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Page 2 Accessories Overview Designation Klick 50mm Bottom Extruded Section (+ glazing bead) Top & Side Extruded Sections Waterproof Seal Fix Key Bracket (intermediate fixing locations) Sealing Connector Bars for Extruded Sections ZEA 578P or 579 (with flap) or 2974 + ZEA 2761 (RPTH) ZEA 577 or 580 (for L > 6 m) or ZEA 2975 + 2756 (RPTH) or ZEA 696 N + 4041 ZEA 2002 or ZEA 2763 + 2764 (RPTH) ZEA 4021 or ZEA 4044 (double) ZCF 261 (solid) or ZCF 139 (micro-perforated) ZEA 244 (for ZEA 578P) ZEA 246 (for ZEA 577 or 580) ZEA 245 (for ZEA 579) ZEA 4005 (for ZEA 696 N) ZEA 2429 (for ZEA 2974 + 2975) ZEA 2754 + 2761 or ZEA 2760 + 2761 (RPTH) ZEA 2755 + 2756 or ZEA 2762 + 2756 (RPTH) ZEA 2763 + 2764 ZEA 2757 or 2758 (double) ZCF 243 (micro-perforated) or ZCF 262 (solid) ZEA 2429 (for ZEA 2760 + 2762) ZEA 2872 (for ZEA 2754) ZEA 2873 (for ZEA 2775)
Page 3 Accessories Aluminium Frame Extruded Sections Single Bottom Extruded Section Ref.: ZEA 578P pre-drilled extruded section for drainage Single Bottom Extruded Section with 50mm Flap Ref.: ZEA 579 Length: 6,000 mm Two-part Bottom Extruded Section with a Thermal Bridge Break Ref.: ZEA 2974 To be used with the ZEA 2761 glazing bead (length: 3,000mm) Single Top Extruded Section Ref.: ZEA 577 Single Top Extruded Section for Length > 6m Ref.: ZEA 580 Two-part Side Extruded Section Ref.: ZEA 696N To be used with the ZEA 4041 glazing bead (length: 3,000mm) Two-part Top Extruded Section with a Thermal Bridge Break Ref.: ZEA 2975 To be used with the ZEA 2756 glazing bead (length: 3,000mm)
Page 4 Accessories Aluminium Frame Extruded Sections Klick 50mm Two-part Bottom Extruded Section Ref.: ZEA 2754 pre-drilled extruded section for drainage To be used with the ZEA 2761 glazing bead (length: 3,000mm) Two-part Bottom Extruded Section with a Thermal Bridge Break Ref.: ZEA 2760 To be used with the ZEA 2761 glazing bead (length: 3,000mm) Two-part Top and Side Extruded Section Ref.: ZEA 2755 To be used with the ZEA 2756 glazing bead (length: 3,000mm) Two-part Top Extruded Section with a Thermal Bridge Break Ref.: ZEA 2975 To be used with the ZEA 2756 glazing bead (length: 3,000mm) Glazing Bead /50mm Glazing Bead for 40mm / 50mm Klick Ref.: ZEA 2756 Length: 3,000mm To use with ZEA 696N and 2975, 2755, 2762 Glazing bead for 40mm / 50mm Klick Ref.: ZEA 2761 Length: 3000 mm To use with ZEA 2974, 2754, 2760, 696N Ref.: ZEA 4041 Length: 3,000mm To use with ZEA 696N
Page 5 Sealant Joints /50mm Grey Exterior Joint for 40mm Klick with Cold Extruded Section Ref.: ZEA 2002 Packaging: 100m roll Grey Exterior Joint for 40mm Klick with RPTH Extruded Section and 50mm Klick Ref.: ZEA 2763 Packaging: 50m roll Grey Interior Joint for 40mm Klick with RPTH Extruded Section and 50mm Klick Ref.: ZEA 2764 Packaging: 50m roll Anti-dust Tape /50mm Solid Aluminium Tape for 40mm Klick Ref.: ZCF 261 Packaging: 50m roll Solid Aluminium Tape for 50mm Klick Ref.: ZCF 263 Packaging: 50m roll Breather Tape for 40mm Klick Ref.: ZCF 139 Packaging: 33m roll Breather Tape for 50mm Klick Ref.: ZCF 243 Packaging: 33m roll
Page 6 Accessories Fix Key Bracket for Intermediate Fixing Position Fix Key Bracket for 40mm Klick Ref.: ZEA 4021 length 60mm Ref.: ZEA 4044 length 120mm Fix Key Bracket for Intermediate Fixing Position Klick 50mm Fix Key Bracket for 50mm Klick Ref.: ZEA 2757 length 60mm Ref.: ZEA 2758 length 120mm Connector Bar for Aluminium Extruded Sections Connector Bar for ZEA 578P Extruded Section Ref.: ZEA 244 Connector Bar for ZEA 577 or 580 Extruded Section Ref.: ZEA 246 Connector Bar for ZEA 579 Extruded Section Ref.: ZEA 245 Connector Bar for all Extruded Sections with a Thermal Bridge Break Ref.: ZEA 2429 Connector Bar for ZEA 696N Extruded Section Ref.: ZEA 4005 Connector Bar for ZEA 2754 Extruded Section Ref.: ZEA 2872 Connector Bar for ZEA 2755 Extruded Section Ref.: ZEA 2873 & 50mm Klick 50mm Klick 50mm
Page 7 Installation Instructions Preparation of the Sheets Storage Condition Kingspan Day-Lite Klick sheets are delivered on a pallet and protected against dust and humidity by means of a polyethylene cover. Sheets and packages containing extruded sections must be stored in the shade, protected from foul weather and in a well ventilated place. Packages of extruded sections must be opened in order to avoid any condensation inside. The pallets must be placed on a flat and dry floor. Take all necessary precautions during handling to ensure: Refraining from excessive use of straps; The pallets must be handled using an appropriate forklift or else with a spreader bar, in order to avoid any bending that could pop out pallet nails and damage the sheets; maximum stacking: one pallet on top of another. Cutting Tips Use a fine-toothed and well sharpened saw blade with a cutting speed of 3,200 rev/min. If the last Kingspan Day-Lite Klick sheet is cut along the width, the saw cut should not exceed the last vertical spacer next to the cut by 5 mm. In all other cases, we recommend using an aluminium strengthening U-shaped aluminium trimming flashing. Kingspan Day-Lite Klick sheets are normally delivered to the exact length and do not require any further trimming. Nonetheless, if a length adjustment proves necessary on the project site, it is essential to remove the dust and shavings by blowing with dry compressed air free of any oil. Breather or anti-dust tapes should then be applied to close the exposed multi-wall cells. Take care not to cause any scratches, indentations or other damage to the surface of the sheets. Sheets are supplied with a protective film which should be removed immediately following installation. Protective film left exposed to UV can be extremely difficult to remove. Taping the Ends of Multiwall Polycarbonate Sheets Industrial building in a very dusty environment or a mechanical workshop releasing smoke or fine particles (e.g. by welding, diesel motor, others): taping of upper and lower parts of the sheets with a solid adhesive aluminium foil and, for extreme cases, a butyl compound type containing a silicon layer compatible with polycarbonate, which serves to prevent any penetration of particles by a draft inside the sheets. This system can be completed with a transparent TPE seal on the interlocking elements. Sports facility or public building: taping with a microperforated foil on both the upper and lower parts of the sheets. Swimming pool or humid environment: avoid taping the cells which encourages evacuation of the condensation water the ventilation of the cells. Note: As polycarbonate is hygroscopic (permeable to water vapour), the appearance of condensation is indeed possible despite all the precautions taken; this condition however does not constitute a grounds for complaint. It is common for condensation to appear especially during the construction phase of a project or when floor slabs are poured, however this will normally dry out during the annual temperature cycle.
Page 8 Installation Instructions Preparation of Aluminium Extruded Sections & Supports Before assembling the bottom extruded sections, it is necessary to drill drainage holes 6mm in diameter positioned in the middle of each sheet. The space between these holes must be between 500 and 600mm maximum. Some ZEA 578P and ZEA 2754 extruded sections are delivered pre-drilled for drainage to be installed on cladding. We also recommend covering the inner surface directly behind the polycarbonate cladding in a white or clear paint, in order to avoid any accumulation of heat. Assembly of Aluminium Extruded Sections Install the bottom extruded sections onto the support and seal with an appropriate butyl or similar sealant, with a minimum 10mm bead. Fix at maximum 500mm centres using a stainless steel fixing with sealing washer. Ensure that the fixing heads do not protrude beyond the bearing surface of the Klick polycarbonate panels. Where two extruded aluminium section butt join a connector bar can be used to facilitate alignment. A small expansion gap is recommended which should be filled with a flexible sealant. The connector bar need be fastened only to one side of the butt joint, permitting the other side to move slightly. Only sealant compatible with polycarbonate can be used. Allow a 4mm expansion joint between aluminium butt jointed sections, or slightly greater if installed in cold temperatures (less than 5 C). At corners between base and jamb or jamb and top extruded aluminium sections, sealant must be used to complete a weather tight seal. To form corner intersections follow the cutting diagram shown here, to the dimensions indicated. Cutting Table for Simple Extruded Sections Designation ZEA B C D E F G H Cutting Table for Extruded Sections with a Thermal Bridge Break Designation ZEA B C D E F G H 40mm Klick 579 + 696N 30 33 80 53 - - - 578P + 696N 30 29 80 57 - - - 40mm Klick 2974 + 2975 40 40 104 70 - - - 2975 + 2975 40 - - - 40 104 104 50mm Klick All dimensions in mm. 577 + 696N 30 - - - 60 80 80 2754 + 2755 40 43 104 70 - - - 2755 + 2755 40 - - - 40 104 104 2760 + 2762 40 40 104 70 - - - 50mm Klick 2762 + 2762 40 - - - 40 104 104 All dimensions in mm.
Page 9 Preparation of Aluminium Extruded Sections & Supports Caution: the printed film on the Klick panel identifies the side with anti-uv treatment which must be positioned on the exterior of the cladding. Slide the first Klick panel sheet inside the top extruded section and slide it down into the bottom extruded section. Push this first sheet as far as possible into the side extruded section, then remove the sheet by 15 mm to leave side tolerance for thermal expansion in the product width, ensuring Klick panels remain square. Insert the second Klick panel sheet, clip it onto the first and continue in this way until the entire surface is complete. Before inserting the penultimate sheet, cut if necessary the last panel to the necessary width and insert it as far as possible into the side extruded section by interleaving a strap for final assembly. The remaining opening corresponds to the total width of the penultimate Klick panel sheet, which will then be inserted and clipped to the previous ones. All that is left to do is to clip in the final Klick panel sheet using the strap that you positioned earlier. Assembling the final Klick panel sheet is made easier with the use of the side extruded section in 2 parts. If assembly requires the use of fix key brackets at intermediate fixing positions these must be installed as work progresses in the leading edge of the polycarbonate sheets. They cannot be retrospectively installed. Protective film should be removed as soon as possible following installation as film left exposed to UV (sunlight) can be very difficult to remove. Cleaning Prohibit all abrasive pastes that would scratch the polycarbonate. Use only soapy water or water mixed with a neutral detergent. Do not use solvents or alkaline detergents. Avoid cleaning during hot weather or when the sheets are hot. Avoid cleaning with any material that could have accumulated grit or dirt, or otherwise cause significant abrasion to the polycarbonate surface.
Page 10 Installation Instructions Example of Flush Installation: Example of Flush Installation: Klick 50mm with Thermal Bridge Break
Page 11 Calculation of Sheet Length (x) Surface-mounted Installation Flush Installation The Klick panel sheets are cut to the precise dimension either on the project site or at the factory. At the time of ordering, it is necessary to account for any recesses or excess lengths, depending on the type of installation and extruded sections used. For factory cut sheets please advise at the time of ordering if factory applied seals (breather or aluminium tapes) are required, and specify which is required. An additional charge is made for factory applied tapes. Designation Cold Extruded Sections Extruded Sections with Thermal Bridge Break Surface-mounted Flush Surface-mounted Flush 40mm Klick X = B + 90 X = B - 40 X = B + 90 X = B - 80 40mm Klick Length >6m X = B + 70 Use extruded section ZEA 580 instead of 577 X = B - 50 Use extruded section ZEA 580 instead of 577 X = B + 80 X = B - 70 50mm Klick X = B + 90 X = B - 70 X = B + 90 X = B - 80 50mm Klick Length >6m X = B + 70 X = B - 70 X = B + 80 X = B - 70 All dimensions in mm.
For the product offering in other markets please contact your local sales representative or visit www.kingspan.com Care has been taken to ensure that the contents of this publication are accurate, but Kingspan Limited and its subsidiary companies do not accept responsibility for errors or for information that is found to be misleading. Suggestions for, or description of, the end use or application of products or methods of working are for information only and Kingspan Limited and its subsidiaries accept no liability in respect thereof. 05/2017 Kingspan Limited Carrickmacross Road, Kingscourt, Co Cavan, Ireland Tel: +353 (0) 42 96 98500 Fax: +353 (0) 42 96 98572