12 - 2011 Metal Construction News

December 2011
Annual Building & Roofing Awards
Weatherproof Walls Innovative Shading Project Focus: Religious

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VOL. 32 NO. 13
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Editor's Comments
Metal: Its Just Cool

We all know the value metal building products bring to the built environment. They provide long-lasting materials that require less maintenance than alternative products. Much of their content is recyclable and many of the products on the market today have a high percentage of recyclable content, including the ever important post-consumer content. But there is another element of metal building products that I find even more intriguing and exciting. They just look cool. I have always loved the look of metal in both residential and commercial construction. It offers a feeling of strength and durability that pleases my aesthetic sentiments. Whether its sharp panels that offer smart looks or a revealed metal infrastructure on the inside of a building, metal building products make builders better and more pleasing. I dont think Im alone in this feeling, and Im pretty certain that it isnt just people in the metal construction industry who feel this way. The Metal Construction News Building and Roofing Awards feature projects that showcase metals in a huge variety of ways. LIVESTRONG Sporting Park (featured on page 14) is our overall winner, and the multiple uses of metal in this projectfrom panels to the canopy to the fins to the sunshades all speak the design and engineering flexibility of this fabulous product. Simultaneously, the metal, which has a reputation for being cold and harsh, appears in this project as warm and inviting. The Arc House on page 22, uses metal roofing panels to define the entire look of a custom home that seems to ground the structure and give it a strong sense of place. The residents must feel like that home is as much a part of the land as the most element living space. The metal wall panels in the Poetry Foundation (page 20) define the exterior of the building, giving its the elemental essence that is the building in a way that no other building product could. You cant imagine this building with concrete or masonry or wood as its finishing material. The Utah State University USTAR building has an equally important resonance of metal that supports both the setting of the building and its high-tech function. Take a look at the project on page 18 and youll see a building that fairly screams that important research is going on within its metal structure and behind its metal walls. Whether its protecting home owners living in reused metal cargo containers in the harsh Mojave desert (page 24), speaking to the syncopated rhythms of jazz patrons and practitioners (page 26) or ushering in patrons of the creative arts (page 25) with dynamic metal panels that resemble 1950s fins on Detroit steel, metal delivers robust and exciting visions. We are engaged, challenged and thrilled by its uses.
Editorial & Production

Paul Deffenbaugh, Editorial Director pdeffenbaugh@moderntrade.com Marcy Marro, Managing Editor mmarro@moderntrade.com Mark Robins, Senior Editor mrobins@moderntrade.com Patricia Brehm, Associate Editor pbrehm@moderntrade.com Quentin Brown, Production Manager qbrown@moderntrade.com Grant Kollar, Art Director
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DECEMBER 2011
METAL CONSTRUCTION NEWS
GET MORE LEADS - SELL MORE PROJECTS
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.
December 2011 Vol. 32 No.13
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27
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.
30
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:
3 8 9 10
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:
27 30
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
32 44
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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
47 48
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.
48
DECEMBER 2011 METAL CONSTRUCTION NEWS 5
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Online Contents
Features Top Stories Industry News
December 2011 Vol. 32 No.13
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.
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Attractive Efficient Economical
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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Social Media
Have you liked us on Facebook? Followed us on Twitter and LinkedIn? Do you read our blogs? We are now updating our social media channels with the latest news and information. You dont want to be left out of the conversation.
Directory
Search our extensive online database for: Metal product suppliers Manufacturers Services that fit your needs
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PROFIT BUILDING
INDUSTRY PERSPECTIVE
Dont Make New Year's Resolutions You Wont Keep!

By George Hedley 5. Balance your budget!
Why make New Years resolutions? If youre like most people, you dont want to waste time committing to something youll never do. But, I bet you really want to improve something in your business or personal life. Maybe you want to get more organized, spend more time with your loved ones, get started living more healthy, take more time off from work, delegate more tasks to your employees, find someone to help you at the office, get rid of a bad customer or troublesome employee, seek new business opportunities, or start looking for ways to build some wealth. Whatever you want, youll never get it without taking the first step. A few simple New Years resolutions will help you and your business become better. Could you imagine a professional football coach starting the season without a written plan and specific goals to win more games than they did last year? Of course not! A great coach always takes a look at their strengths and weaknesses after the season ends to determine what it will take to do better next year. As a business owner, manager, employee, spouse, parent or friend, this process of assessment and improvement is a necessary factor in achieving the goals you want. A year-end review and goal setting session will get you started off towards new targets with a renewed spirit of excitement. People who write down their goals achieve them. Those who dont write down what they want, never make their dreams a priority and go through life searching for success. Every time I have a target or goal written down, I stay focused on doing what it takes to make it become a reality. Start by addressing these ideas for improvement: guarantees you dont have time to buy your spouse flowers on your anniversary. Whats your excuse? Too busy, work is slow, or you cant afford time to get organized. Promising to spend more time with your family and friends is a popular resolution. But most never achieve it. Why? They dont make their dreams specific and write them down. Living way beyond your means is the new normal in business and personal life. For example, in business, buying too much equipment, forces you to hire mechanics, buy service vehicles and rent a bigger yard. This way youll have to work hard just to make the payments and cover your overhead. When youre strapped, you make desperate decisions and poor choices just to keep afloat. A resolution to get a handle on your personal and business finances is important.
Demand for Metal Building Systems to Increase
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.
2. Start a fitness and health program!

I belong to a country club that has a great health club and workout facility. When I go there early, I always see several successful business owners working out every morning. How do they make time to exercise? They have determined fitness benefits their performance at work and home. After their workouts, they get to the office around 8 a.m. or 9 a.m. You could never do that, right? Why? The health of your company is dependent on you getting to work first and leaving last. I guarantee your company could live without you for an hour or two every morning if you want to make it happen.
6. Get focused on your top three priorities!

In business, only a few things are worth stressing over. What are your top three priorities in your company? I suggest the only things business owners need to stress about are sales, revenue and customers. When you have enough sales and customers, the rest will sort itself out with good systems and people. How many more hours will you dedicate to your top three priorities over the next year?
3. Improve your companys fitness.

Are you taking a hard look at what needs to improve, where you need to trim the fat or what areas need to get fit? Look at your business fitness goals for the next 12 months. Consider these following areas you may want to improve: customers, projects, personnel, management, training, quality, service, sales, marketing, estimating, technology, subcontractors, suppliers, profits, productivity, financial systems, operations, field systems, project management, equipment or your paycheck.
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.
4. Re-Structure your company management team!

In your business, where should you add better people to lighten your load and allow for growth? Perhaps you need to add a professional office manager, accounting controller, project manager, estimator or field superintendent. When you add a real pro who can help take some of your workload, youll be able to focus on the priorities that will increase your sales and improve your bottom line.
1. Spend more time with family and friends!

I know its easier to continue to do what youve always done and hope things get better. Continue to try to do everything yourself at work, operate without a strong management team, make every decision and stay at work late and you will continue to miss your sons football games. This style also
DECEMBER 2011
DECEMBER 2011
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."
Steel Construction Manual goes digital

The American Institute of Steel Construction is offering a digital download of the 14th Edition Steel Construction Manual at www.aisc.org/manuals. This is a full version of the manual in PDF form with digital rights management applied. You can view the entire manual, print out sections, copy and paste from the file, and search for keywords but you can only download the file to a single computer and it cannot be transferred later. AISC has augmented its classic Steel Construction Manual with a digital edition in response to industry requests. The price for the digital edition is the same as for the printed version$175 for AISC members and $350 for non-members. The price for both the printed and digital editions is $275 for AISC members and $550 for non-members. More than 150 detailed design examples, updated dimensions and properties of structural sections, along with other useful resources that complement the 14th Edition Steel Construction Manual, are now available. Design Examples V14.0 and Shapes Database V14.0, as well as Reference Lists contained in the latest edition of the manual, are available for free downloading on AISC's website at www.aisc.org/manual14.
D I V I N E
C R A F T S M A N S H I P
The Episcopal Church of the Nativity

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Blue Sky Homes changes name, launches new website

Blue Sky Homes has announced that it has renamed itself Blue Sky Building Systems, a move made to recognize its growing offerings of innovative materials to the entire building industry. The company also launched a new website, www.blueskybuildingsystems.com, designed to provide detailed information about each of its products to industry professionals. The new site also features a complete list of projects in development as well as the architects affiliated with them.
Radius Track offers new applications on website

Designing curved surfaces is now greatly simplified, thanks to an expanded Applications & Details section on the Radius Track website at www.radiustrack.com. Radius Track Corp. is a provider of curved cold-formed steel framing solutions, enabled by advanced use of BIM technology and 3-D design. The site features a wide assortment of curved construction applications, including interior walls, curtain walls, headers, ceilings, roofs, domes and knife edges, followed by a wide array of specific detail drawings for each application. These drawings can be downloaded in .pdf, .dxf or .dwg formats.
Takoda Group acquires Danco Metal Products Inc.

Takoda Group LLC announces the completion of its acquisition of Danco Metal Products Inc., a precision metal fabricator that has served the metal and lexan fabrication industry for more than 70 years. The official date of the transaction was Oct. 31, 2011. Takoda Group LLC has acquired 100 percent of the stock from Danco Metal Products Inc. Glenn Harbold, a Takoda Group operating partner, will assume the role of president of Danco Metal Products. Throughout his 20-year career, Harbold has held a variety of senior operating, finance, and business development roles in both emerging growth businesses as well as Fortune 500 companies. Prior to joining Takoda Group, he co-founded Market Capital Partners, a boutique investment bank and small business advisory firm.
Steel import permits down 3 percent in October

Based on the Commerce Department's most recent Steel Import Monitoring and Analysis data, the American Iron and Steel Institute reports that steel import permit applications for October totaled 2,192,000 net tons. This was a 3 percent decrease from the 2,269,000 permit tons recorded in September and a 2 percent decrease from the September preliminary imports total of 2,238,000 NT. Import permit tonnage for finished steel in October was 1,819,000 NT, up 9 percent from the preliminary imports total of 1,662,000 NT in September. Year-to-date 2011 total and finished steel import permit tons would annualize at 28,989,000 NT and 22,203,000 NT, up 21 percent and 18 percent, respectively, versus the 23,929,000 NT and 18,857,000 NT imported in 2010. The estimated finished steel import market share in October was 22 percent and is 22 percent year-to-date.
Nucor Building Systems donates metal building training structure to university

Nucor Building Systems has donated a metal building to John Brown University in Siloam Springs, Ark., as a training tool for its Construction Management students. The 20- by 25-foot metal building will be used to train these students on how
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
FMA certification program added to NAM-endorsed system

The Fabricators & Manufacturers Association International announces that it is partnering with The Manufacturing Institute to bring
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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.
Alexandria Roe named 2011 Woman of Accomplishment

Alexandria Roe, director of university planning for the University of Connecticut, has been named the recipient of the second annual "Woman of Accomplishment in the Architectural/Engineering/ Construction Industry" award by Professional Women in ConstructionConnecticut Chapter. The award was presented to Roe on September 20, 2011, in a ceremony held during a PWC-CT monthly meeting and professional development program at the Marriot in Rocky Hill, Conn. As director of university planning, Roe oversees the development of the UCONN's physical environment. She is responsible for all planning and programming efforts, real estate activities, space management and environmental policy. Previously she worked as the assistant vice chancellor for planning and technical services for the Connecticut
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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
Traco appoints Thomas VanSumeren to general manager

Cranberry Township, Pa.-based Traco announces that Thomas "Tom" VanSumeren has been appointed general manager for Traco. VanSumeren will draw on his more than 20 years of experience in manufacturing management and engineering to deliver operational and service excellence and drive profitable growth for Traco. Most recently, VanSumeren served as plant manager for Kawneer's curtainwall and window plant in Springdale, Ark., where under his leadership the plant achieved record results. VanSumeren began his career with Alcoa in 1992 as senior manufacturing engineer for the Alcoa Technical Center near Pittsburgh and later held various leadership positions in Alcoa's automotive businesses. In 2006, he joined Alcoa's Kawneer business as the corporate technical manager where he was responsible for developing and carrying out technical solutions to help improve manufacturing operations and which led to his promotion to Springdale plant manager. Prior to joining Alcoa, he spent six years with Kaiser Aluminum.
Kawneer appoints Norris McElroy to lead California operation

Kawneer Co. Inc. announces that Norris McElroy has been appointed plant manager for its Visalia, Calif., operation. In his new assignment, McElroy will leverage his 35-year industry experience to lead both manufacturing
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BUILDING AND ROOFING AWARDS OVERALL WINNER: LIVESTRONG SPORTING PARK

By Paul Deffenbaugh, Editorial Director
MCN Building Awards Judges

Tony Cosentini, AIA, is the project design coordinator for Perini Building Co., in Henderson, Nev. Before joining Perini is 1991, Cosentino practiced architecture in the southwest for more than 20 years. In addition to managing Perinis LEED Group, Cosentino is responsible for the management and administration of specific Perini projects, and is involved in all phases of a project from preconstruction through the duration of construction. Ted Miller is the president of the Miller-Clapperton Partnership Inc. in Austell, Ga. Founded in 1978, the Miller-Clapperton Partnership is one of the leading national fabricators and regional installers of metal composite material. Miller-Clapperton designs, fabricates and installs several standard MCM systems for the exterior walls of commercial, institutional and industrial building projects. Marcy Marro is managing editor for Metal Construction News and Metal Architecture. She has more than four years experience covering the metal construction industry. In the course of her career, Marro has reported on and written about hundreds of commercial, institutional, residential and government projects that feature metal building products.
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
DECEMBER 2011
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BUILDING AND ROOFING AWARDS OVERALL WINNER: LIVESTRONG SPORTING PARK

displays the wide variety of solutions available with metal walls. The detailing is expert and the quality of workmanship is excellent. That kind of design detail helped make the stadium more fan friendly, reducing the imposing scale to a more intimate feeling. The owners prioritized the fan experience in their goals, Albers says. Fans are able to use social media to connect with the team and Internet Protocol TV systems to select individual programming on the TVs in the private suites. Albers points to two major areas as the signature design elements of the stadium. The first is the 360-degree canopy covering the spectator seating, which is a combination of corrugated metal deck and cellular polycarbonate panels. The panels lighten the look of the canopy, protect all the spectators from the elements, but still allow sunlight to reach the edges of the natural grass field. The second element is the angular metal fins, which represent the idea of stop-action photography and depict the motion and action on the field. The panels were custom fabricated by A2MG from perforated metal and align over the length of the building.
LIVESTRONG Sporting Park Kansas City, Kan.

Completed: June 2011 Total Square Feet: 340,000 on 14 acres Building Owner: Sporting Club, Kansas City, Mo. Architect: Populous, Kansas City, Mo., www.populous.com
Photo Credit for small photos: Alistair Tutton
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
Photo Credit: Chris Mann
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BUILDING AND ROOFING AWARDS BEST METAL BUILDING: USTAR BUILDING

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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DECEMBER 2011
BUILDING AND ROOFING AWARDS BEST METAL PANELS: POETRY FOUNDATION

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.
Poetry Foundation, Chicago

Completed: June 2011 Total Square Feet: 26,000 square feet, including a 4,000-square-foot garden Building Owner: Poetry Foundation Architect: John Ronan Architects, Chicago, www.jrarch.com General Contractor: Norcon Inc., Chicago, www.norconinc.com Metal Panel Fabricator and Installer: Tuschall Engineering, Burr Ridge, Ill., www.tuschall.com Metal Panels: 1-mm Corrugated ANTHRA-ZINC panels, solid and perforated, Umicore Building Products USA Inc., Raleigh, N.C., www.vmzinc-us.com
Photo Credit: Jim Tuschall
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BUILDING AND ROOFING AWARDS BEST METAL ROOFING: ARC HOUSE

By Mark Robins, Senior Editor
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
Arc House, East Hampton, N.Y.

Completed: Summer 2011 Total Square Feet: 6,400 square feet Architect: Maziar Behrooz Architecture, East Hampton, N.Y., www.mbarchitecture.com General Contractor and Installer: Mark Proctor Construction, East Hampton, N.Y. www.markproctorconstruction.com Metal Roof and Wall Panels: SteelMaster Buildings, Virginia Beach, Va., www.steelmasterusa.com
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BUILDING AND ROOFING AWARDS HONORABLE MENTION

By Patricia Brehm, Associate Editor
Using metal to build a home in a hot desert location is risky. Even more so when the home is made up of unorthodox building materials. Located in the Mojave Desert, this building is unique due to the main building material, ISO corrugated metal cargo shipping containers. Five cargo containers make up the main living area including the kitchen, living room, a half bath on the first floor, and a full bath on the second floor. The sixth cargo container is used for equipment and material storage. The stairwell is covered with corrugated metal siding and the residence also features a private photography studio made out of a 21-foot-high pre-engineered steel building from Kansas City, Mo.-based Butler Manufacturing. Keeping cool in a desert climate proved to be a design challenge. However, Walter Scott Perry, AIA, of Los Angeles-based Ecotechdesign, was inspired by a lightweight perforated panel. T he custom-built, 2,400-square-foot private residence features 1,800 square feet of 16-gauge Designer Perforated Aluminum Metal with 3/16-inch round holes on a 1/4-inch staggered pattern from McNICHOLS Co., Tampa, Fla. The panels were secured onto 12-gauge Unistrut T1001 steel framing from Atkore International Inc., Harvey, Ill. The steel framing is bolted together on 4-foot centers, and sits 8 inches off the exterior wall and 4 to 6 inches above the roof. Initially, the planning team wanted to use the perforated aluminum to create a shade canopy for a 500-square-foot outdoor living and recreational area, but the concept soon gave way to an exoskeleton covering the two roofs along with the south and west exterior walls. The space and position of the metal was extremely important in creating a building envelope that would diffuse light and give the residents stunning visuals of the outlying desert landscape. Additionally, the perforated metal panels decrease the homes solar and wind impact by 50 percent. Another advantage of the perforated metal is its transparency which changes during the day, based on the suns relative position, explains Perry. During the late afternoon, it becomes more reflective due to the lower sun angle, thereby reducing glare. In the morning, its transparent from the inside, thereby enhancing the views out over the desert landscape. Inside the photography studio, Greenwood, S.C.-based VELUX America Inc.s Velux Sun Tunnels help control the build-up of heat and daylight from the deserts arid climate. Additionally, a cool roof and reflective cool white paint along the body of the house help regulate temperature in the residence. The residence also accommodates photovoltaic, hot water solar panels and green roof modules that along with the perforated metal skin, make this home unique and sustainable.
HONORABLE MENTION BUILDING AND ROOFING AWARDS

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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Photos by Jack Parsons Photography
DECEMBER 2011
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BUILDING AND ROOFING AWARDS HONORABLE MENTION

By Patricia Brehm, Associate Editor
WEATHERPROOF WALLS FEATURE

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. (Photo courtesy of Georgia Pacific Gypsum)
Jazz It Up Metal panels add flair to music conservatory building

The Bertram and Judith Kohl Building at the Oberlin Conservatory of Music in Oberlin, Ohio, houses a jazz studies program. The building creates a visual that brushes up against a historic Oberlin neighborhood and right into the Oberlin Conservatorys Tappan Square. Nestled within a campus filled with buildings designed by the famous architect Minoru Yamasaki in the 1960s, the building also houses a recording studio, performance spaces, practice rooms and the largest jazz recording archive in the United States. Practice rooms and spaces with acoustical requirements are found on the lower levels while faculty offices can be found on the upper level. From the interior spaces, the buildings occupants are treated to a wide range of visuals. Windows of differing sizes look out to multiple views of the campus and the surrounding community. The three-story, 37,000-square-foot facility was designed to meet LEED Gold standards. The designers chose to clad the building in 25,000 square feet of Eastman, Ga.-based Alcoa Architectural Products 4-mm Reynobond aluminum composite material panels with a PE core in a custom Pre-weathered Zinc Durabrite finish over brushed aluminum for the exterior walls, and 3,000 square feet of 4-mm Reynobond ACM with a PE core in an Anodic Clear finish for the soffits of the building. Additionally, metal fabricator and installer Riverside Group, Windsor, Ontario, Canada, supplied its R4-300 dry joint pressure equalized rainscreen system which was custom designed to suit actual built conditions. From the beginning, we planned to clad the exterior in aluminum, explains Jonathan Kurtz, AIA, of Westlake Reed Leskosky, Cleveland. It was a natural choice because Charles Martin Hall, an Oberlin alumni and one of the founders of Alcoa, donated the Tappan Square property to the college. Kurtz notes that meeting LEED certification requirements presented a challenge as the music building, housing a large number of instruments, must maintain constant humidity levels so as not to damage the instruments. Specifically a green roof system and stormwater run-off and filtration systems help the building meet specific targets for LEED accreditation. While working on the project, the architects wanted to tie the building to the rest of campus.. The Yamasaki buildings contain precast concrete with an opalescent sheen, which appears to transform under different lights. To replicate the design aesthetic of the Yamasaki buildings, the Riverside Group worked with Alcoa to create a custom finish that mimics the effects of the precast concrete. The end result is a vibrant visual created by the sheen of the aluminum that fits the creative atmosphere of the campus.
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
Moisture management helps metal building solutions

Weatherproof Walls Keep Water Out
Water damage in buildings can destroy wood, steel and plywood. Short-term exposure to water won't harm most building materials, but over the long term its a major contributor to property loss. Water intrusion via rainwater, snowmelt and wind-driven moisture can occur through air leaks in wall assemblies. Without moisture-, airand water-protective wall barriers, mold, mildew and fungus growth can occur, causing expensive building repairs and replacements, occupant sickness and even structural deficiencies. The correct weatherproof wall can prevent or at least minimize water and moisture migration into buildings. The best definition of a weatherproof wall in metal construction is an assembly of metal and accessory components that work together to provide air, moisture and temperature barriers designed specifically for the projects local climate and the intended use of the building, says John Garland Co. Inc., Cleveland. Local climates and regional considerations influence weatherproof wall use, as do site conditions, exposure and overhangs. Some groups, such as the Building Science Corp. and National Research Council of Canada, define certain regions that are more prone to excessive rainfall or that have a certain moisture index and vital areas in need of something like a rainscreen or a drainage system, says Ted Kerwood-Winslow, product development specialist, Benjamin Obdyke Inc., Horsham, Pa. Other areas have adopted building codes that require the use of providing drainage, like Oregon and Minnesota.

windows, vents, and you have transitions from the roof above or floor slab below, weather and moisture will always be a potential issue, says Warren Barber, Dens brand product manager, Georgia-Pacific Gypsum, Atlanta. The better termand goalis a wall that is weather resistive. They are also referred to as an air barrier, or air- and water-resistive barriers. A weather-resistive exterior wall provides air- and water-movement control, creating an ideal scenario for protection and durability. To understand weather elements effects on metal buildings, its important to understand how building science has evolved over the past 50 to 100 years. In the past, the primary building materials were wood and stone; both of which had the ability to hold the moisture that naturally influenced it, and then let it go and dry out, Barber says. These walls were thick, containing a lot of mass, giving the wall the ability to absorb the moisture as it moved through 27
Pierson, PE, engineering services manager, The
Weatherproof wall realities

While many try, the reality is no wall or building is fully weatherproof. As long as there are doors,
photos courtesy of Bob Perzel Photography 26 METAL CONSTRUCTION NEWS DECEMBER 2011 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
FEATURE WEATHERPROOF WALLS

contributes to the buildings appearance, but also acts as the first line of defense, providing a drainage plane to keep moisture out of a building. Rainscreen walls neutralize wind currents on the claddings inside and outside surfaces so that pressure differences do not drive water through gaps or flaws in an assembly and into a building interior. Walls designed with these pressure differences in mind are said to conform to the so-called rain-screen principle and are sometimes referred to as pressure-equalized rainscreens, says Doug Todd, market manager at Dow Building Solutions, Midland, Mich. Such systems are composed of an airtight plane protected by an open-jointed or vented cladding. Separating these two layers is a cavity or air chamber. The joints are sized so that air, but little or no water, can pass through as gusts buffet the cladding, equalizing the pressure on the exterior and within the cavity. Because of this air chamber or ventilation space, any wind-driven rain or moisture that does get past the exterior siding can dry out or escape, avoiding damage to interior walls. It doesnt get trapped and is able to free-drain out of the system, says Kerwood-Winslow. Any residual moisture is able to dry out due to convective air movement. One way of looking at these systems is that although they may cost more upfront, they can prevent some very costly callbacksit is like a
The accel-E Steel Thermal Efficient Panel (S.T.E.P.) prevents moisture intrusion. (Photo courtesy of SYNTHEON Inc.)
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)
New technologies minimize moisture

Continuous insulation is currently receiving a lot of attention and many are seeing it as a growing trend to manage moisture. With continuous exterior insulation, the risk of condensation is dramatically reduced, says Nelson. This is because the dew point is pushed to the outside of the wall assembly. With the stud cavity and interior wall assembly kept warm and dry, the risk of mold and other fungal growth is heavily reduced. Continuous insulation will also dramatically increase a buildings energy efficiency as well due to increased levels of insulation and higher R-values. There are new software programs to help manage moisture with weatherproof walls. WUFI (Wrme und Feuchte instationr or Transient Heat and Moisture), offered by Oak Ridge National Laboratory and the U.S. Department of Energys Energy Plus analysis software can actually help remotely analyze wall systems to ascertain their efficiency and durability, says Barber. Oak Ridge National Laboratory is a national multi-program research and development facility managed by UT-Battelle LLC for the U.S. Department of Energy. The program inputs the climate in the area of the building to be reviewed. Users just enter a zip code and the assembly type of the wall, and the program puts that data and the wall through a 12-month analysis based on weather. Enhanced housewraps are gaining attention in the fight against moisture. They feature additional functions beyond the traditional drainage plane that allow the moisture that gets behind the cladding to drain even more freely. We have combined a rainscreen ventilation matting product to a highly regarded housewrap to combine the benefits of both products in one simple installation step, says Kerwood-Winslow. We are also in the process of launching a one-of-akind housewrap that features a 3-D pattern that is incompressible and will retain its drainage space in any wall installation. This ensures protection from the damaging effects of mold due to bulk water penetration. The continuous gap allows the water to drain freely. This ensures the system meets the code requirements to provide the wall assembly the ability to drain out the water that will get in. Many companies are constantly innovating in this space and new products are introduced monthly if not weekly. Barber predicts many code changes will impact the construction world in the next years, such as the International Green Construction Code and LEED changes related to weather resistance and indoor environmental quality. All these code and program changes will dictate the use of weatherresistant barriers and help drive new technology like improved weatherproof walls, he says.
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.
The design of the faade was very rigorous,
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.
Freeport-McMoRan Center, Phoenix

Photos by Bill Timmerman
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.
A modern high-rises contemporary design responds to its environment

By Marcy Marro, Managing Editor
space on 30,000-gross-square-foot floor plates with 8,000 square feet of ground-level retail. The building is unique to the Phoenix market as it incorporates a large office plate that is typically found in suburban office buildings, and places it on top of a stacked parking structure. The office market demanded on-site parking but providing it belowgrade was cost prohibitive, resulting in this unique solution of stacking 16 floors of office space above nine levels of parking. The office program is characterized by large efficient floor plates with 9-foot floor-to-ceiling glass, which provide dramatic panoramic views of the surrounding city and mountain ranges. Additionally, eliminating the corner columns and cantilevering the plate 15 feet each way expresses the building corners, resulting in a visual significance to the corners of the building, offering unobstructed views from the interior. The buildings integrated parking structure is naturally ventilated, accommodating views, airflow and natural light by using a perforated standing seam metal roof panel. During the day, cars are completely screened, and at night the parking structure becomes transparent. easy to use the different components within the unitized curtainwall system. Using varying shading strategies on each faade makes it possible to provide floor-to-ceiling transparency on all sides. Insulated glass units that are a combination of low-E coated clear and spandrel glass are used on the north and south facades. The same units are also used on the east and west faade, but include an additional 15 percent graduated ceramic frit patter that reduces the solar heat gain coefficient, thereby reducing the buildings overall cooling load. Additionally, each faade responds fittingly to its orientation, Roddy says. Each individual faade works simultaneously with the others, facilitating a didactic expression of the buildings relationship with its environment. We used modeling for shading analysis to determine shading performance that in turn dictated frequency of shade fins, depth and orientation, Buchanan says. The curtainwall contractor, Walters and Wolf, mockedup the facade at its fabrication facility in Gilbert, Ariz., to determine its aesthetic appeal, ensure tenant views and maintain quality craftsmanship and constructability. The faade also was tested at the Construction Consulting Laboratory West testing facility in Ontario, Calif., for water and air filtration. The building features sky gardens, or patios, on the 25th floor and an array of dichroic glass fins that indicate the entry on the south faade. The dichroic glass feature is made up of SCHOTT NARIMA dichroic glass from SCHOTT North America Inc., Elmsford, N.Y., sandwiched between 1/4-inch low iron tempered glass, each separated by 0.060 PVB layers. The glass is point-supported at the ends of each 5-foot unitized section. The perceived color change of the dichroic glass depends on several factors, such as the angle of the sun, the angle at which the glass is viewed and the background it is against, explains Buchanan. In essence, the biggest challenge was designing an all-glass building in the desert, Roddy says. The client very much wanted an all-glass building so that drove decisions about the performance of the curtainwall system. This resulted in the different shading strategies for the east, west and south facades. Preserving the all-glass strategy with shading elements gave the client what they wanted from a leasing perspective while having the building maintain its environmental responsiveness to heat gain. 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
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
Metal Products Used

Primary system: 6-inch aluminum unitized curtainwall fabricated by MK Architectural Metal Inc., North Canton, Ohio. Addition components include: 48,000 square feet of perforated aluminum ribbed metal wall panels from Kalzip Inc., Michigan City, Ind. 25,275 square feet of Chesapeake, Va.-based Mitsubishi Plastics Composites America Inc.s ALPOLIC aluminum composite material panels 25,630 linear feet of sunshades from C/S Group, Cranford, N.J. Insulating glass units from Viracon, Owatonna, Minn. Dichroic glass from SCHOTT North America Inc., Elmsford, N.Y.
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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PROJECT FOCUS RELIGIOUS
For more projects, visit
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.
St. Leon Cathedral of the Western Dioceses, Burbank, Calif.

Architect: 2K Forum Inc., Glendale, Calif. Installer: Cal Pac Sheet Metal, Santa Ana, Calif. Distributor: Blue Diamond Supply, Grand Terrace, Calif.
Cultural Cathedral
32 METAL CONSTRUCTION NEWS DECEMBER 2011 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
Metal roof panels: ATAS International Inc.,
Church mixes modern and traditional in a unique design

Allentown, Pa., www.atas.com, Circle #35
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Sykes Chapel and Center for Faith and Values at the University of Tampa, Tampa, Fla. As a private, secular university serving more than 5,000 students from 50 different states and approximately 100 countries, the University of Tampa sought to build a structure that would strengthen student development through spirituality and independent growth. Funded by John and Susan Sykes, the Sykes Chapel and Center for Faith and Values at the University of Tampa allows students to balance their educational and intellectual development with their personal and spiritual growth relative to life values and goals. An architecturally significant structure, the chapel ties the University of Tampa to the local community. Located in the center of campus, the center serves as a meeting place for student organizations and activities involving the local Tampa community. Future plans call for an adjacent planned quadrangle plaza that will create greater space for campus events and student gatherings. The chapel/center was designed to elicit spiritual, sensory and emotional responses by the building users, explains Robert Balke, principal for tvdesign, Atlanta. The building interior is shaped by light and sound. Like two cupped hands held slightly apart, light enters from above and from the east. Daylight and music are reflected and diffused by the warm, curving interior forms of the undulating wooden walls. The 15,000-square-foot structure includes a main hall with seating for 260 people for lectures, ceremonies, discussions and musical performances including those with its 55-foot-tall custombuilt organ. In addition, the facility offers meeting rooms, two meditation rooms and a gallery. Brick, high-performance glass, granite and RHEINZINK comprise the primary materials of the buildings exterior palette. RHEINZINK supplied three different products for this project. Approximately 17,500 square feet of 0.8-mm, 22-gauge RHEINZINK Double Lock Standing Seam Panels clad the roof, while approximately 6,500 square feet of 1.2-mm, 18-gauge RHEINZINK Vertical Reveal Panels clad the faade and soffits. Additionally, 3,000 square feet of zinc composite material were used on the fascia and canopies. All RHEINZINK products were finished in Pre-weathered Blue Gray. The durability and sustainability of RHEINZINK was an important factor. We see this as an enduring, 100-year building, Balke notes. The self-healing nature of zinc and the fact that it will patina over time was important to us. The building will look even better as it ages. The standing seam profile was also a key factor in the design according to David Fulmer, senior associate and member of the tvsdesign team. The scale of the material, the rhythm and the texture help reinforce the shape of the curve, Fulmer adds. The form is delineated by the ribs of the standing seam profile. Metal roof and wall panels: RHEINZINK America Inc., Woburn, Mass., www.rheinzink.com, Circle #36 Construction manager: Peter R. Brown Construction Inc., Tampa Architect: tvdesign, Atlanta Building and site design team: Walter P. Moore and Associates Inc., Atlanta; Anston-Greenlees Inc., Tampa; Kirkegaard Associates, Chicago Fabricator: MetalTech-USA, Peachtree City, Ga. Installers: General Works of Tampa, Tampa; Architectural Systems Inc., Tampa Bald Knob Cross of Peace, Union County, Ill. Originally completed in 1963 and clad with white porcelain veneer steel panels, the Bald Knob Cross of Peace stands as a distinct landmark against the backdrop of Union Countys close proximity to the Ozark Mountains. The 110-foot cross history dates back to 1937 when worshippers gathered at the site for Easter sunrise services. However, what used to be a town landmark and tourist attraction quickly deteriorated. Installation of 10,500 square feet of Metl-Spans 4-inch CF36 Architectural Flat insulated metal panels in Polar White highlight the repair and major refurbishment of the cross, which remains an integral part of the surrounding communitys history and faith background.
Construction manager: JMS Metals, Sparta, Ill. Metal wall panels: Metl-Span, Lewisville, Texas, www.metl-span.com, Circle #37
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Cissna Park Apostolic Christian Church, Cissna Park, Ill. The Cissna Park Apostolic Christian church building was built in 1949, replacing a wood frame building that stood across the road since 1890. The buildings original slate roof lasted for 61 years. However, after more than six decades of service, the roof needed to be replaced. The building is about 57 feet tall and contains steel frame trusses clad with 3-inch-thick pre-cast concrete sheeting. First, the metal roof installer, Eisenmann Construction removed the original slate roof and installed synthetic underlayment while anchoring 2 by 4s to the concrete sheeting with head lok fasteners. Afterwards, Eisenmann installed the Medallion Lok panels finished in a Patrician Bronze color from McElroy Metal Inc. The installer also placed ridge vents from Plyco Corp. at the roofs peak and counter flashed many of the trims into the masonry parapet walls. Langlois Roofing worked on five flat roof areas done in rubber. Special deep gutters were designed by Ed Knittel of McElroy Metal, and two rows of snow rails from S-5! Attachment Solutions were installed. Now completely installed and approved by the church trustees, the new metal roof should provide
Project1-cbsad4:Layout 1 4/9/10 8:44 AM Page 1
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
longevity and maintain the historic integrity of this long-standing congregation.
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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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Buffalo Baptist Church, Shelby, N.C. The Buffalo County Baptist Church started as a small congregation worshiping in an outdoor area known as the Brush Arbor. Later, the congregation moved into an old school house that they used for worship services. In 2008, the decision was made to build a new series of structures, including a sanctuary, education building and fellowship hall. The structures feature Ultra-Dek roof panels in Signature 300 Medium Bronze from Metallic Building Co., on Building As 5:12 roof pitch, as well as Building B and Cs 3:12 roof pitches. All of the roof slopes are gable symmetrical, and two out of the three buildings employ the use of Metallics 16-inch-wide Designer Series texture-coated concealed fastener panels. These panels are equipped with factory-applied dryvit finish with additional areas of stone veneer, supported by Metallic panels and girt framing. Metallic and the general contractor, Hoke Also available in stainless steel! Enterprises Inc., worked hand-in-hand with the churchs building committee to optimize the layout of the facility and maximize parking availability. Additionally, Metallic provided the porte cochere with a factory-fabricated valley to the main roof. The roof framing was designed with special deflections to accommodate interior finishes. In addition to the pre-engineered metal building, this project features 2-foot overhangs/soffits, Demand North American Quality! Architect: PSA Dewberry Inc., Tulsa, Okla. Metal canopy: Mapes Canopies LLC, Lincoln, Neb., www.mapes.com/canopies, Circle #43 General contractor: Vanguard Builders Inc., Broken Arrow, Okla. First United Methodist Church, Claremore, Okla. Completed in June 2009, the project features a 116-square-foot Super Lumideck Hanger rod canopy from Mapes Canopies LLC. Coated in a two-coat Kynar Colonial Red finish, the canopy has a 4-foot projection by 15 1/2 feet with 14 1/3-foot legs and 2 3/4-inch extruded decking.
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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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DECEMBER 2011 METAL CONSTRUCTION NEWS
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Union Theological Seminary, Richmond, Va. The seminarys buildings attest to the facilitys longstanding history. From the outside, the red brick Tudor Revival buildings reflect their historical surroundings while the interiors reflect growth and change. Originally housing eight levels of library tacks, the seminary tasked Glav & Holmes Architecture to transform Spence Library into a state-of-the-art facility for teaching and worship. To renovate the library, the architects removed the self-supporting stacks to create a 40- by 40- by 40-foot worship room, meeting location and teaching space. Using contemporary styling, overlaying materials and moveable walls for maximum flexibility, the library now stands as a modern testament to design without having sacrificed any of the buildings original integrity. Glave & Holmes used GKD-USA Inc.s Omega 1520 woven metal mesh finished in bronze and stainless as the overlayscreating the illusion of walls without compromising the filtered daylight, infusing the space with light to help to create the welcoming feeling of openness. The chapel, now sitting in the place once occupied by the eight levels of library stacks, is nestled within the other spaces, separated by huge mesh screens woven of bronze. The metal mesh Houston Roofing contractor: Skweres Services, Houston Metal roof panels: MBCI, Houston, www.mbci.com, Circle #45 Architect: Ziegler Cooper Architects, St. John Lutheran Church, Spring, Texas Designed by Ziegler Cooper Architects, the churchs roof is made up of 10,000 square feet of MBCIs 24-gauge SuperLok standing seam roof in Medium Bronze. With the addition of the roof, the new facility was completed in September 2011 and contains more than 25,000 square feet available for the congregations use.
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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The Dr. Miriam & Sheldon G. Adelson Educational Campus, Las Vegas Husker Glass Inc. installed the Beit Midrashs skylight, which Linetec finished the aluminum framing in the same durable 70 percent PVDF coating as the rotundas skylight. For both skylights, Viracon Inc. fabricated the insulated, low-E laminated glass units with white silkscreen, maximizing thermal performance under the desert sun. The $ 65 million project and its two, signature skylights were completed in 2009, following two years of construction.
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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
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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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DECEMBER 2011 METAL CONSTRUCTION NEWS 43
SERVICES PROVIDED NATIONALLY

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
FEATURED PRODUCTS Fans and Ventilation Big Ass Fans

Yellow Jacket is the portable fan that takes abuse and stays in use. Five years in development, Yellow Jacket is designed for incredible flexibility and amazingly quiet operation, but most importantly, its so durable it will never need to be replaced. The Yellow Jacket is engineered with a number of heavy-duty and operational characteristics including: Heavy-gauge steel carriage engineered to withstand the harshest environments. Powerfoil-inspired blades for maximum efficiency and airflow coverage. Acoustically designed fan, motor and carriage for quiet operation. Oversized wheels and ergonomic handle for maneuverability. Multiple speeds and an easily operated locking position mechanism put the amount and direction of airflow at your control. High-efficiency design to cut energy use by more than 50 percent. Flexible with ceiling, wall or multiple floor mounting options available. www.bigassfans.com Circle #53
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Atlas Roofing Corp.

Atlas Roofing announces Techni-Flo, the engineered ventilation system for steep-sloped roofs. Techni-Flo is a component system manufactured to meet the specific needs of steep-sloped roofs and engineered to ensure consistent intake and exhaust airflow underneath the roof covering of commercial building applications. The three TechniFlo componentsTechni-Flo RV, CrossVent and Techni-Flo EVcomprise the only complete system in the industry for steep-slope roofs with features engineered to deliver prescribed ventilation capacity specific to each job. The system works with shingle or standing-seam roofs. Techni-Flo components are designed to work together to create balanced air flow which optimizes temperature. www.atlasroofing.com Circle #55
Northwestern Ohio Foam Products

MicroFoil is a cost effective, high-performance reflective foil radiant barrier and vapor retarder, designed to reflect radiant energy and retard moisture migration in a building. The core of the product is made of flexible four-ply, 1/4-inch-thick polypropylene foam that provides excellent insulation. This unique core has a state-of-the-art pure aluminum foil film laminated to both sides. The aluminum foil films provide the high reflectance radiant barrier properties, the vapor retarding performance specifications and the superior physical attributes of this product. MicroFoil can reflect up to 97 percent of radiant energy thereby reducing heat build-up and loss as compared to a non-insulated metal building. Its tear-resistant, moisture-proof and bug-resistant. The product uses non-toxic materials that can be safely installed without the use of protective clothing. All that is needed is a utility knife, tape and safety glasses. www.nofp.com Circle #57
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
Cambridge Engineering
Cambridge Engineering
Kelley Co.
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
Covertech Fabricating Inc.

Covertech Fabricatings rFOIL Ultra White Metal Building Reflective Insulation is a single or double layer of polyethylene bubbles bonded to and sandwiched between a radiant barrier metalized foil and white polyethylene sheet. It is specifically designed to control heat gain or loss, and prevent interior condensation, in all types of metal and metal-clad buildings. www.rfoil.com Circle # 58 DECEMBER 2011 METAL CONSTRUCTION NEWS 45
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DECEMBER 2011
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Sukup Manufacturing Co. seeks Metal Building Detailers, Estimators, Designers, and/or Structural Engineers with metal building experience at our Sheffield, Iowa manufacturing facility. We are a familyowned company, manufacturing a full line of grain handling equipment including grain bins and dryers with sales throughout the world and are expanding into the metal building industry. 5 years of metal building experience is required. Candidates must be detailoriented and have the ability to multi-task. Experience with MBS Software preferred. EOE. For more information, please contact: Mary Amsbaugh Sukup Manufacturing Co. P.O. Box 677 Sheffield, IA 50475-0677 Ph: 641-892-4222 Fax: 641-892-4254 Email: Mamsbaugh@sukup.com or visit our website: www.sukup.com
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NAC Plasma Cutter S/N 9831. Nutech Engineering Automatic Frame Welder S/N 99-137. Piranha Iron Worker S/N 9081. MRS Double Deck Roll Former 26 & 29 Ga. Like new with Decoiler. 3 1/2 ton Jib Crane. 21 CNC Bradbury Folder 18 Ga. Like new. 80 ENF 8 Enforcer TS 48 Slitter, five knives. Like new. Portable Hydraulic Punch
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46 METAL CONSTRUCTION NEWS DECEMBER 2011
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.
EDITOR'S PICK
By Marcy Marro, Managing Editor
Insurance company saves green by adding solar

The new rooftop solar photovoltaic system at Harleysville Insurance corporate headquarters in Harleysville, Pa., is expected to generate approximately 15 percent of the companys annual energy needs.
Tecta Solar, a division of TectaAmerica Corp., Rosemont, Ill., installed the 511.5 kWp DC rooftop solar system, which is made up of approximately 47,600 square feet of solar panels to cover nearly half of the total roof surface of the building. Each of the 1,860 ET Solar 275 watt panels from Pleasanton, Calif.-based ET Solar, weighs 50 pounds and measures 77 by 39 inches. SunLink Corp., San Rafael, Calif., supplied the racking system, and SMA America LLC, Rocklin, Calif., supplied the inverter that converts the DC power generated by the panels into AC power. The solar panels are projected to produce approximately 623,000 kilowatt hours of energy each yearenough to power 62 average Pennslyvania homes. Tecta Solar provided a full-service solution for the insurance company, managing the project from start to finish, including development, securing a grant, design, engineering, procurement, construction and commissioning of the roofmounted project. The benefits to be derived from going green are impressive and serve to underscore Harleysvilles commitment to the preservation of our environment and conservation of our natural 48 METAL CONSTRUCTION NEWS DECEMBER 2011 resources, says Michael L. Browne, Harleysville Insurance president and chief executive officer. Financial assistance from both the federal and state governments helped offset a significant portion of the project's $2.8 million cost. Theres a 30 percent federal tax creditamounting to $840,000coupled with as much as a $90,000 benefit due to bonus depreciation that will help defray about one-third of our investment, explains Arthur Chandler, senior vice president and chief financial officer at Harleysville Insurance. On top of those federal incentives, the Commonwealth of Pennsylvania Financing Authority provided us with a $355,000 solar energy program grant. Andrew Shields, assistant secretary and director of facilities services, expects long-term energy cost savings for the company, along with contributing to a healthier environment. Because the system will generate about 15 percent of our annual energy needs at a fixed cost, we expect both cost savings and protection from rate increases on some of our power costs. In fact, we expect to re-coup our overall investment within the first seven years of operation. In addition to the new photovoltaic system, Shields notes that the insurance company has completed other environmental projects that have resulted in total energy cost reductions of 25 percent since 2008. These projects include an ice storage and air conditioning system, and upgrades to lighting, heating, ventilation and air conditioning controls. 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 www.sma-america.com, Circle #59 Mounting system: SunLink Corp., San Rafael, Calif., www.sunlink.com, Circle #60 Photovoltaics: ET Solar, Pleasanton, Calif., www.etsolar.com, Circle #61 Rosemont, Ill. Inverter: SMA America LLC, Rocklin, Calif., We are especially pleased with the collective results of our efforts to reduce energy consumption during the peak hours of the mid-afternoon, says Shields. In addition to reducing our annual total building load from 6 million kilowatt hours to 4.5 million kilowatt hours, these initiatives also assist the local and regional power grid meet their growing demands.
Harleysville Insurance, Harleysville, Pa.

Developer/installer: Tecta Solar,
Green. Its worth it.

At Metallic, we manufacture metal buildings. We also manufacture those buildings with the highest quality, cost-effective materials and products available. And we do it all in a way that impacts your bottom line through LEED points, ASHRAE, energy savings and much more. So, you get a structure that keeps the earth and your wallet happy. Being environmentally-conscious has never been more important than it is now and Metallic is happy to put its green face on. It is easy being green. Let us show you how. Visit metallic.com/mcn for your next award winning, environmentally-friendly project.
800.755.7339

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December 2011

Annual Building & Roofing Awards

Weatherproof Walls Innovative Shading Project Focus: Religious

WE JUST IMPROVED ENERGY EFFICIENCY IN METAL BUILDINGS. AGAIN.

OptiLiner Banded Liner System

ELAMINATOR Insulation System

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Metal: Its Just Cool

Editorial & Production

Business & Sales

In short, metal is cool.

Official Show Publication:

Paul Deffenbaugh Editorial Director pdeffenbaugh@moderntrade.com

Official Residential Publication:

Toll-Free: 800.684.5761 Outside USA: 972.536.6415

www.TheRoofingExpo.com/attendee to receive FREE Expo Only admission.

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METAL CONSTRUCTION NEWS

GET MORE LEADS - SELL MORE PROJECTS

December 2011 Vol. 32 No.13

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Use Lamtec Facing for High-R Insulation

December 2011 Vol. 32 No.13

Long Tab with Banding

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Hole Metal Designs

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GUARdEd HoT Box TEsT REsULTs* By CERTIFIEd TEsT LABoRAToRy

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InsUlatIon R-19/R-11 R-25/R-19

Perforated Metal 1/2 rnd on 1.191 str row centers

McNICHOLS Designer Metals

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Dont Make New Year's Resolutions You Wont Keep!

Demand for Metal Building Systems to Increase

2. Start a fitness and health program!

6. Get focused on your top three priorities!

3. Improve your companys fitness.

4. Re-Structure your company management team!

1. Spend more time with family and friends!

METAL CONSTRUCTION NEWS

METAL CONSTRUCTION NEWS

Steel Construction Manual goes digital

The Episcopal Church of the Nativity

Blue Sky Homes changes name, launches new website

Radius Track offers new applications on website

Takoda Group acquires Danco Metal Products Inc.

Steel import permits down 3 percent in October

Nucor Building Systems donates metal building training structure to university

FMA certification program added to NAM-endorsed system

EuroGutterUSA | Historic Restorations | Ornaments

METAL CONSTRUCTION NEWS

NOVEMBER 2011 METAL CONSTRUCTION NEWS

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Alexandria Roe named 2011 Woman of Accomplishment

Traco appoints Thomas VanSumeren to general manager

Kawneer appoints Norris McElroy to lead California operation

Insulated Metal Panels keep you cool when the heat is on