Design And Specification of ACM/MCM In Today`s Architecture

© Ron Blank & Associates, Inc. 2011
Design And Specification of
ACM/MCM In Today’s Architecture
Please note: you will need to complete the conclusion quiz online at ronblank.com to receive credit
Course Number: alp07a
An AIA Continuing Education Program
Credit for this course is
1 AIA HSW CE Hour
Bill Yannetti
Sr. Manager Technical Services
Mitsubishi Plastics Composites America
401 Volvo Parkway
Chesapeake, VA, 23320
info@alpolic.com
1-800-422-7270
An American Institute of Architects (AIA)
Continuing Education Program

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
Ron Blank & Associates, Inc. is a registered provider with The American Institute of
Architects Continuing Education System. Credit earned upon completion of this
program will be reported to CES Records for AIA members. Certificates of
Completion are available for all course participants upon completion of the course
conclusion exam with +80%.

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through RBA.
This program is registered with the 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 or Ron Blank & Associates, Inc. of any material of construction
or any method or manner of handling, using, distributing, or dealing in
any material or product.
An American Institute of Architects (AIA)
Continuing Education Program





Course Format: This is a structured, web-based, self study course with a
final exam.
Course Credit: 1 AIA Health Safety & Welfare (HSW) CE Hour
Completion Certificate: A confirmation is sent to you by email and you can
print one upon successful completion of a course or from your
RonBlank.com transcript. If you have any difficulties printing or receiving
your Certificate please send requests to certificate@ronblank.com
Design professionals, please remember to print or save your certificate of
completion after successfully completing a course conclusion quiz. Email
confirmations will be sent to the email address you have provided in your
RonBlank.com account.
Please note: you will need to complete the conclusion quiz online
at ronblank.com to receive credit
Course Description
Today, aluminum composite material (ACM) and metal composite materials
(MCM) have helped to provide a variety of finishing advantages. Because of its
strength, durability and sleek modern appearance, architects have been
fabricating buildings with aluminum and metal cladding for generations. In this
one hour online course, design professionals will be able to explore different
architectural cladding options. Designers will discover how ACM panels and
MCM panels have broadened architectural horizons through weatherability,
fire resistance, long service life, and design flexibility. We will conclude this
course with a brief 10 question quiz.
Learning Objectives
Upon completion of the course, the design professional will be able to:

Knowledgably discuss ACM & MCM, their characteristics, and their
manufacturing process

Identify the various fire tests used to evaluate ACM/MCM performance

Distinguish ACM/MCM finishes and explain the different surface
technologies

Compare the different ACM/MCM attachment systems in terms of
application process and performance

Define key points for specifying ACM/MCM and identify application
possibilities
Architectural Metal Cladding
An Introduction
Weatherability and Design

Whether a multi-story building or smaller scale project,
weatherability is a major consideration in architectural design.

After countless hours of design and construction, a project must
ultimately be able to withstand the test of time. The facade of a
building, in particular, is subject to a number of wearing factors that
can affect the entire building envelope without a proper protective
system.
Weatherability and Design

Resistance to the elements, including UV rays, wind, moisture, rain,
heat, and other factors that contribute to deterioration is
imperative to maintain the integrity of a project.

This integrity also includes the long-term ability of the facade to
maintain its initial look and luster.

A system that both protects the
building exterior and preserves
the look of the building with
little maintenance is optimal.
Protecting the Building Envelope
Constructing a proper building envelope and providing long-term
protection, such as found with architectural metal cladding, can reduce
maintenance and repair costs associated with weathering and general
wear and tear. It can also help lower energy costs and even save lives
(e.g. using fire-resistant cladding).
Metal Cladding

Architects have been fabricating buildings with aluminum and metal
cladding for generations because of its strength, durability, and sleek,
modern appearance.

More recently, aluminum composite material (ACM) panels and
metal composite material (MCM) panels have broadened
architectural horizons with
flexibility of design, longevity
of performance, and a wide
array of brilliant finishes.
Today’s Metal Cladding
ACM & MCM feature such attributes as:

Superior flatness

Vibration dampening

Durability

Ease of maintenance

Pre-finished and coil-coated in
a variety of paint finishes

Rigidity of heavy-gauge sheet
metal

Lightweight
Design Flexibility
In addition, ACM/MCM has the added benefit of versatility. It can be applied
to any type of project and can achieve a variety of different looks and styles
while providing optimal durability and ease of maintenance.
ACM/MCM Architectural Cladding
Composite Technology and Characteristics
What are ACM/MCM Panels?

ACM and MCM composite panels are manufactured by continuously
bonding two thin skins of aluminum (or other metal) under tension
to both sides of a thermoplastic core.

The thermoplastic core allows for uniform expansion and
contraction of both metal skins.

Metals used in MCM include steel, stainless steel, titanium, copper,
and zinc.
ACM/MCM Composite Panels
Metal Skin
Core
Metal Skin
ACM/MCM Structural Strength



ACM/MCM composite
panels are similar to “Ibeams,” in that the two
skins are connected by a
thermoplastic core.
This configuration
provides more structural
stiffness than would be
present if the skins were
in direct contact.
As core thickness
increases, this effect also
increases (refer to flexural
stiffness chart).
Aluminum
0.5mm (.020”)
X
Aluminum
0.5mm (.020”)
ACM
Weight
Ratio
Solid
Weight Equivalent Weight
PSF
Thickness PSF Aluminum
= 100%
Solid Aluminum
Thickness
mm (inch)
Flexural
Stiffness
C-393 (PSI)
3 (.118)
1.04 x 10
4 (.157)
1.99 x 10
6 (.236)
4.98 x 10
9
0.93
2.7 (.106)
1.50
62.0%
9
1.12
3.3 (.130)
1.82
61.5%
9
1.50
4.5 (.177)
2.50
60.0%
ACM/MCM Manufacturing Process
1) The aluminum / metal coils are introduced into the process from two pay-off reels.
2) The laminating rollers bond the aluminum to the continuously extruded
thermoplastic core.
3) The laminated material then enters the cooling chamber and is
constantly moved at a steady rate by the pulling rollers.
4) A protective masking film is applied to the ACM / MCM to protect
the surface finish.
5) The ACM / MCM is trimmed to the required width, sheared to
the required length, and stacked for inspection and final
packaging.
2
3
5
1
4
ACM/MCM Characteristics

Thickness:
Available in 2mm, 3mm, 4mm and 6mm thickness. Application use
determines thickness required.

Widths:
Range from 38” to 62”. Typical architectural application is 50” and 62” for
4’ or 5’ module respectively with a 1” route and return fabrication.

Cores:
Manufactured with either polyethylene (pe) or fire-resistant (fr) cores. Type
of core is determined by application and/or local building codes.

Aluminum Skins:
Range from .005” to .032” thick. Typical thickness is .020”. Application use
determines the skin thickness required.
ACM/MCM Advantages

Strength:
ACM/MCM offers the structural strength of steel with the inherent
lightness and flexibility of aluminum. ACM/MCM has a strength to weight
ratio far below conventional materials, resulting in faster construction times
and significant savings in terms of labor and materials.

Durability:
ACM/MCM offers superior durability, weather-resistance, and resilience.
ACM/MCM panels retain remarkable tensile strength, delivering superior
flatness, rigidity and stability under changing thermal conditions.

Flexibility:
ACM/MCM can be used as a cladding material for exterior and interior
applications; for walls, ceilings, canopies, beam wraps, column cladding,
fixtures, free-standing kiosks and signage. ACM/MCM panels are prefinished, flexible, and can be molded, curved, bent and routed into complex
shapes.
ACM/MCM Advantages
In this video clip, ACM and MCM in a signage application are being wind
tested, illustrating the materials rigidity, strength, and withstandability.
video available in online format only
ACM/MCM vs. Other Alternatives
Alternatives to ACM/MCM possess
certain limitations. For example:

Monolithic Metals/ Aluminum Plate:
Limited to post-coated finishes,
heavier weight, problems with
post-finish color consistency.

Batch Laminated Panels:
Limited widths, problems with skin
blistering, pimpling, delamination,
and oil-canning.

Sheet Metal:
Heavier weight, problems with rust
and oil-canning.
Oil-canning
Delamination
ACM/MCM vs. Other Alternatives
ACM/MCM overcomes these limitations – providing light weight, a full
spectrum of durable and beautiful finish options, and superior flatness
in addition to vibration dampening, durability, ease of maintenance, and
flexibility.
ACM Application
Sustainability
ACM/MCM panels also offer several sustainable attributes:

Made up of a high percentage of recycled content

Uses one third to one fourth the amount of aluminum/metal

Finished with coatings that have a long life cycle

Fire resistant material available

When used for a building envelop, can
increase energy efficiency as part of a
compressive strategy

Can contribute to achieving credits
for LEED project certification
ACM/MCM Fire Resistance
Testing and Standards
Fire Resistant Standards

Recent wildfire events and resulting devastation in the southwest,
have made clear the importance of specifying materials based on a
location’s environmental conditions.

Fire-resistant (fr) cores are required by IBC codes for buildings over
40’ in height. Fr cores must pass an intermediate scale, multi-story
test, such as the National Fire Protection Association’s (NFPA)
standard 285 utilizing the Intermediate Scale Multi-Story Apparatus
(ISMA).

Lighter and more flexible than fr cores, polyethylene (pe) cores also
meet IBC2009 and NFPA 5000 codes for buildings of 40’ or less.
ACM/MCM Fire Resistance
Standard (Polyethylene)
Fire-Resistant (Polyethylene w/
Additives)
Manufacturer A
LDPE
2mm, 3mm, 4mm, 6mm
LLDPE with inorganic mineral
fillers. 4mm, 6mm
Manufacturer B
LDPE
2mm, 3mm, 4mm, 6mm
Polyolefine with inorganic
mineral fillers. 4mm
Manufacturer C
HDPE
3mm, 4mm, 6mm
HDPE with inorganic mineral
fillers. 4mm, 6mm
ISMA Fire Test



The ISMA simulates a fire in which
the flame shatters a window and
spreads to the exterior wall.
The 18’ high, two-story mock-up
has two gas burners, one inside
the room and one outside the
window.
The test lasts 30 minutes, during
which the flame height and wall
temperature are checked. The test
material passes only if the flame
fails to reach the second floor.
14‘
Fire-resistant
4mm ACM
18‘
Room burner
Window
burner
ISMA Fire Test
ACM/MCM mockup with window in
center of ground
floor.
ACM/MCM panels
are unaffected 7
min. after ignition
After 30 min. the
flame has not
spread upward.
When the gas is
shut off, the flame
gradually weakens.
Full Scale Exterior Wall Fire Test



The Full Scale Exterior Wall Fire
Test (CAN/ULC-S134-92)
conducted in Canada is similar to
the ISMA test; however, the mockup is larger.
In this case, the mock-up is 20’
wide and 24’ high, as opposed to
14’ wide and 18’ high as in the
ISMA.
In this test, intensity of heat flow
and flame height are checked for
25 minutes. In order for a material
to pass, the flame must not exceed
a height of 16’.
Roof Covering Test
The Roof Covering Test (ASTM E 108)
consists of three types of fire test:
Fire-resistant ACM
Burning Brand
Burning Brand Test
2. Spread of Flame Test
3. Intermittent Flame Test
1.
In each of these tests, the specimen is
installed on the inclined deck in order
to simulate a roof.
Burning Brand Test
Roof Covering Test



Burning Brand Test:
Burning timber is laid directly on
specimen surface, and the damage to
the specimen and smoke evolution are
observed.
Spread of Flame Test:
The specimen is exposed to a
ho9rizontal flame for 10 min. and the
damage is observed.
Intermittent Flame Test:
Specimen is repeatedly exposed to 15
Flame On and Flame Off cycles. One
cycle consists of 2 min. of Flame On
and 2 min. of Flame Off.
Fire-resistant ACM
Burner
Thermocouple
Burner Gas Supply
Air Supply
Specimen
Holder
Floor Level
Intermittent Flame Test & Spread
of Flame Test
Room Corner Test



The Room Corner Test (UBC 26-3)
simulates a fire that starts in the
corner of a room and grows until it
reaches a critical flashover point.
When the fire reaches the flashover
point, it suddenly expands toward
the door similar to an explosion.
The test simulates this situation in
order to assess whether flashover
will take place during the 15 min.
testing period when the interior
surfaces are finished with the
testing material.
12’
8’
3
1
2
8’
1
Front wall
2
Side wall
3
Ceiling (optional)
ACM/MCM Finishes
ACM/MCM Finish Types

Painted:
Standard and custom colors in solid, metallic, mica, prismatic, lowgloss or multi-color systems. Use of polyester or fluorocarbon
resins is determined by application use and desired life-expectancy.

Anodized:
Typically available in clear, bronze, black, or special order colors .
Architectural Class 1 finishes have 0.7 mil. or thicker anodic
coatings.

Natural Metals:
Typically used for aesthetic purposes. Available metals include
titanium, stainless steel, copper, galvanized steel, and zinc.
ACM/MCM Finish Types

Decorative:
Can be brushed hairline or highly polished. Panels utilize coil that
has been surface anodized or mechanically treated and coated with
a clear fluoropolymer paint.

Faux Finishes:
Provide the look of natural wood and stone products with the
flexibility of ACM/MCM panels. Faux finishes are manufactured using
image transfer systems or high performance vinyl.

Multi-Color:
Two or three distinct colors painted lengthwise on a panel

Clean Room Finishes:
Include fluoropolymer conductive and static dissipative.
* Finish options available depend on the supplier.
ACM/MCM Finish Types
2 COAT SOLID COLORS
Color Coat
Primer
Pretreatment
Substrate
Core
2 COAT MICA
Mica Flake in Color Coat
Primer
Pretreatment
Substrate
Core
3 COAT METALLIC
Clear Coat
Metallic Flake in Color Coat
Primer
Pretreatment
Substrate
Core
3 COAT PRISMATIC
Specialized Flake in Clear Coat
Color Coat
Primer
Pretreatment
Substrate
Core
Metallic Finishes

When installing mica, metallic,
or prismatic finishes, it is
necessary to install the panels
in the same direction.

This ensures color consistency
as the finish grain or flake flop
will reflect the light directly.

It is also advisable to use one
width and one lot per elevation
in order to minimize
inconsistencies.
Grain Runs
Perpendicular
Grain Runs
Parallel
Paint Systems

Polyester:
Not available in an air dry system for touch ups and repairs. Does
not have the long-term durability seen with fluoropolymer systems.

Thermoplastic Dispersion Fluoropolymer:
Poly Vinylidene Fluoride (PVDF) combined with Acrylic. The C-F
Bond that provides the basis for the durability is dispersed in an
acrylic resin. A first generation fluoropolymer, it can re-melt when
exposed to high temperature and pressure.

Thermoset Solution Fluoropolymer:
Fluoro Ethylene Vinyl Ether (FEVE) combined with catalysis. The C-F
bond is part of the base resin. A second generation fluoropolymer, it
“DOES NOT” re-melt when exposed to high temperature and
pressure.
Paint Systems
PVDF






70% PVDF + Acrylic,
Milky Resin
Dispersion Solution
Gloss range 30%-40%
Moderate color range
Thermoplastic
FEVE






100% FEVE
Clear Resin
Amorphous Solution
Gloss range 30%-70%
Wide color range
Thermoset
Both FEVE and PVDF meet AAMA 2605 Standard.
Natural Surfaces

The U.S. and other emerging markets are starting to adopt a more
European attitude regarding durability – expecting finishes to provide 50 to
100 years of maintenance-free performance.

Recent architectural trade magazines have featured a number of projects
using natural materials as cladding, including stainless steel, galvanized steel,
titanium, copper, and zinc.
TITANIUM
COPPER
Titanium Skin
Core
Stainless Steel Skin
Copper Skin
Core
Copper Skin
STAINLESS STEEL
Stainless Steel Skin
Core
Stainless Steel Skin
ZINC
Zinc Skin
Core
Zinc Skin
Attachment Systems and
Specification
ACM/MCM Specification

When specifying a panel attachment system it is important to define what
your aesthetic and performance requirements are. Joint detail, wet or dry,
water and air infiltration control, as well as the requirement for a tested
system and warranty are all important factors to consider.

It is also important to identify
any complex detail
requirements, along with any
special installation requirements.
Be sure to specify the correct
performance required to meet
local codes. The manufacturer is
always your greatest resource for
specifying installation.
Considerations

There are many different attachment systems for ACM/MCM materials,
from very simple to very sophisticated. Performance requirements as well
as size, width, thickness, core and paint system will have a direct effect on
the overall cost.

Remember that the attachment system type will determine the design
detail, “The Look”, and performance of the wall system.

Local codes can also impact the
cost by requiring specific tested
systems or if a specific fire
resistance material is
required.
Wet Seal Attachment
Wet Seal Systems are predominantly the most cost effective systems.
Horizontal Detail
Vertical Detail
Wet Seal Attachment
Wet Seal Systems utilize a backer rod and caulked joint detail to achieve
weather tightness.
Head Detail
Sill Detail
Wet Seal Attachment
Wet Seal Systems require good caulking workmanship for optimal appearance
Rectangular Column
Circular Column
Wet Seal Attachment
Wet Seal Systems do not allow penetration of water or air flow.
Parapet Detail
Dry Seal Attachment
Dry Seal Systems are normally the most expensive system.
Horizontal Detail
Vertical Detail
Dry Seal Attachment
Dry Seal Systems use open joint system with gasket and/or filler strip.
Head Detail
Sill Detail
Dry Seal Attachment
Dry Seal Systems are watertight based on design.
Rectangular Column
Circular Column
Dry Seal Attachment
Dry Seal Systems do not allow penetration of water or air flow.
Parapet Detail
Rain Screen Attachment
Rain Screen Systems are designed to allow water and moisture along with air
to enter and drain from the wall cavity.
Horizontal Detail
Vertical Detail
Rain Screen Attachment
Rain Screen System are either Pressure Equalized or Drained Back Ventilated.
Head Detail
Sill Detail
Rain Screen Attachment
Pressure Equalized Rain Screen Systems minimize the pressure differential on
the inside and outside of the exterior cladding. AAMA 508 defines the
performance requirements.
Rectangular Column
Circular Column
Rain Screen Attachment
Drained Back Ventilated Rain Screen Systems are not pressure equalized.
AAMA 509 measures ventilation and water penetration.
Parapet Detail
Application Examples
NC State University, College of Engineering

Architect:
Perkins and Will

Fabricator:
Vicwest

Panel:
Custom Taupe

Attachment System:
Rain Screen

Location:
Raleigh, NC
Winnie Palmer Hospital

Architect:
Jonathan Bailey Associates

Fabricator:
Kistler McDougall

Panel:
MBX Med. Bronze Metallic
& OPT Mica Platinum

Attachment System:
Glazed In

Location:
Orlando, FL.
United Therapeutics Corporation

Architect:
O’Neal

Fabricator:
Altech Panel Systems

Panel:
BBR Red and LTG Grey

Attachment System:
Dry Seal

Location:
Durham, NC
Mark Sweeney Pontiac - Buick

Architect:
K4 Architecture

Fabricator:
TFC Canopy

Panel:
TBL Black, HLA &
HPA

Attachment
System:
Dry Seal

Location:
Cincinnati, OH
Course Summary
Course Summary

ACM and MCM are very cost effective materials to use on your metal
panel projects, providing superior weatherability and strength.

Its design flexibility lends itself to projects big and small for both interior
and exterior applications, including fascias, columns, beam wraps, ceilings
and signage.

The advanced finish and surface technology available with today’s
ACM/MCM materials allows for an almost unlimited array of colors and
looks.

When specifying ACM/MCM, make sure local codes and requirements are
met or exceeded.

Remember, the manufacturer is your best resource, as their experience and
knowledge can help ensure your vision becomes a reality.
Course Review
Now, the design professional will be able to:

Knowledgably discuss ACM & MCM, their characteristics, and their
manufacturing process

Identify the various fire tests used to evaluate ACM/MCM performance

Distinguish ACM/MCM finishes and explain the different surface
technologies

Compare the different ACM/MCM attachment systems in terms of
application process and performance

Define key points for specifying ACM/MCM and identify application
possibilities
© Ron Blank & Associates, Inc. 2011
Design And Specification of
ACM/MCM In Today’s Architecture
Please note: you will need to complete the conclusion quiz online at ronblank.com to receive credit
Course Number: alp07a
An AIA Continuing Education Program
Credit for this course is
1 AIA HSW CE Hour
Bill Yannetti
Sr. Manager Technical Services
Mitsubishi Plastics Composites America
401 Volvo Parkway
Chesapeake, VA, 23320
info@alpolic.com
1-800-422-7270