•Cladding•Solar Screening•Acoustic Panels•Balustrades•Walkways•Structural Support

Architectural Concepts Guide

A GIBRALTAR INDUSTRIES COMPANY

Cladding •

Balustrades •

Walkways •

Structural Support •

Solar Screening •

Acoustic Panels •

The New Museum of Contemporary Art, New York, USA.Expanded aluminium cladding system. The outer skin of this 7 storey building is clad in expanded metal. The bright aluminium surface catches the light, reflecting the changing moods of every day throughout the year.

Photograph courtesy of Sanaa & Christopher Dawson

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ContentsWhat is Expanded Metal?

Structural Support

Cladding

Metals & Finishes

Solar Screening

Balustrades

Ceilings & Acoustic Panels

Project Updates & Other Products

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The company has begun a brand new and exciting chapter in it’s long and successful history. The Expanded Metal Company is now part of US based Gibraltar Industries. Gibraltar Industries is a leading manufacturer, processor, and distributor of primarily metal materials for the building, automotive, and industrial markets. Employing 3,600 staff across 77 facilities in the USA, Canada, China and now in the UK, Germany and Poland.

Over the following pages we hope to change your perceptions of expanded metal mesh, particularly with regard to it’s use as an architectural tool. Expanded metal could be described as a blank canvass, on which architectural concepts can be brought to life.

The Expanded Metal Company began producing it’s ubiquitous expanded metal products at it’s Hartlepool site in 1889. Since that time the company has undergone several transformations, developing technology, expertise and exploring brand new market places as it grew. More recently, The Expanded Metal Company has been gathering knowledge and honing skills in one particular area - Architecture. We believe we are able to offer, not only the finest range of architectural expanded metal meshes in the UK, but across the whole world!

Who We Are...

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What is expanded metal?The process for expanding metal was first patented in Hartlepool, UK in the 1880’s and despite the amount of time which has elapsed since then, the process remains true to the original idea. Most types of metal, including precious and specially produced metals, can be expanded. Other materials, such as some plastics or any other ductile material can also be expanded. The process is simple but incredibly effective...

The machines are then programmed or manually controlled to ensure the metal is expanded to the exact specification.

Sheets or coils of metal are fed into the expanding machine. A little metal can create a lot of mesh.

Each machine is fitted with a unique “knife”, dedicated to a particular pattern.

Using the unique shearing and stretching process means very little waste is created. The metal is sheared and then stretched in a single process creating the apertures and therefore expanding the metal. The mesh is then either cut into sheets or wound onto coils ready for shipping or further processing.

Adding Strength

Recent research carried out by Teesside University has found that by expanding metal, you also significantly increase it’s strength. Remember - the metal is sheared and stretched so, at each intersection of the aperture, metal from the original sheet or roll gathers into knuckles. This three-dimensional form inherits strength, whilst the overall weight of the metal is reduced because, a relatively small amount of raw material is creating a huge amount of mesh!

This additional strength combined with less waste can have significant advantages for the architect, particularly in terms of walkways, flooring, escapes and structural support.

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Structural Support Mesh

The Birth of a Whale...

Behind this building’s cladding system lies a galvanised expanded metal mesh, retaining and shaping. The mesh was fixed to the metalwork and concrete was sprayed on to it in layers to create the unusual curved shape of the building.

The Selfridges store’s roof and wall blend seamlessly into one. This particular mesh’s flexible but strong nature, helped create the large curved organic form of the building.

Over 10,000m2 of specially cut mesh was supplied for this project with on-site visits and technical expertise on hand at all stages.

Traditionally, expanded metal mesh has been used to act as a support and a key for plaster and render. Progressing these applications one stage further, The Expanded Metal Company has developed the material to act in a supporting role on much larger projects.

The Expanded Metal Company has developed a mesh which can be fixed to the supporting steelwork of new buildings, yet can be curved in both el-evation and plan. The significance of this is that, when sprayed concrete is applied to the supporting structure, to create a shaped or sculptured surface, the amount of concrete used can be greatly reduced. This has the combined benefits of reducingmaterial costs, shortening application times (and therefore labour costs), and keeping the weight of the finished surface to a minimum. Around 10,000m2 of mesh was used in the first project, Future System’sSelfridges store in Birmingham, also known as “The Whale”.

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Expanded Metal Cladding

In terms of sheer visual impact, expanded metal cladding systems are hard to beat. Combining the best of modern metallic materials, unique patterns, profiles and a range of finishes with practical solar and acoustic properties, such systems allow architects to ensure any new building stays at the very cutting edge of modern building materials technology. In terms of refurbishment, dull, grey, concrete surfaces can be clad to revive buildings and send them hurtling into the 21st Century.

Woodlands Community Centre, London. EnglandEger Architects used two different types of mesh to create an external skin around this environmentally self-sustainable community centre, located in East London. The “Bilbao” mesh was used to cover the bland concrete elevation, whilst a large louvered mesh was used as both glazing screen and transparent balustrade panels. Both were powder coated to a verdigris colour to match the buildings surroundings. The Expanded Metal Co. worked closely with both architect and contractor to ensure the correct product was specified and delivered to site.

Theresienwiese Service Centre, Munich, GermanyHighlighting the range of materials that can be expanded, this Bavarian centre effectively combines the use of both solid and expanded copper sheeting on the elevations. Additionally doorframes and window grilles have been fabricated, incorporating the “Bilbao” type mesh. Because of increased material yield and minimal wastage during the expanding process, mesh lends itself easily as a cost effective way to use high value materials in architecture.

Forth Road Bridge Toll Booth, Edinburgh, ScotlandDesigned by Edinburgh based architects Reiach & Hall, the new Forth Road Bridge Toll Booths include a decorative aluminium mesh to the front sides and soffits of the structure. The Expanded Metal Co. worked closely with the design teams to create a mesh which when fixed back to structural purlins was both aesthetically pleasing and also resistant to the high wind loads anticipated at the bridge. The mesh allows a high degree of light transmission creating a calming effect for queuing drivers, when it is backlit on an evening.

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Photograph courtesy of Eger Architects

Photograph courtesy of FETA/Reiach & Hall

Metals & FinishesThe variations of expanded metal are limited by nothing except your own imagination. Most types of metal are suitable for expanding, such as aluminium, mild steel, pre-galvanised and stainless steel. Fashionable materials such as corten and copper as well as most other precious metals, amongst many others, can all be expanded using the same process. Each material brings it’s own characteristics of course. For instance, steel gives strength, aluminium is light and weathers well and copper ages beautifully. But when an application demands something a little different, other alternatives can now be found.

Metal polishing can quickly and effectively protect and enhance the beauty of many materials. For longer lasting protection, anodising, painting or powder coating can all be used, creating a multitude of potential finishes.

The Young Vic

Haworth Tompkins’ 2006 refurbishment of the Young Vic theatre in London, saw expanded metal employed as not just a cladding system, but a lighting feature and art work too!

Corten Polished Aluminium

Pearlescent Paint Anodised Aluminium

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Solar ScreeningAs global warming continues to prove it is here to stay, so the resultant air conditioning units put additional demands on electricity suppliers, who in turn, exacerbate global warming! It is a vicious circle which needs to stop and expanded metal offers an excellent solution to the problem, by reducing solar gain through blocking the sun’s rays as it moves through the day.

The Bilbao Exhibition Centre, Bilbao, SpainThis massive project utilised an Expanded Metal mesh to create a high sunscreen around the Exhibition Centre. The mesh is fixed to the structural metalwork at angles to create not only a cantilevered striped effect but an effective sun and glare screen. The mesh was coated to a very high standard in order to combat the temperatures of Bilbao.

The actual mesh which was used, was christened the “Bilbao” mesh, because of the huge impact it had on the marketplace. The 115mm x 48mm mesh size and very wide strand width means that light is allowed through in one direction but not the other. This invaluable feature is unique to expanded metal mesh, and has meant it has been used in a variety of cutting edge projects since.

Business Centre, Stokesley, North Yorkshire, EnglandThe new business start up centre in Stokesley, North Yorkshire was designed by McDowell & Benedetti Architects. The unusually shaped build-ing was clad in a special grade aluminium mesh with a 43mm x 17mm diamond which was anodised bronze. Not only does the mesh act as a cladding to the exterior walls, but it also serves as a sunscreen over the windows. The mesh is cut into narrow strips that are framed and fitted to an actuator rod which can be moved to prevent glare as the sun moves throughout the day.

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Photograph courtesy of McDowell Benedetti

Balustrades

Day Night

The Public Library, Des Moines, USAThis striking building shows just how versatile and effective expanded metal mesh can be. Designed by David Chipperfield Architects, the outer walls of this public building are made from glass panels filled with expanded metal. German manufacturer Okalux designed the panels with mesh supplied from The Expanded Metal Company’s German counterpart, Sorst. The panels were designed to act differently in either light or dark conditions. During the day the panels appear to be solid copper and prevent solar heat gain. In the evening the light spills out from inside the building creating a more open. almost transparent, effect.

Photographs courtesy of David Chipperfield Architects & Des Moines Public Library / Credit Farhid Assassi

Manhattan Shopping Centre, PolandThis internal application used a flattened expanded metal mesh in galvanised steel. The mesh was incorporated into the hand rail. Both sides were put in a C-profile and fixed with stainless steel screws. Mesh panels were also supplied in raked panels leading to and from the landing areas.

Tintwistle Footbridge, Derbyshire, UKDerbyshire County Council used one of the new square meshes in a new public footbridge over the River Etherow. A 25mm square mesh was chosen in hot dipped galvanised steel and was framed with angle. This was then fixed to the metal framework.

Expanded metal offers the architect or interior designer a whole new range of options when it comes to balustrades. Once again, the choice of patterns, materials and finishes available, combined with strength, make expanded metal an ideal material for such applications.

Tolbooth Centre, Stirling, ScotlandDuring its renovation in 2001, Edinburgh based Richard Murphy Architects cleverly combined a conventional expanded metal mesh with a dark powder coated finish, optimising transparency on the liftshaft and stairwell panels. This meant the mesh could be used functionally as a balus-trade, without detracting from the prominence of the surrounding stonework. Expanded Metal was also used on acoustic wall panelling within the recording studio.

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Ceilings & Acoustic PanelsThe structure of expanded metal aides the disruption of sound waves, deadening noise and reducing echo. This practical feature of the material, in conjunction with its already proven architectural features make it perfect for both decorative ceiling tiles and acoustic panels.

MIMA, Middlesbrough, EnglandA flattened, galvanised steel mesh was used to create both the external and internal ceiling of Middlesbrough’s new art gallery, designed by Erick van Egeraat Associate Architects. The steel mesh sheets of 1200mm x 2130mm were galvanised to give a rough, uneven industrial effect synonymous with the working heritage of Teesside. The sheets were then simply screwed directly onto the unistrut gridwork, supporting the ceiling.

Tolbooth Centre, Stirling, ScotlandAcoustic insulation has come a long way since bedroom walls were covered in egg boxes. Already specified on balustrades and as an architectural feature throughout, the recording studio of The Tolbooth Centre also benefitted from expanded metal. Used to create a sound-proof room, expanded metal reduces noise, looks attractive and dispenses with the need for egg boxes!

Canary Wharf Tube Station, London, EnglandFoster and Partners designed this underground rail station, where the ticketing hall included expanded metal as part of the noise reducing measures.A medium duty, flattened, galvanised steel mesh was used, giving optimum open area to allow sound energy into the absorbing material fixed behind it. The oversize panels were polyester powder coated dark blue to match the surrounding metalwork.

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Photographs of MIMA courtesy of MIMA / Credit Marcus Ginns

Project UpdatesProject Updates from The Expanded Metal Company can be stored here...

Securilath™Securilath gives you the opportunity to “build-in” maximum security. Easily fixed to brickwork, blockwork, stud partitioning, ceiling joists and roofs in metal or timber, Securilath drastically reduces the risk of forced intrusion and has LPCB accreditation.

Ideal for safe-rooms, banks and computer rooms etc, Securilath has a dedicated brochure, available from www.expandedmetalcompany.co.uk.

WalkwaysHeavy duty expanded metal walkways are suitable for use in both domestic and industrial applications. Available in a range of materials with varying properties, including Supagrip™ expanded metal walkways offer a cost effective and sustainable solution for access areas, balconies, walkways and wheelchair access ramps.Learn more at: www.expandedmetalcompany.co.uk.

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The Expanded Metal Company was the worlds first manufacturer of expanded metal mesh, following it’s invention, in Hartlepool, England, during 1889. This incredibly versatile material is still

manufactured in the same, sustainable and environmentally friendly way - a simple slitting and stretching process - which creates very little waste. The product was used in many industrial and

agricultural applications in it’s early life, and soon found many uses in the shipbuilding industry and, in time, the building industry.

Expanded metal was traditionally used to strengthen and support structures, and became a household name in terms of plaster lathing. Now, in the 21st Century, this fantastic material has undergone a

transformation, from inside - to out! Specified for many iconic new buildings around the world, expanded metal has become a critical tool for the architect and designer, not only practical, but eye

catching and kinder on our environment too.

This brochure intends to open up your eyes, and imagination, to expanded metal. We hope to provide a blank canvas on which, ideas can be brought to life.

The Expanded Metal Company LimitedPO Box 14Greatham StreetLonghill Industrial Estate (North)HartlepoolEnglandTS25 1 PR

T: +00 (44) 1429 867 388F: +00 (44) 1429 866 795

E: sales@exmesh.co.ukI: www.expandedmetalcompany.co.uk

A GIBRALTAR INDUSTRIES COMPANY

Quality AssuranceBS EN ISO 9001: 2000

BSI RegisteredCertificate Number: FM01344

Environmental Management SystemBS EN ISO 14001: 2004

BSI RegisteredCertificate Number: EMS 39483