Fabrication and Installation

Fabrication and Installation Fabrication and Installation 1. Processing methods 24 2. Installation procedures 25 3. Precautions on fabrication and installation (Important) 28 4. Examples of installation detail 28 Appendix 1: Equipment list 29 Appendix 2: Typical fabrication procedures 31 Appendix 3: Examples of complicated panel 33 Appendix 4: Welding method 41 Appendix 5: Typical sealing procedures 42 Appendix 6: Examples of installation detail 43 Pag. 1 a 29

Fabrication and Installation 1. Processing method ALPOLIC panels can be shaped with ordinary aluminum processing and woodworking machines and tools: (1) Saw cutting Running saws and panel saws for woodworking can cut ALPOLIC panels easily. We recommend the carbide tip blade made for aluminum and plastic. (2) Shear cutting A square shear is the most efficient method for sizing a large quantity of panels. Some shear droop may occur at the cut edge. The appropriate clearance and rake angle is: Panel Thickness Clearance Rake Angle 3mm 0.04mm 1 4mm 0.04mm 1 30' 6mm 0.2mm 2 30' (3) Grooving It is important to leave 0.2 to 0.4mm of core material in U-grooving. We recommend 110 of a grooving angle for 90 bends. Panel saw or NC routing machine is suitable for mass grooving production Router and Trimmer: Use a modified router bit as shown in the drawing. [Example of router bit] Number of teeth: 2-4 Number of rotations: 20,000-30,000 rpm Feeding speed: 8-12 m/min. Material: Solid carbide or carbide tip Groove Cutter: When processing a large quantity of panels, use a circular saw or panel saw equipped with a groove cutter. [Example of groove cutter] Material: Carbide tips Outside diameter: 220mm in diameter Number of teeth: 18 Number of rotations: 3,000 to 5,000rpm Feeding speed: 10-15m/min. (4) Folding Pag. 2 a 29

Fabrication and Installation Fold U-grooved panels with a folding jig, press brake or plate punch. To ensure a straight line on folded corners, fold the grooved panel on a flat table. To prevent the coating from cracking, we recommend that you do the folding at a temperature of 10 C or higher. (5) Rout and return system Locate the rout 25-50mm from the sheet edge, and fold it to form a tray type panel. After assembling, seal the corner with sealant to prevent water leaks, if you notch the end of corner out with 90 square. (6) Bending with press brake In case of bending ALPOLIC panel with a press brake, use a top die with the desired radius. The minimum internal bending radius is: Thickness Minimum Bendable Radius (mm) Traverse Parallel ALPOLIC 3mm 40 55 ALPOLIC 4mm 40 55 ALPOLIC 6mm 55 80 Note: In case of ALPOLIC /fr comprising of non-combustible mineral filled core, the minimum radius becomes larger than the above. Please refer to ALPOLIC /fr brochure. (7) Bending with three roll bender For a larger bending radius, use a three-roll bender. Groove and slit the curving edge before bending, as shown below: (8) Rivet & bolt Use an aluminum blind rivet for your junction. Do your fixing work Aluminum from the same direction, and use a stainless steel bolt/nut. When panels are connected with a junction hole, make sure the distance from the hole center to the panel end (e) is larger than twice the hole s diameter (D) to ensure that the hole has sufficient tensile strength (e 2D). Refer to Guidance on Design, 1-3. Strength of junction point. (9) Welding The core of ALPOLIC can be welded with a hot air gun. Use a low-density polyethylene rod for a welding rod, or substitute a scrap piece of ALPOLIC panel. Reinforce it after welding. Refer to Appendix 4 for detail. ALPOLIC Suitable machines and tools for ALPOLIC fabrication is summarized in Appendix 1. Typical fabrication procedures for tray-type panel are summarized in Appendix 2. Sometimes we come across very complicated panels, which might have a three dimensional corner. Fabrication methods of some of these panels are introduced in Appendix 3 Pag. 3 a 29

Fabrication and Installation Pag. 4 a 29

Fabrication and Installation 2. Installation (1) General Installation is executed in accordance with the drawings and specifications of the project. In the event that those not mentioned in the drawings and specifications should be found or that some modification should be required, consultation with controllers are necessary for approval. (2) Installation procedures Typical installation process consists of the following procedures: Installation procedures Unloading Equipment to be provided Truck and crane Marking Scaffold Substructure work ditto Rust inhibiting coating ditto ALPOLIC work ditto Accessories work ditto Joint sealing ditto Clearing and cleaning Scaffold & it s clearing (3) Comments on each procedure a. Unloading Unload ALPOLIC panels on roof, each floor or suitable places on site. The unloaded panels on each floor will be just those required for the relevant floor. Fasten the panels together with rope and covering sheet for protection. b. Marking Confirm the reference line in the presence of superintendent. Based on the reference line, installation lines will be marked. Installation line will be allotted in accordance with the approved shop drawing. c. Substructure work In order to install the substructure, weld bracket (for example, L-50 50 4t, piece angle, L=70mm) onto hole-in anchor. Weld continuous angle (L-40 40 3t) onto the bracket. All the angles will be finished with rust inhibiting coating, which conforms to Project Standard. During welding operation, watch the spark dropping on cover sheet and veneer, to prevent from fire. During substructure work, Pag. 5 a 29

Fabrication and Installation check the level with flush thread and plumb-bob line, or water level, if necessary. d. Rust inhibiting coating Apply rust inhibiting paint that conforms to Project Standard onto all the welded points including back and edge. e. ALPOLIC work Mark the installation line in accordance with shop drawing. Fix ALPOLIC panel onto substructure with self-tapping screw, 4mm in diameter, after confirming left, right, top and bottom of the panel. The fixing interval will be normally 300-400mm depending on strength calculation. After confirming the fixed conditions, peel off the protective film and clear the removed film. f. Accessories work Bring the accessories to scaffold passage, as allotted in shop drawing. The quantity of accessories brought to scaffold passage must be reasonable to avoid precipitation. The large accessory will be placed diagonally on scaffold. Mark the installation line onto substructure to meet the position of window frame. The joint line can be ignored in case of aluminium extrusions. Fix the accessory with self-tapping screw, 4mm in diameter, with @=300mm interval. After installation, check the installed level and precision. After the check, peel off the protective film. Clear the removed film. g. Clearing and cleaning Clear and clean the working area everyday after work. Especially, whenever the work is completed in the area, transfer the area smoothly to the next procedure, not to hinder the next work. Collect and clear remains to damp point everyday, to transport out from the site immediately. Sealing work is outlined in Appendix 5. Pag. 6 a 29

Fabrication and Installation 3. General precautions on fabrication and installation (Important) (1) Weatherability of protective film The protective film on ALPOLIC consists of two polyethylene layers of white and black. Do not peel off the protective film during fabrication and installation to protect the surface from scratching and soiling. Under normal weather conditions, the protective film will withstand six months exposure without losing any of its original peel-off characteristics or causing stains or other damages. However, peel off the protective film as soon as possible after completion. (2) Slight color difference due to coating direction In the cases of our Metallic Colors, Sparkling Colors and Stone Series, always install panels in the same direction as marked on the protective film. Slight color differences will be noticeable if you install panels in different directions. In our Solid Colors, any color difference due to coating direction is negligible. (3) Gloss increase due to plasticizer Do not stick, put or apply PVC tapes, polyurethane sealant and modified Silicone sealant onto our protective film. The plasticizer contained in these materials can penetrate the protective film and cause a gloss change in the coating. 4. Examples of installation detail Refer to Appendix 6. Pag. 7 a 29

Fabrication and Installation Appendix 1 Equipment list for ALPOLIC fabrication Cutting & grooving Panel saw Grooving Handy grooving machine Cutting Circular saw blade Precision grooving Handy router & bit Grooving Grooving cutter blade Grooving, cutting and notching CNC Router Corner-notching Notching tool Drilling & assembling Pneumatic drill & rivet tool Pag. 8 a 29

Fabrication and Installation Appendix 1 Punching for hanging holes Punching press Folding, assembling & inspection Flat working table Cutting for aluminum extrusions Circular saw and dust-collector Utility for pneumatic tools Air compressor Bending after grooving Bending jigs Pag. 9 a 29

Fabrication and Installation Appendix 2 Typical fabrication procedures 1. Check fabrication drawings 2. Check ALPOLIC panels 3. Marking on panels Check up on every fabrication drawing, to confirm the details. Check ALPOLIC panels, to confirm the size, color and quantity, based on the drawing. Mark the cutting and grooving lines on panels, based on the drawing. 4. Cut 5. Groove 6. Corner-cutout Cut the panel with circular saw, based on the drawing. Remaining thickness and bending radius to be confirmed after pre-test. The panel corners are removed by a notching tool or punching press. 7. Punch for hanging holes 8. Cut aluminum extrusions 9. Fold Hanging holes are removed by punching or press machine. Cut aluminum extrusions, if any, based of the details. Fold the grooved edge with a folding jig. The bent angle to be confirmed after folding. Pag. 10 a 29

Fabrication and Installation Appendix 2 10. Cut off protective film 11. Fix corner angle pieces 12. Fix aluminum flange The protective film of edge is peeled and cut off by a utility knife. Corner angle pieces are fixed with rivets. Aluminum flange bars are fixed with rivets, to complete the tray panels. 13. If necessary, apply sealant on panel corners 14. Final check A suitable sealant is applied on the panel corner from the backside, to ensure the waterproof, if necessary. Inspect the completed panels. Pag. 11 a 29

Fabrication and Installation Appendix 3 Examples of complicated panel Example 1: 3-dimension curving panel Example 2: Corner panel of cornice Example 3: Corner panel of coping Example 4: Corner panel of water drip Example 5: Corner panel of recessed window Example 6: Corner panel of curving canopy Note: Dimensions of fabricated panels below are those for miniature samples scaled down to 1/2 to 1/5. Please replace the dimensions so as to fit to your case. Pag. 12 a 29

Fabrication and Installation Appendix 3 Example 1: 3-dimension curving panel Front view 25mm or less Application example 3-dimension curving panel 1300mmR or larger Flat panel 3-dimension curving panel Elevation Section Cutting and grooving method Flat panel 3-dimensional curving panel Cutting Grooving Notching Bending method Bend ALPOLIC panel and filling board together. Filling board ALPOLIC Pag. 13 a 29

Fabrication and Installation Appendix 3 Pag. 14 a 29

Fabrication and Installation Appendix 3 Example 2: Corner panel of cornice Completed panel Elevations aluminum flange, large A-A section B-B section aluminum flange, small aluminum angle, 20x20 C-C section aluminum angle, 20x20 D-D section aluminum sheet, continuous water gutter, aluminum sheet, continuous behind upper junction line, adhered with VHB tape. Grooving & cutting method Cutting Grooving Notching A detail Pag. 15 a 29

Fabrication and Installation Appendix 3 Example 3: Corner panel of coping Completed panel Section Elevations aluminum flange, large aluminum flange, small A-A section B-B section C-C section D-D section aluminum flange, large drain hole water gutter, adhered with 3M s VHB tape Pag. 16 a 29

Fabrication and Installation Appendix 3 Grooving & cutting method Cutting Grooving Notching A A detail water gutter, adhered with 3M s VHB tape Pag. 17 a 29

Fabrication and Installation Appendix 3 Example 4: Corner panel of water drip Completed panel Section detail A-A section ALPOLIC support, adhered with 3M s VHB tape edge to be touched up Cutting and grooving method Cutting Grooving Notching Pag. 18 a 29

Fabrication and Installation Appendix 3 Example 5: Corner panel of recessed window Completed panel Application example Corner panel of recessed window A-A section ALPOLIC support, adhered with 3M s VHB tape edge to be touched up Grooving & cutting method Main panel Cutting Grooving Notching Supplementary panel Aluminum support plate Pag. 19 a 29

Fabrication and Installation Appendix 3 Example 6: Corner panel of curving canopy Completed panel Elevations A section B section Cutting and grooving method Pag. 20 a 29

Fabrication and Installation Appendix 4 Welding method An edge of ALPOLIC can be connected to another edge by means of welding core with hot jet gun. The rod for welding can be produced by cutting a piece of ALPOLIC waste to a slender rod of core material. The welded point is less strong, and so, normally reinforcement is necessary after welding. 1. Example of welding machine 2. Welding rod 3. Milling for welding 4. Suitable pushing pressure 5. Support plate 1. Tools for welding: Welding machine: Hot jet gun for thermoplastic resin 2. Preparation of welding rod Cut a piece of ALPOLIC waste to 3 to 5mm slender rod of ALPOLIC. Peel off aluminum skins of both sides, to have a rod of core material. Sharpen the starting edge of the welding rod (approx. 45 ). 3. Milling for welding Mill or rout ALPOLIC panel edge with grooving or routing machine, to fit to welding. 4. Welding Prior to welding, pre-heat the tip of welding rod and ALPOLIC core surface with hot jet gun. When both surfaces become wet, push the rod against ALPOLIC core, and slide the rod forward with a feeding speed of 5 to 6 cm per min. Note 1: The temperature of the air blown from the hot jet gun is approx. 130 C around the welding area. Note 2: Push the welding rod against the core surface with such pressure as the rod can bend to approx. 45, as shown in the left illustration. Note 3: Heating too much will cause a thermal decomposition of the core material, and the rod will not adhere to the core. Note 4: The feeding speed must be neither too quick nor too slow. The feeding must be uniform and continuous. 5. Reinforcement with support plate Finally, adhere a support plate of ALPOLIC or aluminum sheet with a suitable adhesive or a both-sided tape, to reinforce the welded pint. Note 5: In case adhesives are applied, pre-testing is necessary to confirm that the adhesive does not cause a distortion on the surface side, since some adhesives will cause a distortion due to shrinkage after hardening. Pag. 21 a 29

Fabrication and Installation Appendix 5 Typical sealing procedures 1. Clean work surface Remove gravel. Clean joints, to remove moisture, oil and dust. Dry the joint, if moist. 2. Insert back-up material Back-up material is necessary as a bond breaker to avoid triangle adhesion. 3. Apply masking tape Apply masking tape to both sides of joint, to avoid smearing the adjacent area. 4. Apply primer Apply primer with brush or spray, if primer is required for compatibility. 5. Mixing (2-component type) In case of 2-component type, mix base component and curing agent, and stir it. 6. Filling operation (2-component type): Before filling, wash and wipe the gun and nozzle to remove smear and oil. Avoid bubble. 7. Filling operation (1-component type): In case of 1-component type, cut the nozzle at 45 and fit the cartridge into a caulking gun. 8. Tooling Tooling is carried out for uniform adhesion, clean finish and elimination of bubble. 9. Remove masking tape After tooling, remove masking tape. Small bar is often used for efficient work. Note 1. The above is excerpt from a sealant manufacturer s brochure. Refer to manufacturer s brochure for details and particular notice to the sealant. 10. Curing After completion, the joint is carefully cured until completely hardening. Note 2. Gloss increase due to plasticizer: Do not stick polyurethane sealant and modified Silicone sealant on ALPOLIC protective film. The plasticizer contained in these materials can penetrate the protective film and cause a gloss change in the coating. During tooling, do not smear ALPOLIC protective film with surplus of sealant. Pag. 22 a 29

Fabrication and Installation Appendix 6 Examples of installation detail (1) Canopy of petrol service station This detail is just an idea and does not refer to a particular project. Renovation work of petrol service station generally requires simplicity and promptness in installation. Therefore, supposedly, suspending method has become widely applied. Aluminum substructure is installed on the existing canopy, so as to permit the sub-structure surface sufficiently flat. ALPOLIC panel is suspended on the substructure by aluminum support plates and suspension bolts. Afterward, panel top and bottom are fixed to the substructure with screw. (2) Corporate sign board This corporate sign was organised for a newspaper company s distribution network consisting of 2,300 shops countrywide in Japan. The panel finish is blue color of polyester coating and 3M Scotchcal film is applied for logo-mark and lettering. ALPOLIC panel is inserted in pocket of aluminum flange coated with the same color as ALPOLIC. The flange is fixed to steel substructure. The panel is reinforced with stiffeners, which is adhered to the panel with 3M s VHB tape and also fastened to flange at top and bottom with aluminum angles. Water drip is provided on the top to prevent from staining by rain. Water drain holes are provided on the bottom. (3 & 4) Facade This is an example of facade with sealing joint, rubber gasket and hanging system. (5) Cover panel for balcony ALPOLIC is widely used for cover panel of flat balcony in Japan. The panel is fixed to aluminum substructure with bolt/nut of stainless steel. (6) Guide sign (interior) This example is an interior guide sign in subway station. The map and letters are printed by screen print. ALPOLIC is inserted in aluminum flange and two pieces of panels are connected by rivet and aluminum sheet behind the panel. Pag. 23 a 29

Fabrication and Installation Appendix 6 Example of installation detail (1) Canopy of petrol service station 2 3 1 7 4 5 6 8 9 10 1. ALPOLIC, Lumiflon-based fluorocarbon coating 2. Gradient of ALPOLIC for drain 3. Roof plate, aluminum sheet 4. Suspension bolts 5. Suspension plate, aluminum sheet 6. Aluminum rivet 7. Existing wall or steel structure 8. Anchor & level-adjustment 9. Sub-structure for ALPOLIC, aluminum rectangular pipe 10. Bottom cover Note: This detail is just an idea and does not refer to a particular project. Pag. 24 a 29

Fabrication and Installation Appendix 6 Example of installation detail (2) Corporate sign board 50mm 20mm 3 2 4 5 6 1 7 1200mm 8 9 1. ALPOLIC, polyester coating with 3M s Scotchcal film for logo-mark and lettering 2. Aluminum drip 3. Aluminum rivet 4. Countersunk tapping screw, @=450 5. Steel sub-structure, L-30 30 1.6, chromate, piece L=300 6. Anchor, @=900 7. Corner plate, aluminum, L-40 40 2, L=40 8. Aluminum stiffener, square pipe, 30 30 2 9. Aluminum flange coated with the same color as ALPOLIC 10. Drain hole, 10mm diameter 10 Pag. 25 a 29

Fabrication and Installation Appendix 6 Example of installation detail (3) Facade Vertical section 1 2 5 6 4 7 3 8 1. ALPOLIC, Lumiflon-based fluorocarbon coating 2. Aluminum flange 3. Tapping screw, stainless steel 4. Aluminum rivet 5. Sealing material 6. Back-up material 7. Sub-structure, steel angle galvanized or coated with rust-preventive paint, continuous 8. Adjusting bolt, stainless steel 9. Bracket, steel angle, galvanized or coated with rust-preventive paint, piece 10. Hole-in anchor or built-in bolt 9 10 Horizontal section Pag. 26 a 29

Fabrication and Installation Appendix 6 Example of installation detail (4) Facade Double grooving 1 2 1. ALPOLIC panel with double grooving 2. Tapping screw Rubber gasket 1 2 4 5 3 6 1. ALPOLIC panel with rout and return system 2. Aluminum rivet 3. Tapping screw 4. Rubber gasket 5. Aluminum angle 6. Sub-structure of ALPOLIC Hanging system 1 2 3 1. ALPOLIC panel with rout and return system 2. Horizontal sub-structure 3. Tapping screw 4. Galvanized steel channel 5. suspension bolt, stainless steel 4 5 Pag. 27 a 29

Fabrication and Installation Appendix 6 Example of installation detail (5) Cover panel for balcony ALPOLIC panel Pag. 28 a 29

Fabrication and Installation Appendix 6 Example of installation detail (6) Guide sign (interior) 2 1 3 4 1. ALPOLIC panel 2. Aluminum flange 3. Aluminum reinforcement (Center only) 4. Aluminum rivet Pag. 29 a 29