Expertise in Plastics

Size: px

Start display at page:

Download "Expertise in Plastics"

Ophelia Sims
6 years ago
Views:

1 Expertise in Plastics

The ideal material for almost any decorative or cladding application, including signage, point of sale, exhibition stands, displays, internal cladding, portable buildings, kiosks, boat interiors and

2 The ideal material for almost any decorative or cladding application, including signage, point of sale, exhibition stands, displays, internal cladding, portable buildings, kiosks, boat interiors and external cladding. Aluminium composite sheet is durable, versatile and easy to use. Lightweight and extremely flat, the sheet is exceptionally rigid and does not corrode. The high quality finish polyester coating makes it an ideal substrate for printing. Rightbond Superlight Ideal for lightweight flat sheet applications including exhibition panels, photo mounting, internal signage, temporary or short term external signage. Rightbond Superlight is suitable for flat sheet applications only. Rightclad A heavy duty aluminium composite sheet particularly suited to external use for new building cladding or for building renovation projects. A white/mill finish with a white PVDF paint system, this material offers a 15 year warranty for outdoor applications. Five sheet sizes are available in a 4mm thickness with a 0.5mm aluminium layer. All sheets are supplied with a fire resistant core. Accessories A range of special aluminium sections in silver anodised aluminium are available in 5 & 5.5m lengths to complement our 3mm thick aluminium composite sheet range. 29

3 Stock Range Rightbond White Rightbond Standard mm aluminium layer White/White Bright White polyester paint 2500 x 1250 x x 1250 x x 1500 x x 1500 x x 2000 x x 1500 x x 1500 x x 2000 x 3 Rightbond Digital 0.21/0.18/0.12mm aluminium layer White/White Bright White polyester paint 2500 x 1220 x x 1230 x x 1250 x x 1500 x 2 Gloss/Matt. Standard core. 60% tack film. Rightbond Economy Grade White 2440 x 1220 x 3 Rightbond Superlight Bright white matt one side. Aluminium reverse. PE film bright white side only. White 2440 x 1220 x x 1220 x 3 Aluminium Layer Bright white matt. White service coating reverse. Standard black core. White film on bright white matt side only. Rightbond UV Grade Special paint formulation to aid printing with UV curing inks. White/White White/Mill Aluminium Layer Aluminium Layer Rightbond Colours Red Yellow Green Blue Black Cream NHS Blue Aluminium Layer /0.21 /0.21 /0.21 /0.21 / Gloss level: 85% gloss side, 45% matt side. High tack film: Clear on gloss side. White on matt side

4 Stock Range Brushed Finish Dual Metallic Finish Brushed Finish Aluminium Layer Gold/Bronze Aluminium Layer 2550 x 1250 x 3 Mirror one side, mill aluminium reverse. Standard core. High tack film. For interior use only. Will tarnish in outdoor applications. Brushed aluminium one side. Metallic silver polyester paint reverse. Exterior grade. Standard core. High tack film. Arrow on protective film indicates direction of brush finish. Mirror Finish Mirror Finish Silver & Gold Aluminium Layer 2440 x 1220 x 3 Bright Silver/Champagne Silver Champagne/Metal Silver Clear film. Standard core. Rightclad Rightclad 2500 x 1250 x x 1250 x x 1500 x x 1250 x x 1500 x 4 Aluminium Layer Rightclad is made to order. 31

5 Right-trim Aluminium Extrusions Edge Protector Panel Joint U Section Suitable for 3mm thick sheet. Will also act as a stiffener for PVC foam. Supplied in 5m lengths, 10 lengths per sealed bundle. White or Silver anodised. H Section Suitable for joining two 3mm thick sheets or panels. Supplied in 5m lengths, 10 lengths per sealed bundle. White or Silver anodised. Corner Joint Section 0 This allows for sheets to be joined together through 90 without sheet fabrication. Aluminium Composite Accessories Sign Post System A range of sign post accessories suitable for aluminium composite or aluminium signs. Stock Range 50mm stainless steel clip c/w bolt, nut & washer 76mm stainless steel clip c/w bolt, nut & washer 89mm stainless steel clip c/w bolt, nut & washer 114mm stainless steel clip c/w bolt, nut & washer 140mm stainless steel clip c/w bolt, nut & washer Also available: PVC coated & galvanised poles in various diameters & lengths up to 7.5m medium sign channel in 5 & 6 metre lengths. 32

6 Sign Post System A range of sign post accessories suitable for aluminium composite or aluminium signs. System Fit Guide Bolt post into base plate and ensure bolt is tight before placing into pre-dug hole and filling with concrete. Ensure concrete is dry before fitting sign systems. Slide post clip and bolt into rail before fixing around the post. The number of rails required will depend on the size and weight of the panel used. Material choice will determine whether the panel should be bonded, screwed or rivetted to the rail. For back to back signs, the clip is attached to the front rail and then bolted to the back face to secure it permanently. Once fixed, a top pole cap can be fitted to provide weather protection and an aesthetically pleasing finish. 33

7 Colour Matching Rightbond Bright White colour matched to RAL 9016 Red close to RAL 3020 Sea Blue close to RAL 5002 Light Blue RAL 5017 (NHS) RAL 5013 Green close to RAL 6016 Can be matched if required Yellow close to RAL 1003 Black close to RAL 9005 Cream RAL 1015 *The mill can colour match to any RAL number, Pantone or sample piece for a minimum order 2 quantity of 600m. Warranty Summary - Rightbond & Rightclad Aluminium Layer Internal External Rightbond Polyester/Polyester E.g. Whites, Colours years 8 years 6 years 6 years 5 years 5 years 3 years 1 year Feve Paint Min 10 years 10 years Mirror 6 years None White Satin 8 years None Brushed Aluminium External Grade 10 years 5 years PVDF 0.5 Min 15 years 15 years 34

8 Rightbond Data Sheet Rightbond Colour Finish White. Polyester coating. Gloss/Matt Tolerances for Rightbond & Rightlam Length Width Thickness Squareness Standard +/- 3mm +/- 2mm +/- 0.2mm < 5mm Coating thickness Pencil hardness Coating flexibility Impact resistance Face density Bending strength Bending elastic modulus Shearing strength Thermal expansion co-efficient Heat distortion temperature Fire certification Rightbond Min > 16um 3H 2T 50 kg.cm 3.5 kg/m 83MPa 5.0KN 21.1MPa x 10 C C BS476 Part 7 Class 1 Polyester coatings can be used for interior and outdoor applications. The coating may experience some fading or chalking after 4 years exposure to the sun. For prolonged outdoor use, material with a PVDF coating and a 15 year warranty can be supplied. 35

9 Rightclad Technical Data Sheet Colour Finish White PVDF White one side, mill reverse. Standard Average Test Result Length +/- 3mm mm Tolerances Width Thickness +/- 2mm +/- 0.2mm mm mm Squareness < 5mm 1.4mm Testing Item Standard Finish coat thickness Pencil hardness Toughness Adhesive force Impact resistance Abrasion resistance Mortar resistance Humidity resistance Boiling water resistance Salt-spray resistance Acid resistance Alkali resistance Solvent resistance Colour retention Chalk resistance Gloss retention Fireproof core ISO 2360 (CNS 8406) ASTM D ASTM D ASTM ASTM D ASTM ASTM ASTM D714-97/ASTM D ASTM D3359-B ASTM B ASTM D /AAMA , TEST 7, 7.31 ASTM D ASTM D /ECCA T5&NCCA NO ASTM D ASTM D ASTM D Fire rating BS476 Part 7 Class 1. BS476 Part 6 Class 0. UK Building Regulations 1991 Approved Document B (Amendments 2002) Appendix A, Paragraph

10 User Guidelines Fabrication Prior to fabrication, ensure both sides of the panel and all work areas are clean and free from dust. Cutting chips generated from saws, routers and drills as well as particles caught in between panels will cause damage to the surface. Saw Cutting Rightbond panels can be cut using various types of circular saws including table saw, hand circular saw and panel saw. Carbide tipped blades suitable for aluminium or plastic use can also be used for cutting Rightbond panels. Example of Suitable Saw Blade Operating Conditions Blade diameter Number of teeth Cut width Rake angle Tip 255mm 80 to to 2.6mm 0 10 Carbide Rotation of saw blade Feed speed rpm m/min Notes on Saw Cutting a. When cutting, ensure the effective side is facing upwards to prevent the surface from being scratched and to prevent the film from peeling off. b. Remove any cutting chips from the surface of the panel to avoid dents appearing during storage or assembly. c. Ensure saw blade is sharp to avoid distortion of the panel at the cut edge. Shear Cutting Square shear permits an efficient sizing work. Generally, the most suitable clearance and rake angle are as follows: Clearance: mm 0 Rake angle: 1 Trimming It is important to ensure the exposed cut edge of the panel is carefully checked. In saw cutting, burr appears on both sides of edges. In shear cutting, either droop or burr appears on each edge. Therefore in saw cutting the saw blade should be kept sharp and in shear cutting the clearance of the die should be adjusted correctly. Generally, the condition of the edge is more important for interior applications and a trimmer, plane or sand paper may be used for trimming after edge cutting. For solid and metallic colours, deep trimming like chamfering will have a visual effect. However, for granite or woodgrain effect finishes this is unsuitable as it damages the appearance of the finish. To avoid any cuts, make the edge dull using fine sand paper. 37

11 User Guidelines Hand Grooving Machine This machine can be used to create grooves in Rightbond panels. Suitable cutter blades and operational conditions are as follows: Cutter Blade Operating Conditions Outside diameter Number of teeth Material mm 4-8 Carbide tip Rotation Feeding speed 5,000-9,000 rpm 5-20 m/min Hand Router A hand router can groove straight or curved lines. The suitable bit and operating conditions are as follows: Router Bit Number of teeth Material 2-4 Carbide tip Operating Conditions Rotation Feeding speed 20,000-30,000 rpm 3-5 m/min Panel Saw Efficient grooving work is possible with a panel saw. The typical conditions are as follows: Cutter Blade Operating Conditions Outside diameter 20mm Rotation 2,500-5,000 rpm Number of teeth 8 Material Carbide tip Feeding speed 30 m/min Folding After U-grooving, it is possible to fold Rightbond panels with a folding jig. The typical folding procedures are demonstrated in the diagram below. 1. U-groove Leave mm core. 2. Folding jig Folding is made of aluminium or steel angle. 3. Fold Use a little longer jig than folding length. 4. Roundness Suitable roundness is 2-3 mm R. 5. Support Support with aluminium angle, if necessary. 2-3mm R 38

12 User Guidelines Notes on Folding a. To ensure the fold line is straight, panels should be folded on a flat & steady work table. b. To avoid a crack in the coating, the folded corner should have a suitable roundness of 2-3mm in 0 radius and should be worked at temperatures of 10 C or higher. c. Folding after U-grooving creates a slight elongation of mm depending on the roundness of the folded corner. Therefore, the position of the grooving lines must be pre-adjusted when the fabrication drawings are prepared. Drill Holes Holes can be made with a hand drill, a drill press equipped with drill bit, a hole saw or a circle cutter. To reduce burr, make the hole from the side you wish to have on display. Punching & Notching A punching machine can be used for notching and cutting out. The suitable clearance between the punch and die is 0.1mm or smaller (material thickness x approximately 2%). A small droop will appear at the punched edge. Bending with a Press Brake Rightbond panels can be bent using a press brake. The minimum bendable radius with a press brake is as follows: Bending Direction Traverse Parallel Minimum Bendable Radius 50mm 80mm Notes on Press Brake Bending a. Traverse and parallel show the bending direction towards the rolling (coating) direction, printed on the protective film. b. The minimum bendable radius means the limit with which visible wrinkles appear on the aluminium surface of the Rightbond panel. c. Use the top die (punch) with a similar radius to the desired radius. If the radius of the top die is too small, it is possible for the bending radius to become partially smaller than the above limit. d. Use a urethane pad for the bottom die or place a rubber mat between the bottom die and the Rightbond panel. e. Use a scratch free top die. Polish and wipe the top die. Do the bending work without peeling off the protective film. Bending with a 3-Roll Bender Rightbond panels can be bent using a manual or electric-drive 3-roll bender. The minimum bendable limit is normally 250mm in radius, but it depends on the length of the bender and the type of machine. The following is an example of the relationship between the length of the bender and the minimum bendable limit. 39

13 User Guidelines Bending with a 3-Roll Bender Roll Length (mm) Minimum Radius (mm R) Notes on 3-Roll Bending a. Prior to the bending operation, wipe the roll surface carefully. b. Remove any burr on the edge of the Rightbond panel, to avoid any dents being caused with rolling. c. Remove any dust particles on the Rightbond panel and ensure the protective film is wrinkle free to avoid dents during rolling. d. Do not tighten the panel with the rolls. If the roll clearance is rigid in the machine, adjust the clearance to panel thickness plus 0.5mm approximately. e. If a notch is required in a curved panel, make it after edge bending to avoid any distortion in the curve. f. When bending to a small radius, gradual bending is necessary, achieved by adjusting the elevation of the bending roll. g. If a consistent curving line is required near the edge of the panel, additional edge bending will be necessary after regular bending. CNC Router Rightbond panels can be cut and grooved using a CNC router, particularly where a process is being repeated. The recommended bit and operating conditions are the same as for a hand router. Turret Puncher A turret puncher can be used for the perforation of Rightbond panels. The suitable clearance between the punch and the die is 0.1mm or smaller (material thickness x approximately 2%). A small droop will appear at the punched edge. Water Jet Cutting A plunge cut (piercing at the starting point) in water jet cutting may cause some delamination between the aluminium skin and core material of a Rightbond panel. Therefore, a plunge cut must be made in a disposable area of the panel or at the start of the panel edge. After penetrating the panel, water jet cutting can be successfully used on Rightbond sheet. Laser Cutting Testing to date has shown that Rightbond panels are not suitable for laser cutting. This is because the fumes generated from the panel may harm the optical instrument of the laser system. 40

14 User Guidelines Rivets Rivets, nuts & bolts and tapping screws can be used for joining panels to aluminium extrusions. Blind rivets should be made from aluminium whilst, nuts, bolts and tapping screws may be either aluminium or stainless steel. Riveting work can be done from one direction only. Adhesive Commercial adhesives can be used for joining and assembling Rightbond panels. The exception is any adhesive that may corrode aluminium, for example vinyl acetates that are widely used for timber and styrene foam. The main adhesives that are suitable for the adhesion of Rightbond panels and other materials are as follows: Adhesives Applicable to Rightbond Panels Adhesive Type Epoxy Chloroprene Silicone RTV Cyano-acrylate Metal Suitable material Timber to be adhered Gypsum board Styrene foam Notes on Adhesives a. Prior to adhesion ensure the panel is clean and free from dust, particles, grease, water etc. b. Select the most appropriate adhesive that will ensure the necessary adhesion power in the given atmospheric conditions. The adhesion power will depend on the surface conditions of the substrate. Follow the adhesive manufacturer s instructions carefully. c. It is important to pre-test the adhesive before fabrication and installation, as it is possible for a Rightbond panel, when adhered to a different material, to show a deflection due to the thermal expansion difference or dimension change of the material. d. Some adhesives may cause a distortion after hardening due to shrinkage of the adhesive. Generally epoxy, polyurethane and silicone adhesives may show this kind of distortion, therefore pre-testing may be necessary. Welding of Core One end of a Rightbond panel can be adhered to the end of another panel by welding the core with hot melt adhesive (glue). For good adhesion, the core surface must be pre-heated before heating a glue stick. Normally, mechanical reinforcement is necessary after welding. Double-sided Tape Double-sided tape such as 3M s VHB tape is suitable for joining Rightbond panels to other materials. The tape simplifies the joining work and the thicker tapes allow some movement of the two materials. Hook/Loop Fastener These removable and restorable fasteners can be used for guide signs and displays. 41

15 User Guidelines Sealant A sealing material is used to ensure waterproofing of joints between panels. The sealing material should meet the performance required for the atmospheric conditions. Generally, the sealants that can be used are silicone, modified silicone, polysulphide and polyurethane. To ensure the necessary performance, please follow the sealant manufacturer s specifications. Screen Printing Vinyl and polyurethane type inks are suitable for all Rightbond finishes. Normal adhesion is 0 achieved with these inks after drying at 80 C for 30 minutes and curing at room temperature for 24 hours. Before printing, remove dust and dirt with a soft cloth. Any oily dirt residue will cause printing defects. It is important to cure or dry under the correct conditions. Please follow instructions from ink manufacturer. Notes on Screen Printing 0 a. To avoid deflection of the panel, keep the curing temperature below 90 C for less than 30 minutes. b. Select the ink suitable for the atmospheric conditions where the panel is located. Cutting Film Various types of cutting film can be used with Rightbond panels. If you are going to fold the area where the film is applied, the film may change the colour at the folded corner. Confirm with pretesting. Digital Print with Ink Jet Printer Various types of decorative films and wallpapers printed with inkjet printers can be applied on Rightbond panels. Confirm the fire approval conditions of the film. Direct digital print is also possible with special ink jet printers. Touch-up Coating Method Commercial or custom acrylic paints are suitable to repair the coating of all Rightbond panels. Typical procedures are as follows: a. Clean the surface of the panel and remove any dirt, if any. b. Stir the paint well and apply with brush. c. Dry and cure at room temperature, as per manufacturer s instructions. Normally acrylic paints show good adhesion once cured, however the touched-up portion may have a slightly different appearance even with an exactly matched paint. For granite and woodgrain finishes, use an intermediate solid colour diluted with clear paint for touch-up. The suitable dilution rate is, depending on the colour, 10-90% of clear content. 42

16 User Guidelines General Cleaning Firstly, try removing any stains by applying a little pressure with a soft sponge and water. If the stain remains after the panel is dry, then use neutral detergents or household cleaners diluted with water. Typical cleaning procedures are as follows: a. Dilute a detergent or a cleaner to 1-5% with water. b. Apply the solution and spread on the panel surface with a soft cloth or sponge. Wait for one minute and the foam will blacken. c. Dry the solution with a squeegee and wipe the remaining solution with a wet cloth and clean water. According to tests, dilute Magiclean is suitable for all finishes of Rightbond panels. Magiclean is a household detergent with ph 8. For all other detergents, please pre-test in a small area. a. Add detergent to water 5 litres of water: Detergent ml b. Apply detergent and spread on Rightbond surface. Wait for 1 min. c. Dry with squeegee and wipe off with a wet cloth. Stubborn Stains According to tests, alkali cleaners such as Sharpshooter (from 3M, alkali, ph 12) and Windex (from Johnson, alkali, ph 11) are suitable for cleaning stubborn stains on Rightbond panels. However, metallic finishes will require a good rinsing with water afterwards as non-rinsing may cause a colour change due to any remaining alkali. For solid colours, granite and woodgrain effect finishes, rinsing with water is not necessary. As with all alkali solutions, avoid contact with eyes and skin and follow the manufacturer s safety instructions. For other cleaners or stain removers, please pre-test in a small area. Generally, strong acid and alkali cleaners may cause a gloss change, colour change or swelling of the film coating. Do not use cleaners containing abrasives. Do not use strong solvents or paint thinners. 1. Apply Sharpshooter or Windex with sprayer, soft cloth or sponge. 2. Rinse with wet cloth and clean water. 43

17 User Guidelines Handling Always unpack and pack the wooden crates in a clean place. Remove any dust and chips from the sheet and the packing paper as any hard particles such as sand and cutting chips can cause dents if they are caught between the panels. Always handle Rightbond on a work table and not on the floor. Sheets should be picked up by two people with the effective surface upward to avoid possible rubbing of the sheet surface during handling. Transporting Material Lay Rightbond sheets horizontally and do not place any heavy objects on top. Packaging should be clearly marked with Handle with Care, Keep Dry, No Hooks & This Side Up. Pallets should be handled with care during transportation and loading and unloading. Incoming pallets should be inspected for transport or moisture damage. Protective Film The protective film may become invalid if subjected to direct sunlight and moisture. Panels must be stored in a dry area not exceeding 6 months. The film should be removed immediately after installation, particularly in the case of the reversible series where protective film is applied to both sides of the panel. Although the film is translucent it can sometimes be difficult to notice it. If the protective film becomes partly delaminated from the surface during handling, it may be possible for the build up of dirt deposits. Storing Rightbond panels must be stored in a cool, dry and temperate area and must not be subject to rain, moisture or condensation. Pallets should contain only same size panels and you should not stack pallets more than four high. Recycling We can offer a recycling service for used sheets or offcuts. All material will be collected free of charge. This service is only applicable for products supplied by Righton Limited. Due to the cost of shipment back to the reprocessing plant, no financial offer can be made for the product being collected. 44

Fairview TECHNICAL INFORMATION A1 RATED NON-COMBUSTIBLE CLADDING PANELS

Fairview TECHNICAL INFORMATION A1 RATED NON-COMBUSTIBLE CLADDING PANELS ABOUT THIS MANUAL This manual has been developed to effectively assist fabricators and contractors to work with Fairview s Aluminium