Balancing Performance and Aesthetics with Metal Panels

Metal Panels at the Saratoga County Airport

By Abishek Shah – Project Manager, Performance Contracting

As airports evolve into architectural gateways for their regions, material selection becomes a critical factor in balancing aesthetics, performance, and durability. At the Saratoga County Airport in New York, PCI collaborated with project partners to deliver a metal panel system that met high-performance demands, harmonized with the upstate New York context, and stood up to the rigors of construction and climate, all on a tight timeline.

The Opportunity: Sleek Form, Smart Function

Metal panels offered the perfect solution for the airport’s transformation. The design team aimed for a contemporary, resilient façade that echoed the natural surroundings of the Adirondack region while signaling progress and modernization. The selected single skin metal wall panels, in a clean, modern profile, were paired with slate tiles, mass timber, and curtain wall glazing to create a high-performance envelope with architectural depth.

Metal panels provided the versatility needed to bring the design to life. Flat and ribbed profiles, crisp lines, and durable finishes allowed the architect to play with texture, light, and shadow, adding richness and movement across the building’s surface. Their modular nature and precise fabrication enabled refined detailing and a consistent, high-quality finish.

Performance in a Demanding Climate

Upstate New York’s weather presents real challenges for building materials, including extreme cold, freeze-thaw cycles, snow, wind, and UV exposure. Metal panels were selected for their proven durability in these conditions.

Key performance benefits included:

Corrosion-resistant finishes with excellent UV stability
Lightweight construction to reduce structural load
Tight detailing that enhances airtightness and thermal performance
Long-term reliability with minimal maintenance

At the Saratoga Airport, the panels themselves were single skin, but careful attention to joint detailing, weather barriers, insulation and air sealing helped deliver a high-performing envelope. Strategic coordination between PCI and the project team ensured moisture control and minimized air leakage, key to year-round comfort and efficiency.

Speed and Precision on a Tight Timeline

One of the standout benefits of metal panels is installation efficiency. At Saratoga, panels were prefabricated and delivered to the site, ready for installation, which accelerated the building envelope schedule and avoided costly weather delays.

Despite winter conditions, PCI’s field team maintained steady progress in coordination with the general contractor. Prefabrication meant reduced on-site waste, faster enclosure, and predictable sequencing, all of which are critical for a public project with fixed deadlines.

Seamless Integration with Adjacent Systems

A key success factor at Saratoga was the seamless integration of metal panels with curtain wall systems, entrance glazing, and roof assemblies. Panels were carefully detailed and installed to ensure clean transitions and continuous performance across the envelope.

Metal panels are uniquely suited to these types of high-performance interfaces. Their fabrication precision allows for exact tolerances at corners, parapets, and openings, ensuring drainage, air and moisture control, and a clean, refined aesthetic.

A Successful Outcome

Despite the project’s complexity, which included detailed coordination and winter construction, the result is a crisp, durable façade that enhances the airport’s role as a regional gateway.

At PCI, we specialize in envelope systems that strike a balance between design, performance, and long-term value. The Saratoga County Airport is a strong example of what metal panels can achieve when installed with care, coordination, and craft. As public and private clients continue to demand smarter, more resilient building solutions, we’re proud to help push the envelope, literally.

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