At Northeastern University’s Portland campus, home to the Roux Institute, Alfond Center, the building’s radiused footprint, 14-degree slope and prominent cantilever created a highly complex custom unitized curtain wall system comprising 1,472 prefabricated units. Because of the building’s curved geometry and cantilevered design, every curtain wall panel was uniquely engineered and fabricated.

By engaging a design-assist façade partner nearly two years before installation began, Consigli enabled early collaboration among architects, engineers and fabricators to coordinate structural tolerances and installation sequencing. Through advanced 3D modeling, the team integrated structural steel, concrete and façade fabrication models to identify clashes and evaluate compounded tolerances long before production started.

Once the design was finalized, the team completed both a visual mockup and a full-scale performance mockup in Italy, where the curtain wall system underwent rigorous testing for air infiltration, water penetration and structural performance. With half-inch installation tolerances of at anchor locations and approximately one inch between panels, every connection point required precise verification before the overseas-manufactured units arrived on site.

The successful installation of the façade reflects more than two years of planning and problem-solving to transform a highly complex design into a constructible reality.