Neolith by Marble Trend "Sintered Stones for Building Facaes"

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Sintered Stones for Building Facades


Continuing Education The Size Surfaces, SL is a Registered Provider with The American Institute of Architects Continuing Education Systems. Credit earned on completion of this program will be reported to CES Records for AIA members. Certificates of Completion for non-AIA members are available on request. 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 of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product. Questions related to specific materials, methods, and services will be addressed at the conclusion of this presentation.

Sintered Stones for Building Facades

This presentation is protected by US and International copyright laws. Reproduction, distribution, display and use of the presentation without written permission of the speaker is prohibited.

Course Number: AIACE4012016


Learning Objectives After completing this presentation, you will be able to: • Identify and recognize the characteristics and beneficial properties of sintered stones. • Investigate the manufacturing process of sintered stones and the suitability of the product to both interior and exterior building applications. • Assess the functional contributions of sintered stones as they contribute to green and sustainable building design. • Specify sintered stones in a variety of green and conventional buildings and formulate appropriate selections related to specific applications.

Sintered Stones for Building Facades

Course Number: AIACE4012016


Building Facades in Context

Need to withstand: • • • • •

Water Wind Sunlight / UV Radiation Severe weather Vandalism

Design based on: • • • • •

Appearance Size Weight Cost Installation

Sintered Stones for Building Facades

Course Number: AIACE4012016


1. Sintered Stones Overview: Why it is good for building facades

Course Number: AIACE4012016


1. Sintered Stones Overview: Why it is good for building facades Sintering: Sintering as a process has been used traditionally for: • Manufacturing ceramics • Industrial processes Powder metallurgy is the study of sintering and powder-related processes. Relies on using natural materials processed under heat, pressure, or both.

Course Number: AIACE4012016


1. Sintered Stones Overview: Why it is good for building facades Atomic Diffusion of Particles: • Sintering is based on atomic diffusion of particles. • Occurs most quickly higher temperatures.

at

• Atoms in powder particles diffuse across the boundaries of the particles, fusing them together, and creating one solid piece.

Powder Particle

Pores

Course Number: AIACE4012016


1. Sintered Stones Overview: Why it is good for building facades Sintered Stones: Manufactured products are: • Thin • Lightweight • High strength Similar to porcelain tile except: • Denser • Non-porous • Stronger

Course Number: AIACE4012016


1. Sintered Stones Overview: Why it is good for building facades Sintered Stones Building Facades: For building facades it RESISTS: • • • • • • • •

High heat Fire Scratches Abrasion Freeze/thaw cycles Ultraviolet (UV) rays of Sun Water (0.08% porosity) Chemical cleaners

Described as truly “ageless”

Course Number: AIACE4012016


1. Sintered Stones Overview: Why it is good for building facades Sintered Stones Building Facades: Design attributes: • Many different appearance options: - Stone - Tile - Wood - Smooth - Textured • Lightweight: - 1.1 psf for 1/8” thick - 5.5 psf for 1/2” thick • Easy to clean • Suitable for interior and exterior

Course Number: AIACE4012016


1. Sintered Stones Overview: Why it is good for building facades Sintered Stones Comparison:

Cost

Proven repeatedly as highly cost effective in: • First costs: Cost-neutral in construction when compared to many commodity facade products such as aluminium composite panels. • Life cycle costs: Beneficial over the long term life of the building due to agelessness, low maintenance, ease of care an vandalism-proof surface.

Course Number: AIACE4012016


2. Manufacturing Process How sintered products are made

Course Number: AIACE4012016


2. Manufacturing Process How sintered products are made Raw Materials: Different natural required such as: • • • • •

ingredients

Silica Quartz Feldspars Clays Mineral pigments

Mix of powdered or sand materials determines strength, hardness, chemical stability and workability. Natural materials contribute to responsible green characteristics.

Course Number: AIACE4012016


2. Manufacturing Process How sintered products are made Pressing: • First step is to prepare materials into a spray dried mixture of sands, clays, and pigment. • Mixture is pressed to form an unfired slab ready to be decorated or colored. • Specific, but limited, amount of water needed in order to be pressed. • Pressing up to 15,000 psi to properly densify the slab.

Course Number: AIACE4012016


2. Manufacturing Process How sintered products are made Firing: • Compact fired in large kiln at temperatures below the melting point of the minerals at normal atmospheric pressure. • Due to vitrification, some limited shrinkage may occur. • Sintering takes place allowing material to densify and become non-porous. • Note: no extrusion involved. • Thickness plus the overall face size of the sheets, or panels, can vary by manufacturer.

Course Number: AIACE4012016


2. Manufacturing Process How sintered products are made Fabricating: • “Raw slab” comes out of the kiln with rough edges so it needs to be squared and rectified first into panels. • Panels can be fabricated either at the plant or in the field. • Cut using wet diamond saws or high pressure water jet machinery. • Corners formed from a mitered edge cut at 45º and 135º using a bridge saw or waterjet. Then, the two pieces can be adhered together creating a full mitered edge.

Course Number: AIACE4012016


2. Manufacturing Process How sintered products are made Handling: • Panels are strong but, like all stone need to be handled properly. • Use same methods as for handling glass with frames and mechanical suction cups. • Intent is to move panels uniformly and induce unwanted stresses. • Keep people and panels safe.

Course Number: AIACE4012016


3. Building Applications Using Sintered Stones in buildings

Course Number: AIACE4012016


3. Building Applications Using Sintered Stones in buildings Interior Applications: Being used successfully in new or renovated buildings for: • Wall coverings • Floor coverings • Hygienic countertops • Kitchens • Bathrooms • Cabinetry • Furniture • Modular components

Course Number: AIACE4012016


3. Building Applications Using Sintered Stones in buildings Exterior Applications Building Facades Sintered Stones fit well with building facades: • Trend is toward lighter weight façade systems using framed walls instead of masonry walls. • Energy codes require continuous insulation behind outer cladding which can be done with panels. • Panels can be used over virtually any structural, insulated, wall assembly system.

Course Number: AIACE4012016


3. Building Applications Using Sintered Stones in buildings Attachment Systems: General building approach based on proven performance: • Adjustable attached structure.

clip angles to building

• Aluminum channels or tees attached to clip angles. • Panels attached to channels at edges or tees for mid span support. • System is adjustable. • All structural loads are transferred to the building.

Course Number: AIACE4012016


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3. Building Applications Using Sintered Stones in buildings Attachment Methods: There are four common methods of attach panels to the aluminum channels / tees: 1. Chemically Bonded Systems 2. Visible Mechanical Support Systems 3. Non-Visible Mixed Systems 4. Ventilated Rainscreen Systems.

3

4

Course Number: AIACE4012016


3. Building Applications Using Sintered Stones in buildings 1. Chemically Bonded Systems: • Panels attached using adhesives to create a chemical bond between the panel and the support system. • Appropriate on low rise residential buildings • In some cases, it may be possible to adhere the panels directly to an underlying, smooth substrate. • More commonly, the panels are adhered to aluminum using an elastic chemical adhesive-tape or applied adhesive. • All based on tested and certified materials and assemblies.

Course Number: AIACE4012016


3. Building Applications Using Sintered Stones in buildings 1. Chemically Bonded Systems: Attributes: • Completely hidden method of assembly. • Everything done on back side of panels. • Continuous bond distributes stress evenly. • Flexibility reduces transfer of vibrations from building. • Non-conductive adhesive enables connection of different materials without concern of galvanic corrosion.

Course Number: AIACE4012016


3. Building Applications Using Sintered Stones in buildings 2. Visible Mechanical Support System: • Full mechanical system that wraps over the edges of the panels with exposed clips or clamps. • Small square ones used on sintered stones. • Connected with steel screws.

stainless

• Elastic adhesive can be added for extra stability.

Course Number: AIACE4012016


3. Building Applications Using Sintered Stones in buildings 2. Visible Mechanical Support System: Attributes: • With the support square clamps, the location of the panel can be adjusted to achieve proper levelling. • The stainless steel screws allow the panels to be quickly and easily replaced if needed. • The elastic adhesive improves the system’s reaction to wind pressure or suction and loads.

Course Number: AIACE4012016


3. Building Applications Using Sintered Stones in buildings 3. Non-visible Systems:

Mixed

• Support system designed to connect to the unexposed, rear side of a sintered compact panel. • Angled grooves in the back side of the panel receive horizontal aluminum channels into the grooves and adhered. • Achieved with a double groove at opposing 45 degree angles (like a dovetail in carpentry terms). • Connected channels are then secured to horizontal aluminum channels on support system.

Course Number: AIACE4012016


3. Building Applications Using Sintered Stones in buildings 3. Non-visible Systems:

Mixed

Attributes: • Panels can hang and be levelled to align with adjacent panels or to be staggered without additional vertical supports. • Support system is invisible due to the concealed fastening and aluminum members. • Eliminates risk of panels separating from the structure in the event of breakage. • Allows for easy removal and replacement of panels when necessary.

Course Number: AIACE4012016


3. Building Applications Using Sintered Stones in buildings Curtain Wall Non-visible System: • Use sintered compact panels as spandrel panels in a curtain wall system. • Curtain wall is secured to the structure with metal clips and anchors creating frame for the panels to be inserted. • Thinness and light weight allows panels to be substituted for glass in a curtain wall system. • Panels fully conceal and protect the area behind them, allowing full continuous insulation.

Course Number: AIACE4012016


3. Building Applications Using Sintered Stones in buildings 4. Ventilated Rainscreen Systems: Rainscreen system: • Works on principle of separating the exterior cladding from the full wall assembly. • Space between allows air to enter and ventilate the wall • Allows any water that enters to drain out of the bottom • Rather than completely isolate water from penetrating walls plan for its escape. • Cladding is first line of defense, wall surface behind is second. • Three systems described can create a ventilated rainscreen.

Course Number: AIACE4012016


3. Building Applications Using Sintered Stones in buildings 4. Pressured Equalized Rainscreen Systems: • Higher wind loads mean more pressure is applied to the exterior cladding • The solution is a pressure equalized rainscreen which creates smaller compartments across a façade • These compartments independently

ventilation respond

• The air pressure inside the cavity matches the wind’s pressure and “pushes back” against it • Can meet the approval of Miami / Dade County for hurricane resistance and California for seismic concerns.

Course Number: AIACE4012016


3. Building Applications Using Sintered Stones in buildings Installation Remember:

Points

to

• Install the support frame and the panels in accordance with manufacturers’ recommendations and instructions • Large sizes available help reduce installation time thus saving labor costs. • Can be installed over existing surfaces, thus avoiding or reducing demolition and waste disposal activity and costs. • The very light for size / weight ratio means that it can be installed on light gauge metal framing wall systems.

Course Number: AIACE4012016


4. Green Building Contributions of Sintered Stones Good for the environment and good for people

Course Number: AIACE4012016


4. Green Building Contributions of Sintered Stones

Materials and Resources • Sintered Stones are 100% natural. • They will not emit toxic fumes into the environment when exposed to fire or extremely high temperatures. • 100% recyclable. • Up to 52% of Sintered Stones are made up of recycled natural content.

Course Number: AIACE4012016


4. Green Building Contributions of Sintered Stones

Indoor Environmental Quality • Porosity of less than 0.08 percent - does not contribute to water problems such as mold, mildew, or other issues. • Hygienic material that is resistant to bacteria growth that can cause disease and trigger allergies. • No paintings or coatings needed means no volatile organic compounds (VOCs). • Environmentally neutral in terms of the effects on people. • Preventive in terms of the things that it helps avoid.

Course Number: AIACE4012016


5. Specifying Sintered Stones Making selections to suit the building design

Course Number: AIACE4012016


5. Specifying Sintered Stones Making selections to suit the building design Part 1 - General Section • Scope: • • • •

Preparation work Substrate review Product choices Final installation

• Quality control standards: • Recognition by other groups • ASTM testing • NFPA compliance

Course Number: AIACE4012016


5. Specifying Sintered Stones Making selections to suit the building design Part 1 - General Section • Submittals: • Shop drawings • Material Information • Maintenance and cleaning information • Protection: • Proper handling • Proper storage

Course Number: AIACE4012016


5. Specifying Sintered Stones Making selections to suit the building design Part 2 - Products • Identify each Sintered Compact Surface product in design. • Identify mounting system used. • Specify color and texture or pattern. • Identify finish: • Rough/textured • Matte finish • Polished/shiny • Shade variation tolerance on color. • Breaking strength as measured using standard tests. • Any finishing details of the products specified.

Course Number: AIACE4012016


5. Specifying Sintered Stones Making selections to suit the building design Part 3 - Execution • Examination and Preparation: In addition to the architect, the installer should review and examine the substrate • Attachment: The system for attaching may need to be based on manufacturer’s recommendations and instructions. • Placement: According to the patterns and layouts shown on the drawings. • Protection: keep unwanted construction activity away from it. • Cleaning: cleanied with a damp cloth.

Course Number: AIACE4012016


6. Case Studies Sintered Stones very successfully used on building facades

Course Number: AIACE4012016


6. Case Studies Sintered Stones very successfully used on building facades

Case Study #1: Transforming an outdated buiding into a sophisticated Nordstrom retail store in Rideau Centre, Ottawa • Project type: Renovation • Location: Canada

Retail

Ottawa, Ontario,

• Architect: Callison RTKL, Seattle, Washington, USA • Scope: Exterior façade; interior storefront; interior wall cladding • Square Footage: 15,000 sq. ft. • Panel Thickness: 6mm • Panel Size: 6-inch, 12-inch and 18-inch wide panels in 5- and 10-foot lengths

Course Number: AIACE4012016


Course Number: AIACE4012016


Course Number: AIACE4012016


Course Number: AIACE4012016


Course Number: AIACE4012016


6. Case Studies Sintered Stones very successfully used on building facades

Case Study #2: Custom Design of Sintered Compact Surfacing Creates a New Look for the Latest Hotel Design Prototype for La Quinta Hotels • Project type: Hospitality • Location: Across the United States • Architect: 5G Studio Mayse & Associates

and

• Scope: Exterior façade prototype in a variety of colors and patterns

Course Number: AIACE4012016


Course Number: AIACE4012016


6. Case Studies Sintered Stones very successfully used on building facades

Case Study #2: Custom Design of Sintered Compact Surfacing Creates a New Look for the Latest Hotel Design Prototype for La Quinta Hotels Sintered compact surface in standard “iron� finish. Custom colors were used for LaQuinta Del Sol.

Course Number: AIACE4012016


Course Number: AIACE4012016


Course Number: AIACE4012016


7. Conclusion Sintered Stones are worthy of your consideration

• Sintered Stones are becoming an exterior cladding product of choice for many building types. • Natural, lightweight cladding available in many different colors and textures is getting the attention of architects • Its economy and long term durability address both first costs and life cycle costs. • Methods of attachment make it easy to install and maintain • It is growing in use because of this variety of design and performance characteristics.

Course Number: AIACE4012016


Sintered Stones for Building Facades Thank you!

This completes the AIA continuing education portion of the program.

Course Number: AIACE4012016


THESIZE SURFACES SL P.I. Cami Fondo, Supoi 8. C/ Ibers 31 12550 Almazora (Spain) P: +34 964 652 233 info@thesize.es www.neolith.com

Sintered Stones for Building Facades Thank you!

This completes the AIA continuing education portion of the program.

Course Number: AIACE4012016


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