Alucobond Ghid Prelucrare English

8/10/2019 Alucobond Ghid Prelucrare English

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Processing


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2

Jointing

Drilling holes for jointingsee page 8

wi th dr i l l b i ts for aluminium sheetand plastic panels (for larger holes usea dri l l b it w i th locat ing point )

Rivetingsee page 16

wi th normal tools and rivets or bl ind r ivets

Screwing see page 17

wi th normal s tainless s teel screws or bol tsfor w ood, sheet or metal

Weldingsee page 18

the PE core material w i th hot-ai r weldingdevices and PE w elding rod

Glueingsee page 19

Outdoor use adhesive seal ing compound

Indoor use metal adhesives for aluminium double-sided adhesive tape

Clamp connectionssee page 19

wi th toothed butt jo int and corner sect ionsfor 3, 4 and 6 mm

Surface treatment

Lacqueringsee page 21 overlacquering of ALUCOBOND

surfaces possible with suitablelacquer qualit ies

Note:For processing ALUCOBOND A2 and ALUCOBOND plus please refer toseparate leaflet.

Processing at a

glanceCutting to shape

Sawingsee page 7

wi th vert ical panel saw,circular or jig saw

Cuttingsee page 8

w i th gu i l lo t ine shears(slight drawing of the panel cover sheet),cushion clamp

Punching / Decorative work

Punchingsee page 8

with conventional sheet punching machines.

For clean cuts pl ease use evenly groundtools. Drawing of the panel cover sheet

Contour cuttingsee page 8

w ith water torches, CNC machining centresand j ig saws

Shaping

Bendingsee page 9

wi th folding machine or bendingpress, min. inner radiusr = 10 x t ALUCOBOND and

ALUCOBOND plusr = 25 x t ALUCOBOND A2(t = panel t hickness)return travel greater than with solid sheet

Roll bendingsee page 9

wi th rol l bending machines.M ake sure to use ground rolls.

Folding (routing technique)see page 11

manually after routing a V-groove using

a panel saw w ith routing device, a CNCmachining centre or a panel routingmachine


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P a g e

Transport / Storage / Handling 4/5

Cutting and Fabricating 6 - 9

Routing and Folding Technique 10-13

Jointing / Fixing Technique 14-19

Surface Treatment 20/21

Cleaning and Maintenance 22/23

Technical Data sheets 24-26

ALUCOBOND Information 27

Contents


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4


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Transport

Handling

Storage

5

ALUCOBOND is a prefabricated panel l ing

material, i.e. the surface of the standard panel

is either lacquered, anodised or mill-finished.

These surfaces are protected by a special foi l

during transport, storage and processing.

Nevertheless, the fol low ing information must

be observed w hen storing and handling the

panels:

The pal lets must be handled careful ly

during transport and unloading. Do not handle

open pallets.

Upon delivery the pallets must be examined

for any damage due to moisture (ALUCOBOND

panels that have become w et must be dried t o

avoid any spots or corrosion formi ng). Any

damage must be reported immediately and

confirmed by the forwarding agent.

Store the pallets so that they are protected

against any w etness penetrating due t o rain

and spray water and avoid any condensation

forming (e.g. when transporting cold panels to

warmer rooms).

Store the pallets stacked one over the other

(do not store ALUCOBOND panels standing

vert ically), wi th a maximum of 6 pallets of the

same format stacked on top of each other

(heavy pallets at the bottom).

Individual panels must be l i f ted of f the pal-

let by tw o people holding all four corners and

not drawn over each other. Carry the panels

vertically. Wear gloves to avoid staining.

If stacking panels, nothing should be put in

between to avoid markings.

The following should be observed asregards the ALUCOBOND protective foil:

Storage exceeding 6 months should be

avoided.

Strong f luctuations in temperature reduce

the long-term durability.

Do not mark the panel surface or protection

film with inks (markers), tapes or labels.

Solvent or plasticiser may penetrate the film

and affect the lacquered surface.

Should the protective foi l part ial ly come off

during processing, dirtied edges can occur in

the course of t ime.

Remove protective f i lm as soon as possible

after erection. Protective film that remain on

panels for an expanded period of exterior

exposure may be very difficult to remove.


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6


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J ig saw blades

for wood or plastics, e.g. T101 B (Bosch),

tooth t hickness 2.5 mm for precision cuts

Saw blades for ALUCOBONDA2 andALUCOBONDplus

for max. number of revs 2,500Rpm

Tooth geometry see above

Saw blade dia. D = 3 00 m m

(for Striebig Saw Standard II)

N um be r o f te et h t = 7 2

Speiser Code No. 07060651Saw blade dia. D = 2 50 m m

(for Holz-Her Saw 1255)

N um be r o f t ee th t = 6 0

Speiser Code No. 02040151

Manufacturer / supplierand Sharpening serviceSpeiser W erkzeugvertriebs-GmbHSalzstetter Strae 29D-72221 HaiterbachPhone + 49 7456 9449 0Fax +49 7 4 56 9 4 49 1 1

For further information on machines and tools

please refer to the separate leaf let on Processing

of ALUCOBOND A2 and ALUCOBOND plus.

Carbide tipped (CT) saw blades

Blade geometry Tooth thickness approx. 2 4 mm,

tapered to the inside to prevent jamming

Tooth geometry t rapezoid tooth /

f lat thooth

Pitch 10 12 mm

Clearance angle 15

Rake angle 10 posit ive

M aximum cut t ing speed 5,000 m/ min

M aximum feed 30 m/ min

Carbide tipped (CT) saw blades for HOLZ-HER and Striebig circular panel saws

Trapezoid/flat tooth saw blade, flat teeth 45chamfered for burr-free edges

Saw blade dia. D = 300 mm

(for Striebig vertical panel saw Standard II)

Number of teeth t = 72 (for cuts of up to 5 panels)

LEUCO Code N o. 1817 24

t = 9 6

(for single cuts without burrs)

LEUCO Code N o. 1817 25

Saw blade dia. D = 250 mm

(for Holz-Her vertical panel saw 1255ALUCOBOND)

Number of teeth t = 60 (for cuts up to 5 panels)

LEUCO- Code No. 181726

t = 8 0 (f or cu ts w i th ou t bu rr s)

LEUCO- Code No. 181727

Bore dia. D = 30 mm

Tooth thickness 3.2 mm

Clearance angle 15

Rake angle 10 posit ive

Manufacturer / supplier: Leuco

Ledermann GmbH & Co.KG

Willi-Ledermann Strae 1

D-72160 Horb

Phone +49 7 4 51 9 3 - 0Fax +4974 51 93 - 270

E-Mail [email protected]

www.leuco.com

7

Sawing

Sketch showing the edge geometry for professional reshapening:

Cutting and

Fabricating


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8

Routing

ALUCOBOND can be easily routed on conven-tional routing machines and CNC machiningcentres.

To avoid pressure marks on the ALUCOBOND

surface, please use plastic or wood vice jawswhen chucking the workpieces.

High-speed steel or carbide tipped cutters

suitable for aluminium and ALUCOBOND

have a wide tooth pitch, radiused and smoothgrooves and small lip angles.

They produce perfect cuts, e.g. under thefollowing condit ions:

H igh-speed s tee lmax. cutt ing speed max. 3,000m /min.feed max. 25 m/m in.

Carbide t ipped cut termax. cutt ing speed max. 5,000 m/min.feed max. 30 m/m in.

Suitable end m illing cut ters for A LUCOBOND:

Carbide end milling cutter serie F 113Manufacturer / supplier:Gienger IndustrieserviceWeimarstrae 15D-78532 Tuttli ngenPhone +4974 6116 20 - 20Fax +49 74 61 16 20 - 21www.gis-tec.de

HSS end milling cutter, shank dia. 8 mm

Dim. 5 x 14 x 60 mmArt. No. 100 56 0008

Dim. 3 x 12 x 60 mmArt. No. 100 36 0008

Manufacturer / supplier:Be We Przisionsw erkzeugeIm Wiesental 7D-75446 W iernsheimPhone +4970 4491 5838 - 0Fax +49 70 44 91 58 38 - 3 8www.bewe-online.com

Drilling

ALUCOBOND can be dri l led with tw ist dri l lsnormally used for aluminium and plastics onmachines common for metals.

Drill material:High-speed steel (HSS)

Tool geometry:Lip angle: 100 140

Dril l ing without burr is possible using the fol-lowing dri l ls:

spot facing cutter with centre-point.

A ng le o f w h ist : 30 45

e.g. Extreme 2 TM HSS-G M etal drill DIN 338 ofDe WALT, D-Idstein

Countersink

Three-lipped core drills and counterborescommon for aluminium are used for counter-sinking pre-drilled holes. Counterbored holesare less out of centre than those produced bytwist drills. Countersinks for aluminium can beused for countersinking flat head screws intoALUCOBOND. Head and shank counterboresfor aluminium are mainly used for countersink-

ing screw heads or for making holes throughALUCOBOND.

Counter cutting

ALUCOBOND can be cut to size with j igsaws, CNC machining centres and watertorches. Please cut abrasively w hen using awater torch. Pre-drilling of the panels is nec-essary when start ing the cut in the middle ofa panel as it is not possible to dri l l throughwith a water torch.

Shearing

ALUCOBOND is easily sheared with a guil lo-t ine. A sl ight drawing of t he aluminium coversheet caused at the impact side should benoted. The clamp on the shear should be fittedwith a shock-absorbing rubber pad to preventdamage to the cover sheet.

Punching

ALUCOBOND panels of any t hickness can bepunched with conventional sheet punchingmachines. For clean cuts pl ease use evenlyground tools and the narrowest possible cut-

ting gap (0.1 mm). This punching method a lsocauses a sl ight draw ing of the panel coversheet. Holes of a minimum diameter of 4 mmcan be punched. The minimum w idth of w ebbetween hole edges is also 4 mm.


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Bending

ALUCOBOND can be formed by conventionalmetal and plastic fabrication methods. Certainspecific points should be noted relating to themultilayer structure combining materials ofdifferent characteristics:

The minimum radius i sfor ALUCOBOND andALUCOBOND plus r = 10 x t

for ALUCOBOND A2 r = 25 x tt = panel thickness

The spring-back effect experienced when fold-ing sheet metal is larger with ALUCOBOND.For production series a prot otype should bemade.

The surface should be protected from damageby affixing plastic film or i nserting polyethyleneof 1 2 mm thickness or plastic f i lm stripsduring processing.

The panel surface must be free from anyadhesive materi al (e.g. labels, etc.).

Important:W hen bending A LUCOBOND with ananodized surface, the bent area i s brighter.

Bending with a brake press

(Fig. 1)ALUCOBOND, l ike sheet metal, is easilyformed with a brake press. The air-bendingprocess is used w hen forming w ith a brakepress.

The A LUCOBOND panel rests on the edges ofthe die (rails, channels) and is bent by thepunch (tube or shaft). The bending angle isdetermined by the width of the die and thestroke of the punch. The die edges should berounded and smooth.

Ideal die width:2 x t + 2 x protec t ive fo i l t h ickness +punch diameter + 15 mm

The minimum side length of the bent partshould be 5 times t he ALUCOBOND thickness.

Bending with a folding machine

(Fig. 2)W hen working with f olding machines, thepanel to be bent is clamped between tw ocheeks. The projecting e dge is bent aroun d

the upper clamping cheek and former usingthe movable swivel bar. The bending radius isdetermined by interchangeable formersattached to the upper clamping cheek.

Bending with aroll bending machine

ALUCOBOND can be bent with sheet metalroll bending machines mainly w ith three andfour-roll machines. Please make sure that thefeeder does not exert too much pressure.

Bending rolls which are also used for bendingother metals must be thoroughly cleaned from

swarf before pro cessing ALUCOBOND

. W erecommend ground rolls to avoid damagingthe cover sheets.

9

Note:For processing ALUCOBOND A2 and ALUCOBOND plus please refer to the separate leaflet.

Fig.1 Bending with a brake press

Fig.2 Bending wit h folding m achine

r min.: ALUCOBOND andALUCOBOND plus = 10xt ALUCOBOND A2 = 25xt

Protective f oil

Die width

Die

Upper clamping cheek

Swivel bar

Former

Lower clamping cheek

Protective f oil

t

t


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10


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11

Routing and Folding Technique

and Designfor individual Shaping

Advantages

The convincing advantages of the routing andfolding techniques are:

M i n i mum invest m en t

Simple operat ing technique

Folding need not be done in the workshop,it can be done on site; this means lowtransport and storage costs

Low-cost manufacture of shaped parts l ikefascia claddings, roof edgings, corner pieces,

column casings and many more are possible Versat i le fo rmabil i t y

Good ec onom y

Shapes are not rest ric ted by machinedimensions

Folding wi thout cut t ing, therefore nobuckling in the corner area and thus evenelements

Rectangular groove for edges up to 150 depending on panel thickness

Groove 135 (V-shaped) for edges up to 135

Method

ALUCOBOND composite panels can beshaped by means of a simple processing tech-nique. This procedure, the routing and foldingtechnique, enables a variety of shapes andsizes to be manufactured.

V-shaped or rectangular grooves are routed onthe rear of the panels with disk or end mil l ingcutters, whereby the aluminium cover sheet atthe front and part of the polyethylene core areretained. The small thickness of the remainingmaterial then allow s folding by hand. A brakepress is not required. The groove shape deter-

mines the radius of the bend.The grooves can be produced with a panel sawwith routing device for ALUCOBOND, o n aCNC machining centre, with a panel routingmachine or a hand routing machine. The rout-ing and folding technique can be used forcomposite panels of all standard surfaces.

Important:When folding ALUCOBOND wit h an anodizedsurface, the edges are bright er.

Tracing roller for exact groove-depth-adjustment

Disc milling cutter

not suitable for ALUCOBOND A2

Groove (V-shaped) for edges up to 90

ALUCOBOND


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12

Tools and machinery for routing and folding technique

For special machines and dust extractor systems please refer to the separate leaflet Processing ALUCOBOND A2 and A LUCOBOND plus.

1 2

Panel sawsALUCOBOND routing device(special accessory)

Holz-Her vertical panel sawPK 1255 A LUCOBOND

Code No. 278.6133

Striebig Vertical panel sawStandard II for composite panels

Manufacturers / suppliers:Reich Spezialmaschinen GmbHPlochinger Strae 6 5

D-72622 NrtingenPhone +497022 7 02- 0www.holzher.de

Striebig AG M aschinenbauGromatte 26aCH-6014 Litta uPhone +4141 2 5002 57www.striebig.com

Other panel saws can subsequently be providedby the manufacturer with an addit ional routingdevice. Please ask for de tails.

CNC machine centres

Manufacturers / suppliers:Onrequest.

Panel routing machinePF 1200 E-Plus ALUCOBOND

(Fig. 1)

Supplied w ith:

Tracing rol ler for 4mm Cutter disk for V-grooves 90 Adjustment template Transport box

Supplier:TTS Tooltechnic Systems Deutschland GmbHM arket ing sale s: FESTOOLW ertstrae 20D-73240 W endlingenPhone +49 7024 804 - 640Fax +497024 804 - [email protected]

Hand routing machines

(Fig. 2)

Commercially available hand routing machines

w ith a minimum rating of 800 W are suitable.Collet chucks 8 mm dia.


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13

Carbide tipped disk milling cutters fo vertical panel saws

Suppliers for profile cutters

GIS Gienger Industrie-ServiceWeimarstrae 15D-78532 Tuttli ngenPhone + 4974 611620 - 20Fax +4974611620-21www.gis-tec.com

The diameters of tracing rollers and cutterdiscs are adjusted so as to le ave a residualcore thickness of 0.3mm (V-groove) or 1 mm(rectangular groove). The dimension s given inthe draw ings show t he cover panel thicknessof 0.5 mm plus the corresponding residual corethickness.

Carbide tipped cutter No. 491444 (Festool)Carbide tipped cutter No. FV09.01.090 (GIS)Carbide t ipped cutter No. 79 803 (KWO)

Please address all enquiries relating to new machines wi th accessory parts for

milli ng of ALUCOBOND

possible retrof it t ing of exist ing machines(stating machine type/No. and year ofconstruction)

accessories such as cutter disks, tracingrollers, etc.

directly to the manufacturer of the panel saws.

Di sk m il li ng cut ter f or V-g rooves 90 Di sk m il li ng cu tt er f or V-gro ove s 135

End mil l ing cut ter for V-grooves 90 End mil l ing cut ter for V-grooves 135 End mil l ing cut ter for rectangular grooves

Carbide tipped cutter No. 491443 (Festool)Carbide tipped cutter No. FV09.01.135 (GIS)Carbide t ipped cutter No. 79 804 (KW O)

HSS cut ter 10mm No.79800(KWO)HSS cut ter 15 mm No.79801 (KWO)

Important:

Please state the fol lowing in your enquiry ororder for processing A LUCOBOND compositepanels.

Milling cutters with cylindrical shank for hand routing machines

Disk milling cutter f or rectangular grooves

up t o4 mm

up to 4 mm

KWO-Werkzeuge GmbHIm Riegel 1D-73450 NeresheimPhone +49732696 42 - 0Fax +4973269642-10www.kwo.de

TTS Tooltechnic Systems GmbHWertstrae 20D-73240 W endlingenPhon e +49 7 0 2 4 804 - 6 40Fax +497024804-24www.festool.com


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15

J ointing /

Technique

Fixing

ALUCOBOND can be joined by means ofstandard processes used in metal and plasticstechnology.

If A LUCOBOND is to be joined to structuralparts of metals other than aluminium, or iffasteners (e.g. bolts, screw s) are to be used,the fol low ing material guidelines should beobserved:

Fasteners and structural parts made of alu-minium, plastic or stainless steel should besuitable for the assembly with ALUCOBOND.

W hen using other materials please insertinsulating washers etc. or apply protectivecoating to prevent corrosion.

Please take the t hermal expansion of the panelinto account f or outdoor use of ALUCOBOND

to avoid jamming or deformation.

The minimum gap depends on the expectedexpansion of the panel.

Please refer t o processing recommendationsfor rivets and bolts for additi onal measures toprevent jamming.

The linear t hermal expansion of ALUCOBOND

is determined by t he aluminium cover sheets.

At a temperaturedifference of 100C thelongitudinal expansion is 2.4mm/m.


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16

ALUCOBOND panels can be fastened together

or joined to other materials with rivets common

to aluminium constructions.

For outdoor use and for use in areas of high

humidity, aluminium blind rivets w ith stainless

steel mandrils should be used to prevent ugly

corrosive edges. When using aluminium blind

rivets with steel mandrels, the mandrel shoulddrop out after riveting (detachable version).

Countersunk rivets are suitable for indoor use

only.

For outdoor use please note:

For outdoor use aluminium blind rivets thathave been approved for construction with a5 mm shaft diameter and an rivet head diameterof 11 or 14 mm are used.

Please take the thermal expansion of thepanel into a ccount (2.4 mm/ m/ 100C). Toavoid jamming, the hole in the panel must belarge enough to allow for expansion.

W ith the shaf t of the r ivet f i t t ing c losely tothe edge of the hole, the rivet head mustcover over 1 mm of the area surrounding thehole.

M ul t i -step dr i lls or hole gauges hav ingcorresponding diameters are used forcentrically drilling holes into the panel and thesubstructure and for centrically fitting the rivet.

Rivet at tachment j igs are used for f i t t ingblind rivets wit hout jamming allowing for atolerance of 0.3 mm. M ake sure to use rivetattachment jigs and rivets from the samemanufacturer, as the height of the rivet headaccording to DIN 7337 m ay vary.

The clamping thickness results from thethickness of the material to be riveted plus anaddit ional value of 2 mm to ensure that theclosing head is perfectly formed. In accor-dance with this clamping thickness the corre-sponding shaft length is determined in thetables provided by the rivet manufacturers.

(min. = 14 mm

Important:

Since during riveting many factors may havean influence on the exact tolerance of therivets of 0.3 mm (e.g. rivet head tolerance), werecommend that you make a test on a faade

panel.Please alw ays remove the protective foil in theriveting area prior to riveting.

Manufacturers / suppliers:

Blind rivets

In the trade or from:

GESIPA-Blindniettechnik GmbHNordendstr. 13-39D-64546 M rfelden-WalldorfPhone +496105962-0Fax +496105962-287www.gesipa.com

Gebr. Titgemeyer GmbH & Co. KGPostfach 4 309D-49033 OsnabrckPhone +495415822-0Fax +495415822-490www.titgemeyer.de

VVG-Befestigungstechnik GmbH & Co.Haber Strae 29D-24537 Neumnster

Ph on e +4 9 4 3 2 1 96 7 1 - 7 1Fax +49 43 21 96 71 - 96www.vvg.de

Blind rivets lacqueredM BE GmbHPostfach 252 5D-58685 M endenPhone +49237317430-0

Fax +49237317430-11www.mbe-gmbh.com

SFS intec GmbH & Co.KGIn den Schwarzwiesen 2D-61440 OberurselPhone +4961717002-0Fax +4961717002-46www.sfsintec.biz

Multi-step drills (not available ex stock)KWO Werkzeuge GmbHIm Riegel 1D-73450 NeresheimPhone +4973269642-0Fax +4973269642-10

www.kwo.de

Hole gauges

Please refer t o blind rivets lacquered: M BE GmbH

Rivet attachement jigs

Appropriate rivet attachment jigs are availablefrom the manufacturers or suppliers of rivets.

Riveting

Blind rivet withstandard head

Distancemin. 15 mm

Conical hole gauge

Countersunk rivet(for indoor use only)

Stainless steel

mandrel

Stainless steel

mandrel

Hole gauge for hole dia. 8.5 mm

Aluminium substructure

Aluminium bl ind r ivet d ia. 5 mmwith stainless steel mandrel

Rivet head dia.11 or 14m m

Rivet attachment jig for screwingto the r iveting tool

(for fixing ALUCOBOND panelswithout jamming)

dia. 7.0mm Rivet K11dia. 8.5mm Rivet K14

Hole gauge

Rivet attachment j ig for rivet head dia. 11m m and 14 mm mountable on riveting tool AccuBird (MBE)

Riveting tool

Rivetattachment jig

Blind rivet 0.3 mm


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Fascia screw thread-cut t ing Fascia screw thread-cut t ing

17

Manufacturers /Suppliers:Fascia screwsEJOT Baubefestigungen GmbHPostfach 11 35D-57323 Bad LaasphePh one +49 2 7 5 2 9 0 8 - 0Fax +49 27 52 9 08 - 731www.ejot .de

Fascia screws, lacqueredM BE GmbHPostfach 252 5D-58685 M endenPh on e +4 9 2 3 17 4 3 0 - 0Fax +49 23 17 430 - 11

www.mbe-gmbh.com

SFS intec GmbH & Co. KGIn den Schwarzwiesen 2D-61440 OberurselPhone +4961717002-0Fax +4961717002-46www.sfsintec.biz

Threaded fasteners

1

22

Sheet metal screw,roundhead

Plastic covers for screwsHA-WI Kunststoffe GmbH &Co. KGSiegener Strae 117IndustriegebietIn den EspenD-57334 Bad LaasphePhone +4927543746226Fax +4927548119www.ha-wi .com

Distancemin. 15 mm

Distancemin. 15 mm

Screws for indoor use no outdoor use

1

Fascia screws for metal substructures

Threaded fasteners foroutdoor use

Please take the thermal expansion of thepanel into account w hen using threaded fas-teners outdoors. To avoid jamming, the holediameter in the panel must al low for theexpansion.

Fastening without jamm ing is possible w ithfascia screws made of stainless steel w ithsealing w asher (Fig. 1) that have beenapproved for construction. The screws mustbe suitable for the corresponding substructure(please note the information given by themanufacturer). The screws should be tight-ened wit h a torque w rench or screwdriver sothat the sealing w asher is placed on the panelfor sealing the bore hole w ithout exert ingpressure onto the panel.

M ulti-step dril ls or hole gauges having corre-sponding diameters are used for centrically

drilling holes into the panel and the substruc-ture and for centrically f i t t ing the rivet.

Important:

M ake sure to remove protective foi l prior toscrewing.

Threaded fasteners forindoor use

Screws for sheet metal and wood w ith dif fer-ent head-shapes are suitable for indoor use(Fig. 2). They do not norm ally allow for anypanel expansion.

Countersunk screw s can be inserted by theusual countersinking method or by depressingthe aluminium surface into the panel. W hendepressing the aluminium surface, the holediameter in the panel must be larger than thescrew diameter.

.

Thread Typ Awith point

Thread Typ Bwithout point

Sheet metal screw,raised countersunk headwith tapered washer

Sheet metal screw,countersunk head,countersunk bore

Sheet metal screw,countersunk head,cover sheet depressed

Wood screw,raised countersunk headwith tapered washer

Wood screw,flat cheese head

2

Correct screwing with fascia screws

Washer without deformation the panel can move under the washer

The washer is deformed the panel is clampedand cannot expand under the washer

Right Wrong !


18/28

Hot-air welding has proved useful for joiningthermoplastic plastics and for w eldingALUCOBOND. The plastic core and the plasticw elding rod are heated and welded wit helectrical hot-air w elding sets. The fol low ingconditions are essential for good results:

Wel l p repared welding join t

Good quali ty welding rod Clean hot a i r

Correct temperature

Correct contact pressure

We l di ng speed

Welding withrapid welding nozzle

(Fig. 1)The rapid welding nozzle method ensuresuniform heating of the core material and the

w elding rod and thus results in a betterw elding quality.

Rod A is inserted manual ly through nozzletongue B. By applying constant pressure to thenozzle tongue, the rod is pressed into the joi nt.

Preparing of welding joint

For butt-welding, the edges of theALUCOBOND panels must be chamfered(Fig. 2).

Before folding and welding ALUCOBOND

panels, grooves have to be routed into thepanels using corresponding milling cutters(Fig. 3).

As the pl astic core oxydizes relatively quicklywhen exposed to air, welding should be com-pleted w ithin 24 hours after chamfering.

Welding rod

Please use the following quality:Polyethylene, soft, Type: 1800-hColour: black, diameter: 3-4 mm

The outer layer (oxide layer) of the weldingrod should be removed with emery clothimmediately before welding. Please chamfer

the starting end of the rod to approx. 45.

Temperature

The following air t emperature is required forhot-air welding:

ALUCOBOND: 265C +/- 5C

The temperature must be continuouslyadjustable and is measured with a mercurythermometer or bimetal measuring unit 5 mmfrom t he nozzle point . To measure the t emper-ature, please take off the rapid w elding nozzle.

Contact Pressure

The required pressure to the nozzle shoe(rapid w elding n ozzle) should be approx. 3 kp.

Hot-air welding sets

W e recommend that the Leister hot-airwelding set, Type DIODE PID, be used in

connection w ith the ventil ator, Type M INOR.

Skimming the welding seam

A scraper blade or knife is used at a very f latangle to shave the welding seam as soon as ithas cooled down. For visible welding joints,the seam on butt and corner welds is removedusing a crescent-shaped knife (Fig. 4).

18

Hot-air welding(for A LUCOBOND w ith PE core only)

Manufacturer / Suppliers:

Hot-air welding sets, temperaturemeasuring devices, crescent-shapedknives and welding rodHeiluft technik Flocke GmbHLeister-VertriebElssser Strae 14 - 18D-42697 SolingenP hone + 4921238260 -0Fax +49212312324www.heisslufttechnik.de

Herz GmbHLeister VertriebBiberweg 1D-56566 Neuw iedPhone +492622810-86F ax + 492622810 -80www.herz-gmbh.com

Welding rodKetterer + Liebherr GmbH & Co KGGndlinger Strae 20D-79111 FreiburgPh one +49 7 61 4 78 1 4 - 0F ax + 4976147814 -90www.ketterer-l iebherr.de

Milling cutters(not available ex stock)KWO Werkzeuge GmbHIm Riegel 1D-73450 NeresheimPhone +4973269642-0Fax +4973269642-10www.kwo.de

1

2

4

adjacent

Crescent shaped knife

3

Grooving with milling cutter

For t = 3 mm Code No.79805For t = 4 mm Code No.79806

For t = 6 mm Code No.79807

r = 2 t o 3 mm

t

r


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Metal adhesives /Universal adhesives

For indoor use, trade fair/exhibition standstructures and machines, most metal oruniversal adhesives are suitable.

Tapes / Velcro tapes

Double-sided tapes (such as the 3M -VHB highcapacity jointing systems) can be used for theabove applications wit h low tensile or trans-versal strength requirements. Velcro tapes areavailable for detachable joints, for exampleSCOTCHM ATE or tapes market ed under theDual Lock trademark.

Both products are also available from3M Deutschland GmbHCarl-Schurz-Strae 1D-41460 NeussPh one +49 2 1 3 1 1 4 - 0

F ax + 49213114 -2649www.3m.com

19

Clamp connections incorporating aluminiumor plastics are part icularly suitable forALUCOBOND. They generally consist of twoparts with the clamping effect achieved bybolt ing.

Various designs of clamping elements areused for display and store fitting purposes(no outdoor use).

Suppliers:

Klemetric system:KlemProductsGesellschaft fr W erbemittel mbHTalangerstrasse 3aD-82152 Krail ing/M nchenPh on e +4 9 8 9 8 57 7 2 8 0Fax +49 89 895 83 48www.klemproducts.de

Voluma system:M ERO Raumstruktur GmbH & Co.KGAusstellungssystemePostfach 6 169D-97064 WrzburgPh on e +4 9 9 31 6 6 7 0 - 5 71Fax +49 931 66 70 - 189

www.mero.de

Adhesive sealing compounds

For high-strength and elastic connections werecommend the fol low ing one-componentadhesive sealing compound:

Sika Bond-T2 (polyurethane base)Sika GmbH

Stuttgarter Strae 139D-72574 Bad UrachPhone +497125940-0Fax +497125940-321www.sika.de

For outdoor use, thi s adhesive can be used forfastening parts of minor stat ic importance.

Important:

Please observe the man ufacturers instructionsregarding the application and use of adhe-sives/tapes.

Adhesives and sealing compounds do notadhere t o the ALUCOBOND plastic core(cut edges).

Laminating of ALUCOBOND panels to othermaterials may result in deformation of thelaminates (dif fering expansion/bimetal effect).

Glueing

Clamp connections

Klemetric system

Voluma system

Any suitable connection or shock-resistantframe can easily be made with aluminiumsections.

The inevitable tolerances signify differentretention forces. A uniform and solid f i t of thesections is obtained by pressing the sectionsides together prior to inserting the panels.

Butt joint, corner and edge sections are avail-able for panels of 3, 4 and 6 mm. Please askfor our stock list.

For fascia cladding a pplications specialaluminium sections are provided for clampconnections.

For furt her inf ormation on ALUCOBOND

special sections and types for fasciacladdings please ask for the respectivedocumentation.


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20


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Lacquering of mill-finished

ALUCOBOND surfaces

21

Surfacetreatment

Customer requirements for special colourshades of ALUCOBOND composite panelsare met in small amounts at our plant byoverlacquering standard stove-lacqueredALUCOBOND surfaces or mill-finishedsurfaces.

The composition of lacquer coating for

ALUCOBOND is basically the same as those

for mill-finished aluminium surfaces. However,

it is advisable to be famil iar w ith coating

systems and materials as well as working

methods for aluminium.

Please note:

For general informat ion on paint ing,

lacquering and coating of aluminium w erecommend the leaflets on 02, 03, 012,

015 surfaces issued by

Gesamtverband der Aluminiumi ndustrie e. V.

Postfach 105 463

D-40045 Dsseldorf

Phone +49211 47960

Fax +49 211 47 96 408

www.aluinfo.de

Please note:

The maximumpermissible temperature

of the material (ALUCOBOND

panels)must not exceed 70C when applyingfast-drying methods. During the dryingprocess at high temperatures theALUCOBOND panels must be posi-tionedwith great care to preventdeforming.

ALUCOBOND cut edges should not be incontact with organic solvents for a pro-longed period of t ime t o avoid weakeningthe bond.

ALUCOBOND panels lacquered or overlac-quered at a later stage should not be bentor folded. The lacquer in the bends or folds

may be damaged due to the low elasticityof the top coat.

Upon request, we can name you lacquersuppliers who are able to apply lacquer thatcan be bent and folded.

Only inferior lacquer adhesion can beachieved on core material exposed at cutedges.

Please make a test prior to overlacqueringand follow the instructions of the lacquersuppliers.

Overlacquering of

stove-lacquered ALUCOBOND

surfaces


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22


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Non-suitable cleaning agents

Please do not use any powerful alkalinecleaning agents such as potassium hydroxide,sodium carbonate or caustic soda, or anypowerful acidic products or heavily abrasivescouring agents such as Vim, Ajax, Imi orlacquer-dissolving cleaning agents.

23

Cleaning and Maintenance

Surfaces

of stove-lacquered

Cleaning agents

A list of neutral cleaning agents for organicallycoated or anodized aluminium components isavailable at

Gesamtverband der Aluminiumi ndustrie e. V.

Postfach 105 463

D-40045 DsseldorfPhone +4921147960

Fax +49 211 47 96 408

www.aluinfo.de

Please observe the manufact urers cleaningand safety instructions!

For further informat ion such as addresses ofapproved and recommended cleaning compa-nies, please contact

Gtegemeinschaft fr die Reinigung vonM etallf assaden e.V. (GRM)

Irrerstrasse 17 - 19

D-90403 NrnbergPhone +499 1120 4441

Fax +49911226755

www.grm-online.de

Expert and regular cleaning not only maintainsthe aesthetic and representative finish ofstove-lacquered surfaces but also maintainstheir quality through the removal of dirt andaggressive deposits.

Cleaning intervals depend on local environ-mental condit ions and the result ing amount ofsoiling. Surfaces should be cleaned either

manually or w ith a suitable cleaning devicefrom top to bottom.

Please do not u se any abrasive pads on lac-quered surfaces. We recommend that thecleaning agent be tried on an unobtrusive partof the object to be cleaned to check whetherthe surface is affected.

Do not clean hot surfaces (>40C) asthe quick drying process may causeblemishes.


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25

Standard Data sheet

plus

Panel-Thickness: Standard Unit 3mm 4mm

Thickness of Aluminium Layers [mm] 0.50

W eight [kg/ m2] 5.9 7.6

W idth [mm] 1250 / 1500

Technical poperties:Sect ion M odulu W DIN 53293 [cm3/ m] 1.2 5 1.7 5

Rigidi ty (Poissons rat io = 0,3) EI DIN 53293 [kNcm2/ m] 1250 2400

Al loy EN 573-3 EN AW -5005A (AlM g1)

Temper of Aluminium Layers EN 515 H22/ H42M odulus of Elast icity EN 1999 1-1 [N / mm2] 70

.000

Tensile Strength of Aluminium EN 485-2 [N / mm2] Rm 130

0.2 % Proof Stress EN 485-2 [N / mm2] Rp0.2 90

Elongat ion EN 485-2 [% ] A 50 5

Linear Thermal Expansion EN 1999 1-1 2.4 mm/ m at 100C temperature difference

Core:M ineral f i l led polymer

Surface:

Lacquering Coil Coat ingFluorocarbon based (e.g. PVdF)

Gloss (init ial value) EN 13523-2 [% ] 30 - 80

Pencil Hardness EN 13523-4 HB - F

Acoustical Properties:Sound Absorption Factor s ISO 354 0.05

Sound Transmission Loss Rw ASTM E90 [dB] STC: 30 OITC: 24

Thermal properties:Thermal Resistance R ASTM C518 [m 2K/ W ] 0.007 0.009

Temperature Resistance [C] - 50 ... + 80


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26

Panel-Thickness: Standard Unit 3mm 4 mm

Thickness of Aluminium Layers [mm] 0.50

W eight [kg/ m2] 5.9 7.6

W idth [mm] 1250 / 1500

Technical properties:Sect ion modulus W DIN 53293 [cm 3/ m] 1.25 1.7 5

Rigidity EI DIN 53293 [kNcm 2/ m] 1250 2400

Alloy EN 573-3 EN AW -5005A (AlM g1)

Temper of Aluminium Layers EN 515 H22/ H42M odulus of Elast icity EN 1999 1-1 [N/ mm2] 70000

Tensile Strength of Aluminium EN 485-2 [N/ mm2] Rm 130

0.2 % Proof Stress EN 485-2 [N/ mm2] Rp0.2 90

Elongation EN 485-2 [% ] A50 5

Linear Thermal Expansion EN 1999 1-1 2.4 mm/ m at 100C temperature difference

Core:M ineral compound, polymer bonded

Surface:

Lacquering Coil Coat ingFluorocarbon based (e.g. PVdF)

Gloss (init ial value) EN 13523-2 [% ] 30 - 80

Penci l Hardness EN 13523-4 HB - F

Acoustical Properties:Sound Absorption Factor s ISO 354 0.05

Sound Transmission Loss Rw ISO 717-1 [dB] 27 27

Loss Factor d EN ISO 6721 0.004 0.005

Thermal properties:Thermal Resistance R DIN 52612 [m2K/ W ] 0.002 0.003

Thermal conductivity DIN 52612 [W / mK] 1.5 1.33

Heat Transit ion Coef f icient U DIN 4108 [W /m2K] 5.81 5.78

Temperature Resistance [C] - 50 ... + 80

Standard Data sheet

A2


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Informations(Please re quest)

ALUCOBOND Information folder

ALUCOBOND Colours

ALUCOBOND Product Catalogue:Alumini um Special Sections and Fitti ngs

ALUCOBOND Documentation filewith examples for fascia claddings and texts for tenderingincl. CD ROM

27

Original samples with standard surfaces

Samples


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1/08/2007

Processing

GB

www.alucobond.com

ALCAN COM POSITES

Alcan SingenGmbH

ALCAN COMPOSITES

atruly global player

Offices and manufacturing operations in Europe, the

Americas and Asia

Widest selection of sheet material

Partnerships with top distributors

Dedicated salesforce

ALCAN COMPOSITES

aglobal organisation

Alcan Airex A G, Sins, Sw itzerland

Alcan Kapa GmbH, Osnabrck, Germany

Alcan Singen GmbH, Singen, Germany

Alcan Thermoplastics Chelmsford, UK

Alcan Baltek Corporation, Northvale, NJ USA

Alcan Composites USA Inc., St. Louis

Alcan Composites Ltd., Shanghai, China

Alcan Composites Brasil S.A., So Paulo

Alcan Composites India Private Ltd., M umbai.

Alucobond Ghid Prelucrare English

Documents

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