Solutions
Ventilated façades
Integrawall
VENTILATED FAÇADES SYSTEM
Integrawall joins the technical porcelain of ALCALAGRES and a substructure of aluminium sections to achieve completely-integrated designs, making it possible to create double-skin façades which are very aesthetically-pleasing, making our building stand out from the rest and which, in turn, will be protected from adverse weather conditions..
Our porcelain tiles with continuous or discontinuous grooves are available in four sizes of various thicknesses and may be reinforced on the backside with fiberglass mesh for improved tile flexibility resistance. These sizes of porcelain tiles, their moisture resistancy, lightness, resistance to atmospheric agents, as well as design, make Integrawall an excellent solution for all types of façades.
All of our double-skin façades will be provided with a study carried out by our Technical Department consisting of a project on the façade with the positions of each element, an estimate and depending on the project, computer graphics of the façade. The only requirements are to complete a form in full provided by ALCALAGRES and submit project drawings in AutoCAD.
INTEGRAWALL offers three double-skin façade systems among those which are currently available: visible clip (Integra-view), concealed clip (Integrago T40) and Keil system (Integra-key). These systems are explained in more detail below. For double-skin façades, Alcalagres offers various thicknesses of technical porcelain: 11, 14 and 20 mm. These all have a continuous and discontinuous groove with a width of 2 to 5 mm in the following sizes.
VENTILATED FAÇADES SYSTEM >
Alcalagres offers the fullest range of solutions for porcelain tiles ventilated façades system
Several options are currently available when it comes time to design and build a façade. The ventilated façade systems proposed by ALCALAGRES, which are based on the internationally prestigious systems of STROW SISTEMAS FACHADAS DEL NORTE offer an effective, reliable way of meeting the needs that arise in the cladding and protection of all types of building exteriors, whether newly built or refurbished.
ALCALAGRES offers the fullest range of solutions for porcelain tiled ventilated façades system with officially sanctioned systems that comply with the most stringent international standards.
The main feature of a ventilated façade is the creation of a chamber of circulating air between the original building wall and the façade covered with ALCALAGRES porcelain tile, improving acoustic and thermal insulation while preventing the appearance of moisture produced by rain or condensation. This chamber can be designed in the planning phase to suit the building’s needs.
The use of ALCALAGRES integral porcelain tiles, which have an average weight of 25 Kg/m2 and thickness of 10-11.5 mm, represents a considerable reduction of loads on the façade when compared to other stone materials (granite, marble, limestone, etc.) exceeding 50 kg/m2 , yielding a savings in structures and assembly.
System types
There are essentially two types of systems: the Visible Fixing System and the Hidden Fixing System. The choice of one or the other will depend on the specific needs of each project.
For both systems, pieces are fastened to the structure of aluminium profiles with stainless steel anchors. The calculations and characteristics of this structure are studied on a case-by-case basis, taking into account the fac;:ade type, location and other technical requirements such as in the case of seismic regulations. In the event it were necessary, individual pieces can be replaced
any time afterwards.
Fixing systems
The basis of these systems is a network of extruded aluminium profiles, joined together by different stainless steel hardware (AISI 304). This network is divided up into vertical and horizontal tie anchors.
The extruded aluminium elements are manufactured with a thickness of 2 mm. in accordance with “international standards” in order to avoid the effects of galvanic coupling between fixing elements.
HORIZONTAL TILE ANCHORS
The purpose of these profiles, which are fixed to vertical tie anchors solely by mechanical means, is to absorb and withstand the loads transmitted by the porcelain panels as well as those produced by the effect of wind and other forces on this cladding material.
Horizontal profiles are in charge of transmitting shear stress and enable the free expansion and/or contraction of materials. This union is always made near support points, that is, at the intersection of both tie anchors.
VERTICAL TIIE ANCHORS
The purpose of vertical profiles is to transmit the loads generated by horizontal tie anchors to the rigid points on the wall. These loads are transmitted through officially approved anchors that function by both mechanical and chemical means. The vertical tie anchors are mechanically braced to the walls. The brackets are responsible for anchorage and also perfom the triple function of fixation, retention and support.
SYSTEM INSTALLATION >
GENERAL RECOMMENDATIONS
All INTEGRAWALL systems must be assembled in façades by qualified personnel. We recommend only working with experienced professionals in this type of work, as well as complying with the instructions of the site management and reviewing the information contained in the data sheets or on packaging before using any product. The appropriate tools for each type of work must be used and the occupational safety regulations must be followed.
FAÇADE DESIGN
The tile size may be chosen from the formats available: 45×90, 60×90, 30×120 and 60×120 cm. The position of the tiles, the width of the grout joint and the façade modulation. should be defined. The measurements of all the façade elements must also be adjusted in order to reduce the number of cuts and prevent materials from breaking.
CONSIDERATIONS REGARDING THE BUILDING WALL
The building wall or base for laying must be stable, nondeformable and at no risk of cracking. The building wall must have deviations of less than 3.5 mm per vertical metre and less than 10 mm per 2 horizontal metres. The height of the facade must be determined, taking into consideration the out of plumb, projections or any other element that projects vertically from the facade. The structural joints must be conserved as well as the expansion joints.
LAYING THE SUBSTRUCTURE OF THE FAÇADE
The axles of the vertical sections shall be laid according to the dimensions of the tile at a distance equal to or less than 100 cm. Separators must be chosen with a length which is appropriate for each point of the facade, then aligned vertically between slab edges with a distance of no more than 90 cm. In seismic zones, the number of primary separators in the slab edges should be doubled. Once this has been done, the vertical sections must be screwed into the separators in their corresponding holes and the sections must be completely aligned to assure that a perfectly level framework has been laid. The minimum horizontal joint between adjacent vertical sections must be 2 mm per metre of section.
VENTILATED AIR CHAMBER
The air chamber must have a minimum space of between 3 and 10 cm so that natural ascending convection is produced behind the covering. The total effective area of the ventilation openings must be 120 cm2 per 10 m2 of facade surface between slabs. The thickness and characteristics of the thermal insulation must be defined according to the project.
LAYING CERAMIC TILES
A vertical joint ≥ 1 mm is required, while the horizontal joint must measure at least 5 mm depending on the design of the façade. A construction adhesive must be on the vertical sections and in the area in contact with the ceramic tile, in order to
prevent a rattling and chattering. Ceramic tiles must be laid on the sealant when it is still wet and then place the visible or concealed clip, which have been chosen for the project. Each tile must be fastened by four clips placed in each corner, plus one clip every 60 cm in the horizontally.
BASE OF THE FAÇADE AND SPECIAL POINTS
The façade mounting base must be planned correctly so that all parts fit together and the double-skin façade fits perfectly to the wall of the building. It is also advisable to determine the type of framing to be assembled: ceramic or metal work. If in doubt, please contact our Technical Department to discuss possible solutions for special points in the façade.
ADVANTAGES OF ALCALAGRES VENTILATED FAÇADES SYSTEM
AESTHETIC ADVANTAGES
The porcelain tiles installed on the façade are completely flat, which produces a stunning visual effect. The
brackets make it possible to modify the vertical angle of pieces at the anchoring points of the profiles. The variety of models manufactured by ALCALAGRES give customers the freedom to choose from among a variety of finishes, colours and formats.
ACCESSIBILITY
Full accessibility to the original building fa<;:ade whenever repairs, refurbishments or other maintenance operations need to be carried out. Building operations can be housed in the air chamber so these will not affect the aesthetic appearance of the façade.
ACOUSTIC INSULATION
The combination of porcelain coverings and the ventilation chamber yields a 10% to 20% reduction in externa!
noise pollution.
EXTERNAL SAVINGS
A building with a ventilated façade (that is, one which is externally insulated by a ventilation chamber between
the porcelain panels and the original building wall) yields energy savings between 25% and 35% and has greater control over the interior temperature.
ELIMINATION OF MOISTURE
Full accessibility to the original building fa<;:ade whenever repairs, refurbishments or other maintenance operations need to be carried out. Building operations can be housed in the air chamber so these will not affect the aesthetic appearance of the façade.
SAFETY
For certain projects, safety reasons may require that porcelain tiles be backed with a fibre mesh, which in the
case of accidental breakage avoids the broken piece from becoming detached.
ALCALAGRES porcelain tiles are light weight in comparison to other materials, therefore it is easy to perform maintenance on the façade.
INTEGRA-VIEW
VISIBLE FIXING SYSTEM
In the INTEGRA-VIEW visible fixing systems, the clips used to secure the Alcalagres Porcelain Tiles to the profiles are slightly visible from the exterior.
These stainless steel clips are enamelled in the same colour as the selected Alcalagres porcelain tiles, so as to minimise the visual impact which could occur if they were left in their natural colour. Furthermore, the clips simplify the dismantling of the tiles should they need to be replaced for any reason.
The type of clip varies in accordance with the porcelain tile to be used on the façade, and the exterior conditions where the building is located.
INTEGRA-GO
HIDDEN T40 FIXING SYSTEM
The INTEGRA-GO T40 vertical profile system is economic and easy to install. It has been scrupulously designed to resist all types of mechanical stresses and corrosion problems that can arise in construction work. As it is a profile system, it can be installed on solid, perforated or hollow supporting walls.
T40 System has two channels where to put Delta Fastenings,
assuring the position. Besides the ceramic supports and secured with a MS putty and nail view, a fluffy profile is incorporated for proper reception.
The system can be loaded immediately, and can be assembled regardless of the weather conditions. Also, thanks to reducing the number of fixing points on the support, more continuous thermal insulation is achieved by eliminating a large number of thermal bridges.
The system has an European Technical Assessment document that includes the technical evaluation of the performance of a product or kit of a manufacturer in relation to the essential characteristics applicable for the use foreseen by the manufacturer. The ETA is prepared in accordance with the European Evaluation Document-DEE, which covers the product and intended uses. The ETA is the document that makes it possible the Declaration of Performance and the CE marking.
Please contact our technical department for information on other types of systems.
INTEGRA-KEY
HIDDEN FIXING SYSTEM KEIL
In hidden systems, as indicated by the name itself, the anchoring used to secure the porcelain parts to the structure are not visible from outside.
For this, the porcelain tiles of ALCALAGRES are mechanised on their rear face by means of undercut drilling where the suspension hooks, made of extruded aluminium, are anchored with KEIL anchors. These hooks are also anchored into the horizontal support section.
In this system, the hook and anchor are installed to the rear of the ceramic parts and are placed on the aluminium fixtures on the façade of the building. Any of the ceramic components of any part of the façade may be easily adjusted or replaced.
European standards
General: Aluminium and structure
EN 12020 (1÷2) – Aluminium and aluminium alloys – Extruded precision profiles in alloys EN AW-6060 and EN AW-6063.
EN 755 (1÷9)– Aluminium and aluminium alloys – Extruded rod/bar, tube and profiles.
EN 573 (1÷3) – Aluminium and aluminium alloys – Chemical composition and form of wrought products.
EN 15088 – Aluminium and aluminium alloys – Structural products for construction works – Technical conditions for inspection and delivery.
EN 1990 Eurocode – Basis of structural design.
EN 1991 Eurocode 1 – Actions on structures.
EN 1998 Eurocode 8 – Design of structures for earthquake resistance.
EN 1999 Eurocode 9 – Design of aluminium structures.
Ventilated façade systems
ETAG 034, part 1 – Kits for external wall claddings, Part I: Ventilated cladding kits comprising cladding components and associated fixings.
ETAG 034, part 2 – Kits for external wall claddings, Part II: Cladding kits comprising cladding components, associated fixings, subframe and possible insulation layer.
CWCT Standard for Systemized Building Envelopes.
EN 13830 – Curtain walling – Product standard.
EN ISO 6946 – Building components and building elements – Thermal resistance and thermal transmittance – Calculation method.
EN ISO 10211 – Thermal bridges in building construction – Heat flows and surface temperatures – Detailed calculations.
EN ISO 14683 – Thermal bridges in building construction – Linear thermal transmittance – Simplified methods and default values.
EN 13116 – Curtain walling – Resistance to wind load – Performance requirements.
EN 12179 – Curtain walling – Resistance to wind load – Test method.
EN 14019 – Curtain Walling – Impact resistance – Performance requirements.
EN ISO 10140 – Acoustics – Laboratory measurement of sound insulation of building elements.
EN 20140 – Acoustics – Measurement of sound insulation in buildings and of building elements.
EN ISO 717-1 – Acoustics – Rating of sound insulation in buildings and of building elements – Part 1: Airborne sound insulation.