Sheet Metal & Air Conditioning Contractors’ National Association


Air Systems creates unique design-assist entry for internet firms’ new hub

SMACNA contractor Air Systems Inc., an EMCOR company in San Jose, Calif., recently created and fabricated sleek new entry designs for a global internet company headquarters in Northern California. Air Systems delivered the project on time and under budget—despite multiple change orders and a deluge of rainy weather.

On the three-month design-assist project, Air Systems custom-fabricated and installed a unique framing system, blackened wall cladding, flashing, sand-blasted stainless steel soffit panels, and brushed stainless steel wall fins on the client’s corporate office building.

IMG_4073Air Systems started with a small contract to design the project that turned into a very large project that provided 6,800 man-hours on the job. Air Systems credits the high-quality and true craftsmanship to the sheet metal workers of Local 104 for the project’s success.

“We received a call from one of our customers on a project they were working on, stating they couldn’t get anyone to bid this aspect of the project,” Air Systems Architectural Sheet Metal Department Manager Scott Long said. “So, we told them we’d take a look it and see if we could become involved. After site visits and meetings on what they were trying to achieve, we felt we could assist.”

“The Air Systems design team—Project Manager Brandon Klein, Superintendent Joe Lema, and General Foreman Rudy Noble—developed a design that we believed was unique, strong, and was constructible,” Mr. Long noted. “The team fabricated a mock-up for our model of the project which was favorably received by the client, and we’re pleased to say that we closed the deal.”

IMG_4072The general contractor provided the Air Systems team with a set of plans and renderings. The team worked out some rough details and built a mock-up, which was used as a basis to build the project.

“A lot of this was done by field verification and Bluebeam,” Mr. Long said. “We did some BIM modeling in the beginning, but there were a lot of obstacles to plan around, so we ended up using field calculations.”

The work originally consisted of three entry soffit features and three entry fins, all to be completed in three months. Air Systems received change orders for additional flashing, wall cladding, and stainless steel fins during the course of the project, however, the completion date did not change. Throughout the project, the weather wouldn’t cooperate; during the three months on the job, more rain fell from the skies in northern California than in the previous 25 years.

The entry design updates included:

  • Replacing weathered steel with stainless steel and blackened steel
  • Modifying fin panels to align with perforations
  • Simplifying pattern of ground plan at front porches
  • Updating material to incorporate pedestrian pavers

IMG_4163Materials used included a 16-gage shop-fabricated framing system, 4mm aluminum composite soffit panels, 12-gage perforated stainless steel wall fins, and prefinished metal flashing and wall cladding of .050 blackened aluminum.

Air Systems’ field team included General Foreman Rudy Noble and Job Foreman Trae Millett, who worked to meet the schedule date and brought the job in under budget.

A single-source provider of facility solutions, Air Systems Inc., an EMCOR company, has more than 43 years of providing total facility solutions for HVAC installation, architectural sheet metal and custom metal roofing, design services, and innovative energy solutions in the California Bay Area.

Air Systems Inc. is a subsidiary of EMCOR Group Inc. a leader in mechanical and electrical construction, industrial and energy infrastructure, and building services. Visit Air Systems Inc. on LinkedIn or their website.

Photos courtesy Air Systems Inc.

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