Metal composite material (MCM) is a versatile building material that provides creative freedom when designing buildings. Its sleek, timeless, and modern aesthetic works well in a variety of project types, everything from retail, commercial, corporate, health care, education, and more. It is also a malleable material, which gives it the ability to be curved and bent into a variety of shapes and configurations. This design flexibility gives architects the ability to use MCM in everything from intricate curvilinear forms to column covers and facias.
Creative curves
Curved panels can add unique and functional features to projects, which can modernize and transform the look of a building. Besides adding visual appeal with an array of different colors and finishes, MCM’s malleable properties allow it to be bent or curved to adapt to almost any geometric shape or configuration and meet any designer’s needs.
This versatile building material can be used on everything from curved facias, arched canopies, undulating waves, and column covers. It is also a long-lasting, durable, and sustainable building material made up of approximately 70 percent recycled content, requiring minimal maintenance.
Fabrication capabilities
Curving MCM is a process that takes a lot of time and expertise. While there are a variety of ways to do this, the most common way is with a pyramid roller. It is made up of three rollers—two on the bottom and one on top—through which the material is fed, and various degrees of tension change the radius on the roll. There are two types of pyramid rollers: computerized numerical control (CNC) machines, in which the desired panel radius is programmed in, and manual radius, which uses radius templates to achieve the proper panel radius.
When feeding material through the pyramid rollers, the metal is rolled continuously back and forth until the proper radius is achieved. Pyramid rollers can vary in size, allowing different lengths and radii. Examples include a 4.9-m (16-ft) roller, which gets the material down to a 229-mm (9-in.) radius, and a 1.5-m (5-ft) roller, which can achieve a 102-mm (4-in.) radius. When curving material, the optimal effective roll length is 4.76 m (15.6 ft).
The longer the panel length, the harder it can be to maintain the desired radius throughout the entire roll. Even at the right radius, column rolls tend to be tightest in the center and open up on the ends, requiring some over-rolling in anticipation of this happening. Called “hour glassing,” an example is of a 305-mm (12-in.) radius at the center that can flare out to 330 or 356 mm (13 or 14 in.) on the ends. To adjust for this possibility, the material can be over-rolled through the center to help maintain the desired radius throughout.
Unlike column covers, which are made from rolling a length of the MCM, curved fascia are two parts. These multi-plane fasciae require layups, which is a vertical piece attached to a crescent-shaped piece, the flat return into the soffit piece.
To create multi-plane fascia, the cut shapes need to be married with the aluminum angles on the backside of the panels reinforced with silicone to hold the two pieces together. Called a trimless edge, the backside of one of the panels needs to be rounded out to ensure they nest together, creating a nice, clean edge. It is important to note that silicone requires time to properly cure before panels are put into crates for shipping. Otherwise, there is a risk of damage to the panels when they move or shake during transit.
Knowing the curve
Finally, it is very important that the architect clearly defines on the drawings whether they want a true curved fascia or a segmented fascia. If curved, have it clearly noted, list the required radius, and show the joint locations. If segmenting is OK, which often is the case with large radiuses, also have it clearly noted and define the joint locations.
Zeke Miller is CEO of MillerClapperton in Austell, Ga. With more than 34 years of experience in the construction industry, Miller is passionate about creating value for customers, partners, and employees, and advancing the standards and sustainability of the architectural cladding industry. Miller is a former board member of the Metal Construction Association (MCA) and former chairman of the MCM Council and MCM Alliance.