BRAVO - Etem

VENTILATED FAÇADE SYSTEM
BRAVO
JUN/2011
FOR INSTALLATION OF ALUMINIUM
COMPOSITE MATERIAL
ETALBOND®
USER MANUAL

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Horizontal section of the system
Vertical section of the system
Installation plan
System profiles and accessories
Static scheme selection
Mounting the fixing bracket on a metal “grid”
Brackets mounting
Substructure assembly - Steps and General
Principles
Fixing of the main supporting profile
Joining of the main suporting profiles
Templates for hangers mounting
CONTENT
Preparing the cassettes from composite material
Installing the first row of hangers
Installing the hangers by means of a template
Making the cassettes from composite material
Cutting the sheet and preparing the cassette
Hanging the cassettes
Cassettes installation steps
Reinforced profile
Ventilation grid

SYSTEM BRAVO
HORIZONTAL SECTION
anchor M8
thermo-pad
thermal insulation
fixing bracket
rivet ø4.8x12
self drilling screw M4.8x32
main joint profile
hanger
etаlbond®
SYSTEM BRAVO
VERTICAL SECTION
rivet ø4.8x12
single fixing bracket
for fixed support
4 5
main profile
etаlbond®
supporting
profile
hanger
self drilling
screw M4.8x32
че ни уважихте и бяхте част от
нашето Roadshow 2011!
anchor M8
thermo-insulation pad
single fixing bracket
for flexible support
plug ø8
thermal insulation

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MAIN COMPONENTS AND INSTALLATION
PLAN OF THE MAIN CONSTRUCTION
Main supporting profile
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1.
2.
3.
4.
5.
6.
7.
Wall brackets
Thermo-insulating pads
Self-drilling screw M 4.8x32
Hanger
Rivet ø4.8 x12
Construction base – masonry/aerated concrete
8.
9.
10.
11.
12.
13.
Joint profile
Washer
Anchor/dubel
Substructure base – reinforced concrete
Thermo-insulating mineral wool
Plywood-nail for mineral wool securing
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SYSTEM PROFILES AND ACCESSORIES
The system is supplied with a full set of end profiles and accessories allowing for unique details execution,
different finishes and transition to other faзade materials.
Fixing bracket
cod
07 vario 072
07 vario Q 52
07 vario 082
07 vario Q 102
07 vario Q172
07 vario Q152
07 vario Q182
07 vario Q212
Main profile
40 40 40 - 210 - 210 - 210 mm
160 160 160 mm
40 - 210 mm 40 - 40 210 - 210 mm mm
dimensions
40 mm
50 160 mm
75 mm
100 mm
125 mm
150 mm
180 mm
210 mm
21895 - 71 х 71 х 2.8 mm
160 mm 160 mm 07 vario Q 5
30 mm
cod 40-300 dimensions
mm 40-300 40-300 mm mm
07 vario 07
07 vario 08
07 vario Q 10
07 vario Q17
07 vario Q15
07 vario Q18
07 vario Q21
40-300 mm
80/90 mm
40 mm
50 mm
75 mm
80/90 mm
100 mm
125 mm
150 mm
180 mm
210 mm
80/90 80/90 mm mm
71 mm 100 mm
90-250 mm
07variosh 90-250 mm21090-250
90-250 mm mm
21958 - 100 х 71 х 2.8 mm
80-160 mm
80-160 mm
60 mm
80-160 80-160 mm mm
8 9
Accessories
Hanger
07bravo00
F profile
07support02
Fastening elements
Chemical anchor
07ITH380EA
Anchor M8x100/96
07M1096A4F
07M10105F
Rivet ø4.8x12
07P4812AlSS
Supporting profile
31064
Grating
07vfsgrating
Self drilling screw M4.8x32
07M4832QS
Joint profile
07shina
Thermo-insulation pad
07pvcbreak00
Threaded rod M10 x100
07M10TR
Plug M ø8x100
071080A4FUR
0710100FUR
07pvcbreak01
Aluminum strap
07support02
Washer
07washerQ10
Plastic siever
906050000355

STATIC SELECTION
DIAGRAM
Static diagram selection is based on the results
of the static analysis and the preferred variant
for fixed support is mounted to the main supporting
vertical profile ( in the upper end, in the
middle or in the bottom end).
Each main supporting profile is mounted to one
fixed and /or several flexible supporting points.
As a result of the aluminum thermal expansion,
it is recommended that the main supporting
profile has a length of about one floor height.
The length of the main supporting profile is precisely
determined depending on the building
location and the respective daily temperature
amplitude.
Options for mounting the fixed and flexible supports in the space
between floors
A fixed support bears the load of the own
weight for the loaded panel and a part of the
wind load. There is only one fixed support for
every single profile. It is obligatory this support
to be fixed in a solid base-reinforced concrete
or metal (steel or aluminum). When installing
a wall bracket as a fixed support at the reinforced
concrete base the distance from the
edge of the concrete floor to the anchor R axis
should not be less than 120 mm.
The oval shaped holes of the VARIO
wall brackets are designed to compensate
for thermal expansions of the
main supporting profile.
10 11
G
H
H
The flexible support bears the wind pressure.
It is not obligatory to assemble the mounting
wall brackets to reinforced concrete or metal
base. Selection of anchoring element depends
on the type and quality of the construction
base. Plugs and chemical anchors are most
commonly used. The wind suction load is twice
as high in the corner zone of the building than
in the inner zone, which requires the mounting
brackets to be positioned at distances twice
shorter at the corner zones.
G
R
H
H

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MOUNTING OF A WALL BRACKET TO A METAL
CONSTRUCTION
The circular holes on the fixing bracket are
used when mounting it to the metal substructure
(grid). The fixing is realized through
a bolt connection. If the metal grid is not an
aluminum one, then an additional treatment
of the contact zone between the profile and
the bracket is required so that the effect of
bimetal corrosion is eliminated.
BRAVO

WALL BRACKET INSTALLATION -
FIXED SUPORT
correct
minimum 120 mm
minimum 120 mm
< 120 mm
< 120 mm
correct incorrect
minimum 120 mm
The fixed support bears the load induced by
the weight of the panels mounted on it and
a part of the wind load. It is mandatory that
this support is fixed to a solid base - reinforced
concrete < or 120 metal mm(
steel or aluminum).
When installing a wall bracket as a fixed support
directly on reinforced concrete base, the
distance from the edge of the concrete floor
to the anchor axis should be no less than
120mm, if aluminum sheet is used for covering
the area around the bracket.
< 120 mm
1Drill a hole with a size as per installation
instructions
3…or by compressed air
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Place the bracket
2Clean up the hole by the use of a brush
4Hammer in the anchor
Place the reinforcing washer and fix the
bracket
14 15

WALL BRACKET INSTALLATION -
FLEXIBLE SUPORT
correct
incorrect
The flexible support bears the wind pressure.
Wall brackets are mounted on a steady brick or
aerated concrete wall. The project designer inspects
the construction base and recommends
the appropriate anchoring elements. The wind
load is twice as high in the corner zone of the
building than in the inner zone, which requires
the mounting brackets to be positioned at twice
shorter distances at the corner zones.
1Drill a hole with a size as per installation
instructions
3Place in the anchor and rotate it as to spread
the mixture uniformly
5Place the reinforcing washer and fix the
bracket
2Pour the chemical product into the hole - it
should fill 2/3 of the volume
4Place the bracket
16 17

SUBSTRUCTURE ASSEMBLY - STEPS AND
GENERAL PRINCIPLES

1Reference points are marked on the wall by
means of a laser level. Their purpose is to help
in outlining a coordinate system – horizontal
and vertical base lines.
2The benchmarks are put onto the wall
3The central horizontal and vertical axis of the
frame of reference are marked on the façade by
means of a coloured thread.
The horizontal and vertical lines are passing
throughout the entire façade and are used for
determining the position of the wall brackets
and the distances between the supporting profiles.
The positions of the main supporting profiles
(depending on the façade grid) are marked using
a measuring device (tape-measure).
4The exact position of the main supporting
profiles is marked by a coloured thread.
5The positions of the flexible and fixed points
(depending on the selected static diagram) are
marked.
6All wall brackets are mounted (if the building
height and shape as well as the scaffolding
allows).
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7The final fastening of the elements should be
performed by use of a torque wrench while
controlling tension. The tightening force is
indicated by the manufacturer of the fastening
elements. The tension force for anchors of
type Sormat M10 x 100 mm is 30 Nm (3 kg).
The maximum value of the tension torque for
plugs of type Fischer FUR SXR in concrete is
11 Nm. For the different types of masonry it is
not recommended to apply tension torque but
only ‘tightening the screw to open the plug’
8The vertical supporting profiles are mounted in
both ends of the façade and are leveled using
the horizontal axis of the frame of reference.
They are aligned in vertical direction and bracketed
by means of vertical level or laser plumb.
9A screw is tightened in the already leveled end
verticals and a cord is tied.
inner supporting profiles are mounted and
leveled against the cord.
10The
spring parts in both ends of the wall
bracket allow for easy and simple mounting
11The
of the profile. Depending on the brackets, the
standard main supporting profiles allow the lev
levelling eling of the brackets from 11 to 40 mm.
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min 20 mm

must be assured that the distance a (measured
at the top and at the bottom) between the verti-
12It
cals is one and the same.
several of the inner supporting profiles
are installed they are leveled with the horizontal
13After
axis of the frame of reference
a
a
14After the profiles are aligned horizontally and
vertically, they are temporarily fixed by screws.
After that the rivet holes are drilled for the permanent
fastening.
ATTENTION: The screws used for fixing the
vertical supports must be removed after the
permanent fastening of the vertical supports
to the wall brackets with rivets.
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MOUNTING OF THE
MAIN SUPORTING
PROFILE TO A
FIXED SUPORT:
The main supporting profile is mounted to a
fixed support with rivets 4,8 x 12 mm in the
circular holes of the mounting wall bracket,
thus not allowing movement of the profile.
FIXING OF THE
MAIN SUPPORTING
PROFILE TO A
FLEXIBLE SUPORT:
The main supporting profile is mounted to a
fixed support with rivets 4,8 x 12 mm in the
centre of the oval shaped holes of the wall
bracket. They allow movement of the profile
caused by thermal expansion.

max 300mm
>10mm
>10mm
max 300mm
JOINING OF THE
MAIN SUPORTING
PROFILES
max 300mm
The connection between the main supporting
vertical profiles is assured by joint profile
(code07shina00), providing the free movement
of the profiles. Rivets 4,8 x 12 mm are used as
fastening elements.
Note: the suggested diagram for mounting of
a joint profile is applied when the fixed support
is chosen to be at the upper part of the main
supporting profile.
The distance from profile’s end to the
first fixing point with a fastening element
(rivet) should not exceed 300 mm.
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2mm
2mm
2mm
2mm
a
a1
a2
a3
a4
a5
a6
TEMPLATES FOR
HANGERS MOUNTING
The template is intended to help in determining
the exact position of the hangers and the spacing
between them. A template can be made
from a stripe of etalbond®. The die-cut slots
in the template follow exactly the dimensions
of the slots, cut on the etalbond® cassetes. In
order to minimize the error accumulation, the
length of the template should be chosen as big
as possible (one floor height).
* Each cassette should be mounted on two
hangers only ( in its upper part ). For this
reason the bottom two hangers on which
the cassette is mounted have to be fixed 2
mm lower than the upper end of the cassette
slot.
2mm

MAKING THE TEMPLATE
Note: The number of hangers and their spacing
depends on the cassette size and the loads
exerted on it.
The position of the upmost hanger on the main
profile serves as a base point in the process
of template making. The first slot is die-cut.
The second slot is then cut, displaced from the
first slot on a distance, equal to the distance
between the cassette slots plus 2 mm.
a
a1
a2
a3
The next slot on the template (the upper slot of
the second cassette) is determined, again taking
as a base the position of the upmost hanger
on the main profile. The distance between the
slots depends on the raster of the sheets and
the minimal distance allowed between the slots
and the cassette corners.
a4
a5
a6
INSTALLING THE
FIRST ROW OF
HANGERS
The hangers have a specially designed shape,
which allows direct installation of the hangers
on the main vertical profile, instead of stringing
them. The hanger is placed perpendicularly to
the profile and then is fixed in the channels by
means of a slight pressing towards the profile.
The shape of the hanger allows movement in
vertical direction, in order to make it level.
Note: The distances between the hangers and
the distances to the corners are chosen according
to the cassette size and the desired façade
raster. The calculations are done in the initial
project stage, before the actual installation.
Initially, the hangers in the upper end of the two
end vertical main profiles are installed. Then we
measure the distance between them and the
established base horizontal level.
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a
a
a
After we make sure that the upmost hangers
are properly positioned on the first and the
last profile, we fix them permanently with
self-drilling screws М4,8х32mm. The hangers
on the intermediate profiles are then vertically
aligned by means of coloured thread or a laser
level.
In the cases when the hangers are aligned by
means of a coloured thread, the two end hangers
must be secured with self-drilling screws.
The thread is tied on the screws. The hangers
on the intermediate profiles are then aligned on
the straight line created by the thread and are
secured with screws М4,8х32mm.
Note: Each cassette should be mounted on two
hangers only (at the upper part). The bottom
two hangers on which the cassette is mounted
are to be fixed 2mm lower than the upper end
of the cassette slot.
PREPARING THE CASSETTES FROM COMPOSITE
MATERIAL
After we have the upmost hanger installed,
we put the template over it, moving the template
downwards until the upper part of its slot
reaches the pipe of the hanger. Then we adjust
the second hanger, until its pipe touches the
upper end of the second slot of the template.
After that we fix the hangers with self-drilling
screws.
32 33

The steps described above are repeated for the
first row of hangers on each subsequent floor.
The next hangers on the profiles are installed by
means of templates.
Note: Depending on the raster of the façade,
there may be different cassettes, which will
require different templates to be made.
MAKING THE CASSETTES FROM COMPOSITE
MATERIAL
The contours of the cassettes (unfolded) are
transferred to the composite sheet. The dimensions
of the unfolded cassette are determined
as follows:
h = the height + size of segments (returns) –
the number of segments
w = the width + segment size (returns) –
number of segments
Example:
h = а + b + c + d - 3mm
h = 750 + 20 + 25 + 35 - 3
h = 827 мм
Note: In order to die-cut the hanging slot, a
minimal segment size of 30 mm is required.
34 35
3200 mm
d
c
a
b
1250 mm
w
h
d=35mm
c =25mm
b =20mm
a=750mm

CUTTING THE SHEET
AND PREPARING THE
CASSETTE
The places where the channels will be routed
are marked on the back side of the sheet. The
milling depth is 0.8 times the thickness of the
composite sheet ( for example, if the sheet
thickness is 4 mm, the routing depth is 3.2 mm).
4mm 3.2mm 4mm
4mm 3.2mm 4mm
1Milling the channels
2Die-cutting the corners by means of a pneumatic
die
3Die-cutting the slots by means of a pneumatic
die, with predetermined distance between the
slots and the cassette edges, according to the
static analysis
36 37

4Die-cutting the oval shaped and the cylindrical
holes
5Folding the segments and fixing the corners of
the cassette
6Removing the protective foil at the edges of
the cassette
HANGING THE CASSETTES
Thus prepared, the cassettes are mounted on
the fixed hangers. The grout width between the
cassettes is kept constant during installation by
means of spacers and may vary from 4 to 26
mm. The cassettes is permanently riveted to
the main profile, with rivets 4,8 х 12 mm running
through the oval and cylindrical holes.
А - Cylindrical hole
B - Oval hole
38 39
A
B

CASSETTES INSTALLATION STEPS
The cassettes are installed starting from the
bottom-up. The lowest row is first laid, followed
by the leftmost (or rightmost) vertical
column. After the façade is fixed, we proceed
with installation of the finishing details.
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REINFORCED
PROFILE
The reinforced profile is fixed by rivets or
screws to the segment in the middle of the
bottom part of the cassette. The necessity
of the reinforced profile (cod. 07support01)
depends on the cassette size and the loads
exerted on the cassette.
VENTILATION GRID
A perforated grid is installed in the upper and
the bottom end of the ventilated façade, allowing
free air movement, and in the same time
stopping the insects and impurities.

This brochure only reflects the state of our products at the time of printing.
You can find updated information on our website:
WWW.MADEINETEM.COM
Technical or any other questions can be directed to us by e-mail at: pdimitrov@steelmetbg.vionet.gr
or use our telephone number: T: +359 894 754 158
OFFICES
ETEM BULGARIA
T: +359 894 754 158, ventilated@madeinetem.com, www.madeinetem.com
ETEM GREECE
T: +30 210 489 8605, marketing@etem.vionet.gr, www.etem.gr
ETEM ROMANIA
Strada Drumul Intre Tarlale nr 42, Sector 3, Bucuresti
T: +40 21 209 09 70, contact@etem.ro, www.madeinetem.com/ro
ETEM SERBIA
T: +381 22 32 80 19, +381 22 32 80 20, office@etemscg.rs, www.etem.gr
ETEM UKRAINE
T: +38 (044) 499 07 87, info@etem.com.ua , www.etem.com.ua,
www.etalbond.com.ua, www.ventfacade.com.ua
Elval Colour S.A.
Plant B, 3rd km Inofyta Peripheral Road, Agios Thomas 32011, Viotia, Greece
Tel: +30 222620 53576; E-mail: ecs@elval.vionet.gr
www.elval-colour.com