a technically challenging design. "This is something we can be really proud of. FENIX is a calling card for our craftsmanship and the knowledge of our team," Vermeeren said. Last spring, FENIX opened its doors to the public.