Resilient and Sustainable Design with Sunshade Systems  

Architectural metal sunshades manage heat gain while delivering daylighting and aesthetic appeal

Sponsored by AMICO Architectural Metal Systems | By Andrew A. Hunt

Photo courtesy of AMICO

Controlling solar gain and adding a unique aesthetic element are the key qualities of expanded mesh and perforated metal.

 

Expanded mesh and perforated metal can play a key role in helping new and retrofit building projects become more durable, resilient, and sustainable in design and operation. The thoughtful placement and orientation of expanded mesh as a sunshade helps lower heating and cooling costs, reduces glare, and creates more comfortable spaces for occupants. Besides saving monthly energy costs and improving occupant well-being, expanded mesh or perforated metal as a sunshade can also be a way to future-proof a project and lower the carbon footprint. With the adoption of Building Performance Standards (BPS) in major urban areas, reducing the operational carbon footprint of commercial and residential buildings is becoming more of a factor. Identifying permanent and durable solutions in the early design stages is key to helping address current carbon estimates. Architectural metal sunshades can help buildings remain compliant with the eventuality of evolving building and energy codes. This article will explore the flexible design benefits of how architectural metal sunshades can help a new building or existing structure enhance natural daylighting while controlling solar heat gain and glare.

 

EXPANDED MESH AND PERFORATED METAL—AN OVERVIEW

Few building materials offer the diversity of both beauty and function.  Expanded mesh and perforated metal are frequently used to create beautiful surfaces that are visually appealing while concealing unsightly (but necessary) building elements.

The distinctiveness of these materials has frequently contributed to award-winning design work, bringing amazing texture and color to both interior cladding and exterior facades across residential, commercial, and institutional applications. While these materials excel at creating beauty and fresh, original aesthetics, their value can be much more than superficial.

Functionally, because of their degree of openness, these materials can serve as barriers that allow for airflow and heat dissipation in equipment screens and parking garage cladding. Expanded mesh and perforated metal can also help control sight lines, provide privacy, reduce nuisance winds, and eliminate light pollution from exiting a structure. Possibly more important, these materials can be used as a sunshade.  This can reduce heat gain and allow for more carefully managed, equitable access to natural light inside a space.

Expanded Mesh

Expanded mesh is a die-punching process in which sheet or coiled metal feeds into the press while the dies pierce and stretch the metal. The press rapidly repeats the process, offsetting back and forth with each stroke. This is a low-scrap and highly efficient manufacturing process that takes a given length of sheet metal and allows it to cover larger areas. When trimming panels to ensure square dimensionality, the bits of scrap left over can easily be separated and reclaimed, as the product is 100 percent recyclable. Base metal options can impact weight, strength, and possible finishes. Aluminum is the most common choice for expanded mesh because it is lightweight, can contain considerable pre- and post-consumer recycling content, while offering the longest-lasting finishes available on the market.

The panels can be oriented with the diamonds going in any direction; however, the panel is more rigid in the long way of the diamond. The sheet’s metal thickness will impact the rigidity of the mesh. Meshes are typically only 1/8-inch-thick material, but can be specified thicker to make the panels more rigid as needed to span distances.

Image courtesy of AMICO

There are many different styles of expanded mesh that deliver different looks and levels of openness and air flow.

 

There are many different styles of expanded mesh that deliver different looks and levels of openness and air flow. Here is a step-by-step approach to evaluating a mesh for your design objectives:

Decision #1: Choose an aesthetic.  What style of expanded mesh delivers the aesthetic you hope to achieve? Small strand widths may be hard to read from a distance, whereas meshes with thick strands will deliver great visual impact even from a distance.

Decision #2: Define your objectives around the visual open area.  This is defined by looking at the mesh perpendicular to the panel.

Decision #3: If critical to your design, define the mechanical open area necessary for air flow.  This is defined by the open area when looking at the mesh in its most optimal and open direction, the amount of open space.

Image courtesy of AMICO

 

Orientation of the mesh is also important.  The mesh’s opacity will vary depending on where you are standing in relation to the mesh. Because the mesh is dimensional, many mesh styles open in a particular direction. This is functionally useful on parking garage screens, for instance, because the mesh can be oriented to open upward, maximizing the amount of opacity to people viewing the parking garage from below. On an aesthetic level, some architects will rotate panels in different directions to create areas of varied opacity.

Expanded mesh can also have varied strand widths within the same panel. This creates a panel with a highly customized appearance for little added cost. This can functionally assist your design by creating zones of more or less opacity—this approach could be used on a parking garage, creating high opacity zones that greatly reduce light-pollution from escaping the garage and then opening up more in other areas of the panel to provide the required airflow.

Photo courtesy of AMICO

Both mesh directionality and viewing angle can change the appearance of the mesh. The example at left shows how simply rotating the same style of mesh panels can create a different appearance.

 

Perforated Metal

Perforated metal is created by taking sheet material and simply punching holes of different sizes and patterns. The resulting sheets make for excellent facade cladding, railing infill, canopies, sunscreens, louvers, and more. This style of sheet metal has an exceptional strength-to-weight ratio, making it excellent for applications such as railing, where strength and safety are key.   

There are two primary methods of manufacturing perforated sheets. The first die-based manufacturing is where dies rapidly punch fixed patterns into the metal rolled sheet. This process is fast and efficient, allowing for more economical production; however, the pattern of the punched holes is the same from row to row. If the design calls for a custom, varied hole pattern, sheets are instead manufactured on a turret press. In this process, a CNC (Computer Numerical Control) turret punch machine is used to punch a series of holes, slots, or custom shapes into a metal sheet using a variety of interchangeable tooling heads. The machine consists of a rotating turret loaded with different punches and die combinations that can be automatically selected to create complex patterns without stopping production. Turret presses, in addition to punching holes, can dimple a surface by striking the metal sheet with a formed head instead of a punching die. This not only stiffens the material but also creates a unique design on the surface.

The perforation process is excellent for creating complex hole patterns that use small holes that are close together. Other cutting processes, like laser or water jet cutting, are either too slow or incapable of producing smaller geometries. If you are considering patterns that require unique shapes, or are over 3 inches in diameter, laser cutting is likely something you should consider. 

Most perforated panels are specified with round holes, the most economical choice, but squares, hexes, slots, and rectangles are also very common. When considering the design for perforated material, there are a few constraints to consider. First, holes in the material must be less than 1 to 1 ratio to the sheet thickness. For example, a 1/8-inch-thick sheet cannot have holes 1/8-inch-thick or smaller. Secondly, Areas with extreme openness are prone to distorting due to a lack of structural integrity; it is recommended to stay lower than 70 percent openness in the design.

Photo courtesy of AMICO

The combination of visual transparency with a high strength-to-weight ratio makes perforated metal a popular choice for railing when safety is a concern.

 

IMAGE TO PERFORATION OPTIONS

Photo courtesy of AMICO

Architects can incorporate the image-to-perforation process to create abstract custom textures and bring unique looks to large-scale areas of a building.

 

An increasing trend with perforated material is to translate images into perforated metal.

This process is a simple software conversion of a raster image into hole patterns that are then manufactured on a CNC turret press. Designers have used this process to display objective photographs, such as portraits, or it can be used to present graphical content, including logos or text. This feature allows direct messaging to an audience, such as memorializing individuals, communicating specific messages, or offering direct outreach to enhance a community’s well-being.

Architects can also incorporate this process to create abstract custom textures and bring unique looks to large-scale areas of a building.

Photo courtesy of AMICO

Controlling solar gain and adding a unique aesthetic element are the key qualities of expanded mesh and perforated metal.

 

Expanded mesh and perforated metal can play a key role in helping new and retrofit building projects become more durable, resilient, and sustainable in design and operation. The thoughtful placement and orientation of expanded mesh as a sunshade helps lower heating and cooling costs, reduces glare, and creates more comfortable spaces for occupants. Besides saving monthly energy costs and improving occupant well-being, expanded mesh or perforated metal as a sunshade can also be a way to future-proof a project and lower the carbon footprint. With the adoption of Building Performance Standards (BPS) in major urban areas, reducing the operational carbon footprint of commercial and residential buildings is becoming more of a factor. Identifying permanent and durable solutions in the early design stages is key to helping address current carbon estimates. Architectural metal sunshades can help buildings remain compliant with the eventuality of evolving building and energy codes. This article will explore the flexible design benefits of how architectural metal sunshades can help a new building or existing structure enhance natural daylighting while controlling solar heat gain and glare.

 

EXPANDED MESH AND PERFORATED METAL—AN OVERVIEW

Few building materials offer the diversity of both beauty and function.  Expanded mesh and perforated metal are frequently used to create beautiful surfaces that are visually appealing while concealing unsightly (but necessary) building elements.

The distinctiveness of these materials has frequently contributed to award-winning design work, bringing amazing texture and color to both interior cladding and exterior facades across residential, commercial, and institutional applications. While these materials excel at creating beauty and fresh, original aesthetics, their value can be much more than superficial.

Functionally, because of their degree of openness, these materials can serve as barriers that allow for airflow and heat dissipation in equipment screens and parking garage cladding. Expanded mesh and perforated metal can also help control sight lines, provide privacy, reduce nuisance winds, and eliminate light pollution from exiting a structure. Possibly more important, these materials can be used as a sunshade.  This can reduce heat gain and allow for more carefully managed, equitable access to natural light inside a space.

Expanded Mesh

Expanded mesh is a die-punching process in which sheet or coiled metal feeds into the press while the dies pierce and stretch the metal. The press rapidly repeats the process, offsetting back and forth with each stroke. This is a low-scrap and highly efficient manufacturing process that takes a given length of sheet metal and allows it to cover larger areas. When trimming panels to ensure square dimensionality, the bits of scrap left over can easily be separated and reclaimed, as the product is 100 percent recyclable. Base metal options can impact weight, strength, and possible finishes. Aluminum is the most common choice for expanded mesh because it is lightweight, can contain considerable pre- and post-consumer recycling content, while offering the longest-lasting finishes available on the market.

The panels can be oriented with the diamonds going in any direction; however, the panel is more rigid in the long way of the diamond. The sheet’s metal thickness will impact the rigidity of the mesh. Meshes are typically only 1/8-inch-thick material, but can be specified thicker to make the panels more rigid as needed to span distances.

Image courtesy of AMICO

There are many different styles of expanded mesh that deliver different looks and levels of openness and air flow.

 

There are many different styles of expanded mesh that deliver different looks and levels of openness and air flow. Here is a step-by-step approach to evaluating a mesh for your design objectives:

Decision #1: Choose an aesthetic.  What style of expanded mesh delivers the aesthetic you hope to achieve? Small strand widths may be hard to read from a distance, whereas meshes with thick strands will deliver great visual impact even from a distance.

Decision #2: Define your objectives around the visual open area.  This is defined by looking at the mesh perpendicular to the panel.

Decision #3: If critical to your design, define the mechanical open area necessary for air flow.  This is defined by the open area when looking at the mesh in its most optimal and open direction, the amount of open space.

Image courtesy of AMICO

 

Orientation of the mesh is also important.  The mesh’s opacity will vary depending on where you are standing in relation to the mesh. Because the mesh is dimensional, many mesh styles open in a particular direction. This is functionally useful on parking garage screens, for instance, because the mesh can be oriented to open upward, maximizing the amount of opacity to people viewing the parking garage from below. On an aesthetic level, some architects will rotate panels in different directions to create areas of varied opacity.

Expanded mesh can also have varied strand widths within the same panel. This creates a panel with a highly customized appearance for little added cost. This can functionally assist your design by creating zones of more or less opacity—this approach could be used on a parking garage, creating high opacity zones that greatly reduce light-pollution from escaping the garage and then opening up more in other areas of the panel to provide the required airflow.

Photo courtesy of AMICO

Both mesh directionality and viewing angle can change the appearance of the mesh. The example at left shows how simply rotating the same style of mesh panels can create a different appearance.

 

Perforated Metal

Perforated metal is created by taking sheet material and simply punching holes of different sizes and patterns. The resulting sheets make for excellent facade cladding, railing infill, canopies, sunscreens, louvers, and more. This style of sheet metal has an exceptional strength-to-weight ratio, making it excellent for applications such as railing, where strength and safety are key.   

There are two primary methods of manufacturing perforated sheets. The first die-based manufacturing is where dies rapidly punch fixed patterns into the metal rolled sheet. This process is fast and efficient, allowing for more economical production; however, the pattern of the punched holes is the same from row to row. If the design calls for a custom, varied hole pattern, sheets are instead manufactured on a turret press. In this process, a CNC (Computer Numerical Control) turret punch machine is used to punch a series of holes, slots, or custom shapes into a metal sheet using a variety of interchangeable tooling heads. The machine consists of a rotating turret loaded with different punches and die combinations that can be automatically selected to create complex patterns without stopping production. Turret presses, in addition to punching holes, can dimple a surface by striking the metal sheet with a formed head instead of a punching die. This not only stiffens the material but also creates a unique design on the surface.

The perforation process is excellent for creating complex hole patterns that use small holes that are close together. Other cutting processes, like laser or water jet cutting, are either too slow or incapable of producing smaller geometries. If you are considering patterns that require unique shapes, or are over 3 inches in diameter, laser cutting is likely something you should consider. 

Most perforated panels are specified with round holes, the most economical choice, but squares, hexes, slots, and rectangles are also very common. When considering the design for perforated material, there are a few constraints to consider. First, holes in the material must be less than 1 to 1 ratio to the sheet thickness. For example, a 1/8-inch-thick sheet cannot have holes 1/8-inch-thick or smaller. Secondly, Areas with extreme openness are prone to distorting due to a lack of structural integrity; it is recommended to stay lower than 70 percent openness in the design.

Photo courtesy of AMICO

The combination of visual transparency with a high strength-to-weight ratio makes perforated metal a popular choice for railing when safety is a concern.

 

IMAGE TO PERFORATION OPTIONS

Photo courtesy of AMICO

Architects can incorporate the image-to-perforation process to create abstract custom textures and bring unique looks to large-scale areas of a building.

 

An increasing trend with perforated material is to translate images into perforated metal.

This process is a simple software conversion of a raster image into hole patterns that are then manufactured on a CNC turret press. Designers have used this process to display objective photographs, such as portraits, or it can be used to present graphical content, including logos or text. This feature allows direct messaging to an audience, such as memorializing individuals, communicating specific messages, or offering direct outreach to enhance a community’s well-being.

Architects can also incorporate this process to create abstract custom textures and bring unique looks to large-scale areas of a building.

BALANCING DAYLIGHTING WITH SOLAR HEAT GAIN

The problem that many architects battle is finding a balance between natural light and shading.  Including large expanses of windows brings in beautiful natural light as well as numerous health and psychological benefits to the occupants; however, with the light comes glare and heat gain, challenging energy goals.

Daylighting is more than just a method of reducing electricity use—it is a critical design strategy with far-reaching benefits for both building performance and occupant well-being. According to the National Institute of Building Sciences, effective daylighting involves more than simply introducing natural light into occupied spaces. It requires a careful balance of illumination, glare control, thermal regulation, and consistency throughout the day. When done correctly, it enhances not only the energy performance of a building but also the experience and health of its occupants.

Natural light reduces dependence on artificial lighting, which contributes to overall energy efficiency. But beyond energy savings, daylighting plays a central role in biophilic design, a concept rooted in the human affinity for nature. Biophilic design connects occupants to the natural environment through elements such as sunlight, fresh air, and outdoor views. When integrated into architectural form, this connection has been shown to enhance psychological well-being, increase social interaction, and foster a greater sense of comfort and satisfaction within a space.

Exposure to daylight also supports essential physiological functions. Natural light helps regulate circadian rhythms, influencing sleep patterns, mood, and overall health. A lack of daylight can contribute to mood disorders such as Seasonal Affective Disorder (SAD), which is commonly treated with light therapy. Clinical studies have consistently demonstrated that access to daylight can reduce symptoms of depression, improve alertness, and lower stress levels. Furthermore, natural light provides a more comfortable visual environment than artificial lighting, offering better color rendering and reducing eye strain.

The strategic placement of windows and the control of light penetration not only facilitate daylighting but also play a vital role in connecting people to their surroundings. Windows serve as both physical and visual thresholds between the indoors and outdoors, offering access to views, natural ventilation, and dynamic lighting conditions that shift with the weather and time of day. They are key elements in biophilic design, helping to fulfill the innate human need to engage with the natural world, even from within built environments.

However, without proper control, daylighting can introduce challenges, particularly glare. In office settings, glare caused by direct sunlight reflecting off screens or work surfaces can reduce productivity by up to 21 percent, leading to eye strain, headaches, and visual discomfort. Mitigating glare through shading systems, thoughtful orientation, and diffused light solutions is essential for maintaining visual comfort and supporting work efficiency.

The benefits of daylighting and biophilic design extend beyond aesthetics. Numerous studies have shown measurable improvements in occupant outcomes, such as faster recovery times in healthcare settings and increased productivity in workplaces. Employees with access to daylight and views of nature report higher levels of focus, reduced absenteeism, and a greater sense of well-being. One landmark study found that patients recovering in hospital rooms with views of nature healed more quickly than those facing blank walls. In another, access to a naturally lit, plant-filled atrium significantly improved employees’ concentration and mood.

In addition to providing health, safety, and welfare for occupants, shading and daylighting solutions also improve a building’s energy efficiency by limiting heat gain and loss, thus reducing the use of HVAC systems. Incorporation of a successful shading strategy, especially one that supports the aesthetic design of the project, can prove a financial benefit both during the original build and long after due to reduced operational costs. For building owners, the reduced capital costs associated with a possibly downsized HVAC system can be an opportunity to either reduce investment or upgrade other sustainable features like onsite power generation.

By reducing the reliance on artificial lighting, natural daylighting can potentially reduce building energy use by up to one-third. This is significant. Electric lighting accounts for 35 to 50 percent of the total electrical energy consumption in commercial buildings. Shading systems can help maximize energy savings by reducing the reliance on automated shading systems and light controls.

Proper sizing and potentially downsizing of heating and cooling equipment also translate into long-term financial benefits. Short cycling of equipment happens when systems are “overbuilt” to keep the space comfortable and indoor air quality at healthy levels. When equipment runs short cycles, it tends to need more maintenance and wear out faster, meaning early replacement costs.

It is at this intersection of occupant benefits, lowered operational costs, and sustainability goals that expanded mesh and perforated metal as a sunshade system perfectly align with project and occupant needs. As we will discover in the next section, expanded mesh and perforated metal offer a wide range of options and applications in buildings to help ensure a more comfortable and efficient occupied space.

 

SUNSHADE AS A SOLUTION

Moving from the challenges of controlling glare and solar heat gain to a solution, a long-standing practice of architects is to utilize architectural metals as a sunshade element. Expanded mesh and perforated metal can maintain visibility, allow ample natural daylight, and control glare and solar heat gain. The materials can be used in various applications, from individual window treatments to fully integrated rain screen and facade solutions.

Photos courtesy of AMICO

Expanded mesh and perforated metal are often incorporated into sunshade design systems parallel to the ground, parallel to the facade, or perpendicular to the facade.

 

Expanded mesh and perforated metal can be used to help provide quality light while reducing direct glare, as well as shading the sun from reaching the building. Architects achieve this by either positioning mesh and perforated sunshades parallel to the ground above windows, parallel to the facade in front of windows, or with fins perpendicular to the facade. Often, these structures are designed to complement the building style and design and take many different shapes and forms.

Horizontal Sunshades: Parallel to the Ground Over the Window

The most traditional application is the horizontal sunshade, positioned above a window and parallel to the ground. This configuration is especially effective on south-facing facades, which can significantly reduce direct solar penetration during summer months while allowing passive solar gain during the winter. Expanded mesh and perforated metal in this orientation provide a visually lightweight yet structurally durable solution that allows air and partial daylight to filter through. The degree of solar shading is influenced by the depth of projection, pattern density, and the material’s open area. From a design standpoint, horizontal sunshades can contribute to a building’s architectural expression by creating strong linear elements and deep shadow lines without obstructing any views.

Vertical Sunshades: Parallel to the Window

A second common configuration involves installing the sunshade parallel to the window surface—essentially as a second skin facade or brise-soleil. This approach is particularly useful for controlling solar gain on east and west facades, where the angle of the sun can be more challenging to mitigate with horizontal devices alone. In this format, the expanded mesh or perforated metal becomes an integral part of the facade composition, offering continuous shading across the window plane while maintaining outward visibility. Additionally, this technique can be used to create a unified architectural language across both glazed and opaque sections of the elevation, contributing to both performance and aesthetic cohesion.

A popular variation for vertical sunshades parallel to the window is to partially cover the exposed window. This can allow an exact percentage of the window to remain uncovered and permit daylight, while shading a specific percentage to achieve precise solar heat gain reduction.

Vertical Fins: Perpendicular to the Window

The third typical approach involves positioning sunshades as vertical fins, installed perpendicular to the window plane. These devices are highly effective at blocking low-angle sunlight, especially in the early morning and late afternoon. When made from expanded mesh or perforated metal, these fins allow filtered light and partial views, contributing to a dynamic interplay of light and shadow throughout the day. Perpendicular fins also introduce rhythm and depth to the facade, and when spaced in repeating patterns, they create a striking visual texture. From a performance perspective, the orientation, spacing, and angle of these fins can be fine-tuned to achieve optimal solar control based on the building’s orientation and geographic location.

Each of these sunshade configurations offers unique opportunities to address solar control while contributing to the architectural identity of a project. Whether deployed horizontally over a window, in parallel as a screen system, or as vertical fins, expanded mesh and perforated metal provide flexible, durable, and visually compelling options for modern building design. Architects can use these strategies individually or in combination to tailor facade performance and aesthetics to the specific climate, solar orientation, and functional goals of a project.

Before moving on to potential interior applications, let’s explore some other options for incorporating expanded mesh and perforated metal into the building design.

More Benefits of Architectural Metals

Facades are one of the most common architectural uses for expanded mesh and perforated metal. The materials often provide unique textures and are an excellent means of breaking up monotonous glass surfaces. When comparing expanded mesh to flat insulated metal cladding, the textured and variegated surface will inherently hide visible dirt buildup better due to the non-uniform shadowed surface. Less washing improves welfare by lowering the cost of ownership, reducing chemical runoff during cleaning, and improving safety by reducing the number of times a person may be put in harm’s way by being elevated above the ground to clean.

Parking garage cladding is another great use for expanded mesh and perforated metal, and it also offers functionality as well as aesthetics. First, parking structures are typically a visual blight on a neighborhood, but these architectural metals can play a great role in creating unique and attractive structures. For larger projects like airports and municipal buildings, expanded mesh or perforated metal for exterior siding on both main buildings and parking structures can create a uniform and consistent visual appearance. Functionally, expanded mesh and perforated metal provide security to structures by controlling access and creating a safer environment. They also provide a wind break while still allowing daylight illumination and proper fire-code required airflow, as well as safe vehicle emission diffusion. For the nearby residents’ welfare, it can reduce nuisance light pollution from vehicle headlights shining into surrounding areas at night.

Photo courtesy of AMICO

This San Jose parking garage is clad in APEX03 expanded mesh, offering a high level of opacity, beautifully hiding the unsightly elements behind it.

 

Equipment and rooftop screen applications are also excellent candidates for perforated metal and expanded mesh. These metals can provide secure access to equipment while hiding unsightly HVAC equipment, generators, electrical substations, or plumbing equipment.

Moving inside, expanded mesh and perforated metal are increasingly popular materials for interior applications—not only for their visual impact but also for their performance advantages.  One of the standout qualities of expanded mesh is its ability to introduce dynamic texture and dimensional contrast to interior spaces. Its open pattern and geometric surface add depth, create interesting shadow play, and can serve as an impactful surface for vibrant color treatments. Whether used to accentuate a contemporary interior or add edge to an industrial aesthetic, expanded mesh allows for creative freedom without sacrificing practicality.

Common interior applications include column wraps, mechanical and duct covers, privacy screens, feature walls, and wall or ceiling accents. These treatments can conceal unsightly systems while maintaining a modern, cohesive appearance. The visual permeability of expanded mesh and perforated metal also allows for filtered transparency, providing both visual interest and spatial delineation without full enclosure.

Image courtesy of AMICO

Interior ceiling applications are ideal for expanded mesh and perforated metal as the spaces can help support and conceal acoustic-dampening materials while hiding mechanical equipment or noise-dampening insulation.

 

Ceiling applications represent a particularly innovative use of these materials. Expanded mesh panels can be suspended or mounted around lighting fixtures to create layered lighting effects or hung independently to allow light to diffuse through the material. This openness also brings practical benefits. The perforations and mesh patterns facilitate air circulation, helping to reduce the risk of stagnant air in enclosed environments. Additionally, these panels are typically acoustically transparent, meaning they can be used as protective yet discreet cladding over acoustic materials, preserving sound absorption performance while enhancing visual appeal.

Beyond performance, the longevity and low maintenance of metal surfaces make them a cost-effective solution for high-traffic or commercial interiors. Resistant to wear, corrosion, and deformation, expanded mesh and perforated metal hold up well over time, ensuring that their form follows function for years to come.

Ultimately, expanded mesh and perforated metal bring together beauty, performance, and durability, making them an ideal choice for architects looking to create high-performing, aesthetically driven interior spaces.

CALCULATING THE EFFECTIVENESS OF PASSIVE SHADING

While providing shade to a building to reduce glare and solar heat gain makes common sense, quantifying potential energy savings is also important. Before investing in expanded mesh or perforated metal, other than as an aesthetic choice, a designer should be able to answer the real-world question of how effective these sunshade elements are at reducing heat gain.

To answer this, RWDI, an international climate engineering and environmental consulting firm specializing in understanding how the built and natural environments interact, launched an independent study using digital simulations to quantify heat gain change for a sunshade mounted parallel to a facade.

Study Assumptions and Set-Up

Every building will have unique site-specific variables that impact heat gain, such as window direction, local weather patterns, or nearby buildings providing shade. What RWDI set out to accomplish was to create a scenario that could observe and measure if a significant change in heat gain could be observed under a controlled condition. For the simulation, several assumptions were made, including:

  • The hypothetical digital building was 32 X 32 feet with a south-facing window wall on one side only.
  • Interior attributes: Floor, ceiling, and walls were based on the LM-83 standard defined by the Illuminating Engineering Society of North America (IESNA).
  • The building site was defined as Los Angeles using a Typical Meteorological Year profile.
  • No surrounding buildings were assumed.
  • The structure was oriented so that the window wall faced due south.
  • Window sizes were continuous 6-feet, 7 inches by 29-feet, 6 inches.
  • The window had a solar heat gain coefficient of 0.46, a common performance.

For the sunshade, a conventional expanded mesh was utilized with a horizontal diamond opening. The mesh included a large visual opening of 46 percent, meaning it would provide the most open visual experience for an occupant inside the building and block the least amount of light and therefore heat. The sunshade was defined as a matte gray fluoropolymer painted finish.

Image courtesy of AMICO

Above is a representation of the digital simulated structure with south facing window and expanded mush passive sunshade.

 

Simulation Details

The simulation was run using ClimateStudio software with the industry standard Radiance rendering program and involved the calculation of a Bidirectional Scattering Distribution Function (BSDF), which allows the transmission and reflection characteristics of arbitrarily complex geometries to be defined mathematically. This is a common approach for studying daylighting, solar heat gains, and building energy use since it allows for efficient calculations of solar characteristics without the need for a detailed model of the geometry. The simulation was then arranged to measure heat gains at each point in the room on an hourly basis over the entire course of a year.

The results were nonambiguous and predicted meaningful heat gain reduction using expanded mesh as a sunshade when placed within 5 feet of the window. For instance, when the window was covered 66 percent with expanded mesh panels, 45 percent of the heat gain was mitigated.

Figure 1 summarizes the heat gain reduction predicted under various levels of window coverage. An additional projection of heat gain analysis was completed using a slightly smaller visual opening of 26 percent.

Image courtesy of AMICO

 

What the data revealed was that even with a partial 66 percent of the window covered by the expanded mesh, a 45 percent total heat gain reduction to the space resulted. When coverage was increased to 100 percent of the window, total heat gain was reduced by 67 percent. A strong linear relationship exists between the fraction of window area covered by the product and the percentage reduction in solar heat gains, as shown in Figure 2. Figure 3 shows visual heat maps representing the interior floor of the simulated building with the variation of the percentage of window coverage with expanded mesh material at 46 percent visual opening characteristics.

Images courtesy of AMICO

 

Real-World Applications

Moving from a hypothetical structure to the real world, data calculated from the RWDI simulation was extrapolated onto a project design from the SmithGroup for the University of Utah, SJ Quinney College of Law Building. Located in Salt Lake City, UT, the modern facility was designed with sustainability in mind and holds a LEED Platinum certification. The building is complemented with a large south-facing wall of windows across three stories. This level of solar exposure was an ideal opportunity to leverage the solar heat gain reductions possible using the computer-simulated assessment.

Photos courtesy of AMICO

The SJ Quinney Building incorporated partial window shading with expanded mesh to control solar heat gain, reduce glare, and incorporate a unique visual appearance both inside and outside.

 

Similar to the hypothetical building, the project was designed with an expanded mesh covering of approximately 66 percent of the windows, with the more conservative 26 percent visually open characteristic used in place of the 46 percent openings.

To calculate potential energy savings, cost savings, and operational carbon reduction, the following assumptions were included:

  • HVAC coefficient of performance (COP) = 4
  • The south-facing facade has 9,000 sf of windows at 0.46 solar heat gain coefficient.
  • Project location duplicate to the original scenario—Los Angeles
  • California’s electricity cost is $0.25 per kWh.
  • California’s PG&E produces approximately 0.542 pounds of CO2 per kWh.

Results of the performance simulation found that heat gain models estimate the mesh would eliminate 15.72 kWh per square foot of glass per year from entering the building, or 141,513 kWh in total per year. Based on California’s electrical cost, the mesh facade would save the owners $35,378/year in HVAC energy use.

Assuming building owners will renovate their building facades every 20 years, the expanded mesh facade will save owners over $707,000 during the life of the sunscreen. The reduction in electrical demand would also prevent an estimated 76,700 pounds of CO2 from being emitted each year, or over an estimated 1.5 million pounds of CO2 over the life of the screen. To put that into context, this is equivalent to preventing 111,000 pounds of coal from being burned per year, or roughly 2.3 million pounds over the life of the facade.

Based on the research, including expanded mesh in this scenario provides several distinct benefits to occupants and building owners beyond the financial projections. With a deliberate balance between controlling heat gain and allowing access to daylight for all facility users, the overall experience for occupants was thoughtfully enhanced. The expanded mesh allows natural light to penetrate deep into the space, helping provide free illumination to students, faculty, and visitors. Glare is reduced, especially during winter when the solar arc drops lower on the horizon and south-facing windows provide a direct line of sight to the sun.

Another benefit comes into play when local municipalities or project specifications require sustainable design considerations that include capping energy usage. The expanded mesh sunscreens play a significant role in reducing both energy use and projected operational carbon emissions. Including solar management systems allows for more windows to be included in the design without energy use or carbon penalties. Overall, the study found that expanded mesh sunscreen systems can be a solution for deploying more windows in the design and increasing occupant access to natural light.

 

FUTURE PROOFING NEW AND EXISTING BUILDINGS

In an era when sustainability and long-term resilience are critical drivers in building design, futureproofing is emerging as a key strategy for architects. Future Proofing refers to the proactive design and planning of buildings to ensure they remain efficient, functional, and compliant with evolving performance requirements and environmental challenges. This approach not only considers today’s needs but also anticipates the shifting regulatory landscape, changes in energy availability, and advancing technological standards.

Driving these shifts in design are Building Performance Standards (BPS), which have been adopted or proposed in major metropolitan areas across the United States. BPS regulations require buildings to meet specific energy or emissions performance thresholds over time. Unlike voluntary sustainability frameworks, BPSs are enforceable mandates aimed at improving energy efficiency and reducing carbon emissions across entire building portfolios.

Cities such as New York, Washington, D.C., Boston, and Denver are leading the charge, implementing BPS policies that directly influence how new and existing buildings are designed, retrofitted, and operated. These standards compel architects and developers to integrate high-performance features much earlier in the design process.

At the core of this conversation is operational carbon—the greenhouse gas emissions associated with the day-to-day energy use of a building. This includes heating, cooling, lighting, and powering equipment. Reducing operational carbon is now a top priority for jurisdictions seeking to lower their overall environmental impact. 

While embodied carbon remains significant, operational carbon reduction offers immediate and measurable benefits, particularly when paired with high-performance building systems and smart design strategies.

As codes and energy mandates continue to evolve, designing for tomorrow’s standards means incorporating durable, adaptive solutions into early-phase planning. For this task, expanded mesh or perforated metal can help support both energy efficiency and occupant comfort.

Passive strategies like metal sunshades become valuable tools, providing immediate energy savings and long-term compliance solutions. The permanence and low-maintenance nature of metal sunshades provide a long-lasting response to the unpredictable trajectory of climate and energy demands. Unlike temporary solutions or those dependent on external energy sources, such as automated window shades, expanded mesh, and perforated metal offer a robust, static barrier against solar heat gain. This enables buildings to maintain thermal comfort while decreasing reliance on mechanical cooling systems, regardless of fluctuations in energy pricing or availability in the future.

Expanded mesh and perforated metal sunshades, when applied thoughtfully, contribute to the building envelope’s thermal performance and visual character. They allow for natural daylighting while mitigating heat gain, thus supporting a building’s ability to meet—or exceed—BPS requirements. As energy codes become more stringent, these architectural solutions help bridge the gap between design excellence and environmental responsibility. Incorporating such features ensures that buildings not only perform today but also continue to thrive tomorrow.

 

CONCLUSION

Expanded mesh and perforated metal offer architects a set of durable, resilient, and sustainable solutions that enhance building performance. When strategically placed as sunshades, these materials reduce energy use, control glare, and improve occupant comfort. As Building Performance Standards (BPS) continue to shape design requirements in urban areas, architectural metal sunshades present a forward-thinking approach to lowering operational carbon and meeting evolving energy codes, making them a smart, future-ready choice for both new construction and retrofit projects.

 

 

Andrew A. Hunt is Vice President of Confluence Communications and specializes in writing, design, and pro-duction of articles and presentations related to sustainable design in the built environment. In addition to in-structional design, writing, and project management, Andrew is an accomplished musician and voice over ac-tor, providing score and narration for both the entertainment and education arena. www.confluencec.com https://www.linkedin.com/in/andrew-a-hunt-91b747/

Originally published in Architectural Record

Originally published in July 2025

LEARNING OBJECTIVES
  1. Explain the manufacturing process, options, and styles available when specifying expanded mesh and perforated metal as a building material.
  2. Evaluate the benefits and challenges of solar exposure in buildings and how excessive heat gain and glare can impact occupant comfort and health.
  3. List the features and benefits of expanded mesh when specified as a sunshade to reduce solar heat gain and control glare.
  4. Discuss Building Performance Standards (BPS) and how this carbon conscious program is changing the landscape of urban design.