The future of glass – examples of innovative

products and forms

Peter Tückmantel
Hunsrücker Glasveredelung Wagener GmbH & Co. KG
New Products & Applications

Glas Wagener, Glaswerke Arnold, Germany

Keywords
1 = Freeform 2 = Laminated glass 3 = Cable net structure
4 = Bird-strike 5 = Structural glazing 6 = Hybrid

Abstract
Of the many interesting developments
in the field of glass, such as coating
technology or adaptive systems, three
topics are of outstanding importance:
• laminated glass, see figure 1
• glass constructions, particularly with
adhesions, see figure 2
• free-form surfaces, see figure 3

In order to carry out all-glass

constructions, special sticking
techniques are needed to an increasing
degree. Moreover, considerations for
the security of the system become more
and more important. Laminated systems
are of crucial importance for safety. Figure 1: Figure 2:
They enable us to work with high-tech Hologaphic elements inside the glass, (Artist: Canteen Dresden, (Architect: Maedebach, Re-
connection techniques and make it Michael Bleyenberg, picture [1]) deleit und Partner [2], execution: Glas Wagener
possible to take various design elements [3]
into consideration. Furthermore,
technical aspects such as energy
production by use of the photovoltaic as
well as sun protection can be taken into
account.
Protection of birds by use of the
innovation Ornilux is another safety
aspect.
Finally, free-form surfaces demand high
standards to planning and execution,
especially concerning the transformation
of the already complex glass topic from
relatively simple geometric tasks to
complex spatial solutions. Such free-
form surfaces can be realized with
trussed frameworks. There are already
many excellent solutions using such a
kind of structure. However, it is also
possible to realize this by use of a cable
net which is shown below.

Laminated glass:
Toughened safety glass (ESG) and
toughened safety glass with heat
soak test (ESG-H) are important,
indispensable products. In fact, in many Figure 3:
cases in which float glass is used it Cable façade Heinsberg (Architekt: Dörstelmann [4], execution: Glas Wagener [3])
would be wise to substitute it by the
– admittedly more expensive – ESG-H, therefore laminated glass will become layered elements become thinner and
especially in public spaces. Toughened state of the art. This means that we thus more economic. As a result, the
glass, however, is a product, that can need laminated safety glass that allows fields of use for such glasses will grow.
always be destroyed by a spontaneous the post-breakage splinters to stick to In many cases, the use of laminated
break and in that case there will be the PVB interlayer. Today it is possible glass is of further interest because of the
splinters of glass. More and more and beneficial to take the shear strength added value of “safety” or “design”:
people want to reduce this risk and of the interlayer into account. The multi- Assuming that a solution for a glass

152 GLASS PERFORMANCE DAYS 2009 | www.gpd.fi

plate with bearings at two sides is
needed and one decides to work with
laminated glass for aesthetic reasons
this involves an increased safety level
of the construction – on the basis of a
realistic calculation of the construction
of course.
Why then should one for aesthetic
reasons decide to use laminated glass

New Products & Applications

instead of tempered glass?
Laminated glass permits the use of
colored foils. In addition, it also permits
to incorporate various interlayers such
as metal (fig. 4), stone, wood, woven
Figure 4: Figure 5:
fabric (fig. 5), and glass – in particular:
• holograms, see figure 1 laminated glass, wire mesh – with sun protec- glass with textile and other fabric interlayers,
tion, Glaswerke Arnold [1] Glaswerke Arnold [1]
• coloured slotted glass, tinted glass,
see figure 6 and 7
• dichroitic glass, see figuere 8
• photovoltaics, see figure 9
• integrated elements such as LED,
projection surface, Visionar by
Glaswerke Arnold etc., see figure 10

Some of the possibilities mentioned

here are presented below, see figures 1
and 4 -14
In general, laminated glass has to
be produced with laminated safety
glass qualities according to the german
standard VSG.
Extremely interesting is the fact that
by using the technology of multi-layered Figure 6:
elements it is possible to realise over- detail of slotted laminated glass, [1]
sized formats and to combine small and
thin formats to a bigger and solid unit. Figure 7:
Furthermore, different colours can be
Project: Novartis, Basel: Façade with color glass,
combined like a mosaic – this could not [1]
be done with coloured foils. There are
no limitations regarding UV persistence.
Tinted glass has a special effect when
it comes to colour and deepness. It
can be used for exterior and interior
applications.
Two aspects are primarily important:
protection and stabilization of the
interlayer material. See fig. 6. For
renovation for example you need light
materials. If you need a stone façade
you can use a laminated glass-stone
system. The stone could be very thin
and light, maybe therefore translucent
and porous. The porous stone is
Figure 8:
protected by the glass.
It is possible to produce standard IG- dichroic glass, Artist: Michael Lapper [1]
units and also multiple IG-units.
As an addition to the topic “metal
and glass”, metal elements can be
laminated between glasses or onto the Figure 9:
glass by using an interlayer material like Photovoltaic and coloured glass. Modules semi-
SGP or PVB, see figure 11 – 12. What transparent, g-value 10% [1]
loads a steel glass laminate can bear is
shown in figure 11.
Backpoint [5], see figure 13, is a transparency is achieved. If you compare
point-fixing which is integrated in the such knots with the solution at Dresden
laminate. This fixing is also attached to University of Technology you will notice
the outer glass pane with a transparent a significant difference, see Figure 2 and
adhesive. Because of this durable 16
connection an additional mechanical
safeguarding is not necessary. Bird-strike resistant glass
Figure 14 shows a connection
ORNILUX is a specially developed
technology of glass transoms and glass
impact-resistant insulating glass that
pillars. Metal elements which are joined
can be used in all window or façade
together and screwed together by
Figure 10: installations, just like conventional
bolts are brought into the laminated
insulating glass. The Max Planck
glass, thus an essential increase of display wall, Glas Wagener [3]

GLASS PERFORMANCE DAYS 2009 | www.gpd.fi 153

 Institute for Ornithology supported the
development of ORNILUX by conducting
extensive field testing in the Radolfzell
Bird Sanctuary to investigate a bird’s
ability to recognize glass sheeting.
Based on these test results, ORNILUX
can now be recommended to architects
or builders to minimize the effects
of bird-strike in buildings with large
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glass installations – without requiring

the use of visual barriers which can
be disturbing to people. There is a
significant reduction of bird strike of
-76%. The thermal insulation properties
are the same as a modern IG-unit –
because it is the same unit, only with Figures 11-12:
an additional feature.Ornilux is a very metal glass laminate [1]
important innovation, bearing in mind
that in Europe 250,000 birds per day
are killed by bird-strike, compare figure
15. [6]

Whole glass constructions

Whole glass constructions [7, 8]
by themselves are not unusual
constructions any more. Various
solutions have already been brought
about, for example by the following:
• Canteen Dresden, Architect
Maedebach, Redeleit & Partner
• Bathing Badenweiler, Architect:
Architektengruppe F 70, [9]
• Marktkirche Essen, Architect:: Gerber

These constructions still contain a

certain amount of steel although it was
reduced as far as possible. This was
achieved by an intelligent design which
uses the potential of adhesions. Glass
constructions completely without steel
over the floor plate have been done
before, too. Such solutions, however,
only make sense for subordinate Figure 13:
applications, e.g. if no insulating backpoint [5]
glasses are needed. If insulating glasses
are needed the renunciation of steel
elements is still possible but generally
dispensable for economic and also for
aesthetic reasons. [10], [11], [12]
Figure 15:
Mensa Dresden Bird impact on a façade
with conventional – con-
Because of the available heterogeneous cerning the protection
of birds – IG-units. Glas
structure with different styles, a Wagener built this con-
connecting nondirectional glass struction before Ornilux
construction should work out the was developed [3]
previous inner courtyard as a heart
of the complex above a central meal
serving area. See Figure 2 and [13], [14],
[15]
A roof as flat as possible was desired
on a construction that only appears to
be a carrier rust. The carrying structure
is, however, a hierarchical construction.

Figure 14:
connection technology glass beams and tran-
soms: metal elements in the laminate [3]

154 GLASS PERFORMANCE DAYS 2009 | www.gpd.fi

 New Products & Applications
Figure 16:
check of the glass carriers at TU Dresden

The basic unit is a ladder-like truss.

There are transparent, continuous,
main carriers which are approximately
6 metres long. Three secondary beams
are attached bend-resistantly and
stabilizing between the main carriers. Figure 17:
The beams between the ladders are Roof construction of canteen, Dresden (Architect: maedebach, Redeleit und Partner [2], execution:
articulated connected with joints for the Glas Wagener [3])
taking up of tolerances and temperature
stretchings. To obtain the appearance
of a carrier rust, a special knot was
developed.
The area around the corner of the
glass court with burden concentrations
was decisive for the dimensioning of
the glass pillar. The necessary height (35
cm) and composition of the carrier (4 x
12 mm toughened glass, only the inner
plates carry) were transferred to the
complete carrying construction because
of the required uniform appearance.
A german ZiE was necessary for this
construction. Three tests in the original
size have been carried out to scrutinize
the carrying capacity, another three to
examine the remaining post-breakage
structural capacity. As one result, the
breaking load turned out to be the 4.5-
fold calculated load, see figure 16.
The profiles which have been
attached to the top edge of the carriers Figure 18: Figure 19:
with silicone DC 993 ensure the linear Marktkirche Essen (Architekt: Gerber [16], ex- Marktkirche Essen, detail (Architekt: Gerber [
bearing of the insulating glass units, ecution Glas Waganer [3]) 16], execution Glas Wagener [3])
the second sealing level and the joint
drainage. All contact surfaces of metal
and glass were separated by elastic under one steel sub-train between Hybrid glass constructions and glas
layers. This project is an example for the wall pillars of the church. The two beams
a new approach to constructive glass lateral half-frames made of steel run
The combination of steel and glass
engineering where the construction into the main profiles of the roof area
will have to be improved in the future,
design is subordinate to the architectural right-angledly and are connected to
primarily in hybrid solutions. To some
concept. In order to enhance the spatial these bend-resistantly. See figures 18-19
extent first solutions have been
effect, a display of the power flow is and figure 15.
found (fig 21), e.g. in the museum in
deliberately renounced. [8] See figure The load of the roof glazing is
Nürnberg, see figure 20 and [19].
17. partly routed into the glass wall. The
Façades conventionally are built for
connection between the glass wall
instance with glass supports or steel
Market church, Essen and the steel supports must be built
supports which are connected with
horizontally shiftable. The steel supports
The magnitude of modern sticking the insulating glasses through point
cannot take on any forces from the
techniques becomes even more evident holders or an adhesion. Through this
wind load. The wind loads are derived
by regarding the building project of the combination the transparency can be
by the structural glazing adhesion of
market church of Essen. increased and in addition an optimum
the horizontal joints downwards into a
The filigree steel construction could of safety and economic viability can be
steel profile. Because of bad weather
not have been calculated confirmatorily attained. [20]
conditions the adhesion had to be
without glass as a primary carrying or There are first researches in this area
carried underneath a housing on the
stiffening component or without the by various research facilities e.g. at
construction site. For more details see
adhesive devices. The two main profiles University Duisburg-Essen and Dresden
[17] and [18].
made of steel go on the outside of the University of Technology to find a
front up to a height of +10.0 metres systems solution to possible façades.
and then at an angle of 90 degrees To demonstrate the potential, first

GLASS PERFORMANCE DAYS 2009 | www.gpd.fi 155

 possibilities are shown in pictures 21
and 22. See also the whole glass carrier
in fig 23.

Free-form surfaces
Free-form surfaces make additional,
very high demands on the planning
process. This is to be explained by the
following three examples for different
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projects: the glass construction at the

project Novartis, Basel (architect: Gehry),
a villa in Moscow (architect: Zaha Hadid)
and the SPK Heinsberg (architect:
Dörstelmann).
Complex geometries, e.g. freely
formed areas, are realizable today since
the required planning programs such as
3D programs are now available. These
make the draft and the realization
possible in the first place. There should
be a continuous chain of process from
the the architect finding the form (e.g.
with programmes like Rhino), the work
of the engineer (keyword: distribution
of forces) and the detailled planning to
production and installation. To reach the Figure 20:
highest quality an additional controlling Museum Nürnberg with hybrid carrier. Glass takes on strengths – a very transparent solution, (Archi-
by the architect and the engineer should tect: Volker Staab, Berlin, Hybrid by Glaswerke Arnold [1], picture: Margherita Spiluttini)
be existing in the execution because
even by most exact planning tolerances
on the construction cannot be
avoided (for instance by the size of the
dimensions). Hereby a controlling circuit
arises which includes all performances
and executives. Working with complex
and complicated shapes and forms
means that it will be essential for the
success to work with a real fitting
solution.
A comprehensive planning is vital
which takes into account as early as
possible essential boundary conditions,
for example production necessities,
which make the complex spatial
organization possible and allow a Figure 21: Figure 22:
necessary later detailled planning and hybrid carrier and whole glass carrier [20] hybrid façade, with triple insulating glass, Ucw =
whose results tie into the complex 0.79 W/m²K by Glas Wagener [3]
planning. The distribution of tasks and
information to everyone must be done
easily. The functionality must be perfect
since an improvisation has to be avoided
by all means.
At the project “Novartis, Basel” for
example the architect [21], [22] specified
that all planning had to be done
mandatorily in CATIA [23] – if necessary
as an addition. See figure 24 -25.
Supplementary measures like the
digital visual façade measurement are
part of the optimized process besides
the continuous use of planning tools like
CATIA, assuring that for example the
glass will fit perfectly. See figure 26. The
data flow for the construction software
of the element manufacturer and the
planner is also guaranteed. Together
with the 3D-Software the architect gets
the possibility to do a very exact design
– regarding all other conditions and in
collaboration with other planers.
For a construction such as the villa
in Moscow, see fig. 27 - 29, such a
photometric measurement of the shell
or also of finnished partial performances Figure 23:
is simply the best solution to achieve
whole glass beam – or column. Limit load approx. 75 kN [3]

156 GLASS PERFORMANCE DAYS 2009 | www.gpd.fi

 New Products & Applications
Figure 24:
CATIA in use, CATIA model Novartis Basel (archi-
tect Gehry [21] and ANW [22]], execution plan-
ning: Group5F AG [23])

highest precision, this system allows

to guarantee the highest accuracy
level possible. This is particularly the
case in the rehabilitation area and
at an increasing use of industrially
prefabricated elements to the façade
facing. As a consequence, elements
with minimal tolerances then can
be fastened with minimal tolerance
elements on the shell. Compensation Figure 25:
elements can be kept small and thus the the glass ceiling Novartis, Gehry Building in the making [3]
detail solutions can be very exact. This
method is decisive also at the marking-
out of the fastening elements at the
construction since error-prone and time-
consuming individual records of detailed
measures become obsolete. Most
difficult geometries can be included
even in a complicated environment.
This makes good economic sense and
provides additional information.

Integrated project execution

Like FE programms make it possible
for the engineer to calculate complex
geometries and situations, 3D programs
and especcially CATIA allow architects
and engineers integral implementation Figure 26: Figure 27:
of all performances and a profound, Digital measurement, [24] CATIA model villa Moscow (architect: Zaha Had-
exact planning – indispensable at id [25], execution planning: Group5F AG [23])
complex geometries [26]. CATIA is much
more than a standard 3D programm. For
further information see [27].
The transfer possibilities, for example
the possibility of the transmission
of Rhino files, are important. The
integration of additional crafts is
holistic up to the facility management
because an optimization can be made
by the complete illustration of the
house technology, the façade and
the shell. As an example the project
Novartis can be mentioned again.
By the highly complex illustration of
all elements it was possible for the
architects to give full particulars of the
entire design up to the tiniest screw.
The individual planning was included
in the complete model and tuned to
each other optimally. Furthermore,
modern CAD systems make component-
oriented construction methods possible.
Besides geometry further information
like the composition and qualities of
the components are being processed.
The connection between different
information and information levels are
essential! The evaluation and handing
over of data into other programs are Figure 28:
Rhino model, villa Moscow (architect and rendering: Zaha Hadid [25])

GLASS PERFORMANCE DAYS 2009 | www.gpd.fi 157

 therefore also possible, for example into
an FEM or a program for calculating
heat requirement or into a 4D expiry
simulation.
Real holistic solutions are possible
here. The draft by the engineer goes
with the design of the architect.
These procedures are already standard
processes in industrial design and in
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automobile manufacturing. The house

actually becomes a machine – however,
this does not mean it was developed as
a soulless, purely functional machine for
industrial means – in fact it means that
the emotional and aesthetic aspects,
the “human needs” and human
culture as the essential functions of a
habitat which means more than mere
protection can be taken into account
comprehensively.
After the drawing-board the 2D
solutions will disappear and be replaced
by 3D solutions. This will be effortful
at first, however, the added value will
even in the medium term lead to better
solutions also at less complex tasks.
To make the continuous planning
and execution possible, the architect as
the one who is permanently involved
Figure 29:
in the project or also a consulting,
specialized planning office should twisted transoms, SG glazing, steel construction, project Moscow, execution Glas Wagener [3]. See
[28] for further possible solutions of such structures.
carry out the care of the data and its
coordination with all facilities. Here the
planning team (wing assembly planner,
house technician, light planner, building
physicist, fire protection expert etc.) is
of a great importance again, too, since
the different approaches of the architect
must be coordinated efficiently.
It is important that the form of such
a “free” form area is never a pure end
in itself. It is not that free at all.[30] It
is parametrized. It is modelled after Figure 30:
nature’s organic forms. But one should bridge A8 Wendlingen/Kirchheim, design and
be aware of wrong connotations: engineering Schlaich Bergermann and Partner,
[29]
It is not about a put-on friskiness,
“organic” ornaments and ameba
structures. Nature is not that way that the world, that space is bent.
either – on the contrary, it is extremely We also quite certainly see and feel
efficient: enormously complex, always that the shortest connection between
new, always growing but never going two points is not necessarily always
“broke”. How does nature pull this a straight line, for example when we
off? By adapting to its surroundings, enter the motorway and accelerate: life
is a clothoid, a curve with determined Figure 31:
by fitting-in and efficiently using the
forces that affect it and converting parameters therefore to be chosen Heinsberg, detail [3]
information – and by finally prevailing. consciously, just because there are
Nature is not free: The organic forms of laws of nature. It is nice anyway that
nature are pure function. Ben van Berkel engineers and architects can meet and
once said: “Form must be loaded with argue splendidly here again. Animated moved back covers the prominent
information! If the form is nothing but forms are in no way simple, neither location is emphasized.
formed I’m not interested in it.” [31] concerning construction nor physics and There is a steel cable level for
See also figure 30. This is decisive. Of by no means from an intellectual point horizontal burdens and a glass level
course it can also be several, different of view. Today they are a symbol of with a rope for the vertical unladen
forms of information, e.g. about the positive aspects of our time: Openness, weights. The distance between glass
flow of power the engineer is interested communication, individuality, flux and level and rope level is minimized (340
in, the communicative functions, the dynamics, tolerance, complexity. mm). An anti-dazzle device, the inner
beauty of proportions – and a medieval heating as well as an area absorber for
master builder perhaps would have Cable façade Heinsberg sound optimization are integrated into
agreed that he wants to give some the façade. Prestressed double ropes
Here, see figure 3 and 31, we are
information about God and the builders. form the steel cable level (2 horizontal
looking at a biaxially bent rope network,
So the form must fulfill functions and and 2 vertical ropes, diameter 16 mm).
measuring 29.5 x 18.0 m including
meet requirements. All senses have The two levels are coupled by bolts.
the edge disks, supporting point kept
to be appealed to. Information is also A sun protection was put together on
insulating glass. The façade is the
a statement in this context, and this is the outside. The façade is edged by a
conclusion of a customer hall like a
conveyed through emotions. We know winded, unhitched portal framework.
tense “cloth”. By a glass roof and glassy,

158 GLASS PERFORMANCE DAYS 2009 | www.gpd.fi

 All required calculations, the ZiE, For all ropes, different pre-loads References
experiments and detail developments developed: from approx. 20-40 kN [1] Glaswerke Arnold, Remshalden, Germany
were done by Glas Wagener. Three vertically to 130 kN (top) to 50 kN [2] Maedebach, Redeleit & Partner, Berlin
engineering offices were assigned (bottom) horizontally. [3] Hunsrücker Glasverdelung Wagener GmbH &
with the façade development by Glas For the assembly, a spanning plan Co. KG, Kirchberg, Germany
[4] Dörstelmann, Heinsberg, Germany
Wagener, the office Prof. Pfeifer and was developed. The most important [5] www.backpoint-system.de
Partner (statics), SUP (expert opinion) thing about that was to start at the [6] www.ornilux.de
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At undertow the rope net softens ropes – and then to assemble everything Sicht des ausführenden Unternehmens, pages
to a maximum flexing of approximate accordingly in a reversed order. The 277-306,
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Special laminates offer many
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appearing under strain must be adjusted
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The interfaces have to be managed. [25] Zaha Hadid Architects, London, UK
The forces were chosen to avoid limp
For planners, that means it becomes [26] Knippers J., Helbig T.: “Vom Entwurf bis zur
supporting cables among general load. Ausführung frei geformter Netzschalen – eine
increasingly important to coordinate
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and assemble the data of many facilities Sohn, pages 10-15
some failure scenarios had to be
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examined. The stability had to be
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[29] Schlaich Bergermann und Partner, Stuttgart,
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[31] van Berkel B.: Crystal Talk, BauNetz. www.
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[32] Professor Pfeifer und Partner, Darmstadt,
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[33] SUP, Darmstadt, Germany
[34] Becker Görz Meister, Hagen, Germany

GLASS PERFORMANCE DAYS 2009 | www.gpd.fi 159