10 Questions on Product Design
With Mike Maguire, Senior Designer, AGT

Describe your role at AGT – When do you come into the project development process?

My role is Design Development.  I work between estimating and pre-engineering to make sure that the way a project is sold, is buildable.

I get involved as early as possible, during the estimating and budgeting process, on the more custom jobs.  I help to determine if we will use our standard system to meet the architect’s design, or if it makes more sense to develop a completely custom system.

I spend a lot of time up front with the architect helping them with their design so that there are no pitfalls along the way.

How does design at AGT blend design flexibility with more rigid engineering requirements?

We have our own structural engineer in house, which allows collaboration between design and engineering.  That way, we clarify what the design intent on the project is.

I continue working with the structural engineer during the design process to guarantee the structural requirements, performance characteristics (air, water, aesthetics) and constructability.

How can you accommodate an architect’s requirement for unique design, using a standard system for skylights or curtain wall?

Our system is designed as basic components that allow for a pretty wide range flexibility in the ways that the pieces can be put together.  Sometimes, we’ll use the standard system, and develop just a single component, like a custom end cap, to meet the architect’s specific aesthetic requirements.

Fortunately, we can accommodate custom components without the set up time required in a traditional manufacturing environment, since our engineering software is directly linked to computer aided manufacturing equipment.

The final product is ultimately simpler and more efficient, since we’re developing that specific part from the ground up, rather than trying to force a standard component to fit where a custom one should be created.

Is it possible to build groundbreaking design while adhering to a budget?

Yes.  For all of the complexities of a project like the Peabody Essex Museum, there is a lot of repetition in framing components and glass panels.  We find the ways to get efficiencies out of the production of these components.

When we developed the skylight for the MBTA station in Boston, we helped to meet the construction budget by incorporating flat glass in a way that makes it look like curved glass.  We did that by sharing our 3D models with the architect early on.  They were able to change their framing pattern to allow for the use of flat glass, without having to change the overall shape of the skylight.

What are the most important issues for architects to consider when designing custom skylights and curtain wall?

They should know that nothing is out of the question, and with unique design, it is most helpful to work with a design and engineering team that has done complex work in the past.  At AGT, we take these complex projects on as a personal challenge.  In many of the jobs that we’ve worked on in recent years, such as the Peabody Essex Museum, the architect had been previously told that it was impossible to build their design.  By doing all of our design in 3D, in a collaboration with the architect and our in-house engineering, we can often deliver just what they want.

The other thing that the architect should know is that unique design doesn’t have to cost a fortune.  Our CNC manufacturing environment allows us to retool for custom extrusions without the kind of set up costs normally associated with this approach.  The bottom line is that you shouldn’t have to settle for someone’s standard system if you’re looking to achieve something truly unique.

What should contractors and installers know about the differences between building with custom glass structures vs. standard construction?

When it’s a custom structure, it gives the contractor and the installer to have a lot of input into the design up front.  This is especially important when it comes to things like the anchoring system.  We can work together to make the system very efficient for that particular job, rather than trying to force feed an existing anchoring approach to a unique application.

Which skylight or curtain wall jobs have been the most challenging/rewarding for you?

The Peabody Essex Museum for the uniqueness of its geometry.  It really required mathematical gymnastics to get that one right.

For curtain wall, it would be the Blue Tower in New York City.  The geometry required in the plane changes of each of its exterior walls, and the different patterns of colored glass both required a lot of planning and logistics.  We created product management systems to cross reference patterns, and ensure that they were manufactured and delivered in the right order.

The Kimmel center was another favorite for its sheer size.  On a job of that size, if you can save 1/8” of silicone, it adds up to $300,000 in savings to the owner.  

In your view, what are some of the most impressive changes in the building industry over the last 10 years?

- The use of glass as a structural component.

- Green buildings with LEED certification.

- The use of photovoltaic panels glazed into skylight frames.  We’ve done a couple of jobs with them so far, and I’m hoping to do more.  They’re still a bit too expensive for consideration on many jobs, but we’re looking to take the lead on them and we’re hoping that they will become more common place in time.

What are the most common myths and misconceptions about building with glass?

A common misconception is that all skylights leak.  The connection between the skylight and the roof is the control point.  If it is designed and installed properly, any water will be managed by the gutter system – even in a catastrophic situation.

How do you accommodate for geography in your design?

Most often, we adjust glass thickness, glass make-ups, and rafter depths to accommodate the seasonal loads that they will need to support.  We can also build panels and install them in stages to help installers manage their schedules.

On the Natick Mall, for instance, our panels were glazed to be installed in the winter time, and we waited until spring for installation of the weather seal.  This allowed the installer to close the building envelope and keep on schedule.

Learn More:

Contact our Sales Department to learn more about this topic, or to obtain additional information about our projects and services.

Read more Q&A interviews