MCM PANEL CLADDING: BEST PRACTICES FOR

DESIGN AND LESSONS LEARNED FROM FAILURES

John W. Kurpeski – Consulting Engineer, P.E.
Derek B. McCowan – Associate Principal, P.E.

Credits: 1 AIA LU/Elective; 1 IIBEC CEH; 0.1 IACET CEU

*AIA course numbers: BE041520 (live webinar); BE041520D (on-demand webinar)
*BNP Media is authorized by the IACET to offer 0.1 CEU for this program Photo by Max Touhey, Amherst, MA
Copper Composite Material Panel Cladding
About the Presenters
Primary Speaker:
John W. Kurpeski, P.E.
Consulting Engineer
Simpson Gumpertz & Heger Inc.
781.907.9117 direct
781.547.9371 mobile
JWKurpeski@sgh.com
Secondary Speaker (Q/A Support):
Derek B. McCowan, P.E.
Associate Principal
Simpson Gumpertz & Heger Inc.
781.907.9226 direct
781.424.2727 mobile
DBMcCowan@SGH.com
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Credit earned on completion of this course will be reported to AIA CES for AIA members.
To receive a Certificate of Completion, you must complete and pass the 10-question quiz at
continuingeducation.bnpmedia.com following this presentation with an 80% or higher, then a
certificate of completion will be available for immediate download.
This course is registered with AIA CES for continuing professional education. As such, it does not
include content that may be deemed or construed to be an approval or endorsement by the AIA
of any material of construction or any method or manner of handling, using, distributing, or
dealing in any material or product.
Questions relating to specific materials, methods, and services will be addressed at the
conclusion of this presentation.

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 Copyright Materials
This presentation is protected by US and International Copyright laws.
Reproduction, distribution, display and use of the presentation without
written permission of the speaker is prohibited.

© 2020 Simpson Gumpertz & Heger Inc.

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Learning Objectives

1. Identify the pros and cons of Metal Composite Material (MCM) panel cladding.
2. Describe MCM panel design, fabrication and best practices for use.
3. Explore the various parties involved in MCM panel cladding projects and their roles.
4. Discuss exterior wall components, including subframing for MCM panels.

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 Presentation Outline

• Introduction
• Design
• Fabrication
• Installation
• Lessons from Failure
Investigations
• Suggestions/
Best Practices
• Closing
Thoughts
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Photo by Peter Vanderwarker, Boston, MA
ACM Panel Cladding
 Presentation Outline

• Introduction
• Design
• Fabrication
• Installation
• Lessons from Failure
Investigations
• Suggestions/
Best Practices
• Closing
Thoughts
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Photo by Peter Vanderwarker, Boston, MA
ACM Panel Cladding
Introduction – Types of Metal Panels
• Metal Composite Material (MCM)
Panels
• Aluminum (ACM)
• Stainless Steel
• Copper
• Zinc

• Other Types
• Metal plate (1/16 in. to 1/8 in.
thick is common)
• Corrugated/formed profile
• Insulated metal panels
• Sheet metal (light gauge)
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Boston, MA
ACM Panel Cladding
Introduction – Types of Metal Panels
• Metal Composite Material (MCM)
Panels
• Aluminum (ACM)
• Stainless Steel
• Copper
• Zinc

• Other Types
• Metal plate (1/16 in. to 1/8 in.
thick is common)
• Corrugated/formed profile
• Insulated metal panels
• Sheet metal (light gauge)
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Boston, MA
ACM Panel Cladding
Introduction – MCM Layers and Manufacturing

Core material
Sheet metal skins

General Layers in MCM

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Introduction – MCM Layers and Manufacturing
In: Raw Materials MCM Manufacturer

Core material
Sheet metal skins

General Layers in MCM Image from MCA Environmental Product Declaration Document

Out: Flat Stock to Local MCM Panel Fabricator

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Introduction – History and Popularity
• First introduced in late 1960s
• Epcot in late 1970s
• Popular 1990s-to-early 2000s
Spaceship Earth, SGH Testing ACM Panel Cladding
• Popularity affected due to
combustibility/flammability
concerns
• NFPA 285
• Fires in Grenfell (UK), Dubai,
other places
Image from Massachusetts Port Authority Website
Rendering showing ACM Panel Cladding

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Image from BBC Website
Introduction – General System Types

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Introduction – Stiffeners

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Introduction – Storage and Installation Examples

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 Presentation Outline

• Introduction
• Design
• Fabrication
• Installation
• Lessons from Failure
Investigations
• Suggestions/
Best Practices
• Closing
Thoughts
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Los Angeles, CA
Corrugated Aluminum Cladding with Stainless Steel Sheet Panel Metal Ribbon Rain Screen
Design – Cladding, General Considerations
• Panel fabrication and attachment
• Weatherproofing & drainage
(underlayment, flashing)
• Sub-framing
• Code compliance (fire safety, NFPA 285)
• Dead load, lateral loads
• Thermal movement,
structural/differential movement
• Service life
• Appearance
• Integration with surrounding work
• Other
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Boston, MA
ACM Panel Cladding (upper)
Design – Weatherproofing and Sub-framing

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 Design – Code Reference
IBC 2015 (MA MSB 9th Edition), IBC 2018 is similar
• Ch. 14: Exterior Walls
• Weather Protection, Structural
• Section 1407: Metal Composite Materials (MCM)
• Fire Safety Focus
• Flame spread index
• Smoke-developed index
• Full-scale NFPA 285 testing is required unless
certain conditions are met
• Conditions vary depending on height of
the MCM installation above ground

From 2015 IBC Commentary

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Design – Delegated Design
• Delegation of design responsibility goes to specialty
subcontractor/fabricator (and their engineer)
• Often Architect specifies basic requirements
• Materiality Who is
• Appearance, finish, sightlines responsible?
• Performance
• Detailing (schematic)
• Minimal code requirements, no industry standards
• Lots of opportunities for disconnects, omissions, etc.
• Shop drawings, calculations, product submittals...
• Design-assist pros/cons
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Design – Calculation Examples

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Design – Calculation Examples

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 Design – Calculations
• Common issues with MCM panel calculations:
• Atypical conditions missing
• Lack of checking stiffener adhesion/attachment method
• Not accounting for impacts on clip engagement
• Thermal effects
• Panel deflection
• Installation tolerances

Sample SGH Calculations 23

 Presentation Outline

• Introduction
• Design
• Fabrication
• Installation
• Lessons from Failure
Investigations
• Suggestions/
Best Practices
• Closing
Thoughts
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Denver, CO
Titanium Sheet Metal Panel Cladding
Fabrication – Forming Returns

From STYLECNC Website

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Fabrication – Perimeter

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Fabrication – Stiffeners

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Fabrication – Storage and Shipment

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 Presentation Outline

• Introduction
• Design
• Fabrication
• Installation
• Lessons from Failure
Investigations
• Suggestions/
Best Practices
• Closing
Thoughts
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Boston, MA
ACM Panel Cladding
Installation – Access

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Installation – Typical Application Examples

Clips and sub-

framing - need to
make sure water
cannot be trapped
on horizontal ledge
above.

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 Panels that have
disengaged and

Presentation Outline panels that have

actually fallen.

• Introduction
• Design
• Fabrication
• Installation
• Lessons from Failure
Investigations
• Suggestions/
Best Practices
• Closing
Thoughts
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Tysons, VA
ACM Panel Cladding
 Lessons from Failure Investigations 6" soffit returns

A) Stiffeners

Cross-Section
Blue = extrusions, clips
Green = subframing
Gray = panels
Panels rotated about routed
inside corner - upward wind
force popped panel loose

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 Lessons from Failure Investigations
A) Stiffeners

Cross-Section
Blue = extrusions, clips
Green = subframing
Gray = panels
Panels rotated about routed
inside corner - upward wind
force popped panel loose

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 Lessons from Failure Investigations
A) Stiffeners

Stiffeners not Full

Length and no
Soffit Stiffeners

No Inside
Corner Stiffener
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 Lessons from Failure Investigations
B) Subframing

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 Lessons from Failure Investigations
C) Clip Engagement

1 – Design

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 Lessons from Failure Investigations
C) Clip Engagement
Large panels installed on
institutional building
NOTE: large panels are
typically considered to be in the
6' to 10' wide range, can be

1 – Design even larger though

- 1/4" space for thermal

movement

Failure mechanism was

disengagement of the clips.
Safety clips could have helped

2 – Actual
prevent.

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 Lessons from Failure Investigations
D) Installation

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 Lessons from Failure Investigations
D) Installation

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 Misalignment of mechanical fasteners
over hot-channel sub-framing -- stresses

Lessons from Failure Investigations the importance for QA/QC during

installation ... 4 panels had to be reset

D) Installation

OK
NG

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 Presentation Outline

• Introduction
• Design
• Fabrication
• Installation
• Lessons from Failure
Investigations
• Suggestions/
Best Practices
• Closing
Thoughts
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Allston, MA
ACM Panel Cladding
 Suggestions/Best Practices
A) Perimeter Frame
and Full-Length
Stiffeners
Full-length skeleton frame recommended.

Full-Length
Stiffeners

Perimeter
Skeleton
Frame

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 Suggestions/Best Practices
B) “Safety Clips”

SIDE A

Potential for Disengagement

Primary Clip
SIDE A

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 Suggestions/Best Practices
B) “Safety Clips”

SIDE B
SIDE A

Safety clip

Potential for Disengagement

Primary Clip
Add safety clip panels to "Side B" for
SIDE A further redundancy to prevent clip
disengagement failures

SIDE B

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 Suggestions/Best Practices
B) “Safety Clips”
Side B

Side B

Side A

(more out of frame)

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 Suggestions/Best Practices
C) Inside Corner &
Bracket Stiffeners

Bracket Corner
Stiffeners
Inside Corner
Stiffener

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 Presentation Outline

• Introduction
• Design
• Fabrication
• Installation
• Lessons from Failure
Investigations
• Suggestions/
Best Practices
• Closing
Thoughts
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Washington, D.C.
Copper Sheet Metal Panel Cladding
Closing Thoughts – MCM Panel Takeaways
• Not solid metal
• Lack of industry standards
• Opportunity for omissions
• Careful with large/corner panels
• Provide skeleton frame
• Stiffeners, Perimeter Extrusions
• 100% structural adhesion
• Brackets/gussets at big returns
• Clip engagement
• Include “safety clips”
• Require calcs (delegated design)
• QA/QC fabrication & installation
(panels, sub-framing, etc.)
SGH’s Yearly Hands-On Training for New Hires at SGH Headquarters in Waltham, MA 49
Installation and Water Testing of Waterproofing, Windows, and Cladding
THANK YOU FOR YOUR TIME!
THIS CONCLUDES THE AMERICAN INSTITUTE OF ARCHITECTS
CONTINUING EDUCATION SYSTEMS COURSE.

QUESTIONS/COMMENTS

Continuing Education:
ceu@bnpmedia.com

Webinars:
webinars@bnpmedia.com

John W. Kurpeski, P.E. Derek B. McCowan, P.E.

Simpson Gumpertz & Heger Simpson Gumpertz & Heger
781.907.9117 direct 781.907.9226 direct
781.547.9371 mobile 781.424.2727 mobile Photo by Max Touhey, Amherst, MA
JWKurpeski@sgh.com DBMcCowan@SGH.com Copper Composite Material Panel Cladding