~ 4th Qtr Project Profile ~ Camden Potomac Yard Condos, Arlington, VA

Conveniently located in Arlington, Virginia, Camden Potomac Yard is the newest luxury apartment community within minutes of DC's best hot spots. Resort-style luxury amenities, on par with the finest high-rise condominiums and modern apartment homes, each equipped with stylish features and conveniences. Featuring private patios and balconies with a roof top pool and sundeck with expansive city views. Travel via the Metro to shopping at the Pentagon City Mall and Crystal City and also have easy access to the Potomac River Park and the Regan National Airport.

We at Kingbird have been manufacturing custom aluminum balcony railing since 1977. We offer a wide variety of standard designs to choose from however our speciality is our one of a kind custom designs. Many of our unique designs include multi horizontals, radius horizontals and verticals, motifs, rings, spears, wire mesh, glass, stainless steel cable, canvas, etc. The possibilities are endless. Each design is engineered to meet all building codes and standards.

Camden Potomac Yard Condos is another great project with Donohoe Construction that features over 3,000 feet of various designs of aluminum railings to include a balcony screen divider.


The first design is 1,975 feet of single line railing secured with Hard-Rok anchoring cement into preformed block outs within a cement wall cap atop block. An aluminum escutcheon plate accompanies each post inserted into wall cap to ensure a nice clean look. This type installation involves tedious measurements with practically no tolerance.



Second is 1,256 feet of five horizontal line balcony railing which features several radius balconies. It is essential that all radius horizontals are perfectly aligned in order to produce this beautiful architectural look. This railing was installed with foot plates using stainless steel concrete wedge anchors for superior stability.

Next is two line horizontal railing for two pool areas. The West side involved plate mount installation and the East side is side-plate mounted. The roof pool railing is a six horizontal railing system which is side-plate mounted.


For the fitness center we designed a 24" high railing with five horizontals. It was core drilled utilizing hard rock grout in to precast. Escutcheon plates were also installed to complete the look.



Lastly, but certainly not the least, a 12' high architectural balcony screen divider.



All railings have a baked on powder coat finish with a custom color of Pewter.



All work was performed by an in-house team of professional manufacturers and installers.

Project of the Month, June 2010 ~ One Park Crest, McClean VA

Park Crest is a new luxury residential development in Tyson's Corner Virginia that will eventually include seven new buildings. The first building is called One Park Crest and consists of 335 condominiums in a 19-story high-rise. Park Crest is the latest addition to the list of TOD (transit oriented development) built in anticipation of what is known as the Dulles Line or the Silver Line railway. The site sits on 13-acres of land right in the popular Tyson's Corner in Washington DC's metropolitan area. The Tyson's area is a popular urban setting that includes the "world famous" Tyson's Corner. The site is close to two proposed metro stations -- Tyson's Central 123 and Tyson's Central 7. The Park Crest features rooftop pools and sun terraces, gracefully landscaped to create a luxury urban environment. The new community is pedestrian focused with a sweeping central park as the focal point of Park Crest that creates a cool, green, outdoor mall. The building was design by WDG Architecture includes floor-to-ceiling glass along with aluminum, brick, and concrete accents. Kingbird Industries is proud to have been the provider of the pair of magnificent aluminum architectural pergolas located in this central green-space, as well as (3) pool-side pergolas and (5) balcony pergolas, as well as several hundred feet of aluminum balcony railing and aluminum balcony privacy screens.

At Kingbird Industries, we fabricate refined garden structures, pergolas, and trellis work from extruded aluminum to create bold and time-honored architectural statements. The pergola, whose design dates back to ancient Egypt, Greece, and Rome, is an overhead structure used to make the outdoors more inviting, to extend livable space, to create a shady retreat, and serve as a major landscaping element. Pergolas can extend from a building to an open garden feature such as a terrace or pool, or may be entirely free-standing structures providing shelter and shade to a length of walkway. Transforming the green-space at One Park Crest included the unique challenge of implementing the pair of arch-designed aluminum pergolas over the proposed park. The resulting aluminum structures are spectacular beyond words and designed to last decades. At Kingbird Industries, we welcome the opportunity to create one-of-a-kind designs that make a difference.

The pair of large arched pergolas were each slightly different, with one main impressive 48-foot long structure with an arched trellised canopy and two sweeping side canopies, the other a smaller arched trellis – both mounted on 8ft high brick columns. The large entry pergola was constructed from (8) 4" x 8" x 23 ft. beams fashioned with angles at both ends with (4) 4” x 15” x 16ft. horizontal spans notched into place to create the frame. Then (4) 20’ sections with a 13 ft. radius spanned the side sections with (29) 13 ft. ribs between the radiused or arched sections. Each segment: the arch, and the two side canopies, measures 16 feet in length, creating a majestic walk-through canopy measuring 48 feet wide. The smaller arched pergola is 16ft x 20 ft. also mounted to 8ft high brick columns, but without the side canopies. The impressive One Park Crest 15ft high arched pergolas, like all Kingbird Industries aluminum projects, were built with all welded construction. We provided a baked on powder coat finish in a standard color with bracketed installation.


The (5) balcony pergolas were each constructed to be 37 feet long and 11 feet high, and with specially positioned support posts determined by the center line between windows secured with chemical anchors. At the pool, (3) 22ft long pergolas were installed to provide filtered shade yet let light and breeze through. All were crafted using Kingbird’s all-welded construction and powder coat finish.

The One Park Crest project also included over 6000 linear feet of 3-line aluminum balcony rail, of which over 1000 lf was radius railing. Varying heights of aluminum 3-line pool railing from 22” – 85” were installed. 800 lf of 2-line aluminum balcony railing was installed as well as courtyard railing, ramp railing and grip rail. All were finished with 3-coat Kynar for superior resistance to the elements. A large percentage of the railing was being mounted in a precast wall cap. In order to provide mounting hardware that was both secure and attractive, kept the aluminum rails out of the way during the wall procedures, and prevented the need to drill into the precast concrete, Kingbird installed over (600) 4" x 4" steel buckets that our aluminum railing was then mounted to with 1/2" 5" chemical anchors creating a seamless attachment method.

As the finishing touch for the One Park Crest project, Kingbird Industries built 340 balcony privacy screens, with plate aluminum panel construction, a radius top, and 3-coat Kynar finish.

Kingbird Industries worked through Donohoe Construction Company (www.donohoeconstruction.com) on this fine project that demonstrates the quality and versatility in design, manufacture, and installation that we bring to all our aluminum projects. Kingbird Industries has created many such custom-designed pergolas and trellises to add architectural grandeur to the surroundings, complete with engineering seals to guarantee our workmanship over the long haul. The unique requirements involved with transforming the One Park Crest with its many design elements is the type of project Kingbird Industries excels at and is best known for. Custom designs are our hallmark!

To implement a one-of-a-kind aluminum accent to your next construction project – whether it be a new construct or a renovation – pergola, trellis, louver, sunshade, grille, or railing - contact Kingbird’s sales and engineering team at 800.882.7092 to review your plans and specifications.

Deflections and Safety for Balcony Railings

Balcony railings that do not meet code requirements or have excessive deflection present a danger to the public and result in a multitude of insurance and construction-related claims. There are common areas of railing design that are code or serviceability deficient.

The International Building Code does not prescribe allowable or tolerable rail deflections. The code has no deflection limits for handrails and guards. Good design practice would limit how much a handrail or guard could be pushed outward or downward. Regardless of IBC specifics, it remains a very important aspect in the construction and design of railings, and thus must be considered.

When a railing has a significant amount of deflection such that it causes a person to feel unsafe or gives a sense that the railing is not structurally sound, the railing can be considered improperly constructed or designed. Although the railing can adequately withstand the designed structural loads, the significant amount of deflection will exceed an individual’s perception of safety. Also, the repeated deflections will weaken the structural members through fatigue or overstress, creating the potential for failure resulting in injury.

In order to establish the design criteria for rails, the minimum standards of the building code include the design loads for railings. These are addressed in the 2006International Building Code (IBC)ii Section 1607.7 Loads on handrails, guards, grab bars and vehicle barriers. According to Section 1607.7.1 Handrails and guards, “Handrail assemblies and guards shall be designed to resist a load of 50 plf (0.73kN/m) applied in any direction at the top and to transfer this load through the supports to the structure.” The International Residential Code (IRC) for one- and two-family dwellings also indicates that only the single concentrated load as required by Section 1607.7.1.1 shall be applied. According to Section 1607.7.1.1 Concentrated load, “Handrail assemblies and guards shall be able to resist a single concentrated load of 200 pounds (0.89 kN), applied in any direction at any point along the top, and have attachment devices and supporting structure to transfer this loading to appropriate structural elements of the building.” These standards have existed throughout previous versions of the Code and in ASCE 7 Structural requirements for Engineering.

Beyond strength resistance requirements, the 2006 IBC, Section 1604.3 addresses the serviceability requirements of structural members. According to Section 1604.3 Serviceability, “Structural systems and members thereof shall be designed to have adequate stiffness to limit deflections and lateral drift.” According to Section 1604.3.6 Limits, “Deflection of structural members over span, L, shall not exceed that permitted by Table 1604.3.”

Railings are typically exposed to live loads only, such as a person leaning or pushing against the rail. If one turns to serviceability requirements of the codes, the 2006 IBC Table 1604.3 for floors, roofs, and walls applies: floor member deflection is limited to L/360 under live loads; roof members that do not support ceilings are limited to L/180 under live loads; exterior walls and interior partitions with flexible finishes are limited to L/120 when loaded with snow or wind. Another important element is that for cantilevered members, the span (L) shall be taken as twice the length of the cantilever. When standard railings are cantilevered from the surface, twice the length of the cantilever is considered for the drift calculation when utilizing the IBC table. Based on this analysis, the deflection limits could be calculated utilizing h/60, h/90 and h/180 deflection limits, based on the IBC table.

Chapter 35 of the 2006 IBC also adopts the ASCE Standard ASCE/SEI 7-05 Minimum Design Loads for Buildings and Other Structuresiii by reference. Section 4.4 of ASCE/SEI 7-05 has similar load requirements as the IBC including the 200-pound point load, the 50 pound-force per linear foot and the infill load of 50 pounds over a 1-foot square area. According to the ASCE 7-05 Section 1.3.2 Serviceability, “Structural systems, and members thereof, shall be designed to have adequate stiffness to limit deflections, lateral drift, vibration, or any other deformations that adversely affect the intended use and performance of buildings and other structures.”

According to ASCE 7-02 Section C1.3.2 Serviceability, “The fact that serviceability limit states are usually not codified should not diminish their importance. Exceeding a serviceability limit state in a building or other structure usually means that its function is disrupted or impaired because of local minor damage or deterioration or because of occupant discomfort or annoyance.” Therefore, deflections on railings must be considered and the deflection limits must be set based on the amount of allowable deflection developed under lateral loading requirements.

Consider a typical “cantilevered” railing that extends 36 inches beyond the surface. The height of the rail post (h) as defined by IBC Table 1604.3 is two times the height, or 72 inches (L). The following table indicates the design deflection to be used to size the rail for minimizing the deflection:
Another source that aids in the review of standards available for original design/construction is the American Standards and Testing of Materials (ASTM) E 985 the Standard Specification for Permanent Metal Railing Systems and Rails for Buildingsiv. According to section 7.2.2 of the standard, “When the load is applied at the line of vertical support, the horizontal deflection shall not exceed the rail height (h) divided by 12, or h/12, with h being the distance between the surface of the post anchorage and the top of the top rail.” Per section 7.2.3, “When the load is applied at the midspan of the rail, the horizontal deflection shall not exceed the sum of the rail height (h) divided by 24 plus the rail length (l) between the vertical supports divided by 96, or h/24 + l/96.” According to this ASTM standard, a 36-inch-high rail would be allowed to have a maximum deflection of 3 inches, and a 42-inch-high rail would have an allowed deflection of 3.5 inches. These deflections would be perceived by the user to be large when compared with a stiff system.

The International Code Council (ICC) Evaluation Service, Inc. prepared an Acceptance Criteria For Handrails and Guards, published February 2007. Under the heading “Structural Tests,” a concentrated load test includes testing a rail with 500 pounds per foot at the midspan of the top rail and at the top of a single post. When the applied load reaches 200 pounds, the deflection at the point of loading is measured. The ICC document has the same deflection limits stated as the ASTM E 985 standard that relates to metal rails. According to the ICC document, the allowable deflection at the point of loading shall not exceed the following:

a. “The sum of the rail (guard) height, h (in inches/mm), divided by 24 plus the effective rail length, l (in inches/mm), divided by 96 or (h/24 + l/96). Where the effective rail length is the distance between the edges of the posts, the deflection at the midspan of the to rail (guard) is measured relative to the center of the two posts (i.e., it does not include post deflection).

b. “The effective newel post height (vertical support) divided by 12, or (h/12), where the effective newel post (vertical support) height is the distance from the top of the top rail to the first point of fastener connection to the supporting construction.”

The following is a summary of findings in regards to deflection limits (shown in the table as the least stringent (most deflection) to most stringent (least deflection):

Based on a review of the 2006 IBC requirements and the other reviewed documents, railings should be designed for a maximum allowable deflection of L/120 (h/60). That deflection limit is also the largest allowable deflection shown in Table 1604.3 of the code for other components of the building. In fact, the IBC states that all structural members shall not deflect more than the limits specified in the table.

With those minimum standards, the maximum allowable railing deflection is 0.6 inch for a 36 inch railing height and 0.7 inch for a 42 inch railing height. Another aspect of design and construction is the consideration of complete load paths. The railing should be analyzed as part of a true “system” that includes posts and guards such that the total deflection does not exceed those minimums required by code. Providing this level of deflection in the design and construction would meet the intent of the codes for serviceability in addition to providing a comfort level to occupants regarding the structural stability of railings. For critical service facilities, tighter design criteria should be considered.

All Kingbird Industries aluminum railing products are built in accordance with the 2006 IBC codes. We provide stamped engineering drawings with calculations to assure you of the highest possible safety standards. Contact us at 800.882.7092 to talk with our engineers about your next railing project.

Aluminum Paint Finishes ~ AAMA Specifications ~ Care & Warranty

Modern times have seen the rise of aluminum as a prime exterior material, largely due to its rugged durability, design versatility, and aesthetic possibilities. However, for all its bravado and beauty, in order to be both functional and pleasing to the eye, aluminum must be coated with a unique finish that allows the metal to resist chalking, pitting, chipping, or premature aging.

Many advances have been made in recent years to aluminum coating technology. In response, the American Architectural Manufacturers Association (AAMA) has raised the bar for peak performance requirements for the long-term durability of organic coatings for aluminum extrusions. The AAMA has documented a new series of performance standards that places stringent performance requirements fir grades of applied organic coatings. The performance standards prior to this change were basically 'good' (AAMA 603) or 'better' (AAMA 605) where 'better' was the high-performance coating grade.

The new voluntary specification performance requirements are now broken into three categories: AAMA 2603, AAMA 2604, and AAMA 2605.

The new specification standards will allow architects, building owners, engineers, and contractors to better select and specify the most appropriate organic coating performance level as each individual project requires.


The new AAMA specifications for paint finishes

AAMA 2603 is primarily intended for interior coatings of at least 20 microns (0.8 mil) thickness. This specification requires test methods and acceptance criteria for color uniformity, gloss, dry film hardness, adhesion, impact resistance, chemical resistance, corrosion resistance, and weathering. This standard submits that a 1-year outdoor exposure test in a South Florida environment that verifies chalking, crazing (small hair-line cracks in the finish), adhesion loss (peeling), chalking and fading is optional.


AAMA 2604 and 2605 specifications are intended for architectural and commercial-grade applications and require a coating of at least 30 micron (1.2 mil) thickness. Both of these standards require the same test methods and performance criteria that tests color uniformity, gloss, impact and chemical resistance. To differentiate between AAMA 2603, these standards require additional testing for abrasion and chemical resistance, and weathering. Weathering tests look at color and gloss retention, chalk resistance, and erosion resistance in a South Florida environment.


AAMA 2604 sets the standards for finishes that do not utilize chromium pretreatment processes. In some areas, this process is disallowed for environmental reasons due to the heavy metal application.


AAMA 2605 sets the standards for complete coating processes that do use chromium pretreatment and high performance coating formulas. Chromating, or the pretreatment process for the chemical conversion process, has a profound influence on the properties of the coating. The substrate metal is part of the coating reaction, becoming a component of the coating. The chemistry involves reaction between the metal surface and an aqueous solution that contains chromates and activator ions. The activators include fluorides, phosphates, and other compounds.

Chromates for aluminum fall into two categories: chrome-phosphates, primarily those used on architectural aluminum extrusions to provide a paint-bonding coat, and chrome oxides applied to almost every type of aluminum. Baths for applying chrome phosphate consist of chromate ions, phosphates and fluorides. Many finishers apply this type of chromate by spraying it on cleaned aluminum extrusions, but some dip lines are in operation. It is common practice to use a passivating hexavalent chromium rinse as the final step in the treatment. A typical cycle would be:

+ Alkali clean.
+ Rinse
+ Chromium-phosphate.
+ Rinse.
+ Hexavalent chromium rinse (seal).

Paint is customarily applied in-line by electrostatic spray and then baked, producing a finished extrusion ready for assembly. This process produces remarkable adhesion. Corrosion resistance is also excellent if the final seal and paint are properly selected.

Warranties

It is extremely important to note that corrosion resistance tests all include varying conditions of humidity and salt spray exposure. Read finishing warranties carefully. Many state a given warranty coverage, with exceptions for coastal exposure such as the following:

"In order for [...] warranty to be effective in environments with a salt atmosphere or relative to bodies of salt water the following criteria must be adhered to:
(1) Application in proximity to a coastline with surf, the distance from the coast must be at a minimum of 2,800 feet."

"This limited warranty [...]is not valid for failures resulting from [...] damage caused by corrosive or aggressive atmospheres such as those contaminated by chemical fumes or salt spray."

"Subject to the conditions set forth below, [...] warrants its coil coated Kynar 500 material to perform as follows in normal atmospheric conditions (which term excludes corrosive aggressive atmospheres such as those contaminated with chemical fumes or salt spray)..."

Normally a reputable certified coating applicator will want to know the location of the aluminum project and will warrant the finish accordingly.

Kynar® high-performance fluoropolymer resin

In addition to the pretreatment process, KINGBIRD INDUSTRIES recommends finishing aluminum products for coastal environments with a PVDF finish. Polyvinylidene Fluoride, or PVDF is a highly non-reactive and pure thermoplastic fluoropolymer.

PVDF is a specialty plastic material in the fluoropolymer family and is used in applications that require the highest strength, and resistance to solvents or acids. KYNAR® 500 PVDF or HYLAR® 5000 PVDF is used as the principal ingredient of high-end paints for aluminum. These PVDF paints have extremely good gloss and color retention, and they are in use on many prominent buildings around the world.

Noted by architects around the world Kynar 500® PVDF resin-based coatings is precisely the product necessary to provide protection and preservation to aluminum architectural products. No other coating system withstands the rigors of time and nature like those based on Kynar 500® resins. This high-performance fluoropolymer resin, with its extraordinary capability to retain color and gloss, keeps painted metal looking vibrant and appealing.

Kynar 500 resin-based finishes are available worldwide through a strict licensing program. This licensed distribution ensures the quality, consistency and high performance of Kynar 500® resin-based coatings.


Protecting the Finish

Today's high-quality architectural finishes are extremely durable, but even the best finish needs care and protecting, just like your car!

All finished aluminum products, and particularly those located along the coast, require a routine cleaning and maintenance program so that the finish retains its original beauty. When selecting a cleaning solution, use mild soap solutions taht are safe enough for use with your bare hands, or products similar to what you would use to wash your car. Avoid the use of strong acid or alkali cleaners, such as window cleaners, that may damage the finish.

Solvents no stronger than mineral spirits or denatured alcohol may be used to remove grease, sealants, or other materials. Never mix cleaners or cleaners and solvents as the mixture can often cause harmful or extremely dangerous results. Do not use abrasive cleaners or materials such as steel wool or abrasive brushes, which will also harm the finish.

Once heavy soil and grease is removed, the mild soap solution should be applied with a soft cloth, sponge or soft brush. Rinse the surface thoroughly with clean water and dry with a soft cloth.

In coastal areas where the finish is exposed to salt spray or in areas containing heavy industrial pollutants, clean your aluminum architectural feature at a minimum of every 3-month intervals. In other areas, cleaning should be scheduled every 6-months. Note that a routine cleaning and maintenance schedule may be required under the warranty.

KINGBIRD INDUSTRIES provides (3) standard aluminum finishes: anodic (strong but not recommended for close-up viewing - ask us why), powder coating (our most popular finish for standard applications), and KYNAR® 500 PVDF for premium finish durability. At our facility in Salisbury North Carolina, we perform our own powder coating process. For AAMA 2605 and Kynar finishes, we out-source the finishing to a premium licensed finishing company.

KINGBIRD INDUSTRIES offers powder coat standard colors including white, gloss black, gray, dark green, and bronze. Color samples can be sent upon request. Custom colors are available at an additional cost. For restoration projects, we will match any custom color to other colors on your building by collecting a sample and having it custom color-matched at our finishing partner's facilities. Custom color-matching can be quoted on request per your project requirements. Samples are available for any project. Please allow 3-weeks lead time for a Kynar finished sample.

For more information about custom aluminum architectural products, AAMA standards, paint finishes and warranties, contact KINGBIRD INDUSTRIES at 800.882.7092 or email us at sales @schaeferinterstate.com.

Project of the Month, February 2010 ~ Rhythm at Music Row, Nashville TN

Rhythm at Music Row, a posh resort in the heart of Nashville, Tennessee's music district is complete and ready for move-in. Rhythm's fourteen stories of upscale, contemporary Nashville condominiums offer views in every direction of the city's nightlife, shopping, and restaurants.

Music Row is an area just to the southwest of Downtown Nashville that is home to hundreds of businesses related to the music industry. Centered around 16th and 17th Avenues South (called Music Square east and Music Square west), Music Row is widely considered the heart of Nashville's entertainment industry. Numerous record labels, recording studios, music publishers and licensing companies, and video production firms can be found as well as radio station and network offices.

Kingbird Industries LLC of Salisbury NC, contracted by Choate Construction (http://www.choateco.com/), is proud to be the aluminum architectural feature provider for the uniquely designed Rhythm at Music Row project. The most prominent feature of the building design by architects Wakefield Beasley & Associates (http://www.wbassociates.com/) are the (9) bronze-metallic 30-foot tall aluminum serpentine "music" scrolls that adorn the building.

These serpentine scrolls that are the signature feature of the Rhythm at Music Row structure presented some interesting challenges to the Kingbird Industries design, production, and installation teams. At 30-feet in length with a waved design, a special frame was developed to accommodate the scrolls, give them structural strength, and provide mounting capability.

Each of the beautiful (9) serpentine scroll panels included 1-1/2" square x 1/8" aluminum tube horizontal members placed at 4-ft intervals and (2) each vertical 30-ft members shaped to the serpentine curvature. The decorative infill was created using 4' x 30' panels of 1/8" perforated sheet aluminum bent to contour to the vertical members. As will all Kingbird products, the serpentine scrolls are built with all-welded construction for long-term strength and stability. Because the scrolls were so long, each was built in sections that would fit Kingbird's in-house finishing process facility. On-site, each smaller panel was welded to construct the singular 30' scroll. The scrolls were finished with baked-on powder coat in a unique custom dark bronze metallic finish. The scrolls were curled around long tubular aluminum rods for the final touch to this custom project.

An added decorative feature at Rhythm at Music Row are the (9) aluminum 4' x 4' Medallion Grilles inset above each serpentine scroll, finished in the same dark bronze metallic to match the giant architectural scrolls.

The additional aluminum architectural features that Kingbird Industries provided for the Rhythm building are:

• 2178 lf of 2-line balcony railing
• 345 lf of radius balcony railing
• 114 lf of 3-line glass infill railing with 3/8" glass

Kingbird's Value-Added Engineering service recommended changing the original railing-mount plan from core-drilled installation to footplate installation. Kingbird, due to our extensive work with replacing railing for concrete balcony restoration projects, recommends footplate installation with chemical anchors and escutcheon plates to minimize both stress to the concrete and moisture infiltration opportunity that will ultimately damage the structure. The project was able to deduct block-outs, posts, and grout while adding longevity to both the structure and the railings.

Kingbird also provided 6-foot high 2-line fence and double gates at Rhythm's loading docks and (9) 2-line aluminum arched single gates throughout the property. Engineering seals were provided for all Kingbird's aluminum features of this project. Kingbird's team of expert craftsmen installed the aluminum serpentine scrolls, the decorative medallions, and all gates and railing on this 14 story structure in the spring of 2009.

Rhythm at Music Row is an outstanding feature of Nashville's music corridor and a proud entry in Kingbird Industries project portfolio, demonstrating once again that Kingbird goes above and beyond simple railing projects. Our Production Design Specialist, Horacio Romero, says, "If you can dream it, we can make it." The truly unique aluminum serpentine scrolls, testimony to this statement, are spot lit at night to illuminate the quality artisan workmanship that was devoted to this signature project.

For more information on the Rhythm at Music Row building (and to see photos of Kingbird Industries work), check http://www.rhythmnashville.com/. For your unique project, call Kingbird's sales engineers at 800.882.7092.

Project of the Month, January 2010 ~ Wisconsin Place Residential Towers

The very best cities have one - a luxurious corridor of the finest shops and retailers decorating one lucky street. And Wisconsin Place sits comfortably amidst DC's best retail in Chevy Chase, Maryland. Kingbird Industries cannot think of a better way to ring in the new year than to celebrate Wisconsin Place as January 2010's Project of the Month just after Wisconsin Place celebrated its inaugural holiday season!

Located in the DC area, Wisconsin Place (www.wisconsinplace.com) is one of Chevy Chase’s most coveted addresses. This mixed-use complex incorporates an 11-floor office building, residential housing, retail shops, a community center with a multi-purpose gymnasium and meeting center, and two public parks. The office tower features a two-story clerestory lobby, state of the art life safety and building systems, and well-lit and secure underground parking. Ideally situated on Wisconsin Avenue, this stunning new complex of fashionable retail stores, offices and residences is the crown jewel in one of the region’s most affluent and discriminating neighborhoods.

Developed by a partnership of New England Development, Archstone, and Boston Properties, Wisconsin Place just finished a 4-½ year construction program and celebrated its first holiday season this December 2009. The project is comprised of The Shops at Wisconsin Place – 305,000 square feet of retail, 432 unit luxury apartments, a 295,000 rentable square foot office building, a 1765 space underground parking garage, and a 21,000 square foot community center.

Kingbird Industries, with Turner Construction Company, is proud to be the provider of over 5200 linear feet of mesh infill railing for the Wisconsin Place Residential Towers project. Aluminum mesh infill railing manufactured by Kingbird Industries is attractive and unsurpassed in rigidity, quality, and design appeal. The aluminum mesh infill railings are manufactured in Kingbird's plant in Salisbury NC, where we provide mesh infill railing in mesh or woven wire in many decorative architectural styles, such as diamond, square, or rectangular. The mesh is securely welded to a four-sided frame. The infill panels are then welded directly to the railing system for exceptional strength and architectural beauty. Kingbird offers aluminum mesh infill railing with channel frames that hide visible welds for an architecturally sleek and pleasing look. It surpasses the traditional industrial look of flat bar capping that shows the welds on the seams of the panel face.

For the Wisconsin Place Residential Towers, Kingbird provided:
+ 53 linear feet of aluminum 2-line railing, 100’ of which was radiused, with core-drilled installation
+ 5000 linear feet of aluminum 4-line mesh infill railing, plate-mounted to the balcony slabs
+ 70 linear feet of aluminum 2-line railing with side-mount installation
+ Another 184 feet of aluminum 4-line mesh infill railing at the pool.

An interesting additional feature of this project was Kingbird's manufacture and installation of a 16-foot aluminum canopied juice bar.

All the Wisconsin Place aluminum architectural elements provided by Kingbird Industries feature all-welded construction and baked-on powder coat finish to provide for lasting durability, hardness, and scratch resistance. Kingbird provided engineering seals for this project, further exemplifying our quality workmanship we are known for.

Kingbird Industries worked with Turner Construction Company (www.turnerconstruction.com) on this project. The project included some “uncommon challenges in logistics and schedules”. Turner Construction expressed their appreciation to Kingbird Industries for our professionalism and “can-do” attitude that produced such high quality results. Their letter of thanks hangs today in our offices with our many similar expressions of praise for our quality workmanship.

Kingbird Industries agrees with Turner Construction: The Kingbird Industries Team also looks forward to bringing this same kind of quality, skill, and dedication to future projects!

Contact Kingbird Industries at 800.882.7092 for quality workmanship on your next project.

Project of the Month, December 2009 ~ The Bluewater Resort's Aluminum Sunshades

Hilton Head is ranked among the top U.S. vacation destinations. Hilton Head is known for its ivory beaches, fertile salt marshes, azaleas and magnolias. People enjoy its 14 miles of wide, sandy beach, championship golf courses and tennis courts, miles of biking and walking trails, intracoastal excursions, and hundreds of restaurants.

The preserved and natural beauty of the island provides the charm that lured Spinnaker vacation resorts here over 25 years ago. Spinnaker's Bluewater Resort and Marina now has four phases of its Key West style units complete and the project continues to undergo development.

Kingbird Industries was contracted to provide the aluminum features for the project ~ and there were quite a few! A special feature of this beautiful resort is the many sunshades you will find, protecting the internal features from the glare of the sun, minimizing the need for high-energy consumption, as well as providing a graceful decorative feature.

Kingbird Industries designed, manufactured, and installed over 200 linear feet of louvered sunshade shutters for Bluewater, sometimes referred to as “Bahama Shutters” or “Charleston Shutters”. Within the design scope of the sunshades, there were many variables such as arched or isosceles triangle shaped peaks. Kingbird's sunshade portion of the project broke out as follows:

(6’) Louvers: 3' x 8' with isosceles top
(9’) Louvers: 18" x 8-1/2" with isosceles top
(60’) Louvers: 7-1/2' x 5-1/2'
(14’) Louvers: 7' x 3-1/2' with arch top
(30’) Louvers: 5' x 6' - Louvers: 7-1/2' x 5-1/2' –
(22’) Louvers: 3-3/4' x 4-1/2'
(21’) Louvers: 7' x 6'
(7’) Louvers: 7' x 2-1/2' with arch top
(14’) Louvers: 7' x 3-1/2' with arch top
(24’) Louvers: 14' x 5' with isosceles top

In addition to the 100% recyclable aluminum sunshading for this project, Kingbird manufactured and installed over 1300 feet of aluminum Three-Line Balcony Rail, 42-1/2" installed height, with 4" square posts and pyramid caps; nearly 300 feet of Three-Line Stair Rail; and another 500+ feet of aluminum Grip Railing.

Kingbird Industries contract also included providing numerous “false balcony” railings or railing for Juliet balconies. Juliet balconies (named after Shakespeare's Juliet, whom Romeo courted from her balcony in the play Romeo and Juliet) do not protrude out of the building. Juliet balconies are in fact a simulated metal balcony rather than a full-fledged one and are often found in coastal areas to take advantage of the views. The design is basically a very shallow balcony (sometimes only inches deep) with balustrades, typically paired with patio doors or floor-to-ceiling windows. The benefit of this is that the expanse of glass allows for more light and airflow to pass and gives the feel of balcony access to a possibly mundane window. The balustrade itself is made from open aluminum metalwork, such as provided by Kingbird Industries.

Kingbird’s aluminum architectural features for Bluewater featured all welded construction with baked-on 3-coat Kynar white finish.

One of the crowning touches for the Bluewater project were the two large aluminum triangular shaped trusses with 9' sides and 15' base ~ designed, manufactured, and installed by Kingbird Industries. These aluminum trusses make a design statement like no other at the Bluewater Resort.

Come delight in the beauty of the Intracoastal Waterway and the stunning sunsets from the Bluewater Resort and Marina. This resort has something for everyone. Water lovers, tennis players, golfers, nature-lovers, loungers and shoppers will all be enchanted. And while you’re there ~ check out the quality aluminum sunshades and other aluminum features provided by Kingbird Industries, premier designer, manufacturer, and installer of custom aluminum product for every construction project.

Special Note: All Kingbird Industries aluminum sunshades and louvers contribute to more sustainable buildings and can help the building achieve LEED credits for sustainable design. To obtain LEED credits for regional material, calculate the distance from Zip code 28144 to your job site. (MR Credit 5.1 & 5.2: Up to 2 points available if your project falls within a 500 mile radius of Salisbury, NC). Because Kingbird Industries is located in Salisbury, North Carolina, the Bluewater project qualified for up to 2 LEED credits for using regional material.

Contact Kingbird Industries at 704.215.3306 for more info or email us at sales@shaeferinterstate.com

Aluminum Sunshades, Reduced Energy Consumption, & LEED Credits

Solar Shading is the most underestimated source of passive cooling. Kingbird Industries offers quality architectural extruded Aluminum External Louvers and Sunshades that reduce cooling energy demand by avoiding solar heat gains, and doing it without compromising the benefits of daylighting.

Both vertical and horizontal exterior louvers and sunshades are growing more popular in new building design due to their aesthetic quality and sun control functionality. Cantilevered, horizontal, vertical and inclined exterior sun shades filter the sun’s heat and glare, cut wintertime radiant heat loss and integrate natural light into atriums, walkways, skylights, reception areas and work spaces.

Kingbird Industries aluminum sunshade products, designed for zero solar heat gain, are well suited for both new construction and renovations offering many configurations while solving glare and heat infusion issues. Kingbird’s exterior sunshades are custom designed to meet the most stringent design criteria as well as being a 100% recyclable product. Our strong, durable aluminum sunshades are strategically used to block the sun's glare and heat in the summer, yet admit the sun's energy in the winter.

Benefits:
· Aluminum sunshades create dramatic savings in air conditioning requirements. Smaller air conditioning units can be specified.
· Aluminum sunshades enable the use of more natural, and less artificial light, eliminating the need for interior window treatments or expensive darkened glass that increases artificial light requirements.
· Aluminum sunshades are virtually maintenance-free.
· Aluminum sunshades lower peak electrical demand. Smaller switchgears can be installed because the building requires less power.
· Aluminum sunshades produce continual savings year after year with little or no additional expenditures.

Sunshades contribute to more sustainable buildings, reducing energy consumption and helping to achieve LEED accreditation. Points toward LEED accreditation are not awarded by product but on the building sustainable design, construction and operation performance. Kingbird Industries sunshades can contribute to this overall performance. The LEED applicant is responsible for determining the products that will enhance energy efficiency and reduce the environmental impact. Kingbird aluminum sunshades can assist building teams in obtaining LEED points as long as the overall design meets or exceeds the LEED performance standards. Kingbird extruded aluminum products perform at higher levels beyond the scope of the standards in the LEED rating system. The high-level performance of any Kingbird Industries architectural products from a whole building design perspective can be documented for LEED credits. Project teams can request for a Credit Interpretation Ruling (CIR) from the USGBC. The architect, designer, or contractor should document your building’s sustainable design, construction, operation and performance data, and make that data available to the USGBC for any final decisions.

Every Kingbird sunshade, sunscreen, or louver project is individually engineered to withstand the loads implied under local building codes. All Kingbird Industries aluminum exterior sunshades and louvers are custom designed by our in-house engineers and are engineered for superior product durability. Kingbird aluminum sunshades are available in Kynar paint, powder coat, and anodized finishes for durability and appearance. Kingbird is the expert in exterior sunshades for balconies, railings, brise soleil, and architectural solar screens, meeting the needs of your custom specifications. We provide engineered shop drawings of all our custom aluminum structural products, going above industry standards.

Shielding windows from the direct rays of the sun is nothing new. Sunshades have been around for a long time, so why are they suddenly in the spotlight? The new inclination to use more sunscreening is directly related to the increased desire to save energy, protect the environment, and create more sustainable buildings. Let Kingbird Industries aluminum sunshades help to create your sustainable building.

For more information on aluminum sunshades and louvers, contact Kingbird Industries LLC at 800.882.7092 or email sales@schaeferinterstate.com.

Project of the Month, November 2009 ~ Duke Smart Home, Durham NC

Kingbird Industries LLC recently completed the custom aluminum railing project for the Duke Smart Home Program at Duke University in Durham, North Carolina. Kingbird Industries (Schaefer Interstate Railing) was awarded the project in 2007.

The Duke Smart Home Program is a research-based approach to smart living, encouraging students from different academic disciplines to form teams and explore smart ways to use technology in the home. The emphasis on 'smart' means finding the best technology answer for a particular problem--not just finding the high tech solution or the latest gadget on the market.

The Duke Smart Home Program encompasses a 6,000 sq. ft. residential dorm and live-in research laboratory at Duke University, North Carolina, and runs on electricity generated by solar panels. The dorm is designed to meet LEED (Leadership in Energy and Environmental Design) green building standards, which is a national standard for developing high-performance, sustainable buildings. The Duke Smart Home building earned a Platinum rating in LEED from the United States Green Building Council USGBC. Many of Kingbird Industries aluminum products meet the specifications for LEED ratings.

For this project, Kingbird Industries designed, manufactured, and installed:

• 123 linear ft 3-line balcony rail with mesh infill
• 60 linear feet of 2-line inside mesh balcony
• 3-line stair rail with mesh infill
• 2-line rail below stairs with grip rail
  

All balcony rail components were welded construction with a baked on powder coat finish with stock color and plate-mount installation (grip rail with bracket installation).

The Smart Home features (18) 160 watt photovoltaic solar panels mounted to the upper Kingbird Industries balcony rails. The energy generated by these panels is connected to the public power grid and reduces the home's energy output by as much as 30%.

Bovis Lend Lease, based in Raleigh, was the contractor for the project. The website for the project is smarthome.duke.edu. Contact Kingbird Industries LLC at 800.882.7092 for more information, or email us at sales@schaeferinterstate.com.

Kingbird Industries' Commitment

Kingbird Industries is an innovative leader in high-end custom aluminum architectural products. Our in-house design team works with general contractors, architects and others to form solutions that are on-time and within budget. We assure quality and professionalism by anticipating challenges and providing technical expertise. Our unique approach enables us to not only produce aesthetically alluring/decorative products, but we do so without sacrificing structural integrity or durability. All of our products are engineered to surpass each of the local building codes and standards, including BOCA, OSHA, SBC, UBC, ADA, ICC, ANSI, NFPA, AA & AWS.

Kingbird Industries places its focus on large general contractors that build high-rise condominiums, large hotels and college dormitories. Our primary geography includes: North Carolina, South Carolina, Georgia, Virginia, Maryland and the District of Columbia. The company additionally provides restoration work on projects beyond this geography. Headquartered in Salisbury, North Carolina, Kingbird Industries is committed to consistent quality. Commitment unlocks the doors of imagination, allows vision, and gives us the "right stuff" to turn your design into reality.