OrtOst-Fasad company often works with architectural decor of complex geometry and developed, detailed plastics. The company's specialists were engaged in the facing of such buildings as the Moscow hotel, the house on Trubetskoy, 28, the English quarter residential complex and the Italian quarter residential complex - they are ready to fulfill the complex tasks set by the architects. But even for this company, sophisticated in the manufacture of complexly traced forms, the task of facing the facades and interiors of the main temple of the Armed Forces became a challenge and a reason for new discoveries and inventions.
According to media reports, the entire work took 598 days, less than two years. Construction went on for a year and a half, and the facade cladding was designed and installed in eight months. The OrtOst-Facad company in a short time completed the most difficult - the most difficult task in the memory of its specialists - cladding of tens of thousands of parts, and developed an innovative system for fastening these parts.
But first, a few words about the temple
The Cathedral of the Resurrection of Christ in the Patriot Park is, at the same time, the main temple of the armed forces of the Russian Federation and a temple-monument to the victory in the Great Patriotic War. The building of the temple is surrounded by the museum's multimedia gallery "Memory Road" along the contour: it, in particular, contains photographs of war participants collected throughout the country. The height of the cathedral with the cross is 96 m, almost the size of a 30-storey building, and the quadrifolium of the museum gallery is about 500 m.
-
Image 
zooming 1/4 The main temple of the RF Armed Forces Photo © Archi.ru
-
zooming 2/4 The main temple of the RF Armed Forces Photo © Archi.ru
-
zooming 3/4 The main temple of the RF Armed Forces Photo © Archi.ru
-
zooming 4/4 The main temple of the RF Armed Forces Photo © Archi.ru
The building contains a lot of numerical symbols: the height of the bell tower means 75 years from the Victory Day; the diameter of the drum of the main dome is 19.45 m, which means 1945; the height of the small dome is 14.18 m, because the war lasted 1418 days; plus 1418 steps are required to walk the Memory Road Gallery from start to finish. The height of the temple together with the cross is 96 m, and this figure is no longer associated with the Great Patriotic War, but with the 960th year of the birth of Prince Vladimir Svyatoslavich, to whom the Lower Church is dedicated.
The RF Armed Forces Cathedral has four main prototypes: the Moscow Cathedral of Christ the Savior, the Nikolsky Naval Cathedral in Kronstadt, the Alexander Cathedral in Sofia and the monument to the heroes of Plevna, all of which are listed on the temple's website. And if from the first he inherited the five-domed and cruciform volume, from the other two - the Byzantine exedra, from the third - the tower bell tower, then from the chapel - the approach to the material. The chapel-monument to the heroes of Plevna is cast-iron; in the 19th century, the metal chapel was an innovation, in addition, the material enhanced the memorial sound of the building, making it look like a large bell and a monumental monument, recall the monument to the millennium of Russia in Novgorod the Great, likened to a bell. It was the idea of the material that was used in the VS temple: on the facades of the museum and in the interior of the temple, you can see large metal bolts, and the color of the walls - protective, like that of armor - clearly indicates that we have a temple melted down from armored vehicles. In a metaphorical sense. As a kind of figurative opposite of cannons melted from bells. But the cathedral is not a chapel, and it would be unwise to build it entirely from armor.
-
zooming 1/4 The main temple of the RF Armed Forces Photo © Archi.ru
-
zooming 2/4 The main temple of the RF Armed Forces Photo © Archi.ru
-
zooming 3/4 The main temple of the RF Armed Forces Photo © Archi.ru
-
zooming 4/4 The main temple of the RF Armed Forces Photo © Archi.ru
Therefore, the architect Dmitry Smirnov used fiberglass concrete, mass-painted in a protective shade of green - like armor. But the sculptures are bronze, and part of the decor in the interior is also metal, with blue-blue enamel, reminiscent of a 19th century folding icon. So the "armor" also acquired a copper tint, being painted over with bronze paint on the protruding parts. It turned out something on the verge between protective metal and a sculpture-monument to the heroes. Most of the finely detailed decor is made of glass-fiber-reinforced concrete panels by OrtOst-Fasad. Everything looks very holistic, at first glance it is impossible to distinguish where there is SFB and where is bronze - from a distance the volume seems to be cast from solid metal, covered with patina and "polished" on the relief parts.
Non-trivial task
The volume, which is completely normal for a temple, has a complex shape: there are many turns, corners, protrusions, roundings, arches - all this requires the individual formation of each element, a careful study of the "cutting" of the facade and mating of parts, similar to a complex constructor. In addition, the facades are covered with ornaments, simple and complex, from order gables, archivolts and faceted columns to Varangian braids and striped embossed shading - which greatly complicated the task, since due to the detailed drawing passing from panel to panel, the issue of high-quality pairing of parts became especially responsible. And, as we remember, the deadline for the execution of the order was extremely short.
-
zooming 1/5 The main temple of the RF Armed Forces Photo © Archi.ru
-
zooming 2/5 The main temple of the RF Armed Forces Photo © Archi.ru
-
zooming 3/5 The main temple of the RF Armed Forces Photo © Archi.ru
-
zooming 4/5 The main temple of the RF Armed Forces Photo © Archi.ru
-
zooming 5/5 The main temple of the RF Armed Forces Photo © Archi.ru
Total
glass fiber concrete products - 22 935 pieces.
2243 of them are typed parties, 4043 - unique parts.
Manufacturing process
All elements are made on the basis of a single three-dimensional model of the building, broken down into separate parts. The work was carried out according to the spraying method, traditional for glass fiber reinforced concrete. Simple geometric elements, in particular smooth wall slabs imitating blocks of stone, were made in plywood molds. When translating the 3D model into working drawings, the fastening system was worked out, the location of the embedded parts was determined, then glass-fiber-reinforced concrete mortar was sprayed into the mold.
For parts with relief or complex geometric shapes, a model was first made, based on a three-dimensional model of this element, from gypsum or MDF panels, on CNC machines. For this, more than 60 CNC machines were involved. Next, a rubber mold was removed from the model, under which a rigid fiberglass base was made. Fiberglass concrete was poured into the resulting form, after installing the embedded parts. In this way, patterned decorative belts were made, framing arches, rows of ribbed rollers, decorative panels with biblical animals, quotes from the Bible or military orders. The dimensions of the parts were determined based on the architectural logic of the partitioning of parts and weight restrictions for transportation and installation. As a rule, they did not exceed two square meters.
-
zooming 1/5 The main temple of the RF Armed Forces Photo © Archi.ru
-
zooming 2/5 The main temple of the RF Armed Forces Photo © Archi.ru
-
zooming 3/5 The main temple of the RF Armed Forces Photo © Archi.ru
-
zooming 4/5 The main temple of the RF Armed Forces Photo © Archi.ru
-
zooming 5/5 The main temple of the RF Armed Forces Photo © Archi.ru
After the initial set of strength, the glass fiber reinforced concrete elements were removed from the mold, polished, and primed with a special deeply penetrating primer. After drying, the surface was sanded with an abrasive material and painted with a base color. The embossed surfaces were then painted with a metallized paint, after which they were patinated separately, dried again and finally covered with a protective layer of polyacrylic lacquer.
Coating samples have been successfully tested for weather resistance in temperate climates. The tests were carried out by the Center for Testing, Certification and Standardization of Functional Materials and Technologies (ANO TsISIS FMT).
Installation
For the innovative fastening methods developed by OrtOst-Fasad specialists for the Resurrection Church, see here. About the prospects for further application of the system - here.
Due to the tight deadlines for implementation, the work was carried out simultaneously on several tiers of the building, on several "grabs" in each tier. About 800 installers were involved at the same time, they worked around the clock.
Director of the company "OrtOst-Fasad" Muslim Aliyev:
“For the organization of installation work in this mode, taking into account the complex configuration of the building, non-standard solutions for the configuration of the scaffolding were used - multi-span support trusses, consoles, suspended scaffolding, the organization of unloading platforms on the scaffolding, the elements to which were lifted around the clock by four cranes. Also, I cannot fail to note the work of the heads and specialists of the technical customer, technical supervision, FGAU "UISP" of the Ministry of Defense of Russia, and the authors of the project, "Sretensky Architectural Workshops". Without their prompt and effective participation, the implementation of the project within such a timeframe would have been impossible."
-
zooming 1/4 The main temple of the RF Armed Forces Photo © Archi.ru
-
zooming 2/4 The main temple of the RF Armed Forces Photo © Archi.ru
-
zooming 3/4 The main temple of the RF Armed Forces Photo © Archi.ru
-
zooming 4/4 The main temple of the RF Armed Forces Photo © Archi.ru
Note that for architects working in traditional styles, the quality of the details is an important component of a successful project. If in past eras the end result depended on molders, and the order decor and stucco molding itself were made of stone, brick or plaster, now fiber reinforcement, digital three-dimensional models, and programmed machines come to the rescue. Which, however, does not mean that the solution is simple: Even with the support of modern technologies, a lot of attention to detail is required, the experience and professionalism possessed by the specialists of the OrtOst-Facad company, who have completed a very difficult task in a very limited time.
