What are Cladding Attachment Solutions? (Part II)
Cladding attachment solutions are essential products in the building industry created to improve the project's characteristics. Designers and architects who prefer to use modern materials such as ACM panels and slick sidings for cladding applications require attachment solutions to ensure energy efficiency and building stability. In the "what are cladding attachment solutions (part 1)" article, we discussed energy codes, exterior insulations and standard requirements for cladding attachment solutions. This section will provide information about cladding attachment solutions available in the market for ACM panels, Aluminum sidings, Wood sidings, and other practical facade materials.
Available Cladding Attachment Solutions and Systems
A wide array of proprietary and generic cladding attachment systems are available in the market, designed to satisfy ACM panels and different siding materials requirements. They also feature various materials, including galvanized steel, Corten steel, stainless steel, pure aluminum or alloys, fiberglass, and plastic. Each system has its unique approach for different projects. However, these approaches can be classified as continuous framing, intermittent clip and rail, sub girts systems, long fasteners, masonry and other engineered methods.
Almost all cladding attachment solutions and systems are suitable for ACM panels, one of the best products for exterior applications. Attachment systems are available to accommodate numerous claddings for constructions of all latitudes and exposures. However, typically more extreme the wind load or the heavier the cladding material, the tighter the gaps and spacing of the solutions compromise the practical thermal functionality. Therefore, the ideal solution is the one that provides optimal structure and thermal functionality for the cladding materials needs of the particular project.
Each cladding attachment solution for ACM panels and decorative boards comes with exceptional thermal efficiency, cost, and installation ease. All of the cladding materials and systems can be installed with steel stud wood, concrete block backup walls, and almost all solutions lending themselves better to commercial facilities than residential projects. However, some architects and designers manage to utilize them for homes and personal properties.
Continuous Framing or Sub-girts Attachment System
Sub-girts which are continuous framing systems, are the forerunners to the more thermally efficient clip and rail attachment solutions that have been produced in the past few years. Due to the advantages and unique characteristics of metal sub-girts, architects prefer to use them as cladding attachment solutions in various applications. However, three primary types of sub-girts are used in the construction industry: vertical sub-girts, horizontal sub-girts, and crossing sub-girts.
Vertical Sub-Girts
The vertical sub-girts system features continuous galvanized steel framing pieces, generally eight-to-twenty-gauge z-girt or c-channel profiles. These profiles are vertically attached to the backup wall section. Commonly, the girts have space to line up with the stud framing behind the main structure. ACM panels and other cladding systems are installed or attached directly to the outer flange of the support. In vertically oriented cladding usage, additional horizontal supports can be applied to the exterior of the verticals.
The vertical z-girts are typically not thermally efficient cladding solutions. Due to the excessive thermal bridging, it is better not to use these particular supports in typical applications.
Horizontal Cladding Attachment Solutions
The horizontal metal-sub girt cladding attachment solution for ACM panels consist of continuous galvanized steel framing members. In this system, eighteen to twenty thickness or gauge sub-girt profiles are horizontally attached to the steel studs or a concrete wall. Installers consider standard gap sizes between the backup wall and the supports depending on the cladding material loads.
Like vertical sub-girts systems, the cladding material is directly attached to the external flange of the supports. In this system, it is better to use additional vertical supports for more stability. The thermal efficiency of these supports is not considered high. Thus, architects may reconsider using them if thermal properties are essential for the facility. The exterior insulation system installed between the sub-girts is degraded significantly, and it is only 30% to 50% effective for ACM panels cladding systems. However, the horizontal approach is more recommended in typical applications compared to vertical support systems.
Crossing Continuous Framing
The crossing sub-girts are the most popular type of continuous framing in the cladding attachments industry. This attachment solution features two straight galvanized steel or aluminum framing particles. They consist of eighteen to twenty gauge supports profiles attached in a crossing pattern to the concrete backup wall or the steel studs. Depending on the cladding loads, designers define the spacing between these framings and attach the cladding material directly to the outer rim of the girts.
Crossing sub-girts are more thermally efficient and can be used for different applications. For example, exterior insulation installed between crossing continuous frames is not degraded considerably, and they provide more than 50% efficiency for the cladding material. However, this particular system can be improved by using low conductivity isolation thermal washers or breaks between the girts and the backup wall.
Check the part 3 of this article to know more about cladding attachment solutions that building industry requires.
What are Cladding Attachment Solutions? (Part I)
Cladding attachment solutions are practical factors in creating more efficient buildings for modern architecture. The use of external installed cladding systems such as ACM panels is becoming increasingly common in the world. Architects use these products to meet new energy standard requirements. Commonly referred to as rain screens or exterior insulations, builders continuously install these materials outside the primary structure.
Cladding materials are generally more thermally efficient than the insulation placed between the inboard of the structural system. Additionally, cladding attachment solutions provide significant advantages for durability and thermal comfort. As a result, investors and designers pay greater attention to the design of thermally efficient cladding attachment solutions. Thus, manufacturers have produced several practical systems for the market in recent years. These attachment options include sub girts, rail systems, long screws, ties, intermittent clips and other engineered supports.
The greatest challenge that contractors and designers face is selecting and evaluating the suitable cladding strategy for their upcoming projects and understanding the implications of their options on thermal performance, installation methods, and system costs.
Energy Standards and Exterior Insulation
There are different energy standards and codes in power across Canada and America for commercial and residential buildings. The two well-known energy codes are National Energy Code for Buildings (NECB) and the International Energy Conservation Code (IECC). However, ASHRAE Standard is the most commonly referred building and energy code in most Canadian provinces. Different adaptations and versions of these standards are in effect in most areas.
While various versions and adaptations of these regulations and codes are enforced in different provinces, each requires consideration for the effectiveness of installed cladding and thermal bridging. Exterior cladding materials, including various types of ACM panels, showcase efficient and cost-effective methods to provide thermal performance improvement and meet all regulations requirements. However, the effectiveness of this particular approach depends on the selection of thermally efficient cladding attachment solutions. The attachment solution can be a significant thermal bridge to reduce exterior insulation performance by as little as 5% to 10 % for modern high-performance systems.
Cladding Attachment Solutions Requirements
There are several requirements for choosing the most efficient cladding attachment solutions for a building. It is recommended to consider all factors for achieving the best results. Followings are the cladding attachment solutions requirements that designers and contractors should know:
- Gravity loads (cladding materials weight)
- Wind loads
- Seismic loads
- The Back-up Wall Construction Material (wood, steel, concrete, concrete blocks)
- Attachment points back into the building's structure with various materials such as studs, slab edges, and sheathings
- Exterior insulation thickness
- Utilization of rigid, semi-rigid, or spray-applied system
- The ability of fastening cladding supports directly through the face of the insulation panel
- The ability to fit the semi-rigid or spray-applied system tightly around the supports and their ease of installation
- Tolerable thermal efficiency loss orientations and requirements from supports
- Attachment solutions location and direction for the cladding system, whether it is paneled, vertical or horizontal
- Details required for attachment of cladding material ar corners, penetrations and returns
- Combustibility requirements (this factor is essential)
- Dimensional tolerance adaptation
- Allowable thickness for walls
The engineer working for the cladding manufacturer, contractors, or the project's architects will typically perform the design of the attachment solution. Many manufacturers produce pre-engineered and designed cladding support systems by utilizing load tables.
It is crucial for the cladding support and solutions designer to understand the requirements of the demanding project, including thermal needs. This is for designing a system and spacing of supports to be optimized for making the best use of the exterior cladding or insulation. There are various options available that will be selected equivalent to the number of factors as discussed earlier.
One of these solutions that designers choose is the discrete clip and rail type cladding support that features semi-rigid insulation placed between pin supports inboard and the continuous vertical rail. The cladding is attached to the back section of the vertical rails on the exterior side of the insulation. Another one is called a long screw, which is screwed through the rigid insulation with continuous vertical strapping. This creates a truss cladding solution system. The masonry ties are also expected, which are appropriate for semi-rigid insulations. The connection provides lateral resistance without supporting gravity loads.
To know more about cladding attachment solutions, continue reading the second part of this article.
The Most Popular Types of Exterior Wall Claddings
Wall claddings are the primary products when customers consider enhancing the appearance of their homes. There is a range of fabulous cladding materials available in the market which architects can utilize for creating aesthetics and modern looks for the facility. In addition, these facade systems are practical for new construction and renovation projects for old buildings.
Any homeowner can obtain a visually stunning facility with personality, character, and individual style with suitable wall claddings products and design advice. However, wall claddings are not just for providing first impressions and exterior appeal. But they are high-performance materials that also serve as a protective layer for the buildings and their interiors. Suitable quality materials such as Aluminum Composite Panels act as shields for the structure of the building against rain, sun, wind, fire, noise, humidity, and pollutants. In addition, wall claddings are excellent insulators, guards against structural deteriorations, making the interior more energy efficient for saving expenditure.
Why Choose Exterior Wall Claddings?
Exterior Wall claddings are versatile and affordable solutions that enhance the aesthetics of a building and boost its durability and functionality by improving its tolerance and resistance to external factors. Various alternatives are available in the market with numerous styles, finishes, performance, durability, and material.
Wall claddings over weatherboards and decorative panels are often considered first materials during building makeover applications due to their relatively simple installation process.
While costs and money are essential factors while selecting the cladding material, whether it is a simple metal cladding or a complex and modern ACP material, it is also crucial to a few other considerations in the decision-making process. For example, the local environment is essential because the cladding system must handle heavy wind loads, extreme heat and cold, and a corrosive marine atmosphere. For this purpose, ACM panels can reduce the environmental impacts of the facility through their beneficial characteristics such as thermal performance and corrosion resistance, and they ensure safety by meeting compliance requirements for fire-proof features.
What are ACP Wall Claddings?
ACP or ACM wall claddings materials are low-maintenance and durable facade products made from a combination of pure aluminum and other substances. As a consequence, they are less unprotected from water, sun, dust and debris.
Aluminum composite panels are long-lasting, low maintenance, lightweight, and cost-effective wall claddings. In contrast with other cladding materials, ACM panels are resistant to moisture, fire, and insects. These materials also have the ability not to expand or extract considerably with temperature change. While earlier versions of ACP materials were experiencing moisture-related failures, manufacturers applied a protection coat to their products to solve the problem.
ACM panels are relatively new in the wall claddings industry. Manufacturers and the production process of these panels dictate that they are reusable or recyclable at the end of their lifespan. However, they can last for decades without causing issues for the building. In addition, the energy efficiency of ACP materials varies greatly. Thus, these wall claddings are suitable for the modern-era building industry due to their environmentally friendly and energy-saving properties.
What are Metal Sheet Claddings?
Metal wall claddings are also exterior sidings that require low maintenance and are highly durable. They are made from different metal materials, including galvanized and Corten steel materials. Like aluminum composite panels, metal sheet claddings are available in various styles and color finishes, making them perfect for modern building applications.
The primary advantage of metal sheet claddings is their longevity in service. Once they are installed, these wall claddings will last for decades, and they will not be damaged by rain or snow. Corten steel claddings do not provide a medium for fungal growth and mold. Both of these can cause health issues to homeowners and occupants. Metal sheet sidings are essentially insect-proof, meaning homeowners will not have to spend money on spraying the exterior of their building with anti-insect substances. Additionally, these cladding materials are fire-proof, meaning they will protect the house in the improbable event of a fire.
Like ACM panels, metal sheet claddings are recyclable, and many companies offer recycled steel sidings and roofing. However, while Corten or galvanized steel sidings are more resistant than aluminum composite panels, they are more expensive and heavier. In addition, their heavy hail can cause dents that could be considerably costly to replace.
Among Metal sheet and Aluminum Composite Panels, there are other wall claddings available in the market. These products include brick sidings, vinyl sidings, wood sidings, PVC materials, fiber cement claddings and stucco. All of the materials above provide unique advantages and can have different cons due to their physical properties. Most designers and architects prefer to utilize aluminum and steel to create long-lasting buildings wall claddings.
What are Stick and Unitized Curtain Walls Systems
Curtain Walls are becoming common and practical materials due to the increase in the number of high-rise and modern buildings projects. These products are thin, aluminum-framed cladding systems that create functional and energy-efficient characteristics for the construction. They come with a variety of fillings which include metal panels, delicate stones, or even glass. The curtain wall system features a framing that is joined or attached to the buildings primary structure. It is essential to note that they do not bear the load of the roof or the floor; instead, it relies on the construction's system, particularly at the floor section. Thus, the gravity and wind loads of these products are transferred to the structure of the building. One of the most immeasurable things about curtain walls is that these systems range from the manufacturer's standard catalogue methods to the specialized custom wall panel.
History of Curtain Walls Systems
Curtain walls system production is dating back to the 1930s. They rapidly came into use in World War II. By that time, industries were started to utilize aluminum for various purposes other than military ones. In the modern era, curtain wall systems are gaining structural importance equivalent to new buildings elements and standards. Due to the fact that the cladding materials are constantly exposed to external factors such as atmosphere, wind, dust, and rain, the curtain wall should have an appropriate design, installing methods, and regular maintenance. These factors depend on the durability and functionality of cladding and wall systems installed on the construction to support the facility's structure. The expense of these materials depends on the type of curtain wall the landlord would like to utilize for the building. However, buying them can be a perfect investment for the owner because these products shield the facility's exterior and even protect the interiors from further damages.
Most Practical Types of Curtain Walls Systems
Manufacturers precast curtain walls at their factory and assemble them before sending them to the construction site. Depending on the method of the components assembly, they are typically two types of curtain walls systems. These types include stick curtain wall systems and unitized curtain wall systems. Knowing the unique characteristics of each product allows designers and builders to complete any project equivalent to their customer's demands while providing the best result. The following sections are a practical introduction to both types.
Stick Curtain Walls Systems
In the stick curtain walls method, installers should assemble the components piece by piece on the primary structure of the construction. These systems are mainly practical for low-rise buildings which are often in small regions. The installation method makes limitations for high-rise building because it is essential to have exterior access for reaching higher elevations. The stick system promises flexibility as it provides space for onsite arrangements. Additionally, it features the advantage of low shipping costs. The time and labor consumption will not be underestimated as tending to be relatively high.
Unitized Curtain Walls Systems
As the name itself tells, the unitized curtain walls systems are already assembled in the manufacturer's factory. In these systems, the production process installs and brings the components together as a single unit and then sends them to the buildings site. Thus, they do not require individual installation, and it negates the need for higher time consumption. The unitized curtain wall systems' size and height are directly comparative to the floor-to-floor measurement of the facility. They are common and popular materials for high-rise buildings. One of the noticeable benefits of these systems is that they do not need external supports such as scaffolding or cranes. Utilizing temporary hoist or mini cranes for any projects will often do the job. These particular systems offer the advantages of quick installation in constructions and perfect quality as the components are predeveloped in a modern factory with precise machines. However, the unitized curtain wall systems tend to increase the shipping cost due to the need for more extensive and more efficient protection during the transportation to the construction sites.
Components of Curtain Walls
Various components play an essential role in using curtain walls for buildings claddings. The following are the structural elements of a single curtain wall product that need to be installed on the construction's structure.
Back Pans
Back pans are metal sheets that are sealed and attached to the system framing around the perimeter behind the opaque areas.
Transom
These are horizontal railing members that are used to support the dead weight of the system.
Mullions
Mullions are components that are created on each curtain grid segment and extremities.
Vision Glass
They are transparent glasses installed on the curtain walls system called vision glasses.
Anchor
The curtain wall anchor system is utilized for attaching cladding materials assembly to the construction's structure.
Aluminum Plates Specifications and Characteristics
Aluminum plates are uniquely versatile and durable materials that can satisfy numerous applications in the modern era. Their chemical and physical specifications make them among the most popular industrial materials. Many builders prefer to purchase these suitable materials for their renovation or construction projects. However, before buying them, we recommend you to read this article to have a better vision of aluminum plates and their advantages to utilizing them most efficiently.
What are Aluminum Plates?
Aluminum plates are products that are made from pressing and rolling pure aluminum under severe pressure. Typically, these products are lightweight materials while being strong enough to be suitable for a wide array of applications. The ease of installation and maintenance process of these products boost their versatility and durability. Thus, this is the reason why these industrial materials are among the most popular metal sheets. Manufacturers apply various coatings to these materials to increase the strength and durability of aluminum plates and make them appropriate for different conditions.
Aluminum plates come with a variety of surface finishes. Some of these products feature smooth and uniform surfaces, while others are rugged or rough. The choice for adding textures to these panels depends on the demanding applications and the construction area. Additionally, these materials come in various sizes. Architects and designers can choose the size that will fit their design and desires. Fortunately, manufacturers provide customizable designs and sizes for their aluminum plates, and the price entirely depends on the products' dimension.
Essential Properties of Aluminum Plates
Now it is time to introduce aluminum plates' main characteristics and properties that can benefit builders and industrial companies fortifying their creations and products. The followings are the primary characteristics of these products to know before purchasing them:
Lightweight Characteristics
Aluminum plates are among the lightest metal products in the market, and they almost have 1/3 a weight of steel plates. These characteristics provide ease of installation resulting in decreasing the labor cost.
Strength
Regardless of aluminum plates lightweight characteristics, they are considerably strong materials. Their strength allows industrial companies to benefit from these materials in different projects. This specific characteristic of aluminum sheets makes them cost-effective and durable materials for buildings that require a long lifetime.
Corrosion Resistance
It is a common question that if the aluminum corrodes or not. These materials are among the metal sheets that have high corrosion resistance property. They will rust only when exposed to extremely harsh conditions. However, they can naturally generate an oxide layer which can increase this particular characteristic.
Formability
Aluminum plate systems have a relatively lower melting point compared to other industrial metals. Thus, manufacturers can quickly form them into any demanding shape by subjecting them to a certain heat level. Their physical properties also allow industrial companies to fabricate them without putting in so much effort.
Functionality for Sensitive Applications
One of the advantages of aluminum materials is that they are suitable for sensitive applications such as food and chemical packaging. This is due to their low chemical reactivity, which makes them difficult to react with other materials.
Fireproof Characteristics
Nowadays, they are strict regulations and standards for safety purposes, including fireproof and non-combustibility of cladding materials for construction projects. Aluminum plates do not burn when exposed to fire flames, and the event can only affect a thin layer of the material. Another significant thing to remark is that these panels do not release toxic gases when a fire occurs.
Reflective Property
Another beneficial characteristic of aluminum plates is their light reflectivity, followed by avoiding heat infiltration and perfect lighting systems. Additionally, this can help the facility maintain its interior temperature during both hot and cold season, saving more energy and decreasing overall expenditure.
Recyclability
Modern industries are focusing on utilizing materials that are environmentally friendly and recyclable for different applications. Aluminum plates most popular advantage is their ability to be recycled which makes them eco-friendly materials. Thus, most products, such as aluminum composite materials, are already made from recycled aluminum materials.
Gauge and Thickness Variety
The flexibility of aluminum plates allows manufacturers to produce their products in various dimensions. Thus, customers can choose the thickness of their products equivalent to the active project. The thickness of these materials is also called gauge among industry experts. The gauge of aluminum plates does not have defined metrics or standards. Thus, it is essential to have a conversion sheet to determine the perfect thickness of the metal when using these materials, which can be measured in terms of inches or millimeters.
Types of Aluminum Plates
It is essential to know that aluminum plate products are not all the same, and they come in various forms. Here are a few of the practical plate systems that are common in the market.
- Perforated Panels : These panels are perfect for aesthetics and modern designs, including sun shades, screens and ceilings.
- Brushed Aluminum Plates : They have a uniform pattern and are ideal for creating appealing looks.
- ACP Materials : ACPs are lightweight materials that can be an efficient choice for buildings claddings.
- Anodized Plates : These particular products can form strong bonds with other materials, and designer can utilize them for decorative purposes.
Techniques for Cutting Tubes and Pipes
Tubes and Pipes are suitable industrial products that can be made from different materials of different flexibility and density for plumbing systems such as copper, galvanized steel, aluminum and cast iron. Many factors involve choosing the particular technique or technology to cut the product for tubes and pipes fabrication. The process's primary factors are the tubes and pipes material, the squareness of ends, wall thickness, end conditioning requirements and secondary process needs. Other features that affect the cutting procedure include production volume, overhead costs, cutting efficiency and unique requirements.
Before Cutting Tubes and Pipes
Before getting to the introduction of the most practical tubes and pipes cutting methods, experts should consider initial steps to ensure the quality of the process. The followings are essential steps before starting the cutting procedure:
- Regardless of the material, it is necessary to measure the diameter of the product to be cut to ensure that the operator utilizes the suitable size cutter for the job.
- For determining a line for a straight cut, it is appropriate to use a tape measure and a pencil or other writing instruments to mark on the surface of the product. It is better to mark around the product's circumference, especially when the cutting tool is a handsaw.
- By securing the pipe and tube with a clamp, miter box or even duct tape, it is possible to ensure the cut as straight as possible, and this way, the operator can keep the length from slipping out of place during the cutting process.
Abrasive Cutting
This cutting method is a basic, manual technique for cutting-to-length product to the customers demanding in any alloy. The process operates by utilizing a circular abrasive blade or a wheel with resin composition to grind through the product. The cut size of the fabrication depends entirely on the device. This particular system is suitable for small product runs that do not need end conditions.
Band Saw Tubes and Pipes Cutting
This cutting method is a fully automated process, and most manufacturers utilize the system to cut rods, bars, pipes and tubes. The band saw way is perfect for large volume production. The blade used in this system is a continuous band of metal material with various tooth configurations that rotates on two wheels. The blade approach can be horizontal and vertical depending on the demanding design. Each format has its unique advantages for particular projects. However, this method is not an efficient process for fabricating thin-walled products, and it can produce burr and will not achieve a stable threshold.
Cold Sawing
The cold sawing method is famous for its precision in cutting smaller diameter or thin-walled material with tight tolerance using a wheel blade and cutting fluid applied with a film lubricator. The cutting tool in the cold saw system is fixed and does not have movement with which manufacturers can create square or perpendicular cuts with minimal or no burrs. This precise cutting system can bundle cut products with small length tolerance. The cold cutting process does not produce HAZ, which is considered an advantage for a material that requires subsequent finishing.
Cutting Tubes and Pipes with Laser Cut
The modern laser cutting method provides a range of advantages despite its high cost. This system can be controlled easily with CNC or other automation devices, and it allows the operator to inspect and cut the material. At the same time, the laser beams run continuously on the surface. Utilizing the laser cut method makes it possible to fabricate more rigid materials, including stainless steel alloys, titanium, and nickel alloys. However, this particular method is also used to manufacture other industrial materials such as aluminum composite panels.
Shearing
The shearing method utilizes a particular automatic and high-speed machine that features two shearing plates and two punches under extreme pressure to complete the fabricating process. The process is done in the same way for all sizes and wall thicknesses with almost maximum limits. The primary advantages of shearing technology are its speed and volume. Due to the high output rate of this operation, it can create about 7,000 pieces per hour, and the specific abilities depend on the material's wall thickness and shear.
Lathe Cutting
The single-spindle lathe machines are used to provide high-volume production and cutting of round tubes and pipes. The operator needs to feed the material through the spindle and gauge the cut length. A collet holds the stock and rotates it to start the cutting with mounted tools. Using a cooling liquid is essential to control the temperature and reduce the tool wear for preventing further damages. It is good to note that this technique is efficient for thin-walled material to produce square cuts with a minimum bur. One of the vital advantages of this method is high production yield while setup time ranges from thirty minutes to an hour.
Ultimate Guide of Bending Metal Sheet Techniques
Metal sheet bending is one of the practical fabrication procedures which is used for producing a V-shape, U-shape along a straight line. The bending process is also a practical production method for other industrial materials. The equipment that is useful for the procedure includes box and pan brakes, brake presses and other particular pressing devices. By utilizing the process, manufacturers can produce a wide range of products for different projects, from industrial to construction purposes.
Metal Sheet Bending Process
In the metal sheet bending process with a press brake forming, manufacturers place the working material over the die block and then press the sheet to fabricate it into the demanding shape. This fabricating process needs to overcome both tensile and comprehensive stresses. After completing the bending, the residual stresses can spring back the material towards its previous position. Thus the manufacturers must overbend it to achieve the appropriate angle. The quantity of spring back depends on the character of the material and the forming process. The bending process increases the length of the working piece. Another essential term is bend deduction referring to stretching measurement from the outside edges of the bend during the process. The bend radius, which depends on the using dies, material properties and thickness, refers to the inside radius of the working piece.
Metal Sheet Bending Types
There are three primary types of metal sheet bending process that manufacturers utilize on a press brake. Each type definition depends on the relationship of the ending tool position to the thickness of the working piece. These methods and techniques including Air bending, Bottoming and Coining. The configuration of the equipment for all three ways is almost identical. The die is a long rail tool that features a concave or V-shaped lengthwise channel that locates the outside profile of the fabrication. These tools are often stationary, and their placement is under the material on the base of the bending device. The other types of metal sheet bending that are also practical utilize special tools with unique designs or machines to perform the process, including three-point bending, folding, wiping, and rotary bending.
Air Bending
The air bending method can form sheet metal by pressing a punch into the material while focusing it on the mounted bottom V-shaped die. The process comprises the bend to create a distance between the sidewall of the V and punch to be greater than the workpiece thickness. Due to the fewer force requirements, this bending process tends to utilize smaller tools than other techniques. Manufacturers can create different profiles and products due to the adjustability of devices. One of the advantages of the air bending system is that it can bend the material at various angles. The downside of this fabricating method is that it is not ideally precise due to the lower contract between the sheet and the dies.
Bottoming
In the bottoming metal sheet bending process, the manufacturers force the material against the V opening in the bottom tool. Therefore, the U-shaped openings are not practical for this method. A particular space is required between the bottom of the start and the sheet metal. The most efficient width of the opening is 6 T, about 3mm thickness up to 12 mm thick metals. The curving limit must be at least 0.8 to 2 T for sheet metals such as steel. A more considerable bending radius requires almost the same force for bottoming as they need for an air bending system. The advantages of this method include less spring back and greater precision. The only disadvantage of the bottoming method is that it requires various toolset for each angle, thickness and material. Generally, the air bending is more efficient compared to the bottoming.
Coining
The coining method utilizes 5 to 30 times the force of the air bending technique to force the material into the bottom die with the top tool. With the unique technique of coining, manufacturers can cause permanent deformation through the material without a considerable spring back. This system can create an inside radius as low as 0.4 T with a 5 T width of the opening. However, the disadvantage of the coning method is its cost which is higher than other practical techniques.
Three-Point Metal Sheet Bending
The three-point method is a modern system that utilizes dies with adjustable bottom tools, and it moves the device with a servo motor. The hydraulic cushion is used to make the requiring adjustments between the upper toll and the ram. The method is exact and entails higher costs. Thus, it is practical for high-value niche markets.
Folding
Manufacturers utilize a clamping beam to hold the long side of the metal and rise and fold the working piece around a bend profile. The shaft moves the metal down or up, allowing positive and negative fabricating bend angles. However, the pitch is depending on the tool geometry and metal properties.
Wiping
This method is similar to folding with a higher working pace. However, it has a tremendous risk of damaging the metal by producing scratches. The trouble is more considerable in sharp angles, but it will overcome the spring back.
Rotary Metal Sheet Bending
The rotary bending is almost like the wiping, but the top die features a freely rotating cylinder with the demanding shape cut into it, and it matches the bottom die. The roll contacts on two-point on the sheet, and it rotates to do the bending process. The rotary bending method is known as non-marking suitable for the painted surfaces, and it can create angles greater than 90 degrees in a single punch on standard press brakes.
Other methods are available for metal sheet bending fabrications such as roll bending, elastomer, and joggling which are less common than the methods above. However, some manufacturers still utilize these methods for creating different construction materials.
Different Types of Decorative Railings
Decorative Railings and hand railings are one of the safest ways to increase the safety of staircases to prevent injuries and falls while creating an aesthetic appearance for the building. These practical products come with different types and materials, including composite materials, metal, glass, and wood, to create various visual effects. These types will impact the overall appearance of the place. The perfect materials for these products depend on the environmental factors and the demanding design. Metals such as aluminum, steel, and iron are popular choices for industrial and commercial projects which require contemporary looks. On the other hand, wooden products provide a more classic vibe and appearance, and the glass is efficient when the view beyond the stairs or balcony is required. Followings are the introduction to the top types and materials of decorative railings with their pros and cons.
Composite Decorative Railings
Composite decorative railings are among the most popular types of products for outdoor applications due to their wide range of benefits. The product's composition and durability make it a perfect material to hold up in any climate while requiring low maintenance. It is constructed from a combination of metals and other substances. They come with boards, and then after being fabricated, they are ready to be utilized as a decorative railing material.
Composite Decorative Railings may seem perfect without any issues. However, like any other industrial products, they have a few drawbacks. When damages occur on the material, it is hard to repair or replace it with a new one, and it will need a complete installation process. It is good to note that these products come in kits to provide more straightforward installation methods featuring a single top and bottom rail with spindles for connections.
Steel Railings
Another suitable railing material for commercial and industrial facilities is steel. Manufacturers also produce galvanized and stainless steel to prevent the product from rusting. The coating material for these products is often zinc, a corrosion-resistant substance, and can protect the steel below.
The steel railings are compatible with any environment. The handrail is often created with the galvanized steel, and the other components are made of ordinary steel. These products provide a sleek and modern look for commercial spaces and homes. However, the rails that exist for commercial and industrial sites are more functional.
The steel material is solid and is famous for its durability. It allows manufacturers to apply unique coats and paint finishes to improve the performance. Galvanized and stainless steel are materials that require low maintenance, and individuals can clean them by only utilizing simple tools such as sponge and mild divergent.
Stainless steel also has its drawbacks. The first disadvantage of these products is that in extreme heat, they can buckle and weaken. They are relatively expensive, and it is hard to utilize them in DIY projects due to their heavyweight. The installation process for decorative steel rails is also more complicated compared to other products.
Solid Aluminum
Aluminum is one of the common prevalent elements found on our planet, which has a lower density than other metals. Thus, they have become popular due to their lightweight characteristics. The metal has a reflective and silver-like appearance, which makes it suitable for modern buildings and applications. Additionally, it is resistant to rust and corrosion without requiring an extra coating process. The unique characteristics of aluminum railings allow designers to use them for interior and exterior applications in homes, commercial and industrial buildings.
The decorative aluminum railings are solid and durable and are practical to create a safe environment for occupants. These products can overcome the harshest weather conditions without requiring a regular maintenance process. They provide an easy installation system due to their lightweight, and individuals can utilize them in their DIY projects. Another advantage of aluminum railing is that manufacturers can cut and fabricate their product straightforwardly due to their physical properties. Additionally, these practical railings can accept almost every type of finishes without causing future issues.
The only drawbacks of decorative aluminum railings are their cost which is more expensive than steel, and they can scratch and dent more easily than galvanized steel.
Wrought Iron Decorative
Wrought iron is one of the most popular iron alloys that contain carbon in its structure. Designers utilized this material for decades to create decorative effects. Manufacturers produce this substance on large scales. Similar to aluminum railings, they are practical for interior and exterior applications. Besides, they are applicable for curved and straight stairs. However, it is commonly used for private residences and office facilities.
The primary benefit of wrought iron decorative railings is their versatility. Their malleable characteristics can be used to achieve an endless array of modern styles to elaborate scrolls. They are strong materials to provide strength to the stairways and increase stability. It is easy to apply a various range of color as finishes to allow designers to create limitless aesthetic railings.
On the other hand, the wrought iron is a custom-made material, and it is more expensive than the other railings. The installing of these materials can be challenging due to their heavyweight physical property, and the process can be time-consuming, which can increase the labor cost. The crucial disadvantage of these materials is that if the owner does not maintain them properly, they can rust due to the wether exposure in time. To prevent rusting and other damages, they require periodic recoating and repainting.
The Ultimate Guide to Metal Laser Cutting
Metal Laser Cutting is a modern and precise method for fabricating metal sheets to produce various industrial materials for different projects. The laser technology utilizes a light beam with high energy to cut and slice materials. The method is standard for industrial manufacturing applications along with small businesses and hobbyists’ projects. The CNC device, which stands for computer numerical control device, produces the material and the beam to provide accurate workflow. The generated laser for cutting metal sheets utilizes a motion control system to follow G-code or a CNC of the demanding pattern to be fabricated onto the material. The machine focuses the laser beam directed at the material to either melt, vaporize, burn or blown away by a jet gas device. The metal laser cutting method leaves an edge with a high-quality surface finish on the underproduction material.
History of Metal Laser Cutting
The first usage of laser cutting goes back to 1965, which was mainly for drilling holes into diamond dies. The Western Electric Engineering Research Center was the first in manufacturing these machines. About two years after the primary laser cutting machine production, the British used a laser-assisted oxygen jet to improve the device and made it practical for metal laser cutting. In the early 1970s, the technology received progression to cut other hard materials such as titanium for professional applications, including aerospace. At the same time, the CO2 laser cutting system was introduced to fabricate non-metal substances such as textiles. However, this system was not able to overcome the thermal conductivity of metal materials. Nowadays, manufacturers utilize laser cutting for creating other materials such as aluminum composite panels and different sidings.
Metal Laser Cutting Process
The laser cutting process involves stimulating a lasing material with optics and electrical discharging devices within a close-range container. As the laser beam generating begins, a partial mirror internally reflects the beam until it produces significant energy to escape as a stream of intelligible light. Mirrors and optics primary roles are to direct the beam to a lens to focus the light at the working point. The thinnest part of the focusing laser is often less than 0.32 millimeters in diameter. Depending on the workpiece material thickness, it is possible to produce kerf widths as small as 0.10 millimeters. Manufacturers do pierce to have the allowance of starting their cutting process from somewhere other than the edges. The piercing generally involves a high-power pulsing laser beam which can make a hole onto the material within 5-15 seconds for different metal sheets.
Advantages of Laser Cutting System
Like any other industrial fabricating methods, metal laser cutting has its unique benefits, making it popular over time. These advantages of this practical system over mechanical cutting include workpiece contamination reduction and easier work holding. The metal that is underproduction with this method has no cutting edge of becoming contaminated. The laser beam does not wear during its process and provides high-level precision for the manufacturer. Additionally, there is a low chance of warping the product that is being cut due to the small heat-affected area of laser systems. It can fabricate rigid materials that are hard or even impossible to accept the cutting process with traditional methods.
Methods for Metal Laser Cutting
There are various methods available for metal laser cutting system that manufacturers utilize to produce their industrial products. Each of these methods has its unique approach and characteristics. However, the good news is that all of the systems are practical for numerous purposes.
Vaporization Cutting
In the vaporizing system, the goal is to heat the surface with the laser beam until it reaches its flashpoint point and, as a result, generates a keyhole. The keyhole can increase the absorption quickly by deepening the hole. When the hole deepens and the material boils, by blowing ejecta out by eroding the vapor generation, the hole gets enlarged.
Melt and Blow
Melt and blow method, also known as the fusion cutting system, utilizes high-pressure gas to blow molten material off the cutting zone. This system often decreases the power requirements and can save a considerable amount of energy. The first stage of this method is to heat the material until it reaches its melting point. A gas jet device involves blowing the molten material out of the kerf while avoiding the rise of temperature needs. Melt and blow system is one of the practical ways to cut metals in industry.
Thermal Stress Cracking
This method is particularly suitable for metals that have brittle characteristics. Metals with these properties are sensitive to thermal fracture. In thermal stress cracking system, the operator focuses the beam on the surface of the material to cause thermal expansion and localized heating. As a result, the materials start cracking by the laser movement, and it follows the m/s order.
Reactive Cutting
The last most common method in metal laser cutting systems is reactive cutting, also known as "flame cutting" or "burning stabilized laser gas system". The reactive approach is similar to oxygen torch cutting. Instead of oxygen, the energy and ignition source are the laser beams. This method is often used for fabricating carbon steel metal in thickness of over one millimeter. Additionally, the reactive process is practical for cutting very thick steel panels with a relatively small amount of power.
Ultimate Guide for Making Perforated Panels
The ultimate guide for making perforated panels is created to help individuals with information improvement and help manufacturers produce better products for the industry. These panels have become one of the most practical systems of sheet metal materials in the construction business. Punching and stamping machines are required for producing these versatile materials due to the patterns and holes that exist on these products. Most of the perforated panels feature pre-painted galvanized steel, aluminum composite, zinc, copper and even simple stainless steel in their structural system.
Production of perforated panels started about a hundred and fifty years ago, and the primary reason for creating these panels was to filter coal in the mining industry. However, it had one big drawback: requiring many laborers to punch the patterns and holes into the metal panel manually. The process was energy and time consuming, and it was not efficient. The excellent data is that the process has become relatively fast due to the automotive machines by the growth of technology and manufacturing improvement. These industrial and modern machines increase the punching speed and provide precision in creating particular patterns.
Along with many functional materials such as aluminum composite panels, architects admire the beauty of perforated panels and utilize them in interior and exterior projects in the modern era. Using these decorative panels, creating new and creative designs has become possible while providing eco-conscious and efficient performance for the building. Most designers recommend using these products in their construction applications due to their significant sustainability and functionality. The great thing about perforated panels is that they can be used for renovation and current construction projects interior and exterior remodeling applications.
Advantages of Perforated Panels
Architects and designers can benefit from the range of various color finishes and patterns that come with the panels' production and fantasize limitless designs and create a modern and unique looking appearance for any type of facilities from residential to commercial purposes. These panels consist of many advantages that make them perfect for any demanding projects. The followings are some of the noticeable benefits of perforated panels.
Aesthetics: Perforated panels offer a modern rhythmic and unique appearance to complement constructions. They come with various types of shapes, sizes, patterns and finishes, and they make the material perfect for achieving a specific look for the facility. While creating aesthetics for the facility, they also allow owners to maintain the standard privacy factors.
Versatility: The panels used as perforation are incredibly versatile, meaning that they can be bent and configured easily to the demanding design. They are also structural components and lightweight decorative elements.
Durability: Another essential advantage of perforated panels is that they can withstand harsh weather conditions while providing the ability to control and equalize pressure due to the high strength to weight ratio characteristics.
Energy Efficiency: Perforated panels balance the ventilation and light, allowing the designers to manage interior heat from the sun's natural source. With the heat deflection, the energy requirements from HVAC systems' energy requirements start decreasing, and the internal temperature becomes more consistent.
Eco-Friendly: Due to the recyclability, energy reduction, sustainability and innovation invitation in creative designs, perforated panels are considered as the ultimate green material of developing construction projects. Additionally, these panels decrease the amount of using metal, reducing transportation fuel consumption to the construction site.
Production of Perforated Panels
Manufacturers often start the perforation production with a winding sheet of metal with a particular thickness. Sheet metal is thin metal materials that are easy to be fabricated. However, the primary production process relies on few practical methods that each method has its unique advantages and purposes. These methods are punch press, rotary pinned and laser process.
Punch Press: This method is the most common system for creating perforated panels. The machine features sharp tools, and the properties of them are chosen depending on the shapes and holes sizes. They are two types of punch presses in the industry which are Wide press and XY axis machine. The first one contains long rows of ram, and it produces the panels by striking and perforating an entire line of holes in one motion. In contrast to Wide press, the XY axis machine does not feature a long row of ram and contains a single die or limited number of clumps for pattern punching. The XY axis machine's perforation is done section by section across the panel, and it is suitable for producing complex and non-repetitive designs.
Rotary Pinned: Another fundamental method or machine for creating perforated panels is the rotary pinned system. The method features large cylinders that have sharp needles along the exterior side of the machine. The perforation is done by moving the sheet metal underneath the machine and punching the panel to create holes with a rotating pattern. Manufacturers heat the needles to melt the hard metal and simplify the process. The rotary pinned method is relatively fast, and it is perfect for producing identical patterns at a high pace.
Laser: Laser perforation is the newest and the most modern method for creating perforated or decorative panels, which utilizes beams to produce holes by melting the metal's surface under the production. One of the laser method's advantages is its precision, and the only drawback of the system is that it is time-consuming and costly.