Rancho Monte Alegre is a modernist residence nestled in the hills of Carpinteria, California, featuring a striking curved façade that pushes the boundaries of cold-formed steel (CFS) design. McClure served as the specialty CFS engineer, delivering a custom solution for the project’s complex geometry.

To achieve the doubly curved façade, McClure engineered laser-cut tabbed box assemblies forming non-standard parallelogram cross-sections with varying member depths. Cut from flat plates with alignment tabs, the assemblies created self-jigging shapes that simplified installation while maintaining precision.

Structural challenges included varying stud depths, unconventional wall angles, and minimizing movement joints to preserve the seamless aesthetic. In one area, McClure adapted the CFS system to carry unexpected stair loads by integrating a custom box beam between steel columns.

Rancho Monte Alegre showcases the adaptability of cold-formed steel in high-end residential architecture, combining elegance with engineering innovation.

This project earned First Place in the Residential/Hospitality category of the 2025 CFSEI Design Excellence Awards.