AR 17-53 BUILDING MATERIALS

AND CONSTRUCTION - IV

MODULE I - WALL FINISHES

MODULE -I

• Plaster: Lime plaster and gypsum plaster. Fire resistant plaster, X-Ray
shielding plaster and acoustic plaster. Plaster over masonry and ceiling.

• Paints and varnish: Characteristics of an ideal paint and varnish.

Classification – various types of paints. Painting process. Defects in painting
works. Process of varnish.

• Wall cladding : stone cladding, tile cladding, Wooden cladding and metal
cladding. Stucco finish and other finishes.
• Sketches : Stone cladding, Metal cladding
WALL CLADDING
 CLADDING SYSTEMS

Cladding has to service a number of critical functions in a series of complex relationships:

1. •protection and security - from the environment, from negative aspects of society
2. •comfort - light, humidity, sound, ventilation
3. •sustainability - contribution to life cycle costing; maintenance and durability
4. •Another function of cladding is to provide some insulation. The multiple layers of a building are designed in part
to trap air, creating an insulating barrier which keeps temperatures stable.
5. •Impacts such as high winds and collisions with object can also be absorbed in part by the cladding, protecting
the structural elements of a building.
6. Generate an 'airtight' building envelope.

The more layers of insulation, the less climate control is needed, because the climate control is built into the structure.
Cladding

• Cladding is a non-loadbearing skin or layer

attached to the outside of a home to shed water
and protect the building from the effects of
weather.
• The primary roles of cladding are to control the
infiltration of weather elements and the egress of
water vapour while providing a durable,
aesthetically pleasing appearance.
• Secondary roles can include sound and thermal
insulation, fire resistance, and the capacity for
cleaning in dusty, polluted or vandal prone
environments
CLADDING
• Cladding is the application of one
material over another to provide
skin or layer intended to control the
infiltration of weather elements, or
for aesthetic purposes.
• It is mainly done for protecting the
exteriors or for increasing the
aesthetic value of the walls.
• This in turns helps increase the
durability of the external walls. It
also helps in preventing noise.
 https://youtu.be/qyY9Fx8pNts
TERMINOLOGY Curtain wall – unitised system

• The terms cladding and curtain wall are confusing in the

technical literature. Even in technical dictionaries the terms
cladding and curtain wall are defined with similar properties
i.e. non- load bearing wall of a skeleton frame.
• The cladding materials of the exterior wall is bonded to the
back structure with its whole back surface or stone panels
anchored directly to the back structure even if it is ventilated
is called cladding.
• The curtain wall is defined as the external wall element of
the building envelope which is non-load bearing wall and
suspended in front of the structural frame.
• Similar to attached system except it is attached to the
structural frame with clip angles or sub-framing.

• ‘Cladding’ as the external covering of a building.

• The cladding (siding) is defined as “the finish covering of an exterior wall of frame building; the siding may be cladding
material such as wood, aluminum or asbestos cement (but not masonry) applied vertically or horizontally”
• cladding as external covering of a skeleton frame, such as steel frame building with thin stone blocks.
Stone claddings to
the main body of
the wall and
ventilated stone
façade with metal
fixing anchored
directly to the
back-up load
bearing or non-
load bearing walls
are called cladding

The ventilated
stone façades with
metal fixing
anchored to the
framework which
is carried by the
load bearing
structure of the
building is called
stone curtain wall
Curtain
wall
• Infill system Infill panel walls are a
form of cladding built between the
structural members of a building.
• The structural frame provides support
for the cladding system, and the
cladding provides separation of the
internal and external environments.
• Infill walling is different to other forms
of cladding panel in that it is fixed
between framing members rather
than being attached to the outside of
the frame.
• Many materials and processes are used in cladding:
• Masonry stone (in blocks and veneers),
• Concrete
• Ceramic tiles
• Steel
• Aluminum and other metals, glass, and plastics.
• Aluminium composite panels (ACPs),
• HPL
• Glass fibre reinforced concrete
• Metal claddings (zinc, copper, and steel)
• Fibre cement boards and wood
• FRP (Fibre-reinforced Plastic), GRG (Glass Reinforced
Gypsum), UHPC (Ultra High Performance Concrete),
Stone CNC (Computerised Numerical Control)
• Precast Concrete
• GFRC
• Cladding can be made of any of a wide range of
materials including wood, metal, brick, vinyl, and
composite materials that can include aluminium,
wood, blends of cement and recycled polystyrene,
wheat/rice straw fibres.[2]
• Rainscreen cladding is a form of weather cladding
designed to protect against the elements, but also
offers thermal insulation.
• The cladding does not itself need to be waterproof,
merely a control element: it may serve only to
direct water or wind safely away in order to
control run-off and prevent its infiltration into the
building structure.
• Cladding may also be a control element for noise,
either entering or escaping. Cladding can become a
fire risk by design or material.
 EXTERIOR WALL SYSTEMS

• Water can penetrate exterior wall joints and assemblies by the kinetic energy of raindrops, gravity flow,
surface tension, capillary action, and pressure differential.
• According to how exterior walls deter water penetration, they can be categorized as follows:
• Mass wall systems, such as concrete and solid masonry walls, shed most rain at the exterior face, absorb
the remainder, and dry by releasing the absorbed moisture as vapor.
• Barrier wall systems, such as EIFS walls, rely on a continuous seal at the exterior face, which requires
ongoing maintenance to be effective in resisting solar radiation, thermal movement, and cracking.
• Drainage walls, such as traditional stucco and clapboard walls, use a drainage plane or moisture barrier
between the exterior cladding and supporting wall for additional moisture resistance.
• Rainscreen walls consist of an outer layer ofcladding (the rainscreen), an air cavity, and a drainage plane on
a rigid, water-resistant, and airtight support wall.
 Installation Methods for Stone
Cladding

Direct-Adhered
• The cladding will be placed directly onto your wall and stuck in
place using glue, cement, or a specialized adhesive. The method
nonetheless only works best for interior walls.
• This is because these are shielded from the exterior elements that
might affect the functioning of the adhesive. These elements
contribute to the premature failure of your cladding.
Spot Bonding
• This, like the direct-adhered technique, will use an adhesive to
stick the stone cladding onto your walls. Even so, the adhesive, in
this instance, is only applied to about 10% of the installation area.
• This way, there are gaps left between the cladding to allow water
and air movement. This reduces water damage and staining to
your substrate. Spot bonding is more costly compared to direct
adhering because it uses strong specialized epoxies in place of
glue.
 Installation Methods for Stone
Cladding
Mechanical Bonding
• This is the ideal choice for exterior stone cladding. It uses anchors
embedded in your walls to support the cladding.
• Since holes will be drilled into your cladding to be tied using
mechanical ties to the anchors, the stone cladding used in this
case should be adequately thick and strong.
• The ideal cladding is one with a minimum thickness of one inch.
• A 3/4-inch gap is left between your walls and the cladding to
promote water drainage and air movement.
Aluminum Backing
• Structural support for installation comes from aluminum panels
attached to your wall using runner clips.
• The stone cladding pieces are then mounted to these panels. The
panels are often interlocked to generate a seamless cladding
appearance.
• Though inexpensive, aluminum backed installation only supports
lightweight stone cladding.
STONE CLADDING

https://youtu.be/f7msKBBtEfw
Control+click

https://youtu.be/hJGerTpfzsw
Stone Cladding
CLADDING STONE - DEFINITION :
• “A facing of thin stone - limestone, sandstone,
slate, marble or granite – additional to the
required statutory construction, but not so bonded
to that construction as to exert common action
under load”.

The design phase.

• The decision on the type of cladding needs to be
made early in the design process and will be
determined by the function of the cladding, the
size, height and location of the project, the type of
structure and the programme.
STONE CLADDING

https://youtu.be/f7msKBBtEfw
Control+click

https://youtu.be/hJGerTpfzsw
 PRECAST CONCRETE PANELS

• Precast concrete wall panels may be used as

nonbearing facings supported by a structural
steel or reinforced concrete frame.
• A variety of quality-controlled smooth and
textured finishes are available.
• Ceramic tile and thin brick or stone facings may
be fixed to the wall panels.
• Thermal insulation may be sandwiched in
the wall panel, attached to its backside, or
provided with a backup wall constructed on site.
• A precast concrete (PC) curtain wall is panelized
construction. The panels are constructed off-site,
under controlled conditions, and transported to
the site in ready-to-erect condition, greatly
reducing on-site construction time.
ARCHITECTURAL PRECAST CONCRETE (PC) CURTAIN WALL
PRECAST CONCRETE CLADDING

• Precast concrete cladding is formed by off-

site manufactured precast concrete panels,
which can be used to clad a wide range
of buildings, such as commercial
buildings, residential, retail, leisure,
hospitals, schools, and so on.
PRECAST CONCRETE CLADDING
• Precast concrete cladding is formed by off-
site manufactured precast concrete panels, which can be
used to clad a wide range of buildings, such
as commercial buildings, residential, retail, leisure,
hospitals, schools, and so on.
 CONNECTING THE PC CURTAIN WALL TO A STRUCTURE

• A concrete cover on both sides and the two way reinforcement in a

panel generally give a total of about 4 in. of thickness. Add to this the
thickness that will be lost due to surface treatment, such as abrasive
blasting and acid etching, and the total thickness of a PC wall panel
cannot be less than 5 in.
• The connections of PC curtain wall panels to the building’s structure are
among the most critical items in a PC curtain wall project and are
typically designed by the panel fabricator. Two types of connections are
required in each panel:
• Gravity load connections – BEARING SUPPORTS
• Lateral load connection – TIE BACKS
• There should be only two gravity load connections, also referred to as
bearing supports , per panel located as close to the columns as
possible. The lateral load connections, also referred to as tiebacks ,
may be as many as needed by structural considerations, generally two
or more per panel,
 CONNECTING THE PC CURTAIN WALL TO A STRUCTURE
Dimensional irregularities, both in the panel and in
the structure, require the use of leveling shims (or
bolts) under bearing supports during erection.
A tieback is designed to allow movement within
the plane of the panel. The connection must,
however, permit adjustment in all three principal
directions during erection
Brick – Masonry Veneer
Cladding
• Masonry veneer may either be
• (a) anchored masonry veneer
• (b) adhered masonry veneer
• Masonry veneer construction
consist of a single Wythe of
masonry serving as a weather
barrier and anchored but not
bonded to a supporting structural
frame.
• A brick veneer generally consists of
a single-wythe brick wall (generally
4 in. nominal thickness).
• In residential construction wood or
metal stud walls are typically faced
with brick veneer.
• The backup wall used with brick veneer may be
load-bearing or non-load- bearing and may consist
of one of the following:
• Wood or cold-formed steel stud
• Concrete masonry
• Reinforced concrete
• A wood stud (or steel stud) load-bearing backup
wall is typically used in low-rise residential
construction.
• Concrete masonry, non-load-bearing steel stud,
and reinforced-concrete backup walls are generally
used in commercial construction.
• In fact, brick veneer with concrete masonry backup
is the wall assembly of choice for many building
types, such as schools, university campus buildings,
and offices.
Brickwork Cladding Support System

Application
multi-storey buildings, where a traditional
brick facade is required.

Brickwork movement
to allow for climatic changes and differential
movement between the cladding and main
structure
Vertical movement joints may also be
required at a maximum of 12 m spacing.

Lateral restraint
provided by normal wall ties between inner
and outer leaf of masonry, plus sliding brick
anchors below the support angle.
Brick – Masonry Veneer Cladding
• Among all contemporary exterior wall cladding systems, masonry (brick,
CMU, and stone) veneer is most widely used, and within the three
masonry veneer systems, brick veneer is by far the most popular system.
• Its popularity lies in its durability, fire resistance, and aesthetic appeal.
• Additionally, the system requires almost no maintenance and can be used
for buildings of all heights and complexity—from high-rise to low-rise and
from simple rectilinear facades to intricate ones.
SUPPORT FOR BRICK VENEER

• The dead load of brick

veneer may be borne by the
wall foundation without any
support at intermediate
floors up to a maximum
height of 30 ft above ground.
• Uninterrupted foundation-
supported veneer is
commonly used in one- to
three-story wood or cold-
formed steel frame buildings,
SUPPORT FOR BRICK VENEER —
SHELF ANGLES ANCHORED TO
STRUCTURAL FRAME
• In mid- and high-rise buildings, the veneer is generally
supported at each floor using (preferably hot-dip
galvanized) steel s helf angles (also referred to as
relieving angles) .
• Shelf angles are supported by, and anchored to, the
building’s structure.
• In a frame structure, the shelf angles are anchored (welded
or bolted) to the spandrel beams,
LINTEL ANGLES
• LOOSE-LAID - Whether the veneer is
supported entirely on the foundation or at
each floor, additional dead load support for
the veneer is needed over wall openings.
• The lintels generally used over an opening in
brick veneer are of steel (preferably hot-dip
galvanized) angles, Figure 28.8 .
• Unlike the shelf angles, lintel angles are not
anchored to the building’s structural frame
but are simply placed (loose) on the veneer,
Brick – Masonry Veneer Cladding
• Availability: Most common cladding system.
• Maintenance: Lowest maintenance if unpainted
and not rendered; otherwise high.
• Durability: Highly durable on well designed
footings. Less suited to seismic loads and reactive
soils.
• Breathability: High with very low condensation risk
when breathable sarking is used, due to well
ventilated, wide cavity.
• Waterproofness: Low. Requires wide cavity and
specially designed ties, flashings and cavity
drainage. Cavity ties and weep holes must be
cleared of mortar droppings on completion.
• Insulation: Poor insulator.
• Fire resistance: Excellent but structural capacity
during fires is under-utilised in non-loadbearing
cladding applications (e.g. brick veneer)
•
• FIBRE CEMENT
•
Manufactured in a strict factory controlled
environment, most fibre cement products have
high sustainability credentials.
• However, considerable variations can occur
between brands and manufacturing plants
depending on waste recovery rates, water
sourcing and recycling, and energy efficiency
(particularly the recovery of autoclave energy).

• Typically produced as planks, weatherboards or

sheets.
• Sheet products are generally thinner and
therefore less material intensive but often have
higher site waste rates — particularly on complex
designs and shapes.
Maintenance: Low maintenance due to stability
but requires painting to maintain waterproofness.
Some applications in sheltered locations require
one-off staining. Stamped or sawn patterns
applied during manufacture can add aesthetic
variation.
• FIBRE CEMENT
•
• FIBRE CEMENT
•
Fiber cement is usually compared to other budget-
friendly heavily processed materials
like PVC or aluminum panels.
• One of the main reasons that architects opt for
fiber cement over other low-cost alternatives is
that, when detailed properly, it looks like a much
more expensive product.
• Dense, high-quality fiber cement panels can mimic
the appearance of stone or concrete at a much
lower cost.
WOODEN CLADDING
WOODEN CLADDING
WOODEN CLADDING
WOODEN CLADDING
Typical wooden
siding
Plywood siding
• Maintenance: Moderate to low depending on grade.

Durability: Moderate to very high depending on grade, species,

glues and maintenance. Low grade ply requires similar protection to
timber. While expensive, marine grade ply is among the most
durable finishes available for corrosive environments (e.g.
waterfront) but can contain toxic glues and preservatives.

Breathability: Generally low but variable with thickness and grade.

Breathable sarking is essential and vapour cavities are strongly
recommended in high condensation risk climates.

Waterproofness: High depending on finish and joint detailing.

Insulation: Limited.

Fire resistance: Poor to average.

Finishes: Generally painted, oiled or stained.

•
METAL CLADDING
Metal Cladding
 The four types of metal that are most
Metal cladding commonly used are:

•Steel: Generally the most affordable but not

as durable. Usually supplied hot-drip
galvanised to provide a robust finish.

•Aluminium: Very lightweight, with a hard

protective layer that protects
against corrosion.

•Zinc: Highly durable and weathers to an

aesthetically-pleasing lead-like hue if left
untreated.

•Copper: Capable of achieving long

lifespans and requires very
little maintenance.
 METAL Cladding options

• ACM Panels
• Corrugated Panels
• Dry Joint Panel Systems
• Metal Skin Panels (thick and thin)
• Open Joint Panels
• Perforated Panels
• Phenolic Panels – HPL PANELS
 https://youtu.be/YC7fzxXwb24
MATERIAL OVERVIEW:
• HPL (High Pressure Laminates) are
highly durable exterior wall cladding
products that are available in a diverse
range of decors to create a
contemporary, cost effective
rainscreen façade.
• HPL panel manufacturers have a large
range of colors and patterns to select
from, and can offer either printed
images or actual wood grains.
• Brands : 1. FunderMax exterior wall
cladding
• Produced in lamination presses under
great pressure and high temperature.
• Double-hardened acrylic PUR resins
provide extremely effective weather
protection that is particularly suitable
for long-lasting balconies and façade
claddings.
MATERIAL OVERVIEW:
• HPL (High Pressure Laminates)

1. Scratch resistant
2. Easy to clean
3. Solvent resistant
4. Easy to install
5. Extremely weather resistant
6. Optimal light-fastness
7. Double hardened
 Steel
•
Steel cladding comes in a wide variety of cold formed profiles with varying base metal
gauge and structural capacity. New steel finishes are being trialled which rely on
weathering to produce a thick rust coating that protects the steel from further
corrosion and allows it to become more corrosion resistant over time.

Maintenance: Very low. Steel finishes are very durable and, while coloured finishes
often fade, they rarely require repainting for maintenance. Because steel expands,
adequate tolerances must be left at joins and junctions.

Durability: Durability is very high: galvanised corrugated steel can last more than 100
years on a building and is a material highly sought after for decorative reuse. However,
it must be installed carefully, with fixings and flashings that are compatible for
corrosion and life span. Scratches, lead pencil marks and swarf from cutting can lead
to early corrosion.

Breathability: Steel cladding is a vapour barrier and its excellent conductivity makes it
highly susceptible to dew-point formation and water vapour condensation. It should
always be fixed via a breathable cavity (often provided by the profile).
Metal cladding profiles
• Unique secret-fix joint design allows
primary fixings to be hidden from view,
which combined with the smooth flat
face provides outstanding external
aesthetics.
• Flexible design allows vertical and
horizontal panel installation.
• Available with a wide range of flashing
options, ancillaries, integrated window,
integrated louvre, fabricated corner
and curved panel options
 Aluminum Composite Material (ACM
• Aluminum Composite Material (ACM) panels are
commonly used for cladding buildings, typically as
a form of rainscreen.
• A rainscreen (sometimes referred to as a ‘drained
and ventilated’ or ‘pressure-equalised’ façade) is part of
a double-wall construction.
• The rainscreen itself simply prevents significant amounts
of water from penetrating into the wall
construction. Thermal
insulation, airtightness and structural stability are
provided by the second, inner part of the wall
construction.

ACM cladding consist of two skins of aluminum bonded to either

side of a lightweight core of materials such
as polyethylene (PE), polyurethane (PUR), profiled metal or a
mineral core. It is a popular product because of its precise flatness,
variety of surface finishes and colours, light weight and formability.
However, during a fire, the panels can delaminate, exposing
the core material.
RAINSCREEN
• Rainscreen is constructed as panels with a
ventilated cavity between them and an inner air
barrier.
• Rainscreen is either built by mounting support
rails and panels on an inner wall of concrete,
brick or blockwork (overcladding) or is part of a
curtain wall (panelised, unitised or stick) that is
self-supporting with integral cavity and air barrier
(integral rainscreen) Figure
• The panels may be of any material including
metal, gfrp, stone, glass and ceramics.
https://youtu.be/Y23Rx_mU5e0
There are two basic types of rainscreen:
• Drained and ventilated rainscreen cladding systems allow any penetrating moisture to drain or
evaporate and vent to the outside. In this case it is necessary to detail the façade so that any
penetrating water cannot cross the gap between the rainscreen and the
internal wall construction.
• Pressure-equalised (PE) rainscreen cladding systems allow the movement of air between the
inside and outside of the rainscreen. This equalises the pressure across the rainscreenso
that water is not driven, or sucked through the joints.
 RAINSCREEN CLADDING
• Comprises a number of layers each with a separate
function with regard to weather tightness, insulation
and ventilation.
• Overcladding - a superficial treatment, applied either as
a component of new construction work, or as a facade
and insulation enhancement to existing structures.
• The outer weather resistant decorative panelling is
`loose fit' in concept, which is easily replaced to suit
changing tastes, new materials and company image.
• Panels attach to the main structure with a grid of simple
metal framing or vertical timber battens.
• This allows space for a ventilated and drained cavity,
with provision for insulation to be attached to the
substructure; a normal requirement in upgrade/
refurbishment work.
RAINSCREEN CLADDING

Note (1): Cladding materials include, plastic laminates, fibre cement, ceramics,
aluminium, enamelled steel and various stone effects.
Note (2): Anti-bird mesh coated with intumescent material to form a fire stop cavity
barrier.
RAINSCREEN WALL SYSTEMS
 Rain-screen cladding system
• Rain-screen cladding system is a form of double-wall construction that uses an outer layer to
keep out the rain and an inner layer to provide thermal insulation.
• It prevents excessive air leakage and carries wind load. The outer layer breathes like a skin while
the inner layer reduces energy losses.
• The main benefit of rain-screen cladding systems is that it protects the structure of the building,
whether it’s a steel frame or masonry based system, from the weather elements, especially
rainwater.
• It does this because the cladding panels form a barrier to rainwater, preventing it from
penetrating across the rear ventilated cavity and reaching the exterior wall of the building.
• This process is helped by air continually circulated up through the ventilated cavity, driving away
any moisture that penetrates between the panels, upwards and out at soffit level before it
reaches the building structure.
• Most wall systems (brick and stone veneer, siding, EIFS, cement board, etc, are designed to work
as part of a rain screen wall system – there are few barrier walls left, other than precast concrete
panels, which have a rain screen caulking system that helps drain these assemblies.
 RAINSCREEN WALL SYSTEMS
• Simple rainscreen walls, such as
brick cavity walls and furred out
clapboard walls, rely on cladding to
shed most of the rain while the air
cavity serves as a drainage layer to
remove any water that may
penetrate the outer layer.
• The cavity should be wide enough to
prevent the capillary movement of
this water from bridging the cavity
and reaching the support wall
1.Drained cavity wall
2.
 RAINSCREEN WALL SYSTEMS - Pressure-equalized
rainscreen (PER) https://youtu.be/V7rHcVbhjEY

• Pressure differential can drive water through

an opening in a wall assembly, no matter how
small, when water is present on one side of the
opening, and the air pressure on that side is
greater than that on the other side.
• Pressure-equalized rainscreen (PER) walls
utilize vented cladding and an air cavity, often
divided into drainable compartments, to
facilitate pressure equalization with the
outside atmosphere and limit water
penetration through joints in the cladding
assembly.
• The primary seals against air and vapor are
located on the indoor side of the air cavity,
where they are exposed to little if any water
 PER - RAINSCREEN
• Rain screen cladding systems aim to protect a
building’s wall construction from damages that
can occur through moisture penetration.
• The air cavity design behind a cladding
material allows air to flow through the space,
which dries the insulation as well as the back
of the cladding panel.
• In theory, pressure equalization means a zero
air pressure differential at all times across the
rainscreen, i.e., a complete elimination of the
driving force for pressure-induced water
penetration.

In practice, the wall assembly must comprise three components

1. a rainscreen (i.e., vented cladding),
2. a compartmented air chamber
3. an air barrier system.
The air chamber compartments must be small enough, the air barrier system
must be airtight enough, and the area of the venting through the rainscreen must
be large enough to allow sufficient air to move in and out of the compartments
under the applied air pressure.