New Glazing Product: Low E Coated Glass Launch

Solarplus TLE 62 new glass product

G.James Glass and Aluminium pride ourselves on being at the forefront of the latest product developments and are proud to offer a new range of high performance Low E coated glass products, Solarplus TLE62. This new range of coated glass will be incorporated into G.James TwinGlaze Insulated glass Units and will supersede the current range of Solarplus Low E products offered.

Benefits

Low E glass has a range of distinct benefits – the major function is to provides better thermal performance. The new Solarplus TLE 62 glass produces results in an efficient method, requires shorter lead times for production, and is ideal for jobs large or small.

Solarplus TLE 62 has high visible light transmittance and neutral appearance in both transmittance and reflectance which is low internally and externally.  Please refer to the performance table below for data, and please note, this is for glass only performance. Contact G.James for whole of window data.

Solarplus TLE 62 new glass product

The thermal performance is excellent with low U Values and Solar Heat Gain figures.

Colour Options

The Low E coating is on clear glass and can be combined with tinted glass to provide different aesthetic qualities. The range includes:

  • Grey
  • Green
  • Bronze
  • Blue
  • Super Green

The Solarplus TLE 62 is a durable coating that is able to be heat treated for toughening where it is required.

The G.James manufacturing facilities are currently being upgraded, and this product will be available in October, 2013. Please contact us with any further enquiries about this new product range.

Gasworks – A Modern Development with a Heritage Heart

Gasworks building developmentOngoing development of a historical site located at Newstead (Brisbane), sees it transforming in stages to a new mixed use precinct. The name derives from the sites original use – the gasworks, and part of the project is to protect the heritage listed gasometer located prominently amid the gasworks buildings.

Originally built in 1863, the gasometer once stored gas in a large bladder contained within its frame work.  The Gasometer has been fully restored ensuring the ornate pinnacles and lace work beams stand as equal alongside its newly constructed neighbours.  It creates a unique contrast set amidst the strong lines and bold shapes of the modern architectural features of the Gasworks building development.

Designed by the same team that worked on the adjacent Energex building – Architect Cox Rayner and builders FKP, the buildings in this phase of construction comprise of Building A on Skyring Terrace (five storeys) and Building E on Longland St (three storeys).

G.James Role

G.James Glass and Aluminium supplied and installed glazing facades, doors, windows and some extruded sun hoods. Building A has a proposed 5 star green star rating – so energy efficiency, acoustics and air infiltration were important design factors. As such, products with proven test results were selected for use.

Building A

Building A comprises ground floor shop front retail with four upper levels of offices. The offices utilise the flush glazed 651 series glazed with IGUs made up of green glass with a low E coating for energy efficiency, a 12mm air space, and 6mm clear glass internally. This also assisted in achieving a better acoustic rating.  Spandrel panels were made with a green ceramic painted surface – a premium spandrel glass option  that maintains the look set by the vision area.

Building E

Building E was a combination of two levels of residential apartments along Longland Street, two levels of office space along the breeze way between the buildings, and a retail shop front precinct on the ground level. The offices in building E utilize the 650 series, also flush glazed, but to accommodate 11.52mm laminated glass. The glass has a low E coating and the same colour, but didn’t require the same level of acoustic rating or energy efficiency. The office glazing also incorporated architectural features such as glass fins for extra strength and sun hoods for protection.

The residential apartments use a range of glazing styles. Fixed framing used the 650 series system with 265  series awning windows spaced across the facade. Balconies feature four side supported 550 series balustrades with access through 445 series sliding doors.

Shopfront Design Problem

The retail areas required a centrally glazed pocket, but the opening size and wind loads exceeded the constraints of the current system.  As many architects are looking for options to make windows larger, the decision was made to replace the current aluminium vertical members, the mullions, with a stiffer option. The new design also incorporated the ability to strengthen it further. This new addition to the G.James range is used extensively throughout the Gasworks project.

Practically Completed

Practical completion was achieved on the 3rd August, 2013, however there are still minor works, interior fit outs and landscape work under way.  Building E has been designed so a residential tower can be constructed above it in the future.

The Gasworks project is an aesthetic feast, and well worth a look if you are in the area. Please consult the interactive map project to get the location and a summary of the project information.

IGUs. A sound acoustic solution?

sound and noise acoustic control with IGUsInsulating Glass Units (IGUs) or double glazing, have been a popular solution to control noise, but they aren’t the only, or even the best solution in many cases. The aim of this article is to explain how acoustic problems are identified, assessed and provide solutions to properly address them.

Acoustics

The acoustic performance of façades is becoming more important in building design, and not surprisingly is included as part of the Green Star rating process. Although it is a small part, it’s raising the profile of sound reduction and the need to find better solutions to the increasingly worsening noise problems in today’s society.

To better understand how to mitigate sound, it is beneficial to have an awareness of a few key ideas; how sound is transferred, the way different noises are measured, know about the principles to minimise the variety of sources and coordinating appropriate solutions. Prior knowledge makes finding a solution a lot quicker and easier when you are consulting a professional.  Using advice to compare test results, it is imperative to know the difference between glass only and window system results if you want sound acoustic solutions.

Determining sound factors

Noise sources in the vicinity of a project need to be identified to best determine the most efficient glazing solutions. Look for risk sources, some examples of which are below;

  • Traffic noise from vehicles – cars and/or trucks
  • Trains
  • Planes and flight paths
  • Trams
  • Boats
  • Entertainment venues
  • Industry – a warehouse, factory plant, a truck depot up the road

For each source, be aware of the proximity and direction it will be coming from.  Future changes that will affect sound transfer must also be considered – empty or older blocks that will be used for building development, planned roads and motorways to be constructed, or a feature that may be removed to expose the project to heightened noise distribution. This information will be assessed by an acoustic engineer or glazing contractor looking at the requirements of the project.

The two main properties that contribute to disturbance from noise are the frequency and intensity level at various frequencies, or volume. Both influence the selection of appropriate glazing systems for a project.

Frequency

Sound travels as sound waves (variations in pressure) that have different frequencies. When the sound wave hits an object, this will be absorbed, transferred or reflected dependant on the properties of the object and the frequency of the sound. Below is a table that describes the frequencies associated with different noises;

Frequency distribution

Volume

The inherent volume or loudness of noise is measured in decibels (dB). Following is a table that gives you an idea of how loud different noises are;

comparison of sound

 Acoustic fact:

The human ear cannot distinguish a change in noise level of 3dB or less.

Different types of glass will assist deadening the various frequency and sound levels. To decide what the best solutions are, the window systems need to be comparable.

Measuring how much a glazing system suppresses noise

The current standard unit that is used to nominate the amount of acoustic insulation achievable is the Rw. An Rw rating is applied to many products to compare its capability to reduce sound against similar products. However, the nature of glazing systems means that frequency plays a large part in the transference of sound. So correction factors are applied to the Rw and expressed as Rw(C, Ctr).

Using Rw Data results:

When looking at results, ensure you understand what the Rw rating applies to.  Glass only data will give you just that – a figure for the glass.  It will not be comparable with a whole of system framing. Glass only data has a higher figure, and misrepresents the effectiveness of the desired glazing solution.

Rw

The Rw, or weighted sound reduction index, is a material or system’s ability to reduce sound transferring through to the other side, of a window or wall. As a rough guide, an increase of 1Rw reduces the sound perceived on the other side by about 1dB.

Rw(C, Ctr)

The correction factor for the Rw takes frequency into account. Medium to high frequency noise like conversation, and faster traffic (travelling more than 80kmh) are nominated as the C number. Low to medium frequency sound like urban traffic and planes flying overhead are the Ctr figure.
If a project has a requirement of Rw = 32(-1,-4), then the Rw = 32, the Rw+C = 31 and the Rw+Ctr = 28. The noise frequency distribution determines the correction factor figure to be used. If the predominant noise source affecting a project is traffic noise, being a low frequency problem, the Rw+Ctr figure is used. In this case, the figure to achieve is 28. If a window system is rated at Rw30(-2,-2), the Rw+Ctr = 28, therefore achieving the above requirement. The Rw number should always be used with correction factors.

Testing the Acoustic Performance of Glazing Systems

Testing is done by accredited organisations in an acoustic laboratory. The testing space consists of two rooms of known acoustic properties separated by a wall with a high sound insulation. The rooms are constructed of thick block work with the entire laboratory sitting on airbags to isolate it from ground vibration. An opening is made in the wall for the glazing system. One of the rooms is set up as a source room, and one is the receiving room. The difference in noise level measured between the rooms is used to calculate Rw, C and Ctr figures that are attributed to the system tested.

Acoustic Solutions

There are several acoustic principles that are applied to the design of glazing systems to obtain the best performance to guide you in choosing the optimal glazing products.

Glazing design

Keeping sound out is like keeping water out – any gaps provide a path by which the acoustic efficiency of a system is reduced. Even the smallest crevice or notch out of a system makes a difference. Glazing systems can be riddled with gaps – good systems minimise these as much as possible. Testing is the only way to know how any system will perform.

Product selection

Restricting sound penetration is only as good as the barrier’s weakest point. Opening or operable parts of a façade are the hardest places to control sound, but improvements in technology are minimising the issue. With changes in door design to allow for access according to AS 1428, it is good to be aware these points are made weaker, acoustically.  With glazing developments, there are solutions to help minimise this issue.

Window systems with a positive closing force are more effective at blocking out sound. Awning windows and hinged doors generally perform better than sliding windows and doors.

Acoustic seals can be used to improve glazing performance and achieve a better Rw rating. The only way this can be accurately assessed and used for compliance, is if the glazing system is tested with the acoustic seals.

An air gap between the glass panels in a glazing system can provide a degree of sound reduction dependant on the size of the air gap. Typical IGUs with an 8, 10 or 12mm air gap, the improvement is marginal. Larger double glazed air gaps are much more effective, with 50mm being the “sweet spot” with only marginal improvement beyond this. These large air gap systems are generally the best performing of any glazing system.  Jockey sash systems can also be used to create large air gaps but have size restrictions and may cause internal condensation issues.

Laminated glass can provide equivalent or better performance than a standard air gap IGU. Typically the thicker the laminate, the better the acoustic performance. Specifically designed acoustic interlayers are now available that provide an increase in performance in standard interlayers

Looking for assistance with acoustic design

Window fabricators can help you understand the acoustic performance that their products provide. If you are aware of the nature of noise pollution in the vicinity of your project, then it’s a matter of matching the correct products to minimise this problem. Look for new technology becoming available to better deal with the increasing noise issues in today’s society.

When using window acoustic data, ensure you are discussing whole of window system data. There is a lot of glass only data available, but it’s the frame that is typically the weakest acoustic point of a glazing system. The glass only data will not give you a proper representation of noise control.

5 Points to Remember

  1. Understanding Rw(C,Ctr).
  2. Gaps in Systems = sound transfer. Minimise these weak points, especially in operable glazing.
  3. Larger air gaps in between glazing layers helps acoustically.
  4. Familiarity with latest technology in sound reducing products like acoustic seals and interlayers.
  5. Test results need to be comparable. Look at whole glazing systems, not glass only test results.

Helpful Links

For further information on the subject, please refer to the suggested following resources:

Generic and Custom Plastic Extrusions, Gaskets and Seals

PVC extruded plastic gasketThe G.James Glass and Aluminium Plastics department has been operating since 1995, and started out manufacturing just 2 products for in house use. Type and quantity of manufacturing has been growing steadily ever since. Commercial sale of products initiated 5 years ago, and now supports several industries.

G.James Extrusions

The industries that G.James manufactures PVC plastic extrusion for include – building and construction, automotive, commercial refrigeration, marine, shop front, internal fit outs and railways to name a few. They come in a range of colours and PVC types, from rigid, semi rigid and flexible, including nitrile or rubber modified and TPV (Thermo Plastic Vulcanite) or Santoprene equivalent (this has the same properties, characteristics and function, but without the Santoprene brand name) as well as Santoprene, if its specifically required. Co extrusions (extrusions made from two different materials) and bushfire (BAL) rated extruded gaskets are also available.

The G.James facilities are capable of large scale commercial production. The production lines can produce up to approximately 2000m of plastic extrusion an hour – depending on the size and shape of the profile. Products are designed up to 100mm in Circumscribing Circle Diameter (CCD). At peak times, it will use up to 40 ton of material a month – and that’s not at full capacity.

Extrusion design

After initial contact, the design process involves an in depth look at what is required – the use, appropriate material for the conditions – sun and weathering, heat and chemical exposure. Identifying potential issues and mitigating them, or troubleshooting issues that may have occurred previously. Assessing die design and making a more effective proposal are all looked at prior to signing off drawings for a die to be made. Die trials are run and the resulting profile measured up for quality assurance purposes before commercial runs begin.

This process can take up to a couple of months if there is a lot of design involved, but is usually less. Ordering plastic extrusion has a two week lead time, but standard runs or more urgent requests can be processed to cater to customer needs.

Quality

During the design process

Efforts are made to ensure the die design is as beneficial and cost effective to the customer as possible. For example, a recent job started out with a profile design from a customer that required considerably expensive tooling and production costs.  Working with the customer and making a few die modifications, these costs were brought down by 60% . No impact was had on the effectiveness of the extrusion.

As an initial saving, G.James can arrange to have the tooling price amortised into the production price per metre to offset the lump sum.

Use in situ

18 years of experience by the PVC extrusion manager, Jason Clarke, ensures personal service from someone who knows how to make it work. Trouble shooting feeding problems, stopping gaskets from “popping” out of position, gasket “wave” problems and better shape design are among other issues that are addressed.

Point of manufacture

A length from every roll of extruded plastic is tested to ensure a quality product. Measurements are taken and information is recorded and stored so it can be tracked back to when and how it was made. Materials that work into other G.James products are also trialled for a suitable fit on completion to ensure a whole of system customer service.

Back end quality control

G.James conduct investigations into existing scenarios that are having problems. Extrusion and glass checks, incorrect use and out dated design issues can be looked at to assess the cause of any issues. Advice is given on the findings, whether it is a change in plastics die design, or other members that are found to be out of tolerance.

Manufacturing Process

It’s a short but interesting manufacturing process. The material comes in pellet form that is control fed through a hopper into a spiralling screw or ram. The pellets are heated, mixed and compressed as they are fed through the spiralling screw, and finally forced through the die into its final shape. After the gasket is extruded, it is immediately cooled in chilled water, and then dried before being cut into designated lengths and boxed, or rolled onto a spool.

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Recycling

All off cuts of plastic extrusion are recycled on site. They are shredded and prepared to go through the same hopper feed and production process. As a quality control issue, recycled material is only used on non-structural gaskets, such as fly screen splines.

Brisbane designed and made, supply is distributed Australia wide, with much of our standard range available off the shelf at any G.James branch. For more information on product and supply, call the PVC manager, Jason Clarke, on 0403 352 703 or 07 3815 4908. Keep up to date by looking up the PVC page on the G.James website.