Aluminum Composite Panels Installation Procedure
Aluminum Composite Panels are modern materials that are very practical for external cladding applications for different types of buildings. To ensure that the panels have a proper fixture and efficient structure, contractors utilize various practical installation methods. There are prior considerations and action that builders need to take before starting the installation process: thermal conditions and taking care of the protective film.
Thermal Conditions of Aluminum Composite Panels
ACM panels fasteners are common to have unacceptable overstressing and bowing due to thermal changes. Thus, before installing them, it is essential to apply ambient air and heating to avoid such issues. Aluminum composite panels will receive damage if the temperature exceeds 100 centigrade. Thus, manufacturers always fabricate thermal resistance.
Removing Protective Film from the Aluminum Composite Panels
ACP manufacturers create the panels while putting a non-transparent protective film onto them. It is essential to remove the protective film as soon as the product comes to the construction site. Humid and hot weather conditions can stick the residual glue on to the coated surface of the panels. After removing the protective film, the installer should not use a marker pen, vinyl tape on the painted surface since particles such as robber epoxy and solvents in the material can harm the covering integrity.
ACP Installation Direction
The installation direction of ACP materials is an essential factor for the process. Manufacturers define the process directly with a paint that follows a consistent track. For maintaining the finish material and color consistency across the ACPs, all panels should have the same directional course. Most of the boards come with an arrow on the protective film and show the finishing direction.
Installation Methods
After completing the prior consideration, the most challenging part is installing the aluminum composite panels. The procedure includes three main types, which are the hanging method, wet sealant joint, and dry gasket joint.
Hanging Method for Aluminum Composite Panels
One of the most common methods that ACP installers utilize is the hanging system. This method can simplify the process and allow experts to work at a higher pace. The panels are not fastened firmly to the mainframe and are just suspended.
Installers carry out the product to the civil work's elevation point, which is the center line. The design of the cladding depends on the axis of the building. The panels have vertical and horizontal composition, and it is best to install the vertical rod with the anchor points determination. Experts utilize electric welding for fixing the connecting piece and prevent the rust paint from double welding procedure. The connection piece sets the embedding part of the main structure. In case of iron piece connection absence, the expansion bolt can fix the primary system with a connecting metal. The frame is the material to install the skeleton on it. The installing process involves checking the centerline position and elevation and treating the cross-section with an anti-rust finish. The last stage of this method is installing the panel on the profile's inner frame with screws and fixing the ACP to the frame with a rivet. For sealing the gap between the products, installers inject silicon materials into the area.
Wet Sealant Joint System
Another method for installing aluminum composite panels is a wet sealant joint system that is very practical for new and renovation projects. The wet sealant is very necessary for ensuring water-tightness.
In the wet sealant joint method, builders fold the panel to a tray-type board. It is common to create a continuous V-shape groove and the panel parameter at a specific distance from the ACP edge. Installers leave face skin and core material with a minimum thickness of 0.51 millimeters. Then, experts fold the edges to create 25 millimeters depth cassette. Stiffing the units is essential by using rivets in the corner with panels angles. One of the stages of installing ACP with a wet sealant method is to attach pre-punch clips on the center to the pan edges for transferring the wind load to the structural supports. To allow sequential installation, experts stagger the pins from one panel to another. Smooth thermal movements should enable the route and return jointly to have a minimum of 16 millimeters of width. The final step is applying caulk sealing to provide better moisture and air resistance characteristic.
Dry Gasket Joint Method
The dry gasket joint method is almost similar to the wet sealant system. The difference between the two ways is that one utilizes sealants, and the other uses dry gaskets. The gasket method's superiority can reduce the amount of dirt and strain on the aluminum composite panels.
It is essential to check if the gasket is free of defects before installing it. Experts insert the gasket between ACPs with precision while placing it in the center part and they avoid applying release joint compounds on the surface of the gasket. It is good to use 2 to 3 bolts through both panels and gasket to fix the sealing material. While considering temperature and other factors, experts lubricate load-bearing with particular substances. Then, installers apply the suitable torque to the nuts to secure the aluminum composite materials.
Methods for Cutting Tubes and Pipes
Cutting tubes and pipes is one of the practical industrial fabrication procedures that many manufacturers utilize to create products for different applications. Choosing the method for the process involves various factors. The pipe and tube cutting's primary factors are the material, thickness, end-conditioning requirements, squareness of ends, and secondary process needs. Other circumstances that play an essential role in the system include cutting efficiency, production volume, overhead costs and special equipment for the material.
Tube and Pipe fabricators utilize various methods, including lathe cutting, sawing, rotary, shear cutting, dual-blade, laser cutting, band saw cutting, cold sawing, abrasive cutting, etc. Each of these methods has its assets and limits. The followings are the introduction to different methods for cutting tubes and pipes.
Tubes and Pipes Saw Cutting
Saw cutting is one of the most versatile methods that manufacturers adapt for fabricating tubes and pipes. Regardless of each sawing process's uniqueness, this method is suitable for production that requires both low-volume and large-volume. There are two main types of saw cutting: "band saw cutting" and " cold sawing".
The band saw cutting is a fully automatic system and is the most common way to fabricate bar, pipes, and tubes. The method is perfect for large-volume production and can manage large product bundles. The blade in this system is a metal material that is available in various tooth configurations and properties. The blade rotates on a two-wheel and, depending on the design, it can cut the product in horizontal or vertical directions. Many manufacturers prefer to utilize band saw cutting due to the various shapes such as squares, channels, and rectangular, which they can achieve. Some industrial experts use CNC machines for this method. Despite the many advantages that the process provides, it is not an efficient way to cut thin-wall materials, and it can produce burr and cannot achieve tight tolerances.
On the other hand, the cold-saw cutting method is suitable for thin-wall or small-diameter materials that require tight tolerance. This circular system uses a cutting fluid and a wheel blade. Manufacturers apply a mist lubricator to their equipment. This method's most noticeable characteristics are that the edge has a fixed placement and does not move or wander. It can produce square or perpendicular cuts with minimal or no burrs. Due to the cold cutting process, this type of sawing does not create a HAZ which is beneficial for production systems that require subsequent finishing.
Lathe Cutting for Tubes and Pipes
The lathe cutting machine's design is efficient for projects that require high-volume production of round tubes and pipes. The operator should feed the material through the shaft to a stop which measures the cut length. A holding college holds the material, and the product starts rotating as tools on cross lines cut it. It is essential to apply a cooling liquid to control the temperature and reduce the tool wear. The lathe method is perfect for thin-wall pipes, which can create square cut ends with minimum burr. During the process, multiple crosses slides permit deburring. The significant benefit of this method is the high production yield. One of the limits of this process is that it can only manage round products.
Rotary Cutting
The rotary cutting method has been in the industry for almost 50 years, and it is very suitable for different materials, mainly for aluminum. This method's advantages include no material loss with no burrs and can integrate with secondary operations such as chamfering and grooving. It can cut coiled materials and straight lines in soft metals such as copper and aluminum. A rotary system can achieve high production rates on short part lengths.
Shear Cutting
The hear cutting method is fully automatic, which provides high speed and uses two plates and two ID punches. The surpassing thing about this system is that the action is the same for all sizes and thicknesses with maximum limits. The pace of the method depends on the magnitude of the product. The Shearing process leaves no kerfs. Thus, it can save a considerable amount of material. Another advantage of this system is that it can achieve tight tolerance, and the drawback is that the tooling cost is high, and it is not cost-effective for small runs.
Laser Cutting Method for Tubes and Pipes
Despite the high capital cost, a laser cutting method provides various capabilities and advantages. The laser machine is automated, and the operator can control it easily for different purposes. The system allows the operator to deburr, cut, inspect and pack the material while the laser continues its process. The laser beam concentrates tremendous heat energy into minor points and produces narrow kerf widths with tight tolerances and minimal HAZ. The process can cut hard materials, including stainless steel, aluminum alloys and nick alloys. However, the tube and pipe need coating with anti-spatter fluid during the process.
All about Decorative Metal Fence panels
Decorative metal fence panels are trendy products that provide beauty and harmony to a house's front yard or stairs. These products are more likely to have aluminum or steel material in their structure. These panels are efficient for improving deterring burglars without creating a fortress looking boundary. Thus, these panels are mainly for protection and security. Manufacturers produce various types of fences for the market, and each one has unique characteristics and benefits. However, choosing the best panel for the exterior is an essential step and knowing the overall benefits of these products can be very handy. Before getting to these panels' services, it is good to see decorative metal fence panels' history.
History of Decorative Metal Fence Panels
In ancient times, only the wealthiest people had the opportunity to afford metalwork for their fine stone and brick houses. By the early 1800s, as the blacksmithing profession started growing domestically, delicate iron began to decorate the more varied house styles of the day. The metalwork showed its peaking in popularity during the Victorian era. In that time, foundries started mass-producing and casting elaborate posts, pickets and scrolling details.
Metal Fence Panels in Modern Era
Metal fence panels aim to provide more available and durable materials such as steel and waterproof aluminum. Modern panels usually come with hollow pickets to match solid 5/8-inch square stripes. While being lighter weight, the panels come together with fasteners to provide a more straightforward installation process. Even classic black paint iron panels received modern upgrades and turned into longer-lasting products with the multistep powder coating process that reduces the maintenance procedure.
Craftsman relies on salvaged material when a restoration project in demanded. This material's physical properties allow the manufacturer to melt it down and rework it to produce genuine fencing prohibitively expensive. Thus, the standard material in the market is often aluminum or steel. Production factories dress up these materials with cast details and machine-made scrolls. A custom fabricator generally mixes materials and production methods with hollow pickets to save costs on the fabric. High-end producers utilize molds to cast metal fence panels that feature Victorian shapes existing in catalogues.
Benefits of Using Decorative Metal Fence Panels
Before buying any industrial products, it is an essential factor to identify their benefits. Like other products, decorative metal fence panels come with various advantages, making them ideal for security and aesthetic purposes. Followings are a few of the most noticeable benefits of these products.
Longer Life Span
Metal fences are popular due to their long-lasting characteristic, which is significantly higher than wood, particularly in adverse weather conditions. Wooden walls in humid areas can warp and lose their shape after continuous exposure to strong sunshine. They also have the potential to ignite and burn more quickly. Rot and wet conditions can not affect and damage metal fences, and termites will never harm an aluminum panel. Initial savings from affording wooden fencing can prove false because they are more likely to require repair and replacement in a few years.
Maintenance Saving
Metal fences dominate other types of products when it comes to maintenance. Most products require painting in a few years, which is a real chore and can increase expenditure. However, aluminum or steel fences are maintenance-free and are more likely to stay clear of rust and keep their coating or finish for a long time. Metal products are durable for not being warped without needing a perfect straining or sealing process. Even if there is a need for replacement and repair, aluminum fencing panels will be cheaper than wood products.
Peace of Mind
Many people worry a lot about burglars. Metal fencing systems are an effective solution for crime deterrent. There are different types of products available for the purpose, such as tall fences with pointing barbs, making it challenging to climb.
Common Types of Decorative Metal Fence Panels
Metal fence panels have various types, and each class will provide almost all of the advantages in its way. Here are three of the most standard types of fence panels that have become very popular due to their characteristics. However, other practical styles can be helpful in different facilities, from residential to commercial purposes.
Garrison System
This system is a high-end protection solution that is made from heavy-duty steel. This type of fencing has a robust structure with spear type heads and provides the best security and intruder deterrent. They also offer good visibility, and manufacturers finish them in a range of colours and substances. The additional strength of these fences means that they won't need regular maintenance and can be at service for a long time.
Palisade Fencing
For commercial and industrial facilities, it is very beneficial to utilize a palisade fencing system. This system is robust and provides a steel solution that also has a relatively low cost. The Palisade system has an easy installation procedure and follows the ground's contours, making sure no gaps appear under the scheme. They also require no maintenance, and cutting them is almost impossible.
Security Mesh Fencing
This type is also a solid and reliable system that can protect industrial sites, sports stadiums, airports, schools, and commercial buildings. They are cost-effective and resistant to weathering. Mech fencing does not block sightlines and function well with planted shrubbery, where having more privacy is a priority
Everything You Need To Know about Perforated Panels
Perforated panels, also known as decorative panels, are among the most popular construction material in the modern architectural era. These materials are perfect for balancing the building and visual appeal and are ideal for eco-conscious and creative designing projects. In modern times, many manufacturers and constructors prefer to accommodate their projects with perforated panels due to their sustainability, versatility and functionality. Experts can utilize perforated panels for both remodelling or renovation applications and building a new facility. These decorative panels are available in various colours, finishes, grains, textures, and unique patterns to enhance a facility's aesthetic appearance. This characteristic of these panels makes it easy to utilize in both interior and exterior applications.
The most important thing about perforated panels is that their development procedure is designed to provide many advantages: sound insulation or solutions, lighting balance, thermal requirements and safety. These panels are considered a combination of precision, functionality, and strength. Thus using them as exterior or interior material can be beneficial for the building. Many designers prefer to incorporate perforated materials in their designs due to their cost-effective specifications, especially when it comes to enhancing the atmosphere of the light and space while maintaining durability and strength. Perforated and decorative panels have a design suitable for utilizing a wide range of applications, deliver acoustic properties, and improve the construction's energy efficiency.
Advantages of Perforated Panels
Perforated panels have proven that they can be convenient in the architectural industry. However, some architects and designers may not be aware of these panels' advantages and benefits, which can help their designs. Thus knowing their services can make any designer considering utilizing perforated panels. Here are the most noticeable characteristics of perforated panels.
Privacy, Acoustic Control and Functionality of Perforated Panels
Perforated panels are perfect replacing material for privacy walls, mainly attached to solid materials and do not provide aesthetic for the area. These panels are also suitable for projects which require different screen effects, including sun softening in the afternoon. Perforated panels consist of holes on their surface, which are customizable. Thus the travelling light amount that goes through the panels can be increased or decreased by choosing the correct size. Some applications or projects such as park benches and outdoor staircases that require water drainage can be optimized with this type of panels. Other commercial settings and facilities such as factories can benefit from these panels for their floorings and even cladding systems.
Perforated panels are modern construction materials that can absorb sound unnecessary sound, reduce bothering noise and echo in busy areas. Many areas will need perforated panels for sound insulation purposes, such as facilities that contain large or open portions or even vaulted ceilings that will indeed create a high level of noise and echo.
Aesthetic Appearance and Durability
All of the world's designers have similar goals: creating a building with a long-lasting impression and compelling appearance. Perforated panels come to help architects in constructing stylish and aesthetic appearance for a facility. These panels made of aluminum sheets or steel panels can provide different patterns, shapes, and thicknesses for various projects. They are also available with a variety of hole size, which is customizable depending on the environmental factors. When people talk about the appearance of the perforated and decorative panels and the elements' elegancy, they also mean the material's durability and strength. These panels are solid and weather-resistant; thus, they can last longer and maintain their beauty without any crucial damage. They can overcome almost all of the harsh weather conditions and damaging elements exposures compared to other panels, especially wood.
Energy Efficiency
Perforated panels have increasingly gained popularity among designers due to their energy-efficient specifications in controlling airflow and light and their sustainability. These panels provide better control of the indoor climate without relying heavily on HVAC systems or blinds. Despite being a metal product, the board can help the facility stay cooler if placed perfectly. Designers utilize these panels as sidings for reducing sunlight exposure, resulting in cooling expenditures decrement. While preventing strong glares and deflecting heat from the sun, perforated panels allow ambient light to travel through them and create unique lighting harmony in the room. Another vital advantage of perforated panels that make them an efficient material is that it is entirely recyclable, and many designers consider it environmentally friendly.
The customizability of Perforated Panels
One of the essential factors in choosing any material or product for a building is the material's customizability. A perforated panel provides this factor at its best, and designers can create limitless designs using them. There are unlimited sizes, patterns, textures, shapes, and cutouts available in the market. Even if not fitting in the structure due to the size, these panels can be fabricated in a desirable size using a CNC router or laser cut correction.
Materials Variety
The perforated and decorative panels are generally made of metal materials such as copper, aluminum, stainless steel, brass, corten steel, bronze. Some manufacturers prefer to create these panels from carbon-based materials. They all have their unique characteristics and advantages and can be suitable for different kinds of construction applications. For example, aluminum panels are popular due to their shiny and flat surface, which can be very resistant to rusting and corrosion.
Fundamentals of Curtain Wall Systems
Curtain Wall systems are defined as thin materials with aluminum frames and contain in-fills of delicate stones, sheet metals, and glass. The mainframe is bonded to the base structure, and it does not carry the load of the building's roof or floor. The curtain wall supporters transfer the force caused by wind, gravity, and other environmental factors to the construction's floor line. Curtain walls were created for military purposes. However, after the growth of technology, construction builders began utilizing them for residential and commercial purposes.
Fundamentals
Curtain walls bring many benefits and advantages such as thermal performance, moisture protection, aesthetic, etc. However, they are also classified by their fundamental properties. Knowing these properties can help the building owner in utilizing the most efficient wall system for the facility.
Forms of Curtain Walls
There are three main curtain walls available in the form of rain-screens, face-sealed, water managed and pressure-equalized. The pressure-equalized product is generally the ideal type of curtain wall, which provides higher weathering, air and water infiltration resistance with their unique water-managed systems.
The pressure-equalized wall systems prevent water infiltration across the barrier with their functionality, blocking almost every force that can cause the liquid penetration. PE screen systems are utilized to design the inside surface of the curtain walls, glass or pocket. The airtight barrier of these products is generally created from a wet sealant or an interconnecting gasket
The most effective portion of curtain walls that work as a rain-screen is the exterior glazing materials, outside face of glass, and the frames outer exposed surface, which is made from aluminum plates. Manufacturers form a PE chamber between the interior air barrier and the exterior raining screen in the glazing pocket. This portion reduces the water infiltration by equalizing or eliminating the pressure difference across the panels that tend to push the water inside the buildings structure or the curtain system. However, it is very typical to witness a minor amount of water to penetrate the system, typically wiped to the exterior without causing any damage.
The Water-managed system is almost similar to the PE system at first glance. This system incorporates weeps and drains from glazing pockets. However, there is no effort made to place an air barrier on each glass or spandrel unit. Thus, a more considerable amount of water will infiltrate the aluminum curtain wall system, which should be wiped away. The pressure difference, which is strong enough to force the water to reach a higher position vertically than the internal gaskets, is due to the absence of air barriers resulting in higher leakage. Pockets and holes in this system have high functionality in draining the water that infiltrates the structure.
In contrast, in PE systems, holes function as vents for allowing air movement between the glazing pocket and the exterior wall. The best way to recognize the PE system is to determine that if the pocket around each unit of glass isolated airtight or not. This characteristic can be detected by finding plugs or seals at the gap between screw splines at joint intersections
Some industrial manufacturers prefer to design aluminum curtain walls in face-sealed systems. Their functionality depends on the quality of sealing between the glass units and the aluminum frame or all frames members perform in the application. The long-term usage and reliability of these seals are not safe, and avoiding utilizing them is recommended.
Support of Curtain Walls
They are two types of supporting curtain walls available in the market: stick-framed and unitized systems.
Vertical mullions run pas two floors in the stick-framed systems, usually combined with gravity anchors on the same floor. In some cases, a lateral anchor is used on another floor to increase the support. The splice which exists in between the vertical mullions is designed to provide lateral resistance and vertical movement. In larger scales of this type of support, split vertical mullions are used periodically to provide thermal activity. The glass movement, which takes place within the frame, and the anchors' involuntary movement tend to persuade additional stresses into the stick-framed method.
Unitized curtain wall systems incorporate the differential movement between the frame's thermal movement at the joints of each curtain wall and the structure. Due to these products' customizable characteristics, the amount of action needs to be engineered very precisely. Anchoring and attaching unitized systems involves a proper assembly with three-way dimensional adjustability. There is an existing stack joint in curtain systems that are designed to increase the lateral load resistance, while the two-floor anchors are both utilized for lateral and gravity resistance improvement.
Fire Safety
Curtain walls contain gaps between the floor edges and the back of their structure for slowing down the passage of combustion gases and fire between different levels and floors. For ensuring fire safety, the product must be approved by being tested in fire-rated assemblies. The PFCS needs to be equal to or more significant than the flooring rate. Firefighters who try to extinguish the flame require venting and emergency access, which the curtain walls provide. This specific characteristic is known as a knockout panel. It can be identified by a non-removable reflective dot, which is generally located in the lower corner of the opaque or glass.
Maintenance Access
Curtain walls are designed in a way to provide accessibility for maintenance purposes. Maintaining buildings with low latitude is more comfortable due to the accessibility of equipment that has articulated arms. On the other hand, high-rise buildings need to be designed for swing stage access for general maintenance, repairing, and window cleaning.
Advantages of Curtain Walls
Curtain walls are products, which are developed having a thin thickness and are usually made from aluminum frames while containing fills of metal panels, delicate stones, or glass. The frame is generally bonded to the construction’s structure; thus, it does not carry the load of the roof and floor of the building. The load caused by environmental factors such as gravity and wind is typically transferred to the structure's floor line. This product development started in the 1930s, and the manufacturing services expanded rapidly after World War II. It was first utilized for military purposes, and then designers turned it into a suitable exterior product like other industrial materials such as ACP.
Architects and builders use a wide range of curtain wall systems to specialize in custom walls. These products have become a cost-effective solution and a strong competitor to other standard walling systems.
A Brief Description
Curtain wall systems are classified by their installation and fabrication methods into two main categories, which are unitized and stick systems. In the stick system, the frame and opaque or glass panels need to be connected piece by piece, and then the installing process must be completed afterwards. On the other hand, curtain walls that follow unitized systems are composed of large units glazed and assembled in the manufacturing factory and then shipped or transported to the construction site. Adjoining modules attach the vertical and horizontal mullions together. These modules are generally created with a longer length and are often five to six feet wide.
Another method for classifying curtain walls is considering them as pressure-equalized or water-managed systems. All types of these walls are designed for both interior and exterior glazed systems. Interior systems are used to allow the opaque or glass panel to be installed into the wall opening from inside the building. Due to the air infiltration issue, the interior glaze system does not provide details. It is suitable for applications with limited inner obstructions for providing adequate access to the inside of the wall. Outside glazing is specified for low altitude buildings with easy access to the construction.
In some specific cases, the interior curtain type is used for high-rise buildings to provide glass replacement logistics from a swing stage. Glass panels need to be installed from the outside of the wall in exterior glaze systems. These systems require scaffolding access to the outer space of the wall for replacement and repair purposes. Some of the designs can be glazed from both interior and exterior areas.
Glass panels used in curtains are predominantly insulating and are usually fixed or glazed into operable frames placed in the wall system. Metal panels are varied in aluminum plates, stainless steel, or other corrosion-resistant materials such as aluminum composite panels created from two sandwiched layers. Panels that are made from stone substances are usually granite.
Beneficial Characteristics
Curtain wall systems provide many advantages for any construction project. Thus their popularity is still growing day-by-day. Determining these products main benefits can help architects and building owners create their unique and efficient facility. Followings are the most beneficial characteristics of Curtain walls.
Back Pan Insulation and Thermal Performance
Back pans are metal sheets, which are usually made of aluminum or galvanized steel. These sheets sealed when attached to the curtain wall framing. They act as an air and vapor barrier when the insulation is installed between the exterior cladding and back pans in colder climates. They also create an additional defense against infiltration for areas that are not easy to access. Curtain walls are trendy for their high thermal performance. This is due to the conductivity of aluminum. It is common to use thermal breaks of low conductivity for improving the performance of these products. They can prevent the heat infiltration and save a tremendous amount of energy. This is due to the presence of an extra layer across the building. Thus, these type of walls can stabilize the overall temperature of the building. Additionally, UV light, which can increase the pace of fading or degrading the building, can be significantly reduced by curtain walls.
Water Penetration and Condensation Resistance (Moisture Protection)
Water penetration resistance of curtain walls results from glazing details, drainage details, frame gaskets, weather-stripping gaskets, interior sealants, and flashings. Water can penetrate through the building's exterior cladding system employing five important forces: kinetic energy, gravity, air pressure, capillary action, and surface tension. To decrease the water penetration, these forces should be considered in the building’s design. Curtain walls usually cover large areas of the wall without flashings, and this makes them a better choice compared to small and discontinuous windows.
Visual Aesthetics
Sightlines and glazing appearance of curtain walls is the key feature of these products. Visual profile of the horizontal and vertical panels are defined as sightlines. They create both the width and depth of the curtain wall frames. Most modern buildings require curtain systems due to their unique, clean, and sophisticated appearance. The installation systems for these beautiful products are commonly better, faster and more cost-effective than other cladding products.
Sound Insulation
Another function of the internal seals used for preventing air leakage is the acoustic of curtain walls. This characteristic can be improved by installing sound attenuating infill. The incorporation of glasses with different thicknesses will also help in exterior sound deadening. This is achieved by increasing the glass or opaque thickness or utilizing a laminated layer with an interlayer, which has noise-reduction specification. These layers are typically made of PVB or polyvinyl material.
Read the Fundamentals of Curtain Walls for more detailed information about these products.
CNC Router for Aluminum
Most people thinks that machining metals such as Aluminum should involve the usage of high-end milling machines that can carry out extremely complicated work. There is no denial that spindles of these machines can spin their cutting tools at a speed comparable to the best drills. However, the CNC router provides spindles that can operate and rotate at a higher speed than the regular mill.
Is It Possible to Cut an Aluminum Material with a CNC Router?
Machining materials such as Aluminum with a CNC router is possible with most of the CNC types. The material can be easily cut by matching the right feed rate and end mill bit with its properties. It is essential to consider that cutting process is about separating aluminum sheets by cutting them into pieces and making pockets and holes into aluminum plates. This means that the CNC router can remove desired material parts from both plates, sheets, and create products such as perforated panels, aluminum composite panels for cladding, etc. It is just about the right way of using the end mill cutting bit.
While cutting Aluminum products, it is important to have in mind that the procedure is not as same as plastic or woodcutting. These materials have smaller sweet spots for optimal feeds and speeds. This means that the cutter tool can break if the sweet spots are left out fast and can cause a poor surface finish. There is another important factor when it comes to using a CNC router for cutting Aluminum, which is called the stickiness factor. This material is a kind of metal that tends to stick to the cutting tools. This almost happens on the point where it welds itself to the tool. Once a gummy aluminum deposit is created on the cutting edges, the tool will no longer be usable. This is especially essential if the rotation rate is fixed on 20,000 RPM or more.
How to Manage Cutting an Aluminum Using a CNC Router?
As it is obvious, cutting aluminum has its unique complexities. It is not as same as the wood and precision for certain aspects is the key to obtain the best results. The first important thing to have in mind is taking the procedure slowly. The goal for most industrial cases is to complete the job with speed and quality. This does not apply to this type of machining process. When using a CNC router for an aluminum product, steady and slow removal of desired material is the main goal.
The next important step is choosing the right router bits and small diameter cutters to obtain better control over the product and gain higher precision on the process. Using two or three flute carbide end mills is suggested due to their ability to have greater spindle speed on the machine. When working with aluminum sheets, HSS and cobalt cutter are not required. Small tools often work better for this material. Aluminum is a soft metal; however, the cutter can be easily broken during the procedure. The 1 flute end mills which are popular for plastic will not overcome the job pressure. Since the aluminum material tends to friction weld itself on the cutter, it is recommended to have a smooth surface finish to reduce the possibility of potential damages. Another important note is that the operator must remove the produced chips very fast because they can break the expensive router bits because of being recut. This process must be continued until a high-quality result is achieved.
Rigidity is another important factor when it comes to cutting aluminum with a CNC router. Small routers and large professional industrial machines definitely have differences. Aluminum is a material, which requires more rigidity than wood and plastic. Using tools that have longer bits can increase the advantage of the workpiece. When buying bits, it is important to keep an eye out for end mills that have stub ends and they should be kept short in the collet. Some manufacturers use aircraft cable and steel pulleys to add extra tension to the bridge and some others add extra ball screws and bearings to enhance their machine’s rigidity.
Another important step is to calculate and utilize the suitable and right feed rate to achieve better results. Predicting and calculating this can be very challenging. However, they are some starter standards that utilizing them can help to find the optimal feed rate in a short amount of time. For example, the cutting speed for aluminum in the case of the carbide tool is about 1,500 surface feet per minute at the highest point, and 1,000 at the lowest.
AS told the Aluminum metal has stickiness factor in its physical properties. The stickiness of the material can be controlled by putting it in oodles of lubrication. Some manufacturers recommend using oil mist as a lubricator. If an upgrade is required, then installing one is definitely recommended. It is not hard to install and it only needs a kit, compressed air, and oil. However, they are other alternatives available for the purpose. One of the most common systems is using lubricant sprays. This system can be challenging for machines that have a downward exhaust. In this type of routers, tons of air will be blown around the tool without actually reaching the cutter. It can be very tricky to have perfect spraying around the air blast. Another method is using cutting wax, which can be applied to the cutting surface. Using this method can solve the issues for downward exhaust machines and works perfectly for the process that requires single or shallow Z depth. If the routing needs more depth, it is recommended to get the lubricant further down by reapplying it in the recent cut channel.
What are The Types of Welding Systems?
Human has been welding pieces of metal together to create new products for centuries. Today, our race has achieved vast knowledge of the process and has expanded the techniques and applications equivalent to the modern era. For people who tend to enter the welding industry or need to buy welded products, knowing the definition of the process, types of it, and the purpose of each can be very helpful.
What is Welding and Why Manufacturers Use it?
Welding is one of the metal fabrication procedures in which high temperature is used to melt and fuse pieces together. However, in some cases, pressure can also be used additionally to provide a weld. It is eminent from lower metal fusing methods like soldering or brazing, which do not usually melt the base metal. There are other fabrication methods along with welding, which are commonly used, such as laser-cut, bending, shearing, and notching.
All types of Welding systems usually involves the use of a material called “a filler” or “a consumable”. This is used to provide a filler or pool of molten material that helps smooth the formation of a strong bond or link between the base metals. Most of these fabrication processes will require a shielding coat to protect both main components and filler from being oxidized during the procedure.
Metal Welding can be performed utilizing various forms of energy sources. These sources include a gas flame, laser, an electric arc, an electron beam, ultrasonic, and friction. Some of the welding methods can even fit underwater and space settings.
Types of Welding
More than thirty types of welding processes exist in the sheet metal industries. They range from simple oxy-fuel to modern and high-tech processes such as laser welding. However, they are some a few of these techniques, which are commonly used for the process. Each of them come with their special characteristics and advantages. Followings are the most popular welding techniques utilized in the industry.
MIG – Gas Metal Arc Welding Known as GMAW
This type of welding is done by continuously fed of the electrode through a welding gun. The expert or operator should pull the trigger to feed the consumable through the certain joining part. Between the base metal and the electrode, an electric arc forms which heat the metal until it reaches or exceeds its melting point property. This type requires an extremely supplied shielding gas. Some of the most common gases for the purpose are carbon steel, stainless steel, copper, aluminum, and silicon bronze.
The most important advantage of using the MIG method is waste reduction. These types of welding systems results in the minimal cleanup, lower heat inputs, and fume reduction. Additionally, it is the easiest technique to learn and is suitable for beginners.
MIG system is commonly found in automotive industries due to its strong weld characteristics, which can withstand large forces. When it comes to MIG welding, the operator needs to be precise about the power setting adjustment to have an appropriate thickness result. The speed of the process also affects the penetration of the weld. By decreasing the speed, the penetration will be increased.
TIG – Gas Tungsten Arc Welding Known as GTAW
TIG is another type of welding process in which a tungsten electrode is utilized that is not for heeding the base metal but for creating molten puddle for the joint. In this method, external gases such as argon and argon/helium mixtures are required. The most common applications for TIG systems are piping, tubing, aerospace, and motorcycles.
The greatest advantage of this technique is allowing the operator to weld very thin materials while having-high quality cleaning and highly aesthetic joints. Thus, this type of welding system is the most popular type of all in the current industry. It is generally utilized for applications, which involve metals such as stainless steel, aluminum, and copper.
Stick – Shielded Metal Arc Welding Known as SMAW
In the SMAW method, also an electrode is used to carry electric current. The electrode that is utilized for this system consists of a core wire that is coded. The electric arc is created as soon as the tip of the electrode makes close contact with the base metal. As the procedure starts, the joint part exceeds 6500-Fahrenheit degrees. The molten material is protected from oxides and nitrates that exists in the atmosphere during the process. Thus, this type of welding is suitable for the pipeline, construction or cladding, heavy equipment repair, and steel erection.
This welding method allows the customer to gain results with low cost of equipment, which are also portable. There is no need for shielding gas in the STICK method. This means that experts can use this system in open-air even during rain or wind. Additionally, this technique can be utilized on dirty and rusty metals thus it is an appropriate alternative for projects where using TIG or MIG is not required.
Flux – Core Arc Welding Known as FCAW
This welding technique is very similar to the MIG method. However, instead of solid wire, it requires a tube-shaped wire, which is filled with flux. The most noticeable advantage of this method is the electrode efficiency, which means less waste creation. With the use of this system, there is no need for utilizing external shielding gases and it provides welding fumes reduction regardless of the metal that is used for the process.
FCAW method is very easy to learn and many professionals prefer to use this system due to its extremely inexpensive benefits. On the other hand, there are some limitations when it comes to having aesthetic results.
CORTEN Steel Sealing Method
CORTEN Steel which is also called COR-TEN or weathering steel is one of the most popular materials in building and construction industry. The COR part of the word refers to metal’s property of corrosion resistant and the TEN denotes the material’s tensile strength. This material is very applicable and widely used in landscaping, exterior cladding and other outdoor applications such as garden sculptures, stairways, artificial fountains, storage etc. This product is a steel alloy which contains zinc after having galvanization process.
This material is perfect for creating an architectural masterpiece for roofing and cladding projects and it can allow the designer to combine the best of the old with modern innovation and create something extremely aesthetic. COR-TEN offers an age-old rustic look which can add stunning contrast to the appearance of the building. This cladding material is extremely robust metal which provides high structural strength despites its thickness which is ¼ inch. In addition, it is a lighter weight material and need lower maintenance in comparison to other metal materials in market. The texture, color and its specifications quality such as having ability to be bent, laser cut and weld, make it suitable for any application which demands a spectacular and unique visual statement. From gardens to office buildings and mentions or holiday homes, this material can deliver function and image in one package.
CORTEN Steel has the ability to form a protective layer of rust after being exposed to moisture, humidity and oxygen for approximately six months. Since the created rust layer protects the material from the further damage and corrosion, additional painting or weatherproofing is not required. In addition, this ability can bring unique and rustic look to the cladding. It is important to note that in order to have this protective layer, this steel requires exposure to wet-dry cycles. If this material is buried in a wet grounds or submerged in water, it cannot form the additional rust layer. Areas which are close to ocean may also prevent the forming of the protective film. However, the anti-corrosion characteristic of this material is superior to those of ordinary and general steels in many applications including industrial projects exposed to exhaust products from fuels which contain Sulphur or scaling at high temperature.
Sealing CORTEN Steel
There are variety of CORTEN steel profiles available which include interlocking panel, standing seam, traditional corrugated and snap lock. These cladding profiles are strong architectural lines which are very eye catching with their rich earth colored patina. There are other industrial products which are made from this material such as CORTEN plate, flat sheets, coil, flat bar, tube, pipe, angle, channels, beams, perforated panels etc. However, in some cases, sealing CORTEN steel will be necessary in order to avoid extra damage and expenditure. Here are the important things to know about corten steel sealing method.
- Finding the best coat sealant which is compatible with the CORTEN steel is the prior task to do for both small residential and big commercial facilities.
- Clearing sealants are not 100% accurate sealer. It is a fact that this steel is a natural weathering metal, however it does always react differently depending on many factors such has batch, profile, thickness, shape of fabricated item, location in which the façade is installed, chemicals or residue on the existing sheet, the time period in which the sheet has been weathered before clearing apply and many other.
- Using a clear coat sealer which is utilized for numerous times on screens, claddings and other fabricated product and has very high success rate and other costumer’s satisfaction is recommended.
- As a standard corten steel sealing method, all CORTEN products must receive a minimum of one or two coats. This depends on the factors which were told earlier.
- Each coat of applied clear adds extra protection to the CORTEN steel panel. This definitely increases the limitation and elimination of the rust run off and leach. Thus, in areas which have high humidity level, adding more than two coating layers could be helpful. In general, each layer of clearing material cause additional cost once the standard amount of coats has been already used.
- Every time a coat of clear is utilized, the CORTEN Steel will change it colors and will appear more dark. It can even have brownish or reddish, as opposed to the powdery orange color finish.
- It is important to have in mind that once this steel is sealed, it will not weather anymore and it will remain the way it is arrived.
All You Need to Know about Cassette Panels Systems
Cassette paneling system is a hook-on metal cladding method which is widely utilized for both interior and exterior projects. This product is having outstanding versatility and can be installed in multiple directions onto a variety of substrates such as concrete, plywood and even glass. This techy and modern looking cladding is appropriate for horizontal and vertical constructions from low height to high-rise buildings for renovation and novel applications and projects. Cassette panels are typically fixed and bent by utilized clips and top hats to a metal frame such as aluminum, which has high level security due to having load bearing structure. This system is considered as open jointed product and is almost like rain screen system, which means they can have ventilated airspace after being installed.
Cassettes which are applied to façade section, are created from the development of components which are used in vast areas and they are produced for cost-effective and fast pace assembly process. These paneling system contains sheet metal which reduces the cost alternative to any composite cladding material. In addition, unlike pure sheet metal cladding method, this system has the ability of not having need for silicon or caulking during the project. The patented mounting system helps the panels to snap into a specific area which often moves from top to bottom very quickly and easily. For having additional features, trims and pre-fabricated flashes are approvable and it can fit onto any demanding channel.
Cassette panels cladding allow designers to have variety of innovative façade solutions with which they can create modern and flat appearance. They design the building in a way to provide suitable substrates for installing the panels on them and as a result generate a technological and futuristic characteristic which is perfect for commercial buildings and administrative facilities. This paneling method is typically specified for designs which require longer lengths or wider widths in comparison to other paneling systems.
Horizontal and Vertical Cassette Panels System
Horizontal and vertical cassette panels systems are defined from their mounting and installing direction which are respectively from top to bottom and from right or left or vice versa. These panels are indirectly bonded in hidden areas. This ability allows the designer or architect the required freedom to create different stylistic aspects when it comes to using cassette system. These products are often produced in a way to have 25 millimeters of depth and a specified shadow space with 20 millimeters diameter. Shadow gap values are mirrored with a rail, which is suitable for fastening and is considered as an important part of forming the system. These panels are especially appropriate for external claddings which need length of up to 3.000 millimeters. In addition, façade grids will be chosen and installed depending on the taste, need and demand of customers.
Installation System of Cassette Panels
Installation system of cassette panels demands to have predefined positions of the elements which are going to be utilized in the structure’s frame-work. During frame-work procedure, exact measurement which includes width and center to center height and amount of panels which should be utilized must be defined. In general, cassette panels contain an upstand at the one end which is attached and fixed to the framework with clips and the other end has another up-stand which locates into the clips on the previous surface. Slotting is required for panels which exceed 1.5 meter in length due to need of expansion tolerance. Clips which are utilize for fixing the products need to be designed and tested in a way to have compatibility with the performance basis of the project and the specific application. These fixing materials are dual functional. These two functions are about ensuring the lift up resistance and providing free space for expansion to the cladding and the panels.
Advantages and Benefits of Cassette Panels Systems
Cassette panels bring dozens of benefits to building owners. Thus they have become more and more popular by the time. Followings are few of the many advantages which these panels provide.
Elegant Appearance
Cassette panels systems are popular among designer due to their smooth and flat finish which allows them to create aesthetic external appearance for the construction. They have glossy and sleek surface which make them perfect for elegant looking modern buildings.
Stability and Safety
These systems require heavy gauge materials such as aluminum clips to have an overall structural stability. In addition, interlocking method which is installing solid panel directly on to a galvanized top hat and fixed firmly, increases the safety of the building. These material are also fire proof, which is considered as an advantage for safety standards.
Sustainability
Another important advantage of cassette panels is their water proof ability without having additional sealants or mastics. This prevents the water from entering the wall structure by allowing it to flow on the material. They are also produced with robust systems, which can have 50-100 years of lifetime. Thus they can stay functional and healthy with minimal maintenance procedure.
Affordability and Economically Friendly
These panels are hundred percent recyclable material and due to its purity, it creates minimum waste of metal material. This makes them more affordable and economically friendly which is a very important factor when it comes to building a facility or renovating it.