VitrabondG2® and VitraPlate® Non-Combustible Aluminum Façade Materials
Offering choices so you can use the RIGHT product for the RIGHT application
Fairview Architectural North America has earned the reputation of being the innovator in the façade industry, even from manufacturers of competing façade products. Inventors and creators of unique materials and concepts come to Fairview when they have an innovation that could be introduced to the Building Facades market.
We hear from these visionaries that Fairview NA stands out as the partner of choice, a trustworthy partner to integrate their concept into the building façade industry in a safe and responsible way, creating realistic solutions.
By having many product offerings within the building façade industry, Fairview Architectural North America is in the unique position of having a much wider understanding of the industry than many of the manufacturers who have just a single product range. It is natural then that we get many questions relating to the results of our product development.
Some of these questions relate to our VitrabondG2 Non-Combustible Metal Composite Material and VitraPlate® Pre-Finished Aluminum façade panels. These products have been confirmed by independent analysis to be rated as Non-Combustible in compliance with current code requirements and definitions.
How can VitrabondG2® and VitraPlate® be considered non-combustible?
The IBC defines in Section 703.4 how to determine if a product is considered non-combustible. The code must have a definition like this, otherwise no manufactured or painted product could be considered non-combustible as defined by the ASTM E-136 non-combustibility test.
Does VitrabondG2® and VitraPlate® pass the ASTM E-136 test to prove that they are non-combustible?
The ASTM E-136 test is for elementary materials only and is therefore not for any painted product. As such, the aluminum used in VitrabondG2® and VitraPlate® have been tested and passed the ASTM E-136 and is therefore rated as non-combustible.
Has VitrabondG2® or VitraPlate® passed an NFPA 285 full scale wall assembly fire test?
The NFPA 285 test does not apply to VitrabondG2 and VitraPlate®. It also does not apply to the non-combustible wall assembly applications where we recommend using VitrabondG2® and VitraPlate®. The NFPA 285 is specifically made for combustible products, to allow their use in wall assemblies that are meant to use products rated as non-combustible according to the building code. Fairview Architectural North America has many products for many applications. Other MCM/ACM manufacturers with a single product range must try to make their product fit where it shouldn’t. By contrast, Fairview promotes VitrabondFR® where wall assemblies are permitted to contain combustible products and promotes VitrabondG2® and VitraPlate® for use in non-combustible wall assemblies.
Why not have VitrabondG2® and VitraPlate® tested in an NFPA285 wall assembly test? Wouldn’t that open up a greater market share?
It is not about market share – we simply develop the RIGHT product for the RIGHT application, and don’t try to promote saving pennies at the cost of life safety. Fairview Architectural North America were the first to discontinue the use of the flammable PE core ACM, and the first to develop two feasible non-combustible façade products: VitrabondG2® and VitraPlate®.
These images show Fairview’s VitrabondFR® ACM and a competitor’s FR ACM product after the NFPA285 test. Both tests passed because it is the wall assembly design that affects the result of the test more than the products used. Yet the burden and responsibility of testing is put on the product manufacturers, rather than those responsible for the wall design. VitrabondFR® is available for use where the code allows.
Is there a full-scale wall assembly fire test for VitrabondG2® and VitraPlate® in North America?
At this time non-combustible products themselves are not required to undergo full-scale wall assembly testing, and there are no full-scale fire tests for non-combustible products in the North American market. Fairview Architectural North America does not test products just to say it meets this or that criteria, but rather develops the RIGHT product for the RIGHT application and performs the RIGHT tests to meet the RIGHT criteria.
We envision a building façade industry free of flammable cladding materials. We all understand that buildings need paint, adhesives, waterproofing, paper backers on drywall, etc… and we are working with conscientious insurers, code consultants, fire marshals, and architects who have embraced our vision and are together leading the change to a safer, yet realistic, building façade industry.
What is Engineered Metal Plate?
Metal Wall Panels (MWP) take many forms, and is not always recognized at first glance to the untrained eye. However, it is one of the most common façade cladding products in use.
One of the materials used for Metal Wall Panels is Aluminum Plate. Many elementary materials in construction now have an “Engineered Version” to improve on the benefits of that material. Examples include Engineered Hardwood Floors, Engineered Floor Joist, and Engineered Metal Plate.
VitrabondG2 is a Non-Combustible Metal Composite Material, a perfect example of an engineered metal plate product.
What is Engineered Metal Plate?
Metal Plate wall panels have been used for years on building facades, however some of the challenges faced in working with this products include oil canning (rippling of panels after installation due to thermal expansion and contraction), difficulty in handling due to the weight, multiple processes like welding, grinding, painting, etc…, and design limitations due to limited finish options.
Engineered Metal Plate, on the other hand, has all the benefits of Metal Plate, but is lighter weight, more rigid, has a higher strength to weight ratio, less tendency for oil canning, easier to handle, and comes in nearly unlimited finish options like what can be had with Metal Composite Material.
What Finishes are Available?
Practically any design or pattern can be used for the visible portion of this cladding. Modern buildings often use solid or metallic finishes, but the material can also be made to look like bricks, stones, or other unique finishes and textures, allowing a wide scope in design options for the architects.
What Materials is Engineered Metal Plate made of?
In any engineered product, the materials used are far more advanced than its traditional predecessor. Engineered Metal Plate is still comprised of metal, but uses modern manufacturing means and methods in order to yield more benefits.
Top 10 reasons Engineered Metal Plate is an ideal cladding product for the building façade industry:
VitrabondG2 is a Non-Combustible Metal Composite Material, a perfect example of an engineered metal plate product. Here are some benefits that are unique to VitrabondG2:
- All the benefits of MCM, but in a non-combustible product.
- Variety of finishes that can’t be achieved in the traditional spray-applied plate products.
- Most durable finishes known in the industry.
- Higher strength to weight ratio than metal plate façade materials.
- Coated prior to fabricating to eliminate additional handling and outsourcing to painters.
- 50% lighter weight means for less structural support needed within the wall assembly and attachment systems.
- Fully recyclable without needing grinding equipment to separate components.
- Much less tendency for oil canning from thermal expansion and contraction.
- Easier to machine and work with than solid aluminum plate
- Works with standard MCM systems, such as the Arrowhead Installation System.
Learn more at www.fairview-na.com!
Progressive Vs. Non-Progressive Panel Installation Systems
Progressive vs. Non-Progressive Panel Installation Systems
In buildings, it is typical for the exterior walls to be covered with some sort of panels to both protect the "guts" of the walls and to present a properly-finished appearance. To those passing by, the differences between the options aren't always immediately apparent except for their visual appeal. However, if you're in the construction business, you need to be quite aware of the benefits and drawbacks of the two main panel installation systems: Progressive and non-progressive.
What is a Non-Progressive Installation Panel System?
This type of installation gets its name from the fact that the installation of one part does not progress from that of the prior module. It has many benefits, such as the ability to remove or replace a section without the need to dismantle those that are around it. This makes it easy to repair or update a wall on an as-needed basis without high costs, other benefits include having multiple crews installing in all directions
What is a Progressive Installation Panel System?
Progressive systems use panels that interlock in some fashion. One of the easiest ways to imagine these systems is as being like bricks. Each one builds upon and interlocks those that were installed before it and that will come after it. The biggest downside to this is that it takes a long time - and therefore, a lot of money - to install. It also makes remodeling or repairs into complex, expensive procedures. Installation is one directions only, so you can not expedite installation with multiple crews, like you can with a Non-Progressive Panel System.
Which is Best for a Building Project?
In most cases, the non-progressive installation system is superior. Therefore, there is no need to forego the ease of installation and repair that comes with a non-progressive installation system. In fact, the non-progressive version is almost always the best option.
To learn more, just contact us. We'll be glad to explain all of our structural offerings so that you can make the best choice for any project.
All MCM Is Not Created Equal
ALL MCM IS NOT CREATED EQUAL
The building façade industry has seen a continuous increase in the use of Metal Composite Materials (MCM). This light weight and rigid material provides and attractive appearance and is well suited to many building styles.
Like any product growing in demand, more and more brands start hitting the market, and finally some companies, struggling for market share, begin to drop prices and engage in the losing battle of a Price War.
Low Cost Providers:
When it comes to MCM (also known as Aluminum Composite Material, or ACM) many low-cost providers are trying to push their way into the market. This began with some low cost imported products suited to the signage industry being used for building facades, because it looked about the same. Following this, some domestic MCM manufacturers begin competing in this price-driven boxing ring and as a result must sacrifice quality to maintain their slim margins.
Pricing
As with all products in any industry, a drastic price difference either means there are product variables being exploited, or margins are being cut leaving the vendor no room for servicing the client. Either way, the validity of any warranties is called into question. Will they use a loophole in their warranty to get out of product failure? Will they be in business for long, if they are selling at little to no margins?
Warranty
Warranty is one of the most important aspects in choosing your MCM product. If a company has great confidence in their product they will offer you a great warranty. If they don’t, you might want to ask some more questions.
Cost
Cost and price are two different things. Price is what you see up front. Cost is how your purchase affected your bottom line profits. Risk is a major factor in a purchasing decision. If a MCM product manufacturer can reduce your risk by offering better warranties, and better service, and goes the extra mile to help see your project through to success, you can be sure that they will stand behind you when you need them. Their price might look higher, but the cost of doing business with them might be much less than the headache of dealing with a “low-cost provider”.
An example of how price driven manufacturers might try to cut costs is to increase the production speed of the ACM manufacturing line to get more output, with effects which may not appear until years later. Or they might use lower grade raw materials, or cut their customer service.
Conclusion:
Quality is sustainable and with that creates a long lasting look on your building that you worked hard to create. You deserve to have the best products representing that building and your vision. And you don’t deserve to be replacing the “cheap” product when it fails, which is much costlier than the small percentage saved at the initial product selection!
STATEMENT REGARDING THE USE OF POLYETHYLENE CORE ALUMINUM COMPOSITE MATERIALS ON BUILDING FACADES IN NORTH AMERICA.
FAIRVIEW Products are distributed in many countries globally. Please be aware that FAIRVIEW product features and availability may differ between locations. Each location is independently operated by local management and ownership to ensure the individual needs of the local markets are satisfied. This statement relates to the North American market only.
June 19, 2017
STATEMENT REGARDING THE USE OF POLYETHYLENE CORE ALUMINUM COMPOSITE MATERIALS ON BUILDING FACADES IN NORTH AMERICA.
Our thoughts and prayers with all those affected by the Grenfell Tower fire in London UK. While the tragedy is yet to be fully investigated, we hope that everyone in the industry will be affected enough to ensure the correct use of materials and follow the appropriate codes and standards.
No Fairview Architectural products were used on the Grenfell Tower project, nor on any of the similar fire incidents. There are several types of ACM suitable for different uses when correctly specified, fabricated and installed in accordance with the appropriate building codes and industry standards.
Fairview Architectural North America will cease production of Vitrabond® PE (Polyethylene Core) for building facade use in North America as of July 1st 2017.
This decision was made and deadline set in March 2017 to ensure that our products align with our vision of a façade industry free of flammable cladding materials. Although the codes allow for this product in certain applications, we feel this is a responsible action to help reduce the risk potential of any Fairview products ever being misused, which is beyond our control.
For more information or to learn about non-combustible ACM cladding please contact us at helpdesk@fairview-na.com, or visit our website at www.fairview-na.com.
Sincerely,
Jerry Fossey
General Manager
Fairview Architectural North America
Expansion and Contraction of Aluminum Composite Material
Why is it important to use a panel mounting system that allows for expansion and contraction of Aluminum Composite Material ?
Aluminum Composite material (ACM) consists of two skins of aluminum, typically 0.020" thick each, sandwiching a core material. ACM is routed from the back to create a V-Groove, leaving a little bit of the core material on the back side of the front skin. This routed panel can then be folded easily by hand along the groove.
The remaining aluminum face skin is now what holds the panel in place for years to come. As with any building product, there is a certain "coefficient of linear expansion", meaning that as temperature changes, the material will shrink (when it cools) or expand (when it warms up).
In a typical “rout and return” system panels are v-grooved and folded to make “returns” around the perimeter and Panel Extrusions are fastened to these returns. These fabricated panels, sometimes called cassettes, are then fastened to the building using a variety of methods, either with wall extrusions, mounting clips, etc… Many times however, these panels are mounted to the substrate without allowance for thermal expansion, often pushed tight one against the other.
When there is no allowance for thermal expansion the panels may begin to show "wrinkles" or "waffling" on the panels exposed surfaces, often called the "oil can" (pictured) effect and must be avoided. Thermal expansion may also cause bending at the weakest parts of the panel which is at the folds of the returns.
(https://www.stortz.com/what-you-need-to-know-about-oil-canning-in-sheet-metal/)
This means expansion and contraction will in effect be opening and closing the fold repeatedly, although it is a very small amount, potentially weakening the fold or allowing for uncontrolled water penetration.
What happens when you repeatedly bend Metal? Finally it breaks! Unfortunately this is one feature that many façade designers and consultants overlook when specifying an ACM Rainscreen System.
There are a lot of factors involved that increase or decrease the likelihood of there being a problem with thermal expansion. One is the color of the ACM. Another is temperature ranges. Some regions have very small temperature ranges all year long and other have radical changes not only from day to day but from season to season as well.
The Fairview Arrowhead Panel Installation System (pictured) has been designed, engineered and tested to safely allow for thermal expansion and contraction.
Learn more at http://www.fairview-na.com/products/arrowhead-panel-systems/
Source: https://www.stortz.com/what-you-need-to-know-about-oil-canning-in-sheet-metal/
The Benefits Of Coil Coating For Exterior Facade Use
Designing the exterior facade is the fun part, but getting your building from blueprint to ribbon-cutting requires a marathon of attention to detail. To get the look you want plus the durability your clients need and the ease-of-use your contractors demand, you need to pick the right cladding material. Metal panels fit the bill, and with the right coating, they can serve a nearly endless number of design purposes. Coil coating provides a range of benefits that make it a superior choice for exterior facade use.
HOW COIL COATING WORKS
Before the colorful finished product reaches your worksite, the metal used in your exterior panels arrives in a gigantic coil or roll from steel and aluminum rolling mills. As this coil is unwound at the factory where the coating is applied, the long sheet of metal is pulled through a highly specialized machine that cleans it, primes it and paints it before winding it all back up again at the end of the process. The continuous nature of this manufacturing process is incredibly efficient and leads to a high-quality final product.
THE BENEFITS OF COIL COATING
The high-tech coil coating process creates metal panels with many advantages over ones that need to be painted after installation:
- Durability: Because it's pre-painted, a coil coated finish is less likely to be breached by weather, UV rays or installation errors. The coating is continuous, rather than having joints and edges that can result in a post-painted product. Coil coatings protect the metal from corrosion for a long-lasting, waterproof finish.
- Uniformity: The highly-controlled factory process ensures that every panel you order is the exact same color — no need to worry about different dye lots or formula changes. Each section of the long coil of metal is also primed and cured in the same way, so the thickness, sheen and durability of the final product is the same on every portion of your order.
- Sustainability: Metal is one of the most readily recycled construction materials in the world, and coil coated metal panels are often made from recycled materials. The coating process also captures VOCs to reduce air pollution and exceed EPA standards.
- Adaptability: Those amazing metal coils can be used to make any length of the final product. This reduces the need for awkward joints and seams that can subtly break up the look of your design. Larger, customized panels also require less handling and modification during installation, which may even save labor costs.
- Flexibility: Coil coated finishes that use Kynar PVDF resin are flexible enough to be formed after painting, allowing manufacturers to bend and mold the panels to exact design specifications without cracking the paint — a major improvement over traditional spray finishes. These panels can be fabricated either on site or in the shop, depending on your needs.
- Versatility: There are several ways to work with coil coated metal, depending on your contractors' preferences and expertise. Adhesives and mechanical fastening are all possible with this product. Vitrabond also offers a virtually endless array of colors and finishes, including various metallic looks and simulated wood and stone finishes. Custom matches are also available, so your imagination is your only limit in bringing your design to life.
Because there's simply nothing out there as durable and beautiful as Vitrabond metal composite panels, be sure to spec Vitrabond for your exterior facades. Coil coating makes all the difference, and we're happy to show you more about this fascinating process.
Unique Use Of Vitrabond ACM - Life-Size Replica Of Voyager 2
Vitrabond Aluminum Composite Material is not only limited to use on building facades!
The vision of artist Peter Hennessey; ‘My Voyager’ is an actual size model of Voyager 2 - the same size, shape and form. In developing this piece, Vitrabond was utilized to assist in the creation of Peter’s vision not so much to reproduce the Voyager, but more-so to “physically invoke it; to summon the spirit of the Voyager so that we might apprehend it as a physical object”.
http://fv.com.au/wp-content/uploads/2015/03/My-Voyager_email.pdf
What unique products have you seen using MCM?
MCM Panel Manufacturers And MCM Panel Fabricators... The Difference
How do I specify Metal Composite Material (MCM) manufacturers vs. fabricators?
This is probably one of the most confused topics in the ACM/MCM industry, so I hope that this short post will help clarify the difference between the Manufacturer and Fabricator of Metal Composite Material (also known as Aluminum Composite Material or ACM).
MCM consists of two skins of metal sandwiching a core material, which provides greater rigidity and superior flatness than sheet metal or plate.
The MCM Manufacturer is the one that makes sheets of MCM, in a process where the skins and core are fused together in a continuous coil process. There are also some manufacturers that press skins to a core one sheet at a time, however this is generally known to be a lower quality bond, which is important when you consider the harsh conditions an exterior building envelope is required to withstand.
The MCM Fabricator cuts, routs, folds and otherwise processes the MCM to fabricate panels to mount on the building. These fabricators can either have their own tested installation system using aluminum extrusions, or they can use a third party’s installation system.
So which one should I specify? The MCM Manufacturer or the Fabricator?
The answer is BOTH! There are many testing requirements, some of which apply to the Manufacturer and some to the Fabricator. Anything related to the MCM itself, such as fire rating and surface finish belong to the Manufacturer. Tests that require panel fabrication generally apply to the Fabricator, such as wind loads and water penetration.
It is important then to clearly differentiate between the Manufacturer and the Fabricator in your specifications. A sample of specifications that make this clear can be found at http://www.fairviewarchitecturalusa.com/s/Vitrabond-FR-Specs-82015.docx
I hope this helps build a greater understanding in the Composite Metal Wall Panel industry!
Jerry Fossey is the General Manager at Fairview Architectural USA, manufacturer of Vitrabond Metal Composite Material.