EDM. The Technical Handbook for Façade Fabrications ARCHITECTURAL METAL PRODUCTS. Façade Aerofoil and Soffit Panels

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1 EDM The Technical Handbook for Façade Fabrications Façade Aerofoil and Soffit Panels Façade Architectural Metal Features Façade Rainscreen and Infill Panel Systems Façade Profile Metal Cladding EDM-CECO GROUP OF COMPANIES

2 Ever since early man started to construct buildings there has always been a desire to add embellishments or façade components. These may have been functional or purely decorative but they served to differentiate the building and set it apart from other buildings. The designers and builders of today are no different in looking for materials and methods to differentiate their buildings and set them apart from others. The highly refined metals such as aluminium, stainless steel and copper along with very technologically advanced paint finishes and surface treatments are available to create unique façade components manufactured to the designers requirements. 1 Modern buildings are now more than functional. The clients building has now become a statement that projects the company s image throughout the life of the building. The statement of the art design, performance and warranties are all of paramount importance. The architects and designers involvement with EDM Architectural Metal Products at an early stage can greatly help the design and budget costs, for the metal fabricated components and the sophisticated design details incorporated with-in the façade. EDM Architectural Products have in-house design and production teams working with the latest CNC CAD technology and skilled personnel operating to controlled and stringent ISO9002 procedures. EDM Architectural products have made this possible by the combination of over thirty years experience in forming metal with the very latest CAD drawings, software and CNC controlled production machinery and powder painting technology. Now the engineering is catching up with the imagination. ART, DESIGN AND ENGINEERING IS ONLY LIMITED BY IMAGINATION.

3 FAÇADE AEROFOIL AND SOFFIT PANELS It is so important to complete the major façade elevations of a building with details that compliment the overall design. Project specific bullnose and aerofoil shapes can be created in a range of metals and paint finishes. Soffit systems in single skin or composite bonded panels are available up to 4000mm in length. FAÇADE METAL FEATURES The latest design software and manufacturing equipment allows EDM Products to manufacture 2 complex folded and curved shapes in wide range of precoated or post coated metals. FAÇADE RAINSCREEN AND INFILL PANEL SYSTEMS Large areas of a building façade can be quickly and easily clad using metal rainscreen panels hung on extruded metal support systems. Fully insulated bonded composite infill panels can be manufactured to integrate with all major curtain walling systems. FAÇADE PROFILE METAL CLADDING Large areas or discreet feature panels of profiled metal cladding can be used to great effect to enhance a building façade. Profiles can be roll formed as standard or pressbraked to order to integrate with other building elements.

4 Aerofoil and Soffit Panels 3

5 EDM Products do not have a standard aerofoil shape or size. We work with the Architect to create a detail in both scale and shape which compliments the overall building design. The wide range of metals along with pre-coating or post coating finishes can offer a solution to any project budget. The soffit panels can be fabricated in the same sheet metal material or as a bonded composite panel in modules to integrate with the aerofoil joints. Aerofoil and Soffit Panels 4 A wide range of complex aerofoil shapes can be formed in polyester powder coated or pre-coated aluminium. The aerofoil coping can also be manufactured in stainless steel, zinc, copper, etc. complete with it s own set-out Bracket and Support system. The soffit panel can be manufactured in matching metal finished in single tray or as a bonded panel for panel flatness and greater spanning between supports. C COPYRIGHT OF THE DESIGNERS

6 The aerofoil section shall be manufactured with integral butt straps. The aerofoil shall be supported on 2mm galvanised adjustable brackets which can be truly aligned off the structural steelwork. The aerofoil shall be formed from mill finished aluminium and finished in a polyester powder paint to the selected RAL colour. Aerofoil edging have a min radius of 125mm. please contact our Technical Department reference aerofoil shapes, min/max radius dim s. Aerofoil and Soffit Panels Typical Aerofoil Section R125 min 5 20mm open joint to soffit panel tray C COPYRIGHT OF THE DESIGNERS

7 Typical Specification (A) The soffit panels shall be manufactured from 0.9mm thickness PVF2 coated aluminium skins fully bonded to an extra high density insulation core. The panels shall be fixed onto the secondary steelwork supports by means of an extruded aluminium pressure plate with a 20mm wide black EPDM gasket seal from the Spanwall Panel System. Typical Specification (B) The soffit panels shall be manufactured from 3mm thickness mill finished aluminium fully formed on all four sides. The panels shall be fixed onto the secondary steelwork supports by means of self drilling, self tapping stainless steel screws in the 20mm open shadowline joint. The panels shall be finished in a polyester powder paint to the selected RAL colour. Aerofoil and Soffit Panels Soffit Panel Joint Details Bonded soffit panel with gasket joint Secondary steel support system 20mm 6 Secondary steel support system Tray soffit panel with open joint 20mm Scale 1:1 C COPYRIGHT OF THE DESIGNERS

8 Architectural Metal Features Stainless Steel Louvre Blades 7

9 These two piece stainless steel louvre blades were specially designed for the pyramid roof enclosures on the George s Quay development. Each metal section shape was individually drawn and developed using Solid Edge computer software. They were then cut exactly to shape before being formed into the aerofoil edge shape prior to assembly into completed blades with a stainless steel rafter/frame support system. Architectural Metal Features Stainless Steel Louvre Blades 8 C COPYRIGHT OF THE DESIGNERS

10 Architectural Metal Features Stainless Steel Feature Tees 9

11 Architectural Metal Features Stainless Steel Feature Tees The lightweight stainless steel Tee section façade features supplied to the George s Quay Project in Dublin were manufactured using the most advanced combined turret punch and laser cutting equipment available in Europe. The product design was evolved between the project architect, the glazing contractor and the EDM design team to create a truly unique façade feature. The laser cut blank before folding 10 The stainless steel Tee section installed into the curtain wall mullion C COPYRIGHT OF THE DESIGNERS

12 Architectural Metal Features Brise Soleil Aerofoil Louvre and Support Systems 11 EDM Architectural Metal Products manufacture an aerofoil louvre with support arms, rods and brackets to fit into their Spanwall panel systems. the brackets can also be designed for installation to curtain wall glazing systems. The aerofoil louvre blade can be fabricated in stainless steel or in pre-coated aluminium in a range of sizes. Along with the practical aspect of giving solar shading to large areas of glazed facades well designed Brise Soleil can add greatly to the overall aesthetic design appeal of a building. The limitless combinations of support brackets, cantilever arms, outriggers and blade shapes supplied by EDM ensure that every project budget can be catered for. C COPYRIGHT OF THE DESIGNERS

13 Architectural Metal Features Brise Soleil System Support Details Details showing installation into Spanwall panel system. Can also be installed into curtain wall glazing system. Detail A: Rod support brackets fitted into Spanwall panel system 12 Detail B: Arm support bracket Rod support bracket C COPYRIGHT OF THE DESIGNERS

14 Architectural Metal Features Brise Soleil Aerofoil Louvre and Support Systems Detail A: Rod support bracket fitted into Spanwall panel system 13 Detail B: Louvre support arm bracket fitted into Spanwall panel system Details are for installation into Spanwall panel system. C COPYRIGHT OF THE DESIGNERS

15 Rainscreen and Infill Panel Systems Rainscreen Cassette Panels 14

16 Rainscreen and Infill Panel Systems Rainscreen Cassette Panels 15 C COPYRIGHT OF THE DESIGNERS EDM as well as manufacturing and supplying the Spanwall MF3 rainscreen system also fabricate metal faced cassette panels for other proprietary rainscreen hanging systems. The speed and accuracy of the combined turret punch and laser along with the powerful multibend folding cell gives EDM lower production costs than any other comparable manufacturer. For details on the systems and the full range of panel materials and finishes contact our Technical Sales Office.

17 Rainscreen and Infill Panel Systems Rainscreen edge details for the hanging of rainscreen panels to alternative carrier system. Detail A 16 Detail B Detail C C COPYRIGHT OF THE DESIGNERS

18 Rainscreen and Infill Panel Systems Detail A 17 C COPYRIGHT OF THE DESIGNERS

19 Rainscreen and Infill Panel Systems Detail B 18 C COPYRIGHT OF THE DESIGNERS

20 Rainscreen and Infill Panel Systems Detail C 19 C COPYRIGHT OF THE DESIGNERS

21 Rainscreen and Infill Panel Systems Folded Louvre Panel 20

22 Rainscreen and Infill Panel Systems Folded Louvre Panel 21 C COPYRIGHT OF THE DESIGNERS These press formed banks of look-a-like louvres can be used to great effect in creating a different facade texture in large building facades. Manufactured from 0.9mm thickness aluminium PVF2 painted coil material or 1.2 to 1.5mm mill finish aluminium with a polyester powder paint finish to a standard RAL colour. Standard profiles are available or the blade pitch and depth can be designed to integrate into other building elements. The louvre banks can be made active by perforating the horizontal return surface to give varying degrees of free air space.

23 Rainscreen and Infill Panel Systems Folded Louvre Panel 22 C COPYRIGHT OF THE DESIGNERS The EDM Architectural Metal Products folded louvre panel in a range of metal finishes is designed to be installed into Spanwall panel systems. The folded louvre can also be installed into complete louvre bays with it s own support system.

24 Rainscreen and Infill Panel Systems Folded Louvre Panel Optional Profiles Girth 340 Material Aluminium Gauge To Project Specification Length Up to PPC Standard Colour Girth 200 Material Aluminium Gauge To Project Specification Length Up to PPC Standard Colour cutout cutouts C COPYRIGHT OF THE DESIGNERS The folded louvre panel edge frame detail can be designed to suit most installations. The profiles shown below were manufactured in stainless steel for the George s Quay in Dublin. A ventilation requirement to the offices required air intake panels at each floor level.

25 Rainscreen and Infill Panel Systems Spandrel Infill Panels into Curtain Walling System 24 C COPYRIGHT OF THE DESIGNERS Spandrel panels can be manufactured as folded trays in many different metals and finishes. The spandrel panels can also be made as a bonded/insulated panel to suit the glazing rebate in curtain wall systems. With all the knowledge and experience of the Spanwall composite panel manufacturing company within the Group EDM can offer fully insulated bonded composite infill panels for all major curtain walling systems. The edge details can be designed to give recessed, fully flush or expressed panels. The outer skin can be prepainted PVF2 finish aluminium or P.P.C finished aluminium to any standard RAL colour. The insulation core can be high density polystyrene or rockwool lamella slabs with a designed thickness to meet required U values.

26 Rainscreen and Infill Panel Systems Spandrel Infill Panels into Curtain Walling System Flat faced infill panel 25 Rebated infill panel EDM Products in conjunction with Spanwall composite panels can manufacture a wide range of fully bonded composite infill panels. For fitting into curtain walling these bonded insulated panels can have various edge details to create flush façades or rebated panel details. Designs to suit all major glazing and curtain walling sections are available in a range of external paint finishes. Insulation cores to meet building regulations and fire performance can be specified. C COPYRIGHT OF THE DESIGNERS

27 Rainscreen and Infill Panel Systems False Beam Channel Feature 26

28 Rainscreen and Infill Panel Systems False Beam Channel Feature 27 C COPYRIGHT OF THE DESIGNERS This is one example of the complex folded shapes that are possible using the latest folding and pressing machinery in the EDM manufacturing plant. All the integration details between the folded feature product and the building façade are designed for structural integrity and fully weathered. The constant investment in new production software and equipment means EDM can offer increasingly more complex shapes in lengths up to 6000mm.

29 Rainscreen and Infill Panel Systems Columns Casings & Enclosures 28

30 Using the same technology as for the bullnose features EDM offer press formed or rolled column casings in circular, square or elliptical aerofoil shapes. The same full range of metals and finishes are available along with the adjustable secondary steel support work and jointing methods. Rainscreen and Infill Panel Systems Columns Casings & Enclosures 29 C COPYRIGHT OF THE DESIGNERS

31 Rainscreen and Infill Panel Systems Column Joint Details Joint details open or gasket joints with adjustable set-out support system. Secondary steel support system Open joint 20mm 30 Adjustable set-out support system Gasket joint 20mm C COPYRIGHT OF THE DESIGNERS

32 Profile Metal Cladding 31

33 EDM can supply a range of single skin profiled metal sheeting in steel or aluminium. Manufactured on our own equipment or in liaison with affiliated suppliers EDM can supply from deep profiled structural decks and structural wall trays to very light gauge sinusoidal and trapezoidal outer sheets. By the use of careful and inventive detailing of the flashings and closure pieces a striking façade can be created at relatively low cost. Profile Metal Cladding 32 C COPYRIGHT OF THE DESIGNERS

34 The standard sinusoidal wave form cladding sheet was used to great effect on the new terminal building for Belfast City Airport. Using a built up system of an inner steel liner sheet, rockwool insulation slabs and a sinusoidal outer sheet in three coat PVF2 painted aluminium the main criteria of thermal insulation and fire performance was easily achieved. The attention to detailing at the vertical junction of the horizontally fixed cladding sheets with project specific designed details at vertical joints and corners gave the whole façade a hi-tech engineered finish. Profile Metal Cladding 33 Scale 1:1 C COPYRIGHT OF THE DESIGNERS

35 Profile Metal Cladding Folded Copings & Cills 34 The attention to detail on pressed metal copings can either make or destroy a good panelled façade. EDM fabricate all the copings for Spanwall panel projects either in the same coil material as the panel skins or in post coated aluminium. Copings are supplied in lengths to correspond with vertical gasket joints to avoid run off smears on panel faces. Cills are also made in the same materials and lengths to complete the continuity of the panel façade layout. C COPYRIGHT OF THE DESIGNERS

36 EDM s custom built design department currently utilises leading edge 3-dimensional CAD software to design and manufacture it s complex sheet metal components. This 3D parametric software delivers superior productivity with regards to the design process, producing shorter manufacturing lead-times, ensuring the delivery of higher quality products at a faster rate. This powerful CAD software gives the designer the advantage of visualising sheet metal components on screen to ensure they exactly meet the customers requirements, prior to actual manufacturing taking place. Using these 3D sheet metal models, the designers can then generate flat pattern geometry of the components, ready for the automated NC/CNC processes.

37 Design and Programming Department 35

38 The combination of highly trained and experienced personnel working with the most modern NC and CNC production machinery at every stage of the production process ensures high quality components can be produced at competitive costs. The combined turret punch and laser allows for very accurate cutting of the flat metal patterns developed on the solid edge software program. These can then be processed on the multi-cell fully automated folding centre or a range of press-brakes and folding machines up to 8 metres long. The quality and consistency of products produced cannot be rivalled by any other company in the UK or Ireland.

39 Manufacturing 36

40 Advanced Industrial Coatings specialise in the pre-treatment and powder coating of architectural aluminium. Advanced Industrial Coatings is an ISO9002 registered company in partnership with major paint companies who lead the field in the production of architectural powder finishes. The AIC system demands strict adherence to the British Standards BS6496 and BS6497. The system follows the rigorous testing procedures laid down by the paint companies who offer substantial product guarantees which architects, specifiers and fabricators increasingly require. AIC is the only company in Northern Ireland licensed to apply the Syntha Pulvin range of colours. This business partnership with HB Fuller Company clearly demonstrates a commitment to quality, service and reliability, placing AIC at the forefront of the powder coating industry in Ireland. Syntha Pulvin Plus, guaranteed for 25 years, formulated to decorate and protect architectural metalwork exposed to extreme weather and ultra-violet conditions. Standard polyester powder coatings, with their ease of application and wide colour choice, have served the architect well since their introduction in the 1970s. In the demanding new millennium, increased pressure on total costs has necessitated the search for coatings with a longer life to first maintenance. Syntha Pulvin Plus exhibits a 300% improvement in UV resistance over standard polyesters, giving guaranteed performance and a reduction in total build costs.

41 Powder Coating 37 Automated powder line Assembly pre-painting Computerised control centre Oven cured finished product

42 Modern technology has brought engineering to the point where architects and designers can free their imaginations. New materials and methods enable ever-evolving shapes, finishes and embellishments to bring unprecedented levels of aesthetic sophistication to modern buildings. With over thirty years experience in design and production, and a highly skilled and experienced in-house team, EDM Architectural Metal Products is the perfect partner to bring your ideas to life with our seamless integration of art, design and engineering. Now, the sky really is the limit! By offering an extensive range of façade components along with Spanwall composite insulated architectural panels and pressed metal Rainscreen Systems, EDM SPANWALL can supply the TOTAL FAÇADE SOLUTION. Discussion with a member of our Technical Sales Team at an early stage in the project design can ensure a VALUE ENGINEERED DESIGN to meet both the aesthetic design and project budget requirement. Technical Sales Office Tel: Fax: info@edmspanwall.com

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44 EDM Architectural Metal Products, Unit 1, Carryduff Business Park, Comber Road, Carryduff, Belfast BT8 8AN, Northern Ireland. T: +44 (0) , F: +44 (0) U.K. Sales Office: EDM Spanwall Ltd, Brooklands Court, Tunstall Road, Leeds LS11 5HL T: , F: E: