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Structural Mullions & Transoms: The vertical mullions (running floor to floor) carry the weight of glass and transoms, and transfer wind loads to the structure. Our systems have mullion profiles in various depths (e.g., 50mm face width by 150mm to 250+mm depth) depending on span and load. Deeper mullions handle bigger spans/high winds. They often splice at each floor with expansion joints hidden behind cover caps. Transoms (horizontal members) lock into mullions with either screws or brackets and also have drain paths for water. Mullions can be set at different spacings to align with architectural grids – often ~1.5m to 3m apart depending on design. The face can be capped (with pressure plates and snap-on cover caps externally making a grid look) or capless (structural silicone holds the glass and only a slim silicone joint is visible). We can also do toggle systems where glass has concealed toggles – from outside looks frameless except a gasket joint. For aesthetic variations: we can use different cover cap shapes (flat, rounded, Gothic, etc.) if a certain look is desired.
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Glazing and Panels: Typically, double-glazed units with thickness ~28-42mm are used, lodged into the frame. Glass can be clear, tinted, reflective, low-E coated, etc. For spandrel areas (covering slab edges), we often use a glass panel with opaque back film or an insulated panel that looks like glass from outside (shadow box effect). Alternatively, aluminum composite or solid panels can slot in for colored bands or opaque sections. These infill panels are held with the same pressure plates and gaskets as glass, making the facade continuous. We always use safety glass (laminated or tempered as required) to ensure broken pieces don’t fall. Large units can be installed with suction equipment; our design accounts for glass size feasible by manufacturers and site handling.
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Thermal and Moisture Management: Curtain walls are built as rain screen systems – the outer seals intentionally allow some moisture past, but then interior gaskets and drainage channels manage it. Each glass/panel has an EPDM gasket, and mullions have vertical channels to lead water down to horizontal transoms, which have weep holes to exterior. This way any water that sneaks in is safely channeled out. There are continuous thermal breaks in pressure plates and caps to prevent conductive heat loss; mullion bodies themselves have polyamide break inserts splitting inside vs outside metal. U-values typically meet building codes (we calculate per project, but using good low-E glass and breaks, meeting ~0.23 BTU/ft2.hr.F or ~1.3 W/m²K is common). Also, we include insulated infills at spandrels so they aren’t thermal weak points. The system will be tested to withstand whatever design wind pressure, often e.g., no water penetration at 600 Pa, structurally tested to e.g., 2400 Pa – we ensure to match or exceed spec requirements.
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Integration of Operables: We can integrate vent windows or insert windows/doors within the curtain wall grid. Often, they appear identical to fixed glass but have a sash frame. These could be tilt-turn windows for ventilation or parallel outward vent windows for minimal disruption to look. They latch into the curtain wall framing and maintain weather and sightlines. We can also add sunshades: brackets on mullions to hold projecting fins or louvers for shading (frequently seen on offices). Another integration is facade lighting – some building designs want LED strips along mullions; we can accommodate mounting channels for those. Similarly, roof transitions (like sloped glazing rooflights) can connect to vertical curtain wall seamlessly with our system parts for slope.
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Fire Safety: At every floor slab, we include a fire stop – usually a mineral wool barrier with intumescent coating – between the curtain wall and floor edge to prevent fire/smoke spread between floors. This works with back pan of spandrel to provide at least the required fire rating (often 1 hour). Mullions also have fire break insert options if needed. So our curtain wall won’t become a chimney in event of a fire – it’s properly compartmentalised.
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Anchor & Support: The curtain wall attaches to the building via anchors – typically steel brackets at each mullion to the structural columns/slabs. These allow mullion movement for expansion and building sway (e.g., one fixed, one sliding point per floor). We engineer these anchors (often L-brackets bolted to embeds or concrete inserts) and supply or spec them. It’s critical for alignment and load – we ensure they are positioned precisely with tolerances for site adjustment. Once installed, the whole grid is plumb and true.
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Seismic/Movement: If in seismic zones or high-rise with significant sway, our system can accommodate inter-story drift (glass bite depth and gasket design allow for some racking without glass fallout). We can design for differential movement between curtain wall and main structure too.
All these features combine to produce a curtain wall that is tailored, high-performance, and visually stunning, effectively the “skin” of your building doing all the protection and aesthetic heavy lifting.
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