This document provides details on the manufacture processes of various building facade materials and systems, including low-E coated glass, stainless steel cladding, and terracotta panels. It also summarizes two case studies of building projects that utilized these materials - 100 Eleventh Avenue in New York City, a residential condominium, and 200 Eleventh Avenue, another New York building. The document discusses the technical specifications and advantages and disadvantages of the different facade material options.

1. SCHOOL OF ARCHITECTURE, BUILDING AND
DESIGN
BACHELOR OF QUANTITY SURVEYING (HONOURS)
CONSTRUCTION TECHNOLOGY 3 (BLD 60304)
GROUP ASSIGNMENT
LIM HONG WEI 0322741
LOH MUN TONG 0323680
LOO SIAH MONG 0321995
LECTURER: IR CHAI VOON CHIET
SUBMISSION DATE: WEEK 13

2. 2
TABLE OF CONTENT
NO. TOPIC PAGE
1. INTRODUCTION OF CURTAIN WALLS /
FACADE SYSTEMS
3
2. MANUFACTURE PROCESS OF
LOW E-COATED GLASS
4
3. MANUFACTURE PROCESS OF
STAINLESS STEEL CLADDING
6
4. ANGEL HAIR PATENT SYSTEM 9
5. MANUFACTURE PROCESS OF
TERRACOTTA PANEL
10
6. ADVANTAGES AND DISADVANTAGES OF
LOW E-COATED GLASS
14
7. ADVANTAGES AND DISADVANTAGES OF STAINLESS STEEL &
TERRACOTTA PANEL
15
8. CASE STUDY - 100 ELEVENTH AVENUE 17
9. CASE STUDY - 200 ELEVENTH AVENUE 20
10 CONCLUSION 24
11 REFERENCES 25

3. 3
Introductionof Curtain Walls/ Facadesystems
It is the skin of the building or known as cladding. Curtain wall or facade is non-load bearing, it
supports no vertical structural loads aside from its own weight. The primary function is to act as
a separator or boundary between interior and outdoor environments. Curtain Wall or facade
system is the elegant components that helps to define the unique architectural aesthetics of the
building,
Typesof Curtain Walls
● Stick system
Fabricated in the shop and shipped in pieces to the site where it is assembled and
glazed and installation process combines assembly and glazing
Unitized curtain wall
Fabricated and assembled at the manufacturer’s shop, then shipped to the site for
installation and done in controlled environment improves curtain wall durability
● Unit system
In the unit panel system, panels are fabricated and assembled at the shop, and may be
glazed there as well. The panels are then taken to the field, where they are attached to a
building structure
● Unit and mullion system
Similar to the stick system, mullions are the first tube to be installed in the unit and
mullion system. Spandrel and glazing, however, are inserted into the stick system as a
complete unit
● Column-cover and spandrel system
While column cover and spandrel systems are similar to unit and mullion systems, they
differ in that the building frame is emphasized with column covers, which act as sticks

4. 4
ManufactureProcessof Low E-coated Glass
There are two different types of manufacturing processes for low-e glass.
Passive low-e coatings
Passive low-e coatings designed to maximize solar heat gain into a home or building to create
the effect of “passive” heating and to reduce reliance on artificial heating
Solar Control low-e coatings
Solar Control low-e coatings designed to limit the amount of solar heat that passes into a home
or building for keeping buildings cooler and to reduce energy consumption related to air
conditioning
Both types of low-e glass are produced by two primary production methods.
Pyrolytic (Hard Coat)
Glass is coated by spraying a thin film of special reflective material at high temperature directly
onto the surface of float glass during its primary manufacturing.
Pyrolytic coating process is generally used in colder climates to create passive low-e glass.

5. 5
Magnetron Sputter Vacuum Deposition (MSVD) / (Soft Coat)
Vacuum chambers are used to apply a succession of special coatings onto glass sheets to
achieve highly efficient low-e glass products.
Magnetron coating deposit microscopically thin silver based films onto glass. Silver is vulnerable
to environmental damage, and must be enclosed in insulated glazing to protect it from contact
with moisture or corrosive agents. Therefore, this precision coating process creates a high
performance low-e glass coating which is highly effective and yet microscopically thin which
results in producing a beautiful low-e thermal glass window product which lets visible light
through and keeps the heat on the right side of the glass.
Arcon’s solar control low-e glass products are created using magnetron coating.

6. 6
ManufactureProcessof Stainless SteelCladding
Hot roll bonding
Clean plates of carbon steel and stainless steel are placed on each other (single cladding), or
sandwiched between two stainless steel plates (double side cladding). The composite plates are
heated around 1200°Cin a reheat furnace and roll the sheet, squeezing it between sets of
cylinders or rolls.
Cold forming
A forming process in which stainless steel sheet is progressively shaped through a series of
bending operations. The process performed on a roll forming line in which the sheet metal stock
is fed through a series of roll stations.

7. 7
Explosive Welded
The bonding is produced by plastic deformation of metals because of intense collision during
explosive bonding. It is followed by hot rolling process sometimes to improve the bond between
carbon steel and stainless steel.
Brazing
Brazing is a joining process where metals are bonded together using a stainless-steel metal
with a melting (liquidus) temperature greater than 450 degrees, but lower than the melting
temperature of the base metal.

8. 8
Weld Overlay
Weld overlaying refers to the deposition of a filler metal on a base metal (substrate) to impart
some desired property to the surface that is not intrinsic to the underlying base metal.

9. 9
Angel Hair Patent System
A patented fabrication system for producing Angel Hair non-directional finishes on stainless
steel surfaces.
An apparatus for applying a lightly scratched surface to stainless steel comprises a motor, a
disk, a frame, and a motion guidance unit.
The motor may provide a rotational motion to the disk which includes abrasive elements
configured to create a plurality of microscopic scratches on the surface of the metal sample.
The appearance of Angel Hair polish on stainless steel has a bright diffuse reflectivity and
produce a high-reflectivity of standard grain finishes compared to vibration finish produced by
usual industry manufacturers.
Angel Hair Patent System
Angel Hair Stainless Steel Vibration Finish by Industry Manufacturers

10. 10
ManufactureProcessof Terracotta Panel
Select quality clay, and after the clay
is sifted and coarse broken, stale the
clay for six months and turn the clay
over again and again to dry it to
appropriate moisture and particles.
Raw material is stalling in indoor
warehouses to ensure further stalling and
homogenization of the naturally dried raw
materials.
Mix the raw materials according to the
formula, and then crush the raw
materials according to certain fineness
requirements using professional
Raymond machines.

11. 11
Put the raw materials powder into the
third stale homogenizing equipment
and start full automatic computer-
controlled dosing.
Add water to the prepare dry raw
material powder and stir for
granulation, and then put it into
discharge warehouses with constant
temperature and humidity settings.
Put the granulated raw materials
into a vacuum extruder for vacuum
extrusion forming.

12. 12
After human inspection of size
and glancing flatness, send the
formed materials into a 80-meter
five-layer drying kiln to dry the
materials slowly for 8 hours.
After drying, do inspection and
sifting, and send them for high
temperature burning for 8 hours.
After the roller kiln process, do
inspection and classification,
and then proceed with product
edging and cutting.

13. 13
The final products are stored in the warehouse after inspection and packaging.

14. 14
Advantages of Low-E coated glass
Less Condensation
Protected by a thin layer of metal which repels condensation that can cause frost to build up on
window
Less damage to furniture
Reduce ultraviolet (UV) rays by up to 75 percent which prevent fading of furniture
Lower HVAC costs
Help reduce peak heating and cooling loads which allows homeowners to install smaller heating
and cooling systems
Disadvantages of Low-E coated glass
Light pollution
Coated glass from different angles reflex the light that pedestrian and drivers, residents
blindfold, thus forming serious light pollution
Cost
Expensive initial capital but becomes sustainable in the long run with savings in electricity bills

15. 15
Advantages of Terracotta Panels
Excellent building performance index
High pressure extrusions at high temperature burning with very stable and high compressive
strength to the building
Easy installation and quicker construction progress
Do not need slotting on the back during construction, and can be installed directly and in the
meanwhile the panels can be cut at will and laid out flexibly
Convenient maintenance
It is anti-static and not easy to adsorb dust and have the ability of self-cleaning dust on the
surface can be cleaned after rain wash
Disadvantages of Terracotta Panels
Recommended to buy only from established, reputable dealers
Principle drawback is the fact that its quality can vary a great deal and is difficult for an
inexperienced person to evaluate
High initial cost
Depending on quality, new terracotta tile costs about 3 to 7 dollars per square foot, and for rare
antique tiles, it could be cost more
Required skilled labour
Terracotta tiles need to laid by a professional labour as well as skilled labour to calculating the
total costs of the tiles

16. 16
Advantages of Stainless SteelCladding
Resist Corrosion
Stainless steel performs well in environments that may cause other alloys to deteriorate
over time
Durability & technical properties
More durable and resistant to environmental factors; its polish and shine can easily be
maintained for decades
Environmental Benefits
It is 100% recyclable and the material does no harm to the soil as it does not release
any toxins or harmful chemicals
Disadvantages of Stainless SteelCladding
Selection of powder is essential
Lack of control on powder characteristics, including chemical contamination such as oxidation,
oil and other metal impurities
Lack of flexibility, shapes and dimensions
The shape of the powder is irregular and coarse

17. 17
Case Study - 100 ELEVENTHAVENUE
Official Name: 100 Eleventh Avenue
Country: United States
City: West Chelsea, New York City
Building Function: Residential Condominium
Number of Floors: 23
Construction Start: 2008
Completion: 2010
Facade formed by: 1700 colourless glass panels of each with different sizes and unique angle
Height of facade: 76m

18. 18
Structure
The walls are designed from the inside out. It comprises seven mega panels on the facade, and
each corresponds to a quarter Mega Panel.
The curtain wall windows are fixed and operable trucks, in various sizes and shapes, a random
series of folding planes.
To give regularly to the wall, the team created mega panels special, some with a height of 3.66mx
11.28m wide that contain within a maximum of 20 smaller, individual panels.
Mega Panel joints are the only areas of the facade with a continuous vertical mullion. The curved
section of the front has a concentration of smaller panels.

19. 19
Installation process
From the pictures, above, the mega panel were transported to site,
then lifted by a crane to be erected on the building.
In order to install the panels and hang them off the floor plates, a clip
system was needed where three to four clips areused per horizontal
span for the connection.
Theometrics and Gotham Construction used a laser technology and
transferred information from the BIM model directly onto the edge of
the floor slabs.
This technology was also able to map the 51 different mega panels
onto their exact location on the slabs, organizing the entire layout of
the facade as if it was done digitally on the computer.
Mega Panel Clip

20. 20
Case Study - 200 ELEVENTHAVENUE
Official Name: 200 Eleventh Avenue
Country: United States
City: West Chelsea, New York City
Building Function: Residential Condominium
Number of Units: 16
Number of Floors: 19
Construction Start: 2007
Completion: 2010
Facade formed by: Angel Hair stainless steel rain screen and terracotta tile cladding
Height of facade: 68m Angel Hair stainless steel, 13m terracotta tiles

21. 21
Structure
The 19-story building consists of a 16-story tower supported by a 3-story plinth.
The plinth connects the building to its context in several important ways:
- By reflecting the neighbourhood’s primarily low-rise scale
- By maintaining the street wall along both 24th Street and 11th Avenue and through a
material palette (terracotta cladding and blackened steel window frames) that matches
the masonry façades and industrial details of the surrounding buildings.

22. 22
Stainless Steel Rain Screen Cladding
The tower's Angel Hair stainless steel rain screen appears above a ceramic-cladding
terracotta plinth which brings an ornate aspect to an otherwise orthogonal building.
DETAIL OF THE 200 ELEVENTH AVENUE STAINLESS STEEL FACADE.
Rain screen system is a fully drained, ventilated and pressure equalised facade which forms the
external aesthetic element of a multi-layer wall.
Benefits of this system:
- Allows air movement around each stainless-steel panel to provide ultimate pressure
equalisation
- To minimise water penetration to the inner wall.
- Protects the structural wall against wind and solar damage.

23. 23
Curve Connection
The curve connection of stainless steel cladding is highly crafted and finished with premium
stainless steel surface known as the Angel Hair surface which has high reflectivity of standard
finishes.
Angel hair surface is an innovation to scatter light particles and prevent glaring hot spots.
It is the finest, smoothest and most uniform light-diffusion metal surface available in the world.
The 3-frame diagram below shows the design assist process for the curving form connection,
from the original 3D model to the final unitized system
Original Drawing
Revision 1
Final drawing

24. 24
Conclusion
Based on our findings and own understanding about facade system/curtain wall,
it can be classified as a multi-functional purpose to the building exterior, whether it is for
aesthetic value or even used it for functional purposes. For instance, the reason why we
chose 100 11th Avenue as our case study is because of its unique facade system which
was designed by Jean Nouvel. Not only being able to deliver a high aesthetic value
facade, functional purposes is also achieved by using Low E-Glass which able to
minimize the amount of ultraviolet and infrared light that can pass through the glass.
As for the other building, we chose for our second case study, 200 11th Avenue
that is a 19-story building consists of a 16-story tower supported by a 3-story plinth. The
building also proved that even by implementing two different facade system which
creates conflict in terms of connectivity, it is able to achieve by using angel hair surface
which is the finest, smoothest and uniform light- diffusion metal surface available around
the world, not only showing high caliber of the facade, it has also proved how building
technologies bring us to where we are today.
While we can conclude that each facade system has their own specialty in terms
of design or function, we also understand that new design option for a building will never
be restrained by the human mind because we humans are always improving so do the
building technologies.

25. 25
References
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