Ajax Illuminated: New sign on the block

by marika_gabriel | 16 August 2024 1:49 pm

Ajax recently completed a significant project at Pat Bayly Square, unveiling a massive 3D sign weighing 6,000 lb (2,718 kg) and stretching over 9.1 m (30 ft) wide. This landmark integrates into the town’s character, enhancing its cultural identity.

By Marika Gabriel

Many Canadian town squares are now adorned with 3D signs that serve as landmarks incorporating the region’s character. One of the latest towns to feature such an attraction is Ajax, Ont. A massive 3D sign, weighing 6,000 lb (2,718 kg) and stretching over 9.1 m (30 ft) wide, was unveiled in May at Pat Bayly Square.

Letters of light

The sign’s hollow clad, transparent, aluminum letters are illuminated by 760 colour-changing red-green-blue (RGB) LED modules along the perimeter. These lights can pulse to music during concerts and events, when the sign is connected to a music source. The Town also plans to use the lights to commemorate, celebrate, or remember culturally significant days.

The custom designed illuminated base is etched with leaves and waves—paying homage to the town’s natural landscape. The Town hopes the sign will not just enhance Ajax’s identity and serve as a landmark for residents, but also attract visitors to the region. The project received partial funding from the federal government’s Fed Dev Ontario Tourism Relief Fund, and was a collaboration between the Town of Ajax and local businesses, showcasing community pride and commitment to beautifying public areas.

Local businesses

Ajax decided the responsibility of designing the sign should be given to local businesses—apt since the goal of the signage is to promote the locale.

FASTSIGNS of Ajax was hired to put together a project team, each with expertise in their respective fields. The team included Signature Engineering, which took charge of structural engineering; Allanson International, which oversaw LED lighting. onsite technical support, and research and development (R&D) prototyping from start to finish; Gregory Signs, which looked after fabrication; and Mitchell Electric spearheading electrical works.

Nearly a year before, Bhajan Kumaresan from FASTSIGNS and Nigel Isaac from Allanson discussed the programming details with Robert Gruber, Town of Ajax’s manager of culture and events. The project then began as an internally RGB-DMX lit venture, but through discussions with the Town of Ajax and FASTSIGNS, Allanson decided to showcase the multi-protocol programming capability of their tablet controller, enabling it to run two or more separate RGB colour mix systems from one controller.

FASTSIGNS, as project manager, partnered closely with the other companies to craft a captivating visual experience. The conceptual design was provided by FASTSIGNS, with input from the Town of Ajax and support from Signature Engineering. Structural drawings were provided by Signature Engineering.

Lettered to perfection

Each company faced its own challenges and found creative solutions to deliver the interactive sign to the people of Ajax. The whole process—from the start of working through plans to the sign being unveiled—spanned nearly 15 months (February 2023 to May 2024). The sign was unveiled on May 13.

The completed project involved designing, fabricating, and installing the aluminium sign with programmable, colour-changing 3D illuminated letters (spelling AJAX) on an indigo blue platform. Additionally, the Town of Ajax staff received training at Allanson’s facility on how to use and program the LED lighting control system.

Level up

The design process presented several challenges. One of the primary obstacles was the construction of large, thin letters that not only needed an internal structure for stability, but also had to accommodate multiple illumination systems. The search for suitable materials led to the use of high-density polyethylene plastic (HDPE) panels, which provided a sturdy base for the design.

Once the problem was solved, another emerged: integrating the desired pattern onto the bases proved a challenge. Working together, Gregory Signs, FASTSIGNS, and Signature Engineering refined the design approach to ensure the concept was manufacturable.

The design also had to provide adequate access and space within the bases of each letter to house the LED controls and power systems. This aspect of the design was critical for the functionality and longevity of the signage. Additionally, establishing access points for power and data cabling was essential, which involved the installation of a specialized conduit to meet the requirements.

Each letter represents a section, so there were four sections brought to the location on flatbed trucks. Each piece needed to be lifted and assembled on site. A crane was used to offload the sign from the transport vehicle and lift each piece into place. Once offloaded, fork trucks were used to manoeuvre the sign into its exact, intended position.

The Town’s vision that the sign should be interactive for the public—each letter is hollow, allowing a person to go inside the letter for photo ops—also posed a few hurdles while designing the lights.

Allanson International worked with the limitation of the channel depth of the perimeter letters. Chris Sharpe, lead engineer at Signature Engineering, said the design allowed a maximum depth of the letter perimeter channel of only 76.2 mm (3 in.). The fabricated perimeter channel was approximately 76.2 mm deep and wide.

However, ideally, the optimal depth for best illumination is the RGB addressable modules. These are lighting strips allowing users to control every single LED individually and are 101.6-203.2 mm (4-8 in.) at three modules per foot. By testing the prototypes, Allanson solved the problem by increasing the linear footage to four modules per foot, which adequately illuminated a depth of 76.2 mm without creating hot spots on the sign face.

To meet all the programming and control requirements, Allanson used its ACL-MC-MP-V1 multiprotocol tablet controller, which allows for the control of different protocol devices using a single interface, enabling both RGB-DMX and RGB-addressable systems to be managed from the same tablet controller. The final stage of the project involved training dedicated AJAX personnel and integrating the system into the existing customer network— which was completed by Allanson’s engineering team.

Let there be light

The sign has been red and white for both Victoria Day and Canada Day, and also displayed rainbow colours during Pride Durham celebrations held in Ajax. The Town will be developing a full calendar of significant days/months and will illuminate the sign in associated colours to commemorate these, such as orange for the National Day for Truth and Reconciliation, red and green for Christmas, blue and white for Hanukkah, and purple for Alzheimer’s Awareness Month, to name a few. The lights can also be dimmed, if needed for days such as the Anniversary of the Battle of Vimy Ridge. These functions can be performed simply through the multiprotocol tablet controller, either manually or by programming it to do so. The tablet control can also initiate pre-programmed functions on selected calendar days, all managed through the intuitive touch screen interface.

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After the sign was unveiled, Gruber, of the Town of Ajax, requested Allanson create a special program that would deliver a light show with a selected thematic opening song. Sheng You, Allanson’s in-house programmer, created this program.

The fabrication process was not without its own challenges. Gregory Signs had to customize the fabrication in many ways, from welding to creative thinking on the labour force side—especially for the letter J. The company used computer-numerical control (CNC), laser tables, band saw, mitre saw, table saw among others to deliver the finished product. “Welding this sign required almost every piece of equipment we have in our factory,” said Boris Kaminsky, a company representative. Due to the unique shape of the letter “X,” which is crossed, there was concern about whether the bottom lights would effectively illuminate the top. Allanson’s research and development team confirmed that installing at least 50 RGB-DMX modules (25 modules per leg) would provide optimal lighting for the 2209.8-mm (87-in.) letter “X”.

The final step was the transportation and installation of the sign at Pat Bayly Square. Each letter was built as a separate section, so four sections were brought to the location on flatbed trucks. Each piece was then lifted and assembled together on site. A crane was used to offload the sign from the transport vehicle and lift each piece into place on to the platform, which was designed to have removable wheels with locks. Once offloaded, fork trucks were used to manoeuvre the sign into its exact intended position.  

By the numbers: Information by FASTSIGNS

Approximate weight of sign: 6,000 lb (2,718 kg) Sign end-to-end: 9,398 mm (370 in.) Depth of letters: 609.6 mm (24 in.) Thickness of letters: 101.6 mm (4 in.) Each base piece: 1,289 mm (50.75 in.) Secured to based: 32 total – 19.05 mm x 63.5 mm (0.75 in. x 2.5 in.) galvanized bolt and nut with a split washer (8 are needed per letter)

LED modules: 760 colour-changing LED modules A: 135 modules J: 106 modules A: 135 modules X: 144 modules Platform: 240 modules

Scope of work: 1) Design Structural engineering drawings Visual renderings LED lighting design 2) Fabrication Material sourcing Welding Assembly Testing 3) Training LED lighting control system 4) Installation Developing a health and safety plan Trenching power and data (CAT6 cable) to sign location Shipping signage to site using a flatbed truck

Acknowledgements extend to all partner companies for their invaluable technical contributions to this feature.

Source URL: https://www.signmedia.ca/ajax-illuminated-new-sign-on-the-block/

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