multiwall polycarbonate standing-seam technical guide · sunpal is an advanced multiwall...
TRANSCRIPT
Creating New Solutions for over 40 Years
ww
w.p
alr
am
.co
m
SUNPAL®Multiwall Polycarbonate
Standing-Seam
Architectural System Technical Guide
2 | SUNPAL® Technical Guide
Contents Page
Introduction 3
Panel Specification 4
Colors and Solar Transmissions 5
Thermal Insulation Properties 5
Typical Physical Properties 5
System Components Definition 6
A) Joiners 6
B) Fasteners 6
C) Sealing & end cap Strips 6
D) Alu Span-Bar 7
System Components List 8
Installation Data 11
Roof structure 11
Assembled System Width 11
Purlin Design - Recommended spans 11
Rafter Design - Recommended Spans 11
Installation Instructions 12
Assembly Details 15
Cladding Details 16
Roofing Details 20
SUNPAL® Technical Guide | 3
Introduction
SUNPAL is an advanced multiwall polycarbonate panel system that combines smart design, light transmission, high
thermal insulation and strength. It offers a lightweight, expansion-free and leak-proof design that withstands very high
loads. The system’s many advantages make it ideal for long term installations in various design projects. As architectural
glazing system, SUNPAL is applied in a variety of roofing and cladding uses, in flat or curved designs.
SUNPAL is a self fastening system, based on extruded Sunlite panels of 8mm, 10mm, 18mm and 20mm thickness.
The panels join together by polycarbonate or aluminum joiners which are sealed at the ends by End-caps.
T-Fasteners fix the system to the structure by clamping, without any penetration through the panels.
Aluminum Sealing Strip closes the panel lower end to prevent dirt from entering the flutes, and provide efficient drainage.
U-Profile (PC / aluminum) or Al F-Profile seals the upper end of the panel. Aluminum F-Profile fits to the panel side edges, to
interface with the structure for a completely framed installation.
4 | SUNPAL® Technical Guide
Panel Specification
SUNPAL panels are of multiwall structure, available with thicknesses of 8mm, 10mm, 18mm and 20mm. Standard SUNPAL
panels have UV protection on both sides (specific order can be produced with UV protection on one side only). Maximum
panel length is 11.99 (typical stoke length).
Panel Data Drawing
SU
NP
AL
® 8
/60
0 L
ite
Width: 600mm
Height: 23.5mm
Height with PC-Joiner: 33mm
Weight: 1.10 Kg/m, 1.83 Kg/m²
Min. cold bending radius: 2.0m
SU
NP
AL
® 8
/60
0 Width: 600mm
Height: 23.5mm
Height with PC-Joiner: 33mm
Weight: 1.20 Kg/m, 2.00 Kg/m²
Min. cold bending radius: 2.0m
SU
NP
AL
® 1
0/6
00 Width: 600mm
Height: 25.5mm
Height with PC-Joiner: 35mm
Weight: 1.56 Kg/m, 2.60 Kg/m²
Min. cold bending radius: 2.4m
SU
NP
AL
18
/10
00 Width: 1000mm
Height: 33.5mm
Height with PC-Joiner: 41mm
Weight: 3.11 Kg/m, 3.11 Kg/m²
Min. cold bending radius: 3.0m
SU
NP
AL
® 2
0/1
00
0
Width: 1000mm
Height: 35.5mm
Height with PC-Joiner: 33mm
Weight: 3.19 Kg/m, 3.19 Kg/m²
Min. cold bending radius: 3.0m
SUNPAL® Technical Guide | 5
Colors and Solar Transmissions
Color LT SHGC SC Color LT SHGC SC
SU
NP
AL
® 8
/60
00
Clear 65% 0.63 0.72
SU
NP
AL
® 1
0/6
00
Clear 65% 0.63 0.72
Bronze 25% 0.40 0.46 Bronze 25% 0.40 0.46
White Opal 26% 0.37 0.43 White Opal 26% 0.37 0.43
White Ice 50% 0.56 0.64 White Ice 50% 0.56 0.64
Solar Ice 20% 0.28 0.32 Solar Ice 20% 0.28 0.32
Solar Grey 30% 0.45 0.52 Solar Grey 30% 0.45 0.52
Solar Control Grey 20% 0.30 0.34 Solar Control Grey 20% 0.30 0.34
Green 50% 0.56 0.64 Green 50% 0.56 0.64
Blue 50% 0.60 0.69 Blue 50% 0.60 0.69
Red 20% 0.52 0.60 Red 20% 0.52 0.60
Color LT SHGC SC Color LT SHGC SC
SU
NP
AL
® 1
8/1
00
0
Clear 50% 0.54 0.62
SU
NP
AL
® 2
0/1
00
0
Clear 50% 0.54 0.62
Bronze 20% 0.35 0.39 Bronze 20% 0.35 0.39
White Opal 20% 0.30 0.34 White Opal 20% 0.30 0.34
White Ice 40% 0.48 0.55 White Ice 40% 0.48 0.55
Solar Ice 15% 0.23 0.26 Solar Ice 15% 0.23 0.26
Solar Grey 30% 0.44 0.51 Solar Grey 30% 0.44 0.51
Solar Control Grey 15% 0.25 0.29 Solar Control Grey 15% 0.25 0.29
Green 38% 0.46 0.53 Green 38% 0.46 0.53
Blue 36% 0.50 0.57 Blue 36% 0.50 0.57
Red 15% 0.44 0.50 Red 15% 0.44 0.50
LT (Light Transmission) = The percentage of incident visible light that passes through an object.
SHGC (Solar Heat Gain Coefficient) = The percentage of incident solar radiation transmitted by an object, which includes the direct solar transmission and the part of the solar absorption radiated inward.
SC (Shading Coefficient) = The amount of the sun’s heat transmitted through a given window compared with that of a standard 1/8- inch-thick single pane of glass under the same conditions.
Thermal Insulation Properties
Property SUNPAL® 8/600 Lite SUNPAL® 8/600 SUNPAL® 10/600 SUNPAL® 18-20 /1000
U-Value [Watts/m²·°C] 2.45 2.45 2.10 1.50
R-Value [m²·°C/ Watt] 0.41 0.41 0.47 0.67
Typical Physical Properties
Property Method** Conditions Units Value
Density D-792 g/cm³ 1.2
Heat deflection temperature (HDT) D-648 Load: 1.82 MP °C 130
Service Temperature - Short term °C -50 to +120
Service Temperature - Long term °C -50 to +100
Coefficient of linear thermal eaxpansion D-696 cm/cm °C 6.5 x 10
Tensile strength at yield D-638 10 mm/min MPa 62
Elongation at break D-638 10 mm/min % >80
Impact falling dart ISO 6603/1 J 40-400
Thermal expansion/contraction rate mm/m 3
*ASTM method except where noted otherwise
6 | SUNPAL® Technical Guide
System Components Definition
The SUNPAL system is generally defined by the panel type. All the other components are selected to match this panel.
A) Joiners
The Joiners (PC or aluminum) fit all panel types. The choice between them is generally by the application -
PC Joiner or Alu Joiner ‘R’ for roofing (or any situation where the seam is external); Alu-Joiner ‘C’ for cladding
(hidden seam).
PC-Joiner (part 02) is 22mm high by 39mm wide, extruded polycarbonate colored to match the panels.
Maximum length is 11990mm, with weight of 160gr/m. The PC-Joiner should overhang about 100mm beyond the last
fastener.
End-Cap for PC-Joiner (part 03) is a clear acrylic cap, designed to plug the PC-Joiner ends. This end-cap prevents water
and dirt from entering the joiner, it helps to reinforce the joiner ends, and provides harmonic finished appearance to the
systems ends.
Alu Joiner ‘R’ (part 12) is 40mm wide and 22mm high, mill-finish extruded aluminum. Maximum length is 6000mm. The
Alu-Joiner ‘R’ should overhang about 150mm beyond the last fastener.
End-Cap for Alu Joiner ‘R’ (part 13) is a mill-finished aluminum plate, designed to close the Alu Joiner ‘R’ ends. This end-cap
is fixed by inserting two screws into the joiner.
Alu Joiner ‘C’ (part 04) is 39mm wide by 54mm high, extruded aluminum with mill finish. Maximum length is 6000mm. The
Alu-Joiner should overhang about 250mm beyond the last fastener.
End-Cap for Alu Joiner ‘C’ (part 05) is a mill-finish aluminum plate, designed to close the Alu-Joiner ends. This end-cap is
fixed by inserting two screws into the joiner.
B) Fasteners
T–Fastener (part 08) - SUNPAL roofing system is attached to the supporting structure by the T-Fasteners. These
are stainless steel concealed clips that are fixed onto the structure with screws. The fasteners have four different
sizes to match each panel type. For installing SUNPAL system onto wooden structure, the T-Fasteners are fixed
with Wooden Screws (part 12). For metal structure, Metal Screws (part 13) are used. As standard, each fastener is fixed with two
screws. For high wind areas, using three screws per fastener is recommended.
T-Stopper (part 09) - To prevent “travelling” of the panels, it is recommended to fix one T-Stopper at a certain fixing point along
each Joiner. This will be the only longitudinal fixed point, while all other fixings are floating. It is a T-Fastener with added stopper
plate, which fits into slit in the attaching panels (prepared on spot).
C) Sealing & end cap Strips
The Alu Sealing Strips (part 06) are mill-finished aluminum profiles in four sizes, to match each type of
panel. Maximum length is 6000mm (stock length). These are used as a closure for the panels end (usually
the lower), to prevent penetration of dirt end moisture, and provide efficient drainage. U-Profile is used for
sealing the panel’s upper end, to prevent penetration of moisture and dirt.
PC U-Profiles (part 07) are made of polycarbonate, and have two types to suite 8mm and 10mm panels. Their maximum length
is 12mm (stock length).
SUNPAL® Technical Guide | 7
Alu U-Profile (part 16) is an aluminum profile mill finished, with two types of sizes to suit 18mm and 20mm panels. Their
maximum length is 6000mm (stock length).
Alu F-Profiles (part 11) are available at four sizes to match each panel type. These are aluminum profiles mill finished, with
maximum length of 6000mm (stock length). The F-Profiles are used generally as a side fixing detail, also possible as an upper-
end closure.
D) Alu Span-Bar (part 10)
This is an aluminum profile that can be used as a rafter on a structure frame. It can be straight or curved (by rolling),
and designed to perform both as a rafter and a fastener (no T – Bar Fasteners required in Span-Bar applications).
The Span-Bar has four sizes to match each panel type, and its maximum length is 6000mm.
8 | SUNPAL® Technical Guide
System Components List
# Component Drawing Specification Stock Length / Quantity
0200 PC Joiner (8-20mm) Panel matched 12m
0300 End-Cap for PC Joiner (8-20mm) Natural clear 200 per box
1200 Alu Joiner ‘R’ (8-20mm) Mill finish 6m
1300 End-Cap for Alu Joiner ‘R’ (8-20mm) Mill finish
0808 T-Fastener (8 mm) Stainless steel 200 per box
0810 T-Fastener (10 mm) Stainless steel 200 per box
0818 T-Fastener (18 mm) Stainless steel 200 per box
0820 T-Fastener (20 mm) Stainless steel 200 per box
0908 T-Stopper (8 mm) Stainless steel 50 per box
0910 T-Stopper (10 mm) Stainless steel 50 per box
0918 T-Stopper (18 mm) Stainless steel 50 per box
SUNPAL® Technical Guide | 9
# Component Drawing Specification Stock Length / Quantity
0920 T-Stopper (20mm) Stainless steel 50 per box
1400 Metal Screw (8-20mm) Self-Drilling 500 per box
1500 Wood Screw (8-20mm) Tapping 500 per box
0608 Alu Sealing strip (8mm) Mill finish 6m
0610 Alu Sealing strip (10 mm) Mill finish 6m
0618 Alu Sealing strip (18mm) Mill finish 6m
0620 Alu Sealing strip (20mm) Mill finish 6m
0708 PC U-Profile (8mm) Clear 6m
0710 PC U-Profile (10mm) Clear 6m
1618 Alu U-Profile (18mm) Mill finish 6m
1620 Alu U-Profile (20mm) Mill finish 6m
10 | SUNPAL® Technical Guide
# Component Drawing Specification Stock Length / Quantity
1108 Alu F-Profile (8mm) Mill finish 6m
1110 Alu F-Profile (10mm) Mill finish 6m
1118 Alu F-Profile (18mm) Mill finish 6m
1120 Alu F-Profile (20mm) Mill finish 6m
0400 Alu Joiner ‘C’ (8-20mm) Mill finish 6m
0500 End-Cap for Alu Joiner ‘C’ (8-20mm) Mill finish 6m
1008 Alu span-bar (8mm) Mill finish 6m
1010 Alu span-bar (10mm) Mill finish 6m
1018 Alu Span-Bar (18mm) Mill finish 6m
1020 Alu Span-Bar (20mm) Mill finish 6m
SUNPAL® Technical Guide | 11
Installation Data
Roof structure SUNPAL system fits for both rafter and purlin construction. The recommended minimum roof slope for SUNPAL
applications is 5%. For lower slopes rafter design is recommended.
Assembled System Width
SUNPAL® 8/600 and 10/600 SUNPAL® 18/1000 and 20/1000
Purlin Design - Recommended spansfor wind load of 1kPa (mm)
Polycarbonate Joiner Aluminum Joiner - R Aluminum Joiner - C
Panel Type Panel Width Mid-Span End-Span Mid-Span End-Span Mid-Span End-Span
SUNPAL Lite 8 mm 600 900 700 1,300 950 1,500 1,100
SUNPAL 8 mm 600 1050 825 1,400 1,000 1,600 1,200
SUNPAL 10 mm 600 1,250 950 1,600 1,200 1,800 1,400
SUNPAL 18/20 mm 1,000 1,350 1,000 1,600 1,200 1,800 1,400
Rafter Design - Recommended SpansWith max. intervals of T-Fasteners along rafters for wind load of 1kPa(mm)
Polycarbonate Joiner Aluminum Joiner - R Aluminum Joiner - C
Panel Type Rafter CentersInternal
Fasteners
Fasteners at
Rafter Ends
Internal
Fasteners
Fasteners at
Rafter Ends
Internal
Fasteners
Fasteners at
Rafter Ends
SUNPAL Lite 8 mm 602 900 700 1,300 950 1,500 1,100
SUNPAL 8 mm 602 1050 825 1,400 1,000 1,600 1,200
SUNPAL 10 mm 602 1,250 950 1,600 1,200 1,800 1,400
SUNPAL 18/20 mm 1,002 1,350 1,000 1,600 1,200 1,800 1,400
Note 1: The above spans are specified for wind loads of 1000 Pa (21 psf ) in roofing applications. For vertical or internal applications, contact your local SUNPAL distributor.
Note 2: In curved applications, Aluminum Joiners will have to be pre-rolled, while Polycarbonate Joiners can be cold curved to the roofing radius.
1002mm602mm
12 | SUNPAL® Technical Guide
1. Cut to size
Cut panels to length allowing for an overhang of no more than 100mm at each end. We recommend a penetration of minimum
50mm into the gutter!
Use a circular saw or hand saw with fine tooth blades for easier and better cutting.
2. Slit for Alu Sealing-Strip
Using a small cutting disc (2 mm thick), prepare 18 mm deep horizontal cuts at each end of the panel teeth. This cut should be
in parallel to the panel top face, but without injuring the panel surface.
Since it needs precision, it is highly recommended to perform this action before assembly.
Cut to SizeA Slit for AIu Sealing StripB Remove Inner MaskingC
Fix Sealing StripG Fix Side FlashingsI
AssembleEFix T-Bar FastenersD Remove Outer MaskingF
Fix Joiner End-CapsH
Installation Instructions
SUNPAL® Technical Guide | 13
3. Remove cutting chips
Using a vacuum cleaner or an air compressor with blow gun – blow out any “swarf” or loose particles from inside the panel
(ensuring both ends of panel are free of the plastic envelope/ sleeve).
4. Position first panel
For symmetric installation - determine the layout of the first panel, starting in the centre of the structure (this can be determined
by dividing the structure width x 2 and adding half the width of the panel).
For “side to side” installation - Set-up the first panel, fitted to the side flashing.
5. Remove inner Masking
Remove the protective foil from the internal face only. Keep this side away from the roof purlins until final positioning of the
panel, to avoid scratching.
6. Fix T-Stopper
At the top purlin (100mm from end of sheet for rafter only) place a T-Stopper up against panel and fix into place using hex head
fixings provided.
For curved application on arched structure, the T-Stopper should fix as the mid fastener at the top of the arch.
On wall application the T-Stopper should fix at the opposite to the expansion allowance.
7. Fix T-Fasteners
Along panel on remaining purlins (see span table for rafter design), place T fasteners against panel and fix into place using hex
head fixings provided (2 fixings for standard, 3 fixings for high wind areas and cyclonic regions).
8. Position next panel
Remove protective film from underside of second panel and place against T fasteners.
9. Locking the 2 panels together
Using a rubber mallet, start to fix the Joiner, locking the 2 panels together by striking with short intervals (5-10cm) along the
joiner. Start at the bottom end, and work your way up the roof (ensure that the joiner overhangs the panel ends by 13mm,
where the aluminum sealing strip will be installed later).
10. Aluminum Joiner
If using Aluminum Joiners ‘R’, before installing, drill 7mm diameter holes through the joiner sides along the line provided,
1000mm centers and install as per step 9.
After locking, fix M6 bolt through holes pre-drilled previously through aluminum joiner with lock nut and tighten (making
sure it’s firm. Do not over tighten).
11. Remove outer Masking
Remove the protective foil from the panel’s external face shortly after installation.
Delaying foil removal can make it very difficult to remove later (on hot days remove top protective film straight away to prevent
film from bonding with the panel).
14 | SUNPAL® Technical Guide
12. Repeat steps 5 to 9 (or 11) until all panels are in place except for end panels.
13. Determine width of end panels required. Using a circular saw (fitted with fine tooth blade) or jigsaw cut the end panels to
width.
14. Along the cut edge of the SUNPAL panel, push on the aluminum F section (cut to size) so that it is firmly secured.
15. Lift the end panel into place and repeat step 9 (or 9-11). The aluminum F section should be hard up against last rafter or
end of purlins (note: if fixing to metal purlins, make sure the ends of the purlins are closed off ).
16. Fix the F-Section to the rafter or end of purlin using tek screws.
17. Start installing the U-Profile at the panel top end by pushing on. It is designed to be a tight fit so start by pushing one
end on and slowly tap it until it is firmly inserted. PC U-Profile (for SUNPAL 8-10mm) is to tap by hand, for Al U-Profile (SUNPAL
18-20mm) use a rubber mallet.
18. Start installing the Al Sealing Strip at the panel bottom end by pushing it on. It is designed to be a tight fit so start by
pushing one end on and using a mallet slowly tap it until it is firmly inserted. These sealing strips are necessary to prevent
penetration of dirt end moisture.
19. Joiner End-cap fixing
Insert Joiner End-cap in both joiner ends.
The End-cap for PC Joiner is pushed into place. The End-cap for Alu Joiner is fit with screws. There is no need to use silicone
sealants or adhesives of any kind.
20. Side flashings
These are used on both sides of the structure, as a fastener as well as a flashing.
They are fit either for full width or cut to size panels. Purpose made flashings are required in some situations. End-cap should fit
to these flashings on both ends.
Notes:
SUNPAL system does not require using silicones or adhesives for parts interface. For sealing of flashing assemblies Use
only PALRAM approved accessories, silicones, sealing tape, closure fixtures etc.
For cleaning SUNPAL multi panels use a pressure cleaner and allow natural drying. Do not use cloth/ sponge/ chamois or
similar, doing this can scratch the panels and harm their performance.
SUNPAL® Technical Guide | 15
Assembly Details
Legend
01 Panel
02 PC Joiner
03 End-Cap for PC Joiner
04 Alu Joiner ‘C’
05 End-Cap for Alu Joiner ‘C’
06 Alu Sealing Strip
07 PC U-Profile
08 T-Fastener
09 T-Stopper
10 Alu Span-Bar
11 Alu F-Profile
12 Alu Joiner ‘R’
13 End-Cap for Aluminum Joiner ‘R’
14 Metal Screw
15 Wood Screw
16 Alu U-Profile
8
4
1
2
3
6
5 7 9
10
14
11
15
12
16
13
16 | SUNPAL® Technical Guide
Cladding Detail 1: Cladding Base Note: Set T-stopper (09)
at the opposite to allow
for expansion at this end.
Cladding Detail 2: Cladding Base - Hidden Seams
SUNPAL® Technical Guide | 17
Cladding Detail 3: Corner Details
Cladding Detail 4: Panels Cladding Joint
Note: Set T-stopper (09)
at the opposite to allow
for expansion at this end.
18 | SUNPAL® Technical Guide
Cladding Detail 5: Parallel Apron Flashings
Cladding Detail 6: Parallel Apron Flashings - Hidden Seams
SUNPAL® Technical Guide | 19
Cladding Detail 7: Cladding Top Flashings
Cladding Detail 8: Cladding Top Flashing - Hidden Seams
Note: Set T-stopper (09)
at the opposite to allow
for expansion at this end.
20 | SUNPAL® Technical Guide
Roofing Detail 1: Apron Flashing
Roofing Detail 2: Eave
Note: For information on allowed
overhang please refer to “a) Joiners”
section on page 6.
SUNPAL® Technical Guide | 21
Roofing Detail 3: Barge Details
Roofing Detail 4: Parallel Apron Flashing
22 | SUNPAL® Technical Guide
Roofing Detail 5: Ridge Flashing
Roofing Detail 6: Hip Flashing
SUNPAL® Technical Guide | 23
Roofing Detail 8: Overlap Panels
Roofing Detail 7: Valley Gutter Note: For information on
allowed overhang please
refer to “a) Joiners” section
on page 6.
24 | SUNPAL® Technical Guide
©2008 PALRAM Industries Ltd.
HYG Technology is a trademark of PALRAM Industries Ltd.
EUROPE
.PALRAM EUROPE LTD
Tel (44) 1302 380776
Fax (44) 1302 380788
PALRAM UK
Tel (44) 1302 380738
Fax (44) 1302 380739
ISRAEL
PALRAM ISRAEL
Tel (972) 4 8459 900
Fax (972) 4 8459 980
USA
PALRAM AMERICAS
Tel 610 285 9918
Fax 610 285 9928
THE STANDARDS INSTITUTION OF ISRAELTT
07
.08
- 69
13
7
Inasmuch as PALRAM Industries has no control over the use to which others may put the material, it does not guarantee that the same results
as those described herein will be obtained. Each user of the material should make his own tests to determine the material's suitability for his
own particular use. Statements concerning possible or suggested uses of the materials described herein are not to be construed as constituting
a license under any PALRAM Industries patent covering such use or as recommendations for use of such materials in the infringement of any
patent. PALRAM Industries or its distributors cannot be held responsible for any losses incurred through incorrect installation of the material. In
accordance with our company policy of continual product development you are advised to check with your local PALRAM Industries supplier to
.ensure that you have obtained the most up to date information
Manufacturer’s Lifetime Warranty
SUNPAL panels are guaranteed for water leak-proof performance for 25 years. SUNPAL panels bear a limited lifetime warranty not
to lose more than 8% of light transmission for 15 years and no more than 1% per year thereafter, when measured according to
ASTM D1003-77. SUNPAL panels are warranted for up to 10 years from the date of purchase not to break or fail as a result of impact
by hail measuring up to 20mm in diameter, in speed of up to 21m/s.
Note: these warranties will apply only if the panels are installed and maintained according to PALRAM specifications and installa-
tion instructions.