How Malone Roofing Delivered Excellence in ACM Panel Installation
Project Highlights
- Square Footage Installed: 29,000 square feet of ACM panels.
- Timeline: Six months from start to finish, including two months of fabrication and four months of phased on-site installation.
- Column Covers Fabricated: Over 60, with some extending beyond 30 feet.
- Project Value: Estimated between $1 million and $2 million.
- Architectural Adjustments: Collaborated to realign oversized panels and resolve design omissions, ensuring the project met its aesthetic and functional goals.
Client & Project Overview
Baldwin Academy, a public school near Mobile, Alabama, embarked on a transformative project to enhance the school’s visual appeal and functionality by revitalizing its exterior façade. Malone Roofing was selected as the subcontractor thanks to their long-standing reputation for delivering high-quality metal wall systems and ability to navigate large-scale, publicly funded projects.
Malone’s multi-faceted role involved designing, fabricating, and installing approximately 29,000 square feet of aluminum composite material (ACM) panels. The project, valued between $1 million and $2 million, was completed over six months, including two months of fabrication and four months of phased on-site work, during which Malone leveraged advanced CNC machinery, 3D scanning technology, and a proprietary fastener-free system to ensure a resilient and modern aesthetic.
Overcoming Challenges
Like any construction project, Baldwin Academy presented a variety of challenges that tested the limits of design, coordination, and craftsmanship.
In one example, the architect’s original design included panel sizes that exceeded material constraints. Fortunately Malone’s team identified these discrepancies early and collaborated closely with the architect to realign panel joints so that both structural integrity and aesthetics were in no way jeopardized.
Another complexity stemmed from the directional finish of the ACM material. Each panel’s paint finish required precise orientation to achieve a uniform appearance without any gaps, and Malone’s unparalleled attention to detail ensured this was done without impacting quality or any project timelines.
On-site challenges included unanticipated design omissions. Electrical wiring meant to run behind large column covers — some exceeding 30 feet in height — had not been fully incorporated into the design. Malone coordinated with the general contractor to temporarily remove and reinstall panels and enabled electricians to complete their work, once again proving their ability to adapt quickly to unforeseen circumstances while keeping the project on track.
Craftsmanship and Collaboration in Action
Malone’s involvement extended beyond installation, starting with their proactive role in the design phase. Their team provided critical input on panel joint alignment, field measurements, and specifications for material limitations. They also created physical mockups to refine the project’s signature Baldwin Blue color for the column covers and Cadet Gray for the wall panels
Fabrication, as always, was a meticulous process. Each panel and column cover was custom-crafted using advanced CNC machinery formed to meet precise specifications. Malone’s proprietary system concealed all fasteners to deliver a clean and polished look. These panels were then uniformly aligned with other architectural elements, including windows, louvers, and structural joints.
The team also utilized 3D scanning technology to guarantee ultra-accurate measurements and eliminate discrepancies between the building’s field dimensions and the original design drawings. These scans were critical in adjusting layouts and ensuring the panels fit perfectly upon installation, minimizing delays and rework.
Key Milestones
- Perfecting the Midnight Blue Finish: Physical mockups ensured precise alignment with the architect’s vision, establishing a bold and unique color for the building.
- Fastener-Free System: Malone’s proprietary system provided a polished appearance that elevated the overall design.
- Adaptability in Action: Addressed unforeseen issues, such as reworking panel joints and accommodating late-stage electrical installations, without derailing the timeline.
- Continued Collaboration: Trust earned from the architect and contractor led to additional projects, including a large-scale school in Florida and a military base project in Pensacola.
Process & Lessons Learned
The Baldwin Academy project underscores the importance of early-stage collaboration and adaptability in delivering the highest quality of work possible. By addressing design challenges proactively and maintaining open lines of communication with architects and contractors, Malone once again proved that a consultative approach is the key to success. Their expertise not only resolved issues but also elevated the project’s overall quality.
The completed Baldwin Academy project is a shining example of what can be achieved through collaboration, innovation, and meticulous craftsmanship. The building’s exterior now combines striking visual appeal with functionality, meeting the rigorous demands of a public institution. Despite challenges, Malone completed their portion of the work on time and within budget, leaving a lasting impression on all stakeholders.
Crafting Success with Malone Roofing
Malone Roofing’s expertise spans the entire lifecycle of a project, from consultation to fabrication and installation. Their commitment to quality, precision, and collaboration ensures that even the most challenging projects are delivered with excellence. The Baldwin Academy project is a testament to their ability to transform visions into reality, leaving a legacy of innovation and trust in their wake.
Client Testimonial
“This was my first project designing with ACM panels, and I was initially hesitant due to the complexity of a large-scale metal wall project. Malone’s team, however, made the process seamless. They provided innovative solutions, maintained open communication, and delivered a flawless product that has exceeded our expectations. Their adaptability and expertise have truly set a new standard for quality.”
– David C. Adams, Architect at Adams Stewart Architects