Modern Construction Envelopes

MODERN CONSTB ENVELOP ANDREWWATIS MOD ERN CONSTRUCTION SERIES

fl SpringerWienNewYork

TION

2 INTRODUCTION Int ro ductio n

6 METAL WALLS 6

Envelopes and digital fabr ication

14

8

10

( I) Stick glazing:

74 CONCRETEWALLS 156 76

Syste m assembly

Fixing method s

Envelopes as form-defining systems

( I) Sheet metal:

12 GLASS WALLS

3 ( I) Cast in sit u / cast -in-place:

Openings

Framing profi les

Parapets, drips and cills

Substrates and

Opening light s

Finishes

suppo rt ing wa lls

Corner s

As-cast finish

Corn er s, parapets

Spandrel panels

Was hed finish

and cills

Po lished finish (2) Uniti sed glazing:

(2) Profiled metal cladding:

24

86

jo int ing panels

jun ct ion s

Opening light s

(2) Storey height precast panels:

Parapets and gutters

Corner panels, parapets and cills

Panel ty pes

W indow/door o penings

Penetrations

Therm al Insulati o n

Insulation , liner trays

Silicone-bond ed glazing

joints

D evelopm ents

34

96

Patch plate glazing

(3) Small precast/GRC cladding

Parapets and cills

Clamped glazing

panels:

W indow/door o penings

Opaque glazing

Individually suppor te d

D evelopm ents

Sealing clamped glazing

panels

Corn er s

Self suppor t ing

Therm al br idges at cills

(4) Metal rainscreens:

(4) Bo lt fixed glazing:

44

106

stacked panels

Support meth od s

Parapets and cills

Bottom suppo rted glazing

Openings

Mater ials

Top hung glazing

Sand blasted finish

Fixing method s

Corner s

and t oo led finish

Backing walls

Seals and int erfaces

Constru ction sequence W indow/door o penings

(5) G lass blocks:

Parapets and cills

11 6

Fixing glass blocks Support fr ames and walls

(5) Mesh screens:

54

Cast glass channels

Rigid mesh Meshes flexible in

(6) Steel w indows :

one direction

Small-scale glazing

Fully flexible mesh

Large-scale glazing

126

Mesh used o n curves Perforated metal

(7) A luminium and PVC-U w indows:

(6) Louvre screens:

64

132

W indows in o penings

Metal lo uvres

W indow wa lls

Glazed lo uvres

Composite w indows

Solar shading W alkways

168

Ac id etc hed finish (3) Clamped glazing:

(3) Composite panels:

158

(8) T imb er w indows: Window wa lls W indow design W indows in op enings

146

178

CONTENTS

4 MASONRY WALLS

188 Plastic-based cladding

( I) Masonry loadbearing walls: Brick, sto ne and concrete block

( I) Sealed panels: 190

Mortars

( I) Cladding the t imber

242

GRP panels

Timber frames

Polycarbonate cladding

Ground level

264

Upper fl oors

Parapets Cills and openings

(2) Rainscreens:

252

Flat polycarbonate sheet (2) Masonry cavity walls: Brick

frame:

Corners Roof eaves and parapets

Multi-wall polycarbonate sheet 200

Profi led polycarbonate sheet

(2) Cladding panels

Plastic-composite fi at panels

and rainscreens:

W indow and door openings

UPVC board cladding

Timber boards

Eaves and parapets

UPVC windows

Finishes

GRP panels

Cladding panels and rainscreens

Ground level

Plywood sheets

(3) Masonry cavity walls: Sto ne and concrete block 2 10 Wall structures Ground level Openings in walls Eaves and parapets (4) Stone cladding:

220

Fixings Cladding to precast concrete panels Joints Closed joints Movement joints Sto ne fi nishes (5) Terr acotta rainscreens: Manufacture of panels Corner pieces Fixing syste ms Panel sizes Openings

230

274

7

8

METAL ROOFS

284 GLASS ROOFS

( I) Metal standing seam

286

9 336

( I) Greenho use glazing and

Site-based meth od

capped systems

CONCRETE ROOFS 388 ( I) Co ncealed mem brane

338

Mat erials

Prefabricated method s

Greenhouse glazing

Str uctural joint s

Sealed and vent ilate d ro ofs

Mo dern roof glazing

Parapet upstands

Roof o penings

Capped systems

Balustrades and plinths

Ridges and valleys

Rainw ater o ut lets (2) Silicone-sealed glazing

Eaves and parapets

and roofii ghts (2 Profiled met al sheet

296

Penetratio ns for pipes and ducts 348

Silicone-sealed syste ms

(2) Exposed membrane

Juncti on s

as substrates

Use of capped profi les

PVC membranes

Profiled met al roof sheet ing

Ro ofiights

FPO (T PO) membranes Mechanically fixed method

Sealed and vent ilate d meth od s

Bo nded fixing meth od

(3) Bo lt fixed glazing: small scale

Tw in skin const r uction

ro ofiights

Ridges Openings

Generic struct ural suppo rt

Eaves and parapets

meth ods

Ridges and valleys

Supporting brackets

306

358

(3) Planted

Bo lt fixings

System design

A rrangeme nt of bolt fixings

Planted roof com po nents So il dept h O verfiow s

Tw in wall panels

Roof junctions

(4) Bolt fixed glazing: large scale

Ridges Verges

ro ofiight s

Eaves

Base of glazed ro of

Parapets and valley gutters

Exte rnal and int ern al fo lds

368

3 16

Larger roofiight s

Panel arrangement (5) Bonded glass roofii ghts

Parapets

Generic conical roofiight

Mo no pit ch ridges and verges Roof geomet ry

Generic rect angular roofiight

Roof soffits

Generic mo nopitch ro ofiight Glass roof decks

(5) Met al cano pies Bo lt fixed panels Fixed metal lo uvre cano pies Electrically o perate d louvres

326

Rainw ater o ut lets Balcony planter s

Small glazed roofii ghts (4) Rainscreens

Parapets and upstands Ballasted ro ofs

Glazed unit s

Single wall composite panels

406

Po lymer-based membr anes

Profiled met al decks

(3) Composite panels

390

378

4 10

CONTENTS

10 TIMBER ROOFS

420 PLASTIC ROOFS

( I) Flat roof Bitumen -based sheet membran es

( I) GRP ro ofi ights 422

462 464

Eaves and upstands

~~ ~ ( I) ETFE cushions Cushions

Th e mater ial

Verges

A ir supply

Roof build-up

A but ments

Th e mater ial

Solar protection

Sliding ro of panels

Fabri cation Durabi lity

Fixing methods Parapet upstands

(2) GRP panels and shells

Junction w it h til ed roof

Smaller panels and shells

Eaves and verges

Larger panels and shells

474

Performan ce in fire

(2) Single membrane: Con e-shaped roof

(2) Pitched roofTil es

486

432

Plain t iles

496

Fabri c roof prin ciples Fabr ic t ypes

Interlocking til es

Comparison of ty pes

Vent ilat ion

Th erm al insulati o n

Eaves

Aco ust ics

Ridges

Durability

Verges

Performan ce in fire

Hip s and valleys

Cond ensation

A but ments (3) Single membrane: (3) Pitched roof Slates

442

Barrel-shaped roof

Roof fo lds

Membrane roof fabrication

Vents

Membrane ro of edges

Mon op itch ridges

Suspension points

Dormer w indows

Membrane fold s

A but ments

(4) Pitched ro of Metal Standing seam co ld roofs Eaves and valley gutters Ridges and abutm ents Penetrations Metal ti led ro ofs

452

506

I IN DEX

51

A ut horship

5 16

Index

518

Intra uction

MODERN CONSTRUCTION SERIES Th e series is based aro und th e Mod ern Co nstr uct io n H andbook.Top ics from th e Walls and Roofs chapte rs from th e MCH are develop ed to provide more comprehensive information.

CONCRETE WAL LS

Chapter 3 Th e Con crete chapte r compares in-sit u (cast-in-place) concrete, and its use of form work o n site, w it h precast concrete and

Bo oks in th e series discuss mater ial syste ms based o n th e pr ima-

it s use of mou lds in a factory away from th e site . In th e use of

r y mater ial used.Th e series current ly comprises Mod ern Con -

eit her t echnique, th e constraints of th e panel sizes imposed by cast-

st ruct io n Facades, Mo dern Co nstr uctio n Roofs and Modern

ing methods influence th e use of th e material.

Con stru ction Envelop es.

MASONRY WALLS AIMS O FTHIS BOOK Mod ern Con stru ction Envelo pes combines th e earlier Mod -

Chapter 4 In th e Masonry chapter th e construct ion meth od o logy is clas-

ern Co nst ruction Facades and Mod ern Con stru ction Roofs into a

sified by wall construction: loadbearing, cavity wall o r cladding

single book w it h updated illust rati o ns and more exploded views

attac hed t o a backing wall.W it hin each construct ion method , th e

of materi al systems.This is a t extbook for st udents of architect ure ,

use of materials is very similar from brick t o sto ne and concrete

as we ll as st udents of st ruct ural and enviro nmenta l engineering

block.Th e differences in th e specific use of a particular mater ial are

w ho w ish t o broaden th eir study beyon d th e information provid-

shown in th e details.

ed in th e Walls and Roofs chapte rs of th e Mod ern Co nst ructio n H andbook. It shows th e pr inciples of th e main facade t ypes used t oday and illustrates thi s th rou gh t ypical generic details.Th e six chapte rs examine envelo pes from th e standpo int of th e pr imary materi al used in th eir const ructio n, from metal t o glass, concrete,

T he Plastics chapte r explores th e range of plastics from cellu-

masonry, plastics and t imber. Each set of five doub le page spreads

lar mater ials, such as po lycarbonate, t o composite mat er ials such

explains a specific form of co nstr uct io n w hich is accompanied by

as GRP, w hich is a combinat ion of a wove n fibrou s mater ial and a

drawn and annotated det ails.Th e t echniques describ ed can be

polymer matri x. N ewer compos ite materials combine th e econo-

applied int ernati o nally.

my of plastic w it h th e durability and st iffness of metal in com posite sheet materials.Th e recent re-introduction of plastics int o mainstream construct ion has been possible due t o th e improved quali-

METAL WALLS

ty and colour durability of th ese materials.A n advantage of plastics

Char:>ter I

in wa ll const ruction is th at th ey can provide translucency,rath er

Th e Metals chapte r explores th e use of sheet metal from a materi al fully suppo rte d o n a subst rate t o its use as a self-sup-

th an t he transparency associate d w it h glass, combined w it h high levels of th erm al insulation.

porting materi al in th e form of profiled decking and composite panels.Th e use of profiled decking in th icknesses normally used for shipping containers, rath er th an buildings,has led t o t he intro duction of semi-mo noco que co nstr uct ion w it h thi s materi al. Some composite panel syste ms are being manufactured w it ho ut an o ute r facing of metal sheet t o allow a separate wate rproo fing layer t o be added.

T he Timb er chapte r shows bot h recent developments in tim ber walls and developm ent s in tradit ion al t echniques.Th e low levels of em bod ied energy in thi s materi al, parti cularly in locally grown t imber, have helped th e revival in th e use of th is mater ial. Traditionally shunned for large-scale applicat ions due t o its poor

GLASS WALLS

fire resistance, particularly in Europe, th e use of t imber is now bet -

Chapter 2

te r understood to reduce th e spread of fire.Timber ty pes are also

Th e Glass chapte r investigates th e range from framed systems t o po int fixed glazing.W indows and shop fronts are discussed as separate systems w hich can be used as full glazing syste ms in th eir ow n right.

MC E

6

discussed as t heir selection has considerable enviro nmental impact.

METAL ROOFS Chapte r 7 Th e Metals chapte r discusses th e use of met al sheet in ro ofs

PLASTIC ROOFS Chapter I I Po lycarb on ate panels have th e advantage of providing we ll

both as a substrate and as a wa te rt ight cove r ing.W hen used as a

insulated translucent panels th at are more eco no m ic th an th o se in

substrate, in th e form of profi led met al decking o r co m posite pan-

glass. Th ey are mu ch light er th an glass, allowing more visually deli-

els,a wate r proof membrane can be formed in different materials.

cate suppo rt str uct ures t o be used for th ese panels. G lass rein-

U sed as a cove r ing materi al, m etal sheet can be em ployed in

forced pol yester (G RP) can produce opaque ro of form s th at are

standing seams, profiled sheet and rainscreens. Solar shading devic-

free of joints, forming co nt inuo us roof str uct ures such as shells and

es formed from met al are also discussed.

dom es co m pose d of a mon olith ic, light w eight mater ial w it h a watert ight finish o n its o utside face. A ll th ese ty pes are ex plained in th is chapte r.

GLASS ROOFS Chapter 8 Th e G lass chapte r sets o ut th e use o f th e mater ial as both ro ofii ght s and as large glass ro ofs. St ick fr amed ro ofii ghts and glazing syste ms are related t o th o se used for wa lls, but are usual-

Th e Fabr ic chapte r discusses t ensile ro of str uct ures, air sup-

ly fixed w it h pressure plates o n th e t w o sides parallel w it h th e

po rted t ypes and smaller scale cano pies. PT FE membranes can be

line o f slo pe . Bolt fixed glazing systems for roofiights and roofs

st retc hed ove r suppo rting st r uct ures, ty pically stainless stee l cables

fo llow principles used in wa ll co nst r uct io n. Bond ed glass decks

w it h tubu lar steel suppo rts. PTFE sheet is also used t o form inflat -

and roofiights are a developm ent o f glass bloc k deta ils, w hich are

ed 'air pillow s' th at are suppo rted o n an alum inium fr ame.Th eir

also discussed . Finally in th is chapte r. glazed cano pies are dis-

advantage o f high th erm al insulat ion and light ness in we ight is mak-

cussed, fo cusing o n th o se th at use point fixin gs w it h a minimum

ing th em an increasingly preferred o pt io n for ro of str uct ures.

of suppo rt st r uct ure .

QUALIFYING COMMENTS CO NC RETE ROOFS Chapter 9 Ro of decks co nstr ucte d in co ncrete are cove red w it h a var iety

Th e building t echniqu es discussed and th e built exam ples shown are designed t o last for an exte nded per iod w it h a relati vely high perform ance. Co nsequent ly, buildings for ex hibit io ns

of wate r proof membranes and finishes.W hen th e membrane is

and for t emp orary use are excluded. In addressing an int ernati o n-

applied directly t o th e co ncrete, th erm al insulation and finishes,

al reader ship, references t o nation al legislation, buildin g regulation s,

such as plantin g, paving slabs or timber decking, are applied. Con-

co des o f practi ce and nation al sta ndards have spec ifically not been

str uct io n can also be finished w it h anot her ro ofing syste m, such as

inciuded.T his bo ok ex plains th e pr inciples of accepte d building

met al standing seams, o r rainscreens in ot her materi als.A ll th ese

t echniqu es curre nt ly in use. Building co des th rou ghout th e wo r ld

ty pes are discussed in th is chapte r.

are und ergoing increased harm on isat ion because of increased eco no m ic and intellectu al glo balisat io n. Building co m po nents and assem blies from m any different co unt r ies are ofte n used in a sin-

iTIMBER ROOFS Chapter 10 Tim ber roofs are a traditi on al form o f co nstr uct io n th at use

gle buil ding. Since building co des are w ritte n t o protect users of buildings by providing for th eir health and safety, goo d co nstr ucti on pract ice w ill always uph old th ese codes as we ll as assist th eir

mainly t iles, slates and shingles in hou sing proj ects. In recent years,

advanceme nt. T he co m po nents, assem blies and det ails shown in

th e increased use of met al sheet o n timber roofs has led t o an

thi s bo ok describe many of th e building t echniqu es used by th e

increase in more co m plex geo met r ies th at do not need t o fo llow

building indust ry t od ay, but t his bo ok do es not necessar ily

th e principles of th o se tradition al lapped ro ofing mater ials. Flat

endorse o r ju stify th eir use since t echn iques in building are in a

timber roofs, thin planting and met al sheet, in addit io n t o th e more

co nt inual state o f change and development. A ll deta ils shown aim

tradition al single m embrane finishes, are set out here.

t o d em on str ate co nt inuity in th erm al insulati o n and wate rproofing, t ogeth er w it h t w o defences against rainw at er penetrati on. W here spec ific it ems are not clear ly present o n draw ings, th ese prin cipl es sho uld st ill be foll ow ed.

MC E 7

Panelisation for manufacture , using 3-D parametric software,

)

Fixing detail for panels using a minimum set of cast and extruded components,

While th e building envelope syst ems

panels w ere eit her single curved or double

described in t his book are most ly described

curved t o pr ovide a co nt inuously curved sur-

through rectilinear building form s,th ey can

face made from a combinat ion of GRC (glass

equally be applied t o complex geo met ries

reinfo rced co ncret e) and GRP (glass rein-

and assoc iate d mass customisat ion t ech-

forced po lymer) t ypes,Th e GRC is used

niques described in t he int ro duction essays in

mainly o n surfaces t hat are walked upo n in

th e seco nd edit ion of t he Modern Con stru c-

th e plaza spaces aro und th e building,w hile

t io n H andbook,

t he GRP is used as roof cladding panels

A n example is describ ed here w here th e

Panelisation of geometry for manufacture,

MCE

8

w hich are light er in w eight and have a com -

aut hor, a directo r of N ewtecnic, facade

parable co lour and surface finish, Panels we re

designers based in Lo ndon, wo rked w it h t he

manufact ured w hich follow ed t he geomet ry

United A rab Emirates' based co nt racto r,A ra-

required by th e architect w it ho ut th e need

bian Profiles (A PL) o n an exte rnal envelope

for flat o r facetted panels, w hile being eco-

of complex geomet ry,T he proj ect w as a cul-

nomi c in th e met hod of manufacture.Thi s

tu ral cent re in A zerbaijan, w hich involved t he

o utco me was achieved by translating th e dig-

manufacture of 16,000 cladding panels.These

ital 3D mod el describin g th e geomet ry into

Triangulated roof structu re to which envelope system if fixed

12·- - ---..,....,- -

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7, 8, 9,

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10, I I. 12.

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14. 15. 16. 17.

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Metal cover st rip set Ho rizontally-set profiled sheet Vert ically-set profiled sheet Z section steel fixing rails Thermal insulation Backing wall. typically t imber/meta l frame with pIyM:xxJ facingandwaterproof membrane. or concrete block Vapour barrier Int ernal finish Roof.typically profiled metal sheet Curved eavesprofile Concealed gutter Exposed gutter Supporting structural frame Structural slab Window frame Metal tri m to w indow Metal parapet coping

f

,1--1' ~,

"

,, ) J

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H

H

t--

, "

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~

:---:I

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l 8>

Vertical section I :25,Vertically set profiled metal cladding with gutter

I

~

f

rl

~-

8> Vertical section I:25V ert ically set profiled metal cladding with gable end

Vertical section I:25, Horizontally set profiled metal cladding with parapet

_ _ .r1. _ _, " - - -

Vertical section I: I0, Roof junction at gable end

Typical profiled sheet profiles

MCE

25

@

Vertical section I: IO. Gutter detail for large span enclosure

Vertical section I: IO. Parapet detail

Vertical section I 10.Ground level cill detail

3-D view of profiled metal sheet as roof material

th e upper sheet set ove r th e low er o ne in

seal along a potent ially vulnerable jo int as

th e traditional manner.W hen laid hori zont ally,

we ll as a crisp line t o th e corne r. Regardless

horizontal joints are formed w it h laps as

of sheet o rientat ion, edging and jo inting piec-

w hen laid vert ically, but horizontal jo ints are

es are clearly visible, making th em an impo r-

not usually lapped in th e same w ay,Thi s is

ta nt part of th e design.W hereas profil ed

mainly because it is difficult t o form a co nt in-

sheet can be lapped t o give a co nt inuous

uous straight line in a joint th at moves in and

appearance o n a large area of facade, th e

o ut w it h th e shape of th e profi le. Instead a

edging and joint ing pieces of parapets, cills

recessed t op hat sect io n o r proj ecting cover-

and co rne rs are clearly visible.T he visual

plate is used.Th e profi led sheet is butted up

impact of th ese junct ion s can be reduced

t o th e C-shaped sect io n and sealed w it h sili-

w it h recessed joints.Th e use of curve d eaves

co ne or mastic.Th e same pr inciple is used for

sheet s and curved (in plan) co rne r sheets

a projecting coverplate .

was develop ed t o avoid th e need for visible

Co rne rs are treated in a sim ilar w ay, Co rners t o vert ically- and horizontally-set clad-

available, from some manufacturer s, th at can

ding use proj ecting o r recessed coverst rips.

be lapped smoot hly over adjacent profi led

Th e profiled sheets th at meet are lapped

metal sheet s.

how ever.t o pro vide a w eat hert ight seal and Vertical section I 10.Meta l door detail

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26

co rner pieces.90° co rner sheets are now

th e coverplate, pro vides both an addit ional

IV

o l

@ 3-D view of gutter at connection between profiled metal wall and roof system

Vertical section I 10, Sloping roof junction at gable end

@ @

[-""'--,

Vertical section I : I0, Gable end with external metal gutter

Parapets and gutters

m itred corne r panels to allow a curved pro -

Parapet s are usually fo rm ed by eit her pro -

file to be used continuously arou nd a building.

jecting th e pro filed sheet above th e roof line

Visible gutters are fixed on th e outside

in o rder t o conceal th e roof complete ly,

face of th e cladding.The roof projects over

w hich is ofte n in th e same material in th e

th e t op of th e cladding in o rder t o dr ain rain-

case of industrial buildings,A lte rnat ively, a low

wate r into th e gutter. resulting in th e ro of vis-

parapet is formed at th e level of th e intersec-

ually proj ecting fo rw ard of th e wa ll. unlike a

t ion of wa ll and ro of, w it h a recessed gutter

parapet gutte r.A n advantage of t his method

set immediately behind th e parapet. A varia-

is th at rainw ater is kept o ut side th e building,

t ion on t his latter so lut io n is t o use curve d

avoiding th e need t o run vertical rainw ater

eavest o give th e idea of complete cont inuity

pipes w it hin a building,th en runnin g rainw a-

between walls and roof w it h o nly a recessed

t er back o ut th rough t he found atio ns below

gutter creat ing a line between th e two.T he

gro und level. Since gutters are needed o nly

recessed gutter in any of th ese configurat ions

at th e base of ro of slopes, gutters are often

is useful w hen a pitched ro of is used. On th e

not needed o n all facades, giving an uneven

gable elevat ion th e parapet can remain th e

appearance t o th e building.A solut ion t o

same height w hile th e roof rises and falls

making gutters wo rk o n all facades is t o

independently of th e cont inuing line of th e

design a hipped roof th at drains equally into

parapet o n all sides,Curved eaves have

all gutters, but thi s can complicate roof

Verti cal section I :IO. Roof junction at gable end

D etails I. 2.

Metal cover strip set Horizontally-set profiled sheet 3. Vertically-set profiled sheet 4. Z section steel fixing rails 5. Thermal insulation 6. Backing wall,typically timber/metal frame with plywood facingand waterproof membrane, or concrete block 7. Vapour barrier 8. Internal finish 9. Roof,typically profiled metal sheet 10, Curved eaves profile I I, Concealed gutter I 2, Exposed gutter

MC E

27

rl etal W alls 02 Profiled metal cladding

Vertical section I 10, Curved eaves with hidden gutter

Vertical section I:I 0, Curved eaves without gutter

Details .--

I, 2,

Metal cover strip set Horizontally-set profiled sheet 3. Vertically-set profiled sheet 4, Z section steel fixing rails 5, Thermal insulation 6, Backing wall,typically timber/metal frame with plywood facingand waterproof membrane, or concrete block 7, Vapour barrier 8, Internal finish 9, Roof,typically profiled metal sheet 10, Curved eaves profile I I, Concealed gutter I 2, Exposed gutter I 3, Supporting structural frame 14, Structural slab 15, Window frame 16, Metal trim to window 17, Metal parapet coping

3-D view of curved eaves connection with hidden gutter

@

@

=.:::::_=.--_

F=:==:=::::::::::::::::::=___

---=-

Vertical section I: I0,Junction with roof

MC E

28

Vertical section I: I0, Roof junction at abutting wall

..

3-D view and cut-away of profiled metal sheet assemblywith gutter

design. Gutter s require suppo rt by brackets

t ors to ensure a co nsistent co lour through-

Insulation and liner trays

back t o primary st r ucture in o rder t o sup-

o ut t he project.A n alte rnat ive approach is t o

A lt ho ugh profiled met al sheet is capable of

port th e we ight of w ate r w hen in use.The

reduce reveals t o a small dept h and use a

lo ng vert ical spans, t he th erm al insulat io n and

suppo rt ing brackets usually need t o pene-

colour fo r t he w indows different from t hat

int ern al finish mat erial require addit ional sup-

trate th e cladding, requirin g seals aro und th e

of th e adjacent cladding. For example, w it h

port.The insulation cannot be fixed directly

penetratio ns in order t o make t hem weat h-

a silver met allic finish fo r cladding, a darker

t o t he metal sheet w it ho ut being bo nded t o

ert ight. If t he roof construct ion is required t o

grey might be used fo r w indow frames w it h-

it. Fixing br ackets t o t he pro filed sheet wo uld

be vent ilate d t hen th e dept h of th e gutter

o ut creat ing any cont rast betw een th e two

involve penetratin g th e sheet. creat ing a pos-

w ill increase if th e roof is int ended t o be hid-

colours used.

sible po int for w ate r ingress.Welding a sup-

den fro m view. D eep gutters have a stro ng visual presence o n th e facade.

Cills are formed in pressed met al w hich

port bracket wo uld be both expensive and

is inclined t o drain w ate r from its horizont al

easily distort t he surface of th e cladding.

surface and has a pro jecting dr ip t o avoid

Bond ing t he insulati o n t o t he liner w ould be

W indow and door openings

dirt. washed off t he cill, runnin g onto th e

th e next practical method, but thi s is done as

T he reveals for w indows and doo r s are

cladding below, w hich wo uld cause staining.

a composite panel, w hich has const raints and

formed in flat met al sheet. usually th e same

Some drips have rising edges at th e sides t o

is dealt w it h in th e next section.

met al and same colo ur as t he profiled sheet-

avoid wate r runnin g off at t he sides t hat

ing. In pr actice th e colour matching can be

causes st reaking in lines below th e edges of

mediary sheet ing rails th at are also used t o

difficult if t he coat ing (usually po lyester pow -

t he o penings. Cills at gro und level o r at t he

suppo rt an inner metal lining sheet. Sheeting

der coat ing o r PVDF) is applied in different

base of t he cladding are eit her flush o r pro -

rails are made from pressed steel sections.

wo rksho ps or by different coat ing applica-

jecting,t o suit visual requirement s.As w it h

Since t he lining sheets are usually flat, t o cre-

t o r s. Cont rasting colo urs are somet imes

sheet met al cladding, t he cill is usually rein-

ate a smoot h finish w it hin t he building, t hey

chosen for t his reason .This is also tru e of

forced both t o ensure it lies in a st raight line

do not span very far and require sheet ing

w indow sect ions,w hich are usually supplied

and protect it from accidental damage.

rails set at close cent res.T he rails can be used

Flexible insulati on quilt is fixed t o int er-

predated by a different manufacturer. Close

to give addit ional rigidity to th e o ute r profi led

co- o rdinat io n is needed between cont rac-

sheet. but thi s requires penetrating th e sheet

MCE

29

fl etal ails 02 Profiled meta l cladding

@

Vertical section I : I0. A luminium window recessed into profiled metal cladding system

3-D view of recessed aluminium window in profiled metal facade

w it h screw fixings w hich are sealed from th e

not suite d t o cladding since t he st anding

o ut side w it h plasti c caps and w ashers.

seam joint. w hich is not designed t o be tightly

A n inner lining tray can also be form ed

@

folded t ogether, does not wo rk w hen set in

from th e same metal profi led sheet. as used

t he vert ical plane.This pr inciple is also tru e of

in wareho use buildings w here a smooth inner

wall cladding types w hich are lapped and are

wall finish is not needed. Som e interm ediary

not suite d t o use in ro ofs, w here th e seam is

sheet ing rails are still required t o suppo rt th e

not high enough t o be submerged under

th erm al insulati o n.A more econo mic form of

wate r during rain.A recent developm ent has

lining w all th at does not interfere w it h th e

been th e use of flat metal rainscreen panels

o ute r profiled cladding is concrete blockwork.

fixed directly t o a profi led sheet.This provides

In thi s instance, closed cell th erm al insulation

a smoot h finish visually t o th e outside face of

is fixed t o th e out side face of th e wa ll.

t he cladding, w hile maintaining th e economy and st r uctural efficiency of t he profiled sheet.

3-D views of head and cill details of recessed aluminium window in profiled metal facade

Developments

A lt ho ugh th e oute r metal panel is fixed t o

Th e range of profi le ty pes is steadily increas-

th e profiled sheet w it h screws o r rivets th at

ing, w it h w ider,deeper profi les th at we re

penetrate it. th e pin jointed rainscreen config-

o riginally designed for use as ro of decking

uration protects t he fixings from th e wo rst

being used as w all cladding. How ever, some

effects of w indblow n rain.

of th e inter locking ty pes used on roofs are

MC E

30

Vertical section enclosure

10. Gutter detail for small span

Vertical section upstand

10. Cill connection to concrete

@

Vertical section I 10, Roof connection to composite metal roof system

@

Horizontal section I :I0, Internal corner

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Horizontal section I: I0. External corner

n U l ILVllLdl :::.eCLlUII I . I v . \.....UlllleClIUII LV Illeldl UUUI

Deta ils I, 2, 3, 4, 5, 6,

7, 8, 9, 10. I I. I 2. 13. 14. 15. 16. 17.

Metal cover strip set Horizontally-set profiled sheet Vertically-set profiled sheet Z section steel fixing rails Thermal insulation Backing wall,typically timber/metal frame with plywood facing and waterproof membrane, or concrete block Vapour barrier Internal finish Roof,typically profiled metal sheet Curved eaves profile Concealed gutter Exposed gutter Supporting structural frame Structural slab Window frame Metal trim to window Metal parapet coping

3-D view of rear of recessed aluminium window in profiled metal facade

MCE

31

fletal Wa Is 02 Profiled metal cladding

Details I. 2.

3. 4. 5. 6.

Metal cover strip set Horizontally-set profiled sheet Vertically-set profiled sheet Z section steel fixing rails Thermal insulation Backing wall,typically timber/metal frame with plywood facingand waterproof membrane, or concrete block

7. 8. 9. 10. I I. I 2. I 3. 14. 15. 16. 17.

Vapour barrier Internal finish Roof,typically profiled metal sheet Curved eaves profile Concealed gutter Exposed gutter Supporting structural frame Structural slab Window frame Metal trim to window Metal parapet coping

3-D detail view of profiled metal sheet connection to blockwork wall

3-D detail view of profiled metal sheet with gutter

3-D exploded detail view of profiled metal sheet connection to blockwork wall

MC E

32

3-D exploded view of profiled metal sheet assembly with gutter

,

3-D exploded view of horizontally set folded metal sheet

3-D exploded view of vertically set folded metal sheet

3-D view of recessed aluminium window in profiled metal facade 3-D view and exploded axonometric of window head detail

3-D exploded view of recessed aluminium window in profiled metal facade

3-D section of recessed aluminium window in profiled metal facade

3-D view and exploded axonometric of window cill detail

MC E

33

Metal W alls 03 Composite panels ------

l - @--

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CD Horizontal section 1:5. Panel to panel connect ion with visible cap

CD

Horizontal section 1:5. Panel to window connect ion with visible cap

@ 3-D view of compos ite panels fixed to aluminium supporting frame with inter locking joints on two sides with vertical (right) and horizon tal (left) capping pieces

@

(2)

Horizontal section 1:5. Connection between composite panel and curta in wall type glazing with cap

(2)

Horizontal section 1:5.Connection between composite panel and curta in wall type glazing with metal flashing

Comp osite metal panels require few er com-

w here made specifically as part of a proprie-

th e trim projects beyond th e face of th e

pon ents th an for th e 'kit of parts' used in th e

t ary system. In pr actice, w indows are usually

cladding t o th row wate r clear and prevent

assembly of profiled metal cladding. Like pro-

supplied by a specialist manufacturer.

staining t o panels below.The back of th e dr ip

filed metal.panels are set eit her vert ically o r horizontally.Some panels int erlock o n tw o

T he steel suppo rt fr aming is set o n th e

proj ects up th e back of th e upper panel t o

face of th e slab, making it easier t o take up

prevent wate r from penetrating th e jo int.

sides,w hile ot hers interl ock o n four sides.

deflect ions in floor slabs. However, as is th e

Panels are also suppo rte d o n eit her an inter-

Four-sided panels require no separate int er-

case w it h curtain wa lling,th e gap between

locking frame o r occasionally th ey span

face com po nents for jo inting but it is more

composite panel and floor slab needs filling

between columns if panels are st iff enough t o

difficult later t o remove a damaged panel.

w it h a smo ke seal o r fire barri er.Th e floor fin-

span unassisted.A n additional method of fix-

ish usually has a metal angle t o close off th e

ing panels is t o position th em between floor

Horizontally-set composite panels can be easily int egrat ed w it h ribbon w indows

gap at slab level and at th e soffit level below.

slabs spanning from floor t o ceiling w hen

and suit building facades covering several

Four-sided int erl ocking panels use t he same

used as part of a rainscreen syste m. Panels sit

floors. Panels are stacked o ne above th e

prin ciple for fixing o n all four sides.This also

o n th e floor slab w it h th eir o ute r face flush

ot her w it h th eir vert ical joints closed by rub -

makes it easier t o integrate w indows w it hin

w it h th e edge of th e slab.Th e oute r rain-

ber-based gaskets, recessed channel sect ions

th e system since a w indow panel is locked in

screen is set forw ard of th e composite panel,

in alum inium, o r proj ecting coverst rips in alu-

like any ot her panel.

minium. Panels are fixed back t o t he pr imary

Vertically-set composite panels are more

str uct ure o r o n a secondary stee l frame, typ-

commo n in single storey applicat ions, but

concealing both th e panels and th e edge of th e floor slab. Interl ocking vert ically-set panels are of

ically box sect ions, fixed t o th e sides of floor

multi-storey applicat ions are used increasingly.

several ty pes, unlike horizontally-set types,

slabs if colum ns are spaced t oo far apart o r

Panels are int erlocked at vert ical jo int s, w hile

w hich have a ste pped jo int t o avoid rainw a-

columns are not position ed o n th e edge of

hori zont al joints are formed by using a cill-

te r penetration.T he most commo n type for

floor slabs.

t ype detail similar t o th at used in a transition

vert ical jo ints is also a stepped jo int w it h a

from vert ical panel t o low pitc hed roof A cill

recess o n th e oute r face.A n alte rnat ive is t o

in extruded o r fo lded aluminium o r stee l

have projecting nibs o n th e sides of th e panel

opening.T his is because w indows are not

(de pending o n w hich met al is used for th e

t o w hich a coverp late is fixed over th e gap

suppo rted by th e composite panels except

composite panel faces) is used.Th e front of

between th e t w o panels. Rubber-based seals

W here w indows are used in a facade, addit ional support is needed t o frame th e

MC E 34 A. Watts, Modern Construction Envelopes © Springer-Verlag/Wien 2011

Details I, 2,

3. 4, 5, 6, 7, 8, 9, 10, I I, 12, I 3, 3-D view of framework supporting composite panels interlocking horizontally with vertical capping piece

3-D view of framework supporting composite panels interlocking horizontally with vertical capping piece

@

14, 15, I 6, 17, 18, 19,

Vertically-set composite panel Horizontally-set composite panel Silicone-based seal Outer metal facing Inner metal facing Inner insulation core Metal capping Concealed fixing Supporting structure 4-way interlocking composite panel Window frame Sectional roller shutter formed from composite panels Roof construction, composite panels are shown Metal trim Exposed gutter Concealed gutter Metal parapet coping Stick glazed curtain walling Door frame

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3-D view of profiled composite panel fixed to steel supporting structure with vertical capping piece

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"r1 ~ Vertical section I: I0, Parapet and cill with curtain walling type window set into c1adding.Typical in industrial applications

3-D view of horizontal interlocking joint between profiled composite metal panels

Vertical section I: I O~Parapet and ground ' level cill

MC E

35

@ ,,""'"'

® Details I, 2,

3. 4, 5, 6, 7, 8, 9, 10, I I, I 2,

3-D view of concealed gutter detail

I 3. 14. 15. I 6. 17. I 8. 19.

Vert ically-set composite panel Horizontally-set composite panel Silicone-based seal Outer metal facing Inner metal facing Inner insulation core Metal capping Concealed fixing Supporting structure 4-way interlocking composite panel W indow frame Sectional roller shutter formed from composite panels Roof construction. composite panels are shown Metal trim Exposed gutter Concealed gutter Metal parapet coping Stick glazedcurtain walling Door frame

Vertical section I:I O. Junction with roof including concealed gutter. Integrated windows flush with face of composite panels

3-D view of junction with window frame

are set int o th e depth s of all th ese jo int ty pes.

panels.A large number of different panel

A not her jo int is a C- shaped channel profile

ty pes cannot be produ ced economically for a

w hich interl ocks w it h th e profil e of th e adja-

single proj ect. A lt hough folded metal fiashings

cent panel.The o utside face of th e panel has

and ext r usions can appear more visually

a slight ly projecting edge instead of a

int r usive th an a specially made composite

recessed joint in th e st epped joint types.

panel, thi s meth od is far more fiexib le for

A ll th ese panel ty pes use jointing methods th at avoid th erm al brid ges. Drips often penetrate from o ut side but th e low condensat ion risk is assessed durin g th e design stage.

dealing w it h varied parapet and gro und level junction s. parti cularly for complex junctions. Like fully suppo r t ed sheet metal facades. parapets can be set eit her level w it h th e ro of. t o create a cont inuo us smoot h envelope, o r

Parapets and cills

be stepped t o allow th e roof profile t o be

Parapet copings and dr ips at gro und level can

concealed.T he same pr inciples apply as

also be made as com posite panels. form ing

th ose for cont inuously suppo rt ed sheet

an integrated part of a proprietary syst em.

met al parapets and cills.

Th is can be an advantage w hen seeking a

3-D view of junction with ground slab

MC E

36

seamless effect across a facade, but set s limi-

Windows and door openings

t ations o n th e variety of junction s (in t erm s

Th ere are two meth od s of creat ing an o pen-

of w idt h and height) at parapet and base due

ing in a composite panel for both hori zont al-

t o th e need for repetiti on in specially made

ly- and vert ically-set panels.Th e fir st method

@

I Vert ical section I: Ia. Cross section through roof with integrated parapet

3-D view of spandrel panel connection

1 3-D view of composite panel facade assembly with flush glazing and concealed parapet

Vertical section I : I a.lntegrated parapet. window and doors all flush with face of composite panels.

is a special reveal panel t hat int erl ocks w it h

t o avoid penetrating eit her o ute r o r inner

t he composite panels.W it h vert ically-set pan-

face of t he panels. Instead it is fixed back t o a

els t he w indow inter locks into vert ical joints

floor slab or t o th e prim ary struct ure.

and has coverstrips on hori zont al joint s.

Since th e inclusio n of reveals is not really

W here ho rizont ally-set panels are used. t he

in t he nature of composite panel detailing,

w indow int erlocks w it h t he horizont al jo ints

and th e wall has littl e depth, th e addit ional

and has coverstrips applied o n t he vert ical

fr ame is also used t o suppo rt th e w indow,

joints.Th e second meth od is t o use metal

t ypically aluminium framed w it h a th erm al

sheet t o form a reveal.A single sheet of

break and doub le glazed units. More ofte n,

metal, 1200 or I SOOmm w ide coil (4ft o r Sft),

w indows and do ors are fixed w it h th e o ute r

is fixed t o a light gauge steel frame w hich is

face of th e glass o r door aligned w it h th e

insulated.The inner framed w all has a vapo ur

o ute r face of th e adjacent composite panels.

barrier and an inner met al sheet, usually

A n alte rnat ive form of glazing to w indows

mat ching t he adjacent inner face of t he panels.

and door s is t o use curta in walling.T herm ally

Heads and cills of openings are form ed in

broken stick systems are fixed directly against

t he same way w it h eit her a purp ose-made

t he adjacent com posite panels w it h a seal set

corne r panel (t he cill is an inclined surface) o r

against th e prim ary struct ure forming th e

w it h sheet metal and t hermal insulati on.

o pening (ty pically vert ical sheet ing rails). If

How ever,th e lightweight metal fr ame is not

hori zont ally-set panels are used. th en th e

usually fixed back t o th e composite in order

curtain w alling can be sealed against adjacent

Vertical section 1:5. Metal door set flush with face of composite metal panel

MC E

37

fletal ails 03 Composite panels

I

views of composite panel curtain wall with recessed window with deep metal reveal, with cill and gutter detail

0..;;;..

@

CD

I I

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CD Vertical section I: I0. Parapet with concealed gutter and curtain wall type wind ow recessed with deep metal reveal.

Details I. Vertically-set composite panel 2. Horizontally-set composite panel 3. Silicone-based seal 4. Outer metal facing 5. Inner metal facing 6. Inner insulation core 7. Metal capping 8. Concealed fixing 9. Supporting structure 10. 4-way interlocking composite panel I I. W indow frame 12. Sectional roller shutter formed from composite panels 13. Roof construction , composite panels are shown 14. Metal trim IS. Exposed gutter I 6. Concealed gutter 17. Metal parapet coping 18. Stick glazed curtain walling 19. Door frame

MC E

38

~

Horizontal section I: I0. Door jamb with metal sheet forming panel in door reveal.

composite panels w it h a vert ical cover st rip

D evelop ment s

used for all vertical joints.

Th e use of composite metal panels is increas-

W here many w indows are requ ired at a

ing int o building ty pes beyond industrial

parti cular height o n a facade, as w hen pro vid-

buildings, into office buildings and spo r ts facil-

ing light into an upper floor, it is co mmo n t o

ities. In th e case of office buildings, th ey pro -

create a co nt inuous ribb on of w indows t o

vide an eco nomic spandrel panel w here cur-

avoid small infills of composite panels

t ain wa lling is not always effective. In spo rt s

between w indows.Th e cont inuo us line of

facilities, composite panels enclose large

w indow s is fixed back t o a secondary frame

indoo r spaces w it h a durable, crisply-made

of steel box sect ions, w hich may be exposed

and relatively eco nom ic cladding system.

in th e building or be co ncealed behind an

A lt ho ugh th e appearance of th e exte rnal face

inner finish such as a plasterb oard lining. Co n-

is smoot h and gridded, th e suppo rting st ruc-

tinu ous w indows can also be glazed int o hor-

t ure is visible and usually set on t he inside

izo nt ally-set panels int erlocking o n two sides,

face t o avoid penetration s t o th e o utside

o r fou r-sided panels.Thi s can avoid th e need

th rou gh th e joints betw een panels. If th e

for addit ional suppor t framing. In th is instance

exposed st ruct ure is enclosed w it h an eco-

th e w indows are br aced back in th e same

nomi c lining wall co ncealing th e st r uct ure, thi s

way as th e composite panels.

addit ional element can add considerable cost

10

3-D view of cur ved internal corner panel with partially interlocking joints

Ho rizontal section 1:5. Partially interlocking curved internal corner

Horizontal section 1:5. Partially interlocking connection between composite metal panel and window

3-D view of partially interlocking joint between composite panel and win dow

t o th e cladding, making it much less econo m ic. For th is reason, suppo rt ing st r uct ure th at

be dictate d by t he direction in w hich panels are laid. H orizontally-set panels do not have

is designed t o be seen, such as tubular stee l

w indows arranged ho rizont ally.Tr ansitio ns

post s, is increasingly used.Th e co m po site

between w indow o penings and com po site

panels span betw een st eel posts o r tru sses

panels are becom ing mo re eco no m ic w it h

w it h littl e o r no int er locking suppo rting

standard extr usions and rubber-based seals.

str uct ure . In o rder t o keep t he suppo rt ing

T his is ever-mo re t he case w it h fo ur-sided,

str uct ure as visually elegant as possible, truss-

int er locking panels, w here w indow panels

es o r posts are spaced as far apart as possi-

and met al panels are fixed in t he sam e way.

ble.Thi s has led t o panels getting lo nger,w it h

Increasingly, irregular facade gr ids are being

a maximum length current ly aro und 15

develop ed in designs t o create a richer mix

metres (49ft) . Some prop r iet ary syste ms

of panel sizes in visual patchw o r k of different

include edges t o panels w hich are deeper,

sizes of panels.

Ho rizontal section 1:5. Partially interlocking external corner

making t he co nt inuo us vert ical joint s and hori zontal joints more rigid, allowing t hem t o span greate r distances, and t hus reducing t he amo unt of visible supporting str ucture needed.

Horizontal section I :5. Insulated corner connection detail

Increasingly, w indow o penings need not

MC E

39

- - -Metal Walls 03-

....

Com osite l2anels

Horizon ta l section I:5. Joint between co mposite panels w~h fu l~ interlockin g connection

Horizontalsection 15 Panels interlocking on 4 sides spanning either vertically or horizontally

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Horizontal section 1:5 Jointbetween composite panel and curtain w all type glazing w ith fully interlocking co nnection

3-D view of partiallyinterlocking panels with Aush window and curved comer panel

~

Horizontal section I :5.Joint between com po site

panel and concrete wall with fully interlockingconnection

Vert ical section 1:10, Fully interlocking composite panels w ith curved eill and window set into reveal in cladding

Corners Composite panels are connected at comers

by one of two methods. Either specially made comer panels are used (typically why 90" is standard) or a cove-strip is addedto cover

@

the junction w here the panelsmeet Comer panels are more suited to vertically-set arrangements. though panels for horizontallylaid panels are sometimes used for visual effect Wh ere comer cover-strips are used. their appearance resembles t hat of profiled metal cladding,w hich can give a facade an overall framed appearance. Metal trims at the parapet base and corners can give this appearance. For this reason, the special corner panelsand parapet panelsare used Vertical section 1:5 Curved parap et deta il w ith fully interlocking connections

Me E 40

Ver t ical section I S-Aluminium window set into

reveal in cladding

increasingly.

Ho rizontal section I :5. Insulated corne r connection betwe en composite panels with fully interl ocking connection

Hori zontal section 1:5. Fully interloc king external corner panel

D etails

Horizontal section 1:5. Fully interl ocking curved internal corner panel

I. Vert ically-set composite panel 2. Hori zontally-set composite panel 3. Silicone-based seal 4. Outer metal facing 5. Inner metal facing 6. Inner insulation core 7. Metal capping 8. Concealed fixing 9. Supporting structure 10. 4-way interlocking composite panel

Hori zontal section 1:5. Fully interlocking internal corner panel

I I . W indow frame 12. Sectional roller shutter formed from composite panels 13. Roof construction , composite panels are shown 14. Metal t rim 15. Exposed gutter 16. Concealed gutter 17. Metal parapet coping 18. Stick glazed curtain walling 19. Door frame

Horizontal section 1:5. Fully interl ocking curved external corner panel

Thermal bridges at cills A weakness in composite panels syste ms has been th e use of pressed metal sect ions o r alum inium extrusions t hat pass from o ut side t o inside w it hout a th erm al break.This is being remedied by th e use of insulated cills, made in t he manner of composite panels. Thi s reduces th e th erm al brid ge, in some cases a break in t he section from o ut side t o inside can be formed by turning th e metal cill int o t he inject ed foam o r polystyrene in t he same way as a co mposite panel.

3-D views of fully interlocking corner pieces with square and rounded corners

MC E 4 1

Metal Walls 03- Com osrte . l2anels

3-D view of com flush glazing and coree, panelfacade with ncealed parapet

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Exploded axonom ' as>emb~ with flusheug1az,ng -c viewand of ccom posrte pane l facade oncealed parapet

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Details , 2I. Y,erncally-set com 3' _

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l-lorizontalfy-set cposite panel Sitcone-based ompoSlte panel

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uter metal fae i

Inner metal' ' r;g I ' laCing

nner insolat

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10. Clamped glazed wall II . Inner framed curta in walling 25. Therma l insulation 12. Fixing bon 26. Single or double glazed unrt 11 r-taotenaoce access deck 14. Fixing bracket IS. Extruded aluminium mullions 16. Opaque glazing

Me E

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arIg Ug 9. PrOjectl'lg tranSOffi

,O. Rubber-based seal II . Fixed light 12.Inward opening Iigtlt 13. Ovtwara openrog light I"'Wndow61

15.Cc:nOensabon tray 16.Damp proof ccc-se (DPC) 17. Internal fin,sh

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18. Drip 19. Packing 20.A!l.rniruum clipto secure

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VIew of pressed steel

oxx system

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3-D secbOnaI_ of pressed steel door ~em assembly

MC E

134

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21. Steel dI

21 Meebng stile 21 Pressed steel frame

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of ruIIed steel facade

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3-D exploded view of pressed steel window set wttIWl ~ waf

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3-0 exploded VIeW of pressed steel

MC E_ 135

GlassWalls 07 Al uminium and PVC- U w indows ~

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