Version 2. May ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

Transcription

1 Version 2. May ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

2 Table of Contents INTRODUCTION TRANSPORT, LOADING, UNLOADING AND STORAGE FABRICATION/PROCESSING METHODS SAFETY PRIOR TO FABRICATION/PROCESSING SAW CUTTING PUNCHING GROOVING ROUTING CURVING/BENDING BOLTING/SCREWING RIVETING BOLTING DRILLING PERFORATING GLUING INSTALLATION SPECIAL CONSIDERATIONS THERMAL EXPANSION DIRECTION OF ASSEMBLY COMMON INSTALLATION METHODS HORIZONTAL JOINT DETAIL VERTICAL JOINT DETAIL SOFFIT DETAIL EXTERNAL CORNER PARAPET DETAIL WINDOW SILL DETAIL WINDOW HEAD DETAIL JAMB DETAIL SOFFIT DETAIL AT WINDOW HEAD CONCRETE WALL TO CLADDING INTERFACE HEAD DETAIL AT SLAB EDGE FLOOR SLAB DETAIL ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

3 INTRODUCTION This manual provides relatively simple and convenient fabrication and installation details on CLADEX Aluminium Composite Panels (ACP), provided that some simple rules are adhered to. The information contained in this guide, although being fairly comprehensive, is by no means exhaustive. Additional information is available from the CLADEX service team. Note: All design and construction of façade systems need to comply with the latest version of the Building Code of Australia (BCA) Standards and Regulations. Please note that the guidelines provided in this manual are of a general nature and that the onus remains with the purchaser to make an assessment on the conditions under which the CLADEX range of products will be used by their clients. 1. TRANSPORT, LOADING, UNLOADING AND STORAGE To ensure the CLADEX panels are protected during delivery, they are transported in solid wooden crates (see photo below), with the panels wrapped in a PE film and the crates sealed using steel strapping/bailing bands. Unloading of crates from containers or trucks can be accomplished with the use of forklift(s) or slings of adequate loading capacity. They should be lifted off the stack individually with care, to ensure that they do not scrape adjacent crates or cause damage to any panels. Upon delivery of your order, please check the inventory and inspect each panel, all accessories and packaging, noting any transport and moisture damage or unaccounted items. Panels that are moist should be dried immediately to prevent spotting/staining. 3 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

4 Should there be any signs of damage or missing items, make a note of the reference delivery docket at the time of delivery and have the details confirmed by the forwarding agent, since failure to do so will make it difficult to file a claim. Forward a list of the missing or damaged items to ISG Architectural and make contact with your ISG Architectural representative for further instructions. It is imperative that any damaged panels, accessories, or packaging be reported to ISG Architectural s representative immediately upon discovery. The following guidelines are provided to safeguard CLADEX ACP s from mechanical damages as well as the detrimental effects of moisture and weather conditions: CLADEX panels should only be transported using ISG Architectural solid wooden crates. The crates should be handled carefully during transportation and unloading. Note: do not handle open crates. Any strapping/bailing bands are to be removed upon receipt of delivery. The crates are to be lifted from each stack individually, taking care not to scratch or damage any adjacent crates when removing them from the stack. Crates and ACP s need to be stored in an area that is well protected from the elements, i.e. a cool, dry and ventilated location, where temperatures are relatively stable. Should storage of crates and ACP s be required for an extended period of time, they should be tarped (to remain dry and clean) and stored such that they are protected against water leakages, rain as well as penetration of moisture or condensation (likely to occur when cold panels are moved to a warmer room). Crates can be stacks one on top of another (not vertically), with heavy crates at the bottom. However there should be no more than three (3) crates per stack. No heavy objects are to be placed on top of the crates/panels. Individual panels should be lifted out of the crates by two people holding all four corners and not drawn over each other. Panels should be carried vertically, with gloves worn to avoid any staining of the panels. Conduct any unpacking and repacking work in a clean area. Should panels be stacked, nothing is to be placed in between them to avoid markings. They need to be placed horizontally on a clean, flat surface free of debris or onto pallets with adequate supports located at a maximum of 300 mm from the centre (to prevent sagging). Avoid the stacking of CLADEX panels of different sizes together, since the surface or panel can be scratched by the edges of the smaller panels. Preferably store them according to size in racks. All horizontal surfaces, including panels and crates, should be covered with a clean membrane or board to protect the panels from damage. All unwrapped stacks should be covered with plastic sheeting in order to minimize damage from dirt and moisture. Remember to remove all strapping/bailing bands prior to storage. Handle CLADEX panels on a worktable and not directly on the floor. 4 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

5 The following guidelines are provided to safeguard the effectiveness of the protective film on the CLADEX ACP s: Panels should not be stored for periods longer than six (6) months. Avoid severe temperature fluctuations and exposure to direct sunlight as they reduce the long-term durability of the protective film and could result in it being very difficult to remove. Do not mark the protective film with inks (marking pens/texters) or stick labels, PVC tapes (including duct tape, packing tape and insulation tape), polyurethane or modified silicon sealant onto it, since the solvents or plasticizers may penetrate the film and affect the lacquered surface. Should the protective film somewhat come off during processing or after assembly, stained edges can occur over time, which may be difficult to remove. Remove the protective film as soon as possible (or within three (3) months) after assembly. Protective film residue that remains on the panels for an extended period of exterior exposure may be very difficult to remove. Do not remove the protective film at temperatures below 10 C. 5 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

6 2. FABRICATION/PROCESSING METHODS Fabricating CLADEX panels is as easy as working with metal or wood, with no requirements for any special tools. CLADEX panels can be cut, curved, bent, routed, grooved, drilled, sawed, sheared, punched, trimmed and moulded into complex shapes with a range of conventional woodworking or metalworking tools. 2.1 Safety Various, individual protective equipment should be worn in accordance with the safety regulations enforced at the various workshops or building sites, when CLADEX ACP s are being handled, installed or worked on. Besides these requirements it is also recommended that gloves be worn when handling the panels at any given time, to prevent potential staining of the panels. Furthermore safety glasses should also be used with any fabrication operation that produces swarf (sawing, milling, drilling) and ear protection whenever very noisy machinery is being used, i.e. a panel saw/router. 2.2 Prior to fabrication/processing Prior to fabrication, ensure that: The panels are stored/conditioned at room temperature for at least one day. The worktable, temporary stand and both sides of the CLADEX panel is cleaned. To avoid scratching the panel finish, perform any cutting, routing, drilling etc. from the backside of the CLADEX panels. Ensure that any cutting chips generated from saws, routers, drills and any other tools are completely removed from the interface between the CLADEX panels and the tools. 2.3 Saw cutting CLADEX panels can be cut using various types of circular saws, i.e. table saws, hand/ circular saws and panel saws. An example of a suitable saw blade to use is as follows: 6 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

7 Blade diameter 255 mm No. of teeth 80 to 100 Cutting width 2.0 mm to 2.6 mm Rake angle 10 Tip material Fine tungsten carbide Operational parameters Saw blade rotational speed 2000 to (rpm) 4000 Feeding speed (m/min) 10 to 30 Note the following: Cut the panel with the external side facing upwards to prevent the panel from scratches and the protective film from peeling off; When processing large quantities, it is best to conduct a number of trial saw cuttings, to evaluate the tool working conditions as well the recommended cutting speeds. The panels can be marked up with the use of a soft pencil. The CLADEX substrate consists of a polyvinylidene fluoride (PVDF) paint finish and care should be taken during the sawing operation. It is therefore preferred that the saw blade be moved rather than the panels when sizing the panels. Saw blades need to be sharpened (or replaced) when they become dull. Dull blades result in large burrs or distortion of the carved edges of the panel. They also increase heat generation and applied pressure to the panel. Carefully remove all cutting chips from the panel after cutting to avoid dents and scratches during storage and assembly. After cutting the panel, make sure that the edges are deburred as they will be sharp and pose a cutting hazard. For CNC cutters, a spiral cutter is recommended to assist with swarf removal. No coolant is required on the cutter. CLADEX panels can be contour-cut with the use of water jets, CNC routers, copy routers and jigsaws. 2.4 Shear cutting 7 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

8 The shearing of CLADEX panels can easily be accomplished with the aid of rotary shears or a guillotine. Bear in mind that shearing causes a slight roll-down of the aluminium cover sheet (on the impact side). This roll-down area is often referred to as the edge zone, where the polyethylene core experiences compression, leading to increased stress between the core and the aluminium cover sheet. Shearing should be avoided when the edge of the panel is exposed to the environment due to this additional stress. To prevent any panel damage due to indentations to form on the panel surface (caused by the hold down pads), ensure that the blanking tools on the shear is padded or fitted with a shock absorbing rubber pad. For shear cutting of CLADEX panels the following can be used as a guide however it s best to always conduct a test before commencing full production: Thickness of CLADEX panel Clearance Rake angle 4 mm 0.05 mm 1.5 Applications that require visible cut edges, i.e. riveted facades, shearing of CLADEX panels does not satisfy the required decorative demands and therefore should be avoided. 2.5 Punching CLADEX panels can be punched using conventional sheet punching machines and dies. Press punching sometimes leads to shear droop in the aluminium surface of the panel, similar to shear cutting. For achieving clean cuts, ensure that evenly grounded tools are used and that the clearance of punch and die be made as small as possible (preferable 0.1 mm or as a general guide: thickness of panel x 5%). In the case of small diameter holes (< 3mm) the tool may require modification to ensure that the core material is completely removed in the process. 8 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

9 2.6 Grooving Grooving of CLADEX panels is fairly simple and an easy process to accomplish. A perfect solution to on-site routing, resulting in saving time is to utilise a V-Groove routing blade, since it allows fabricators to route and fold a range of CLADEX panels on-site, without the need to return the material to the workshop for CNC routing. The V-Groove routing blade mounts onto almost any circular saw making it completely portable. The ability to fabricate panels on site offers significant time and cost savings. With a CNC router one can accomplish an exact depth which just brushes up against the back of the skin on the aluminium face. It is recommended that a minimum of 0.3 mm Polyethylene should be left to ensure suitable strength and performance. 2.7 Routing CLADEX panels can be cut to size using portable, commercial or automated routing equipment. Furthermore CLADEX panels can be cold shaped, to form various shapes and sizes. A rectangular or V-shaped groove can be routered on the back of the panel by following potential fold lines. A thin layer (between 0.3 mm and 0.5 mm) of core should remain at the base of the routed groove. The panel can then be hand folded along this groove, creating a precise and even fold. Too much core material can result in delamination of the panel corners as well as result in a larger radius fold than desired. It also makes folding the panel more problematic and prevents the required fold angle from being obtained. The routing method should preferably be used if clean cut edges are required/desired. 9 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

10 To prevent pressure marks from appearing on the surface, plastic or wood vice jaws should be used when chucking the panels. Use vacuum tables with medium-density fibreboard (MDF) as sacrificial boards. 2.8 Curving/Bending CLADEX panels can be curved using any of the following processes: Press Break, Roll Bender, Folding Table and Pipe Fixture. The following are guidelines and limitations associated with the curving of CLADEX panels. Press Break The minimum bending radius using a press brake is shown in the following table. Thickness of CLADEX panel Traverse (Width in mm) Parallel (Length in mm) (mm) The following precautions associated with the bending process are recommended to prevent the panels from being scratched: Place a protective pad on the die of the press brake; Check that there are not any scratches on the punch and that a fully polished punch is used; Leave the factory supplied protective film on the CLADEX panel during processing and ensure there are no wrinkles or air bubbles present; The volume of recoil varies somewhat in relation to the bending direction, thickness of panel, material temperature and the radius of the required bending angle. Roller bender CLADEX panels can be bent with a roll-bending machine. Roller benders allow for a larger bending radius than a press brake. The bending angle is a function of the diameter of the roll and the distance between the rolls. The inside bending radius is roughly 10 times the Cladex panel thickness. Unfortunately a flat surface will appear at the beginning and the end of the panel. When this is not acceptable it will be necessary to cut off and remove the flat surface, in the finish fabrication process. Use protective foils to prevent damage to the panel surface as 10 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

11 well as polished rollers free of imperfections. For mass production, trials should be conducted on sample panels. Clamped pipe fixture CLADEX panels can be bent over a pipe of the proper inside diameter that is securely clamped to a table. Bending can be made easier using a hinged leaf attached to the end of the table. Bending beyond 90 may be required to counteract for any recoil of the material. 2.9 Bolting/Screwing CLADEX panels can be screwed together by means of standard processes used in metal and plastics technology. Should CLADEX panels be joined to structural parts of metals other than aluminium, or if fasteners (e.g. bolts, screws) are to be used, the following material guidelines should be observed: a) Fasteners and structural parts made of aluminium, plastic or stainless steel should be suitable for the assembly with CLADEX panels. b) In the case where aluminium materials come into contact with dissimilar metals, a proper insulator or caulking tape should be applied to insulate between the dissimilar materials to prevent corrosive and/or electrolytic action from occurring. c) Thermal expansion of the panel needs to be taken into consideration for outdoor use of CLADEX panels to avoid jamming or deformation Riveting Riveting of CLADEX panels is possible with the use of a riveter as well as rivets common to aluminium constructions, i.e. solid or blind rivets. For outdoor use allow for thermal expansion. Note that countersink rivets do not allow for panel expansion and are therefore unsuitable for outdoor use Bolting Considering the deformation limit, formula e > 2D is the best way to calculate the aperture and the distance from hole centre to the end of the plate. 11 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

12 2.12 Drilling CLADEX panels can be drilled with twist drills commonly used for aluminium and plastics, and on drilling machines customarily used for metals. Working parameters Drill bit Twist drill made from high speed steel (HSS) Tip angle 100 to 140, alternatively counter-bore grind with centering tip Cutting speed 164 to 984 rpm Speedy removal of chips can be accomplished by using a high RPM, slow feed speed drill and occasional lifting of the bit Perforating CLADEX panels that are exclusively used for interior and ceiling designs can be perforated using CNC punching machines. Holes with a minimum diameter of 4 mm can be punched, with the minimum width of webbing between the hole edges also being 4 mm. The best results will be obtained using a punch die for single punching, however multi-station punching machines are more economical. After punching operations the panel flatness will generally require further processing due to indentations Gluing High strength contact adhesives that do not require lengthy setting times can be used for interior design purposes. Where moderate cure times are adequate, construction adhesives and silicones can be used to obtain a stronger bond, instead of contact adhesives. Care must be taken in the selection of an adhesive regarding the thermal expansion of the materials to be joined. Where significant thermal expansion can occur, i.e. exterior applications, adhesives should be of medium or low modulus materials to allow for movement without shear or loss of bond. Usually metal adhesives or double-sided, very high bonding (VHB) tape, for indoor use should be used. Note: Adhesives and sealants do not adhere to the plastic core. Apply adhesive to aluminium surface only and consult sealant manufacturer for correct application. Note: Tape fixing of the Cladex cladding system is only permitted on Type C construction, on walls that do not require a fire resistance level in accordance with 3M VHB Tapes design guidelines. 12 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

13 3. INSTALLATION The versatility of CLADEX panels makes it readily flexible to other standard systems available from a variety of vendors, including rout & return systems, glazed-in systems as well as highly-creative custom designed systems. In addition, complex assemblies can be created with CLADEX panels in combination with polyethylene welding as well as a range of support systems attached using structural adhesives. Surfaces can be connected to one another as well as to other materials through conventional methods of attachments using rivets, bolts or screws. For interior installations the surface of the panels can be attached to such substrates as drywall, gyprock and plasterboard with double-faced tape or non-hardening adhesives. 3.1 Special considerations Thermal expansion CLADEX panels will thermally expand or contract in a similar manner to that of solid aluminium plate or sheet. This thermal expansion must be considered when choosing the fastening system and calculating dimensions and joint widths (refer to CLADEX Technical Specifications). Some consideration should be given to the following: The minimum tolerance requirements depends on the expected expansion of the panel, support, joinery, wall openings etc.; Larger panel hole diameters must be taken into account when the panel is fixed with screws and rivets; Panel holes and holes in the substructure must be drilled centrically (drilling jigs to be used); The distance between panel and rivet head is approximately 0.3 mm (rivet attachment jigs to be used); Take care not to over-tighten the screws on the panel; Position the butt joints of the supporting sections with the panel joints to avoid jamming, as a result of opposing thermal expansions. Bear in mind that panels with outer coatings in darker colours, absorb more heat than lighter coloured panels. Account must be taken of this when calculating the 13 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

14 temperature differential (about 20 C more for a black panel, compared to a white or metallic panel). Expansion is only one of the tolerance factors to be taken into consideration during design calculations. Tolerances of the support (masonry, structural steel) as well as the installation tolerances (joinery, wall openings) must also be considered Direction of assembly Note that CLADEX panels are directional, i.e. during manufacturing of the panels the paint is applied to the composite panels in one uniform direction. Solid Colours Solid colours present the best case for panel to panel and batch to batch consistencies. However it is likely that there will be variations in colours from one batch to another. The industry standard for allowable colour variation with solid colours is Delta E 1.0 or less. The brighter colours (reds, yellows, blues, etc.) tend to be less opaque. They depend somewhat on film building (paint thickness) to achieve their appearance and are likely to exhibit more variation than subdued colours. Metallic Colours The industry standard for allowable colour variation with metallic colours is Delta E 2.5 or less. This is significantly larger than the standard for solid colours. The reason for this is that in the coating process the flakes will tend to align in one direction, greatly increases the directionality of the panel s appearance. The larger the flake size the greater the probability that the lots/batches will not be able to be mixed. CLADEX panels have arrows displayed onto the protective film, indicating the direction in which the finish was applied. It is therefore recommended that CLADEX panels are installed in the same direction as marked on the protective film, with lots/batches not to be mixed on a building face (unless deliberately required otherwise), to avoid any possible reflective differences. Subtle colour variations could occur between panels originating from different production batches, therefore to ensure panel colour homogeneity, the total panel requirement (with a couple of extra/spare panels) for a project should be ordered in one batch, i.e. the front of a building should be composed of panels of the same batch (see label attached to the pallet or stamp on the reverse side). Notes should be made on the drawings to verify the direction in which to install the panels. 14 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

15 3.1.3 Panel fixing CLADEX panels can be mechanically fixed (Type A, B or C buildings) or flat stick adhesive fixed (Type C buildings) directly to the wall frame or be connected via a top hat sub-frame. The fixing technique is dependent on the fixing location and wind impact. Where fixed in high wind areas the system design is to be reviewed by an appropriately qualified façade engineer. Where the top hat sub frame system is used, they are to be spaced at intervals no greater than 600 mm, with the panel fixed on one side no greater than 1200 mm. The various installation and approved fixing systems are detailed further below Accessories The accessories for installation of CLADEX ACP s include the following items and are generic items that can be interchanged: 1. Aluminium profile and angles 2. Hangers 3. Weather resistant silicon sealer 4. Anchor bolts 5. Backing rods 6. Rivets 15 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

16 7. Self-tapping screws Images for illustrative purposes only. 4. COMMON INSTALLATION METHODS The methods detailed below are examples of approved fixing techniques. As the core is a low combustible hazard, its exposure to free air does not present a fire hazard. The panel in the following fixing methods can be installed within the horizontal or vertical plane, to the interior or exterior of a building. 4.1 Horizontal Joint Detail 16 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

17 17 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

18 4.2 Vertical Joint Detail 18 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

19 4.3 Soffit Detail External Corner 19 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

20 4.4 Parapet Detail 20 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

21 4.5 Window Sill Detail 21 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

22 4.6 Window Head Detail 22 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

23 4.7 Jamb Detail 23 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

24 4.8 Soffit Detail at Window Head 24 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

25 4.9 Concrete Wall to Cladding Interface 25 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

26 4.10 Head Detail at Slab Edge 26 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.

27 4.11 Floor Slab Detail During the process of installation, it is important to make sure all the panels are being installed in the same direction, as illustrated on the protective film. Otherwise, it will result in a serious problem to the visual impact of the whole curtain-wall, especially for those panels with metallic color coating. Usually, our panel with size of width no more than 1600mm and length unlimited, however, specific offers are available for those customers who have special purpose, with the consideration of transportation convenience. The installation details provided in this manual are for conceptual purposes only. By no means are they the only methods that can be utilised to attach CLADEX panels, neither can they be used generically without consideration for each unique and individual application. Proper design engineering may prevent/exclude the choice of installation method being selected. 27 ISG Architectural, Kirkham Rd West, Keysborough, VIC, Copyright 2017 All rights reserved.