PWS AND PWD SANDWICH PANELS WITH EXPANDED POLYSTYRENE CORE

Transcription

1 PWS AND PWD SANDWICH PANELS WITH EXPANDED POLYSTYRENE CORE TECHNICAL CATALOGUE

2

3 PWS and PWD Sandwich panels with expanded polystyrene core April 2013 The content of his folder does not constitute a commercial offer in the understanding of the Civil Code regulations. Information included in this study demonstrates only sample solutions that require consultation and specification by the designer of a particular building according to individual clients needs. Balex Metal does not bear any responsibility in case of any technical irregularities or errors resulting from inappropriate application of information included in this paper.

4

5 TABLE OF CONTENTS I. TECHNICAL SPECIFICATION OF THE ENCLOSURE MADE OF SANDWICH PANELS WITH EXPANDED POLYSTYRENE (EPS) CORE 1. General information about the company PWS and PWD sandwich panel construction Technology of production Types of panels Scope of application of the panels Types of sandwich panel joints PWS sandwich panel - wall type PWD sandwich panel - roof type General technical specification Materials and facing coatings Facing profile scheme Profile type combinations Sample marking of PWS and PWD panels Facing colour scheme Strength issues Thermal performance Fire safety Corrosion resistance Noise reduction performance Fasteners Lengthwise roof panel joining General assembly guidelines Transport guidelines Certification documents...27 II. CONSTRUCTION AND ARCHITECTURE DETAILS OF THE ENCLOSURE MADE OF SANDWICH PANELS WITH EXPANDED POLYSTYRENE CORE 1. PWS Sandwich wall panels PWS01 PWS Wall panel - joint, types of profiles PWS02 Panel fastening vertical panel arrangement PWS03 Supporting the panels on the ground beam or the foundations vertical panel arrangement PWS04 Supporting the panels below the top of the ground beam or the foundations vertical panel arrangement PWS05 Supporting the panels on the ground beam or the foundations horizontal panel arrangement PWS06 Supporting the panels below the top of the ground beam or the foundations horizontal panel arrangement PWS07 Joining the panels in the corner - horizontal or vertical panel arrangement - option I PWS08 Joining the panels in the corner - horizontal or vertical panel arrangement - option II PWS09 Joining the panels in the corner - horizontal or vertical panel arrangement - option III PWS09/1 Joining the panels in the corner - horizontal or vertical panel arrangement PWS10 Joining the panels in the corner - horizontal or vertical panel arrangement - option IV PWS11 Lengthwise panel joining - vertical panel arrangement PWS12/1 Fastening the panels to the outermost support - horizontal panel arrangement - option I PWS12/2 Fastening the panels to the outermost support - horizontal panel arrangement - option II PWS13 Fastening the panels to the outermost support - horizontal panel arrangement - option II PWS14 Joining the panels to the window strip - horizontal panel arrangement - option I PWS15 Joining the panels to the window strip - horizontal panel arrangement - option II (for panels of 75, 100 thickness) PWS16 Joining the panels to the window strip vertical or horizontal panel arrangement option III PWS17/1 Joining the panels to the PVC window - vertical or horizontal panel arrangement PWS17/2 Joining the panels to the PVC window - vertical or horizontal panel arrangement section X-X PWS18 Fastening the panels, sliding joint - vertical panel arrangement...50

6 2. PWD Roof sandwich panels PWD01 PWD Roof panel - joint, types of profiles PWD02-1 Fastening the panels to the purlins PWD02-2 Fastening the panels to the purlins section X-X PWD03 Panel endings in case of a monopitch roof PWD04-1 Gable-end roof edge PWD04-2 Gable-end roof edge PWD05 Joint of the panels with the PWS wall panel by the attic PWD06 Joint of the panels at the roof ridge PWD07-1 Joint of the panels with the internal gutter option I Balex Metal PWD07-2 Joint of the panels with the internal gutter - option II PWD08-1 Joint of the panels with the prefabricated internal gutter - option I BALEX METAL PWD08-2 Joint of the panels with the prefabricated internal gutter - option II PWD09-1 Joint of the wall panel with the roof panel in the eaves of the roof PWD09-2 Joint of the wall panel with the roof panel in the eaves of the roof - option II BALEX METAL PWD10-1 Lengthwise joining of the roof panels (L > 18m) PWD10-2 Lengthwise joining of the roof panels (L > 18m) - section A-A PWD11-1 Joint of the panels with the prefabricated gutter at the attic - option I BALEX METAL PWD11-2 Joint of the panels with the prefabricated gutter at the attic - option II PWD11-3 Joint of the panels with the prefabricated gutter at the attic - option III BALEX METAL PWD11-4 Joint of the panels with the prefabricated gutter at the attic option IV PWD12/1 Roof ridge continuous skylight - longitudinal section PWD12/2 Roof ridge continuous skylight cross- section PWD13 Roof ridge skylight cross-section PWD14 Expansion gap PWD15/1 Installation of additional canopy roof at the wall - existing wall option PWD15/2 Installation of additional canopy roof at the wall- basic option with the drip cap...76

7 I. TECHNICAL SPECIFICATION OF THE ENCLOSURE MADE OF SANDWICH PANELS WITH EXPANDED POLYSTYRENE CORE

8 1. GENERAL INFORMATION ABOUT THE COMPANY Balex Metal Sp. z o.o. is the leading manufacturer of steel construction materials in Poland. The Company s offer includes complete solutions as well as steel roofing and facade systems for housebuilding industry, commercial and agricultural construction. The range of products is recognised by customers in Poland, Belarus, Russia, Lithuania, Latvia, Estonia, Ukraine, Czech Republic, Slovakia, Germany, Denmark, Sweden and Norway. Consulting and sales services are provided through own network of regional branches, cooperating distributors and a team of professional sales advisors. Its leading position in the market of manufacturing double-clad insulating core sandwich panels, the Balex Metal Company owes to its technologically advanced production lines purchased from the most renowned European companies, the team of employees with excellent qualifications as well as its special attention to quality. 2. PWS AND PWD SANDWICH PANEL CONSTRUCTION Balex Metal company provides a wide range of modern wall and roof sandwich panels with the expanded polystyrene core with the PWS and PWD trademark. The PWS and PWD sandwich panels consist of two stainless steel facings and a construction insulation core. The core, made of self-extinguishing expanded polystyrene class EPS CS (10) 80, is responsible for transferring shear stresses, maintaining fixed distance between facings and ensuring high thermal performance. The joining of the panel facings to the core with the use of single component glue characterises in high cohesion on the entire surface and long term parameter replicability. Milling of each expanded polystyrene core joint inside the sandwich panel results in their coupling and full thermal insulation, the core is solid and no delamination occurs. The facings of the panels are made of steel sheet S220GD, S250GD, S280GD of 0.50 to 0.60mm thickness, covered with organic and metallic coatings. A panel with single side facing made of coated sheet, used mainly for thermal insulation. The main function of the facing is transmission of the regular stress as well as protecting the facility from weather conditions. The construction of the panel makes it very light yet of high load-bearing capacity and stiffness allowing for larger support span (purlins, transoms). The range of PWS and PWD sandwich panel production comprises 6 thicknesses, 3 profiles and 25 colours, which allows for customisation of the elevation with balanced aesthetic and functionality values. 3. TECHNOLOGY OF PRODUCTION The production process is continuous and performed on a fully automated assembly line The core is made of selfextinguishing expanded polystyrene class EPS CS (10) 80. The technological production process of sandwich panels with an expanded polystyrene core is based on fully automated feeding of the expanded polystyrene blocks, between two continuously moving steel tapes (with previously profiled edges and main outline). The high quality and replicability of PWS and PWD sandwich panel technical parameters were achieved through the use of the finest materials and constant control of all production stages. 4. TYPES OF PANELS We offer two types of sandwich panels with polystyrene core: PWS wall panel of 1155 mm modular width (so called covering) allows for a quick installation of the construction with the use of eyelet fasteners. It may be double sided (coated sheet on both sides) and single sided (coated sheet on one side/unbleached paper with aluminium foil, coated with polyethylene of approx. 160g/m 2 total basis weight, on the other. PWD roof panel (may also be used as a wall panel) 1100 mm modular width, trapezoidal surface shape, guarantees high load-bearing capacity for the transfer of service loads, as well as during installation. It is available as double sided (coated steel on both sides) and single sided (coated sheet on one side/unbleached paper with aluminium foil, coated with polyethylene of approx. 160g/m 2 total basis weight, on the other). Due to trapezoidal surface shape the panel is capable of auto compensation of the thermal expansion.this shape allows for the use of panel in dark colours which characterize in high degree of sunlight energy absorption eliminating the risk of local bulging of the coating. 6

9 Table1. Types of sandwich panels Panel type Panel thickness [mm] Panel shape PWS wall panel Modular width 1155 PWD roof panel 75 / 91, / 116, / 141, / 166, / 191, / 216,50 Modular width 1100 Half-panel PWS wall panel Modular width 1155 Laminated paper Half-panel PWD roof panel 75 / 91, / 116, / 141, / 166, / 191, / 216,50 Laminated paper Modular width 1100 Microventilation ducts 5. SCOPE OF APPLICATION OF THE PANELS Sandwich panels are commonly used as building material for light enclosure of industrial, warehouse, sports and production halls, pavilions and commercial buildings, offices, social facilities, hangars, garages, workshops, administrative buildings, public use facilities, storage rooms, carrying freezers, cold stores (including food industry facilities). The wide range of colours and panel profiles allows for realisation of numerous facilities. The construction of the panels enables quick and simple installation in vertical or horizontal configuration regardless of weather conditions. Double-sided sandwich panels are to be used as wall, roof, ceiling elements. The single-sided are to be used only to make thermal insulation facings. The application of the panels should be in agreement with the technical design in regard to Polish standards, construction codes. When using sandwich panels it is required to take into account decisions enclosed in the Ordinance of the Ministry of Spatial Economy and Construction in the matter of technical conditions to which buildings and their location should comply with (J. of L. No. 1/99, item. 140) taking into consideration fire classification for sandwich panels specified in this catalogue ( chapter Fire safety ). Wind load and support spacing in the wall elements and roof coverings should not exceed the values specified in this catalogue. In respect to the acoustic values sandwich panels may be used in industrial, commercial facilities or of a similar profile in cases where the indicated individual acoustic requirements are not higher than those specified in this catalogue ( Noise reduction performance ). The panels may also be used for objects with no acoustic requirements. Use of the panels with structures increasing their acoustic insulation and/or limiting lateral sound transmission should be examined individually. Due to the heat and humidity characteristics the panels may be used in the scope compliant with the mentioned above ordinance in the matter of technical conditions. 7

10 6. TYPES OF SANDWICH PANEL JOINTS The unique shape of the longitudinal joints with their optimal proportion between thickness of the feather and the depth of the groove in both of the facings on the inner as well as the outer side, substantially increased the fire resistance parameters of the PWS wall panels. In order to facilitate lengthwise joining of the panels and the gutter installation ( BALEX option) a factory undercut of the lower facing and the core has been introduced in the PWD roof panel as a standard. The distinctive element is also the specially milled joint improving thermal performance in the joint point and also facilitating the installation of the panels and their mutual pressure. Laboratory tests showed that in case of PWD panel the required pressure power is 4 times lower. For example to properly tighten the lock of the PWD 150 in a classical flat lock, the required pressure power is approx. 5 kn (~500 kg). In case of the same panel and the milled lock it is approx. 1,2 kn (~120 kg). In practice, it means that the panels lock under their own weight. The way of panel installation recommended by Balex Metal is presented in chapter 21. PWS : PWD : 8

11 7. PWS SANDWICH PANEL - WALL TYPE PWD SANDWICH PANEL ROOF TYPE ) joint fasteners 2) double-sided shape of the panel joint in the form of a double lock, increasing the joint tightness 3) self adhesive polyurethane tape (PUS) guarantying thermal insulation and joint tightness applied on the construction site 4) self -extinguishing expanded polystyrene core class EPS CS (10) 80 5) profiled external facing, provide pleasing aesthetic values ) joint fasteners 2) self - drilling fastener or pop rivet 3) self adhesive polyurethane tape (PUS) guarantying thermal insulation and joint tightness applied at the construction site 4) self-extinguishing expanded polystyrene core class EPS CS (10) 80 5) unique custom milled joint, enabling easier installation and mutual pressing of the panels as well as improving thermal insulation (patent application no. W ) 6) trapezoidal profile of the facing improving the load-bearing capacity of the roof panel 7) chamber - water draining capillary groove 9

12 9. BASIC TECHNICAL SPECIFICATION Table 2. Technical specification coated metal sheet + coated Facing thickness [mm] coated metal sheet + laminate Panel metal sheet 3) Panel type standard custom made thickness Panel length L [m] Panel Panel length L [m] Panel [mm] mass mass ext. int. ext. int. min max [kg/m 2 ] min max [kg/m 2 ] PWS PWD ,00 10,00 6,00 5, ,39 6,35 8, ,00 10,80 6,76 0,50 0,50 0,50-0,60 2,00 2, ,20 7,16 9, ,61 7,57 17, ,01 10,00 7, ,50 10,34 6,00 6, ,74 6,49 8, ,15 6,90 0,50 0,50 0,50-0,60 2,00 17,00 4) 2, ,55 7,30 9, ,96 7, ,36 10,00 8,11 1) minimum length of the panel with an undercut amounts to 4 m 2) mass indicator for PWS and PWD panels with a 0,50 mm thick sheet facing. In case of application of 0,60mm thick sheet facing it is required to increase the mass of one running metre of: - double-sided panel : PWS 1,57 kg, PWD 1,40 kg - single-sided panel: PWS 0,78 kg, PWD 0,70 kg 3) unbleached laminated paper with aluminium foil and polyethylene (approx. 160 g/m 2 ) 4) after consultations there is a possibility of manufacturing longer panels up to 18 m 10

13 10. MATERIALS AND FACING COATINGS Material STEEL S220GD,S250GD,S280GD (acc. to PN-EN 10326:2009) increased parameter steel, galvanized on both sides permanently protected with anticorrosion coatings sheet thickness: 0,50; 0,60 mm coated with organic and metallic coatings PWS and PWD sandwich panels are coated by foil from external side; in PWS there is a possibility of coating by foil from both sides on customers demand LAMINATE occurs only on the inner side of the sandwich panel unbleached laminated paper with aluminium foil and polyethylene (approx. 160 g/m 2 ) Coatings PREMIUM offer CESAR PUR 55 - unequalled durability and vitality polyurethane coating with polyamid of overall thickness 55 μm extraordinary resistance for corrosion RC5 unequalled durability up to 30 yaers depending on the environment very good resistance to intensiveuv radiation RUV4 solution for standard, demanding and agressive environments high scratch resistance aesthetic and colour durability for the whole life cycle NEW on the polish market ROOF OF THE 2012 used for roof coverings, wall claddings, standard environments, as well as those agressive and demanding: cold, humid, of high UV radiation, industrial and polluted colors: 3009, 8004, 8017, 9006, 9007, 7016, 9005, 9010 Standard offer POLYESTER thickness of the coating 25 μm for external use resistant to temperature changesand the weather conditions, good corrosion resistance colour scheme according to the Balex Metal World of Colours palette. POLYESTER MATT PEARL thickness of the coating 35 μm for external use resistant to temperature changesand the weather conditions, good corrosion resistance, ideal for industrial and commercial facility roof tops colour scheme according to the Balex Metal World of Colours palette. Offer on special demand PVDF thickness of the coating 25 μm good corrosion and mechanical damage resistance, long lasting and fade resistant colours (in temperature up to 110ºC), easy to form, with fairly hard surface, which greatly prevents the accumulation of dirt and loss of gloss recommended for external use (external facing of the building) colour scheme according to the Balex Metal World of Colours palette. 11

14 PCV(F) food safe thickness of the coating 120 μm white colour foil, special increased hardness coating for use in food industry facilities and cool stores, washable and resistant to most cleaning detergents ALUZINC + Easyfilm metallic coating : 150 and 185 g/m 2 basis weight for each side of the sheet thickness of the coating - 20 μm (for 150 g/m 2 ), 25 μm (for 185 g/m 2 ) double-sided thermally applied coating in a continuous process, additionally protected with a thin organic coating SPT (Special Protection Treatment), Easyfilm (environmentally friendly, thin organic layer which protects aluzinc coating against discoloration resistance to higher temperatures, high corrosive resistance, excellent heat and light reflection, good abrasive resistance. 11. FACING PROFILE SCHEME R = GROOVED T = TRAPEZOIDAL G = FLAT 12

15 12. COMBINATIONS OF PROFILE TYPES The table below presents possible types of external and internal facing profiles combination for particular types of panels. Table 3. Combinations of profile types Panel type R T G Internal facing LAMINATED PAPER R External facing T PWS PWD 13. EXAMPLE OF PWS AND PWD PANEL MARKING PWS sandwich panel: BALEX PWS zew. 0,50 SP 25 μm R / wew. 0,50 SP 25 μm G PWS Name of the panel Thickness Modular width zew. External facing 0,50 SP 25 μm R / wew. 0,50 SP 25 μm G Metal sheet thickness Type of coating Colour Type of profiles Internal facing Metal sheet thickness Type of coating Colour Type of profiles PWD sandwich panel: BALEX PWD 100/ P/150 zew. 0,50 SP 25 μm T / wew. 0,50 SP 25 μm T PWD 100/ Name of the Thickness Modular panel width - P/150 Overlap length zew. External facing 0,50 SP 25 μm T / wew. 0,50 SP 25 μm T Metal sheet thickness Type of coating Colour Type of profiles Internal facing Metal sheet thickness Type of coating Colour Type of profiles 13

16 14. FACING COLOUR SCHEME Colour scheme according to the Balex Metal World of Colours palette PREMIUM coating CESAR PUR 55 - polyurethane with polyamid: 3009, 8004, 8017, 9006, 9007, 7016, 9005, 9010 Organic coatings 25 μm polyester: 3016, 3011, 8012, μm MAT Pearl polyester: 8637M, 8620M, 3301M, 7591M, 6490M, 9005M PVC(F) food safe: PVDF: 9010 applied with the BALEXTHERM-MW-W-ST panels colouring to be agreed Metallic coatings ALUZINC + Easyfilm : Galvanization AZ 185 (25 μm) Table 4. Classification of colours by relative brightness Symbol Name Group 9010 white 9002 grey-white 7035 light-grey very bright 1015 ivory 6011 reseda-green 9006 silver-metallic 9007 grey-aluminium 5012 light-blue bright 1003 signal-yellow 1017 sapphire-yellow 9005 black 5010 signal-blue 6005 dark-green 6020 fir-green 7024 graphite-grey 7016 graphite 8017 chocolate-brown dark 8012 red-brown 3009 cherry 8004 brick-red (including Rustika) 3016 coral-red 3011 red 14

17 15. STRENGTH ISSUES Table 5. Maximum load of very-bright- and bright-coloured single-span PWS wall panels with 0.50-mm-thick facing load towards the support core thickness Maximum load, kn/m 2, at the span of [m] load due to 2,10 2,40 2,70 3,00 3,30 3,60 3,90 4,20 4,50 4,80 5,10 5,40 5,70 6,00 bearing capacity 3,19 2,44 1,93 1,56 1,29 1,09 0,92 0,8 0,69 0, rigidity 1,66 1,34 1,1 0,91 0,75 0,63 0,53 0,44 0,37 0, bearing capacity - 3,00 2,37 1,92 1,58 1,33 1,13 0,98 0,85 0,75 0,66 0,59 0,53 0,48 rigidity - 1,60 1,34 1,14 0,98 0,84 0,73 0,63 0,55 0,48 0,42 0,37 0,32 0,28 bearing capacity - 3,76 2,97 2,41 1,99 1,67 1,42 1,23 1,07 0,94 0,83 0,74 0,67 0,60 rigidity - 2,12 1,81 1,55 1,34 1,17 1,02 0,90 0,79 0,70 0,62 0,55 0,49 0,44 bearing capacity - - 3,58 2,9 2,39 2,01 1,71 1,48 1,29 1,13 1,00 0,89 0,80 0,72 rigidity - - 2,27 1,97 1,72 1,51 1,33 1,18 1,05 0,93 0,83 0,75 0,67 0,61 bearing capacity ,39 2,80 2,35 2,00 1,73 1,50 1,32 1,17 1,04 0,94 0,85 rigidity ,39 2,09 1,85 1,64 1,46 1,31 1,17 1,06 0,95 0,86 0,78 bearing capacity ,87 3,20 2,69 2,29 1,98 1,72 1,51 1,34 1,20 1,07 0,97 rigidity ,81 2,48 2,20 1,96 1,75 1,58 1,42 1,29 1,17 1,06 0,97 Table 6. Maximum load of very-bright- and bright-coloured multi-span PWS wall panels with 0.50-mm-thick facing load towards the support core thickness Maximum load, kn/m 2, at the span of [m] load due to 2,10 2,40 2,70 3,00 3,30 3,60 3,90 4,20 4,50 4,80 5,10 5,40 5,70 6,00 bearing capacity 2,89 2,49 2,18 1,75 1, rigidity 1,83 1,54 1,32 1,14 0, bearing capacity - 3,49 3,06 2,72 2,21 1,62 1, rigidity - 1,71 1,47 1,28 1,13 1,01 0, bearing capacity - 4,45 3,90 3,47 3,12 2,42 1,82 1,40 1, rigidity - 2,22 1,92 1,69 1,49 1,33 1,20 1,08 0, bearing capacity - - 4,75 4,22 3,80 3,39 2,53 1,94 1,51 1, rigidity - - 2,38 2,09 1,86 1,66 1,50 1,36 1,24 1, bearing capacity ,99 4,49 4,07 3,35 2,56 1,99 1,58 1, rigidity ,51 2,23 2,00 1,81 1,64 1,50 1,38 1, bearing capacity ,76 5,18 4,70 4,30 3,27 2,54 2,01 1,62 1, rigidity ,92 2,60 2,34 2,12 1,93 1,76 1,62 1,49 1, Table 7. Maximum load of very-bright- and bright-coloured single-span PWS wall panels with 0,50-mm-thick facing load from the support core thickness Maximum load, kn/m 2, at the span of [m] load due to 2,10 2,40 2,70 3,00 3,30 3,60 3,90 4,20 4,50 4,80 5,10 5,40 5,70 6,00 bearing capacity 3,19 2,44 1,93 1,56 1,29 1,09 0,92 0,80 0,69 0, rigidity (3) 1,37 1,16 0,99 0,86 0,74 0,63 0,53 0,44 0,37 0, rigidity (2) 0,93 0,80 0,69 0,60 0,53 0,47 0,41 0,36 0,32 0, bearing capacity - 3,00 2,37 1,92 1,58 1,33 1,13 0,98 0,85 0,75 0,66 0,59 0,53 0,48 rigidity (3) - 1,33 1,16 1,02 0,91 0,80 0,72 0,63 0,55 0,48 0,42 0,37 0,32 0,28 rigidity (2) - 0,90 0,80 0,71 0,64 0,57 0,52 0,47 0,42 0,38 0,35 0,32 0,29 0,26 bearing capacity - 3,76 2,97 2,41 1,99 1,67 1,42 1,23 1,07 0,94 0,83 0,74 0,67 0,60 rigidity (3) - 1,66 1,46 1,30 1,16 1,04 0,94 0,85 0,77 0,70 0,62 0,55 0,49 0,44 rigidity (2) - 1,10 0,99 0,88 0,80 0,72 0,66 0,60 0,55 0,50 0,46 0,42 0,39 0,36 bearing capacity - - 2,58 2,90 2,39 2,01 1,71 1,48 1,29 1,16 1,00 0,89 0,80 0,72 rigidity (3) - - 2,07 1,81 1,60 1,42 1,26 1,13 1,02 0,91 0,82 0,74 0,67 0,61 rigidity (2) - - 1,50 1,36 1,23 1,12 1,03 0,94 0,87 0,80 0,74 0,68 0,63 0,59 bearing capacity ,39 2,80 2,35 2,00 1,73 1,50 1,32 1,17 1,04 0,94 0,85 rigidity (3) ,17 1,92 1,71 1,53 1,38 1,25 1,12 1,02 0,93 0,85 0,77 rigidity (2) ,56 1,41 1,30 1,19 1,10 1,02 0,94 0,88 0,81 0,75 0,70 bearing capacity ,87 3,20 2,69 2,29 1,98 1,72 1,51 1,34 1,20 1,07 0,97 rigidity (3) ,52 2,24 2,01 1,81 1,63 1,48 1,34 1,23 1,12 1,02 0,94 rigidity (2) ,74 1,60 1,47 1,35 1,25 1,16 1,08 1,01 0,94 0,94 0,82 rigidity (3) load permissible due to not exceeding the deflection of a panel fastened with 3 fasteners at the width rigidity (2) - load permissible due to not exceeding the deflection of a panel fastened with 2 fasteners at the width Load per one fastener should not exceed 0,82 kn. 15

18 Table 8. Maximum load of very-bright- and bright-coloured multi-span PWS wall panels with 0,50-mm-thick facing load from the support core thickness Maximum load, kn/m 2, at the span of [m] load due to 2,10 2,40 2,70 3,00 3,30 3,60 3,90 4,20 4,50 4,80 5,10 5,40 5,70 6,00 bearing capacity 2,89 2,49 2,18 1,75 1, rigidity (3) 1,48 1,25 1,08 0,93 0, rigidity (2) 1,11 0,93 0,80 0,69 0, bearing capacity - 3,49 3,06 2,72 2,21 1,62 1, rigidity (3) - 1,39 1,20 1,04 0,92 0,83 0, rigidity (2) - 1,03 0,89 0,77 0,68 0,61 0, bearing capacity - 4,45 3,90 3,47 3,12 2,42 1,82 1,40 1, rigidity (3) - 1,80 1,56 1,37 1,21 1,08 0,98 0,88 0, rigidity (2) - 1,35 1,16 1,02 0,90 0,80 0,72 0,65 0, bearing capacity - - 4,75 4,22 3,80 3,39 2,53 1,94 1,51 1, rigidity (3) - - 1,89 1,69 1,52 1,37 1,25 1,15 1,06 0, rigidity (2) - - 1,44 1,28 1,15 1,04 0,95 0,87 0,80 0, bearing capacity ,99 4,49 4,07 3,35 2,56 1,99 1,58 1, rigidity (3) ,99 1,79 1,62 1,48 1,36 1,25 1,16 1, rigidity (2) ,52 1,36 1,23 1,13 1,03 0,95 0,88 0, bearing capacity ,76 5,18 4,70 4,30 3,27 2,54 2,01 1,62 1, rigidity (3) ,27 2,05 1,87 1,71 1,57 1,45 1,34 1,25 1, rigidity (2) ,74 1,57 1,42 1,30 1,19 1,10 1,02 0,94 0, rigidity (3) - load permissible due to not exceeding the deflection of a panel mounted with 3 joints at the width rigidity (2) - load permissible due to not exceeding the deflection of a panel mounted with 2 joints at the width Load per one joint should not exceed 0,82 kn. Table 9. Maximum load of very-bright- and bright-coloured single-span PWD roof panels with 0.50-mm-thick facing core Maximum load, kn/m 2, at the span of [m] load due to thickness 2,10 2,40 2,70 3,00 3,30 3,60 3,90 4,20 4,50 4,80 5,10 5,40 5,70 6,00 75 bearing capacity 2,01 1,76 1,56 1,41 1,28 1,17 1,08 1,01 0,94 0, rigidity 1,91 1,52 1,23 1,00 0,82 0,68 0,57 0,47 0,39 0, bearing capacity - 2,46 2,18 1,97 1,79 1,64 1,51 1,40 1,31 1,23 1,15 1,03 0,92 0,83 rigidity - 1,82 1,52 1,28 1,09 0,93 0,80 0,69 0,60 0,52 0,45 0,40 0,35 0, bearing capacity - 3,16 2,81 2,52 2,30 2,10 1,94 1,80 1,68 1,58 1,49 1,40 1,26 1,13 rigidity - 2,41 2,04 1,74 1,50 1,30 1,14 1,00 0,88 0,77 0,68 0,61 0,54 0, bearing capacity - - 3,43 3,08 2,80 2,57 2,37 2,20 2,06 1,93 1,81 1,71 1,60 1,44 rigidity - - 2,56 2,21 1,92 1,68 1,48 1,31 1,16 1,04 0,93 0,83 0,75 0, bearing capacity ,64 3,31 3,03 2,80 2,60 2,43 2,28 2,14 2,02 1,92 1,75 rigidity ,68 2,34 2,07 1,83 1,63 1,46 1,31 1,18 1,06 0,96 0, bearing capacity ,20 3,82 3,50 3,23 3,00 2,80 2,63 2,47 2,33 2,21 2,07 rigidity ,15 2,77 2,45 2,19 1,96 1,76 1,59 1,44 1,30 1,18 0,98 With load working from the support, load per one fastener should not exceed 0,75 kn. Table 10. Maximum load of very-bright- and bright-coloured multi-span PWD roof panels with 0.50-mm-thick facing core Maximum load, kn/m 2, at the span of [m] load due to thickness 2,10 2,40 2,70 3,00 3,30 3,60 3,90 4,20 4,50 4,80 5,10 5,40 5,70 6,00 75 bearing capacity 1,85 1,60 1,40 1,25 1,12 1,02 0,93 0,77 0,65 0,55 0,47 0, rigidity 2,26 1,90 1,63 1,41 1,23 1,08 0,96 0,85 0,76 0,68 0,62 0, bearing capacity - 2,29 2,01 1,79 1,61 1,46 1,34 1,23 1,14 0,91 0,77 0,66 0,57 0,50 rigidity - 2,04 1,76 1,54 1,36 1,22 1,09 0,98 0,89 0,81 0,74 0,68 0,62 0, bearing capacity - 2,97 2,61 2,32 2,09 1,90 1,74 1,60 1,48 1,34 1,13 0,96 0,83 0,73 rigidity - 2,57 2,23 1,96 1,74 1,56 1,40 1,27 1,16 1,06 0,97 0,89 0,82 0, bearing capacity - - 3,21 2,86 2,58 2,34 2,14 1,97 1,83 1,70 1,54 1,30 1,12 0,97 rigidity - - 2,70 2,38 2,12 1,90 1,72 1,56 1,42 1,31 1,20 1,11 1,03 0, bearing capacity ,40 3,06 2,78 2,55 2,35 2,17 2,02 1,89 1,68 1,44 1,25 rigidity ,81 2,50 2,25 2,04 1,85 1,70 1,56 1,44 1,33 1,23 1, bearing capacity ,95 3,56 3,23 2,93 2,72 2,52 2,35 2,20 2,06 1,79 1,55 rigidity ,23 2,89 2,60 2,36 2,15 1,97 1,81 1,67 1,55 1,44 1,34 With load working from the support, load per one fastener should not exceed 0,75 kn. 16

19 Table 11. Permissible span of single-span and multi-span PWD sandwich roof panels under tropical coat. Notes on using tables: core thickness Maximum span [m] [mm] 0 o C -5 o C -25 o C 100 6,30 5, ,30 5,70 3, ,30 6,30 3, , ,50 - permissible load for one fastener should not exceed 1 kn - given permissible load and maximum span spacing apply to sandwich panels with light colour facings - the minimum in-between support width is 60mm and end supports width is 40mm - values given in tables do not apply to half panels with outer side steel coating and laminate on the inner side 16. THERMAL INSULATION Table 12. The value of the heat transfer coefficient Uc determined with design value of the polyester heat transfer coefficient 10ºC, λ obl = 0,039 W/mK. Item Type of panel Core thickness [mm] U C [W/m 2 K] , , ,30 PWS wall panels , , , , , ,32 PWD roof panels , , ,20 17

20 Table 13. PWS panel insulating power for cooling facilities Heat flux density [W/m 2 ] Panel type Temperature difference Δt PWS 75 PWS 100 PWS 125 PWS 150 PWS 175 PWS 200 Item Heat transfer coefficient [W/m 2 K] [K] 0,47 0,36 0,29 0,25 0,21 0, ,70 3,60 2,90 2,50 2,10 1, ,05 5,40 4,35 3,75 3,15 2, ,40 7,20 5,80 5,00 4,20 2, ,75 9,00 7,25 6,25 5,25 4, ,10 10,80 8,70 7,50 6,30 5, ,45 12,60 10,15 8,75 7,35 6, ,80 14,40 11,60 10,00 8,40 7, ,15 16,20 13,05 11,25 9,45 8, ,50 18,00 14,50 12,50 10,50 8, ,85 19,80 15,95 13,75 11,55 9, ,20 21,60 17,40 15,00 12,60 10, ,55 23,40 18,85 16,25 13,65 11, ,90 25,20 20,30 17,50 14,70 12, ,25 27,00 21,75 18,75 15,75 13, ,60 28,80 23,20 20,00 16,80 14, ,95 30,80 24,65 21,25 17,85 15, ,30 32,40 26,10 22,50 18,90 16, ,65 34,20 27,55 23,75 19,95 17, ,00 36,00 29,00 25,00 21,00 17,90 The recommended scope of application is marked with colour ATTENTION! a) Carrying freezer minimum temperature, for which the use of PWS expanded polystyrene panels is efficient, is -20 o C b) In the summer season the appropriately assumed outside temperature is 35 o C c) In the winter season the appropriately assumed outside temperature is -20 o C Example1: In order to check, which panels are suitable for carrying freezer with the inside temperature of -20 o C Δt = = 55 Check in line 10, with Δt = 55, which of the panels is 10 W/m 2 flux density. The only possible choice: PWS 200 is in column 7. Example 2: In order to check, which panels are suitable for a division wall between two rooms, with -20 o C inside temperature in one and 0 o C in the other Δt = = 20 Check in line 3, with Δt = 20, which of the panels is 10 W/m 2 flux density. The result is that even PWS 75 panel found in column 2 fulfills the minimum insulation requirements. Units: 1 o C = 1K Conversion from o C do K: K = 273,15 o C 18

21 17. FIRE SAFETY Walls made of PWS panels have received fire classification presented in the table below and have E60 fire integrity, provided that supporting structure of the fire resistance of at least E60 is used and the maximum spacing between the bearing elements in the case of walls is 3 m. In order to retain this fire integrity parameter, no heavy elements, such as installations, ventilation pipes, etc., can be suspended on the wall made of sandwich panels. In the case of roofing, the fire tightness is E30, provided that the supporting structure is applied. Table 14. Fire resistance of walls made of PWS panels. Wall made of panels Panel thickness [mm] Degree of fire spread wg PN-90/B Fire resistance of non-bearing walls, in accordance with PN-EN A1:2009 Fire resistance of non-bearing walls, in accordance with PN-EN : BALEX PWS BALEX single-sided panels 75 to (NRO) NFS Non Fire to 200 Spreading E 60 E60 / EW 60 (NRO) NFS Non Fire Spreading 1) - - 1) Provided that the panels are mounted to the non-flammable surface, at least A2-s3,d0 class of reaction to fire In the case of roof coverings, the fire tightness is E30, provided that the supporting structure is applied. Table 15. Fire resistance of roof coverings made of PWD panels. Roof covering made of panels Panel thickness, mm Degree of fire spread ITB 401/2004 Resistance of roofing to outer fire according to EN Fire resistance of loaded roof coverings according to PN-EN A1: , BALEX PWD (NRO) NFS Non Fire 125 do 200 Spreading B ROOF (t 1 ) RE 30 1) BALEX single-sided panels 75 do 200-1) RE30 classification means, that the criterion of load-bearing capacity and fire tightness of roof made of PWD sandwich panels (of thickness 125,150,175, 200 mm) is fulfilled in the time of minimum 30 minutes. Fire resistance classification means that the fire integrity criterion for walls and roofs made of PWS and PWD panels is met in at least the number of minutes specified after E. NRO means that the panel has been classified as an element that does not spread fire. Classification RE30 means, that the fire integrity and bearing criterion for roofs made of PWD panels (in scope of panels of thickness 125, 150, 175, 200 mm) is met in at least 30 minutes 18. CORROSION RESISTANCE The research conducted in the Warsaw Building Research Institute in the Department Of Durability And Protection Of Buildings showed that BALEX METAL PWS and PWD sandwich panels with expanded polystyrene core meet the EN ISO requirements in classes C1 to C3. PWS and PWD panels with facings covered with organic coatings SP 25 or SP 35 or PVDF 25 on the face side of the panel may be exploited in C1, C2, C3 corrosion class environment acc. to EN ISO standard. PWS and PWD panels with facings protected with AZ185 aluminium and zinc coating may be exploited in C1, C2, C3 corrosion class environment acc. to EN ISO standard. PWS and PWD panels with facings protected with AZ150 aluminium and zinc coating may be exploited in C1, C2 corrosion class environment acc. to EN ISO standard. 19

22 Corrosion classes and example of typical environments acc. to EN ISO C1 corrosion class indoors heated buildings with a clean atmosphere e.g. offices, shops, schools and hotels C2 corrosion class outdoors slightly polluted atmosphere, mainly countryside indoors not heated buildings with a possibility of condensation e.g. warehouses, sports halls C3 corrosion class outdoors urban and industrial atmospheres, medium pollution with sulphur oxide (IV), coastal area with low salinity indoors production rooms with high humidity and certain level of air pollution e.g. food industrial facilities, laundries, breweries, dairies. C4 corrosion class external - industrial areas and coastal areas of moderate salinity internal - chemical facilities, swimming pools, shipyards C5 corrosion class outdoors - industrial areas with high humidity and aggressive atmosphere indoors -buildings or areas with almost permanent condensation and with high pollution In sandwich panels PW/PWD can be used facings of C4 and C5 category of corrosiveness declared by steel manufacturer. 19. NOISE REDUCTION PERFORMANCE PWS and PWD sandwich panels are characterized by the following noise reduction parameters in the 75 mm to 200 mm core thickness scope. Table 16. Noise reduction index Types of panels Core thickness [mm] R W [db] R A1 [db] R A2 [db] Balex PWS 75 to 200 >26 >24 >22 Balex PWD 75 to 200 >23 >22 >20 NOTE: In the design process the given values should be decreased by 2 db in accordance with PN-B :1999 standard requirements R W - weighted noise reduction index R A1 - noise reduction assessment index R A2 - noise reduction assessment index Values of the indexes in table were calculated acc. to EN-ISO 717-1:1999 based on research acc. to EN :1999. The above indexes mean that soundwise PWS and PWD sandwich panels may be used in following types of facilities: - enclosures of walls and roofs of industrial and sports halls, production and storage facilities, for constructing commercial, service and gastronomic pavilions, construction site back-up facilities, administration and social buildings if they meet individually settled acoustic requirements. - for construction of buildings that do not have to meet any acoustic requirements 20

23 20. FASTENERS PWS and PWD sandwich panels are fastened to a steel construction with the use of self-drilling fasteners. Due to that it is possible to avoid initial drilling of holes in the panel and the construction. Moreover self-drilling fasteners increase the quality of the fastening and limit the number of used tools. In the case of self-drilling fasteners a new drilling bit is used as the fastener is to be used once only which influences the fastening durability. Fasteners are made of hardened carbon steel with anti-corrosion protective coating. All fasteners are equipped with cured EPDM gaskets. The application of EPDM increases the rigidity and tightness of the connection. ZD6 a fastener of drilling ability up to 6 mm, intended for cold-rolled steel bases ZD12 a fastener of drilling ability up to 12 mm, intended for hot-rolled steel bases ZD16 - a fastener of drilling ability up to 16 mm, intended for hot-rolled steel bases A fastener for wood and concrete intended for direct assembly in a wooden or concrete base. Before assembly, it is recommended to pre-drill the sandwich panel facing with a 5 mm drill. In the case of concrete base, it is necessary to pre-drill a hole of 5 mm diameter with a concrete drill. Self-drilling fastener intended for steel bases of thickness over 12 mm. Before the assembly it is necessary to pre-drill the sandwich panel and in the steel structure with a 5.8 mm drill. 21. FASTENING ROOF PANELS LENGTHWISE Recommended roof inclination for PWD roof panels is: >7 % - for panels fastened lengthwise or with roof skylights >5 % - for continuous panels and without roof skylights PWD panels have endings formed at the production stage that facilitate gutter assembly next to the eaves (BALEX option) or lengthwise panel fastening. A - standard 50 mm next to the eaves (BALEX variant) - standard 150 mm next to the overlap - max. 200 mm next to the overlap A L = Panel length A L = Panel length Undercut thickness A[mm] Minimum panel length L min [mm] Undercut of lower cladding of PWD panel made during a production process, the cut core is not removed during the production process. The useless part should be removed on the construction place during the appliance. 21

24 PWD panel is produced exclusively as Left: 22. GENERAL ASSEMBLY GUIDELINES Before starting assembly it is recommended to verify the carrying construction in terms of precision of performance and its accordance with the design. PWS and PWD panels are secured against dirt and damage with a protective foil applied to facings in the production process. It is recommended to remove the protective foil from facings which are to form the internal side of the building, before fastening them to the construction. In the case of external facings the protective foil should be removed within 1 month from the date of production. It will prevent both the foil from binding permanently with protective varnish of facings and varnish from getting dirty while removing the foil. Fig 1. For sandwich panel fastening it is recommended to use appropriate fasteners depending on type of carrying construction and panel core thickness. Types of fastening elements are specified in chapter FASTENERS. To fasten sandwich panels to a steel construction with thickness not exceeding 12 mm it is recommended to use self drilling fasteners made of hardened galvanized carbon steel. All fasteners are equipped with cured EPDM gaskets, which allows for long-term use with retention of the elasticity of the sealing element. In the case of steel base (> 12 mm thickness) or wood base special self drilling fasteners, with properly shaped working thread profile, are recommended. For screwing in fasteners use specialised power tools. Drivers should be equipped with a proper long join driving head and a penetration depth limiter, fig. 2. This guarantees appropriate assembly i.e. maintaining perpendicular location of a particular fastener in relation to a panel, minimised risk of damaging panels surface and tightness of the fastening fig. 3. It is possible to use universal drivers with standard short heads. However, tools of this type should be equipped with a penetration depth limiter. Optimal parameters of power tools for sandwich panel assembly are provided in the list below: - power W - rotation rpm. - torque Ncm Fig 2. A power screwdriver with a limiter of the fastener driving depth 22

25 - too loose (undertightened) - correct - too tight (overtightened) Fig 3. Proper tightening of fasteners After cutting and drilling it is necessary to remove all the metal chips and fillings which can cause discoloration of the facing surface. The tightness of the enclosure is obtained through the use of appropriate tapes and sealing foams. All facing sheet varnish damages that occurred during installation should be protected with touch-up paint. PWD panel assembly example: PWD panel PUS sealing tape Pop rivet Ground beam 120x120 Support Fastener PWD PWS panel assembly example: PUS sealing tape PWS panel Support Fastener PWS 23

26 PWS panel assembly example: Tightening belt Wall transom Hall frame pillar Board Board Reference assembly drawing Press the panel to the required crevice in the joining FORCE DIRECTION Board Hall frame pillar Wall transom FORCE DIRECTION Board FORCE DIRECTION Board Reference assembly drawing 24

27 23. TRANSPORT GUIDELINES Recommended means of transport and its technical conditions: Lorries with an open load-carrying body or an open trailer enabling loading long panels (up to 13,60 metres) from both sides of a car constitute the basic means of transport for sandwich panels. The following technical conditions are recommended for vehicles transporting sandwich panels: load-carrying body with canvas cover ( CURTAIN type) load-carrying body longer than transported panels (a package of panels should be placed on the platform in its entire length). transport belts holding the load should be placed on a package of panels on each support (belt tension should not cause panels to deform) Table 17. Way of sandwich panel packaging Panel thickness [mm] Number of sandwich panels in a package PWS/PWD - double-sided metal sheets PWS - with laminate [pcs] PWD with laminate [pcs] double-sided PWS wall panels with the length of 12 m is set as the example load ( m 2 ). The number of packages for the whole load is: the number of panels/the number of panels of particular thickness in a package = 36/10 = 3 packages x 10 pcs and 1 package 6 pcs Total load weight is: total panel surface x weight of 1m 2 = x kg Transport requirements regarding load: Load carrying body length min. 12.5m Load capacity min. 6,50 t A truck-tractor with a covered trailer min 2,45 2,60 m wide is an optimal means of transport for the load specified above. The load is placed in two piles, two panel packages each. Unloading, transport: During loading and unloading extreme caution should be kept, one should avoid point supports as it may lead to damaging the facing of the lowest panel. In order to avoid this problem you should distribute the load over a greater surface area. You should also pay attention not to drag one panel along another one not to scratch it. 25

28 Panel storage: Sandwich panels should be stored on ground beams, not less than 250mm over the ground. It is allowed to store two packages placed one on another at the most. It is recommended to store panels in airy rooms, at normal temperature, far away from acids, lye, salts and other corrosive substances. Storing uncovered panels is unacceptable. In case of storing panels under canvas cover for a short period of time (a fortnight at the most) you should ensure free air flow. If storing period is longer than 2 weeks panels should be placed in a well ventilated room and left uncovered as well as provided with free access to air in order for all layers to be ventilated. Not following these recommendations can lead to coating decolouration, so called white rust, permanent core damage as well as loss of warranty. Minor repairs and maintenance: All damage to coating caused during transport or assembly should be covered with touch up paint. Maintenance of sandwich panels consists in performing regular inspections and securing possible damages. During inspection close attention should be paid to uncovered edges and joints. Notes concerning usage: Sandwich wall panels with dark facings are characterized by high heat absorption capacity which can cause local deformation of facing s surface in the period of high air temperatures. As a result allow for panels thermal motion and use panels of limited length. This effect does not have any influence on the properties of sandwich panels but the producer warns that clients purchase wall panels in those colours at their own risk and do not have rights to claim against the producer due to this fact. Local deformations in roof panel surface practically does not occur. Pursuant to the EN standard, it is assumed that sheets in dark colours heat to the temperature of 90ºC. Therefore, Balex Metal shall not be responsible for any damages caused by high temperature, which may result in changing the position of the facing in some places. Dark colours are defined in Item E.33 of the EN14509 standard. 26

29 24. CERTIFICATION DOCUMENTS 27

30

31 II. DETAILED CONSTRUCTION SOLUTIONS OF ENCLOSURES MADE OF PWS AND PWD SANDWICH PANELS WITH EXPANDED POLYSTYRENE CORE

32 1. PWS wall panel 1.1. PWS 01 PWS wall panel - joint, types of profiles Modular width 1155 Recommended spacing of PWS fastening Modular width 1155 Modular width 1155 Detail A Detail B PUS tape TYPES OF PROFILES EXTERNAL FACINGS: Modular width 1155 grooved INTERNAL FACINGS: Modular width 1155 grooved Modular width 1155 flat 30

33 1.2. PWS 02 Panel fastening - vertical panel arrangement Modular width 1155 Modular width 1155 Modular width PWS wall panel 2. LB 1 or LB 2 PWS wall panel fastener 3. PES 3x20 self adhesive sealing tape (recommended) 4. Wall transom acc. to construction design 31

34 1.3. PWS 03 Supporting the panels on the ground beam or the foundations vertical panel arrangement 1. PWS wall panel 2. OBR 100 flashing 3. OBR 101 flashing 4. LB 1 or LB 2 PWS wall panel fastener 5. LB 6 self drilling fastener or blind AL/Fe rivet approx. every 300 mm. 6. PUS 5x40 self- adhesive sealing tape 7. Butyl sealing tape (recommended ) 8. Panel joint sealant 9. Impregnated polyurethane seal 20 mm thick 10. Angle acc. to construction design 11. Damp proof insulation acc. to architecture design 32

35 1.4. PWS 04 Supporting panels below the top of the ground beam or the foundations vertical panel arrangement 1. PWS wall panel 2. OBR 100 flashing 3. OBR 101 flashing 4. LB 1 or LB 2 PWS wall panel fasteners 5. LB 6 self drilling fastener or blind AL/Fe rivet approx. every 300 mm. 6. PUS 5x40 self- adhesive sealing tape 7. Butyl sealing tape (recommended) 8. Panel joint sealant 9. Angle acc. to construction design 10. Damp proof insulation acc. to architecture design 11. Facing with approx. 10 mm width gap in case of increased thermal insulation requirements 33

36 1.5. PWS 05 Supporting the panels on the ground beam or the foundations horizontal panel arrangement approx. 23mm 1. PWS wall panel 2. OBR 102 flashing 3. LB 1 or LB 2 PWS wall panel fasteners 4. PES 3x20 self- adhesive sealing tape (recommended) 5. Impregnated polyurethane seal 20 mm thick 6. Angle acc. to construction design 7. Damp proof insulation acc. to architecture design 34