254 Front Street – Zinc Facade System
Located in the South Street Seaport Historic District of New York and in the shadow of the Brooklyn Bridge, The design of this 41 unit rental apartment building is clad in corrugated zinc panels and double-hung windows are made from mahogany. Beside this is another portion of the site that the owner acquired during the course of design. Rather than simply extending the design for the zinc façade, this second building is similarly proportioned in brick with aluminum window frames so that the entire building mass remains in keeping with the scale of the 19th century buildings in the immediate context.
Maloya designed the entire zinc façade system and aluminum framing system using 3D modeling. The design of the paneling system was especially complex due to the dissimilarity of the various components that needed to be fabricated. To solve this challenge, Maloya designed a spreadsheet driven program to aid in driving the CAD software. In addition, Maloya designed custom tooling to facilitate the fabrication process. In order to maximize the efficiency of the installation process Maloya created a parts and skid numbering and marking system to indicate where each panel would be installed by floor and elevation.
Landmarks building requiring custom interlocking zinc panels
Building envelope required high quantity of unique panels sizes and shapes.
Developed interlocking panels and had custom bending tool made for high tolerance fit.
Used design tables to drive SolidWorks models to build all the unique configurations