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How laminating soft coat Low-E maximises IGU safety and performance
Laminated soft coat Low-Es are a configuration rarely seen in Australian glass processing due to highly complex handling requirements. However, with high risk comes high reward. In overhead glazing applications, AS1288 calls for a laminated solution. Specifying a laminated Low-E configuration offers greatly increased performance outcomes for overhead glazing applications, where the typical performance solution is a standard hard coat Low-E. Located in Cronulla, the Ozone apartments feature a 17.52mm soft coat Low-E within a series of circular skylights glazed with high performance IGUs.
Designed by PBD Architects, the Ozone apartments are a bespoke residential project featuring 35 oversized residences across 9 levels. The architecture embraces the coastal aesthetic, seamlessly blending modern living with breathtaking ocean views. Each apartment is crafted to maximise space and light, with house-like proportions and expansive entertainer terraces.
Two double story, 300sqm penthouse apartments are located on the top floor of the project with views of the ocean from South Cronulla to North Cronulla beach. A stunning circular glass lift wrapped in a spiral staircase connects each floor, with a circular skylight located directly above each lift.
PBD associate director Bill Clements was lead architect for the project: “One of our primary objectives for the penthouses was maximising sunlight and the expansive water views simultaneously. The circular glass lift brings 360 degree views while the circular skylights create a seamless connection to the sky above. The skylights are critical in completing the visual connection between the indoors and external environment and maximising light transmission to the lift space.”
Skylights that are simple in shape, complex in nature.
Measuring 3600 x 3600mm, each skylight features Cooling Brothers Ultra Cool E IGUs - a high-performance soft coat IGU suitable for a range of applications. When compared to a typical IGU, the soft coat for these units sits within a 17.52mm heat soaked configuration, rather than as a single pane.
Magic Glass delivered the glazing package for the project, lead by COO Michael Pascoe. “While circles are perhaps a simplistic form when it comes to glass, the simple shape conceals a range of complexities that makes these IGUs anything but simple" comments Michael. "Not only is a 17.52mm soft coat specification technically outrageous, we have two 3600mm diameter skylights suspended over a two story circular glass lift, on top of a 9 story penthouse. All things considered, it is one of the most technically challenging glazing projects we have delivered to date.”
Understanding soft coat processing challenges
Soft coats are manufactured by applying thin layers of metallic coatings onto the glass surface to deliver incredible performance outcomes. However, these layers are incredibly delicate and far more sensitive to damage and require special handling procedures. Improper handling, cleaning, or direct contact can easily damage the soft coat, leading to performance issues, visible imperfections and failure of the low e surface.
As a result, laminating soft coats becomes inherently difficult due to the complexity of glass handling required during interlayer lay-up and autoclaving. The high risk of contamination and damage to the soft coat surface means most glass processors within Australia will not manufacture laminated soft coats.
However, with the correct handling procedures and expertise, laminated soft coats offer high thermal performance engineered solutions that are not possible in a standard soft coat IGU configuration.
Ozone Apartments: project outcomes
The Australian Standards requirement for overhead glazing is for heat strengthened, laminated glass. Without the use of a laminated soft coat, the outcome could have been one of two options:
- Compromise on light transmission to meet performance requirements by way of a significantly darker body tinted glass.
- Utilise two hard coat Low E surfaces within the IGU, resulting in a significant cost increase
Alternatively, by specifying a laminated soft coat within the IGU the outcomes achieved are:
- Superior thermal performance (compared to same configuration in hard coat Low-E)
- Maintains light transmission requirements
- Meets project budget requirements
Achieve additional benefits of increased safety in any application
The safety benefits of laminating soft coat Low-E extend beyond just overhead glazing requirements. Specifying a laminated soft coat into any IGU will result in greatly increased safety in the event of breakage, when compared to a monolithic (single) panel of soft coat Low-E.
Specifying tips for Custom Laminated Soft coats
From a glass processing perspective, laminating soft coat Low-E is a high risk, highly technical workflow that can result in a high degree of failure in lamination. Before specifying we suggest:
- Engaging in detailed preliminary discussions with an experienced glass processor and façade engineer to identify risk factors and confirm glass design requirements
- Ensure documentation shows the low e coating specified within the IGU, not encapsulated with the interlayer
- Ensure the correct heat treatment for the Low-E is specified – heat soaked / heat strengthened / toughened
Our technical sales team is available to assist with specification details as required. To speak with one of our team, contact us on 1300 040 799, or email info@coolingbros.com.au