Case Study
Sunrise Toll Plaza, Fort Lauderdale, Florida

Photos courtesy of Petersen Aluminum / PAC-CLAD

Corrugated and Perforated Metal Panels Combine to Create Vibrant Design

The new Sunrise Mainline Toll Plaza on the Sawgrass Expressway west of Ft. Lauderdale represents a transformation of the aging Expressway to a "highway of tomorrow." The $26 million design/build project offers the first open road tolling (ORT) in South Florida, using a double-span signature gantry for collection of tolls from high-speed vehicles. The Sawgrass Expressway has become a major commuter corridor with more than 90,000 vehicles per day. The toll plaza project included 1.33 miles of roadway widening north and south of the plaza and complete reconstruction of the approaches.

The toll plaza utilizes approximately 11,000 sq. ft. of corrugated 7/8" aluminum panels finished in Silver Metallic. In addition, 5,400 sq. ft. of .125 plate aluminum was custom perforated and spray coated. Miami-based MCM Corp. was the lead contractor and Orlando-based RS&H was the lead design firm and engineer of record. "The assignment from the Florida Turnpike Enterprise was to create a 'showcase toll plaza'," according to Jesse Forst, project manager for RS&H. According to Forst, "The use of corrugated metal was part of the design/build criteria established by the Turnpike. We designed the project to have a contrasting look between the corrugated and the perforated material. The installation challenges involved detailing to make sure the two materials meshed together properly without creating maintenance or constructability problems. It's a great project and a definite toll road showcase in south Florida."

Allied Architectural Metals, Inc. of Ft. Lauderdale fabricated the custom perforated material as well as installed the corrugated panels and intricate trim details.

Case Study
Pine Rest Postma Center in Cutlerville, MI

Photo courtesy of Petersen Aluminum / PAC-CLAD

Existing Facility is Transformed

A dilapidated 1960's era gymnasium was masterfully transformed into a modern and inspirational worship and education center at Pine Rest Christian Mental Health Services' facility. The new 15,500 sq. ft. Postma Center has become the centerpiece of the 220-acre campus.

While a significant portion of the existing structure was re-used, only a shadow of the former image remains. The exterior is highlighted with an undulating wall clad with 5,000 sq. ft. of custom flat lock wall panels using pre-patinated copper. Vertical colored glass windows are inset in the radius wall at varying heights. Above and below each window opening are composite metal panels finished in classic bronze and platinum colors. Approximately 1,800 sq. ft. of composite material was utilized. The composite and custom copper panels were fabricated by the manufacturer and installed by Buist Sheet Metal Company, Grand Rapids, MI. In addition, Buist installed extensive fascia using a complementary composite wall panel system.

"Certainly the most complicated part of the job was the custom wall panels," said Don Buist. "The architect wanted to maintain a consistent 58 inch joint width across the entire wall, including the joints at the 24 vertical window openings. That meant we had panels ranging from the full 58 inches to as small as 2 or 3 inches in order to keep the consistent joint locations. The design really required careful layout."

Buist also custom fit 190' of curved EverGreen coping to cap the radius wall. The top of the coping was hand cut in 5' lengths to fit the curve. Separate face pieces were then soldered to the front and back of the coping while maintaining the curve.

Design for the project was provided by Integrated Architecture, Grand Rapids. The general contractor was Pioneer Construction, Grand Rapids.

Case Study
Chanooka Healthcare in Morris, IL

Photo courtesy of Petersen Aluminum / PAC-CLAD

Rain Screen Panels Provide Desired High Tech Look

Morris Hospital & Healthcare Centers has opened its new Chanooka Healthcare Center to provide comprehensive medical services to the Illinois communities of Channahon and Minooka. The first floor of the 26,000-square-foot facility provides immediate care, laboratory testing, and diagnostic imaging services. Physician office space is located on the second floor.

Approximately 4,000 square feet of composite wall panels finished in a bright silver metallic were utilized to provide the high-tech look. Fabrication of the rainscreen system panels was done by the manufacturer.

The panels were installed by Sullivan Roofing, Inc., Schaumburg, IL. According to Gianni Pellegrinon, senior project manager, "The biggest challenge was alignment of the seams on the vertical fin at the entryway. The fin is about 10" wide and has mitered corners that really turned out nice. We also used the composite material to finish off the top of supporting brick columns under the entrance canopy soffit." Construction design services for the design/build project were provided by CD Group, Mount Prospect, IL.