One of the most effective ways of enhancing the performance of a building envelope is to use a rainscreen cladding system. The rainscreen principle began to be understood in the early 1900’s, as out lined in our blog post – History of the Rainscreen Principle and has become the standard in building envelope construction.  

Metal panel rainscreen systems, whether composite (ACM/MCM) or solid aluminum, are praised for their sustainability and aesthetics. Their adaptability to various design trends and ease of installation make them a superior choice compared to other rainscreen products.

A rainscreen system acts as a protective screen against rain, allowing moisture to penetrate behind the screen and then evaporate through ventilation. An air space behind the rainscreen ensures constant airflow, while a weather barrier serves as the primary defense between the exterior and interior. The structural wall is located inside the weather barrier, with insulation placed either inside or outside the barrier, depending on the building envelope design.

Selecting a metal panel rainscreen installation system for your cladding project can be challenging due to the variety of available options and the need for integration with other products. This guide focuses specifically on metal panel rainscreen installation systems:

1. Arrowhead Rainscreen Cladding Installation Systems by Fairview Architectural

Fairview Architectural stands out as the only metal panel façade product manufacturer offering both sheet materials and extrusions/components, ensuring installers receive a complete package from a single source for guaranteed compatibility. Additionally, Fairview mandates training and vetting for fabricators and installers, providing architects and building owners with confidence that the project will be executed correctly. This thorough approach helps prevent issues like mold growth caused by under-qualified installers or under-tested rainscreen systems.

Arrowhead is a family of rainscreen panel installation systems that offers a wide variety of design possibilities, unparalleled installation efficiencies, and long-term product lifecycle benefits.

There are numerous ways that Arrowhead saves you both money and time over any other metal panel rainscreen installation system:

• Non-sequential installation avoids interruptions from other trades
• Unique installation process avoids many steps in the installation process required by other systems
• Multiple systems to choose from offering the widest variety in aesthetics in one system

 2. EVO and FUSION by Carter Architectural Panels 

Carter Architectural Panels call themselves the “North American Extrusion System Specialists”. According to their website, as they evolve, so do their products and partnerships. Originally in sheet metal and architectural panel fabrication, supplying and installing panels on site, they turned to offering fabricating rights to other fabricators across North America for their extrusions. Their objective was to cause change in the specification process through Architects and Specifiers, to accept tested panel systems, which perform exceptionally. 

The Carter website states that “EVO™ RIVETLESS™ panels are value engineered and designed to withstand the harshest elements and toughest competitors”, and that they are “strictly a distributor of the FUSION™ DRILLFREE™ extrusion system to fabricators across North America, and do not compete in the manufacturing of any products.” 

3.SAF Rainscreen Installation Systems 

SAF is a fabricator of a wide variety of metal building products, from column covers to sunshades, and metal wall panels. They can custom fabricate architectural bollards and apply custom finishes. SAF glazed and rainscreen systems come with time-tested securing systems including one with no screws or rivets visible.  

By using a pre-engineered system approach, SAF can quickly design and fabricate a building panel and extrusion system that is easy to install, enabling smooth workflows on the job site.  

As we mentioned at the start of this article, choosing a metal panel rainscreen installation system for your cladding project can be a challenge but we hope that these comparisons prove helpful. We also highly recommend specifying a rainscreen installation system that will enable your design intent while also ensuring a sound building envelope that will protect the building in any situation. Specification documents for Arrowhead Installation systems can be downloaded below: 

👉Fairview Architectural Binder 

Learn more about the Arrowhead family of rainscreen systems:  

• What is a Non-Sequential Cladding installation system, and why does it matter? 
• History of the Rainscreen principle 

Get Connected – Customer Service is ready to assist by phone 860-242-2711 or by email at helpdesk@fairview-na.com.  

Cladding Safety with Metal Composite Material (MCM) and NFPA 285-19

One of the most talked about points when specifying MCM panels, is NPFA 285 compliance. Fire safety standards are a big concern globally, and understandably so.

Since the 1980s, innovative exterior wall systems have been developed to enhance a buildings appearance, and to improve the overall performance of a facade. Over the last decade several high-rise building fires including structures in Dubai, Shanghai, Atlantic City, and the much-publicized Grenfell Tower in 2017 has raised concerns over buildings and façade cladding safety.

The NFPA (National Fire Protection Association) has developed research and resources to help building owners and global enforcement authorities, assess the fire risk of existing high-rise building portfolios, as well as identify what fire testing procedures should be applied when designing new buildings.  It has been suggested that the absence of severe apartment building fires in the U.S. is a testament to the American Building Code and additional standards such as NFPA 285.

What is NFPA 285?

The NFPA 285 test evolved from previous building and fire codes and first came into existence in 1998. The Code was updated in 2018 following the Grenfell Tower fire and has been continually revised, and improved to ensure the safety of buildings and their residents. NFPA 285 -19 (2019) is the current test standard.

What does the NFPA 285 involve?

The NFPA 285 test is classified as the ‘Standard Fire Test Method for Evaluation of Fire Propagation Characteristics of Exterior Wall Assemblies Containing Combustible Components’. This standard provides a test method for determining the fire propagation characteristics of exterior wall assemblies that are constructed using combustible materials or that incorporate combustible components.

The actual test itself is performed as an assembly test for exterior walls that contain combustible components or materials. The test determines vertical and horizontal flame spread by simulating an interior flashover fire that impacts the exterior cladding through a compromised window opening. It is important to stress the fact that NFPA 285 is a large-scale assembly test. This means that individual products and systems cannot pass the test alone. Materials are only considered acceptable when evaluated in conjunction with and as part of the entire wall assembly.

An example of a typical NFPA 285 compliant MCM wall assembly includes the following components that are often sourced from multiple manufacturers: insulation, exterior cladding panel, air barrier, water-resistive barrier, fasteners, lintels and furring.

The fire exposure duration for NFPA 285 is 30 minutes. See example diagram below:

Image: courtesy of the Metal Construction Association

When is NFPA 285 compliance required?

NFPA 285 compliance is required for an exterior wall assembly containing MCM panels as follows:

• Installations on buildings of Type I, II, III or IV construction that are greater than 40 feet in height where the fire-separation distance exceeds 5 feet.
• Installations of up to 50 feet if the MCM has a limited self-ignition temperature.
• Installations up to 75 feet (or beyond if sprinkler protected).

The graphic below provides a visual reference on when and where the Code is required:

Note: There are situations where a combustible Water Resistant Barrier can be used without being tested such as when the only combustible component in the wall assembly is covered with brick, stucco, concrete and a few other materials or meets certain technical parameters.

How does MCM perform against NFPA 285?

Although continually faced with updated test protocols for fire protection, metal composite material cladding is passing the test. With its Fire Retardant (FR) mineral core, MCMs perform well when subjected to NFPA’s stringent testing procedures.

Note: not all manufacturers have tested their products against the current standard, so it is important to make sure that the MCM you are specifying is compliant and accompanied by an ISO/IEC 17065 accredited report.

When exposed to fire, the metal skins of the MCM initially deflect the heat and fire away from the core material. While the metal skins will eventually melt, the material remains in place, and the metal limits both the amount of combustible core available to the fire and the spread of flame.

Also, of note is the fact that wall cavity heat gain is not typically an issue in MCM systems in the absence of exterior flames. In other words, the wall does not self-sustain once the flame source is eliminated. This is also a benefit of the FR core as it has shown to self-extinguish almost immediately.

This is due to the FR core utilizing the addition of minerals, such as alumina trihydrate or magnesium oxide, that effectively break down when subjected to extreme heat. This then releases water vapor, helps suppress the fire, and causes the self-extinguishing process mentioned above once the flame source is removed (see diagram below).

Are there alternatives to using MCM panels?

MCM panels are a popular construction material and there are many advantages to continue using and specifying them as part of your compliant wall assembly. Alternative options to MCM are non-combustible solid metal panels or engineered metal plate, however, current supply chain issues caused by the high demand for raw aluminum materials, is seeing prices for these products reach all-time highs.

How to specify MCM compliant products

If you require a non-combustible cladding solution that is compliant to NFPA 285, MCM is the more reasonably priced option with the addition of being available in an extensive range of colors, easy to fabricate and install and long-term warranties.

At Fairview our range includes the MCM panel product, Vitrabond FR, that is fully compliant to NFPA 285 (report available on request) as well as the 3mm pre-finished solid aluminum panel (Vitraplate). Contact our team for more information and to discuss your specific project needs.

(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.

1. Where can I find non-combustible cladding in stock, “ready to ship”?

Fairview Architectural manufacturs Vitraplate® pre-finished 3mm(1/8″) solid aluminum in USA, and maintains inventory of coil, ready to coat, with lead times as low as 4 weeks. Ask about our Coil Retainer Program to reduce your lead times to a minimum.

2. How long does it take to get a custom color sample for pre-finished solid aluminum cladding?

Barring unforeseen circumstances, getting a custom color sample for our coil-coated aluminum Vitraplate® is no different than any other paint match. Although this varies depending on the time of year and workload of the paint manufacturer, it is typically 2–4 weeks.  Specialty finishes and patterns can take longer, and always keep in mind that there is a certain amount of trial and error, with some finishes being more difficult to match than others. We recommend starting the process as soon as possible, especially as there is no cost to you for this service.

3. How long does it take to get a custom color pre-finished solid aluminum non-combustible cladding material produced after the color sample has been approved?

Using our Vitraplate® as an example, once the color has been approved, there are multiple processes including manufacturing the coating, preparing and coating the coil, transport, leveling and cutting, and packaging. Each one of these steps can take more or less time, resulting in an overall lead time anywhere from 4 to 8 weeks, depending on the finish.  A more accurate lead time is available at the time of quoting, and the most accurate will be available at the time of placing your order. We recommend you keep in communication with your contact at Fairview until the order is ready to be processed.

4. If a color is requested that has been produced before and you have a sample of it available but do not have it in stock, what is the anticipated lead time for that order?

Although the color has been produced previously, a new order requires exactly the same process. Therefore, the lead time would be similar to a first-time order, unless we have paint remaining in stock from the previous order. 

5. If you apply a 3rd coat of paint on a stock color that wasn’t requested already, what would be the additional lead time and cost to add the 3rd coat?

Once again, using Vitraplate® as the example, this product is coated with one of the highest quality baked-on finishes, and as such after coating an additional coating cannot be applied. A standard 2 coat with a clear coating added would be treated as a 3 coat color.

6. Do pattern or unique design finishes, such as woodgrains, take longer than solid color paint finishes to produce? Is the same Coil finish process used to achieve these finishes?

Although patterned finishes are produced on the same coating line as solid or metallic finishes, due to scheduling and economies of scale unique patterned finishes will take longer than standard solid or metallic finishes. Please discuss this with your sales representative to get a more accurate lead time.

7. Do non-stock colors on solid metal cladding such as Vitraplate have a longer lead time than ACM?

Manufacturing Vitrabond® and Vitraplate® are two different processes, each with its own set of variables. This means that either one could be quicker than the other, depending on those variables. 

8. Are there any setup charges for custom color projects or any other unique product colors?

Fairview Architectural has no setup fees or charges. However, there are costs associated with every order that must get covered by the sale.  This means that on smaller orders the cost will increase, sometimes significantly.

9. Where can I find current inventory numbers of what non-combustible material is currently in stock and in which finishes?

Call 860-242-2711 or email helpdesk@fairview-na.com at any time to inquire about our current inventory. This is subject to change at any time. All stock is sold on a first come first served basis.

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

Palette of Finishes

The exterior finish is a polyvinylidene fluoride (PVDF) finish meeting AAMA 2605 performance standards3, providing an exceedingly high level of durability. Additionally, PVDF finish-coating resists dirt accumulation because of its fluoropolymer formula². There is an array of PVDF finish coatings for not only color options but also gloss level, texture, and color mottling. The finish is factory-applied by coil coating⁴, 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 layered coil coating capabilities, variations such as blotches, markings, or patterning of coats are applied in sequence according to preconfigured design having a collective aesthetic effect. The resulting coil-coated print can have a distinctively aged and weathered appearance, while in actuality it is exceptionally resistant to aging and weathering. Specifically, the finishes used at CSX East were: Nimitz Blue, Azure Patina, Longhorn Rust, Nebula Blue, Mesa Rust, Mojave Rust, and Sierra Rust. Fairview Architectural takes special ownership of having worked in coordination with the architect to develop these customized faux metal finishes.

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.

References

¹Vitrabond® Aluminum Composite Panel Technical Information. 2013. Fairview Architectural.

²Ehrlich, B. 2014. Cladding: More Than Just a Pretty Façade. Environmental Building News 23(9): 1-10.

⁴Vitrabond® FR Metal Composite Material, Façade System Specification Template. 2016. Fairview Architectural.