Tribhuvan University

Institute of Engineering
PURWANCHAL CAMPUS
Dharan-8, Sunsari, Nepal

‘Aluminum- an exterior metal cladding’

Submitted by:
Sabita Guragain (35)

This report is submitted in partial fulfillment of the requirements of the Bachelor of

Architecture Program

Seminar and Directed studies (AR801)

Submitted to:
Department of Architecture
Institute of Engineering
Purwanchal Campus

Date:
May 7, 2020
 ‘Aluminum- An exterior metal cladding’ 7 may 2020

Contents
ABSTRACT ...................................................................................................................................... 3
1 INTRODUCTION...................................................................................................................... 4
1.1 INTRODUCTION TO METAL CLADDING ..................................................................... 4
1.1.1 METALS IN THE DEVELOPMENT IN “HIGH-Tech”.............................................. 5
1.1.2 DIFFERENT METALS IN EXTERIOR CLADDING ................................................. 5
2 ALUMINUM AS A BUILDING MATERIAL ........................................................................... 7
2.1 Aesthetic appeal ................................................................................................................. 8
2.2 Optical mechanical and thermal properties .......................................................................... 8
2.3 Easy design and assembly ................................................................................................... 8
2.4 Energy savings ................................................................................................................... 9
3 ALUMINUM COMPOSITE MATERIAL .................................................................................. 9
3.1 Advantages of aluminum composite material: ................................................................... 10

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ABSTRACT
Beauty lies in what we see that we can see. Talking about architecture, beautiful buildings are
the expectations of the society which the architects try to deliberately fulfill. Society changes
with time and so does architecture. The architectural style evolves with a new dimension with
the use of new materials. Creative ideas require inspiration and inspiration begins with the
material. Design elegance, interesting surfaces, harmonious backgrounds, functionality,
efficiency and eventually surprising effects- all of these and much more can be easily achieved
with the use of correct materials in the buildings. All these qualities when come appropriately
combined with overwhelmingly fantastic finishes in the exterior envelope makes an impressive
architectural statement. After all, exterior is the most visible element and the implications of
the exterior cladding are the most defining aspect in architecture.

At the dawn of the new millennium, what kind of material poses greatest demand in the
application as exterior facade cladding, how they have secured an important place in
architecture, all these secrets have been tried to be unfolded in this research. This research is
an attempt to discover the significance and use of aluminum as a metal wall cladding material
on the exterior, its importance and benefits, and the face it gives to the contemporary
architecture style.

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1 INTRODUCTION
If the facade is a building’s skin, then exterior cladding might be considered both the makeup
and sunscreen of architecture. It’s aesthetically pleasing, yes, but also functional. It can enhance
the structure’s overall appeal while protecting it from environmental conditions at the identical
time. Wall Cladding is that the application of one material over the wall for aesthetic purpose.
In construction cladding is employed to supply a degree of thermal insulation and weather
resistance, and to boost the appearance of buildings.

Non- load bearing claddings in building, often in panel form are most commonly employed in
conjunction with a structural framework. The two concepts which have most closely influenced
the development of those form of construction are firstly, these was the development of frame
construction, and secondly, the introduction of systems of prefabrication.

Building technology has gone a long way from the wooden and stone implements of primitive
man to sophisticated automatic manufacturing line and power materials handling machines.

There are many factors that determine the standard of present-day industrialized construction
as well as the architectural value and performance of buildings. The range and quality of
available mass-produced articles directly influence the structural performance and aesthetics
of that project and the durability and hence the long term quality of the structural and finishing
materials employed.

Architectural quality is a function of the quality and efficiency of building materials. Of course,
high quality building materials are no guaranty of adequate architectural quality. In assessing
the overall quality of architecture, at least three components need to be taken into consideration,
namely the quality of design, the quality of materials and products used, and the quality of
erection and finishing work.

1.1 INTRODUCTION TO METAL CLADDING

Metal architecture is all around us: it is used to make roofs, gutter systems and is growing in
popularity for wall applications in commercial and residential buildings. They offer a multitude
of design capabilities and a sustainable barrier to weather. While most often utilized in
commercial office, educational and manufacturing buildings, metal wall panels also have
unique uses in residential homes.

Metal cladding 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

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cladding for its formal flexibility and finish. Its popularity is primarily down to its incredible
versatility, both avant-garde and off-the-shelf. Metal is commonly used for non-structural, rain-
screen cladding systems, where the priority is to provide protection from the elements as well
as a striking external finish.

Many buildings do not use a single material on the facade though one tends to predominate and
characterize the design. A combination of materials, colors and textures offer greater
possibilities creating mixed facades for the composition of the building, differentiating planes
and volumes and even the different uses in the interior of the building.

1.1.1 METALS IN THE DEVELOPMENT IN “HIGH-Tech”

In 1960s, an advanced manufacturing process was integrated into practice, which made it
possible to combine the continuous casting of the metal with rolling. New materials and
processes are gradually being accepted by the architectural profession. Nowadays metals are
the probably the most popular forms of exterior cladding in new architecture. Metals have
created a new look in architecture. Trends in architectural design are now leading designers to
explore more and more the use of lightweight construction and clip-in gasket-jointed panels,
commonly known as ‘High Tech’.

1.1.2 DIFFERENT METALS IN EXTERIOR CLADDING

Most commonly used materials are aluminum and galvanized steel, though one can also find
panels of stainless steel, copper and zinc. Metal wall systems offer an advanced, attractive and
durable form of wall construction which maintain high levels of thermal performance, weather
resistance and also, when required, acoustic and fire resistance.

i. STEEL
Steel has been around in its present form from the mid-1800s. As for steel's facade use,
the usual material is stainless steel, with a high chrome content to prevent corrosion.
Steel is rolled into plates of 0.5-1.2 mm thickness and used in skyscrapers mostly as a
part of the glass facades.
Nirosta ("non-rusting") steel was a type of stainless steel used in the Chrysler Building,
perhaps the most famous use of facade steel cladding. A (non-high-rise) example is the
Ford Foundation.

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FIG: Chrysler Building FIG: Ford Foundation, USA

ii. COPPER
Copper is generally used also as a facade material in buildings. It has very good
resistance against corrosion in all conditions. A prominent characteristic of copper is
the fact that it slowly weathers into a green surface, a sure way to tell apart an old copper
surface. As copper, like aluminum, oxidizes to create a protective surface (which in
copper's case darkens the surface) there is really no need for specific protective
treatments -- it can be, however, treated to weather into green faster than naturally.
iii. GALVALUME/ ZINCALUME
These sheets are expensive but fully engineered and pre-painted. They are maintenance
free, leak-resistant and available in greater sheet lengths that allow low slopes with no
overlapping.
Wall cladding made from zincalume steel is lightweight, versatile, attractive and has
excellent corrosion resistance and available in a range of attractive profiles. Ever since
it was developed in 1976, zincalume steel has been proven to withstand the harshest of
Australian conditions.
iv. ALUMINUM
Aluminum is the third most common element on the Earth. Aluminium sheets are
noncorrosive, have a high strength-to-weight ratio, high reflectivity, long life and are
recyclable with minimal maintenance costs. Structural savings and long-term economy
are guaranteed. The embossed facade of the Socony-Mobil Building is of aluminium.

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Flat, corrugated, and channeled aluminum alloy sheets are widely used for three-layered
filler structures (non-load bearing wall panels).Their surfaces may be anodized or
covered with polymer film to protect them against corrosion and to give them a pleasing
appearance. In finishing, use is made of thin walled light weight sections whose surface
may be anodized, painted, enameled, or film-covered.

2 ALUMINUM AS A BUILDING MATERIAL

There are various types of metal which will be employed in cladding. Aluminum cladding is
very popular. It is very useful for cladding as it is very light weight material and very easier to
install than steel. And also it is a recyclable material. The utilization of aluminum cladding
contributes to green building design by enabling high ratings within the energy efficiency of
building. While this can sometimes save costs, aluminum cladding is also easier to damage
during the installation process, so potentially there might be more waste involved when
installing aluminum cladding. That’s why we’ve a track record of reference buildings with the
best LEED and BREEAM energy efficiency ratings.

Aluminum Cladding elements are panels formed either by specially coated 2-3 mm thick
aluminum sheet or aluminum composite materials (ACM) with a typical total thickness of 4
mm. Aluminum cladding facades can also be used to renovate the external envelope of existing
buildings as well as on new buildings, providing an easy to apply and aesthetically attractive
material. Curved, flat and multiplanar surfaces, of various colors can meet any architectural
requirement.

Aluminum Composite Panel was created back in the 1960’s. Its original design and purpose
was a material for signage. However, by the mid to late 1980’s, the architectural and
construction industry discovered this material and began using it as a building material. It is
lightweight and also durable properties made it a great facade material and soon it was being
used internationally on residential and commercial properties, improving architectural
performance and reducing costs.

During the past 30 years, the use of Aluminum in buildings has grown continuously. This
growth is due to a number of key performance advantages arising from the following material
characteristics:

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2.1 Aesthetic appeal

a) Aluminum and composite materials can be easily transformed to flat, curved or angled
surfaces, in line with the demand of contemporary fluid architecture. (Fig.9) Aluminum
panels can be placed on facades, with horizontal or vertical patterns, with designer-
selected gap width between elements. Curved, flat and multilane surfaces, of various
colors can meet any architectural requirements.
b) Aluminum is available in a wide range of colors. Aluminum can be anodized or coated
with various colors. In this way, it can meet numerous aesthetic and decorative needs,
while at the same time enhancing its natural durability and corrosion resistance with an
easy-to-clean surface.

2.2 Optical mechanical and thermal properties

a) Aluminum is a light material. Given the low specific gravity of aluminum (2,7 g/cm3),
one square meter of a 2 mm thickness flat aluminum panel weighs only 5,4 kg.
Aluminum composite materials have similar properties.
b) Aluminum has an excellent strength-to-weight ratio for strong cladding units.
Aluminum cladding material can withstand natural forces, such as wind pressure,
earthquakes (elastic character), and gravity (own weight), the effect of solar radiation
(chemical deterioration caused by UV radiation) and thermal expansion / contraction.
Its high elasticity that makes it safer for regions with high earthquake activity.
c) Aluminum exhibits vastly better optical and thermal properties compared to other
metals. Bare or coated with appropriate light colors, aluminum has a high reflectivity
to radiant energy (visible light, sheath radiation and electromagnetic waves) together
with low emissivity.

2.3 Easy design and assembly

a) Aluminum cladding elements are fixed on a metallic supporting frame, preferably made
of aluminum, which is secured on the building’s load bearing structure. Thermal
bridging can be minimized or eliminated. Sheet elements elastically bonded to the
supporting frame with special adhesives.
b) Aluminum panels are easily formed and assembled. They offer precise fit, facilitated
by a consistent parametric design of the cladding system.
c) Aluminum panels are interchangeable, allowing the appearance of the façade to be
changed by selectively replacing panels with others of different color or finish at any
time throughout the lifetime of the building.

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2.4 Energy savings

The building envelope determines the energy exchange between outdoor environment and
indoor spaces and hence governs the overall energy performance of the building. Energy
conservation for heating and the reduction of heat losses are mainly governed by thermal
insulation of the building envelope. The objective is to limit thermal losses during winter and
thermal gains during summer. Application of aluminum cladding on buildings can provide
significant energy savings all-year round. Heat losses through the building envelope are
responsible for about 10- 25% of the total energy consumed in buildings, depending on outdoor
weather conditions and building materials. For a non-insulated building, the addition of a
proper insulation layer on the building “body” plus aluminum cladding at an appropriate
distance from the main building body wall on existing and new buildings, can reduce heating
loads by up to 30% and cooling loads by up to 50%.

Thus aluminum facades can create sustainable architecture. Sustainable architecture

characterizes the design of buildings that offer comfortable and safe indoor spaces for the
occupants, while respecting the environment by minimizing the use of natural resources and
exploiting life cycle economics.

3 ALUMINUM COMPOSITE MATERIAL

Aluminum composite material (or sandwich) panel consists of a 3 mm thick, non-toxic
polyethylene core bonded between two 0.5 mm aluminum skins with a PVDF coating on the
external surface. It has three layer.

Aluminium system bolted

to main structure

Insulating core

4mm

Outer Aluminum panels

Aluminum composite material is suitable for both interior and exterior applications on new
and refurbished buildings. It can be used in false ceiling, curtain wall, sidings, fascias and

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soffits, balcony cladding, column and beam covers, canopies and facades or wherever a strong,
lightweight, non-flammable panel is required.

3.1 Advantages of aluminum composite material:

a) Add true beauty to a structure
b) Easier to handle, long lasting durability
c) Excellent weather resistant
d) Improves sound dampening
e) Least maintenance required and maintenance cost is cheap
f) Good weather resistant

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