In just six years, Fairfield Metal has become a leading fabricator of metal panel systems
During the great recession of 2009, a Fairfield, N.J.-based roofing company was asked to bid on a project that had metal panels on it. The company tried it, the results were good and it made money off of the project. The roofer realized that this could be a profitable business and Fairfield Metal was born.
Now just six short years later, Fairfield Metal is a leading fabricator of ready-to-install composite metal panel systems. It specializes in aluminum composite material (ACM) panel fabrication, using the top ACM manufacturers to fabricate custom products that include column covers, curved panels, exterior and interior metal wall cladding, louvers, and accent, soffit, and fascia panels.
This new fabricator has evolved from small projects like automotive dealerships to 100,000-square-foot corporate headquarters and residential towers. Delivering and fabricating wall panel systems of any size, Fairfield Metal’s range spans from aluminum composite panel façades and entryways, all the way up to complete building envelopes.
Great Growth
How did Fairfield Metal become so successful so fast?
“It’s amazing how it’s grown in six years,” admits Ryan Hunt, general manager at Fairfield Metal. “I think it’s a combination of our technical ability and a great understanding of the architect’s intended design. These two factors let us design better metal panel systems that optimize aesthetics, strength and material usage. By working closely with both architects and builders/installers, we can tailor the panels to their exact needs and allow for a great level of customization. It was crucial to us to provide a solid product early on, and make a good reputation among material suppliers, builders and architects. The positive referrals allowed us to be considered for jobs we would not be able to get otherwise.”
Innovative products have contributed to Fairfield Metal’s growth. While some fabricators limit their product line to flat rectangular panels, Fairfield Metal has tried to push the envelope and offer creative and engaging options, like 3-D panels. Two award-winning, metal-based projects didn’t hurt Fairfield Metal’s reputation either. Its work on the 200,000-square-foot, North Bergen, N.J.-based Cullum Tower’s exterior facelift helped win the project an Architects League of Northern New Jersey 2013 Peer Design Award. For it, Fairfield Metal fabricated more than 4,000 individual panels with custom-made ACM louvers matching the different colors of Alucobond Spectra material from 3A Composites USA Inc., Statesville, N.C. The panels were installed using the Fairfield Metal Gasket system.
Its work on the Blooming Grove, N.Y.-based Mediacom Headquarters helped earn the building multiple awards, recognition and coverage, including the building profile in Metal Architecture’s March 2014 issue. Fairfield Metal fabricated the building’s exterior with three colors of Norcross, Ga.-based Alcoa Architectural Products’ Reynobond ACM panels. The interior features Anodic Clear panels installed using Fairfield Metal’s Rainscreen system (RFM), while the exterior panels were installed using the Fairfield Metal Wet Joint system (CFM).
High-Tech
Fairfield Metal’s growth is largely due to advances in its technological front. This has allowed it to offer a better product, with fewer fit issues and therefore shorter production/installation time, and faster turnaround time. “The all-digital workflow allows us to spend less time on the job site and more time devoted to making panels,” says Hunt. “The 3-D scanning process has significantly helped with intricate details in the building design, such as curved structures. There’s no longer a need to draw up a template to create curved panels. We also include very detailed installation drawings and instructions, which guide the installer to a smooth installation process.”
The company’s 3-D scanning helps in almost every aspect of metal panel fabrication. Firstly, it lets Fairfield Metal measure the structure faster, more accurately and without interrupting other trades on the job. Safety is also an aspect during the measurement phase. Since most buildings can be measured from the ground, there is lesser need for lifts and scaffolds. 3-D scans serve as a persistent reference of the building, so if new reference points are needed during panel design, the company does not have to travel back to the job site.
“The detailed scan data also lets us see irregularities in the framing and sheathing, which allows us to account for them in our panel system design,” Hunt says. “Overall, 3-D scanning requires more qualified labor and computer resources, but that cost is more than made up in savings resulting from fewer mistakes, travel costs and on-site time.”
Challenges
Hunt admits that the past six years haven’t been without challenges. He acknowledges that one of the biggest hurdles facing the growing company is acquiring, hiring and training qualified, new employees.
“[The ACM panel] is still a fairly new product out there,” he says. “You can find someone with a similar product history, like sheet metal experience, and try to make them understand the differences between flat metal and composite panels. The big
[placement] issues are on the drafting side of things because new employees need to prepare shop drawings. They need to have a good understanding of the material, what you can do with it, and how it works with the different systems we offer to achieve the goal that the architects set out. That seems to be a universal hurdle for everyone in the industry today.” With its technical savvy, outstanding relationship- building and good luck, Fairfield Metal will overcome this hurdle and keep innovating, fabricating and adapting to its customers’ needs.
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Sidebar: Company Profile
Year Founded: 2010
Location: Fairfield, N.J.
Geographic Areas of Service: New Jersey, New York, Connecticut, Pennsylvania, and ready-to-install metal composite panel systems for customers in Boston, Washington D.C. and nationwide.
Services Offered: ACM panel fabrication and custom products that include column covers, curved panels, standing seam roofing and roofing accessories.
Number of Employees: 20 employees
Metal Building Square Footage Fabricated:
2015: 415,000 square feet
2014: 385,000 square feet
2013: 335,500 square feet
2012: 225,000 square feet
Revenue:
2015: $6,250,000 Million
2014: $5,825,000 Million
2013: $5,125,000 Million
2012: $3,575,000 Million
Management team:
Ryan Hunt, General Manager
Kris Zyla, Chief Estimator
