New York city mesh

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New York City's latest architectural icon is a world-class building in which every department at The Expanded Metal Company can genuinely say they played a part.

The city's New Museum of Contemporary Art was officially opened to widespread acclaim on December 1st. Expanded Metal Company Architectural Specification Managers Paul Whitton and Paul Bushnell were among the guests at the gala event but, says Mr Whitton, "This really was a team effort. The job encompassed everyone from the operators, toolmakers and engineers at The Expanded Metal Company. They all made their own specific contribution to the process."

His words underline the fact that the company in general and its architectural specification team in particular have geared themselves to provide architects and designers with a bespoke service. He recalls that the New York job began with an email from a US-based design consultant enquiring whether the Expanded Metal Company could provide the aluminium mesh skin required to clad the seven-story building.

Japanese architectural partnership Sejima +Nishizawa/SANAA are renowned for buildings that exude what The New Yorker described as "almost diaphanous lightness". Paul Whitton and his team used their expertise to come up with sample meshes that illustrated what expanded metal could achieve. But, he says, aesthetics were not the only consideration.

"We had to look at the structural feasibility which in New York not only has to cope with strong winds, but also ice loading. A lot of engineering work was required."

To satisfy the warranty requirements the chosen aluminium mesh was anodised but, notes Paul, "This process can make the product appear somewhat dull
and this was exactly the opposite to what SANAA was looking for, so we had the aluminium specially polished prior to anodising to minimise this effect."

Expanded Metal Company engineers created a special tool to suit the requirements of the specific job and worked closely with the US-based specialists in architectural metalwork MG McGrath who would be responsible for installing the actual mesh cladding.

"They came over to inspect our facilities, they went through the manufacturing and quality procedures, the supply chain both upstream and downstream. They were very pleased with what they saw," says Paul.

The Expanded Metal Company sourced special rolled aluminium for the contract and the process of creating the specific mesh was closely monitored throughout "and" says Paul, "as a company we have the capacity to take on this sort of project."

For Messrs Whitton and Bushnell the cherry on the cake came when, not only were they invited to the New Museum's grand opening, but they were given a personal tour around the building by the architects Sejima and Nishizama.

Although obviously familiar with their product Paul admits to being overwhelmed by the final result. "We were really excited by what we saw. We were absolutely amazed and have never seen anything like it before using expanded metal," he says. The principles expressed their delight at the finished facade - far greater than their expectations.

Also, while in the States, the team gave presentations to other architects who were equally impressed by the versatility of the material and the willingness of the Expanded Metal Company to offer a fully tailored service to clients.

"We have learned a lot from our hands-on involvement with this project and have proved that we can work to meet the architect's creative needs," says Paul. "This will stand us in good stead for the future."


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