12 - 2011 Metal Construction News
12 - 2011 Metal Construction News
12 - 2011 Metal Construction News
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At Owens Corning were always looking for new ways to improve energy efciency in metal buildings. We started by making roof insulation faster and safer to install with the ELAMINATOR Insulation System.
R-values. Next we developed a Commercial Energy Calculator to demonstrate the energy cost savings benets associated with higher levels of insulation. And now, with our new OptiLiner Banded Liner System, you can ll the metal building roof and wall cavities to achieve maximum thermal performance. What will we think of next?
Then we helped drive the development of the NAIMA 202-96 Certied Fiber Glass Metal Building Insulation Standard, ensuring post-lamination
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THE PINK PANTHER & 19642010 Metro-Goldwyn-Mayer Studios Inc. All Rights Reserved. The color PINK is a registered trademark of Owens Corning. 2010 Owens Corning.
VOL. 32 NO. 13
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DECEMBER 2011
Contents
Features:
14 Metal Construction News Building and Roofing Awards
The winners of our annual award program recognizing the top achievements in metal construction in the area of metal roofing, metal wall panels and metal buildings. LIVESTRONG Sporting Park, Kansas City, Mo., takes the overall winner spot.
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Weatherproof Walls
Getting the details right on walls to prevent moisture infiltration requires careful design, attention to installation and the right use of the right product.
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Feature: Faades
A modern high-rise in downtown Phoenix uses innovative shading techniques to manage the unrelenting sun and heat of the Arizona desert.
Departments:
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Find out how Simple Saver Synergy Designsm has helped contractors be successful in a down economy and how we can help you get more sales. Thermal Design will provide a Simple Saver Synergy Designsm analysis that includes:
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Editors Comments Profit Building Industry Perspective: The Freedonia Group Industry News and Events Project Focus: Religious New and Featured Products: Thermal Barriers and Fans, Ventilation and Heat Ad Index Editors Pick: Solar Savings
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Superior Insulation Reduced HVAC Optimal Lighting Building Controls Efficiency Incentives
Insulation system, HVAC & lighting designs Free energy analysis & performance comparisons Contractor competitive analysis Owner savings analysis (customized) Manufacturer consulting & support services List of available incentives, grants & rebates $1.80 sq. ft. tax deduction assistance
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Call now to learn how Synergy Design will create more opportunities to get more leads and sell more projects!
800-255-0776
On the cover: LIVESTRONG Sporting Park, Kansas City, Mo., is the overall winner of the MCN Building and Roofing Awards. Photography by Chris Mann.
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DECEMBER 2011 METAL CONSTRUCTION NEWS 5
www.thermaldesign.com
Copyright 2010 Thermal Design, Inc. All Rights Reserved.
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Features Top Stories Industry News
Visit www.MetalConstructionNews.com and see whats happening in the metal design and construction community from the industrys premier news resource.
Learn why metal roofs are tops for PV system installation. Find out why energy efficiency is key to building design. Understand the importance of energy-efficent building envelopes.
Gain a new perspective on the industry through the Aluminum Association and Metal Buildings Institute. Discover how a metal solar heating roof will save federal lab money.
Check for the latest updates from the AISC, AISI, the EPA and more. Stay informed on updates to the 14th Edition of the Steel Construction Manual.
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McNichols 2011 MetArch#2:Layout 1 1/26/11 2:54 PM Page 1
The west wing of the Barnes-Jewish Hospital in St. Peters, MO, is wrapped in bands of McNICHOLS Perforated Metal that act as a sunshade.
Architects and contractors look to McNICHOLS Designer Metals for sustainable, functional and aesthetic solutions for their projects.
McNICHOLS offers endless design opportunities with their Designer
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PROFIT BUILDING
INDUSTRY PERSPECTIVE
A new study from The Freedonia Group shows the potential for metal building systems
By David Petina
Nonresidential prefabricated building system demand in the U.S. is expected to increase 7.8 percent annually to $15.2 billion in 2015, a strong showing compared to the weakness over much of the previous decade. The recovery in office and commercial construction, coupled with continued gains in institutional, industrial and agricultural construction, will provide opportunities. The development of new products and technologies, including more tailored designs, greater cladding options for metal buildings and improved concrete mixes, will also support demand. However, competition from traditional site building will remain intense, and moderating prices for many of the raw materials used in prefabricated building systems will restrain value growth. Metal building systems (including components) have long been the largest segment of the U.S. nonresidential prefabricated building system industry and will remain so for the foreseeable future. While gains are not expected to match the overall prefabricated building system average, demand for metal building systems is expected to post strong 7.2 percent annual gains through 2015. Demand for metal building systems will benefit from product enhancements such as improved coatings, the increased use of nonmetal cladding systems, and greater customization. In addition, solid gains in many types of nonresidential construction, particularly the industrial and agricultural segments, will support the metal building system market. The market for metal building systems is dominated by the standard building and components segments. Standard metal building systems, which are used in industrial, commercial, office and institutional settings, are the largest single product segment and accounted for half of metal building system demand in 2010. Metal components, which are sold separately from complete metal building systems and include roof and wall panels, secondary framing elements, fasteners and accessories, comprised an additional 37 percent of the market in 2010. The smaller agricultural and other metal building segments make up the remainder of the market. Through 2015, demand for standard metal building systems will increase 8.3 percent annually to $3.4 billion, the fastest gains in any segment of the metal building industry. The market will be supported by continued growth in the industrial and institutional building sectors, and the recovery in office and commercial building. Efforts to broaden the appeal of metal building systems in many nonresidential applications will also support growth. Among nonmetal building systems, the modular building system segment is expected to see the strongest gains, just ahead of the panelized precast concrete segment. The modular building system market will benefit from robust growth in both commercial and institutional construction activity, as well as from the growing popularity of prefabricated bathroom and kitchen modules. Gains for panelized precast concrete systems will be driven by increases in office and commercial construction, which are among the more popular applications for these systems. This article is based on independent research conducted by The Freedonia Group. The full report can be purchased at www.thefreedoniagroup.com. Search for Study #2780, Nonresidential Prefabricated Building Systems to 2015. David Petina is a senior research analyst who joined The Freedonia Group in 1996. He has authored a number of industry studies, including Green Building Materials, Home Organization Products and HVAC Equipment. Through 2015, commercial applications are expected to post the fastest gains of any major market for prefabricated building systems. The commercial market will benefit from solid growth in construction spending and the prevalence of prefabricated structures in several commercial niches, including mini-storage facilities. In addition, both the retail and hospitality segments are expected to rebound from weak 2010 levels. In contrast, the industrial market will post the slowest gains through 2015, rising 3 percent annually. On a regional basis, the fastest gains in nonresidential prefabricated building demand are expected in the West, which will benefit from relatively strong nonresidential construction activity, as well as from above-average population and economic growth. Traditionally, the South has led the U.S. nonresidential prefabricated building system market. Over the forecast period, this region will continue to provide solid opportunities for producers, with the market expanding by $2.1 billion from 2010 levels.
7. Write it now!
Now for the fun part. Write down your New Year's resolutions for the next year. First, write down the one HUGE thing you want to accomplish plus three goals you want to achieve. Be sure to be specific and make your targets measurable. Keep your goals in front of you to refer to often. When you see targets in writing, you stay focused and constantly think of action plans and steps to achieve what you want. By using the year end as a trigger to sit down and write out your goals and identify New Years resolutions, your future will become what you want it to be. Dont wait another year to identify what you want. The clock is ticking! George Hedley owns Hedley Construction & Development Inc. and Hardhat Presentations in Newport Beach, Calif. He is an entrepreneur, best-selling author, popular speaker and business coach. Visit www.hardhatpresentations.com for more information.
DECEMBER 2011
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INDUSTRY NEWS
top stories
precision metal fabrication certifications to the NAM-endorsed Manufacturing Skills Certification Systems. The partnership adds FMA's Precision Sheet Metal Operator certification program to the SCS offerings. "The content of the PSMO program is extensive and has been developed over a period of years by a dedicated task force of industry professionals," says Jim Warren, FMA's director of education and membership. "The certification validates that the employee who passes the exam has a solid grounding in the science and math behind the technology. It focuses on the fundamentals of metal fabrication like blueprint reading and math calculations and assesses the basic knowledge needed for working with press brakes, shears, lasers or other precision fabricating equipment." The majority of manufacturers we survey lament the difficulty they have in hiring properly skilled employees. Now is the time to expand the SCS and the educational pathways to careers in all sectors of our manufacturing economy. And, we know there are many high skill career paths available in metal fabrication," notes Emily Stover DeRocco, president of the Manufacturing Institute. "After careful consideration by the SCS Approval Committee, we were pleased to extend an invitation to the Fabricators & Manufacturers Association International to join the system, with FMA's Precision Sheet Metal Operator certification program," says DeRocco. More information about the FMA's Precision Sheet Metal Operator Certification is available at fmanet.org/certification. In addition to Comer, the Council's members include: Randy Brooks, Aagaard-Juergensen Inc., Orlando, Fla.; Chris Rice, Rice Building Systems Inc., Sauk Rapids, Minn.; Marius Rygg, Gateway Building Systems Inc., Fargo, N.D.; Scott Eiker, Design & Build Corp., Fishers, Ind.; Art Hance, Hance Construction Inc., Washington, N.J.; John Westheimer, Cincinnati Commercial Contracting LLC, Cincinnati; Kyle Kent, Kent Construction Inc., Mandeville, La.; Chuck Harper, Harco Constructors Inc., North Little Rock, Ark.; Aaron Wolf, Fleming West Building Co. Inc., Chandler, Ariz.; Tim Viol, Tim Viol Construction Co. Inc., Tarzana, Calif.; Roy Timms, Timbro Design Build Construction, Welland, Ontario, Canada; and Scot Rutherford, Scott Builders, Edmonton, Alberta, Canada. Integrated Project Delivery. I am very excited about the direction we're headed and the progress the group has already made in bringing a unique solution to market." The Operations Group will be announcing its first product offerings in early 2012. "Look for more than a few new applications," says Chaney. "Look for a whole new approach to project collaboration software from Dexter + Chaney."
D I V I N E
C R A F T S M A N S H I P
Dexter + Chaney forms construction operations group Butler Manufacturing Advisory Council meets
The 13 members of the Butler Manufacturing Advisory Council recently traveled to Kansas City, Mo., for the bi-annual meeting of the Butler Builders who represent the six business regions in the United States and Canada. The Council's chairman this term is Don Comer, president and CEO of Bobbitt Design Build, which has offices in Raleigh, N.C., and Columbia, S.C. Each member serves a two-year term, with four members carried over for a second term. Dexter + Chaney announces the creation of a new business unit focused on innovative technology solutions for construction operations. The Dexter + Chaney Operations Group will deliver new construction software platforms and applications to those involved in construction operations across all phases of the project life cycle, from preconstruction through live construction. According to John Chaney, president and cofounder, "What we've done with the Operations Group is gather the right people together with the skills and industry domain experience to address the challenges of construction collaboration and
to erect a metal building. Over the next year, more than 40 students will have the opportunity to participate as they assemble and disassemble the structure using riggings and harnesses. In addition to learning how the pieces of a metal building fit together, students will learn about safety procedures and precautions. "Nucor Building Systems is committed to providing new training opportunities for students," says Tom Batterbee, general manager for the Terrell, Texas office of Nucor Building Systems. "These students are the future of our industry, and we want to ensure that they have all of the training tools to make a successful transition into the workforce." John Brown University reached out to Nucor Building Systems after doing research on pre-engineered metal building companies. According to the University's Construction Management Department head and professor Jim Caldwell, NBS' design documents and fabricated steel members have exceeded the school's expectations. "I have been very impressed with the staff at Nucor Building Systems and appreciate their willingness to partner with us in higher education," says Caldwell. "They've
Made in the USA European St yle Sustainable Products
256.255.0190 www.ornametals.com
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provided us with a high-quality product that will allow us to have hands-on labs with our students to instruct them on safe methods for constructing pre-engineered metal buildings. Many universities don't offer this type of training, which gives our students an advantage." The metal building will be utilized in the University's high-bay lab, which is part of a new stateof-the art building for the Engineering and Construction DepartmentBalzer Technology Center. The high-bay lab has a ceiling more than 25 feet tall, allowing students to use lifts inside the building to work on the metal building and other projects.
personnel update
arranging complex meetings and his compassion for helping all of those around him." Funeral services were Monday, October 31, in West Point, Miss. State University System. She obtained her Bachelor of Architecture from Virginia Tech, and is a licensed architect in Massachusetts as well as in Connecticut. She serves as a member of the North Atlantic Regional Council for the Society of College and University Planners, and is a member of the Association of University Architects, the American Institute of Architects and the Association of Higher Education Facilities Officers. The "Woman of Accomplishment" award, newly created last year by PWC-CT, is designed to honor a woman who has been working in the A/E/C industry for at least 10 years, and who exemplifies outstanding professional achievement, performance and contributions within her field of endeavor. Last year's award went to Lynn R. Fusco, CEO of Fusco Corp. and customer service personnel as they connect their efforts with the commercial organization to help drive benchmark customer service satisfaction levels for quality, service and communications. McElroy's career with Alcoa and Kawneer has spanned decades and a wide geographical range, including management positions in Florida, Georgia and California. McElroy served as general manager for the Alcoa Architectural Products plant in Eastman, Ga., as well as general manager with Kawneer. As general manager for Kawneer, he supervised facilities in Visalia; Lethbridge, Alberta, Canada; Seattle; Salt Lake City; and Kansas City, Mo.
DYNAMIC FASTENER
Everything for the Builder & Contractor
Ceco Building Systems marketing coordinator and training director David Malone passes
Veteran Ceco Building Systems marketing coordinator and training director David Malone was killed in a three-vehicle traffic accident Friday, October 28. A 40-year Ceco employee, Malone is survived by his wife Linda, a son, a daughter and three grandsons. "We are mourning the tragic loss of our friend and long-time colleague," says Ceco President Roger Burlingame. "The Ceco Family is in shock. David was a multi-talented person well-known in the industry for his acumen in
2012
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Soccer Specific and Fan Friendly LIVESTRONG Sporting Park takes top honors in the Metal ConstructionNews Building and Roofing Awards
This year, Major League Soccer surpassed both the NHL and the NBA in average game attendance. No small part of that feat can be attributed to the construction of great soccer stadiums such as LIVESTRONG Sporting Park in Kansas City, Kan. The team owners wanted to create a uniquely American soccer stadium to help elevate soccers standing as a major league sport, says Brad Albers, AIA, associate principle of Populous, Kansas City, Mo., and lead designer on the project. To do this, we looked at the model of European stadia for inspiration. The modern design and the 360-degree canopy over the seating bowl are two of the more evident elements influenced by the European model. The stadiums seating and other fan amenities are a continuation of the American standard of comfort and convenience that exists in other new professional sports venues. The judges appreciated the breadth of the use of metal in the project from the dynamic use of metal panels to the defining structural canopy. LIVESTRONG Sporting Park is a 340,000-squarefoot facility set on 14 acres. It includes 185,900 seats and 36 luxury suites as well as five clubs. The field is natural grass and measures 75 by 120 yards. Alucobond aluminum composite panels by 3A composites USA Inc., Mooresville, N.C., were selected as the cladding for the both the buildings exterior and the interior concourse. The 60,800 square feet of cladding was in 6-mm thickness and included four custom colors. The fabricator and installer, A2MG, Kansas City, Mo., was instrumental in making in both specifying the panel selection and making sure the project flowed smoothly. In particular, the tight construction schedule made the task more difficult. Chris Mann, project manager at A2MG, says, We were building panels from November to the end of May. In six months, we turned around thousands of panels, 30 percent of which were typical, but 70 percent werent. Most of the panels were installed in bands around the building that serve to drive the design. One band had three panels, says Mann. The center panel was typical, but the top and bottom were edge panels. Albers explains that the color choice was driven by the team colors and the need to match the work with the other building materials such as the CMUs, limestone cladding and curtainwalls. Used in either a solid or variegated pattern, he says, the colors create visual interest. Contest judge Ted Miller of The Miller-Clapperton Partnership, Austell, Ga., says, The multitude of applications of metal walls on this project 14 METAL CONSTRUCTION NEWS DECEMBER 2011
Photo Credit: Chris Mann Photo Credit for small photos: Alistair Tutton
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General Contractor: Turner Construction Co., Kansas City, Mo., www.turnerconstruction.com Metal Panel Fabricator and Installer: A2MG, Kansas City, Mo., www.a2mg.com Metal Panels: Alucobond, 3A Composites USA Inc., Mooresville, N.C., www.alucobondusa.com Canopy: Structural Steel installed by Bratton Corp., Kansas City, Mo. Metal Deck Wheeling Corrugating, Wheeling, W.V., installed by Bratton Corp. Polycarbonate Panels Series 3000 Long Span, Duo-Gard, Canton, Mich., installed by A2MG
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A Cutting-edge Research Facility Utah State University Life Science Research building reflects sustainable practices and promotes commercially viable research
The Utah Science, Technology and Research (USTAR) building at Utah State University in Salt Lake City is a high-tech research facility for life sciences that promises to advance research that will lead to commercialization and economic benefits for the state. Plus, according to the judges, it was as fine an example of metal building design as they saw in the Metal Construction News Building and Roofing Awards. Joshua Greene of AJC Architects, Salt Lake City, says, The USTAR Building was designed to maximize human health, comfort and workability, featuring an open lab environment, centralized formal and informal collaboration zones, and adjacent private and open office spaces (seamlessly incorporated despite high-security requirements), all with 12-foot-tall windows infusing ample sunlight and views of Cache Valley into the narrow floor-plate. The building symbolizes Utah States embracing the future of research and technology. The Cache Valley is an agrarian area and the gentle palettes reflect the farmland around the building. That effect is enhanced by the corrugated, zinc metal panels from Umicore Building Products USA Inc., Raleigh, N.C., that clad the majority of the faade. The panels give the building a texture and color that recalls the utilitarian architecture dotting the surrounding landscape, says Greene. The metal panels were selected in large part because of their sustainability, as well as aesthetic appeal because sustainability is a key element of the building construction. The upper levels of the office wing of the building were clad exclusively in 1-mm VMZINC corrugated zinc panels and, to provide greater visual interest, have a 50 percent perforation with small-diameter holes. This provides sun shading on the south and east sides of the building, and at night offers a dramatic see-through effect from the lights inside the building. The project had a goal of using 20 percent recycled products, and the zinc panels, with their high recycled content contributed significantly to achieving that goal. In addition, the project aimed to divert 89 percent of the waste from the landfill. Careful planning allowed the installers, Southam & Associates, American Fork, Utah, to vastly reduce construction waste when cutting panels. The 118,000-square-foot facility sits on the Innovation Campus, two miles from Utah States main campus. Judges reacted strongly the innovative use of the metal building materials to recognize this project as the winner in the Metal Building category.
Photo Credit: Gilbertson Photography
Utah Science, Technology and Research building at Utah State University, Salt Lake City
Completed: October 2011 Total Square Feet: 118,000 square feet Building Owner: Utah State University Architect: AJC Architects, Salt Lake City, www.ajcarchitects.com General Contractor: Gramoll Construction, North Salt Lake, Utah, www.gramoll.com Lab Consultant: Payette Associates, Boston, www.payette.com Metal Panel Fabricator and Installer: Southam & Associates, American Fork, Utah www.boostdemo.com/southam Metal Panels: 1-mm VMZINC Flat Lock Panel and 1-mm VMZINC Corrugated, Umicore Building Products USA Inc., Raleigh, N.C., www.vmzinc-us.com w w w. m e t a l c o n s t r u c t i o n n e w s . c o m w w w. m e t a l c o n s t r u c t i o n n e w s . c o m DECEMBER 2011 METAL CONSTRUCTION NEWS 19
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The Outer Wall The Poetry Foundation building presents an austere wall that protects and invites
To enter the Poetry Foundation building in the River North area of Chicago, you need to enter through breaches in a series of walls that transition you from an urban environment to a garden sanctuary to the glass-enclosed inner sanctum of the poetic universe. The outer wall, paneled with corrugated black zinc, shows a dramatic and austere profile to the public. But is a drama that also invites pedestrians to enter the revealed garden behind. John Ronan, John Ronan Architects, Chicago, says: The building is conceived as a series of layers of different materialszinc, glass, woodthat visitors move through and between, creating an unfolding sequence of spaces, not unlike a poem unfolds line by line. The outer layer of oxidized zinc gave the building an air of mystery that would intrigue people and make them want to explore. The judges of the Metal Construction News Building and Roofing Awards loved the effect of the black zinc panels, acknowledging how dramatic the effect is in the more traditional urban environment. Ronin notes that pedestrians often are engaged by the paneling and reach out to touch it as they pass. Workers from Tuschall Engineering, Burr Ridge, Ill., installed 19,500 square feet of 1-mm ANTHRAZINC panels from Umicroe Building Products Inc., Raleigh, N.C., on the 22,000-square-foot building. The 4,000-square-foot garden area was wrapped with 6,500 square feet of perforated paneling. The project provided some significant challenges for Tuschall. The installation began in January 2011 and was completed in June, but Tuschalls work began long before with mock-ups that were delivered on site for approval. In particular, Ronan wanted to ensure that the perforation pattern on the panel did not create a moray or a dense visual pattern. Jim Tuschall, president of Tuschall Engineering, addressed other challenges. To meet the production schedule, the panels needed to be preordered and cut to length so coordinating with actual field measurements required special care. Also, since the panels were fabricated in hot, dry Arizona and shipped to cold, moist Chicago, they needed to be shipped and stored in temperature and humidity controlled environments to prevent moisture building up on the panels. Finally, the site itself presented particular obstacles including not enough space to store panels on site and, along one side of the building, a very narrow (less than 3 feet) clearance for installing. We had to put our skinny guys in there, says Tuschall. Nonetheless, the effect is exciting and this corner lot in Chicago has a new breath of fresh air. The corrugated panel is probably an extremely generic product profile, says Tuschall, that was turned into something wonderfully aesthetic with dramatic effect.
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Arc Houses Historic Winning Look Custom home mirrors historic hangar radius roof
The Arc House in East Hampton, N.Y. is a custom home designed with an arching corrugated metal roof supplied by SteelMaster Buildings, Virginia Beach, Va. The arch is the defining element of the 6,400-square-foot home and requires no weight-bearing columns. The Arc House is fashioned after a Quonset Hut, a lightweight pre-fabricated structure made of corrugated galvanized steel or iron. Originated in 1941, the United States Navy needed an all-purpose, lightweight building that could be shipped anywhere in the world and assembled quickly and easily. The idea was to go back to the original Quonset Hut airplane hangars, says William Swafford, senior design specialist, SteelMaster Buildings. This is what the owner and the architect thought would be a good idea. Its strength and durability, and the clear span of steel make it the only choice. The radius roofing system was selected due to its unique design and its material strength. The column-less independent steel canopy covers all the major public spaces of the house. We were trying to make it look voluminous inside, Swafford says. But since it is also a living room, keep it somewhat intimate. The challenge for the architect was to find a scale for the steel arch that will change the system of the building into both intimate and enclosed spaces. The challenge was to not make this look like an airport or a stadium, says the architect Maziar Behrooz, owner and founder, Maziar Behrooz Architecture, East Hampton. The dimensions are 16 feet to the top of the arc from the ground. The front-to-back length is 32 feet, and side by side length is 64 feet. Steel was used in this design to achieve the desired look and provide a clean span design. In addition, the steel used in the structure contains both post-consumer and post-industrial recycled materials. This aspect compliments the other green aspects of the home, including geothermal temperature controls, water recycling system and a Zen garden on the roof of the lower level. Im trying to phase out the use of conventional lumber in my projects, says Behrooz. This is due to the fact that we are depleting our forests. Also, steel is much stronger than wood. Its resilient and it doesnt rot like wood does. It doesnt hold mold or mildew like wood does. It lasts longer than conventional lumber. Photography By Matthew Carbone, www.matthewcarbone.com
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Beat the Heat Perforated metal exoskeleton provides shade for desert home
An Artistic Arts Center Creative and innovative arts center optimizes metal
Located in Providence, R.I., Brown University's Perry and Marty Granoff Center for the Creative Arts is intended to advance new directions in teaching and research, and cross boundaries between the arts, sciences and the humanities. Designed by New York City-based Diller, Scofidio + Renfro, the 38,800-square-foot center features a recital hall, recording studio, multi-media lab and studios. All space within the building will be assigned for multi-disciplinary work. Programs and courses will be developed where collaboration among artists, scientists, and humanists will seek to create new art forms, new approaches to collaborative work, and will explore, examine, and extend our understanding of the creative process. The building structure contains a concrete and steel moment frame from Seekonk, Mass.based J.L. Marshall & Sons Inc. Boston-based Karas & Karas Glass Co. Inc. fabricated the building envelope. The building envelope features 60,000 square feet of Raleigh, N.C.-based Umicore Building Products USA Inc.'s 0.70-mm VMZINC QUARTZZINC with a Preweathered Gray patina. The building envelope also contains 26,000 square feet of Eastman, Ga.-based Alcoa Architectural Products' 4-mm Reynobond Zinc Composite Material panels with an FR core and prepatina VMZINC finish in addition to 4,000 square feet of 4-mm Reynobond Aluminum Composite Material panels with an FR core and custom Grey Velvet Kynar finish. Karas & Karas' Chief Estimator Thomas Mayo
Perry and Marty Granoff Center for the Creative Arts, Providence, R.I. Private Residence, Joshua Tree, Calif.
Completed: 2011 Total Square Feet: 2,400 square feet General Contractor: 44 West Construction Inc., Topanga, Calif., www.44west.net Architect: Ecotechdesign, Los Angeles, ecotechdesign.com Metal Building: Butler Manufacturing, Kansas City, Mo., www.butlermfg.com Metal Framing System: Atkore International Inc., Harvey, Ill., www.unitstrut.us Perforated Metal Panels: McNICHOLS Co., Tampa, Fla., www.mcnichols.com Skylights: VELUX America Inc., Greenwood, S.C., www.veluxusa.com Completed: January 2010 Total square footage: 35,000 square feet Building Owner: Brown University Architect: Diller Scofidio + Renfro, New York, N.Y., www.dsrny.com General Contractor: Shawmut Design and Construction, Boston, www.shawmut.com Fabricator: Karas & Karas Glass Co., South Boston, Mass., www.karasglass.com Structural System: J.L. Marshall & Sons Inc., Seekonk, Mass., www.jlmarshall.com Metal Wall Panels: Alcoa Architectural Products, Eastman, Ga., www.alcoaarchitecturalproducts.com Zinc: Umicore Building Products USA Inc., Raleigh, N.C., www.vmzinc-us.com w w w. m e t a l c o n s t r u c t i o n n e w s . c o m Photos By Diller Scofidio + Renfro
notes, "I think that the greatest challenge for us was the varied geometry of the application and that fact that each panel was one of a kind. Shop drawings paint a broad picture and really tell a very small portion of the story; the real work comes after they are approved. Our project engineers and fabricators worked hand in hand to determine the sizing, folding and assembly requirements of the individual panels and how they had to fit into a specific sequence of panels to create a specific pleat within a specific section of a specific elevation on the faade to achieve 'the look' the architects envisioned for the project. The coordination between shop and field was intense." The building in made up of large uninterrupted floor plates with interior surfaces ranging from raw to refined. The building has three floor plates that fill the site envelope cut in the short axis along a shear line. They are displaced in section to create six half levels, each with different technical and physical properties. The structural misalignment is a sectional opportunity allowing each floor to interface tow others conjoined by a shear glass wall. The overall effect of the glass wall allows students and visitors to become spectators of creative activities occurring throughout the whole building allowing a creative connection and dynamic to flow throughout the entire structure.
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The Bertram and Judith Kohl Building at the Oberlin Conservatory of Music, Oberlin, Ohio
Completed: April 2010 Total Square Feet: 37,000 square feet Building Owner: Oberlin Conservatory of Music, Oberlin Architect: Westlake Reed Leskosky, Cleveland, www.wrldesign.com General Contractor: The Krill Co., Cleveland, www.krill.com Metal Panel Fabricator and Installer: Riverside Group, Windsor, Ontario, Canada, www.riversidegroup.net Metal Wall Panels: Alcoa Architectural Products, Eastman, Ga., www.alcoaarchitecturalproducts.com
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manager, Knight Wall Systems, Deer Park, Wash. And usually the substrate that the faade, or panels are to be attached to should be completely wrapped with a weather-resistant barrier, an air barrier, and sealed at all service openings and/or penetrations prior to the faade installation. This is what ultimately stops, or blocks any water from infiltrating the interior wall assembly. Think of a rainscreen as a building envelope support mechanism. This is because the sole purpose of a rainscreen is to significantly limit the forces that act on the wall, therefore limiting the amount of water that actually contacts the weather-resistant barrier.
bridge, Mass. Grace offers Perm-A-View Modeling Service that generates critical information to help optimize wall design and guide selection of proper air barrier and vapor barrier material. Grace Perm-A-Barrier air barriers provide continuous water and air resistance to ensure buildings are protected from water and air intrusion. They are continuous and fully bonded to construction surfaces to resist positive and negative air forces, Wu adds. Their elongation can bridge cracks and fissures even in cold temperature. Vapor retarders are rated for their permeability (perm rating) and the lower the perm, the better the product retards the migration of moisture. When insulation is left exposed and the vapor retarder on the insulation becomes the exposed surface, the surface integrity becomes critical. In most applications where the vapor retarder is exposed, it serves a dual purpose as an air barrier enhancing its importance. Recent testing by the Metal Building Manufacturers Association has shown that a properly sealed vapor retarder covering the insulation does indeed meet most air infiltration requirements for an assembly, says Mark Engebretson, director of marketing and business development, Therm-All Inc., North Olmsted, Ohio. All seams, joints and any tears should be treated. When exposed to the interior, appearance and light reflectivity of the vapor retarder should also be considered. Ultraviolet rays from the sun and interior lighting can degrade vapor retarders, so it is important to choose the appropriate facing based on the conditions it will be exposed to.
The Dow-Knight CI-System continuous insulation rainscreen is a validated weather-resistant barrier system. (Photo courtesy of Knight Wall Systems)
Minimizing mold
Mold has been in the news a lot lately. Liquid water collecting in the wrong places can cause mold development, which is usually left unseen and therefore can grow to be a very expensive problem to correct, says Jane Wu, product marketing manager, W.R. Grace & Co., Cambridge, Mass. Mold is a living organism requiring food in order to be sustained. It feeds on organic material such as wood and paper found in homes and buildings. It originates from two separate problem areas. It is not enough to look at toxic mold as a problem coming from the exterior of the building, says John Pierson, PE engineering services manager, The Garland Co. Inc., Cleveland. Moisture problems that lead to mold are not only generated from leaks, but also result from condensation inside the building. Metal wall assemblies need to be designed to address moisture from both inside and out. Hundreds of species of mold are found in the United States that are not harmful to people. However, certain toxic molds such as aspergillus, penicillium and toxic mold atra (also known as stachybotrus chartarum) can cause illness. Toxic mold or black mold can be deadly, especially to children with mold allergies. Toxic mold has become almost epidemic in some parts of the United States where foam board was used as wall insulation with no air space to let walls breathe. After black mold begins to grow, microscopic mold spores quickly become airborne and travel throughout air conditioning and heating systems. Weatherproof wall manufacturers are trying to stop mold. The expandable polystyrene (EPS) in our accel-E Steel Thermal Efficient Panel (S.T.E.P.) does not hold moisture and is not a food source, says Bob Ross Sr., construction technician, SYNTHEON Inc., Pittsburgh. This is also true of the steel framing thats embedded in the EPS of the STEP panel. Georgia-Pacific Gypsum manufactures substrates that act as weather-resistant barriers in response to todays tight buildings that dont allow for moisture that enters a building to dry. Our gypsum products fiberglass mat technology allows for some moisture to be let in and also for it to dry back out, which helps reduce the potential for mold growth, says Warren Barber, Dens brand product manager, Georgia-Pacific Gypsum, Atlanta. The fiberglass facings are mechanically bound to the gypsum core, eliminating the starch bond and paper facings that are potential food sources for mold growth.
Vapor retarders
A vapor retarder is any element that controls and limits water flow in its vapor form across exterior wall systems. The primary line of defense against condensation damage is a good vapor barrier, says Robert A. Zabcik, P.E., LEED AP, director of research and development/Green Building Initiative, NCI Group Inc., Houston. But it doesnt stop there. Even the strongest vapor barrier is a detriment to the building and occupants if it is not installed properly. This obviously includes sealing and boundary detailing but also physically where the vapor barrier is installed relative to the dew plane in the envelope. Vapor barriers position and usage in a wall assembly depend on climate conditions, location of insulation relative to the subcavity and cladding absorptiveness. Many air barrier products also act as a vapor barrier, says Jane Wu, product marketing manager, W.R. Grace & Co., Cam-
moisture security system. A rainscreen is not a watertight assembly. Typically on the rainscreen wall assembly, the portion of the wall I would consider to be weatherproof is the substrate, says Brain Nelson, general
Weatherproof walls can prevent or at least minimize water and moisture migration into buildings. (Photo courtesy of Benjamin Obdyke) Inc.
the wall, allowing it to dry back out to the interior or the exterior of the wall. Today, building science is all about energy conservation. We are building our buildings airtight to reduce energy loss and air loss across the exterior walls. And, we are using highly engineered building materials. Many of these new materials are not able to withstand moisture and todays walls are thinner. This new way of building brings new concerns. Many times in todays new buildings, when air enters buildings it brings moisture with it, which can accumulate. The moisture has nowhere to go and it cannot dry out because the air movement that would carry the moisture out of the building has been restricted, Barber says. Water can cause rust and produce corrosion in metal buildings. The water-affected metal can oxidize over time, causing weakness within the buildings framework and ultimately shortening the life expectancy of the building.
Rainscreen walls
A rainscreen wall is actually more than a wall. It is an entire cladding system designed to keep moisture out of the building. The rainscreen can be brick, stucco, terra cotta, metal or even glass, says Barber. It
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FEATURE FACADES
26-story high-rise located in downtown Phoenix. The building's transparency creates a beacon at night. Vertical shade fins located on the east and west facades protect the building from low-angle sun.
Shade fins on the south facade of the tower blend with smaller decorative fins on the parking garage below.
he continues. The team had to work diligently in order to get everything to line up between the different exterior building systems. With the various connections to structure, floor-to-floor heights and fly-bys, it was imperative that the final product came across as a cohesive building even though each faade orientation is treated to respond to the environment differently.
Development manager: Mesirow Financial, Chicago Design architect/MEP engineer: SmithGroup, Phoenix General contractor: Holder Construction Co., Phoenix Structural engineer: PK Associates LLC
Innovative Shading
In the heart of downtown Phoenix stands a modern high-rise office building that is distinctly different from the ones around it. By using innovative technology instead of opaque materials, the 26-story Freeport-McMoRan Center mitigates the intense heat gain and glare of the desert environment. Formerly known as One Central Park East, the building currently is named after the FreeportMcMoRan mining company headquartered in the tower. Surrounded by the new development of Arizona State Universitys downtown campus and Civic Park, along with the central bus transit hub and a light rail station across the street, this is one of the newest large-scale, transit-oriented development projects in Phoenix.
Consulting Structural Engineers, Scottsdale, Ariz. Cival engineer: Evans Kuhn & Associates Inc., Phoenix Landscape architects: Laskin & Associates Inc., Phoenix Curtainwall fabricator: MK Architectural Metal Inc., North Canton, Ohio Curtainwall subcontractor: Walters & Wolf, Gilbert, Ariz. Faade testing: Construction Consulting Laboratory West, Ontario, Calif. Metal wall panels: Kalzip Inc., Michigan City, Ind. Aluminum composite material: Mitsubishi Plastics Composites America Inc., Chesapeake, Va. ACM panel fabricator: Armetco Systems Inc., Justin, Texas Sunshades: C/S Group, Cranford, N.J. Insulating glass units: Viracon, Owatonna, Minn. Dichroic glass: SCHOTT North America Inc., Elmsford, N.Y.
Structural glass wall and stone flooring blend interior space with exterior.
A New Concept
The concept was to create a new type of office building that would attract a major national or international prime tenant, says Mark Roddy, AIA, design principal at SmithGroup, Phoenix. Part of a recent rebirth within the downtown area, the building incorporates office and environmental strategies. The design is an alternative to the existing context that has attempted to respond to the intense heat gain and glare of the desert environment by simply incorporating opaque materials, Roddy explains. This project takes the opposite approach by using transparency, and incorporating current glass technology and a high-performance curtainwall system, along with innovative shading to provide sun control. Completed in November 2009, the building includes approximately 485,000 square feet of office 30 METAL CONSTRUCTION NEWS DECEMBER 2011
Faade Strategies
According to Roddy, the project has three primary faade strategies. First is the cladding of the above-grade parking structure that features perforated panels to allow for airflow and natural ventilation, while still visually screening the cars. Next is the horizontal shading on the south faade by two custom 17-inch airfoil blade shade fins per floor that block direct heat gain and bounce indirect light into the building. Lastly is vertical shading for low angle sun on the east and west facades. Continuous custom 17inch airfoil blades at 5 feet on center provide shading while maintaining views. The custom graduated ceramic frit pattern on the glass adds an additional 15 percent shading. Only the north faade does not require the use of shading devices. w w w. m e t a l c o n s t r u c t i o n n e w s . c o m
Critical Shading
The goal was to design a high-performance modern high-rise office building using a sophisticated curtainwall system while maintaining an appropriate response to the Arizona desert environment, explains Greg Buchanan, AIA, project architect at SmithGroup. Shading is critical. The use of aluminum allowed for a cohesive design connection between all the facade components. It also was
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www.metalconstructionnews.com/articles/projects/religious.aspx
As the headquarters of the Western Dioceses of the Armenian Church of North America, the St. Leon Cathedral of the Western Dioceses in Burbank, Calif., was an important project for an entire cultural community. The cathedral represents Californias Armenian community that has more than 100 years of history tied into developing a life and cultural identity in the United States. One of the earliest Armenian communities sprang up in Fresno around 1871. With more than a centurys worth of history and belief, any new religious establishment needed to reflect the history as well as the current state of the Western Diocese of the Armenian Apostolic Church. St. Leon continues to mixes the modern and traditional. The church was consecrated in 2010 and the buildings interior reflects the faith of the community in the numerous stained glass windows and icons within the cathedral. Like many parishes, the Armenian Apostolic Church offers parishioners bible study, sacraments, Sunday services, and Saturday or Sunday school for children. Kaaren Khoudikian, with 2K Forum Inc., designed the church by combining elements of Armenian and American culture. The base of the church is built with stone imported from Armenia, symbolizing the tradition of the Armenian church and its people. The upper portion of the church utilizes modern materials, such as metal. ATAS International Inc. supplied its 0.032-inch Dutch Seam (MRD150) metal roof panels in Coppertone for the project. Khoudikian notes, The symbolic meaning is that even though we as people are old and traditional, we are also modern people, as well. In addition to its aesthetic effects, Khoudikian explains that metal was also chosen for its weatherability, watertightness, durability and strength.
Cultural Cathedral
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Construction manager: JMS Metals, Sparta, Ill. Metal wall panels: Metl-Span, Lewisville, Texas, www.metl-span.com, Circle #37
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St. Joseph Church, Scott City, Kan. The St. Joseph Church features a metal building and ADP-1 metal roof system from Behlen Building Systems. The 18,400-square-foot building is 115 feet wide and 160 feet long. The exterior walls are brick and combined with the gentle slope of the roof creates a pleasing aesthetic for parishioners and the community at large.
Builder: Mid American Millwright Service Inc., Garden City, Kan. Architect: Terry and Joel Chapman, Prairie Village, Kan. Metal building and roof panels: Behlen Building Systems, Columbus, Neb., www.behlenbuildingsystems.com, Circle #41
Structural engineer: Swiss Valley Associates, Sardis, Ohio Roofing contractor: Langlois Roofing, Kankakee, Ill. Metal roof installer: Eisenmann Construction, Cissna Park Metal roof panels and gutters: McElroy Metal Inc., Bossier City, La., www.mcelroymetal.com, Circle #38
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Ridge vents: Plyco Corp., Elkhart Lake, Wis., www.plyco.com, Circle #39 Snow rails: S-5! Attachment Solutions, Colorado Springs, Colo., www.s-5.com, Circle #40
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Architect: Patterson Design Group, Shelby, N.C. Metal building and roof panels: Metallic Building Co., Houston, www.metallic.com, Circle #42
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provides a warm and dramatic backdrop for the chapel, and works as a balustrade for the balconies. Huge bronze mesh screens placed over the many windows provide sun shading by day, and add shimmering metallic detail to the chapel at night when illuminated by carefully placed lighting.
Architect: Glav & Holmes Architecture, Richmond Metal mesh: GKD-USA Inc., Cambridge, Md., www.gkdmetalfabrics.com, Circle #44
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As Nevadas only Jewish educational center, offering classes from 18 months through 12th grade, the educational campus has thrived, growing from 145 students in 2006 to an enrollment of 500 students thanks to a 146,000-square-foot addition designed by DLR Group. Founded with the support of Dr. Miriam and
Sheldon G. Adelson, the building reflects the heritage of the students attending the campus. Students and visitors enter The Adelson middle and upper schools through a grand, glass dome finished in a two-coat 70 percent Kynar PVDF in Bone White from Linetec. The coating protects the dome from the arid Nevada heat while creating an aesthetically pleasing entrance space. This free-standing, circular glass rotunda measures 30 feet in diameter by 32 feet in height with a free spanning multi-sloping glass dome structure on top, explains Ryan Navis, project manager at Super Sky Products Enterprises LLC. The students heritage continues to be represented throughout the campus in features such
Rotunda dome contractor: Crisci Builders, Las Vegas Star of David contractor: Husker Glass Inc., Omaha, Neb. Architect: DLR Group, Las Vegas Glazing system manufacturer and installer: Super Sky Products Enterprises LLC, Mequon, Wis., www.supersky.com, Circle #46 Glass fabricator: Viracon Inc., Owatonna, Minn., www.viracon.com, Circle #47 Finisher: Linetec, Wausau, Wis., www.linetec.com, Circle #48
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as the floor, which includes the school logo inlaid with granite, marble and lapis lazuli. To build the schools walls, 160 tons of Jerusalem stone was imported from Israel. Continuing to honor the students heritage, the campus also provides a Beit Midrash. Originally intended for the purpose of studying the Torah, today the Beit Midrash provides a study space for students of multifaith backgrounds. Illuminating the learning space, the building is crowned with a 15-foot-wide by 10-foot-tall skylight shaped as a Star of David that shines with natural light.
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NEW PRODUCTS New Varco Pruden roof product responds to need for high-wind performance
Varco Pruden now offers its new standing seam roof product, the High Wind Roof system that is uniquely designed for projects that require highwind codes or have Factory Mutual requirements. The HWR system can provide performance and protection against winds above 130 miles per hour. When incorporated with a complete Varco Pruden building system, the HWR can withstand wind conditions in excess of 180 miles per hour. The HWR system combines sturdy steel roof panels with a patented clip and 180-degree fieldformed seams to create a single roof membrane. The unique clip assembly allows the HWR to maintain normal thermal expansion and contraction of the roof while still offering the high-wind protection. Additionally, the ridge condition for HWR incorporates the patented VP seamed ridge cap with bull-nosed closures to provide a weather-tight seal at the ridge. Panels are offered in 14 cool paint finishes as well as acrylic-coated unpainted Galvalume. HWRs panels are 24 inches wide and have a 3-inch trapezoidal rib. Panels are available in the standard 24- or an optional 22-gauge thickness. HWR is designed to work with secondary structural options including purlins or bar joists. Roof slopes range from 1/4:12 up to 4:12.Thermal performance and energy efficiency may be achieved with the HWR system by installing up to 6 inches of fiberglass insulation over thermal blocks. The adaptive HWR system also works with up to 4 inches of thermal board or with other highefficiency insulation options. www.vp.com Circle #51
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Airolite sun controls add value to new and retrofit building projects
Airolite custom-designed aluminum sun controls help control energy costs, ensure occupants comfort and contribute to sustainable design projects earning LEED certification credits. Airolites cantilevered, horizontal, vertical and inclined sun controls can filter up to 80 percent of the suns heat and glare, cut wintertime radiant heat loss and integrate natural light into new and retrofit building projects. Airolite sun controls are manufactured with Airolites All-Welded Assembly providing extra strength and durability. A wide selection of paint and anodized coatings applied after assembly provides maximum protection against corrosion. www.airolite.com Circle #52
Crystal Window & Door Systems introduces new tilt and turn window
Crystal Window & Door Systems Ltd. recently introduced its new Evolution Series 9000 Tilt & Turn window line. European inspired, tilt-andturn windows offer the dual-action functionality of a large project-in hopper window, which tilts in at the top, and a casement window, which is hinged at the side to swing in. The new window line is available in a tiltand-turn model, Series 9000, and a fixed picture window, Series 9100. Multiple units of either style can be combined using either a continuous master frame system or a zero-mullion system which allows windows to be stacked atop one another or ganged side-by-side. The Evolution 9000 Series design is the perfect blend of heavy-duty construction, graceful design and advanced energy efficiency. The 3 1/4-inch jamb aluminum windows boast extrusion wall thickness of 0.093 inches. The window has achieved an AAMA rating of AW-PG70. www.crystalwindows.com Circle #50
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Kelleys High Volume Low Speed Fan series is designed to provide facilities with an energyefficient and cost-effective cooling and heating solution. The slow movement of the fans does not disturb workers or kick up dust and debris, and effectively circulates the air to increase air quality and worker productivity. Kelleys HVLS fans also assist in exhausting air and preventing moisture build up in extreme or humid environments. The Fusion series fan comes in a variety of sizes and motor horsepower for various applications, and the Fusion-PV is a 100 percent solar model for sustainability and additional energy efficiency. The Orbit series fan provides the benefits of HVLS fans in spaces where ceiling height or other obstructions may be an issue. www.kelleycompany.com Circle #54
announces a low-cost, energy-efficient Blow-Thru space heating product line with 100 percent combustion efficiency. Up to 70 percent energy savings are documented by third party building studies and energy modeling. Blow-Thru heating systems have qualified for utility rebates and EPA federal tax benefits worth millions of dollars. Typical applications include: warehouses, indoor sports facilities, aircraft hangars, boat storage, automobile services areas, maintenance facilities and other metal buildings with big open spaces that require ventilation. All direct-fired Blow-Thru heaters include proprietary Cambridge stainless steel burner technology and extended warranty. Ratings up to 3,400 MBtuh and five popular mounting options are available to fit the needs of any metal building. www.cambridge-eng.com Circle #56
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Classified advertising rates are $110 per column inch for black and white or $145 for color, up to a total of 5 column inches per page. Use display advertising rates for ads over 5 column inches. Call (847) 674-2200. Closing date is the 3rd of the month preceding publication.
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