metal architecture magazine - april 2011

A p r i l 2 0 1 1

Plus:+ AIA Preview+ Daylighting & Retractable Roofs+ IMPs Meet Building Efficiency Objectives

Expanded & Perforated MetalsAn in-depth look at its uses, plus featured projects

w w w . m e t a l a r c h i t e c t u r e . c o m

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www.metalarchitecture.com April 2011 METAL ARCHITECTURE 3

The snow has finally melted and spring is in the air. The days are longer, birds are chirp-

ing, and people are emerging from hiding after the long and cold winter. As spring warms up, I

know I will be getting out a lot more often and exploring all that living in a big city has to offer.

I will also be doing some traveling to other cities, including New Orleans for the AIA 2011

National Convention and Design Exposition on May 12-14 at the Ernest N. Morial Convention

Center. Drop me a note if you’re going to be there; I would love to meet up. Before heading to

New Orleans, be sure to check out our preview starting on page 34. Learn more about this year’s

convention, including recommended educational programs that will be of interest to the metal

architecture community and highlights of things to discover and explore while in New Orleans.

This month we focus on expanded and perforated metals. In “Choosing the Right Metal for

your Design,” on page 20, Bob Farber, president of the Milwaukee-based Industrial Perforators

Association looks at the differences between expanded metal, perforated metal and wire cloth.

Additionally, Expanded Metal Manufacturers Association member Rick Bahner with Expanded

Solutions LLC, Oklahoma City, discusses some of the many uses of expanded metals in “The

Versatility of Expanded Metal” on page 22. Starting on page 24, we highlight several projects that

feature expanded and perforated metals.

New this month is Ted’s Corner, a monthly column designed to showcase specific aspects

of using Metal Composite Material panels, written by Ted Miller, president of The Miller-Clapper-

ton Partnership Inc., Austell, Ga. Turn to page 16 to check it out, and see also the Market Report,

featuring the a backlog report, as reported by the Associated Builders and Contractors.

There are a lot of very exciting things going on at Metal Architecture. In June, we celebrate

our 25th Anniversary, so be sure to keep an eye out for that very special edition. Additionally, the

deadline for submissions for Metal Architecture’s 2011 Design Awards is May 6. Winners will be

published in the July issue. Go to www.metalarchitecture.com/contests.aspx to download the

contest entry form.

We are always looking for ways to connect with our readers. Check out Metal Architecture’s

new website at www.metalarchitecture.com to read our online exclusives, blogs and daily news

items covering what’s going on in the industry. Don’t forget to check out our Facebook page and

follow us on Twitter at www.twitter.com/MArchitecture.

Have a great spring and hope to see you at AIA!

Marcy MarroManaging Editor

Spring into Action

METAL ARCHITECTURE (ISSN-0885-5781) is published monthly by Modern Trade Communications Inc., 7450 N. Skokie Blvd., Skokie, IL 60077. Subscriptions are free for those in the metal construction industry in the United States. For those outside the industry, the subscription price is $45 per year, in the United States; $75, in Canada and Mexico; and $150 per year, in all other countries. Periodicals class postage paid at Skokie, IL, and additional mailing offices. POSTMASTER: Address service requested. METAL ARCHITECTURE, 7450 N. Skokie Blvd., Skokie, IL 60077.

Editor’s Corner

Circle #3 on reader service card.


v o l u m e 2 7 n u m b e r 4

April 2011Contents

32

56

features

Cover Story: Perforated & Expanded Metals

20 Choosing the Right Metal for Your Design Discoverthedifferencesbetweenperforatedmetal,expandedmetalandwire cloth,andlearnhowtochoosetherightoneforyournextproject.

23 The Versatility of Expanded Metal Learnaboutsomeofthemanyapplicationsofexpandedmetal.

27 Featured Projects

32 Light Up Your Space Therearemanybenefitstousingretractableroofenclosuresinabuilding.Inadditionto maximizingnaturallight,theybringinfreshairandgreatviews.

34 Special Report: The AIA National Convention: Reinvented and Rebuilt AsneakpeakattheAIA2011NationalConventionandDesignExpositiontakingplace May12-14attheErnestN.MorialConventionCenterinNewOrleans,including recommendededucationalprograms.

38 The Building Envelope—A Key to Energy Efficiency Bydeliveringmaximumthermalperformance,productsmadeforthebuildingenvelope,such asinsulatedmetalpanels,helpmeetbuildingefficiencyobjectivesandearnLEEDcredits.

departments

3 Editor’s Corner

8 Firm Strategies

10 LEEDing the Way

13 Industry News and Events

16 Ted’s MCM Corner

16 Market Report

18 Product Focus: Daylighting, Rainscreens, Moisture Barriers, Metal Tile and Shingles

40 Market Feature: Retail & Mixed-Use

55 Ad Index

56 Top Honors

38

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A p r i l 2 0 1 1

Plus:+ AIA Preview+ Daylighting & Retractable Roofs+ IMPs Meet Building Efficiency Objectives

Expanded & Perforated MetalsAn in-depth look at its uses, plus featured projects

w w w . m e t a l a r c h i t e c t u r e . c o m

On the cover: Perforated metal panels at The National Center for Crisis and Continuity Coordination. Photo courtesy of the Industrial Perforators Association.

40

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CMY

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lamtec ad full tab bleed.pdf 1/4/08 2:12:48 PM

5010 River Road, Mount Bethel, Pennsylvania 18343-5610Toll Free: (800) 852-6832 • Phone: (570) 897-8200 • Fax: (570) 897-6081

www.lamtec.com www.metalarchitecture.com April 2011 METAL ARCHITECTURE 7

v o l u m e 2 7 n u m b e r 4

April 2011Online Contents



CheckouttheNEW

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andseewhat’shappeninginthemetalarchitecture

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8 METAL ARCHITECTURE April 2011 www.metalarchitecture.com

By Ronald A. McKenzie

Mik

e S

tanfi

ll

Firm Strategies

Thisisanongoingstoryofencountersbetweenthe

King,everyone’sfavoriteowner;hisarchitect,Slide

Rule;andhiscontractor,Igor.Charactersareinspired

inpartbyGaryLarson’sFarSide.

“It was love at first sight,” announced the King.

“What!” said Igor. “Your Majesty, have you

fallen in love?”

The King, Igor of Moat Designs and Slide Rule

of Building Blocks Inc., were sitting on a river bank

enjoying the early morning sunshine and a spot of

tea. Behind them stood several Knights in shining

armor who were there to protect their King.

“No, no. I was speaking of the river. But even

more important, I was reciting the first line of a

famous novel, Catch-22, by Joseph Heller. It was a

very clear statement.”

“The first line of a famous novel! Now why

would you do that?” asked Slide.

“‘The moment one learns English, complica-

tions set in.’ See, another first line of a famous

novel. This one by Felipe Alfau in Chromos. Do you

have any idea of what my point is about?”

Slide skipped a stone into the river. Several ring-

lets formed and grew larger and then disappeared.

“I have to admit your Majesty, I have no idea of

what your point is about. Is it about this river? Is it

about the Castle and your first year here?”

“In the late summer of that year we lived in a

house in a village that looked across the river and

the plain to the mountains.”

“Don’t tell me,” Igor said. “It’s another first line.”

“Of course. Ernest Hemingway’s AFare-

welltoArms.”

“You’re speaking in first lines of famous novels.

What does this have to do with marketing and

business development? That’s what you said you

wanted to talk to us about.”

“In my younger and more vulnerable years my

father gave me some advice that I’ve been turning

over in my mind

ever since,” said

the King with a smile.

Igor looked at Slide. “He’s

got us on this one.” Igor

turned toward the King. “I haven’t

a clue of what’s going on. What

novel was that from, your Majesty?”

“TheGreatGatsby by F. Scott

Fitzgerald.”

Slide looked at the King. “Regardless of this

first line in a novel nonsense, it’s a beautiful day.

The sun is shining and giving us warmth. Only the

sun can do this, don’t you think so, your Majesty?”

“Far out in the uncharted backwaters of the un-

fashionable end of the western spiral of the Galaxy

lies a small unregarded yellow sun.”

“I give up. I have no idea what is going on. Per-

haps there is another sun?”

“I have no idea, your Majesty,” Igor stated.

“You should read TheHitchhiker’sGuidetothe

Galaxy by Douglas Adams.”

“I see, so that’s where the quote came from.”

“Hey, it was Slide that brought up the sun.”

“Whatever you say, your Majesty.”

“Call me Ishmael,” responded the King, laughing.

Both Igor and Slide were completely confused.

“That was from Moby-Dick by Herman Melville.”

“This is getting annoying. I hope you have a

point someplace that makes some sense. Don’t you

agree, Igor?”

“Completely.”

The King turned to both of them and said, “It

was the best of times, it was the worst of times, it

was the age of wisdom, it was the age of foolish-

ness, it was the epoch of belief, it was the epoch

of incredulity, it was the season of Light, it was the

season of Darkness, it was the spring of hope, it

was the winter of despair.”

“Okay. I’m outta here.” Slide got up and

Igor followed.

“Wait a minute. I do have a point. But first, that

was from ATaleofTwoCities by Charles Dickens.”

“Doesn’t help me one bit,” Slide said.

“Please sit down. Igor, you said last week that

you were developing copy for an ad. Now, tell me,

what is the most important thing about an ad?”

“Haven’t a clue,” said Igor.

“It’s the first line. It’s the attention getter, the

one that’s going to get them to read all about your

services. I was just demonstrating that point by

quoting famous lines from novels. Doesn’t that

make sense?”

Igor suddenly saw the light of the King’s wis-

dom. “Your Majesty, you have made a good point.

You are so right. One must concentrate on the first

line of an ad, or even a letter or an email. It’s prob-

ably the most basic marketing tactic that is all too

often overlooked. You are very tactful. You made

something happen just sitting out here by the river.”

“How about you, Slide?” asked the King.

“All this happened, more or less,” said Slide

proudly. “Slaughterhouse-Five by Kurt Vonnegut.”

Withtheexceptionofanoccasionalguest

appearancebytheauthor,anysimilaritytoactual

eventsorpeoplelivingordeadispurelycoincidental.

Ronald A. McKenzie is director of business devel-

opment for ARCON Associates Inc., a Chicago-area

full-service architectural firm. He has made nation-

wide presentations about the subject of thought

leadership relative to strategic planning.

A Novel Idea



LEEDing the Way

By Thomas Taylor

Recently a student working on a class project to

design a LEED certified building asked me what the

easiest way is to achieve the Materials and Resources

(MR) credit for recycled material. My response was,

“It depends.” When one sets out to design a building

in hopes of obtaining LEED certification, few things

are absolute. There are definitely thresholds that must

be met or definitive aspects that must be demon-

strated in the design, but as far as how to go about

achieving them, it is all up to the delivery team.

Achieving GoalsIt is very restrictive and at times expensive to focus on

any particular LEED credit. The easiest way to achieve the

sustainability goals for a project seeking LEED certification

is to take a more holistic approach. When looking to incor-

porate materials with high amounts of recycled content, a

building owner or operator must first look at some of the

overall design drivers for the project, such as:

• Building type

• Intended use of the facility

• Geographic location

• Energy performance goals

• Building aesthetics

All of these factors will influence the strategy for achiev-

ing the MR credits found in the LEED rating system.

Getting the PointThe majority of the Materials and Resources credits are

based on some type of ratio or percentage threshold:

• MRc1: Building Reuse is available to building

renovation projects and is determined based on

the ratio of the amount of materials reused

versus the amount of materials available for reuse.

• MRc2: Construction Waste Management is based

on a ratio of how much waste generated on a project

site is diverted from landfills compared to the total.

• Credits MRc3: Materials Reuse through MRc6:

Rapidly Renewable Materials are all based on

a ratio of how much of the specified materials are

used when compared to the total materials cost

for the project.

It is relatively simple for a project team to read the

requirements of MRc3 through MRc6 and assume

they will get that point. Making sure all the individual

components of the design as a whole will work to-

gether to achieve each of those thresholds is another

thing entirely.

So how can a team affirm that a project in the early

stages of design will achieve a targeted MR credit?

They can’t. However, a team can put together a strat-

egy built on the concepts of sustainability that allows

them to make a strong prediction that can morph into a

validated estimate as the design matures.

Give and TakeEarly design decisions will impact the material strategy

for the project. For example, a building design utilizing a

combination of cast-in-place concrete and precast or tilt-up

exterior wall components can predict relatively easily that

the structural components made from concrete will make

up at least 20 percent of the total material cost of the

project. In this case, compliance with MRc5: Regional Ma-

terials should be simple for the team to achieve because

the base materials of the concrete are extracted, manufac-

tured and processed within 500 miles of the job site.

However, a team with this same building design

may struggle to find ways to incorporate materi-

als with enough recycled content to achieve the 20

percent threshold requirements of MRc4: Recycled

Content. Teams often believe that between using

rebar and specifying a concrete mix with 15 percent

fly ash, they can achieve the recycled content credit.

However, as the following example illustrates, speci-

fying fly ash and rebar will likely not be enough of a

contribution to achieve MRc4: Recycled Content.

The recycled content of an assembled material is cal-

culated based on the weight of the individual components

of the assembly. Assume a project is using a cubic yard

of concrete with the following component breakdown:

The total recycled content of this yard of concrete is

equal to the fly ash component (6 pounds). Fly ash is

considered a pre-consumer recycled material, meaning

it is recycled directly from industry before entering the

consumer market stream. The calculations for MRc4:

Recycled Content require that only 50 percent of the

value of pre-consumer recycled materials contribute

toward the total recycled content value. Therefore, the

total recycled content from this yard of concrete is 3

pounds, which equals only 3 percent of the total weight

of the concrete. For each $100 of this concrete mix

that is used on the job, only 3 percent—or $3.00—will

contribute toward the overall recycled content value.

LEED allows for an alternate calculation method

for supplementary cementitious materials such as fly

ash, but the overall contribution toward the project’s

total recycled material value may still be compara-

tively small. And even with its high recycled content,

rebar alone will likely not be sufficient to achieve the

20 percent threshold for recycled content and the

team will need to carefully specify other materials to

meet the project’s LEED goals.

Conversely, look at a design featuring a steel-framed

structure with structural studs, sheathing and metal panel

façade. The structural and other steel components used

in the building will likely easily constitute greater than 20

percent of the total materials cost for the project. Given the

high levels of recycled content in steel, a team should be

able to comply with the 20 percent threshold needed to

achieve MRc4: Recycled Content. However, the extraction

distance of steel products can be difficult if not impos-

sible to obtain. Therefore, these materials often cannot

contribute toward MRc5: Regional Materials, and unless

careful attention is paid to the sourcing of all other building

components, the team may struggle to achieve this credit.

Successful StrategiesTeams can more reliably predict their successful

achievement of LEED Materials and Resources cred-

its by implementing the following strategies:

• Develop an overarching materials strategy early in

the project.

• Build realistic, highly detailed estimates and

collect cost information for each component

proposed in the design.

• Make sure you understand how the MR

credits are calculated.

• Ensure that product manufacturer’s claims of

LEED materials contributions are vetted through

supporting backup documentation such as

cutsheets or technical data sheets.

• Refrain from promising that the project will achieve

a certain credit or percentage threshold until you

have sufficient information to substantiate your claim.

In the end, it all comes down to a team effort. The de-

sign has to incorporate the best mix of materials; the

contractor has to purchase and install the right things

and all of the documentation has to be assembled in

a way that is acceptable to the LEED reviewer before

final certification can be awarded.

Thomas Taylor, a 29-year veteran of the construction

industry and noted expert on sustainability, is the general

manager of St. Louis-based Vertegy. His recent book,

“Guide to LEED 2009: Estimating and Preconstruction

Strategies,” provides step-by-step information about

the LEED 2009 for New Construction process. To

learn more about Vertegy or Taylor’s new book, visit

www.vertegyconsultants.com for more information.

Strategies to Achieve LEED Materials and Resources Credits

Component Weight (lbs.)Rock 25

Sand 25

Water 5

Cement 34

Fly Ash 6

Add Mix 5

Total Material Weight 100

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ClarkWestern Building Systems and Dietrich

Metal Framing have united to form ClarkDietrich

Building Systems.

“ClarkDietrich Building Systems has the ca-

pability to answer the challenges of any project

in the nation, regardless of size or complexity,”

says Bill Courtney, chief executive officer of

ClarkDietrich Building Systems. “With a com-

plete lineup of innovative products, plus techni-

cal support services and smart tools for design

and specification, we’re forging a new future for

steel framing.”

To provide a seamless transition for the

customers of both ClarkWestern and Dietrich, this

company will integrate the two separate compa-

nies over the next six months.

In addition to Courtney, ClarkDietrich Building

Systems will be led by Greg Ralph, vice president

of business development; Jack Slattery, chief finan-

cial officer; Todd Barnett, vice president of human

resources; Bill Craig, vice president of purchasing;

John DiPietro, vice president of operations; and

Todd Fischer, vice president of sales and marketing.

For more information, visit www.clarkdietrich.com.

ClarkWestern and Dietrich unite

Firestone honors reputable roofing firms Firestone Building Products Co. LLC, Indianapolis,

recently honored 262 contractors throughout the United

States, Canada and Mexico at the Terranea Resort in

Rancho Palos Verdes, Calif., during the 2011 Master Con-

tractor Award ceremony. Established in 1988, the Master

Contractor program recognizes reputable roofing firms for

upholding Firestone’s high standards.

This year, Firestone also acknowledges 33 esteemed

firms as winners of the President’s Club Award, 32 as

Platinum Council Award winners and 177 as recipients of the

Inner Circle of Quality Award. Through a combination of new

construction and reroof applications, the 2011 Master Con-

tractors have collectively installed nearly 201 million square

feet of warranted Firestone roofing systems in the last year.

Visit www.firestonebpco.comto find Master

Contractor firms.

Design-build Institute expands credential program The Design-Build Certification Board has expanded the

reach of Design-Build Institute of America’s certification

program. The program is intended to establish an accept-

ed and recognized standard of design-build knowledge

and experience. DBIA has certified “hands-on” profes-

sionals since 2002. Through coursework and testing,

these individuals demonstrate an understanding of best

practices in every phase of design-build project delivery,

from proposal preparation to substantial completion.

Previously, only practitioners with design or construc-

tion degrees and significant design-build experience quali-

fied for permanent designation status.

Recognizing the importance of full team integration early

in the process, the DBCB decided the existing program failed

to properly recognize the team members and owners’ repre-

sentatives who are key early on in the design-build process.

Examples include acquisition specialists, as well as legal, mar-

keting and business development professionals who are critical

to the owner and the pre-award design-build team. Individuals

more involved in the post-award process will continue to be

recognized under the existing Professional DBIA credential.

VIP Structures recognizes outstanding job performance VIP Structures, Syracuse, N.Y., has recognized several

staff members.

Architect Robert Garner, AIA, received the Architecture

Craftsmanship Award for his work on some of the most

challenging projects in which VIP is currently involved. The

award recognizes Garner’s superior attention to architectural

design and detailing and to his ability to stay at the forefront

of ever-changing architectural technology. The Architecture

New Employee of the Year award was presented to Archi-

tect Amy Bloss in recognition of her leadership on several

projects, as well as her skill at converting complex architec-

tural concepts into computer images.

Midland, Mich.-based Dow Building Solutions, a

business unit of The Dow Chemical Co., is donat-

ing insulation and air sealing products in support of

Habitat for Humanity’s Neighborhood Revitalization

Initiative. Dow will provide select products from

its building envelope product portfolio, including

STYROFOAM Brand Extruded Polystyrene (XPS)

Foam Insulation, GREAT STUFF Window & Door

Insulating Foam Sealant, the new GREAT STUFF

Work Wipes and other products, as needed, for a

Jonesboro, Ga. home construction project of South-

ern Crescent Habitat for Humanity.

Dow Building Solutions’ products support Habitat for Humanity

As the first Zinc Composite Material ever, VMZINC

bonded with an ALPOLIC/fr core has been tested to

and is complaint with the fire testing requirements for

noncombustible construction as detailed in section

1407 of the International Building Code (IBC 2009).

Bill Yannetti, senior manager of technical

services at Mitsubishi Plastics Composites America

Inc., Chesapeake, Va., announces: “When we, at

Mitsubishi, bring a product to market we make sure

it is thoroughly tested both internally and externally.

We make sure our products perform to the highest

of standards. After all, a commitment to quality is a

commitment to the customer.”

For VMZINC, Laurent Heindryckx, Raleigh,

N.C.-based Umicore Building Products’ director of en-

gineering, adds: “It is our philosophy that leadership

also requires the responsibility to have products that

are code compliant. Therefore, we are thankful to

Mitsubishi for performing the test with us. Our mu-

tual customers will benefit from this co-operation.”

The panels used to perform the tests were

fabricated by NOW Specialties, Dallas.

VMZINC by ALPOLIC compliant with fire testing

Industry News

Alcoa’s Kawneer and Traco businesses announced

that John Kalakos, manager, Commercial Operations

for Traco has elected to retire from the company.

Traco, Cranberry Township, Pa., a division of Kaw-

neer, is a premier window manufacturer. Kalakos

has been with Traco for 42 years and concluded his

tenure with the company on Feb. 28, 2011 to begin

a new phase in his life.

Kalakos joined Traco as a sales representative

in 1969 when the company was a seven-person

operation. During his time with the company, Kala-

kos held several key positions.

“As John embarks on a new chapter in his life,

we want to thank him for his numerous contribu-

tions to the company and the imprint he leaves

behind,” says Bob Leyland, director of sales for

Kawneer North America. “John has done a wonder-

ful job helping to grow the Traco business and assist

us as we take it to an exciting new level. We wish

John and his family many years of happiness.”

Kawneer and Traco veteran begins new phase of life

Correction: On page 33 of the January issue of Metal Architecture, the architect for the Oswego Fire Station No. 1 was incorrectly identified. FGM Architects, Oak Brook, Ill., is the correct architect.

The W. P. Hickman Co., Asheville, N.C., began label-

ing all Hickman products tested and classified by

Underwriters Laboratory on April 1. The Hickman

products that have been specifically engineered and

tested to meet the requirements of the ANSI/SPRI

ES-1 Wind Design Standard for Edge Systems Used

with Low-Slope Roofing Systems, required by the In-

ternational Building Code will now be embossed for

identification. The miters of UL Classified Hickman

products will be embossed on the roof-side back leg

with “HICKMAN R25074 UL CLASSIFIED ES-1.”

A link to UL’s online Classifications Directory

that lists Hickman products can be accessed from

Hickman’s website at www.wph.com.

W. P. Hickman labeling UL classified products

Alcoa Architectural Products • 50 Industrial Boulevard • Eastman, GA 31023-4129 • Tel. 800 841 7774 • reynobond.com©2011 Alcoa Architectural Products. Reynobond® is a registered trademark of Alcoa Inc.

At first glance you’d swear it’s really mahogany. Or granite. Or copper patina. Reynobond® Design Line is a breakthrough line of

Colorweld® DL paint fi nishes so realistic they’re virtually indistinguishable from nature’s own creations. Each fi nish provides environmentally

sensitive architects with the ability to incorporate eco-friendly, cutting-edge materials without sacrifi cing style or quality. It’s another

example of Excellence in Innovation from Alcoa that can help you make an impact on our world.

Nature. Now available in aluminum.

AAP0513_DL_MetalArch.indd 1 3/23/11 5:57 PM



Industry News

METALCON reinforces networking with executive clubMETALCON International has introduced a red carpet

style amenity called the METALCON Executive Club.

Located conveniently in the exhibit hall, MCEC provides

a place for exhibitors to meet with customers and pros-

pects in a private business-like setting.

The concept reinforces METALCON’s reputation

as the place to meet, notes METALCON Show Director

Claire Kilcoyne. “Exhibitors recognize METALCON as a

significant industry event, where professionals the world

over gather to develop business. We took that a step

further by providing an additional platform for exhibitors

to grow their business. The METALCON Executive Club

makes it easier for exhibitors to streamline relationship

building and augment their sales process, whether

they’re a start-up or a well established business. Our

core philosophy is customer service and that centers

around helping companies advance their businesses.

Creating MCEC is an extension of our reliable service

orientation that is the foundation of METALCON.”

For more information about participating in

MCEC, contact Linda Griffin, director of sponsor-

ships at [email protected].

Aluminum celebrates commercial production anniversary One hundred and twenty-five years ago, Charles Martin

Hall discovered a method by which to produce alumi-

num commercially—transforming it from a precious

metal to an everyday material. With the advent of

aluminum windows, curtainwall and siding, aluminum

transformed the modern construction industry.

By passing an electric current through a carbon

crucible filled with a cryolite bath containing alumina—

producing a congealed mass that contained pure alumi-

num within—the precocious 22-year-old had achieved

what had eluded scientists for decades. That same

process is used to this day by aluminum companies

to produce aluminum from ore. Hall’s work had only

begun, however. He would patent the process, found a

company—the Pittsburgh Reduction Co. (precursor to

today’s Alcoa)—and manufacture aluminum cookware

to help establish a nascent market for the metal.

“Aluminum’s utility across a wide swath of

product applications is, by now, well understood by

the American consumer,” says Aluminum Association

President Steve Larkin. “What consumers may not be

aware of are the sustainable characteristics of this re-

markable metal. In particular, its light weight, durability

and recyclability make it a crucial part of the solution

to our society’s growing concerns over the environ-

ment, energy security and resource management.”


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MCM Pricing FactorsMetal Composite Material, or MCM, has become the go-to

product for designers where complex geometry is required

to fill in the gaps between other materials. The growth of

the product applications has grown tremendously over the

last 20 years.

Metal Architecture has asked me to start a column that specifically deals with all of the aspects of this great product. My intention is to write very short articles that explore a specific aspect of MCM in each issue of Metal Architecture. The first will be on “Parameters that Affect Pricing in MCM.” The second will be “How Can You Assure You Get a Great Fabricator.” I look forward to establishing a dialogue with you about MCM.

Parameters that Affect Pricing in MCMPanel SizeOn an average size project, the parameter that has the most affect on pricing is panel size. It really is a simple concept; it takes about the same amount of fabrication time to make a small panel as it does to make a large panel. Let us look at an example:

SAy We WANT TO COVeR 100 SquARe FeeT OF A BuIlDINg:

Scheme 1 Scheme 2

Panel size: 2 feet by 2 feet 5 feet by 10 feet

Panels required: 25 panels 2 panels

Fabrication: 2 man hours 2 man hours per panel per panel

Man hours for 100 square feet: 50 man hours 4 man hours

Cost per man hour: $20 $20

Cost to fabricate: $1,000 $80

Fabrication cost per square foot: $10 per $0.80 per square foot square foot

In addition to the fabrication time, you will also require more extrusions, sealant and several other items because the length of perimeter around all of the panels is much higher with 25 panels versus two. So the installation cost differential will be even higher. While this is a simple example, the concept is clear. If you are concerned about cost, use larger panels.

Ted S. Miller is the president of The Miller-Clapperton Partnership Inc., Austell, Ga. For more information, visit www.millerclapperton.com.

Ted’s MCM Corner

Project an image of real innovation.

Associated Builders and Contractors reported on February 15 that its Construction Backlog Indicator for the fourth quarter of 2010 averaged 7.1 months, up from 7 months in the third quarter of last year—an improvement of 1.4 percent. In addition, CBI is up 21.3 percent from a low of 5.8 months in the fourth quarter of 2009. CBI is a forward-looking indicator that measures the amount of construction work under contract to be completed in the future.

© Associated Builders and Contractors, Construction Backlog Indicator

Market Report


Large panels at Embry Riddle, Daytona Beach, Fla.

Small panels at Sentara Obici Hospital, Suffolk, Va.

18 METAL ARCHITECTURE April 2011 www.metalarchitecture.com www.metalarchitecture.com April 2011 METAL ARCHITECTURE 19

Featured Products: Daylighting, rainscreens, moisture barriers, metal tile and shingles

Firestone Metal Products

The UNA-CLAD LS-1 honeycomb

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CENTRIA

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Major Industries Inc. Major Industries recently released two new daylight-

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If you want to see your products in Metal Architecture, email our Senior Editor, Stefan Schumacher, at [email protected], with product descriptions and photos.

Duo-Gard Industries Inc.

Duo-Gard Indus-

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Combining sustainability, versatility and affordability, Duo-Gard’s

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The new HPR Aqua Shield self-adhering

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pinta acoustic inc.

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Choosing the Right Metal for Your Design A look at the differences between perforated metal, expanded metal and wire cloth From function to aesthetics, perforated

metal, expanded metal and wire cloth have

many overlapping architectural applications.

In recent years, suppliers have been working

with architects to incorporate these materials

into many new applications.

As the applications diversify, it’s more important than ever for architects to distinguish the strengths and weaknesses of each material to achieve opti-mum performance and value. This article will broadly compare the three ma-terials against specific applications, providing tips on material selection.

Defining your OptionsPerforated metal is a sheet of metal (or plastic) with a series of holes punched into it. It comes in a virtu-ally endless variety of sizes, gauges, hole shapes and material types. Hole diameters range from a few thousandths of an inch to more than 3 inches, punched in material as thin as foil or as thick as 1-inch steel plate. Expanded metal is made from a sheet of metal that has been slit and stretched to form diamond-shaped openings in the sheet. The diamond-shaped trusses form a sharp angle to the original plane of the sheet adding strength and rigidity. Expanded metal is available in standard, raised, flattened and decorative diamond patterns, and comes in a range of gauges, opening sizes, materials and sheet sizes. Wire cloth, also known as wire mesh, is metal wire that is woven or welded to form a cloth. Metal wire is made from various alloys including stainless steel, brass and copper. Wire cloth can be woven or welded to create a variety of opening sizes and wire diameters.

Price and Other Selection IssuesBecause of raw materials costs, perforated metal typically carries the highest up-front price of the three options. However, many other attributes con-tribute to the overall value of a material in any given application, including:

• Aesthetics• Strength• Durability• Sustainability• Resistance to environmental elements• Fabrication costs• Application-specific needs such as acoustical capabilities and radiation containment

AestheticsExpanded metal, perforated metal and wire cloth all offer a unique look that will enhance any design. Out of the three materials, however, perforated metal offers the greatest visual variety. Endless op-tions in hole shapes, sizes, materials and geometric patterns are available to achieve a specific look. Per-forated metal also is more easily painted than either expanded metal or wire cloth. Wire cloth presents several options depending on the weave of the metal wire, while expanded metal is the most limited in design due to the stretching of the raw material. Both materials can only be cut to shape and framed.

AcousticsAll three of the materials can be used as a pass-through to support sound absorption in ceilings and walls. They can function as protective or decorative coverings for special acoustical materials. Perforated metal, however, is the only material to offer more extensive sound-managing capabilities. It can play an active role in eliminating specific frequen-cies in sound-filtering systems, such as enclosures surrounding large air-conditioning or compressor units.

VentilationIn addition to sound filtering, all three materials can be used in other ventilation and filtration applica-tions, as well. The openings in each permit passage of light, air, heat and gases. In harsh environments, the estimated energy loss or pressure loss is often an important design consideration. If pressure control is important in your application, perforated metal provides the greatest ability to control or equalize pressure due to its high strength-to-weight ratio.

Structural ConsiderationsThe structural strength of perforated metal is one of its key attributes. It can be used as a standalone component in several architectural designs such as sun screens and panels. The “open area” is the sheet of perforated metal, which has its own strength and physical properties. With expanded metal or wire cloth, however, the “open area” can’t stand alone. Wire cloth and expanded metal are lightweight, less rigid materi-als that need additional fabrication processes. They must be fastened and secured to a structure.

Fabrication CostsIn many cases, additional fabrication can significantly increase the total cost of expanded metal and wire cloth, despite their lower up-front price.

Wire cloth and expanded metal both require ad-ditional operations, including a punch press to open the material, bending to form the structure and three welding operations to fasten the open material to the structure. Perforated metal typically requires less fabri-cation. Stainless-steel perforated parts often are finished in two operations: punching in a single pass and forming with a press brake.

The Right Material for your DesignIf any of the qualities discussed here is important in your circumstances, perforated metal’s ability to outperform the other options may offset the higher initial price tag. So, should you use perforated metal, expanded metal or wire cloth in your design? It’s important to discuss the particulars of your application with engi-neers who have expert knowledge of the properties of each material option. Doing so will help you choose your best option, and ensure the material is specified for optimum performance in your application.

Bob Farber is the president of the Milwaukee-based Industrial Perforators Association. Discover more about the IPA and perforated materials at www.iperf.org.

OPPOSITe PAge: Heifer International Headquarters ThIS PAge: The National Center for Crisis and Continuity Coordination

By Bob Farber

Cover Story To learn more about Expanded and Perforated metals, go to www.metalarchitecture.com/online-exclusives.aspx


Cover Story

The Versatility of Expanded MetalMost people in North America have no idea who

makes expanded metal. They don’t know how

it’s made. And chances are they don’t even know

what expanded metal is, but they see it every day.

It’s in their homes, in their offices, in the cars they

drive, their lawn mowers, and is on virtually every

production machine that has moving parts. It screens

the good guys from the bad guys in a police car, plays

an integral part of the batteries on the space shuttle,

and forms much of the fencing on their national

borders. They know what it is, but they have probably

never thought of it from a design standpoint

Expanded metal is produced from nearly any malleable sheet metal product (carbon steel, alu-minum, nickel alloys, copper and other red metals, stainless steel, titanium, and zinc). It is produced by simultaneously slitting and stretching the material forming openings and increasing the rigidity of the original base metal. And it is one of the most flexible building materials available.

A uniquely Changeable Building MaterialExpanded metal is widely used where light diffusion is needed. A recent project on a library in Cham-pagne, Ill., utilized this aspect to mediate the impact of the afternoon sun in reading areas. While provid-ing shade, it allowed light to flow in most of the day.

Because of its transparent nature of the product, people inside could still see the daylight. Many sunshade products are produced by the expanded metal manufacturers and these typically have a wide strand to modify the light diffusion to suit the specific application. Just this one attribute of expanded metal makes it a unique architectural material. But expanded metal can be infinitely modified to meet the needs of nearly any application. The patterns can be the typical dia-mond or they can be hexagonal or round. The pattern size can range from less than one eighth of an inch to 8 inches or longer in the long axis of the diamond. The short axis can vary nearly as much. The strand width, which is the amount of material that makes up the

By Rick Bahner

Walker Art Center in Minneapolis


www.metalarchitecture.com April 2011 METAL ARCHITECTURE 2524 METAL ARCHITECTURE April 2011 www.metalarchitecture.com

Cover Story

sides of the diamond, can be as narrow as the thick-ness of the material or as wide as an inch or more. Of course, the thickness of the material can be adapted to whether the sunshade is for a parking garage, a façade on a building or as above an attached, mov-able shade. And the choice of materials is left to the architect, construction engineers or building owner.

Security on your TermsBuried beneath the wall board in most pharmacies, gov-ernment offices, banks and other buildings where se-curity is an issue, is a layer of expanded metal. Attached to the studs, whether steel or wood, expanded metal is completely unobtrusive yet provides a very high level of security. After the sheet of expanded metal is attached to the studs the wall board or other interior wall mate-rial is attached in the same way as it normally would be. This has become very prevalent in the construction of strip malls to prevent movement from a non-secure lessee’s premises to the next business. More visible is the use of expanded metal for security fencing. Whether the facility is a water treatment plant, a nuclear power plant or a govern-ment building, expanded metal prevents penetration and scaling as well as any fencing material and much better than most. For a facility that needs security but aesthetics are important, the product can be powder coated so that the fence blends in with the environment. Again, the patterns can be varied to accommodate the projects specific needs.

Just Because It looks goodThere are some applications where the building owner, the construction engineer or architect just wants to use something that is unique. Expanded metal has been described as a material which will go from “functional to fanciful” depending upon the needs of the specifier. Ceiling tiles from expanded metal have been used for years. They are now be-ing used not only for light diffusion or to convey a sense of an industrial history (as in a refurbished warehouse loft), but the product is also being used because of its inherent look. Schools, offices and car dealerships have used the product for ceiling tiles just because they look good. An Oklahoma City steakhouse used expanded metal as an interior wall covering because of its appearance. The Walker Art Center in Minneapolis, designed by world famous architects Herzog & De Meuron of Switzerland, utilized expanded metal for the outer shell of the building to reflect the ever changing environment in Minneapolis. The point is that this product is available to build-ing owners, construction engineers and architects, and can do what ever you ask it to do.

expanded Metal Manufacturers Association (eMMA) is a division of the Chicago-area based trade association, the National Association of Architectural Metal Manufacturers (NAAMM). The six member companies of EMMA are Alabama Metal Industries

Corp., Exmet Industries Inc., Expanded Solutions LLC., Fisher & Ludlow, New Metals Inc. and Spantek Expanded Metal. To learn more about EMMA and its members visit www.emma-assoc.org.

Rick Bahner is the managing member of Expanded Solutions LLC. Based in Oklahoma City, Expanded Solutions supplies North America with the complete array of industrial products in all sizes and produces micro mesh products from precious metals, as well.

Security fencing Steakhouse in Oklahoma City

Library in Champagne, Ill.




Cover Story

Geico Garage, Amway Center, Orlando, Fla.Serving Amway Center, home to the Orlando Magic basketball team, the Geico Garage makes a design statement. Named for its auto insurance sponsor, the 1,875-car garage is gaining notice as much for the beauty of its metal as its function. Wrapped in a combination of perforated and metal mesh from Tampa, Fla.-based McNICHOLS Co., the eight-level garage contains some of the same metal design features of the Amway Cen-ter, an intentional plan to visually connect the two structures, says architect Bill Walker with C.T. Hsu + Associates, Orlando. Linking the metal design elements in the parking garage with the sports arena was a natural step for the architect, who served as the associ-ate architect on the Amway Center. The overrid-ing concept—and design tie-in—was to give the impression of one piece of steel ingot, which was articulated through using metal elements. The long, horizontal windows are there to relate to the automobile traffic, Walker says. Unique to the garage is a set of folding “el-ephant” doors on the ground floor that open verti-cally in a bi-fold fashion to accommodate transport trucks and buses serving event productions at the sports center. The doors are paneled with the Mc-NICHOLS perforated metal panels to match the private parking area at the Amway Center where Orlando Magic players park. Orlando-based Atlantic Steel Inc., custom fabricated the McNICHOLS perforated metal panels, with 1-inch (25-mm) perf-free borders, and installed them into the giant doors. The structural and miscel-laneous steel and aluminum fabrication company also applied the metal skin throughout the garage. “We actually installed the perforated alumi-num panels directly onto the roll door system on

site,” says Eric Johnson of Atlantic Steel. The two doors measure approximately 43 by 19 feet and 31 by 19 feet and are comprised of 140 perforated panels of 1/8-inch-thick aluminum. Two hole pat-terns were used and carefully designed to look random—one with a 0.5-inch-hole pattern stag-gered at 0.697 inches with 48 percent open area, the other with a 1-inch-hole pattern staggered at 1.25 inches with 58 percent open area. C.T. Hsu’s design called for several types of metal cladding throughout the garage as “part of the overall design plan to break up the massing and make a more attractive building,” Walker says. The mix of specialty metal satisfied the desire of the city of Orlando and the Orlando Magic to maintain the transparent look, yet obscure the parked vehicles from sight. The perforated metal also helped provide the appropriate ventilation. Two exterior staircases on the garage’s south-west and northeast corners project a certain style all their own. Created in a vertical zigzag pattern topped by an angular overhang, the staircase is accented with infill panels, creating a tower-like element similar to the iconic wire mesh tower icon on the Amway Center. Using McNICHOLS perforated infill panels, the architect satisfied safety and aesthetic require-ments. “The material is relatively transparent, in an effort to prevent someone from hiding behind it,” Walker says. The base of the staircase and the openings along the garage’s street level are enclosed in Mc-NICHOLS wire mesh with 2-inch openings, provid-ing another safety precaution for those parking for events at the center. For protection and aesthet-ics, the perforated metal and wire mesh materials are powder-coated in shades of silver and grey to retain the metal look. The Geico Garage also has a glass-enclosed staircase that features infill panels of anther vari-ety of McNICHOLS metal—0.250-inch diameter

aluminum wire mesh, with 2-inch square open-ings. Designed with a lock crimp weave to prevent the wire from shifting, the mesh is mounted inside an inner-frame that is bolted to an outer frame that is secured into the building structure. Together, with its companion parking garage, this new sports center is fast becoming a memo-rable image on Orlando’s skyline comprised of two urban structures with intriguing design linked by striking metal features.McNICHOLS Co., www.mcnichols.com, Circle #62

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Questions? 800-242-3837 or [email protected]

AHL107_AIA11_CONF_ARCH.indd 1 1/13/11 4:12 PM


DESIGN KNOWLEDGE IS POWER.ARM YOURSELF FOR THE REVOLUTION.Join the nation’s leading architects at the AIA 2011 National Convention and Design Exposition May 12-14 and strengthen your practice for what’s to come. Arm yourself with the new approaches, vital knowledge and powerful connections you need to join the design revolution—and be part of the future it creates. For serious architect and design professionals, there’s no more critical place to be.

CUSTOMIzE A UNIqUE EDUCATIONAL ExPERIENCE

from more than 400 sessions. Apply what you learn immediately in your own practice.

ACqUIRE ALL YOUR LEARNING UNITS (LUS)

AT ONE TIME. Nothing could be more efficient or cost-effective.

MAKE IMPORTANT CONNECTIONS. AIA

brings together industry leaders––meet them here.

LEARN FROM THE bEST. Daily keynotes explore how

innovative approaches to planning, design, and construction, along with evolutionary or revolutionary approaches to practice, collaboration, and partnerships can create more resilient urban ecosystems where cities of all scales contribute to a region’s sustainability and regeneration.

GET INSPIRED. AIA Expo2011 is now an all-new expo experience,

with new energy, new resources and inspiration everywhere.

ACT NOW. Take advantage of early discounts: Register and book your hotel by April 11, 2011.

www.aia.org/convention

Questions? 800-242-3837 or [email protected]

AHL107_AIA11_CONF_ARCH.indd 1 1/13/11 4:12 PM


Cover Story

U.S. Land Port of Entry, Champlain, NY. When entering the United States in Cham-plain, the first thing travelers see is a stun-ning etched metal fabric from Cambridge, Md.-based Cambridge Architectural. Two different Cambridge mesh systems lend aesthetic appeal and functionality to the U.S. Land Port of Entry’s primary inspec-tion booths and two processing facilities. Located at the intersection of Cana-da’s Highway 15 and U.S. Interstate 87, the Champlain Port of Entry is one of the northern border’s busiest crossings. The 100-acre site consists of five buildings linked by roads and inspection plazas, all

built to increase the capacity of passenger and commercial vehicle inspection and processing. A 10-lane-wide expanse of metal fabric placed directly above the primary inspection booths and etched with the words “United States of America” is the centerpiece of Cam-bridge’s contribution to the Port of Entry. The im-pressive signage, a Cambridge MeshFX system, provides a unique and modern visual touchpoint upon entering the country. “A slight rise in the roadway contributes to the dynamic unfolding of both words and horizon as visitors slow for inspection,” says Henry Smith-

Miller, design partner and architect with Smith-Miller + Hawkinson Architects LLP, New York City. “The sign’s transparency and its purpose-ful openness allude to the ideas of an open and democratic society founded in an Arcadian landscape.” The Port’s Commercial Pro-cessing Facility, which inspects and processes 1,400 trucks each day, is located next to the primary inspec-tion booths. The facility utilizes a Cambridge Solucent shading system to screen harsh sunlight entering the

south side of the building without obstructing views from the interior. Additionally, for privacy purposes, the mesh is opaque when viewed from the exterior. The inherent open-yet-closed nature of Cambridge’s woven metal fabric makes all of this possible, playing on the angles at which it is viewed. Another Cambridge MeshFX system etches the word “Champlain” on the Port’s two-story cargo processing facility, adding a nice touch of branding to the otherwise utilitarian warehouse. For this project, Cambridge worked with the architect to develop an ideal system to address all

the visual and functional needs of the site. Each system was then specifically engineered to each exterior to assure a streamlined installation. “We worked closely with Cambridge to de-termine, via full-size mock-ups, the ideal products for the project’s different signs, and to make sure that every component performed according to our design drawings and specification,” says Smith-Miller. “Cambridge was willing to experiment and did a first-rate job of engineering, manufacturing and installing the products, delivering everything on schedule. The end result is spectacular.” The MeshFX signage above the primary inspection booths and the Solucent system on the Commercial Processing Facility were fabricated with mesh in Cambridge’s Graph pattern, which features rigid, open weaves, and was installed using Cambridge’s U-frame attachment hardware. On the cargo processing facility, the MeshFX signage was fabricated with mesh in Cambridge’s Shade pattern, which features large-scaled, flex-ible open weaves, and was installed with Cam-bridge’s Scroll tension attachment hardware. Completed in March 2010, Northland Associates Inc., Liverpool, N.Y., was the general contractor.Cambridge Architectural, www.cambridgearchitectural.com, Circle #63

DDC Domus Design Collection/Minotti on Madison Avenue, New York CityInspired by the New Museum of Contem-porary Art in New York, the showroom at DDC Domus Design Collection/Minotti on Madison Avenue features a custom ceiling designed, engineered and manufactured by Birmingham, Ala.-based AMICO. When entering the store, the three-di-mensional profile of the expanded aluminum mesh creates an illusion of a solid, textured ceiling and, when exiting, an open mesh feel. Additionally, the ceiling system was powder coated to a high gloss black finish, which gives the feeling of movement.

AMICO was commissioned to work with the owner, Milan, Italy-based architect firm Dordoni Architetti and New York-based Cor-porate Interiors Contracting Inc., the general contractor, to create a ceiling system using their APEX01A expanded aluminum mesh. After a couple rounds of design, the final system was selected and production of the ceiling began. The framework is made up of aluminum I-Beams. The expanded alumi-num mesh is attached to the I-Beams using AMICO’s APEX ceiling clips.AMICO, www.amicoarch.com, Circle #64

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Cover Story

United Union Building, Washington, D.C.Completed in February, the project includes a layered, two-story feature wall along a staircase that showcases perforated met-als in an unorthodox way. The first layer includes perforations in three different sizes, while a second layer of corrugated perforated metal uses 0.5-inch diameter holes. The third layer of material is wall-mounted glass that increases the visual depth of the assembly. The three patterns in the 18-gauge steel are 0.313-inch diameter by 0.375-inch on-center and 63.18 percent open; 0.157-inch diameter by 0.188-inch on-center and 63.37 percent open; and 0.500-inch diameter by 0.625-inch on-center and 58 percent open. Carbondale, Pa.-based Hendrick Architec-tural Products supplied the perforated metal for the project. Benedict Metal Works, Upper Marlboro, Md., was the metal fabricator. “The combination of various colored, die-cut metals and exquisite attention to detail create an ever-changing moiré effect,” notes architect Anik Jhaveri with Washing-ton, D.C.-based Mancini Duffy Architecture. Jhaveri also says that the design is meant to remind visitors of the workmanship of the trades that achieves the level of art—a fitting concept for the building’s occupant. Hendrick Architectural Products, www.hendrickarchproducts.com, Circle #66

Metro Transit Parking Ramp, MinneapolisThe parking ramp features 17,400 square feet of Lancaster, Pa.-based Fabral’s Deep Rib IV metal panels that were custom anodized. The vertical metal siding was hung over horizontal stainless furrings with custom embeds by Maplewood, Minn.-based M.G. McGrath. For security reasons, the panels were designed to be see-through. Since the parking garage is frequented in the evening and night, a panel system was requested that would allow security to see through the façade. The spans were stretched to the limits of corrugated metal panels so Fabral’s Deep Rib IV was a perfect fit. After installation, crews anodized the panels to insure that no corrosion would occur. Julie Snow Architects, Minneapolis, was the architect, and Adolfson & Peterson, Minneapolis, was the general contractor.Fabral, www.fabral.com, Circle #65

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Light Up Your Space

People are drawn to the sun. Everyone wants

to live, work and play in places that have plenty

of natural light. Studies have shown that natural

sunlight boosts productivity, memory, health and

overall enjoyment—making sunlight a major factor in

creating effective, usable spaces.

Glazed retractable roof enclosures maximize natural light. Imagine a building atrium that offers a warm sunlit environment in the winter—and opens up into an outdoor space in summer. An indoor pool that turns into an outdoor playground at the touch of a button. A restaurant patio where customers are bathed in natural light during the day or can enjoy a view of the stars at night. Retractable roof enclosures offer lots of natural light—as well as fresh air, great views and versatile spaces. They can open up in nice weather or close easily when it gets cold or rainy. Commercial buildings, leisure facilities and aquatic applications can all benefit from the indoor-outdoor advantages. A retractable roof:• offers year-round usage and great flexibility of the indoor environment• provides up to 360 degree views of the outside surroundings• reduces and/or eliminates the need for air conditioning and dehumidification systems • eliminates the need for electrical lighting during the day• contributes to maximize LEED points • can be custom designed to meet any vision• offers tremendous opportunities for daylighting

More light = More SavingsRetractable enclosures don’t just illuminate their im-mediate area. They light up areas close by, adding to cost effectiveness and energy savings. For example, the LEED Gold Certified Salinas Aquatic Center in Salinas, Calif., incorporated a retractable roof enclo-sure and earned an additional LEED point due to the high percentage of space with daylighting. The glazed structure fills the pool area and the adjoining lobby and office areas with natural light, saving electricity and providing appealing sunlit spaces.

Thermal Comfort, All year longOne of the biggest challenges with daylighting is maintaining comfortable temperatures. Heat loss through win-dows can be a problem in the winter, and in summer, the sun can raise temperatures to uncomfortably high levels. A retractable roof enclosure addresses these challenges: when it’s

warm out, roof panels and side walls open so heat can escape and fresh outdoor air can flow through. In cooler seasons, sunlight warms the area naturally, and the sealed enclosure keeps heat in.

Design with Daylighting in MindThere are a number of key elements to consider when designing a space with a retractable roof enclosure.

1. Materials. Choosing glass or polycarbonate can make a difference to the overall look, design, and performance of your structure. • Polycarbonate costs less than glass and is quicker to install. It is also very lightweight, which allows for larger opening panels. It lets in lots of light and comes in a variety of colors; however, since it is an extruded plastic, isn’t as quite as clear as glass. Polycar- bonate is ideal for large projects such as a waterparks or other aquatic enclosures with large roof areas. • Glass is beautifully clear, and can take on tints and coatings that enhance energy performance. Low-E coatings can bounce heat towards their source; in summer, they reflect heat back to the outdoors, and in winter, they direct it back into the room. Thermal pane units can be filled with Argon gas to increase R Value. To determine the best solution, look at the amount of light coming in versus the energy cost of heating and cooling the space, and take the performance of the glass—including light transmission, shading coefficient and solar heat gain coefficient—into account. 2. The height of your structure at its peak. The taller the structure, the more light is captured in the space. Heights can range dramatically depending on the application and design requirements. For example, waterparks often require extremely high roofs or specially designed cupolas to accommodate multistory waterslides.

3. Building type. • Freestanding—all four walls are made of glass/polycarbonate. • Lean-to—three walls are made of glass or polycarbonate, with the fourth wall being the structure to which the enclosure is attached.

4. Roof opening. The way in which a roof opens also affects daylighting. Typically, panels open from the top and retract over the bottom fixed glazing, which results in more light in the center of the building. A lean-to application may need panels that open from the bottom up, which directs light to the base of the eave of instead of shining it on a wall. Retractable roofs can bi- part from the center or telescope to each end, bathing the entire space in direct sunlight.

5. Application. The amount of daylighting you want will depend on how the building is used. A structure that makes sense for a pool won’t have the same requirements as an atrium in an office building.

6. Climate. Your needs will be different if you’re building in a warm, sunny climate than if your structure is in an area that gets severe winters or has a lot of cloudy days and rain. If the area is unusually sunny, plan to minimize solar gain. If there’s heavy snowfall, factor in snow loads. If you’re dealing with sub-zero winter temperatures, design to capture heat.

7. Sustainable construction. If one of the goals for your project is to make it environmentally friendly or LEED certified, a retractable enclosure contributes a number of credits towards daylighting in addition to a number of other LEED categories. The controls for the roof are designed such that air conditioning or any heating or dehumidification units shut off when the roof is opened.

A retractable roof has tremendous potential to im-prove daylighting—and boost efficiency and sustain-ability. Talk to an experienced firm that specializes in retractable roof enclosures. They will work closely with you to understand your vision and maximize natural light—while helping you create a beautiful, ef-ficient, dramatic, sunlit structure that meets occupant and user needs.

Mark Albertine is president of OpenAire Inc., Oakville, Ontario, Canada. For more information, visit www.openaire.com.

By Mark Albertine

Feature: Daylighting & Retractable Roofs

Improving daylighting with a retractable roof enclosure

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Special Report: AIA Preview

The design profession is undergoing a

revolution, and so is the AIA convention.

This year, attendees of the AIA 2011 Na-

tional Convention and Design Exposition

will experience an event that has been

reinvented and re-energized.

The convention still focuses on en-hancing professional skills for architects and design professionals as well as provid-ing an opportunity for them to expand their

professional network. However, attendees will experience a more participatory and experiential convention, from Design Sa-lons that initiate dialogue on design issues to a redesigned AIA Expo2011. Regional Design Revolution: ecology MattersBy 2030, 60 percent of the world’s popula-tion will live in towns and cities. This shift brings significant social and environmental challenges—air and water quality, trans-portation, affordable housing—all regional in scope, all demanding regional solutions. The design revolution is all about creat-ing a future in which communities of all scales contribute to a region’s sustainability and regeneration.

Reasons to AttendAttendees will benefit from the vital edu-cation, powerful connections and innova-tive products that sustain their work now and into the future.

The AIA 2011 National Convention and Design Exposition

May 12−14, 2011

Ernest N. Morial Convention Center

New Orleans

Convention Education Programs of Interest to Metal Architecture Readers: Building enclosures of the Future: Meeting energy Conservation RequirementsFriday, May 13 | 2:15-3:15 p.m.Program Code: FR337Speaker(s): Wagdy Anis, FAIAevent Type: Seminarslearning units: 1 HSW/SD/LU Hour, 1.00 GBCIProvider: AIA Committee on the Environment and Building Enclosure Technology and Environment CouncilBuilding enclosure design must evolve in order to accommodate whole building energy efficiency goals of net zero. This seminar will explore available technologies designed to achieve the highest en-ergy efficiency, will explain where the bottlenecks are, and will explore dynamic façade technologies that are an important consideration in building de-sign. The seminar also will address regional energy efficiency impacts of enclosure systems.

Designing for Changing environmental and economic ClimatesFriday, May 13 | 6-7:00 p.m.Program Code: FR362Speaker(s): Hitoshi Abe, Ph.D., Coleman Coker, Alejandra Lillo, Assoc. AIA, James H. Timberlake, FAIA, LEED APlearning units: 1 LU HourProvider: Alejandra Lillo, Assoc. AIAThis session will share knowledge and insights acquired by architects participating in the Make It Right project (MIR). The NOLA region experi-enced extreme challenges triggered by Hurricane Katrina. MIR—a direct response to this region’s unique climactic and economic challenges—has given rise to the “largest and greenest community of single-family homes in the world” (USGBC). This successful and proven collaboration between the sometimes conflicting interests of design, sustainability, safety and affordability is demon-strated in the production of 41 LEED Platinum homes (to date) at a targeted cost of $150,000 per home. Three MIR architects will walk participants through the design, collaboration and construc-tion processes. As MIR engaged the talents of national and international architects, as well as those local to the NOLA region, one architect of each type will be represented in the seminar. The panel will discuss the constraints and challenges they faced and how their ideas were shaped by the collaborative process as the project evolved. Creating high design, highly sustainable and safe houses with restrictive budgets stands as a valu-able lesson for all architects today. These lessons will bolster the knowledge of attending architects, and subsequently will increase the value of their work. The presentation aims to dispel the common perception that high design and sustainability are accompanied by high price tags and to show that

affordable housing can have unique architectural character and can create a unique sense of place tied to the historical context.

Trust but Verify: your Design looks great, But Does it Perform? using Facility Performance evaluation to ensure your Project Delivers on its Promises Friday, May 13 | 2:15-3:15 p.m.Program Code: FR336Speaker(s): Lane J. Beougher, AIA, LEED AP BD+C, Patricia Chaput, Assoc. AIA, LEED APlearning units: 1 HSW/SD/LU Hour, 1.50 GBCIProvider: AIA Public ArchitectsThis session will provide information on the use of Facility Performance Evaluation (FPE) as a tool for determining building performance, including, but not limited to, the effectiveness of sustainable design and energy efficiency strategies in public facili-ties. This session will address the following topics: introduction to FPE, why and when to conduct an FPE, what kind of information is discovered when conducting an FPE, description of the key features of an FPE, who is currently utilizing FPE and who should consider using FPE, how to conduct an FPE, and resources for conducting FPEs. Also known as a Post-Occupancy Evaluation or POE, an FPE can validate the assumptions made during the design process regarding human comfort, energy and water efficiency, as well as other critical metrics. It can also be used to evaluate existing facilities under consideration for renovation or replacement, or to track changes in those facilities over time.

Truths and Truisms for the Next Twenty years Thursday, May 12 | 4-5:30 p.m. Program Code: TH254Speaker(s): Hugh M. Hochberg, Assoc. AIAevent Type: Seminarslearning units: 1.5 LU Hours Provider: The Coxe Group Inc. The next two decades will see significant changes in virtually all aspects of architecture practice. While

the short-term effects of the economy are clear, the longer term effects are, for most people consider-ably less clear. Equally cloudy are the futures of such things as clients’ evolving expectations, the changing face of competition, issues and opportuni-ties related to identifying, recruiting, developing and retaining talent. Technology will continue to evolve, both with and without the input of practitioners who use—and presumably benefit from—it. Certain patterns are evident already in how architects deliver their work, and savvy practitioners will want to know more about where it is going. This ses-sion will identify keys to achieving and sustaining a thriving practice in light of the anticipated changes. One aspect of this will be the increased importance of profitable operations and how to achieve and sustain such a level.

Keynote Presentations• Thomas Friedman, New York Times foreign affairs columnist and bestselling author, describes an increasingly flat world in which American workers are competing with workers in countries with emerging markets.• Jeb Brugmann, founding partner of The Next Practice, takes a microscope to our cities to explain how better building and urban development will enable us to solve the world’s current and future problems.• Mayors from New Orleans, honolulu and Detroit participate in a panel discussion on how political, community and design leadership will transform iconic urban centers.

Building Careers and Practices• More than 200 convention education sessions offer attendees the ability to customize their learning experience and expand their knowledge and capabilities. • Architects can maximize their professional development by earning annual continuing edu-

The AIA National Convention: Reinvented and Rebuilt



Special Report: AIA Preview

cation learning units for licensure in one convenient, stimulating environment. Nothing could be more time and cost efficient.• Attendees will increase their professional network. Join the country’s leading architects and design professionals who will be in atten- dance. Exchange ideas, connect with colleagues and build contact list of specialists in other fields.

The Rebuilt AIA Expo: Preparing for Projects• Attendees will expand their sources for new products and technology. AIA Expo2011 has been completely re-thought, with new products, demonstrations and design ideas throughout. Interact with more than 800 exhibitors to see and compare what’s new and what’s next. Find relevant exhibitors quickly and effi- ciently in six concentrated product pavilions, including one for metal resources.• More than 100 exhibitors will introduce attendees to the latest in green products and technology. These innovative, sustainable products may be just what the next client is asking for.

Join the Design RevolutionThe AIA 2011 National Convention and Design Exposi-tion brings the nation’s leading architects and designers together to chart the course of our profession. Registration is now open at www.aia.org/convention. Advance registration discounts are available through April 11.

And while you’re not busy at the convention…

New OrleansA primer on the Big easy

Getting AroundWalking through the streets of New Orleans is a favorite means of transportation. Many of the city’s attractions and venues are within walking distance of each other and the paths are relatively easy to navigate on foot. Besides, there is no better way to discover interesting sites off the beaten path, as well as street performances in various nooks and crannies around town. If walking is not an option, historic streetcars still run through the city and offer a unique way to see the city and relive the old charm of New Orleans.

Sight SeeingEach neighborhood in New Orleans has its own flare. The French Quarter is known as the city’s cultural hub. With an architectural mix of Spanish, French, Creole and American styles, the Quarter is as culturally diverse as its buildings. Jackson Square and Royal Street are usually bustling with street entertainment; you can see everything from clowns making balloon animals to impromptu shows presented by street performers. Tak-ing a walk down Chartres, Royal and Decatur streets will lead you past some unique shopping experiences including mask and costume shops, novelty stores fea-turing handcrafted items and bookstores that carry new and used books. And don’t miss the French Market, where not only can you buy something for everyone but you will have the opportunity to taste some unusual New Orleans treats. Alligator po-boy anyone?

Theater and Nightlife• Breakfast at Cafe Du Monde: The Original Cafe Du Monde Coffee Stand was established in 1862 in the New Orleans French Market. The Cafe is open 24 hours a day, seven days a week. It closes only on Christmas Day and on the day an occasional hurricane passes too close to New Orleans.• Mr. B’s Bistro: Nestled in the heart of the French Quarter, Mr. B’s Bistro is located at the intersection of Royal Street and Iberville, one of New Orleans’ most celebrated food corners. Since the 1860’s, this corner has been a New Orleans landmark. In 1868, this once quiet corner was transformed into Solari’s Market. New Orleanians came from all over town to visit this soda fountain and lunch counter whichalso specialized in merchandise not found anywhere else—like out-of- season fruits and vegetables, rare liquors, exquisite candy and imported cookies. • Pat O’Brian’s: There is always a party going on at Pat O’s on the River, Pat O’s Courtyard or The Briars Suite. • Palm Court Jazz Café: The Palm Court Jazz Cafe is housed in a fully restored early 19th century historic building on Decatur Street in the French Quarter and is a focal center for live traditional jazz music.• house of Blues: House of Blues is a home for live music and southern-inspired cuisine in an environment celebrating music and folk art.

MuseumsThe Arts/Warehouse District is filled with art gal-leries, restaurants and museums. It has even been referred to as the “SoHo of the South.” When you are ready to take a break from looking at the arts, get your dancing shoes on and try some authentic Cajun dancing. Mulate’s, located across from the Conven-tion Center and Riverwalk, offers authentic Cajun cuisine and nightly live Cajun music and dancing. Information courtesy of the American Institute of Archi-tects. For more on the convention, visit convention.aia.org.

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Today’s building professionals recognize that

a well-planned building envelope leads to

greater energy efficiency and a reduced carbon

footprint. Motivated by energy challenges and

green building mandates, they share a newfound

enthusiasm for wall and roof performance.

Insulated metal panels (IMP), for example, help optimize a building’s performance, beginning with the envelope, so a building can achieve LEED goals

and net-zero energy targets identified by the U.S. Department of Energy commercial building initiative. Focusing on enclosure performance, including durability, air tightness and moisture and thermal control, IMPs provide an aesthetically appealing and highly sustainable solution to architectural, commer-cial/industrial and cold storage markets.

Sustainable Designs Begin with the envelopeA critical first step to a high-performance, net-zero energy building begins with the envelope, followed by energy conservation measures that include day-lighting, HVAC systems, lighting and controls.

Among the most important envelope criteria are building shape and orientation; service life and durability of materials; quality assurance in the construction phase; energy efficiency during building operations; and resistance to air and moisture intrusion. IMPs contribute positively in all of these categories because of a continuous rigid insulation core that provides high R-values and unsurpassed airtightness. According to the Metal Construction As-sociation’s publication, “Insulated Metal Panels: Proven Performance Meets New Needs,” under normal circumstances, insulation placed within a

By Louise Foody

Products made for the building envelope, such as insulated metal panels, help meet building efficiency objectives by delivering maximum thermal performance.

building’s stud cavity can be as little as 33 per-cent effective. In contrast, IMPs can provide up to 95 percent thermal efficiency. Engineered as factory-assembled, single-component systems, IMPs are designed to reduce construction time and site-related environmental impacts. With all types of IMPs, the factory controlled, uniform insulation thickness provides continuous insulation that leaves no gaps, seams or thermal bridges in the enclosure and accounts for the high thermal efficiency of IMPs’ core. IMPs have R-values that range between R-4 and R-48 and a durable metal shell, which protects the building for its entire service life. In addition, the rigid insulation prevents the energy efficiency loss caused by insulation compression. And be-cause the insulation is located on the outside of the building structure, it prevents heat transfers through the framing. Testing and field results show IMPs contribute to energy efficiency and sustainability in a number of ways, most notably:

• Energy efficiency. IMPs have a core of continuous, rigid insulation for industry leading R- and U-values with superior airtightness performance.• Recycled and recyclable. The exterior skins contain a substantial amount of recycled content, and the panels themselves are ecyclable at end of life.• Faster construction times. IMPs are simple to detail and attach, reducing schedule times and installation errors.• Life-cycle benefits. IMPs last as long as the service life of a typical commercial building. The durable panels also reduce operation costs for energy and maintenance and offer multiple end-of-life reuse options.• Building certification and green targets. IMPs potentially contribute to LEED certification programs and the path to net-zero energy targets.

Preparing for the FutureThe continuous, structural integrity of IMPs leads to consistent lifetime thermal performance and

associated reductions in energy use, operational costs and carbon footprint. A well-insulated, low-leakage envelope provides a foundation for all other energy efficiency strategies. By reducing the heating and cooling loads that must be handled by other systems, the cost of making those systems efficient is decreased. In addition, an efficient envelope will be in place throughout the life of the building, while other systems are often replaced at some point in the building’s life. Installing efficient building systems, beginning with the building envelope, followed by energy con-servation measures and renewable power generating systems, represents an ideal approach for creating net-zero buildings and a sustainable future.

louise Foody is the marketing manager at Kingspan Insulated Panels North America, Deland, Fla. For more information, visit www.kingspanpanels.us.

Green Scene

The Building Envelope— A Key to Energy Efficiency

OPPOSITe PAge: IMPs were used to achieve the high-performance building envelope goals set by the design team for the Glazer Museum. The striking building serves as a dem-onstration tool, teaching children about sustain-ability and protecting the environment. ThIS PAge: IMPs were chosen for the renovation of Verizon’s building envelope. The variety of colors, profiles and sizes of the panels, along with the high insulation benefits provided the best building solution.


Award-winning DevelopmentThe Pacific Plaza building in downtown

Tacoma, Wash., was once a four-story,

decades-old and crumbling parking garage.

Now, the striking new state-of-the-art six-story

structure is the state’s only LEED Platinum

core and shell construction project.

The $35 million, 250,000-square-foot project features two new floors of 68,800 square feet Class A commercial space; 32,000 square feet of refurbished storefront office and retail space; and a 28,000-square-foot green roof. More than 26,000 square feet of Lewisville, Texas-based Metl-Span’s CF insulated panels were used to clad the inhabited portion of the office building/parking garage structure. The 3-inch panels were finished in Weathered Zinc and installed horizontally in 24-, 30- and 36-inch widths. The Metl-Span panels interface with a cement composite façade system used to clad

the exterior walls on the parking garage portion of the building. Pacific Plaza is the result of a successful public-private partnership between the city of Tacoma and the local development team of Pacific Plaza Development LLC. The city replaced a seismically deficient garage with a larger, like-new facility while the developer obtained street front retail space and air rights for commercial space without the burden of providing structure parking. The result has rejuve-nated a key commercial district. BLRB Architects, Tacoma, designed the award-winning project. “We were the only development team that proposed to keep the existing building and not put it in a landfill,” says Ben Ferguson, project manager and lead administrator on the proj-ect. The original parking structure, built in 1970 as part of a HUD urban renewal effort, was clad with a hammered concrete finish. It was stylish at the time but aged quickly.” According to Ferguson, the firm had not used Metl-Span before but was familiar with the concept of insulated metal panel products. “Our contrac-

tor looked around for different brands and the Metl-Span was the most price-competitive by far,” Ferguson says. “From an architectural standpoint, the Metl-Span enabled us to get the very flat aes-thetic that we wanted. It creates a very monolithic, structured and polished look.” BLRB designers used a peel and stick air and vapor barrier. “By having the insulation outboard, it enabled us to break our dew point outside the air and vapor barrier, which helped eliminate any concern for mold in the cavities of the walls,” Ferguson explains. “What we really like about Metl-Span is that the system is really an air and vapor barrier on its own. The building is extremely tight and energy efficient.” Kenco Construction Inc., Seattle, installed the Metl-Span panels; Absher Construction, Puyallup, Wash., was the general contractor; and PCS Structural Solutions, Tacoma, was the structural engineer. Pacific Plaza was named the 2010 Sustainable Project of the Year by NAIOP, the Commercial Real Estate Development Association.

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Washington’s first LEED Platinum Core-Shell building rejuvenates key commercial district

Metl-Span, www.metlspan.com, Circle #67


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Vicwest and AWIP: Joining forces to serve the IMP market better

Vicwest and All Weather Insulated PanelsTOGETHER… how cool is that? From sub-zero cold to dry heat or humidity, Mother Nature tests the very limits of building envelopes. Vicwest / AWIP Insulated Metal Panel Systems are engineered to maintain interior climate control, regardless of the weather. Plus, they allow for a one step pass around the building for faster installation and reduced labor costs. Available in various profiles, colors, sizes and finishes, Vicwest / AWIP Insulated Panels are the way of the future. www.awipanels.com www.vicwest.com

Renovated restaurant features ACM panelsThe third Flip Burger Boutique/Flip III used to be an Atlanta Block-buster Video building. Completed in November 2010, this is the only Flip Burger Boutique to feature 4-mm-thick APOLIC aluminum composite material panels with a PE Core from Mitsubishi Plastics Composites America, Chesapeake, Va., says Brian Bollins from Atlanta-based Strutor Group, the general contractor. The building features 2,050 square feet in “TOB” Black; 1,688 square feet in “MZG” Mica Gray; and 420 square feet of Mica “OPT” Platinum. According to Brian Burton, senior designer/webmaster at Atlanta-based Graphics Central Inc., the Flip Burger exterior panels were produced using a direct-to-substrate printing process that creates a panel, which will withstand the harsh exterior environments and surpass the potential to crack, peel or curl over time. “Once each of the panels was printed with the unique design, they were delivered in a ready-to-install package,” Burton says. “We brought the unconventional and edginess of the cuisine to the design using reflecting ceiling elements, bold colors and finishes, and playful graphics,” says Dave Heimbuch, Design Expert at AI3 Inc., Atlanta, the architect. “The result is a design that’s invigoratingly modern, yet like the menu, doesn’t take itself too seriously.” Additional companies involved in the project include the owner, Flip III LLC; the fabricator, Altech Panel Systems, Cartersville, Ga.; and the installer, SECO Architectural Systems Inc., Snellville, Ga.

AlPOlIC-Mitsubishi Plastics Composites America, www.alpolic.com, Circle #68

New market brings convenience to local residentsThe 650 residents of the small farming community of hamel, Ill., 30 miles northeast of St. Louis, had not enjoyed the convenience of a local grocery store in more than 10 years. To remedy this, four local couples joined together to finance and build D.K.’s Market, which was named after the initials of the owners’ children. Ceco builder R.W. Boeker Co. Inc., Hamel, was chosen as the design-builder, and E.R. McDonough & Associates, Edwardsville, Ill., was the project architect.

Completed in eight months, the 18,000-square-foot market serves not only those in Hamel, but shoppers within a 20-mile radius. The facility is 150 feet wide by 120 feet long, with a portion along one side built for future leasable office space. Unique bays feature an “in-and-out design,” says Boeker Vice President Scott Boeker. “Each bay has dif-ferent wall panels—some panels run horizontally, some vertically. And the bays are painted different colors, too, for dramatic effect.”

Ceco Building Systems, Columbus, Miss., sup-plied its CXP panels in Galvalume for the roof and MAP panels in Lightstone for the walls. Decorative panels included PBA panels in Desert Sand and Rustic Red, and a 7.2 panel in Lightstone.

Ceco Building Systems, www.cecobuildings.com, Circle #69




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Successful mall renovationBuilt in 1964, east hills Mall has been a strong economic catalyst for St. Joseph, Mo., and has drawn customers from a multistate region. As the mall became dated, a major renovation became critical for future success. Hollis+Miller Architects, Lee’s Summit, Mo., in collaboration with ComArts, Boulder, Colo., rede-signed the 676,000-square-foot mall. To create ap-peal and highlight strategic entrances, Indianapolis-based Citadel Architectural Products Inc. supplied approximately 14,000 square feet of its Envelope 2000 metal composite material panels. The Citadel panels were finished in Regal Red and Regal Blue, and were installed using the Reveal (RV) System. Walton Construction Co., Kansas City, was the general contractor; Seaman and Schuske Metal Works, St. Joseph, was the installer; and J.D. Day & Co., Overland Park, Kan., was the sales representative.

Citadel Architectural Products Inc.,www.citadelap.com, Circle #72

Industrial look desired for specialty food and wine storeThe Oxbow Public Market is a locally-owned specialty food and wine store in Napa, Calif. The 19,815-square-foot pre-engineered metal building system from Houston-based Metallic Building Co., utilized IPS RWP 250 roof panels from Houston-based IPS. Located in the heart of downtown, Oxbow of-fers food choices and an extensive wine selection, along with hosting events, and featuring music and dancing. The building boasts a vented system

with air movement for wine tempering. Addition-ally, the project architect utilized exposed wide flange beams around the perimeter for a structur-ally pleasing effect. Fourteen-foot roof overhang extensions and roof panels were used for greater R-values, as well as giving the building an industrial look. The exposed beams on the interior create an industrial look. BCV Architects, San Francisco, was the architect; Terra Nova Industries, Walnut Creek, Calif., was the general contractor; and Striplin Walker Construction Inc., El Dorado Hills, Calif., was the builder. Stafford, Texas-based IPS and Striplin Walker Construction were the erector/roofing contractors.

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Prototype design includes metal roofDover Federal Credit union may be more than 50 years old, but it recently embarked on a new look for its banking facilities. The prototype was rolled out with their New Castle, Del., branch. Becker Morgan Group, Dover, Del., designed the 4,700-square-foot branch on 2.5 acres. The design incorporates a metal roof from ATAS International Inc., Allentown, Pa. A quantity of about 9,000 square feet of Field-Lok (FLM125) was installed. These 12 1/2-inch-wide by 1-1/2-inch-high panels are 0.032-inch aluminum in a Teal finish. The roof

also includes curved Field-Lok panels (FLX125) with the same specifications. The distributor and installer was Eastern Metals, Newark, Del., and construction management services were provided by Lighthouse Construction Inc., Dover.

ATAS International Inc., www.atas.com, Circle #73

Metal building provides flexibilityTotaling 12,096 square feet, the grand Oaks event and Business Center in grove City, Ohio, utilized a single-ply roof with a Star parapet system from Oklahoma City-based Star Building System and Star’s wall systems—DuraRib in Galvalume-Acrylic and StarMark in Polar White. Frame walls were used inside and out of the StarMark wall system to create depth and shadow lines to help promote the build-ing design. Completed in August 2010, the multiuse metal building utilized Star’s SMTS structural system. Additionally, EIFS siding at various heights added depth and dimension to the exterior profile. Round columns added aesthetic accents and framed porch-es with a drive canopy covered in copper architectur-al panels enhance the buildings appeal. The structure was designed to carry rooftop HVAC equipment and snow loads from the parapet walls and the weight of the two moveable walls in the main assembly area. Reinforced insulation was used under Star siding and full insulation was used throughout frame walls. The interior boasts suspended clouds at three different levels in the main assembly area that add architectural interest and create an acoustical baffle for the area. The building’s clear span design was critical for providing the flexibility for changing the facility from multiple meeting rooms to one large assembly area. CDI Design Group Inc., Grove City, was the archi-tect, and Maverick Builders Inc., Grove City, was the builder, general contractor and steel erector.

Star Building Systems, www.starbuildings.com, Circle #74


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Metal roof provides “country look” for new shopping centerThe new el Dorado Market Place in Frisco, Texas, is a 400,000-square-foot shopping center designed to meet the city’s standards for lasting elements and durability. More than 31,000 square feet of PAC-CLAD material from Petersen Aluminum Corp., Elk Grove Village, Ill., was used in roof and façade applica-tions, including:

• 12,375 square feet of 24-gauge 16-inch Snap-Clad Panels• 1,260 square feet of 24-gauge 16-inch Tite Loc Panels used exclusively for curved applications• 5,373 square feet of 24-gauge 11-inch Flush Panels• 12,400 square feet of 24-gauge Flat Sheet All PAC-CLAD material was finished in Weathered Zinc O’Brien & Associates, Dallas, provided the design for the project. “Frisco has very rigid design criteria for all new construction and wants designs that include lasting elements that are built for du-rability,” says David Culbertson, project architect.

“We always like to use metal for pitched roofs, awnings and canopies. And we think metal gives somewhat of a ‘country look’ which was important in this rural area.” The El Dorado Market Place buildings are mainly concrete tilt wall construction with brick and stone applied as veneer over concrete walls. In some places, the concrete walls were left exposed and painted with an acrylic textured coating. “The weather in north Texas can be harsh,” Culbertson says. “The Petersen roof is durable and stands up well to the weather. We like it.” Lee Lewis Construction, Dallas, was the general contractor, and BRI Roofing & Sheet Metal, Haslet, Texas, did the installation.

Petersen Aluminum Corp., www.pac-clad.com, Circle #76

Urban high-rise blends local cultural traditionsLocated in the New Orleans business district, 930 Poydras is an urban, high-rise residential apart-ment complex with ground-level retail spaces for added amenities and an improved streetscape. The inspiration for the facility’s design came in part from the European, African and Caribbean traditions that have blended together over the years in creating New Orleans’ culture. The architects, New Orleans-based EskewDumezRipple, looked to the city’s French Quarter for inspiration to develop a sense of community among residents and to reinterpret the notion of a shared, yet private domain. An eight-story parking garage was built above the street-level retail space and the ninth floor of the 21 story apartment building is used as a consolidated space for resident amenities and social activities, including a pool deck. The 462,000-square-foot building includes 8,700 square feet of retail space. CENTRIA, Moon Township, Pa., supplied 34,446 square feet of 22/26-gauge Formawall Dimension Series vertical and horizontal wall panels in Blue Gray with an embossed Sundance AM coating and Forma-vue FV400 windows. The Formawall Dimension Series are Cradle to Cradle Silver certified. Gibbs Construction LLC, New Orleans, was the general contractor, and F.L. Crane & Sons, Fulton, Miss., was the dealer/installer.

CeNTRIA, www.centria.com, Circle #75






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Colorful exterior panels envelop LEED Gold animal shelterLouisville, Ky.-based Metal Sales Manufacturing Corp. brought colorful durability to the new humane Society Silicon Valley Animal Community Cen-ter in Milpitas, Calif., by providing nearly 1,000 square feet of metal panels. Metal Sales’ 7/8-inch corrugated 24-gauge pan-els surround the new facility, offering a long-lasting, sustainable exterior with a vibrant aesthetic. Five Energy Star listed colors were chosen to bring visual interest to the structure, including Copper Penny, Tahoe Blue, Terra Cotta, Hemlock Green and Jade Green. The facility is the first animal shelter in the nation to achieve LEED Gold certification from the U.S. Green Building Council. The building’s eco-friendly features include an extensive on-site solar energy generation system, a highly-efficient kennel cleansing system to minimize water usage, stained concrete flooring to reduce the need for chemical cleaning, bioswales to remove pollution from rainwater run-off and artificial turf to lower irrigation water demand. The Metal Sales panels contribute to LEED credits by reducing solar heat into the building and lowering cooling costs. Spanning nearly five acres, the $25 million facility was funded through public donations. Completed in March 2009, its L-shaped site plan encourages a sense of community as it organizes the building’s many public entrances around a common entry space. For more than 80 years, HSSV has served Silicon Valley and has helped to find homes for more than 500,000 animals. The new building will facilitate improved care for ani-mals, and its colorful metal-paneled exterior provides a cheerful environment for employees, volunteers and community members to enjoy. Swatt Miers, Emeryville, Calif., was the archi-tect, and Robert L. Brown Construction, Martinez, Calif., was the general contractor.

Metal Sales Manufacturing Corp., www.metalsales.us.com, Circle #77

Architectural grilles highlight mixed-use facility

The Williams Mullin Center in Richmond, Va., not only serves as the downtown headquarters for its namesake law firm, but also provides leased space to a mix of businesses, retailers, café and other amenities. Accommodating the many tenants and visitors, the Class A building’s three-story parking garage features architectural grilles from Alsip, Ill.-based Doralco Archi-tectural Metals, finished by Linetec, Wausau, Wis. “The architectural grilles were designed to keep headlights from shining into adjacent buildings through the use of tilted blades,” says Shawn Bow-man, marketing director at Doralco. The aluminum architectural grilles contain a minimum of 50 percent post-consumer recycled content, while the Linetec finish was an eco-friendly Class II clear anodize. “This carefully-controlled factory process mini-mizes imperfections in secondary billet to create an aesthetically-appealing matte finish. Because it is an integral part of the substrate, the anodic coat-

ing results in a hard, durable substance providing excellent wear and abrasion resistance with minimal maintenance,” says Linetec’s Senior Marketing Spe-cialist Tammy Schroeder, LEED Green Associate. Doralco pre-assembled the finished grilles and shipped them to the glazing contractor, Emmitsburg Glass Co., Emmitsburg, Md., for a convenient and smooth installation. The entire 15-story, 210,000-sqa-ure-foot project was completed in summer 2010. HBA Architecture & Interior Design Inc., Virginia Beach, Va., was the architect, and Armada Hoffler, Virginia Beach, was the developer and general contractor.

Doralco Architectural Metals, www.doralco.com, Circle #78

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Form and function key to retail buildingsThe 26,800-square-foot holgate Square in Seattle is owned by Puget Properties, Medina, Wash., and is made up of four metal buildings with a 20-foot eave height from Memphis, Tenn.-based Varco Pruden Buildings. The first building has a 3:12 roof slope and utilizes a Varco Pruden SSR metal roof and R-32 Simple Saver roof insulation from Thermal Design, Stoughton, Wis. Buildings two, three and four have a 4:12 roof slope and utilize Varco Pruden’s SLR standing-seam roof panels and Thermal Design’s R-32 Simple Saver roof insulation. Anderson Construction Group, Seattle, was the general contractor, and CHG Building Systems Inc., Renton, Wash., was the installer. Designed by Seattle-based Johnson Architecture & Planning, the buildings fit into the industrial charac-ter of the neighborhood and feature natural light and large volumes of space and durable low-maintenance finishes. “The unfinished space is designed to be flex-ible and can be divided into various sizes,” says Steve Johnson, principal of Johnson Architecture & Planning. “We worked with CHG to customize the VP Buildings pre-engineered systems that are economical and ap-propriate for this use. We were able to incorporate the mezzanines, the large glazed roll-up doors and create very useful industrial and business incubator spaces that can accommodate what each tenant needs.” Fontana, Calif.-based AEP Span supplied its Mini-V-Beam wall panels in Cool Metallic Champagne Kynar type paint for the majority of the building’s wall panels. Accent walls utilize AEP Span’s NuWave wall panels in Cool Zactique II Kynar type paint, applied horizontally. Modesto, Calif.-based Kingspan Insu-lated Panels Inc.’s API Century Wall insulated metal panels in a smooth Metallic Champagne finish were used as accents. The wall insulation is R-19. While the project did not pursue LEED certi-fication, it does feature a number of sustainable features, including:

• recycled and reclaimed material from the existing buildings that were demolished• recycled content and recyclable natural of the steel building components• the use of glass including natural ventilation• the canopies and sunscreens• high insulation values • local source of many materials

To provide the most flexibility for future owners or tenants, the original building lot was divided into five separate areas—four building lots and one com-mon area for parking—providing multiple possible configurations. The buildings are built out to nearly 100 percent coverage on the separate building lots. The broken-up wall surfaces on the street side and on the interior lot sides provide interest and function. The exposed wall bracing is used as a feature, and portal frame bracing as a function, to make door and window spaces as open as possible. The quality of the architectural metal roofing and siding shows bold verti-cal lines with wide flat insulated wall panels providing subtle features at the corners. Additionally, the cantile-vered canopies feature stainless-steel interior gutters.

AeP Span, www.aep-span.com, Circle #81

Kingspan Insulated Panels Inc., www.kingspan.us.com, Circle #82

Thermal Design, www.thermaldesign.com, Circle #83

Varco Pruden Buildings, www.vp.com, Circle #84

Retail building incorporates advanced materialsThe Fay-Penn Economic Development Council developed a multitenant building to provide retail services to more than 1,000 employees who work at the nine businesses operating within the Fayette Business Park in Fayette County, Pa. In a departure from the more typical emphasis on designing the building for lowest initial cost, the 10,800-square-foot property incorporates advanced materials, energy-saving HVAC and an alternative electrical technology, resulting in an attractive, environmentally friendly building with life cycle-based features the development agency uses in marketing the business park. The agency initially envisioned six 1,800-square-foot spaces, but the nearly 5,000 square feet committed to by the project’s comple-tion presented a broader range of sizes. The tenant mix thus far includes a restaurant, physical therapy clinic, child daycare and a beauty salon. Fairchance Construction, a Butler Builder in Fairchance, Pa., utilized design-build services for

the project, which includes Kansas City, Mo.-based Butler Manufacturing’s Widespan structural system with its MR-24 standing-seam metal roof system and Shadowall metal wall panels at the rear. The balance is made up of 4-inch split face block and stucco over a pre-insulated panelized wall system. McMillan Engineering, Uniontown, Pa., provided architectural services, and Pine Hollow Mechanical, Uniontown, Pa., provided the me-chanical and electrical design. Significant energy savings are derived from a windmill electric generator that powers the exterior lighting and a geothermal system of water source heat pumps for heating and cooling.

Butler Manufacturing, www.butlermfg.com, Circle #80


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Modern Trade Communications Inc.7450 N. Skokie Blvd., Skokie, IL 60077Phone: (847) 674-2200 Fax: (847) 674-3676www.moderntrade.comwww.metalarchitecture.com

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Volume 27 Number 4

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Company Page Phone Website Circle #

3A Composites 2 (800)626-3365 www.alucobondusa.com 3

Accelerated Building Technologies 46 (888)9-accel-E www.accel-E.com 32

Accurate Perforating 24 (800)621-0273 www.greenperf.com 15

AIA/Hanley Wood Exhibitions 26 (800)242-3837 www.aia.org 17

Alcoa Architectural Products 12 (478)374-4746 www.reynobond.com 9

Alpolic / Mitsubishi Chemical FP America Inc. 17 (800)422-7270 www.alpolic-northamerica.com 12

AMICO 31 (800)366-2642 www.amicoarch.com 22

ATAS International IBC (800)468-1441 www.atas.com 46

Aviation Building Systems 46 (866)454-1800 www.aviationbuildingsystems.com 31

C.R. Laurence Co. 42 (800)421-6144 www.crlaurence.com 25

Cascade Coil 52 (800)999-2645 www.cascadecoil.com 43

Ceco Building Systems BC (800)474-2326 www.cecobuildings.com 47

Citadel Architectural Products 37 (800)446-8828 www.citidelap.com 24

Contrarian Metal Resources 53 (800)360-5100 www.metalresources.net 45

Dri-Design 11 (616)355-2970 www.dri-design.com 8

DuraCoat Products Inc. 45 (951)341-6500 www.duracoatproducts.com 29

East Coast Lightning 48 (888)680-9462 www.icebrakes.com 34

Firestone Metal Products/UNA-CLAD 33 (800)426-7737 www.unaclad.com 23

Flex-Ability Concepts 49 (866)443-3539 www.flexabilityconcepts.com 36

Follansbee Steel 51 (800)624-6906 www.follansbeesteel.com 41

Hendrick Manufacturing Co. 25 (877)840-0881 www.hendrickarchproducts.com 16

Lamtec Corp. 6 (800)852-6832 www.lamtec.com 5

Lapeyre Stair 47 (800)535-7631 www.lapeyrestair.com 33

LMCurbs 51 (800)284-1412 www.lmcurbs.com 40

McNICHOLS Co. 29 (866)754-5144 www.mcnichols.com/ma 19

Metallic Building Co./ NCI Building Systems 14 (800)755-7339 www.metallic.com 10

Metallic Products 52 (800)356-7746 www.mpvent.com 42

Metl-Span IFC (877)585-9969 www.metlspan.com 1

NAAMM 30 (630)942-6591 www.emma-assoc.org 21

New Metals Inc. 30 (888)639-6382 www.newmetals.com 20

Petersen Aluminum Corp. 1 (800)PAC-CLAD www.pac-clad.com 2

ProFab Custom Fabricators 44 (866)590-0008 www.profabmetal.biz 27

Quality Perforating 22 (800)872-7373 www.qualityperf.com 14

R & M Steel Co. 44 (866)454-1800 www.rmsteel.com 28

Roof Hugger Inc. 50 (800)771-1711 www.roofhugger.com 38

S-5! 50 (800)825-3432 www.s-5.com 39

Schweiss Doors 52 (800)746-8273 www.bifold.com 44

Sheffield Metals 15 (800)283-5262 www.sheffieldmetals.com 11

Sno-Gem 46 (888)766-4367 www.snogem.com 30

SnoBlox/SnoJax 7 (800)SNOJAX1 www.snoblox-snojax.com 6

Storage Concepts 49 (281)286-0861 www.roundcaps.com 37

Thermal Design 4 (800)255-0776 www.thermaldesign.com 4

Triangle Fasteners Inc. 48 (800)486-1832 www.trianglefastener.com 35

Umicore Building Products USA 9 (919)874-7173 www.vmzinc.com 7

Vicwest 43 (905)825-2252 www.vicwest.com 26

W.S. Tyler 29 (800)321-6188 www.wstyler.com 18


New pavilion aids city’s goal of providingresidents a vibrant and viable lifestyle

A little innovative planning has brought an underutilized plot of land in lexington, Ky., to life. Juxtaposing old and new, a remarkable open air pavilion—the Fifth Third Bank Pavilion—houses concerts, weddings, festivals and the ever-popular Saturday morning farm-er’s market. The pavilion architecture is reminiscent of historic markets familiar to Lexington in the early 19th century, yet with a more contemporary twist. A colonnade of steel posts and simple brackets define

the framework of the pavilion. Tubular purlins attach the steel trusses to the roof where a raised clerestory provides natural ventilation. According to lead archi-tect, Clete Benken from Kinzelman Kline Gossman Architects, Covington, Ky., the challenge of maintain-ing the intimate scale inherent to the surrounding buildings was addressed by carefully calculating the height of the structure so as not to compete with the historic façades surrounding the park, including the old courthouse and adjacent restaurants. Galvanized steel was used in the overall fram-ing to reinforce the simplicity of the contemporary form as permeable clay pavers mark the path of the original carriage way. The market pavilion, along with the adjoining landscape, demonstrates the city’s commitment towards providing the residents a vibrant and viable lifestyle. Sustainable features of the pavilion include the use of polycarbonate sandwich panels in the

roof monitor and soft LED lighting that turns on at sundown. As night falls, the hidden LED strip light fixtures cast a soft, even light on the underside of the internal wood roof deck and provides a lantern-like glow when viewed from the outside. Form and function come together with five commercial-grade large diameter, low speed ceiling fans from Lexington-based Big Ass Fans, aiding in the natural ventilation of the space. The fans’ silent, comfort-ing breezes are especially welcome during hot summers when concerts and art festivals are non-stop in this population-dense environment.

Big Ass Fans, www.bigassfans.com, Circle #85

Smokehouse rebuilt for energy efficiency The Quintal family watched their third-generation busi-ness burn to the ground over 2009 Labor Day week-end and were devastated. But as the smoke cleared, they recognized an opportunity to rebuild it better for future generations and better for the environment. The facility, Oscar’s Adirondack Smokehouse in Warrensburgh, N.y., is where all of Oscar’s meat and cheese products are prepared, seasoned, smoked, stored, sold, shipped and savored. Completed in March 2010, American Buildings Co., Eufaula, Ala., supplied the Rigid Frame metal building system, roof and wall panels. The project is made up of three buildings—the processing, cooler and equipment. The processing building is 105 feet long by 65 feet wide with 16-foot eave heights; the cooler is 34 feet long by 52 feet wide with 15 1/12-foot eave heights; and the equipment building is 18 1/6 feet long by 22 feet wide with 15 1/12-foot eave heights, making up a total of 8,990 square feet. The new processing building is an M1 rigid frame that houses the three massive smokers that can process

1,500 pounds of meat at a time, 1,500 square feet of walk-in coolers and freezers, and the famous and friendly meat counter and enlarged retail area. An adjoining por-tion of the original foundation was salvaged and retrofit for another 2,200 square feet of pre-engineered structure that houses the shipping and receiving and equipment stor-age. The front sidewall has a continuous 6 feet at eave canopy, and the daily delivery and pick-up carriers appreciate the 15- by 32-foot endwall canopy that offers protec-tion from the elements of the upstate New York seasons. To maintain the Adirondack appeal, the high eave wall, or front of the building, was conventionally framed with light-gauge metal studs to a laterally reinforced spandrel beam at 14 feet and fit-up with a shingled roof walkway canopy, lighthouse red horizontal clapboard siding and a gran-ite veneer water table. The remainder of the perime-ter walls is finished with 3-inch thick insulated panels. To add to the energy-efficient building envelope, Greer, S.C.-based Guardian Building Products’ R-32 Purlin Glide insulation system was used under Ameri-can’s Standing Seam 360 roof panels with a Polar White finish lending a Solar Reflectance Index value of 81. The ceilings were fully lined with American’s Long Span III panels—in Polar White in the process-ing area and Galvalume in the retail area—to emulate the original smokehouse ceiling.

Additionally, an open loop geothermal system was installed to facilitate all of the HVAC and refrig-eration needs of the building. Munter Enterprises Inc., Middle Grove, N.Y. and Paone Architecture P.C., Saratoga Springs, N.Y. were the architects. Munter Enterprises Inc. was also the general contractor.

American Buildings Co., www.americanbuildings.com, Circle #86

guardian Building Products, www.guardianbp.com, Circle #87


Having already suffered from the abuse of time and

neglect, L.B. Landry High School in New Orleans was

nearly destroyed by Hurricane Katrina. Although many

believed the school would not reopen, it was chosen

by the Federal Emergency Management Agency, Loui-

siana Recovery Authority and Recovery School District

to receive funding and grants to rebuild.

The architectural team from New Orleans-based Eskew+Dumez+Ripple was challenged with design-ing a new sustainable high school that retained the old school’s basic layout with modern upgrades. The architects achieved this goal by using two unique ceiling applications from Hunter Douglas Contract Ceilings, Norcross, Ga., that enhance the aesthet-ics of the facility, encourage learning with a didactic approach to the interiors, and provide ceiling and

exterior walls with sustainable properties. The ceil-ing and exterior wall applications, along with other sustainable features, have put the facility on track to receive LEED Silver certification. The first ceiling installation was the application of 33,000 square feet of Hunter Douglas’ Hook-on Plank ceiling system in the high school’s public areas, corridors and cafeteria. The openness of the perforat-ed hook-on plank system was chosen, designed and engineered to feature two levels. The architectural team created two environments: an everyday space for students below the ceiling, and a separate space above the ceiling, which housed building services, such as HVAC, sprinklers and lighting. The second installation was the application of 37,000 square feet of Hunter Douglas’ Tubrise, roll-formed, tub-shaped baffles and louvers that function as interior ceiling covers (baffles) or as a sun louver system to provide solar control. In the gymnasium, there are 13,000 square feet of Tubrise that provide

the ceiling with a one-way mask with easy access. This also allows the Tubrise to serve as passive sky-lights, creating lighting conditions that the product is normally intended to control. Additionally, there are 24,000 square feet of exterior louvers that provide solar control while allowing outward visibility and free circulation of air. The contractors overcame a variety of obstacles to complete the project in time for the August 2010 opening, including matching custom prod-uct designs with strict installation and alignment requirements. The most difficult project-engineering task was the proper alignment of two levels of very different perforated panels. The effect of the two, aligned open panel perforations creates a design that students enjoy. Also, the external and internal baffle/louvers used to control solar heat from the exterior of the building and enhance solar lighting conditions in the interior, makes this an aesthetically pleasing design.

Two unique ceiling applications create an aesthetically pleasing design for new school

Top Honors

High-tech Ceilings

Award: CISCA 2010 Gold award winner in the ceilings category

Architect: Eskew+Dumez+Ripple, New Orleans

Metal ceiling systems: Hunter Douglas Contract Ceilings, Norcross, Ga., www.hunterdouglascontract.com, Circle #88

L.B. Landry High School, New Orleans


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metal architecture magazine - april 2011

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