System

The Zephyr System, a flexible and resistant façade

For creativity, durability, simplicity

Zephyr Mesh: a variety of uses

Zephyr Mesh's industrial manufacturing process produces panels. Dimensions vary according to project requirements.

 

The panels are then joined invisibly. Thanks to a mechanical system made of 316 stainless steel. This system ensures the continuity of a motif, without revealing the layout.

 

Tensioning a primary structure deploys the Zephyr mesh. Facade builders, carpenters and others develop the structure to measure.

 

Finally, Solid Studio provides a static study. It concerns the forces exerted by the tensioning and the own weight of the Zephyr Mesh. This study provides the data needed to design the load-bearing structure.

Installation systems

Zephyr Mesh is implemented using a Zephyr System developed by our design office. So, depending on the project and its specific features, we set up dedicated installation systems.

Pictogram of zephyr high mesh fastener

High mounting:for vertical installation, Zephyr Mesh is installed on fixed points. This ensures the geometry of the entire project.

Pictogram of zephyr mesh assembly stud

The connecting stud: thisstainless steel and concrete element provides a strong connection that integrates the desired concrete pattern. It is an essential element for joining the different panels.

Pictogram of zephyr mesh side lacing

Lacing: a lacing system maintains the perimeter of the installed surface. This allows tension the Zephyr mesh on its support.

Pictogram of stud fastening zephyr mesh spacer

Tension cables: the entire installed surface is covered by tension cables. The cables themselves are attached to the Zephyr mesh using 316 stainless steel cable clamps and spacers.

High mounting: forvertical installation, Zephyr Mesh is installed on fixed points. This ensures the geometry of the entire project.

Pictogram of zephyr high mesh fastener

The connecting stud: this stainless steel and concrete element provides a strong connection that integrates the desired concrete pattern. It is an essential element for joining the different panels.

Pictogram of zephyr mesh assembly stud

Lacing: a lacing system maintains the perimeter of the installed surface. This allows the Zephyr mesh to be tensioned on its support.

Pictogram of zephyr mesh side lacing

Tension cables: the entire installed surface is covered by tension cables. The cables themselves are attached to the Zephyr mesh using 316 stainless steel cable clamps and spacers.

Pictogram of stud fastening zephyr mesh spacer

Zephyr System repair

Finally, in the event of deterioration, a technician can intervene on the Zephyr mesh. To replace the system, either a single concrete stud or an entire or an entire panel.

Replacing a stud :

Panel replacement :

Mesh panel with damaged stud

Deteriorated block: in the event that a concrete element is damaged during installation or as a result of deterioration . A technician can complete the removal of the damaged stud.

Damaged panel can be replaced by a technician

Deteriorated panel: ifa sub-assembly has too many defects due to mishandling or deterioration, the technician can easily remove the panel concerned.

Mesh panel with repaired stud

Repair stud:once the concrete stud has been removed from the Zephyr mesh, a repair stud with the correct pattern can be installed by the technician using a stainless steel mechanical fastener. The repair is then completely invisible.

Panel repaired and replaced by a technician

Repair panel: a replacement panel with the correct pattern can then be installed by the technician. The panel can then be reattached to the rest of the surface using the binder pin system.

Replacing a stud :

Mesh panel with damaged stud

Deteriorated block: inthe event that a concrete element is damaged during installation or as a result of deterioration. A technician can complete the removal of the damaged stud.

Mesh panel with repaired stud

Repair stud: once the concrete stud has been removed from the Zephyr mesh, a repair stud with the correct pattern can be installed by the technician using a stainless steel mechanical fastener. The repair is then completely invisible.

Panel replacement :

Damaged panel can be replaced by a technician

Deteriorated panel: if a sub-assembly has too many defects due to mishandling or deterioration, the technician can easily remove the panel concerned.

Panel repaired and replaced by a technician

Repair panel: a replacement panel with the correct pattern can then be installed by the technician. The panel is then simply reattached to the rest of the surface using the binder-pad system.

Technical data

Ultra-high-performance fiber-reinforced mortar
Tested propertiesMinimum guaranteed values
Compressive strength (MPa)≥100
Tensile strength (MPa)≥5
Density2.2~2.4g/cm3
Modulus of elasticity (GPa)≥40
Proportional flexural strength
(MPa)
≥7
Flexural strength (MPa)≥12
Flexural strength limit after 100
freeze-thaw cycles (MPa)
10~25
Shock resistanceNo through cracks on the slab
Air permeability<7,14*10-17m2
Chloride diffusion coefficient<1,2*10-12m2
/s
Carbon dioxide penetrationProfondeur de carbonisation <0,5mm
Water absorption<3%
Poisson's ratio0,24
Shrinkage on drying<1000 µm/m
Creep coefficient Cu0,8~1,2
Coefficient of linear expansion (1/°C)(1,0~1,5)*10-5
Drying shrinkage (x10-6)≤300
Self-treatment (x10-6)≤800
Modulus of rupture (first crack (MPa))10-25
Mohs hardness4
Shock resistance K/m2≥8,0
Frost resistanceAfter 50 freezing and defrosting cycles, there is no evidence of damage such as
such as lifting, peeling, etc.
Zephyr knitwear - by Solid Studio
Minimum-maximum pattern thickness10-20 mm
Minimum spacing5 mm
Frame width and height (axis to axis)Customizable
Maximum weight (full pattern)5-30 kg/m² (5-30 kg/m²)
Order no. stainless steel threadSCX015040S400M
Maximum width and height per panelCustomizable
Panel assemblyInvisible joint - stainless steel mechanical fastener
316
Hard and soft impact testNF P08-301 & NFP08-302 standards
Freeze/thawNF P18-424
Sinusoidal vibrationsIEC 60068-2-6 standard
Fire resistanceA1
Salt sprayISO 92227 standards
Anti-graffiti cleaningInternal protocol
Repair protocolInternal protocol
X-TEND CXE super micro net - Carl Stahl
MaterialAISI 316 STAINLESS STEEL
Construction cableVaries according to net
ManufacturingSet
Mesh shapeCustomizable
Mesh sizeCustomizable
FinishRaw passivated
Cable - Carl Stahl
X-TEND CXE super micro - Carl Stahl
(Variable product/Project)
Protocols
ReferenceSCX015040S400M
MaterialAISI 316 STAINLESS STEEL
Cable diameter3 mm
Nominal resistance 1570 N/mm2
Breaking load5.12 kN
Weight for 100/173 mm0.90 Kg/m2
*Reference data for X-TEND CXE super micro 3 mm. Depending on the project, the mesh can be customized.

Maille Zephyr is available worldwide.

Contact us to discuss your project.