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.

(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.

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

Photo credit: ES

Curtain Wall System by ES

The ES-UN8030 is a preglazed curtain wall system. The term “curtain wall” refers to the aluminum framing that supports the glass, more specifically with the capability of spanning multi-story heights. It is also known as a “unitized” system referring to the unitization of panels, whether glass or metal, with preassembled aluminum extrusion framing. As a “preglazed” system, the panels are sealed to their aluminum frames at the factory as opposed to on-site, so that the sealant is applied and cured in a controlled environment, where there is no variation of temperature and humidity, and no exposure to airborne contaminants¹. The advantages of a preglazed unitized system include quality control of assembly, exterior side hermetically sealed, and expedited installation. The maximum size for the unitized panels is 5 feet width and 11 feet height². Continuity of the curtain wall is achieved by joining adjacent unitized panels together with reciprocal framing profiles. The framing system is thermally broken³ to minimize conductive heat transfer. ES is part of a vertically integrated conglomerate and the products are assembled and unitized in the same manufacturing complex as processed glass operations and aluminum extrusion production. This consolidation maximizes coordination efficiency and streamlines the supply chain. The material of the extrusions for the ES-UN8030 is 6063-T6 aluminum alloy or 6005-T5 aluminum alloy, depending on the component². Aluminum is lightweight, high-strength, and reflective⁴, and these aluminum alloys have excellent extrudability⁵. Although the exterior of the building is total curtain wall, differences of color quality and texture, and the massing of the wall planes, provide complimentary contrasts aesthetically.

Integral Metal Panels

The non-glass areas are Vitrabond® aluminum composite panels produced by Fairview Architectural, which are two sheets of 0.02” aluminum fused to a fire-retardant core for a total thickness of 0.157 inch⁶, ⁷. The panels use 70% less aluminum than conventional 1/8” aluminum plate, thereby having the advantages of aluminum but in significantly lower quantity. The exterior finish is a polyvinylidene fluoride (PVDF) finish meeting AAMA 2605 performance standards³, providing an exceedingly high level of durability. The color Anthrazit Grey VB1255 is used at the bulk of the tower, around the 3-story glass curtain walls. Panels at the building’s secondary massing areas have customized Ivory Concrete VBC864803 textured and speckled finish.

High-Specification Glass

The high-performance glass units are 1” nominal thickness, comprised of 1/4” clear glass with R53/33 coating at the inward surface, plus 1/2” insulating airspace filled with argon gas, plus 1/4” clear glass. The R53/33, which is an acronym for Tecnoglass R-series (Reflective) low-E with nominal light transmittance of 53% and solar heat gain coefficient of 0.33, has a reflective exterior appearance with cool color tones⁸. Argon gas is invisible and nontoxic, having lower thermal conductivity than air. It is used in combination with a low-e coating for optimal thermal performance. Spandrel glass, intermediate between floors, is solid opaque “charcoal” colored ceramic frit applied to the interior-facing surface of the glass, resulting in minimal aesthetic contrast with the typical glass because of continuity of reflectance and coloration at the exterior.

Photo credit: ES

References

¹Takish, M. S., M. H. Haugsby, C. M. Schmidt, and W. J. Schoenherr. 1989. Structural Silicone Sealant Curtain Walls: Field or Factory Glazing? In: Science and Technology of Glazing Systems, ASTM STP 1054, American Society for Testing and Materials, pages 58-65. C. J. Parise (ed.).

²ES-UN8030 Technical Datasheet. 2018. Energía Solar (ESWindows).

³Architectural Guide. 2020. ESWindows.

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

⁵Davis, J. R. 2001. Aluminum and Aluminum Alloys. Page 351-416. In: Alloying: Understanding the Basics.

⁶Vitrabond® Technical Manual. 2022. Fairview Architectural.

⁷Technical Evaluation Report TER 1809-01 Fairview Architectural Vitrabond® Metal Composite Material (MCM). 2022. DRJ Engineering, LLC.

⁸Low-E Series. 2019. Tecnoglass.

Awards

Best Luxury Multifamily Development, Westchester Home Builders Awards program