b'Architectural Sheet MetalA Brief Introduction & History to Aluminum Composite PanelsBy Norman Menegay, Jr.Sheet Metal Operations Manager - Advanced Industrial Roofing, Inc.A luminumCompositePanels,ACP,years,everyonelearnedaboutthechallengesthissystem are sandwiched panels consistingbrings. First, keeping it clean. If owners dont maintain their ofatopandbottomlayerofbuildingthiswillbecomeanissue.Asmostknow,silicone analuminumalloysheetbondedtoacaulking attracts dirt and overtime between rain cycles, dirt middlelayerofanon-toxiclow-densityweeps from the caulk and down the face of the composite polyethylene(PE)corepanel.Inmostpanels. If left go, this will cause the caulk joints and panels instances, a layer of protective film, whichto look extremely dirty within a very short period of time, and canbepeeledoff,isinstalledoverthepossibly result in the silicone caulk needing replaced. Second, top layer of aluminum to safeguard against scratches. managing the moisture that will inevitably enter the panel The idea and testing of combining aluminum alloy sheetssystem.Aswithanytypeofexteriorconstruction,moisture withvariousothermaterialswasproposedbyresearchersenteringthesystemisapotentialproblem.Controlling at Swiss Aluminum back in the 1960s, with the intention ofmoisture was one of the biggest problems with the Wet Seal, meeting particular demands of certain industries with distinctbecause the caulk joint is the primary weather barrier and featuressuchas:lightweight,highstrength,andvariouspinholes in caulk happen. Its near impossible to install a bead aestheticpossibilities.Asaresultofthoseintentions,earlyof caulk with not so much as a pinhole within the bead. Now aluminum composite panels were mainly marketed to thewhen you throw wind load and negative pressure in the mix, Transportation Industry. every single pin hole will suck moisture into the wall system with no way out, creating black mold. Lastly, this system is the In 1965, the production process of aluminum compositeleast complicated to install. Which inevitably brings a gang of panels was confirmed, and after years of analysis and study,contractors that want to give it a try, followed by quotes that aluminumcompositepanelswereintroduced.Thebranddont make sense, followed by a lot of unacceptable work ALUCOBOND, for the first time in 1969 by the joint venture ofbeing completed and unhappy customers. This is something Alusingen and BASF. that happens in every trade, and just needs overseen more Overthepast50years,especiallyafterAlusingensby manufacturers and evaluated by CMs, GCs, and Owners. patent on the process of ALUCOBOND expired in 1991, theThis is now happening more with the CM at Risk Projects.industry has seen several players enter the industry. ALCOA,Now the Route and Return Dry system operates similar ETEM, and MITSUBISHI to name a few. ACM developing intoto the Wet Seal but utilizes gaskets at the panel joints in lieu MCM,reflectingtheinclusionofsteel,copper,zinc,andof the silicone caulking, continuous extrusions around each stainless steel. Learning more about the advantages of ACMpanel, and a secondary gutter system to ensure a water-/ MCM through testing and engineering. Some advantagestight system. Obviously, with the elimination of the silicone, includeweatherresistance,corrosionresistance,impactit allows the panels to stay much cleaner through the years. resistance, fire prevention, moisture proof, sound insulation,In general, a typical rainfall should be enough to keep the heatinsulation,andearthquakeresistance.Multiplepanels looking clean. Decent selling point to an owner, low Installation Systems have been introduced such as: 1 and 2maintenance. Unfortunately, a couple disadvantages are the piece Molding Seal, Rain Screen, Route and Return Wet Seal,increased cost, (which is most likely due to increased install Route and Return Dry Seal, and multiple variations to the Raintime,andcontinuousaluminumextrusions),anditdidnt Screen. scare the gang of unqualified contractors away.With this small piece of history in mind, hopefully it sparksLastly,TheRouteandReturnRainScreenSystem.This aninteresttodosomeresearch,askquestions,andhelpsystem has pretty much combined all the positive features open the door to new ideas. of the wet and dry joint composites and left all the negatives Wet Seal, Dry Seal, and Rain Screen Composite Panels in the past. Theres no silicone caulking, negative pressure is Ill start by saying these panel systems function efficientlyeliminated due to open joint ventilation, and its typically an whendesigned,engineered,installed,andmaintainedeasy install. These negative features have been eliminated correctly. When Designers are selecting a panel system, theyover the years by Fabricators and Engineers taking the time have to consider several items such as: budget, aesthetics,to research, test their systems, and using their experience to maintenance, and the function of the wall assembly on thebring multiple variations of this system to the table. Its by structure. far the most common type of panel system I see specified onprojectstoday.Ibelievethisisduetothetestingthat Assomeofyouknow,overtheyears,thetechniquesthese fabricators have done on their specific systems, which andsystemshaveevolvedconsiderably.Atthebeginningenables them to share data with architects, designers, and ofthisdevelopment,theRouteandReturnWetSystemengineers. Its also allowed for additional options with reveal wasconsideredtobethemostreasonablewaytoinstallsizes. Aluminum Composite Panels. It relies on silicone sealant at allIn conclusion, I believe that all of the different composite panel joints, intersections, and end walls for the air and waterpanel systems, even the ones not directly discussed, will work barrier. This system utilizes male and female clips to attachvery well on any building if the time is taken during the design the panel to the structure and can accommodate any typeand engineering stage to evaluate all aspects of the project. of panel design whether simple or complex. Im looking forward to seeing where the industry will be in the After a number of projects had been installed over thenext 10-20 years.42 www.mrca.orgMidwest Roofer'