SAF, a global metals distributor, fabricator, anodizer, and finisher recently played a critical role in the complete retrofit of the Harrison PATH train station in Harrison, N.J.

Constructed in 1936, the original station featured a cramped design and lacked accessibility for those with disabilities. The project goal was to revive the train station to provide greater, easier access for all travelers through a bright and modern architectural design.

The defining architectural characteristic of the new Harrison PATH station comes from the large-scale, curving glass curtainwalls secured via a series of vertical, horizontal, and diagonal columns and beams. For the main vertical columns, the team at BAMCO Inc. selected SAF to fabricate a series of intricate column covers that required them to manufacture a litany of components with complex geometries.

The project included 8,900 square feet of more than 600 individual metal panels and column cover components. The main, oversized vertical columns at the front of the structure are encased in SAF’s M-2000 1/8” aluminum column covers.

“At the time of the project, BAMCO had limited capabilities of roll forming panels that exceeded 10’ lengths, so we needed to rely on a company that was capable of fabricating the oversized columns for the project,” said Ryan Kusmick, project manager at BAMCO Inc. “We have worked with SAF in the past, and given the complex geometries of the design, we wanted to go with a competent fabricator that we were comfortable with. We didn’t want to give a project with this level of difficulty to an unknown, first-time vendor.”

“We were proud to serve as a partner on a project of this size and scope, and we know that our work enabled the architectural team to bring their vision to life so that Harrison PATH can continue to serve train passengers for decades to come,” added John McClatchey, vice president of sales and marketing at SAF.

SAF had to carefully engineer the column covers for the train station so they could accommodate various penetrations and cutouts that serve as connection points for the intersecting beam structure. In addition, the ground-floor portions of the column covers feature rails for vertical sliding doors. This was yet another complexity to take into consideration during 3D modeling and fabrication, one that needed to be executed flawlessly to allow for the doors’ operation. The SAF column covers are painted in a Fluropon Special White PVDF finish. Fluropon coatings are long-lasting and maintain their color consistency, making them ideal for exterior applications such as those for Harrison PATH.

“The Harrison PATH station was a difficult project in terms of engineering and design. We scanned the as-built steel structure with the help of Kennon Surveying Services, Inc., who laid out the point cloud data. Microdesk then took this data and created the BIM model,” Kusmick added. “That information was all unfolded and relayed to SAF, who delivered on the design. We are very pleased with the outcome.”

The northeast and southeast station houses were completed and officially opened at the end of 2019. Construction of the southwest and northwest station houses is scheduled to commence in 2022.

In addition to SAF, the project team included contractor BAMCO Inc.; land surveyor Kennon Surveying Services, Inc.; BIM modeling company Microdesk; glazing contractor County Glass & Metal; engineering professional services firm WSP; architects Dattner Architects; and the Port Authority of New York & New Jersey (PANYNJ).