Birdair Turns Complex Design Vision into Reality at Breathtaking New Under Armour Global Headquarters
Baltimore HQ features 21,000 sq. ft. of Birdair’s single-layer TensoSky® ETFE film
Birdair, the world’s leading specialty contractor for custom tensile membrane structures for over 65 years, helped bring an innovative, game-changing design vision to life at the new Under Armour Global Headquarters in Baltimore through the installation of a 21,000 sq. ft. single-layer TensoSky® ETFE façade system. The façade system helps enhance the building’s striking glass envelope while delivering cutting-edge design and aesthetic appeal.
Technical Expertise Meets Innovative Design
Through a collaborative, iterative design-assist process with the project team – including Gensler Architects and general contractor Whiting Turner – Under Armour selected Birdair’s TensoSky® ETFE film for its transparent lighting advantages to change the dynamic look of the building.
Birdair’s project scope included design, engineering, fabrication and installation of the signature single-layer ETFE membrane with a customized frit print pattern, associated clamping hardware and the structural steel arched framing system featuring a tapered projection weighing a total of 105 tons. This intricate framework required meticulous coordination to ensure seamless integration with the building’s striking design and the iconic Under Armour branding.
To meet logistical demands, all components were designed to fit into 40-foot cargo containers for transport from fabrication facilities overseas. On-site, the assembly required detailed planning for lifts involving both tower and mobile cranes as well as innovative techniques to distribute weight across the green roof’s restricted load capacity.
Mike Sparks, Vice President of Construction at Birdair, explained some of the challenges and precision required on the project.
“Final lifting is done with one crane, but you need two cranes to rotate the pieces vertically and get them in place, which made this a critical lift,” he said. “We had to start with the second truss in and stabilize back to the building so the pieces didn’t rotate horizontally to the left or right.”
Another significant challenge Sparks and the team faced involved the Under Armour logo on the front of the building, as certain parts of the structure were inaccessible with typical man lifts or boom lifts. Ultimately, a beam system was designed to distribute load across the green roof.
“We spent a great deal of time working with the engineers to design a way to distribute the weight of the machines to get boom lifts on the roof,” Sparks said. “Creating access for film and steel installation was certainly a challenge.”
The Benefits of TensoSky® ETFE Film
Birdair’s TensoSky® ETFE film was chosen for the project because of its advanced performance and aesthetic qualities. Its deployment as a single-layer façade enhances the building’s visual dynamics, creating a transparent and modern look while complementing the glass envelope behind it.
TensoSky® ETFE film is considered the material of choice for everything from traditional skylight applications to long span structures and building facades like Under Armour HQ. It provides approximately 70% acoustic transmission as well as ample natural daylighting, minimizing energy costs by lowering the demand for indoor lighting. Few building materials can match TensoSky® ETFE for its impact or presence when designing a structure that stands out from the crowd.
Collaboration Beyond Expectations
The project team’s collaboration and expertise were critical to the project’s success. Birdair coordinated with Under Armour’s team to ensure the iconic branding and design elements aligned seamlessly with the structural system.
The entire façade project was completed ahead of schedule, with Birdair’s on-site crew of 10-12 ironworkers and rope technicians working between May and August 2024. Despite challenges like strong wind conditions and the complexity of the site and structure, Birdair’s focus on design-build excellence and meticulous execution resulted in an architectural feature that redefines Under Armour’s corporate aesthetic and functional appeal.
“You have to think outside the box, and you have to make the design buildable,” Sparks said. “That’s what we do best. We go beyond what our general contractors expect from us.”
About the Under Armour HQ and Birdair
Located in Baltimore’s Port Covington district, the new Under Armour HQ is a 280,000 sq. ft. mass timber building that supports all corporate teammates and includes office, retail and fitness facilities. The headquarters also exemplifies the latest sustainability standards, earning LEED Platinum certification, achieving net zero energy operations, and adhering to the WELL Building Standard.
A full-service design-build specialty contractor for tensile architecture, Birdair features a comprehensive range of pre-construction services including design assistance, budgeting, construction methodologies and project schedule development. Birdair’s in-house capabilities include design development, engineering, fabrication, construction (installation) and service and warranty services.
For more information on Birdair’s innovative roofing systems, canopies and skylights, visit Birdair.com and follow Birdair on Facebook and LinkedIn.
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About Birdair
Birdair, Inc., is the leading specialty design build contractor of custom tensile structures around the world. In addition to pre-construction services such as design assistance, budgeting, construction methodologies and project scheduling, Birdair provides design-build solutions in all aspects of project design, fabrication, installation and maintenance. The company offers a selection of architectural fabric membranes, including PTFE-coated fiberglass, TensoSky® ETFE film, PVC and Tensotherm™, an insulated tensioned membrane system. Birdair, based in Buffalo, NY, is a member of the Taiyo Kogyo Group, with operations serving North and South America and other international locations. For more information about Birdair, call 1-800-622-2246 or visit Birdair.com.
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