Curveline Case Studies

ROOFS

Curveline can curve a wide range of exposed fastener and concealed fastener roof panels, including 3” standing seam profiles. Benefits include outstanding aesthetics, attractive shadow lines and leak-proof performance. Curveline’s proprietary crimp-curving process also enhances the strength and rigidity of panels, increasing their spanning capabilities and minimizing structural support requirements.

PREFABRICATED CAR WASH

Developed by Illuminated Designs, Inc. this project is an example of the Metrocurve model of the MODERNWASH car wash. It was created to be an innovative, complementary system of structures that are extremely adaptable and flexible in order to meet the specific needs of the modern carwash industry.

The Metrocurve model as shown is a bright, open building design that alleviates safety concerns with a glass sidewall system framed in anodized aluminum, allowing for an unobstructed view.

The structure incorporates a prefabricated exposed structural frame supplied by Classic Recreation Systems in a choice of standard or custom colors. The building features a distinctive design element in the form of a curved HR-36 profile metal roof supplied by AEP Span and curved to specifications by Curveline, Inc.

According to designer Timothy Hogue, “The building system is extensive and adaptive to comply with several custom configurations. The unique contemporary structural framework combines with high-tech plastics, glass and aluminum, to create the future in carwash design.”


CHINO AIRPORT HANGER FACILITY

When the building team set out to plan the 47,000 sq ft Chino Airport Hangar Facility (Chino, Calif.), the developer wanted something more aesthetic than a standard plain-box hangar. The solution: “Instead of placing office space within the hangars, as is the custom, we used office bungalows with curved design elements on the outside of the structure as an architectural enhancement,” says William Handley, P.E., owner of Handley Engineering (Tustin, Calif.), engineer of record for the project who provided the architectural plans. “The curved metal panels provided a nice, clean look and were surprisingly cost-effective.”

“We had seen curved metal panels on other projects and felt that a design incorporating curves would reflect the shape of an airplane and blend nicely with the aviation setting,” adds Bryan Clendenen, head of project management for Aviation Development Corporation (Corona, Calif.), the developer and general contractor.

Approximately 10,300 sq ft of 24-gauge Klip Rib® concealed fastener roofing panels from AEP Span were curved to required specifications at the Curveline service center.

Curveline’s proprietary crimp-curving process increases the strength and rigidity of panels, allowing curved roofs to be erected with minimal framing. For the hangar project, panels were applied directly over Z-purlins. The design required panels in five different lengths, curved into varying outside radii and angles. “Despite the complex curving requirements, every panel proved to be a perfect fit,” Clendenen comments.

The systems building erector was American Buildings Company, Bellaire, Tex. Curved panel installer was Steelwood Erectors, Riverside, Calif.


CARTER HIGH SCHOOL

Flexibility was a priority in the design and construction of Carter High School. One of the buildings in California’s Rialto Unified School District, the school was planned with evolving needs in mind.

Designed by Ruhnau Ruhnau Clarke of Riverside, CA, the school consists of a series of two-story buildings situated around a terraced courtyard and circular pedestrian street. The intent of the arrangement was to create an efficient campus footprint that could be easily supervised while minimizing the distance students needed to travel to get from building to building. It also provides a measure of relief from seasonal weather extremes, whether in the form of wind or sun.

To evoke a traditional civic building image, the school’s exterior walls are covered with plaster. To provide a contemporary flair, the architect added curved metal roofing and modernist details. In combination, the materials used on the project meet the school district’s requirements for durability, ease of maintenance and a long service life.

The curved metal roof assembly included curved metal decking, with both the panels and decking curved to specification by Curveline. It’s crimp-curving process can be used with hundreds of profiles of metal roof, deck and wall panels.

For the roofing, the architect specified 24-gauge Klip Rib, a concealed-fastener roof panel produced by the Fontana, CA, plant of AEP-Span. The panels were provided with a factory-applied Rawhide PVDF paint finish. The installation of the roofing was completed in phases with Crowner Sheet Metal of Baldwin Park, CA, and Action Sheet Metal of Los Angeles, CA, both involved.

The metal roof deck was 18-gauge B-36 decking by ASC Steel Deck of West Sacramento, CA. The G-60 coated steel panels have a bare finish. Sharing the installation duties were The McIntyre Company of Pomona, CA, and Columbia Steel of Rialto, CA.

The construction manager was Ledesma & Meyer Construction Co., Rancho Cucamonga, CA. McManhon Steel of San Diego was the general contractor for a portion of the project designated Phase 3.


WALLS

Curved wall panels make it possible to think “outside the box”, adding visual appeal to all types of new or renovated buildings. Applications include curved exterior walls, fascias and mansards, mitered corners, and interior acoustical wall treatments. The Curveline service center approach allows you to source panels from the manufacturer of choice in a wide range of profiles, substrates and finishes.

LANDERBROOK PLACE OFFICE BUILDING

From the day they started planning the Landerbrook Place office building, the owners and designers wanted to create something different from the conventional granite-and-glass, brick and stone buildings that dominate the area. The resulting design weds unconventional materials with equally unconventional contours and curves. The three-story building’s exterior is a dynamic combination of horizontal stainless steel panels, aluminum sidewall, and wraparound reflective glass.

Payto Architects (Cleveland) chose stainless steel as the dominant material because of its progressive, high-tech look. To “soften” the steel with sweeping, smoothly curved lines, they relied on Curveline crimp-curving technology.

The building uses a vocabulary of curving walls and rounded corners, column covers, flashings and trim – all horizontally applied and dramatically punctuated at intervals with contrasting dark reflective curtainwall. According to the architect, the softly curved lines “provide a playground for the sun and light to dance on the glass and stainless steel surfaces. The overall effect is a constantly changing kaleidoscope of color, light and shadows.”

The exterior uses nearly 26,000 sq. ft. of stainless steel, including 7,200 sq. ft. of curved panels. The profile is a 22-GA 1-1/2” deep siding panel. Curveline shaped panels into a variety of radii – from an approximate one-foot radius for the column covers to a 14-ft, 7” radius for the curved walls. Flashings, copings and feature bands designed for horizontal installation between panels also received radius treatment.  H.S. Westover, Inc. (Brunswick, OH) installed the panels.


SPACE HABITAT

Designed by The Design Compendium of Oklahoma City, OK, and constructed in the late 1980s, the Space Habitat at the Space & Rocket Center in Huntsville, AL, was one of the first major projects in the U.S. to use Curveline Inc.’s “crimp-curving” technology. And today, after all these years, it remains one of the most noteworthy curved panel projects ever constructed.

Metal building panels, innovatively curved to mimic the Space Station Freedom, enabled the project’s designers to create this space station on Earth to accommodate campers and counselors at the U.S. Space Camp.

Longer than a football field, the Space Habitat uses about 42,000 sq. ft. of 24-gauge curved panels and another 28,000 sq. ft. of 24-gauge flat panels. To achieve the desired space station look, the panels were curved into “S” shapes using the Curveline process and were finished with a silver paint system with a peel coat for extra protection.

According to the architect, Curveline’s ability to do multiple-radius curves enhanced the design. Instead of creating a system of separate tubes, which would have been required with other curving technologies, they were able to design curves that flowed into one another for a cleaner look.

Also, there were only two horizontal joints or seam-lines along the entire four-story structure, minimizing potential leakage problems – so the advantages were practical as well as aesthetic.

Canam Construction Co., Edmond, OK, was the project’s general contractor. Curveline Inc. is located in Ontario, CA.


WEST POINT JUNIOR HIGH SCHOOL

The center of the new West Point Junior High School (Salt Lake City) is a large glass box with a curved metal roof. This glass-enclosed space, which is 2-1/2 stories high, is the heart of the school comprised of a dining room and common area surrounded by a library, faculty room, and administration and counseling rooms.

“We needed an acoustical treatment for this central gathering space; and in designing it we wanted to carry over a curved motif used on the exterior wall and roof panels, by incorporating the same type of horizontally curved panel,” states Boyd McAllister, AIA, a partner at VCBO Architecture, Salt Lake City. “To meet functional and aesthetic goals, we selected an M.B.C.I. perforated ‘U’ panel with insulation behind it.

“When we first came up with the design, we weren’t sure how the perforated panels would be curved,” McAllister adds. “The exterior panels had a gentle enough curving radius so that they could be bent into place during installation, but the interior perforated wall panels had a much tighter radius,” he explains.

“It turned out that Curveline’s crimp-curving process was ideally suited to the job. By going with crimp-curving it was possible to curve the panels with the seams running horizontally instead of vertically, for a much nicer look.”

Curveline shaped the perforated wall paneling into two sections. The larger section (which used 1,917 sq. ft. of curved panels) was convex in curvature, and the smaller section (which used 915 sq. ft.) was concave.


CANOPIES & WALKWAYS

From functional to fanciful, curved canopies and covers come in all sizes, shapes and colors. These open-style roofs may be used to cover pedestrian walkways, gasoline station service islands, transit shelters and many other applications. Curveline’s crimp-curving process increases the strength and rigidity of the panels, achieving wide spans with minimal framing and substructure support.

HARLOW GARDENS

When Harlow Gardens nursery owner Bill Harlow set out to create an outdoor sales area that would be protected against the hot Arizona sun, he wanted a covering that would be functional and blend in aesthetically with the existing property. Designer Peter Wrona states: “Efficiency, strength and beauty were the three features we were seeking. We wanted a covering that would be economical and span the required area without having to use trusses and various substructures that would clutter up the space. By using metal panels in a vaulted configuration, we could create a self-supporting structure that made sparse but effective use of materials.”

The project is located in Tucson, AZ, and Wrona is from Rimrock, AZ. The panel he selected to accomplish his objectives was a 4”-deep profile from Metal Sales Manufacturing Co. They were curved to specification by Curveline Inc. of Ontario, CA, using a proprietary crimp-curving process.

The panels were installed by Bovell Builders, Tempe, AZ, over a system of square tube posts and rafters, with a flat-bottom V channel into which the panels are fastened. The resulting structure is very strong, but has the light, open-air feeling the owner wanted.


IOWA RIVER GAZEBO

The Iowa River Gazebo in Coralville, IA, is a trail rest stop that overlooks the river and features free-standing exhibits and historical displays that explain Coralville’s history and founding.

According to Jesse W. Lewis, ASLA, a partner at RDG Planning & Design: “The gazebo’s arched metal roofs link the structure to the arches of the new pedestrian bridge that crosses the Iowa River and connects the Iowa City peninsula to the Coralville riverfront. The brick and stone gazebo materials pay homage to the architectural materials of the adjacent 1900’s vintage Iowa River Power Restaurant (an adaptive re-use of the Iowa River Power Company). The appearance and form of the gazebo established the design benchmark and building materials vocabulary for future development along the Iowa River in Coralville.”

The gazebo’s roof panels are HR-36 24-GA exposed fastener panels, manufactured by AEP Span at its Fontana, CA, plant. The panels were curved using Curveline’s patented “crimp-curving” method, which creates a dimpled effect that catches sunlight and adds visual interest to the arched roofs.

The crimp-curving process used by Ontario, CA-based Curveline increases the load factor of the panels so that they are virtually self-supporting. Classic Recreation Systems of Dewey, AZ, prefabricated the gazebo framing and roofing for fast and easy final assembly at the project site using hidden bolt connections. The installer fastening roof panels were attached to the tube steel framing without decking.

RDG Planning & Design, located in Des Moines, IA, collaborated on the gazebo’s design with NNW Inc. of Iowa City, though RDG maintained responsibility for the final planning and design. The adjacent bridge was designed by NNW Inc. and Neumann Monson Architects, also of Iowa City.

All American Concrete Inc., West Liberty, IA, was the project’s general contractor and gazebo erector.
Curveline is headquartered in Ontario, CA. In addition to profiles offered by AEP Span, the company is able to curve products offered by other leading metal roofing manufacturers as well.


SCHOEFIELD BARRACKS SHOPPING CENTER

The buildings at Schofield Barracks in Oahu, HI date back to World War II and have a strong historical context. Steve Hindley, president and partner-in-charge for ALSC Architects of Spokane, WA said the character of those buildings was top of mind as his firm developed the design of a new base PX/shopping center.

“The older buildings use graceful arched forms in windows and entrances, and it was important that we capture this historical quality and regional character. The curve was a tool we used to accomplish that goal and was incorporated in the window openings, in major portals for entry, and in the curved roof form for the canopy.”

The curved canopied walkway structure connects remote parking areas to three main entries. “We considered a translucent canopy but abandoned the idea because of concerns about durability and cost,” says Hindley. “We quickly realized we wanted a roof form that would offer a finished surface from below and structural span capabilities to reduce secondary framing.

“Crimp-curved metal B-deck was durable, economical, and gave us the look we wanted,” he notes. “Also, the structural characteristics of the panels gave us a clean and simple design: A single span of curved panels could be attached directly to primary framing with no need for a substrate. Standing seam panels were applied over the curved deck to provide a color accent to the project.”

The decking chosen for the project was manufactured by ASC Steel Deck of Sacramento, CA, and then crimp-curved to specification by Curveline Inc. Crimp-curving is a process that adds strength and rigidity to the panels while creating the desired radii. Once the panels were curved as required they were installed by Sure Steel Inc. of Sandy, UT. The structure was completed with the addition of the roll-curved standing seam roof panels over the top. Handling that aspect of the project was Standard Sheetmetal, Honolulu, HI.

Coffman Engineers of Spokane, WA, was the project’s structural engineer while Bodell Construction of Salt Lake City, UT, served as the general contractor.
The shopping center was developed by the Army & Air Force Exchange Service (AAFES), Dallas, TX, but is the property of Schoefield Barracks. The arrangement is not unique. AAFES facilities are present on virtually every Army and Air Force base in the world and in every case are the sole property of the host base.


STRUCTURAL DECKING

Where domed roofs and other vaulted designs are planned, decking panels curved by Curveline and installed “against the grain” save time and money vs. straight panels applied “with the grain”. Crimp-curving increases panel strength to allow use of lighter-gauge material, and achieves 15-20% longer spans for reduced framing and substructure costs. Capabilities include B or N deck in 22-18 GA.

LA DEPARTMENT OF PUBLIC WORKS

This facility, owned and operated by the Los Angeles Department of Public Works Bureau of Sanitation, is used for maintenance and parking of trash collection trucks. According to project architect Hoi Luc, “This facility is located on a new, expanded site. Our objective was to build a facility to the latest standards of the Bureau of Sanitation, while also coming up with a design that would be compatible with the surrounding neighborhood.”

He explains: “Most of the buildings in the area use curved roof forms with wooden trusses. We decided to mimic the same roof form using steel instead of wood, for non-combustible construction.”

Three of the seven buildings on the site are open-type structures that utilize wide-span beams and curved metal roof decks formed using Curveline, Inc.’s proprietary crimp-curving process. The galvanized decking is left exposed and unpainted for aesthetic, cost and maintenance reasons.

A very interesting feature of these three buildings is a built-in clearstory that works with the curvature of the decks to create a natural venturi effect, constantly circulating the air to remove odors from the trash containers.  “This design takes advantage of the windy local conditions, providing a natural ventilating system that eliminates the cost of mechanical ventilation,” says Luc.

Luc also comments: “We were initially concerned about the deck being curved in another location instead of onsite, but it fit like a glove. In fact, the use of metal building materials helped to speed up construction.”


PA TURNPIKE MAINTENANCE FACILITY

When JSA Architecture Planning Engineering Interior Design (Pittsburgh) set out to design a maintenance facility for the Pennsylvania Turnpike Commission (Harrisburg, Pa.), they wanted a modern design that would convey the idea of motion and transportation. They settled on ample use of curved design elements to create a feeling of movement.

The design team wanted to bring the curved metal motif into the interior of the building for aesthetic and functional purposes. To accomplish this, they used nearly 30,000 sq. ft. of 20 GA steel “N” deck panels custom-curved by Curveline, Inc.

“By using a curved metal deck and leaving the underside exposed, we were able to express the true structure of the building without covering anything up. The crimp-curved deck and supporting bow-string trusses create a language of architecture on the interior that is both beautiful and honest. If we had used a more conventional dropped ceiling, we would have lost that impact,” the architect reports.

Curveline’s proprietary crimp-curving process adds rigidity to metal decking panels, creating a virtually self-supporting deck that is extremely strong and economical. The Curveline process can achieve 15-20 percentlonger spans, for reduced framing costs.

The 17,876 sq. ft. maintenance building features an 82-ft. clear span bow-string truss that rises to 34-ft. 4-1/2” and has a clearance height of 18-ft. The 11,264 sq. ft. vehicle storage building has the same clear span and clearance height, with the truss rising to 28-ft. 11-1/2”.

The ability to achieve such large spans has enabled the Pennsylvania Turnpike Commission to facilitate the movement of trucks and provide efficient flow-through to areas such as the truck wash bay in the rear of the maintenance building.


VANCOUVER CLINIC

The Neenan Company of Fort Collins, CO, utilized curved metal decking as an aesthetic element in its design of the Vancouver Clinic in Vancouver, WA. The project incorporates approximately 10,000 sq. ft. of the curved deck panels to support a barrel vault roof that accents the distinctive main entrance and then extends back 260’ over the second floor. Curved decking also shelters an attached carport.

The deck product chosen for the application was 20-gauge B deck panels from ASC Steel Deck of West Sacramento, CA.

These panels were then curved to specification by Curveline Inc. of Ontario, CA, using its proprietary crimp-curving process. The 18’-3”-long panels were curved to an outside radius of 37’-6” and a 28-degree angle. The crimp-curving process increases the strength and rigidity of the panels, allowing the deck to be installed with minimal framing.

According to the architect, “The Vancouver Clinic employs buildings as vehicles for change; enabling the deployment of recruiting, staffing and new operational processes in order to improve utilization and throughput.

The new Salmon Creek facility embodies the spirit of the clinic and creates image, familiarity and adaptability for the rapidly changing world of a ‘super clinic.’ With deliberate design and planning, the Salmon Creek facility transformed a clinical environment into a wellness environment with an unmatched environment for outpatient care.”

R.F. Stearns Inc. of West Linn, OR, installed the steel decking and erected the necessary support framing.


ACOUSTICAL DECKING

Curveline can produce custom-curved acoustical panels that provide economical “two-in-one” performance, functioning simultaneously as a roof deck and an acoustical ceiling. Use of the Curveline process can eliminate the need to use a separate roof deck and paneled acoustical ceiling, bringing significant construction economies. In addition, project designers may now use domes and arches where flat ceilings were previously required and still achieve the desired acoustical characteristics.

MEMORIAL UNIVERSITY OF NEWFOUNDLAND

When Memorial University of Newfoundland (MUN), St. John’s, Newfoundland, Canada, set out to convert a 4,000 sq. ft. unused space into a student gathering center, the design challenges were numerous. The university wanted a space that would be suited to multiple purposes ranging from seminary, classroom and study use to performances and social events. It also needed to be exciting – a space that would capture the imagination of the students who used it.

The solution from Sheppard Case Architects, Inc. of St. John’s was a flexible design using high-end materials and aesthetics. “We believe that if you build quality into a school or any other public space, the occupants will respect it and use it more effectively,” comments partner Jim Case.

The gathering center was to be located at the southwest corner of the building, adjacent to a busy food court. Case observed that the students enjoyed sitting at the existing window bays in the area. “We created two rows of benches along the windows, where students could sit with their laptops or books and enjoy the natural daylighting,” he explains

“The bench risers extend almost to the level of the windowsills, posing a challenge for head space. So we began to look at different ways to create a raised ceiling above the window area,” he continues. The design team agreed on an S-curved motif to echo the curvilinear form of the window benches. They considered gypsum board and floating panels in various materials, but the cost would have been over $20,000 – more than twice the allotted budget.

After further research, Case discovered that corrugated metal building panels – perforated and lined with acoustical batt insulation – offered an economical solution. “I wasn’t sure if such panels could be S-curved. But after reviewing the project requirements with Curveline, we learned that their crimp-curving process could produce the results we were seeking,” he says. The cost – even with transcontinental shipping – was also comfortably below the $10,000 budget.

The project uses about 570 sq. ft. of 24 GA, 7/8” corrugated, perforated panels manufactured by VICWEST. Curveline shaped the 9-ft 6” long panels into S-curves using 68 and 84.4 degree angles and outside radii of 26-1/2” and 52”.

The Curveline service center is located in Ontario, California – “about as far as you can get from Newfoundland in North America”, notes Case. Distance was a concern, especially when a shipping problem prior to the curving process resulted in delays. “We worked closely with Curveline and they pulled all the stops out to fast-track the project and ship the panels directly to the site. They arrived just before the grand opening in September 2007 – on time and on budget,” he concludes.

The installation process was simple: The acoustical lining was taped to the curved panels, which were then secured to support framing. The panels were pre-painted a simple white, and were mounted to appear free-floating in the space with four inches of free space on all sides. Dimmable pinhole down-light fixtures were suspended in the void just above the panels to create a concealed light feature, similar to a theatre setting.

For maximum flexibility, Sheppard Case also incorporated a Skyfold acoustic partition so the area can be divided or used as a whole. Unlike most partitions, the wall does not stack but folds completely up into the ceiling.

General contractor for the project was Diversified Construction Limited of Conception Bay South, who installed the panels using their own crews. MUN manager for the project was Judy Power of the Department of Facilities Management. According to Jim Case, “Vision for the project was amply supplied by an enthusiastic Dr. Lilly Walker, Dean of Student Affairs and Services.”


SWEETWATER UNION HIGH SCHOOL DISTRICT

When the San Diego-based architectural firm of Martinez & Cutri Corp. set out to plan a series of athletic facilities for the Sweetwater Unified High School District, they needed to combine aesthetics with function, budget constraints and fast-track construction. To meet these criteria, they specified curved acoustical decking panels that provide economical “two-in-one” performance, functioning both as a roof deck and an acoustical ceiling.

“Our original design called for the use of acoustical wall and ceiling panels, but that approach would have added significant cost since it would have required an additional metal deck,” commented Lisa Castagnola, architect at Martinez & Cutri who designed the gyms.

The curved acoustical decking panels were installed to span from beam to beam and were topped with rigid insulation and standing seam metal roofing. The decks were left exposed on the underside and then post-painted, along with beams and overhead ductwork, into “school colors” appropriate to each location.

The decking is Verco acoustical “B” deck from Verco Manufacturing. The 1-1/2” deep, 20-gauge galvanized panels have perforations for sound control. 20,600 sq. ft. of decking was used per facility, with a four-building total of 82,400 sq. ft. Panels were supplied in varying lengths up to 24-ft. 9” and were crimp-curved into a 164-ft. 6” radius at the Curveline Inc. service center.

The school gymnasiums are in four locations: San Ysidro, CA; National City, CA; Imperial Beach, CA; and Chula Vista, CA. The general contractor was Rudolph & Sletten, San Diego, CA, and the metal decking installer was McIntyre Company, Pomona, CA.


PERFORATED PANEL

Curveline has the capability to curve a wide selection of perforated roofing, wall and decking profiles. The curved perforated panels may be used aesthetically and/or functionally in exterior and interior applications to perform natural ventilation, light diffusion, sound control and other functions.

Panels suitable for perforating and curving include 20 to 24 GA exposed fastener profiles in depths of 7/8” to 1-1/2” and in a variety of configurations, including standard 7/8” corrugated. Panels are available in painted or unpainted galvanized or Galvalume steel, stainless steel, aluminum, copper, and other specialty metals. Spacing and dimensions of the perforated holes may vary, with up to a 40% open area.

MEMORIAL UNIVERSITY OF NEWFOUNDLAND

When Memorial University of Newfoundland (MUN), St. John’s, Newfoundland, Canada, set out to convert a 4,000 sq. ft. unused space into a student gathering center, the design challenges were numerous. The university wanted a space that would be suited to multiple purposes ranging from seminary, classroom and study use to performances and social events. It also needed to be exciting – a space that would capture the imagination of the students who used it.

The solution from Sheppard Case Architects, Inc. of St. John’s was a flexible design using high-end materials and aesthetics. “We believe that if you build quality into a school or any other public space, the occupants will respect it and use it more effectively,” comments partner Jim Case.

The gathering center was to be located at the southwest corner of the building, adjacent to a busy food court. Case observed that the students enjoyed sitting at the existing window bays in the area. “We created two rows of benches along the windows, where students could sit with their laptops or books and enjoy the natural daylighting,” he explains

“The bench risers extend almost to the level of the windowsills, posing a challenge for head space. So we began to look at different ways to create a raised ceiling above the window area,” he continues. The design team agreed on an S-curved motif to echo the curvilinear form of the window benches. They considered gypsum board and floating panels in various materials, but the cost would have been over $20,000 – more than twice the allotted budget.

After further research, Case discovered that corrugated metal building panels – perforated and lined with acoustical batt insulation – offered an economical solution. “I wasn’t sure if such panels could be S-curved. But after reviewing the project requirements with Curveline, we learned that their crimp-curving process could produce the results we were seeking,” he says. The cost – even with transcontinental shipping – was also comfortably below the $10,000 budget.

The project uses about 570 sq. ft. of 24 GA, 7/8” corrugated, perforated panels manufactured by VICWEST. Curveline shaped the 9-ft 6” long panels into S-curves using 68 and 84.4 degree angles and outside radii of 26-1/2” and 52”.

The Curveline service center is located in Ontario, California – “about as far as you can get from Newfoundland in North America”, notes Case. Distance was a concern, especially when a shipping problem prior to the curving process resulted in delays. “We worked closely with Curveline and they pulled all the stops out to fast-track the project and ship the panels directly to the site. They arrived just before the grand opening in September 2007 – on time and on budget,” he concludes.

The installation process was simple: The acoustical lining was taped to the curved panels, which were then secured to support framing. The panels were pre-painted a simple white, and were mounted to appear free-floating in the space with four inches of free space on all sides. Dimmable pinhole down-light fixtures were suspended in the void just above the panels to create a concealed light feature, similar to a theatre setting.

For maximum flexibility, Sheppard Case also incorporated a Skyfold acoustic partition so the area can be divided or used as a whole. Unlike most partitions, the wall does not stack but folds completely up into the ceiling.

General contractor for the project was Diversified Construction Limited of Conception Bay South, who installed the panels using their own crews. MUN manager for the project was Judy Power of the Department of Facilities Management. According to Jim Case, “Vision for the project was amply supplied by an enthusiastic Dr. Lilly Walker, Dean of Student Affairs and Services.”


WEST POINT JUNIOR HIGH SCHOOL

The center of the new West Point Junior High School (Salt Lake City) is a large glass box with a curved metal roof. This glass-enclosed space, which is 2-1/2 stories high, is the heart of the school comprised of a dining room and common area surrounded by a library, faculty room, and administration and counseling rooms.

“We needed an acoustical treatment for this central gathering space; and in designing it we wanted to carry over a curved motif used on the exterior wall and roof panels, by incorporating the same type of horizontally curved panel,” states Boyd McAllister, AIA, a partner at VCBO Architecture, Salt Lake City. “To meet functional and aesthetic goals, we selected an M.B.C.I. perforated ‘U’ panel with insulation behind it.

“When we first came up with the design, we weren’t sure how the perforated panels would be curved,” McAllister adds. “The exterior panels had a gentle enough curving radius so that they could be bent into place during installation, but the interior perforated wall panels had a much tighter radius,” he explains.

“It turned out that Curveline’s crimp-curving process was ideally suited to the job. By going with crimp-curving it was possible to curve the panels with the seams running horizontally instead of vertically, for a much nicer look.”

Curveline shaped the perforated wall paneling into two sections. The larger section (which used 1,917 sq. ft. of curved panels) was convex in curvature, and the smaller section (which used 915 sq. ft.) was concave.


FLASHING & TRIMS

In addition to radiused panels of all types, Curveline can provide crimp-curved mitered corners and either smooth or crimp-curved flashings and trim to complement your project. When used to form standard or customized trim, ridge caps, corners and other components, Curveline’s proprietary process is more economical than stretch-forming and other conventional fabrication methods. Segmented curved flashings can be of any size and can improve the appearance and water-tightness of a crimp-curved, roll-formed or curved membrane roof.

NAFE KATTER THEATER

Crimp-curved metal roofing panels are used to form the soffit and canopy system that links the new Nafe Katter Theatre and two adjoining buildings on the University of Connecticut campus in Storrs, CT. The curved panel soffit system forms a transition from the top of the masonry wall to the built-up roof. The soffit also ties into open curved canopy sections that complete this visual link.

Joseph E. Leone, University architect, designed the soffit and canopy system. The panels he specified to turn his vision into reality were exposed-fastening T-7 panels from Metal Sales Manufacturing Corp. of Sellersburg, IN. They were produced from mill-finish aluminum at the company’s Fontana, CA, plant.

The panels were then curved for the project by Curveline Inc. of Ontario, CA. The T-7 profile is one of more than 100 Curveline is able to bend to specification using its crimp-curving process.

In addition to the curved panels, Curveline fabricated inside and outside miters to create smoothly flowing junctions wherever the installation of the panels required a directional change. In addition to providing an interesting look, the crimp-curving process creates panels that are structurally stronger than their original, which reduces the requirements for support framing.

The metal panels were installed by V.C. Roofing of West Hartford, CT. Allphase Construction of Stafford Springs, CT, was the project’s general contractor.


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