Have a look at these architectural uses of perforated metal from around the world.

4 amazing perforated metal architectural projects from around the world

At Locker Group we make no secret of our love for perforated metal. We have over 60 years experience in manufacturing this bold and versatile product, and know how much it can add to both the interior and exterior of architectural projects.

However, you don't have to just take our word for it. This article gives 4 recent examples of perforated metal in architectural action from across the globe. Prepare to be amazed:

1. The Miami Museum Garage

Any building constructed in Miami's Design District will have stiff competition when it comes to standing out from the crowd – this area is known for innovative design, art and architecture.

We'll let you judge for yourself, but we'd say the Miami Museum Garage does a pretty good job. The facade is inspired by ant colonies, with the structure representing a similar hive of activity. Public areas such as a playground, a garden and an art space are selectively shown, with the rest of the building disappearing behind an epic perforated metal screen.

This is a perfect example of why perforated metal is excellent for use in facades. Not only is it visually striking, this building makes use the material's natural capacity for sun and wind shelter while also permitting great air and light filtration.

2. Yokohama nursery

There are many aspects of the Yokohama nursery that make it a great piece of architecture. From the warm interior feeling created by the plywood boards to the windows designed to resemble traditional dwellings in the area, every aspect is well thought through and well executed.

However, the aspect of this building that really stands out to us is the perforated metal facade. Not only does it stand out from the white structures on either side of the nursery, the perforation pattern has been cleverly arranged to resemble the constellations of a galaxy. Now these kids get to literally play among the stars!

3. Salesforce Transit Center 

Opened to the public on the 11th of August 2018, the Salesforce Transit Center is a truly iconic addition to the city of San Francisco. The building, which was 17 years in the making and will serve as a central transport hub for the city, is said to be inspired by nature as well as art and math. 

The design features a jaw-dropping 3,992 perforated white aluminium panels.

The design features a jaw-dropping 3,992 perforated white aluminium panels, decorated with an intricate geometrical pattern designed by mathematician and physicist Sir Roger Penrose.

For those who want to take things a step further, Locker Group offers a Pic Perf range of facades where images can be precisely perforated into the metal sheet, creating a truly unique and eye-catching result.This structure really shows off the artistic capabilities of perforated metal. One of the features of this product that makes it so engaging for architects is the fact that there is an almost limitless variety of patterns and shapes that can be punched in.

4. The Vancouver 'Tree House'

Here's one for the future. 

The slopes of West Vancouver will soon be graced with the presence of a 12 story condo building, which at this point is being called the 'Tree House'. 

The perforated metal will be used in the soffits of individual units which will cantilever from the main structure.

The facade will feature a range of materials including dark painted metal, exposed concrete and, you guessed it, perforated metal. Here, perforated metal will be used in the soffits of individual units which will cantilever from the main structure.

The material was chosen for this project for reasons similar to the Miami Museum Garage – namely its ability to provide visual contrast and shade. The 'Tree House' is designed to blend into its surroundings, and the capacity that perforated metal has for establishing natural feeling light flow will be of great use in fulfilling this aim.  

We hope this article goes someway to showing you the amazing potential that perforated metal has for use in architecture. Each of these projects use the material in different ways, and architects need to be able to count on suppliers to deliver products on schedule, and to their exact specifications. Locker Group prides itself on working closely with our clients to ensure that high quality and reliable deliverables. 

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Powder coating is durable and eco-friendly.

The benefits of powder coating in architectural projects

With so many ways to treat and finish metal products, it can be hard to choose which method is best for your project. Since the 1970s, powder coating has been a favourite option among architects due to its versatility and durability, as well as its eco-friendly credentials. But how does this technique work, and what makes it so popular?

Here's the Locker Group guide to powder coating in architecture.

Planning is needed when powder coating different metals.Architects need to consider the stages of the powder coating process.

The process of powder coating

Powder coating is the addition of a protective plastic layer to a metal substrate using a spray gun. It may sound like child's play, however there's a little more to the process than meets the eye:

  • Do I need to prepare the metal? Before any spraying takes place it's crucial that the metal is decontaminated and cleaned. The presence of unwanted substances on the base product may mean the powder doesn't stick well, causing bumps and other unwanted features. Common contaminants include grease, corrosion patches, oil and mill scale. Later on we'll discuss which pre-treatments best suit different metal types.   
  • What's in the coating? The spray emitted from the gun comprises ingredients including polymer resins, levelling agents and pigments, which have been melt mixed and ground into a powder. By changing the colour of the polymer, you are able to get a wide variety of different colour coats.
  • How does it stick to the substrate? The spray gun itself supplies an electrostatic charge to the powder particles (a process called electrostatic spray deposition), meaning they're attracted to the earthed metal.
  • Why is this process so effective? The adhesive properties of the coating are increased further when the parts go through a curing oven. The heat reacts with the chemicals in the coat to create dense cross-links between the molecules that are very difficult to breakdown. 

Powder coating is the addition of a protective layer of plastic to a metal substrate using a spray gun.

The benefits of powder coating for architects

The process described above gives powder coats some unique characteristics that make it ideal for use in architectural projects. Here are some of the most important:

Choice – You can powder coat your chosen features in just about any colour, meaning powder coating provides aesthetic function in addition to the practical benefits we will mention shortly. However, don't stop at colour – from matte to ultra glossy you have an almost limitless selection of textures too.

Durability – Powder coats are long lasting. Unlike many of the paint based finishing techniques with which it's often associated, powder coating has a high tolerance for a variety of environmental conditions, as well chemicals and abrasion.

Environmental compliance – 2018 has seen awareness of human impact on the environment reach new levels, and it's important that architects and industrial practitioners minimise their negative effect on the planet. There are a number of features of the powder coating process that make it more ecologically sound than many alternative techniques:

  • It eliminates, or greatly reduces, the emissions of volatile organic compounds (VOCs), which are traditionally found in paints.
  • Powder coating also minimises or removes the release of hazardous air pollutants (HAPs) associated with conventional liquid coatings.
  • If more powder is sprayed than necessary, the excess can be retrieved for future use.
  • Powder coats usually don't contain heavy metals that can be dangerous for people as well as the environment.
Powder coating is ecologically sound.Powder coating is more environmentally friendly than most wet paint techniques.

As well as offering choice and durability to architects, powder coatings are environmentally friendly.

Which metals suit powder coating?

The good news if you like what you're hearing about powder coating so far, is that it's a technique applicable to a wide range of products. For architects this means that it can be used extensively on both the inside and outside of builds. 

Here we'll have a look at three specific metals which are the primary materials for many of our favourite products. They all make excellent candidates for powder coating, but require unique treatment prior to spraying.

  1. Aluminium – The lightweight yet strong nature of aluminium means that it's a firm favourite in building design. However, the oxide coating that gives aluminium its rust resistant reputation must be removed prior to powder coating to allow the polymer to bond with the metal itself, rather than this protective outer layer. This can be achieved through surface blasting or submerging the metal in a phosphate solution.
  2. Galvanised steel – As galvanised steel has already been finished (through the process of galvanisation), it may seem like an odd choice to include here. However, as powder coating adds another layer of protection, this substrate is actually one of the most common to undergo the process. In addition, the fact that galvanised steel has the capacity to form a layer of zinc oxide or zinc carbonate, similar to the oxide layer on aluminium, means that similar techniques must be employed to remove this before spraying can commence.
  3. Stainless steel – For stainless steel the focus is on profiling the surface of the metal to make it easier for the powder to stick. This could involve blasting with a sharp substance such as aluminium oxide or, at a more advanced level, an acid etch. 

A few drawbacks

While powder coating has a lot going for it, it wouldn't be fair to paint it in a perfect light, if you'll excuse the pun. Here are two drawbacks you should consider:

  • Achieving a thin layer is difficult – This is due to a relative lack of control over the rate and amount of powder applied to the target. If you're looking to apply 6 millimetres or less, this isn't the technique for you.
  • It's hard to remove – We told you it's durable. However, the flip side of this advantage is that removing powder coats will take some time if mistakes are made.

Powder coating is a useful tool in an architect's arsenal, but only when implemented correctly for your unique project. At Locker Group we work directly with our architectural clients to deliver products tailored to your requirements, engaging with you every step of the way.

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There's a lot of choice when it comes to using woven wire in architecture.

How to choose woven wire for an architectural project

So you've decided to incorporate woven wire into your next architectural project. Firstly, congratulations – you've chosen a versatile and aesthetically interesting product that can be used to add flair to a wide range of builds. 

However, now you're faced with the happy problem of choice. Due to its ability to perform both visual and practical roles in the design of a building, and the fact that it can be used internally and externally, there's a fair bit of thought required when selecting woven wire for use in architecture.

Here are a few factors to bear in mind:

How will it function?

With a variety of materials and profiles to choose from, you need to consider the function of the woven wire you're planning to install.

Woven wire has a number of common purposes, including:

  • Sun shading.
  • Providing a shield from wind and rain. 
  • Creating a partition. 
  • Allowing the flow of air and light through a space.

However, a wire mesh feature intended to give a feeling of privacy is clearly going to require a different profile to one where the desired outcome is allowing more light into an area.

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For example, in the redevelopment of the PwC premises in Sydney, Design Director Gavin Harris wanted a woven wire product for the ceiling that allowed transparency and reflectivity without losing light, aesthetics or sound in the space. Ultimately Locker Group's Planar 441 provided exactly the right balance, and was incorporated into this unique and interesting design.

You need to consider the function of the woven wire you're thinking of installing as part of your design.

You should also consider how the use of different metal substrates will impact the look of your design. Locker Group provides woven wire mesh in a variety of materials, including stainless steel, aluminium, brass and galvanised steel. Each contributes a different aesthetic to a space, so think about the atmosphere you're attempting to create.

Will it be used internally or externally?

Clearly there are different requirements for any metal-based architectural feature depending on whether it's used internally or externally. Wire mesh used to provide a feeling of privacy in a restaurant will be under a lot less stress from the elements than the same feature used to create a 3D effect on the outside of a building.

In addition to choosing the woven wire mesh that's best suited to the environmental conditions of your project, it's also important to think about finishing techniques. As well as protecting the metal substrate from the elements, finishing techniques can enhance its the visual proprieties – contributing to how it will impact your design.

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How much does it weigh?

The relative weights of the elements you include in your building design are of great importance when establishing safety and costs. We'll return to costs in a bit more detail later, but let's have a look at the weights of woven wire mesh, and what this means for your design.

Of all the metal materials you're likely to use in your project, woven wire products will probably be the lightest. They range from 0.178 kilograms per square metre (kg/m²), for grade-316 stainless steel, to 8.1 kg/m² for galvanised steel. 

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Whilst there are obvious benefits of using lightweight elements such as wire mesh, there are still important safety considerations – especially for architectural applications such as building facades. The installation of any panel facade, whether wire mesh or perforated metal, should be preceded by a thorough examination of the fixing system, and what the implied load will be for the support structure.  For external uses, it's also important to factor in wind loads, especially on corners. 

Of all the metal materials you're likely to use in your project, woven wire products will probably be the lightest.

AS/NZS 1170 is the most important standard regulating load requirements for buildings, so ensure that your mesh manufacturer is able to provide full certificates for the products they supply to you.

As well as the implications for the building itself, you should consider how weight will impact on the ease of installation. Returning to our example from the PwC design in Sydney, a supporting spring line was required to ensure a fast and safe implementation of the woven wire on the ceiling. Making these considerations in advance can save you time and money when it comes to bringing your design to life.

What will it cost?

After safety, costs and deadlines are the biggest considerations. Builds have tight budgets and timeframes, so you need to ensure that the materials you choose aren't going to break the bank or cause you to fall behind.

This, again, is where the lightweight nature of wire mesh really comes into its own. Woven wire mesh is typically easy to install, reducing labour costs and helping you stick to deadlines.

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For example, when Locker Group supplied stainless steel woven wire for use in Vogel House, a high profile building in the parliamentary district of Wellington, New Zealand, the installation process was completed in a matter of days. The mesh was delivered in three rolls and attached at the top and bottom of the staircase it was screening, with Locker Group providing technical assistance to ensure a fast but safe installation. 

As such a versatile and easy material to work with, it's no wonder that woven wire plays a role in so many architectural designs around the world. Locker Group works closely with its clients to create tailored products that fit your requirements, and your budget. 

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What are the benefits to using a double-skin facade?

What are the advantages of using double skin-facades?

Building design has evolved significantly to meet changing requirements for comfort, function, and energy efficiency. This evolution has led to all kinds of innovation in the design space, from using new materials to integrating smarter design elements.

One such development is the double-skin facade, which in most cases comprises of a traditional single-skin facade doubled-up with an additional outer layer covering all or part of the building within. The advantages to this kind of facade system are considerable, let's look at the four biggest benefits in more detail.

What materials are used in a double-skin facade?

Before we look at benefits, a quick note on materials. Double-skin facades are being built across the world, and the majority of them are built using glass for the internal layer. Outside layers tend to be made of either a second layer of glass, or perforated metal sheets. In this article, we are referring to double-skin facades utilising a mixture of glass and perforated metal.

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1. Reduced energy consumption

The cavity between the two layers can act as insulation during the colder months. This happens in two ways. The first is that sunlight generates heat which gets trapped between the two layers, while the second is that less heat escapes the inside of the building due to the additional layer. This reduces the need to heat the inside of the building, eliminating reliance on HVAC systems and the cost of operating them.

2. Natural ventilation

In warmer climates, the air in the cavity between the two facade layers effectively monitors itself. Excess heat is drained out through a process known as the stack effect, wherein the differences between air density create air buoyancy. This essentially means that as the temperature of the air in the cavity rises, it's pushed out of the cavity.

The result is that the temperature of the inner skin is kept much lower, and less heat is transferred from the building's exterior to its interior. Ultimately, the ventilation properties of a double-skin facade act to keep the building and its occupants cooler, and reduce the need to run air conditioning.

3. Acoustic insulation

The beauty of a double-skin facade is that even when internal windows are open, you can achieve acoustic insulation that performs as well as any single-skin facade. Sound insulation effectiveness can be greatly increased by incorporating perforated metals in the right way. There are two key methods for this.

By utilising one of two techniques, your perforated metal outer facade can mute external frequencies. The first method, "sound transparency" incorporates elements of soundproofing and uses the perforated sheets as a protective cover. With this methodology, sheets need to allow sound to pass through them, letting the additional sound-controlling material soak up the frequencies.

The second method, "tuned resonance" requires specialised perforation sizes matched to the frequencies that need to be blocked. The sound waves oscillate in the holes rather than passing through, leading to a significant reduction in noise.

4. Occupant comfort

With improved temperature control providing a more human-centric environment, the comfort of the occupants is increased significantly. Coupling this with a perforated metal outer facade which provides shading from direct sunlight while still allowing the passage of natural light, occupants benefit even further.

Why use perforated metal in a double-skin facade?

Beyond what we've covered, there are numerous other benefits to using perforated metal in a building facade:

  • Flexibility in terms of perforation size and profile, not to mention the possibilities for custom images with Pic Perf.
  • An extensive choice of colours and finishes.
  • Available in a range of coatings for long life.
  • Availability of different metals to suit different environmental needs.
  • Supports all manner of creative and innovative designs, limited only by imagination.

For more information on how perforated metal can be utilised as a facade material, get in contact with the team at Locker Group today.

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What's influencing facade design in 2018?

The next big thing: 5 architectural facade design trends

The way building facades are approached is changing. In addition to their waterproofing, insulation and aesthetic functions, facade design now encompasses energy efficiency, which adds another layer of complexity to the process. Further, facade engineers have access to a greater number of materials, and developments in technology allow them to do more with what they have. 

When we talk about facade design trends, we're not looking at "what's hot" so much as how the design approach has changed, what's important now that wasn't before, and what's possible now thanks to technological development.

1. Design approach

Usually when people think of facades, they think of the most iconic in the world; St Peter's Basilica, the Parthenon, or one of the many striking works by Frank Gehry. It's true that facade design can leave an impression, oftentimes leading buildings to become iconic, integral parts of their cityscapes that can last for centuries.

Mic Patterson of Facade Tectonics describes the current approach to facade design in commercial architecture as "the pursuit of the iconic." This is an approach that values the unique appearances of the classics, and attempts to create designs that will be remembered.

This is not to say that the aesthetic aspect of a facade is the only consideration, or at least, it shouldn't be. As previously mentioned, waterproofing and insulation are just as important as aesthetic features, but with new technology, facades can make even more meaningful contributions to the buildings they envelope (we'll go into more detail on this shortly).

Today's design approach is one that balances striking visuals with classic functionality, while incorporating smart new technologies to boost efficiency.

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2. Materials

Developments in technology mean materials are easier to produce in bulk and easier to manipulate for particular applications. Producing thousands of perforated metal sheets for example, is far simpler and less time consuming than it would have been in eras past.

Woven wire mesh and perforated or expanded metal used in facades (whether for the entire building skin or as individual textural or shading elements in more complex designs) certainly fit the bill when it comes to functionality. Facade materials need to strike a delicate balance of allowing natural light to enter the building, but restricting glare from the sun.

This can be achieved using open profiles or screens oriented in a such a way to allow the all-important passage of natural light while still offering optimal protection from direct sunlight. Traditionally, many facade engineers opted for glass to provide natural light to a space, but this isn't always the best option in Australia's climate – where the glare from the slow-moving sun can cause problems with vision.

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3. Sustainability

Sustainability is another factor of facade design that is more important now than ever. In this context, sustainability is all about reducing the footprint – using smarter materials, optimising design and layout, and reducing long-term costs.

One of the key strategies here extends from our last section. We covered how materials like glass and open-profiled metal sheets allow the entry of natural light, but the reason for this is to reduce the volume and intensity of indoor lighting. More natural light means less reliance on the electricity grid, which ultimately reduces energy spend.

Facades are generally oriented so they can respond to solar movement. Depending on the local climate, facades can also prevent heat loss, or maintain cooler temperatures inside the building. Again, this reduces the amount of energy building managers need to use to keep the environment comfortable for those using it.

Another hot trend in facade design is the "vegetated facade", wherein a facade is designed and built to support the growth of vegetation. The vegetation then becomes part of the building skin, reinforcing biodiversity and offering shade and amenity spaces for building inhabitants.

4. Smart elements

Smart building design is about sustainability, but it's also about improving lives. Smart elements creatively reimagine what's possible in design, to remove limitations, to create spaces where humans can flourish and to add functionality previously only dreamed of.

Utilising smart elements in your facade isn't a matter of selecting pre-established elements, rather it is an innovative design approach. Let's look at a couple of examples of how smart elements can be used in a project.

A few years ago a new hospital was built in Mexico City, the facade of which has "smog eating" capabilities. The material was initially introduced in 2011, and contains titanium dioxide. As exhaust-filled air passes around the facade, it interacts with the material's "free radicals" which cleanse the air of the gases that smog is made up of; nitric oxides, sulfur dioxide and ozone.

Another example of smart facade elements in use is the communications and design building at the University of Southern Denmark which utilises gorgeous perforated metal panels with a twist. All of the panels are installed on mechanical hinges that are capable of adjusting themselves to regulate the natural light entering the building (pictured below).

A final example of smart facade design comes from material technologists Decker Yeadon. Their homeostatic facade comprises two sheets of glass with the newly developed material in between. This material was created to act like a muscle, and it expands or contracts based on the temperature of the outer surface. This in turn, alters the amount of light and heat that can enter the building.

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5. Maintenance

Maintenance plays a large role in design. As the "face" of a building, a facade needs to maintain its appearance for the building's entire lifecycle. This means carefully considering how materials will age over time, whether access points for cleaners can be incorporated, as well as looking at compatibility with new maintenance technology.

Where perforated or expanded metal sheets are used, hot-dip galvanisation helps them go the distance over time. In terms of access, this can often be achieved by having stairwells and access points between the facade and the building's exterior – or otherwise allowing room for a cherry-picker to get close to the building. There are also a few companies currently producing robots for cleaning facades – in many cases they need a place to dock, so incorporating this into design can also be useful for maintaining the facade in the long haul.

There are a huge number of factors involved in design, and we haven't even touched on compliance, but the possibilities for what can be done are growing every day. If you're ready to talk materials, we'd love to hear from you, so get in touch with the team at Locker Group today.

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How can wire mesh curtains be utilised in architecture and interior design?

How wire mesh curtains can liven up your space

Wire mesh curtains are an ideal architectural solution for delineating space, adding texture to an interior, or for decorative use in a facade. Locker Group's curtains are made from uniquely shaped interconnected metal threads, custom made in a variety of profiles and materials to meet the unique requirements of your project. Our curtains add a touch of modern sophistication wherever they're applied – here's how they can liven up your spaces.

How can wire mesh break up large spaces?Space delineation in the dining room of the Cremorne Hotel.

Mesh curtains make great partitions

If you have a large open space, wire mesh curtains are a fantastic way of delineating areas when the entire space isn't necessary. This can make a larger room much more intimate and add a sense of privacy. It's also a way to create private seating areas in a restaurant, cafe or bar. The great thing about using mesh curtains in this way is that they can be installed on tracks so they can be drawn or retracted, allowing you to get the best of both worlds; smaller intimate spaces as well as larger, open ones. Wire mesh curtains allow air to move freely through them, so there's no need to think about ventilation if you're using them as permanent partitions or screens

How can wire mesh curtains add texture to a space?An internal screen adds texture at Ausnet Victoria.

Mesh curtains add texture

Locker Group produce mesh curtains in an extensive range of profiles and they are available in stainless steel, brass or aluminium. This means you have quite a few options for how the curtains will look and feel. Mesh curtain segments can be used in two dimensional surfaces to add a little bit of texture to an interior design scheme, and can be created for use in three dimensional structures as well.

Wire mesh curtains be used to create striking facades.Wire mesh curtains used in the stunning facade of Monash Library Caulfield.

Mesh curtains bring style and function to facades

Using wire mesh curtains in your building facade can create striking visuals and make a grand impression on those who come into contact with it. But there are additional reasons why this is a fantastic material for facades. The open profile of wire mesh curtains limits visibility, providing privacy, though at the same time our curtains do allow light to pass through. Acting as a screen against the glare of the sun while still allowing the passage of natural light, these curtains give a building's occupants the best of both worlds.

We've established that wire mesh curtains can contribute to the aesthetic of a building or space, but once you've seen some of the applications, you'll understand that this is a product that speaks for itself. For more information about wire mesh curtains, get in contact with us today.

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Locker Group produced perforated zinc sheets for Monash University's new Learning and Education building at the Clayton campus.

Case study: Monash University Clayton

The new Learning and Teaching building at the Clayton campus of Monash University was recently completed. John Wardle Architects designed the building and utilised perforated metal products from Locker Group to create the facade. The folded perforated metal facade covers all sides of this four-storey building and acts as a sunshade without hindering visibility from the inside out. It was no small project, and there were a number of hurdles on the way to completing this truly stunning project.

What were the requirements of this project?

Monash University made a commitment to sustainability, and implemented goals to reduce its carbon footprint. Since their buildings make up an approximate 80 per cent of their emissions, sustainability was a priority for Monash University in constructing the Clayton campus. The zinc sheets that make up the facade played into this. Zinc is easy to recycle, as it retains its integrity and performance properties so it can be reused. The International Zinc Association states that 95 per cent of zinc products used in buildings are recycled.

The facility is truly state of the art. With collaborative and unconventional learning spaces throughout, the campus reflects new ways of approaching education. As a cutting-edge education facility, it was important that the facade of the building was as unique as the spaces inside. This is why Monash University partnered with the award-winning John Wardle Architects, who in turn utilised products from Locker Group's extensive portfolio to give the building its flair.

How does the building's facade reflect that which is inside?The building needed to be as unique on the outside as it is inside.

Which Locker Group products were used?

While Locker Group supplied perforated sheets for the entire facade, it's not actually a single uniform product the entire way around. The large sheets covering the north, east and west sides of the building had three different perforation patterns per sheet. For the parts of the facade that cover windows, a profile with 50 per cent open area was used. Often, smaller profiles can play with your eyes, and so the chosen profile was to allow occupants of the building to see clearly out the windows. The other profiles used on these sheets had a much lower open area, in order to act as weather shielding. The south facing side of the building has one uniform perforation pattern.

The sheets are made of 99.9% pure zinc. As a natural material, zinc requires minimal maintenance over time due to the self-protective patina that forms over the metal to maintain surface integrity. Zinc has a tendency to age gracefully, which combined with its strength, is why it has been a popular roofing material in Europe for over 150 years.

What challenges were faced in producing these perforated metal sheets?Manufacturing the perforated metal sheets for the facade was something of a challenge.

What were the challenges in producing these sheets?

Locker Group's manufacturing team had to get creative in producing the zinc sheets. The facade is approximately 11 metres tall, and the architects wanted as little joinery and steelwork as possible. We were able to produce sheets large enough that only two would be required to span the height of the facade.

In order to keep the steelwork down, these were fixed to three beams running perpendicular to the sheets, and each sheet was fixed only at the top and bottom. Since zinc is fairly lightweight, this was more than sufficient support to hold the panels in place. Since they were being folded in a unique way, they became more rigid, meaning we could make them longer and minimise the steelwork as per the designers preference.

To give you an idea of the scale of this facade, which envelops the building, approximately 1,552 panels were used, which is equal to about 95 tonnes of metal. The perforated zinc panels were folded in such a way that they spanned approximately 8.5 thousand square metres on a surface only 4.5 thousand square metres in size.

The zinc used in this perforated metal facade is 90 per cent recycled.The finished product is simply stunning to behold.

The finished result

The completed project is a facade that really catches the eye. You might be impressed by our photos, but they in no way compare to how grand this building looks when you stand in front of it. The zinc is simply beautiful, and it will look better and better over time, offering something special and unique to every new generation of students and educators that use it. Locker Group is proud to have supplied the materials that give the building's exterior its character. Although manufacturing the sheets wasn't easy, we can find the solutions necessary to deliver our clients metal products that stand up on the world stage.

Whatever it is you need to give your next project a unique visual character without sacrificing functionality, Locker Group has the expertise to make it happen. For more information, contact us now, or check out more of our work via the link below.

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What does your perforated metal profile say about you?

The unique characteristics of perforated metals

Locker Group has over 60 years experience in the business of manufacturing perforated metal. We produce a huge range of perforated profiles, and each has its own unique, distinctive character. But what are the characteristics that make each product unique? It's not just a shape, it's a personality, so without further adieu, here is what each profile has to say for itself.

Perforated metal profile: Champagne

Champagne

Champagne is literally the life of the party, but not in an obnoxious way. Interesting, witty, and not afraid to be a little bit silly, Champagne is naturally charismatic and turns heads without even trying. It's said that Champagne once performed karaoke for 36 straight hours and only stopped because there were no songs left. Champagne might not be for everyone, but no one can deny its magnitude.

Perforated metal profile: Aztec

Aztec

While Aztec has its fair share of academic credibility, it certainly doesn't think it's better than you. Well-read, well-traveled, and concerned for the wellbeing of all living things, the uninitiated may refer to Aztec as a "hippy" though in truth it's a hard-working profile that is proactive about bringing about positive change in the world. Fun fact: Aztec is fluent in three languages and continues to appear as a guest lecturer at Universities around the world.

Perforated metal profile: Sheer 2800 / Hexagon

Sheer 2800

Sheer 2800 (or Hexagon to its friends) is smart and creative, like a scientist with a flair for experimentation. Obsessed with the complex geometric relationships of living cells*, Hexagon is a leader in its field and tends to garner respect from all corners. Though it seems fairly simple at first, Hexagon is more impressive every time you look at it and even its detractors will admit there is something intrinsically fascinating about this profile.

*We're not sure what this means either, you'll have to pick up Hexagon's latest book.

Perforated metal profile: Ribbon

Ribbon

Ribbon is often the shyest of the profiles, but when it comes out of its shell you'd be surprised by how kooky and fun this profile can be. Ribbon tends to view the world through the eyes of a child, and when you interact with it, this tendency sometimes rubs off – leaving you to enjoy a wondrous world of colour and shape. Ribbon enjoys play-doh, fire-engines, and spaghetti.

Perforated metal profile: Niche

Niche 250

Not a lot is known about the profile that is Niche. Some say it was created in a small town on the SA/NSW border in the late 1970s, others say that Niche has simply always been. Niche is a night-dweller with a serious composure, often preferring its own company to that of others. Highly motivated and darkly attractive, rumours persist that Niche is either a sith lord or a vampire. Attempts to confirm either rumour have been met only with maniacal laughter.

Perforated metal profile: Herringbone

Herringbone 19

Remember the good old days? Herringbone certainly does. By no means a simple profile, Herringbone has a certain depth and elegance all its own. It would be wrong to call Herringbone a relic, since this is a modern profile in a changing world. Quietly wise, Herringbone has seen it all but won't stop smiling – it knows that best of times is still to come. Herringbone was a confidante of Ernest Hemingway and supposedly taught Stephen Fry everything that he knows.

So, which one of these profiles resonates best with you? Contact Locker Group today for more information.

Check out some of the work we've done in the past.
The Sportshub at the University of Queensland is a great example of creative facade design.

First impressions count: What your facade says about you

Locker Group's range of perforated metal offers excellent materials for building facades, and make no mistake, this is one of the most important design elements of your project. Cognitive scientists have proved buildings can affect mood and feelings of well-being in humans, thanks to specially attuned cells in the hippocampus.

In coming years, these psychology-based insights could begin to play a major role in how cities are designed. In the meantime, it's worth considering how your building will fit, not just into its location, but into the hearts and minds of those who will interact with it.

How can building design affect people?

In his 2015 book Places of the Heart: The Psychogeography of Everyday Life, Colin Ellard (a cognitive neuroscientist) describes an experiment he undertook in a suburb of New York's Lower East Side. Ellard walked small groups of people around a partially gentrified neighbourhood and found that his subjects were unhappy and bored when faced with modern, slab-like structures with little creativity exercised in facade design.

Furthermore, pre-eminent urbanist Jan Gehl has observed that people will increase their walking speed when passing a blank building facade. Psychologist Daniel Berlyne has stated that humans are biologically disposed to prefer locations with some architectural complexity, and are easily bored when this complexity is absent. Even brief episodes of boredom have been proven to increase levels of bodily stress hormones, according to a 2015 study from the University of Waterloo.

While this is an extremely brief example of how buildings can affect people, the implications of these studies suggest an increased need for more human-centric facade design.

Generic facades leave a lot to be desired because we humans prefer some level of complexity.Pictured: Not a whole lot, actually.

How can this be manipulated?

While certain design theories may point to individual methods for adding a human touch, there is no single guaranteed feature that will make a facade more interesting to humans. The flip side to this is there are no hard and fast rules. An architect has a lot to juggle, and a facade needs to do many things. Getting creative with a facade will lead to a greater engagement from those who use the building, and more positive feelings and associations for those who live in the area.

How perforated metal can be used in facade design

Our perforated metal can be manufactured to any specification, meaning the only limit is your imagination.  Check out our 2017 Lookbook for some amazing finished projects, using perforated metal and Locker Pic Perf, by some of Australia's greatest architects.

For more information about perforated metal in architectural contexts, contact us today.

Contact us today

Perforated metal is a versatile material, but how is it made?

How is perforated metal made?

Perforated metal has been used for the last 150 odd years for a number of purposes. First developed as a filtering system for coal miners, the original perforation process was lengthy and exhaustive. In the old days, labourers would manually punch individual holes into a metal sheet, but thankfully, more efficient manufacturing processes have been developed since then.

Our manufacturing process

We start with a coil of sheet metal in the desired gauge of the product we're making. There are a few different methodologies for different products, however for standard products the coil is fed into one of the machines. The machine's rollers pull the metal through, and the holes are punched by needles mounted on a rotating cylinder as the sheet metal moves through the machine.

For more specialised products such as Pic Perf, the whole sheet would be loaded into a turret punch, where the pattern is programmed in. This way the machines can punch the right configuration of different sized holes to present the larger image. The turret punch allows multiple needle profiles and sizes to be swapped into the punching position, so it's perfect for jobs that require unconventional patterns or greater detail.

Perforated metal manufacturingOur factory is set up in such a way that we can produce perforated metal in a huge range of profiles.

Our flexibility with customisation

One of the things we pride ourselves on is our ability to provide unique tailored perforated metal solutions to our customers. We've set up operations in such a way that we can be flexible in terms of delivering specific or one off products. In many cases we've had to create new tooling to complete custom jobs. We are not put off by this, and we are certainly not the type of company to say "we can't do it." If it can be made, we can find a way to make it.

Our team are always looking for ways to improve the range.

Our engineering team are always looking for ways to improve the range, and this involves some experimentation. Trying out new methods, experimenting with tensile strengths and folding/trimming techniques to the get the best possible product out of the design and manufacturing teams. It's this dedication to flexible solutions and experimentation with materials and processes that helps us stay ahead of the market.

Perforated metals have a huge range of applications. From facades, screens and balustrades to filters, grilles and ventilation. Meshstore is your one stop shop for pre-made perforated and expanded metals, woven and welded wires, and metal planking and railing products. Backed by the industry leading Locker Group, you can shop online right now, check out one of our branches, or contact us for more information.

Gold on the ceiling: A case study of PwC Sydney, by Futurespace & Civardi Furniture

Global accounting and consultancy firm PwC recognised that business is changing. Their clients were implementing new technologies and processes that eclipsed those that came before, and PwC realised that in order to meet the demands of this changing landscape, they needed to change too. Looking to make a fresh start, PwC worked to establish new premises that would integrate technology and modern, sustainable design to create a space that is less business, and more destination. The goal was to provide an environment that lent itself to creativity and collaboration, one that could boost efficient workflow while retaining the flexibility to support the working processes of a multitude of different clients.

PWC SydneyPwC's client experience centre in their new Barangaroo offices. A design that welcomes from the get-go.

Project background

While PwC developed new premises in many of their locations, it's the Sydney office that utilised Locker Group's woven wire. Situated west of the CBD in the multi-award winning Barangaroo development, PwC is situated at One International Towers, Watermans Quay. Their clients will find the new customer experience centre over four levels, beginning at the welcoming centre on level 17.

PwC brought in Futurespace for the interior design. As a forward thinking architecture and interior design agency, Futurespace had the passion and approach to create a truly unique design. Inspired by the emergence of companies introducing disruptive business models, PwC hoped to to change the way their business operated, and this needed to begin with where the business was operating. Dedicated to many of the same principles that PwC hoped to integrate into the design, Futurespace was the best agency for the job.

Futurespace Design Director, Gavin Harris, explained that moving away from a more traditional consultancy layout was essential. It was important to design a space that had multiple settings, that would foster collaboration and greater results for PwC's client base. Harris described how the Futurespace team looked at hospitality, branded airport lounges, and other types of co-creation spaces to inform the way that the PwC customer experience would need to function.

Of course, it was more than simply function that PwC required. The customer experience centre also needed to look and feel unique – the multiple interactive elements had to come together as a cohesive whole. This is where the gold ceiling comes in. Locker Groups Planar 441 woven wire was used as a ribbon that winds its way through the space and connects everything together. The wire is visually striking, particularly where it dips and becomes a shield for the window of the foyer. This feature, coupled with the unique viewing portal, makes an immediate impression as soon as clients step out of the lift.

PWC Sydney foyerThe foyer of PwC's client experience level.

Why Locker Group's Planar 441?

In bringing Planar 441 to PwC, Futurespace teamed up with Civardi Furniture, a specialist joinery manufacturer dedicated to pushing the boundaries of materials and design. Civardi have their own extensive portfolio of innovative and visually pleasing solutions, and this is what drew the team at Futurespace to collaborate with them.

Gavin and his team had an idea early in the design process about using a material that would render the ceiling a transparent gold. The downward curve of the wire against the foyer window was something the team had hoped to implement early on, believing it to be a strong welcoming statement that was both interesting and inviting. While trialing possible materials, tone, colour and profile were taken into consideration as the designers weighed up the strengths of different types of metal to see if their vision was possible.

Gavin explained that finding the right woven wire product is what brought the idea to fruition. Locker Group's Planar 441 offered the right amount of reflectivity and transparency without sacrificing lighting, sound, or aesthetics. It was ideally suited as the consistent texture between the shielding in the foyer and the ceiling panels, lighting the way for PwC clients.

PwC client loungeFuturespace and Civardi make the most of Planar 441.

Implementing the woven wire

While Gavin and the Futurespace team had hoped to implement a feature like the woven wire ceiling, it was not without it's challenges. Initially there was some concern around how it would be mounted, and whether this would negatively impact the lighting, sprinklers and fire alarms, and that optimal acoustics would remain intact. In turn, it was also important that these essential fixtures didn't detract from the metal's beauty. With proof of concept coming from Civardi, the panels were able to be installed via a supporting spring line.

The final product

Ultimately, Gavin, the Futurespace design team and the specialists from Civardi created a wonderfully vibrant and engaging environment. Locker Group's Planar 441 woven mesh panels create a strong impression from the very moment a client enters the building. This new space will change the way PwC interact with their clients, and it was all achieved by a winning combination of creative minds, skilled hands, and top quality materials. For more information about Locker Group products, or to find out what materials we have that will suit your next project, get in touch today.

Finding the right architectural products to blend with nature can be challenging.

3 Locker Group products that blend industrial and green

Sydney Park marks one of the city's most visually distinctive open spaces, due to its post-industrial brick kilns towering over the north-western corner and recently revitalised wetland areas.

In 2014, the City of Sydney metropolitan council launched an ongoing park management strategy for the coming years which will redevelop the area. The council put communicating the cultural heritage of the area and increasing public amenities high on the agenda, with a specification towards architectural designs in keeping with the area's industrial history.

What better way to embrace the industrial history of the the Sydney Park area than with art installations and innovative architectural structures that blend visual appeal with a durable industrial edge? Locker Group have a range of architectural products that would suit.

Our range

Locker Group have a range of products that provide a striking architectural look, and have a history of use in integrating green spaces into an urban environment:

  • Perforated metal – one of our most popular products, perforated metal offers users an innovative architectural look. Perforations can be adapted to client specification, taking into account shape, size and profile. Their design allows for water run-off, which prevents rusting, and the sheets come in a variety of surface treatment options to ensure minimised natural wear-and-tear. Available in a variety of metal substrates, they add a rugged industrial edge to sun shading canopies or art installations.

Perforated metal allows ample light and airflow.Perforated metal allows ample light and airflow.

  • Hi Light louvres – these colourful products are ideal for sun shading, vital in a park space that will draw the public to stroll in the sunshine. With treatments available to reflect glare and prevent sun damage, Hi Light louvres are available in a range of bright and bold colours that truly make your space stand out. The aluminium grating is also perfect for screening private spaces and parking areas from view.
  • Expanded metal mesh – a truly multifunctional product, this metal mesh fabric is customisable to client needs and easily installable, instantly providing a distinct architectural look that also functional. The metal mesh can provide sun shading on hot days while still encouraging air flow. Additionally, creeper plants growing through the perforations perfectly blend the industrial with the natural, a visual best serving the history of Sydney Park.
Sydney Park can be the model of innovative architectural products meeting nature. Sydney Park can be the model of innovative architectural products meeting nature.
Sydney Park's rich heritage deserves distinctive architectural concepts that beautifies the park for public access and embraces the area's industrial past. Locker Group have a range of products to suit, blending visual appeal with industrial durability. If you have an architectural project with a similar specification, speak to our friendly team today and we can figure out what's best for you.
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