Many new commercial construction projects are designed with large glass curtain walls that are attached to the exterior structure of the buildings. These glass walls allow filtered natural light to enter the interior of the building and create a beautiful exterior appearance. Another benefit of these wall systems is to increase the spread of fire between floors and prevent the entry of air and water. A curtain wall typically spans more than one story and is made up of metal framing with glass infill units. Unfortunately, these glass walls are often damaged during construction activity at considerable cost.
Curtain walls can be damaged during shipment to the job site, during installation, and after installation while the rest of the construction work is taking place. There are several methods manufacturers can use to protect aluminum windows and mullions from damage during shipping. Protecta foam strips can quickly adhere to metal surfaces and act as a protective barrier between stacked wall units. Reinforced cardboard edge protectors from 2.5 to 4.0 inches can be affixed to all edges of units for shipping. Lastly, in some cases rolled cardboard can be used if the weight of the units is not enough to crush the cardboard. Wall glass can be protected from scratches during shipping by using adhesive window film.
Once curtain walls have been delivered to the job site, unpacked and installed correctly, they are at the greatest risk of damage. Various construction trades will work both on and off the construction project for months or years. Not only can aluminum get dented or scratched, but glass is also at high risk of scratching and breaking. Some glass can be very expensive if it provides seismic or hurricane resistance or ballistic proof glass specified in court projects. Protecting both glass and metal once the curtain wall has been installed is a smart move for any contractor.
Most curtain wall damage occurs in the lowest 5 feet of walls on each floor of the building. This is where workers and equipment will be in closest contact with the walls. The best protection is provided by a “wall” against the glass wall itself. This protection wall can be made of wood or plastic. While wood is the strongest wall protection available, it is also expensive and time consuming to erect. Corrugated plastic sheets in 4-foot by 8-foot sections can be taped together in front of the curtain wall, providing a lightweight, easy-to-build wall. Unlike wood, plastic can be cleaned to remove dust and dirt as needed. Since there is no electricity for the lights during the early stages of construction, protective walls constructed of white or clear plastic allow natural light to enter the building.
As the demand for curtain walls continues to increase, the need to protect these walls during construction will be a challenge. Forward-thinking architects and building owners are taking the next step with wall systems by moving from energy conservation to power generation. These newer walls with PV modules will be even more expensive and difficult to repair or replace. With proper anticipation and the use of temporary curtain wall protection, the savvy contractor won’t have to worry about damage to their curtain wall systems.