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Designing with Perforated Metal

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©2006, 2011 · Table of Contents Slide 2 of 81

Designing with Perforated Metal

Presented By: Accurate Perforating3636 South Kedzie Avenue Chicago, IL 60632

Description: Provides an overview of perforated metal, including its history, applications, specifying standard and custom perforated metal, along with a discussion on how it is used to sculpt light, control sound, and compose views.

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The American Institute of Architects · Course No. AEC497 · This program qualifies for 1.0 HSW/LU hour.

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Learning Objectives

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

• Discuss the history, features, and uses of perforated metal products

• Explain how perforated metal is used as a valuable tool for composing light and views, orchestrating sound, and managing HVAC flow

• Discuss the manufacturing process and available finishes of perforated metal

• State the factors that influence perforating costs and specification considerations






Table of Contents

Introduction and History 6

Sculpting Light 14

Controlling Sound 26

Composing Views 44

Decorative Accessories 50

Making Perforated Metal 57

Specifying Perforated Metal 67

Summary 77

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Introduction and History






Historical Overview

Perforated metal has been used for more than 120 years, beginning as a filtering tool for coal mining and agricultural purposes in the late 1800s.

Engineers discovered the benefits of using perforated metal to control the size of particles moving through a screen by controlling the size of the holes. Perforated metal emerged as an essential tool for anything requiring filtering, such as air, water, solid particles, and even light.

It wasn’t until the 1950s that perforated metal began to be utilized as a decorative element for home interiors. At that time, the trend was focused on futuristic, space-age design, and perforated metal became the material of choice for cabinets, furniture, and accessories. Its benefits were also functional: it allowed for the movement of air and light so that the environment could be harnessed.






Perforated Metal Today

Today, the architectural uses for perforated metal span a wide variety of interior and exterior applications for both residential, industrial, and commercial use.

One of the main reasons for its growing popularity is its versatility.

Perforated metal is available in a vast array of materials, hole sizes, and hole shapes, each offering distinctive characteristics and customizable solutions.

Not only has it become a valuable architectural tool for creating unique, functional designs, architects can use perforated metal as a powerful and dramatic tool for composing light, orchestrating sound, and managing HVAC flow.

This presentation explores these design challenges and solutions and focuses on the possibilities of perforated metal, limited only by imagination.






Uses of Perforated Metal

• Audio: Custom speaker grilles are made from perforated metal, allowing for the projection of sound while still providing durability, especially in outdoor applications.

• Architectural: Perforated metal is used to execute the designs of architects/designers for building and parking structure facades, outdoor furniture, and other components.

• HVAC: Products used to create comfortable environments, such as commercial air diffusers, fan guards and screens, can be made with perforated metal.






Uses of Perforated Metal, cont’d…

• Electronic Enclosures: Panels made from perforated metal provide shielding from electronic interference, while allowing for air flow to the electronic components stored inside.

• Noise Control: Perforated metal products aid in controlling unwanted sound in public, professional, and technological areas.

• Store Fixtures and Displays: A variety of retail outlets - department stores, hardware stores, and video retailers, display their merchandise using perforated metal shelving and racks.







• Perforated Baking Pans: Perforated blanks are used to bake a large percentage of North America’s bread and pizza.

• Filtration: Many types of oil, air, and water filters are made with perforated metal.

• Medical: It’s used to make components for the medical field, including laboratory equipment, such as sterilizer racks and test tube holders.

• Automotive: The automotive industry uses perforated metal for muffler components, filter wraps and cages, grilles, and guards.







• Decorative: Decorative applications that are attractive and functional include: covers, guards, sunscreens, and door/wall/ceiling panels.

• Agriculture: Perforated products can be found in baskets and filters, grain dryers, hammermill screens, and construction equipment.

• Appliances: Commercial and consumer appliances use perforated products in dryer drums, fans, refrigeration units, dishwashers, and coolers.






Features of Perforated Materials

Perforated metals can be utilized for a variety of functions including applications with special conditions such as sanitary, corrosive, abrasive, and high-low temperatures.

Function:

Cover

Enclose

Divide

Decorate

Ventilate

Provides Display Surface

Create Lighting Effects

Minimize Weight

Controls Passage of:

Air

Gases

Liquids

Light

Sound

Architectural Components:

Ceilings

Walls

Floors

Conduits

Stairways

Grills

Dividers

Acoustical Surfaces






Slide 14 of 79

Sculpting Light






Introduction

Capitalizing on perforated metal’s ability to direct light and diffuse harsh sun, architects often choose it to create:

• window screens• building facades, and• sun shades.

Perforated metal provides shade for areas where sunlight combats comfortable lighting and air-conditioning systems.






Valley Health Center, Gilroy, California

The exterior glass and aluminum fascias of the 59,000 square foot Valley Health Center came to life through a series of custom perforated sun shades.

The manufacturer was tasked with fabricating the complex curved perforated sun screens to fit the shape of the building. Extra thick .190” 3003H14 Aluminum sheet was perforated one hole at a time to follow the curvature of the building. Special mounting brackets were welded to each panel to match the unique curvature of the main entrance. Since each panel was unique but similar, construction numbers were stamped onto each panel to guide installation. The panels were then custom-packaged and shipped to the job site where the customer installed and painted them on-site.






Tenley-Friendship Library, Washington, D.C.

Over 480 27” x 72” perforated panels were made for the Tenley-Friendship Library's picturesque vertical sunscreens.

The vertical sunscreen fins were designed to shield the glass curtain walls from the sun's glare to provide the occupants with ideal reading conditions.

The orange-colored perforated sunscreen edges were aligned in vertical rows that emulate the edges of an open book's pages. Ideal for sun control, extra thick 3/8” 3003H14 Aluminum was perforated.

The material was sent through a Herr-Voss CNC leveler to prepare the material for fabrication. The sheets were then sheared, packed, and shipped to the customer for final fabrication and assembly.






Building Facades

Building with perforated metal can help control light, yet maintain the integrity of a building’s design.






Tampa Museum of Art






Light and Window Screens

These interior applications illustrate how perforated metal is used to soften artificial and natural light, while providing architectural accents within the space.






Ideal Material for Outdoor Environments

Because of its ability to diffuse sunlight, perforated metal is an ideal material for many outdoor environments, including:

• skyways• bus and train shelters, and • atrium areas.






Protection and Security

Here, not only do the perforated metal panels provide protection from UV rays, they also are used to limit noise, and keep small children safe from falls.






National Emergency Response Centre, Springfield, IL

The National Emergency Response Center in Springfield, IL features perforated metal made from .043" thick corrugated copper perforated .50" round on .75" staggered centers.

Using perforated copper not only provides shade for the southern exposure offices, but also aids with EMI RFI shielding for the electronic systems in use.






Illinois Institute of Technology, Chicago, IL

Perforated and corrugated 16-gauge stainless steel panels were used to join several buildings at the Illinois Institute of Technology in Chicago.

The material shades the building’s occupants and allows for easier maintenance of the plants and trees between the buildings.






Colorado Convention Center






Controlling Sound






Introduction

In the last few decades, acoustical applications have experienced the most dramatic growth of all the architectural markets for perforated metals.

And while architects and designers currently implement noise control into their projects, the demand for effective noise control systems is increasing due to the urbanization of today’s population.

To meet consumer demand, perforated metal manufacturers, in collaboration with audio engineers, have developed perforated metal products that provide the best solutions in noise control systems.






Sound Absorptive Layer

Perforations not only absorb noise and minimize sound reflection, but also reduce weight, contour light, and provide aesthetic appeal.

To enhance their functionality, panels are often laminated with a sound-deadening fiber material.

The thickness and type of the sound absorptive layer is dependent on the application.

Sound Absorptive Layer

Perforated Metal Sheet






Transparency Approach

There are two principal acoustical applications for perforated metals: 1) Transparency Approach 2) Tuned Resonant Absorber.

With the transparency approach, the perforated metal is used as a protective or decorative covering for a specific acoustical material. That material may be designed either to absorb sound or to reflect sound in a particular way. The purpose of the perforated metal is to be so "transparent" that the sound waves pass right through it, without being diminished or reflected, to meet the acoustical treatment that lies behind.

In this case, the design goal is to choose the perforated metal for greatest sound transparency, for sounds of all frequencies. Facing applications are ideally suited to auditoriums, concert halls, and theatres in which sound is allowed to pass freely through a false, decorative, perforated surface in order to reach specially designed acoustical treatment.






Orpheum Theatre, Vancouver, B.C.

Pictured at right is an example of perforated metal used as a facing in the Orpheum Theatre, Vancouver, B.C.

Although the curved surfaces above the stage appear to be plaster, they are actually made with finely perforated metal sheet.

The perforations allow the sound to pass through and reflect back into the hall at desired locations.






Sound Absorbing Efficiencies for Glass Fiber Materials

This chart at right shows typical sound absorbing efficiencies for glass fiber materials at frequencies ranging from 125 Hz to 4000 Hz.

Notice that one inch of glass fiber is effective absorbing sound at high frequencies above 2,000 Hz but very inefficient absorbing low frequencies.

Conversely, six inches of glass fiber is very efficient at all frequencies (about 99% of the incident noise energy is absorbed).






Tuned Resonant Absorber

In some applications, we may wish to absorb sound selectively, only in a narrow range of frequencies but not at frequencies lying above and below that particular band. For example, an enclosure around a power transformer must be especially effective at a frequency of 120 Hz.

Since the absorbing material takes up space and is expensive, it is not cost effective to provide thick absorbing layers when only a limited frequency range requires treatment. For such applications, it is possible to design a sound absorption system in which perforated metal plays a significantly active role.

This kind of system is known as a Tuned Resonant Absorber. This system provides remarkably high sound absorption in the targeted frequency range, without requiring a large amount of space for absorptive material.






Tuned Resonant Absorber, cont’d…

This is how it works. In response to an incident sound wave, the air oscillates in and out of the holes in the perforated metal sheet, as well as back and forth in the sound absorptive layer. The resulting friction converts the acoustic energy into heat and is thereby removed. Factors that determine the frequency of oscillation are: the mass of the air in the perforations, and the springiness of the trapped air layer.






Ceiling and Wall Panels

Common architectural uses for perforated metal are acoustical ceilings and wall panels, widely used in airports, indoor swimming pools, university auditoriums, and applications requiring acoustic management.

Ceiling panels, as well as wall panels, can be used as an excellent sound barrier while yielding a diversity of visual effects.






American Airline Terminal #9, JFK Airport, NY

The American Airlines Terminal of John F. Kennedy International Airport features ceiling panels, fashioned from 0.50"-thick perforated aluminum.






American Airline Terminal #9, JFK Airport, NY, cont’d…

The material was perforated, notched, formed, painted, and acoustically-backed, allowing the contractor to easily insert the panels into the existing grid system.






New World Symphony Center, Miami Beach, Florida

Creating an ideal acoustical environment for concert halls, like The New World Symphony Center in Miami Beach, Florida, is largely achieved through sound isolation from external noise and vibrations. Designing an immersive experience posed a challenge for designers and builders.

The solution was to line the mullions of the windows with acoustically transparent perforated metal panels lined with an absorptive acoustical layer. This pairing reduces noise transmission and eliminates sound reverberation while also providing a unique yet unobtrusive appearance.

The precisely engineered acoustical panels for the mullions of the glass walls were installed into the interior windows and doors.






Vienna Subway Station

Perforated metal facing is used for the sound absorptive ceiling treatment for the subway station in Vienna.






EMPAC Studios

The EMPAC studios acoustic wall tiles offer a completely novel approach to the acoustics of immersive sound environments. The studios are quiet and highly networked, rewarding audiences and supporting experimentation by artists and researchers alike.






Choosing the Right Perforated Metal

Once a sound absorptive material is chosen for the noise control task, the proper type of perforated metal, providing the greatest transparency, can be selected.

Most people assume that the greater the percentage of open area, the more easily sound can pass through it. Generally, this assumption is accurate … but not always.

For example, illustrated at right are two sheets, both with 40% open area-one with larger holes, and the other with very fine perforations.






Choosing the Right Perforated Metal , cont’d…

Instead of acting as a transparent facing material, the sheet with the one large hole would be completely opaque to sound, reflecting all of it, save for the small open area at the center (10%).

Conversely, because the tiny solid areas between the holes on the finely perforated sheet are too small to intercept sound waves, the entire sheet is almost completely transparent to sound.

This example demonstrates that for high transparency, the most important consideration is to have many small perforations, closely spaced. Furthermore, it’s better to minimize the bar size, and to a lesser extent, the sheet thickness, rather than focusing on the percentage of open area.






The Transparency Index (TI)

The Transparency Index (TI) was developed to aid designers in choosing suitable transparent materials for their projects and is used for either straight or staggered patterns.

When the value of “b” is unknown, an approximation for the value of “a” is:a=d[(cont./P ½)-1].

The value of the constant is 8.9 for straight perforations and 9.5 for staggered.

TRANSPARENCY INDEX

TI = nd2/ta2 = 0.04 P/pta2

where:

n = number of perforations per sq in;d = perforation diameter (in);t = sheet thickness (in);a = shortest distance between holes(in); a = b – d, whereb = on-center hole spacing (in);P = percentage (not fractional) of open area of sheet.






Benefits of Using Perforated Metals

Some of the great advantages of using perforated metals as components of acoustically absorptive treatments are:

Cleanability: Unlike other commonly used treatments, perforated metal can be cleaned or refinished without damaging the absorptive properties for which they were designed.

Strength: In contrast to woven or felted facing materials, the inherent structural strength allows perforated metals to stand alone, if necessary.

Formability: Perforated metals can be formed into complex curved shapes.

Durability: Having a high resistance to abuse, damage and wear, perforated metals are extremely resilient.

Versatility: Perforated metals can be made to look like other materials, such as plaster, to blend into its surroundings.






Composing Views






Privacy and Security

In architectural applications requiring privacy and security, perforated metal can be utilized without sacrificing the outside view.

Certain perforated hole patterns offer the building’s occupants a full outside view, while the view from outside is mostly obstructed at longer distances.

In such applications, the perforated metal is often corrugated, providing a more rigid structure, concealing panel seams, and giving the façade an appealing look and texture.






Interior Screen Walls

Perforated metal can also provide privacy for building interiors, allowing architects/designers to create screen walls that define a space, without completely isolating it from the surrounding areas, or the building’s HVAC system.

Depending on the hole size and pattern density, a wall system can be designed that is virtually transparent, yet maintains airflow for a comfortable environment. The smaller the holes, the more opaque the panel becomes.






Camouflage Unsightly Areas

For unsightly areas, on or around buildings that detract from their visual appeal, perforated metal is an ideal camouflage.

Used on rooftops where HVAC units and communications equipment are installed, perforated metal helps blend these areas with the rest of the building.

In addition, it can be used at ground level to hide electrical, water and sewage fixtures, trash dumpsters, and parking facilities.






Camouflage Unsightly Areas, cont’d…

Parking garages and other less-appealing structures are often refaced with perforated metal to provide a more attractive look that is consistent with the surrounding structures.

In fact, many municipalities require that perforated metal is used in their parking garages.

The perforations allow airflow for dissipating engine exhaust and reducing sound levels transmitted to nearby areas.

Perforated metal is ideal for these types of applications given its resilience from the weather, graffiti, and general wear and tear.






Kitsap Medical Center






Decorative Accessories






Shelving, Furniture, and Lighting Enclosures

Perforated metal can be utilized to create stunning and distinctive decorative accessories, such as shelving, indoor and outdoor furniture, and lighting enclosures.






Architectural Accents and Displays

Because it is both aesthetically pleasing and functional, perforated metal is commonly used for a variety of architectural accents and displays.






Stairways

Materials can be perforated with non-symmetrical patterns to create unique and eye-catching spiral staircases, landings, and winding stairs.






Railings and Infill Panels

Decorative railings and infill panels made of perforated metal offer the perfect balance between strength and lightness, providing protection for the building occupants without hindering visibility, air-flow, and light.






Railings and Infill Panels: 235 Van Buren Building






Signage

Easily customized perforated metal is perfect for outdoor signage applications due to its versatility and durability.






Making Perforated Metal






The Perforating Process

Most perforated metals are manufactured using specialized perforating presses. Usually, the tooling in these presses contain one to four rows of punches (depending on the hole size and pattern selected) running the width of the material being perforated.

Coils or sheets of material are fed through the press as the tooling cycles down, punching out evenly spaced perforations. Each stroke can create hundreds of holes, running from 50 to 400 strokes per minute, depending on the hole size and thickness of the material.






The Perforating Process, cont’d…

Many perforated metal companies have the capability to program their presses to create:

• Blank areas, • Custom designs • Finished end patterns • Locator holes• Special hole sizes

For more intricate patterns, a CNC turret press is often used.






Materials Commonly Perforated

For architectural applications, materials commonly perforated include:

• Stainless steel • Aluminum• Copper• Galvanized steel• Galvaneal steel• Electro-galvanized steel• Cold-rolled steel

Materials up to 1/2" thick and up to 72" wide in sheet or coil can be perforated.






Range of Alternative Materials

Also, more exotic materials are available for industrial, commercial, and residential applications:

• Nickel alloys • Composites• Brass• Copper• Rubber-coated materials• Prepainted materials• Plastics• Bronze






Ready to Install Features

A wide range of standard and ornamental punch patterns are available in a variety of sizes.

Custom patterns can be made with new tooling.

A few perforated metal suppliers provide material that is ready to install. Mounting holes, notches, forming, and profiling can be done by the supplier or through local fabricators.






Mounting Holes and Corrugating

Mounting Holes: Instead of drilling or using the existing perforations to fasten perforated panels to a structure, mounting holes and notches can be selectively placed in solid margin areas.

Corrugating: Forming or ribbing a flat sheet of material (known as corrugating) into a consistent, symmetrical profile can increase the material’s strength-to-weight ratio up to 30%. Available profiles depend on the perforation pattern, material thickness, and type of material.

Mounting Hole

Corrugated Material






Radiusing

Forming and Radiusing: To assist with framing, or where sharp edges are a safety concern, 90 degree bends or more complex forms can be added to the material. Certain sized panels can also be radius rolled for a specific design in applications where using flat panels are not suitable.






Finishing

A variety of finishes can be applied to perforated metal giving the architect the ability to create a very specific look. Finishes most often applied include: powder coating, anodizing and Kynar®.

Powder Coating: A variety of powder types and colors are available and even custom colors can be easily matched. The powder coating process sprays electrostatically charged powdered paint onto the part. It is then placed into an oven where the powder particles melt and coalesce to form a continuous film that is highly resistant to corrosion and abrasion.

Powder Coated Finish






Finishing, cont’d…

Anodizing: A thin film of synthetic oxide can be applied to light metals, such as aluminum, to enhance its appearance, preserve shine, and prevent corrosion. The anodic film may be dyed various colors.

Kynar®: Finishes, based on Kynar 500® PVDF resin, are used to protect aluminum, galvanized steel, and aluminized steel in commercial, industrial, and residential applications, such as metal roofing and siding, window and door frames, curtain walls, and other miscellaneous components. In addition to several standard colors, custom color matching is available.

Anodized Finish

Kynar® Finish






Specifying Perforated Metal






Introduction

In this section, a list of factors influencing perforating costs will be presented, as well as the required information when specifying perforated metal for both standard and custom orders.

Architectural structural concerns and responsibilities will also be discussed.






Perforating Cost Influences

Material Type: The least expensive material may not have the lowest cost. The characteristics of the material and fabricating considerations may be more important in determining the final price tag. For instance, a higher strength alloy with less thickness (gauge) may provide cost savings. Keep in mind, material hardness should remain below 80 Rb.

Hole Shape and Pattern: Round holes are the most economical. The strongest and most versatile pattern is a 60" staggered round hole.

Hole Size: Although the minimum guideline is 1:1 ratio (hole size to sheet thickness) a 2:1 ratio of hole size to thickness of material is needed when perforating stainless steel. For aluminum, a 1:1 ratio is sufficient.






Perforating Cost Influences, cont’d…

Bar Size: The measure of the material from the outer edge of one hole to the outer edge of the nearest hole is referred to as bar size, bar width, or bridge thickness and the same guidelines for hole size apply to bar size: minimum 1:1 ratio, 2:1 recommended.

Center Distance: Refers to the distance from the center of one hole to the center of the nearest hole in the adjoining row. Center distance is a major factor in controlling feed rate, thereby the production rate. Patterns with longer center distance are perforated more rapidly, and for saving costs, are the best choice.

Open Area: The percentage of total area of holes divided by total area of the solid material is known as open area. For example, a perforated sheet with 60% open area has 60% open area and 40% solid area. It’s recommended to stay under 70% open area since extreme open area proportions tend to increase distortion.






Perforating Cost Influences, cont’d…

Margins: The margins are the unperforated areas along the edges of the material and can be specified several ways. Unfinished end margins is the standard, but if the standard cannot be used for a specific design, margins should be kept to a minimum to reduce distortion.

Blank Areas: Consider the die pattern when locating blank areas and consult your supplier if needed.

Stick to Standards: To reduce costs, whenever possible, specify standard hole patterns, material dimensions, and tolerances. Before specifying a custom product, contact your supplier to discuss your options. Perhaps there is a cost-effective alternative that can be produced with existing tooling.

Burrs: Unless deburring is specified, expect normal commercial burrs (thin ridges or section of roughness appearing on metal).






Ordering Established Patterns

Ordering established patterns is straight forward and requires basic, but specific, information be given to the supplier including:

Quantity: Provide the number of perforated sheets or pieces required for the project.

Thickness: Specify the thickness of the material in either gauge or in decimal inches.

Material: Decide the type of material best suited for the application.

Width and Length: Determine the width and length of the perforated sheets or pieces; the length is considered the long dimension of the sheet, unless otherwise specified.






Ordering Established Patterns, cont’d…

Perforation Size: Give the size of perforations, expressed in inches.

Perforation Shape: Round, square, and slotted hole are the most commonly used perforation shapes, but there are many special perforation shapes to choose from.

Arrangement of Perforation: Hole pattern is available in a number of patterns, the most common are “staggered” and “straight line”. Generally, the straight row of a staggered pattern runs the long way of the sheet.

Please remember the exam password STAGGERED. You will be required to enter it in order to proceed with the online examination.






Ordering Established Patterns, cont’d…

Spacing of Perforation: There are several options of specifying the spacing of perforations: as the distance between hole centers, as the percentage of open area or, in the case of small perforations, as the number of holes per square inch.

Margins: Specifying margins requires choosing one of four alternatives: no margins; minimum margins all sides; minimum side, no end margins; specific margins. If margins are not critical to your project, specify either minimum or no margins.

Other Information: Included here would be other special requirements, such as flatness tolerances beyond standard, shearing, and finishing options.






Ordering Custom Work

Custom work requires collaboration between the architect, the builder, and the perforated metal supplier.

Some perforating companies, that focus on the architectural industry, have the ability to receive AutoCad and .pdf files that allow them to work directly from the drawings to produce custom pieces, having exact pattern measurements.






Structural Concerns

When selecting perforated metal for an architectural application, keep in mind perforating companies do not typically have structural engineers on staff; structural concerns are the responsibility of the architect.

Additionally, with the myriad if different metals, plastics, and finishes available, functional considerations of the perforated pieces should be addressed.

Designers should, at all times, consult a structural engineer on materials, thickness, dimensions, margins, patterns, and wind loading information.






Summary






Important Points

Perforated metal has become a valuable architectural tool for creating a wide variety of products for interior and exterior applications for residential, industrial, and commercial use.

Architects can capitalize on perforated metal’s ability to direct light and diffuse harsh sun by using it to create canopies, window screens and building facades that not only provide shade for the building’s occupants, but shield electronic systems from EMI RFI.

Used in a transparency or tuned resonant absorber application, perforated metal can be used as a valuable component of acoustically absorptive treatments to absorb noise, minimize sound reflection, reduce weight, contour light, and provide aesthetic appeal.

Perforated metal can also be utilized in exterior applications to camouflage unsightly areas and provide privacy or definition for building interiors.






Important Points, cont’d…

For decorative applications, perforated metal is used to create unique, functional designs for: shelving, indoor and outdoor furniture, stairways, displays, railings, and signage.

Many types of materials are available for perforating. A variety of standard and custom hole sizes, shapes, and patterns can be used, along with various finishes to create a custom look. Mounting holes, notches, forming, and profiling can be done by the supplier or through local fabricators.

When ordering established patterns, it’s important to provide precise information to the supplier.

Finally, it’s crucial that the designer consult with a structural engineer concerning the functional considerations of the perforated pieces.






Course Evaluations

In order to maintain high-quality learning experiences, please access the evaluation for this course by logging into CES Discovery and clicking on the Course Evaluation link on the left side of the page.

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©2006, 2011 Accurate Perforating. The material contained in this course was researched, assembled, and produced by Accurate Perforating and remains their property. Questions or concerns about this course should be directed to the instructor.

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