CPD 25: Perforated metal facades

25 October 2013 The latest in our series of CPD modules focuses on the exterior and interior applications of perforated metals, and the methods of manufacture. This module is sponsored by RMIG

How to take this module To take this module read the technical article below and click through to a multiple-choice questionnaire, once taken you will receive your results and if you successfully pass you will be issued automatically with a certificate to print for your records.

Introduction Incorporating precision-perforated metals within building facades allows architects not only to create unique decorative designs and aesthetic effects, but also offers practical solutions for issues such as solar shading and sound management. As part of a lightweight cladding system, perforated materials can be used to provide more pleasant internal environments and reduce energy consumption by allowing natural ventilation and daylighting to enter while shading spaces from direct sunlight. They can also improve building security, or be combined with sound-absorbing material to enhance acoustic performance. Perforated, embossed or indented facades can be created from metals including aluminium, steel or copper, and manufacturers offer a range of finishing techniques such as bending, rolling, forming, coating or anodising. The shape, size and pattern of the holes in a perforated material can all be specified during the manufacturing process to meet a projects exact requirements. While perforations involve the complete penetration of the metal, patterns can also be embossed or indented, either instead of or in combination with perforation. In some cases, the embossing or indenting process and the choice of pattern can also add rigidity to the materials. This CPD module will discuss the exterior and interior applications of perforated materials, the most common metals used in perforated facades and how perforated materials are manufactured. RMFR has participated in the rehabilitation of an old castle for a Mediatheque at the Chteau de Cang in Saint Avertin, France. RMFR has delivered decorative sunscreens for the project.Raw material: Corten. Thickness: 2 mm. Pattern: R15T22. Cut by laser. APPLICATIONS OF PERFORATED MATERIALS Facades The nature of the precision-manufacturing processes used in metal perforation enables

complex designs to be accurately rendered within perforated facades. This allows the incorporation of geometric shapes, graphic designs and perforated representation of photographic images, known as picture perforation. In most projects, images are split across a large number of panels, which are then assembled on site to an installation template to create the final photographic effect. This may be used for dramatic effect or to reflect a design theme, an aspect of a buildings use or its surrounding environment. In some cases, the perforated material performs the supplementary function of solar shading; in other applications, reducing solar gain may be its primary purpose. In addition to complex graphic and picture perforation, a range of standard perforation patterns, hole shapes and configurations can also be selected, which are produced by standard tooling. This approach is often used for projects where individual design and aesthetics may not be primary considerations, such as public transport shelters, car parks and security applications, as well as balconies and balustrades. Acoustic uses of perforated materials A common interior use of perforated metals is within acoustic and sound management applications. Depending on the size and spacing of the holes, perforated materials can either block sound or allow it to pass through in specific ways. Perforated materials offer building designers a solution for noise control, whether keeping external noise from penetrating within - if a building is next to a busy road, for example - or keeping noisy activities within a building from disturbing the surrounding community. According to a report produced for the Industrial Perforators Association in the US, there has been dramatic growth in acoustic applications of perforated materials over recent decades. In construction, perforated materials are used in two main ways: as a facing for something else or as tuned resonant sound absorbers.

Facings This is where the perforated material is used as a protective or decorative covering for an acoustic material, which may be designed to absorb sound, or to reflect or scatter it. Using a facing protects the acoustic material and disguises it - perforated metals can be made to look like plaster, for example. The purpose of the perforated material in these applications is to disappear acoustically - that is, it must be transparent for the sound waves to pass through it. In this case, specifiers must choose the perforated metal that offers the greatest sound transparency, across all frequencies. For example, in a concert hall, perforated metal surfaces can allow the sound to pass through and be reflected back into the hall by specially designed surfaces behind the metal. This is known as a broad-band sound absorptive treatment, and is appropriate when the acoustic treatment is intended to control sound at all frequencies. Tuned resonant sound absorbers In some instances, it is desirable to absorb sound selectively, only blocking those sounds within a certain band of frequencies and allowing sounds with frequencies either side to pass through. For this purpose, a resonant sound absorber is designed, where the perforated metal plays an active part in tuning the absorber - that is, in determining which frequencies are absorbed. The sound transparency of perforated material depends on the pattern of the hole and the percentage of the open area. Generally, the greater the percentage of the open area, the more easily sound can pass through, but the spacing of the holes is also important. For example, a solid sheet with one large hole in the centre might have the same percentage of open area as one with tiny perforations all over it. The sheet with the central hole would block sound across most of its surface, whereas the finely perforated sheet is almost completely transparent to sound because the solid areas between the perforations are too small to intercept the sound waves. For high transparency, it is therefore better to have many small, closely spaced perforations. To create a tuned resonant sound absorber, the diameter and the spacing of the holes must be designed to be transparent or opaque to air molecules vibrating at certain frequencies. The distance between the perforated material and the surface behind is also a factor in how sound will pass through it, and different sound absorbing materials may be contained within the cavity depending on the required effect. Further details can be found in the report, Acoustical Applications for Perforated Metals: Principles and Applications, by Theodore J Schulz. The COMMON METALS USED IN PERFORATED FACADES Rsidence Andr de Gouvia - Maison du Portugal. Renovation of students house in the Perforated facades can be made from various metals. The choice of metal is a key design consideration, and will depend on requirements such as aesthetics, strength, durability, sustainability, resistance to environmental factors and cost. The three most commonly perforated metals are mild steel, stainless steel and aluminium. Mild steel Mild steel is the least expensive and the most vulnerable to corrosion. It is manufactured in either sheet or coil form by passing it through rollers to flatten it to the desired thickness. This is done either while the steel is still hot (hot rolled) or after it has cooled (cold rolled). The resulting products differ in cost, quality and physical properties.

Hot rolled steel is typically less expensive and produced in thicker gauges of 1.5mm and upwards, whereas cold rolled steel offers lower tolerance and higher quality surface finishes. It can be produced in almost any gauge, but is most readily available in thinner gauges from 1.5mm down to 0.4mm. As mild steel is susceptible to corrosion, it is used in either unexposed applications or with a protective coating. Coatings such as paint and powder are applied after perforating and completely protect the material. Metals to which a zinc or aluminised-based coating is applied, such as aluminised pregalvanised steel or galvannealed steel, are coated at the mill before the perforation process and therefore may not completely protect the material where the mild steel substrate is exposed during perforation. Manufacturer RMIG recently supplied Corten alloy steel for a chateau refurbishment project in France (see image, previous page), which shows how the need for rust protection can be used to aesthetic advantage. Stainless steel Stainless steel was developed to be resistant to corrosion, and can be used where coating mild steel is impractical. Stainless steels are steel alloys containing a minimum of 10.5% chromium, steel itself being produced from iron and carbon. Chromium makes the steel more resistant to corrosion because a chromium oxide film forms on the surface of the material, which blocks oxygen from reaching the steel and from causing oxidation to occur. This is a very thin layer, which can reform if the metal is scratched, under the right conditions.

Other elements may be used in stainless steel, such as molybdenum, nickel and nitrogen, which creates materials with different molecular structures and therefore properties. For example, nickel is used to improve the formability and ductility of stainless steel. Stainless steel is recyclable, which means that it can be melted down and reused when scrapped. Aluminium Aluminium is the third most abundant element and the most abundant metal in the Earths crust, making up around 8% of the earths solid surface by weight. It is much lighter and softer than both stainless and mild steel. It is also resistant to corrosion, due to the formation of a very thin surface layer of aluminium oxide, which prevents further oxidation. This can however result in a dull appearance so aluminium may be either clear or colour anodised after perforating. Unlike paint or powder coatings, which are applied to a surface, an anodised film is built from the aluminium itself and has a translucent appearance.

STANDARDS There are a number of relevant British, European and international standards relevant to the production of perforated materials. These include: BS 7792:1995, ISO 10630:1994 - Specification for industrial plate screens BS EN 1090-1:2009 - Execution of steel structures and aluminium structures. Requirements for conformity assessment of structural components BS 5502-51:1991 - Buildings and structures for agriculture. Code of practice for design and construction of slatted, perforated and mesh floors for livestock BS EN ISO 9001:2008 - Quality management systems. Requirements BS EN 9100:2009 - Quality management systems. Requirements for aviation, space and defence organisations. MANUFACTURE OF PERFORATED MATERIALS Perforated materials are manufactured by punching holes in a sheet of metal or plastic. There are two main methods of perforating a material: by using an all across press, or by using a turret press. All across press An all across press punches holes in whole sheets of material as they are fed through, using a single tool. Because many holes are made in a single stroke, an all across press can produce up to 50,000 holes per minute, which makes this the fastest and most cost-effective way of creating large-scale perforated materials. Turret press A turret press moves quickly over the surface of a material, punching holes as it goes. The main advantage of turret press perforating is that up to 65

different tools may be used throughout the process, whereas an all across press uses only a single tool. This machine will add additional holes for fixing purposes and can emboss and indent the material as well as making perforations. It can also countersink holes, which is often used to hide fixing holes on facades. The turret press is also cheaper - with a standard tool cost of approximately 250-1,000, compared with 2,500-20,000 for the all across press, according to perforated materials manufacturer RMIG. Its drawbacks compared to the all across press are that there may be greater deformation or distortion due to multiple tool hits and there is less uniformity. It is also unsuitable for creating very large areas of perforation. All of the burrs removed from the material can be recycled in both manufacturing methods.

CPD credits: 1 hour

To complete this CPD, read the module and then answer the questions online at www.building.co.uk/cpd Closing date: 6 December 2013

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