Dry porcelain ceramic façade or stoneware facade is One of the most up-to-date building facades in the world that implemented by dry installation method. Porcelain dry ceramic as dry porcelain ceramic facade cladding is the most important part of this type of facade, and should have sufficient strength in the single module and the least possible water absorption. The porcelain dry ceramic facade can be used for various commercial, office, residential, as well as interior parts of buildings, terminals and metro stations, etc.
Dry ceramic porcelain – stoneware facade made special for façade, is presented in two general forms in the market of the country’s construction industry, including caved ceramic porcelain and filled porcelain ceramic, which is also referred to as a centimeter or full-body ceramic.
Caved dry ceramic porcelain properties:
- This kind of dry porcelain ceramic with holes in its thickness has more advantages in insulation. Because the air in the cavities prevents cold or hot air from penetrating the ceramic body, they play the role of insulation in the porcelain dry ceramic thickness.
- Because of the existing holes in the ceramic body, a significant percentage of the dry porcelain ceramic volume will include air, which will reduce the weight of the cladding cover.
- This type of ceramic, with the embedding of the palette and the tab on both sides up and down, resolves the horizontal seam sealing issues of the dry porcelain ceramic facade by 100%, so that the air goes behind them, but water and moisture do not penetrate them at all.
- This kind of dry porcelain ceramic has special parts for the cores, floor windows and building flushing, which gives the product a high degree of elegance and ability to strapped and seal.
The price of the product is higher due to the use of high technology and specialty extruded ceramics
Dry filled porcelain ceramic / a centimeter / full body properties:
- These ceramics have the most properties of dry porcelain ceramic, which are low water absorption.
- The standard dimensions produced for this dry porcelain ceramic is 120×60 and is capable of cutting to the desired size of the design.
- Most of the executive datasheets related to caved dry ceramic porcelain either visible or invisible are also used for this kind of dry porcelain ceramic.
- Special systems for the installation of this ceramic have been produced in terms of visibility or Unobtrusive design and components that have all the global standards.
- The final price of this product is lower than caved dry porcelain ceramic.
Installation method with clips and horizontal rails:
In this way, the caved dry ceramic porcelain with a specially designed grooved section is placed on horizontal aluminum rails, and horizontal rails are attached to the iron or aluminum substructures. The thickness of the caved ceramics in this system is less, and thus the weight of the finished facade will be lighter.
Full filled dry porcelain ceramic implementation systems – a centimeter –full body:
Eco Arc Co. as the leading company in field of building industry in the country, installing solid porcelain ceramics is used in 3 different ways in the world, including the following:
- Visible method:
In this method, dry porcelain ceramic tiles are attached to the aluminum structures by stainless steel clip components at specified intervals. The color of the clips with the selected ceramic color is identical with the polyester paint by the electrostatic method, and also in the ceramic link to the rails, high quality EPDM tires placed to prevent the ceramic slip.
- KAIL system:
The KAIL system connections are in fact mechanical hide connections without the need for glue that are created to cover the facade by a variety of different materials. The system in the building industry is widely used to cover the facade, internal and external walls and even roof surfaces (exposed to rain).
In this way, dry porcelain ceramics are connected to special horizontal aluminum rails by special aluminum joints called clamps.
- Groove system:
In this method, firstly, on the back side of the ceramics, grooves inserted through the automatic groove machine. Special grooves are created in two opposite directions and then clamps completely tight by the prominence that are made by special glue inside these grooves. The ceramics are then mounted on the rails through the clamp and strapped in place by the screw on the clamp.
Eco Arc Co. recommends that dry facade execution requirements completely run and none of the items in the materials and substructure should not be left out because the shortest one will cause the greatest damage.
Why the dry facade arose?
For the first time in the 1970s, architects in the United States decided to install stone on massive skyscrapers by dry method. The reason of this system design was due to the resistance of the building’s facade to severe wind force at high altitudes, and this modern and innovative method was endorsed by world standards and considered by many architects around the world. In Iran, in 1970s, this method was used for the first time, and also in recent years, architects and builders of the country’s construction industry have been aware of this systems benefits and have used it in their buildings.
Previously, the facade’s material was fixed with the mortar or adhesive to the main building structure. In this method, it was not possible to use insulation for the builder, and also at high altitudes, the wind load entering the structure reduced the material strength and, ultimately, Causing the crash to endanger irreparable risks. In dry facade system, the facade material is applied by aluminum cushioning and without adhesive force on the main structure, which prolongs facades life and, if properly installed and engineered, will assure you that in hard conditions it will not collapse at all. This installation method makes building’s facade double skin. An empty enclosure can be applied to an insulation structure to protect the building from atmospheric conditions, noise pollution and other disturbances faced by residents, as well as an air chamber between the wall of the structure and the facade, that prevent the building from entrance of the outside air and vice versa. The shape of the air flow inside this compartment will also be determined according to the different climatic conditions, depending on the area’s needs. For example, for warm and wet conditions, this vacant space is designed in such a way that the air inside it is ventilated, but it is designed for cold, warm and dry conditions in such a way that the air is contained in the empty space, which makes insulation coefficient of the building increases the air relative to the outside.
One of the remarkable advantages of a dry facade is that the panels and materials used can be collected and reused. It also significantly reduces the volume of construction waste. This type of building facade helps to optimize energy consumption and, because of the freedom to use different pavements, the building is resistant to water, sound and air entering. The dry facade can be resistant against stresses from wind, storms, earthquakes, and fire.
Can ceramic facade cladding be used in retrofitting existing buildings?
Yes, it is possible to use ceramic facades in the reconstruction of facades of existing buildings. Ceramic facade cladding is a popular method of improving the exterior appearance of buildings and is the perfect solution for old buildings that require renovation or exterior modification.
The use of porcelain-ceramic facades in the reconstruction of existing buildings is very beneficial.
First, this type of coating can significantly change the external appearance of the building, give it order and beauty.
Old buildings can be given a new and modern look by using different designs and colors of porcelain.
Second, dry ceramic facades have high resistance to various climate changes. Ceramic is a non-flammable material and has a very high resistance to heat, water, wind and UV rays. This means that porcelain ceramic facades can protect the building from harsh weather and temperature changes and improve the useful life of the building.
The ceramic facade also has heat and sound insulation. This means a reduction in energy costs for the building and an increase in occupant comfort from outside street noise.
Finally, the use of ceramic facades in the renovation of existing buildings reduces labor and infrastructure and installation costs due to light weight and ease of installation. This means saving time and money and helping budgets for old building renovations
In general, ceramic facade covering can be a suitable solution for the renovation of old buildings.
Tips for performing dry facades should be considered:
The frame to be chosen must have high stability and strength. Connections must be resistant to frost, heat, water vapor and airborne gases, and use thick and durable fittings.
Substandard materials with dry facade materials must be selected to be non-chemically compatible. That means, do not corrode.
Windows, seams, bulges and blind spots of building should be sealed with great care and concentration.
The protective layer on the wall and the fine-grained parts must be carefully controlled and checked.
The type of materials used and the existing cubicles must be aesthetically examined and adapted to each other, have a reasonable price and can be run easily at high speed.
Be sure to check and test the quality of the entire facade structure after installation.
Familiarity with dry facade materials: materials with many differences sued to create façade in dry method, the most common types are: porcelain ceramics, tile and pottery, curtain wall, aluminum composite plates and etc.
How was the building appearance made before the dry facade?
Before the dry facade, the material of the facade was fixed with the mortar or cement adhesive to the main structure of the building. In this method of installation, there was no possibility of using insulation for the builder, and also at high altitudes, the wind load entering the structure reduced the material strength of the facade and ultimately causing it to collapse that will have irreparable risks. In dry facade system, the material is applied by aluminum cushions without using adhesion force on the main structure, which prolongs the life and, In case of proper and engineering installation, will assure you that in difficult conditions also, it will not collapse at all.
This installation method will make facade double skin. An empty enclosure can be applied to an insulation structure to protect the building from atmospheric conditions, noise pollution and other disturbances faced by residents, and also an air chamber arises between the wall of the structure and the facade that will prevent the air from entering the outside air into the building and vice versa. The shape of the air flow inside this compartment will also be determined according to the different climatic conditions, depending on the area’s needs.
For example, for warm and wet conditions, this vacant space is designed in such a way that ventilated the air inside, but for hot and cold weather conditions, is designed to allow the air to be condensed into the empty space which also increases the insulation coefficient of the building relative to the outside air.
The building external modulation is not new. The earliest application of the wall covering of glazed ceramics by the Babylonians has been in the Procession street and Gate Ishtar, about 2,600 years ago.
Recently, in the twentieth century, the implementation of ceramic facades has grown in the advanced architecture cycle around the world. Examples include a building in Barcelona, built by Antonio Gaudi and a large number of glazed ceramic facades in many cities of the United States. These buildings still prove in our day how can one century of ceramic facades resist numerous thermal changes, atmospheric attacks, storms, and acid rain and smoke.
The coating techniques in which the ceramic tiles can be installed by them are in various ways. In using the traditional system, ceramic tiles are bonded to the building with adhesive or cement mortar. The connection method to the substructure is actually named wet. Tile dimensions in the upper floors of the first floor are generally 30 to 30 cm. The system depends entirely on the type of installation of the appropriate binder materials and proper installation techniques. If these wishes are met, its impact can be long-lasting
The second building coating method is the use of ceramic tiles, which has been widely expanded in Europe in recent years, is the implementation of a dry ceramic facade (known as a curtain design), or a ventilated facade that has a very high performance in cold weather like Scandinavia, in those areas, ventilated facade systems insulating items are very well-known. When the Italian architect Denis Santacaria traveled with his companions to Australia and New Zealand in 2002, there were many examples of how to implement the dry ceramic facade that was common in Europe. Many Australian architects were unaware of the features and benefits of such a new system, despite the special weather of Australia.
Why are they named as ventilators? Due to the creation of some kind of air pressure in an area outside the load bearing points of the building walls. This is the result of creating a curtain wall, with a distance ahead of the loader walls. One of the developments in such a dry ceramic facade system is the protection created for the building against atmospheric factors without any heat transfer from the building structure. This can reduce the amount of artificial air required for the building and guaranteeing energy storage in heat and cold.
The porcelain ceramic facade by the chimney effect (due to empty spaces behind the outer cover) provides the possibility of removing moisture and heat from the main structure of the building. In effect, a natural ventilation between the building and the final covering of the facade is created. The open seam system, with precise sealing considerations for the main structure behind these seams, can act as a protective moisture curtain.
Dry porcelain Ceramic Performance Systems have technical characteristics that their proper implementation depends on the following parameters:
- Incoming loads: The first incoming loads are the components loads of the system (the weight of the construction structure, which includes vertical and horizontal metal elements), permanent loads (their own weight of ceramic tiles and sheets) and random loads (wind and displacement of the structure of the structure).
- Displacement and deformation: By wind pressure, structural loads, earthquakes and vibrations of the earth, and thermal expansion.
- Thermal expansion: In modern buildings where indoor temperature remains constant, fluctuations in outside temperature can be up to 50 ° C (this is the main reason why the outer cover should not stick to the walls).
- Sealing and repelling moisture shrinkage: in implementation of the dry ceramic facade by creating open water seams, the water collected behind the main surface repulsed. This is because of the natural ventilation and chimney properties that make this system more useful than the system in which the seams are filled.
- Thermal insulation: In implementation of the dry ceramic facade, the heat transfer is caused by convection flow; convection and radiation; the implementation of a dry ceramic facade, such as an umbrella, protects the building against this heat transfer. Insulation can be improved by the use of auxiliary materials such as polyester impregnated foams, anti-fire polystyrene foam or anti-fire mineral fibers.
- Sound insulation: Sound insulation is directly related to the type of materials used in building. Insulating panels and their proper installation in absorbing shocks in reinforcement brackets will enhance the sound insulation of the building.
- Fire resistance: Porcelain ceramic facades have class 0 in fire.
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