With a surge in demand for clean energy solutions ranging from electric vehicles to solar energy, companies are making significant investments in new technology and manufacturing capacity. Situated in the heart of North Carolina, Siler City is the site of Project Hibs, a cutting-edge chip manufacturing facility.
The project will take place over two phases with the first to be completed in late 2024. By 2030, the new facility is expected to generate up to 1,800 new jobs in central North Carolina. To meet the tight deadlines that large scale construction projects like this require, BZI paired their cutting-edge panelization techniques with energy-efficient, all-in-one insulated metal panels from Metl-Span. As a Nucor IPG brand, Metl-Span has the resources and willingness to collaborate that made this partnership a success—ensuring timely delivery for the first construction phase while achieving cost savings, especially compared to other wall alternatives.
a tight, weatherproof fit. Photo by: Impatient Cow Productions
Â
Construction Efficiency And Building Performance
For large-footprint buildings like Project Hibs, Metl-Span insulated metal panels can be the perfect solution. This versatile product features a clean look on the inside and outside, a high R-value that reduces energy usage while providing greater sustainability, and cost improvements versus concrete alternatives like tilt-walls or pre-cast.
Design teams specified Metl-Span CF Striated metal panels. These panels are an appealing alternative to typical flat wall panels. With an exterior face that is lightly profiled with narrow longitudinal striations, they create a subtle shadow effect while exhibiting a virtually flat appearance from a distance. The longitudinal striated metal panels offer an exceptional value, combining the aesthetics of a flat wall panel with the high insulation ratings of an insulated foam core.
numerous panels at once, slashing installation timeÂ
by 30%. Photo by: Impatient Cow Productions
Â
How To Improve An Already Innovative Product?
While IMPs offer numerous advantages to owners, architects and general contractors, installation methods have remained relatively unchanged for decades. Until now.
The collaboration between the BZI and Metl-Span teams brings to the market a game-changing new approach to IMP installation. Traditional “stick-build” IMP construction requires installers to attach panels directly to the structural steel. BZI, an industry-innovator in steel erection, brought a very different mindset to this project. “BZI's innovative approach combined with our IMP system is a great marriage, offering owners a building solution much faster than traditional methods,” says Joe Calsada of Metl-Span.
With state-of-the-art, proprietary innovations like the IMP Panel Table™ and the Wall Master™, BZI is deploying an all-new panelized approach, where the majority of the work is performed at ground level, drastically improving both safety and efficiency.
These machines enabled teams to assemble large sections of panels on the ground away from active areas of the jobsite and then carry them to the installation area. Since wall sections can safely go up faster, owners can start bringing in revenue earlier once the project is complete.
on the BZI IMP Panel Table™. Photo by: Impatient Cow Productions
Â
Innovation Powered By Collaboration
Through extensive cross-team collaboration and communication, BZI and Metl-Span developed plans, engineering details, and the necessary calculations to ensure the Metl-Span product would perform flawlessly in this new panelized approach. “No one really has a set of details that covers modular construction like we’re doing here at Hibs,” explains Jacob Gillip of the BZI Wall Division. “[the manufacturer] that expressed the most willingness to work out those details and to work out a system with us was Metl-Span.”
The BZI and Metl-Span teams worked together to understand the needs and limitations of the product. That teamwork led to a new way of installing insulated metal wall systems—a solution that both the customer and the architect are very excited about. And with similar core values across both organizations —innovation, safety, trust, and communication—it's a partnership you need to see for yourself.
A New Partnership In Panelization
In lieu of installing the IMP conventionally, this new panelization process helped reduce scheduling conflicts with other trades and reduced the overall construction schedule for the wall phase by 30%. BZI also provided engineering services to provide the client with a delegated design for the IMP support and panel, greatly improving coordination with the trade partners and saving on overall costs of the project.
Robert Hale perfectly sums up the result of the partnership. “Because of all that collaboration that Metl-Span put in, we have a great product that right now the customer and the architect is very excited about.”
Discover what benefits Metl-Span IMP wall systems can provide for your next project. Reach out to schedule a call with a Metl-Span representative today.
