The Dulles Corridor Metrorail Projectis a 23-mile extension of Washington’s existing Metrorail System. Construction of Phase 1 is complete and covers 11.7 miles with five stations. Phase 2 is underway and will complete the extension with six additional stations. Upon completion, the line will provide a one-seat, no-transfer ride from Dulles Airport to downtown Washington, D.C. creating a long-sought connectivity between the burgeoning Washington corridor and the nation’s capital. The two-phase project will cost an estimated $5.683 billion.

More than 150,000 square-feet of RHEINZINK prePATINA blue-grey and prePATINA graphite-grey was used in multiple applications on all five Phase 1 stations. The 1-inch Double Lock Standing Seam Panels strategically highlight the escalator vaults, rider pavilions, pedestrian bridges and platform canopies. In addition, approximately 180,000 square-feet of RHEINZINK Double Lock Standing Seam Panels has been specified for use on five of the six Phase 2 stations which are under construction now.

Chu Contracting, Chantilly, Va., completed installation of the RHEINZINK panels on the Phase 1 stations and is the roofing contractor on all Phase 2 stations as well.  “Phase 1 was an extremely complex design and a challenging installation,” according to Ted Yim, project manager, “and Phase 2 promises to be more of the same.  The site was tight and congested and the job progressed through a very complicated schedule.”

The design for Phase 1 stations specified utilization of both RHEINZINK prePATINA blue-grey and prePATINA graphite-grey finishes. “The two different colors were installed in a complex design on the large platform canopies. The panels were positioned diagonally and interface with diamond-shaped skylights,” Yim said. “The darker, graphite-grey panels provide a dramatic accent in the intricate design.” Phase 2 stations will use both RHEINZINK finishes as well.

The RHEINZINK distributor/fabricator on Phase 1 was MetalTech—USA, Peachtree City, Ga. The distributor/ fabricator on Phase 2 is Dimensional Metals Inc., Reynoldsburg, Ohio.

“It’s been a four year process to get the job to the point where we’re about to begin making panels,” according to Dan Begley, territory manager. The panels will be fabricated at Dimensional Metals’ plant in Ohio. “These are our DL-1020 panels which have a 1-inch seam height and 20 inches width,” Begley said. “We’re fortunate that the roofer (Chu Contracting) also did the Phase 1 installation and are really experienced at this. There’s a lot of challenges on a project of this size and we have a great three-way partnership with Chu Contracting and RHEINZINK America.”

Begley also pointed out the long-term nature of zinc. “These stations will be around for a long time based on their utility,” according to Begley. “RHEINZINK is really a good value, particularly when you look at the lifespan. And it’s obviously a very aesthetically pleasing material. These stations are going to look great for a long time!”

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