Abrasive Waterjet Shop Teams with Architectural Firm to Create a Unique Parking Structure

When architects and designers from the firm of Spillis, Candela & Partners began to conceptualize the design of the Administration Parking Garage project in downtown Orlando, Florida, they wanted to create a unique structure that would be functional and attract attention. To accomplish this, they decided to create designs in the aluminum sides of the structure that were reminiscent of Vienna of the early 1900s. However, they also knew that in order to cut the designs, they needed a solution that was cost effective, quick, accurate, and would provide a smooth cut. With this challenge the design team contacted Advanced Technology Manufacturing (ATM), a Sanford, Florida-based abrasive waterjet job shop, to help respond to the project.

"We had a number of concerns as we began the project," said Tom Hyde, vice president of Spillis, Candela & Partners, and project manager of the parking structure job. "One of those concerns was the cut of the edges of the designs. From a safety perspective, they needed to be smooth."

"The firm first considered using lasers for the project but realized that abrasive waterjets would provide better detail and the best possible cut for the designs," said Stephen Buck, owner of ATM.

Abrasive waterjet cutting uses water pressurized to 60,000 pounds per square inch (psi), with a garnet abrasive entrained in the jet stream. The water is forced through a precision orifice approximately 0.013 of an inch in diameter. The water and abrasive mixture quickly and precisely cut materials such as aluminum, stainless steel and brass with precision accuracy of ± 0.005 of an inch. A cold-cutting tool, the abrasive waterjet leaves a surface free of a heat-affected zone (HAZ). By eliminating HAZ, abrasive waterjet users save time and money previously spent on secondary operations.

Abrasive waterjets also offer numerous benefits for the architectural and design industries. Omnidirectional shape cutting capabilities allow for cutting of complex shapes not possible with conventional tools or by hand. Waterjets are a more cost-effective alternative because jobs that may normally take several minutes to complete can be cut in just seconds for greater productivity.

The design concept for the structure called for openings with integrated detail cuts around the perimeter of the garage instead of the plain "prison-type" bars sometimes found in parking garages. "We needed to have openings throughout the structure for ventilation, and felt the traditional details used in many garages conveyed a 'keep out' message," said Hyde. "We wanted to generate a 'welcome' feel through the designs."

Working side-by-side with the architects and designers, ATM utilized a Paser® 3 cutting system from Flow International Corporation, Kent, Washington, to cut more than 280,000 inches of art deco designs. The project called for 65 percent material removal with numerous-sized cuts of decorative artwork, ranging from a 4 foot by 8 foot opening to stairwells that measured 20 feet across, and cuts in 119.25 inch aluminum panels to create twenty-nine 8 foot by 8 foot openings. As the project progressed and the designers saw what the waterjets were capable of, they decided to use the waterjets to cut the designs in the stairs.

"We saw a whole new paradigm in this cutting technology and decided to use the technique for cutting designs in the stairs," said Hyde.

The project was completed in April of this year as part of the DCC Constructors Design Build Team  on schedule and under budget. Since its completion, the parking structure has received publicity from local television stations and newspapers for its creative appearance. "The parking garage is truly a unique structure," said Buck. "From a production standpoint, the parts, pump and cutting head we worked with to create the structure were flawless throughout the project, and the ease of set-up of the waterjets gave us the flexibility we needed. Flow's waterjet equipment and technology worked beyond my expectations."

The versatility of abrasive waterjet technology is giving job shops a competitive edge by allowing them to take on projects they previously may have had to refer to others. Therefore, shops such as ATM are now able to complete a wider range of projects. In addition to the Administration Parking Garage, ATM works with sign makers, mechanical manufacturers and clients in the nuclear power plant and aerospace industries. But, half of ATM's business comes from Walt Disney World, for which ATM has used abrasive waterjets to cut mechanical parts for rides, decorative panels, vinyl flooring and 1/4 inch aluminum animal silhouettes for Disney's Animal Kingdom. Buck feels the key benefit his waterjet job shop can offer customers is the ability to cut materials that lasers cannot  a selling point that played a key role in helping the shop land the City of Orlando Administration Parking Garage project.

"There are some projects for which waterjets are simply the best cutting method because of the quality of cut you receive," said Buck. "Clients like Disney and designers such as Spillis, Candela & Partners will call with certain projects because they specifically want the state-of-the-art material cut with waterjets."

From an architectural perspective, Hyde and his firm were fascinated by what waterjets can do, and look forward to using the technology again in the future. "We learned many things from this project, especially about waterjets," said Hyde. "I feel there are many opportunities to use waterjet technology again for future projects."

Story used with permission from www.flowcorp.com