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.

Aluminum is becoming the go-to material for designers and construction industry professionals looking for compliant cladding solutions to use on projects in the US. This versatile metal boasts many benefits, including its flexibility, lightweight, and durability. It also comes in various grades, each of which is suitable for different applications. Therefore, it’s important to consider which grade of aluminum is required for your project. Each series is numbered 1-7, indicating the primary alloying element. 

The 3000 and 5000 series are the most commonly used in the building construction industry and we will cover this in more detail, but we will also look at all seven alloys and their most common uses.   

Alloying elements are the backbone of different aluminum grades.  When looking for the right grade of aluminum for your project, it is essential to consider the properties of the alloy. These alloys exhibit varying degrees of workability, corrosion resistance, heat treatability, electrical conductivity, strength, and flexibility, which directly influence their suitability for different applications. 

 

Here is an overview of each different alloy series:  

 

1000 Series: These alloys contain at least 99% pure aluminum and are the most commercial of aluminum grades. They are highly corrosion-resistant and are often softer than other alloys. They are ideal for food processing equipment or use on outdoor structures.  

 

2000 Series: These alloys include copper as the main element. This increases strength following heat treatment but has a low corrosion resistance. Common uses for these alloys include aircraft structures and propellers, automotive bodies and screw fittings. 

 

3000 Series: 3xxx Series: these alloys are known for their formability and weldability due to their high manganese content. Typical uses for 3xxx series alloys include radiator cores, fuel tanks, cooking utensils, and various building products.

 

4000 Series: These alloys contain silicon as the main alloying element. These alloys have a low melting point and are commonly used for welding wires or brazing rods.  

 

5000 Series: Known as ‘marine grade’ aluminum, these alloys contain magnesium which provides excellent corrosion resistance and improved strength, making them a perfect choice for marine applications for example boat hulls, storage tanks and construction materials. 

6000 Series: This type of alloy contains a combination of magnesium and silicon, that improves its strength whilst also enabling it to be formed into complex shapes. These alloys are easy to weld and offer good corrosion resistance. Common applications include transportation equipment.  

 

7000 Series: Contains zinc making it the highest-strength aluminum alloy. However, its formability is limited due to the hardening effect on the metal when heated during welding and other fabrication processes. It is also highly corrosion resistant making it an ideal choice for structural components for use in bridges or aircraft frames.  

 

For construction applications, 3xxx and 5xxx series alloys are most commonly used for fabricating solid aluminum plate. Of these two, the 3xxx series is used more often as it has superior workability to the 5xxx series. The 5xxx series marine grade aluminum is strong and corrosion-resistant, which makes it ideal for ships and decorative features on marine vessels and for buildings near coastal areas. However, the 5xxx series exhibits lower machinability and a higher thermal expansion rate compared to 3xxx series alloys, making the latter more suitable for most construction projects.

 

There are other benefits to using 3xxx series alloys which adds to its appeal amongst fabricators and installers of building facade cladding: 

• rigid structure 
• increased spanning performance 
• superior machinability 
• lower thermal expansion rate

  

For your convenience, our Vitraplate 3mm(1/8”) solid aluminum panels are available in both 3xxx and 5xxx series aluminum. If you need help deciding which alloy is right for your specific project, please contact our team to discuss. You can also request a complimentary sample to see the product for yourself and even trial fabricating the material in your own shop. Contact us to find out more.