2. Joining and Fabrication



There are various joining techniques possible with copper. These include:

  • Butt Weld
  • Bolted
  • Standing Seam
  • Lap Seam w/Fasteners
  • Flat Seam
  • Bolted Flange
  • Spline
  • Flush Lap
  • Batten Seam
  • Lap Seam

When it comes to attaching the various copper and copper alloy components together, a few tips will be of assistance:

1.

Standing, batten or flat seams, which were originally intended for roofs, may also be applied to interiors as a wall treatment creating unique and dramatic shadow lines. These systems do not use mechanical fasteners, but instead rely on loose-lock interconnected joints for their strength. There are many different shapes and patterns that can be created using these types of seaming techniques.



The copper wall, using angled batten-seam joints, is a key component of this room.

2.

For a smooth finish, copper can be butt weld and the welds may be ground down to appear flush too giving a seamless look. This is especially important for large wall applications or any large expanse of sheet material, for example a ceiling or multistorey fireplace.

3.

In some cases, brazing, soldering or other welding methods can be used to achieve certain designs. When considering techniques using high heat input, consideration must be given to the possibility of thermal discolouration of the metal. However, in some installations, heat tinting has been used to create additional effects

4.

Blind mechanical fastening techniques can be used when formed panels are installed in a predetermined pattern with the small space between the panels forming a linear sightline.



An interior ceiling system

5.

Using fasteners is a common joining method, especially for interior applications where, for example, bolts can play a key role in the aesthetic design of the structure. Decorative "bolts" can be also used to reinforce a pattern or create a dimpled effect.



The copper bar and fascia are striking features at this restaurant.


6.

The use of lapped seams and connections with exposed fasteners again can create an unusual wall treatment that is quite reflective.

7.

Bonding of copper or a copper alloy to a substrate of another material is not uncommon in interior applications. Difficulties can result when the substrate and the metal expand and contract at different rates, eventually resulting in delamination. This possibility should be evaluated when considering this type of system.


Note: In the section on Fundamentals, additional important information is provided on the compatibility of fasteners for use with copper, brass
and bronze. More information is also provided on dealing with expansion and contraction.