Innovations in Extruded Aluminum Corners and Trims

© Ron Blank & Associates, Inc. 2015 Innovations in Extruded Aluminum Corners and Trims Course #: ETR05A 1 AIA HSW CE Hour An American Institute of...
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© Ron Blank & Associates, Inc. 2015

Innovations in Extruded Aluminum Corners and Trims

Course #: ETR05A 1 AIA HSW CE Hour

An American Institute of Architects (AIA) Continuing Education Program • Approved Promotional Statement: • Ron Blank & Associates, Inc. is a registered provider with The American Institute of Architects Continuing Education System. Credit earned upon completion of this program will be reported to CES Records for AIA members. Certificates of Completion are available for all course participants upon completion of the course conclusion quiz with +80%. Please view the following slide for more information on Certificates of Completion through RBA

This program is registered with the AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA or Ron Blank & Associates, Inc. of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product.

An American Institute of Architects (AIA) Continuing Education Program • Course Format: This is a structured, web-based, self study course with a final exam. • Course Credit: 1 AIA Health Safety & Welfare (HSW) CE Hour • Completion Certificate: A confirmation is sent to you by email and you can print one upon successful completion of a course or from your RonBlank.com transcript. If you have any difficulties printing or receiving your Certificate please send requests to [email protected] • Design professionals, please remember to print or save your certificate of completion after successfully completing a course conclusion quiz. Email confirmations will be sent to the email address you have provided in your RonBlank.com account.

Course Description

This course focuses on the emerging use of extruded aluminum trim products in single family, multi family and light commercial construction. Participants of this course will be provided and overview and examination of the benefits of extruded aluminum trim products as compared to traditional trim materials. The course goes into detail and defines what extruded aluminum trims are, how they are manufactured and the short and long term benefits of using extruded aluminum trims versus traditional trim materials.

Learning Objectives After completing this course, you will be able to: • Describe the history of corner and trim boards in terms of popular materials used. • Outline the key differences between extruded aluminum corners and trims and bent steel trims. • Specify the key difference between a direct and indirect extrusion manufacturing process and how this impacts metallurgical and dimensional attributes. • Define what extruded aluminum corners and trims are and why they are gaining increased popularity with architects, tradespeople and homeowners. • Explain the cost and installation benefits of extruded aluminum corners and trims over traditional trim materials. • Express Sustainable Design concepts. • Detail how extruded aluminum corners and trims are used as architectural elements in modern architecture. • Convey the key differences between extruded aluminum corners and trims designed for outdoor use.

Corner and Trim Board History

• Early 17th and 18th century log homes used mortise and tenon joints at the corners. • Early 19th century door and window trim boards utilized similar mortise and tenon joints as balloon framed construction increasingly replaced log construction. • Historically, corner and trim materials have been made from wood.

Corner and Trim Board Evolution

• In addition to wood, corner and trim boards are currently available in the following materials: • • • • •

Engineered wood Cellular PVC Fiber cement Galvanized steel Extruded aluminum

How Do Locally Bent Galvanized Steel Corners and Trims Differ from Extruded Aluminum Corners and Trims? • As metal corners and trims continue to gain popularity and acceptance with architects and homeowners, alternatives to aluminum are available. • Bent galvanized steel corners and trims closely mimic the look of extruded corners and trims for a fraction of the cost. • Bent galvanized steel corners and trims lack several performance features of extruded aluminum trims including: • Prone to corrosion • Poor fit and finish produce dangerous sharp edges • Untested by any fiber cement companies • Do not shed water • Unclear warranty protection

Poor fit and finish

Extruded Aluminum Manufacturing Process

• The extrusion process is similar to pushing play dough through a mold. During manufacture, the raw material is pushed through a die which shapes the output to the desired profile. • There are two common types of extrusion processes: Direct and Indirect. Let’s take a closer look at these.

Direct Extrusion Process

• Most common type of extrusion press produces larger, wider shapes vs. indirect. • Stationary die & container. • Ram pushes billet through container, metal flows through die. • Large effort to overcome friction between billet & container wall. • Tremendous frictional heat generated, pressure & temperature vary as billet extrudes.

End Result: More variability in metallurgical & dimensional attributes, front to rear over full extruded length

Indirect Extrusion Process

• Container, billet, ram push together over die (or die’s pushed into stationary container). • Hollow ram holds die, support tooling (tooling more complex), limits circle size. • Cast surface removed from billet (scalped) prior to extrusion. • Can extrude harder alloys, thinner shapes with lower tonnage press. • Minimal frictional heat between billet & container. • Pressure, temperature remain constant as billet is extruded.

End result: More consistent metallurgical & dimensional attributes over full extruded length

Check Point

Which of the following mimic the look of extruded aluminum corners and trims, but lack the same performance features? a) Engineered wood b) Cellular PVC c) Fiber cement d) Galvanized steel

Check Point

Which of the following mimic the look of extruded aluminum corners and trims, but lack the same performance features? a) Engineered wood b) Cellular PVC c) Fiber cement d) Galvanized steel

What Are Extruded Aluminum Corners and Trims? Newest generation outside corners

• Constructed of 6063-T5 aluminum, extruded aluminum corners and trims commonly replace traditional 1x trim boards made of wood, engineered wood, cellular PVC and fiber cement. • Extruded aluminum corners and trims are decorative elements that accentuate joint details and create modern architectural lines on single family, multi family and light construction buildings. • Recent advances in extruded aluminum corner and trim profiles designed for outdoor use deliver enhanced water management features horizontally and vertically.

Early generation outside corner

What Are Extruded Aluminum Corners and Trims?

• Select extruded aluminum corners and trim profiles with large “tabs” provide additional “holding power” on inset panels thus reducing the total number of visible fasteners required to fasten the inset cladding to the wall. • Extruded aluminum corners and trims are made from sustainable material with 75% to 100% post industrial and post consumer scrap and can contribute to LEEDS™ points. • Extruded aluminum corners and trims are primarily used with fiber cement and natural wood products and have been used with vinyl and aluminum claddings as well.

What Are the Benefits of Extruded Aluminum Corners and Trims Versus Traditional Materials? • Creates ultra-modern design aesthetic unavailable from traditional trim materials. • Pre-built corners install quickly and less expensively that traditional materials. • Delivers self-flashed horizontal detail unattainable with a horizontal batten strip. • Extruded aluminum corners and trims offer a wide variety of shapes and broaden and enhance design options for architects and homeowners. • Impact, flame and pest resistant. • Caulk-free design lowers up front material and labor cost and eliminates long term caulk maintenance costs.

What Are the Benefits of Extruded Aluminum Corners and Trims Versus Traditional Materials? • Extruded aluminum corners and trims are available in a variety of anodized finishes that will never chip, crack, peel and underscore modern flair. • Absence of trapped water and dimensional stability provides superior paint adherence on extruded aluminum compared to wood. • Installation friendly, extruded aluminum does not crack or split during installation nor release silica dust when cut. • Due to light weight, extruded aluminum is less costly to ship, handle and install.

What Are the Benefits of Extruded Aluminum Corners and Trims Versus Traditional Materials? Caulk-free

• Blind nailing eliminates unsightly nail holes from the face of the profile. • Latest generation extruded corners and trims designed for outdoor use require zero caulk for water management and helps extend and lower lifecycle cost. • Aluminum is a GREEN product which can be recycled and reused over and over again.

Face nailed

• Extruded aluminum does not corrode or rust. • Delivers high-performance in all weather climatic conditions. Blind nailed

Check Point

Which of the following corners and trims are made from sustainable material with 75% to 100% post industrial and post consumer scrap? a) Galvanized steel b) Extruded aluminum c) PVC d) Fiber cement

Check Point

Which of the following corners and trims are made from sustainable material with 75% to 100% post industrial and post consumer scrap? a) Galvanized steel b) Extruded aluminum c) PVC d) Fiber cement

How do Extruded Aluminum Corners and Trims Express Architectural Elements? • “Elements like line, shape, color and texture do not exist in isolation on a building. They are combined to make formal compositions in an architectural design creating pattern, rhythm, symmetry, balance, contrast, proportion, theme and unity. It is important that the variety of elements used for a building blend together well so the design appears unified.” THE CENTER FOR THE STUDY OF ART AND ARCHITECTURE, 2002 • Extruded aluminum corners and trims express and exalt architectural elements through lines, shape, shadow lines and finish.

How do Extruded Aluminum Corners and Trims Express Architectural Elements? Lines • The creation of lines are achieved vertically and horizontally by the overall length of a given span across which the profile is used and the associated “tabs.” • Tabs vary in size anywhere from 3/8” to ½” in thickness.

How do Extruded Aluminum Corners and Trims Express Architectural Elements? Symmetry • “When there is a correspondence in size or shape of parts on either side of a bisecting whole, we say it’s symmetrical.” THE CENTER FOR THE STUDY OF ART AND ARCHITECTURE, 2002 • Currently, extruded aluminum corners and trims are available in shapes that are symmetrical and asymmetrical.

How do Extruded Aluminum Corners and Trims Express Architectural Elements? Newest generation trims

Symmetric • Outside corner: ½” tabs, ½” return • Inside corner: ½” tabs • Vertical profile: ½” tabs, ½” return, ½” reveal Asymmetric • Outside corner: 3/8” tabs, ½” return • Inside corner: no tabs • Vertical profile: 3/8” tabs, ½” return, ½” reveal

Early generation trims

How do Extruded Aluminum Corners and Trims Express Architectural Elements? Shapes • Extruded aluminum corners and trims are available in a wide variety of shapes that furnish architects and designers greater aesthetic options compared to traditional 1x material commonly used for corners and batten strips. Round outside corner

Square outside corner

How do Extruded Aluminum Corners and Trims Express Architectural Elements? Shadow Lines • The contrast between light and darkness create the defining feature of shadow lines. • Architects and designers manipulate shadow lines to create visual interest on a building by choosing materials that create a sensation of depth.

How do Extruded Aluminum Corners and Trims Express Architectural Elements? Finishes • Extruded aluminum corners and trims and their chosen finish types can deliver, subtle, elegant or bold architectural elements to a building either through the use painted finishes, anodized finishes or a combination of each.

How do Extruded Aluminum Corners and Trims Express Architectural Elements? Finish - Paint • Tone on tone finishes whereby the corners and trims match the color of the inset cladding panels produce subtle shadow lines, hidden tabs which unify and simplify the exterior. • Contrasting finishes whereby the corners and trims differ from the inset cladding add interest and dramatically accentuate the lines of the trims and produce a clear contrast between the corners, trims and inset cladding.

How do Extruded Aluminum Corners and Trims Express Architectural Elements? Finish - Anodized Silver • Clear anodized (silver) corners and trims contrast against the inset cladding and create sleek architectural lines with a post-modern feel.

How do Extruded Aluminum Corners and Trims Express Architectural Elements? Finish - Anodized Black • Black anodized corners and trims produce a distinctly luxurious appearance that in general terms, reduces the size of the building. • Unlike black paint, black anodized aluminum are fade resistant and will not require touch up over time.

How do Extruded Aluminum Corners and Trims Express Architectural Elements? Anodized trims Finish - Paint and Anodized • Cutting edge design incorporates the use of painted and anodized trims to create unique, distinct architectural elements that stand out from the crowd.

Painted trims

What is the Difference Between Extruded Aluminum Corners and Trims Designed Primarily for Outdoor Use Versus Those Initially Designed for Indoor Use? • Initial extruded aluminum corners and trims were derived from PVC trims which had been designed for indoor use with drywall and a variety of other inset panel products. • These profiles were improved and made stronger by switching to aluminum, however they do not shed water, nor install easily because the weren’t designed to be installed outdoors, nor to manage water.

What is the Difference Between Extruded Aluminum Corners and Trims Designed Primarily for Outdoor Use Versus Those Initially Designed for Indoor Use? • The latest generation of extruded aluminum corners and trims engineered for outdoor use can be distinguished form early generation extruded trims by the presence of the following:

Caulk free

• The latest generation of extruded aluminum corners and trims require zero caulk for water management purposes.

Drainage channel

What is the Difference Between Extruded Aluminum Corners and Trims Designed Primarily for Outdoor Use Versus Those Initially Designed for Indoor Use? • The presence of a small bump resting on the nail flange. This bump prevents the inset panel from resting flat atop the nail flange and resists “capillary action” from squeezing water between the cladding and the nail flange back to the nail holes and into the studs. The bump also creates a drainage channel that collects and expels water from the cladding and wall assembly.

Early generation corner

Newest generation corner

• The small bump present on the newest generation of corner and vertical trims also serves as an engagement point for horizontal trims to butt against after being slid inside the cavity. This innovation creates advanced “fit and finish” details devoid of sharp edges.

Smooth horizontal / vertical terminations

What is the Difference Between Extruded Aluminum Corners and Trims Designed Primarily for Outdoor Use Versus Those Initially Designed for Indoor Use? Early generation flange

• Large tabs that “trap” the inset cladding on 3 sides of the board have greater “holding power” than smaller tabs and promote the use of fewer visible face fastening of the inset cladding. • Large flanges on corner profiles will provide the installer with greater tolerance to address rough carpentry deviations associated with framing on a building’s exterior compared to smaller flanges associated with early generation extruded aluminum corners.

Newest generation flange

What is the Difference Between Extruded Aluminum Corners and Trims Designed Primarily for Outdoor Use Versus Those Initially Designed for Indoor Use? 8 degree slope

• Aggressive downward slopes on the latest generation horizontal profiles shed standing water and allow the inset cladding to be rested directly on them without damaging the cladding itself. Early generation horizontal trims have a 2 degree slope and require a ¼” to ½” gap between its surface and the bottom of the inset cladding. • 2 piece vertical profiles speed the installation process and help reduce the total number of visible fasteners because the installer has open, tab-free sections to easily place the panel. The top cap is inserted into the back plate channel after the panel is installed, “locking” the cladding into place with large ½” tabs providing a secure fit.

Early generation vertical

Newest generation vertical

Check Point

The latest generation of extruded aluminum corners and trims engineered for outdoor use can be distinguished form early generation extruded trims by which of the following? a)

Requires zero caulk for water management purposes

b)

Made of recycled aluminum

c)

Lower SRI value

d)

None of the above

Check Point

The latest generation of extruded aluminum corners and trims engineered for outdoor use can be distinguished form early generation extruded trims by which of the following? a)

Requires zero caulk for water management purposes

b)

Made of recycled aluminum

c)

Lower SRI value

d)

None of the above

Course Summary

We have reviewed the following: • Corner and trim board history and evolution. • How bent galvanized trim products differ from extruded aluminum trim products. • The extrusion manufacturing process and how direct extrusion differs from indirect extrusion. • Defined extruded aluminum corners and trims. • Outlined the benefits of extruded aluminum corners and trims over traditional trim materials. • Illustrated Sustainable Design concepts. • How extruded aluminum corners and trims deliver architectural elements to a building. • How trims engineered for outdoor use differ from trims initially designed for indoor use.

© Ron Blank & Associates, Inc. 2015

Innovations in Extruded Aluminum Corners and Trims Please procede to take the online quiz to receive credit for this course

Course #: ETR05A 1 AIA HSW CE Hour