When German steel manufacturer ThyssenKrupp broke ground on its new U.S. mill in Calvert, Alabama, the development stood out for its massive scale, spanning 150 acres and representing a $3.7 billion investment in U.S. manufacturing. But early in the design phase, the cost of the original exterior cladding, channel glass, put the project over budget. To maintain the desired aesthetic while controlling costs, the team turned to EXTECH.
EXTECH responded with a custom-engineered solution: the LIGHTWALL 3100LS system. Designed to deliver the sleek, daylight-filled look of channel glass at a fraction of the cost, the 3100LS is a structural standing seam wall system that spans large exterior surfaces with minimal support. Its patented two-piece aluminum clamping mullion and internal gasketed water stop provide long-term performance in demanding environments.
Specifically engineered for coastal and industrial conditions, the 3100LS meets stringent wind-borne debris and cyclic pressure testing standards. Its resilient and clean appearance made it the ideal solution for ThyssenKrupp’s climate and design priorities.
The system helped reduce façade costs by 66 percent compared to the original specification. The completed installation covers over 310,000 square feet and includes nearly 40 linear miles of aluminum mullions, making it one of the largest cellular polycarbonate glazing applications in North America.
As the final featured project in EXTECH’s 50th Anniversary series, it exemplifies the scale, innovation, and trust that have defined five decades of daylighting solutions and continue to guide the company’s future.
