MANUAL INSTALLATION MAINTENANCE ARCHITECHURAL GUIDE

Transcription

1 MANUAL INSTALLATION MAINTENANCE ARCHITECHURAL GUIDE

2 CONTENTS Secton 1 - Product Overvew Secton 2 - Typcal Applcatons Secton 3 - Lmtatons Secton 4 - Tools and Equpment 4.1 Installaton Tools Lst 4.2 BoClad Thermoformer 4.3 Usng the BoClad Thermoformer 4.4 Measurng for Bends n the BoClad Panel Secton 5- Adhesves Secton 6- Preparaton/Pre-nstallaton 6.1 Envronment 6.2 Wall Substrates 6.3 Preparaton/Pre-nstallaton nstructons Secton 7 - Installaton 7.1 Jontng Methods Overvew 7.2 Two-part Jont Strp Installaton Procedure 7.3 Sngle-part Jont Strp Installaton Procedure 7.4 Heat Weldng Installaton 7.5 Wall to Floor Transton Strp Secton 8 - Cleanng Secton 9 - Safety Procedures Secton 10 - Datasheets Installaton, Mantenance & Archtectural Gude

3 Secton 1: Product Overvew BoClad s a sem-rgd, smooth, and durable vnyl sheet panel system. The materal s thermoplastc and can be cut and thermoformed nto specfc shapes to sut the contours of the buldng. ts sem-rgd propertes allow BoClad to be nstalled over most sound substrates wth mnmal preparaton and dsrupton. All jont, transton, and edge trms are hgh qualty vnyl co-extrusons ncorporatng a neoprene gasket for a watertght surface. When ncorporated wth heatwelded, flash coved floorng, the system s deal for such areas as showers, clean rooms, and laboratores. For detaled specfcatons contact BoClad Ltd. BoClad Product Specfcatons BoClad Sngle Skn PVC Panel Manufacturer: BoClad Ltd - Web: - Tel: Product reference: BoClad Sngle Skn PVC Panel Sze (w x h): [1220 x 2500 mm] [1220 x 2800 mm] [1220 x 3050 mm] Thckness: [2.5 mm] Manufacturer s Standard BoClad PVC Antmcrobal Panel contanng Bocote slver Ion antmcrobal addtve throughout the product thckness wth a lfetme guarantee and a Sngle source Manufacture/nstaller warranty Secton 2: Typcal Applcatons - Showers - Ktchens - Operatng Rooms -Scrub Rooms - Laboratores - Clean Rooms -Veternary Clncs - Food Producton Areas - Servce Corrdors Lmtatons Sem-rgd panels can be appled to most surfaces, t should however, not be nstalled near a heat source such as steam kettles, pzza ovens, cookng ranges, steam rooms, etc, or where exposed flame or severe heat could cause dstorton of the BoClad panel. Once nstalled, BoClad panels should not be exposed to temperatures above 140 F (60 C). BoClad can become brttle at low temperatures and s not recommended for nstallatons subject to temperatures below 23 F (-5 C) where t s exposed to hgh mpact. It s fne n chll rooms and refrgerated storage but s not recommended for freezers. Before the testng of ktchen equpment, whch s lkely to expel severe heat, extracton systems must be operatonal. Falure to do so may result n expanson problems. Fre ratng: BS 476-7, Class 1 BS 476-6, Class 0 ASTM E 84, Class A Installaton, Mantenance & Archtectural Gude

4 Secton 4: Tools and Equpment Installaton Tools Lst Below are tools that you may need for the nstallaton of BoClad: Hand Tools: Stanley knfe and blades Krsten scraper (decorators scrappng tool/pant scraper) square notch trowel wall roller hand roller 3 (1 meter) & 6 (2 meter) levels laser/water level ladders and/or scaffolds Lazer level small block plane tape measure hammer rubber mallet caulkng gun fle hole cutters / drll bts ant-statc wpes Workbench: 1 pece of plywood (mnmum 15mm thck) 10 (3 meter) straght edge, f desred 2 x 4 or 2 x 6 support beams metal stands for Thermoformer 2 sets of legs (saw horses) workng heght of 34 (85cm) Safety Equpment: goggles/safety glasses protectve gloves hard hat safety boots vsual vest Electrcal Equpment: access to electrcty jgsaw wth fne toothed blades electrc sheet metal sheers, f desred drll (for mxng paddle and hole saw) extenson cords BoClad Thermoformer BoClad Thermoformer The BoClad Thermoformer allows nstallers to heat and shape BoClad wall panels to conform to the contours of a room. Ths allows the BoClad wall panels to reman seamless even around corners. If usng the BoClad Thermoformer, work should be done on an approprate szed workbench. Supports should be recessed allowng the Thermoformer to be set nto and ensurng that the heater top (Thermoformer) s level wth the top of the bench. The bench top should be flush wth the sdes of the Thermoformer, and not coverng t. Ths s so the panel can be lad across the heat source whle thermoformng and an even dstrbuton of heat s obtaned along the length of the bend lne. Alternatvely you may set up a 4x8 workbench on saw horses and set the Thermoformer adjacent on separate metal stands Usng the BoClad Thermoformer 1. Assemble workbench wth Thermoformer nset flush wth the workbench. 2. Plug-n the Thermoformer and let t warm up for approxmately 30 mnutes before begnnng thermoformng. 3. Wth pre-establshed bend lnes marked on the face of the BoClad panel (flm sde): centre the bend lnes Installaton, Mantenance & Archtectural Gude

5 over the heat element openng on the Thermoformer heatng from the backsde when allowable. You may heat the face of the BoClad (flm sde) for certan bends beng careful not to melt the plastc flm onto the servce. External to external corners, add the thckness of the panel and adhesve for both corners. Internal to nternal corners, subtract the thckness of the panel and adhesve for both corner. 4. Allow suffcent tme for the BoClad panel to heat up untl there s a vsble softenng of the materal over the lne where the materal s to be thermoformed (ths takes approxmately 30 seconds). Internal to external corners, use the exact measurement of the substrate, do not add or subtract. 5. Immedately move the materal from the thermoformer onto the flat workbench. 6. Thermoformng can be done n one of two ways: Process one, used for sharper corner edges s accomplshed by foldng the materal back upon tself and then returnng to the poston of the corner requred and holdng n place untl the sheet has cooled and become rgd for approxmately 30 seconds. Process two, used for softer corner edges, s accomplshed by foldng the materal drectly to the requred corner angle and holdng untl cool and rgd for approxmately 30 seconds. 7. Make any addtonal bends needed n the materal followng the same procedure Measurng for Bends n the BoClad Panels BoClad recommend; usng thermoformed nternal/ external corner detal when nstallng the BoClad panels. Ths s acheved by heatng the panel on a BoClad thermoformer unt and manually formng the panel to the desred angle. Always measure and mark on the face of the panels. Always measure from the outsde of the prevous corner. Frst, exactly measure the substrate (dstance) to be covered. Then ether: Installaton, Mantenance & Archtectural Gude

6 Secton 5: Adhesves Use only approved adhesves as recommended by BoClad Ltd. Consult the adhesve label for detaled applcaton nstructons. Recommended Trowel Notch: Use a square notch trowel. BoClad 2 Part Adhesve: Two-part polyurethane adhesve s the default adhesve for smooth surfaces for most nstallatons. Ths ncludes wet areas, non-clmate controlled areas and all non-absorbent surfaces. Water-based acrylc adhesve may be sutable for absorbent surfaces n dry, clmate controlled areas Bond test should be performed on all surfaces. Substrate: - Plasterboard - Plywood - Metal - Ceramc tles Provded tles are frmly bonded to the substrate and free from surface contamnaton, grease etc. - Plaster - Concrete - Brckwork Brckwork & blockwork should be good qualty and jonts should be flush - Blockwork Brckwork and blockwork should be good qualty and jonts should be flush - Panted A bond test s advsable to check adhesve does not react wth pant. Secton 6 - Preparaton and Pre-nstallaton 6.1 Envronment BoClad should be nstalled n an area wth ambent temperatures between 65 F (18 C) and 80 F (27 C). Areas to receve BoClad must be weather-tght and of approxmate humdty condtons of the fnshed room Wall Substrates BoClad sem-rgd panels can be appled to most sold wall surfaces. All surfaces must meet these requrements: - Walls should be smooth and level. Hgh ponts must be removed and low ponts flled wth fller ntended for the substrate and envronmental condtons. - Wall tles must be fxed frmly to the wall. As long as the tle edges do not protrude you do not have to skm grout jonts. - Surfaces must be permanently dry and free from all substances that may contrbute to adhesve bond falure. - Remove loose pant and conduct an adhesve bond test wth pant. - Exteror walls must be adequately dampproofed and nsulated. - Dry wall substrates should be pant ready Preparaton/Pre-nstallaton Instructons All surfaces must be free from dust and cleaned pror to BoClad nstallaton. The workng envronment must also be dust free. Falure to comply wth these condtons wll reduce the bond strength between the adhesve and substrate, and may cause the BoClad panels to debond. - Very absorbent / porous substrates (partcularly plaster fnshes and unprmed plasterboard) must have a propretary sealer e.g. PVA prmer or smlar, appled to the surface a mnmum of 12 hours pror to the nstallaton. Installaton, Mantenance & Archtectural Gude

7 - All electrcal swtches, power ponts etc., should be n a frst fx / nstallaton state. All electrcal equpment should only be moved or altered by a qualfed electrcan. - All plumbng should have ppe-work removed to a frst fx or nstallaton state and tals left protrudng from the substrate. BoClad panels can then be drlled and sld over the ppe tals. All holes should be drlled 1/8 (3mm) oversze to allow for expanson, then sealed wth Mastc caulkng. Plumbng should always be done by a qualfed plumber. - Hot ppes and steam ppes should be nsulated and a 1/8 to 1/4 (3-6mm) expanson gap should be created when nstallng panels around these ppes, then sealed wth caulkng. - All ppes, fxng bolts, etc. extendng through the BoClad panels should have a mnmum (3mm) expanson gap and be sealed usng caulkng. - If fttng to door frames, these must be n place pror to the nstallaton of BoClad - Pror to nstallaton, t s advsable to complete any pantng whch comes n contact wth BoClad. as sealant used at junctons s non-pantable. - Panels should be stored flat and be pre condtoned a mnmum of 24 hours n ambent temperatures smlar to the prevalng operatonal condtons. - The panels must be stored on a level flat surface off the ground (rsk of condensaton on the panels f stored on damp surfaces). Storage on uneven surfaces could cause the panels to dstort pror to nstallaton. - Frst, check the room usng a 6 (2 m) level to ensure all walls are flat, payng partcular attenton to the corners, wndow reveals, and door entrances. These need to be nspected to ensure they are free of any debrs or rregulartes, whch could prevent the panels layng flat to the substrate after the adhesve has been appled and the panel nstalled. - The wall surface must be clean and dust free pror to nstallaton. Secton 7 Installaton 1. Apply a datum lne (level lne) around the entre nstallaton area. The datum lne s used for the calculaton of measurements to celng/floor heght, sockets, ppes, etc., and to ensure the panels are plumb as the nstallaton proceeds. It s advsable to set ths datum lne at 51 (1550 mm) off the fnshed floor. Ths way the lne s near eye level and s easy to locate when placng the panels on the wall. 2. Place panel on the workbench and nspect for damage. On the face (BoClad protectve flm), carefully mark your datum lne on the flm, usng a pen. takng care not to press too hard, and possbly damagng the surface of the BoClad panel. 3. Take measurements from the wall datum lne to the floor/cove juncton and to the celng, and then transfer these to the protectve flm of the panel. Cut the panel usng a jgsaw wth a fne toothed blade, makng sure the panel s well supported to reduce any rsk of stress n the materal when beng cut. 4. Once cut. peel back and remove the protectve flm approxmately 2 (50mm) from the edge. 5. Hold the panel up to the substrate, ensurng you have a 1/8 (3mm) expanson jont at all abutments and ppe work. 6. Return panel to the workbench and make any bends as needed usng the BoClad Thermoformer (see Secton 4.2 BoClad Thermoformer and Secton 4.3 usng the BoClad Thermoformer). Installaton, Mantenance & Archtectural Gude

8 7. When the panel has been made to sut the requred fnsh detal lay the panel face-down on the workbench and clean the back of the panel. Adhesve Recommendatons: BoClad two-part polyurethane adhesve s recommended for all nstallatons n wet areas, non-clmate controlled areas and for all non-absorbent surfaces. 9. Prepare and spread the adhesve: - When usng BoClad two-part polyurethane adhesve, carefully mx parts A and B together usng a low-speed mxng drll and paddle for a mnmum of 3 mnutes, untl an even colour of the adhesve s acqured. - Apply the adhesve to the back of the panel, usng the recommended trowel notch sze. The adhesve should be appled approxmately (12mm) from the edge of the panel, and rght up to the tapes. - The workng tme of the adhesve s approxmately 40 mnutes dependng on the ambent temperature of the room. The trowel must be held so that the adhesve s appled to an even fnsh, and the trowel notches are replcated to the same depth over the entre panel. - At any ponts where there may be a gap between the wall and panel, apply addtonal adhesve. 10. Carefully remove the protectve flm from the double-sded tape, lft the panel to the wall and adhere to the requred locaton usng the datum lne prevously appled to the wall. Apply pressure to the datum lne area of the panel so as to set the double-sded tape. Apply pressure to the whole panel face to ensure the adhesve has been transferred and wll be fully bonded to the substrate. Ths s normally done wth a wall roller or rubber mallet, and a pece of scrap materal to prevent the surface from beng damaged. 11. Falure to ensure a good transfer of adhesve to the substrate could result n the panel debondng. 12. The curng tme of the adhesve s approxmately 8-12 hours dependng on the ambent temperature Jontng Methods Overvew There are three types of jontng methods used wth BoClad. Jont Strps Jont strps should be used n areas where there are temperature changes such as ktchens, showers, and spa areas. The jont strp gves the wall panel room to expand and contract due to the temperature and humdty changes. There are two types of jont strps - a one part strp and a two part strp. Sngle-part jont strps should be used n areas wth publc access or controlled areas such as prsons or mental health nsttutons where people could scratch or peel off the strps. Two-part jont strps are recommended for all other nstallatons. Heat Weld Heat weld n envronments where hygene s crtcal to the applcaton and a seamless flat wall surface s requred. Heat weldng should not be used n areas where there are notceable temperature changes that cause the panels to expand and contract. These are envronments where the nature of the actvtes takng place cause temperature changes such as ktchens and showers. When heat weldng, a small area should be heat welded and nspected for clent approval pror to proceedng wth entre nstallaton Two-part Jont Strp Installaton 1. Once the panel s n poston, slde the back part of the two-part jont strp under the nstalled panel. Leave a small gap (about 1mm) between the panel edge and the centre part of the back sde of the jont strp (there s a slghtly ndented lne n the strp to use as a gude). If a transton strp s to be used to create a horzontal jont between the panel and the vnyl floor fnsh, the back part of the vertcal strp should be cut short to allow the horzontal transton strp to be ftted at the base of the panel. Installaton, Mantenance & Archtectural Gude

9 2. When formng the front cover around nternal and external corners, the back of the trm should be carefully undercut to allow the trm to bend around the angles. 3. After ths procedure has been completed, nstall the next BoClad panel n the sequence. Fnsh by nstallng the front cover secton of the two-part jont strp. 4. The front jont strp covers should be ntally postoned by hand pressure. They can then be fully set n place by tappng wth a rubber mallet or a hand roller Sngle-part Jont Strp Installaton The process of the sngle-part jont strp s smlar to the two-part jont strp except that durng preparaton, a small chamfer / bevel wll need to be appled to the edges of the panel where the jont strp s ft onto the panel. Ths wll enable the sngle-part jont strp to be ftted more easly to the panel. The jont strp has a mosture resstant gasket seal on the nner edges whch could be damaged f forced onto the panel. 1. Bevel the panel edges where the jont strps wll be used (use an electrc or hand fle, a small block plane, or a Skarsten scraper to bevel the panel edges). 2. Ft the jont strp onto the leadng edge of the panel. Tap the jont strp all the way onto the panel. 3. Apply tape and adhesve to the back of the panel remove the protectve flm from the double-sded tape, and nstall the panel onto the wall. 4. Prepare the next panel ensurng that edges are chamfered, nstall a jont strp to the leadng edge of ths panel (tap jont strp all the way nto and seated aganst the panel). 5. Apply tape and adhesve to ths panel and remove the protectve flm from the double-sded tape. 6. Install the panel that has just been prepared. Ths panel s set onto the wall so t overlaps the back leg of the prevous jont strp. Remember to use the datum/level lnes to set the heght. 7. Use a tappng block or plastc star tool (chsel) to adjust the jont strp sdeways so t overlaps the two panels equally (make sure the jont strp s straght and level). Start at the top and work your way down the strp. As a summary of the sngle-part jont strp nstallaton; nstall the panels n sequence from left-to-rght and ft a connector strp to the rght sde of each panel before you place t on the wall. After two panels are ft to each other, the jont strp s then tapped over and onto the rght hand sde panel beng nstalled. A tappng block or plastc star tool (chsel) must be used to adjust the jont strp sdeways so t overlaps the attached panels equally Heat Weldng Installaton 1. Remove burrs from panel edges, leavng a slght bevel at the edge to be welded. 2. Apply 2 wde double-sded foam tape on the wall so t s centred at the seam. Apply adhesve and nstall panel to the wall. 3. As you place the adjonng panels on the wall, allow a 1.8mm - 2.2mm gap between each panel. 4. Clean both the seam area and the weld rod wth a safe solvent cleaner - one that wll not attack the vnyl or leave a flm. 5. Wat untl temperature and speed have been satsfed. 6. Test weld on a scrap pece of BoClad before proceedng. Refer to 7.1 Jontng Methods Overvew for Heat Weld concernng approval of weld. 7. The weld may be trmmed flush when sem-cooled usng the round part of the trmmng spatula Wall to Floor Transton Strp The transton strp s ftted to connect a panel to the floorng. As descrbed prevously, the vertcal jont strps are cut shorter than the full panel length. To fnd the correct length of the vertcal secton requred, use a small pece of Installaton, Mantenance & Archtectural Gude

10 transton strp (as a template) and ft ths to the bottom of the panel. Then measure the length of the vertcal jont strp requred and ft. Secton 8 Cleanng Intal Cleanng Once all panels and jonts are nstalled, remove the protectve flm and clean all surfaces down wth antstatc soluton or antstatc wpes. Ths s requred as the panel may have statc buld up and any dust n the atmosphere wll adhere to the surface of the panel. Regular Cleanng - BoClad can be cleaned wth a dluted soap/detergent soluton. - When cleanng the Boclad surface, we recommend the temperature of water does not exceed 140 F (60 C). -Pressure cleanng wth hot water may be used wth the pressure nozzle a mnmum of 2 feet (600mm) away from the surface. - To reduce the buld-up of statc, cleanng the panels wth ant-statc soluton s recommended. -For stubborn stans use alkalne cleaner. - Some cleanng agents may adversely affect BoClad. - Do not use materals contanng abrasves or solvents. Cleanng Agents Antstatc soluton can be obtaned from a varety of cleanng product manufacturers. Secton 9 - Safety Procedures Apart from the normal health and safety rules employed wthn the ndustry, the followng rules should be noted: - Safety nformaton dsplayed on all materals must be strctly adhered to. - Wear approprate safety equpment. - Safety eye wear must be worn when cuttng materals, mxng of adhesve, cleanng and preparaton of ste, and where necessary to adhere to ste regulatons. - Use face masks and all approprate safety shoes, clothng, and all other tems that are requred. - Ensure good ventlaton, provde forced ar f requred. - Remove and dspose of waste as per all local, state and federal gudelnes and requrements. - Wear protectve gloves. Operatng temperature BoClad wll wthstand servce temperature of up to 140 F (60 C). If cleanng wth hot water, temperature should be regulated to a maxmum of 140 F (60 C) and not to be localsed. Stanless steel panels Use stanless steel panels for temperatures over 140 F (60 C) for use near deep far. frars/gas cookers/wall mounted grlls/ back vented ovens etc. Also portable tems.e. kettles/ toasters/mcrowave ovens and back - vented commercal type. Antstatc solutons for walls can also be used on BoClad walls. Installaton, Mantenance & Archtectural Gude

11 Sutable surfaces Installaton temperature (Check adhesve data for specfc requrement) 1. Good qualty, brck or blockwork wth well algned jonts and all rregulartes repared and made smooth. Must be straght to wthn 1/8 over 6 feet and brcks/blocks flush wth those adjacent 2. Plaster, sand, and cement renderng 1:3 to a steel trowel fnsh. BoClad recommends that the sheet s nstalled at approxmately the ambent servce temperature at whch the room area wll be when commssoned. Ths s to ensure that expanson parameters are not exceeded. Normal expanson s provded for n the fnng of the materal wthn the jont strps and the slcone mastc seals at abutments. 3. Plasterboard. 4. Plywood. 5. Dense wood 6. Ceramc tles are securely bonded to the substrate. 7. Most sound panted surfaces (an adhesve test s advsable to ascertan sutablty). 8. New plasterboard, plaster, and pnk fnshng plasters are generally dusty. Surfaces to be brushed and thoroughly sealed wth dluted PVA prmer. Surface Preparaton 1. All substrates to be dry to 16% WME (wood mosture equvalent) on protmeter Survey master equpment. 2. All loose flakng pant and dust to be removed. 3. Frable surfaces to be removed or made sound 4. All surfaces to be free from grease and ceramc tles to be thoroughly degreased, rnsed and left to dry. 5. All loose tles are to be removed and area s to be made good usng repar mortar, sand, cement or plywood nfll. 6. Depressons n substrate surface should be flled wth repar mortar, sand, cement or plywood nfll. Installaton, Mantenance & Archtectural Gude

12 PVC H Trm Sngle Part Ths hgh mpact PVC co-extruson s fxed to walls and the sheets pushed nto each secton. The slcone free gasket jont ensures a water-tght seal that can be power hosed or handwashed and wll provde a full sealed easy clean fnsh. Slcone-free gasket jont BoClad PVC H Trm BoClad PVC End stop/ J Trm Manufactured and nstalled as the BoClad PVC H trm. Can be used at the top, bottom and when startng / fnshng claddng. BoClad trowel-appled adhesve Slcone-free gasket jont BoClad PVC Sound/dry substrate BoClad trowelappled adhesve BoClad PVC J Trm PVC H Welded BoClad can be cold or hot welded along ts length to provde a sealed fnsh. N.B Not sutable for hgh temperature range changes. PVC H Trm 2 Part Ths hgh mpact PVC co-extruson s fxed to walls and the sheets pushed nto each secton. The slcone free gasket jont ensures a water-tght seal that can be power hosed or handwashed and wll provde a full sealed easy clean fnsh. BoClad PVC H Trm 2 Part Slcone-free gasket jont BoClad PVC Sound/dry substrate BoClad trowelappled adhesve Installaton, Mantenance & Archtectural Gude

13 Wndow/Door Openngs BoClad PVC BoClad J Trm Foodsafe slcone sealant Installaton, Mantenance & Archtectural Gude

14 BoClad Two-part Jont Strp The man features of the new Boclad and jont/ transton strps are as follows: - A narrower and flatter extruson - Tghter fnshed jonts - a two part extruson - Improved nstallaton methods - Increased hygene levels ncorporated nto the manufacturng process - Improved nstallaton when used n conjuncton wth safety floorng - Easer and qucker to repar n the event of damage only replace the front cover Fttng the two-part jont strp: - Apply frst sheet of BoClad to the wall - Cut to length, f requred -Slp backng strp behnd edge of frst sheet - Ensure edge of sheet s lned up wth the marked lne on backng strp - Apply second sheet - Ensure edge of second sheet s lned up wth marked lne on backng strp - Cut front cover to length allowng for cut tle transton f requred - Snap front cover to backng strp - Ensure male barbed front cover s completely housed n to the female backng strp - Use ether a rubber mallet or roller to ensure full contact between front cover and sheet PVC H Trm Sngle Part Ths hgh mpact PVC co-extruson s fxed to walls and the sheets pushed nto each secton. The slcone free gasket jont ensures a water-tght seal that can be power hosed or handwashed and wll provde a full sealed easy clean fnsh. Slcone-free gasket jont Sound/dry substrate BoClad PVC H Trm BoClad wall system to FlexJont detal BoClad hygenc wall system 2.5mm thck s nstalled over most sound, dry substrates, wth the approprate BoClad adhesve and double sded tape. Jont gaps formed (3.4mm) wdth by usng metal spacer bars for parallel edges. Apply a unform bead of polymer sealant wthn the gaps. Insert flex jont trm nto the gap and roll wth a small hand roller. Fttng the FexJont Profle BoClad PVC Prepare and fx the BoClad panel as descrbed n ths gude. -Prepare the next panel as before then dry ft ths panel to check that the jont between both true and parallel - Aganst the leadng edge, temporarly fx three metal spacer bats (top, mddle, and bottom) to set the gap between the panels about (3.4mm) wdth. - Prepare and ft the next panel usng the same procedure as prevously descrbed. Leave the protectve cover on the strp of double-sded tape whch butts aganst the metal spacer bars (ths wll allow for easer fttng when buttng uptght to the spacer bars). -Roll the panel to transfer the adhesve thoroughly to the substrate then remove the metal spacer lars. -Ease out the edge of the panel to allow the protectve cover to be removed from the double-sded tape. -Press the panel back down to the substrate and reroll. BoClad trowelappled adhesve Installaton, Mantenance & Archtectural Gude

15 Fttng the Flex Jont Profle - Apply a unform bead of polymer sealant to the substrate n between the jont gap max (2 mm) bead. - Cut a length of Flex Jont slghtly oversze for the jont and then push frmly nto the jont gap. - Once the profle has been fully ftted to the jont, roll the jont thoroughly wth a small hand roller. - Trm off the surplus as requred. - Door heads, wndows heads and sll sectons need to be carefully scrbed and cut to adjacent panels to ensure a gap of (3.4mm) wdth s mantaned for the Flex Jont profle. Recommended tools for cuttng panels Due to the tght fttng of the Flex jont profle, t s mportant that the panel edges are smooth, square, true, and free from burrs. - Jgsaw wth a fne tooth cuttng blade - ensure the panel s cut slghtly oversze and then bent to a crsp, clean, square edge. - Crcular saw - use the fne toothed cuttng blades (for plastcs) wth cuttng gude. - Router cutter - use straght edge router bts (for lamnates) wth cuttng gude Fttng the FexJont Profle Prepare and fx the BoClad panel as descrbed n ths gude. - Prepare the next panel as before then dry ft ths panel to check that the jont between both true and parallel - Aganst the leadng edge, temporarly fx three metal spacer bats (top, mddle, and bottom) to set the gap between the panels about (3.4mm) wdth. - Prepare and ft the next panel usng the same procedure as prevously descrbed. Leave the protectve cover on the strp of double-sded tape whch butts aganst the metal spacer bars (ths wll allow for easer fttng when buttng uptght to the spacer bars). - Roll the panel to transfer the adhesve thoroughly to the substrate then remove the metal spacer lars. -Ease out the edge of the panel to allow the protectve cover to be removed from the double-sded tape. -Press the panel back down to the substrate and reroll. Recommended tools for cuttng panels Due to the tght fttng of the Flex jont profle, t s mportant that the panel edges are smooth, square, true, and free from burrs. - Jgsaw wth a fne tooth cuttng blade - ensure the panel s cut slghtly oversze and then bent to a crsp, clean, square edge. - Crcular saw - use the fne toothed cuttng blades (for plastcs) wth cuttng gude. - Router cutter - use straght edge router bts (for lamnates) wth cuttng gude. BoClad Heat Welded System Substrates When nstallng BoClad panels wth welded jonts, t s mperatve the substrate s n good condton. Surfaces must be sound and level. Recommended substrates nclude plasterboard, plywood, fnshng plaster and most types of sand & cement. Plannng Layout When plannng the layout of the panels t s mportant to mnmse the number of jonts n the wall system. Ensure jonts do not fall too close to corners. Ths wll avod any algnment problems between the jont when the next panel s ftted. Installaton, Mantenance & Archtectural Gude

16 Preparng the jont Before nstallng the panels, you must ft the double-sded tape to the substrate at the centre pont where the two panels meet. PVC H Welded BoClad can be cold or hot welded along ts length to provde a sealed fnsh. N.B Not sutable for hgh temperature range changes. Panel Preparaton Ensure all panel edges (where jonts are to be formed) are clean, smooth, true and level. Always nspect new panel edges to check they are undamaged or scored. When cuttng panels, you should always cut panels fractonally long and then plane to 3 crsp square edge. Check that there s no loose debrs left on the edge of the panel from where t was cut. Ths debrs could burn when hot weldng the jont and wll leave a blemsh whch can t be removed from the jont. When preparng the fttng of the panel, always ensure there s an adequate gap between the panel and any rgd abutments (celng, wndows, doors, servces etc) to allow for expanson. Adhesves BoClad recommends BoClad adhesve for all welded nstallatons. Applcaton Methods After fttng the double-sded tape, leave the protectve top flm n place (ths wll be removed later). Once the panels have been prepared and dry ftted to check everythng s correct, apply the adhesve to the back of the pane. Install the panel n the normal way, ensurng the panel s temporarly supported on wood blocks (or smlar) to prevent slppng. Check that the panel s algned wth the datum lne before rollng the panel to acheve a transfer of the adhesve to the substrate. When rollng the panel, start n the mddle and work outward. At ths stage do not roll rght to the edge where double sde tape s located. Once the panel has been rolled (almost to the edge), carefully cut down along the edge of the panel where the tape s located and cut through the tape s protectve top flm. Carefully ease the edge of the panel to facltate the removal of that half of the protectve top flm. Once ths has been removed, press the panels frmly onto the tape to acheve a full bond. Fnally, complete the full rollng of the panel rght up to the edge to ensure good transfer of the adhesve. Prepare the next panel n the same way as descrbed above. Before fttng ths panel you must ft a seres of spacer pns aganst the edge of the prevous panel. Ths s to provde the correct gap spacng between each panel. A spacer pn s anythng from a fnsh nal (on gypsum board and drywall) to the thckness of a penny (on concrete or cement block) that provdes the correct amount of space between each panel. Ft the next panel as descrbed above, ensurng the panel s butted tghtly to the spacer pns. Once the panel has been rolled almost to the edge, remove the spacer pns and then remove the fnal part of the double-sde tape s protectve cover. Press the panel frmly onto the foam tape and then complete the rollng of the panel. Check that all edges are clean and free of adhesve resdue. Once the nstallaton of the panels s complete, you are then ready to weld the jonts. On larger jobs, you can weld the panels as you go. However, we recommend weldng does not take place untl the adhesve has completely set up. (Usually the next day). Installaton, Mantenance & Archtectural Gude

17 Hot weldng Ensure your weld rod and the jont gap to be welded s clean and free of dust and contamnaton. The hot weldng technque used to weld BoClad panels s largely smlar to that used n wth sheet floorng. The same type of tools and weldng gun can be used. Trmmng Off Excess Weld rod Ths s often the part of the job whch can be most dffcult because you are weldng a plan, smooth wall fnsh, whch can hghlght any mperfectons n your work. After completng the welded jont you should pre-cut the Jont usng the spatula trmmng knfe (also known as the quarter moon knfe). Durng ths process, apply a lberal amount of Antstatc soluton sprayed on to the jont before any trmmng takes place. Ths wll reduce any frcton between the cuttng blade and the panel and mnmze the rsk of scratchng the panel. After pre-cuttng the weld rod, allow the rod to cool down suffcently before completng the fnal trmmng. Once the rod has cooled down (cold) you can commence fnal trmmng wth the spatula. Take care not to scratch or damage the BoClad surface whle undertakng ths fnal part of the operaton. BoClad to door frame archtrave detal BoClad hygenc wall system to door fxed wth 2 double sded-tape and Advanced Adhesve to most sound and dry wall substrates, sealed wth slcone sealant. BoClad hygenc wall system 2.5mm thck s nstalled over most dry substrates, to quarry tle base/ skrtng (typcal 100mm by 12mm thck) wth smlar floor tles fxed wth approprate BoClad Adhesve an double-sded tape sealed wth slcone sealant. Installaton, Mantenance & Archtectural Gude

18 BoClad hygenc wall system nstalled to glazed tles detal BoClad hygenc wall system nstalled over sound, well adhered, ceramc wall tles wth plywood nfll uses BoClad Adhesve and double-sded tape and sealed wth slcone sealant. BoClad to stanless steel panels BoClad stanless steel panels, nstalled over most sound, try substrates fxed wth BoClad Adhesve for hot areas where surface temperatures exceed 140 F (60 C). Panels joned wth stanless steel strp. Seal stanless steel trm wth clear slcone sealant. Installaton, Mantenance & Archtectural Gude

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