WHY IS SO IMPORTANT ON MY FACADE PROJECTS!

The facade industry construction in the last years has evolved immensely in terms of complexity and modern technology. This fact leveled up the scenario of possibilities and façade geometries–only feasible with a professional, accurate and detailed design. In the end, it becomes a tremendous challenge.

Nowadays, through automated design (parametric and algorithmic) and digital fabrication, it is possible to have a complete façade 3D model on conceptual phase that will be detailed (cladding, glass, structural connections, HVAC, etc.) and tested before construction starts. The beginning of robotization and 3D printing is also part of this facade evolution and they will play an important role on new era.

The functionality, durability and stability of each project element depend on the accuracy and quality of the detailing during the analysis and design. Therefore, to achieve a reliable design is imperious detailing.

Detailing of the design model requires an interactive process developed by different team members, architects, engineers and manufacturers  with constantly updated and common detailed design information under Design & Build process.

The outputs of the detail design offer the opportunity to eliminate any possible discrepancies, errors and predict the building performance with accuracy (Airtightness, Solar Radiation, Energy Efficiency, etc.)

For weatherproofing design, the equally complex and standard solutions covering all the applications are rare.

If all the project elements were studied in detail, the advantages would be immeasurable and we could predict and solve any air, water and vapour issue in advance at drawing board. Below are some of the most important advantages of weatherproofing thematic.

• Predict a weather sealing difficulty between interfaces, curtain wall fixings, steel joints, façade perfurations, rainscreen cladding fixing and its irregular shapes.
• Define the exact product/solution for each location where all the project constraints were taken into consideration.
• Predict compatibility problems between different materials.
• Guarantee the design performance and extending the building life span.
• Increase the off-site fabrication works.
• Turns the application more clear for all the parties. Highlight the most difficult works that require special attention, allowing for the production of detail project documents (Method Statements, Application 3D drawings, Specifications).

However, we would like to highlight that to accomplish the above, it is imperative that the waterproofing design starts on the conceptual facade building design and go deeply into details on a later design stage. Synergy between conceptual and detail design is vital to a successful building.

Another change on facade building projects was the design & construction process. Previously, the contractor and manufacturer were involved after construction tender to simplify the design and make it feasible. Currently the contractor and manufacturer are invited to develop a solution within budget and schedule before tender stage. This change allowed all the process after tender to besped up, more detailed, more accurate and more predictable.

In conclusion, detailing becomes essential nowadays; it turns the process less costly and within the project time frame.

“The difference between something good and something great is attention to detail.” Charles Swindoll

PRACTICAL CASE

Project Name/Location: Royal Wharf & Gresham Street, London

Client: Martifer

In this practical case, we would like to present two projects: Royal Wharf and Gresham Street in London. This is because we consider them to be well detailed in weatherproofing thematic.

Initially, all the project requirements, concept drawings and specifications were collected and studied in detail. Also at this stage, the project goal was defined in terms of weatherproofing design: wind, water, vapour and air permeance. In addition to the technical specs, it was also discussed under another relevant technical aspect–Fire.

Later, all the project interfaces between aluminium, concrete slabs, rainscreen cladding and curtain wall were reviewed in detail. Also, it was pointed out on a list of materials involved on these locations for further compatibility technical assessment. At this stage, meetings and conference calls were done in order to clearly understand the projects.

Afterward, it was presented as the concept design with 3 alternative options for the main products. In parallel, a comparison chart was made to highlight the pros/cons of each solution.

Overcome this phase and the detail design has started. It was then collected as the products sample that will be in contact with weatherproofing products for further compatibility tests (adhesion, cohesion and climate chamber).

In parallel, it was detailed to be the interfaces between curtain wall, rainscreen cladding and concrete super structure. The same was done for all the membrane (Effisus Ecofacade, Effisus Breather and Effisus VCL Vap X) fixing, overlaps and connections between them.

After reception of the compatibility test results, the full picture is made clear. Based on this information, all the accessories were designed in detail (adhesives, sealants, water sealing air and vapour tapes, façade perforations sealing solution, etc.).

All the detailed design was shared, discussed and approved in detail between façade applicator, main contractor, architect and Effisus design/production.

The next phase was provided, setting out the project execution:

1. Project Method Statements – Method of Installation;
2. Project Specifications;
3. Project Documents for Site Training.

All the aspects related to delivery schedule, site conditions (application temperatures, humidity, rain, wind, etc.) were taken into consideration.

During the construction phase, several technical site trainings and inspection were carried out in order to confirm that the detail design was well applied. And if there was any project modification, the solution planned was properly replaced. This is a mandatory quality procedure to attest the durability, stability and efficiency of the final project.

In conclusion, the detail crossed over the entire project schedule from conceptual, passing through detail design and finishing at site installation. The projects outputs are considerable valuable.

On a final note, all the parties involved took considerable benefit. Therefore, without doubt, detail will become a standard practice of the new era facade projects.

“It is not the beauty of a building you should look at; it’s the construction of the foundation that will stand the test of time.” David Allan Coe

A – GUTTERS AND ITS IMPACT ON THE INTEGRITY OF A BUILDING

Gutters have one function: collect rain running off a roof and channel it, with proper slopes, to downspouts that carry the rain water to the ground and away from the façade and foundations. Even though they’re “out of sight and most of the times out of mind” for the majority of the time, gutters actually play a huge role in the structural integrity of any building.

A clogged or leaking gutter can represent serious problems such as structural damages or health issues. Despite of this, most of the times it can be too easy to forget about them until something goes wrong – and at this stage the cost of any repair would be much higher than if a regular maintenance program was installed and problems were detected at an earlier stage. Experience show us that in most of the cases gutters suffer a quick deterioration, much quicker that the roof and the remaining of the building, requiring repairs or integral renovations in order to maintain its function for as long as the building service life.

When defining solutions to avoid the need of gutter repairs, it’s important to remember one simple fact: clean gutters are far less susceptible to deterioration than blocked gutters. In fact, the two most common gutter related topics facing building owners are blockages in the gutter itself, and blockages in the downpipes. These blockages are often caused by debris like fallen leaves, moss and other developed vegetation, and (in some undesirable cases) dead animals.

B – COMMOM GUTTER PROBLEMS

An Inadequate Gutter System

The specification and installation of a proper gutter system is key in order to avoid future problems. The choice of design, base material, and other particularities of the final solution, should take in consideration the project location, the gutter area of influence, and other aspects such as the existence of trees on the surrounding, otherwise it will not address properly the challenges to which it will be submitted during its lifetime, and will most probably fail prematurely. Improper location of downspouts, or not having enough of them, can lead to standing water and overflows during heavy rains. Standing water will cause among other: erosion, rust, siding damage and damage to the gutter support system and roof from excess weight.

Inadequately Pitched Gutters

In order for water to flow properly, gutters need to be angled accurately. The slope should sit at the correct angle. Possibility of standing water should be completely avoided – standing water will promote a quicker deterioration of the gutter – no matter of which is the gutter base material.

Gutters not Draining or Clogged Gutters

The most common problem we see with gutters is clogging. When gutters become clogged, they can’t drain properly and can start to overflow during rainstorms. When the water can’t flow properly, it can start to cause problems. That’s why it’s so important to keep gutters clean — the water must to be able to flow through easily. Clogged gutters cause water to stand and stagnate and often overflow. As we have seen before possible consequences of stagnate water are among others: erosion, rust, roof damage, siding damage, and damage to the gutter and roof support system from excess weight.

Leaking gutter joints

Leaking gutter joints are another common problem: in fact, leaking gutters are one of the most common causes of isolated damp in building’s interiors. Leaks can occur when bits of debris get caught in the joints, or simply from general wear and tear. As in any situation joints are critical points, and special care should be taken when defining solutions for joints or with its maintenance.

Damaged Gutters

Gutter damage can happen by various causes – the most common being the weather. During a heavy rainstorm or windstorm, gutters can be knocked down or damaged. In this case, it might be necessary fixing them, or to replace certain sections. In this case, there’s not much one can do to prevent it, other than making sure your gutters are properly installed and aren’t already loose.

Sagging Gutters

For clogged gutters with debris, moss, and standing water, overflowing water isn’t the only problem. The extra weight can also cause gutters to sag. This is usually caused by loose hangers or hangers too far apart, which pull out when they can’t hold the extra weight. This can usually be fixed by simply tightening the screws again, or installing new ones, ensuring the necessary mechanical resistance.

Corrosion

Corrosion on metal gutters will be a consequence for any of the problems identified earlier. It can also appear due to other causes: gutter sections are typically bolted together and this is where the problems start. Fabrication and welding processes destroy the gutter coating requiring local post manufacturing treatment to restore corrosion resistance – most of the times this is not done properly and corrosion will start here. Also gutter systems are usually the first part of the building envelope to be installed after the construction of the frame. The result is that the gutter is used as an access way and / or storage area during the roof construction causing surface damage and wear even before building use started – at these points the material will become fragile and there is an increased probability for corrosion to appear. If left untreated, corrosion continues – it will continually eat into the surface, the exposed cut edge of the sections and the fixings.

Failures in any system will always become evident at its weakest point, which in a gutter system is going to be the joints and changes of direction. Once corrosion has set in and a joint has started to fail, building movement, thermal expansion, freeze/thaw will further exasperate the problem. Once a joint has opened up it can be difficult to fix because of the build-up of dirt, debris and moisture around the opening.

C – MAINTENANCE IS KEY

Industrial or residential rainwater gutter systems are designed to give many years of reliable service but to achieve this, a regular inspection and routine maintenance program should be undertaken. Prevention is always better than cure and establishing a regular maintenance program is the most effective way of ensuring that serious problems do not arise.

In the course of collecting water, open rain gutters also collect leaves, acorns, pine needles, and other debris which can cause clogs anywhere in the gutter itself or sometimes in the downspouts. In dry conditions clogged gutters are a fire hazard; and during heavy rains, clogged gutters and downspouts can cause rainwater to overflow, potentially causing substantial damage to the building. To keep gutters free of debris, a maintenance program has to be defined. This might vary depending on the climate, but usually, it’s a good idea to maintain at least a twice a year program – clear them out in late fall after most of the leaves have fallen, and in spring to make sure they’re clear for some showers. On locations where the existence of particularities that contribute to a higher probability and quantity of debris inside the gutter, such as for example, the existence of many trees on the surrounding area or the existence of seagulls frequently on the roof, it may be necessary to clean the gutter more frequently.

First of all it is necessary to define the periodicity of the maintenance program depending on the building specificities. Secondly, it is important to define clearly a checklist for any maintenance operation. All maintenance operations should consider at least the following tasks:

• Clean leaves and debris from the inside of gutters
• Clean all downspouts, elbows, and joints

In addition to this, and depending on the project and gutter age, the following tasks should be considered:

• Verify all gutter joints
• Verify screws and all fixing / holding elements
• Look for excessive movement and re-secur or re-pitch when necessary
• Look for parts and accessories that may need to be replaced in order to keep them functioning properly
• Install extra screws or hidden brackets to extend the life of the system a little longer
• Look for signs of rust and address properly these areas

D – WHEN REPAIRS OR RENOVATION ARE REQUIRED: SOLUTIONS

When simply due to age, or due to more specific causes such us improper maintenance, it might came to a scenario where a more deep intervention has to be considered: it might be the case for an intervention with focus only on the gutter joints, or some other specific points, or of an integral renovation of the gutter.

Typical solutions

The most common used solution for gutter repairs or gutter renovations are liquid applied solutions. The most frequent difficulties associated with such solutions are its limitation to handle movement – and movement on gutters can be quite significant. Usually such solutions, in order to function properly, need to be applied carefully: the correct thickness of each layer should be respected. The problem is that on such constrained area as a gutter, it is quite hard to assure that a specific thickness of material is being applied, and to maintain this same thickness at all areas where the material is being applied. Typically, if the thickness applied is higher that the recommended, the elasticity of the material will not be able to absorb the expected movement and it will fail; if the thickness of the material is lower than the recommended it will not have the necessary resistance and it will fail prematurely.

If we analyze the offer for non-liquid applied solutions, we can find some solutions on the market with membranes, that are specifically promoted for gutter waterproofing. With membrane solutions usually the quality of the material and its performance is easier to control as this is factory controlled. The downspout of such solutions is that they usually require specialized tools for installation and very specialized labor. As conclusion we may say that there is a lack on the market for efficient, sustainable and easy to install solutions for gutter repairs or renovation.

The Effisus Solutions – A step further

1 – Effisus Titegutter3 – Integrated system for sealing gutter joints

Effisus Titegutter3 is the innovative integrated system for sealing gutter joints. The system’s efficiency and added value are guaranteed by its three waterproofing levels. Their properties give it the capacity of accommodating joint movements originated by structural or thermal expansion.

The system solves, in an efficient and sustainable manner, the common gutter joint sealing job. Due to its speed and ease of application, the job can be done without the need of specialized labour and its completion time is largely reduced. With Effisus Titegutter3, one can reduce the probability of human error, reduce application time and assure gutters’ waterproofness.

Effisus Titegutter3 – Characteristics:

• Exceptional adhesiveness
• Increased ageing resistance
• Application temperature from -5ºC to +35ºC
• Fully customisable
• Permanently flexible
• Resistant to structural and thermal expansion
• No need for soldering or heavy machinery

Level 1 Effisus 2Bond DS Tape

• 100% waterproof and both air and moisture tight
• Active sealants with exceptional adhesiveness
• Double-sided adhesive tape

Level 2 Effisus Ecofacade Membrane and Effisus Bonding KF+P Adhesive

• Resistant to UVs and extreme temperature variations
• Recyclable and with an elongation of up to 300%
• Tough, puncture resistant and 100% waterproof

Level 3 Effisus Bonding KF+P Adhesive

• Permanently flexible
• UV resistant

2 – Effisus Alltitegutter – Waterproofing liner for gutter repairs

Effisus AllTiteGutter is a waterproofing membrane for the repair of deteriorated gutters. It is a very flexible and self-adhesive EPDM waterproofing membrane, featuring state of the art technology, that brings everlasting sealing security to the most critical parts of the roof – gutters.

A gutter is usually the first area of a roof to get seriously damaged. At the same time it is an area that is quite often difficult to repair with traditional methods or materials – there are limitations of spacing to work, sharp edges, high movements, etc. Effisus AllTiteGutter is the ideal solution to overcome such challenges and assure a waterproofing gutter, with an easy and quick installation method. Details are quickly solved in conjugation with the Effisus Bond FT Tape.

Effisus AllTiteGutter – Characteristics:

• Self-adhesive EPDM membrane
• No limitations on dimensions
• Fully customisable
• Expected service life of 50 years
• Service temperature from -30ºC to +120ºC
• Permanently flexible
• Unaffected by permanent contact with water
• Resistant to structural and thermal expansion
• No need for soldering or heavy machinery

QUICKER, EASIER & SAFER

YES, WE CAN MAKE A DIFFERENCE ON YOUR FACADE BUILDINGS PROJECTS!

At the present time, the competition between companies is stronger and extremely difficult! For those who are in the game becomes a challenge to find space for innovation and differentiation in a busy market rated by low prices or price orientated.

Obviously, the result of the above paradigm is standardization! Standardization on organizations, business models, industry, project, and products. Therefore if a client or a project requires a non-standard approach the current market provides limited solutions and always involving a big amount of time and money.

We believe that the breakthrough is grounded in knowledge, experience, and expertise, well known as, Consulting.

Taking the above as valid it is almost impossible to have a full domain of all the areas! It becomes essential to find highly skilled professionals consultancy in some specific areas.

On facade, weatherproofing thematic is crucial Consulting. Taking into consideration each project constraints it is always a set back to find the best facade solution for each project.

It is therefore essential to listen to the client needs and fully understand the requirement in detail. In this phase should be auscultated the below:

• Project Technical requirements;
• Materials involved and compatibilities between them;
• Methodology – Method Statement;
• Site conditions;
• Project Schedule;
• Client Goals;
• Transportation.

To acquire all the information above it is therefore crucial to fully analyze all the inputs and how they interact with other variables and identify existing incompatibilities versus accurate or possible solutions.

The thorough job should be done with a conceptual/preliminary design. At this stage is important to have flexibility and technical knowledge in order to find the most accurate and effective solution that suits the project goal. Sometimes the solution can be an alternative or a complement of standard and conventional solutions.

The above non-standard approach is supported by compatibility tests, product technical analysis and feasibility evaluation into the project methodology, site conditions, project schedule and other constraints in order to technically validate or eliminate each solution.

It is important to finalized the technical assessment by presenting them in details correlating to each tangible solution in relation to the project inputs, highlighting the pros/cons for further discussion.

Finally, your consulting should pursue a solution agreement with the client and only if this meets consensus we move on for the next phase.

Mr. Ignacio Fernandez
ARUP Associate Director | Facade Design & Technology Specialist

“Detailing for building envelopes is becoming trickier these days. We need to balance more exigent and contradicting requirements as building science progresses.

An especially difficult area is the contact zone between facade elements where we are, by definition, “out of the catalogue. Consulting in the business world may not always have a good reputation, however it is key to identify and solve potential issues where separate systems get in contact, or when one system crosses over another. These points may be the perimeter of a window, the joints of modular construction at the cladding, external beams or cantilever penetrations, roof to parapet to wall clashes, etc.

Here is where knowledge and experience are most valuable. After all, water, dampness, vapor and air can pass through very tiny joints! At these points a consultancy-based, open minded approach is essential.”

PRACTICAL CASE

FACADE PERFORATIONS

As a Consulting example, we have frequently facade penetrations that need lose technical analysis in terms of weatherproofing thematic.

I many facade building projects the penetrations through a rain screen cladding, flashing sheets (or other) are not part of the project dealing and therefore they are currently solved at the site without the time and proper step, leading to an inefficient solution and sometimes involving extra high costs not budgeted. The facade system scheme is always a different concept and it is almost difficult to have a standard solution that corresponds to each different project requirements.

Therefore a different non-standard approach is extremely required almost at the initial project phase.

Before any step, listening to the client needs is crucial. During the design of the facade perforations it is highly recommended to be acquired from the following aspects:

a) Quantity and Geometry of the facade perforations;
b) Method of Installation of all the facade elements/materials;
c) Architectural constraints;
d) Movements to be considered on the interface between the perforation and facade elements;
e) Watertighness/ Air/Wind facade requirements;
f) Compatibility analysis for the substrates and adhesion;
g) Site conditions: Temperature/Humidity/Wind;
h) Project Schedule.

It is possible to have plenty of solutions and the above information is relevant to define the next phase.

Consequently all the information collected has to be treated and studied in detail.

Below some pratical examples of different projects with a different non-standard solution:

a) Facade Coping Detail:
Perfuration: Steel H beam through facade flashing
Solution: Effisus Ecofacade Customized Mold (with open joint)

Project Requirement: Waterseal the steel beam perforation.

Project Contraints: Movements expected between elements. Wind and driving rain. Method of installation. Perforation geometry.

b) Facade Structural Rod Connection:
Perforation: Structural rod through facade curtain wall
Solution: Effisus Ecofacade Pre-Fabricated Piece

Project Requirement: Waterseal , Air/Vapour barrier of the structural connection perforation.

Project Constraints: Movements expected between elements. Method of installation.

c) Facade Balcony Detail
Perforation: Structural steel box through facade
Solution: Effisus Ecofacade Mould (with close joint)

Project Requirement: Waterseal the steel beam perforation.

Project Constraints: Movements expected between elements. Architectural design. Method of installation. Perforation geometry.

d) Facade/Roof Intersections
Perforation: Structural beam through facade windows flashing
Solution: Effisus Stopper

Project Requirement: Waterseal the steel beam perforations.

Project Constraints: Movements expected between elements. Wind and driving rain. Method of installation. Perforation geometry.

To conclude these analysis, it should be noted that Consulting is a key element to find several weatherproofing solutions for the facade perforations in order to achieve an efficient product that fulfills the project requirements, that always generates a value engineering always with cost saving for all the parties involved: Facade Contractor; Main Contractor; Architect, Developer, and End User.

A – Fastener / nail perforations on the building envelope – An inevitable need

A building’s envelope is the filter between the climate outside and the conditioned space inside and as such it has to ensure, among other functions, protection against water and air infiltrations. The number one rule to ensure a building’s enclosure watertightness and airtightness, is to ensure the continuity of the water and air control layer. While it may be easier to define the watertight and airtight solutions for the planer components, usually the bigger challenges arise at the connection areas of these planar components, or at points where these planar components need to be perforated or penetrated by the passage, or fixation, of singular construction elements, with fasteners or nails.

Fastener / nail penetrations should be analysed as early in the design stage as possible, as well as being specified in the construction documents. Prior to construction starting, all contractors with responsibilities in the building envelope will need to acknowledge the treatment of these penetration points. It is the responsibility of the installing contractor to properly identify all fasteners / nails or other associated components that will interface / penetrate the water or air barrier of the building envelope, and assure continuity of the assembly by properly sealing all of these penetration points.

The interfacing or penetration areas are the most common façade water and air leakage paths. Compromising the quality of a sealing solution for these areas means compromising the façade’s complete watertightness and airtightness.

The need for mechanical fasteners / nails to penetrate the finishing building envelope layers is inevitable. In this technical bulletin we will present the benefits of using the Effisus 2Bond DS solution to address this need and warranty its perfect sealing.

B – The status quo

Clearly at the moment the market does not address these points and the need to preconize and install a long-term sealing solutions properly. The most common solution will be to use silicones that shrink over time and no more assure any sealing capacity, or to simply trust on the fasteners / nails self-sealing capacity which, due to the continuous material movements, most of the times will not last long.
The pictures below show the most common scenarious seen on the roofs / facades around us.

C – Effisus 2Bond DS: the right solution

Effisus 2Bond DS is a bi-adhesive tape specifically developed for sealing nail / screw perforations. It is an active sealants based adhesive, sandwiched between two protective and removable layers, sticky on bots sides and in all its surface, completely adhering to the surfaces in which its gets in contact with – it will totally embrace any nail / fastener that goes trough it. It can be folded or rolled into a bead if additional thickness is required, and it can be used as a moldable sealant to fill gaps and holes.

It has an extremely adhesion strength to most common construction materials, such as metals, concrete, plastics, etc.

HOW IT WILL SHAPE THE FACADE BUILDING PROJECTS!

Nowadays facades buildings projects become more and more demanding and are constantly pushing the boundaries. Currently the façade design is challenged to deliver unique aesthetic façade (curved, twisted, transparent, etc.), energy efficient to fit into an inflexible budget/schedule. Most of the cases this is a high challenge!

Therefore a clear and efficient communication becomes mandatory through all the design stages and fabrication process, between all the parties (Architect, Facade Consultant, Producer, Facade Applicator and End Users) and through all the project phases (Conceptual, Preliminary, Detail Design, Tender, Testing, Fabrication, Installation and Maintenance).

Also full domain of all expertise areas is almost impossible!

Take into consideration the above complexity, partner relationship increases the efficiency to find the better solution!

What is a real Partnership?

Nowadays is difficult to define Partnership and what the guidelines are. In our opinion Partnership in weatherproofing thematic means a lot but essentially is based in a simple concept defined below:

We need to bring an added value offer so we make true our partner desire!

Based on our experience as a weatherproofing specialist, partnership is a key factor to support façade buildings projects and find the solution for a giant puzzle of different, individual components and materials part of a building!

Project Constraints:

• Architectural Design;
• Façade Design Requirements;
• Climate Loads: Solar Light/ Water/Air/Moisture;
• Application and Fabrication Process;
• Project Schedule;
• Site Conditions;
• Experience Factors;
• Project Weather Conditions;
• Transportation Logistics;
• Government & Local building Regulations

What are the advantages of a real Partnership?

Easily enable both parties to overcome the project constraints and built an added value solution on each project/situation. In addition to this, below are highlighted the main advantages based on EFFISUS practice:

• Service Quality;
• Continuous Support – Concept design until life span of product;
• Availability – Everything at everywhere, whenever is required;
• Non-Standard solutions never considered before;
• Mutual knowledge and awareness of partner company skills/defects potentiate the proposal/solution efficiency;
• Timeless;
• Competiveness;
• Innovation;
• Finance.

Another fact that is a must in Partnership relations is when a partner has a critical problem episode and the other partner instantly predispose to solve the episode in contrast of moving away from the responsibility.

“People don´t care how much you know until they know how much you care”

Theodore Roosevelt

Below a graphic that shows a good example of a partnership at weatherproofing thematic:

Based on above is possible to assess that, as much as, the both parties are involved and have more interactions during the project time (axis X) the project design/solution is valued (axis Y).

In conclusion is clear the high benefits of a Partnership and the importance of each partner role in all the project phases in order to achieve Excellence practice on Facade Weatherproof thematic at each project.

Mr. Ignacio Fernandez
ARUP Associate Director | Façade Design & Technology Specialist

“Achieving real partnership in design and construction projects is the Holy Grail of our practice. As Architects, Engineers, Suppliers and Contractors, we are all sitting a round table of knowledge, experience and responsibility. We are all expected to play a role, say our word and listen to the others. When one of the parties tries to skip its responsibility, or hide away from the problems (consciously or not), the balance is destroyed and the result is much poorer.

The real client of the facades is the end user. Insufficient water and air tightness is a clear fail that does not go unnoticed, and it affects everyone involved in the process. The best way to avoid issues with permeability in facades is to have good partners, actively listen to them, and learn on every project. The right outcome is usually a combination of three values: a good design of details and interfaces, select the right materials (properly tested in advance), and think on buildability before installation starts.

Let’s face it: water always finds a way when the solution is not good enough…”

PRACTICAL CASE

Primarily, it was listened the client needs (1) in conjunction with the project constraints. All the project phases are important but this was crucial to characterize the project for further technical study & assessment.

Therefore it was collected the below inputs from client:

a) Necessity to find a solution to seal the precast pre-fabricated façade;
b) Multiple types and dimensions for precast panels & windows;
c) Project quantity;
d) Pre-Fabricated solution is mandatory since the application at site has limited access with high impact on costs & assembly methodology;
e) Minimal structural movements are expected on windows interfaces;
f) Minimal movements are expected during the lorry transportation;
g) Project schedule.

Take into consideration the above it was studied in detail how, where and how much the dimensions varies in all the windows schemes. In parallel in was started the draft of some solutions options and shared with client for further discussion (2).

The general concept was accepted by client and some inputs were added on preliminary design. In sequence of this interactions between the both design teams Effisus/Client it was achieved the basis for the next step: detail design (3)

It was approved a solution of Pre-fabricated Ecofacade individual pieces made specifically for the project with customized shape and dimensions. This pieces were assembled and combined as per windows type at client facilities. In combination with above it was held several meetings with the Architect/Developer to participate and to be aligned on solution approved.

Consequently it was developed the detailed design (3) for the entire weatherproofing solution. It was identified that the solution shape for upper/bottom corners were in all the windows types the same. However for windows bottom central part (precast sill) it was completely different as there were several different shapes and dimensions. The solution found was to cut/split the central part by pieces and so was possible to achieve different combinations and arrangements.

This solution was the key for entire project!

Below a project detail design excerpt from window bottom for a specific window type. It was made detail drawings per each windows type in order to all the parties involved understand the installation methodology.

The detail design was discussed and approved in general. The next phase was to do a full scale mock up tes (4) to validate the weatherproofing solution. Consequently the tests were done and passed successfully.

The next phase was project planning (5) and compatibilization of the Effisus/Client production to project programme.

Overcame the above it was started the production Effisus/Client (6). In parallel specialized teams were engaged by client for Effisus technical training (7). This phase was also very important. It was crucial that the installation team knew and understood in detail the solution, the feasibility and the goals to be achieved!

If not, all the previous added value solutions and considerations were not put in practice and consequently the client would pay a higher cost without any of the benefits designed.

On the next phase and based on a project schedule agreed the Effisus products were delivered by batches.

Below its described a small example of partnership excerpt from the project. It was identified on technical training that the pre-fabricated pieces identification and relation with the windows typology was difficult and critical to the team installation since the project has 10 windows types, plenty of combinations and consequently different pre-fabricated pieces per window scheme. Therefore it was developed a logistic plan to facilitate the above.

Each windows type was packaged in 1 carton box clearly identified the typology, composition and it was also created a color per window type. For instance, if the client production is to assembly 20 windows type A (green) and 10 windows type B (blue), easily it was collected and distributed 20 green box an 10 blue box.

The next phase was monitoring the application (7; 8) at workshop, precast facilities and site assembly, so when necessary it was made some corrective actions in order to guarantee an upper final quality.

This was the final stage and was also elementary to deliver to the End Users a project that remains in perfect conditions in accordance with the life span designed.

This practical case clearly shows what is a Partnership and the added value achieved to each façade weatherproofing project challenge.

“It’s about consciously and subconsciously shaping in the client’s mind what your role is, how you see your roles together and what you can bring that could add value”

Wright, N. (2012) – The Partnership Business

A – Polycarbonate on roofs – Benefits and drawbacks

Polycarbonate has a series of advantages that makes it a very interesting choice for certain roofing applications, when compared with glass or acrylic. It is:

• a very strong and resilient thermoplastic material – virtually unbreakable with 250 times the impact strength of float glass and 30 times that of acrylic
• can withstand force
• extremely lightweight
• capable of withstanding extreme temperatures
• resistant to heat, sunlight, snow, and rain – lasts without fading or discoloring
• has an UV blockage feature

As said before, due to above mentioned qualities it is an effective roofing material for many applications, being used more and more on structures such as:

• decks
• garages
• patios
• sheds
• conservatories
• pool covers
• roofing on industrial warehouses
• awnings in commercial buildings

As the panels are extremely light in weight, they can be easily transported and installed wherever they are required.

Nevertheless polycarbonate panels have a few disadvantages when they’re compared to plastic or glass:

• they are not scratch resistant
• have a quite high coefficient of linear thermal expansion – its value equals 0,067 mm/m*ºC, which is one of the highest values of this parameter among currently used construction materials.
• its particular surface properties represent a major difficult for the bonding of adhesives or sealants

B – Joints on polycarbonate – The no.1 challenge when working with polycarbonate roofing structures

Typical joints on polycarbonate structures

High linear thermal expansion of polycarbonate has to be taken into account during the process of installation – sheets should be loosely, rather than rigidly installed within the profiles, which enables the expansion of the material under temperature changes. The aluminum profiles system should be designed with regard to these conditions.
However, most of the times, the high expansion and movement of the panels puts so much pressure on joining materials, making it to failure and break. Many times the sheets start coming out or bulging. This is the no.1 pathology associated with polycarbonate roofing structures.

A failure of the joints of such systems represent a major failure of the system, as it represents water leakages, damages on roof components and its interior, contributing to the rapid degradation of the building. To the roofing contractor water leakages are the no.1 cause for additional costs after the installation is concluded.

Most of the times, the solution will be sealing these joints with silicone or similar materials, or using standard bitumen or butyl sealing tapes. These solutions are not able to absorb the movement – silicones – and do not adhere properly to polycarbonate – tapes will get loose from the substrate very soon.

C – Sealing polycarbonate joints – Effisus Easyrepair: the solution

The Effisus Easyrepair Tape is the ideal solution to seal joints on polycarbonate sheets. It creates a waterproof, moisture, and airtight barrier, with no additional sealing required. It has an exceptional adhesiveness to polycarbonate and is installed in a fast and easy process.

It can be used to seal joints between polycarbonate sheets, or joints between polycarbonate sheets and other construction materials, such as metal, concrete, plastics, etc.

D – Effisus Easyrepair on polycarbonate joints – Typical applications

1 – Sealing joints on polycarbonate curve skylights

3 – Sealing joints between polycarbonate sheets and corrugated metal roofs

2 – Sealing joints between metal flashing and polycarbonate skylights

4 – Sealing joints between polycarbonate sheets

EFFISUS EASYREPAIR: SEALING POLYCARBONATE JOINTS – CASE STUDY 1

1 – Industrial building – Joints between polycarbonate panels

EFFISUS EASYREPAIR: SEALING POLYCARBONATE JOINTS – CASE STUDY 2

1 – Football stadium – Joints between polycarbonate and metal

EFFISUS EASYREPAIR: SEALING POLYCARBONATE JOINTS – CASE STUDY 3

1 – Commercial building – Joints between polycarbonate and me

The solution to the nº1 cause of leaks on roofs

Effisus Stopper seals the most common source of water leakages on roofs: roof penetrations of any size or configuration, such as mechanical equipment, electric conduits, pipes, ventilation ducts or solar panels, for example.

Solutions traditionally applied to seal such penetrations do not have the necessary resistance to the aggressive conditions to which they are subjected: repeated cycles of load, heat, cold, moisture, water ponding, and ultraviolet. Effisus Stopper is an innovative solution that seals such penetrations effectively and definitely.

Effisus Stopper is an extremely versatile solution, with precast molds that are bonded to the roof (or façade) substrate, creating a cavity, adaptable to any configuration, that is filled with innovative sealants with no need for mechanical fastening. It can be installed on the most common roofs: asphaltic membranes, PVC, TPO, EPDM or metal. Application on sloped, metal roofs or even facades is also possible.

System components

Typical applications

Cultural Center – Leisure Complex

Shopping Center Xyami – Commercial Building

Residential Building

BOSCH R&D and production facilities – Industrial Building

The 1^ST Chapter of our new eBook is now available. Click here to:  READ ONLINE | DOWNLOAD

Our previous eBook, about how to improve a building’s value through waterproofing its façade connections, is also available. Click here to:  READ ONLINE | DOWNLOAD

This eBook is being written whilst taking into account the everyday challenges that most façade professionals encounter, when trying to ensure a proper façade weatherproofing.

In case you have any suggestions, comments or issues that you would like to see covered in the eBook’s following chapters, please do not hesitate to contact us, we will do our best to address them in the following chapters.

Over the past months, the first 8 chapters of our eBook were released.

The newest, 9th chapter, is now available. You can read it online or download it for later reading: READ ONLINE| DOWNLOAD

In case you want to read the eBook version that includes all previous chapters, you can also do it online or by download: READ ONLINE | DOWNLOAD

This eBook is being written whilst taking into account the everyday challenges that most façade professionals encounter, when trying to ensure a proper façade weatherproofing.

In case you have any suggestions, comments or issues that you would like to see covered in the eBook’s following chapters, please do not hesitate to contact us, we will do our best to address them in the following chapters.