Daniel Cohen,
Posted
06/01/2009
Perforators can
help contractors and builders by opening the door to both new and
established ways of obtaining optimal solutions for their project
needs. Perforators can produce a wide range of perforation
patterns, sizes and shapes in a host of various materials. These
capabilities provide a broad, blank canvas for the creation of new
functional and aesthetic elements that add to a building's appeal.
A seasoned perforator will also provide solutions and ideas that
could lead to designs that you might not have thought possible.
This collaborative relationship will allow you to leverage off the
perforator's experience and knowledge for improved aesthetics,
increased functionality and greater cost efficiencies.
The Checklist
On the occasion that the architectural prints are unspecified for
the job, it is important to consider the following before ordering
perforated metal. The following is an abbreviated checklist for any
contractor inquiring about the perforated metal required for the
job.
• Quantity-State the number of perforated pieces or square footage
of coverage required.
• Thickness-Specify in gauge numbers or in decimal inches, such as
1/4-inch (6-mm) thick, 16 gauge, 0.040 inch (1 mm), etc.
• Metal-State type of metal required: aluminum, stainless steel,
copper, galvanized, etc.
• Perforation Size-Specify the size of perforated hole in inches,
such as 0.125 inch (3 mm), 0.375 inch (9.5 mm), etc.
• Arrangement of Perforations-Specify "staggered," "straight line"
or other patterns.
• Finish-Specify powder coating, anodizing, Kynar, plating or
degreasing.
Thickness of the Material
Thin material would be appropriate for nonstructural applications
or strictly for a decorative element where deflection is not going
to be a problem. Thin material can also be used if the contractor
needs to form in the field (following the curvature of the
building). Material thickness is ultimately the responsibility of
an architect or a structural engineer in factoring things such as
wind load, material span and attachment methods, to name a
few.
Metal Options
Accurate Perforating Inc., Chicago, can perforate anything from
stainless steel to copper to brass and bronze. There is no limit to
the type of metal. Often times, architects want to look mainly at
copper or brass for purely aesthetic purposes. But the raw material
cost is so much more expensive using material like copper or brass.
A similar look can be achieved with powder coating, anodizing,
etc.
Another issue with material type is corrosion resistance. There are
several options to minimize corrosion, beginning with the material
type (stainless steel, aluminum or galvanized) and again by using
powder coating, anodizing or other secondary finishes.
Interior Applications
For an interior application, regular ferrous can still be
appropriate if the material needs to be protected. Galvanized and
electro-galvanized offer superior corrosion resistance for carbon
steel. However, when you perforate the metal, you are exposing an
edge of the ferrous material and creating a potential for rust.
Therefore, a second finish of paint or powder coat is still
necessary.
The Illinois State Emergency Operations Center, Springfield
In March 2004, the state of Illinois announced that the new State
Emergency Operations Center would open in Springfield and would
house the State Terrorism Intelligence Center, the Illinois
Terrorism Task Force and other emergency personnel. A local design
firm specified the use of 18,000 square feet (1,672 m2) of
perforated copper panels as exterior classing to the SEOC. A local
subcontractor was in charge of the installation of the panels.
Thanks to a progressive pricing structure and attentive, detailed
service during the proposal process, Accurate Perforating was
assigned the project and given the specifications.
The paneling was formed using a special 6-inch- (152-mm-) deep
sheet made from 32-ounce copper, double the typical 16-ounce
weight. The screen was perforated with 1/2-inch (13-mm) round holes
on 3.4-inch (86-mm) staggered centers. The screen's overlapping
panels were bolted to a tubular frame affixed to the building's
exterior. The panels were attached to the frame in overlapping
sections. However, the design had to be customized to ensure that
when the panels were installed, the holes would line up where the
panels overlapped.
Accurate Perforating's attention to details and advanced CAD
capabilities identified the fit of each panel against each other
and to its respective place on the frame. The preproduction design
was authorized and the production run began. The fabricated parts
were shipped to Springfield and attached to the structure-they fit
perfectly.
Balcony-21 Kristin Drive, Schaumburg, Ill.
Decades before, the balconies of this brick apartment building were
created with painted plywood panels attached to aluminum railings
for safety. This combination produced a dated outer shell and a
barrier that obscured sunlight from the apartment interiors.
Understanding the building owner's need to creatively update the
balconies with minimal disruption and within budget, Accurate
Perforating knew the importance of merging function, aesthetics and
cost efficiencies. The goal was an open look that meets code and is
just as appealing from the outside in as from the inside out.
Accurate Perforating, with the help of a local partner, created
custom panels of perforated metal with 3/16-inch (5-mm)round holes
on a 1/2-inch staggered pattern with large solid borders. They
combined this with a thinner, 0.125-inch-thick 5005 aluminum to
meet the project budget without sacrificing safety or beauty.
A clear anodized finish was recommended for the balcony to retard
the rust, peeling or fading that can occur with exterior metal
product applications. Durability of the panels was also a key
element, as residents use the balconies as an extension of daily
living. Clear anodizing was an inexpensive solution in line with
aesthetic preferences in the architectural community. Installation
was made easy with screws and pop rivets. Because the existing
railings were aluminum, no bushings were needed to prevent galvanic
reaction.
Accurate Perforating played a significant role in making a large
property exceedingly marketable. The large-scale design and
implementation solution met all structural requirements of the
project while providing an aesthetically pleasing look that was the
right fit for the building and the budget.
Daniel Cohen is the special projects manager at Accurate
Perforating Co., Chicago. For more information, visit
www.accurateperforating.com.
www.accurateperforating.com