design & specification of mcm in today’s...

Design & Specification of MCM in Today’s ArchitectureProvides an overview of metal composite materials (MCM), including uses and applications, product characteristics, finishes, manufacturing processes, construction details, and specifications

Best Practices

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Learning Objectives

• Define both the physical and finish characteristics of MCM, and explain how these characteristics contribute to sustainability.

• Discuss the manufacturing process and the application of coatings.

• Analyze the cost considerations and life cycle of MCM versus other materials.

• Demonstrate how MCM contributes to the safety and well-being of building occupants.

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Table of Contents

MCMDefinitions and AttributesMaterial StructuresManufacturing Process

Physical CharacteristicsStrength of MaterialPE and FR Core

Finish CharacteristicsPaintPVDF vs. FEVENatural Metals

MCM vs. Other Alternatives

Attachment systemsExterior: Wet Seal, Dry Seal, RainscreenInterior

Application Examples

Cost Considerations

MCM Specification Writing

Project Communications

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What is MCM?MCM: metal composite material: aluminum (ACM), stainless steel (SCM), titanium (TCM), copper (CCM), zinc (ZCM), etc.

MCM is produced through the continuous bonding of two thin skins of metal under tension to either side of a thermoplastic core, with a minimum density of 20 lbs/ft3, as required by the International Code Council Evaluation Service Acceptance Criteria 25.

MCM offers the rigidity, superior flatness, and thermal stability of heavy-gauge metal sheet.

MCM has an excellent strength-to-weight ratio.

MCM is prefinished, flexible, lightweight, and can be prefabricated or curved.

MCM is used as a metal-faced cladding material for exterior and interior applications, including walls, ceilings, canopies, beam wraps, column cladding, fixturing, free-standing kiosks, and signage.

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Natural Metal Skin

Core

Natural Metal Skin

Surface TreatmentAluminum Skin

Core

Aluminum Skin

Surface Treatment

PrimerColor Coat

Clear Coat

Structure of MCM

Painted MCM

Natural Metals

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Surface Treatment

Aluminum Skin

Core (Fire-Retardant)

Aluminum Skin

Surface Treatment

Primer

Color Coat

Structure of MCM Interior Application

Interior MCM

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Coil Coating – Continuous1. The aluminum coil is continuously unwound into the process from a pay-off reel.

A coil stitcher mechanically notches two coils together, allowing for continuous production. The aluminum then travels through an accumulator tower and onto the finish coaters.

2. The finish coaters apply a coat of paint, which is then cured by the finish ovens and cooled. The process is repeated for each required paint layer.

3. The painted aluminum passes through an exit accumulator tower and then rewound on a recoiler. The painted aluminum coil is now ready for the lamination process.

1 2 3

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MCM Product Characteristics

FinishesPainted Aluminum: Standard and Custom

Solid, metallic, mica, prismatic, low-gloss, and dual-color systemPolyester or fluorocarbon; determined by the application and life expectancy

Anodized Colors: Clear, bronze, black and special orderArchitectural Class I

Patterns (Image transfer systems)Provides look of natural wood and stone products with the flexibility of MCM

Natural Metals Titanium, stainless steel, copper, and zinc

Decorative Metals High polished and brushed

Dual ColorTwo distinct colors painted length wise on a panel

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Solid, Mica, Metallic & Prismatic Colors

2-Coat Solid Colors 2-Coat Mica Colors

3-Coat Metallic Colors 3-Coat Prismatic Colors

Core

Substrate

Primer

Color Coat

Pretreatment

Core

Substrate

Primer

Mica Flake in Color Coat

Pretreatment

CoreSubstrate

PrimerMetallic Flake in Color Coat

Pretreatment

Clear Coat

CoreSubstrate

PrimerColor Coat

Pretreatment

Specialized Flake in Clear Coat

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Directional Flop of Metallic Finishes

Grain Runs ParallelGrain Runs Perpendicular

When installing mica, metallic, or prismatic finishes, it is necessary to always install the panels in the same direction to ensure color consistency as the finish grain or flake flop will reflect the light directly.

To ensure color uniformity, use only one lot per elevation.

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Basic Paint Components

Resin

The basic component of the coated layer. The resin determines the functionality and performance of the paint.

The resin forms the basis for the paint film.

Solvent

The solvent acts to “wet out” the resin, permitting paint flow and allowing uniform application.

Pigment

The pigment provides color and the selection of durable pigments is critical to the colors durability.

Pigments also include any metallic or mica flakes

Additives

Additives allow for the dispersion, stabilization, cure, flow, etc.

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Coil Coating Paint Evolution

1946 1950 1960 1965 1970 1980

Solution Vinyls

Alkyds

Fluoropolymers FEVE(Thermoset Solution)

Fluoropolymers PVDF(Thermoplastic Dispersion)

Thermoset Acrylics

Organosols, Polyesters,Silicone Polyester, Plastisol

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Paint Type Characteristics

Polyester Interior use or limited exterior with high performance polyester

Warranties: typically 10 years with high performance

PVDF (Kynar/Hylar)Thermoplastic Dispersion Fluoropolymer

70% PVDF + Acrylic: The C-F Bond (PVDF) that provides the basis for the durability is dispersed in an acrylic resin.

A first-generation fluoropolymer, it CAN re-melt under high temperature and pressure.

Warranties: up to 20–30 years

FEVE (Lumiflon)Thermoset Solution Fluoropolymer

FEVE + Catalysis: The C-F Bond (FEVE) is part of the base resin.

A second-generation fluoropolymer, it DOES NOT re-melt under high temperature and pressure.

Warranties: up to 20–30 years

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UV rays

Fluorocarbon Chemical Structure PVDF

The weatherability of PVDF itself is high; on the other hand, it is necessary to add acrylic resin in order to formulate PVDF into coatings. Because acrylic resin is easily attacked by UV rays, the amount of acrylic resin added to PVDF resin is very important.

F-monomer Acrylic

PVDF polymer

Molecularstructure

Coatedsurface

F F F F FFFFFF

FCF

HCH

70% PVDF, C-F bond dispersed in acrylic resinLimited gloss 10-40Limited colorsThermoplastic

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Fluorocarbon Chemical Structure FEVEFluoroethylene/vinyl ether copolymer (FEVE) comprises alternating sequence of fluoroethylene and several specific vinyl ether units and is completely amorphous. This alternating sequence is responsible for high weather resistance of the resultant paint finishes. The chemically stable fluoroethylene unit protects the neighbor vinyl ether unit, which can be easily attacked by UV rays and other corrosive factors.

F-monomer Vinyl Ether

FEVE polymer (CTFE)

Molecularstructure

Coatedsurface

UV rays

FCF

HCX

100% FEVE, C-F bond integral to the resinWide gloss 10-70Bright colorsThermoset

F F F F FFFF

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Fluorocarbon Paint System Properties

Both FEVE and 70% PVDF paint systems meet the performance criteria of AAMA 2605 standard.

FEVE PVDF

FEVE Resins

100% FEVEClear resinHomogeneous SolutionGloss range 10–70Wide color rangeMuted and bright colorsThermoset

PVDF Resins

70% PVDF + AcrylicMilky resinDispersion Solution Gloss range 10–40Moderate color rangeMuted colors onlyThermoplastic

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Natural Metals

Titanium Copper

Stainless Steel Zinc

Stainless Steel Skin

Core


Titanium Skin

Core


Copper Skin

Core

Copper Skin

Zinc Skin

Core

Zinc Skin

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Natural Metal Projects

TitaniumBeijing People’s Theater

Beijing, China

CopperCeridian HeadquartersMinneapolis, Minnesota

Stainless Steel108 N. State Street

Chicago, Illinois

ZincAnnette Strauss SquareDallas, Texas

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Laminating – Continuous1. The metal coils are introduced into the process from two pay-off reels.

2. The laminating rollers bond the metal 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 MCM to protect the surface finish.

5. The MCM is trimmed to the required width, sheared to the required length, and stacked for inspection and final packaging.

1

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4

5

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MCM Product Characteristics

PhysicalsThickness: 2 mm, 4 mm, and 6 mm

Application use determines thickness required

Cores: Polyethylene (PE) and Fire-retardant (FR)Core type determined by local codes and/or the application

Metal Skins: 0.005–0.032" thickApplication use determines skin thickness

Metal Widths: 38–62" wideStandard stocked architectural aluminum widths are 50" and 62"

Other custom widths available

Panel Lengths:Standard stocked architectural lengths are 146" and 198"

Other custom lengths easily manufactured but not stocked

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Strength of Material

The composite panel with two skins connected by the thermoplastic core function as an I-beam, showing more structural stiffness than would be present if the skins were in direct contact. As the core thickness increases, this effect increases.*

*See flexural stiffness chart

Aluminum 0.5 mm (.020")

Aluminum 0.5 mm (.020")

X

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Sheet1

ACMSolid AluminumWeight ratio Solid Aluminum = 100%

Thickness mm (inch)Flexural Stiffness C-393 (PSI)Weight PSFEquivalent ThicknessWeight PSF

3 (.118)1.04 x 1090.932.7 (.106)1.5062.0%

4 (.157)1.99 x 1091.123.3 (.130)1.8261.5%

6 (.236)4.98 x 1091.504.5 (.177)2.5060.0%

Sheet2

Sheet3

Fire-Retardant/Non Fire-Retardant Cores

The polyethylene (PE) and fire-retardant (FR) cores both offer special advantages.

The PE core is lighter and more flexible than the FR core, allowing for easier bending.

The PE core is acceptable to the IBC for building heights of 40 feet or less.

The FR core is required for buildings over 40 feet adhering to IBC. FR products are required to pass an intermediate scale,multistory test (NFPA 285).

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NFPA 285

(ISMA Test)The NFPA 285 is a well-recognized mock-up test in a controlled environment. The NFPA 285 test simulates an event where the flame will shatter the window and spread from the room to the open air for more oxygen along the external wall.

The mock-up is 18 feet high, consisting of two stories. There are two sets of gas burners: inside the room and outside the window. During the 30-minute test, the flame height and wall temperature are checked. If the flame does not reach the second floor during the test time, the material passes.

Test apparatus Fixating method

Test duration: 30 minutesPass/Fail: No spread of flame beyond the area directly exposed to flame from fire source.

Fire-retardant MCM 4 mm

Room burner

Window burner

Steel stud41 x 92 mm

Gypsum wallboard16 mm

Foil backed fiber glass insulation

14'

18'

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NFPA 285

(ISMA Test)

Left:Mock-up of fire-retardant MCM panels before the test. The mockup is two floors at 18 feet high, and the window burner is positioned in the center of the ground floor

Before ignition 7 minutes after ignition

Right:The panel 7 minutes after ignition. Within 7 minutes, nothing happens with fire-retardant MCM panels.

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NFPA 285

(ISMA Test)From 15–30 minutes, a part of fire-retardant MCM panels starts burning, but the flame remains in a limited range, and it does not spread upward.

After 30 minutes, when the gas supply is shut off, the flame weakens due to the self-extinguishing FR material.

15 minutes after ignition 25 minutes after ignition

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CAN/ULC-S134

(Canadian Full-Scale Exterior Wall Fire Test)The fire test for Canada is similar to the NFPA 285 test, but the mock-up size is larger; 7.3 meters (24') high by 6 meters (20') wide.

In this test, the flame height and the intensity of heat flow are checked. The flame should not exceed 5 meters (16') high. The test period is 25 minutes.

CAN/ULC-S134-13Wall assemblies near the start of the fire test.

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ASTM E-108

(Roof Covering Test)

Roof covering test, ASTM E-108, consists of three types of fire tests:1. Burning Brand Test

2. Spread of Flame Test

3. Intermittent Flame Test

In all these tests, the FR panel is installed on an inclined deck like a roof.

Burning Brand Test:Burning timber is laid directly on specimen surface, and the damage to the specimen and smoke evolution are observed.

Burning Brand Test

Fire-retardant MCM

Burning brand

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ASTM E-108

(Roof Covering Test)

Spread of Flame Test:Specimen is exposed to a horizontal flame for 10 minutes, and the damage is observed.

Intermittent Flame Test:Specimen is repeatedly exposed to Flame On and Flame Off. One cycle consists of Flame On 2 minutes and Flame Off 2 minutes .The test consists of 15 cycles.

Intermittent Flame Test & Spread of Flame Test

Burner Gas Supply

Specimen Holder

Burner Thermocouple

Air Supply

Fire-retardant MCM

Floor Level

30

NFPA 286

(Room Corner Test)

Room corner test, NFPA 286 is a fire test for interior materials.

If a fire happens at a room corner, the flame will grow slowly until the fire reaches a critical point called flashover. When the fire reaches flashover point, the fire will suddenly expand toward the door opening like an explosion.

The flashover is hazardous and sometimes lethal. This test simulates this situation to check whether the flashover will take place with the interior material during the testing period of 15 minutes.

(3)

(2)

(1)

12'

8'

8'

Heater: Gas burnerTime:15 minutesThe interior is finished with the testing material:(1) Side wall: The area close to the opening can be exempted.(2) Front wall(3) Ceiling: Optional

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MCM vs. Other Alternatives

Monolithic Metals/Aluminum Plate Limited to post-coated finishes, weight, and post-finish color consistency.

Batch Laminated Panels Oil-canning, limited widths, delamination, skin blistering, and dimpling.

Sheet Metal Weight, oil-canning, and rust.

MCM Application Oil-canning Delamination

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Exterior Attachment Systems

RAINSCREEN Pressure Equalized: Minimized pressure differential on the inside and outside of the exterior cladding.

Design allows for the control of water and moisture entering and draining from the wall cavity.

AAMA 508, a pass/fail standard, which tests pressure equalization, substrate wetting, and water drainage.

Drained Back Ventilated:Design allows for water and moisture to enter and drain from the wall cavity.

AAMA 509 does not have a pass/fail criteria. The standard defines the ventilation and water resistance performance of a drained back-ventilated rainscreen system. It ranks air and water infiltration on a scale of 1 to 10.

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SEALEDWet SealOpen-joint system sealed with caulk and backer rod, watertight

Most economical of the three systems

Dry SealOpen joint system with gasket and/or filler strip, watertight

Typically most expensive system

GLAZED-IN

Glazed-InMCM panels are used as in fill panels and are glazed into a channel in the extrusion

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Horizontal Detail Vertical Detail

Rainscreen

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Head Detail Sill Detail

Rainscreen

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Rectangular Column Circular Column

Rainscreen

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Parapet Detail

Rainscreen

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Butler Tech Bioscience CenterArchitect: McGill Smith PunshonFabricator: Composite Panels InnovationsPanel: BBR RedAttachment System: RainscreenLocation: West Chester Township, Ohio


NC State College of Engineering

Architect: Perkins + Will

Fabricator: Vicwest

Panel: Custom Taupe

Attachment System: Rainscreen

Location: Raleigh, North Carolina

40


Coss Y Leon

Architect: O'Neal

Fabricator: Daissa

Panel: MRT Red/Opt Mica Platinum

Attachment System: Rainscreen

Location: Guadalajara, Mexico

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Wet Seal

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Wet Seal

43



Wet Seal

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Parapet Detail

Wet Seal

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Burj Al Arab Hotel

Architect: WS Atkins & Partners

Fabricator: Al-Abbar Aluminum

Panel: Custom White

Attachment System: Wet Seal

Location: Dubai, U.A.E.

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Obici Hospital

Architect: HKS

Fabricator: Metal Crafters

Panel: OPT Mica Platinum


Location: Suffolk, Virginia

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Bethel Korean Church

Architect: Derevere & Associates

Fabricator: Carvist

Panel: CMX Champagne Metallic


Location: Irvine, California

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Aloft Hotel

Architect: Jonathan Nehmer & Associates, Inc.

Fabricator: Composite Wall Systems

Panels: ABE Blue, AYW Yellow, BGY Grey


Location: Chesapeake, Virginia

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Dry Seal

50



Dry Seal

51



Dry Seal

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Parapet Detail

Dry Seal

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United Therapeutics

Architect: O'Neal

Fabricator: Altech Panel Systems

Panel: BBR Red/LTG Grey

Attachment System: Dry Seal

Location: Durham, North Carolina

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Guy Brown Building

Architect: Smallwood Nickle Architects

Fabricator: Quality Metalcrafters

Fabricators

Panel: BLM/SMX


Location: Brentwood, Tennessee

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St. Mary Medical

Architect: Odell Associates

Fabricator: W.H. Stovall

Panel: BPS Pearl


Location: Richmond, Virginia

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Winnie Palmer

Architect: Jonathan Bailey Associates

Fabricator: Kistler McDougall

Panel: MBX Med. Bronze Metallic,

OPT Mica Platinum

Attachment System: Glazed In

Location: Orlando, Florida

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Trump Tower

Architect: Skidore, Owens & Merrill

Fabricator: Permasteelisa

Panel: 6-mm SCM Stainless Steel

Attachment System: Glazed In

Location: Chicago, Illinois

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Interior Attachment Systems

1. 3mm interior MCM2. Joint cover, MCM strip adhered on aluminum angle3. Holder, aluminum C-30x304. Hanging bolt, M5, covered with rubber tube5. Gypsum board6. Stud

6

5

1 2

3

4

1

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4

6

Interior Hanging

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1. 3mm interior MCM2. Aluminum flange3. VHB tape4. Corner support plate5. Tapping screw6. Suspension bolt/nut7. Hanger8. Double clip 9. Double bar10. Steel channel

Interior Ceiling

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6

89 10

1

23

4

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Attachment System Considerations

Project specific environment

Aesthetic needs

Wall performance requirements

Code requirements

Complex detail requirements of the system

Special installation requirements

Project budget

The performance and flexibility of the system to meet your design and performance requirements should be the criteria for determination of the system you specify.

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Cost Considerations: MCM Projects

Finish Specification A painted finish (solid, mica, metallic, prismatic) is the least expensive, with the natural metals finish being the most costly.

Module Size Use manufacturer’s standard widths. Non-standard widths will increase the overall cost of the project due. Standard architectural modules are 4' and 5' wide utilizing 50" and 62" panels with a 1" route and return

Performance SpecifiedMaterial Thickness: Be sure to specify the correct thickness required to meet the local codes including the wind load requirement for the system.

Product Core Type: Building codes will determine PE or FR core.

Attachment System: Code and performance requirements of the system (sealed or rainscreen) will have a direct effect on the overall cost.

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Writing a Quality MCM Specification

Performance. Include performance vs. descriptive based criteria using reference to AAMA 2605 paint performance.

Code Compliant. Be sure to qualify that the MCM products meet or exceed your performance requirements and have met or exceeded the requirements of the local or national building codes.

Tested System. Verify the fabricator’s attachment system has been tested/listed to AAMA/National standards and the MCM product has been tested and listed with a registered listing agency.

Sustainability. MCM manufacturer should be able to provide sustainability information and how their product contributes to LEED.

Warranty. The warranty should cover the time frame required for the project. Be careful to understand any exclusions written in the warranty as well as the extent of remediation. Not all warranties are equal.

65

MCM Project Flow

Working with the Manufacturer

MCM Manufacturer

DealerEngineer, System Designer, Fabricator, Installer

Installer

SubcontractorGlass Co., Curtain Wall, Other Panel

General Contractor

Architect

Arch

itect

ural

Doc

umen

ts

Shop

Dra

win

gs

Support +Shop Drawings

Support

66

Points to Remember

• MCM are very cost-effective materials.

• Used extensively on interior and exterior applications.

• A great solution for fascia, columns, beam wraps, ceilings, and signage application.

• The advanced finish and surface technology available with today’s MCM materials allows for an almost unlimited array of uses.

• Use your best resource, the MCM manufacturer, as its experience and knowledge can help ensure that your vision becomes a reality.

• The resources and knowledge of the MCM manufacturer and fabricator can be used to minimize costs based on panel size, building codes, and finish selection.

• Carefully review panel warranties for full coverage and liability.

• Panel and finish performance should be specified.

67

Thank You for Your Time

This concludes the American Institute of Architects

Continuing Education Systems Program.


More Information

For more information about MCM design and specifying, please visit:

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Design & Specification �of MCM in Today’s ArchitectureBest PracticesCopyright MaterialsLearning ObjectivesTable of ContentsWhat is MCM?Structure of MCMStructure of MCM Interior ApplicationCoil Coating – ContinuousMCM Product CharacteristicsSolid, Mica, Metallic & Prismatic ColorsDirectional Flop of Metallic FinishesBasic Paint ComponentsCoil Coating Paint EvolutionPaint Type CharacteristicsFluorocarbon Chemical Structure PVDFFluorocarbon Chemical Structure FEVEFluorocarbon Paint System PropertiesNatural MetalsNatural Metal ProjectsLaminating – ContinuousMCM Product CharacteristicsStrength of MaterialFire-Retardant/Non Fire-Retardant CoresNFPA 285NFPA 285NFPA 285CAN/ULC-S134ASTM E-108ASTM E-108NFPA 286MCM vs. Other AlternativesExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsExterior Attachment SystemsInterior Attachment SystemsInterior Attachment SystemsInterior Attachment Systems Interior Attachment SystemsAttachment System ConsiderationsCost Considerations: MCM ProjectsWriting a Quality MCM SpecificationMCM Project FlowPoints to RememberThank You for Your TimeMore Information

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