Metal Cladding

Manufacturing process
Functional requirements
Basic Framework
Metal Cladding Systems
Materials
Different Types of Finishes
Coatings and their materials
Types of Panels
Panel Systems
Flashings and architectural Fabrications
Proprietary Details
Joinery Details
Installation Methods
Advantages and disadvantages
 Metal Cladding
Metal cladding is a method of protecting
one metal (or composite) by bonding a
layer of a second metal to its surface by
using techniques such as diffusion,
deformation and lasers. The outer and
inner metals are typically dissimilar.
It has hugged the twists and turns of
architecture for decades, from the
punched tin of Louis Sullivan to the
titanium swoops of Frank Gehry,
designers have embraced metal cladding for its formal flexibility and finish.

Manufacturing processes

 Clad metals are metals bonded to at least

one layer of a different metal. Cladding can
be achieved by a number of different
processes, including extrusion, pressing,
electroplating and a variety of chemical
techniques.
 Sheets are manufactured in a range of
corrugated and other profiles, such as
trapezoidal, sinusoidal or half-round. The
profiles are manufactured from sheets fed
through banks of forming rollers.
 Modern manufacturing techniques
allow metals to be pre-aged, coated
with preservatives, or painted a wide
range of hues and texture.
 Metal profile sheets can
be installed vertically, horizontally or
diagonally, and are capable of being
applied to curved facades and other
complex shapes.
 Roll Bonding-
 Roll bonding is frequently used to
produce clad metals. In roll bonding,
multiple strips of cleaned and prepared,
dissimilar metals are simultaneously
passed through a high-pressure rolling
mill.
 Due to the pressure exerted by the rolls,
the metals coalesce into a single
material that is bonded on an atomic
level.
 Generally, the resulting material is heat
treated to enhance the strength of the bond. Explosive bonding, which uses the energy produced from
explosive charges, is also used to produce clad metals.
 Both the thickness and distribution of the cladding can be controlled during the production process.
Manufacturers can also apply specialized coatings to specific portions of the metal to prevent it from
bonding.
 Laser Cladding -
 Laser Cladding is a method of depositing material by which a powdered or wire feedstock material is
melted and consolidated by use of a laser in order to coat part of a substrate or fabricate a near-net
shape part (additive manufacturing technology) .
 It is often used to improve mechanical properties or increase corrosion resistance, repair worn out parts,
and fabricate metal matrix composites. Surface material maybe laser cladded directly onto a highly
stressed component, i.e. to make a self-lubricating surface.

Functional requirements for metal cladding include

 Durability: The geographic location and
intended lifespan of a building should be
considered with respect to a material’s
resilience.
 Fire resistance
 Thermal insulation: Metal cladding systems
often contribute little to overall wall insulation
values, so it’s likely necessary to attach a
sheathing board to the external face of the
infill walls for weather and thermal resistance.
If your building has a minimum U-value and
you need the cladding to help reach it, talk to
a specialist metal cladding manufacturer to
find the ideal system. The U-value defines the
thermal transmittance of a building envelope, which Typical fire wall details showing slotted holes for expansion in fire.
is the energy in Watts (W) passing through a square
meter of construction per degree temperature difference from inside to outside.
 Acoustic insulation: Suppliers often calculate whole-of-wall ratings,
factoring in the Rw rating (weighted sound reduction index) or STC (sound
transmission class) of the insulating infill-wall products.
 Environmental factors: Particularly for large
scale projects, it is important to consider the
environmental impact of a building material over its
entire life cycle, including the manufacturing
process, installation process and long-term
maintenance requirements.
 Wind Action and loading: Building cladding systems are required to sustain
wind actions and transfer them to the main building structure.
 Expansion & Contraction: Some metals contract and expand with
changes in temperature, humidity and pressure, and if the wrong material is specified, this can lead to
permanent building damage.
 Seismic design requirements
 Performance criteria for air and moisture barrier or rain screen
 Basic Framework of a Metal Panel
System ( fastened with steel )

Components of steel truss metal panel curtain wall

system. Construction of steel truss metal panel curtain wall system

Fastening of metal panel to steel truss.

Metal Cladding Systems
Some of the most widely-utilized systems are as follows:
System Information Graphics
Standing  One of the most recognizable
Steam systems
 characterized by robust folded
connections between each panel.
 Its concealed fixing details allow for
sleek architectural exteriors, making
it a popular choice across typologies.
 can be used with many different
types of metal, including aluminium,
copper, brass, galvanized or stainless
steel, titanium, zinc and weathering
(Cor-ten) steel.
 This system can be supplied as either
pre-insulated panels or as sheets that
are formed and crimped on
site before being applied to
a plywood or similar substrate.
 have no exposed
mechanical fasteners, but use a
special weathertight clipped joint
instead, which creates a distinctive
projecting seam.
 Custom pan widths available for
design individuality
 Can be easily combine fixed widths or
random panel patterns within the
same façade
 Ability to curve and/or taper panels
 Clean corner details, with no need for
flashings or cover plates
 Superior wind loading capacity
(Double Lock Standing Seam required
for high wind applications)
 Low risk water penetration (with the
option of Double Lock Standing Seam
for advanced waterproofing)
 Minimal maintenance compared to
other cladding materials
 Panels allow for material expansion
and contraction and building
breathability
Snap lock  A simpler alternative to standing
seam, snap lock displays a similar
ribbed profile but does not require
specialist closing equipment to install
it.
 Snap lock panels are designed to
“snap” together, offering a low-fuss
installation.
 Ideal for modern architectural
developments.
 Suitable for commercial and
residential projects
 suitable for installers and/or builders
missing appropriate seam closing
tools
 Custom pan widths available for
design individuality
 Combine fixed panel widths or
random patterns within the same
facade
 Minimal maintenance compared to
other cladding materials
 All Snap lock applications must use a
construction grade substrate.
 When working with zinc, on wall
cladding applications a 20 mm
continuous ventilation gap beneath
the substrate, and a 40 mm gap on
roof installations, must be allocated
(note, this is for zinc only).
 The substrate should be wrapped in a
moisture proof membrane before
cladding panels are laid.
 Approved stainless steel clips must be
used to fix each panel over the
membraned substrate, in conjunction
with countersunk screws.
Nail Strip  Nail strip shares aesthetic attributes
with Standing Seam and Snap lock
 Simple installation, with no clips or
special seam tools required
 Attractive vertical fin, unique to Snap
lock and Nail strip systems
 Custom pan widths for design
individuality
 No visible fixings
 Allows for material expansion and
contraction and building
breathability
 Combine fixed panel widths or
random patterns within the same
facade
 Ability to splay and/or taper panels

Interlocki  An interlocking system that offers up

ng: a smoother appearance with
dramatic, express joints.
 Interlocking metal cladding panels
can vary in width, and can be detailed
to run horizontally, vertically or even
diagonally with custom curve options
available.
 Extensive material suitability.
 Interlocking can be folded
in Aluminium, Brass, Copper,
Galvanised Steel, Stainless Steel,
Steel, Titanium Zinc and Weathering
steel/Corten.
 Polystyrene can be placed behind
panels to reduce wind draw on high
wind load applications. This backing
also increases Interlocking’s acoustic
performance; compared to sheet
metal cladding systems without
backings.

Custom If none of the above options are a fit for

your specific project, a bespoke system
can be developed by a specialist
manufacturer, altering an existing
system or creating something
completely new. Project budget will
need to be considered in the case,
since customization will increase the
cost substantially.
Flatlock  Flatlock panels lock together to
and create a flush, flexible, thin façade.
 Flatlock and Shingle share an
shingle
identical profile design, however
once folded and installed; two
individual wall systems emerge.
 For a striking variation on the flatlock
system, a shingled metal façade can
be created using panels folded into
interconnecting tile shapes.
 The system can also be installed in
reverse, creating deeper express
lines; this is called “Reversed
Flatlock.”
 can be manufactured using Steel,
Galvanised Steel, Aluminium, Brass,
Copper, Stainless Steel, Zinc, and
Weathering Steel.

Typical Axonometric - This detail shows that one side and the lower edge of each panel
lock into adjacent panels. The other side and upper edge are held by two cleats each.
Vertical joints are always staggered for weather resistance.

Typical Section-
This section
shows the single
lock seam and
cleats used for
both horizontal Typical Copper Panel -These elevations
and vertical show the typical panel, before and after
joints. the edges are folded.

Typical Window Head and Sill - Wood blocking can be used at the head as
shown. It provides a solid surface for attaching the copper head flashing and
continuity around the window opening. The lower edge of the copper wall
panels is locked into the head flashing to provide a drip.
Cassette  Ideal for large cladding areas, the
open-jointed cassette system can be
used with huge panels up to 13 feet
in length.
 The cassettes are bent and fixed with
invisible clips, usually to an
aluminium framework, and result in a
contemporary, flat appearance.
 These are similar to composites, and
include insulation and liners, but
differ in that they are designed with
easy-to-use interlocking
jointing systems for
quick installation.
 They are suitable for horizontal or
vertical application on low and high-
rise buildings.

Composit  Two metal skins are bonded to

es an insulating core, forming
a composite ‘sandwich’ panel.
 The metal component, can
be aluminium, zinc, stainless steel,
titanium and so on, available in a
wide variety of colours, finishes and
profiles.
Built-up  Built-up sheeting is assembled on
sheeting site, and generally consists of
four components:
o A thin internal liner to ensure air
tightness.
o Insulation (such as mineral wool).
o Spacer bars/brackets to support
the metal cladding.
o Profiled metal facing sheet to provide
weather protection.
 Built-up sheeting can be fitted in
vertical, horizontal or diagonal
patterns, and is usually fixed
in place by self-
tapping fixings designed to match the
chosen finish.
 While curved systems are possible,
they require careful installation.

1. Structural liner tray - Built up

system with structural liner tray
 Components
o Steel structural liner tray spanning
between main columns
o Insulation – usually mineral wool
placed within troughs of liner tray,
plus as a sheet over the ribs of the
tray.
o Metal profiled outer sheet running
vertically.
 Assembly - Site assembled by
cladding sub-contractor.
 Variations - Fire walls. Special tested
constructions can be used as fire
resting walls
2. Site assembled composite
 Components
o Metal profiled liner fixed vertically
outside rails.
o Insulation – mineral wool or foam
board profiled to match liner and
outer sheet fills space between the
sheets.
o Metal profiled outer sheet running
vertically, held in place by stand off
type fixings.
 Assembly - Site assembled by
cladding sub-contractor.
 Variations - Fire walls. Special tested
constructions can be used as fire
resting walls.
 3. Vertical - Built up system with vertical
cladding profiles
 Components
o Metal profiled liner fixed vertically
outside rails.
o Insulation – usually mineral wool
o Spacer system – to hold sheets
apart and support outer cladding.
o Metal profiled outer sheet.
 Assembly - Site assembled by
cladding sub-contractor.
 Variations
o Fire walls. Special tested
constructions can be used as fire
resting walls.
o Inside rail construction.
4. Horizontal - Built up system with
horizontal cladding profiles
 Components
o Metal profiled liner fixed vertically
outside rails.
o Insulation – usually mineral wool
o Spacer system running vertically –
to hold sheets apart and support
outer cladding.
o Metal profiled outer sheet running
horizontally.
 Assembly - Site assembled by
cladding sub-contractor.
 Variations
o Fire walls. Special tested
constructions can be used as fire
resting walls.
o Inside rail construction.

Different Types of Metals used in Metal panels

MATERIALS DESCRIPTION GRAPHICS

 Steel coated in a thin layer of chromium
oxide is commonly referred to as stainless
steel.
 The chromium helps prevent the
Stainless steel
oxidization process of corrosion occurring,
so the material is resistant to rusting.
 Stainless steel is also popular for its clean,
polished finish Stainless Steel gives an
unique view of solidity and integrity,
providing aspect of unlimited material
 There are basically two types of surface
finishes, Glossy matt and Brilliant
 Glossy matt is normally installed with
double standing seam techniques in roofs,
while a brilliant surface is normally
installed in panel systems in Stainless Steel
gives an unique view of solidity and
integrity, providing aspect of unlimited
material
  Galvanized steel is coated in a thin layer of
zinc, and helps to prevent rusting in a
Galvanized
similar manner to stainless steel’s
steel: chromium layer.
 Visible crystallites in the coating give
galvanized steel a mottled aesthetic
feature known as “spangle”.

Aluminium:  Aluminium is naturally resistant to rusting

or blistering, making it a popular cladding
choice for contemporary projects.
 It also possesses an excellent strength-to-
weight ratio, meaning aluminium façade
attachment systems can be less bulky than
those for steel panels.
 That said, the material is prone to denting
and scratches, and may corrode under
certain environmental conditions without
proper care
 Self Cleaning

The aluminum façade of Essex Crossing by SHoP

Architects
Brass:  Striking a balance between the cool hue of
zinc and the warmth of copper, brass is a
highly malleable cladding material that
makes it well suited to decorative sheet
metal work. Over time, brass takes on a
golden-brown patina as its surface
oxidizes.

brass cladding at the Transfer Centre for Adaptronics

(Fraunhofer Institute), Darmstadt, German

Titanium:  Titanium is favoured by architects for its

light weight, high strength and glossy,
reflective appearance.
 Over time, a protective oxide film forms
on the material’s surface, increasing its
resistance to corrosion.
 That said, maintenance is key with
titanium cladding.
 Guggenheim Bilbao was left with brown
staining when it was not properly cleaned
after construction.

The titanium skin of Guggenheim Bilbao

 Copper:  Another lightweight cladding
option, copper is very durable compared
to other materials, and at the end of the
building life is also 100% recyclable.
 Its subtly reflective appearance evolves
over time due to oxidization, turning the
metal a distinctive green color.
 Besides the natural copper, there are
other surfaces made out of copper:-
 Pre-oxided brown copper- it comes from
the production with typical brown tone of
copper after some months of natural
weathering
 Pre patinated copper- it comes from the
production with the real patina copper
making this material specially used to have
the cladding with green bluish aspect from
Copper cladding at the Columbus Museum of Art
the beginning.
 Tinned copper- this is a hop dipped strip of
copper that gives a matt grey surface
whilst keeping the main characters of
copper.
Zinc:  Lauded for its weatherproof, corrosion
resistant qualities, zinc is immune to the
harmful effects of UV rays and even
possesses self-healing properties,
meaning that if scratched, the material
can recover itself with time.

 Metal cladding encompasses a plethora of different materials, each with its own unique strengths and
weaknesses.
 Material choice will be influenced by a number of project-specific factors, including desired aesthetic, climatic
conditions, chosen structural system, the nature of adjacent materials and the construction budget.
Different Types of Finishes

Almost as important as the selection of the metal itself, finishes can have a significant effect on both
aesthetics and performance of metal cladding systems. There is a virtually unlimited range of finishes for
metal façade panels —
METAL DESCRIPTION GRAPHICS
FINISHING
Sand blasting lends metal a smooth,
Sand blasted matte surface, virtually free from texture.
Sandblasted steel can be vulnerable to
rusting and should be protected with
specialty paint or other coating.

Brushed Brushed or dull-polished metal displays a

unidirectional satin finish with a subtle
grain that varies in intensity depending on
the level of abrasive action during
manufacturing.

Mirrored The most reflective of all finishes, highly

polished finishes offer a striking aesthetic
but requires a high level of maintenance
to ensure their glossiness remains.

Powder Powder coating gives metal a protective

coated layer and a uniform matte aesthetic.
Powder coated finishes are available in an
unlimited choice of colours.

Patterned Intricate patterns and complex color

combinations are possible with patterned
finishing.

Engine Engine turned finishes feature a fine

turned geometric pattern inscribed into the
metal, offering a swirled appearance with
varying reflective qualities.
Perforated
finish

High gloss
finish

Profiles A variety of profiles is offered from very low emphasis simple trapezoids, to striking half round
and deep trapezoidal shapes. Typical profile shapes-
 Coatings and their materials
Different coatings offer varying functional performance. Aesthetically too, there are considerable
variations ranging from hard shiny metallic to softer matt plastisol. Metallic coatings require a very high
standard of product and installation, whereas plastisol-coated cladding requires good workmanship, but
is more tolerant to small inconsistencies. Here is a brief summary of commonly available coatings and
materials available.

 Steel organic coatings

 High build PVC The coatings are thick (200 micron) and tough and therefore are resistant to damage.
They are either supplied with an embossed, smooth or leathergrain finish. All have a matt appearance
once weathered.
 Metallic high build: This is a less thick (120 micron) plastisol coating with a metallic finish. Aesthetically
similar to metallic PVDF.
 PVDF (formerly known as pvf2): A smooth fluorocarbon top coat 27micron thick, available smooth or
in metallic, with good colour fastness and gloss retention. Gives a harder more reflective surface and
is commonly associated with a ‘high-tech’ look
 Polyester and acrylic: More economic pre-painted finishes, used more frequently outside the UK.

 Aluminium cladding coatings

 Mill finish /stucco embossed: It is perfectly viable to use mill finish aluminium, the oxidized layer on
the metal providing considerable durability. However, mill finish is seldom used on walls due to
aesthetic considerations. Aluminium is also offered stucco embossed, which improves the appearance.
Manufacturers do not offer longevity figures for mill finish, whereas they do for coated aluminium.
 ARS A high durability coating with good handling characteristics achieved through its tough
construction based on polyester or polyurethane resin reinforced with polyamide.
 PVDF A smooth fluorocarbon top coat 27micron thick, available smooth or in metallic, with good colour
fastness and gloss retention. Gives a harder more reflective surface and is commonly associated with
a ‘high-tech’ look
 Polyester More economic pre-painted finishes, , used more frequently outside the UK.

 Colour matching - Coil coating plants run a particular colour for a batch of coils, and then change to a
different colour. Tiny colour variations occur between different batches of the same colour runs that are
not visible when viewed on a sample, but can become striking on a large scale on a building. Thus, it is
vital to ensure that all the wall cladding and flashings of the same colour on any building all come from
the same coil coating batch.

 Post coating - Cladding panels and fabrications can be coated after being manufactured, by polyester
powder coating or other means. Expense and practicality limit this to specialised panels and particular
fabrications which cannot be satisfactorily made any other way. Again, care needs to be taken with
colour matching.

Types of Panels-
Type Information Graphics
Vertical  The profiles provide vertical lines on the wall face
cladding which are less emphasised if the cladding is placed
with the broad face out as is usually the case.
 The appearance of vertical profiled cladding varies
considerably with the way that the light falls on it
because of shadowing which can also lead to
pleasing textural effects on the wall.
 Profiled cladding requires surface flashings and is
usually through fixed, so flashings and fixings are
quite visible.
 The flashings form a significant feature of the
construction. Vertical cladding is a tolerant form of
construction.
 The eye cannot pick up small variations in structure
or slight looseness in the metal because the sight
line along the vertical plane is broken by the vertical
lines
Fixings for vertically installed profiled metal cladding.

Horizontal  The profile lines follow the eaves line; for buildings
cladding which have a low height to width ratio, the building
shape is emphasised in a pleasing way and the
effect is frequently highlighted by architects using
more dramatic profile shapes.
 Horizontal cladding also uses surface flashings and
fixings.
 The end joins between sheets may be butted (with
straps behind) or lapped away from the line of sight.
 However, a frequently used detail is the top hat end
joins which provides a feature line, usually at every
building frame.
 The profile shape is emphasised more in the
horizontal which gives more scope for the
expression of shape and colour to add interest to Fixings for horizontally installed profiled metal
large building with simple overall geometric shape. cladding
 Much closer tolerances in product and construction
are required than for vertical cladding however,
because the eye easily picks up any slight variations
in line or flatness when viewing a long horizontal
surface, especially if it also has horizontal lines in it.
 This effect is considerably reduced by breaking the
flat surface in every bay with a vertical line; another
reason for the popularity of top hat end joins.
 Horizontal cladding is frequently used as a feature
band, where the rest of the cladding is vertical; this
tends to achieve the positive qualities of both types
and again gives interest to otherwise bland
buildings.
Plank  Plank is a term referring to a particular profile shape
where the metal is formed to present a wide flat
face outermost and a narrow recess into which the
fixings are placed.
 The effect is to provide a flat appearance without
visible fixings however, the profile lines are still
apparent in other words, it is a cross between a
profiled sheet and a flat panel.
 Plank is treated in the same way as a profiled sheet
and is very popular probably because it provides a
comparatively economic flat appearance.
 For large unbroken areas, plank is aesthetically
better fixed vertically rather than horizontally.

Flat  Composite panels consist of two skins of metal with

composite an insulation core, manufactured in a factory,
usually in an automated process.
panel
 Manufactured with an intrinsic side joint, but not
end joint – so the end join details are assembled on
site.
 A completely flat skin consisting of light gauge metal
would in itself have little strength and display
deformation (oil canning) when fixed vertically.
 Flatness and strength is achieved by composite
action with the insulation.
 Flat composite panels present an extremely clean
finish with a ‘high-tech’ modern appearance and
showcase impressive coatings well.
 This type of panel is usually used in long lengths and
may be fixed vertically or horizontally.
 Both secret fix and through fix panels are available;
secret fix has the obvious advantage in that no
screws heads are visible however, with both types
some flashing detail will be visible at the end joins
and other junctions.
 The inner face is usually provided with a very slight
profile.
 The points made above about horizontal cladding
apply even more so to flat panels as even the most
microscopic deformation will show, especially if
metallic finishes are used.
 A very high (and therefore costly) standard of
material, manufacture and construction is required.
Micro-rib  Exactly as flat panel described above however, the
composite outer face has a micro-rib shape roll-formed into it
usually no more than 1 or 2 mm deep.
panel
 The surface looks flat but diffused which makes
these panels much less susceptible to any
appearance of being ‘out of flat’.
 Micro-rib panels are aesthetically pleasing, less
susceptible to damage and weathering, and are
thus an extremely popular choice.
 Profiled composite panels are also used for wall
construction, and are functionally different from
built-up cladding however, in aesthetic terms there
is no difference between them and profiled cladding
described above

Panel Systems-

PANEL DESCRIPTION GRAPHICS

SYSTEMS
Foam core  Components
composite o Metal inner face, lightly profiled.
o PIR or similar foam insulation core,
panel
injected foamed and cured between
the metal sheets during manufacture.
Core is fully bonded to inner and
outer metal sheets.
o Metal outer face, flat, micro-rib or
profiled.
o Side joints are formed into the panel,
the ends are left plain.
 Assembly - Complete panels are
delivered to site and then fitted by
cladding sub-contractor.
 Variations
o Panels may be fitted horizontally or
vertically.
o End joins may be recessed top hat as
shown, protruding top hat, gasket
joint or other.
o Panels may be secret fix (no screw
heads visible) or through fix by
standoff type screws
 Stone wool  Components
core composite o Metal inner face, lightly profiled.
o Stone wool (rock fibre) insulation
panel
core, with specialised fibre
directionality, autohesively bonded
to inner and outer metal faces during
manufacture.
o Metal outer face, flat, micro-rib or
profiled.
o Side joints are formed into the panel,
the ends are left plain.
 Assembly - Complete panels are
delivered to site and then fitted by
cladding sub-contractor.
 Variations
o Tested panels can be used as fire
resting walls.
o Panels may be fitted horizontally or
vertically.
o End joins may be recessed top hat as
shown, protruding top hat, gasket
joint or other.
o Panels may be secret fix (no screw
heads visible) or through fix by
standoff type screws

Flashings and
architectural
Fabrications
Simple flashing details
provide the connections
necessary at junctions in
wall cladding systems and
at junctions with other
elements. Increasingly
sophisticated architectural
fabrications are also
available, which create
interesting features in their
own right and can be an
important part of the
aesthetic concept. Some
examples of what is
available are illustrated.
 Proprietary details-
1.Copper Clad Honeycomb Systems
Description: Copper clad honeycomb panels are engineered and
fabricated by a variety of manufacturers. They are light weight,
strong, and offer a very flat copper panel appearance. Total
panel thickness is variable to suit project requirements. The
honeycomb material varies depending on whether it is an
interior or exterior application. Copper is bonded to the front
side of the honeycomb and a backer panel is bonded to the back
side. The backer panel is required, to ensure the rigidity of the
A. Typical Elevation - This diagrammatic elevation assembly, thereby minimizing warping. The backer panel is
indicates the locations of Sections B and C. usually of a material compatible with the structural
system.
The details shown are generic, and dont represent a
particular system and illustrate a system attached to a
steel structure. With proper detailing, copper clad
honeycomb panels can be installed on virtually any kind
of structure or wall.
Substrate: Any substrate or structure as required by the
specific system manufacturer.
Fastening Method: Typically screws or bolts, as required
by the specific system manufacturer.
B. Horizontal Joint Section-
 These panels are shaped to provide hidden surfaces for the compressible gaskets. The joint
shape is designed to prevent water penetration.
 Separation of dissimilar metals is an important consideration in the design of copper clad
honeycomb panels.
 Manufacturers have engineered a variety of solutions, depending on the honeycomb and backer
panel material, and the method of attachment to the structure.
 In the system shown, the backer panel is not copper. Separation is maintained between the
copper cladding and the backer panel. Steel or aluminium support angle brackets are bolted to
the backer panel.
 The support brackets are bolted to continuous support angles which are welded or bolted to
the steel structure. Shims or other levelling devices may be required for proper panel alignment.

C. Vertical Joint Section- The vertical joint is detailed

the same as the horizontal joint, with an additional D. Axonometric View - This view shows the relationship of the various parts.
compressible gasket to reduce water penetration. Note the use of structural support angles and alignment support angle brackets.
2. Structural Systems

Description: These panels are designed to be attached directly to the wall structure, without the use of
a continuous substrate. The panels must withstand all forces and transfer those forces to the structure.
Therefore, the panel dimensions and thicknesses, z-clip and structure designs must be reviewed by a
structural engineer to ensure that all codes and structural requirements are satisfied.

Substrate: Structural system. A continuous substrate is

not required.

Fastening Method: Stainless steel z-clips and rubber

isolators.

A. Typical Section - This section shows the rubber isolator clips and
the stainless-steel z-clip required to hold the copper panels and
prevent direct contact with the structural system.
D. Base Detail - Wood blocking is
attached to the structure at the base of
the wall. A continuous copper
flashing/lock strip is nailed to the bottom
of the blocking. The bottom edge of the
copper panel is locked into the strip.

C. Parapet Detail - A continuous copper trim/lock strip is nailed to the

wood blocking. This strip holds the top edge of the copper panels. The B. Typical Axonometric- Staggering the transverse seams, as
coping cover locks into this strip, extends over the wood blocking and shown, is required to avoid having many layers of the copper
is locked into a continuous edge strip on the opposite side of the wall. panels at one point. It also helps improve weather resistance.
 3. Profiled Panels

Description: Profiled copper panels can have a variety of shapes and sizes. The shapes can be formed on
site with a brake or powered forming equipment. They can also be pre-manufactured and specified with
embossed patterns or other designs.

The minimum recommended weight for copper used on profiled panels is 16 ounces, but some panel
profiles may require heavier material.

Note: Support blocking behind the panels may be required depending on panel thickness and
dimensions, along with wall configuration, i.e., straight or curved.

Substrate: Continuous nail able substrate.

Fastening Method: Cleats screwed or nailed to substrate.

A. Typical Section-This
section shows a
common seaming
method used in the
horizontal joint between
runs. Cleats are used to
fasten the panels to the
substrate. The panel must
not be shaped so that it holds
water. A minimum of two
cleats per panel are required.
The actual number and
spacing needed should be
determined by a structural
engineer, to ensure wind and
other loads will not lift or
distort the panels. A
minimum of two copper, B. Typical Axonometric - This
brass, bronze, or stainless- detail shows the single lock used
steel screws per cleat are at transverse seams. A lapped
required for fastening to the seam (6" minimum) may also be
substrate. used. The transverse seams
should be staggered as shown.

C. Inside Corner- Wood blocking is used

to fill the gap left between the copper
panels at the corner. Copper flashing is
installed over the blocking, and extends
a minimum of 4" under the panels. The
flashing is held by cleats at 12" on
centre.

D. Outside Corner- The ends of the panels are closed by copper

flashing over wood blocking. The blocking must be thick enough to
completely close the end void. The flashing covers the blocking and
extends under the panels a minimum of 4". The flashing is held by cleats at
12" on center.
 4. Copper Screen Panels

Description: Copper screen panels are part of a manufacturer's engineered system. The details shown
here illustrate the main concepts in the design of copper screen panels. The system shown uses metal
support brackets and channel tracks to carry the copper panels. The support brackets can be attached
to virtually any kind of building structure.

The copper screen panels act as a lightweight, finish screen. The system shown is designed to be a
water shedding rain screen. Alternatively, the panels can be perforated or have shaped openings acting
as sun or decorative screens. The backup wall system should always be designed to be watertight.

Isolator clips are used between the metal support

system and the copper panels to separate dissimilar
metals. The minimum gauge of the copper panels is
dependent on the size of the panels and the design of
the specific system used. Manufacturer's
recommendations should be followed.

Substrate: Any substrate or structure as required by

the specific system manufacturer.

Fastening Method: Typically screws or bolts, as

A. Typical Elevation- This diagrammatic elevation
indicates the locations of Sections B and C.
required by the specific system manufacturer.
D. Isometric View- This detail shows the
relationship of the various parts. Once all the
panels are in place, any water that passes between
vertical joints is channeled down the channel track.

B. Vertical Section - Horizontal Joint

This section is cut through the vertical channel track to show the support bar
that carries the copper panels. This system uses one stainless steel screw per
panel to ensure panels are not lifted by wind. Isolation tape or a bituminous
coating must be applied where the back of the copper panel contacts the
channel track, to separate dissimilar metals. In addition, isolation clips are
used between the support bars and the copper panels.

C. Horizontal Section - Vertical Joint –

The support brackets are fastened to the structure. Channel
tracks are bolted to the support brackets. The copper screen
panels are hung onto the support bar in the channel track.
 Metal Cladding Joinery Details
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Installation Methods
The three installation methods in more detail, ranked least to most efficient:

Method Description Graphics

Route and  The Route and Return Wet Seal method is
Return the most economical way to install.
Wet Seal  The setup is simple: A silicone sealant is
placed between each panel as an air and
water barrier, then basic male/female clips
simply attach the cladding to the building
— no matter the size, shape or complexity
of the panel designs.
 There’s one problem with this method,
however: It leaks.

The EC-100 Route & Return System is a barrier system in which panels are
fabricated and formed into ’pans’ and then mounted onto the substrate
using aluminium extrusions. All fasteners are concealed. Panel joints (1/2"
reveal typical) are finished with an approved sealant. The EC-100 System is
compatible with 4mm, 6mm, & 8mm.

4 mm Wet Joint Wall Cladding

System Details – CCWJ series

Stainless Steel Wet Joint Wall

Cladding System Details – CCWJ
series
Route and  The Route and Return Dry Seal method is a
Return Dry little less messy.
Seal  It requires gaskets to be inserted into the
joints between the panels instead of the
silicone sealant.
 This allows the façade to stay much cleaner
over time.
 The system also features continuous
extrusions around each panel to enhance
structural integrity and act as a secondary
gutter system.
 But this method often causes concern over Dry Seal - Accent Condition Detail
the durability of the gaskets.

Rain  A rainscreen (sometimes referred to as a

Screen ‘drained and ventilated’ or ‘pressure-
attachmen equalised’ façade) is part of a double-wall
t method construction.
 Typically rainscreens are formed of
relatively thin, pre-fabricated panels.
 The rainscreen itself simply prevents
significant amounts of water from
penetrating into the wall construction.
 Thermal
insulation, airtightness and structural stabi
lity are provided by the second, inner part
of the wall construction.
 Architects can get a rain screen with
inboard or outboard insulation, but
outboard is becoming increasingly popular.
 By definition, a board installed outside of
the building wall means that the walls are
free from the normal penetrations
required by typical inboard insulation
construction.
 In other words, there’s zero seepage, zero
frustration and loads of thermal efficiency.
 Outboard insulation typically costs more
than inboard, but the savings in HVAC costs
far outweigh initial payment. Usually,
fabricators perform rigorous amounts of
testing on their rain screens before doling
them out to customers.
 Advantages-
 Durability:
 Has a strong surface, hardly gets affected by the external factors and does not get damaged easily.
 the surfaces can develop adequate wear resistance to corrosion, water damage, and electrochemical
reactions.
 Have a long lifespan
 Easy to Install:
 No need for extensive labour work.
 As they are manufactured in lightweight and larger sections, covering a larger area within a short time
becomes possible.
 With the specialized fastening systems, installing the metal claddings becomes even easier.
 Versatility:
 Can be used for the entire exterior of the structure or some specific portions to give a contrasting look.
 The process as well as the material can be chosen as per the needs of the application and the bond
strength required.
 suitable for complex shapes as well.
 Variety of Choices: can be chosen from a wide variety of textures, colours, designs, shapes, materials
and sizes.
 Highly Sustainable:
 can be made of recycled materials, making them environmentally-friendly
 because they are made from common metals, at the end of their useful life as cladding, they can easily
be recycled.
 Budget-Friendly:
 very inexpensive as compared to the other cladding materials.
 have fewer labour costs involved
 Protection and Strength
 Non-Combustible
 Low Maintenance:
 require very little maintenance or repair work.
 resistant to harsh weather conditions so can simply be cleaned.
 Lightweight Solution
 does not increase the dead load of the building
 makes them easy to transport and install.
 Effective cooling in such cases ensures better micro-structure, and hence only a smaller area is
thermally affected.
 Provide aesthetics and design flexibility

Common Disadvantages
 Prone to Dents- Softer types of metal like aluminium have the tendency to easily dent when a hard
object hits its surface. For instance, heavy hailstorms could leave dents and punctures on the metal
cladding. This could also happen when stray branches land against it during tornadoes or hurricanes.
 Noisy - Metal can be noisy when rainwater hits its surface.
 Rust - Cladding sheets are coated when they are manufactured to protect them from the elements.
When these sheets are cut to size, the edges aren’t re-coated, leaving them exposed. Over time, the
edges of the cladding sheets are likely to rust. This can lead to leaks and eventually lead to the cladding
panels needing to be replaced
 Colour fading - The technical term for fading is photodegradation which can be caused by a number of
factors including UV light, harsh weather, pollutants and moisture in the air (especially in coastal areas
where the air often contains salt).
 Chalking - Where paint naturally and literally wears away, different types of paint degrade at different
rates.
 Delamination - While the durability of the latest generation of plastisol cladding has improved, ageing
and weathering will still cause it to deteriorate over time. Moisture can seep in and create rust, which
can split the top polyester layer from the metal of the cladding.
THE GOOD NEWS,
Although metal cladding has some disadvantages, any of these problems can be rectified by a good
cladding refurbishment contractor. Existing cladding panels can be repaired and the surface prepared,
prior to applying a protective coating. This can extend the life of metal cladding by up to 20 years.