Undulating Metal Waves Create Modern Façade

The new David L. Conlan Center at Atrium Health’s Carolina Rehabilitation Hospital in Charlotte, N.C., is the first step in the modernization of the Atrium Health Carolinas Medical Center campus and sets the stage for future expansion.

Designed by NBBJ, the new, state-of-the-art facility anchors the Carolina Rehabilitation’s new flagship facility and replaces a structure built in 1950. Opened in January 2023, the five-story, 150,000-square-foot facility features 16,000 square feet of inpatient and outpatient therapy space, 72 patient rooms, private treatment spaces, an aquatic therapy program, an outdoor therapy garden, and a center for independent living.

The one-of-a-kind regional rehabilitation hospital is thoughtfully designed with the latest technology and programs to better serve patients and the surrounding communities. The cutting-edge hospital offers many unique services, such as certified programs for spinal cord injury, traumatic brain injury and cancer. The physical medicine and rehabilitation clinic treats patients with a variety of needs, in addition to offering an OB-GYN clinic for people who regularly use wheelchairs. The Adaptive Sports and Adventure Program is a one-of-a-kind resource for the region, offering new ways for people with mobility impairments to enjoy tennis, kayaking, rugby and more.

A Modern Metal Exterior

To create a modern exterior for the building, the façade features silver metal panels that ripple down from the top of the building to the ground level. The undulating waves of multifaceted panels wrap around the entire building, connecting to create arrows and unique angles for a truly modern design aesthetic.  

MillerClapperton fabricated and installed 52,000 square feet of 3A Composites USA Inc.’s ALUCOBOND PLUS metal composite material (MCM) panels in West Pewter in its System 1500 rainscreen attachment system, as well as 4,000 square feet of Fabral Inc.’s Hefti-Rib exposed fastener corrugated metal wall panels in Silversmith. Approximately 1,500 MCM panels were used for the project, which included the entry canopy and column covers. On the rooftop, the Hefti-Rib metal panels were used to conceal a mechanical equipment room.

The MCM panels were fabricated in various wave patterns that were tapered and joined together to create an arrow shape. During the design stage, extra time was spent to ensure lines were maintained where the two-facet and three-facet panels were connected to flat wall panel areas to achieve the desired aesthetic. The three-facet panels have seven unique gussets to maintain the tapered effect, while the two-facet panels use custom extrusions cut to size to maintain the angle and help the panel hold its shape during installation.

The metal panels were installed over Advanced Architectural Products LLC’s thermally broken, insulated composite GreenGirts sub-framing. Prior to the panels being installed, the framed wall sections were hoisted into place. Thorough coordination with the general contractors, DPR Construction Inc. and Rodgers Builders Inc., allowed MillerClapperton to forgo field measurements and build directly offer the approved shop drawings, reducing the overall duration of the project by cutting out up to six weeks for each defined area. Additionally, more than 99% of the panels fit with no complications.

LOCATION

Charlotte, NC, USA

BUILDING OWNER

Atrium Health

CONTRACTOR

DPR Construction Inc. and Rodgers Builders Inc.

MANUFACTURER

MillerClapperton, 3A Composites USA Inc

SIZE

150,000 square feet

DATE COMPLETED

January 2023