According to the EPA, on average, Americans spend upwards of 90% of their time indoors. Between work, school, shopping and relaxing at home, the vast majority of our time is spent breathing stale, indoor air. The EPA also reports that some pollutants are as much as five times more concentrated indoors than they are outdoors.  

As pandemic restrictions lift and people across the country head back to the office, return to school and venture back into indoor public spaces such as movie theaters, museums and retail establishments, indoor air quality is top of mind for all of us.  

But air quality isn’t a simple, single-variable concept. It’s a dynamically changing interplay of many different factors. The good news is many of those factors are within your control.  

The Energy Crisis 

Up until the 1970s, there weren’t strong and consistent regulations on building energy efficiency. This changed after a series of energy crises in the 70s and 80s which led to regulations which increased the thermal efficiency and air-infiltration of the building envelope. Thermal efficiency, as measured by r-value, is the insulation rating of a system, whether it is the wall, floor, ceiling, roof, etc. Air-infiltration, as measured by air leakage, is outside air that enters a building uncontrollably through cracks and openings. 

Ever since, both the national and local codes have steadily increased the thermal efficiency and air-infiltration of the building envelope – especially in Canada’s northern climate zones. Beyond regulations, building tightness has been incentivized by the R-2000 Program and the EnerGuide Rating System from Natural Resources Canada. This has resulted in structures that are more and more airtight. 

Conflicting Goals 

Air tightness helped buildings maintain more comfortable indoor temperatures better than ever – and more efficiently than ever. However, this air tightness has been detrimental to indoor air quality, because it means virtually no fresh air comes in. Siet ‘Foeng’ Tjong, Ceco Head of Research and Development explains, “We generally do not like to have any leaks, whether it’s water, vapor or air leaks into the building. But in some cases that does create a problem with indoor air quality.” 

We don’t often think of indoor air as necessarily being unhealthy, but it has the potential to harbor all kinds of harmful materials. As Joseph Dachowicz, Ceco’s Vice President of Marketing for Commercial Business, points out, “Buildings are filled with all kinds of man-made materials you’re just basically breathing in all day.” 

Tjong agrees, “When you have a building that is super tight, it also creates a lot more challenges for the HVAC engineer to provide balanced indoor air quality,” she said, ”and it creates a lot more load and requirements on the HVAC system to evacuate the air inside building and replace it with fresh air.” 

Pollutants

Of the pollutants that can end up stuck inside airtight buildings, some are generated indoors, while others find their way in through cracks, open doors or windows, or even on the people going in and out. Some can come from both sources. 

Man-Made Volatile Organic Compounds (VOCs) 

Chemicals used in the manufacture of office equipment, furniture, wall and floor coverings and construction materials can off-gas into your interior environments. Cleaning products, pest control, copying and printing can also leave a variety of harmful compounds in the air. With extra cleaning measures in place due to COVID-19 concerns, and more products being sprayed on more surfaces more often, ventilation to move that particulate matter out is even more crucial. 

Biological Agents 

Bacteria, viruses, fungi and molds can all travel through the air, causing illness, infection and fungal or mold growth. 

Combustion Pollutants 

Whether from idling vehicles, machinery, tobacco smoke, heating or cooking, combustion-related compounds such as carbon monoxide are among the most dangerous interior pollutants. High levels of carbon monoxide from a vehicle left idling in a garage can be lethal in a matter of minutes. Worse still, it’s odorless, tasteless and colorless – virtually imperceptible without a carbon monoxide detector. 

Fine particulate matter 

This is the “dust” you can see floating in a ray of sunlight and can be made up of any of the above as well as other fine particulate matter. 

Pollutants can be generated by the most innocuous seeming sources, such as housekeeping or printers, but are caused more precipitously by renovation, remodeling or applying new paint or finishes. 

Health Effects 

Poor indoor air quality can result in serious health effects. These can range from mild and irritating to life-threatening. Eye, nose and throat irritation are common, as well as headaches, dizziness and fatigue. At the more severe end of the spectrum, poor air quality can trigger asthma attacks, and more hazardous pollutants like radon or carbon monoxide can cause cancer or be lethal. 

Sick Building Syndrome 

When poor ventilation and indoor pollutants combine, they can lead to what’s known as “sick building syndrome.” Many occupants experience similar symptoms after entering in “sick” buildings, and their symptoms tend to resolve after leaving. Air quality this poor has been blamed for everything from sub-par student performance to reduced productivity in occupational settings. 

A Matter Of Opinion 

Perception of poor air quality is important as well. Though these considerations are more subjective, they can still affect how employees, visitors and customers feel inside your building. Odors and temperature are two of the strongest variables affecting perceived air quality, as well as air movement. Too little feels stuffy, but too much can feel drafty and uncomfortable.  

Air Exchange Basics 

According to the EPA, “The air exchange rate is affected by the design, construction, and operating parameters of buildings and is ultimately a function of infiltration, natural ventilation and mechanical ventilation.” These all play a part in how much air needs to be exchanged or moved per minute, which is expressed in cubic feet per minute, or CFM. The more overall air exchanges per hour – including a measure of exchange with outside air – the better. However, the following factors and considerations contribute to what is required to manage and improve a building’s air quality and ventilation: 

 1. Size 

The size of a building determines how much air is inside it, and therefore is an important part of the necessary CFM calculation. 

2. Occupancy 

Buildings with fewer or no people, such as barns or warehouses, require much less ventilation – fewer CFM – than buildings with higher occupancy, such as a school, office building or church. 

3. Number and Type of Openings 

These can be intentional openings such as doors, windows and loading docks, as well as a building’s unintended openings which compromise its overall tightness, such as cracks and broken seals. External pollutants infiltrate a building through such openings, then the building’s tightness keeps them in. 

4. Type of Airflow  

Unoccupied buildings may only have natural ventilation, while livestock buildings or storage buildings might use industrial fans, and buildings designed for people are equipped with complete HVAC systems. 

5. External temperature changes  

Outdoor temperature changes – both day/night cycle and seasonal changes – dictate what level of insulation is ideal.

6. Insulation Type and Quality 

As discussed, insulation is good for energy efficiency but makes integration of fresh air a challenge. 

Think Ahead 

The absolute best way to ensure healthy air quality is to plan ahead and integrate adequate ventilation in your project from the very start. As Tjong points out, “Indoor air quality is the responsibility of HVAC engineers,” and they will be best enabled to provide that quality when their needs and input are included throughout the design process. Simply include HVAC engineers when you work with your Ceco representative. This way, fenestrations and other necessary roof and penetrations are planned for, as well as structural support for HVAC systems.  

What You Can Do 

We understand that while not everyone is in the midst of a new construction design project, everyone could benefit from better air quality. Simply being aware of everything discussed so far will help you rectify any existing problems – and prevent future ones – while following these simple tips will help even more: 

• Get healthy, fresh air into the building when possible. 
• Establish an effective smoking policy that protects nonsmokers from secondhand smoke. 
• Ensure your HVAC system’s HEPA filtration is changed as directed. 
• Be careful not to place furniture or other obstacles in front of air vents, grilles or intakes. 
• Water and maintain office plants properly to avoid extra moisture – and therefore the development of mold. 
• Dispose of garbage promptly and properly. 
• Pre- and post-occupancy flushing, with exterior air is recommended if your system is capable of it.
• Be mindful of the unintended consequences of excessive cleaning product usage. 

Also, be wary of unsubstantiated claims of many air “purifiers” on the market that claim to kill COVID-19 or purify the air through unproven means. At best, these will be an expense that accomplishes nothing. At worst, they can exacerbate indoor pollutants. For instance, ionizers generate ozone. This is unhealthy on its own, but it’s also highly reactive and can combine with other airborne substances to create harmful VOCs like formaldehyde and acrolein. 

There are steps everyone can take to improve air quality and incrementally improve the health of both buildings and the people who live, work, shop and play inside them. To learn more about how Ceco can assist in designing a custom metal building with the latest in air quality features, reach out to your Ceco representative today. 

When architects and building designers think of metal construction, many tend to assume they’re limited to four walls and a roof – basic construction essentially amounting to a box. With advances over the past few decades in every facet of metal construction, nothing could be further from reality. The capabilities and versatility of metal construction have improved drastically, pushing the boundaries of design and surpassing the expectations of architects, designers, builders and clients alike.  

Complex projects like retail establishments, car dealerships, schools and large sporting facilities, which were once thought to be limited to the realm of conventional construction, are now being produced more quickly and efficiently using metal construction methods. 

Customers Come First 

This paradigm shift hasn’t occurred simply because it’s possible, but because customers are demanding more sophistication and complexity in their buildings. They want more than a box. Many want an architecturally pleasing and impressive building, flooded with natural light. Others need a manufacturing facility requiring complex structural specifications for important components like top-running cranes. Oftentimes, municipalities are also demanding more cosmetically appealing buildings for plan approvals. 

Of course, increased complexity can come at an increased cost, but more often than not, it’s worth it. There’s a big difference in complexity between a single-slope, four-walled “box building” and an architect-designed, two-story building with hips, valleys, daylighting and cranes. When building designs become complex, it’s best to involve a Ceco representative up front and throughout the process.  

What Qualifies as “Complex”? 

Though we often use the terms “pre-engineered” or “pre-fabricated”, the truth is all Ceco products are custom-made per order. Every building is custom, but the level of customization complexity is determined by the design requirements of the project. It helps to understand which building conditions can result in the project being considered “complex.”  

Complex Building Conditions: 

Complicated Roof Designs 

Hips and valleys on roofs are one of the most common building conditions that lead to a building being considered complex. 

Aesthetic Features 

Architects are usually hired to make a building more striking, and the embellishments and complex geometries they envision can increase the intricacy of the engineering behind the structure. 

Additional Floors 

Whether it’s a second-level mezzanine or a basement, additional floors add to the complexity of a building. 

Auxiliary Loads 

Manufacturing facilities with structurally mounted equipment such as large top running cranes increase the design loading substantially.  

Long Bays 

Increased spacing between vertical supports is becoming an increasingly common building requirement – especially for indoor sporting facilities, warehouses and large churches.  

Codes and Loads 

Code changes and local differences for wind, seismic activity, snow, temperatures, energy and occupancy category may require more of the building. Likewise, collateral loads for ceiling-mounted systems such as lights, ductwork and sprinklers can increase the complexity of the building. 

Hangars 

Buildings built to house aircraft typically need very wide, high-fold doors for aircraft ingress and egress, requiring additional structural supports. 

Energy Efficiency  

Metal construction is often chosen for its superior insulating values, and insulated metal panels further improve R-values. Another way to cut energy costs is through the use of daylighting – bringing as much natural light in as possible. Though technology for including daylighting on a standing-seam roof has improved significantly, it still makes for a more complex design. 

Teamwork 

When your building meets the criteria for a complex building outlined above, the most important step you can take to save time and money is to involve your Ceco representative early and throughout the process. As Scott Schroer, Ceco’s Engineering Director explains, “Engaging with the architect, the owner, and our customer to help value engineer the building is a huge opportunity.” Complex building conditions require custom solutions from our engineering department. Communication is key, because an engineer can spot problems or complications an architect, builder or customer wouldn’t likely be aware of. They also have the experience and expertise to devise clever fixes.  

Modelling Work 

The inclusion of Ceco early on and throughout the process also means we can take advantage of 3D Building Information Modeling (BIM). This software makes a visual model representing all the complex, interrelated parts of a building’s plan, from the framing and envelope to mechanical, electrical and plumbing systems. This assists all the various trades in foreseeing where these complexities might clash or interfere in reality – so we can avoid problems before they arise. 

Pushing The Envelope Together 

Metal construction can be more sophisticated and elegant than ever before – while still meeting and exceeding specific practical requirements. We just need to work together and communicate well. When we work together, we can push the envelope of metal construction and continue to surprise and impress visitors and clients alike. Contact your Ceco representative to get this important group conversation started as early as possible. 

Peanut butter and jelly. Cheese and wine. Bacon and eggs. Some things just pair perfectly – like stone and steel. At Ceco, we know just how much the rich textures of stone can add to the curb appeal and natural appearance of our steel buildings, so when you work with us you get the benefit of multiple veneer stone suppliers in one resource, making it easier than ever for your projects to be enhanced by this natural pairing. 

Nothing can enhance the curb appeal quite like the rich, organic look of stone – and nothing can blur the boundary between the outdoors and indoors quite like natural stone surfaces. There is something about stone that makes us feel more at home. It seems to call to our ancient, natural instincts. 

Think Twice 

Before you assume that including a stone finish will significantly increase your budget and timeline, you need to understand that veneer stone does not require as much as the traditional masonry exteriors you might be used to. The process has been vastly simplified with manufactured stone, a pigmented concrete product textured to look and feel like natural stone but weigh less than a mere 15 pounds per square foot. Panels of this stone veneer are installed over a plywood or OSB substrate on top of insulated metal buildings, so the insulation and vapor barrier are already in place. That means the cost of cladding a building in stone veneer is 10-30% lower than traditional masonry products, such as natural stone or brick. 

It is a handsome, elegant solution, hence the name: Stoneworks. 

Up Your Game 

Stone cladding can become a striking focal point, completely changing the character of a building and altering the impressions of clients, visitors and employees. The shadows, textures and depth created by stone make any building blend beautifully with natural surroundings – or bring the serenity of nature into a more urban or industrial setting. To further integrate organic surroundings, our eight manufacturing facilities across the nation create a wide array of stone veneer products in shapes, colors and textures inspired by regional geography and geology.  

Ceco can now offer an extensive range of stone veneers for engineered metal buildings, from traditional appearances like ledgestone, cut stone and cobble stone to sleek, contemporary modern styles and even more eccentric products like blended, chiseled, rounded and fieldstone. We even offer stone veneer in a brick pattern that is representative of a modular brick system. Though it is technically not a fired clay brick, it is precisely the same size, shape and color – just made from durable concrete and iron oxide pigments.  

Want some inspiration? Check out some of the breathtaking work done for commercial applications, homes and interiors. 

Outside In 

Even if stone is not the right look for your entire building, accent walls or interior stone surfaces bring the outdoors inside – in a stunning, memorable way. A church altar, a rock wall behind a reception desk or a stacked stone fireplace are just a few ideas. Better still, since they are not load bearing or exceedingly heavy, stone veneer panels do not require any structural reinforcement. They can simply be adhered to the existing wall.  

Eric Aitken, Director of Sales and Marketing for Stoneworks explains that one of his favorite features of stone exteriors is that they are maintenance free. “It’s not something that has to be repainted,” says Aitken. To prove it, the products come with a 50-year limited warranty.  

Which of our Stone Solutions is right for your project? Depending on your needs, there is a solution that can help you accomplish your goals. 

Environmental Stoneworks  

Environmental Stoneworks is the only national manufacturer and installer of stone veneer providing a single point of responsibility for your project from start to finish. It is a business built on providing expert in-house installation of Environmental Stoneworks products – plus the expertise to handle any problem or obstacle that might present itself. 

Next Steps 

With your metal construction company and stone provider under the same umbrella, you can expect unprecedented efficiencies. Whatever your project or vision, the best place to begin is with your Ceco representative. He or she can contact a stone expert, communicate the essentials of your project, determine if any architectural drawings or specifications are necessary and provide you with the best answers. Get started today. 

Computer technology continues to have notable impacts on the people and processes involved in the metal building industry as discussed in an earlier blogpost “How Commercial Buildings are Getting Smarter”. Here we look at one of the emerging technological advances that will bring things to an even higher level of capability and opportunity, namely, the growth of the 5G communications network.

What is 5G?

It is simply an abbreviation for the fifth-generation (5G) of cellular communication technology. The engineering behind it has been focused on substantially increasing the speed and responsiveness of wireless networks and has generated a lot of interest and excitement. At full fruition, it promises speeds fast enough to operate heavy-duty data transfers like video and building operation applications. The promise of 5G is so strong that experts are touting it as a way to replace broadband and Ethernet based Wi-Fi. That’s because it is expected to support more devices with greater speed, reliability, and efficiency as compared to other networks. Clearly then, 5G can become a game-changing technology for many people and applications around the world.

In light of this emerging technology design, construction companies of all types are tracking its progress and trying to decide what actions to take. Metal building manufacturers, installers, and owners are finding that there are three primary areas where the use of 5G can be truly transformative:

Metal Building Systems Manufacturing

The equipment used for manufacturing and forming metal building components has increasingly become automated. Everything from fairly simple electronic control panels to full-scale, robotic operations all rely on being connected to a common communication platform. If that equipment is no longer reliant on a wired Ethernet connection, then equipment can be re-arranged for more efficient operation and greater productivity in potentially less space. Furthermore, the use of wireless 5G as the communication platform in a manufacturing plant means that equipment can more easily be moved and re-arranged at any time as needs change. It also means that manufacturers may have more equipment options that allow for greater automation or mechanization of the plant. This helps everyone since each manufactured part can be controlled with greater efficiency and fewer people actually needing to touch the products.

Design and Construction

Communication between all parties is critical to the success of any project. That communication can become compromised or delayed when design teams, manufacturers, and installer/contractors are remote from each other without reliable ways to share data or other information. 5G is particularly helpful in these situations in a number of ways. First, it can provide a common communication platform where everyone is on the same network. This can help during design allowing all parties to collaborate with ready access to the same engineering data and software. In the field, where Wi-Fi is often not an option, 5G allows mobile access for real-time communication without having to travel to a location where service is available. The second thing 5G offers in design and construction is the opportunity to use additional electronic tools for documenting, recording, and communicating on-site activity. Drones and stationary site cameras for example have become very popular as an economical way to take photos or videos of construction work and details. Connection to the 5G network means that these tools can be used to their fullest potential, allowing all stakeholders to obtain the latest information for accurate timelines, scheduling, and documentation, leading to more efficient construction.

Completed Buildings

Building owners and managers often want more product offerings with technology already built-in or integrated. Many contractors/installers are embracing such product options to help them close bids faster in scenarios where there is a demonstrated desire for the latest technology. For example, coiling metal doors are available with new options such as electronic sensors paired with automated operation. This provides a means to electronically control access through those doors and monitor which people are using them based on their access privileges. The 5G connection allows for a reliable way for this system to work while collecting data that can be used to better understand work and people flows within a building. It can also provide feedback to the metal building systems manufacturer allowing them to improve offerings to their customers.

Overall, 5G holds the real promise of becoming the means with which to seamlessly connect manufacturers, designers, contractors, and building owners/users by providing a reliable, fast, and robust communications platform. Its real-time capability allows timely interaction and collaboration that can make things easier for everyone involved. It can also capture information and data to identify trends, preferences, or issues allowing for better outcomes in the future. To find out more about how to incorporate the latest technology into your current or next project contact your local Ceco representative.

The transformations brought about by computer technology over the last few decades have reached just about every facet of life. Events like the Consumer Electronics Show (CES) showcase the ubiquitous and appealing nature of the fruits of our electronic age, while others like the International Builder’s Show (IBS) display how building design and construction are advancing from technology. In particular, all people involved with metal building systems are benefitting from these available, evolving technologies on several fronts:

Engineers and Designers

Computer-based engineering and modeling programs have been in widespread use for some time. This software allows for different design iterations to be calculated and analyzed much more quickly using structural loading information that is project specific. Cloud-based software for designers allows the programs to update automatically, while providing a platform for multiple parties to access and interact with the design as it is being developed. Integrating other building components and systems into a 3-D model allows for coordination of all of the systems, and the opportunity to identify and resolve space conflicts ahead of time. With all of the above as a basis, the goal is to be able to use software to design in real-time, make changes, and analyze form and function impacts instantly. This computerized approach connects engineering directly to manufacturing so the total process is streamlined and timelines shortened. Using advanced digital tools means there can be an easy and seamless data flow from design to manufacturing.

Manufacturers

Computerization of the manufacturing process applied to metal building components helps to make everything more predictable, allowing more accurate pricing and potential cost-savings to customers. This can start with cost-efficient prototyping of parts using 3-D printing to analyze different options in full-size, allowing refinements, re-printing, and testing to be undertaken in a fraction of the time that conventional processes would require. Once products are in production, robotics can be employed for highly accurate, efficient fabrication. Each individual product can then be electronically linked to an order, and its progress tracked as it moves through the system. Forward-thinking manufacturers can then use the data associated
with all aspects of different products, allowing them to make further refinements and advancements. These computer enhancements streamline the ordering, fabrication, and tracking of metal building systems and components.

Contractor Customers

Giving customers the ability to virtually “see” the building in front of their eyes before they buy is now very possible. Using advanced tools like augmented reality (AR) that adds information to an existing scene, or virtual reality (VR) that creates the entire scene from scratch is a very exciting, emerging development. Once finalized, online ordering and tracking of building components allows for easier and better customer experiences from project inception through to the finish. This can start as soon as the order originates, and allows the customer to monitor the progress of drawings, fabrication, loading, and delivery. Convenience is enhanced by housing this information in a customer specific portal for access via computer, tablet, or cell phone. Manufacturers can also track this data to help improve overall company performance and service to customers nationwide.

Installers

The use of AR and VR can be used to help installers “see” how the different parts and pieces of a metal building system go together, either ahead of time as a preparatory procedure or during erection. The use of prefabricated components makes this possible in addition to reducing job-site waste and onsite labor concerns. In terms of meeting time schedules to erect a building, some companies are leveraging GPS and tracking software not only to know where an order is in the manufacturing process, but also to know where the delivery trucks are. This allows for more accurate scheduling of loading and unloading times, including lean construction concepts such as just-in-time delivery.

Building Owners and End Users

Smart buildings are increasing in popularity for many good reasons, but most significantly, they make it easier for owners and users to operate and maintain a building. For metal buildings, there are some things that are carryovers from the residential market such as smart (electronic) locks that can be added to doors provided by manufacturers. This could be particularly useful in metal storage facilities where security, control, and different levels of accessibility are important. Other technology options are directly relevant to commercial buildings, including energy controls. Smart walls, for example, can use sensors to detect and track information such as surface temperatures allowing for automatic HVAC adjustments. Similarly, smart windows can adjust the amount of solar gain allowed, or tie into security systems.

Whichever of the above categories you fit into, there are real, tangible benefits along with opportunities for exciting new possibilities. Manufacturers who have recognized these benefits and are embracing them, like Ceco, are out in front of the curve providing technological leadership. To find out more, contact your local Ceco representative.

Metal building systems have been part of the American construction scene for well over 60 years. During that time, the people, companies, processes, products, and perceptions have all evolved and matured. As it stands now, a substantial portion of all low-rise commercial buildings in the United States are constructed using metal building systems. That is good news for anyone involved with this dynamic industry. However, the past is simply the foundation of the present and the launching point for the future. So, where is the industry today as we begin 2020? To gain some insight, we look to the Metal Building Manufacturers Association (MBMA), which is the not-for-profit trade association representing metal building manufacturers (including Ceco and our affiliated companies). In their recently released annual report, MBMA cites some key areas that are impacting the industry and prompting proactive efforts to address them across the country.

• Accreditation: It is the norm for manufacturers of metal building systems to be accredited under the International Accreditation Service (IAS) standard AC472. All MBMA member facilities are accredited under this standard (a membership requirement), which sets metal buildings apart from other types of construction with a demonstrated, ongoing commitment to quality control that includes independent inspection oversight. This standard is regularly reviewed and consistently updated to raise the bar for assuring high-quality products and full code compliance.

• Architectural Design: Metal building systems are being used in virtually all types of low-rise commercial, industrial, agricultural, and institutional buildings. There is no longer a “typical metal building,” because every one is custom designed and engineered to suit the needs and aesthetic preferences of owners, architects, and users. There are plenty of examples and case studies to look at, but the current trend is in more diversity of design and a broader use of these systems.

• Education: While industry experts may be up to speed on metal building systems, there are many who can learn from the decades of experience available. In particular, there are now programs for current and future architects and engineers to learn more about the general and specific aspects of metal building systems. These take the form of online continuing education courses for design professionals, capstone courses for students, and online webinars and seminars available through YouTube or directly from MBMA. This ongoing focus on education is expected to bolster and support the architectural and engineering community in designing and specifying even more metal building systems.

• Energy Codes: All buildings need to comply with energy code requirements. The unique nature of using a metal building system requires attention to the ways code compliance can be achieved or exceeded using established fabrication and construction methods. Hence, members of the industry continue to participate with national code regulators (i.e., the International Code Council, ASHRAE, etc.) to accurately define the parameters and methods that are both energy appropriate and constructible. This collaboration is expected to continue as the energy codes develop and evolve around both insulation levels and air infiltration control.

• Resiliency: Many geographic areas are experiencing severe weather or natural events that challenge the integrity of metal buildings. Since metal building systems are engineered to meet specific conditions, there is an increased trend to design building construction assemblies and details that properly resist the effects of seismic activity, fire, high wind, hail, heavy rain, and other extreme conditions. The metal building industry is rising to these challenges and meeting them head on.

• Jobsite Safety: Protecting workers in construction is a concern of any organization involved in the building industry. This issue is applicable both in metal building manufacturing plants and on site. Steps taken to increase jobsite safety include providing training, workshops, webinars, and award programs that promote, educate, and recognize good safety practices.

• Sustainability: It has become an industry expectation with buildings of all types that sustainability is literally built in to every project. The MBMA is providing tools for manufacturers to assess, test, and demonstrate with complete transparency the sustainability of steel products. The fact that most metal buildings currently contain a high degree of recycled steel content helps meet this goal, as do other aspects of metal building systems that are regularly being expanded and enhanced.

• Technical Research: Metal building systems continue to evolve and become more sophisticated in their engineering, design, and assembly. Ongoing research sponsored by MBMA and others is helping to define best practices, improve safety, and deliver even better value moving forward.

To find out more about how the current, advanced state of the metal building industry can help with a building that you are involved with, see the Ceco website or contact your local Ceco representative.

Protecting investments in aircraft from weather and ultraviolet light, as well as making them easy to access and work on, has driven many in the aviation industry to seek out the best ways to meet their needs and budget. Whether the requirement is a small, simple hangar or a large, complex, multi-unit facility,  a pre-engineered steel building is an ideal solution because it’s custom designed for specific project needs, including:

• Type and number of aircraft that will be stored in the hangar now and in the future. (This includes clear span requirements, tail heights, turning radii of tow vehicles used to move aircraft, and dimensions of lifting, rolling, bi-fold, or stacking leaf hangar doors.)
• Type of maintenance that will be performed in the facility: airframe and/or engine repair, systems repair, battery services, and interior finishes repair.
• Energy efficiency, including temperature and humidity control.
• Fire protection and alarm devices.
• Office, lounge, and administrative areas.
• Warehouse space.
• Aesthetics to reflect the aviation company’s image.

Metal buildings have been used very successfully in aviation facilities such as standalone and multi-unit projects, private and commercial hangars, and T-hangars, as well as in storage, maintenance, and repair hangars. Industry estimates indicate that engineered building projects take one-third less time to construct than traditional building projects, allowing owners and users to occupy the building sooner. An engineered steel building can also be designed to easily accommodate future expansion.

Aviation Case Study: As an example of how this can all come together, here is an excellent case study

Project: Hangar 19
Location: Fargo, North Dakota
Architect and General Contractor: Olaf Anderson Construction, Fargo, ND
Ceco Products Used: Double-Lok®, PBC Corrugated Wall Panels, AVP Wall Panels

The Project: In the fall of 2017, Olaf Anderson, Inc. of Fargo, North Dakota broke ground on the Hangar 19 project. Located at Hector International Airport, a civil-military public airport in Cass County, this private hangar is owned by a private company. Hector International Airport is the busiest airport in North Dakota with almost 845,000 passengers passing through in 2018 alone, and is also home to Fargo Air National Guard Base, located adjacent to the airport.

The Problem: The luxury of owning or renting a private plane includes having proper aviation storage space as well as a comfortable, stress-free experience. On average, Fargo sees snowfall 6 months of the year, and freezing weather is just as common. Therefore, it was important that private plane owners and renters should not have to brave these conditions while waiting for their aircraft. The benefits of Hangar 19 would come with certain amenities including storage space, a heated garage for vehicles, office space, a lobby, and a lounge area.

The Solution: Olaf Anderson, both the architect and general contractor, was brought on board to design and construct the facility for what would become known as Hangar 19. Anderson is a well-known design-build general contractor in North Dakota, offering an extensive range of capabilities, and is a longtime Ceco builder. He recognized that metal buildings are the most economical way to get large spans for hangar space as well as accommodate large hangar doors.

Anderson chose a Ceco single-slope clear span frame to maximize space for aircraft. In addition, a mezzanine was incorporated into the design with private office space located on both the first and second floors. For the roof, 25,240 sq. ft. of the Double-Lok^® standing seam roof system in Galvalume^® was used. For the exterior, Signature^® 200 Galvanized horizontal PBC corrugated wall panels and 20,000 + sq. ft. of AVP wall panels in Signature^® 200 Burnished Slate were incorporated along with coordinated stonework, which was subcontracted to Sperle Masonry, Inc. of West Fargo, ND.

A particularly impressive feature of this project included an 85 ft. jack beam (for comparison purposes, keep in mind that a normal size jack beam is 60 ft). This larger beam allowed Olaf Anderson to install a massive 80 ft. hangar door. The 85 ft. jack beam also allows for 90 ft. of building frame and currently carries two frames. The hangar owner asked that the possibility for another addition onto the hangar be included in the design should the need arise in the future for expansion.

The Results: Currently, Hangar 19 can accommodate anywhere from 18 to 20 planes, depending on their size. A 34,000 sq. ft. addition to the north of the facility has been allowed for in the design with a more massive hangar door and additional plane storage.

To find out more about selecting the best metal building options for an aviation building that you are involved with, see the Ceco website or contact your local Ceco representative.

Building owners who are grounded in their current reality but have an eye to the future often seek flexibility in their building design. Therefore, it is not uncommon for a design professional to be asked how the building can be sized to meet the current needs but allow for an economical expansion when the time is right for that. Metal buildings provide an exceptional answer through the proper design and construction of the end wall of the building. Below we identify the different options that are available and how each one impacts the end use of the building.

Bearing Frame

This is a typical endwall consisting of a series of rafter beams supported by columns and can also be referred to as a Beam and Column or Post and Beam frame. Since the rafters only support a portion of the last bay of the metal building, they are smaller members which are not structurally designed for future expansion. X-bracing is often used in one or more of the endwall bays or sections to provide support for horizontal wind and seismic load and is intended to remain as part of the permanent lateral support structure.

Expandable Frame

When the endwall frame is designed for both the structural loads of the existing endwall as well as the anticipated structural loads of expansion, then it can be left in place and is considered an Expandable Frame. This can reduce costs when the expansion is undertaken since only the exterior end wall enclosure system needs to be removed (and possibly re-used on the new end) while the existing end wall expandable frame left can be left in place. New wall and roof systems can then be tied into the existing structure to create a continuous, weathertight, expanded building.

Expandable frames are designed to carry a full bay’s worth of load similar to a mainframe at the interior of the building. This additional capacity allows it to be transformed into an interior frame when the building is expanded. Often called “Rigid Frames” or “Main Frames” that are simply located at an endwall, they consist of members that are joined together with moment connections that allow the frame to support both vertical and horizontal loads without the need for x-bracing. Typically, Expandable Frames will be constructed of large tapered sections that are designed specifically for the building loadings to optimize size, shape, weight and clearances. Straight sections can be requested as well.

Non-Expandable Frame

This type of frame shares many of the same characteristics as an Expandable Frame since bracing in the plane of the frame is not required. However, a Non-Expandable Frame is designed for only half of the endbay roof and wall loading and not for any additional loads from future expansion. This makes the frame lighter compared to an Expandable Frame. Other applications for using a Non-Expandable endframe include buildings with special or heavier load requirements or instances where bracing of a Bearing Frame Endwall would otherwise interfere such as very large openings for hangar doors or crane runways in an endwall.

Rigid Bearing Frame

This frame is a bit of a hybrid combining some of the characteristics of all three frames previously mentioned except that it is not considered an expandable frame. It can be fabricated of straight or tapered sections. Roof beams and sidewall columns are designed with moment connections and thus do not require bracing in the plane of the frame. Intermediate columns are rotated 90 degrees to the roof beams to permit attachment of girts and wall panels, thus eliminating the need for larger setbacks for endwall columns in addition to the frame columns. Because it is a rigid frame it can be designed more easily to accommodate heavier secondary loadings for wall accessories or large openings in the plane of the endwall framing.

Ledger Member

This classification is typically reserved for endwalls of a building that are supported by a concrete or masonry wall with a steel ledger angle fastened to the wall and metal building purlins bolted to the angle. The nature of concrete and masonry walls is that they will likely stay in place if expansion is considered. If that doesn’t suit the building design, then an expandable frame will be much more cost-effective.

Clearly, it is important to address expansion plans early on in the design of the building and pick an endwall design accordingly. The project that follows is a great example of how this was done successfully.

Hangar 19, Fargo, North Dakota

Located at Hector International Airport in Cass County, North Dakota, Hangar 19 is used for private plane owners who need not only airplane storage but protection from the very cold northern climate. The design of this building, therefore, required certain amenities including storage space, a heated garage for vehicles, office space, a lobby and lounge area. Olaf Anderson served both as the Architect and General Contractor. Since he was very aware that metal buildings are the most economical way to get large spans for hangar space as well as accommodate large hangar doors, a custom metal building was designed with single-slope clearspan rigid bearing frames. The facility accommodates 18 to 20 planes with a mezzanine for the other building needs.

The endwall of Hangar 19 is further designed to accommodate the request from the private owner to allow for the possibility of a future addition. With this in mind, Olaf Anderson used an expandable frame on the endwall to accommodate an approximately 34,000 sq. ft. future expansion to the north of the facility.

To read more about this project, visit https://www.cecobuildings.com/resources/case-studies/hangar-19-case-study/. To learn more about designing endwalls for future expansion on other projects, contact your local Ceco representative.

Content for this blog post was provided by Wes Young, Cornerstone Building Brands Product Training Manager

The standing seam metal roof is a very popular roofing solution due to its durability, water-tightness, relative simplicity, and clean appearance. While the standing seam, which is created by forming two adjacent metal roof panels together, contributes to all of these traits, some people may not realize that it also simplifies the attachment of other items to the roof. The most common and effective means to attach anything to a standing seam metal roof is to use an ingenious piece of hardware known simply as a seam clamp.

What are seam clamps?

These are engineered and fabricated small cubes of stainless steel or aluminum that are designed to be mechanically attached directly to the standing seams in a metal roof. They do that with a round-point set screw in the clamp that squeezes and dimples the standing seam for a true mechanical attachment. This approach is truly non-invasive since it does not penetrate or compromise the integrity of the metal in any way and therefore keeps all roofing warranties intact. Once secured onto the standing seam, then the seam clamp is the base for threaded bolts or screws that fit into specific locations on the clamp. From there, specific hardware can be secured to attach a variety of additional items. Specifically, seam clamps have been used for decades on metal roofing to secure accessory items such as snow retention systems, fall protection devices, HVAC equipment, lightning protection, satellite dishes, and even rooftop service walkways.

How do they work with solar panels?

One of the biggest current uses of seam clamps is for the connection of solar photovoltaic (PV) panels to a metal roof. On many roof-mounted PV systems, the use of rails or some similar component may be needed to support the PV panels. By using seam clamps with customized interface hardware designed to connect directly to the solar panels, the standing seams of the roof act as the rails. Eliminating the use of the rails and using the seam clamps means the installation is easier and the cost is reduced notably, both in terms of material and labor.

Why put solar panels on a metal roof?

Solar systems are typically warranted 25 years for power production, but the real service life of the modules can be 40 years or more. Hence when mounting the PV system, the building designer or owner needs to be sure that the roof underneath it has a comparable life. Metal roofing is a very good match since it will last as long or longer than the PV panels. A roof with a shorter life will require removal of the PV to replace the roofing and then a reinstall of the PV at a high cost.

How many seam clamps are needed on a roof?

Some seam clamp manufacturers have independently tested their product in combination with literally every standing seam metal roofing system on all of the available metal gauges that are on the market. As such, very specific information can be provided on things like loading capability, wind uplift resistance, etc. for the seam clamps. With that information, combined with the roofing and solar panel information, an engineer can calculate the needed spacing and locations of seam clamps. Those calculations will take into account the specific design wind speed and wind uplift potential for the project location. It will also take into account the specifics of the building structure and the internal structure of the solar panels. In some cases, locations such as perimeters and corners of groups of solar panels (called an array) may require more frequent spacing while in the field of the array, the spacing may be less. Ultimately, the best location and spacing of seam clamps is determined and the proper quantity identified. It is worth noting that when engineered in this manner, the most common mode of failure is that the module itself fails under windy conditions, rather than seam clamp attachment.

What maintenance is needed on seam clamps?

Virtually no maintenance is required. All of the clamp designs are not friction connections, they are mechanical interlocks, so loosening is rarely, if ever, an issue. We have noted that the set screw dimples the standing seam and compresses it to make a mechanical interlock. In addition, locking head screws, bolts, and nuts all with serrations that are directional allow the hardware to be seated but not unscrew, thus holding everything permanently in place. Since all of the metal is either stainless steel or aluminum, there is no concern of rusting or corrosion.

Where can I learn more?

To learn more specifically about seam clamps and how to use them to mount solar panels on a standing seam metal roof, visit the website of the leading manufacturer of seam clamps known as S-5! To learn more about standing seam metal roofing and metal buildings, contact your local Ceco representative.

Content for this article was provided by Rob Haddock, Founder and CEO of S-5!®

Never in our lifetime has it been more evident than now that design and construction teams are incorporating so many different elements into projects. Customers are increasingly requesting more features and benefits to keep up with changing codes and their own personal requirements. It is our job as the suppliers, builders, contractors and architects to deliver on those needs.

There is something to be said for a tastefully constructed building that brings together many elements. That is quite true for the City of Greenville Public Works Campus project. Not only was sustainability an important factor for the campus, so was the ability for it to be economical and multi-purposeful.

Sustainability

A sustainable building delivers on energy efficiency, reducing waste, conserving natural resources and optimizing performance. The green movement is at an all-time high in almost every industry today therefore, it’s pivotal that companies provide a built-in sustainable strategy. Ceco was able to help achieve that with this project. The roofing system for the campus was comprised of CFR insulated metal roof panels in Kynar Polar White. The white roof reinforces sustainability by being highly reflective of the sun and reducing solar heat gain. The CFR IMP also offers a superior R-30 value, ultimately enhancing energy performance. The building’s walls are comprised of the 7.2 Insul-Rib™ and Striated insulated wall panels and with a R-21 value, these IMP’s provide another effective measure of energy efficiency. Another benefit of Ceco’s products is that they are virtually 100% recyclable, therefore, contributing to the reduction of waste, another huge sustainability benefit.

Economical

Frankly, people want the best value for their dollar. The benefit of low maintenance and low operating costs of metal building’s mean optimization of economic performance throughout the building’s life cycle. Not only are customers looking for value, but they are also looking for short turn around times (within reason). A huge motive for the City of Greenville choosing to build with metal was a faster erection schedule than conventional building materials. Both features of a custom metal building system boded well for the City whose project ultimately came in under budget and finished ahead of schedule.

Multi-Purposeful

Efficiency is important to every company. Bringing together different factions of the business to all be centrally located and housed under one roof was an important ask of the City of Greenville. Ultimately, the end project just did this. The campus contains four buildings for fleet services, operations and administration, a fuel island and truck wash. All of these integral parts of the business now have a home from which to conduct business efficiently.

For more information about Ceco’s City of Greenville project, visit our case study page.