Façade FIXING OF ARCHITECTURAL PANELS to Aluminum... · Façade FIXING OF ARCHITECTURAL PANELS ... In view of the high thermal coefficient of expansion of ... A joint between the

FIXING ARCHIT.PANELS-AI-EPO-ENG 1/18 29/09/05

FaçadeFIXING OF ARCHITECTURAL PANELS

APPLICATION INSTRUCTIONS1

1. GENERAL

These application instructions are specifically intended for the fastening of large-size ETERNIT façadepanels as outside wall cladding on an aluminium substructure that is fixed to a load bearing wall to create aventilated and insulated rain screen cladding.

A number of basic principles are given that must be adhered to. For variations or additional advice one canalways contact EURO PANELS OVERSEAS.

2. CLADDING MATERIAL

Façade cladding with large-size façade panels on an aluminium substructure is possible with the followingETERNIT façade panels:

• GLASAL, ETERFLEX, GRANITEX 7,5mm• CARAT, NATURA, PELICOLOR 8 mm

For product data and the details of the processing of the various panels please refer to the productinformation leaflets available from EURO PANELS OVERSEAS.

3. AREA OF APPLICATION

These instructions apply for buildings up to a certain height and subjected to a maximum wind load.

Position Building height Maximum wind load

Centre area Edge aream N/m2 N/m2

Inland area 0-10 650 1000Inland area 10-20 800 1200Inland area 20-50 1000 1500

The width of the edge area amounts to at least 1 m from the corner of the building and must be furtherdetermined on the basis of prevailing national standards and conditions.

If variations of the aforementioned load limits occur (e.g. due to certain location or form factors, etc.), thedesign must be determined by building services engineers.

The use of aluminium substructures is prohibited in environments where aluminium may corrode, as forexample in coastal areas.

1 These application instructions replace all previous editions. E.P.O. reserves the right to change theseinstructions without prior notice. Readers should always make sure to consult the most recent version ofthis document. The instructions in this document are non-exhaustive. The guarantees are only applicable ifthe application instructions are followed. Ask advice from E.P.O. in case of different applications


4. PATTERNS WITH LARGE-SIZE FAÇADE PANELS

The following patterns are possible:

NOTE: staggered pattern and free pattern are only advised for dark colours.

Straight patternwith vertical panels

Semi patternwith horizontal panels

Staggered patternwith horizontal panels

Free patternwith horizontal panels


5. SUPPORT STRUCTURE

The design and dimensions of the support structure in relation to the load is the responsibility of thesupplier of the support structure. This document only explains a number of general principles.

The ETERNIT large-size façade panels are fixed on vertical aluminium support profiles. The verticalsupport profiles are fixed at a certain distance (depending on the required insulation thickness and aircavity) from the load bearing wall by means of aluminium adjustable brackets.

The support structure must be able to resist the wind forces acting on the building.

• maximum deflection: : < span/300• safety factor on strength : 3

All parts of the aluminium substructure should be made of a high quality aluminium alloy.

When designing the aluminium substructure, one has to follow the rules for a Ventilatedand Insulated Cladding System (see also: VIRSC – downloadable document).

• ventilation openings at top and bottom of the façade : > 10 mm or 100 cm2

/m

Building height 0-10 m 10-20 m 20-50 mMinimum cavity width 20 mm 25 mm 30 mm

Mineral wool is recommended for insulation. The insulation is fixed with appropriate fastenings and inaccordance with the instruction of the manufacturer of the insulation.

If the support profiles are fixed with brackets, the insulation is fastened after the fitting of the brackets andbefore the fitting of the support profiles.


5.1. Support bracket

The aluminium support brackets allow the gradual varying of the distance between the load bearing walland rear of the panel. This means an air cavity can be provided, insulation can be placed, and anyunevenness of the rear wall can be eliminated.

There are different types of support brackets depending on the supplier of the support structure. In thisdocument the support brackets are schematically represented as follows:

The distance between the brackets is determined by the load exerted (as a result of the wind load and deadweight) and the strength properties of the aluminium sections (to be indicated by the supplier of thealuminium support structure).

The fixing of the adjustable brackets to the back construction is individually determined for each projectdepending on the nature and the condition of the wall to be cladded. In general a minimum pull-out valueper fixing point of 3 kN (300kg) is recommended. This must however be verified for each project. Forconcrete and solid brick a stainless steel wood screw (min. 7 mm diameter) with a hexagonal head andassociated nylon plug is used. The screws with hexagonal head are, however, not tightened too firmly sothat the thread in the nylon plug is not damaged. For other surfaces (hollow brick, cellular concrete,system walls, etc.) suitable fastening means must be used to be able to accommodate the tensile forceoccurring as a result of the wind load and the shearing forces as a result of the dead weight. If necessary apull-out test must be conducted on site. An insulation block can be placed between the bracket and theback construction to prevent thermal bridges.To obtain a stable support structure, the support brackets can alternately be fitted left and right of thealuminium section. All the brackets must be installed perpendicularly to the wall so that the aluminiumsections are not are twisted.


5.2. Aluminium support profiles

There are different types of aluminium sections depending on the supplier of the support structure. In thisdocument the aluminium section are schematically represented as follows.

• T-profile: at the vertical joints between the façade panels• L-profile: intermediate support

The vertical aluminium sections must be installed perfectly aligned

• maximum misalignment : ≤ L/1000

The aluminium support profiles are placed vertically so that penetrating or condensation water can rundown at the back of the panel.

The aluminium support profiles must be sufficiently wide for adequate water sealing and the correct fittingof the fixing rivets. At vertical joints it is recommended to use slightly wider support profile than theminimum width to be able to overcome tolerances in alignment.

Fixing method glue rivetMinimal width of intermediatesupport profile (β)

≥ 40 mm ≥ 40 mm

Minimal width support profile atjoint (α)

≥ 100 mm ≥ 120 mm

Depending on the type of aluminium alloy and the spans (to be indicated by the supplier of the aluminiumsupport structure) the aluminium sections must be sufficiently thick to withstand occurring wind loads anddead loads. The aluminium section must also be sufficiently thick to guarantee the required strength of therivet fixing.

• minimum thickness of aluminium section : 2.0 mm


5.3. Fixing system profile – Support bracket

In view of the high thermal coefficient of expansion of aluminium, the aluminium sections must be fixedin such a way that free movement is possible. The system for fixing the support brackets to the profilemust accommodate the expansion of the aluminium sections. This is achieved by fixing the sections withone rigid fixing point in the middle (F: fixed point) and at all other places sliding points (G: sliding point).

All fixed points are located at the same height so that stresses in the panel are avoided.

The sliding fixing points must be strong enough to withstand the wind loads. The fixed point must be ableto withstand both the wind loads and the dead weight of the façade cladding system.

Fixed and sliding fixing points can be obtained in different ways depending on the design of the supportstructure:

- aluminium clamping blocks- fixed/sliding rivets (wire stitcher with/without spacer) in aluminium or stainless steel- fixed/sliding stainless steel bolts

The number of fastening points is determined in view of the loads occurring.

Expansion joints must be provided between the vertical aluminium sections (fit a support bracket on bothsides of the joint).

• width of joint between aluminium sections : 20 mm


5.4. Installation sequence

The following procedure can be used for the fitting of large-size façade panels by means of rivets or glueon an aluminium substructure.

1 Use the façade cladding design plan to mark the centre to centre distances between the supportprofiles on the façade by means of a plumb-rule or a laser

2 Fit the brackets3 Fit the support profiles on the brackets4 Align the support profiles horizontally and vertically in a section by the gradual arrangement of

the brackets (maximum unevenness is less than L/1000)5 Fix the aluminium profiles6 Fit the ETERNIT large-size façade panels. One starts at the top of the cladding and fits the panels

using a metal lath with straight edges that is clamped on the support profiles. The installation isdone from top to bottom. Calibrated spacers can be used to assemble the panels with the correctjoint width.

Rivets (ASTRO) Glue


5.5. Points of particular attention: interaction of support structure and façade cladding

When designing the support structure for an exterior wall cladding it is very important that the expansionof the aluminium sections can be absorbed by the façade cladding system, and does not transmit stressesinto the façade cladding panels.

A joint between the aluminium sections must always coincide with a joint between the panels. Profilesshould be aligned perfectly.

A cladding panel must always be fixed on sections that have the fixed fastening points at the same height.This means, for example, that at windows extra profiles must be installed to avoid a joint between sectionsunder that panel.


6. FIXING METHOD

6.1 Maximum distance between aluminium profiles

The horizontal centre to centre distance between the support profiles is determined by:

- the width of the panel- the maximum distance between the fixings- the distances from the rivets to the edge- the size of the joint

As a general rule the following maximum distances between the fixings must be respected:

Location Countryside

Height of the building 0-20m 20-50m

Centre façade area 600 500

Edge row of façadeSingle span 500 400

Example (fixing with rivets):width of panel = 1220 mm, maximum distance between rivets = 600 mm, distance to the edge = 40 mm,joint opening = 10 mm

centre to centre distance between support profiles = (1220+10)/2 = 615 mm distance between the rivets = (1220-2*40)/2 = 570 mm ≤ 600 mm: OK


6.2. Concealed fixing through bonding2

Bonding must always take place in accordance with the instructions of the supplier of the bonding systemand under his supervision and guarantee conditions.

GLASAL and ETERFLEX can be glued.

GRANITEX cannot be glued.

NATURA and CARAT have to be sanded (P80) at the area of the glue.

PELICOLOR can be glued. The back of the panel must be sanded at the area of the glue.

The aluminium sections must be roughened and are preliminarily treated with a degreaser and primer. Thefaçade panel must be cleaned and an adhesion primer is applied. A double-sided adhesive strip is appliedas support for the façade panel during the hardening period of the glue, while also determining the distancebetween the façade panel and the aluminium profile. The correct quantity of glue must be applied. Theapplication of the façade panel requires the necessary precision.

The following schematic drawing illustrates the gluing procedure.

1. façade panel2. intermediate alu profiles3. alu profile at vertical joint4. adhesion primer5. double-sided adhesive strip6. glue

2 The maximum height of the building where glue fixing is allowed can be restricted by the conditions ofthe supplier of the glue or by prevailing legislation.


6.3. Face fastening

6.3.1. Distance to the edges

The following minimum and maximum distances from the rivets to the edges must be respected. Drillingthe holes can be done using a template.

6.3.2. Fastening system with rivets

The cladding panel is fixed with rivets with coloured heads. The rivets are fixed using an electric rivetinggun.

Drilling through the aluminium section must be done perpendicular and central to the panel perforations.The predrilling of the aluminium section takes place using a centralising drill.

The rivets must be installed perpendicular to the panel surface. The riveting gun should not damage therivets.

The distance from the edge of the drilled hole to the edge of the aluminium section has to be > 10 mm

The drilled hole must be cleaned before installing the rivets.

h = 40v = 70


The cladding panels are fastened by means of fixed and sliding points. Two adjacent fixed points (F) areprovided for each panel. All other pre-drilled holes are sliding fixing points to allow movements of thepanel (G).


Points for particular attention:

Two fixed fastening points of one panel or of 2 adjacent panels may not be on the same profile.

If this is not possible with narrow cladding panels, one must detach the aluminium support section.


The cladding panel is fixed to the aluminium section by means of a stainless steel (quality A2, AISI 304)ASTRO rivet with coloured head. The fastening system also includes ASTRO stainless steel cylinders thatact as a spacer. As a result, the free expansion of the panel is guaranteed.

The following design of the ASTRO rivet and ASTRO cylinder must be respected.

ASTRO cylinder

ASTRO rivet

Holes for fixing points are pre-drilled in the panel.

• diameter of fixed point : 8.3 mm• diameter of sliding point : 11 mm

The pre-drilling of GRANITEX is done from the back of the panel. In order to have the rivet adequatelypositioned against GRANITEX panels, the granulates around the drilled hole must be removed by meansof a special Granitex miller available from E.P.O. . For aesthetic reasons it is recommended not to mill thecoloured epoxy layer right up to the base panel.

After the installation of the aluminium support structure, self-adhesive strips (6x9mm) are appliedcontinuously on the T and L aluminium sections according to diagram below. The foam strips serve toprevent panel vibration. They are applied at the edges of the profile to guide infiltrating rainwaterdownwards.


The panel is then correctly positioned and one can predrill the underlying aluminium section at thelocation of the fixed points (F). The predrilling of the aluminium section takes place using a specialcentralising drill for fixed points.

• diameter for predrilling aluminium section : 4.9 mm

The façade panel is then fastened at the fixed points (F) with the ASTRO blind rivets and ASTROcylinders by means of an electric rivet machine.

The aluminium support structure is then pre-drilled at the free sliding points (G) with the centralising drillfor sliding points.

The façade panel is then fixed through all the sliding points using the ASTRO blind rivets and ASTROcylinders.

Centralizing drill forfixed fastening point

Centralizing drill forfixed fastening point

Fixed fastening point (F)

Sliding point (G)


7. JOINTS

The façade panels are fixed with open joints to allow the free dilatation of the panel.

• joint width (horizontal/vertical) : > 8 mm• maximum thickness of underlying finishing profile : 0.8 mm

The vertical joints can be made black using black self-adhesive tape or a weather-resistant black coating.The vertical joints can be finished with decorative covering sections in wood or aluminium.

The horizontal joints can be left open. If required, the horizontal joints can be finished with a blackaluminium joint profile. This is particularly useful when the underlying insulation must be protectedagainst the infiltration of rain. One could also use a decorative horizontal joint section in wood oraluminium.


8. OTHER CONSTRUCTION DETAILS

Movements in the metal sections (corner section, bottom section, etc.) should not influence the panels. Ifnecessary, the aluminium sections must be pre-drilled, and fixed according to the principle of fixed andsliding points.

Finishing sections in metals such as zinc, copper, lead, etc. are not to be used.

EXTERIOR CORNER: Corner finishing can be provided by means of a joint sealing strip or afinishing profile of aluminium or PVC.

INTERIOR CORNER: A joint sealing strip or finishing profile in aluminium or PVC can also be usedhere.

TOP FINISHING: Sufficient ventilation openings must be provided.

BOTTOM FINISHING: The open cavity between the back of the panel and the insulation or the backconstruction must be sealed at the bottom with a perforated aluminium sealing profile. This profileprevents the entry of birds and vermin. One leg of the sealing profile is clamped between the aluminiumsupport profile and the panel and is not thicker than 0,8 mm.

WINDOW FINISHING WITH RETURN: Sufficient ventilation openings must be provided at thetop and bottom of the window.

WINDOW FINISHING WITHOUT RETURN: Sufficient ventilation openings must be provided atthe top and bottom of the window.

EXPANSION JOINT: The expansion joints of the building must also be included in the cladding. Theyare obtained by placing a support profile at both sides of the joint.


9. ACCESSORIES

The following accessories can be obtained from E.P.O. :

Rivet with coloured head (GLASAL, ETERFLEX,GRANITEX, PELICOLOR, CARAT, NATURA)

SS 4,8x20-K16 9020..

ASTRO cylinder (GLASAL, ETERFLEX,GRANITEX, PELICOLOR, CARAT, NATURA)

SS 10,25 906104A

ASTRO adhesive foam strip PE 6 x 9 906001IJoint profile with rib for horizontal joint ALUMINIUM + black coating 2,5m 906306CSealing profile (perforated profile) ALUMINIUM 50/30

2,5m906307A

Sealing profile (perforated profile) ALUMINIUM 70/302,5m

906307C

Sealing profile (perforated profile) ALUMINIUM 100/402,5m

906308C

Exterior corner profile ALUMINIUM + colour coating 60/10/15tot 3,6 m

CON05

Exterior corner profile ALUMINIUM anodised 40/10/122,5m

906308B

Interior corner profile ALUMINIUM + colour coating 35/253 m

9065..B

End profile window finishing ALUMINIUM + colour coating 8/12/453m

9065..D

EURO PANELS OVERSEAS N.V.Bormstraat 22, B-2830 Willebroek - BELGIUMTel 0032 15 71 82 80 - Fax 0032 15 71 82 89e-mail: [email protected]: www.europanelsoverseas.beVAT BE 0466.056.888 - Bank : KBC 482-9098051-96

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Façade FIXING OF ARCHITECTURAL PANELS to Aluminum... · Façade FIXING OF ARCHITECTURAL PANELS ... In view of the high thermal coefficient of expansion of ... A joint between the