Stainless Steel Portals & Wall Panels for Data Center, Garland, TX
Project Details
- Client: General Contractor
- Location: Garland, TX
- Scope: Fabrication and installation of brushed stainless steel portals and wall panels
Project Overview
Astro was approached by a general contractor who was struggling to find a company willing to take on the architectural metalwork for a data center in Garland, TX. After being turned down by multiple companies, the contractor turned to Astro for its expertise in complex metal fabrication. Astro successfully designed, fabricated, and installed brushed stainless steel portals and wall panels, delivering a stunning architectural finish.
Challenges & Solutions
- Seamless Appearance for Large Stainless Steel Portals
- Challenge: The architect needed two large portals that transitioned smoothly between the building’s exterior and interior, demanding precise fabrication and installation.
- Solution: Astro field-measured the portals, designed the cladding layout to place welds in easily refinished locations, and welded the components together on-site. The surfaces were then refinished to remove all evidence of welding, achieving the desired seamless look.
- Compensating for Structural Inconsistencies
- Challenge: The framing had inconsistencies that needed to be addressed in the design and fabrication process.
- Several portal components were tapered to accommodate irregular framing, ensuring a precise and flawless final fit.
- Managing Heat Distortion from Long Welds
- Welding large stainless steel components may lead to warping from excessive heat exposure.
- Solution: Astro utilized 12-gauge (.105”) brushed stainless steel for increased thickness, minimizing heat-related distortion while preserving structural integrity.
- Precision Alignment of Wall Panels
- Challenge: The architect required brushed stainless steel wall panels installed from floor to ceiling with 1/2″ vertical and horizontal reveals, demanding precise alignment.
- Astro performed detailed field measurements, created 3D CAD models, and arranged the panels in CAD to ensure accurate spacing. Each panel was fabricated, welded, and finished for a seamless appearance before being mounted using Z-Clips and Z-bar for secure attachment.
Fabrication & Installation Process
- Design Review & Planning
- Conducted extensive field measurements for portals and wall panels.
- Created 3D CAD models to ensure accurate panel layout and fit.
- Precision Fabrication
- Sheared, cut, and welded 12-gauge stainless steel components for portals.
- Formed and finished each brushed stainless steel wall panel with exact spacing for reveals.
- Applied welding and refinishing techniques to maintain a seamless appearance.
- Installation
- Portals were field-welded, with surfaces refinished on-site to remove weld marks.
- Stainless steel wall panels were installed with Z-Clips and Z-bar, ensuring secure mounting and perfect alignment.
Results & Impact
- Jaw-Dropping Architectural Features: The seamless brushed stainless steel portals created a bold, modern entryway.
- Flawless Wall Panel Installation: The meticulously aligned stainless steel panels added a sleek, high-end aesthetic to the data center’s interior.
- Structural Durability: Using thick stainless steel materials ensured long-term performance and resistance to environmental conditions.
Conclusion
Astro’s expertise in problem-solving and dedication to precision craftsmanship led to the successful completion of this complex data center project. Astro delivered an impressive, high-quality architectural solution by overcoming significant design and fabrication challenges. This project reinforces Astro’s reputation for addressing intricate metalwork with precision, reliability, and exceptional attention to detail.
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