The Sterling Mason

custom milled aluminum facade

The Sterling Mason project encompassed a unique and never attempted before challenge: To emulate the traditional masonry construction of a local landmark with modern materials. Ferra Invented techniques and methodology to achieve precise representation of the original neighboring building and manufactured specialized tooling to ensure a linear and predictable schedule for completion. Facade detailing rendered in a matte metallic finish.

The base of the facade mimics it’s neighboring limestone masonry, employing a marine grade aluminum panel with CNC-milled patterns. The material is finished with a plasma flame spray involving a mixture of nickel and stainless steel powder.

CLIENT Taconic Partners

CM Sciame Construction

ARCHITECT MA Architects

SECTOR Residential

LOCATION Tribeca, NYC

SERVICES Design Assist, Fabrication, Installation Management

MATERIALS Marine Grade Aluminum

A lap jointed panel system allowed for a mechanical assembly method with all fasteners hidden from view while staying true to the traditional masonry techniques, laying one piece at a time.

A custom mounting armature system was designed using 3D modeling and careful structural analysis of its performance.

To marry the spirit and character of the turn of the century stone with CNC machined metals, Ferra devised a high-spec thermal sprayed finish giving the surface an organic roughness matching the brick of the neighboring building. Craftsmen hand burnished each and every component by hand to achieve the desired metallic luster and texture envisioned by MA Architects.

This new 33-unit condominium in New York’s historic Tribeca neighborhood is composed of two buildings, a restored and converted 1905 coffee and tea warehouse on Washington Street and a matching addition on Greenwich Street. The new building produces a “double negative” effect, with identical facade detailing rendered in a matte metallic finish. Warehouses in the district often were extended as their needs for more space grew. These additions would often mimic the style of the original warehouse. The base of the facade mimics it’s neighboring limestone masonry, employing a marine grade aluminum panel with CNC-milled patterns.

“The use of premium material and finish for the ground floor of the building maximized its exposure to passersby.”

— THE ARCHITECTS NEWSPAPER