Massive Glass Curtain Wall Gives New Dallas Cowboys Stadium a Signature Glow

An architectural and engineering marvel, the new $1.3-billion Dallas Cowboys Stadium in Arlington, Texas, is the largest NFL stadium in the world.  The 2.3 million square-foot stadium has an approximate capacity of 80,000 and the flexibility to accommodate up to 100,000 fans for special events, including Superbowl XLV in 2011.  The stadium features signature monumental arches, an expansive retractable roof, glass retractable end zone doors, and the world's largest center-hung video screen. But perhaps the stadium's grandeur is best exemplified by the venue's stunning glass skin, the dominant visual feature of the stadium. Sloping outward at a 14-degree angle and soaring 86-feet-high, the massive curtain wall is sure to capture the attention of approaching visitors.
    Architects at HKS Inc. and Cowboy owners the Jones family had a distinct vision for the stadium's icon aesthetic, and the striking curtain wall was conceived as both a functional solution and design focal point. The owners wanted to provide additional concourse width on the upper levels of the stadium to accommodate the greater seating capacity on the higher levels.  That idea developed into the outward-canted exterior when the architects determined that the 14-degree angle would allow the concourse on the upper levels to be wider than those on the lower level.  And, because it would stick out further, the upper level would block out the sun, shading the levels below it.
    The owners also wanted the people inside the stadium to have the feeling that they were in an outdoor stadium, so the glass skin needed to bring in subdued natural light.
    The glass aesthetics were also a crucial component of the design. As the home of the storied Cowboys franchise, architects and owners wanted a stadium that would complement the Cowboys silver, blue and white colors.  They also sought an aesthetic that would change colors at different times of the day to represent the different aspects of the Cowboys organization.  In addition, designers wanted the stadium to project a subtle shine during the day and a warm glow at night.
    Creating this unique aesthetic was a true team effort.  Viracon worked closely with Haley-Greer, the architectural team, and the Jones family to select a glass, coating, and ceramic, frit pattern that would create the desired performance and aesthetic.
    "This was a unique job, as we were searching for both a specific color and a specific texture for the entire 86-foot wall," says Garret Henson, director of sales at Viracon.  "Over the course of two years, we provided hundreds of different samples with various combinations of glass substrates, coatings and frit patterns.  The details were crucial in creating the icon aesthetic specified in the design."
    Ultimately, the owners and architects selected Viracon's VE1-52 clear insulating glass with a custom silkscreen pattern for the curtain wall.  The insulating glass configuration and the VE-52 (Low-E) coating contribute to the stadium's energy efficiency; the coating also gives the glass a subtle silver-blue sheen.  The ceramic frit pattern on the number two surface of the glass configuration helps create an every-changing visual statement.
    "Depending on the sun's position, weather conditions, and the angle from which the stadium is approached, the glass aesthetics will change," says Henson. "The color shifts from blue to neutral silver, depending on the different lighting conditions. This is a perfect fit for the architects' design intent and the color palate of the Dallas Cowboys organization."
    The fritted glass wall transitions up the elevation of the building, with a 90-percent density at the bottom of the venue and graduating to a 30-percent density at the top. At night, the color rendering is neutral, which allows the silkscreen pattern to come to life and provide a graduated glow to the facade.
    The more than one million pounds of glass in the curtain wall is supported by approximately 450,000 pounds of steel in an elaborate framing system designed and installed by Haley-Greer Inc.  Each of the 5,071 glass panels arrived at the site completely fabricated.  On-site, the panels were lifted by crane to installers, who were situated in the basket of a material handler.  Installers then had the challenging task of jostling each panel into place so that it landed at the correct angle. Because each piece of glass has a unique ceramic frit pattern, installers also had to match each patterned piece to its correct location in the wall, which required tremendous coordination between the fabricating and installation teams.
    "We worked with Viracon due to the complexity of the project," says Mike Harvey at Haley-Greer.  "They were able to partner with the design team to develop a palate of colors and textures that would meet all the design elements. The expectations were high and they delivered. They designed a complex pattern of frits (both dots-on and dots-off) that allowed the glass to gradate from the bottom to the top of the stadium. This gave the design team the desired effect they were looking for. Due to Viracon's vast product offering and creative design work, everyone involved is extremely pleased with the end result."
    With construction now complete, the years of design and construction have paid off.  The Dallas Cowboys are ready to welcome the NFL and fans around the world to this stunning structure.