bravo user manual

Ventilated Façade System

BRAVO

JUN/2011

for installation of aluminium composite material etalbondÂŽ

User manual

04

Horizontal section of the system

05

Vertical section of the system

06

Installation plan

08

System profiles and accessories

10

Static scheme selection

12

Mounting the fixing bracket on a metal “grid�

14

Brackets mounting

20

Substructure assembly - Steps and General Principles

26

Fixing of the main supporting profile

28

Joining of the main suporting profiles

29

Templates for hangers mounting

CONTENT

30 Preparing the cassettes from composite material 31 Installing the first row of hangers 33 Installing the hangers by means of a template 35 Making the cassettes from composite material 36 Cutting the sheet and preparing the cassette 39 Hanging the cassettes 41 Cassettes installation steps 42 Reinforced profile Ventilation grid

System BRAVO Horizontal section

SYSTEM Bravo Vertical section

single fixing bracket for fixed support

anchor M8

thermo-pad thermal insulation fixing bracket

rivet 4.8x12 anchor M8 main profile etаlbond®

thermo-insulation pad

supporting profile

rivet 4.8x12

single fixing bracket for flexible support

self drilling screw M4.8x32 main joint profile hanger etаlbond®

4

hanger

plug 8

self drilling screw M4.8x32 thermal insulation

5

Main components and installation plan of the main construction

1 2 3

4

1. Main supporting profile

8. Joint profile

2. Wall brackets

9. Washer

3. Thermo-insulating pads

10. Anchor/dubel

4. Self-drilling screw M 4.8x32

11. Substructure base – reinforced concrete

5. Hanger

12. Thermo-insulating mineral wool

6. Rivet ø4.8 x12

13. Plywood-nail for mineral wool securing

7. Construction base – masonry/aerated concrete

1

2 3

5

12

4 6

5 6

7

7 8

8 9

10 13

9 10

11 11

6

7

System profiles and accessories The system is supplied with a full set of end profiles and accessories allowing for unique details execution, different finishes and transition to other faзade materials.

Accessories

Fixing bracket

40 4040 - 210 - 210 - 210 mm mm mm

90-250 90-250 mm mm 90-250 mm

40-300 40-300 mm mm 40-300 mm

160 mm 160 160 mm mm 80-160 mm 80-160 mm 80-160 mm

80/90 mm 80/90 mm 80/90 mm

Hanger

Supporting profile

Joint profile

Aluminum strap

07bravo00

31064

07shina

07support02

F profile

Grating

07support02

07vfsgrating

40 - 210 mm 40 -40 210- 210 mm mm

cod

dimensions

cod

40-300 40-300 dimensions mm 40-300 mm mm

07 vario

072

40 mm

07 vario

07

40 mm

07 vario

Q 52

50 160mm mm

160 mm 07 vario 160 mm

Q5

50 mm

07 vario

07 vario

08

082

75 mm

07 vario Q 102

100 mm

07 vario Q 10

75 mm 80/90 mm 100 mm

07 vario Q 172

125 mm

07 vario Q 17

125 mm

07 vario Q 152

150 mm

07 vario Q 15

150 mm

07 vario Q 182

180 mm

07 vario Q 18

180 mm

07 vario Q 212

210 mm

07 vario Q 21

210 mm

80/90 80/90 mm mm

07variosh 210 90-250 90-250 mm 90-250 mm mm

80-160 80-160 mm 80-160 mmmm

Thermo-insulation pad 07pvcbreak00

71 mm

07washerQ10

100 mm

30 mm

60 mm

Chemical anchor 07ITH380EA

Threaded rod M10 x100 07M10TR

Anchor M8 x100/96 07M1096A4F 07M10105F

8

07pvcbreak01

Fastening elements

Main profile

21895 - 71 х 71 х 2.8 mm

Washer

21958 - 100 х 71 х 2.8 mm

Rivet ø4.8 x12 07P4812AlSS

Plastic siever 906050000355

Plug M ø8x100 071080A4FUR 0710100FUR

Self drilling screw M4.8x32 07M4832QS

9

Static selection diagram

Static diagram selection is based on the results of the static analysis and the preferred variant for fixed support is mounted to the main supporting vertical profile ( in the upper end, in the middle or in the bottom end).

Each main supporting profile is mounted to one fixed and /or several flexible supporting points.

As a result of the aluminum thermal expansion, it is recommended that the main supporting profile has a length of about one floor height.

The length of the main supporting profile is precisely determined depending on the building location and the respective daily temperature amplitude.

Options for mounting the fixed and flexible supports in the space between floors

A fixed support bears the load of the own weight for the loaded panel and a part of the wind load. There is only one fixed support for every single profile. It is obligatory this support to be fixed in a solid base-reinforced concrete H or metal (steel or aluminum). When installing a wall bracket as a fixed support at the reinforced concrete base the distance from the edge of the concrete floor to the anchorR axis should not be less than 120 mm.

G

The flexible support bears the wind pressure.

It is not obligatory to assemble the mounting wall brackets to reinforced concrete or metal base. Selection of anchoring element depends on the type and quality of the construction base. Plugs and chemical anchors are most commonly used. The wind suction load is twice as high in the corner zone of the building than in the inner zone, which requires the mounting brackets to be positioned at distances twice shorter at the corner zones.

H

H

R

G

H

The oval shaped holes of the VARIO wall brackets are designed to compensate for thermal expansions of the main supporting profile.

10

11

Mounting of a wall bracket to a metal construction

The circular holes on the fixing bracket are used when mounting it to the metal substructure (grid). The fixing is realized through a bolt connection. If the metal grid is not an aluminum one, then an additional treatment of the contact zone between the profile and the bracket is required so that the effect of bimetal corrosion is eliminated.

BRAVO 12

Wall bracket installation Fixed suport minimum 120 mm

1

2

3

4

5

6

Drill a hole with a size as per installation instructions

minimum 120 mm minimum 120 mm

Clean up the hole by the use of a brush

The fixed support bears the load induced by the weight of the panels mounted on it and a part of the wind load. It is mandatory that this support is fixed to a solid base - reinforced concrete <or120 metal ( steel or aluminum). mm When installing a wall bracket as a fixed support directly on reinforced concrete base, the distance from the edge of the concrete floor to the anchor axis should be no less than 120mm, if aluminum sheet is used for covering the area around the bracket.

…or by compressed air

correct

Hammer in the anchor

< 120 mm < 120 mm

< 120 mm

Place the bracket

correct

incorrect

14

Place the reinforcing washer and fix the bracket

15

< 120 mm

Wall bracket installation Flexible suport

1

2

3

4

Drill a hole with a size as per installation instructions

Pour the chemical product into the hole - it should fill 2/3 of the volume

The flexible support bears the wind pressure.

Wall brackets are mounted on a steady brick or aerated concrete wall. The project designer inspects the construction base and recommends the appropriate anchoring elements. The wind load is twice as high in the corner zone of the building than in the inner zone, which requires the mounting brackets to be positioned at twice shorter distances at the corner zones.

Place in the anchor and rotate it as to spread the mixture uniformly

correct

Place the bracket

5

Place the reinforcing washer and fix the bracket

incorrect 16

17

Substructure assembly - Steps and General Principles

1

4

2

5

3

6

Reference points are marked on the wall by means of a laser level. Their purpose is to help in outlining a coordinate system – horizontal and vertical base lines.

The benchmarks are put onto the wall

The central horizontal and vertical axis of the frame of reference are marked on the façade by means of a coloured thread.

The horizontal and vertical lines are passing throughout the entire façade and are used for determining the position of the wall brackets and the distances between the supporting profiles.

The positions of the main supporting profiles (depending on the façade grid) are marked using a measuring device (tape-measure).

20

The exact position of the main supporting profiles is marked by a coloured thread.

The positions of the flexible and fixed points (depending on the selected static diagram) are marked.

All wall brackets are mounted (if the building height and shape as well as the scaffolding allows).

21

7

10

8

11

The final fastening of the elements should be performed by use of a torque wrench while controlling tension. The tightening force is indicated by the manufacturer of the fastening elements. The tension force for anchors of type Sormat M10 x 100 mm is 30 Nm (3 kg).

The maximum value of the tension torque for plugs of type Fischer FUR SXR in concrete is 11 Nm. For the different types of masonry it is not recommended to apply tension torque but only â&#x20AC;&#x2DC;tightening the screw to open the plugâ&#x20AC;&#x2122;

The vertical supporting profiles are mounted in both ends of the façade and are leveled using the horizontal axis of the frame of reference.

They are aligned in vertical direction and bracketed by means of vertical level or laser plumb.

The inner supporting profiles are mounted and leveled against the cord.

The spring parts in both ends of the wall bracket allow for easy and simple mounting of the profile. Depending on the brackets, the standard main supporting profiles allow the lev levelling eling of the brackets from 11 to 40 mm.

9

A screw is tightened in the already leveled end verticals and a cord is tied.

min 20 mm

22

23

12

It must be assured that the distance a (measured at the top and at the bottom) between the verticals is one and the same.

a

14

After the profiles are aligned horizontally and vertically, they are temporarily fixed by screws.

After that the rivet holes are drilled for the permanent fastening.

ATTENTION: The screws used for fixing the vertical supports must be removed after the permanent fastening of the vertical supports to the wall brackets with rivets.

a

13

After several of the inner supporting profiles are installed they are leveled with the horizontal axis of the frame of reference

24

25

26

Mounting of the main suporting profile to a fixed suport:

Fixing of the main supporting profile to a flexible suport:

The main supporting profile is mounted to a fixed support with rivets 4,8 x 12 mm in the circular holes of the mounting wall bracket, thus not allowing movement of the profile.

The main supporting profile is mounted to a fixed support with rivets 4,8 x 12 mm in the centre of the oval shaped holes of the wall bracket. They allow movement of the profile caused by thermal expansion.

max 300mm

Templates for hangers mounting

Joining of the main suporting profiles a

max 300mm

2mm

a1 a2

The connection between the main supporting vertical profiles is assured by joint profile (code07shina00), providing the free movement of the profiles. Rivets 4,8 x 12 mm are used as fastening elements.

a3 a4 2mm

a5 a6

Note: the suggested diagram for mounting of a joint profile is applied when the fixed support is chosen to be at the upper part of the main supporting profile.

2mm

>10mm

The template is intended to help in determining the exact position of the hangers and the spacing between them. A template can be made from a stripe of etalbondÂŽ. The die-cut slots in the template follow exactly the dimensions of the slots, cut on the etalbondÂŽ cassetes. In order to minimize the error accumulation, the length of the template should be chosen as big as possible (one floor height).

2mm

* Each cassette should be mounted on two hangers only ( in its upper part ). For this reason the bottom two hangers on which the cassette is mounted have to be fixed 2 mm lower than the upper end of the cassette slot.

>10mm

The distance from profileâ&#x20AC;&#x2122;s end to the first fixing point with a fastening element (rivet) should not exceed 300 mm.

2mm max 300mm

28

29

Making the template

Installing the first row of hangers

Note: The number of hangers and their spacing depends on the cassette size and the loads exerted on it.

The position of the upmost hanger on the main profile serves as a base point in the process of template making. The first slot is die-cut.

The second slot is then cut, displaced from the first slot on a distance, equal to the distance between the cassette slots plus 2 mm.

The next slot on the template (the upper slot of the second cassette) is determined, again taking as a base the position of the upmost hanger on the main profile. The distance between the slots depends on the raster of the sheets and the minimal distance allowed between the slots and the cassette corners.

a a1 a2

The hangers have a specially designed shape, which allows direct installation of the hangers on the main vertical profile, instead of stringing them. The hanger is placed perpendicularly to the profile and then is fixed in the channels by means of a slight pressing towards the profile.

The shape of the hanger allows movement in vertical direction, in order to make it level.

a3 a4 a5 a6

Note: The distances between the hangers and the distances to the corners are chosen according to the cassette size and the desired faรงade raster. The calculations are done in the initial project stage, before the actual installation.

Initially, the hangers in the upper end of the two end vertical main profiles are installed. Then we measure the distance between them and the established base horizontal level.

30

31

Preparing the cassettes from composite material a a

a

After we make sure that the upmost hangers are properly positioned on the first and the last profile, we fix them permanently with self-drilling screws М4,8х32mm. The hangers on the intermediate profiles are then vertically aligned by means of coloured thread or a laser level.

After we have the upmost hanger installed, we put the template over it, moving the template downwards until the upper part of its slot reaches the pipe of the hanger. Then we adjust the second hanger, until its pipe touches the upper end of the second slot of the template.

After that we fix the hangers with self-drilling screws.

In the cases when the hangers are aligned by means of a coloured thread, the two end hangers must be secured with self-drilling screws.

The thread is tied on the screws. The hangers on the intermediate profiles are then aligned on the straight line created by the thread and are secured with screws М4,8х32mm.

Note: Each cassette should be mounted on two hangers only (at the upper part). The bottom two hangers on which the cassette is mounted are to be fixed 2mm lower than the upper end of the cassette slot.

32

33

The steps described above are repeated for the first row of hangers on each subsequent floor.

The next hangers on the profiles are installed by means of templates.

Making the cassettes from composite material

Note: Depending on the raster of the façade, there may be different cassettes, which will require different templates to be made.

3200 mm c =25mm d=35mm

a=750mm

1250 mm b =20mm

The contours of the cassettes (unfolded) are transferred to the composite sheet. The dimensions of the unfolded cassette are determined as follows: h = the height + size of segments (returns) – the number of segments

d c

a

w = the width + segment size (returns) – number of segments

b

Example: h = а + b + c + d - 3mm h = 750 + 20 + 25 + 35 - 3 h = 827 мм

h

w Note: In order to die-cut the hanging slot, a minimal segment size of 30 mm is required.

34

35

1

Cutting the sheet and preparing the cassette

Milling the channels

4mm

3.2mm

4mm

2

The places where the channels will be routed are marked on the back side of the sheet. The milling depth is 0.8 times the thickness of the composite sheet ( for example, if the sheet thickness is 4 mm, the routing depth is 3.2 mm).

Die-cutting the corners by means of a pneumatic die

3

Die-cutting the slots by means of a pneumatic die, with predetermined distance between the slots and the cassette edges, according to the static analysis

4mm

36

3.2mm

4mm

37

4

Hanging the cassettes

Die-cutting the oval shaped and the cylindrical holes

5

Folding the segments and fixing the corners of the cassette

Thus prepared, the cassettes are mounted on the fixed hangers. The grout width between the cassettes is kept constant during installation by means of spacers and may vary from 4 to 26 mm. The cassettes is permanently riveted to the main profile, with rivets 4,8 Ń&#x2026; 12 mm running through the oval and cylindrical holes.

A

B

Đ? - Cylindrical hole B - Oval hole

6

Removing the protective foil at the edges of the cassette

38

39

Cassettes installation steps

The cassettes are installed starting from the bottom-up. The lowest row is first laid, followed by the leftmost (or rightmost) vertical column. After the faรงade is fixed, we proceed with installation of the finishing details.

40

41

Reinforced profile

The reinforced profile is fixed by rivets or screws to the segment in the middle of the bottom part of the cassette. The necessity of the reinforced profile (cod. 07support01) depends on the cassette size and the loads exerted on the cassette.

Ventilation grid

A perforated grid is installed in the upper and the bottom end of the ventilated faรงade, allowing free air movement, and in the same time stopping the insects and impurities.

42

This brochure only reflects the state of our products at the time of printing.

You can find updated information on our website:

www.madeinetem.com Technical or any other questions can be directed to us by e-mail at: pdimitrov@steelmetbg.vionet.gr or use our telephone number: T: +359 894 754 158

OFFICES ETEM BULGARIA T: +359 894 754 158, ventilated@madeinetem.com, www.madeinetem.com ETEM GREECE T: +30 210 489 8605, marketing@etem.vionet.gr, www.etem.gr ETEM ROMANIA Strada Drumul Intre Tarlale nr 42, Sector 3, Bucuresti T: +40 21 209 09 70, contact@etem.ro, www.madeinetem.com/ro ETEM SERBIA T: +381 22 32 80 19, +381 22 32 80 20, office@etemscg.rs, www.etem.gr ETEM UKRAINE T:Â +38 (044) 499 07 87, info@etem.com.ua , www.etem.com.ua, www.etalbond.com.ua, www.ventfacade.com.ua Elval Colour S.A. Plant B, 3rd km Inofyta Peripheral Road, Agios Thomas 32011, Viotia, Greece Tel: +30 222620 53576; E-mail: ecs@elval.vionet.gr www.elval-colour.com