Europanel. Technical manual. delivering low risk building solutions

Transcription

1 Europanel Technical manual delivering low risk building solutions

2 Contents About Eurobond Laminates 1 Structural Performance 2 Fire Performance 3 Environmental Performance 4 Thermal & Acoustic Performance 5 Weights, Dimensions & Tolerances 6 Panel Clamp 7 Standard Details Europanel horizontally laid 8 Europanel vertically laid 10 Ancillaries Fasteners 12 Corners & Omegas 13 Integrated Windows, Doors & Louvres 14 Eurobond Doors 15 Technical Expertise 16 Colorcoat Products & Services 17 If you would like any additional information on any of the topics highlighted in this technical manual or project specific technical information not included then please contact us and we would be happy to discuss your requirements Telephone Fax technical@eurobond.co.uk Please note that the information contained in this technical manual is not comprehensive and additional information can be found on our website delivering low risk building solutions

3 Structural Performance Manufactured using metal facings bonded to a high density structural stone wool core, Eurobond s panels offer exceptional spanning characteristics. Following significant development and testing, Eurobond composite panels can be used to span up to 12m*. Using panels that can span up to 12m means that secondary steelwork can either be eliminated or significantly reduced allowing the following benefits: Reduction in build time Reduction in steelwork cost Cleaner, uncluttered internal appearance Increase in useable internal area of the building Wind pressure, suction and temperature are the only significant load elements, except for handling considerations, constraining the length of the panel. Wind loads are dependent on the building location and dimensions. The calculation of the wind loads, as laid down in BS 6399: Part 2: 1997, is a complex and demanding procedure, and must be undertaken by a qualified engineer. Please visit to view a range of span tables for Europanel. Please note that the tables provided on the website are not comprehensive and for specific calculations please contact our technical department who will be happy to provide detailed span information based on your project needs. *Dependant on project/building environment we can sometimes offer spans in excess of 12m please contact Eurobond technical department for project specific information. 2 delivering low risk building solutions

4 Fire Performance All Europanel composite panels offer high levels of fire resistance and have been tested and approved by the Loss Prevention Certification Board (LPCB) and FM Approvals (FM). The following table details the panel specifications and fire performance achieved. Product Panel thickness Fire resistance (minutes) Maximum unsupported span (m) (mm) Insulation Integrity LPS 1208 BS476 Pt 22 and/or LPS 1181 BS EN 1364 Pt EXT-A EXT-A EXT-A EXT-A EXT-A EXT-A60 Europanel EXT-A60 Lite EXT-A EXT-A EXT-A EXT-A EXT-A EXT-A EXT-A EXT-A EXT-A EXT-A EXT-A * EXT-A EXT-A EXT-A * EXT-A90 Europanel EXT-A120 Extra EXT-A EXT-A EXT-A EXT-A EXT-A EXT-A EXT-A EXT-A EXT-A EXT-A EXT-A120 *Joint stitched on both sides at 3m centres FM Global FM Approvals accepts Europanel to standard 4880 Class1 fire classification of metal faced insulated wall panels with a non combustible core for installation with no height restriction. Panels can be installed either horizontally or vertically. Non-Combustible Core All our panels have stone wool cores which are noncombustible as defined by the Building Regulations applicable to all parts of the United Kingdom and the Republic of Ireland. This includes materials classified as Class A1 in accordance with BS EN : 2002 Fire classification of construction products and building elements Part 1: Classification using test data from reaction to fire tests, when tested to BS EN :2002. T +44 (0)

5 Environmental Performance As a responsible UK manufacturer, Eurobond is justifiably proud of it s environmental record and recognises the importance of sustainable construction. Our philosophy is one of continual improvement and we strive to manufacture the most environmentally responsible products available whether that is through Life Cycle Assessment (LCA), implementation of Environmental Management Systems or the demonstration of a truly sustainable approach. BREEAM & Environmental Product Declarations The BREEAM family of assessment methods and tools are designed to help construction professionals understand and mitigate the environmental impacts of the developments they design and build. When the building has been evaluated through BREEAM, the building owner, developer, and/or occupant may use the assessment rating to demonstrate the sustainability performance of their building in the marketplace. The environmental credentials of Eurobond's products ensure that, within the materials section of BREEAM assessment, buildings are given an ideal start to achieve a high rating. WRAP Approved Recycling Eurobond has been given the seal of approval by leading recycling government backed organisation WRAP (Waste & Resources Action Programme). In independent tests WRAP found Eurobond s products are fully and independently recyclable, allowing new stone wool cored composite panels to be made diverting waste from landfill. Life Cycle Assessment Europanel panels are BREEAM-ready. Full Life Cycle Assessments are available on all Eurobond products and help to quantify the total environmental impact. End of Life Solutions & Recycled content The construction sector is the largest producer of waste to landfill in the UK, Eurobond recognise that a more efficient use of materials would help to minimise the environmental impact of construction, reducing carbon emissions by diverting materials from landfill and limiting the depletion of finite natural resources. As such we advocate a 'Cradle to Cradle' approach to recycling where materials are recycled in a closed loop. This maximises material value whilst minimising the damage to ecosystems - products are used, recycled and re-used again without losing any material quality. This ensures that all materials used in the manufacture of Eurobond panels have a high content of recycled materials. The separated steel and stone wool are returned to their respective manufacturers and entered back into the supply chain as undiminished materials. Eurobond's stone wool composite panels pose minimal impact to the environment as they rely upon trapped air to attain their thermal properties. Stone wool is manufactured from diabase rock, a natural resource found in abundance around the world. Hazardous & flammable chemical compounds such as pentane are not required as blowing agents during production reducing the overall environmental impact of Eurobond composite panels. If you would like further information on the performance credentials of Eurobond's panels please contact our technical team on or us at technical@eurobond.co.uk 4 delivering low risk building solutions

6 Thermal and Acoustic Performance Thermal Performance: Eurobond panels have been specifically designed to meet the as built thermal requirements of the Building Regulations and/or Technical Handbooks in England and Wales, Scotland and Northern Ireland. U-value calculations (W/m 2 K) Panel thickness (mm) Europanel Lite Extra N/A 0.20 Based on a mineral wool core with a k value of W/mK for Lite and W/mK for Extra All figures have accounted for any thermal bridging at the interlocking joint. Typical example of a Trisco Thermal Model for Europanel [ C] Acoustic Performance: As buildings all need some form of acoustic control to meet specific client and/or regulatory requirements (Building Regulations Approved Document E), the following guidance is intended to provide the architect, designer, acoustic engineer and end user with qualification of Europanel performance in England and Wales, Scotland and Northern Ireland. Weighted sound reduction index Rw (db) Panel thickness (mm) Europanel Lite Extra N/A 34.5 All calculations based on the following panel specification: External face: 0.7mm thick steel Airborne sound transmission Noise source Reflection reverberation Noise source Rain impact sound transmission Flanking Flanking Internal face: 0.5mm steel Core: 99 kg/m 3 Europanel Lite; 135 kg/m 3 Europanel Extra The information shown above is based on The Metal Cladding and Roofing Manufacturers Association (MCRMA) acoustic performance software provided by the University of Salford Acoustic Department and is fully substantiated by tests carried out by the C.S.T.B Paris. T +44 (0)

7 Weights, Dimensions and Tolerances Europanel Joint Dimensions Factory fitted foam gasket Panel thickness Structural stone wool core 3mm thick pre-punched spreader washer 2mm nom. Stainless steel fastener Vertical support steel work 5mm open joint Weights (kg/m 2 ) Lite 0.7 / 0.5 mm steel faces N/A* Extra 0.7 / 0.5 mm steel faces Lite 0.7 / 0.7 mm steel faces N/A* Extra 0.7 / 0.7 mm steel faces * 200 mm not available in Lite, only Extra Length Width Thickness Corners (leg length) Flatness Joint gap Tolerance ± 10mm ± 5mm ± 2mm ± 3mm 1.5mm from the theoretical flat plane over a distance of 700mm ± 2mm 6 delivering low risk building solutions

8 Panel Clamp Standard details Eurobond recommends the use of our patented panel clamp for safe and easy installation of panels. The panel clamp is perfect for installing our Europanel, Rockspan and Firemaster range of panels, when laid horizontally. Clamps are available to suit all panel thicknesses. Each pair of clamps has a safe working load of 500 kg, which allows them to safely lift even the longest panels that Eurobond can currently supply. The clamps work by gripping the flanges on the top of the panel by means of a cam and wedge mechanism. A half turn of the actuating lever is all that is required to lock the clamp onto the panel. Safety features are a spring loaded pin that holds the cam in the locked position, a mechanism that tightens the grip on the panel during lifting and in the unlikely event that there is a failure of the panel or the clamp, a set of safety strops that will stop the panel from falling. The clamps are designed to offer an easy installation of horizontally laid panels whilst maintaining the highest levels of safety. The clamps are suspended from the lifting beam by links that allow them to rotate in the horizontal plane, making it possible to pick-up panels directly from the stack as delivered with the minimum of manual handling. Lifting methods can either be a crane or a telehandler as shown below. The Benefits of Mechanical Handling Techniques Increased productivity - realistic installation of up to 600m 2 of panel a day Full compliance with H&S and CITB due to the removal of manual handling on site Time savings - being able to install up to 600m 2 of panel a day allows for earlier project completion, meaning contractors are able to complete more projects in a year Significant labour cost savings are provided, through reduced labour and faster completion on site Reduced damage to panels on site Panel Clamp Components 3m spreader beam Set of safety strops 2 clamps Safety chain D shackles Delivered in a toolbox Each clamp is CE marked and comes with an instruction booklet. If you would like further information on our panel clamps or require additional installation information please contact our technical team on or technical@eurobond.co.uk T +44 (0)

9 Standard Details Europanel horizontally laid Eurobond have a comprehensive library of standard details that cover Europanel horizontal applications. NB: Always check with our website for the latest version of our standard detail. These details are available as PDF files, they are also available as DWG format to allow them to be directly imported into project-specific drawings. Factory fitted foam gasket Silicon seal at end of joint Continuous structural rear air seal 3mm pre-punched spreader washer overlap by 5mm Vertical panel rail to all vertical joints ±5mm tolerance Note: No EPDM washers EHJ filler plug 9x3mm butyl mastic Omega section secured to every spreader washer Structural stone wool core Stone wool insulation infill fitted behind omega section Omega insert (push fit) Direction of lay 8 delivering low risk building solutions

10 Standard Details Europanel horizontally laid (continued) 5mm horizontal joint EPH-01A Factory fitted foam gasket Panel thickness 3mm thick pre-punched spreader washer 2mm nom. Stainless steel fastener Vertical support steel work 5mm open joint Vertical joint steel omega with flush insert EPH-02A Stone wool batten 140 Continuous structural rear air seal 30 Panel thickness E.H.J. filler plug mm thick pre-punched spreader washer Steel omega section with flush insert cap Continuous 9x3mm butyl mastic These are example standard details, for our full range of standard detail drawings please visit T +44 (0)

11 Standard Details Europanel vertically laid Eurobond have a comprehensive library of standard details that cover Europanel vertical applications. NB: Always check with our website for the latest version of our standard detail. These details are available as PDF files, they are also available as DWG format to allow them to be directly imported into project-specific drawings. Factory fitted foam gasket Direction of lay Structural stone wool core 3mm pre-punched spreader washer overlap by 5mm Continuous 12x6mm rear air seal Note: no EPDM washers Cut edge coverstrip Galvanised steel ledger angle Cill flashing 10 delivering low risk building solutions

12 Standard Details Europanel vertically laid (continued) 5mm vertical joint EPV-01A Stainless steel fastener Factory fitted foam gasket 2mm nom. Horizontal support steel work Panel thickness 5mm open joint 3mm thick pre-punched spreader washer Panel module Typical cill detail EPV-05A Continuous 12x6mm rear air seal Panel thickness Base angle Ledger angle fixed with low profile head fastener Cover strip fixed at 450mm centres Typical cill flashing These are example standard details, for our full range of standard detail drawings please visit T +44 (0)

13 Ancilliaries Fasteners Eurobond recommend that fasteners should be stainless steel, the exact specification depends upon panel thickness and the gauge of steel work to which the panels are to be positively fixed. The tables below show our recommended fastener types. FIXFAST fasteners Panel thickness (mm) SFS fasteners Panel thickness (mm) EJOT fasteners Rail thickness 1.2 4mm 5 14mm 75 SXC5 5.5 x 92 SXC x SXC5 5.5 x 113 SXC x SXC5 5.5 x 133 SXC x SXC5 5.5 x 163 SXC x SXC5 5.5 x 193 SXC x SXC5 5.5 x 236 SXC x 218 Panel thickness (mm) Rail thickness 1.2 3mm 4 12mm 75 DF3 SS HT 5.5 x 110 DF12 SS HT 5.5 x DF3 SS HT 5.5 x 130 DF12 SS HT 5.5 x DF3 SS HT 5.5 x 150 DF12 SS HT 5.5 x DF3 SS HT 5.5 x 180 DF12 SS HT 5.5 x DF3 SS HT 5.5 x 205 DF12 SS HT 5.5 x DF3 SS HT 5.5 x 230 DF12 SS HT 5.5 x 240 A2 grade Stainless steel 8mm hexagon head without bonded washer 304 Austenitic Stainless no sealing washer 8mm hexagon head Rail thickness 1.5 3mm 4 12mm 75 JT3 D6H 5.5/6.3 x 87 JT3 D12H 5.5/6.3 x JT3 D6H 5.5/6.3 x 107 JT3 D12H 5.5/6.3 x JT3 D6H 5.5/6.3 x 147 JT3 D12H 5.5/6.3 x JT3 D6H 5.5/6.3 x 167 JT3 D12H 5.5/6.3 x JT3 D6H 5.5/6.3 x 197 JT3 D12H 5.5/6.3 x JT3 D6H 5.5/6.3 x 237 JT3 D12H 5.5/6.3 x Austenitic Stainless no sealing washer 8mm hexagon head Additional information Specifiers can choose from a wide variety of proprietary fasteners and should refer to the manufacturers literature for the full range of available products. Most of the fasteners used for metal cladding applications are self-tapping and self-drilling, although self-tapping only screws are also available. Fasteners can generally be divided into two categories: Primary fasteners transfer the loads from the cladding to the primary and/or secondary steelwork. Their main function is, therefore, structural. Secondary fasteners are used to form the interface between additional features and the panel face (e.g. flashings; rails to carry Rainspan architectural façades). While their primary purpose is to provide a weathertight seal at the joint, their structural properties may be used to provide lateral restraint and to tranfer load. Visible fasteners have the option of factory coloured plastic heads to suit the weathered sheet. Please note Eurobond do not supply fasteners. 12 delivering low risk building solutions

14 Ancilliaries Factory mitred corners & omegas A range of factory mitred corners is available to suit all thicknesses of Europanel. Corners can be supplied with angles to suit, any angles between 65 and 175 are available on request allowing Eurobond to provide a bespoke solution for your project. Horizontal corner panels Eurobond offers both internal and external corner panels for horizontally laid applications in all panel types, the maximum overall girth is 2000mm, with a minimum leg of 300mm. Vertical corners Eurobond manufacture vertical corners to a maximum length of 3600mm, maximum girth is 1200mm with a minimum leg of 300mm. Omegas The Omega section used to cover the vertical joint of horizontally-laid Europanels is 80mm wide and available as a roll-formed steel section. Steel Omega - available lengths 3658mm and 6000mm in pre-coated steel. Horizontal double cranked corners Eurobond can fabricate double cranked corners but due to their complex nature Eurobond should be contacted for confirmation of allowable dimensions. Omega insert Omega insert to cover the fixing in the Omega section. Flush steel Omega insert available lengths 3658mm and 6000mm in pre-coated steel. T +44 (0)

15 Integrated Windows, Doors & Louvres Europanel is a complete architectural system which has been specifically designed for integration with window, door and louvre components. Appearance of joints often depends on the skill of the installer to cut and notch the flashings around the openings. Eurobond has worked closely with a number of suppliers of architectural aluminium systems, to develop a range of windows, doors and louvres which are fully integrated with the Europanel system. The external frame of the window, door or louvre incorporates aluminium extrusions, which mimic the edge profile of the Europanel. This allows them to be installed in exactly the same way as the panels, eliminating the need for flashings and additional mastic sealing which in turn: All windows have been tested, with the panels, to CWCT recommendations for air and water penetration under static pressure. The window-panel system successfully passed the most severe category of 600 Pascals. Ensures a consistent installation standard Improves the aesthetic appearance Improves thermal performance Reduces air permeability Thermally broken aluminium window adaptor Reduces installation time Continuous structural rear air seal Direction of lay Vertical panel rail to all vertical joints ±5mm tolerance Structural stone wool core Stone wool insulation inill fitted behind omega section Omega section Omega insert 3mm pre-punched spreader washer overlap by 5mm Note: no EPDM washers If you would like additional or project specific information regarding integrated components with Europanel please contact our technical team on or technical@eurobond.co.uk 14 delivering low risk building solutions

16 Eurobond Doors Eurobond Doors is a sister company of Eurobond and is a leading designer and manufacturer of composite doors, supplying a range of doors for a variety of applications and due to the quality, technology and performance of the doors they are consistently specified for a wide range of industries. Personnel doors Insulated doors Fire doors In-house design allows us to provide the perfect solution for external and internal door applications. Eurobond combines functionality with outstanding aesthetic appeal, for use in commercial, industrial and public environments. Doors are available in single, double and unequal configurations. Options are also available for side panels, over panels, vision panels and louvers where applicable. The doors are specifically designed for incorporation into Eurobonds panel systems. A range of standard detail drawings are available via the Eurobond Doors website and technical department to allow easy specification of doors as part of your Eurobond building envelope. If you would like further information please contact our sales team on or visit T +44 (0)

17 Technical Expertise To assist in correct specification, detailing and installation of our products, Eurobond provide a comprehensive Technical Service which can assist in a variety of areas: Project Specific Design Advice As well as the standard information and range of details available, project specific information can be developed to cover: Load/span calculations Development of bespoke CAD details In Depth Fire Performance Knowledge Eurobond has extensive knowledge of the performance of composite panels in fires. We have carried out a wide range of recognised and bespoke fire tests, as well as working closely with acknowledged fire experts. This enables us to: Provide guidance in selecting the most appropriate products to achieve the required fire performance Provide correct detailing for each product Advise on the Building Regulations and insurance company specific fire requirements All Eurobond products are: BREEAM-ready with Life Cycle Assessment to ISO Fully compliant with relative Building Regulations and Technical Handbooks High in recycled content Fully recyclable Training We employ dedicated applications engineers to carry out on site training and also conduct a more comprehensive range of training courses at either customer premises or at our factory in Cardiff. This includes: Product application and installation training to ensure the correct specification and use of Eurobond products Pre-installation project guidance Project detail confirmation Sign-off and project completion reports Typical load/span calculation table External Walls External face Material steel Gauge (mm) 0.7 Colour Light Yield strength 220 Core Core Thickness (mm) 125 Applicability of panel OK Internal Face Material steel Gauge (mm) 0.5 Yield strength 220 Panel Landing area end support (mm) 65 Panel Landing area Intermediate Support (mm) 140 Panel Length (m) 6 Panel width (mm) 1000 Internal Temperature Summer 25 Internal Temperature Winter 20 Internal Ambient Temperature 20 External Temperature Summer 55 External Temperature Winter -10 Selected fastener (drop down) Pull out strength of fasteners (N) JT3-D6H Gauge of the support 2 Number of fasteners at end support 3 Number of fasteners at intermediate support 4 Results Single Double Triple Span Span Span Span (m) Maximum Allowable Pressure (kn/m 2 ) Maximum Allowable Suction (kn/m 2 ) Eurobond has its own in house research and development staff who are continually seeking to improve the performance of existing products and develop new ideas. Experience gained through research and development allows Eurobond to speak with authority on the performance of our panel systems, confident in the knowledge that advice given is based on information gained through testing, prototyping and practical experience. Members of Eurobond s Technical Department are available to attend site meetings to provide expert technical advice at the design stage, during installation and post-installation. 16 delivering low risk building solutions

18 Tata Steel Colorcoat Products and Services The Colorcoat brand provides the recognised mark of quality and metal envelope expertise exclusively from Corus. For nearly 50 years Tata Steel has developed a range of technically leading Colorcoat pre-finished steel products which have been comprehensively tested and manufactured to the highest quality standards. Tata Steel supply pre-finished steel to normal and special tolerances according to EN 10143:2006 to ensure that the cladding performs as designed. Our Colorcoat products are supported by a range of services such as comprehensive guarantees, colour consultancy and technical support and guidance. To ensure the long-term performance and appearance of the building, it is important that the pre-finished steel product is specified alongside the cladding system. To secure the peace of mind that comes from a rigorously manufactured and tested product from Tata Steel, ensure Colorcoat as well as the individual product name is specified for your cladding system e.g. Tata Steel Colorcoat HPS200 Ultra. Colorcoat HPS200 Ultra The latest generation product for roof and wall cladding, Colorcoat HPS200 Ultra is the only pre-finished steel product to ensure your building envelope maintains its integrity and aesthetic appeal for up to 40 years, without ongoing maintenance or inspection costs. We guarantee it won t let you down. For more information visit Key benefits include: Confidex Guarantee for up to 40 years including cut edges. 40 standard colours in solid and matt shades. Surpasses requirements of Ruv4 and RC5 as per EN 10169:2009 proving outstanding colour retention and corrosion resistance. Incorporates the most advanced coating technology, to provide twice the colour and gloss retention of standard plastisol products. Scintilla embossed as a mark of authenticity from Tata Steel. Available CarbonNeutral through Confidex Sustain. Colorcoat Prisma Designed to withstand the rigours of the external environment, versatile, lightweight and strong, Colorcoat Prisma pre-finished steel is the ideal choice for your building envelope for long lasting colour. With a contemporary new colour range and an optically smooth finish, inspire your imagination. For more information visit Key benefits include: Confidex Guarantee for up to 30 years including cut edges. 27 standard colours in solid, metallic and matt shades. All solid and metallic colours surpass requirements of Ruv4 and RC5 as per EN 10169:2009 proving outstanding colour retention and corrosion resistance. Reverse side branding making traceability easy, so you can rest assured that your building is protected with the highest quality from Tata Steel. Available CarbonNeutral through Confidex Sustain. Tata Steel Colorcoat services Confidex Guarantee The Tata Steel Confidex Guarantee has evolved from nearly 50 years experience in pre-finished steel development and manufacture. Available with Colorcoat HPS200 Ultra and Colorcoat Prisma, the Confidex Guarantee is clear and simple to register and can easily be transferred if building ownership changes. Tata Steel are so confident in these products that cut edges are guaranteed for the entirety of the guarantee period and there are no mandatory inspection or maintenance to uphold the validity. For more information visit Confidex Sustain TM Confidex Sustain is an enhancement of the Confidex Guarantee. As well as covering the performance of the Colorcoat HPS200 Ultra and Colorcoat Prisma used on your building, it offsets the unavoidable CO 2 emitted during production of the whole cladding system, including the insulation and fixings. For more information visit Colorcoat Building Manual The Repertoire Colour Consultancy can advise on colours and colour strategies using a range of standard shades, as well as discussing individual bespoke colour requirements. For orders over 2000 m 2 Tata Steel can match almost any solid colour from physical swatches to commonly used references such as RAL, NCS and British Standard and more unusual standards. Available with Colorcoat HPS200 Ultra and Colorcoat Prisma and the Confidex Guarantee. For more information visit Colorcoat Technical Papers Tata Steel have published a wide range of technical papers to independently guide and advise you on key issues in building design and construction commonly considered for roof and wall cladding systems using Colorcoat products. From acoustics and air-tightness to low carbon design, gauge tolerance and fire performance, there is a technical paper that will help you find a solution. Visit to download the papers. For more information about Tata Steel Colorcoat products and services visit or call the Colorcoat Connection helpline on +44 (0) Colorcoat, Colorcoat Connection, Colorcoat HPS200 Ultra, Colorcoat Prisma, Confidex, Confidex Sustain, Galvalloy, Repertoire and Verso are registered trademarks of Tata Steel UK Limited. T +44 (0)

19 Eurobond Laminates Ltd Wentloog Corporate Park Cardiff CF3 2ER Telephone: Fax: Ref: ETM - 11/10 In association with our strategic trading partners Rockwool, Sika and Tata Steel. delivering low risk building solutions 18