Rainscreen Panels for U.S Bank Mills Fleet Farm Parking Ramp
Owner: Minnesota Sports Facilities Authority (MSFA)
General Contractor: Ryan Construction Company
Architects: Ryan A & E, Inc.
Perforated Panel Fabrication: StellarCraft
Product: Wire Mesh Living Wall and Starfleet Rain Screen
The Challenge: Integrating Vegetation and Thermal Movement into a Rainscreen Panels
Located in the Downtown East neighborhood of Minneapolis, the Mills Fleet Farm Parking Ramp was designed to serve as a major infrastructure component supporting U.S. Bank Stadium and the surrounding downtown district. The six-level, 530,000-square-foot structure accommodates more than 1,600 vehicles and connects directly to the adjacent office towers and stadium through an integrated skyway system.
For this project, StellarCraft fabricated two highly customized architectural metal systems: wire mesh living wall panels and perforated aluminum rainscreen panels for the parking ramp facade.
Wire Mesh Living Wall
The design team envisioned a facade that incorporated living wall elements capable of supporting greenery and vegetation.
The living wall assemblies introduced several fabrication challenges:
- Large-format panel sizes reaching up to 5′ x 20′
- Long-term finish durability for exterior exposure
- Integration of a growing plant system throughout
Perforated Rainscreen Panels
Complementing the living wall installations, StellarCraft also fabricated more than 250 custom perforated aluminum STARFLEET RAINSCREENs for the parking garage exterior.
Designing exterior metal facade systems for Minnesota’s climate requires careful consideration of thermal movement and long-term material performance. With large seasonal temperature swings, exterior aluminum panels are subject to continual expansion and contraction throughout the year.
For the Mills Fleet Farm Parking Ramp, one of the primary fabrication and installation challenges was accommodating thermal movement after powder coating the aluminum rainscreen panels. If restrained too rigidly, large painted metal panels can experience oil-canning, panel distortion, fastener stress, joint separation, or frame warping over time. Given the facade’s exposure to continuous thermal fluctuation, the attachment system needed to be designed to accommodate controlled movement rather than resist it.
The Solution: Wire Mesh Living Wall & Perforated Rainscreen Panels
Wire Mesh Living Wall
The living wall system was designed as both an architectural screening element and a framework for future vegetation growth. In total, StellarCraft fabricated 12 living wall sections positioned around the perimeter of the ramp using 80 welded wire mesh panel assemblies in multiple configurations, including 5′ x 14′, 5′ x 18′, and 5′ x 20′ modules.
Each assembly incorporated 3″ x 3″ 10-gauge galfan wire mesh set within custom-formed aluminum framing with a true 3″ screen depth. The system also included galvanized vertical flashing, integrated side channels, and two-piece attachment brackets designed to simplify field installation. The mesh infill was welded in-house into aluminum frames engineered to accommodate wind loads up to 105 mph (28 PSF). All components were finished in an AAMA 2605 matte black powder coat to create a clean, recessive backdrop for the living greenery.
The architect’s vision for the system was to introduce a landscape-driven element into the parking structure. Native plants at the base of the screens were designed to grow organically into the wire mesh over time, allowing the facade to evolve seasonally as vegetation matures across the structure. Located within the dense urban fabric of downtown Minneapolis, the living wall creates a stronger connection between the built environment and Minnesota’s natural landscape.
Perforated Rainscreen Panels
In addition to the living walls, the parking structure also incorporated perforated rainscreens panels. Fabricated from 3/16″ aluminum plate, each panel measured approximately 43″ x 83″ and featured a rectangular perforation pattern using .375″ x 1.5″ slots. The panels were powder coated in alternating silver and dark grey AAMA 2605 finishes.
Given Minnesota’s seasonal temperature fluctuations, thermal movement was a critical consideration in the panel engineering and attachment strategy. Rather than rigidly locking the perforated panels into the supporting framework, StellarCraft developed a mechanically fastened system using screws and rivets with carefully coordinated tolerances to allow controlled expansion and contraction. Spacing between the perforated aluminum panels and frame assemblies was intentionally designed to reduce stress concentrations caused by temperature shifts.
The Result: Supplying Elements for Local Landmarks
The completed facade system provides the required environmental screening for the parking structure, helping shield vehicles from wind, weather, and exterior exposure. Beyond its functional role, the living wall and perforated rainscreens were able to provide a subtle way to integrate natural elements into the urban environment.
The Mills Fleet Farm Parking Ramp ultimately delivers critical parking capacity supporting major events at U.S. Bank Stadium and the broader downtown district. The project was developed as part of the Minnesota Sports Facilities Authority (MSFA) initiative tied to the planning and delivery of the stadium and its surrounding infrastructure.
As a Minnesota-based fabricator, being a part of projects like this carries added significance. While our work extends across the country, contributing to civic infrastructure within our own region reinforces the value we place on building local and national relationships.
Visit our Starfleet project page to see how you can implement rainscreens into your next project.
