Envelopes in Architecture (A4113)

Envelopes in Architecture (A4113) Designing holistic envelopes for contemporary buildings

Silvia Prandelli, Werner Sobek New York

A4113 ENVELOPES IN ARCHITECTURE - FALL 2016

2

Supply chain for holistic facades

3

Sys

tem

s

Door systems

Dynamic facades

Glass floors

Green facades

Media Facades

Mesh System

Multiple skins

Panelized systems

Rainscreen facades

Structural glass/Cable

Shading systems

Stick/Unitized systems

4

Curtain wall facades

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What are the components of a façade system?

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Glass

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Glass Types

Base Glass (float glass)

Heat Treated Glass

Laminated Glass

Insulating Glass

Fire Rated Glass

Burglar Resistant Glass

Sound Protection Glass

Decorative Glass

Curved Glass

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Base Glass (Float Glass)

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3500 BC Glass Making: Man-made glass objects, mainly non-transparent glass beads, finds in

Egypt and Eastern Mesopotamia

1500 BC Early hollow glass production: Evidence of the origins of the hollow glass

industry, finds in Egypt

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27 BC - 14 AD Glass Blowing: Discovery of glassblowing, attributed to Syrian craftsmen from the Sidon-

Babylon area.

> The blowing process has changed very little since then.

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Flat Glass Blown sheet

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15th century Lead Crystal Glass: During the 15th century in Venice, the first clear glass called cristallo

was invented.

In 1675, glassmaker George Ravenscroft invented lead crystal glass by adding lead oxide to

Venetian glass.

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16th century Sheet Glass: Larger sheets of glass were made by blowing large cylinders which were

cut open and flattened, then cut into panes

19th century Sheet Glass: The first advances in automating glass manufacturing were patented in

1848 by Henry Bessemer, an English engineer. His system produced a continuous ribbon of flat glass by

forming the ribbon between rollers.

20th century Sheet Glass: On March 25, 1902, Irving W Colburn patented the sheet glass drawing

machine, making the mass production of glass for windows possible.

20th century Sheet Glass: The first real innovation came in 1905 when a Belgian named Fourcault

managed to vertically draw a continuous sheet of glass of a consistent width from the molten tank.

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Flat Glass Bessemer Method

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Flat Glass Drawn Glass

Fourcault Process Colburn-Owens Process

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20th century Modern Sheet Glass:

1953 and 1957, Sir Alastair Pilkington and Kenneth Bickerstaff of the UK's Pilkington Brothers developed the

first successful commercial application

• for forming a continuous ribbon of glass

• using a molten tin bath on which the molten glass flows unhindered under the influence of gravity

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Float Glass Float Process

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Stage 1: Melting and refining

Fine-grained ingredients, closely controlled for quality, are

mixed to make a batch, which flows into the furnace which

is heated to 1500 ºC. Float today makes glass of near

optical quality. Several processes - melting, refining,

homogenizing – take place simultaneously in the 2,000

tones of molten glass in the furnace. They occur in

separate zones in a complex glass flow driven by high

temperatures, as the diagram shows. It adds up to a

continuous melting process, lasting as long as 50 hours,

that delivers glass at 1,100oC, free from inclusions and

bubbles, smoothly and continuously to the float bath.

The melting process is key to glass quality; and

compositions can be modified to change the

properties of the finished product.

Stage 2: Float bath

Glass from the melter flows gently over a refractory

spout on to the mirror-like surface of molten tin,

starting at 1,100ºC and leaving the float bath as a

solid ribbon at 600ºC.

The principle of float glass is unchanged from the

1950s. But the product has changed dramatically:

• from a single equilibrium thickness of 6.8mm to a

range from sub-millimeter to 25mm;

• from a ribbon frequently marred by inclusions,

bubbles and striations to almost optical perfection.

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Float Glass Coating

Stage 3: Coating

Coatings that make profound changes in optical properties can be applied by advanced high temperature

technology to the cooling ribbon of glass.

On-line chemical vapor deposition (CVD) of coatings is the most

significant advance in the float process since it was invented. CVD can be used to lay down a variety of

coatings, less than a micron thick, to reflect visible and infrared wavelengths, for instance.

Multiple coatings can be deposited in the few seconds available as the glass ribbon flows beneath the coaters. Further

development of the CVD process may well replace changes in composition as the principal way of varying the

optical properties of float glass.

Soft coating

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Float Glass Annealing

Stage 4: Annealing

Despite the tranquility with which float glass is formed,

considerable stresses are developed in the ribbon as it cools.

Too much stress and the glass will break beneath the cutter.

The picture shows stresses through the ribbon, revealed by

polarized light.

To relieve these stresses the ribbon undergoes heat-treatment

in a long furnace known as a lehr. Temperatures are closely

controlled both along and across the ribbon.

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Float Glass Inspection

Stage 5: Inspection

The float process is renowned for making perfectly flat, flaw-free glass. But to ensure the highest quality,

inspection takes place at every stage.

Occasionally a bubble is not removed during refining, a sand grain refuses to melt, a tremor in the tin puts ripples into the

glass ribbon. Automated on-line inspection does two things. It reveals process faults upstream that can be corrected. And it

enables computers downstream to steer cutters round flaws.

Inspection technology now allows more than 100 million measurements a second to be made across the ribbon, locating

flaws the unaided eye would be unable to see. The data drives 'intelligent‘ cutters, further improving product quality to the

customer.

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Float Glass Cutting

Stage 6: Cutting to order

Diamond wheels trim off selvedge - stressed edges - and

cut the ribbon to size dictated by computer.

Float glass is sold by the square meter.

Computers translate customers' requirements into

patterns of cuts designed to minimize wastage.

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Heat Treated Glass

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Heat Treatment

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Heat Treatment Tempered Glass

Thermally Fully Tempered Glass:

Generally speaking, “Toughened glass’ is about 4 – 5 times

stronger than its non-toughened equivalent.

Minimum thickness of glass is 3 mm.

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Heat Treatment Tempered Glass

Tempered

potassium

sodium

Chemically Tempered Glass:

When glasses are dipped into a bath with melted

potassium salt at a temperature above 380ºC, an

exchange takes place between the potassium ions

in the salt and the sodium ions on the surface of

the glass.

Chemical tempering should be considered in the

following situations:

• When glass thickness is less than 2.5mm

• Where glass with complex bending or

dimensional characteristics cannot be tempered

with thermal tempering.

Chemical tempering can be used on previously

curved glass, and also on glass that is less than 2

mm thick.

The shape of the glass sheet will not be modified

during tempering, so perfectly coupled sheets can

be obtained during PVB lamination.

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Heat Treatment Brakeage Pattern

Toughened or

Fully Tempered

Heat Strengthened

Float

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Float Glass

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Toughened or Fully Tempered Glass

Heat Strengthened Glass

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Laminated Glass

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Laminated Glass

In 1903, French chemist Edouard Benedictus

accidentally broke a bottle of cellulose acetate in his

laboratory.

As a result, he discovered that the cellulose, upon

hardening, held the fragments of glass together. This

subsequently led to the use of cellulose as a binding

agent in the glass laminating process.

A Saint-Gobain patent of the process followed in

1910. Further development by DuPont and

Monsanto led to the use of laminated windscreens in

cars after the second world war.

• safety

• security

• sound control

• solar energy performance

• ultraviolet radiation protection

• hurricane, earthquake and bomb blast

• Performance?

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Laminated Glass Process

Technical data Minimum glass size 250 x 400 mm

Maximum glass size 3300 x 9000

mm

Glass types

• Float glass, also with the

latest coatings

• Tempered and heat

strengthened glass

Laminating interlayers

• PVB

• EVA

• SGP (SentryGlas®plus)

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Laminated Glass Infill

PVB, SGP,…

PVB, SGP,…

Glass Pane

Infill

Glass Pane

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Laminated Glass Interlayer

1. Butacite® polyvinyl butyral interlayer (PVB) has

been continuously improved over the past 67

years from its inception as the preferred material

for safety glass. It has established all of the

advantages of laminated glass: Safety and

security, sound dampening; ability to offer solar

control for energy savings; protection of interiors

from fading; and added beauty.

2. SentryGlas®Plus interlayer (SGP) for laminated

safety glazing is the latest innovation in DuPont’s

family of glass laminating products. It extends

the performance of laminated glass beyond

current technologies. SentryGlas® Plus

Interlayer offers five times the tear strength and

100 times the rigidity of conventional PVB

interlayer. Because of its added strength, clarity,

durability, fabrication and installation ease, it is

an excellent candidate for demanding

applications in the architectural market place. It

can offer improved ballistic protection or thinner

constructions than are now possible with

conventional laminated glass.

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Laminated Glass Comparison

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Insulating Glass

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Insulating Glass

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Insulating Glass

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Insulating Glass

Hermetically

sealed

insulated glass

units are

fabricated with

dual seals

using

continuous

spacers for

maximum

performance

and longevity.

This

combination

allows to offer

windows with a

standard 10-12

year warranty

against seal

failure.

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Glass sizes

Typical manufacturing limits in the US are governed by the demand of the residential market:

•Maximum panel size 102” x 144”

•Minimum/maximum thickness 6/10mm

Oversized glass is available with this US suppliers:

•Cristacurva

•AGNORA

•AGC

•Rochester Insulated glass

•Glass design Concepts

Oversized glass is available with this EU suppliers:

•BGT

•Cricursa

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Glass sizes

FRITTING LAMINATING COATING TEMPERING

Supplier

Maximum

Width (in)

Maximum

Height (in)

Maximum

Width (in)

Maximum

Height (in)

Maximum

Width (in)

Maximum

Height (in)

Maximum

Width (in)

Maximum

Height (in)

AGNORA Canada

84 240 130 300 130 240 130 275

Guardian US

84 160 96 180 102 144(168*) 84 (96*) 160

Cristacurva Mexico/US

94 240 118 240 130 204 118 240

Viracon US

84 165 84 165 84 147(165*) 96 165

AGC/Interpane

US/EU 60 120 84 144 84 (126)** 144(236)** 84 144

BGT EU

112 236 106 354 Any coating can be

supplied to BGT for

processing 112 236

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Fire Rated Glass

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Fire Rated Glass Fire Performance Classifications

E=Stability

INTEGRITY

Glazing products to contain smoke and

flames

EW=Stability + Radiation Reduction

INTERGRITY & RADIATION

REDUCTION

Glazing Products to reduce radiant

heat transfer

INTEGRITY & TEMPERATURE

INSULATION

EI=Stability + Temperature Insulation

Glazing Products providing a barrier to

radiant and conducted heat transfer

Fire Rated Glass is evaluated

as a component of a complete

fire resistive Assembly:

• Glass

• Frame

• Door

• Hardware

• Gasket & Seals

• Anchoring

• Installation

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Fire Rated Glass Types

Allowable Temp

increase

140º K in the

middle

180º K at one

place

Foamed interlayer

Broken or melted

glass

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Fire Rated Glass Certified Sizes

Glass width (mm) Glass width (mm)

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Fire Rated Glass Fully Glazed

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Bullet Resistant Glass

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$$$$

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Decorative Glass

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Decorative glass

Different glass manufacturers can offer decorative glass solutions

•Fritting/ Double fritting

•Back painted

•Digital printing

•Colored/fabric interlayer

•Patterned glass

•Dichroic glass

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Fritting

Typical manufacturing limits:

•Standard maximum panel size 84”x65” (2100 x 4100mm). Oversized glass up to 84”x240” (2100x6100mm)

•Minimum distance apart and width of lines is 3mm

•Minimum diameter of dot or hole is 2mm

•Minimum distance between dots or holes is 1.5mm

•White, black and grey ceramic ink are the most commonly used colors

•Non-standard color availability should be checked with suppliers on a case by case basis

•Range may be limited to one color per glass

10 mm

3 mm apart

2 mm diameter

2 mm apart

3.6 mm diameter

1.5 mm apart

3.6 mm diameter

1.5 mm apart

2 mm diameter

2 mm apart

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Fritting

IAC building ,New York

• Fritted glass on SSG unitized system

• White fritting at 100% on the spandrel panel, fading at 0% at eye level

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Fritting

Cooper Square Hotel, US

• Fritted glass on unitized system

• Each elevation has its own glass pattern

• White fritted glass is mixed with perforated aluminum panels

Solid metal panels mounted on units

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Fritting

Louis Vuitton, New York

• White fritted glass on solid wall with openings

• Fritting is uniform through the façade, except at the

shop windows where a transparent glass has been

used

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Fritting

Anchorage Museum Expansion, US

• Fritted mirrored glass on capped stick system

• Vertical stripes fritted pattern

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Fritting

Charlotte R. Bloomberg Children’s Center, Baltimore

• Fritted mirrored glass on capped stick system

• 30% fritting on low iron glass – custom pattern

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Fritting

Allianz HQ, Zurich

• Fritted glass on SSG unitized system and stick patch plate system to the ground floor

• 100% fritted framed panels to replicate the marble used on Mies van der Rohe's Barcelona

Pavilion

• Two colors per glass: composite layers of black and white fritting dots

• Curtains have been included into the double glazed unit

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Fritting

Low-e coating

Low-iron

laminated glass

Chrome

mirror dots

Grey dot frit

Solar control

coating

Monolithic

float glass

Elbphilharmonie, Hamburg

• Fritted curved glass on SSG unitized system-

• Double dotted fritting pattern and double coatings.

• Challenge in overlying the laminated front panel to match the

architectural pattern.

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Digital Printing

Different patterns and colours

Printed plastic interlayer can be supplied to glass processors for

laminating.

Typical manufacturing limits:

o Maximum panel size 60”x 144”. Oversized panels from EU up to 2400

mm x 5800 mm

o Different levels of transparency are achievable

o Different colors are possible

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Digital Printing

Icelandic Institute of Natural History

• Digitally printed interlayer in laminated glass: different

patterns are achievable with an higher resolution than

ceramic fritting

• More expensive compared to ceramic fritting

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Digital Printing

Harlem hospital

• Digitally printed glass, patterns will have higher resolution

compared with ceramic frit

• Glass supplied by GGI, NJ

• Standard and bespoke patterns available

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Interlayers

Different types of interlayer can be used including colored, fabric, metal and organic films > $$$ / longer supply

Metallic interlayer

Fabric interlayer

Vanceva interlayer

Organic interlayer (wood,silk)

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Interlayers

Yamaha building, Tokyo

• Glass with laminated interlayer made of gold dust manufactured locally.

• Cable net secondary structure for a lighter appearance.

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Patterned Glass

LASVIT LIQUIDKRISTAL

Maximum sizes105”x145”

OLIVIA BY JOEL BERMAN

Maximum sizes 53”x108”

PATTERNS BY JOEL BERMAN

Maximum sizes varies _ Compatibility with exterior use to be confirmed and dependant

on loading

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Patterned Glass

Vakko Center, Istanbul

• Patterned glass manufactured locally

• Curved shaped to increase glass strength where most necessary (at the bolt connections)

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Dichroic Glass

• Dichroic glass changes color as the viewer

moves in relation to the glass.

• The glass has a transparent color and a

reflective color, which will often be opposite

colors of the spectrum.

• Dichroic glass is an expensive product, but

the dichroic film that we also use is much

more economical.

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Curved Glass

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Curved Glass

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Curved Glass

Single curved

• Single curved process can be mechanized to be cost effective

• Single curved glass has tolerances similar to flat glass

• Coatings should be carefully selected depending on the radius of curvature, the direction of the curve

and the environmental requirements not to be readable or cause any visual distortions on the glass.

• A convex curvature may project the light away from the central point causing the reflected image to

be stretched out in all directions.

Double curved

• Double curved glass is available within selected glass suppliers across the globe.

• Minimum radia of curvature will be different from single curved glass.

• Where tempered glass is required for safety purposes or strenght chemical tempering might be

required if low radia are required.

Cold bent

• More cost effective compared to hot bent glass, single and double glazed panels are installed and

bent on site at room temperatures on a pre-curved secondary structure.

• Certain limitations exist for maximum imposed deflections to the panel. These are dependent on

panel sizes, glass thickness, glass retention system and load imposed onto the glass.

• Glass must be tempered to withstand higher stresses due to the imposed deflections.

• Specific calculations need to be carried out by the glass supplier on the selected glass build up to

confirm the warranty extent.

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Curved Glass

Single curved

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Curved Glass

Double curved

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Curved Glass

Cold Bent

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Curved Glass

Cold Bent

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Curved Glass

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Aluminum framing

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Aluminum extrusions

https://www.youtube.com/watch?v=vHkwq_2yY9E



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Aluminum finishes

Main finishes include:

• Chemical processes

• Anodizing

• Painted processes

• PPC (Polyester Powder Coating)

• PVDF (PolyVinyliDene Fluoride)

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Anodizing

Cleaning:

Alkaline and/or acid cleaners remove grease, and surface dirt.

Pre-Treatment:

Etching, Brightening

Anodizing:

The anodic film is built and combined with the metal by passing an electrical current through an acid

electrolyte bath in which the aluminum is immersed.

Coloring:

Coloring is achieved in one of four ways:

Electrolytic Coloring, Integral Coloring, Organic Dyeing and Interference Coloring

Sealing:

This process closes the pores in the anodic film, giving a surface resistant to staining, abrasion, and

color degradation.

Cleaning Pre-Treatment Anodizing Coloring Sealing

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Paints

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Curtain wall systems

Stick Curtain Wall Unitised Curtain Wall

ADVANTAGES DISADVANTAGES

+ Flexibility

+ Lower Cost

- Labour intensive

- Site Workmanship

- Outside Access

Req’d

ADVANTAGES DISADVANTAGES

+ Factory Quality

+ Fast Construction

+ No outside access

Req’d

- More Expensive

- Greater lead times

- Specialised supply

chain

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Stick System Curtain Wall

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Unitised System Curtain Wall

https://www.youtube.com/watch?v=kE2TsiCD3z

4#action=share

https://www.youtube.com/watch?v=kE2TsiCD3z4



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Limitations? 1

Reykjavik Opera House

Henning Larsen Architects

The Diana Center

Weiss/Manfredi

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1

Reykjavik Opera House

Henning Larsen Architects

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1

Reykjavik Opera House Henning Larsen Architects

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1

The Diana Center Weiss/Manfredi

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1

The Diana Center Weiss/Manfredi

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Limitations? 2

Oslo opera house Snohetta

Sydney Opera House Jørn Utzon

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2


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2

98


2

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2

100


2

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Limitations? 3

Disney Music Hall Frank Gehry

de Young Museum Herzog & de Meuron

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3

103


3

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3

105


3

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Budget costing for holistic facades

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Sys

tem

s

Door systems

Dynamic facades

Glass floors

Green facades

Media Facades

Mesh System

Multiple skins

Panelized systems

Rainscreen facades

Structural glass/Cable

Shading systems

Stick/Unitized systems

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Acrylic/Polycarbonate

Aluminum

Bronze Copper Brass Zinc

Brick/Terracotta/Ceramics

Concrete/GRC/Ductal

ETFE

Fabric

Glass

Plastic/GRP

Steel/Stainless/Titanium

Stone

Wood

Ma

teri

als

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A case study

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Cost Comparison for Roof Systems

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Aluminum Zinc Concrete/GRC/Ductal Carbon fiber/fiber reinforced

plastic

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Cladding Material Preliminary costs

Carbon-fiber Reinforced plastic 76$/ft2 (600€/m2)

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Glass-fiber reinforced plastic 40$/ft2 (315€/m2)

Additional cost for black finish

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Black glass-fiber reinforced/

UHPFRC Concrete 35$/ft2 (275€/m2)

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Stainless Steel 60$/ft2 (480€/m2)


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Aluminum 30$/ft2 (250€/m2)


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Carbon-fiber Reinforced plastic 76$/ft2 (600€/m2)

Glass-fiber reinforced plastic 40$/ft2 (315€/m2)


Black glass-fiber reinforced/

UHPFRC Concrete 35$/ft2 (275€/m2)

Stainless Steel 60$/ft2 (480€/m2)


Aluminum 30$/ft2 (250€/m2)


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Up next

September 22nd Tom Reiner - Critic Team #1 Structural Design

September 29th John Ivanoff - Critic Team #3 Environmental Requirements

October 6th Erik Verboon - Critic Team #2 Geometry Modelling

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See you next month!

Envelopes in Architecture (A4113)

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