Architects looking for long-lasting, attractive and sustainable products to use on a project should consider Metal Composite Material (MCM) or Aluminum Composite Material (ACM).
Consider the characteristics of MCM/ACM:
- MCM/ACM is manufactured in a continuous process by bonding two thin skins of aluminum of other metal under tension to either side of a thermoplastic core using no glues or adhesives in the process.
- MCM/ACM stays extremely flat, can be curved to a radius of 3 inches, is factory coated and thermally stable.
- MCM/ACM is very lightweight, yet strong. It weighs about half as much as solid metal and is 90% as strong.
- MCM/ACM is highly recyclable. The core can be reclaimed and reused, and the metal skins recycled.
- MCM/ACM is most commonly used as a cladding for buildings. It also can be used for column covers, beam wraps, kiosks, signage, canopies and other cladding.
- MCM/ACM panels are available in a range of thicknesses (2 mm to 6 mm) with 4mm being the most common for architectural applications.
- Available skins are 0.008-inch, 0.01-inch and 0.02-inch aluminum plus anodized, Natural metals skins include copper, titanium, zinc, brass and stainless steel.
- Manufacturers offer panels in a variety of sizes with widths ranging from 39.37 inches to 62 inches and lengths ranging from 4 feet to 25 feet.
MCM and ACM are composed as a balanced system of multiple layers that provide the desired durability and aesthetics. At the center is the core, a fire-rated polyethylene material. From the core, moving to the exterior is a bonding lamination layer, a 0.5-mm aluminum or metal skin, and then a two or three-coat high-quality paint system.
You’ll notice there is no glue or adhesive layer in an MCM/ACM, which are created by a continuous manufacturing process (CMP). Imitators use other methods of adhering the core to the metal skins, such as batch, lamination and foamed-in-place. Batch process uses glue and can make quality control more challenging.
Once manufactured, MCM/ACM is fabricated for a specific job. Fabricators possess technical expertise and engineering capabilities. They operate CAD-driven CNC routing saws for precise cutting and forming, as well as high-tech rolling equipment for curving requirements.
Fabricators also may install panels, or they are installed by a subcontractor such as a glazer or a roofer.
MCM/ACM can be installed using different attachment systems. The Rout & Return rainscreen requires a vapor barrier as a primary water seal and removes the need for silicone sealant from the joints. It allows the system to breathe and allows moisture to escape through ventilation. The Rout & Return Wet Seal System is more economical and places the water line outside the cavity.
Typical architectural panels are coated with highly durable PVDF or FEVE (fluoroethylene vinyl ether) systems that last up to 30 years. Manufacturers must meet national model building codes such as IBC, UBC, FBC and local codes for both practices of engineering and fire resistance cores. Code compliance agencies such as ICC and ATI have evaluation services and quality control guidelines for meeting codes. It’s recommended that any manufacturer used has a third-party verification on testing and auditing of their facility.
Typical fire resistance testing for MCM/ACM in the United States are NFPA 285 ISMA test; ASTM E-119; UL 1715 interior room; Can /ULC-S134-92 (multistory evaluation); and ASTM E-84. Other testing includes ASTM standards for bond strength, tensile strength, smoke developed, flame spread and others; ASTM coating tests; AAMA 2605 and 620; ASTM E-330 and E-283; AAMA 508-07 rainscreen; and IBC, FBC, Miami-Dade, etc.
MCM/ACM is sustainable and may contribute to LEED points in several categories, including using recycled content as raw material (LEED credit MR 4.1) and may provide regional manufacturing and processing benefits (LEED credit MR 5.1).
Finally, MCM/ACM is a cost-effective material when compared to curtain wall, precast, marble and granite. Using larger module sizes such as 4 feet by 10 feet or 5 feet by 10 feet can save time and money on fabrication and installation.
Smaller module sizes can be used, but will affect cost. Some variables that will affect the cost include the building height and location; color selection; metal selection and panel geometry.
MCM/ACM offers design freedom with the endless possibilities of colors and geometry to fit your project’s needs. These panels were designed to tackle the problems associated with solid aluminum – post painting and flatness on large dimensions.
Grason Cook is the Commercial Director North America, Alucoil North America LLC, Manning, S.C. It is part of Grupo Aliberico, a family-owned Spanish multinational manufacturer of aluminum products. To learn more, visit www.alucoildesign.com.