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Ar c hi t ec t ur a l E ngi neer i ng( Pr oduc t i on&Pa r t s ) -7X500 As s i gnment2-Repor t

Pa r t : Per f or a t edCompos i t ePa nel T heZol l v er ei nS c hool ofDes i gn BySANAA E s s en Ger ma ny T ut or : J a nS c hev er s

Aut or s : L i daHa s s a nz a de-S 0684725 Ma r j a nMoha mma dz a dehS a r a b-S 105199

6/ 17/ 2011


Table of Context:

The Part ……………………………………………………………………………………………………………………………………………1 Perforated Composite Panels ……………………………………………………………………………………………………………1 Phase 1: Materials ………………………………………………………………………………………………………………..1 Phase 2: Molding ………………………………………………………………………………………………………………….1 Phase 3: Autoclave ……………………………………………………………………………………………………………….2 Perforated Metal Panels …………………………………………………………………………………………………………………..3 Type …………………………………………………………………………………………………………………………………….3 Materials …………………………………………………………………………………………………………………………….4 References ……………………………………………………………………………………………………………………………………..5


References: 1. http://www.wisegeek.com/what-are-composite-materials.htm 2. http://en.wikipedia.org/wiki/Composite_material 3. http://autospeed.com.au/cms/title_Complete-Guide-to-Composites-Part-6/A_108698/article.html 4. http://www.fhbrundle.co.uk/technical


The Part: The most challenging and intriguing part of project for us is perforated composite panels. These panels which are used as false flooring to provide the place for installations becomes an inspiration for us to be adjusted in a way which may be used in outer envelope of building as cladding. Since the actual material and its characteristics are not suitable for exterior purpose, therefore we decide to change it to metal perforated panels with different kind of openings on it. As we started to search for metal perforated claddings, we encountered with so many different types of these materials which are already being used widespread. Going deep into properties and characteristics of these panels gave us an inspiration to think about our own perception of perforated surfaces which can shape a building’s envelope.

Perforated Composite Panel: Phase 1: Materials Composite materials are formed by combining two or more materials in a way that the constituents of the composite materials are still distinguishable, and not fully blended; also take advantage of the different strengths and abilities of different materials. The majority of composite materials use two constituents: a binder or matrix and reinforcement. The reinforcement is stronger and stiffer, forming a sort of backbone, while the matrix keeps the reinforcement in a set place. The binder also protects the reinforcement, which may be brittle or breakable. Generally, composite materials have excellent compressibility combined with good tensile strength, making them versatile in a wide range of situations. 1 In our case composite materials are concrete which uses cement as a binding material in combination with gravel as a reinforcement. Phase 2: Molding Generally there are two pieces in mold, one piece as a "lower" mold and another piece as an "upper" mold. Lower and upper refer to the different faces of the molded panel, not the mould's configuration in space (there is always a lower mould, and sometimes an upper mould). Part construction begins by applying materials to the lower

1

http://www.wisegeek.com/what-are-composite-materials.htm

1


mold. Lower mold and upper mold are more generalized descriptors than more common and specific terms such as male side, female side, a-side, b-side, tool side, bowl, hat, mandrel, etc. The molded product is often referred to as a panel (also as a casting or profile).2 Phase 3: Autoclave This process is generally done at ambient temperature and pressure. Vacuum bag molding, pressure bag molding, autoclave molding, resin transfer molding, hand layup, spray-up, transfer molding and etc. are different methods being used for this phase. In our case the method has been used is Autoclave molding. Panels go under heat and pressure or with solvent, with a precatalyzed resin. The catalyst is largely latent at ambient temperatures giving the materials several weeks, or sometimes months, of useful life when defrosted. However to prolong storage life the materials are stored frozen. The resin is a near-solid at ambient temperatures, and so the pre-impregnated materials have a light sticky feel to them, such as that of adhesive tape. Panels are laid up by hand or machine onto a mold surface, vacuum bagged and then heated to typically 120-180 degrees C. This allows the resin to initially reflow and eventually to cure. Additional pressure for the molding is usually provided by an autoclave (effectively a pressurized oven) which can apply up to 5 atmospheres to the laminate. 3 In general, the reinforcing and matrix materials are combined, compacted and processed to undergo a molding event. After the melding event, the part shape is essentially set, although it can deform under certain process conditions.

2

http://en.wikipedia.org/wiki/Composite_material http://autospeed.com.au/cms/title_Complete-Guide-to-Composites-Part6/A_108698/article.html 3

2


Perforated Metal Panel: The panles can be ventilation, filtering, sorting and the support for sound-absorbing and etc. But the use is limited because of the lack of reliable strength and stiffness properties for use in design. The strongest type is when round holes are arranged in a standard 60째 triangular pattern ranging from .020" to 3/4" account for more than half of the perforating industries production. In perforating this pattern, the direction of the stagger is the short dimension or width of the sheet as illustrated. The straight row of closely spaced holes is parallel to the long dimension or length of the sheet. This is the socalled "closed pattern." Under special order, the holes may be punched in the "open pattern." 4

Types:

Expanded mild steel

Raised (Mild Steel)

Perforated (aluminum)

Woven wire mesh

4

http://www.fhbrundle.co.uk/technical 3


Materials:

Rusted (corten)

Aluminum

Stainless Steel

Copper

4


Perforated composite panel marjan sarab 2011