10

TheStructuralEngineer
November 2014

Project focus
Arena Fonte Nova

Arena Fonte Nova,

Brazil: low prestress for a
lightweight roof
Jorge Chenevey Project Manager, RFR Stuttgart
Yu Hui Project Director, RFR Shanghai

SELLAR PROPERTY GROUP

Mathias Kutterer Office Director, RFR Stuttgart

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Synopsis

The new Arena Fonte Nova in Salvador de Bahia, Brazil offers an innovative
lightweight solution for a large-span roof. The spoke-wheel system is
enhanced by drawing on stiffness and load-bearing capacity from bracings
in the vertical plane of the tension rings and in the horizontal plane of the
compression ring. This allows prestressing to be reduced to 50% of the
usual level.
Other important features that simplify the design and reduce costs are
concave radial cables with compression elements, using fewer arches with
non-uniform membrane prestress, and a at overall roof slope. The low
prestress brings cost savings both by reducing the weight of all primary
structural elements and also by incurring smaller forces during installation.

Introduction
Design criteria for stadia have expanded signicantly
in the past 50 years: to the basic requirements for
stands and circulation has been added the need
for numerous extended features and facilities for
spectators around the sports venue. The stadium
roof, which must provide effective protection for all
stands against sun and rain, has become one of the
primary aspects of stadia design, in terms of both
architectural quality and cost.
An obvious criterion for roof structures, which
cover ever greater spans, is roof self-weight, which is
related to costs. In the past two decades, spokewheel systems have allowed designers to achieve
record-low self-weights for roofs spanning ever
greater distances. Work to develop and optimise
this type of structure continues, giving rise to a large
number of new and sometimes unique solutions
each year.
One such solution is the Arena Fonte Nova (Figure
1) in Salvador de Bahia, Brazil, which was inaugurated
in April 2013. The design of the arena, which hosted
several matches during the 2013 Confederations
Cup and 2014 FIFA World Cup, includes a lightweight
roof based on a spoke-wheel system. This relies
on the combination of a steel structure and cable
system with comparatively low prestress. As the
authors show, its hybrid structural system employs a
series of features that make the Arena Fonte Nova a
unique stadium, not least in terms of cost.
Background
On 25 November 2007, only a month after being
named one of the venues for the 2014 World Cup,
a tragic accident occurred at the existing Estadio
Fonte Nova, with the failure of part of the concrete
stands. The accident killed seven people and injured
40. Faced with the need to nd a solution quickly,
the authorities decided to demolish the old stadium
and build a new one, with a capacity of 56 500. An

TSE35_10-16 Proj Foc v5.indd 11

international design competition was launched.

The winning design was provided by German
architects Schulitz in partnership with structural
engineering rm RFR. The design included a new
lightweight roof, covering all the new stands, which
kept the original, horse shoe-shaped bowl with
an opening towards Toror Lake at the southern
end. The roof is supported by short columns on the
highest level of the concrete stands; the opening on
the south side required 13m high columns (Figure 2).
By the end of 2010, the old stadium had been
demolished, meaning the foundations of the new
Arena Fonte Nova could be built. The stadium is
situated near Pelourinho, the oldest part of the city of
Salvador and a UNESCO World Heritage Site.
Geometry
The Arena Fonte Nova is built on a north-south
orientation. The lightweight roof, which covers the full
perimeter of the stadium as well as part of the inner
area, is entirely supported on the concrete stands.
The roof structure, which is oval in design, is
approximately 260m long by 216m wide (Figure 3). It
is divided into 36 bays, while the concrete stands are
divided into 72 bays. Instead of skipping one axis and
only putting roof columns on every other concrete
column, the roof axes were shifted by half a bay and the
radial cables were split at the outermost node in order to
bring an equal load down to the two adjacent concrete
columns. This offset required the inclusion of split nodes
at each radial roof end. These transfer the loads from
the upper and lower cables to the concrete axes.
The inner part of the roof, covering the stands, is
clad with a polytetrauoroethylene (PTFE)-coated
glass bre membrane, while the outer part is covered
by a lightweight metal deck. Radially, the roof slopes
outwards by approximately 3.5 and 1.5 in the inner and
outer parts respectively. The south side of the stands
has a large opening, which the roof structure ows over
on long, slender columns.

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Project focus
Arena Fonte Nova

TheStructuralEngineer
November 2014

ERIK SALES-VANER CASAES AG. BAPRESS

12

Separation of skin and structure

The architectural preference for a low, at roof
without predominant structural elements, which
would integrate well into its hilly and densely
populated setting, led to a strictly horizontal threering system with a strong outer compression ring and
two inner tension rings.
The further geometric layout of the roof was
governed by several somewhat contradictory
criteria. Spectator comfort required the position of
the roof skin to be as low as possible, while structural
efficiency requires height. Other criteria dictating
the overall form and slope of the roof were the
aerodynamics and rainwater evacuation. To allow
the maximum amount of room for simultaneous
adjustment and optimisation of all these criteria, the
design team decided to separate the roof skin from
its supporting structure by positioning it midway
along the upper and lower cable chords (Fig. 1).
This meant that the skin surface would be at a low
level, providing the maximum amount of protection
from sun and rain, while the structural height between
the upper and lower tension ring could be increased
and optimised without any compromise (Figure 4).
Parametric approach
To accommodate frequently changing architectural
features, and to maximise structural optimisation,
successive calculation models were based on
several parameters, each entered as an independent
input, e.g. slope, convex/concave radial shape, height,
and bay division.
This allowed the team to easily produce, study
and compare a wide range of options. From the very
early stages, the slope was carefully assessed using
computational uid dynamics simulations in order
to provide minimum wind resistance while offering
an adequate drainage angle. The parametrisation
of the model also allowed control to be maintained
over each node and element numbering. This proved
to be of great benet when exchanging 3D model
information with the contractors.
The curvature of the radial cables turned out
to be one of the most interesting parameters in

TSE35_10-16 Proj Foc v5.indd 12

Figure 1
Arena Fonte Nova
roof viewed from inside

Figure 2
Longitudinal
section of stadium

Figure 3
Plan of roof
RFR

Designing a lightweight roof

terms of stiffness and efficiency. It was described

as the f/L ratio varying between concave and
convex in the range of 0.6 to 0.6 (Figure 5). The
output parameter was the deection under a
characteristic uniform load, measured at the tip of
the cantilever (black line) and at mid-span (blue
line). The mechanical interrelationship is clear in
the diagram. For the deection of the tip of the
cantilever, the best conguration is the one which
is almost straight the curvature parameter is
close to zero. For the deection at mid-span, it is
obvious that the stiffness increases in an almost
linear fashion as the curvature becomes more
and more convex. This is due to the direct load
path: a downward load directly activates the lower
radial cable whereas in a convex conguration
the load is rst transferred to the upper cable and
then, via a ying column, to the lower cable. The
dotted line, with a characteristic system change at
the neutral point (f/L = 0), represents a structural
system with tie hangers at the concave (negative)
range, whereas the continuous lines correspond
to a system with strut hangers in both concave and
convex congurations.
The best compromise for mid-span and end
point rigidity can be found somewhere between

f/L = 0.02 and f/L = 0.03, which corresponds to a

convex stitch of about 1m in both the upper and lower
radial cables.
Hybrid system
The roof is based on a closed-ring cable system
with a compression ring concentrating all the heavy
parts of the structure along the outer perimeter. This
principle the spoke-wheel system allows large
spans while keeping the self-weight down . Although
the principle is not new, the Fonte Nova stadium
roof is innovative due to the fact that it requires
considerably lower prestressing forces than previous
examples.
The compression ring is laid out as a two-chord
horizontal truss, providing high in-plane rigidity for
the entire roof system (Figure 6). This counteracts
the non-uniformity of the radial forces, which are due
to the oval shape in plan view and the non-uniform
distribution of wind loads.
The inner roof consists of two tension rings which
are tied in the radial direction to the compression ring
by a set of upper and lower radial cables. Downward
loads (e.g. dead load, rain and wind pressure) are
transferred from the lower tension ring (consisting
of three, parallel, fully locked 95mm diameter

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13

Figure 5
Convexconcave
study results

RFR

Figure 4
Typical crosssection of roof

Figure 6
Two-chord horizontal compression ring and two braced tension rings

TSE35_10-16 Proj Foc v5.indd 13


RFR

Membrane roof
Reducing self-weight in a large span requires a
cladding material which is light and exible, yet
strong and durable. Membrane textiles such as
PTFE-coated glass bre comply with all these
requirements: weighing only 1.3kg/m, PTFEcoated glass bre is non-combustible and has a
lifespan of 25 years. Some claddings are still in use
even after 30 years or more of service. However,
special care needs to be taken during handling and
transportation. Only limited folding of glass bre

RFR

cables) to the compression ring via the lower radial

cables. Upward loads (e.g. wind suction) activate
the upper tension ring (three, parallel, fully locked
70mm diameter cables) and the upper radial cables
(Figure 7). The tension rings are separated by 22m
tall inclined ying columns. To increase vertical
rigidity against non-uniform loads and to reduce
the required cable prestress level, the upper and
lower tension rings are braced by C55 cables which,
together with the ying columns, form a truss able
to take unbalanced loads. These bracings introduce
relatively high friction forces at the tension rings,
which are absorbed by strong clamp plates.
Similar stadia usually rely on very high tension to
withstand unbalanced loading. The hybrid system
of the Arena Fonte Nova roof, with vertical bracing at
the inner ring and horizontal bracing along the outer
ring, allows lower prestressing (half that of other

Wind loads
Stadium roofs which include form-found membrane
cladding rarely conform to the standard geometries
found in either the codes or the literature for
assessing wind loads. Factors such as roof shape,
concrete bowl shape, openings and scale of the
structure may result in incorrect assumptions being
made about wind load. In particular, in the case of the
Arena Fonte Nova, the large opening at the south end
of the stands meant that strong winds were expected
to be funnelled into the stadium, creating high uplifts
on the north side; these would not be covered by the
codes.
A wind tunnel test (Figure 8) was therefore carried
out by specialist engineers (Wacker Ingenieure,
Germany). Based on the architectural and structural
drawings, Wacker built a 3D physical model of the
roof and concrete bowl at its laboratory at a scale of
1:300.
The most important aspects of the stadiums
immediate topography were also modelled. Rough
elements on the tunnel oor were used to simulate
the wider surroundings in order to provide an
accurate assessment of the wind speed prole and
turbulence of the approaching wind. 450 pressure
taps were installed on the top and bottom surfaces of

the cladding.
The wind pressure coefficients obtained from
the test were later combined with the expected
reference pressure at the project location over the
structural life of the stadium, i.e. a 50-year period. This
resulted in a design gust wind pressure of 0.70KN/m
at a height of 40m. Wacker then produced a series of
plots showing wind pressure and wind suction from
eight different directions, distributed on roof loading
regions. The vertical loads were all multiplied by a
resonance factor of 1.05 a gure calculated from
the eigenfrequencies of the roof.
In addition, a study was carried out on the different
erection phases of the membrane roof. An installation
sequence was agreed upon with the membrane
contractor, and a set of wind loads was provided for
the chosen sequence. This made it possible to detect
critical stages and determine the sizing of temporary
bracing elements.

Figure 7
3D rendering of
structural system of roof

RFR

SCHULITZ

similar stadia), a signicant reduction in the total cable

tonnage, and the use of smaller and lighter tension
ring nodes. Machined S355 steel plates could be
used for these nodes.

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Project focus
Arena Fonte Nova

TheStructuralEngineer
November 2014

Figure 8
3D model
at 1:300 scale of
stadium within
wind tunnel of
12m length, 2.5m
width and 1.85m
height

Figure 9
Membrane
geometry isoheight
lines and lines of greatest
slope

RFR

Figure 10
Load paths within
typical panel unit (blue:
downward acting loads;
red: upward acting loads)

is possible or it may break. For the Arena Fonte

Nova, a type III PTFE membrane, with characteristic
strengths of 7000N/50mm in the warp and
6000N/50mm in the weft directions, was applied to
the whole roof. A series of tests was carried out on
the membrane to ensure that it met all performance
requirements.
Geometrically, the membrane roof consists of 36
bays each divided into ve panels. The low number
of arches per bay was compensated for by having
different membrane prestresses in the warp and
weft directions. This allowed an optimum double
curvature to be achieved for the effective wind
pressure and suction.
Each panel (except the rst and last) consists of
two arches in the ring direction and two radial trusses
on each side (Figure 9). Downward loads activate the
warp (radial) direction of the membrane, which in turn
introduces compression in the arches. For upward
loads (wind suction), the weft (tangential) direction
of the membrane is activated. This creates bending
in the radial isostatic trusses which transfer upward
loads to the ying struts in the direction of the upper
radial cables (Figure 10).

columns, the split cables at the end, and the truss

build-up of the compression ring together bring very
high fail safe redundancy to the structure.
In addition to the basic sizing of all elements,
with sufficient margin under the ultimate limit state
(ULS), several failure scenarios were considered:
failure of a lower radial cable; failure of one ying
strut; failure of one ying column; and failure of one
of the three lower tension ring cables. For each
individual scenario:

Robustness
The roof structure, with its two inner tension rings
connected to the outer compression ring, offers a
clear primary load path. Failure somewhere along
this path represents one of the critical scenarios.
However, should an element fail, the roof also offers
several alternative load paths: multiple tension
cables, the ying cross-bracing between the ying

Figure11 shows the effect of one lower radial

cable failing and demonstrates that the roof offers
alternative load paths while avoiding a clash with
the concrete stands.

TSE35_10-16 Proj Foc v5.indd 14

a non-linear analysis was run under a

corresponding worst load case
if the analysis converged (no geometrical
collapse), deections were veried to evaluate
whether the deformed structure clashed with
the surrounding elements (spectators, concrete
stands etc.)
a member check was then carried out on cables
(breaking load) and steel elements (plastication
or buckling)
in case of elements plastfying or cables
breaking, a second analysis was run with nonlinear geometrical and material parameters

Anticipated design life and maintenance

The primary structure was designed with a
minimum lifespan of 50 years. This was achieved

RFR

WACKER

partly by requiring a high level of corrosion protection

for all steel and cable elements. All steel elements
are protected with a paint system reaching corrosion
class C4H according to ISO12944. Cables are
GALFAN-coated with a minimum weight of
300g/m; this offers better corrosion protection
than zinc coating. The cladding was designed with a
minimum lifespan of 25 years.
A maintenance and inspection programme was
also developed. This provides core instructions for
ensuring public safety during use of the building. It
includes a description of the considered loads in
order to assess the structures alteration capacity,
e.g. to what extent audio and lighting equipment can
be modied from the initial design.
The maintenance manual also sets out a
detailed inspection schedule. This includes an
initial inspection, an annual general inspection, a
full inspection every six years, and an exceptional
inspection to be carried out following accidental
loading conditions, e.g. heavy storms close to or
above the 50-year reference wind speed. It also
describes critical details which require special
attention during an inspection (connections
under heavy loadings, cable clamps or water
accumulation on the membrane).
The maintenance manual is an essential tool
for guaranteeing good serviceability of the roof
structure.

Installation
Erection sequence
In order to provide access to the stands and pitch

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Figure 13
Installation phases

Figure 11
Check for
structural robustness

a) Start of
phase 1

b) End of phase
1 pinning of
upper system

c) Start of phase 2
ying columns in place,
lower system lifts off

RFR

Figure 12
Installation of freestanding compression ring

TSE35_10-16 Proj Foc v5.indd 15

RFR

RFR

d) End of big lift

prestress applied,
lower systems
pinned

as quickly as possible, the design team decided

to install the main structure using a lift operation
the rst time this had been attempted in Brazil.
The compression ring, which could be installed in
self-supporting modules, served as the supporting
system for the cable lift (Figure 12).
Before commencing the operation, the
compression ring was closed and all cables were
laid out on temporary platforms (Figure 13a).
The rst phase of the lift began by pulling on
the upper cables (radial and tension) and pinning
all radial split cables (Figure 13b). The next step
involved hanging ying columns and struts to the
upper cables (Figure 14). The jacks were then
connected to the lower radial and tension ring. Prior
to this, all pulling had been against the self-weight of
the raised structure.
The second phase of the lift began by pulling on
the lower cables which, via the ying columns and
struts, pushed the structure in the air (Figure13c).
A transfer of forces occurred at this stage between
the upper and lower tension ring (Figure15). The
ying struts were progressively connected as the
roof was lifted. Towards the last stages of the lift, the
double ring cable stiffness was activated and forces
increased exponentially (Figure13d). The progress
of forces in the tension rings and jacks can be seen
in Fig.15.
Once the lower cables were pinned, the structure
became self-supporting and secondary elements
(e.g. arches, gutters, the membrane and, lastly,
equipment such as audio systems, lights and video
screens) could be installed.

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Project focus
Arena Fonte Nova

TheStructuralEngineer
November 2014

Figure 14
Intermediate
stage of
installation
ying columns
being installed;
lower cable resting
on platform,
waiting to be
connected to ying
columns

RFR

Figure 15
Force
diagram of big
lift (red: upper
tension ring; blue:
lower tension ring

Figure 16
Jacking
forces for two
sequences (green
ultimately chosen)

RFR

RFR

E
Jacking strategy
The Arena Fonte Nova has only 36 inner roof axes and benets from a
comparably low prestress level. This made it possible to use 28 small
120t jacks and 8 220t jacks for the lifting operation. The jacking strategy
(Figure 16) involved:

Acknowledgments

pulling simultaneously on all axes until the structure could be pinned

dening the optimum pinning sequence by comparing different pulling

Client: Arena Fonte Nova consortium (joint venture between OAS and
Odebrecht)

scenarios
pinning the corner axes M2 and M3 with the taller 220t jacks

Conclusion
The new Arena Fonte Nova in Salvador de Bahia offers an innovative
lightweight solution for a large span roof. The spoke-wheel system is
enhanced by mobilising resources in stiffness and load-bearing capacity
from bracings in the vertical plane of the tension rings and in the horizontal
plane of the compression ring. This allows prestressing to be reduced
to 50% of the usual level. Other important features which simplify the
structure and reduce costs are concave radial cables with compression
elements, the use of fewer arches with non-uniform membrane prestress,
and a at overall roof slope. The low prestress level brings cost savings
both by reducing the tonnage of all the primary structural elements,
and due to the smaller forces involved in the installation procedure. The
project involved the use of 1300t of steel, 200t of cables and 28 000m2 of
membrane.
To contact the authors, email: jorge.chenevey@rfr-stuttgart.de,
yu.hui@rfr-shanghai.com or mathias.kutterer@rfr-stuttgart.de

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Architect: Schulitz Architects

Structural engineers: RFR Stuttgart

Main contractors:
Steel: Martifer
Cables: Redaelli
Membrane: Taiyo Birdair
Lifting operations: VSL
Supervisors:
Structure: Nelson Szilard Galgoul
Lifting: Schlaich, Bergermann und Partner
Membrane: Tensys
RFR team:
Project director: Mathias Kutterer
Project managers: Yu Hui, Jorge Chenevey Planella
Engineering: Yu Hui, Jorge Chenevey Planella, Michael Bauer,
Pranjal Saraswat
Draftsmen: Illya Osherov, Volker Hass, Hartmut Haker,
Ccile Gosselin-Neubert

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