User manUal

BRAVOVentilated Façade SyStem

For inStallation oF aluminium compoSite material etalbond®

JUn/2011

content

Horizontal section of the system

Vertical section of the system

Installation plan

system profiles and accessories

static scheme selection

mounting the fixing bracket on a metal “grid”

Brackets mounting

substructure assembly - steps and General Principles

Fixing of the main supporting profile

Joining of the main suporting profiles

Templates for hangers mounting

04

05

06

08

10

12

14

20

26

28

29

Preparing the cassettes from composite material

Installing the first row of hangers

Installing the hangers by means of a template

making the cassettes from composite material

Cutting the sheet and preparing the cassette

Hanging the cassettes

Cassettes installation steps

reinforced profile

Ventilation grid

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31

33

35

36

39

41

42

4 5

SyStem braVoVertical Section

SyStem braVoHorizontal Section

anchor M8

thermo-pad

thermal insulation

fixing bracket

rivet 4.8x12

self drilling screw M4.8x32

main joint profile

hanger

etаlbond®

anchor M8

single fixing bracketfor fixed support

thermo-insulation pad

single fixing bracketfor flexible support

plug 8

thermal insulation

rivet 4.8x12

self drilling screw M4.8x32

main profile

hanger

etаlbond®

supporting profile

6 7

main supporting profile

Wall brackets

Thermo-insulating pads

self-drilling screw m 4.8x32

Hanger

rivet ø4.8 x12

Construction base – masonry/aerated concrete

main componentS and inStallation plan oF tHe main conStruction

1.

2.

3.

4.

5.

6.

7.

1

4

2

3

6

7

10

8

9

5

11

1

2

3

13

5

9

4

6

11

12

10

7

8

Joint profile

Washer

anchor/dubel

substructure base – reinforced concrete

Thermo-insulating mineral wool

Plywood-nail for mineral wool securing

8.

9.

10.

11.

12.

13.

8 9

40 - 210 mm

160 mm

40-300 mm

80/90 mm

90-250 mm

80-160 mm

accessories

Fastening elements

07bravo00

07variosh 210

Hanger

07ITH380eaChemical anchor

07m1096a4F07m10105F

anchor m8x100/96

07P4812alssrivet ø4.8x12

07m4832Qsself drilling screw m4.8x32

071080a4FUr0710100FUr

Plug m ø8x100

07m10TrThreaded rod m10x100

906050000355Plastic siever

07shina

Joint profile

07support02

aluminum strap

31064

supporting profile

07support02

F profile

07pvcbreak0107pvcbreak00

Thermo-insulation pad

07washerQ10

Washer

07vfsgrating

Grating

40 - 210 mm

160 mm

40-300 mm

80/90 mm

90-250 mm

80-160 mm

40 - 210 mm

160 mm

40-300 mm

80/90 mm

90-250 mm

80-160 mm

SyStem proFileS and acceSSorieSThe system is supplied with a full set of end profiles and accessories allowing for unique details execution, different finishes and transition to other faзade materials.

Fixing bracket

main profile

21895 - 71 х 71 х 2.8 mm

30 mm

71 mm 100 mm

60 mm

21958 - 100 х 71 х 2.8 mm

cod07 vario 072

07 vario Q 52

07 vario 082

07 vario Q 102

07 vario Q172

07 vario Q152

07 vario Q182

07 vario Q212

07 vario 07

07 vario Q 5

07 vario 08

07 vario Q 10

07 vario Q17

07 vario Q15

07 vario Q18

07 vario Q21

40 mm

50 mm

75 mm

100 mm

125 mm

150 mm

180 mm

210 mm

40 mm

50 mm

75 mm

100 mm

125 mm

150 mm

180 mm

210 mm

dimensions

40 - 210 mm

160 mm

40-300 mm

80/90 mm

90-250 mm

80-160 mm

40 - 210 mm

160 mm

40-300 mm

80/90 mm

90-250 mm

80-160 mm

40 - 210 mm

160 mm

40-300 mm

80/90 mm

90-250 mm

80-160 mm

cod dimensions

10 11

a fixed support bears the load of the own weight for the loaded panel and a part of the wind load. There is only one fixed support for every single profile. It is obligatory this support to be fixed in a solid base-reinforced concrete or metal (steel or aluminum). When installing a wall bracket as a fixed support at the rein-forced concrete base the distance from the edge of the concrete floor to the anchor axis should not be less than 120 mm.

The oval shaped holes of the VarIO wall brackets are designed to com-pensate for thermal expansions of the main supporting profile.

Options for mounting the fixed and flexible supports in the space between floors

R

G

H

H

R

G

H

H

The flexible support bears the wind pressure. It is not obligatory to assemble the mounting wall brackets to reinforced concrete or metal base. selection of anchoring element depends on the type and quality of the construction base. Plugs and chemical anchors are most commonly used. The wind suction load is twice as high in the corner zone of the building than in the inner zone, which requires the mounting brackets to be positioned at distances twice shorter at the corner zones.

static diagram selection is based on the results of the static analysis and the preferred variant for fixed support is mounted to the main sup-porting vertical profile ( in the upper end, in the middle or in the bottom end).

each main supporting profile is mounted to one fixed and /or several flexible supporting points.as a result of the aluminum thermal expansion, it is recommended that the main supporting profile has a length of about one floor height. The length of the main supporting profile is pre-cisely determined depending on the building location and the respective daily temperature amplitude.

Static Selection diagram

12

mounting oF a wall bracket to a metal conStruction

The circular holes on the fixing bracket are used when mounting it to the metal sub-structure (grid). The fixing is realized through a bolt connection. If the metal grid is not an aluminum one, then an additional treatment of the contact zone between the profile and the bracket is required so that the effect of bimetal corrosion is eliminated.

BRAVO

14 15

1

3

5 6

2

4

The fixed support bears the load induced by the weight of the panels mounted on it and a part of the wind load. It is mandatory that this support is fixed to a solid base - rein-forced concrete or metal ( steel or aluminum). When installing a wall bracket as a fixed sup-port directly on reinforced concrete base, the distance from the edge of the concrete floor to the anchor axis should be no less than 120mm, if aluminum sheet is used for cover-ing the area around the bracket.

correct

correct incorrect

minimum 120 mm

< 120 mm

< 120 mm

minimum 120 mm

< 120 mm

< 120 mm

minimum 120 mm

< 120 mm

< 120 mm

Drill a hole with a size as per installationinstructions

…or by compressed air

Place the bracket

Clean up the hole by the use of a brush

Hammer in the anchor

Place the reinforcing washer and fix the bracket

wall bracket inStallation -Fixed Suport

16 17

1

3

5

2

4

The flexible support bears the wind pressure. Wall brackets are mounted on a steady brick or aerated concrete wall. The project designer in-spects the construction base and recommends the appropriate anchoring elements. The wind load is twice as high in the corner zone of the building than in the inner zone, which requires the mounting brackets to be positioned at twice shorter distances at the corner zones.

correct

incorrect

wall bracket inStallation -Flexible Suport

Drill a hole with a size as per installationinstructions

Pour the chemical product into the hole - it should fill 2/3 of the volume

Place in the anchor and rotate it as to spread the mixture uniformly

Place the reinforcing washer and fix the bracket

Place the bracket

SubStructure aSSembly - StepS and general principleS

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4

5

6

1

3

2 The positions of the flexible and fixed points (depending on the selected static diagram) aremarked.

The exact position of the main supporting profiles is marked by a coloured thread.

all wall brackets are mounted (if the building height and shape as well as the scaffolding allows).

reference points are marked on the wall by means of a laser level. Their purpose is to help in outlining a coordinate system – horizontal and vertical base lines.

The benchmarks are put onto the wall

The central horizontal and vertical axis of the frame of reference are marked on the façade by means of a coloured thread.The horizontal and vertical lines are passingthroughout the entire façade and are used for determining the position of the wall brackets and the distances between the supporting pro-files.The positions of the main supporting profiles (depending on the façade grid) are marked us-ing a measuring device (tape-measure).

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10The inner supporting profiles are mounted and leveled against the cord.

min 20 mm

11The spring parts in both ends of the wall bracket allow for easy and simple mounting of the profile. Depending on the brackets, the standard main supporting profiles allow the lev levelling eling of the brackets from 11 to 40 mm.

min 20 mm

9

7

8

a screw is tightened in the already leveled end verticals and a cord is tied.

The final fastening of the elements should be performed by use of a torque wrench while controlling tension. The tightening force is indicated by the manufacturer of the fasten-ing elements. The tension force for anchors of type sormat m10 x 100 mm is 30 nm (3 kg). The maximum value of the tension torque for plugs of type Fischer FUr sXr in concrete is 11 nm. For the different types of masonry it is not recommended to apply tension torque but only ‘tightening the screw to open the plug’

The vertical supporting profiles are mounted inboth ends of the façade and are leveled using the horizontal axis of the frame of reference. They are aligned in vertical direction and brack-eted by means of vertical level or laser plumb.

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13after several of the inner supporting profiles are installed they are leveled with the horizontal axis of the frame of reference

a

a

12It must be assured that the distance a (measured at the top and at the bottom) between the verti-cals is one and the same. 14after the profiles are aligned horizontally and

vertically, they are temporarily fixed by screws. after that the rivet holes are drilled for the per-manent fastening.aTTenTIOn: The screws used for fixing the vertical supports must be removed after the permanent fastening of the vertical supports to the wall brackets with rivets.

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The main supporting profile is mounted to a fixed support with rivets 4,8 x 12 mm in the circular holes of the mounting wall bracket, thus not allowing movement of the profile.

The main supporting profile is mounted to a fixed support with rivets 4,8 x 12 mm in the centre of the oval shaped holes of the wall bracket. They allow movement of the profile caused by thermal expansion.

mounting oF tHe main Suporting proFile to aFixed Suport:

Fixing oF tHe main Supporting proFile to aFlexible Suport:

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The connection between the main support-ing vertical profiles is assured by joint profile (code07shina00), providing the free movement of the profiles. rivets 4,8 x 12 mm are used as fastening elements.

note: the suggested diagram for mounting of a joint profile is applied when the fixed support is chosen to be at the upper part of the main supporting profile.

The distance from profile’s end to the first fixing point with a fastening ele-ment (rivet) should not exceed 300 mm.

Joining oF tHemain SuportingproFileS

>10mm

max 300mm

>10mm

max 300mm

>10mm

max 300mm

a

a1

a2

a3

a4

a5

a6

2mm

2mm

2mm

2mm

2mm

2mm

templateS For HangerS mounting

The template is intended to help in determiningthe exact position of the hangers and the spac-ing between them. a template can be made from a stripe of etalbond®. The die-cut slots in the template follow exactly the dimensions of the slots, cut on the etalbond® cassetes. In order to minimize the error accumulation, the length of the template should be chosen as big as possible (one floor height).

* each cassette should be mounted on two hangers only ( in its upper part ). For this reason the bottom two hangers on which the cassette is mounted have to be fixed 2 mm lower than the upper end of the cas-sette slot.

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The position of the upmost hanger on the mainprofile serves as a base point in the process of template making. The first slot is die-cut. The second slot is then cut, displaced from the first slot on a distance, equal to the distance between the cassette slots plus 2 mm.

The next slot on the template (the upper slot of the second cassette) is determined, again tak-ing as a base the position of the upmost hanger on the main profile. The distance between the slots depends on the raster of the sheets and the minimal distance allowed between the slots and the cassette corners.

note: The number of hangers and their spac-ing depends on the cassette size and the loads exerted on it.

making tHe template

a

a1

a2

a3

a4

a5

a6

The hangers have a specially designed shape, which allows direct installation of the hangers on the main vertical profile, instead of stringing them. The hanger is placed perpendicularly to the profile and then is fixed in the channels by means of a slight pressing towards the profile. The shape of the hanger allows movement in vertical direction, in order to make it level.

note: The distances between the hangers and the distances to the corners are chosen accord-ing to the cassette size and the desired façade raster. The calculations are done in the initial project stage, before the actual installation.

inStalling tHeFirSt row oF HangerS

Initially, the hangers in the upper end of the two end vertical main profiles are installed. Then we measure the distance between them and the established base horizontal level.

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note: each cassette should be mounted on two hangers only (at the upper part). The bottom two hangers on which the cassette is mounted are to be fixed 2mm lower than the upper end of the cassette slot.

a

a

a

after we make sure that the upmost hangers are properly positioned on the first and the last profile, we fix them permanently with self-drilling screws М4,8х32mm. The hangers on the intermediate profiles are then vertically aligned by means of coloured thread or a laser level.

In the cases when the hangers are aligned by means of a coloured thread, the two end hang-ers must be secured with self-drilling screws. The thread is tied on the screws. The hangers on the intermediate profiles are then aligned on the straight line created by the thread and are secured with screws М4,8х32mm.

preparing tHe caSSetteS From compoSite material

after we have the upmost hanger installed, we put the template over it, moving the tem-plate downwards until the upper part of its slot reaches the pipe of the hanger. Then we adjust the second hanger, until its pipe touches the upper end of the second slot of the template. after that we fix the hangers with self-drilling screws.

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note: Depending on the raster of the façade, there may be different cassettes, which will require different templates to be made.

The steps described above are repeated for thefirst row of hangers on each subsequent floor. The next hangers on the profiles are installed bymeans of templates.

The contours of the cassettes (unfolded) are transferred to the composite sheet. The dimen-sions of the unfolded cassette are determined as follows:

example:h = а + b + c + d - 3mm h = 750 + 20 + 25 + 35 - 3 h = 827 мм

h = the height + size of segments (returns) – the number of segments

w = the width + segment size (returns) – number of segments

making tHe caSSetteS From compoSite material

note: In order to die-cut the hanging slot, a minimal segment size of 30 mm is required.

w

b

a

h

dc

3200 mm

c =25mm

a=750mm

d=35mm

b =20mm

1250 mm

36 37

The places where the channels will be routed are marked on the back side of the sheet. The milling depth is 0.8 times the thickness of the composite sheet ( for example, if the sheet thickness is 4 mm, the routing depth is 3.2 mm).

cutting tHe SHeetand preparing tHe caSSette

4mm 3.2mm 4mm

4mm 3.2mm 4mm

1

2

milling the channels

Die-cutting the corners by means of a pneu-matic die

3Die-cutting the slots by means of a pneumatic die, with predetermined distance between the slots and the cassette edges, according to the static analysis

38 39

4

5

6

Die-cutting the oval shaped and the cylindrical holes

Folding the segments and fixing the corners of the cassette

removing the protective foil at the edges of the cassette

Thus prepared, the cassettes are mounted on the fixed hangers. The grout width between the cassettes is kept constant during installation by means of spacers and may vary from 4 to 26 mm. The cassettes is permanently riveted to the main profile, with rivets 4,8 х 12 mm running through the oval and cylindrical holes.

Hanging tHe caSSetteS

a

b

А - Cylindrical hole

b - Oval hole

40 41

The cassettes are installed starting from the bottom-up. The lowest row is first laid, fol-lowed by the leftmost (or rightmost) vertical column. after the façade is fixed, we proceed with installation of the finishing details.

caSSetteS inStallation StepS

42

The reinforced profile is fixed by rivets or screws to the segment in the middle of the bottom part of the cassette. The necessity of the reinforced profile (cod. 07support01) depends on the cassette size and the loads exerted on the cassette.

a perforated grid is installed in the upper and the bottom end of the ventilated façade, allow-ing free air movement, and in the same time stopping the insects and impurities.

reinForced proFile

Ventilation grid

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This brochure only reflects the state of our products at the time of printing.You can find updated information on our website:

Technical or any other questions can be directed to us by e-mail at: pdimitrov@steelmetbg.vionet.gror use our telephone number: t: +359 894 754 158

oFFiceS etem bulgaria

T: +359 894 754 158, ventilated@madeinetem.com, www.madeinetem.com

etem greeceT: +30 210 489 8605, marketing@etem.vionet.gr, www.etem.gr

etem romaniastrada Drumul Intre Tarlale nr 42, sector 3, Bucuresti

T: +40 21 209 09 70, contact@etem.ro, www.madeinetem.com/ro

etem SerbiaT: +381 22 32 80 19, +381 22 32 80 20, office@etemscg.rs, www.etem.gr

etem ukraineT:  +38 (044) 499 07 87, info@etem.com.ua , www.etem.com.ua,

www.etalbond.com.ua, www.ventfacade.com.ua

elval colour S.a.Plant B, 3rd km Inofyta Peripheral road, agios Thomas 32011, Viotia, Greece

Tel: +30 222620 53576; e-mail: ecs@elval.vionet.grwww.elval-colour.com