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1 HansenGlass Ceramalite spandrel panels - For Appearance and Insulation Ceraphic screen printing - For Decoration and Solar Control Ceragrit surface treatment - For Enhanced Anti-Slip Cerocco sandblasting - For Obscuration and Privacy Polylite edge lighting - For Decoration and Mood Creation

2 Introduction HansenGlass is at the forefront in the design and manufacture of painted and decorated fritted glass panels. Ceramalite is a high quality enamelled toughened glass, available in a range of standard colours, designed for use in the spandrel areas of curtain wall. Ceramalite can also be utilised as a wall cladding product in shower areas and kitchen back splashes. Ceraphic screen printed toughened glass, is available in a range of standard colours and patterns. It can be used both internally and externally to create striking designs, corporate logos and images, solar control and safety manifestations. CeraGrit is a product that gives enhanced anti-slip characteristics to toughened glass when utilised in flooring, stair treads or landing panels. CeraGrit can be applied to either a dot or line pattern. Cerocco sandblasting can be applied to either annealed or toughened glass to create areas of obscuration or defined patterns. A clear water repelling treatment can be applied after sandblasting to reduce cleaning and maintenance. 2

3 PolyLite edge lighting utilises the latest LED and fibre optic lighting technology coupled with an embedded pattern on the glass surface to create stunning visual effects. PolyLite is ideal for applications such as partitioning, balustrading, shower screens and lift cars. HansenGlass products can incorporate multiple decorative processes from the above range of products. Advantages total obscuration of internal structure or services capable of creating a wide range of visual effects aids solar control available in a wide range of standard and nonstandard colours highly durable against abrasion, corrosion and chemicals minimal maintenance no fading impervious to discoloration by internal deposits choice of insulation to suit performance requirements has a wide range of internal finishes single and double glazed options thermally safe can be used for decoration available as a heat soaked toughened glass Product Description Ceramalite is available in thicknesses from 6mm to 15mm as single glazing or as the inner pane of a ThermoCool insulating glass unit, where it can be combined with a variety of outer panes. Both versions can be supplied with an integral insulation backing, in the form of either: foam, covered with aluminium foil an aluminium tray, with a variety of surface finishes, containing mineral fibre or foam; or fire retardant type insulation The U value of the insulated Ceramalite products can be as low as 0.2 W/m 2 K. Ceramalite is manufactured by roller coating the glass - already prepared complete with any edge working, shaping, holes and cutouts - with a water based enamelling paint. The paint is oven dried and the glass is then subjected to a heating and cooling cycle, during which the enamel paint is fired into the glass surface and the glass is toughened. When used as spandrel panels, the Ceramalite can be used either as a single glass or in ThermoCool. The enamelled surface is normally glazed on surface 2 (counting surfaces from the external surface of the building) for single glazing or on surfaces 2 or 4 of ThermoCool. 3

4 Ceraphic is available in thicknesses from 6mm to 25mm as single glazing or as part of a ThermoCool insulating glass unit. Ceraphic is manufactured by screen printing - using a squeegee to deposit ceramic ink through a cloth mesh, which may be masked to form a pattern of ink. The ink is oven dried and the glass is then subjected to a heating and cooling cycle, during which the enamel ink is fired into the glass surface and the glass is toughened. Ceraphic can be used to create striking visual effects for decorative, safety, obscuration and solar control purposes. HansenGlass offer a range of standard patterns and standard colours and can assist in the development of designs and colours in line with the customer s specific requirements. CeraGrit is manufactured in the same way as Ceraphic, except that a grit material, which does not subsequently melt when the enamel is fired into the glass, is added to the screen printing ink. The CeraGrit TM product not only offers enhanced anti-slip characteristics but, by utilising the screen printing process, dot matrix or line patterns can provide an aesthetic appearance in different colours. Cerocco sandblasting can be applied to give 100% surface coverage or masked to specific customer requirements. Cerocco offers obscuration for privacy and security but can also act as a manifestation for safety. PolyLite TM edge lighting utilises low iron FortPlus TM toughened glass with an embedded surface pattern to aid the spread of light across the surface of the glass. By utilising LED and fibre optic technologies it is possible to create programmable lighting effects in different colours. 4

5 Technical Description Dimension Limits 6mm maximum size 4000mm x 2400mm 8mm to 15mm maximum size 4600mm x 2440mm 19mm maximum size 10.5m 2 (up to 4600mm long or 2440mm wide) 25mm maximum size 8m 2 (up to 4000mm long or 2440mm wide) Minimum size 450mm x 350mm Aspect ratio 6mm - 8mm maximum 12:1 10mm maximum 20:1 Tolerance on dimensions up to 1 m over 1 m diagonal difference Ceramalite Thicknesses Ceraphic Thicknesses Ceragrit Thicknesses Cerocco Thicknesses ± 1 mm ± 2 mm 4mm 6mm to 15mm 6mm to 25 mm 12 mm to 25 mm 6 mm to 25 mm Thickness tolerance as BS EN 572 Drilled hole sizes Minimum diameter Maximum diameter Tolerance on drilled holes Diameter Position relative to datum thickness of glass 50mm ± 0.5mm ± 1mm Distortion limits Bow 2mm/m length Roller wave and edge dip: 6mm 8-10mm 12mm Roller wave 0.15mm 0.10mm 0.05mm Edge dip 0.25mm 0.25mm 0.25mm Weight 2.5 kg/m 2 for every mm thickness of glass Strength and Deflection Allowable stress Ceramalite 50 N/mm 2 Allowable glass deflection Ceraphic 59 N/mm 2 L/65 at design load Thermal Insulation Depending on construction Without insulation: U value single W/m 2 K U value ThermoCool W/m 2 K With insulation: U value W/m 2 K Safety Class A to BS 6206 Technical information on PolyLite TM upon application 5

6 Product Performance Thermal insulation applied to Ceramalite All forms of Ceramalite can be supplied with insulation adhesively fixed to the inner surface. The options are: foam with foil backing mineral fibre or foam in an aluminium tray, either mill finished or polyester powder coated; or fire retardant type insulation Some of the standard constructions are: (i) (ii) (iii) (i) single Ceramalite with stepped insulation for glazing directly into a single glazing rebate. (ii) single Ceramalite with stepped insulation and an aluminium channel to fit an insulating unit rebate. (iii) ThermoCool Ceramalite with stepped insulation. Figure 1. Some standard insulated Ceramalite constructions Foam insulation is available in a range of thicknesses. The foam may be bonded direct to the glass with an aluminium foil facing covering the foam, or housed in an aluminium tray which is bonded to the glass. Mineral fibre insulation can be supplied in 25, 50, 65, 75 and 100 mm thicknesses and the normal method of fixing is for it to be housed in an aluminium tray which is bonded to the glass. The thickness of insulation material required depends on the thermal insulation to be achieved. 6

7 Colour Table 1 Ceramalite U values Insulation U value (W/m 2 K) to BS EN 673 type and thickness Single 6 mm ThermoCool 6 / 12 / 6 None Foam 25 mm Foam 35 mm Foam 50 mm Foam 75 mm Fibre 25 mm Fibre 50 mm Fibre 65 mm Fibre 75 mm Fibre 100 mm Black 00 E 53 Graphite 18 B 29 Harmony bronze 08 B 27 Cactus 14 C 39 Grey 18 B 25 Bronze Tone 08 B 29 There are 8 standard Ceramalite colours shown, with references related to BS 4904: The colours shown should only be taken as a guide, since the colour rendering of the printing process will not be accurate. There will be some slight colour variation within normal tolerances. It should be noted that where combinations of different glass thicknesses are used, some variation in colour might be seen, particularly with the lighter colours. A true white colour cannot be achieved due to the inherent pale green colour of glass. There are three standard Ceraphic colours: 10% acid etch effect (which gives a similar appearance to sandblasting) 20% white acid etch Polar white There is one standard colour, graphite, for CeraGrit. Other colours can be supplied, or specimen shades matched, subject to the limitation of the process. Harmonic blue 18 D 34 Polar white 14 C 31 The colours specified for non-standard Ceramalite and Ceraphic are assumed to be as viewed through the glass, unless clearly stated otherwise. The colours specified for non-standard CeraGrit are assumed to be as viewed from the printed side, unless clearly stated otherwise. There will be a minimum charge for the quantity of non-standard paint or ink required to run the process. 7

8 Appearance Ceramalite may have small pinholes and areas of differing density of the enamel. These should not be visually disturbing when the panels are viewed from the exterior of the building, in daylight, against an opaque background. Ceramalite is designed to be positioned in non-vision areas only and not where it may be viewed from inside the building against a bright sky, when the unavoidable irregularities and pinholes in the enamel finish may be evident. A special version, Ceramalite Plus, can be supplied for use where viewed against bright light. This requirement should be clearly stated at the order stage so that it can be taken into account during production. Table 2 Matching Ceramalite spandrel panels Outer pane of insulating glass unit. Silver reflection coated glass. Green reflection coated glass Green tinted glass Blue reflection coated glass Blue tinted glass Bronze reflection coated glass Bronze tinted glass Grey reflection coated glass Grey tinted glass Nearest ThermoCool Ceramalite match Same outer pane, Ceramalite Cactus inner pane Same outer pane, Ceramalite Harmony Bronze inner pane Ceraphic screen print is designed to be viewed from either surface. The printed surface has an eggshell, rather than gloss, finish. It may have a very small number of pinholes. The print may have slight variations in ink density parallel to the direction of draw of the squeegee blade. These are more obvious in large areas of print, especially when the glass is viewed against back-lighting. They are also more obvious in darker colours. 8

9 Ceraphic is available in a range of patterns, for example: - Micropoint 4 4mm printed points in a 5 spot pattern at 6.4mm centres giving 31% cover. Micropoint 6 6mm printed points in a 5 spot pattern at 8.5mm centres giving 39% cover. Micropoint Contour 4 4mm clear points in a 5 spot pattern at 6.4mm centres on a printed background giving 69% cover. Micropoint Contour 6 6 mm clear points in a 5 spot pattern at 8.5mm centres on a printed background giving 61% cover. Microline 5/5 and Microline 10/10 5mm printed lines with 5mm gaps or 10mm printed lines with 10mm gaps, both giving 50% cover. Microline 10/5 and Microline 5/10 10mm printed lines with 5mm clear lines giving 67% cover or 5mm printed lines with 10mm clear lines giving 33% cover. CeraGrit will have variations in the density of the grit coverage. This is obvious if the CeraGrit is printed in large areas. It is recommended that CeraGrit is printed in a dot pattern which makes the variation of grit coverage less apparent. Strength Ceramalite, Ceraphic, CeraGrit and PolyLite are four to five times stronger than ordinary glass of the same thickness. It has increased resistance to mechanical and thermal stresses. If broken it fragments into small relatively harmless pieces. For normal purposes, the allowable stress is: Table 3 Allowable stress Load duration Ceramalite Ceraphic, CeraGrit or PolyLite Short duration loads 50 N/mm 2 59 N/mm 2 Long duration loads 35 N/mm 2 35 N/mm 2 9

10 Safety Ceramalite, Ceraphic, CeraGrit and PolyLite conform to the test requirements of Class A to BS Thermal durability The mechanical properties of Ceramalite, Ceraphic, CeraGrit and PolyLite are unchanged for continuous service up to 250 o C and are unaffected by sub-zero temperatures. They are capable of resisting both sudden temperature changes and temperature differentials up to 200 K. Fire properties Ceramalite, Ceraphic, CeraGrit and PolyLite are Class 0 materials according to the Building Regulations Part B (England & Wales). Heat soaked toughened glass Ceramalite, Ceraphic, CeraGrit and PolyLite are available as heat soaked thermally toughened glass. The heat soaking process will be either: pren DIN 18516: Part 4 Processing Ceramalite, Ceraphic, CeraGrit and PolyLite must not be cut or worked after manufacture. Three types of edgework and many configurations of holes, cutouts and notches can be provided. The arrissed edge consists of removing the sharp edges from as cut glass. Flat ground edges give a flat profile with a smooth arriss. Polishing further refines the edge appearance. Holes should not be positioned too close to a corner, to an edge or to each other, in accordance with the minimum distances shown. t = glass thickness 2t > 2.5t x > 2t 4t no holes in this area 2t x + y > 6t y > 2t Figure 2. Hole positions For complex hole configurations, enquiries should be submitted. 10

11 Many configurations of cutouts and notches can be supplied, but enquiries must be submitted. radius (minimum 10 mm) not less than glass thickness Figure 3. Re-entrant and internal corners Ceramalite, Ceraphic and CeraGrit can be manufactured in various geometric or irregular shapes. Handling and Storage Stack upright, fully support at the back Stand on wood or felt Glass surfaces should be separated at all times Store dry at all times Store out of sunlight at all times Check for damage Handle correctly Protect from impact Avoid contamination Glazing Ceramalite, Ceraphic, CeraGrit, Cerocco and PolyLite should be handled with great care at all times. Correctly stacking and supporting of all glass products, in a manner which prevents the glass from sagging, helps to avoid breakages. To prevent edge damage, the glass must stand on strips of something softer than glass, such as wood or felt. Water must not be allowed to reach the edges of stacked glass as it can be drawn between the glass by capillary action and cause damage to the glass surfaces. Glass should be unpacked on arrival at site and checked for conformity to specification. Any damage should be reported immediately. Use protective clothing and equipment (a minimum of gloves and safety glasses). Lift the glass in a safe manner using appropriate equipment. Note that glass suckers are not appropriate for lifting CeraGrit on the gritted surface. Special care must be taken to protect Ceramalite, Ceraphic, CeraGrit, Cerocco and PolyLite, especially the edges, from impact damage (knocks, abrasions and excessive local pressure) which can cause breakage, scratches, scars, chips or shells. Before use, the glass should again be checked for damage and the size checked with the frame to ensure that the glazing can be carried out as specified. Damaged glass should not be glazed. Ceramalite, Ceraphic, CeraGrit, Cerocco and PolyLite must be protected from site contamination such as welding spatter, or cementitious or plaster products, or adhesives. Particular attention should be paid to protecting the surface of CeraGrit from contamination as it may be difficult to remove. The requirements of BS 6262 and BS 8000: Part 7 should be considered. This publication gives a general description of Ceramalite, Ceraphic, CeramalitePlus, Ceragrit, Cerocco, and Polylite It is the responsibility of the customer to ensure that its use is appropriate for the application and complies with all relevant national and local legislation, standards and codes of practice and any other requirements. Hansen Glass Processing Limited hereby disclaim all liability howsoever arising from any error or omission from this publication and of all consequences of relying on it. Fort, FortPlus, FortPlus Laminated, ThermoSpan, ThermoCool, Tempo, Ceramalite, CeramalitePlus, Ceraphic, and CeraGrit are all trade marks of Hansen Glass Processing Ltd. Polylite is a registered trade mark of David Oliver. 11

12 Product Range ThermoSpan Structural Glazing Fort and FortPlus Toughened Glass Tempo Toughened Glass Doors and Entrance Assemblies Thermocool Insulating Glass Units Ceramalite Enamelled Spandrel Panels Ceraphic Screen Printed Glass Services Glass Processing Contract Co-ordination Site Deliveries ThermoSpan Detailing Technical Support After Sales Support Market Sectors Commercial Leisure Community and Amenity Retail Industrial Transportation Utilities Manufacturing Institutions Military Technical Services Glass Stress Calculations Thermal Stress Calculations Glass Environmental Properties Glass Acoustics Advice Technical Advisory Service (TAS) available at all Group Companies HansenGroup Mission: To be the Company in the industry above all others from whom our customers choose to buy with whom people choose a career in whom the professionals have confidence whom manufacturers choose to distribute their product. HansenGlass Hornhouse Lane Kirkby Merseyside United Kingdom Tel: (44) Fax: (44) sales@hansenglass.co.uk HansenGroup Greengate Industrial Park Greenside Way Middleton M24 1SW United Kingdom Tel: (44) Fax: (44) info@hansengroup.biz