Design And Specification of ACM/MCM In Today's Architecture

Design And Specification of

ACM/MCM In Today’s Architecture

© Ron Blank & Associates, Inc. 2011

Course Number: alp07a

An AIA Continuing Education Program

Credit for this course is

1 AIA HSW CE Hour

Bill Yannetti

Sr. Manager Technical Services

Mitsubishi Plastics Composites America

401 Volvo Parkway

Chesapeake, VA, 23320

[email protected]

1-800-422-7270

Please note: you will need to complete the conclusion quiz online at ronblank.com to receive credit

An American Institute of Architects (AIA)

Continuing Education Program

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Architects Continuing Education System. Credit earned upon completion of this

program will be reported to CES Records for AIA members. Certificates of

Completion are available for all course participants upon completion of the course

conclusion exam with +80%.

Please view the following slide for more information on Certificates of Completion

through RBA.

This program is registered with the AIA/CES for continuing

professional education. As such, it does not include content that may

be deemed or construed to be an approval or endorsement by the

AIA or Ron Blank & Associates, Inc. of any material of construction

or any method or manner of handling, using, distributing, or dealing in

any material or product.

An American Institute of Architects (AIA)

Continuing Education Program

Course Format: This is a structured, web-based, self study course with a

final exam.

Course Credit: 1 AIA Health Safety & Welfare (HSW) CE Hour

Completion Certificate: A confirmation is sent to you by email and you can

print one upon successful completion of a course or from your

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your Certificate please send requests to [email protected]

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completion after successfully completing a course conclusion quiz. Email

confirmations will be sent to the email address you have provided in your

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Please note: you will need to complete the conclusion quiz online

at ronblank.com to receive credit

Course Description

Today, aluminum composite material (ACM) and metal composite materials

(MCM) have helped to provide a variety of finishing advantages. Because of its

strength, durability and sleek modern appearance, architects have been

fabricating buildings with aluminum and metal cladding for generations. In this

one hour online course, design professionals will be able to explore different

architectural cladding options. Designers will discover how ACM panels and

MCM panels have broadened architectural horizons through weatherability,

fire resistance, long service life, and design flexibility. We will conclude this

course with a brief 10 question quiz.

Learning Objectives

Upon completion of the course, the design professional will be able to:

Knowledgably discuss ACM & MCM, their characteristics, and their

manufacturing process

Identify the various fire tests used to evaluate ACM/MCM performance

Distinguish ACM/MCM finishes and explain the different surface

technologies

Compare the different ACM/MCM attachment systems in terms of

application process and performance

Define key points for specifying ACM/MCM and identify application

possibilities

Architectural Metal Cladding An Introduction

Weatherability and Design

Whether a multi-story building or smaller scale project,

weatherability is a major consideration in architectural design.

After countless hours of design and construction, a project must

ultimately be able to withstand the test of time. The facade of a

building, in particular, is subject to a number of wearing factors that

can affect the entire building envelope without a proper protective

system.

Weatherability and Design

Resistance to the elements, including UV rays, wind, moisture, rain,

heat, and other factors that contribute to deterioration is

imperative to maintain the integrity of a project.

This integrity also includes the long-term ability of the facade to

maintain its initial look and luster.

A system that both protects the

building exterior and preserves

the look of the building with

little maintenance is optimal.

Protecting the Building Envelope

Constructing a proper building envelope and providing long-term

protection, such as found with architectural metal cladding, can reduce

maintenance and repair costs associated with weathering and general

wear and tear. It can also help lower energy costs and even save lives

(e.g. using fire-resistant cladding).

Metal Cladding

Architects have been fabricating buildings with aluminum and metal

cladding for generations because of its strength, durability, and sleek,

modern appearance.

More recently, aluminum composite material (ACM) panels and

metal composite material (MCM) panels have broadened

architectural horizons with

flexibility of design, longevity

of performance, and a wide

array of brilliant finishes.

Today’s Metal Cladding

ACM & MCM feature such attributes as:

Superior flatness

Vibration dampening

Durability

Ease of maintenance

Pre-finished and coil-coated in

a variety of paint finishes

Rigidity of heavy-gauge sheet

metal

Lightweight

Design Flexibility

In addition, ACM/MCM has the added benefit of versatility. It can be applied

to any type of project and can achieve a variety of different looks and styles

while providing optimal durability and ease of maintenance.

ACM/MCM Architectural Cladding Composite Technology and Characteristics

What are ACM/MCM Panels?

ACM and MCM composite panels are manufactured by continuously

bonding two thin skins of aluminum (or other metal) under tension

to both sides of a thermoplastic core.

The thermoplastic core allows for uniform expansion and

contraction of both metal skins.

Metals used in MCM include steel, stainless steel, titanium, copper,

and zinc.

ACM/MCM Composite Panels Metal Skin

Core

Metal Skin

ACM/MCM Structural Strength

ACM/MCM composite

panels are similar to “I-

beams,” in that the two

skins are connected by a

thermoplastic core.

This configuration

provides more structural

stiffness than would be

present if the skins were

in direct contact.

As core thickness

increases, this effect also

increases (refer to flexural

stiffness chart).

Aluminum

0.5mm (.020”)

Aluminum

0.5mm (.020”)

X

Thickness

mm (inch)

Flexural

Stiffness

C-393 (PSI)

Weight

PSF

Equivalent

Thickness

Weight

PSF

3 (.118) 1.04 x 109 0.93 2.7 (.106) 1.50 62.0%

4 (.157) 1.99 x 109 1.12 3.3 (.130) 1.82 61.5%

6 (.236) 4.98 x 109 1.50 4.5 (.177) 2.50 60.0%

ACM Solid Aluminum Weight

Ratio

Solid

Aluminum

= 100%

1) The aluminum / metal coils are introduced into the process from two pay-off reels.

2) The laminating rollers bond the aluminum to the continuously extruded

thermoplastic core.

3) The laminated material then enters the cooling chamber and is

constantly moved at a steady rate by the pulling rollers.

4) A protective masking film is applied to the ACM / MCM to protect

the surface finish.

5) The ACM / MCM is trimmed to the required width, sheared to

the required length, and stacked for inspection and final

packaging.

1

2 3

4

5

ACM/MCM Manufacturing Process ACM/MCM Manufacturing Process

ACM/MCM Characteristics

Thickness:

Available in 2mm, 3mm, 4mm and 6mm thickness. Application use

determines thickness required.

Widths:

Range from 38” to 62”. Typical architectural application is 50” and 62” for

4’ or 5’ module respectively with a 1” route and return fabrication.

Cores:

Manufactured with either polyethylene (pe) or fire-resistant (fr) cores. Type

of core is determined by application and/or local building codes.

Aluminum Skins:

Range from .005” to .032” thick. Typical thickness is .020”. Application use

determines the skin thickness required.

ACM/MCM Advantages

Strength:

ACM/MCM offers the structural strength of steel with the inherent

lightness and flexibility of aluminum. ACM/MCM has a strength to weight

ratio far below conventional materials, resulting in faster construction times

and significant savings in terms of labor and materials.

Durability:

ACM/MCM offers superior durability, weather-resistance, and resilience.

ACM/MCM panels retain remarkable tensile strength, delivering superior

flatness, rigidity and stability under changing thermal conditions.

Flexibility:

ACM/MCM can be used as a cladding material for exterior and interior

applications; for walls, ceilings, canopies, beam wraps, column cladding,

fixtures, free-standing kiosks and signage. ACM/MCM panels are pre-

finished, flexible, and can be molded, curved, bent and routed into complex

shapes.

ACM/MCM Advantages

In this video clip, ACM and MCM in a signage application are being wind

tested, illustrating the materials rigidity, strength, and withstandability.

video available in online format only

ACM/MCM vs. Other Alternatives

Alternatives to ACM/MCM possess

certain limitations. For example:

Monolithic Metals/ Aluminum Plate:

Limited to post-coated finishes,

heavier weight, problems with

post-finish color consistency.

Batch Laminated Panels:

Limited widths, problems with skin

blistering, pimpling, delamination,

and oil-canning.

Sheet Metal:

Heavier weight, problems with rust

and oil-canning.

Oil-canning

Delamination

ACM/MCM vs. Other Alternatives

ACM/MCM overcomes these limitations – providing light weight, a full

spectrum of durable and beautiful finish options, and superior flatness

in addition to vibration dampening, durability, ease of maintenance, and

flexibility.

ACM Application

Sustainability

ACM/MCM panels also offer several sustainable attributes:

Made up of a high percentage of recycled content

Uses one third to one fourth the amount of aluminum/metal

Finished with coatings that have a long life cycle

Fire resistant material available

When used for a building envelop, can

increase energy efficiency as part of a

compressive strategy

Can contribute to achieving credits

for LEED project certification

ACM/MCM Fire Resistance Testing and Standards

Fire Resistant Standards

Recent wildfire events and resulting devastation in the southwest,

have made clear the importance of specifying materials based on a

location’s environmental conditions.

Fire-resistant (fr) cores are required by IBC codes for buildings over

40’ in height. Fr cores must pass an intermediate scale, multi-story

test, such as the National Fire Protection Association’s (NFPA)

standard 285 utilizing the Intermediate Scale Multi-Story Apparatus

(ISMA).

Lighter and more flexible than fr cores, polyethylene (pe) cores also

meet IBC2009 and NFPA 5000 codes for buildings of 40’ or less.

ACM/MCM Fire Resistance

Standard (Polyethylene) Fire-Resistant (Polyethylene w/

Additives)

Manufacturer A LDPE

2mm, 3mm, 4mm, 6mm

LLDPE with inorganic mineral

fillers. 4mm, 6mm

Manufacturer B LDPE

2mm, 3mm, 4mm, 6mm

Polyolefine with inorganic

mineral fillers. 4mm

Manufacturer C HDPE

3mm, 4mm, 6mm

HDPE with inorganic mineral

fillers. 4mm, 6mm

ISMA Fire Test

The ISMA simulates a fire in which

the flame shatters a window and

spreads to the exterior wall.

The 18’ high, two-story mock-up

has two gas burners, one inside

the room and one outside the

window.

The test lasts 30 minutes, during

which the flame height and wall

temperature are checked. The test

material passes only if the flame

fails to reach the second floor. Room burner

18‘

14‘

Fire-resistant

4mm ACM

Window

burner

ISMA Fire Test

ACM/MCM mock-

up with window in

center of ground

floor.

ACM/MCM panels

are unaffected 7

min. after ignition

After 30 min. the

flame has not

spread upward.

When the gas is

shut off, the flame

gradually weakens.

Full Scale Exterior Wall Fire Test

The Full Scale Exterior Wall Fire

Test (CAN/ULC-S134-92)

conducted in Canada is similar to

the ISMA test; however, the mock-

up is larger.

In this case, the mock-up is 20’

wide and 24’ high, as opposed to

14’ wide and 18’ high as in the

ISMA.

In this test, intensity of heat flow

and flame height are checked for

25 minutes. In order for a material

to pass, the flame must not exceed

a height of 16’.

Roof Covering Test

The Roof Covering Test (ASTM E 108)

consists of three types of fire test:

1. Burning Brand Test

2. Spread of Flame Test

3. Intermittent Flame Test

In each of these tests, the specimen is

installed on the inclined deck in order

to simulate a roof.

Burning Brand Test

Burning Brand Fire-resistant ACM

Roof Covering Test

Burning Brand Test:

Burning timber is laid directly on

specimen surface, and the damage to

the specimen and smoke evolution are

observed.

Spread of Flame Test:

The specimen is exposed to a

ho9rizontal flame for 10 min. and the

damage is observed.

Intermittent Flame Test:

Specimen is repeatedly exposed to 15

Flame On and Flame Off cycles. One

cycle consists of 2 min. of Flame On

and 2 min. of Flame Off.

Intermittent Flame Test & Spread

of Flame Test

Burner Gas Supply

Specimen

Holder

Burner

Thermocouple

Air Supply

Floor Level

Fire-resistant ACM

Room Corner Test

The Room Corner Test (UBC 26-3)

simulates a fire that starts in the

corner of a room and grows until it

reaches a critical flashover point.

When the fire reaches the flashover

point, it suddenly expands toward

the door similar to an explosion.

The test simulates this situation in

order to assess whether flashover

will take place during the 15 min.

testing period when the interior

surfaces are finished with the

testing material.

12’ 8’

8’

1

2

3

1

2

3

Front wall

Side wall

Ceiling (optional)

ACM/MCM Finishes

ACM/MCM Finish Types

Painted:

Standard and custom colors in solid, metallic, mica, prismatic, low-

gloss or multi-color systems. Use of polyester or fluorocarbon

resins is determined by application use and desired life-expectancy.

Anodized:

Typically available in clear, bronze, black, or special order colors .

Architectural Class 1 finishes have 0.7 mil. or thicker anodic

coatings.

Natural Metals:

Typically used for aesthetic purposes. Available metals include

titanium, stainless steel, copper, galvanized steel, and zinc.


Decorative:

Can be brushed hairline or highly polished. Panels utilize coil that

has been surface anodized or mechanically treated and coated with

a clear fluoropolymer paint.

Faux Finishes:

Provide the look of natural wood and stone products with the

flexibility of ACM/MCM panels. Faux finishes are manufactured using

image transfer systems or high performance vinyl.

Multi-Color:

Two or three distinct colors painted lengthwise on a panel

Clean Room Finishes:

Include fluoropolymer conductive and static dissipative.

* Finish options available depend on the supplier.


Color Coat

Primer

Pretreatment

Substrate

Core

2 COAT SOLID COLORS

Mica Flake in Color Coat

Primer

Pretreatment

Substrate

Core

2 COAT MICA

Clear Coat

Metallic Flake in Color Coat

Primer

Pretreatment

Substrate

Core

3 COAT METALLIC

Specialized Flake in Clear Coat

Color Coat

Primer

Pretreatment

Substrate

Core

3 COAT PRISMATIC

Metallic Finishes

When installing mica, metallic,

or prismatic finishes, it is

necessary to install the panels

in the same direction.

This ensures color consistency

as the finish grain or flake flop

will reflect the light directly.

It is also advisable to use one

width and one lot per elevation

in order to minimize

inconsistencies.

Grain Runs

Perpendicular

Grain Runs

Parallel

Paint Systems

Polyester:

Not available in an air dry system for touch ups and repairs. Does

not have the long-term durability seen with fluoropolymer systems.

Thermoplastic Dispersion Fluoropolymer:

Poly Vinylidene Fluoride (PVDF) combined with Acrylic. The C-F

Bond that provides the basis for the durability is dispersed in an

acrylic resin. A first generation fluoropolymer, it can re-melt when

exposed to high temperature and pressure.

Thermoset Solution Fluoropolymer:

Fluoro Ethylene Vinyl Ether (FEVE) combined with catalysis. The C-F

bond is part of the base resin. A second generation fluoropolymer, it

“DOES NOT” re-melt when exposed to high temperature and

pressure.

Paint Systems

PVDF FEVE

70% PVDF + Acrylic,

Milky Resin

Dispersion Solution

Gloss range 30%-40%

Moderate color range

Thermoplastic

100% FEVE

Clear Resin

Amorphous Solution

Gloss range 30%-70%

Wide color range

Thermoset

Both FEVE and PVDF meet AAMA 2605 Standard.

Natural Surfaces

The U.S. and other emerging markets are starting to adopt a more

European attitude regarding durability – expecting finishes to provide 50 to

100 years of maintenance-free performance.

Recent architectural trade magazines have featured a number of projects

using natural materials as cladding, including stainless steel, galvanized steel,

titanium, copper, and zinc.

Titanium Skin

Core

Stainless Steel Skin

TITANIUM


Core


STAINLESS STEEL

Copper Skin

Core

Copper Skin

COPPER

Zinc Skin

Core

Zinc Skin

ZINC

Attachment Systems and

Specification

ACM/MCM Specification

When specifying a panel attachment system it is important to define what

your aesthetic and performance requirements are. Joint detail, wet or dry,

water and air infiltration control, as well as the requirement for a tested

system and warranty are all important factors to consider.

It is also important to identify

any complex detail

requirements, along with any

special installation requirements.

Be sure to specify the correct

performance required to meet

local codes. The manufacturer is

always your greatest resource for

specifying installation.

Considerations

There are many different attachment systems for ACM/MCM materials,

from very simple to very sophisticated. Performance requirements as well

as size, width, thickness, core and paint system will have a direct effect on

the overall cost.

Remember that the attachment system type will determine the design

detail, “The Look”, and performance of the wall system.

Local codes can also impact the

cost by requiring specific tested

systems or if a specific fire

resistance material is

required.

Wet Seal Attachment

Wet Seal Systems are predominantly the most cost effective systems.

Horizontal Detail Vertical Detail

Wet Seal Attachment

Head Detail Sill Detail

Wet Seal Systems utilize a backer rod and caulked joint detail to achieve

weather tightness.

Wet Seal Attachment

Rectangular Column Circular Column

Wet Seal Systems require good caulking workmanship for optimal appearance

Wet Seal Attachment

Parapet Detail

Wet Seal Systems do not allow penetration of water or air flow.

Dry Seal Attachment


Dry Seal Systems are normally the most expensive system.

Dry Seal Attachment


Dry Seal Systems use open joint system with gasket and/or filler strip.

Dry Seal Attachment


Dry Seal Systems are watertight based on design.

Dry Seal Attachment

Parapet Detail

Dry Seal Systems do not allow penetration of water or air flow.

Rain Screen Attachment


Rain Screen Systems are designed to allow water and moisture along with air

to enter and drain from the wall cavity.



Rain Screen System are either Pressure Equalized or Drained Back Ventilated.



Pressure Equalized Rain Screen Systems minimize the pressure differential on

the inside and outside of the exterior cladding. AAMA 508 defines the

performance requirements.


Parapet Detail

Drained Back Ventilated Rain Screen Systems are not pressure equalized.

AAMA 509 measures ventilation and water penetration.

Application Examples

NC State University, College of Engineering

Architect:

Perkins and Will

Fabricator:

Vicwest

Panel:

Custom Taupe

Attachment System:

Rain Screen

Location:

Raleigh, NC

Winnie Palmer Hospital

Architect:

Jonathan Bailey Associates

Fabricator:

Kistler McDougall

Panel:

MBX Med. Bronze Metallic

& OPT Mica Platinum

Attachment System:

Glazed In

Location:

Orlando, FL.

United Therapeutics Corporation

Architect:

O’Neal

Fabricator:

Altech Panel Systems

Panel:

BBR Red and LTG Grey

Attachment System:

Dry Seal

Location:

Durham, NC

Mark Sweeney Pontiac - Buick

Architect:

K4 Architecture

Fabricator:

TFC Canopy

Panel:

TBL Black, HLA &

HPA

Attachment

System:

Dry Seal

Location:

Cincinnati, OH

Course Summary

Course Summary

ACM and MCM are very cost effective materials to use on your metal

panel projects, providing superior weatherability and strength.

Its design flexibility lends itself to projects big and small for both interior

and exterior applications, including fascias, columns, beam wraps, ceilings

and signage.

The advanced finish and surface technology available with today’s

ACM/MCM materials allows for an almost unlimited array of colors and

looks.

When specifying ACM/MCM, make sure local codes and requirements are

met or exceeded.

Remember, the manufacturer is your best resource, as their experience and

knowledge can help ensure your vision becomes a reality.

Course Review

Now, the design professional will be able to:

Knowledgably discuss ACM & MCM, their characteristics, and their

manufacturing process

Identify the various fire tests used to evaluate ACM/MCM performance

Distinguish ACM/MCM finishes and explain the different surface

technologies

Compare the different ACM/MCM attachment systems in terms of

application process and performance

Define key points for specifying ACM/MCM and identify application

possibilities

Design And Specification of

ACM/MCM In Today’s Architecture

© Ron Blank & Associates, Inc. 2011

Course Number: alp07a

An AIA Continuing Education Program

Credit for this course is

1 AIA HSW CE Hour

Bill Yannetti

Sr. Manager Technical Services

Mitsubishi Plastics Composites America

401 Volvo Parkway

Chesapeake, VA, 23320

[email protected]

1-800-422-7270

Please note: you will need to complete the conclusion quiz online at ronblank.com to receive credit

Design And Specification of ACM/MCM In Today's Architecture

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