Technical Approval 2/03-1038 ENGLISH TRANSLATION

Bardage rapporté External wall-cladding

Vorgehängte hinterlüftete Fassadenbekleidung

Only certified production holding the CSTBat label, can exploit this Tech-nical Approval. The up-to-date list can be consulted on the Internet at the following address:

www.cstb.fr Section:

Building Products Certification

MAESTRAL Holder: TERREAL

47, Rue Louis Blanc F-92400 Courbevoie Tel.: (33) 1 49 97 20 30 Fax: (33) 1 49 97 20 56

Factory: TERREAL 31250 Revel

Distributor: TERREAL Ave Normandie Niemen F-31700 Blagnac Tel.: (33) 5 34 26 31 00 Fax: (33) 5 34 26 21 01 Internet: www.terrealfacade.com

Important notice: Whilst the information provided here is believed to be correct, Terreal cannot be held liable for any translation errors and inaccuracies. Each individual designer or contrac-tor is responsible for checking the specifications with Terreal for a given installation.

Commission in charge of issuing Technical Approvals (Decree of December 2, 1969)Specialised Group no. 2 Constructions, façades and light partitions

Presented for registration on September 8, 2004

Secretariat of the Technical Approval Commission CSTB, 4, Avenue du Recteur-Poincaré, 75782 Paris Cedex 16Tel.: 01 40 50 28 28 - Fax: 01 45 25 61 51 - Internet: www.cstb.fr

The Technical Approvals are published by the Technical Approval Secretariat, provided by, CSTB. The authenticated versions are available free of charge on CSTB's Internet site (http://www.cstb.fr) CSTB 2004

2 2/03-1038

Specialised Group no. 2, « Constructions, Façades and Light Partitions » of the Commission in Charge of Issuing Technical Approvals, examined on July 1, 2003, the MAESTRAL external wall-cladding system, submitted by the TERREAL company. The Group issued the following Technical Approval for this system. The Approval is only valid for productions bearing the CSTBat Certificate accompanying the Approval, issued by CSTB. This Approval is formulated for applications in European France.

1. System description 1.1 Brief description External wall cladding system, based on double-wall terracotta panels, laid without overlap, fastened with non-visible clips on a frame of sup-port timbers or metal profiles fastened to the building structure.

General characteristics: Dimensions of the cladding panels: Standard panels (thickness x height x width in mm):

- 40 x 200 x 1520 - 40 x 300 x 1520 - 40 x 410 x 1520 Angle MAESTRAL:

- Thickness: 40 mm, - Flange width 170 mm, - Maximum height : 1255 mm. Surface weight: approximately 60 kg/m². Installation of cladding panels horizontally with open joints and

continuous vertically, or vertically (only those 200 mm wide, 1520 mm long, or 300 mm wide, 1200 mm long) with open joints and continuous horizontally. Colours: Orange Red, Pink, Champagne, Pearl Grey, Chocolate

Brown and Ebony. Finishes: smooth, sandfaced and grooved. 1.2 Identification of the cladding elements MAESTRAL wall-cladding panels bearing the CSTBat Certificate can be identified by a marking in compliance with Appendix 3 of the Special CSTBat Certification Rules, attached to the Technical Approvals for wall-cladding, insulating wall-cladding products, and wall-facing panels. This marking includes:

On the product: The CSTBat logo, The factory reference, The production batch identification.

On the pallets: The CSTBat logo, The system name, and the number of the Technical Approval to

which it complies, The certificate number with the machine reference and the last

three digits of the Technical Approval number. In addition to compliance with the Rules, the marking includes: On the product:

- The manufacturer's name, - The factory's address, - The shift code, - The colour. On the pallets:

- The manufacturer’s name and the factory’s address, - The colour and surfacing of the visible side, - The dimensions, - The quantities, - The customer's name.

2. APPROVAL 2.1 Accepted field of application Installation on flat vertical supports of coated masonry (from the

outside, installed without primary framing), or of concrete, new or in use, sheer or with wall openings, located in upper floors and at ground level corresponding to exposure class Q3 in compliance with Standard P08 302. Wind exposure corresponding to positive or negative pressures

under regular winds with maximum strengths as follows: - MAESTRAL 40 x 200 x 1520:

* Positioned horizontally or vertically: 1930 Pa, - MAESTRAL 40 x 300 x 1520:

* Positioned horizontally or vertically (maximum panel length 1200 mm) : 1470 Pa

- MAESTRAL 40 x 410 x 1520: * Positioned horizontally: 1120 Pa.

2.2 Assessment of the system

2.21 Usability Stability The outside wall-cladding does not participate in the functions of load transmission, bracing or resistance to severe impacts. The supporting structure must perform these functions. The stability of the wall-cladding on the supporting structure shall be properly provided within the accepted field of application.

Fire safety The system does not impede the application of regulations. The checks to be carried out (in particular with relation to the so-called "C + D" rule, including for buildings already in service) shall take the follow-ing technical characteristics into account: Fire reaction rating of the MAESTRAL elements: M0. The combustible mass of the secondary timber frame corresponds

to the frame weight, expressed in kg/m². This value is multiplied by 17 to express it in megajoules/m². The combustible mass of the mineral wools used is negligible with

relation to the requirement levels.

Stability in Seismic areas System response to seismic tests has not been evaluated.

Prevention of accidents during installation Such prevention can generally be provided.

Thermal insulation The system complies with regulations applicable to new constructions (RT2000). The compliance with regulations shall be justified on a case by case basis.

Thermal calculation information. For installation on timber framing, the thermal calculation data is found in the document "General guidelines for design and installation of timber framing and thermal insulation for external wall-cladding cov-ered by a Technical Approval” (CSTB Book 3316 – January-February 2001 and addendum 3422). For installation on metal framing, the thermal calculation data are given in the document "General guidelines for design and installation of metal framing and thermal insulation for external wall-cladding covered by a Technical Approval” (CSTB Book 3194 – January-February 2000).

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Tightness Air-tightness: must be provided by the supporting wall. Watertightness: is sufficiently provided on the field by the small width of open joints between adjacent cladding panels relative to their thick-ness, given the necessary verticality of the construction and the pres-ence of the air layer. At specific joints, it is provided by profiles. Type XIII walls can be made with the system as described in "General guidelines for the use of outside heat insulation systems covered by a Technical Approval" (CSTB Book 1833, March 1983). The supporting walls shall comply with the specification in Chapters 2 and 4 of this document. When applied to concrete walls or masonry works with outside coating, this system allows to use the walls as type II walls described in "DTU 20.1 – Appendix : Guidelines for the choice of wall types based on the construction site".

Additional useful information The behaviour under horizontal static load in service (for example, pressure from a ladder) is satisfactory. Considering that the method presented in the technical file allows for an easy one-for-one replacement of broken panels, the system per-formances correspond to exposure class Q3 of norm P08-302 for MAESTRAL 200 and 410 mm installed horizontally or vertically, and to exposure class Q4 of norm P08-302 for MAESTRAL 300 mm and angle MAESTRAL elements. Impact resistance is presented below (in joules).

Installation Provisions

Impact bodies (NF P 08-301)

Q rating (P08-302)

D 0.5 D 1 M3 M50

- Horizontal installation 200 x 1520 300 x 1520 410 x 1520

- With or without

intermediate support 200 x 1520 300 x 1200

- Angle MAESTRAL

1 3 1

1 3

3

- 3 - - 3

3

20 60 60

60 60

60

100 130 130

130 130

130

Q3 Q4 Q3

Q3 Q4

Q4

"Easy replacement" mentioned above requires that replacement clad-ding elements be available on the construction site. The structure’s durability is improved by the installation of this wall-cladding system, particularly when associated with thermal insulation. By application of the rating rules defined in the document " reVETIR rating of systems for outside thermal insulation of façades", the system is rated as follows:

Maestral r e V E T I R

40 x 200 x 1520 40 x 300 x 1520 40 x 300 x 1200 40 x 410 x 1520

r2

r2

r2

r2

e4

e4

e4

e4

V3

V2

V3

V1

E3

E3

E3

E3

T1+

T3

T1+

T1+

I4

I4

I4

I4

R4

R4

R4

R4

2.22 Durability - Maintenance The durability of the system's components and their compatibility makes it possible to agree that this external wall-cladding will present a satisfactory durability, equivalent to that of traditional terracotta wall-cladding systems. The replacement of an accidentally damaged panel, independently from the adjacent panels, is possible using a standard element.

2.23 Manufacture and quality assurance The manufacture of the MAESTRAL wall-cladding product is assured by a systematic monitoring regularly inspected by CSTB, ensuring a constantly suitable quality. The manufacturer displaying this Technical Approval must be able to present a CSTBat Certificate issued by CSTB, proving the regularity and the satisfactory results of the monitoring supplemented by verifica-

tion tests carried out by CSTB on products sampled during inspection visits. Products bearing a valid certificate can be identified by the presence on the panels of the CSTBat logo, followed by the identification num-ber. Inspections of the fixing clips at delivery and during production, as performed now, are appropriate to ensure a constant quality. The regularity, the effectiveness and the conclusions of the self-inspection of the panels are regularly verified by CSTB.

2.24 Procurement The various components supplied by TERREAL include the cladding products with their clips and the metal profiles. All other elements are directly supplied by the installer, in compliance with the description that is provided in the Technical File.

2.25 Installation This wall cladding system is installed without any particular difficulty, conditioned by a prior survey of the supporting structure, a layout plan of the cladding elements and of the additional profiles, and by the compliance with the installation requirements (Technical Specification Book). TERREAL provides its technical assistance when requested by the contractor. 2.3 Technical Specification Book

2.31 Design and installation guidelines

Installation without primary frame When laying directly on the supporting structure, planarity defects (shifts, bumps and various irregularities) shall be under 5 mm per 200 mm rule or 1 cm per 2 m rule. For supporting walls that do not comply with the above requirement, defects must be corrected via proper preparation of the support (sand-papering, finishing, etc)

Timber frame The installation of timber framing and of thermal insulation shall comply with the specifications of CSTB Book 3316 – January-February 2001 and addendum 3422, supplemented by the following instructions: The co-planarity of the uprights shall be checked between adjacent

support timbers, with a maximal admissible variation of 2 mm. The relative humidity of the support timbers shall not exceed 18%

(in weight) at the time of installation. The admissible strength of the clip under vertical loads to take in

account shall correspond to a deformation under load of 1 mm. Since protection against water is not properly provided by the joint

cover profile, the timber support needs to be treated as a minimum under Class 3 of biological risks, or to be covered on the visible face by a strip of Ethylene-Propylene-Terpolymer (EPDM) or flexi-ble PVC. The strip shall exceed the width of the visible face of the support timber (by 10 mm off each upright's side).

Metal frame The flanged metal framing shall comply with the specifications of CSTB Book 3194 – January-February 2000, supplemented by the following instructions: The co-planarity of the uprights shall be checked between adjacent

uprights, with a maximal admissible space of 2 mm. The admissible strength of the clip under vertical loads to take in

account shall correspond to a deformation under load of 1 mm. To prevent water's stagnating and to mask the ends of the cladding

panels, the leg of the T-shaped profile supporting panels shall pro-trude outside the cladding by 5 to 10 mm.

In asymmetrical configurations (angles, side ends, etc…), the uprights layout shall be confirmed by calculation in compliance with DTU P 22-703, "Calculation and Design Rules for constructions using panels with thin walls". A calculation and design note prepared by the installing contractor and approved by the holder, is necessary.

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Horizontal framing In case the cladding panels are installed vertically, they can be directly installed on an array of horizontal uprights. The prescriptions for in-stalling the uprights remain identical to the instructions found in the documents mentioned above. However, it is imperative to comply with the following: The clips used for fixing horizontally the uprights to the bearing

structure shall be carefully selected. The clips shall be strong enough so that, under the load resulting from the weight of the cladding, the widening of their dihedral angle leads to a shift of no more than 0.25 mm at the end of the part attached to the upright. This shall be validated by trials based, by analogy, on the test de-scribed in CSTB Book no. 3194, Appendix 1. Under the dead load resulting from the weight of the panels and of

the accessories borne by the frame, the vertical deflection of the upright between two clips shall be no more than 1/300th of the frame's span. Under live loads resulting from the wind (positive or negative pres-

sures from normal winds), the horizontal deflection of the upright between two clips shall be no more than 1/200th of the frame's span.

Layout plan "Bridging" junctions between bearing profiles with MAESTRAL panels is prohibited.

Compartmenting the air layer The air layer shall be compartmented at the angle of adjacent walls; this partitioning, made using a durable material (for example, Z 275 galvanised steel or aluminium sheet) will need to be precise, all the way-up the cladding, to prevent any air coming in at the sides. The air layer thickness shall be at least 20 mm. In the case wall clad-ding is installed horizontally, this thickness may be reduced to 10 mm near the profiles or the support timbers of the horizontal frame.

Conclusions Overall evaluation For the productions of MAESTRAL holding a CSTBat Certificate issued by CSTB, the use of the system in the proposed field of application is assessed favourably.

Validity Until July 31, 2006

For Specialised Group no. 2 The Chairman PJ. GORDY

3. Additional notes from the Specialised group

This revision includes no modifications except for the inclusion of the 1255 mm high angle cladding elements. The system's main components are made from materials of well-known and satisfactory durability (timber or aluminium frame, stainless steel clips and frost-resistant terracotta cladding elements). The only non-traditional material, which is the polyethylene foam used for the spacer shims to hold the panels in position, has been subjected to conventional artificial ageing cycles, at the end of which its behav-iour has turned out to be satisfactory. Special care shall be taken for the design of the supporting frame (esp. brackets and anchors fastening the frame to the bearing wall), given the substantial surface weight of this cladding system (≈ 80 kg/m²), particularly when applying extra-thick thermal insulation. It is mandatory to apply a 10 mm horizontal joint between cladding panels in order to avoid any risk of extra load. For panels installed vertically, the 10 mm joint is obtained by first plac-ing a spacer shim under the bottom clip, then fastening the clip and finally removing the shim. For panels installed horizontally, the yoke of the top clip will come against the top of the panel's last hollow. As to wind resistance, the admissible values mentioned for the effects of positive and negative pressures take into account a safety coeffi-cient of 3.5 on the failure value, which is determined by the opening of the clips and by the loosening of the panels. This Approval is subject to a CSTBat certification procedure covering the MAESTRAL cladding system.

The Rapporteur of Specialised Group no. 2 K. MORCANT

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Technical File prepared by the requester

A. Description 1. Presentation External wall-cladding system, consisting of large hollow terracotta elements, laid horizontally or vertically, and fastened at their ends by stainless steel clips fixed to the supporting structure, either di-rectly or indirectly, using a frame of timber supports or of metal profiles fastened to the underlying structure. An additional insulation is generally placed between the structure and the wall-cladding system. This insulation is ventilated by an air layer located between the insulation and the backside of the clad-ding panels.

2. Materials

2.1 Used for manufacture Terracotta cladding panels, Waterproofing compound for treating the surface of the cladding

panels, applied in the factory, after the firing process.

2.2 Used for installation Stainless steel clips, grade X5 Cr Ni 18-10 (1.4301) complying

with Standard NF EN 10 088. Shims of closed-cell polyethylene foam, density 48 kg/m3 Joint cover profiles of raw or glossed aluminium sheet. Standard components of wall cladding systems on timber fram-

ing in compliance with CSTB Book 3316 – January-February 2001. Galvanised steel or aluminium alloy metal framing components,

in compliance with CSTB Book 3194 – January-February 2000. Stainless steel screws type A2. ACERMI certified insulation with the following minimal rating:

I1 S1 O2 L2 E1.1

3. Elements 3.1 Standard MAESTRAL (fig. 1 to 3) With a 40 mm thickness and 1520 mm maximal length, MAESTRAL panels come in three heights: height 200 mm with 3 hollows (see fig. 1), height 300 mm with 5 hollows (see fig. 2), height 410 mm with 5 hollows (see fig. 3).

Technical characteristics MAESTRAL panels meet the specifications of Standards NF P 13-304 and NF EN ISO 10545 (relating to their physical, chemical and mechanical characteristics), NF EN 539-2 Method C with sub-atmospheric pressure of 300mm Hg relating to frost resistance. Dimensional, appearance and installation characteristics are listed in table 1 below. In case MAESTRAL panels are installed in vertical position, the width of the vertical joints is about 6 mm and the width of the hori-zontal joints between 2 rows of panels is about 30 mm (taking into account the installation of the joint cover profile): MAESTRAL 200 x 40 :

- Number of panels : 3.9 panels per metre wide by 1.52 m high.

- Number of clips : 3.9 right clips + 3.9 left clips + 3.9 lower clips per metre wide by 1.52 m high.

MAESTRAL 300 x 40 (maximum length 1200 mm) : - Number of panels : 2.8 panels per metre wide by 1.2 m

high.

- Number of clips: 2.8 right clips + 2.8 left clips + 2.8 bottom clips per metre wide by 1.2 m high.

Physical characteristics No persistent efflorescence, Water absorption between 6% and 10%, Expansion due to humidity < 1.6 mm/m, No bursting of grains > 10 mm, No cracks on the front side of the panels, No spalls > 1 cm² on the front side of the panels, Bending strength according to Standard XP B 10-601, see table

2 below:

Table 2 – Bending strength

Types of panels

Bending strength in daN (average value)

Rating XPB 10-601

200 x 40 x 580 350 (before freezing) Not applicable

300 x 40 x 580 525 (before freezing) D1

410 x 40 x 580 700 (before freezing) D2

3.2 Angle MAESTRAL (fig. 4) 40 mm thick and with a 170 mm side extension, the Angle MAESTRAL are 1255 mm high. They contain a row of 7 vertical hollows. Depending on the layout plan, Angle MAESTRAL panels can be cut perpendicularly to their height. Angle MAESTRAL present two facing sides, 170 mm wide, making a right angle. The outside vertical rim is rounded, with a radius of 20 mm. The inside vertical rim is also rounded, with a radius of 5 mm. MAESTRAL's outside and inside walls are 13 mm thick.

Technical characteristics Angle MAESTRAL panels meet the specifications of Standards NF P 13-304 and NF EN ISO 10545 (relating to their physical, chemical and mechanical characteristics), NF EN 539-2 Method C with sub-atmospheric pressure of 300mm Hg (relating to frost resistance). Dimensional, appearance and installation characteristics are listed in table 3 below.

3.3 Fixing clips (fig. 5.1 to 5.6) Referred to simply as "clips" in the rest of the document, they come in four types: Standard left clips (see fig. 5.1) and standard right clips (see fig.

5.2) to fasten standard MAESTRAL field panels. Upper left clips (see fig. 5.3) and upper right clips (see fig. 5.4)

to fasten standard MAESTRAL panels in the top part. Lower clips (see fig. 5.5) to fasten standard MAESTRAL panels

in the bottom part. Angle clips (see fig. 5.6) to fasten Angle MAESTRAL.

All these clips sold by TERREAL are made of stainless steel, grade X5 Cr Ni 18-10, thickness 15/10 mm.

3.31 Standard clips (see fig. 5.1 and 5.2) There are two types of standard clips: a left clip (fig. 5.1) and a right clip (fig. 5.2), which are symmetrically identical. Standard clips consist of 2 parts (main and secondary), assembled by 2 spot welds (resistance spot welding).

6 2/03-1038

The main part of the standard clip is made by press-forming a stainless steel sheet previously stamped by a special tool. This stamping makes it possible to round each salient angle of the stan-dard clip's body, thus eliminating all sharp angles, which are dan-gerous for the worker installing the system. The main part consists of: A plate, dimensions 100 x 65 mm, containing 2 holes diameter

6 mm, located at the top of the plate, thus making it possible to fix the standard clip to the vertical frame's uprights. The plate also presents a 5 mm wide return along the side, which goes all the way up the edge, allowing to perfectly fit the regular clip against the upright's central leg. A tongue, which has been folded back and is located at the

lower section of the main part, making it possible to hook and hold the standard MAESTRAL panel onto the clip by introducing this tongue into the upper hollow of the standard MAESTRAL. A closed-cell polyethylene foam shim bonded to the main part,

facing the tongue, that frees an empty space of 10 mm between the foam shim and the tongue. This allows to block the MAESTRAL panel. In addition, this foam shim absorbs poten-tial vibrations and increases the mechanical strength of the cladding system.

The second part of the standard clip, also press-formed, is fixed to the main part by 2 resistance spot welds. The second part has a curved-back protruding piece, designed to fit into the V-shaped groove of the underside of the MAESTRAL panel. This locking mechanism allows to stabilize the standard panel, and avoids any risk of movement perpendicularly to the façade (rotation blocking).

3.32 Clips for Angle MAESTRAL (see fig. 5.6) The right and left angle clips are identical. 2 angle clips are needed for each Angle MEASTRAL, placed on each side of the angle ele-ment, to the right and to the left. Angle clips also consist of 2 parts (one upper and one lower) as-sembled by 2 spot welds (resistance spot welding): The upper part consists, first, of a plate (dimensions 55 x 28

mm) drilled with 4 holes diameter 6 mm located at the top of the plate, which enable the fixing of the angle clip to the uprights of the vertical frame. Second, the upper part presents a return (tongue), of dimensions 30 x 28 mm, which inserts itself into the Angle MAESTRAL's vertical hollows and ensures its stability at the bottom part. A closed-cell polyethylene foam shim, of di-mensions 28 x 28 x 13 mm, is bonded to the plate facing the tongue, letting a free space of 14 mm between the tongue and the foam shim. This allows to lock the Angle MAESTRAL. The lower part is made by press-forming a U-shaped stainless

steel plate, then fixing it upside-down to the underside of the upper part's return with 2 resistance spot welds. This part also contains a 28 x 28 x 13 mm foam shim, used to lock the top of the Angle MAESTRAL located below.

Table 1: Dimensional, appearance and installation characteristics of standard MAESTRAL cladding panels

Dimensions H x Th x W (mm) Colour Surface Unit weight

(kg) Qty / (*)

(units / m²)Weight (*) (kg /m²)

Right clips per m² (*)

Left clips per m² (*)

200 x 40 x 1520

Red orange – Pink – champagne

Pearl Grey Chocolate brown

Ebony

smooth - sandfaced -

grooved 18 3.3 59 3.1 3.1

300 x 40 x 1520

Red orange – Pink – champagne

Pearl Grey Chocolate brown

Ebony

smooth - sandfaced -

grooved 27.5 2.2 60.5 2.1 2.1

410 x 40 x 1520

Red orange – Pink – champagne

Pearl Grey Chocolate brown

Ebony

smooth - sandfaced -

grooved 35 1.6 57 1.6 1.6

(*) The values mentioned here take into account 10 mm horizontal joints and 30 mm vertical joints.

Table 3: Dimensional, appearance and installation characteristics of Angle MAESTRAL cladding panels

Number of clips Dimensions

H x Th x W (mm) Colour Surface Unit weight(kg)

Qty (*) (units / m)

Weight (*) (kg / m) Right clips

(MB0406) (*)

Left clips(MB0706)

(*)

170 x 40 x 1520

Red orange – Pink – champagne

Pearl Grey Chocolate brown

Ebony

smooth - sandfaced 23 0.8 18.4 0.8 0.8

(*) The values mentioned here take into account 5 mm joints.

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3.4 Joint cover profile (see fig. 6.1) The joint cover profiles shield the timber vertical uprights and embellish vertical joints. They are available in 3 or 4 metre lengths, with two different finishes: Raw, thickness 0.8 mm, Glossed, thickness 1 mm.

These joint cover profiles can be simple or double.

3.5 Timber frame elements They shall comply with the specifications of CSTB Book 3316 – Janu-ary-February 2001 and addendum 3422. The visible width (L) of the timber supports depends on the width (X) chosen at the base of the "V" of the joint cover profile, so that L mini = X + 67 mm. These values take into account : A minimum safety space at the edge of the support timber of 3 x

5.5 = 16.5 mm, to insert screws. A positioning margin of + 2 mm between the vertical symmetry

axes of both the support timber and the joint cover profile.

3.6 Metal frame elements and support profiles The flanged metal frame shall comply with the specifications of CSTB Book 3194 – January-February 2000. The elements making the metal frame may be either of galvanised steel or of aluminium alloy. Different types of profiles are available to allow for direct installation on the supporting structure or indirect installation on a primary frame.

3.61 Direct installation on the bearing structure Omega profile of galvanised steel (minimum grade Z 275, mini-

mum thickness 20/10 mm). Extruded profile of aluminium alloy EN AW 6060 T6.

Profiles are available for field panel installation and for installation at the sides (see fig. 6.2).

3.62 Installation with insulation Extruded profile of aluminium alloy EN AW 6060 T6.

Profiles are available for field panel installation and for installation at the sides (see fig. 6.3).

3.7 Fasteners Fasteners for the panel clips :

- On a timber frame: stainless steel screws type A2, ∅ 5 x 55 mm, with a pull-out resistance Pk of at least 1500 N for a penetration depth of 50 mm (determined in compliance with standard NF P 30-310).

- On a metal frame (aluminium or steel): self-tapping stainless steel screws ∅ 5.5 x 22 mm, with a pull-out resistance Pk of at least 1500 N for a 20/10th mm thick galvanised steel support or a 25/10th mm thick aluminium support (determined in compli-ance with standard NF P 30-310).

The clips used for fixing horizontally the uprights to the bearing structure shall be carefully selected. The clips shall be strong enough so that, under the load resulting from the weight of the cladding, the widening of their dihedral angle leads to a shift of no more than 0.25 mm at the end of the flange attached to the upright. They shall be validated by trials based, by analogy, on the test de-scribed in CSTB Book no. 3194, Appendix 1.

4. Production 4.1 Producing the MAESTRAL panels The standard and angle MAESTRAL are produced at the REVEL factory (FR-31250 Revel, France).

4.11 Raw materials The grades of raw clay come from the ST PAPOUL quarry, about ten kilometres north of Castelnaudary. The “degreasing” material is sand prepared at the ST PAPOUL quarry, from terracotta waste ground down to a grain size of less than 0.8 mm. Finely ground, the various materials are then stored in separate silos.

4.12 Production process 1. Grinding of the clay and mixing with other components. 2. Wetting the blend. 3. Moulding and extrusion by drawing the clay paste. 4. Drying the products. 5. Firing. 7. After firing, surface treatment and inventorying. 8. Sawing and packaging of the products when orders are placed.

4.2 Producing the clips and profiles All the clips for the cladding panels are made by PEYRE S.A. (31 - Toulouse) using austenitic stainless steel X5 Cr Ni 18-10 (1.4301). Profiles are made by Technal (31-Toulouse) or SAPA (81– Le Garric).

5. Quality Assurance 5.1 Quality assurance with raw materials Certificate of manufacturer compliance, with analysis report for each batch in compliance with the Specifications, including : Clay and sand: particle size, Blend: particle size, Waterproofing: pH.

5.2 Production monitoring Production parameters, Dimensions before drying (wet), Humidity of the blend after drying (once per day), Dimensions after drying (once per day), Visual aspect after drying (all products).

5.3 Inspection of finished products

By production run and random sampling once per week – Tests according to Standard NF P 13-304 Check water absorption, Check conventional expansion under humidity, Check efflorescence, Check bursting.

By production run and random sampling once per quarter Check frost resistance according to Standard NF EN 539.2.

Method C with sub-atmospheric pressure of 300mm Hg

By production run and random sampling Check dimensions.

On all cladding panels Checking visual aspect.

By production run and random sampling once per week (for standard panels only) Check bending strength according to standard XP B 10-601 :

Panel type (mm) Certified value at failure

under bending (in daN)

200 x 40 x 580 175

300 x 40 x 580 260

410 x 40 x 580 350

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5.4 Acceptance inspection of clips and profiles An delivery inspection of standard, upper, lower and angle clips is carried out at the TERREAL factory in REVEL to check the test sheets and technical information sheets transmitted by the supplier for each delivery batch. This inspection particularly concerns: Checking the dimensional characteristics against the specifica-

tions, Checking the weight, Stainless steel quality, Aluminium alloy quality Foam quality,

6. Procurement The parts supplied by TERREAL include the MAESTRAL panels (stan-dard and angle), the clips and the supporting profiles. All other parts, i.e. fasteners, timber or metal framing elements, insula-tion panels, joint cover profiles and shielding profiles of press-formed sheets, are directly supplied by the installer, in compliance with the descriptions provided in the present document.

7. Identifying the panels Marking in accordance with paragraph 1.2 “Identification of the clad-ding elements” of this Technical Approval.

8. Installation

8.1 Technical assistance TERREAL does not provide any installation. However, its Technical Department, when requested by the installation contractor, can provide technical assistance, both at the design stage of a project and at the start of the construction.

8.2 Field of application The system is applicable on flat and vertical supporting structures, sheer or containing wall openings, made of: cast concrete of ordinary aggregates, coated traditional masonry work.

8.3 General installation guidelines

8.31 Layout plan A layout must be prepared in advance in order to recognize irregular points and identify cut out areas.

For standard MAESTRAL installed horizontally The layout scale is calculated from: The width of the free vertical joint (between panel and joint cover

profile ends), chosen by the architects and engineering firms any-where between 10 and 15 mm maximum, The fixed width of the horizontal joint between MAESTRAL panels.

It is 10 mm, obtained by adjusting the clips.

For Angle MEASTRAL The layout scale is calculated from: The fixed 5 mm width of the horizontal joint between Angle

MAESTRAL panels (obtained by adjusting the clip), The width of the vertical joint (between the right or left end of the

Angle MAESTRAL and the joint cover profile) chosen by the archi-tects and engineering firms, variable from 5 to a maximum of 10 mm.

8.32 Cut-outs on cladding elements The contractor will need to have a sawing table (water-jet based if possible) and be equipped with a sawing disk for ceramic materials. According to the layout, MAESTRAL panels can only be sawn perpen-dicularly to their length (standard panels) or their height (angle panels).

8.33 Supporting uprights Supporting uprights holding the MAESTRAL panels and their clips may be of different natures and shapes (see para. 3.5 and 3.6). The sec-

tions of these supports are to be specified depending on their various loads, specific to each case.

Timber frame The installation of a timber frame shall comply with the technical in-structions of CSTB Book 3316 – January-February 2001 and adden-dum 3422, supplemented by the following instructions: The co-planarity of the uprights shall be checked between adjacent

support timbers, with a maximal admissible variation of 2 mm. The relative humidity of the support timbers shall not exceed 18%

(in weight) at the time of installation. The admissible strength of the clip under vertical loads to take in

account shall correspond to a deformation under load equal to 1 mm. Since protection against water is not properly provided by the joint

cover profile, the timber support needs to be treated as a minimum under Class 3 of biological risks (Standard NF EN 350), or needs to be covered on the visible face by an EPDM or flexible PVC strip wider than the timber upright itself.

Metal frame The flanged metal framing shall comply with the technical instructions of CSTB Book 3194 – January-February 2000, supplemented by the following : The co-planarity of the uprights shall be verified between adjacent

uprights, with a maximal admissible variation of 2 mm. The admissible strength of the clip under vertical loads to take in

account shall correspond to a deformation under load equal to 1 mm. To prevent water's stagnating and to mask the ends of the cladding

panels, the leg of the T-shaped profile supporting panels shall pro-trude outside the MAESTRAL panels by 5 to 10 mm. In asymmetrical configurations (angles, stop ends, etc…), the

uprights layout shall be confirmed by calculation in compliance with DTU P 22-703, "Calculation and Design Rules for constructions us-ing panels with thin walls".

A calculation and design note prepared by the installing contractor and approved by the holder, is necessary.

Horizontal framing In case the cladding panels are installed vertically, they can be directly installed on an assembly of horizontal uprights. The prescriptions for installing the uprights remain identical to the instructions found in the documents mentioned above. However, it is imperative to comply with the following : The clips used for fixing horizontally the uprights to the bearing

structure shall be carefully selected. The clips shall be strong enough so that, under the load resulting from the weight of the cladding, the widening of their dihedral angle leads to a shift of no more than 0.25 mm at the end of the part attached to the upright. They shall be validated by trials based, by analogy, on the test de-scribed in CSTB Book no. 3194, Appendix 1. Under the dead load resulting from the weight of the panels and of

the accessories borne by the frame, the vertical deflection of the upright between two clips shall be no more than 1/300th of the frame's span. Under live loads resulting from the wind (positive or negative pres-

sures from normal winds), the horizontal deflection of the upright between two clips shall be no more than 1/200th of the frame's span.

8.34 Fixing the uprights to the wall It is imperative that the installation contractor plan the method for fixing the support profiles, based on the type of wall (hollow parts, solid, new, old,…), in order to determine, with the help of the fasteners manufac-turer : the appropriate type of fasteners, holding a European Technical

Agreement, a Technical Approval or a Set of Specifications ap-proved by a technical inspector, the on-centre spacing of the uprights, taking into account the sys-

tem's weight, the wind effects on the site, the admissible strength of the system, and the results of the pull-out tests carried out on the bearing wall by the fasteners manufacturer (CSTB Book 1661 - "Determination on the worksite of the maximal admissible load ap-plicable to a mechanical fastener for wall-cladding").

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The supporting uprights which provide the stability of the MAESTRAL system are, most often, fixed to the wall by brackets which allow to adjust the verticality of the frame.

8.4 Installing field MAESTRAL panels. Horizontal installation case (see fig. 7 to 12)

According to the plan, the installation contractor shall chalk the hori-zontal layout corresponding to the locations of the clips on the uprights (theoretical on-centre spacing between 210 and 310 mm, depending on the panels' height). Standard MAESTRAL panels are installed in the following steps: Insertion of the right and left standard clips in the upper hollow, on

each side of the standard panel. This step is carried out on site, at ground level. Installation of the standard MAESTRAL panel and its clips on the

uprights, by fitting the groove on the underside of the panel into the top clips of the panel below. To maximize safety, this operation shall be performed by two people. The two clips are then fastened to the uprights using 2 stainless

steel screws type A2, described in paragraph 3.7. The T-shaped finish (using metal profiles or timber supports asso-

ciated with cover joint profiles) makes it possible to lock the stan-dard clip against the leg of the T, and to avoid any rotation of the clip relative to the upright when fastened. However, it is necessary to use an "installation" shim between the cladding panel and the clip to help fastening the clip. Furthermore, as noted earlier in paragraph 8.31, a 10 to 15 mm free vertical joint shall be let be-tween the end of the panel and the leg the T. This to enable an unobstructed expansion of the various materials and to replace products if necessary as part of the maintenance of the cladding.

8.5 Dealing with irregular points Dealing with irregular points is detailed in Figures 13 to 19.

8.51 External angles (see fig. 13) External angles are dealt with using the following parts: Angle MAESTRAL panels, Angle clips.

Angles cladding panels are installed in the following steps: Insertion of the right and left angle clips in the upper hollows, on

each (left and right) side of the Angle MAESTRAL. This step is car-ried out on site, at ground level. Installation of the angle MAESTRAL panel and its clips on the wall,

by locking the hollow in the lower part of the MAESTRAL into the top of the clips of the angle MAESTRAL located right below. The two clips are fixed to the upright using two fasteners described

in para. 3.7. In addition, as described in para. 8.31, a 5 to 10 mm free vertical joint shall be made between the end of the MAESTRAL panel and the joint cover profile. To install angle cladding panels at the bottom and top parts of the

walls, the angle clips need to be cut out as indicated in Figure 13.

8.52 Re-entrant angles (see fig. 14) Re-entrant angles are dealt with as follows: As described in Figure 14 in the case of installation on metal fram-

ing, By abutting two standard MAESTRAL panels, leaving a 20 mm

free vertical joint for horizontal panels (see fig. 14). Aluminium uprights shall be fastened to the bearing structure at 3 different spots at least.

8.53 Detail at the bottom: Start (see fig. 15) At the base of the work, it is necessary to start with an L-shaped perfo-rated metal section, fixed to the vertical wall. It protects the various elements that constitute the cladding (insulation, foam, ...) and it en-ables water to run-off thanks to a 3% (min.) slope of its lower part. Cladding panels on the first row are fastened using lower clips.

8.54 Detail at the top: End (see fig. 16) At the top end of the work, MAESTRAL panels shall be protected by a waterproof flashing, overlapping as shown in Figure 16.

Cladding panels on the top row are fastened using left and right upper clips (see fig. 18). Installation and fastening of the upper clips is the same as for standard clips.

8.55 Dealing with openings (see fig. 17 to 19) As a general rule, the junctions between cladding panels and joinery is dealt with using metal frames fixed to the uprights, overlapping or butting the panels. However, it is possible to employ more traditional finishes: At the lintel level, the cladding panels start in the same way as

"dealing with the installation of cladding panels at the bottom part". A metal section fastened to the frame, makes it possible to prop-erly finish the underside of the cladding. This section should be designed to correctly drain any accidental water infiltration away from the cladding (see fig. 17). At the sill, the installation is performed using a metal flashing fixed

in compliance with DTU 37/1 (see fig. 18). At the jambs (see fig. 19), side extensions are dealt with using

metal profiles (L-sections, etc.) In case metal sub-frames are used, the finish is provided by the

sub-frame itself (it is then necessary to size the sub-frame based on the space left by the cladding).

Aluminium profiles located along the opening shall be fastened to the bearing structure at 3 different spots at least. Sub-frames and joinery items must be installed in compliance with their relative DTUs or Technical Approvals.

8.6 Special case: installing cladding panels vertically

Only 200 x 40 x 1520 mm and 300 x 40 x 1200 mm MAESTRAL pan-els can be used for vertical installation, with or without middle upright.

8.61 Installation field panels (see fig. 21) The layout scale is calculated from: The 6 mm vertical joint between vertical MAESTRAL panels (as-

sembly must be tight). The 10 mm width of the free horizontal joint (between the lower or

upper end of the panel and the joint cover profile). The insertion of the clips and their fixing to the uprights are similar to the ones described in paragraph. 8.4. The panel is positioned verti-cally on the wall. The 10 mm horizontal joint between the joint cover profile and the end of the panel is achieved: At the bottom, by the use of an 10 mm thick installation shim in-

serted between the cover profile and the lower end of the panel. This shim is removed after the clip is fastened. At the top, by a 10 mm offset of the clip toward the top relative to

the upper end of the panel. The clip is blocked against the under-side of the joint cover profile.

Vertical installation of the panels must be done from left to right facing the wall. The standard MAESTRAL panels shall be oriented so that the panels' edge fitted with a V-shaped groove is placed to the left when facing the façade.

8.62 Dealing with irregular points (see fig. 22 to 24)

Dealing with irregular points is similar to dealing with the installation of cladding panels horizontally (para. 8.5), in particular with: The use of the same types of metal profiles at the start, end and at

wall openings, The use of lower clips at the start, The use of upper clips at the end.

9. Maintenance and repair

9.1 Cleaning No preventive treatment can be applied to MAESTRAL panels without the manufacturer's agreement.

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9.2 Replacement of an accidentally damaged MAESTRAL In case a product is accidentally broken, each cladding panel can be easily replaced, independently from adjacent panels. The replacement is done in the following steps: Remove the broken MAESTRAL panel, Shift the unbroken panel immediately up toward one side until it

touches the joint cover profile, to make a 20 to 30 mm space, wide enough to reach the fasteners of the clip, Unscrew and recover the clip, Repeat steps 2 and 3 on the other side (note: during this step, the

panel immediately up is going to shift down slightly), Insert the recovered clips into the replacement panel, Insert the replacement panel, slightly tilted, in order to slide the

clips under the panel immediately up, and then lock the replace-ment panel into the clips below (see fig. 25), Fasten the clips of the replacement panel. Use temporary installa-

tion shims (to align holes of clips and of support profile) and shift the panel against the cover profile to have enough space to fasten the clips.

The detailed procedure for replacing cladding panels is described in a set of specifications, prepared by TERREAL and available upon re-quest.

B. Test results Tests performed at CSTB: Impact resistance (Ref. No. CL03-032 – April 2003), Wind resistance (Ref. No. CL03-031 – April 2003),

Tests carried out by VERITAS (Test Report No. IEX3B970009L) on closed-cell polyethylene foam shim (Reference ORDOLENE): Measurement of the apparent density (NF T 56-107) , Compressive strength (NF T 56-110), Conventional ageing (XP P 84-402).

C. References Since this system has only been recently introduced, only a few instal-lations have been made.

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Technical File Figures

Figure 1 – MAESTRAL height 200 mm – Dimensional characteristics.

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Figure 2 – MAESTRAL height 300 mm – Dimensional characteristics.

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Figure 3 – MAESTRAL height 410 mm – Dimensional characteristics.

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Figure 4 – Angle MAESTRAL – Dimensional characteristics.

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Figure 5.1 – Left fixing clip (M0401).

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Figure 5.2 – Right fixing clip (M0402).

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Figure 5.3 – Left upper clip (MB0403). Stainless steel.

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Figure 5.4 – Right upper clip (MB0404). Stainless steel.

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Figure 5.5 – Lower clip – Left and right (MB0405).

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Figure 5.6 – Angle clip – Left and right (MB0406).

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Figure 6.1 – Joint cover profile.

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Figure 6.2 – Aluminium profiles for direct installation on the wall.

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Figure 6.3 – Aluminium profiles for indirect installation, with insulation.

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Figure 7.1 – Standard panels laid horizontally, directly on the wall, with metal profiles and no insulation – Horizontal cut.

Figure 7.2 – Standard panels laid horizontally, directly on the wall (no insulation) – Horizontal cut.

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Figure 8 – Standard panels laid horizontally, directly on the wall (no insulation).

Vertical cut

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Figure 9 – Standard panels laid horizontally, with insulation.

Horizontal cut

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Figure 10 – Standard panels laid horizontally on an aluminium frame, with insulation.

Vertical cut

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Figure 11 – Standard panels laid horizontally on a timber frame, with insulation.

Horizontal cut

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Figure 12 – Standard panels laid horizontally on a timber frame, with insulation.

Vertical cut

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Figure 13 – Horizontal installation on an aluminium frame, with insulation. External angle.

Horizontal cut

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Figure 14 – Horizontal installation on an aluminium frame, with insulation. Re-entrant angle.

Horizontal cut

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Figure 15 – Horizontal installation on an aluminium frame, with insulation. Detail at the bottom.

Vertical cut

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Figure 16 – Horizontal installation on an aluminium frame, with insulation. Detail at the top.

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Figure 17 – Horizontal installation on an aluminium frame, with insulation.

Detail at the lintel of an opening. Vertical cut.

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Figure 18 – Horizontal installation on an aluminium frame, with insulation.

Detail at the sill of an opening. Vertical cut.

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Figure 19 – Horizontal installation on an aluminium frame, with insulation.

Detail at the jambs of an opening. Horizontal cut.

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Figure 20 – Horizontal installation of field panels, with insulation.

Expansion joint in the bearing wall. Horizontal cut.

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Figure 21.1 – Installation of MAESTRAL 200 x 40 x 1520 and 300 x 40 x 1520 with additional upright.

Horizontal or vertical installation.

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Figure 21.2 – Installation of MAESTRAL 200 x 40 x 1520 and 300 x 40 x 1520 with additional upright.

Vertical installation.

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Figure 22 – Vertical installation on a timber frame, with insulation. Re-entrant angle

Horizontal cut

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Figure 23 – Vertical installation on a timber frame. Detail at the top.

Vertical cut

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Figure 24 – Vertical installation on a timber frame. Angle.

Horizontal cut

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Figure 25 – Replacement procedure.

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Figure 26 – Breaking the air layer.

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Figure 27 – Fractioning the metal frame.