Tag Archives: choosing metal

New Tech Resource: Oil Canning in Metal Rood and Wall Systems

Metal panels are ideal for roofing and wall applications as long as they are installed properly. Read the MCA paper on oil canning to learn more about different stages where oil canning may occur, including production, fabrication, installation, and more. Learn how to obtain information and minimize its occurrence. Read the White Paper > https://ow.ly/r28850VnNbS Photo Courtesy of MCA Member ATAS International, Inc. #metalconstruction

Metal Elevates this Airport’s Design

Inspired by the relentless Alberta wind, the Edmonton International Airport’s office and control tower soars with functionality, efficiency, and nonstop aesthetic appeal.

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Photos courtesy of MCA Member: RHEINZINK America Designed by DIALOG

The Winners of the 2024 MCA Design Awards Are In!

Every year, MCA’s judges are impressed with the entries. This year is no exception. View all the winners and tell us which you like the most in the comments!

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Congrats to the 1st Place Award Winners: 3A Composites, ATAS International, Inc., Kingspan Insulated Panels North America, Metal Sales Manufacturing Corp, Norbec, PAC-CLAD | Petersen, Sherwin-Williams Coil Coatings

Atlanta’s 1105 West Peachtree Mixed-Use Complex Features Extensive MCM Cladding

Taking up a whole city block in Atlanta’s Midtown, 1105 West Peachtree is a mixed-use development with a Class A 31-story office tower anchored by Google, the Epicurean’s 19 floors of luxury condominiums, the Autograph 178-key hotel, the nearly one-acre Sky Terrace and an amenity deck and green space connecting the three towers.

MillerClapperton fabricated and installed metal materials for the three structures, though the majority of the cladding construction firm’s involvement was with the 730,000-square-foot office tower.

In all, 59,800 square feet of Metal Composite Material (MCM) was designed for the building’s exterior, including office column frames, spandrels, and fascia for the balconies.

“The architectural intent was for the columns and spandrels to look like steel beams and this was achieved through a unique application of MCM in two custom colors and the shape of the panel profile,” said a representative from MillerClapperton.

The columns and spandrels were also specially engineered to work in sync with a custom dynamic RGBW LED façade lighting design highlighting the exoskeleton’s metal beams.

Due to the size and complexity of the project, the firm developed some customized fabrication and installation methods.

For starters, instead of installing the panels onto the substrate as is typically done, the column office frames were pre-fabricated in MillerClapperton’s production facility 20 minutes outside of downtown Atlanta.

Then the columns were installed as units as opposed to individual panels. A specialized equipment supplier was brought in to develop a unique method for lifting the large 14-foot-high units. To accommodate the tall height, the necessary adjustments were made along the way.

Four main columns running the length of the building from top to bottom contain horizontally connected spandrels on the South and North elevations for a total of eight.

The challenging project required a high level of communication and execution from the company’s engineering, fabrication, and project management teams.  Following a year of planning and design, construction took 15 months.

Noted amenities include a conference center, state-of-the-art fitness center, bike and car service, scooter stations, a valet, restaurant, and 20,000 square feet of grown floor retail, all 1,000 feet from the MARTA metro system.

The project picked up several awards including an Urban Land Institute Atlanta Excellence award and multiple Atlanta magazine Georgia Design Awards.

Planting Future Seeds, NC State Plant Science Building Features Extensive Metal Applications

Hosting one of the top ten best plant science programs in the country, the North Carolina State University Plant Science Building (PSB) is an exciting new 185,000-square-foot cutting edge facility in Raleigh.

Earning recognition with a 2023 Metal Construction Association Design Award in the metal composite category, the application of metal building systems in the research facility extends way beyond the high performing metal cladding. Metal sunshades, metal ceilings, exposed structural steel and metal greenhouse framing also boost performance, energy efficiencies and aesthetics for the LEED Gold building.

For this interdisciplinary science hub where students, researchers, professors and corporate agricultural partners study, collaborate and work to advance the state of the industry, Flad Architects was tasked with designing a building befitting of these cutting edge developments.

“The design strategy [for PSB] was developed around integrated system engineering addressing unique aspects of laboratory innovation to reduce energy use and the specification of sustainable materials for construction and finishes,” relates Chuck Mummert AIA, LEED AP BD+D, principal, Flad Architects, Raleigh.

@jkasephoto http://www.jkase.com Credit: Justin Kase Conder Copyright: © 2022 Justin Kase Conder Usage with express permission only.

A terracotta rainscreen wall system compliments the red brick vernacular of the campus and functions as the primary exterior cladding for the building’s two research wings while extensive high-performance glazing and curtainwall systems maximize daylighting, views and transparency for the building porch and social center connecting the two wings. Tying the design together, anodized aluminum finished composite metal panels highlight the main entry space and brings an innovative energy to the space.

“Composite metal panels frame the building’s ‘lantern-like’ structure that marks the entrance to the building and frame the terracotta and glazing with a dramatic prow-shape,” he explains.  

Aluminum sunshades contribute to the facility’s high-tech appearance and provide important solar heat gain mitigation, enhanced occupant comfort and reduced AC consumption and cost.

For the AGS Sunshades used on the south, east and west glazed areas of the building, the shading angles were analyzed with parametric modeling to optimize performance and create the bright, sunlit environment enjoyed by the students and research staff.

The metal theme extends to the ceiling system in the entry lobby and exterior porch. Combining the beauty of wood with the performance, longevity and low maintenance of metal, the Armstrong METALWORKS planks blend with the millwork used throughout the interiors.

“The wood appearance of the metal ceiling abstractly recalls the use of wood in North Carolina agricultural structures. Installed as the exterior ‘porch’ ceiling and lobby ceiling, the design intent was to create a seamless extension of the ceiling material from inside to outside,” states Mummert.

In addition to their high recycled content and acoustic-enhancing quality, the metal ceilings offer a clean integration of light fixtures and audio accessories, and meet flame resistance criteria. 

In addition to the MCM cladding, aluminum shading fins and metal ceilings, structural steel also plays a key role in the design.

Expressing the structural anatomy and skeletal system of the building, the exposed structural steel and steel framing on the rooftop greenhouses are finished in intumescent paint and a white powder coated finish, accordingly, to maximize sunlight reflection and views. For the structural steel, the intumescent materials also serve as fireproofing and occupy a smaller footprint, as compared to cementitious or low-density fiber spray fireproofing, cold formed metal framing and high-impact drywall furr-outs, which were not ideal for the research environment.

In the greenhouse, the slender structural framing maximizes sunlight, minimizes shadows and lends flexibility to the plant species that can be grown and studied in the facility.  

Steel is also used for the stairs, mezzanine framing and the central glass “lantern” structure, including the angled roof element which contributes to the lightness and simplicity of the design.

In addition to the efficiencies and functionality lent by the assorted metal applications in the facility, metal provides a nice contrast to the traditional, earthy materials of terracotta, brick and board-formed concrete site walls.

Texas A&M Rec Center Takes Home Top MCA Honors 

As one of the largest state universities in the country, Texas A&M University was hard pressed to expand its recreational services for its 69,000 enrolled students in College Station, Texas.

To fill the need, the new Southside Rec Center—with 63,500 square feet of indoor recreational space and 15,000 square feet of outdoor space—opened its doors in the late summer.

Earning accolades as the Metal Construction Association’s Design Awards Winner in the Single Skin Panels Category, the sleek structure features a variety of boxed ribbed metal panels, perforated metal scrim and single-skin metal panels.

“The variety of panels creates an energetic pattern across the façade, accurately reflecting the kinetic movement of the live oaks outside and the fitness activity inside,” stated Kalman Nagy, AIA, NCARB, design principal, SmithGroup, Dallas. “This varied pattern extends to other materials in the building façade, such as the vertical frit patterns on the glass and the horizontal reveals in the limestone.”

The architects designed the form as two high-bay spaces flanking a central spine where recreational activities are showcased, thereby engaging the campus at a pedestrian scale.

Metal was selected as a prominent material to complement the campus context and master plan design guidelines. For example, the Dark Bronze finish matches the master plan palette.

Overall, the architects successfully blend the flat composite metal panels and single-skin ribbed metal panels with a limestone and glass curtainwall exterior. Highlighting the combination of materiality and contrast between the stone and metal, the MCA judges were impressed with the detail juxtaposition and range of applications in the facility.

The team selected four different Petersen Aluminum box rib patterns in Dark Bronze to offset the patterns, articulating the building’s base, middle and top. While the patterns in the ribbed metal panels create texture, a change in the pattern’s rhythm emphasizes the transition from one section to the other. 

A perforated box rib metal scrim, located at the main entry plaza, mimics the expression of the adjacent live oak trees. And two different profiles and perforation sizes extend the façade’s visual rhythm, shading the entry plaza and glazing of the courts and lobby.

With the ribbed metal panels extending beyond the building envelope, the cladding transitions to perforated panels to balance shading, views, texture and depth in the façade. 

The single skin metal panels also add value to the building in lending support to the outdoor amenities, including a terrace, two volleyball courts and a turf area for fitness classes and functional training. The 12-inch-wide panels stretches off the façade that enclose the large 100-foot by 200-foot high bay for strength and conditioning and courts.

This large overhang provides shaded exterior space and daylight-protected glazing. High-performance glazing with integrated ceramic frit patterns and perpendicular shading fins further reduces heat gain while maintaining views. 

Also inside the rec center is a bouldering wall, locker rooms and a cardio mezzanine. “Minimal circulation space connects a variety of programs and is a good example of a simple design move with a big impact,” he said.

Showcasing the modest investment required to deliver a high quality, aesthetic building, Nagy again stated, “It’s a shining example of the power of simplicity and how an economical and common material thoughtfully designed to work with campus context can result in a truly beautiful outcome.”

Thirty75 Tech’s Animated, Shimmering Metal Facade

3075 OLCOTT STREET. SANTA CLARA, CALIFORNIA Architect – VDLA

Earning its latest accolade as the Best Overall Winner in MCA’s 2023 Design Awards competition, the dynamic and shimmering metal louvered façade at Thirty75 Tech in Santa Clara, Calif., is a sight to behold.

Custom aluminum extrusions form Brise Soleil, louvers that wrap the curtain wall. In addition to presenting an animated façade, the carefully calibrated louvers expertly shield the building from the California sun.

“The project explored the dialectic relationship between performance and expression: a dynamic façade that, while static in construction, changes based on the viewer’s position and daylight angle,” explains Verse Design Principal Paul Tang. “The complexity of the louvers is not random and is based on performative needs to mitigate heat gain and glare in what otherwise is an all-glass structure.”

Without it, the building would not have been able to shade the required 70 percent of the floor-to-ceiling glass to meet stringent Title 24 energy standards.

In order to achieving this performance target, the design team tested different louver shapes and sizes with the parametric modeling program Grasshopper. The louver length, width and rotation were tested and adjusted in relation to the shading values and evaluated within the context of the façade’s environmental impact on the office space, a landscaped entry plaza and the street.

Ultimately, an airfoil elliptical shape emerged as the best option for meeting all these goals.

3075 OLCOTT STREET. SANTA CLARA, CALIFORNIA Architect – VDLA

While terracotta was originally selected for the louvers, upon further exploration, the team discovered that terracotta would have been too heavy and costly to implement. As a result, metal was chosen based upon its visual experience and ability to add a finish coating for enhanced durability.

“A champagne-colored metallic paint on all louvers captures and reflects the changing daylight colors, providing visual variation not possible with terracotta,” notes Tang.

The architect’s vision and desired effect is a 3-dimensional interpretation of the “digital rain” concept from Matrix films.

The louvers are custom extrusions of Alloy 6005-T5 from Architectural Glass & Aluminum with a PPG Duranar Finish. 

To optimize shading, the design incorporates 28 unitized panel variations with each panel containing seven vertical louver units with some exceptions at corners. The louvers are offset by 5 degrees, rotating every 15 degrees, in six different angles, up to 90 degrees. Designed in depths of three, six and nine inches, each unitized panel is held together by a 4 in. x 6 in. x 3/8-in. aluminum angle frame attached to a catwalk.

Through the process of fabrication and installation, Verse Design worked very closely with AGA, Architectural Grilles & Sunshades, the fabricator and contractor as quite a number of modifications had to be made to make the Brise Soleil system installable.

“The process was not linear, and the team had to keep an open mind to overcome challenges. These challenges included changes to components of the system, methods of attachments and sequence of construction. A mockup was instrumental in identifying these challenges and experimenting with different solutions,” reports Tang.

In addition to creating a first-class façade design worthy of Class A office building, Verse Design also added an additional 33,000 leasable square feet to the original 200,000 square feet program on the two-acre site. This yielded $200,000 more in monthly rent than originally projected. 

Originally designed to house multiple tenants, Amazon ended up leasing the entire building which also incorporates a parking structure, EV charging, café, gym, basketball courts and putting green.

Photo Credit: Tim Griffith

Metal Clad Retreat Home Provides Fire Protection and a Beautiful Aesthetic in the Santa Monica Mountains

In the aftermath of the Old Topanga Fire, which broke out near Malibu, Calif. in the fall of 1993, more than 39,000 acres of land in Malibu neighboring Topanga burned, sending property values plummeting for several years. 

At the time, young architect Joe Day, AIA, and his wife were able to afford an empty plot overlooking the Santa Monica Bay in Topanga.

14 years later, now a firm leader with Deegan-Day Design & Architecture in Los Angeles, Day’s team finally completed the 4/Way 2,250-square-foot retreat home in this once again desirable location.

With fire protection top of mind, Day chose metal for the exteriors. A RHEINZINK prePATINA architectural-grade zinc clads the walls and roof. In addition to resisting fire and corrosion, the long-lasting material is fully recyclable and its dynamic patina will evolve in color over time.

Enhancing the home’s fire protection, steel trusses lend a unique interior aesthetic over the living spaces and concrete was selected for the base of the structure.

“Fear of fire, flood, slides and erosion dictate stringent setback, cladding and planting guidelines enforced by the state-wide Coastal Commission and by a myriad county and city agencies,” explains Day.

In addition, the home sits downslope from its neighbors, essentially making it the first line of fire defense for the community.

“A lot of the rationale for the house has to do with the idea that now we’re the outpost. If you can defend our property, you are defending five houses up the street,” he says.

The property’s surrounding terraces offer a series of outdoor rooms and act as a fire buffer as well.

Like a good neighbor, the design sits low enough on the ridge to preserve views for the homes uphill while showcasing the natural, mountainous landscape through large glass windows.

“To take advantage of a distant, but commanding view of Santa Monica Bay, the house folds across the grain of a steeply sloping ridge, ducking upslope neighbors and cutting into the hillside to cool the lower floor,” notes Day.

The name 4/Way House was inspired by the home’s four rotations.

• The first is a planimetric rotation approximately 18 degrees off the cardinal north-southeast-west to the southeast, toward the Santa Monica Bay view.
• The second rotation comprises the truss configurations that give the house its angular envelope, opening the house toward the view while also providing a faceted fire blanket for the house.
• The third orientation is the garage, designed to municipal specifications to potentially aid firefighters. It tilts 90 degrees upward and doubles as a movie screen.
• The fourth rotation references an internal ruled-surface rotation that governs much of the cabinetry and the transition between floors.

Ultimately, the raw concrete, exposed metal, zinc panels and birch plywood combine to display a beautiful, durable and protective interior and exterior.

WHY SHOULD YOU ATTEND METALCON?

Metal building, residential and roofing contractors, architects, engineers, developers, facility managers, fabricators and building owners from the US and abroad. Attend because it’s the only show of its kind in the world!

http://www.metaconstruction.org/metalcon

METALCON: OCTOBER 14-16, 2015 | TAMPA CONVENTION CENTER        Week1Post3

New Study Verifies Steel Roofs Can Last As Long As The Buildings They Cover: Typically 60 Years Or More.

Low-Slope-Galvalume Roof

By: John Ryan, Metal Construction Association

The cost of replacing a roof can be one of the most significant maintenance expenses in the life of a building. USGBC’s Leadership in Energy and Environmental Design building rating program (version 4) assumes a building service life of 60 years. With most types of roofing, building owners can expect to replace the roof once or twice in that amount of time, incurring significant expense to do so.

Many buildings are The Metal Construction Association (MCA) is proud to announce a new study that verifies that coated steel roofs can last as long as the buildings they cover. The research study concluded that the expected service life of an unpainted 55% Al-Zn coated steel standing seam roof constructed today in a wide range of environments using best practices can be expected to be in excess of 60 years.

Learn more about the study here, and access the full study and executive report in MCA’s Technical Resources  library.