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IPD Process Leads to New Custom Metal Panel

The Z12 Panel creates texture and reflection for façade at Portland Ambulatory Surgery Center

Morin Case Study July18

Integrated project delivery (IPD) is oft lauded as a collaborative process that increases the efficiency of projects by bringing all stakeholders into the discussions early and often, eliminating misunderstandings and redundancies.

At the site of Oregon Health & Sciences University’s Center for Health and Healing–South (CHH–South) in Portland, Ore., IPD was all that—and more. The partnership between engineers, designers, suppliers and installers resulted in something unheard of: an entirely new product at no cost and great value to the client, and is now being sold as a part of Bristol, Conn.-based Morin Corp.’s newest product line.

The Stage

At CHH-South, a 430,000-square-foot ambulatory surgery center, the IPD process included co-location of team members in an onsite office where designers were working elbow-to-elbow with installers, engineers, vendors and contractors. Key players at the co-located office included lead technical designer David Gonrowski and lead designer David Staczek from ZGF Architects, Portland, lead envelope project engineer Tomasz Kaltur from Hoffman Construction Co., Portland, and metal panel supplier and installer Ric Olander from General Sheet Metal, Clackamas, Ore., as well as the installers of metal studs and windows.

The Challenge

During the schematic design phase, the ZGF/Hoffman team for CHH–South was looking for a concealed fastener façade panel that could be both field-installed and glazed into the curtainwall, with a texture dynamic enough to interact well with the building’s scale.

After researching textured stainless steel, extruded aluminum and aluminum composite material (ACM) panels, the team found the Morin W-12, a 1-foot-wide panel with a single fold in the center affording a nice texture to the building’s exterior. Morin W-12 is traditionally popular with both installers and designers because of its visual appeal, ease of installation and overall flexibility.

Given the scale of CHH-South and the designers’ plan to incorporate panels in both 1-and 2-foot sections, however, ZGF’s Staczek and Gonrowski were looking for a panel just slightly more dynamic. The designers had only to swivel around in their chairs and ask Olander, the on-site panel expert, if Morin would be willing to create a custom panel for the CHH–South exterior.

Original Morin W12 Panel (Top) and Proposed Morin Z12 Panel (Bottom)

The Process

That same day, Olander was on the phone with metal panel fabricator Bob Mohr and product vice president Scott Evans of Morin asking whether the company would be able to produce a 12-inch panel very similar to the W-12 offering, but with an additional fold in the panel profile. Mohr and Evans were immediately excited about the proposal, and less than a week later Olander had mocked up a prototype panel in his own shop.

Morin’s Fontana, Calif., facility was instrumental in taking this panel from a paper sketch to panel installation. The proposed panel was a variation on the Morin W-12 Chevron look panel. The staff at Morin was excited with the contemporary design for the highly architectural modern look.

Morin’s technical team created the profile and necessary documents for the spec with the engineering team. Morin, being a nimble niche highly specialized business, could turn around the custom roll forming tooling and be producing panels in about two months’ time. This speed to market with a completely new roll-form panel in one of the strengths of Morin as a manufacturer.

All partners quickly realized that the new panel’s potential applications ranged far beyond just one project, and Morin began talking about finding it a place in their 2018 product line. The panel retains attractive elements of W-12—dynamism, flexibility and ease of installation—but offers designers more options in terms of texture and reflection. Because of its anticipated—and since confirmed—popularity, Morin absorbed some cost of producing the rollformed panels, and the final product was provided at no extra cost to the project.

While the panel was originally considered a one-off, there was so much excitement around the panel in the region that it was quickly adopted into the Concealed Series of panels and is now available in roll form quality and lengths greater than previously done with break forming. With this addition, there are now a dozen panel profiles that can be integrated in future designs.

The Result

From eureka moment to final product, the process of creating this entirely new panel took roughly eight months, an impressive turnaround made possible by the innovation, creativity and collaborative spirit of all players.

The resulting panel was named Z-12 in homage to both the product that inspired it (W-12) and the designers that proposed it (ZGF). The extra fold provides twice the amount of faceted rigidity as the W-12 panel, creating a stronger product that still reflects light dynamically. Morin’s predictions have proved accurate: Z-12 is a highly sought-after part of their 2018 product line. So far, 41,000 square feet of the panel will be installed at CHH–South, slated to open in 2019, and will serve as a testament to the limitless possibilities created when industry players team together to make their ideas a reality.


David Staczek, AIA, is a principal at ZGF Architects, Portland, Ore. For more information on Morin Corp., a Kingspan Group company, Bristol, Conn., visit www.morincorp.com.