What are Fairview’s Standard Colors and Finishes for Metal Cladding Material? 

We currently have millions of square feet of Vitrabond FR ACM in our Connecticut warehouse location. The standard Fairview colors comprise of solids, metallics, and faux zincs. The faux zinc finishes in particular are hugely popular due to their superior quality. See them for yourself by ordering free samples here.

Our special-order range of finishes includes our standard but non-stocking finish series. This series includes painted solid colors, pattern finishes such as woodgrains, faux corten and other rust finishes as well as chromatic color shifting finishes, and natural metals like copper, zinc, stainless steel, and anodized aluminum finishes. 

How do Fairview’s custom colors and finishes work for metal cladding material? 

At Fairview we understand that each and every engineering project is unique and often requires custom finishes for the metal cladding panels. So, while we have many high-quality colors and finishes to choose from that are in stock, the majority of what we supply are custom finishes. We are happy to help create the custom look that you need. 

To create custom colors and finishes, we can exactly custom match a specified paint color, or match an adjacent color such as a custom extrusion color. For this process, we submit a paint chip to our lab to be matched. The lab results are then sent to the client for approval prior to releasing them for production.  

Please note that the color-matching capabilities at Fairview are not just limited to our two-coat and three-coat solid mica and metallic finishes. We are able to leverage our industry-leading finish capabilities to develop incredibly close color, pattern, and texture matches to other materials—whether it’s brick, stone, wood, concrete, or another cladding product. 

Vitraplate® is a 3mm (1/8″) Pre-Finished solid aluminum cladding product made from 3000 series and 5000 series aluminum. The designation refers to the alloy composition of the cladding material, which has significant influence on the structural and physical characteristics. For example, aluminum alloy 3003 has a nominal content of 98.6% aluminum and 1.2% manganese (Mn) as the main alloying element for increased strength and formability. It is used as sheet for exterior cladding applications, and is a good substrate for architectural finishes². The 3003 aluminum alloy has strain-hardened temper for increased strength and hardness.

Pre-Finished Aluminum: Supply Chain and Processing

The supply chain of aluminum is complex. Fairview Architectural purchases coils of the mill-finish aluminum from aluminum coil manufacturers such as Texarkana Aluminum. Coil manufacturing is an intermediate process that involves receiving ingots, the stock form of aluminum, from an outside source. It is important to realize that the aluminum industry has become highly globalized⁷. Production of virgin aluminum metal, known as primary aluminum, is an electrochemical process that is very energy intensive⁷. It is Texarkana Aluminum’s initiative to use primary aluminum that is produced with sustainable energy⁸, such as natural gas or renewable energy sources. Texarkana Aluminum products have a post-industrial (pre-consumer) recycled content of 65%⁹. The aluminum is melted and cast into “rolling ingots” specifically for the hot-rolling process. These are fed through a reversing mill and a continuous hot rolling mill which progressively stretch and reduce the aluminum into sheet⁵. Then cold-rolling is performed to achieve the desired strength and temper, and the continuous aluminum sheet is coiled⁶. The term “mill-finish” describes the exposed finish of the aluminum inherent from the processes of the mill².

Exceptional Finishes

Vitraplate® has a polyvinylidene fluoride (PVDF) exterior finish meeting AAMA 2605 performance standards¹⁰, providing an exceedingly high level of durability¹¹, and resistance to dirt accumulation because of its fluoropolymer formula¹². Fairview Architectural has extensive options regarding the aesthetics of PVDF finishes, and offers architects the opportunity for coordinating custom finishes. The variability of formulations allows for a wide range of colors, gloss, and special effects such as metallic speckling. Specific formulations are proprietary, but constituents such as metal oxides and mica pearlescent are used for aesthetic effects¹¹. The finish is factory-applied by coil coating¹³, a highly automated and highly efficient process. On a continuous coil coating line, the aluminum is uncoiled, pretreated, primed, coated, cured in a finish oven, then recoiled. The continuous coil process minimizes liquid paint waste with nearly a 100% transfer efficiency, and also accommodates controlled collection of volatile organic compounds (VOCs)¹⁴. The exterior finish coating is extremely resistant to adverse conditions including airborne pollutants, salt spray in coastal environments, and other atmospheric corrosives¹¹.

Cladding Efficiency

To understand the efficiency of choosing prefinished Vitraplate® aluminum, the process of post-painting must be understood. The post-painting process for façade cladding panels starts with the fabricator receiving mill-finish aluminum sheets. Fabrication involves cutting to size, then routing and folding at the perimeter edges to result in continuous returns. Panels are packaged and shipped to a post-painter. Each panel is manually cleaned, then sprayed with a primer-coat. Once dried, paint is sprayed on to the panels. Additional coats are sprayed depending on the finish desired. Finished panels are sent back to the fabricator and panel stiffeners are added if required. Completed panels are packaged and shipped to the jobsite for installation.  

By contrast, the coil-coating process is much simpler. Prefinished aluminum sheets are shipped from Fairview Architectural to the façade panel fabricator. Fabrication involves cutting to size, then routing and folding at the perimeter edges to result in continuous returns. When fabricated, panels are ready to mount onto a corresponding attachment system made of extruded aluminum profiles. Completed panels are packaged and shipped to the jobsite for installation. Using coil-coated Vitraplate® reduces the fabrication time and lowers risk. 

Get in touch with a Fairview Architectural team member today for your next façade project! 

Disclaimer

This article of Architectural Stewardship was sponsored by Fairview Architectural North America. Published here.

References

¹Vitraplate® Technical Manual. 2020. Fairview Architectural.

²Aluminum Extrusion Manual, 4th edition. 2014. Aluminum Extruders Council.

³Davis, J. R. 2001. Aluminum and Aluminum Alloys. Page 351-416. In: Alloying: Understanding the Basics.

⁴Raabe D., D. Ponge, and others. 2022. Making Sustainable Aluminum by Recycling Scrap: The Science of “Dirty” Alloys. Progress in Materials Science

⁵Hot-Rolled Aluminum, Environmental Product Declaration. 2014. The Aluminum Association

⁶Cold-Rolled Aluminum, Environmental Product Declaration. 2014. The Aluminum Association

⁷Aluminum: The Element of Sustainability. 2011. The Aluminum Association.

⁸Sustainability Statement. 2022. Texarkana Aluminum, Inc.

⁹LEED Certificate. 2024. Texarkana Aluminum, Inc.

¹⁰Vitraplate® Technical Manual. 2020. Fairview Architectural.

¹¹Iezzi, R. A. 2015. Polyvinylidene Fluoride-Based Coatings Technology. In: ASM Handbook, Volume 5B, Protective Organic Coatings. K. B. Tator (ed.)

¹³Color Design Guide. 2019. Fairview Architectural.
¹²Ehrlich, B. 2014. Cladding: More Than Just a Pretty Façade. Environmental Building News 23(9): 1-10.

¹⁴Pilcher, G. R. 2012. Market Analysis Preview: Coil and Extrusion Coatings. In: CoatingsTech. American Coatings Association

About the Author: Josh Bowditch

As a native resident with architectural experience and environmental regard, Josh Bowditch is intent on publishing about sustainability in the architectural and building construction industry locally. From being in the architectural profession, Josh has an understanding of the processes involved. Is it possible to reconcile environmental considerations with development? The word sustainability has various connotations but indeed can be viewed in the context of stewardship.

In the world of metal fabrication, each decision you make holds significant weight. When it comes to selecting materials and processes for your projects, the choices made can have a  profound effect on the final product’s quality, appearance, and durability. One crucial decision often centers on whether to use coil-anodized material with laser-cut perforations or instead opt for perforating the material and then batch anodizing it.

Discover the unmatched benefits of using coil-anodized material with laser-cut perforations and see why it’s innovative combination is key to transforming your projects. 

1. Consistent and High-Quality Finish

There are some reasons why coil-anodized material stands out for its consistency and high-quality finish over batch anodizing. We’ve outlined these below so you can see why we consider it the preferred choice for architectural and design applications:

• Uniform Color and Finish: Coil-anodized material undergoes a meticulous pre-treatment process, and a consistent continuous process from start to finish, ensuring uniformity and consistency of the anodized finish across the entire coil. This consistency remains even after laser-cut perforations, resulting in a visually appealing and high-quality product.
• Protective Oxidation Layer: Laser cutting introduces a protective oxidation layer along the cut edges, safeguarding them against corrosion and maintaining the material’s aesthetic integrity. This is a significant advantage over batch anodizing, where the dipping process can result in streaks and inconsistencies.

2. Enhanced Durability

Durability is a paramount consideration in metal fabrication, particularly for outdoor or high-traffic applications. Coil-anodized material with laser-cut perforations excels in durability for several reasons:

• Corrosion Resistance: Anodizing creates a protective layer on the metal’s surface, rendering it highly resistant to corrosion. The protective oxidation layer formed during laser cutting ensures that even exposed cut edges remain corrosion-resistant.
• Longevity of Material: Coil-anodized material with laser-cut perforations provides a durable finish that can endure for decades, making it a cost-effective choice in the long run.

3. Cost Efficiency

Efficiency and cost-effectiveness are also crucial factors to be considered in any project. Utilizing coil-anodized material with laser-cut perforations can lead to cost savings in multiple ways:

• Reduced Material Waste: Batch-anodizing after perforation can result in damaged or unevenly anodized surfaces, leading to increased scrap and waste material. Coil-anodized material minimizes this potential waste.
• Lower Labor Costs: Laser-cutting perforations in coil-anodized material can be more efficient and require fewer labor hours compared to batch-anodizing individual pieces after perforation.
• Faster Turnaround: The coil-anodizing process is typically faster than batch anodizing, allowing for quicker project completion.

4. Eco-Friendly Option

Sustainability plays an increasingly pivotal role in metal fabrication. Coil-anodized material with laser-cut perforations offers several eco-friendly benefits:

• Reduced Chemical Usage: Coil-anodizing utilizes fewer chemicals compared to batch anodizing, resulting in a smaller environmental footprint.
• Energy Efficiency: The coil-anodizing process is often more energy-efficient, reducing greenhouse gas emissions.

Conclusion

Choosing coil-anodized material with laser-cut perforations over batch-anodizing after perforation offers a multitude of benefits, including improved aesthetics, enhanced durability, cost efficiency, and eco-friendliness.

These advantages make coil-anodized material with laser-cut perforations a compelling choice for architects, designers, and manufacturers aiming to create high-quality, visually appealing, and long-lasting metal components for their projects. Consider incorporating this innovative approach into your next metal fabrication project.

Project Details

The Stella in New Rochelle, NY is a 27-story mixed-use high-rise development designed by Beyer Blinder Belle Architects. Based in the heart of downtown NY, the aim of the development was to combine affordable residential housing with a large ground-floor commercial space.  

The design intent for the exterior façade was to create a contemporary design that would incorporate a range of building materials. In addition, an intention for the exterior façade was to develop a finish on aluminum composite panels that could mimic the look of real concrete, in particular, Ivory Concrete. This would allow the project to have the look of a concrete façade but with the benefits that come from using metal cladding materials.  

Fairview’s Solution

Fairview Architectural was brought in to assist with the project due to our expertise in creating unique finishes on aluminum composite cladding. Fairview Architectural’s color laboratory was used, in conjunction with the project team at Beyer Blinder Belle and ES Windows. 

The final finish chosen for The Stella not only looks like concrete it also has a textured look and feel that makes it almost impossible to tell the difference between real concrete panels and the Ivory Concrete on aluminum composite panels.  

Mark Knapp from ES Windows who installed the panels commented:

“We were brought on to this project to offer design assistance. The architects were looking for an aluminum alternative to an existing construction material. We couldn’t be happier with the result. Fairview really showed their expertise in creating this custom-matched finish and we wouldn’t hesitate to use them on similar projects in the future. They are the industry’s best-kept secret when it comes to finishes and color matching.” 

The Finish 

Ivory Concrete is a coil-coated finish on 4mm Vitrabond® FR aluminum composite panels. This cladding material consists of two sheets of 0.02” aluminum sandwiching a fire-retardant core. The coil-coated finishes use a Kynar PVDF resin that makes it possible for the panels to be formed and rolled without any cracking or crazing.  

Get your samples of Ivory Concrete today!

Awards

Westchester Home Builders Awards – Best Luxury Multifamily Development

At Fairview Architectural, we are passionate about giving customers, architects and GCs a selection of finishes that provide an indication of the quality of the products and finishes that we are known for supplying.

Whether you are looking for a solution for a large-scale project or a smaller project,our Express Range Kit is a good place to start. This is a curated selection of finishes that our expert team has compiled over a number of years that shows the high standard and quality that we provide.

Each day in our warehouse there is always a lineup of samples being prepared for sending out each day. This is an extremely encouraging sight and shows that the construction industry is thriving as is the popularity of aluminum panels.

Outstanding Finishes

Vitrabond® panels have a polyvinylidene fluoride (PVDF) exterior finish meeting AAMA 2605 performance standards⁴, providing an exceedingly high level of durability⁵, and resistance to dirt accumulation because of its fluoropolymer formula³. Fairview  Architectural has extensive options regarding the aesthetics of PVDF finishes, and offers architects the opportunity for coordinating custom finishes. The variability of formulations allows for a wide range of colors, gloss, and special effects such as metallic  speckling⁵. Specific formulations are proprietary, but constituents such as metal oxides and mica pearlescent are used for  aesthetics⁵. The finish is factory-applied by coil coating⁶, a highly automated and highly efficient process. On a continuous coil coating line, the aluminum sheet is uncoiled, pretreated, primed, coated, cured in finish oven, then recoiled. At The Heming, the finishes are SOG Grey, Dusty Charcoal, which are both custom, Bronze Metallic and Copper Metallic. 

Production to Installation

Sustainability in the architectural industry involves considerations of the building materials, specifically raw materials, supply chain,  and characteristics of the end product. The Vitrabond® aluminum composite panels are produced by merging the PVDF top-coated aluminum sheet fed from above, with the mineral-based core material as a heated extruded layer fed laterally, along with the backside aluminum sheet fed from below, together passed through rollers in a continuous automated process. The combined interactions of cooling, drying, and pressure cause fusion of the aluminum sheets to the core material as an incredibly thin rigid composite, having a top-coating that is exceptionally durable to the exterior environment. Fabrication is a different stage of production by a separate entity, in this case by River Supply Inc. Fabrication involves cutting to size, then routing and folding at the perimeter edge to result in a continuous return for attachment of respective panels. Installation is by Del Metro Inc.

Method of Attachment

Vitrabond® panels can be integrated into various attachment systems available to the building industry. Specifically at The Heming,  the WS-200 system by River Supply Inc. is used, which consists of intricately small linear aluminum profiles to which the panels attach by rivets. The system is fastened to the substructure through shims, which function as a thermal break and also isolate dissimilar materials. Joints are 1/2” gaps sealed by the silicone sealant Dow Corning 795. Silicone sealants are chemically stable and extremely durable with excellent resistance to weathering and aging⁷. Shown below is a detail of the assembly.

Acknowledgments

Special thanks to Arcadis for photos, River Supply Inc. for the assembly detail, and Del Metro Inc. for specifics.

References

¹Tysons Urban Center. Fairfax County Comprehensive Plan, 2017 Edition.

²Vitrabond® Aluminum Composite Panel Technical Information. 2013. Fairview Architectural.

³Ehrlich, B. 2014. Cladding: More Than Just a Pretty Façade. Environmental Building News 23(9): 1-10.

⁴Vitrabond® Technical Manual. 2020. Fairview Architectural.

⁵Iezzi, R. A. 2015. Polyvinylidene Fluoride-Based Coatings Technology. In: ASM Handbook, Volume 5B, Protective Organic Coatings. K. B. Tator (ed.)

⁶Vitrabond® FR Metal Composite Material, Façade System Specification Template. 2016. Fairview Architectural.

⁷Beall, C. 1999. Thermal and Moisture Protection Manual. McGraw-Hill.

The material of the core, thin as it is, is based on minimally processed minerals that are compatible and fusible with the extremely thin aluminum sheets. The Vitrabond® panels are an example of dematerialization, the concept of using less material to fulfill an intended purpose. This correlates with less embodied resources and lighter weight load. As another factor to sustainability, the panels have minimal maintenance and outstanding longevity.

Outstanding Finishes

The exterior finish is a polyvinylidene fluoride (PVDF) finish meeting AAMA 2605 performance standards⁴, providing an exceedingly high level of durability⁵, and resistance to dirt accumulation because of its fluoropolymer formula³. Fairview Architectural has extensive options regarding the aesthetics of PVDF finishes. The variability of formulations allows for a wide range of colors, gloss, and special effects such as metallic speckling⁵. Specific formulations are proprietary, but constituents such as metal oxides and mica pearlescent are used for aesthetics⁵. The finish is factory-applied by coil coating⁶, a highly automated and highly efficient process. On a continuous coil coating line, the aluminum sheet is uncoiled, pretreated, primed, coated, cured in finish oven, then recoiled. At Capitol Vista, the finishes are Ascot White, Pewter Metallic, and Smoke Silver Metallic.

Production of Panels and Fabrication

Sustainability in the architectural industry involves considerations of the building materials, specifically raw materials, supply chain, and characteristics of the end product. The Vitrabond® aluminum composite panels are produced by merging the PVDF top-coated aluminum sheet fed from above, with the mineral-based core material as a heated extruded layer fed laterally, along with the backside aluminum sheet fed from below, together passed through rollers in a continuous automated process. The combined interactions of cooling, drying, and pressure cause fusion of the aluminum sheets to the core material as an incredibly thin rigid composite, having a top-coating that is exceptionally durable to the exterior environment. Fabrication is a different stage of production by a separate entity, in this case by Del Metro Inc. Fabrication involves cutting to size, then routing and folding at the perimeter edge to result in a continuous return for attachment of respective panels.

Method of Attachment

Vitrabond® panels can be integrated into numerous attachment systems available to the building industry. At Capitol Vista, the panels attach by rivets to the Arrowhead® Flex system, also by Fairview Architectural. The patented system is designed to simplify installation, minimize fallibilities, and reduce labor costs⁷. The system consists of small, intricately shaped linear profiles, which in this context can be referred to as pieces. First a base piece is fastened through shims to the substructure. An intermediate piece, to which the Vitrabond® panels are attached, interlocks to the base piece by an innovative T-clip⁸. The Arrowhead® Flex system is non-sequential, meaning respective panels are installed independently of adjacent panels, thereby allowing flexibility in the construction process. Shown below is a detail of the assembly.

Acknowledgments

Special thanks to Grimm + Parker Architects for reviewing the article and Del Metro Inc. for the assembly detail.

References

¹District of Colombia, Office of the Deputy Mayor for Planning and Economic Development. 2015. Request for Proposals: Capital Vista (2nd & H Streets, N.W.)

²Vitrabond® Aluminum Composite Panel Technical Information. 2013. Fairview Architectura

³Ehrlich, B. 2014. Cladding: More Than Just a Pretty Façade. Environmental Building News 23(9): 1-10.

⁴Vitrabond® Technical Manual. 2020. Fairview Architectural.

⁵Iezzi, R. A. 2015. Polyvinylidene Fluoride-Based Coatings Technology. In: ASM Handbook, Volume 5B, Protective Organic Coatings. K. B. Tator (ed.)

⁶Vitrabond® FR Metal Composite Material, Façade System Specification Template. 2016. Fairview Architectural.

⁷Arrowhead Information Flyer. 2020. Fairview Architectural.

⁸DrJ Engineering, LLC. 2021. Technical Evaluation Report TER 2006-02 Arrowhead® Fastening System. Fairview Architectural.

(This article was originally published on www.FLSustainability.com)

The panels use 70% less aluminum than conventional 1/8” aluminum plate, thereby having the advantages of aluminum but in significantly lower quantity. This is significant considering virgin aluminum is especially energy-intensive to produce³, but aluminum can be considered highly sustainable when used sparingly. The material of the core, thin as it is, is based on minimally processed minerals that are compatible and fusible with the extremely thin aluminum sheets. The Vitrabond® panels are an example of dematerialization, the concept of using less material to fulfill an intended purpose. This correlates with less embodied resources and lighter weight load. As another factor to sustainability, the panels have minimal maintenance and outstanding longevity.

Finishes that Make a Difference

The exterior finish is a polyvinylidene fluoride (PVDF) finish meeting AAMA 2605 performance standards⁴, providing an exceedingly high level of durability. Additionally, PVDF finish-coating resists dirt accumulation because of its fluoropolymer formula³. The finish is factory-applied by coil coating⁵, a highly automated and highly efficient process. On a continuous coil coating line, the aluminum sheet is uncoiled, pretreated, primed, coated, cured in finish oven, and recoiled. With PVDF coil coating, solid colors are of unsurpassed color consistency. Specifically at 808-812 Memorial Drive, the finish colors are warm earth-tones of Clay, Sedona, and equivalent of Pantone 41-6U, which are all customized colors.

Production of Panels

Sustainability in the architectural industry involves considerations of the building materials, specifically raw materials, supply chain, and characteristics of the end product. The Vitrabond® aluminum composite panels are produced by merging the PVDF top-coated aluminum sheet fed from above, with the mineral-based core material as a heated extruded layer fed laterally, along with the backside aluminum sheet fed from below, together passed through rollers in a continuous automated process. The combined interactions of cooling, drying, and pressure cause fusion of the aluminum sheets to the core material as an incredibly thin rigid composite, having a top-coating that is exceptionally durable to the exterior environment.

Method of Attachment

Vitrabond® panels can be integrated into numerous attachment systems available to the building industry. Specifically at 808-812 Memorial Drive, the panels, fabricated and installed by Sunrise Erectors, are layered over Kingspan® KarrierPanel® wall system. The assembly includes 4” thick insulation panels of polyisocyanurate faced with light-gauge steel. The panels are profiled at the edges for reciprocal jointing, and the joints are sealed with butyl sealant. A specially designed rail (KarrierRailTM) is fastened over the insulation panels so that the air vapor barrier is not penetrated and the insulating layer is continuous⁶,⁷. The vertical rails extend 1” beyond the insulation panels and function as a substructure for the route and return attachment system by Sunrise Erectors, consisting of intricately small linear aluminum profiles to which the Vitrabond® panels attach. Shown below is a detail of the assembly.

Acknowledgments

Special thanks to Bruner/Cott Architects and Sunrise Erectors for specifics on the exterior wall assembly.

References

¹New Ecology. 2020. 808-812 Memorial Drive: Energy & Water Savings through the Auditing Process.

²Vitrabond® Aluminum Composite Panel Technical Information. 2013. Fairview Architectural. 

³Ehrlich, B. 2014. Cladding: More Than Just a Pretty Façade. Environmental Building News 23(9): 1-10.

⁴Vitrabond® Technical Manual. 2020. Fairview Architectural.

⁵Vitrabond® FR Metal Composite Material, Façade System Specification Template. 2016. Fairview Architectural.

⁶KarrierPanel® Wall System Installation Guide. 2022. Kingspan Insulated Panels Inc.

⁷KarrierPanel® Universal Barrier Wall Solution. 2022. Kingspan Insulated Panels Inc.