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The Alcoa World Headquarters Building

A beautiful sky view of the Alcoa Building adjacent to the shore of the Alleghany River shows the unique design of this aluminum and glass constructed building. Built in 1998, the building houses the World Headquarters of Alcoa Corporation.

Historians and Archeologists have given names to eras in the past. We are all familiar with the terms such as the “Copper Age”, “Bronze Age” and the “Iron Age”. But what most of us probably don’t consider is the fact that future historians and archeologists will most likely look back and refer to the times we live in now as, “The Aluminum Age”.

When the word “aluminum” comes up, most Americans think “Alcoa”. It is a logical progression, seeing that Alcoa has been manufacturing aluminum since 1888 and is the leading producer of the metal in the world. In all likelihood, this same progression will be made long into the future. Aluminum is the most durable metal in use today. Approximately 660 million tons have been produced and of that 440 million tons is still in use. And Alcoa is most probably the most durable manufacture of the metal, leading the world in production with their 127,000 employees in 41 countries and annual revenues of over $20 billion per year.

The Chief Engineer recently visited the World Headquarters of Alcoa in Pittsburgh, Pennsylvania to report on a beautiful and unique building that the company constructed along the north shore of the Alleghany River. Built in 1998, the exterior of the structure is primarily aluminum and glass, and stands out from the city’s skyline like a diamond on the finger of one of the three great rivers that converge there.

Constructed at a cost of around $65 million, the exterior facade of the six story building was designed in the shape of a wave or “S”, maintaining a stylish harmony with the adjacent river or, perhaps, an unintended but classic Feng Shui design, omitting sharp angles and inviting nature’s forces or “chi” to energize the structure and its occupants.

The modern look and feel of the building somewhat parallels the modern uses of the metal upon which Alcoa has built its fortune. Copper has been in use by man for over 7,000 years, bronze for over 4,000 years, and steel and iron for over 3,000 years. But aluminum, although unwittingly used in its raw form within pottery by ancient Persians, Egyptians and Babylonians, and despite it being the most abundant metal found on Earth, was actually only discovered and named in 1808 by Sir Humphry Davy. Today, less than 200 years following its discovery, aluminum has become ubiquitous within our lives and is found in countless products we use every day. The nearly indestructible durability of aluminum, as well as the lightweight and heavy strength of the metal, makes it ideal and essential for modern manufacturing. Indeed it could be said that aluminum has played the key role in ushering in the high-tech civilization we live in today.

As for aluminum in building structures, it has been around longer than most people may think. In fact, in 1884, the pyramidal shaped cap placed on the top of the Washington Monument was constructed of aluminum. And knowing the durability of the metal, it is not too surprising to learn that the original aluminum cap placed on that monument is still there.

Entering into the Alcoa Corporate Center, we were immediately taken by the immense 6-story atrium that allows light to bathe visitors through the roof skylights. The open feel of the main entrance also belies the open theme design that was incorporated throughout the building. Adorning the walls in the main entry were beautiful wood paneled walls constructed with a fire retardant particleboard core and a natural Anigre veneer. The African wood veneer gives an immediate richness to the structure as well as a warmth that keeps visitors from experiencing the usual lost openness feel experienced in most large atrium areas. Attention to detail is evident in the building’s design as we traced the Anigre veneers wood grain from panel to panel, giving continuity to its flow throughout the towering walls.

Jim Sams, Chief Engineer of the facility, met us upon our arrival at Alcoa. We learned that C.B. Richard Ellis Company managed the property for Alcoa and Jim and all other maintenance employees worked for C.B. Richard Ellis under contract at the facility. Jim ushered us into a spacious conference room off of the main entrance where we began our visit by having him explain to us how Alcoa’s World Headquarters building came into being and how his crew maintains the beautiful building.

Under Alcoa’s former CEO, Paul O’Neill, a decision was made to construct the new headquarters, Jim told us. “Mr. O’Neill believed in maintaining communications among all Alcoa employees,” he continued. “This belief led to the open design concept within the building. No one is more than 40 to 50 feet away from the outside,” Jim related. “It was part of Mr. O’Neil’s vision to have a wide open atmosphere within the building”. This, Jim said, translated itself into the floor to ceiling glass walls designed and constructed throughout the structure.

In the conference room we met in, this concept was apparent as we sat in leather chairs surrounding a large table, which was in-turn surrounded by exterior glass walls that gave one the impression of sitting outside in a courtyard rather than within a corporate conference room.

Mr. O’Neil also believed in a corporate team concept according to Jim. Eighty-one square foot cubicles were installed for most employees to facilitate communication exchange among employees. In addition, corporate divisions were placed within the building to facilitate contact and quick response among interdependent departments. “No consideration was given to corporate hierarchy,” Jim said. “It all depended upon how one department interfaced with another in determining where they were placed within the building”. In January of 2001, Paul O’Neil left Alcoa to become the US Secretary of the Treasury.

The most remarkable aspect of the building is its intent to harvest sunlight. All glass used in the exterior windows are of Pittsburgh Plate Glass’, Starfire brand, with no shading or tint. The glass, Jim explained, is of maximum purity and near optical standards. Automatically, shades will rise or lower in sync with sunlight to assist in managing sun load.

The 450,000 square foot interior of the building is surprising easy to heat, Jim told us. “The sun load with all the glass assists us there,” he said. “We do on occasion have to run our chillers in the early months of January and February,” he related. This being the apparent trade off from the harvested sunlight.

The buildings central plant is equipped with two McQuay chillers, one a 400-ton dual compressor unit and the other a 200-ton single. To heat the building, 3 Ajax high temperature hot water generators are used, each with a 1.5mm/Btu capacity.

Jim works with a staff of six Operating Engineers and one carpenter, all employees being represented by the International Union of Operating Engineers, Local 95. Together they maintain the Alcoa headquarters building as well as four Alcoa leased floors in a nearby building.

“The building sometimes operates 24- hours per day,” Jim said. “When outside temperature and humidity require”. Normally, Jim told us, the building will shut down around 7 p.m. at night.

The building automation system is a Seimens Apogee operating on an Ethernet. In addition, a General Electric automated lighting system is also incorporated into the building facility management scheme.

Baltimore brand air handlers are used in the building with a unique floor fed ventilation system. The open concept of the building requires the unique floor duct construction that according to Jim allows for changing floor layouts with a minimum of HVAC change. The building HVAC system is divided into three zones that work in concert with the sun load as it changes throughout the day.

According to Jim, A Clearwater Dolphin water treatment system was installed in the building 6 years earlier. “We have had very good luck with the system,” Jim said.

For emergency use, a 1 Megawatt, Caterpillar diesel generator is kept in stand-by at the facility.

Leaving the conference room, Jim led us on a tour of the building. We were taken to the glass enclosed elevators, which admittedly took us a few moments to become accustomed to, as we ascended in an open-air atmosphere to the upper levels of the building.

As we walked through the impeccably maintained facility, Jim explained to us that the training provided to the maintenance staff by Local 95 had allowed them to stay on the cutting edge of maintenance technology, which has resulted in significant energy and maintenance savings for the building. In addition, he told us how Alcoa’s commitment to safety on-the-job has gone hand-in-hand with the IUOE Local 95 continuing safety education classes and has virtually eliminated worker injuries among his staff. In-fact, Jim told us, it had been over nine years since they had experienced an incident at the facility.

Everywhere we visited within the building we were impressed by the cleanliness and orderliness of the maintenance and engineering spaces. As we encountered staff members, we were equally impressed at their professional appearance and knowledgeable response to our questions.

Upon concluding our tour, we felt that we had just visited one of the more unique buildings within the United States and had visited with one of the finest maintenance and engineering crews we have had the pleasure to meet.

We left with a newfound respect for the metal of our age and the Alcoa Corporation that produces it. But we also left knowing that the durability of aluminum was equally matched by the dedication of the C.B. Richard Ellis engineers who manage the Alcoa world headquarters.

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