03 A Building Finishing 2020 2021 Exterior Wall Cladding

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The Hashemite University Fall Semester

Faculty of Engineering Building Finishing


Architectural Department 2020/2021

DESIGNING EXTERIOR WALL SYSTEMS


CLADDING WITH METAL AND GLASS
INTRODUCTION

The building enclosure (also called the building envelope) separates the indoor environment from the outdoors so
that building occupants remain comfortable, interior conditions are suitable for the building’s uses, and the
components of the building structure and finishes themselves are protected.
Roofs, exterior walls, basement walls, slabs on grade, doors, windows, and skylights are all example parts of the
building enclosure.
Design of the building enclosure is an intricate process that merges art, science, and craft in the satisfaction of the
many demands placed on these parts of the building. Some elements of the building enclosure are also visually
prominent and play important roles in the building’s architectural expression. A part of the building with uniquely
complex functional requirements and exposed to the harshest conditions is at times, also, among the most
important to our visual and spatial appreciation of
the building.

HISTORY

Until the late 19th century, nearly all large buildings were built with exterior loadbearing walls made of solid brick
or stone masonry. In addition to performing as building enclosure, these walls supported a substantial portion of
the floor and roof loads of the building. While such walls can perform well in unconditioned buildings and can be
long lasting, from a modern perspective they have limitations:
They are poor thermal insulators. And they are heavy, requiring large foundations and limiting their height.
In contemporary construction, the loadbearing masonry wall has evolved with higher-strength, reinforced masonry
and the addition of thermal insulating materials, water management provisions, air barriers, and vapor retarders.
These walls can be made thinner, lighter, and stronger, while performing all the functions required of a modern
building enclosure. In addition, the palate of materials available for the construction of contemporary loadbearing
walls has grown to include
site cast and precast concrete, steel, and wood. With all of these improvements, loadbearing exterior walls remain
attractive, economical, and high-performing choices for many low- and medium-rise buildings.
The first steel-framed skyscrapers, built in the late 19th century, introduced the concept of the nonloadbearing
curtain wall, an exterior wall supported at each story by the structural frame. The name “curtain wall” derives
from the idea that the wall is thin and hangs like a curtain on the structural frame.
The earliest curtain walls were constructed of masonry. The principal advantage of the curtain wall is that because
it bears no vertical loads except its own weight, it can be thin and lightweight regardless of the height of the
building. In comparison, a masonry loadbearing wall becomes prohibitively thick and weighty at the base of a very
tall building.
For modern curtain walls, materials such as glass, aluminum, steel, and thin, reinforced concrete and masonry are
favored for their strength, durability, light weight, and weather resistance. Because curtain
walls are used on tall buildings; they are made from noncombustible materials. They may be assembled in place
from individual components or prefabricated offsite in larger sections before being transported to the construction
site, lifted into position, and attached to the building frame. While the term curtain wall applies to any
nonloadbearing wall enclosure system suspended from the building frame, it is sometimes used to refer more
narrowly to only the metal and glass systems that are the typical enclosure of choice for the tallest buildings.

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The Hashemite University Fall Semester
Faculty of Engineering Building Finishing
Architectural Department 2020/2021
We will examine curtain walls that are made of metal and glass, and we will look at curtain walls made of masonry
and concrete.

EXTERIOR WALL CLADDING – (WALL SYSTEMS IN GLASS) TYPOLOGY

Transparency, luminosity, and elegance are the reasons for the popularity of glass walls in modern architecture.
Most glass walls are constructed with aluminum sections to support the glass. In other words, the glass panes are
held within vertical and horizontal aluminum framing members. Therefore, they share some of the characteristics
of their smaller counterparts—the aluminum windows. However, there are many differences between the two:
scale, aesthetic character, performance properties, design, detailing, and installation.
Three commonly used glass-aluminum wall system systems are
• Glass-aluminum curtain walls
• Punched and strip glazing systems
• Storefront systems
The vast majority of contemporary buildings include one or more of these systems in the same building.
Of the three systems listed above, the most frequently used and the most complex is the glass-aluminum curtain
wall system, which is presented here in detail.

GLASS-ALUMINUM CURTAIN WALLS

Because of their common use, glass-aluminum curtain walls (or simply glass curtain walls)
are constantly evolving in their design and performance. Therefore, a succinct classification
that includes all contemporary glass curtain walls is impossible. The American Architectural
Manufacturers Association (AAMA), an association of the manufacturers of windows and curtain walls, however,
classifies glass curtain wall systems into five types based on their anatomy:
• Stick-built (or, simply, stick) systems
• Unitized systems
• Unit and mullion systems
• Panel systems
• Column cover and spandrel systems
These systems are illustrated in Figure 32.1 . The stick system is the oldest and the most widely used system. The
remaining four systems are different from the stick system because they consist of prefabricated wall units similar
to the (opaque) curtain wall panels.

S TANDARD AND C USTOM C URTAIN W ALL S YSTEMS


Most major glass curtain wall manufacturers have their own facility for extruding the aluminum sections. Walls
constructed from a manufacturer’s commonly used and pretested aluminum sections are referred to as standard
walls .
Custom curtain walls utilize cross-sectional shapes extruded specifically for a project in response to an architect’s
design. Because the cost of dies and other equipment required to
extrude custom cross sections can be recovered from just one fair-size project, custom curtain
walls are fairly common. Custom walls should, however, be tested for performance
before they are used in a project. Performance data for standard walls are available from the

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Architectural Department 2020/2021
manufacturers.
Walls made from standard components are obviously more economical. However,
this does not imply that the standard components yield only one type of wall design. In
fact, the components are generally quite adaptable, and manufacturers can provide a
few custom components for a standard system, so that the facade expressions obtained
from the use of standard components can be numerous. If the number of custom components
in a wall becomes excessive, the cost of a standard wall may approach that of a
custom wall.

a) STICK SYSTEM
In the stick system, the curtain wall is
installed piece by piece at the site.
Generally, the mullions are installed
first, followed by the rails.
Subsequently the glass panes are
installed within the mullion-rail
framework.
The anchorage of the wall to the
structural frame is through the
mullions. The mullions may span from
floor to floor or over two floors.
Thermal expansion and contraction of
mullions are accommodated by
expansion joints in mullions.
The system components are shop-
fabricated and shipped to the
construction site in a knocked- down
(KD) version. Therefore, the system has
relatively low shipping costs and also
permits a greater degree of on-site
adjustment as compared to the other
systems.
Its disadvantages include longer on-site
assembly time and more on-site labor
than the other systems.

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Faculty of Engineering Building Finishing
Architectural Department 2020/2021
(b) UNITIZED SYSTEM
A unitized system consists of framed
wall units that are shopfabricated,
preassembled, and generally preglazed.
The units are designed so that the
vertical and horizontal members in
adjacent units interlock to form
common mullions and rails. The units
may be one or two stories high. They
are anchored to the building’s
structural frame in essentially the same
way as the mullions in the stick system.
The advantage of this system is its
greater degree of quality
control resulting from shop fabrication.
Its disadvantages are the
greater shipping cost because of the
added bulk from assembled
units, the need of a greater degree of
protection of units during
transporation, and a lower degree of
field adjustment.

(c) UNIT AND MULLION SYSTEM


The unit and mullion system
combines the
advantages of both the stick system
as well
as the unitized system. It is
constructed by
first installing the mullions;
subsequently,
factory-assembled units are placed
between the mullions.
Because the system is a
compromise between the stick and
unitized systems, it has the
advantages and disadvantages of
both, i.e., its transportation cost is
lower than that of the unitized
system but greater than that of the
stick system. A greater degree of
site adjustability is available in the
unit and mullion system, but it is
less that of the stick system.

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Architectural Department 2020/2021
(d) PANEL SYSTEM
The panel system consists of
preassembled (and sometimes
Pre-glazed) homogeneous sheet
metal panels with glass infills that
generally, span from floor to floor.
The curtain wall’s appearance is
more integrated and
comprehensive rather that a grid
pattern of horizontal and vertical
elements.
The panels can be formed by
stamping or casting. The casting
system is economical only where a
large number of identical panels
are needed.

(e) COLUMN COVER AND


SPANDREL SYSTEM
This system, though not a true glass
curtain wall system, consists of
separate column covers connected
to spandrel covers that generally
span from column to column. Infill
glazing units may either be
preassembled or assembled at the
site like those of a stick-built
system.
The system provides an
independent expression
of the structural system rather than
concealing it behind a (more
homogeneous) wall.

METHOD OF CONSTRUCTION

ANCHORAGE OF A STICK -BUILT GLASS CURTAIN WALL TO A STRUCTURE

Like other curtain walls, a glass curtain wall must be spaced away from the building’s structural
frame to account for the small dimensional variations (within the allowed tolerances)

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The Hashemite University Fall Semester
Faculty of Engineering Building Finishing
Architectural Department 2020/2021
in the structural frame. A 2-in. space is generally the minimum requirement. A wider space
may be required for tall buildings.

D EAD -L OAD A NCHORS AND E XPANSION A NCHORS


As shown in the Figure, a stick-built glass curtain wall consists of vertical members (mullions ) and horizontal
members ( rails ). The profiles of both mullions and rails are almost identical and are tubular in cross section.
The wall is anchored to the building’s structural frame through the mullions. All mullions in a wall are installed first;
then the rails are inserted between them. Three rails are commonly used per floor to create two separate areas of
glass at each floor—vision glass and spandrel glass.
In a building (or part of a building) where there is no vision glass, such as in a multistory parking garage,
intermediate rails are needed only to reduce the size of glass panes. Two rails per floor are commonly used in that
situation. The center-to-center spacing between mullions is generally 4 to 6 ft, depending on the lateral load
intensity and the desired appearance of the facade.
To allow for the expansion and contraction of mullions caused by temperature changes, each mullion must be
provided with expansion joints. Thus, the mullions consist of short lengths (one or two floors tall) that terminate in
expansion joints at both ends.

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Architectural Department 2020/2021

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Faculty of Engineering Building Finishing
Architectural Department 2020/2021

Figure 1 Support systems for single-span and curtain wall mullions

O UTSIDE -G LAZED AND I NSIDE -G LAZED C URTAIN W ALLS


One of the factors that determines the cross-sectional shapes of mullions and rails is whether
the glass in the wall is to be installed from the outside or the inside of the building, referred
to, respectively, as
• Outside-glazed curtain walls
• Inside-glazed curtain walls

In an outside-glazed wall, the glass panes are installed from the outside of the building by
workers standing on a scaffold or staging. This method of installing glass is less efficient and
more expensive due to the cost of scaffolding or staging. It is generally used for low- to midrise

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Architectural Department 2020/2021
buildings. The glass in an outside-glazed wall can be secured in two ways:
• Pressure plate–captured glass (Figures 2 and 3 )
• Structural silicone sealant–adhered glass (Figure 4 )
In an inside-glazed wall, the glass is installed by workers standing on the appropriate
floor of the building. The system is more efficient because it does not require scaffolding or
staging. It is the system of choice for high-rise buildings. However, the cross-sectional
shapes of mullions and rails for the inside-glazed system are more complex than the corresponding
shapes for the outside-glazed system.

O UTSIDE -G LAZED W ALLS (P RESSURE P LATE –C APTURED G LASS )


In an outside-glazed curtain wall, the glass is held by horizontal and vertical pressure plates,
which are fastened to the mullions and rails with screws. A plastic insert is used between the
pressure plate and the mullion (or the rail), which functions as a thermal separator. The
pressure plates are finally covered with Snap-On covers, Figure 2.
Because the covers are the only externally visible part of the curtain wall frame, they have
a major influence on the curtain wall’s appearance. The covers can be profiled into various
shapes.
The exterior and interior gaskets should prevent water from leaking through the wall.
However, a curtain wall system typically includes accommodations for the drainage of
water, should it penetrate beyond the gaskets. This is accomplished through drainage weep
holes in the pressure plates and the covers. Thus, in a typical curtain wall, each glass-pane
frame is drained independently.
.

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Architectural Department 2020/2021

Figure 2 Typical details of an outside-glazed glass curtain wall (pressure plate–captured glass).

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Architectural Department 2020/2021

Figure 3 Typical details of an outside-glazed glass curtain wall (pressure plate–captured glass).

Figure 4 Typical details of an outside-glazed curtain wall (structural silicone sealant–adhered glass).

I NSIDE -G LAZED W ALLS

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In an inside-glazed wall, pressure plates are not used. Therefore, the aluminum curtain wall sections are different
from those used for the outside-glazed wall. These sections include glazing pockets—in both mullions and the
bottom rail—of an opening. The top rail of the opening is open and has no glazing pocket. The openness allows the
glass to be inserted in the opening. After the glass is inserted, a glazing stop is snapped on the top rail of the
opening from the inside. This secures the glass in the opening, Figure 5 (b).
Figure 5 (c) shows a plan view of the process of inserting the glass. Other details of an inside-glazed wall are shown
in Figure 5 (a) and (d). An important point to note is that in the inside-glazed wall, the mullion and rail covers must
be installed before inserting
the glass.

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Architectural Department 2020/2021

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Architectural Department 2020/2021
Figure 5 Typical details of an inside-glazed curtain wall.

Figure 6 In an inside-glazed in an inside-glazed curtain wall, the covers are installed before the
glass. In this photo, an installer is installing the snap-on cover on the mullion from an upper floor
and is helped by an installer at the lower floor. In an outside-glazed curtain wall, the covers are
generally installed after installation of the glass and pressure plates.

Figure 7 Typical floor-level, sill-level, and ceiling-level details of an outside-glazed glass curtain wall

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Architectural Department 2020/2021
STRUCTURAL PERFORMANCE OF A GLASS-ALUMINUM WALL

The most important structural requirement of a glass-aluminum wall is its ability to resist lateral loads (particularly
wind loads), including missile-impact resistance in hurricane prone regions. Just as the design of a glass-aluminum
wall’s anchorage to the structure is accomplished by the wall manufacturer (or installer), its lateral-load resistance
design is also provided by the manufacturer (or installer) based on the lateral-load intensities provided by the
project architect or structural engineer.
Manufacturers generally have several standard sections designed to suit various lateral load intensities. For high
lateral-load intensities, a strategy often used is to enclose structural steel (or aluminum) sections within the
mullions, Figure 8. The enclosed steel sections and the mullions are fastened together to produce a composite
action between them. Structural C- or I-sections are
commonly used as enclosed sections. Channels
provide the advantage of nesting, so that two or three
channels may be used within the same mullion. The
enclosed steel sections are suitably coated to prevent
galvanic action between the aluminum and steel.
An alternative to enclosed steel sections is to anchor
the mullions to an independent steel structural frame,
Figure 9 . This strategy is generally used in a tall glass-
aluminum wall where the mullions do not have
intermediate supports to reduce their span, such as
those provided by the floor structure in a multistory
curtain wall.
Figure 8 One of the ways to increase the lateral-load resistance of
aluminum mullions is to enclose structural steel sections within
them.

Figure 9 A tall glass wall with standard curtain wall sections anchored to an interior structural steel vertical member to provide
lateral load support to aluminum mullions. In this building, a steel pipe support is used. In taller walls, vertical steel trusses are
common.

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ENVIRONMENTAL PERFORMANCE CRITERIA FOR A GLASS CURTAIN WALL

The nonstructural performance of a glass curtain wall is just as important as its structural
performance. For standard curtain walls, manufacturers provide the values for these criteria based on
the tests conducted by recognized third-party laboratories. For custom walls, technical
design support is generally available from the manufacturers. For a complicated wall design,
the architect may need additional help from a curtain wall design consultant and a specialized
testing laboratory to determine the wall’s performance. Among the important nonstructural design criteria for a
glass curtain wall are:
• Keeping water out
– Prevent the entry or rain, snow and ice into the building
– Water is driven inwards by many forces such as wind, air pressures and gravity
– Water problems are more acute in tall buildings
• Preventing air leakage
– Prevent unintended passage of air between indoors and outdoors
– Smaller air leaks waste conditioned air, carry water through the wall and allow noise to
penetrate
– Large air leaks cause imbalance in air distribution within the building
• Controlling light
– Control sunlight to balance between useful illumination and detrimental effects such as glare,
fading of materials and damage to skin
– Control can be provided by balance of amount of windows, exterior shading devices, types of
glass, and interior blinds and curtains
• Controlling the radiation of heat
– Interior surfaces can cause discomfort due to radiant heat transfer in summer and winter
– Shading devices, thermal insulation, thermal breaks
and appropriate glass can be used to control radiant
heat
• Controlling conduction of heat
– Resist the conduction of heat into and out of the
building
– Requires insulation plus avoidance of thermal bridges
– Thermal insulation requirements often dictated by
codes
• Controlling sound
– Isolate the inside of the building from noises outside and vice versa
– Requirements will vary by type of building and their location

• Controlling water vapor

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– Resist diffusion of water vapor to parts within wall with possibility of condensation
– Such condensation can cause loss of insulating value, corrosion of metals, and decay of wood
• Movement – thermal expansion and contraction
– Accommodate movements due to changes in temperature
– Differential thermal expansion and contraction of inside and outside of cladding
– Differential thermal expansion and contraction of cladding relative to frame

• Movement - moisture expansion and contraction


– Bricks, building stone, concrete and wood change dimension due to moisture content and can
cause problems which need to be taken into account

• Movement - Structural
– Adjust to structural movements in frame due to:
– Building foundation settlement
– Shortening of columns
– Wind and earthquake forces can cause racking effect
– Long term creep of concrete
– Wall systems can result in
– Broken glass
– Buckled cladding
– Sealant failures
– Broken cladding attachments
– Failure of whole wall
• Resisting Fire
– The exterior wall of a building can interact in several ways with building fires
– There are a number of building code provisions relating to the construction of building exterior
walls systems with respect to fire safety
• Weathering gracefully
– Cladding must weather gracefully
– Dirt and grime should not detract from the aesthetics
– Cladding must resist oxidation, UV degradation, breakdown of organic materials, corrosion of
metallic components, chemical attack and freeze thaw damage
– Glass-cleaning-equipment load

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RAINWATER PENETRATION CONTROL

BARRIER WALLS
Exterior above-grade walls that rely on the elimination of openings as the primary strategy for keeping water out
are called barrier walls (Figure 10A).

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Examples include precast concrete and glass-reinforced concrete curtain walls, tilt-up concrete, and insulated
metal wall panels. These may also be called
face-sealed walls because the water barrier is
located at the exterior face of the wall. With
face-sealed barrier walls, the most
vulnerable part is often the joints between
wall panels. These must remain as perfectly
watertight as possible, maintain flexibility to
absorb movements between panels, and
withstand all of the stresses of the exterior
environment to which they are permanently
exposed. For these reasons, as an alternative
to face-sealed
joints, barrier wall systems may rely on Figure 10 Three types of exterior walls. (A) Barrier walls prevent water ingress
multistage joints designed with more by eliminating or sealing all openings in the wall. (B) Mass walls allow water
complex strategies for keeping water out. into the wall, where the water is temporarily stored until it can evaporate back
out. (C) Drained cladding includes a drainage space behind the exterior
cladding. Water that penetrates the cladding layer is captured in the drainage
space and then directed back out. In practice, exterior walls frequently combine
MASS WALLS features of two or three of these types. For example, as a second line of
defense against water intrusion, drained cladding walls usually include a water
A mass wall (Figure 10B) is a semipermeable barrier layer at the back of the drainage cavity.
barrier wall that allows water to enter through
small openings or pores. However, because of the
thickness and density of the wall, moisture can be stored safely within it for some time and then gradually released
back to the exterior (or sometimes the interior) through evaporation. Traditional solid masonry walls constructed
without a cavity function as mass walls. Modern masonry and site cast concrete walls, to the extent that
they are constructed without drainage provisions or face-sealed coatings, also may function as mass walls.

NEUTRALIZING THE FORCES THAT MOVE WATER


The third strategy for keeping water out of the building enclosure is to neutralize the forces that move water
through openings in the assembly. This strategy is commonly applied in the design of exterior walls, as illustrated
in concept in Figure 11. Wherever there are possible points of water entry through the building enclosure, the
techniques for counteracting the first four forces illustrated in the Figure 11 are relatively straightforward to
implement, mainly by manipulating the geometry of the joint or opening. Neutralizing the fifth force, air pressure,
is done by creating an airtight boundary behind
the opening. In this way, air pressure within the opening can quickly equalize that at the exterior, and sustained
airflows that could otherwise transport water through the opening are prevented. In idealized form, this strategy
for neutralizing air pressure differences is called pressure-equalized design. In practice, varying degrees of pressure
equalization may occur within an opening or assembly.
Most wall enclosure systems that employ strategies for neutralizing the forces that move water through the
assembly also employ concealed barriers as a final line of defense against water leakage. In fact, continuous water-
resistant and airtight boundaries are essential parts of most exterior wall assemblies. Airtight boundaries are also
important for reducing energy losses in buildings, controlling condensation, and more.

DRAINED CLADDING, RAINSCREEN CLADDING, AND CAVITY WALLS

Drained cladding (also called rainscreen cladding) (Figure 10C) consists of an exterior cladding, a drainage space
behind the cladding, and a concealed air and water-resistive barrier behind
the drainage spaces. Drained cladding combines the strategies of minimizing openings and neutralizing forces to
keep water from penetrating the wall.

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The traditional masonry cavity wall is an example of drained cladding. In such walls, the outer masonry
veneer is separated from the backup wall by a vertical cavity an inch (25 mm) or more in depth. The forces of
momentum and air pressure are resisted primarily by the veneer. Water that penetrates the veneer is prevented
from crossing the cavity as surface tension and capillary action are neutralized by the open cavity space. Gravity is
exploited to drain water down the cavity and outward to the exterior over flashings and through weep holes at the
cavity bottom. A water-resistant coating or membrane
on the face of the backup wall serves as a concealed water barrier and last line of defense against water
penetration. This membrane also acts as an air barrier to control air leakage.
Drainage spaces of virtually any depth can be created in drained cladding. Water-resistant membranes that have
been “crinkled” or that have small plastic dimples adhered to their surface create voids as narrow as
approximately 1⁄16 inch (1 mm).
Thicker plastic drain mats inserted behind cladding are used to create spaces up to roughly 3⁄8 inch (10 mm) deep.
And furring systems made from wood, metal, or plastic can be used to create spaces of greater depths.
Deeper drainage spaces tend to improve drying in the assembly. Spaces approximately 3⁄8 inch
(10 mm) or deeper are sufficient to neutralize surface tension and capillary forces, allowing water to drain as freely
as possible. A space at least this deep also promotes greater air movement and moisture evaporation. When open
only at the bottom, such a space is described as vented, and when open at the bottom and at the top of the wall,
as ventilated.
The continuous flow or air through a ventilated drainage space improves evaporation and provides greater drying
potential compared to a vented cavity, which is open only at the bottom.
The principles of drained cladding are frequently applied in the design of joints within cladding systems
as well.

WATER-RESISTIVE BARRIERS

Drained cladding walls include a concealed surface that serves as the drainage plane, or water-resistive
barrier (WRB), to resist the passage of water further into the assembly. Traditionally, asphalt-saturated building
felts or papers applied over the wall sheathing were commonly used for this purpose. More recently, these
products have been mostly replaced by a variety of synthetic membrane products offering a broader range of
characteristics suitable to walls with different requirements. Synthetic
house wraps and building wraps are stapled to the wall sheathing in the same way as traditional building felts but
offer greater durability and resistance to air leakage. Self-adhered sheet membranes, in which one side of the
material is coated with a pressure-sensitive adhesive, form a continuous bond with the face of the wall sheathing,
as do membranes that are applied in liquid form and cured in place. Some sheathing products, such as plastic foam
insulation boards, specially coated wood panels, or glass-mat-
faced gypsum sheathing, when combined with appropriate sealing tapes and mastics, can also act
as water-resistive barriers.

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Figure 11 The five forces that can move water through


an opening in the building enclosure—gravity,
momentum, surface tension, capillary action, and air
pressure—are illustrated in cross section with the
outdoor side to the left. Each pair of drawings shows
(left) a horizontal joint between wall panels in which a
force moves water through the joint and (right) an
improved design for that joint that neutralizes this
force. Leakage caused by gravity is avoided by sloping
internal surfaces of joints toward the outside; such a
slope is called a wash. Momentum is counteracted with
baffles or labyrinth like geometry within the joint. Drips
and capillary breaks stop leakage caused by surface
tension and capillary action, two closely related forces.
Water pushed by moving air is counteracted by creating
airtight boundaries that neutralize air pressure
differences across the enclosure assembly.

DETAILS

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REFERENCES

Edward Allen and Joseph Iano, 2019, Fundamentals of Building Construction, Materials and Methods, 7th edition.

Mehta, M.; Scarborough, W.; Armpriest, D., 2013, Building Construction, Principles, Materials and Systems

Ching, Francis. Building Construction Illustrated. John Wiley; New York; 1991

Ramsey/Sleeper architectural graphic standards/John Ray Hoke, Jr., editor in chief.10 th

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