THE INTEGRATION OF PERFECTED RAINSCREEN TECHNOLOGY

Transcription

1 THE INTEGRATION OF PERFECTED RAINSCREEN TECHNOLOGY

2 SPANWALL GROUP OF COMPANIES The Spanwall Group of companies have been in the fore front of designing and developing metal forming and bonding techniques for the production of architectural panel systems, rainscreen cladding systems, soffits, aerofoil edgings and column casings for over 0 years. The company was started by experienced and dedicated engineers with a specialist knowledge of materials and the design ability to create a unique range of metal cladding façade products, to offer to designers and installation contractors in the construction industry. By employing highly trained design and manufacturing staff to maximise the benefits from continuing investment in the most modern turret punch and laser cutting equipment, along with computer controlled press brakes and folding cells, Spanwall is able produce a range of dimensionally accurate metal façade rainscreen panel systems unequalled in the industry. A variety of metals and finishes are available, including Polyester Powder Coated aluminium, Anodised aluminium, Stainless Steel and Zinc. Advanced Industrial Coatings Ltd. is a member of the Spanwall group of companies operating on the same manufacturing site in Belfast. AIC is Qualicoat Approved for the application of powder paint operating under the European Standard EN 10. This applies to powder coating on aluminium for architectural applications, setting minimum standards for film thickness and colour consistency This standard along with approvals from individual paint suppliers, means AIC can offer consistency of colour, film thickness and with prior project notification Guarantees up to 5 years. By continually reinvesting in the upgrading of plant and machinery in their manufacturing and painting facilities, Spanwall can offer products, with features which are unmatched in the construction industry and offer many benefits to the designer and client. I N N O V A T I O N E X P E R T I S E Q U A L I T Y

3 SINGLE SKIN METAL CASSETTE THE INTEGRATION OF PERFECTED RAINSCREEN TECHNOLOGY SPANWALL RF50 concealed fix rainscreen Spanwall RF50 is a concealed fix aluminium cassette panel system hung on an extruded aluminium carrier rail, which is fixed to the structural support wall by means of adjustable wall brackets. The system can be used effectively on both new build projects and also as an over cladding to upgrade existing structures. The three dimensional adjustment makes it possible to introduce feature details and to easily deal with irregular building surfaces. With a range of deeper wall brackets it is always possible to use a greater thickness of insulation to meet or exceed the U values required by the current Building Regulations in the UK an Ireland. All the cassette trays are precision made for each contract and the façade can be completed with specific project designed cills, flashings closers etc. all manufactured and finished to the same high standards. Spanwall can also manufacture all other necessary architectural façade detail products such as Window Pods, Column Casings, Soffits, Aerofoil Edgings, and flashings and closers to meet the design team requirements The RF50 system has been developed to meet the demand by Architects and Contractors for a precision made product, which can meet all the necessary statutory structural, thermal, acoustic, and weathering criteria, and therefore offer the following features and benefits. DURABILITY ABILITY TO WITHSTAND HIGH WIND LOADS PANEL FLATNESS RANGE OF PANEL SIZES NEW BUILD OVER-CLADDING VALUE ENGINEERED SOLUTIONS I N N O V A T I O N E X P E R T I S E Q U A L I T Y

4 PERSPECTIVE

5 1 PERSPECTIVE 1 Hanging System Rainscreen Cassette Panel Back-up Insulation Concrete Support Wall

6 1 5 7 VERTICAL JOINT [Scale1:] 1 Support Wall Insulation Wall Fixing Wall Bracket Rainscreen Cassette Panel

7 5 1 7 HORIZONTAL JOINT [Scale1:] 1 Support Wall Insulation Wall Fixing Wall Bracket Rainscreen Cassette Panel

8 7 1 5 PLAN CORNER DETAIL [Scale1:] 1 Support Wall Insulation Wall Fixing Wall Bracket Rainscreen Cassette Panel

9 Roof and Upstand Detail By Others COPING DETAIL [Scale1:] 1 Support Wall Insulation Wall Fixing Wall Bracket Rainscreen Cassette Panel 9 Coping Panel

10 CILL DETAIL [Scale1:] 1 Support Wall Insulation Wall Fixing Wall Bracket Rainscreen Cassette Panel 9 Cill

11 WINDOW JAMB DETAIL [Scale1:] 1 Support Wall Insulation Wall Fixing Wall Bracket Rainscreen Cassette Panel 9 Jamb Flashing

12 WINDOW HEAD DETAIL [Scale1:] 1 Support Wall Insulation Wall Fixing Wall Bracket Rainscreen Cassette Panel 9 Head Window Surround Closer

13 WINDOW CILL DETAIL [Scale1:] 1 Support Wall Insulation Wall Fixing Wall Bracket Rainscreen Cassette Panel 9 Cill Window Surround Closer

14 COPY Copy PROJECT DESIGNED PANELS I N N O V A T I O N E X P E R T I S E Q U A L I T Y

15 PERSPECTIVE WINDOW POD

16 WINDOW POD DETAIL [Scale1:] 1 Support Wall Insulation Wall Fixing Wall Bracket Rainscreen Cassette Panel 9 Window Pod

17 WINDOW POD DETAIL [Scale1:] 1 Support Wall Insulation Wall Fixing Wall Bracket Rainscreen Cassette Panel 9 Window Pod

18 WINDOW POD DETAIL [Scale1:] 1 Support Wall Insulation Wall Fixing Wall Bracket Rainscreen Cassette Panel 9 Window Pod

19 PERSPECTIVE CURVED PANELS RADIUS PLAN CURVED PANELS

20 PERSPECTIVE CRANKED RAINSCREEN PANELS PLAN CRANKED RAINSCREEN PANELS

21 CRANKED RAINSCREEN PANEL DETAIL [Scale1:] 1 Support Wall Insulation Wall Fixing Wall Bracket Rainscreen Cassette Panel 9 Cranked Rainscreen Panel

22 RF 50 RAINSCREEN SYSTEM SPECIAL MATERIALS AND FINISHES To compliment the range of excellent single skin metal cassette type panels Spanwall have further developed unique methods of using other materials to create finishes and effects never before offered to the designers of building facades. HONEYCOMB CORES The high strength to weight ratio of an expanded aluminium honeycomb matrix makes it an ideal material to use in the creation of extremely flat large format rainscreen panels from thin skin precoated metals and natural metal finishes, such as stainless steel, zinc and copper. The experienced gained from twenty years of manufacturing the highest quality fully bonded Spanwall composite architectural wall cladding panels has been used in the design and fabrication of a new generation of honeycomb cored high performance rainscreen panels and support systems. ALUMINIUM COMPOSITE MATERIALS Renobond ACM is a metal/polyethylene/metal composite material which again uses the composite beam effect to create a very light weight but extremely strong and flat material which is easily cut and formed into cassettes and trays. One of the main advantages of this type of material is the wide range of metal finishes available as the outer face including Pdvf painted aluminium, natural brushed aluminium, stainless steel, titanium and natural zinc. PETRARCH FACED RAINSCREEN PANELS The Petrarch range of high strength resin bonded stone effect boards can now be offered as a rainscreen panel finish unique to Spanwall. Used for impact and damage resistance at low level or to meet a planning requirement this versatile product opens up many more possibilities for the architect and designer. HONEYCOMB, REYNOBOND & STONE CASSETTE PANELS DESIGN FREEDOM Along with the traditional finishes of PPC and Anodised aluminium Spanwall are now offering the widest range of materials and finishes available in the construction industry along with full design advice and technical back-up to help the design team to fully realise their design concepts. I N N O V A T I O N E X P E R T I S E Q U A L I T Y

23 PERSPECTIVE HONEYCOMB WALL SYSTEM

24 1 PERSPECTIVE HONEYCOMB WALL SYSTEM 1 Hanging System Rainscreen Cassette Panel Back-up Insulation Concrete Support Wall

25 1 5 7 HONEYCOMB VERTICAL JOINT [Scale1:] 1 Support Wall Insulation Wall Fixing Wall Bracket Rainscreen Cassette Panel

26 5 1 7 HONEYCOMB HORIZONTAL JOINT [Scale1:] 1 Support Wall Insulation Wall Fixing Wall Bracket Rainscreen Cassette Panel

27 PERSPECTIVE REYNOBOND PANEL 1 Wall Bracketl Carrier Mullion Reynobond Rainscreen Panel

28 1 5 7 VERTICAL JOINT DETAIL WITH REYNOBOND PANEL [Scale1:] 1 Support Wall Insulation Wall Fixing Wall Bracket Reynobond Cassette Panel

29 5 1 7 HORIZONTAL JOINT DETAIL WITH REYNOBOND PANELS [Scale1:] 1 Support Wall Insulation Wall Fixing Wall Bracket Reynobond Cassette Panel

30 1 PERSPECTIVE STONE FACED PANELS 1 Wall Bracketl Carrier Mullion Petrarch Rainscreen Panel

31 1 5 7 VERTICAL JOINT DETAIL WITH STONE FACED PANEL [Scale1:] 1 Support Wall Insulation Wall Fixing Wall Bracket Petrarch Cassette Panel

32 5 1 7 HORIZONTAL JOINT WITH STONE FACED PANEL [Scale1:] 1 Support Wall Insulation Wall Fixing Wall Bracket Petrarch Cassette Panel

33 LIGHTWEIGHT STRUCTURAL WALL SYSTEMS In a new build or comprehensive refurbishment project it is often desirable or necessary to use a lightweight structural walling system to quickly close in the structure and to support the rainscreen. These are made up from factory manufactured structural elements which can be quickly installed on site and provide a structural support for the RF 50 rainscreen system. There are two basic methods of achieving this. STRUCTURAL STEEL CASSETTE TRAYS. Rannila Ready Wall structural trays are available in 00 mm wide modules and a range of steel thicknesses and tray depths to met the most onerous wind loads and dead loads. When given the relevant site data on building height, wind loads etc., Rannila engineers will provide calculations for each project. Spanning up to 700 mm horizontally between main vertical supports the trays interlock to give excellent air sealing, and provide a compartment space for insulation batts to meet or better the U values required by the current Building Regulations. Additional layers of external weather boarding or internal plasterboard can be used to improve the insulation and acoustic performance. All necessary support and interface details for windows, curtain walling and the RF 50 rainscreen can be detailed specific to each project. METSEC COLD ROLLED SECTION WALLING Designed specifically for each project these cold rolled galvanised steel sections are used to form a prefabricated wall usually spanning from floor to floor. The Metsec sections can support the internal plasterboard layers as well as providing the zone for the insulation material and any acoustic layers. The light weight steel sections can be site assembled or made up into pre-fabricated walling elements for craning into position and securing to the primary structure. Once again this system can also deal with all the necessary project specific loads, and interface details for windows, curtain walling and RF 50 rainscreen. Care needs to be taken when working up the design on deciding how to provide fixing points for the wall support brackets which carry the rainscreen system. DESIGN OF WALLING ELEMENTS. The design team must carry out reviews of the performance and specification of all the walling elements to ensure compliance with all Building Codes and National Building Regulations STRUCTURAL SUPPORT WALL SYSTEMS I N N O V A T I O N E X P E R T I S E Q U A L I T Y

34 1 PERSPECTIVE RANNILA CASSETTI STEEL WALL SYSTEM 1 Hanging System Rainscreen Cassette Panel Back-up Insulation Structural Steel

35 5 7 1 RANNILA CASSETTI STEEL WALL SYSTEM [Scale1:] 1 Structural Metal Tray Wall Insulation Wall Fixing Wall Bracket Rainscreen Cassette Panel

36 1 5 7 RANNILA CASSETTI STEEL WALL SYSTEM [Scale1:] 1 Structural Metal Tray Wall Insulation Wall Fixing Wall Bracket Rainscreen Cassette Panel

37 1 5 7 RANNILA CASSETTI STEEL WALL SYSTEM [Scale1:] 1 Structural Metal Tray Wall Insulation Wall Fixing Wall Bracket Rainscreen Cassette Panel

38 1 PERSPECTIVE METSEC STRUCTURAL SUPPORT WALL 1 Hanging System Rainscreen Cassette Panel Back-up Insulation Metsec Structural Metal Wall

39 7 5 1 METSEC STRUCTURAL SUPPORT WALL [Scale1:] 1 Metsec Metal Wall Insulation Wall Fixing Wall Bracket Rainscreen Cassette Panel

40 1 5 7 METSEC STRUCTURAL SUPPORT WALL [Scale1:] 1 Metsec Wall Insulation Wall Fixing Wall Bracket Rainscreen Cassette Panel

41 1 5 7 METSEC STRUCTURAL SUPPORT WALL [Scale1:] 1 Metsec Inner Wall Insulation Wall Fixing Wall Bracket Rainscreen Cassette Panel

42 SPANWALL RF50 CONCEALED FIX RAINSCREEN SYSTEM This high quality metal façade rainscreen system has been developed to satisfy the aesthetic demands of clients and specifiers and to meet the thermal, acoustic and weathering standards required by the building regulations in the UK and Ireland. GENERAL PRINCIPLES OF RAINSCREEN CLADDING The principles of using a rainscreen façade fixed to a fully airtight and externally insulated structural wall have long been established and successfully used throughout North America and northern Europe. In this method of wall build-up each element is formed from a material best suited to give the required performance at the most cost effective price. THE STRUCTURAL WALL. This can be formed in many ways ie. mass concrete shear walls, blockwork, lightweight metal studding with external weatherboarding, or long spanning structural metal trays etc. The important requirements are: 1. It should be able to carry the dead load of the rainscreen and any external insulation along with the dynamic wind loads for the location.. It must be effectively airtight and any window frames, door frames etc. must be fully sealed to meet the air leakage requirements. THE INSULATION LAYER. In most applications using a rainscreen on both new buildings and as an over cladding to an existing structure, a layer of insulation is usually mechanically fixed to the structural support wall. A range of materials is available including polyisocyanurate, phenolic and rockwool slabs. Each will have different characteristics and costs depending on the required insulation values. THE RAINSCREEN SUPPORT STRUCTURE. The metal cassette rainscreen panels must be supported off the structural wall by a frame work which will create cavity air space between the face of the insulation layer and the rear of the cassette panel. This is essential to ensure adequate ventilation of the façade. THE METAL CASSETTE RAINSCREEN PANELS. This is a critical element in the build-up as it gives the designer his aesthetic finish as well as keeping out the rain. In fact it has to deal with all the weather elements of wind, frost, sun and rain while keeping the structure protected and in a general ambient condition. I N N O V A T I O N E X P E R T I S E Q U A L I T Y TECHNICAL SPECIFICATION

43 PERFORMANCE OF RAINSCREEN SYSTEMS AND SUPPORT WALLS STRUCTURAL. Like all cassette tray, rear ventilated rainscreen systems the Spanwall RF 50 system requires to be fully connected to a structural walling system. The wall support brackets, vertical carrier, panel hanging hooks etc. of the system can all be designed in size and quantity to accommodate the expected site loading conditions experienced in the United Kingdom and Ireland. Each project should have a full set of wind load and structural design calculations carried out. STRUCTURAL AND THERMAL MOVEMENT. The system components allow for lining and levelling in three dimensions, to ensure façade flatness independently of the support structure. Thermal and structural movement of the building is accommodated by the tolerances and expansion allowances designed into the system. AIR PERMEABILITY. As the RF 50 is a fully rear ventilated rainscreen system the air tightness of the building must be achieved by the structural support wall. Care must be taken at all window and door openings etc. to ensure continuity of the air seal and any necessary DPM`s. WATER PENETRATION The with a fully sealed rear wall RF 50 will act as a rainscreen and prevent the passage of water across the ventilation gap on to the face of the insulation layer. This is achieved by means of the vertical carrier with gasket seal and the up-stand horizontal baffle joints. If any small amount of moisture does cross the ventilation gap or if condensation occurs on the rear face of the metal trays this is drained off to outside atmosphere or evaporated away. FIRE PERFORMANCE. None of the components in the Spanwall RF 50 support combustion, and the use of a rockwool insulation will mean the total installation will be fire safe and comply with a Class O surface spread of flame. If fire stopping is required the design team should consult a specialist supplier such as Siderise Ltd, for design and product advice. ACOUSTIC PERFORMANCE. The acoustic requirements of any rainscreen installation should be considered on a project-by-project basis as the use of anti-drumming materials can be expensive and in a lot of cases unnecessary. I N N O V A T I O N E X P E R T I S E Q U A L I T Y

44 STANDARD INSTALLATION GUIDE The Façade Contractor and the rainscreen Installation Squad should read this guide completely before starting any installation work on site. 1. Before commencing work the rainscreen installation contractor must check that he has received all the materials necessary to complete the designated area of façade.. The contractor must satisfy himself that the supporting structure is sound and capable of carrying the load of the rainscreen and any necessary thermal or acoustic insulation.. The installer must have on site at all times all the relevant project drawings relating to the installation of the rainscreen and the interface details relating to all other façade components.. The installation contractor must start from an accurate datum level usually given to him by the main contractor. 5. The installation contractor must strike off a vertical plumb reference line or ask the main contractor to give him a reference plumb line. VERTICAL CARRIER INSTALLATION. If the vertical carrier is supplied pre-cut for each elevation, these items must be identified and referenced to the correct area of the facade. 7. The quantity and approximate position of the extruded aluminium wall brackets will be identified on the project drawings. They should be friction fitted to the appropriate position on the vertical carrier.. The quantity and approximate position of the extruded aluminium panel support hooks should be identified on the project drawings. These should be fitted to the vertical carrier and temporarily fixed in place using the stainless steel bolts, nylon washers and nylock nuts. 9. The carrier assembly can then be offered up to the support wall and set to the horizontal datum and vertical plumb line. 10. The support brackets can then be fixed using the appropriate wall anchor with washer selected according to the design requirements by the installation contractor or his structural engineer. 11. When the wall brackets are securely fixed the vertical carrier rail can then be adjusted out and plumbed off the support wall to give the correct insulation and ventilation zone, shown on the project drawing. I N N O V A T I O N E X P E R T I S E Q U A L I T Y

45 1. The carrier is secured by using the stainless steel self-drilling/self-tapping screws. Care must be taken not to over torque these fixings. 1. It is essential to have only one fixed point per mullion by using the circular holes in the wall brackets. This will generally be at the mid-point. All other brackets must be secured through the slotted holes to allow for vertical thermal movement but to offer horizontal restraint. 1. This is repeated for all the vertical carriers on the façade, as indicated in the project drawings. 15. Care must be taken to leave an expansion gap of at least mm between the carriers in a vertical run. 1. This vertical gap can be sealed on the face by inserting a small plate of 1.5mm aluminium into the side slots on the carrier and fixing with a pop rivet on the topside only. 17. The gasket can then be fitted continuously down each of the two front edges of the carrier taking care not to join the gasket at a break in the carrier. INSTALLATION OF A VAPOUR BARRIER Installation of a damp proof membrane if required should be carried out as detailed in the project drawings. This is not a standard component of the RF50 system. PANEL INSTALLATION 1. Care must be taken when handling all PPC coated rainscreen panels to avoid damage. 19. The RF50 system is designed to be fixed from the bottom up. 0. The datum level for the first panel must be accurately set. 1. From this datum level the top row of support hooks should be accurately set and securely fixed in place using the nylock bolts (see Figure 1).. The panel will hang on the top two slots sitting on the hooks, which will offer both vertical and horizontal restraint.. The lower hooks should be set to allow a mm gap between the bottom inside of the hook and the top edge of the slot positions. This allows for easier panel adjustment and levelling on the top set of hooks only.. All the hooks will offer horizontal restraint against the effects of the wind and other loading on the facade. 5. Setting and securing of the panel support hooks should proceed in this manner up the façade until all the necessary hooks for the installation of an area of façade are in position. I N N O V A T I O N E X P E R T I S E Q U A L I T Y

46 . Panel installation can then proceed from the bottom row of panels up. 7. The two rows of EPDM gasket act as both a seal and an anti-rattle device and must be in place.. If the installer finds that there is too much resistance when pushing the panels down, then the application of a small amount of soapy water may assist with 9. When each panel is completely lined and levelled it must be secured by fitting the anti-lifting screw through the holes in the up-stand baffle. 0. Care should be taken to ensure that all datum levels are met and that all necessary adjustments are made as the installation proceeds to avoid a build up of tolerances, which would result in joint not lining through. 1. Final stripping of the protective polyfilm should be carried out as work proceeds to avoid tide marking around the edge of pulled back film.. The finished façade must be protected from abuse by other trades to avoid damage to the paint film or aluminium skin.. Details around window openings, door openings, curtain walling etc. should be dealt with as the installation proceeds to ensure all necessary vertical carriers, hooks, closer pieces, and DPM`s are in place to avoid the unnecessary removal and replacement of panels. GENERAL COMMENT This guide is intended to be a general outline only of the standard methodology for installing the RF50 rainscreen system on a suitable support wall / structure. The installation contractor is required to use good practice and to conform to all the requirements of the specific project design and the current national Building Regulations in the relevant jurisdiction. If there is any doubt or ambiguity the installation contractor should in the first instance contact the Façade Contractor and then if necessary the Technical Office of EDM Spanwall Ltd. Figure 1 Hook Set-Out I N N O V A T I O N E X P E R T I S E Q U A L I T Y

47 SPANWALL RF50 HIDDEN FIX ALUMINIUM CASSETTE RAINSCREEN Manufacturer and reference Drawing reference Supports Bearing width for brackets Pitch Rainscreen Panels Support system Manufacturing Tolerances External facing material Profile Finish/Colour Cover width Joint type Insulation Accessories Primary cladding fasteners Number and location of fasteners Special features EDM.SPANWALL Ltd. Unit 1 Carryduff Business Park, Comber Road, Carryduff, Belfast BT AN, Northern Ireland. Tel: + (0) Fax: + (0) Project drawings, and Technical Drawings Reinforced concrete wall or steelwork by others Minium 10mm 90 degrees As per section drawings Factory manufactured metal cassette panels with baffled horizontal joints and double return folds to vertical edges with cut out slots for concealed fixing Extruded aluminium wall support brackets to create the insulation zone and ventilation gap to rear of panels. Extruded aluminium vertical carrier support/ drainage channel with epdm baffle gaskets and fully adjustable aluminium support hooks Length(mm): ± mm Height(mm): ± mm Out of square(mm): ± mm mm Aluminium alloy 01 H1 Flat External paint finish to be polyester powder paint from the Syntha Pulvin Plus range with a coating thickness of 0 microns. Marine specification, applied by an approved Syntha Pulvin painting contractor See Elevation drawings 0mm open shadowline/baffle joints 0mm Rockwool Duo Slab as per clause Flashings/copings etc. to be manufactured by EDM Products Ltd from mill finished aluminium and polyester powder painted to the same specification as the rainscreen panels to ensure colour matching Size and type to be determined by the rainscreen installer and agreed with the Structural Engineer As determined by panel layout and calculations 0mm shadow gap to all sides