System

A flexible, resistant façade system

Creativity, durability, simplicity

Zephyr Mesh: a variety of uses

The industrial manufacturing process for Zephyr Mesh enables the production of 2500 mm x 1200 mm panels.

These panels are joined invisibly by a 316 stainless steel mechanical system developed in partnership with Carl Stahl. This system ensures the continuity of a motif, without revealing the layout.

Zephyr Mesh is deployed and tensioned on a secondary structure developed in collaboration with facade builders, carpenters and others.

We have developed a unique industrial tool, capable of offering modularity and total customization of our product.

Hook systems

Maille Zéphyr is hung in panels using 4 systems:

High mounting: in the caseof vertical installation, Zephyr Mesh is installed on fixed points to ensure the geometry of the entire project.

The connecting stud: to join the different panels, this stainless steel and concrete element provides a strong junction that integrates the desired concrete pattern.

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

Tensioning cables: the entire installed surface is covered by tensioning cables, which are attached to the Zephyr mesh using 316 stainless steel cable clamps and spacers.

High mounting: in the caseof vertical installation, Zephyr Mesh is installed on fixed points to ensure the geometry of the entire project.

The connecting stud: to join the different panels, this stainless steel and concrete element provides a strong junction that integrates the desired concrete pattern.

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

Tensioning cables: the entire installed surface is covered by tensioning cables, which are attached to the Zephyr mesh using 316 stainless steel cable clamps and spacers.

Repair

In the event of a damaged element, a technician can intervene on the Zephyr mesh to replace either a single concrete block or an entire panel.

Replacing a stud :

Panel replacement :

Deteriorated concrete block: if a concrete element is damaged during installation or as a result of deterioration, a technician can finish breaking it.

Deteriorated panel: If a subassembly has too many defects due to mishandling or deterioration, the panel concerned can be easily removed by the technician.

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.

Repair panel: A replacement panel with the correct pattern can then be installed by the technician. Simply reattach the panel to the rest of the surface using the binding stud system.

Replacing a stud :

Deteriorated concrete block: if a concrete element is damaged during installation or as a result of deterioration, a technician can finish breaking it.

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 :

Deteriorated panel: If a subassembly has too many defects due to mishandling or deterioration, the panel concerned can be easily removed by the technician.

Repair panel: A replacement panel with the correct pattern can then be installed by the technician. Simply reattach the panel to the rest of the surface using the binding stud system.

Ultra-resistant materials

Zephyr Mesh consists of two fundamental elements:

- The stainless steel mesh (316 - marine grade, Carl Stahl) is exceptionally elastic and flexible. It can easily withstand the elements, is highly resistant and virtually maintenance-free. This stainless steel net is suitable for both indoor and outdoor applications.

-Ultra-high-performance fiber-reinforced concrete formulated by Ciments Calcia (Heidelberg Group), which is cast onto the stainless steel mesh. Each concrete element is configurable (shape, color, density, etc.).

The overall weight is between 10 and 20 kg/m², depending on the design. The concrete formulation is based on an innovative cement featuring TX Active® technology. Its composition accelerates the decomposition of pollutants and prevents them from forming on substrates.

A depolluting system: Concrete containing products formulated with TX Active® significantly reduces the presence of organic pollutants and harmful gaseous substances (nitrogen oxide NOx) and volatile organic compounds (VOCs: benzene, toluene...) produced by human activity (industry, automobiles, electric heating), thus preserving air quality and the aesthetics of buildings...

Local cement: The cements used come 100% from local quarries, close to where Maille Zephyr is manufactured.

Recyclable: Stainless steel is over 99% recyclable, and concrete aggregates can be reused in the formulation of new concretes.

Technical data

Cement - Ciments Calcia
EFFIX ARCA - Ciments Calcia
Tested properties	Protocols	Results
Density	ND EN 12350-6	2340 = 100 kg/m3
Compressive strength	At 24 hours - NF EN 196-1	>60 Mpa
Resistance to understanding	At 28 days - NF EN 16-1	>100 Mpa
Flexural strength	A 24 heures	> 6 Mpa
Flexural strength	At 24 days	> 9 Mpa
Dynamic Young's modulus	At 28 days	> 45 GPA
Water-accessible porosity	AFREM	2.30%
Total withdrawal	NF P 15-433	Approx. 0.85 mm/
Freeze/thaw resistance	NF P 18-425	compliant
Chipping resistance	WP P 18-420	compliant
Oxygen permeability	FREM	> 2.10-17 m2
Chloride ion diffusion	Tang-Nilson	3.6.10612 m2/5


Net - Carl Stahl
X-TEND CXE super micro - Carl Stahl (Variable product/Project)
Reference
Material	AISI 316 STAINLESS STEEL
Cable diameter	3 mm
Nominal resistance	1570 N/mm2
Breaking load	5.12 kN
Weight for 100/173 mm	0.90 Kg/m2



Zephyr knitwear - by Solid Studio
Max. pattern thickness	20 mm
Min. pattern thickness	10 mm
Minimum spacing	5 mm
Frame height (axis to axis)	140 mm
Frame width (axis to axis)	80 mm
Max. weight (full pattern)	30 kg/m² (30 lb/m²)
Order no. stainless steel thread	IS20261-0200-080
Max. width per panel	1200 mm
Max. height per panel	2500 mm
Panel assembly	Invisible joint - stainless steel mechanical fastener



X-TEND CXE super micro net - Carl Stahl
Material	AISI 316 STAINLESS STEEL
Construction cable	Varies according to net
Manufacturing	Set
Mesh shape	Customizable
Mesh size	Customizable
Finish	Raw passivated

Maille Zephyr is available worldwide.

Contact us to discuss your project.

System

A flexible, resistant façade system

Creativity, durability, simplicity

Zephyr Mesh: a variety of uses

The industrial manufacturing process for Zephyr Mesh enables the production of 2500 mm x 1200 mm panels.

These panels are joined invisibly by a 316 stainless steel mechanical system developed in partnership with Carl Stahl. This system ensures the continuity of a motif, without revealing the layout.

Zephyr Mesh is deployed and tensioned on a secondary structure developed in collaboration with facade builders, carpenters and others.

We have developed a unique industrial tool, capable of offering modularity and total customization of our product.

Hook systems

Maille Zéphyr is hung in panels using 4 systems:

High mounting: in the caseof vertical installation, Zephyr Mesh is installed on fixed points to ensure the geometry of the entire project.

The connecting stud: to join the different panels, this stainless steel and concrete element provides a strong junction that integrates the desired concrete pattern.

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

Tensioning cables: the entire installed surface is covered by tensioning cables, which are attached to the Zephyr mesh using 316 stainless steel cable clamps and spacers.

High mounting: in the caseof vertical installation, Zephyr Mesh is installed on fixed points to ensure the geometry of the entire project.

The connecting stud: to join the different panels, this stainless steel and concrete element provides a strong junction that integrates the desired concrete pattern.

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

Tensioning cables: the entire installed surface is covered by tensioning cables, which are attached to the Zephyr mesh using 316 stainless steel cable clamps and spacers.

Repair

In the event of a damaged element, a technician can intervene on the Zephyr mesh to replace either a single concrete block or an entire panel.

Replacing a stud :

Panel replacement :

Deteriorated concrete block: if a concrete element is damaged during installation or as a result of deterioration, a technician can finish breaking it.

Deteriorated panel: If a subassembly has too many defects due to mishandling or deterioration, the panel concerned can be easily removed by the technician.

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.

Repair panel: A replacement panel with the correct pattern can then be installed by the technician. Simply reattach the panel to the rest of the surface using the binding stud system.

Replacing a stud :

Deteriorated concrete block: if a concrete element is damaged during installation or as a result of deterioration, a technician can finish breaking it.

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 :

Deteriorated panel: If a subassembly has too many defects due to mishandling or deterioration, the panel concerned can be easily removed by the technician.

Repair panel: A replacement panel with the correct pattern can then be installed by the technician. Simply reattach the panel to the rest of the surface using the binding stud system.

Ultra-resistant materials

Zephyr Mesh consists of two fundamental elements:

- The stainless steel mesh (316 - marine grade, Carl Stahl) is exceptionally elastic and flexible. It can easily withstand the elements, is highly resistant and virtually maintenance-free. This stainless steel net is suitable for both indoor and outdoor applications.

-Ultra-high-performance fiber-reinforced concrete formulated by Ciments Calcia (Heidelberg Group), which is cast onto the stainless steel mesh. Each concrete element is configurable (shape, color, density, etc.).

The overall weight is between 10 and 20 kg/m², depending on the design. The concrete formulation is based on an innovative cement featuring TX Active® technology. Its composition accelerates the decomposition of pollutants and prevents them from forming on substrates.

Local cement: The cements used come 100% from local quarries, close to where Maille Zephyr is manufactured.

Recyclable: Stainless steel is over 99% recyclable, and concrete aggregates can be reused in the formulation of new concretes.

Technical data

Maille Zephyr is available worldwide.

Contact us to discuss your project.

BENELUX KO & COBenelux Sales Director+32 3 458 40 40[email protected]Boomsesteenweg 41/10, B-2630 AARTSELAAR

FRANCEAurélien FaugèresFounder, CTO+336 98 48 24 21 -- Paul HaëntjensCo-founder, CRO & CMO+336 77 98 58 15

MIDDLE-EAST Medhi RenautMiddle-East Sales Director+971 50 733 9613mr@galiangulfconsultingUmm Suqeim 3, Al Fateela Street, Dubai, UAE

Contact us directly or fill in the form:

BENELUX

KO & CO
Benelux Sales Director
+32 3 458 40 40
[email protected]
Boomsesteenweg 41/10, B-2630 AARTSELAAR

FRANCE

Aurélien Faugères
Founder, CTO
+336 98 48 24 21
--
Paul Haëntjens
Co-founder, CRO & CMO
+336 77 98 58 15

MIDDLE-EAST

Medhi Renaut
Middle-East Sales Director
+971 50 733 9613
mr@galiangulfconsulting
Umm Suqeim 3, Al Fateela Street, Dubai, UAE