New igus Corporate/Distribution Facility, a Model of Building Envelope Design Flexibility and Construction Efficiency
by Jim McMahon
As companies expand their sales, manufacturing, assembly, and distribution operations, the need for streamlined, efficiently operating facilities becomes an increasingly critical factor. Such is the case with igus, Inc., a German-based manufacturer, distributor, and market leader of plastic components and assemblies integral to machine and robotics operation. Between 1985 and 2015, the company grew from 40 employees to over 2,500, and expanded to 36 subsidiary companies around the world, handling over 100,000 products. In North America alone, igus established sales and service offices in 50 locations throughout the continent. This accelerated growth necessitated an expansion and consolidation of the company’s North American corporate and distribution operations, which until recently, had been functioning out of disparate locations in East Providence, Rhode Island.
Need for a New Facility
“We had been in the same location for 26 years,” said Rick Abbate, vice president at igus North America. “Then we leased an additional building, which we ended up purchasing. Functioning out of two locations is never as good as operating out of one, and within a few years we still needed more space. So we decided to purchase another property that would accommodate our current needs, and allow us to expand incrementally as the company continued to grow.”
Igus wanted to build a greenfield facility that would maintain its North American corporate offices, sales, and light fabrication and assembly of some of the company’s product lines – like its Energy Chain cable carriers, Chainflex motion cables, DryLin linear bearings and linear guides, iglide plastic bushings, and igubal spherical bearings. The facility would also need to manage its North American distribution operations.
“In addition to our need for more space, we also wanted a much more motivating and inspiring work environment for our employees,” added Abbate. “A building that would be much brighter with more natural lighting, and more spacious, was definitely what we wanted. Now we had the opportunity to design a building that would meet our specific requirements.”
Modular Wall Panels Drive Building Envelope Design
But igus did not want a conventional corporate and distribution building design. Being a German-based company, it wanted more of a European design flare. The company’s corporate headquarters in Cologne, Germany has a very innovative and modern look, being designed by the well-known British architect Nicolas Grimshaw. A distinctive feature of that structure is its exterior modular wall panel system, which the igus North American operation wanted to incorporate into its structure.
After considerable research and evaluation of several different modular wall panel systems, igus selected the Murox building system from Canam-Buildings, a division of Canam Group, based in Quebec. One of the key distinguishing elements of the Murox building system is that it is a shop-prefabricated, exterior metal, load-bearing wall panel. Structural elements, such as columns and bracing, are integrated into the panels, which connect directly to structural steel components of the building, like steel joists and decking.
The wall panels provide architectural flexibility, allowing simple and economic relocation of panels for expansion. Because the wall panels are completely modular, when the need for building expansion arises they can be removed and repositioned into a different location, without damage to the foundation, to accommodate a modified building footprint.
“With the acquisition of this property for the new 157,000sf building, we still have space for 50,000sf of future expansion,” continued Abbate. “We really liked the idea of being able to remove a wall panel, expand the building when needed, and then reuse that same wall panel in a different part of the building, without destruction to the existing facility.”
The load-bearing panels that form the exterior envelope of the building at igus are 10 feet wide and 32 feet high. The roof joists around the periphery of the building bear directly onto the wall panels. Inside the building, joist girders support the roof joists. Use of the load-bearing wall panels eliminated the need for peripheral columns, allowing floor space along the interior walls to be completely free.
Les Architectes Odette Roy & Isabelle Jacques, located in Quebec, was retained by igus to integrate the Murox building system into a design that would reflect the company’s vision. Coordinating with Canam-Buildings, igus and D.F. Pray General Contractors, based in Seekonk, Massachusetts, the design team procured a striking and modern look for the building envelope design, incorporating the Murox panels.
“The architects did something very unique with the modular wall panels,” said Abbate. “We went with a horizontal corrugated panel system, with more of a store-front glass window design. This, combined with the aluminum color of the panels, both on the exterior and interior, gave us a timeless look that we were after.”
The architectural firm’s design also met the specifications for another igus requirement for ample natural lighting. In addition to its 160 skylights, the facility has hundreds of windows, of which the openings in the wall panels were shop-prefabricated during their manufacture.
For temperature control, the wall panels are insulated to exceed national standards, with six inches of uncompressed fiberglass batt, and with full air and vapor barriers over the entire panel surface. The panels are UL certified, one-hour fire-rated walls.
Construction Efficiencies
The design and construction of the building envelope for the igus North American corporate and distribution facility is a model for streamlined efficiency. With the go-ahead on the project, the Murox load-bearing panels went into fabrication, with installation of the panels started in September, 2013. Completion of installation was realized eight weeks later, in early November.
“One of the very appealing aspects of the Murox building system was the rapid erection capability,” continued Abbate. “Putting up the exterior walls in a matter of weeks was very impressive to us.”
Although there was much collaboration between igus, the architect, the general contractor, and Canam-Buildings in determining the specifications of the building envelope, the coordination of all technical and engineering aspects relating to the manufacture and installation of the Murox panels, and the building’s envelope, were overseen by Canam’s team of experts operating as a single project development source. The same erection team installed both the load-bearing walls and the structural steel components.
“One of the key benefits realized by igus in using the modular panels is their fabrication under controlled shop conditions,” said Larry Doyon, director of business development for Canam-Buildings. “Manufacturing these panels in-plant, instead of onsite, has ensured consistent and superior-quality fabrication for both their structural and aesthetic components.”
Another direct benefit of using the panels, for igus, was the speed-up time in construction. The fast-track shop prefabrication and installation of the panel systems allowed the other subtrades to gain faster access to the job site, thereby shortening the construction schedule and reducing construction costs.
This time-saving factor was further supported by the fact that the load-bearing wall panels eliminated the need for peripheral columns, which directly reduced time and labor requirements. Each of the load-bearing panels weighs approximately 3,000 pounds, and meets code requirements for structural resistance. At one-tenth the weight of precast concrete, less thickness and concrete is required for foundations.
“Effectively, igus realized a 50% faster installation of its building envelope because of the application of the load-bearing panels,” added Doyon.
