Cladding Systems

Manufactured Aluminum and

Steel Cladding.
 What is Cladding?
 Cladding is a vertical
building enclosure
which supports no
load other than its
own weight and the
environmental forces,
 Cladding is not
intended to assist in
maintaining the
structure of a building.
 The Purpose of Cladding:
 The major purpose of cladding is to separate
the indoor environment of a building from
the outdoors.
 Cladding must prevent the entry of water,
e.g. rain, snow and ice into a building.
 It must retard the passage of water vapour.
causing problems of staining, lost insulating
value and corrosion.
 The cladding must control the passage of
light, especially sunlight. Reducing the effect
of glare.
 It must resist to the required degree of the
conduction of heat into and out of the
building.
 It should isolate the interior of a building
from noise outside, or vice versa.
 Resisting Fire - According to the building
regulations.
 1. Composite Steel panels:
Composite panels have as
sandwich construction:
 two steel sheets bonded either
sides of an insulating core of
foam, mineral fiber or similar
material.
 The bonded panel produces
good stiffness.
 Panels may be fixed using a
variety of techniques including
self drilling, self tapping screws
and secret fixing brackets
located within the panel joints.
 1.1 Manufacturing of Steel
Cladding:
 Coils weighing around 7 tons are loaded
onto the line and the liner or inside sheet is
fed into the roll forming machines and
profiled to a given specification.

 Side sealing tape is applied to contain the

foam. Both top and bottom sheets are pre
heated to between 33 and 35 degree
centigrade. And the blended foam is applied
via the oscillating foam support.

 Both sheets are then brought together

whilst the foam is expanding to control the
chemical reaction. At the same time
polypropylene blocks are used to form the
joint detail and panel thickness. It allows for
faster onsite construction.

 Now, composite strip passes through a

curing chamber before being cut to length.
It is then inspected, automatically packed
and shipped to a holding warehouse before
being transported to site.
 1.2 Fixing Steel Cladding:
 Stick cladding systems consist of a
series of vertical members (Malians)
and horizontal members (transoms)
that form a grid.
 This grid is used to restrain solid
panels and is normally fixed to the
floor edges by especially designed
brackets, which provide wind
resistance.
 The self weight of the curtain wall is
normally taken to the ground
through the Malians. Malian spacings
are normally in the range 1.2 to 2
meters. Although, wider spacings are
possible. Transom spacings are
normally determined by panel
requirements and the architectural
treatment of the façade.
 1.2 Fixing Steel Cladding:
 Strong-back cladding systems
have a sub-frame that supports
thin cladding panels. Units are
normally storey height and 6 –
9 meters wide. They are fixed
either to the edge of the floor
slab, or to the floor edge
beams, or to the columns.
 The supporting frame is usually
constructed from either hot rod
or cold formed steel sections or
from stainless steel.
 Cladding materials include
coated steel and stainless steel;
since panels are relatively large
it is possible to clad buildings
rapidly using storey high units.
 2. Aluminum Cladding:
Aluminum framing is used
for the vast majority of
curtain walling applications,
primarily for its excellent
strength to weight ratio and
its ability to be extrude in
complex shapes. At
2.7g/cm2, aluminum is 66%
lighter than steel. It is also
far less susceptible to brittle
fractures.
 2.1 Processing:

 1. Folding;
 2. Routing;
 3. Riveting;
 4. Mechanical Fixing;
 5. Coating & Spray
Finishing.
 2.2 Processing:
Folding:

 To fold the panel, by

machine or manually, cut
a V groove on the reverse
side using a panel saw
with a milling attachment
or a hand-milling cutter.
The product can then be
easily folded. The
recommended
temperature for folding is
over 10ºC.
 2.3 Processing:
Routing:

 The panel can easily be folded by

hand if a “V” shaped groove is milled
on the rear of the panel.
 This can be done using a
conventional router. For an accurate
and precise by hand folding of the
composite panels, giving a good
finish, we route the rear side of the
panels and extract the aluminum
sheet and a part of polyethylene
core. Normally 25mm from the edge
is grooved and folded. A minimum
thickness of 0.3mm of the
polyethylene must be left on the
bottom / back of the decorative face.
 2.4 Processing:
Riveting:

 Panels can be fastened

together or joined to
other materials with
rivets common to
aluminum constructions.
For outdoor use and for
use in areas of high
humidity, aluminum
blind rivets with
stainless steel mandrils
should be used to
prevent ugly corrosive
edges.
 2.5 Processing:
Mechanical Fixing:

 Can be mechanically
secured in place by the use
of threaded / screw fixings
or rivets. Rivets and screws
must be a minimum of 15-
20mm from the edge of the
panels when fixing. Care
should be taken to make
sure that the hole diameter
allows for expansion and
the fixings are not over
tightened as this will cause
de-formation of the surface.
2.6 Fixing:
 2.7 Joints
 Wind always causes uneven
pressure on a wall. Pressure
variations in the plane of the
wall can cause lively wind
movement behind the
cladding as shown in figure
215. Air movement through
the cladding can move water
into the wall. It is important
to seal the air space at the
corners of the building as
shown in figure 215 c, d and
e.
 2.7 Joints
 Much water can
run into the wall if
the joints have an
inward slant such
as figure 217. If
the climate isn't
too exact one can
use horizontal
joints with an
outward slant.
 2.8
Processing:
Coating and Spray
Finishing:
 The use of air-drying

acrylate or two
component
polyurethane varnishes
is necessary. If the
panel has been over
lacquered it should be
bent or folded at a later
date.
3 Installation at Site:
4. Comparing between Steel
and Aluminum Cladding:

Stainless
Comparison Aluminum
Steel

Heavier
Weight Lightweight

Easy
Ease of installation Easier

Average
Cost High
 4.1 Continued Comparing:
Low
Maintenance Low

Silver
Colour Large variety

Insulation Good
Excellent

flexibility in forming Very Good

Excellent
odd shapes
corrosion-resistance Low
High
 5 Conclusion
 In terms of assembly the cladding system is
very straightforward. The grid is prepared
and controlled easily, accepting any
alterations required during the job in the
local work space assuring the leverage of
any heat expansions causing possible
movements, and any alteration regarding
the fitting and positioning.
 The quality of the work could most probably
be secured regardless of the constructor's
experience, due to the possibility of
corrective interventions and adjustments at
the site. The work respecting the insertion
of the final covering and finishing is
extremely tight and completely controlled,
thus insuring the cladding acts as a high-
quality insulator.
 5.1 Conclusion
 The cladding method is one of many
advantages performing as a high-end
solution, each material having of
course its disadvantages i.e. Steel has
a relatively poor strength to weight
ratio, rusts if untreated and turns
brittle under stress. Whereas aluminum
has a relatively high initial energy cost,
however due to the fact that aluminum
offers a high manufacturing capability
and flexibility, low cost-in-use and also
wide ranges of color. It's predictable
that aluminum will be more widely
used in construction.
 Cladding is a very premium process;
and is now being turned to for more
modernized construction and wide-
ranged flexibility in work. Gevahir Mall,
Istanbul, Turkey.
2007
 6. Examples of Steel Cladding
Worldwide:

London Met. University. London, Uk.

By Daniel Rosbottom.
6.1 Examples of Steel
Cladding:

The Walt Disney Concert Hall in downtown Los Angeles, California. By Frank
Gehry October 23, 2003 and features his trademark steel cladding.
6.2 Examples of Steel
Cladding:

Steel cladding façade,

Egypt, Zamalek 2007
 7 Examples of Aluminum
Cladding Worldwide:

Cladding Covered Dome.

Millennium Doha, Qatar 2007
7.1 Examples of Aluminum
Cladding

Canon building, Amman 2005

 7.2 Examples of Aluminum
Cladding

Egypt Post, Egypt, Cairo.

Modification 2006
 8. Interiors:

Airport, sharm el
sheikh, Egypt.
2007
 8.1 Interiors:

Airport, Sharm el
sheikh, Egypt. 2007
 9 Exteriors:

Airport, Sharm el
sheikh, Egypt. 2007
 9.1 Exteriors:

Airport, Sharm el
Sheikh, Egypt. 2007