AEC Daily Course

8/12/2019 AEC Daily Course

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2012 Aluminum Extruders Council. The material contained in this course was researched, assembled, andproduced by Aluminum Extruders Council and remains its property. LEED and related logo is a trademarkowned by the U.S. Green Building Council and is used by permission. Questions or concerns about thecontent of this course should be directed to the program instructor.

luminum ExtrusionsAluminum Extruders Council1000 N Rand Rd, Suite 214Wauconda, IL 60084Tel: 1-847-526-2010

Email: [email protected]: www.aec.org

Photo courtesy of Scott Norsworthy
mailto:[email protected]://www.aec.org/http://www.aec.org/http://www.aec.org/mailto:[email protected]://www.aecdaily.com/http://www.aecdaily.com/


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Aluminum Extrusions

Presented By: Aluminum Extruders Council1000 N Rand Rd, Suite 214Wauconda, IL 60084

Description: Provides an overview of the characteristics, technical information, and benefits ofaluminum extrusions used as a building material, with a focus on whole building design, sustainabilityand application possibilities.


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Learning Objectives

At the end of this program, participants will be able to:

provide technical information as to the benefits of aluminum extrusions used as buildingmaterial in terms of strength and durability

outline the sustainable characteristics of extruded aluminum building products

present solutions on how to address some of todays building design challenges in lightof the increasing demand for green buildings

showcase various building and construction applications and innovations usingaluminum extrusions, and

relate the holistic applications of extruded aluminum products to the whole buildingdesign concept.


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A Few Facts About Aluminum

Lightweight

Aluminum is lightweight (low density)about of copper or steelyet is one of thestrongest construction materials available.

Aluminums high strength-to-weight ratio means that less of a buildings structure is spentsupporting its own weight.

Aluminum offers undiminished structural integrity over a long service life.

Buildings in seismic zones benefit even more from reduced weight, since seismic forcesare proportional to the structures weight.


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Structural Strength

Aluminums structural strength and stability is consistently strong, even under extremeconditions and temperature changes, in terms of elastic modulus/stiffness. Where plasticsmay become brittle at low temperatures, aluminum actually becomes even stronger atextremely cold temperatures, which is why NASA chooses it for many aerospace

applications.Aluminum:

is 34 times stronger than vinyl

is 43 times stronger than wood, and

when appropriately alloyed and treated, can be stronger than some steels, with ultimate

tensile strengths as high as 80,000 psi to 90,000 psi or more.


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Tensile Strength

Aluminums tensile strength and structural stability and rigidity mean that extrudedaluminum building components are more resistant to deformation caused by climatechanges and building movement over time. Aluminums unique enduring propertiesguarantee long-term performance with minimal maintenance.

Structural integrity is judged based upon the ability of a material to withstand loadsi.e.,its strength.

Tensile strength determines maximum load a material can carry under tension (whenstretched).

Structural stiffness and strength combine with light weight and ease of fabrication to form

the ideal building material.


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Modulus of Elasticity (E-value)

In terms of E-value, the modulus of elasticity, aluminum has greater resistance todeformation than either wood or vinyl.

By using extruded aluminum for window frames and curtain walls, manufacturers candesign slimmer, more elegant framing without sacrificing strength and rigidity. Slimmerframes mean larger glass areas and more natural daylighting.

The modulus of elasticity (E-value) indicates rigidity (stiffness) or resistance to bending.

Aluminum is 72 times more rigid than wood, and 23.2 times more rigid than vinyl (PVC).


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Resists the Ravages of Time and Temperature

Aluminum resists the forces of time. Its impervious to humidity, temperature and warping,or becoming brittle; that translates to longer service life. Because aluminum doesnt absorbmoisture, it wont swell, shrink, split, crack, rot, or rust.

In terms of appearance, aluminums corrosion resistance means that a buildings faadewill retain the finishes and visual appeal envisioned by the designer through decades ofwear.

Aluminum retains its physical properties over time.

Extruded aluminum building components resist deformation caused by climate changes

and building movement, and aluminum extrusions retain their basic structure, strength,stability, and durability.


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Aluminum Comes in Various Alloys and Tempers

Aluminum alloy designations begin with 1xxx series alloys. In the 2xxx series, aluminum isalloyed with copper. The 3xxx series alloys aluminum with manganese. 1xxx and 3xxxalloys are non-heat-treatable. They develop their strength characteristics from cold workafter extruding, section shape permitting. The 4xxx series alloys are not widely used due totheir low level of extrudability.

1xxx Series:99%+ Aluminum 2xxx Series:Al + Copper 3xxx Series:Al + Manganese 4xxx Series:Al + Silicon High corrosion resistance

Excellent finish surface

Easily joined by all methods

Lower strength

Excellent workability/poor machinability

High electrical and thermal conductivity

Applications: heat exchangers, pipe andtubing for carrying chemicals, foodstuffsand refrigerants

High strength

Relatively lowcorrosion resistance

Excellentmachinability

Heat-treatable Applications:

hydrauliccomponents, forgingstocks

Low to mediumstrength

Good corrosionresistance

Good workability andthermal stability

Applications:condensers

Not widely usedin extrusions


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Aluminum Comes in Various Alloys and Tempers

The 5xxx series alloys aluminum with magnesium and is also non-heat-treatable. The 6xxxalloys combine aluminum with magnesium and silicon. The 2xxx, 6xxx, and 7xxx seriesalloys, which are the highest strength aluminum alloys, attain their maximum strengththrough controlled heat treatment in the extrusion press, and sometimes in a separatefurnace. Properties and characteristics of aluminum extrusions, such as density,conductivity, corrosion resistance, finish, mechanical properties, and thermal expansion aremodified, depending on the alloying element.

5xxx Series:Al + Magnesium

6xxx Series:Al + Magnesium & Si licon

7xxx Series:Al + Zinc, Magnesium, Copper

Low to moderate strength

Excellent marine corrosionresistance

Very good weldability

Applications: marine

Most popular extrusion alloy

Good finish surface and strength

Good extrudability

Good corrosion resistance

Good machinability and weldability

Good formability and heat-treatable

Applications: windows, doors, curtain walls,storefronts, sign panels, light fixtures, van bodies,boat masts, scaffolds, cranes, truck trailers,railroad components, substations, towers andgeneral structures

High strength and toughness

Heat-treatable and good machinability

Applications: automotive, bumpers,head-rest bars, bumper back-up bars


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Aluminum Tempers

Temper designation refers to aluminum alloys being classified as heat-treatable or non-heat-treatable, depending on the method used to attain their maximum strength. Non-heat-treatable alloys in the 1xxx, 3xxx, and 5xxx series develop strength characteristics throughcold work after extruding, if the section shape permits.

Basic Temper Designations Typical Extrusion Tempers

F As Extruded No special control over thermalconditions or strain hardening; nomechanical property limits

O Annealed Thermally treated (fully annealed) toobtain the lowest strength temper

O = Fully annealed

H Strain-hardened Cold working used to increasestrength and hardness

H112 = Strain-hardened; used for non-heat-treatable alloys

T Thermally Treated Thermally treated to produce stabletempers other than F/O/H

T1 = Press-quenched and naturally aged

T4 = Solution heat-treated and naturallyaged

T5 = Press-quenched and artificially aged

T6 = Solution heat-treated and artificiallyaged


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Aluminum Is Sustainable

Aluminum is a non-combustible and naturalmaterial:

It is the third most abundant element inthe earths crust next to oxygen andsilicon, and the most abundant metal innature.

Aluminum is environmentally friendly andnon-toxic, including at high temperatures.

AnnualAreasOpened

for

Mining

AnnualAreasRehabili

-tated

-40 -20 0 20 40

Global Bauxite Mining SiteRehabili tation, km2


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Aluminum is recyclable: It is 100% recyclable with high scrap value.

Aluminum can be repeatedly recycled, retaining the same material physical properties.

73% of all the aluminum ever produced is still in use today.

Recycled aluminum retains value: At the end of its life, aluminum is 100% reusable.

In a 2004 study, the Delft University of Technology found that 95% of the aluminumused in building and construction is recycled at the structures end-of-life.

During deconstruction, aluminum is extracted for scrap value and reducesenvironmental impact by not being deposited in landfills.


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Primary Energy Demand for AluminumProduction

Greenhouse Gas Emissions Caused byAluminum Production

Recycling saves 95% of energy and GHG emissions compared to primary production.

0

20,000

40,000

60,000

80,000

100,000

120,000140,000

160,000

180,000

200,000

1991 1995 20060

2,000

4,000

6,000

8,000

10,000

12,000

14,000

16,000

18,000

1991 1995 2006

Primary Aluminum Production

17% Reduction

Secondary Aluminum Production58% Reduction

Primary Aluminum Production

42% Reduction

Secondary Aluminum Production

65% Reduction


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Benefits of Aluminum Recycling

Annually:

About 70 million barrels of crude oil equivalent of energy is savedenough oil to feedU.S. consumption for three days, or nearly one day of the worlds oil supply.

Approximately 2.4 million square meters of land is saved.

More than 45 million tons of fresh and sea water use is avoidedenough water toprovide for the needs of New York Citys eight million people for ten days.

Approximately 7.5 million tons of solid waste is avoided.

About 27 million tons of CO2equivalent of greenhouse gas emissions is avoidedequivalent to eliminating five large (1,000 MW) coal-fired power plants.

Total Life Cycle Impact: Recycling Is Key

Source: The Aluminum Association. Aluminum: The Element of Sustainability. September, 2011http://aluminum.org/Content/ContentFolders/Miscellaneous/Aluminum_The_Element_of_Sustainability.pdf . Accessed May 2012.
http://aluminum.org/Content/ContentFolders/Miscellaneous/Aluminum_The_Element_of_Sustainability.pdfhttp://aluminum.org/Content/ContentFolders/Miscellaneous/Aluminum_The_Element_of_Sustainability.pdf


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What Is an Aluminum Extrusion?

The extrusion process involves taking an aluminum alloy billet and forming it into anextruded shape by forcing it through a die that is designed in whatever configuration isrequired for a particular building component. Complex and customized shapes are oftenordered, as well as a wide range of standard shapes and sizes.


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Formability: Limitless Design Options

Aluminum extrusions are a truly versatile building material, especially when used oncommercial fenestration and building products.

Aluminum is ductile and easily formable, and can be extruded into a vast array of shapes,including complex, multi-void hollows, and customized designs. Extrusions provide for theplacement of metal precisely where its needed. Tight tolerances, even on thin-walledextrusions, can be consistently maintained.

Extrusions enablesophisticated design featuresto be easily incorporated asintegral building components.


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Wide Selection of Finishing Options

For many applications, aluminum needs no protective coatingbecause it is adequately protected by the thin, transparentoxide which covers its surface on exposure to air.

Aluminum extrusions are particularly receptive to high-performance architectural coatings, helping to ensuremaintenance-free performance and longer service life.

Where additional protection or decorative finishes aredesired, aluminum accepts a range of finishing options.Finishing methods include anodizing, painting and powdercoating, allowing a customized look and limitless colorchoices. Technological advances make these finishesextremely durable and environmentally friendly. Pre-treated

aluminum provides the ideal material on which to deposit acoating or finish. Aluminum manufacturers have developedcoatings using pigments and binders which are inherentlylightfast to achieve the longest possible coating life undervarious environmental conditions.


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Finishing: Anodizing

Anodizing is an electrolytic process that forms adurable, porous oxide film on the surface ofaluminum, adding to the protection provided by itsnatural oxide layer.

Durability: Anodic coating is part of the base

metal and will not chip or peel. Environmental: Anodizing emits no VOCs, and no

heavy metals are used in the process.

Recyclability: Anodized aluminum is easilyrecycled without any extra steps.

Photo courtesy ofThe Aluminum Anodizers Council

Color Availability: Two-step electrolytic color is available in bronze and black. More

colors are available in dyed finishes. Color Stability: Two-step electrolytic color will not fade over time in UV light.

Maintenance: Anodized finishes are easily maintained.

Specification: AAMA 611 - Class I 0.7 mils coating, Class II 0.4 mils coating.


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Finishing: Paint and Lacquers

Aluminum readily accepts paints and lacquers. Paints andlacquers may be applied to aluminum by any of thesepopular methods: electrostatic spraying, electrodeposition,powder coating, dip coating, flow coating.

Provides corrosion resistance

Consistent color from lot to lot Color availability: some paints easily mixable in small

batches

Can sometimes cover minor metal defects

PVDF is chemically inert and can outlast other finishesin corrosive environments

Used in a broad range of applications: architectural andconsumer products, industrial equipment, automotiveapplications

34-Story, Midtown Towers IVLofts, Miami, FL. Windows,

Sliding Glass Doors and Railings

Specifications: AAMA 2605 - 70% PVDF-based resins, AAMA 2604 - 50% PVDF-basedresins, AAMA 2603 - Acrylic and most high-solid polyester resins


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Finishing: Mechanical Finishes

Aluminum can be given many different types of surface texture, from rough or patterned tomirror-shiny, by a variety of mechanical methods including:

grinding

perforating

embossing

brushing or polishing satin finishing

barrel tumbling

barrel burnishing

sandblasting, shot blasting, and/or

glass bead blasting.

These methods may be applied as: a final surface finish; to improve surface quality; or, aspreparation for a variety of final cosmetic finishes. They can often enhance the finish whendone in conjunction with anodizing and are an ideal way to hide surface imperfections.


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Easy to fabricate: Often, designing with aluminum extrusions can eliminate many fabrication and

assembly steps.

Aluminum extrusions can be made with almost any cross-sectional shape. Parts can beeasily cut, machined, finished, fabricated, and assembled.

Joinable by various methods:

Aluminum extrusions can be joined to other aluminum products or to different materialsby all major methods, including welding, soldering, brazing, bolts, rivets, clips,adhesives, clinching, and slide-on, snap-together or interlocking joints.

Suitable for easy-assembly designs:

Aluminum extrusions can be designed for easy assembly with other parts includingmating surfaces or shapes that match up for easy joining.

By using aluminum extrusions ability to easily and costeffectively produce complex, integral profiles, designerscan often accomplish tremendous part-count reductions!

Ease of Fabrication

Courtesy ofAlexandria Extrusion


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Extrusion Tooling and Lead-Time Economics

Aluminum extrusion offers advantages over other processes in both the cost and the lead-time of tooling design and manufacture. Aluminum extrusion dies often cost from $500 to$5000 depending on the size and whether the shape is a solid or hollow profile.Comparable injection molding dies, die castings or roll forming can cost $25,000 or more.

The initial costs and lead-times of aluminum extrusion dies and supporting tools are usuallya good deal lower that the tooling required for other processes (often a few weeks versus1220 weeks for comparable processes).

Process Typical Tooling Cost ($)

Aluminum Extrusions $500 to $5,000

Vinyl Extrusion $1,500 and up

Injection Molding $25,000 and up

Die Castings $25,000 and up

Roll Forming $30,000 and up

Stampings $5,000 and up


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Application Examples Using Aluminum Extrusions

Here are some of the innovative applications for aluminum extrusions in commercialbuildings:

The versatility of the extrusion process applied to aluminum continues to stir theimagination of designers and architects everywhere.

Windows and doors (including hurricane- andblast-resistant)

Skylights/rotundas

Curtain walls

Sun shades and louvers Photovoltaic panel framing

Reflective solar roof panel framing

Atriums and enclosures

Sun rooms

Observatories

Walkways, entryways and gateways Panel systems

Store fronts

Elevator cab framing

Bridge decks

Steeples

Gates and archways

Canopies

Space frame systems

Garages and parking covers

Geodesic domes and structures

Rain screens and water collection systems

Supports for aluminum composite panelsystems

Housing for interior lighting grids Demountable interior walls and light-

deflecting shelves

And more


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Application: Commercial Windows and Doors

Aluminum extrusions were used for the windows of Northwestern Universitys Chicagocampus in the Ward Building. Aluminum windows and doors provide energy efficiency,structural integrity, superior resistance to air and water infiltration, aesthetics, as well aslong-term durability.

Northwestern University, Ward Building, Chicago, IL The Apple Group Architectural Photography


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Application: Curtain Walls and Storefronts

There are numerous reasons why aluminumextrusions are the framing material of choice forcurtain walls and storefronts.

Strength-to-weight ratio

Glazing and wind load capability

Minimal expansion and contraction coefficients

Ability to seal to the building structure

Maximal indoor daylighting

Design flexibility

Maintenance

Ease of fabrication and assembly

Aesthetics

Finishing options

Thermal capabilities

W-Austin Hotel and Residences, Austin, TX Wes Thompson Photography

Photo courtesy of Kawneer/Traco


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Application: Skylights and Sun Rooms

Photo courtesy of Light Metal Age magazine Photo courtesy of Four Seasons Solar Products LLC

Aluminum extrusions are also commonly used for skylight applications and are especiallywell-suited for sunrooms and atriums such as these areas in a banquet hall.


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Application: Photovoltaic Panels

Aluminum extrusions provide the framinghardware system for todays photovoltaicpanels for commercial construction.

Here, thin-layer PV is applied on glass, andpolycrystalline silicon wafers are laminated

between two glass panes within an extrudedaluminum framework. The photovoltaic solarcells convert light into electrical energy thatoperates a building, or is fed into a supplynetwork.

Photo courtesy of Hydro Building Systems GmbH


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Application: Ceiling Panels

Photos courtesy of James Steinkamp Photography. Used with permission of Goettsch Partners, Inc.

There are plenty of ways extrusions are used in a buildings interior. Here, the extrudedaluminum framing grid has a pendant-mounted up-lighting system. The lobbys marble-clad elevator core houses high-capacity elevator cabs framed entirely with aluminumextrusions.


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Application: Almost endless.

Photo courtesy of Light Metal Age magazine Courtesy of CST Covers

Aluminum extrusions are used throughout the world for exquisite architectural designs.Aluminum extrusion building components are also used in many types of arches,entryways, and gateways, such as this Florida SunPass gantry which uses round, tubularextrusions. Aluminum extrusions are continuously being used in various constructionapplications.


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Todays Challenges for Commercial Buildings

This section of the course will focus on some of todays architectural and design challengesinvolving overall commercial building performance.

Reducing energy and resource consumption

Energy codes becoming more stringent

Increasing demand for sustainable buildings

New Green Building codes being introduced

LEED being specified

Impact resistance being mandated


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Challenge: Reducing Energy and ResourceConsumption

Buildings use 39% of ALLU.S. energy consumed.

72% of all electricity and54% of all natural gas in the U.S.is consumed in buildings. (U.S.Department of Energy -http://energy.gov/)

Buildings use 40% of worlds rawmaterials3 billion tons per year.(Worldwatch Institute -http://www.worldwatch.org/)

170 million tons of U.S. building-

related construction and demolitiondebris is generated every year. (U.S.Environmental Protection Agency -http://www.epa.gov/)

CommercialBuildings18%

21%ResidentialBuildings

33%

Industry

Transportation28%

Green design and building technologies lowerconstruction costs and reduce operatingexpenses. Buildings are draining our nations totalenergy, much more so than the transportationindustry.
http://energy.gov/http://www.worldwatch.org/http://www.epa.gov/http://www.epa.gov/http://www.worldwatch.org/http://energy.gov/


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Challenge: Energy Codes Becoming More Stringent

Energy codes are all around us. Each state, county, or city has building codes that alsoinclude requirements for building energy efficiency. This includes requirements for thethermal performance of windows, doors, and skylights, based upon location or climatezone.

Climate zones

used by the InternationalEnergy ConservationCodeandASHRAE 90.1.


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Challenge: Energy Codes Becoming More Stringent

Vertical Fenestration U-Factor Insulation Requirements Commercial BuildingsThis table shows the thermal performance U-factor requirements for windows, curtainwalls, storefront, and glazed doors in the two major standards for energy efficiency forcommercial and high-rise residential buildings.

Climate Zone 1 2 34 (exceptMarine)

5 andMarine 4

6 7 8

Nonmetalframing

1.20 0.75 0.65 0.40 0.35 0.35 0.35 0.35 ASHRAE 90.1-2010

No category same as metal framed, fixed or operable 2012 IECC

Metal framing,fixed

1.20 0.70 0.60 0.50 0.45 0.45 0.40 0.40 ASHRAE 90.1-2010

0.50 0.50 0.46 0.38 0.38 0.36 0.29 0.29 2012 IECC

Metal framing,operable

1.20 0.75 0.65 0.55 0.55 0.55 0.45 0.45 ASHRAE 90.1-2010

0.65 0.65 0.60 0.45 0.45 0.43 0.37 0.37 2012 IECC

Metal framing,entrance door

1.20 1.10 0.90 0.85 0.80 0.80 0.80 0.80 ASHRAE 90.1-2010

1.10 0.83 0.77 0.77 0.77 0.77 0.77 0.77 2012 IECC


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Challenge: Increasing Demand for SustainableBuildings

The demand for commercial green buildings is increasing globally, with a focus on: curbing greenhouse gas emissions

increasing overall energy efficiency

reducing heating and cooling costs, and

integrating high-demand design elements:

structural, mechanical, botanic, air quality, lighting, plumbing, and water use.

Increasing demand for green buildings is reflected in end-use shipments of extrudedaluminum products. According to AEC and the Aluminum Association, 1.3 billion pounds ofaluminum rod, bar, pipe, tube, and extruded profiles were used in 2007 in building andconstruction, primarily in windows, doors, and curtain walls. Commercial structures that

use aluminum extrusions emit less carbon dioxide and reduce energy costs throughincreased heating and cooling efficiency. Automatically controlled indoor lighting andimproved natural daylighting also cut energy costs, and provide economic benefits fromincreased worker health and productivity due to the improved indoor environment.


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Challenge: New Green Building Codes BeingIntroduced

Recently, new green building codes have been developed, including the 2012 InternationalGreen Construction Code and ASHRAE 189.1. These incorporate even higher levels ofenergy efficiency, but also bring in concepts like requirements for sustainable materials.

Again, aluminum framed products meet the thermal performance requirements in everylocation, with increased use of thermal barriers, low-e glass, and triple glazing. Also,

exterior shading including aluminum sunshades is requiredin certain buildings. Finally,there is an increasing demand for building materials to be sustainable, recyclable, andsupported by environmental impact studies such as life cycle analysis.


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Challenge: Leadership in Energy and EnvironmentalDesign (LEED)

An ever-increasing number of construction projects, whether new or retrofittingconstruction, are specifying the projects to meet LEED certification. LEED-certified projectsare becoming more and more a requirement rather than an option.

A few facts about LEED:

According to the U.S. Green Building Council (USGBC), as of March 2012, there were

12,000 LEED-certified commercial buildings in the U.S.1

LEED-certified annual construction value is expected to exceed $1 billion by 2013.2

Conclusion: The demand for LEED constructionprojects continues to grow.

1Source: Nathans, Aaron. Green Buildings Hit Milestone. DelawareOnline.com.http://blogs.delawareonline.com/delawareinc/2012/03/27/green-buildings-hit-milestone/. Accessed May 2012.2Source: USGBC. Green Jobs Study. USGBC. http://www.usgbc.org/ShowFile.aspx?DocumentID=6435 . Accessed May 2012.
http://blogs.delawareonline.com/delawareinc/2012/03/27/green-buildings-hit-milestone/http://blogs.delawareonline.com/delawareinc/2012/03/27/green-buildings-hit-milestone/http://www.usgbc.org/ShowFile.aspx?DocumentID=6435http://www.usgbc.org/ShowFile.aspx?DocumentID=6435http://www.usgbc.org/ShowFile.aspx?DocumentID=6435http://www.usgbc.org/ShowFile.aspx?DocumentID=6435http://blogs.delawareonline.com/delawareinc/2012/03/27/green-buildings-hit-milestone/http://blogs.delawareonline.com/delawareinc/2012/03/27/green-buildings-hit-milestone/http://blogs.delawareonline.com/delawareinc/2012/03/27/green-buildings-hit-milestone/http://blogs.delawareonline.com/delawareinc/2012/03/27/green-buildings-hit-milestone/http://blogs.delawareonline.com/delawareinc/2012/03/27/green-buildings-hit-milestone/http://blogs.delawareonline.com/delawareinc/2012/03/27/green-buildings-hit-milestone/http://blogs.delawareonline.com/delawareinc/2012/03/27/green-buildings-hit-milestone/http://blogs.delawareonline.com/delawareinc/2012/03/27/green-buildings-hit-milestone/http://blogs.delawareonline.com/delawareinc/2012/03/27/green-buildings-hit-milestone/


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Challenge: Impact Resistance Is Being Mandated

Many states mandate the use of impact-resistant products in wind-borne debris regions. Asrepresented in yellow, this area stretches from Texas, around the Gulf Coast, up the entireEastern Seaboard and the Hawaiian Islands.


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What Does a Thermal Barrier System Do?

Thermally separating extruded aluminum windowsgreatly improves thermal efficiency in the sash and

frame, and vastly reduces thermal conductivity to

energy-efficient levels. Thermally separating extruded

aluminum windows allows aluminums many key

properties to be utilized.

When thermal barrier materials, such as polyurethane

and glass fiber reinforced polyamide, are used in

conjunction with extruded aluminum framing, the

resulting thermal efficiency in a windows sash and

frame are greatly improved. Manufacturers have

been able to reduce thermal conductivity to a fraction

of the original value. Aluminum fabricators, using

thermal separators as barriers, have overcome

thermal conductivity issues in order to utilize the

sustainable attributes of aluminum, and create highly

thermally efficient window frames.

A thermal barrier is a material of low

thermal conductivity inserted betweenmembers of high conductivity in orderto reduce the heat transfer. Thethermal barrier material conductivityshall not be more than 0.52 W/m*k(3.6 Btu*in/hr*ft2*F). - NFRC 100


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What Does a Thermal Barrier System Do?

The thermal barrier makes an extruded aluminumwindow, skylight, or door highly energy efficient,reducing heating and cooling costs substantially.

Thermal barrier material must not only be strongand resist deterioration over time, but it must also

insulate. The material acts as a barrier to heatflow from a warm interior to a cold exterior inwinter, and blocks heat entering a building insummer.


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Thermal Barrier Categories

The NFRC breaks down the thermal barrier description into two of the most widely usedthermal barrier product categories. The first category describes a thermally improvedmember as a product that enhances efficiency, due to design or thermal materials used. Itmay not offer the highest energy efficiency available.

The NFRC then specifies exactly what a thermally broken member is, and describes the

products used to gain further energy efficiency.


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Thermal Barrier Categories

Thermally Improved Member

System members with a >1.6mm (0.062in.) separation provided by a materialwhere the conductivity is 5.3mm (0.210in.) separation provided by a low-conductance material where theconductivity is


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Thermal Performance

Poured and Debridged Thermal Barrier

High-performance polymer (polyurethane)is poured into a specially designed cavityformed by a thin metal bridge temporarilyconnecting the interior and exteriorsections of the frame. Once the materialhas cured, the metal bridge is removed(debridged) to form the thermal barrier.

Polyamide Strip Thermal Barrier

Reinforced polyamide profiles (nylon-based polymer reinforced with glassfibers) mechanically join separatelyextruded interior and exterior aluminumprofiles.


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Thermal Performance

Fenestration systems manufacturers have responded to energy savings requirements withcontinuous innovation, before it was popular. This timeline demonstrates that aluminumproducts have led in energy savings, improving product efficiency nearly three-fold.


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Thermal Performance

This cross-section shows a typical aluminum framed window. Key thermal improvementsgive this window a U-factor of .41. In this example, the thermal barrier alone representsnearly half of the U-factor improvement. In the second image, adding argon or a similar gasbetween the insulated glass units panels allows extruded aluminum fenestration productsto meet and exceed an overall U-factor of .38, making a highly efficient thermal barriersystem. Nearly 50% of U-factor improvement comes from the thermal barrier.


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Reduced Energy Usage and Cost

In this real world example, the Empire State Buildings six-thousand-plus windows wereretrofitted with extruded aluminum window framing with thermal barriers. Thermalconductivity is minimized by thermally separating both window sash and main frame, usingan outer extruded frame, a central insulating core material, and an inner extruded frame.The structural core acts as a barrier to heat flow in winter from the warm interior to the coldexterior, and vice versa in summer.

Original steel windows, single glaze $1,000,000/year

New, TR-9000 windows with thermal barrier $222,230/year

ENERGY SAVINGS $777,770/year

Lifespan (30 years) $23,000,000

For the Empire State Building, a computer program calculated the savingsin heating and cooling costs with the system versus the non-thermalbarrier windows. There are 102 stories with 6,400 windows.


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Thermal Conductivity

Today, extruded aluminum fenestration products aretypically manufactured with an installed thermal barrier toeffectively insulate and moderate interior temperatures.And with the use of warm edge glass spacers, thesefenestration products provide exceptional condensationresistance. The thermal barrier prevents the inside andoutside aluminum from touching by placing the insulator

between them so that heat and cold do not transfer,keeping the unit rigid, stable, and operating smoothly withlow maintenance.

Conduction, the mechanism by which a solid transmitsheat, causes heat loss through sealed insulating glassunits, and is the primary cause of heat loss throughwindow sashes and frames. The insulating value of sealed

insulating glass units can be improved by increasing thenumber of glass panes and air spaces, or by filling theunits with gas. Sealed glazing units with -inch air spacesbetween panes provide optimal thermal performance.


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Case Study

Thermally broken aluminum windows were a smart choice for replacement windows in thisrenovated building on the University of Notre Dame campus in South Bend, Indiana.

Photos courtesy of Oldcastle BuildingEnvelope


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Increasing Demand for Sustainable Buildings

After only a few years, the energy consumed by a building during its functional life exceedsthe energy required for its construction. Higher initial investment in faades reduces long-term operating costs, especially when coupling thermally-insulated windows withphotovoltaic panels.

One of the most cutting-edge applications for extruded aluminum today is photovoltaicpanels. Based on U.S. Department of Energy models, high-tech photovoltaic panels havethe potential to reduce the cost of producing a buildings electricity from 20 cents perkilowatt hour, down to 5 cents per kilowatt hour.

Photos courtesy of Schco International KG


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Photovoltaic Applications

Aluminum extrusions are also commonly used on photovoltaic applications. State-of-the-artintegrated photovoltaic systems will make solar power affordable, and aluminum extrudersare working to ensure that the housing framework for these systems can be easilyintegrated into a variety of faade elements. Aluminum-glass-photovoltaic faades areplaying an increasingly key role in reducing energy consumption and increasing occupantcomfort.

Ventilated faade

Ventilated/non-ventilated faade

Non-ventilated faade

Skylight construction

Canopy

Solar shading

Balcony

Conservatory


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Photovoltaic Technology and Aluminum Extrusions

Photovoltaic modules, and their extruded aluminum framing, are customized toarchitectural requirements for shape, color and optical structures. Because these modulesare integrated into the building, they perform the function of infill units throughout thebuilding envelope.

This ultra-thin rolled sheet of photovoltaic technology incorporates a polycrystalline thin filmlayer applied to a powder-coated extruded aluminum blade.

Photo courtesy of Schco International KG Photo courtesy of Hydro Building Systems GmbH and Ascent SolarTechnologies, Inc.


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Photovoltaic elements are integrated and positioned into a building faade so that the suninfluences the form and orientation of the building. To prevent overheating on a hotsummer day, the faade does not allow solar rays to penetrate to the buildings interior, yetthe interior receives as much natural daylighting as possible.



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This close-up of the Linz buildings louvers shows the faade must respond actively andflexibly to changing requirements throughout the day, and from season to season,mediating between indoor and outdoor climates. Photovoltaic electricity-generating cellsare fixed onto the louver blades, framed and mounted with aluminum extrusions. The suntracking system is powered by a Girasol thermohydraulic sun tracking device, withoutexpensive or complex electro-mechanical control systems.

Photo courtesy of Colt International Licensing, Ltd.


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Photos courtesy of SchcoInternational KG

Here, multi-functional photovoltaicmodules become insert units inthis skylight construction, framedin extruded aluminum. Theversatility of extruded shapes andconfigurations allows a widerange of designs. The semi-

transparent units protect againstsun, heat, and glare and targetnatural light. Large surface areaswith optimal tilt angles maximizesolar energy use.

Building-integrated photovoltaicinsulating glass modules framed

in extruded aluminum


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The advent of integrated photovoltaicsystems has spurred a new era of solararchitecture, and aluminum extrusions arethe structural framework in which thisrevolution is taking place in commercialconstruction. In addition to aesthetic appeal,the extruded aluminum faade protects

against cold, heat, rain, and noise. This officepark at the Vienna International Airportmaximizes daylighting with strategicallyplaced photovoltaic panels through thefaade.



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LEED

Aluminum extrusions contribute to LEED points:

Energy & Atmosphere

EA1: Optimize Energy Efficiency (1-19 points)

Increased performance

Thermal barrier aluminum frames, sunshades,light shelves, skylights

EA2: On-Site Renewable Energy (1-7 points)

Aluminum framing for rooftop solar panels,PV integrated into windows, overhangs

Being expanded in 2012 version

Photos courtesy of SchcoInternational KG


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Aluminum and LEED

There are also numerous credits related to the use of sustainable materials. Aluminumsability to be infinitely recycled while maintaining its properties means it can contribute anumber of LEED points in these categories:

Materials & Resources

MR2.1 and 2.2: Construction Waste Management (1-2 points) Aluminum recycling

MR4.1 and 4.2: Recycled Content (1-2 points)

Recycled content in aluminum extrusions

MR5.1 and 5.2: Regional Materials (1-2 points)

Recycled content recovered, reprocessed near project Future 2012 version will have credit for Responsible Sourcing of Raw Materials

Aluminum from sources under Framework for Responsible Mining


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Aluminum and LEED

As a sustainable material, aluminum can also qualify for credits for conducting a life cycleanalysis or using Cradle to Cradle CertifiedCMproducts (which also looks at full life cycleanalysis). There is also a credit for reducing or avoiding materials that can be sources ofpersistent bioaccumulative toxic chemicals or PBTs, such as PVC. Aluminum windowframes with thermal breaks are specifically listed as a strategy for meeting this credit.

Innovation in Design

ID1: 1 point for using Cradle to Cradle CertifiedCM materials

Pilot Credits

Pilot Credit 1: 1 point for conducting a life cycle analysis (LCA) Pilot Credit 2: 1 point for reducing halogenated organic compounds (e.g., PVC)

Aluminum frames with thermal breaks specifically listed as an allowed material


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Aluminum and LEED

Indoor Environmental Quality

EQ2, EQ6.2: Ventilation and Thermal Comfort(1-2 points)

Control increased use of operablewindows

EQ8.1 and 8.2: Daylight and Views (1-2 points) Increased use of windows, skylights,

atriums, light shelves


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Aluminum and LEED v4

Proposed MR Changes

The Materials & Resources category focuses on holistic decision making through life cyclethinking. The life cycle approach is used to organize credits into four key areas: resourcereuse, assessment and optimization, human and ecological health and wastemanagement. This revision offers organized, actionable credits around key concepts whilemaintaining effective credits established in previous versions of LEED. The following are

proposed in the revision:

Building Reuse and Whole Building Life Cycle Assessment (1- 4 points)

Material Life Cycle Disclosure and Assessment (1-2 points)

Responsible Extraction of Raw Materials (1-2 points)

Avoidance of Chemicals of Concern (1-2 points)

**Note: On June 4, 2012, the USGBC announced that it was postponing plans to ballot the next version of LEED until aslate as June 2013. USGBC promises to keep LEED 2009 available for a full three years from now, although it intends togradually ramp up incentives for teams to move to the new version of LEED during that time. USGBC is also reverting toa version naming system for the rating system, so the new version will be called LEED v4 instead of LEED 2012.


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The Life Cycle of Aluminum

According to FLSmidth, the world has produced about 800 million tons of aluminum sincethe modern aluminum industry began in 1886, and about 73% is still in use today.Aluminums ability to be recycled repeatedly with no loss in quality is central to its claim asa sustainable material. For aluminum, there is no end-of-life; it can be reused again andagain by future generations. The visual below explains the life cycle of aluminum.

73% of all aluminum producedsince 1886 is still in use today.

Recycled aluminum uses only 5%of the energy, and generates 5% ofthe emissions, associated with theproduction of aluminum from virgin

ore. Recycling makes aluminum last

forever.


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The Living Building Challenge

Google Materials Red List

In 2011, Google reported opening office spaces at a rateof 40,000 square feet per week.

Based on the Cascadia Region Green Building Councils The Living Building Challenge,Google sanctioned the red list of materials used in construction that include componentsmade from materials and chemicals such as: Asbestos, Cadmium, ChlorinatedPolyethylene and Chlorosulfonated Polyethlene, Chlorofluorocarbons (CFCs), Chloroprene(Neoprene), Formaldehyde, Halogenated Flame Retardants, Hydrochlorofluorocarbons(HCFCs), Lead, Mercury, Petrochemical Fertilizers and Pesticides, Phthalates, PolyvinylChloride (PVC), Wood treatments containing creosote, arsenic or pentachlorophenol.

Note: Aluminum and aluminum extrusions are not listed as red materials.


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Aluminum and LEED

Perkins + Wills 1315 Peachtree office building renovation in Atlanta, Georgia demonstrateshow aluminum extrusions are instrumental in achieving a high-performance building thatmeets ambitious sustainability goals using key extruded aluminum components such as:exterior curtain wall, horizontal and racked shading airfoils, caps for glass terrace rail, andinterior demountable wall structures, bench seating systems, and light fixture housings, aspart of a whole building approach that has achieved a LEED Platinum rating for Perkins +Will.


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Impact Resistance

A great deal of thought and care goes into storefront, curtain wall and window design thatcan withstand the wrath of mother nature. Unfortunately, many commercial building ownersand homeowners have learned this lesson the hard way by weathering some of naturesworst storms over the last few years. The slightly higher initial price of impact-resistantproducts can help save thousands of dollars in repair following brutal hurricane winds andthe associated debris.

Hurricane Wilma October 24, 2005

Photo courtesy of YKK AP


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Hurricane and Blast

While maintaining required structural integrity, light weight, andlow cost, aluminum sets itself apart from all other materials.Extruded aluminum thermally broken window framing is rated forhigh-missile impact and hurricane zone requirement areas, suchas Dade County, Florida.

The Impact TestThe High Velocity Hurricane Zone section of the Florida Building Code requires that every exterior openingresidentialor commercialbe provided with protection against wind-borne debris caused by hurricanes. Such protection couldeither be shutters or impact-resistant products.

There are two types of impact-resistant products: large missile-resistant and small missile-resistant.

A. Large missile-resistant testA product exposed to various impacts with a piece of lumber weighing approximately 9 pounds, measuring 2" x 4" x 9' in

size, traveling at a speed of 50 feet per second (34 mph). Then the product is subjected to hurricane loading of 9,000wind cycles, positive and negative.

B. Small missile-resistant test

A product that has been exposed to various impacts with 10 ball bearings traveling at a speed of 80 feet per second (50mph). The product is then subjected to wind loads for 9,000 cycles. If the doors and windows are more than 30 feetfrom the ground, then they must be either large or small missile-compliant.
http://www.pgtindustries.com/Images/Products/WinGuard/ImpactTest.mpg


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Impact Resistance

Aluminum extrusions are commonly used in thedesign of impact- and blast-resistant windows anddoors. The strength of aluminum framing membersmakes this material a viable choice for impact-resistant products.

Aluminum is an effective material for blast hazard

mitigation due to its high yield strength, which hasbeen tested to 40,000 psi without steel reinforcement.4Blast loads require fenestration material to bend butnot break to absorb energy, which is easilyaccomplished with aluminum extrusions. It also meetstesting standards and protocols.

Aluminum fenestration products that have beensuccessfully tested for blast hazard mitigation include:curtain walls, store front entrances and framing, andwindows in a variety of types and configurations.

Photo courtesy of Schco International KG4Source: CSBR, Windows and Daylighting Group. Performance: Energy & Cost. Windowsfor High-Performance Commercial Buildings.http://www.commercialwindows.org/energy.php . Accessed May 2012.
http://www.commercialwindows.org/energy.phphttp://www.commercialwindows.org/energy.php


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Buildings Using Extruded Aluminum

Here is a sampling of the types of commercialbuildings that use aluminum extrusions:

Office complexes

Colleges and universities

Libraries

Hospitals Stores/malls

Airports

Sports stadiums

Schools

Restaurants

Hotels and resorts

Convention centers

Government and public buildings

Mass transit hubs

Hurst Conference Center, Hurst, TX Wes Thompson Photography

Photos courtesy of Kawneer / Traco


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Notable Buildings Using Aluminum Extrusions

The 111 S. Wacker building in Chicago was the first high-rise in the nation to be awardedGold LEED Certification by the U.S. Green Building Council.

The building incorporates aluminum extrusions into every aspect of its design, including thecurvilinear design of its lobby. According to the buildings architect, Steve Nilles of GoettschPartners in Chicago, Aluminum is extremely lightweight in relation to its strength, allowingus to do more with less material. It is aesthetically flexible and inherently recyclable,

concepts that tie directly into sustainable design initiatives.

Photo courtesy ofJames SteinkampPhotography.Used withpermission ofGoettschPartners, Inc.


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The UBS Tower high-rise on Wacker Drive in Downtown Chicago features extrudedaluminum curtain wall sections, including on the towers uppermost floors, where thesections must withstand lateral buckling forces and high winds. The UBS Tower not onlydelivers energy efficiency, but adds streetscape beauty to Wacker Drive.

Photos courtesy of Hedrich Blessing. Used with permission of Goettsch Partners, Inc.


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The United Airlines Terminal at ChicagosOHare International Airport, designed byarchitect Helmut Jahn, won the R.S. ReynoldsMemorial Award for distinguished architectureusing aluminum. The design was achievedusing a variety of aluminum extrusions, tubing,sandwich panels and skylights.

Cincinnati State University in Ohio also usedextruded aluminum window framing extensivelythroughout its campus. Such energy-efficientwindows are often retrofitted into older

buildings, as well as being custom-designed fornew construction.

Top photo courtesy of the Aluminum Extruders CouncilBottom photo courtesy WALTEK & Company, Ltd., and Akzo Nobel


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The 12-story South Tower of the ChildrensHospital of Philadelphia in Pennsylvania usescurved, painted silver expanses of custom-extruded aluminum curtain wall during PhaseOne of their $650-million dollar expansion. Itconnects to the existing hospital via a newatrium, which has been re-clad with aluminum

extrusions.

This custom-designed extruded aluminumentryway overhang provides shelter anddistinctive design, while maximizing naturaldaylighting on the southeast-oriented entrance

of the Fidelity Corporate Office Park in LakeZurich, Illinois.

Top photo courtesy of Childrens Hospital of PhiladelphiaBottom photo courtesy of CST Covers


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This parking canopy enclosure at the MilwaukeeChildrens Hospital uses I-beam and customextrusions. The curvilinear extrusions combinewith the extruded I-beams and integrated lightingfor a lightweight design that withstands thetemperature and weather extremes of Wisconsin.

The Halsell Conservatory in San Antonio, Texasuses round and rectangular extrusions, allowingnatural daylight in to create an interiorenvironment ideal for nurturing the conservatorysplant life.

Photos courtesy of CST Covers


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This dome spans the Hunan Provincial Government Offices and Exhibition Center inChangsha, Hunan, China, using pre-fabricated I-beam extrusions. Its high strength isderived from a proprietary connection design forming geometric patterns using high-strength aluminum alloys. Many shapes are possible with versatile extrusionconfigurations, including oval, circular, and ellipsoid.

Photo courtesy ofCST Covers


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The Texas Star glass in this cupola skylight at the Gaylord Texan Resort and ConventionCenter in Grapevine, Texas is framed in extruded aluminum, and uses 206 tons of glasscovering over 90,000 square feet on the main skylight. Nearly 208,000 pounds ofaluminum extrusions were used in the skylights, curtain wall, and entrances.

Photos courtesy of Oldcastle BuildingEnvelope


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The vast complex of extruded aluminum

and glass at the Halsell Conservatorybecomes an exciting visual forum forblending form and function. Working witharchitects, extruded space frames may bedesigned, engineered, fabricated, andinstalledfrom start to finish.

The original windows in the Empire State

Building had deteriorated and were losingenergy from air leakage. The renovatedhistoric structure boasts 6,400 newextruded aluminum window frames,which were custom matched with theoriginal windows red color and finish.

Photo courtesy of CST Covers, Photo by Greg Hursley Photo courtesy of TRACO


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The Molecular Foundry at the LawrenceBerkeley National Laboratory conductsnanotechnology research for the Department ofEnergy. Its construction site, on a narrow, steepslope in an earthquake-prone zone was a jointpilot project of the DOE and the U.S. EPA fordesign and construction of a sustainable lab

facility. Construction of the six-story foundryutilized aluminum and energy-efficient glass,and required cutting 70 feet into the hillside.Recycled aluminum panels cover the entireexterior, earning LEED points. Twelve-footaluminum-encased trusses help support thecantilevered portion of the building. The lab

expects to consume 30% less energy than thetough California standards currently require.

Photo courtesy of LawrenceBerkeley National Laboratory


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The Michael Lee-Chin Crystal building,an addition to the Royal OntarioMuseum, opened in Toronto, Canadain 2007. The addition was created byStudio Daniel Libeskind. Over 18 milesof aluminum extrusions (90,000 squarefeet) were used in the structure, which

contains one vertical wall and no rightangles. The buildings exterior is 75%aluminum and 25% glass. Theextruded brushed silver aluminumcladding is the outermost of threelayers, and the extrusions arepositioned with gaps in between to

channel water and snow runoff awayfrom the patrons below.

Photo courtesy of Scott Norsworthy


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This is the Biodesign Institute on the Arizona State University campus. The extrudedaluminum interior louvers, seen on the left-hand side of the building facing east, arecomputer-controlled to track the sun to minimize heat gain from the abundance of glassand skylights. The louvers become a major green design feature of the buildings 15-foot-high curtain wall windows.

Photo courtesy of Arizona State University


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The Aluminium Centrum building in the Netherlands is an 11,000-square-foot building thatsits on 368 hollowed-out aluminum pillars. These pillars support the building withlightweight strength while housing all of the electrical and phone cables, and hydraulicsystems. Energy performance is exceeded by 50%, according to Netherlands standards,with the help of high-efficiency heat pumps and heat exchangers, and double-glazedwindows. The building, which uses 100 metric tons of aluminum extrusions, won aprestigious international architecture prize.

Photo courtesy ofAluminium Centrum

N t bl B ildi U i Al i E t i


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Here, aluminum extrusions formed the framing for the expansive storefront and curtain wallsystems of Churchill Downs new 120-million-dollar entryway and clubhouse complexrenovation. Curtain wall and window finishes and details were carefully matched to theoriginal style of the famous Twin Spires area, which is in the National Registry of HistoricPlaces. The 3,000-pound prefab skylight is the centerpiece of the new rotunda at ChurchillDowns in Louisville, Kentucky. The skylights custom-fabricated extruded aluminumframework is strong enough to support 1,500 pounds of downward force from which this

new glass horse sculpture is suspended on a cable system.

Photoscourtesy ofChurchillDowns



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About 700,000 pounds of aluminum

extrusions frame the glass curtain walls ofthe new Dallas Cowboys football stadiumin Arlington, Texas. This one-billion-dollarstadium opened in 2009, seats 80,000fans, and features a quarter-mile-longretractable roof.

Oldcastle BuildingEnvelope supplied

the custom-engineered curtain walls andretractable glass end zone doors, whichare all framed in extruded aluminum.Custom extrusion and finishing helpedmeet the stringent requirements for thecomplex assemblies. The stadiums 86-foot-high walls contain 5,070 glass

panels. The end zone doors, at 120 feethigh x 180 feet long, are the worldslargest movable glass walls. They like todo everything bigger in Texas!

Photo courtesy of the Dallas Cowboys, Arlington, Texasand Oldcastle BuildingEnvelope, Santa Monica, California



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The renovation of the Statue of Liberty involved replacing the 25 windows of Lady Libertyscrown with bronze-colored extruded aluminum windows of varying size, angle, andcurvature. Individual aluminum templates were constructed and custom-engineered. Eachwindow was hand carried to the top of the statue for installation. Even the scaffolding usedto renovate the statue was all extruded aluminum.

Photo courtesyof TRACO

Photo courtesyof the AluminumExtrudersCouncil


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Wh l B ildi D i


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Whole Building Design

The concept of whole design combines the synergies from an integrated design approachand an integrated team process to work together throughout the project, to evaluate thedesign cost, quality-of-life, future flexibility, efficiency, overall environmental impact,productivity, and how the occupants will be enlivened. All the integrated components worktogether to provide the benefits of reduced energy consumption, cost savings, improvedindoor environment for occupants, and a sustainable high-quality building envelope thatperforms for decades.

The knowledge pool of all the stakeholders is being drawn all across the life cycle of theproject, from defining the need for a building, through planning, design, construction,building occupancy, and operations.

Source: Prowler, Don, FAIA. The Role of Buildings and the Case for Whole Building Design. Whole Building Design Guide.http://www.wbdg.org/wbdg_approach.php . Accessed May 2012.

Wh l B ildi D i
http://www.wbdg.org/wbdg_approach.phphttp://www.wbdg.org/wbdg_approach.php


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Modern energy-efficient buildings are designed in the following order:

Mass and orientation

Optimizing the building envelope

Buildings systems and infrastructure

Whole building design allows design flexibility; for example, thermally broken aluminum

window frames may be used in combination with increased insulation, HVAC efficiency,ambient lighting, high-tech glazing, ventilation and shading devices, providing many moreoptions in designing energy efficiency into the overall building envelope. Architects,designers and building engineers are now striking a new balance between performanceand aesthetics.

Wh l B ildi D i Th B fit f D li hti


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Whole Building Design: The Benefits of Daylighting

According the July 2002 study entitled A Literature Review of the Effects of Natural Lighton Building Occupants by L. Edwards and P. Torcellini, daylight provides a better lightingenvironment than cool white or energy-efficient fluorescent electrical light sources. Thestudy indicates that occupants in daylight and full-spectrum office buildings reported anincrease in general well-being. Specific benefits in these types of office environmentsinclude better health, reduced absenteeism, increased productivity, financial savings, andpreference of workers. They state to, First, optimize daylighting through orientation and

greater window-to-wall ratios. Second, use systems such as shading systems andautomated control units to manage the light intensity.6

Benefits to the office worker are so great that many countries in Europe require thatworkers be within 27 feet of a window. Today, the technology for both aluminum frames andglass insulation is evolving to meet the new performance requirements of glazing systemsin all climates, allowing buildings to be designed with greater window-to-wall ratios for moredaylighting.

6Source: Edwards, L. and P. Torcellini. A Literature Review of the Effects of Natural Light on Building Occupants. NREL.http://www.nrel.gov/docs/fy02osti/30769.pdf. Accessed May, 2012.Source: Prowler, Don, FAIA. The Role of Buildings and the Case for Whole Building Design. Whole Building Design Guide.http://www.wbdg.org/wbdg_approach.php . Accessed May 2012.

Whole B ilding Design
http://www.nrel.gov/docs/fy02osti/30769.pdfhttp://www.wbdg.org/wbdg_approach.phphttp://www.wbdg.org/wbdg_approach.phphttp://www.nrel.gov/docs/fy02osti/30769.pdf


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Features of the Linz Office Building in Austria:

A sun tracking aluminum extruded shadovoltaiclouver system generates more than 40% of thebuildings electricity requirements.

The curvature facing southeast results in a goodrelationship between the faade area and usableinternal area.

The aluminum extruded louver system actsautonomously to the suns position and optimizesenergy production through photovoltaic cells.

Daylight entry is carefully controlled, reducingglare. On the right, advanced, high-efficiency

photovoltaic systems, and extruded aluminummetal shading combine sustainable design andinnovative technology for an environmentallyresponsible faade. Linz Office Building, Austria

Photo courtesy of Colt InternationalLicensing, Ltd.



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Integrated photovoltaic technology creates amulti-functional building envelope that both savesand generates energy, and is a viable alternativeto conventional faades and skylights.

Unique design possibilities unfold when combiningphotovoltaic technology with the complex shapes

and curves that are possible with extrudedaluminum.

Photo courtesy of Schco International KG

Endless Design Possibilities


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Endless Design Possibilities

Because the PV panels are framed inaluminum extrusions, their configurationscan be customized to work withuniquely-shaped architectural features.

Installation of rigidly-mounted or guidedphotovoltaic systems in roofs, faades,and sunshades meets both sustainabletechnology and aesthetic requirements.

Photo courtesy of Schco International KG Photo courtesy of Hydro Building Systems GmbH

Summary


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Summary

The use of aluminum extrusions in the wide range of product applications as covered

throughout this course provides the most benefits to the holistic approach of the wholebuilding design concept:

Performance

Durability

Flexibility Sustainability

Aesthetics

What other materials provide all these advantages?


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AACOA Extrusions

ABB, Inc.

ABC Aluminum SolutionsAerolite Extrusion Company

AKZO Nobel Coatings, Inc.

Albarrie Canada Limited

Alcoa, Inc.

Alexandria Industries

Alexin LLC

Almag Aluminum, Inc.

Al-Taiseer Aluminium Factory

Aluminio de Centro America

Aluminium Products Co.Aluminum Shapes, LLC

Amcol Corporation

APEL Extrusions Limited

Apex Aluminum Extrusions Ltd.

Arabian Extrusions Factory

Arkema, Inc.

Astro Shapes Inc.

Azon USA Inc.

Belco Industries Inc.

Benada Aluminum Products

Bonnell Aluminum

Bosch Rexroth Corp.

Bulk Chemicals, Inc.

Butech Bliss

Capral Ltd.

Cardinal Aluminum Co.

CASTOOL Tooling Systems

Compes International

Crown ExtrusionsCrystal Extrusion Systems

Crystal Finishing Systems, Inc.

Custom Aluminum Products Inc.

Dajcor Aluminum Ltd.

Danieli Corporation

Dienamex

DUBAL

EFCO Corporation

Emmebi

ETS - Exco Extrusion Dies Co.ETS - Exco Tooling Solutions

Extruded Aluminum Corporation

Extruders Div. Atrium Companies

Extrudex Aluminum

Foy Inc.

Futura Industries

General Extrusions, Inc.

Granco Clark

Gulf Extrusions Company LLC

Houghton Metal Finishing

Hydro Aluminum North America, Inc.

ILSCO Extrusions Inc.

iNOEX , LLC

International Extrusions

Kaiser Aluminum

KeymarkCorporation

The Loxcreen Company Inc.

Magnode Corporation

Marx GmbHMatalco Inc.

M-D Building Products, Inc.

Metal Exchange Corporation

Metra Aluminum

MI Metals

Mid-South Extrusion Die Co.

Mid-States Aluminum Corp.

NALCO

Nanshan America Co.

Noranda Aluminum, Inc.Ohio Valley Aluminum Co. LLC

Oilgear Company, The

OMAV S.p.A.

PanAsia Aluminium Ltd.

Peerless of America, Inc.

PengCheng Aluminum

Penn Aluminum International Inc.

Pennex Aluminum Company

Postle Extrusion

PPG Industries

Presezzi Extrusion S.p.A.

Pries Enterprises Inc.

Reliant Aluminum Products LLC

Republic Chemical Co.

Richardson Metals

Rio Tinto Alcan

Sapa Extrusions, Inc.

Service Center Metals

Sherwin-Williams CompanySilver City Aluminum Corp.

SMS Meer Service Inc.

Spectra Aluminum Products Ltd.

Spectrum Metal Finishing

Spraylat Corporation

Superior Extrusion, Inc.

Taber Extrusions, LLC

Technoform Bautec North Am. , Inc.

Tecnoglass S.A.

Tellkamp Sytems, Inc.Thumb Tool & Engineering

Tri City Extrusion

Ube Machinery

Valmont Industries

Valspar Corporation

Vidrieria 28 de Julio S.a.C.

Vitex Extrusion

Wagstaff, Inc.

Walgren Company

WEFA Cedar, Inc.

Werner Co.

Werner Extrusion Solutions, LLC

Western Extrusions Corp.

Whitehall Industries

YKK AP America, Inc.

Youngstown Tool & Die

AEC Daily Course

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