Processing

2

JointingDrilling holes for jointing see page 8

• with drill bits for aluminium sheet and plastic panels (for larger holes use a drill bit with locating point)

Riveting see page 16

• with normal tools and rivets or blind rivets

Screwing see page 17

• with normal stainless steel screws or boltsfor wood, sheet or metal

Welding see page 18

• the PE core material with hot-air weldingdevices and PE welding rod

Glueing see page 19

Outdoor use• adhesive sealing compound

Indoor use• metal adhesives for aluminium• double-sided adhesive tape

Clamp connections see page 19

• with toothed butt joint and corner sectionsfor 3, 4 and 6mm

Surface treatment

Lacquering see page 21• overlacquering of ALUCOBOND® surfaces possible with suitable lacquer qualities

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

Processing at aglance

Cutting to shapeSawing see page 7

• with vertical panel saw, circular or jig saw

Cutting see page 8

• with guillotine shears (slight drawing of the panel cover sheet), cushion clamp

Punching / Decorative workPunching see page 8

• with conventional sheet punching machines.For clean cuts please use evenly groundtools. Drawing of the panel cover sheet

Contour cutting see page 8

• with water torches, CNC machining centresand jig saws

ShapingBending see page 9

• with folding machine or bending press, min. inner radius r = 10 x t ALUCOBOND® and

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

Roll bending see page 9

• with roll bending machines. Make sure to use ground rolls.

Folding (routing technique)see page 11

• manually after routing a V-groove using a panel saw with routing device, a CNCmachining centre or a panel routingmachine

Page

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

4

Transport

HandlingStorage

5

ALUCOBOND® is a prefabricated panellingmaterial, i.e. the surface of the standard panelis either lacquered, anodised or mill-finished.These surfaces are protected by a special foilduring transport, storage and processing.Nevertheless, the following information mustbe observed when storing and handling thepanels:

• The pallets must be handled carefully during transport and unloading. Do not handleopen pallets.

• Upon delivery the pallets must be examinedfor any damage due to moisture (ALUCOBOND®

panels that have become wet must be dried toavoid any spots or corrosion forming). Anydamage must be reported immediately andconfirmed by the forwarding agent.

• Store the pallets so that they are protectedagainst any wetness penetrating due to rainand spray water and avoid any condensationforming (e.g. when transporting cold panels towarmer rooms).

• Store the pallets stacked one over the other(do not store ALUCOBOND® panels standingvertically), with a maximum of 6 pallets of thesame format stacked on top of each other(heavy pallets at the bottom).

• Individual panels must be lifted off the pal-let by two people holding all four corners andnot drawn over each other. Carry the panelsvertically. Wear gloves to avoid staining.

• If stacking panels, nothing should be put inbetween to avoid markings.

The following should be observed asregards the ALUCOBOND® protective foil:

• Storage exceeding 6 months should beavoided.

• Strong fluctuations in temperature reducethe long-term durability.

• Do not mark the panel surface or protectionfilm with inks (markers), tapes or labels.Solvent or plasticiser may penetrate the filmand affect the lacquered surface.

• Should the protective foil partially come offduring processing, dirtied edges can occur inthe course of time.

• Remove protective film as soon as possibleafter erection. Protective film that remain onpanels for an expanded period of exteriorexposure may be very difficult to remove.

6

Jig saw bladesfor wood or plastics, e.g. T101 B (Bosch), tooth thickness 2.5 mm for precision cuts

Saw blades for ALUCOBOND®A2 and ALUCOBOND® plusfor max. number of revs 2,500 RpmTooth geometry see aboveSaw blade dia. D = 300mm(for Striebig Saw Standard II)Number of teeth t = 72Speiser Code No. 07060651Saw blade dia. D = 250mm(for Holz-Her Saw 1255)Number of teeth t = 60Speiser Code No. 02040151

Manufacturer / supplierand Sharpening serviceSpeiser Werkzeugvertriebs-GmbH Phone +49 74 56 94 49 0Fax +49 74 56 94 49 11

For further information on machines and toolsplease refer to the separate leaflet on ‘Processingof 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 trapezoid tooth / flat thooth

Pitch 10 – 12mmClearance angle 15 °Rake angle 10 ° positive

Maximum cutting speed 5,000m/min

Maximum feed 30m/min

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

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

Saw blade dia. D = 300mm (for Striebig vertical panel saw Standard II)

Number of teeth t = 72 (for cuts of up to 5 panels)LEUCO Code No. 181724t = 96 (for single cuts without burrs)LEUCO Code No. 181725

Saw blade dia. D = 250mm (for Holz-Her vertical panel saw 1255 ALUCOBOND®)

Number of teeth t = 60 (for cuts up to 5 panels) LEUCO- Code No. 181726t = 80 (for cuts without burrs) LEUCO- Code No. 181727

Bore dia. D = 30mmTooth thickness 3.2 mmClearance angle 15 °Rake angle 10 ° positive

Manufacturer / supplier: LeucoLedermann GmbH & Co.KGPhone +49 74 51 93 - 0Fax +49 74 51 93 - 270E-Mail info@leuco.comwww.leuco.com

7

Sawing

Sketch showing the edge geometry for professional reshapening:

Cutting andFabricating

8

RoutingALUCOBOND® 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 cutterssuitable for aluminium and ALUCOBOND®

have a wide tooth pitch, radiused and smoothgrooves and small lip angles.They produce perfect cuts, e.g. under the following conditions:

• High-speed steel max. cutting speed max. 3,000m/min.feed max. 25m/min.

• Carbide tipped cutter max. cutting speed max. 5,000m/min. feed max. 30m/min.

Suitable end milling cutters for ALUCOBOND®:

Carbide end milling cutter serie F 113

Manufacturer / supplier:GIS Gienger Industrie-ServiceTel. +49 74 61 16 20 - 20Fax +49 74 61 16 20 - 21www.gis-tec.com

DrillingALUCOBOND® can be drilled with twist drillsnormally used for aluminium and plastics onmachines common for metals.Drill material: High-speed steel (HSS)Tool geometry: Lip angle: 100 ° – 140 °Drilling without burr is possible using the fol-lowing drills:spot facing cutter with centre-point.Angle of whist: 30 ° – 45 °e.g. Extreme 2TM HSS-G Metal drill DIN 338 ofDe WALT, D-Idstein

CountersinkThree-lipped core drills and counterbores common 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 cuttingALUCOBOND® can be cut to size with jigsaws, CNC machining centres and watertorches. Please cut abrasively when using awater torch. Pre-drilling of the panels is nec-essary when starting the cut in the middle ofa panel as it is not possible to drill throughwith a water torch.

ShearingALUCOBOND® can be cut with a conventionalguillotine. A shearing angle of ≤ 1.5° and asmall shearing clearance (paper test) are necessary to achieve an optimum cutting quality. To prevent damage to the cover sheet,make sure to use shock-absorbent rubber padsbetween the clamp and the ALUCOBOND®

surface. Important:For applications with visible cutting edges(e.g. riveted façades) shearing of ALUCOBOND®

pre-cut sheets is not suitable for decorativeuse and should be avoided.

PunchingALUCOBOND® panels of any thickness can bepunched with conventional sheet punchingmachines. For clean cuts please use evenlyground tools and the narrowest possible cut-ting gap (0.1 mm). This punching method alsocauses a slight drawing of the panel coversheet. Holes of a minimum diameter of 4 mmcan be punched. The minimum width of webbetween hole edges is also 4mm.

BendingALUCOBOND® 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 is for ALUCOBOND® and ALUCOBOND® plus r = 10 x tfor 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 prototype should bemade.The surface should be protected from damageby affixing plastic film or inserting poly ethyleneof 1 – 2mm thickness or plastic film stripsduring processing.The panel surface must be free from anyadhesive material (e.g. labels, etc.).Important:When bending ALUCOBOND® with ananodized surface, the bent area is brighter.

Bending with a brake press(Fig. 1) ALUCOBOND®, like sheet metal, is easilyformed with a brake press. The air-bendingprocess is used when forming with a brakepress. The ALUCOBOND® 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 protective foil thickness + punch diameter + 15mmThe minimum side length of the bent partshould be 5 times the ALUCOBOND® thickness.

Bending with a folding machine(Fig. 2) When working with folding machines, thepanel to be bent is clamped between twocheeks. The projecting edge is bent aroundthe upper clamping cheek and former usingthe movable swivel bar. The bending radius isdetermined by interchangeable formersattached to the upper clamping cheek.

Bending with a roll bending machineALUCOBOND® can be bent with sheet metalroll bending machines – mainly with 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 fromswarf before processing ALUCOBOND®. Werecommend 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 with folding machine

r min.:ALUCOBOND® and ALUCOBOND® plus = 10xtALUCOBOND® A2 = 25xt

Protective foil

Die widthDie

Upper clamping cheek

Swivel bar

Former

Lower clamping cheek

Protective foil

t

t

10

11

Routing and Folding Technique

and Designfor individual Shaping

AdvantagesThe convincing advantages of the routing andfolding techniques are:• Minimum investment• Simple operating 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 likefascia claddings, roof edgings, corner pieces,column casings and many more are possible

• Versatile formability• Good economy• Shapes are not restricted by machinedimensions

• Folding without cutting, therefore no buckling in the corner area and thus evenelements

Rectangular groove for edges up to 180° depending on panel thickness

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

MethodALUCOBOND® 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 millingcutters, whereby the aluminium cover sheet atthe front and part of the polyethylene core areretained. The small thickness of the remainingmaterial then allows 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®, on 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® with an anodizedsurface, the edges are brighter.

Tracing roller for exact groove-depth-adjustment

Disc milling cutter

not suitable for ALUCOBOND® A2

Groove (V-shaped) for edges up to 90°

ALUCOBOND®

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 ALUCOBOND® plus”.

1 2

Panel saws ALUCOBOND® routing device(special accessory)Holz-Her vertical panel saw PK 1255 ALUCOBOND®

Code No. 278.6133Striebig Vertical panel saw Standard II for composite panels

Manufacturers / suppliers:Reich Spezialmaschinen GmbH Phone +49 70 22702 - 0www.holzher.deStriebig AG Maschinenbau Phone +41 41 2 500257www.striebig.comOther panel saws can subsequently be providedby the manufacturer with an additional routingdevice. Please ask for details.

CNC machine centres

Manufacturers / suppliers:On request.

Panel routing machinePF 1200 E-Plus ALUCOBOND®

(Fig. 1)Supplied with:• Tracing roller for 4mm• Cutter disk for V-grooves 90°• Adjustment template• Transport box

Supplier:TTS Tooltechnic Systems Deutschland GmbHMarketing sales: FESTOOLPhone +49 7024804 - 640Fax +49 7024804 - 724ebg@tts-festool.comwww.festool.com

Hand routing machines (Fig. 2)Commercially available hand routing machineswith a minimum rating of 800 W are suitable. Collet chucks 8mm dia.

13

Carbide tipped disk milling cutters fo vertical panel saws

Suppliers for profile cuttersGIS Gienger Industrie-Service Phone +4974611620 - 20Fax +49 74 611620 - 21www.gis-tec.com

The diameters of tracing rollers and cutterdiscs are adjusted so as to leave a residualcore thickness of 0.3 mm (V-groove) or 1 mm(rectangular groove). The dimensions given inthe drawings show the cover panel thicknessof 0.5mm plus the corresponding residual corethickness.

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

Please address all enquiries relating to• new machines with accessory parts formilling of ALUCOBOND®

• possible retrofitting of existing machines(stating machine type/No. and year of construction)

• accessories such as cutter disks, tracingrollers, etc.

directly to the manufacturer of the panel saws.

Disk milling cutter for V-grooves 90 ° Disk milling cutter for V-grooves 135 °

End milling cutter for V-grooves 90 ° End milling cutter for V-grooves 135 ° End milling cutter for rectangular grooves

Carbide tipped cutter No. 491443 (Festool)Carbide tipped cutter No. FV09.01.135 (GIS)Carbide tipped cutter No. 79 804 (KWO)

HSS cutter ø 10mm No.79800(KWO) HSS cutter ø 15mm No.79801(KWO)

Important:Please state the following in your enquiry ororder “for processing ALUCOBOND® compositepanels”.

Milling cutters with cylindrical shank for hand routing machines

Disk milling cutter for rectangular grooves

up to4 mm

up to 4 mm

KWO-Werkzeuge GmbH Phone +4973269642 - 0Fax +49 73 269642 - 10E-Mail info@kwo.dewww.kwo.de(not available ex stock)

TTS Tooltechnic Systems Deutschland GmbHMarketing sales: FESTOOL Phone +4970248047- 89 Fax +49 70 248047- 24 E-Mail asem@tts-festool.comwww.festool.com

14

15

Jointing /

TechniqueFixing

ALUCOBOND® can be joined by means ofstandard processes used in metal and plasticstechnology. If ALUCOBOND® is to be joined to structuralparts of metals other than aluminium, or iffasteners (e.g. bolts, screws) are to be used,the following material guidelines should beobserved:Fasteners and structural parts made of alu-minium, plastic or stainless steel should besuitable for the assembly with ALUCOBOND®.When using other materials please insertinsulating washers etc. or apply protectivecoating to prevent corrosion.

Please take the thermal expansion of the panelinto account for outdoor use of ALUCOBOND®

to avoid jamming or deformation.The minimum gap depends on the expectedexpansion of the panel.Please refer to processing recommendationsfor rivets and bolts for additional measures toprevent jamming.The linear thermal expansion of ALUCOBOND®

is determined by the aluminium cover sheets. At a temperature difference of 100°C thelongitudinal expansion is 2.4mm/m.

16

ALUCOBOND® panels can be fastened togetheror joined to other materials with rivets commonto aluminium constructions.For outdoor use and for use in areas of highhumidity, aluminium blind rivets with stainlesssteel mandrils should be used to prevent uglycorrosive edges. When using aluminium blindrivets with steel mandrels, the mandrel shoulddrop out after riveting (detachable version).Countersunk rivets are suitable for indoor useonly.

For outdoor use please note:• For outdoor use aluminium blind rivets thathave been approved for construction with a 5mm shaft diameter and an rivet head diameterof 11 or 14mm are used.• Please take the thermal expansion of thepanel into account (2.4 mm/m/100°C). Toavoid jamming, the hole in the panel must belarge enough to allow for expansion.• With the shaft of the rivet fitting closely tothe edge of the hole, the rivet head mustcover over 1 mm of the area surrounding thehole.• Multi-step drills or hole gauges having corresponding diameters are used for centrically drilling holes into the panel and thesubstructure and for centrically fitting the rivet.• Rivet attachment jigs are used for fittingblind rivets without jamming allowing for atolerance of 0.3 mm. Make sure to use rivetattachment jigs and rivets from the samemanufacturer, as the height of the rivet headaccording to DIN 7337 may vary.• The clamping thickness results from thethickness of the material to be riveted plus anadditional 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. = 14mm

Important:Since during riveting many factors may havean influence on the exact tolerance of the rivets of 0.3mm (e.g. rivet head tolerance), werecommend that you make a test on a façadepanel. Please always remove the protective foil in theriveting area prior to riveting.

Manufacturers / suppliers:

Blind rivetsIn the trade or from:

GESIPA-Blindniettechnik GmbH Phone +49 61 05962 - 0Fax +49 61 05962 - 287www.gesipa.com

Gebr. Titgemeyer GmbH&Co. KG Phone +49 541 5822 - 0 Fax +49 541 5822 - 490www.titgemeyer.de

VVG-Befestigungstechnik GmbH&Co. Phone +4943219671 - 71Fax +49 43219671 - 96www.vvg.de

Blind rivets lacqueredMBE GmbH Phone +49 23 7317430 - 0Fax +49 23 7317430 - 11www.mbe-gmbh.com

SFS intec GmbH Phone +49 61 717002 - 0Fax +49 61 717002 - 46www.sfsintec.biz

Multi-step drills (not available ex stock) KWO Werkzeuge GmbHPhone +49 73 269642 - 0 Fax +49 73 269642 - 10www.kwo.de

Hole gaugesPlease refer to blind rivets lacquered: MBE GmbH

Rivet attachement jigsAppropriate rivet attachment jigs are availablefrom the manufacturers or suppliers of rivets.

Riveting

Blind rivet withstandard head

Distancemin. 15mm

Conical hole gauge

Countersunk rivet(for indoor use only)

Stainless steelmandrel

Stainless steelmandrel

Hole gauge for hole dia. 8.5 mm

Aluminium substructure

Aluminium blind rivet dia. 5mmwith stainless steel mandrelRivet head dia. 11 or 14mm

Rivet attachment jig for screwingto the riveting tool

(for fixing ALUCOBOND® panelswithout jamming)

dia. 7.0 mm – Rivet K11dia. 8.5 mm – Rivet K14

Hole gauge

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

Riveting tool

Rivet attachment jig

Blind rivet 0.3 mm

Fascia screw thread-cutting Fascia screw thread-cutting

17

Manufacturers /Suppliers:Fascia screwsEJOT Baubefestigungen GmbH Phone +492752908 - 0Fax +49 2752908 - 731www.ejot.de

Fascia screws, lacqueredMBE GmbH Phone +492317430 - 0Fax +49 2317430 - 11www.mbe-gmbh.com

SFS intec GmbH Phone +49 61 717002 - 0Fax +49 61 717002 - 46www.sfsintec.biz

Threaded fasteners

1

22

Sheet metal screw,roundhead

Plastic covers for screwsHA-WI Kunststoffe GmbH &Co. KGPhone +49 27 543746226 Fax +49 27 548119www.ha-wi.com

Distancemin. 15mm

Distancemin. 15mm

Screws for indoor use – no outdoor use

1

Fascia screws for metal substructures

Threaded fasteners for outdoor usePlease take the thermal expansion of thepanel into account when using threaded fas-teners outdoors. To avoid jamming, the holediameter in the panel must allow for theexpansion.Fastening without jamming is possible withfascia screws made of stainless steel withsealing washer (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 with a torque wrench or screwdriver sothat the sealing washer is placed on the panelfor sealing the bore hole without exertingpressure onto the panel.Multi-step drills or hole gauges having corre-sponding diameters are used for centricallydrilling holes into the panel and the substruc-ture and for centrically fitting the rivet.

Important: Make sure to remove protective foil prior toscrewing.

Threaded fasteners for indoor useScrews for sheet metal and wood with differ-ent head-shapes are suitable for indoor use(Fig. 2). They do not normally allow for anypanel expansion.Countersunk screws can be inserted by theusual countersinking method or by depressingthe aluminium surface into the panel. Whendepressing 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 !

Hot-air welding has proved useful for joiningthermoplastic plastics and for welding ALUCOBOND®. The plastic core and the plasticwelding rod are heated and welded with electrical hot-air welding sets. The followingconditions are essential for good results:• Well prepared welding joint• Good quality welding rod• Clean hot air• Correct temperature• Correct contact pressure• Welding speed

Welding with rapid welding nozzle

(Fig. 1) The rapid welding nozzle method ensures uniform heating of the core material and thewelding rod and thus results in a better welding quality. Rod A is inserted manually through nozzletongue B. By applying constant pressure to thenozzle tongue, the rod is pressed into the joint.

Preparing of welding jointFor butt-welding, the edges of the ALUCOBOND® 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 plastic core oxydizes relatively quicklywhen exposed to air, welding should be com-pleted within 24 hours after chamfering.

Welding rodPlease use the following quality:Polyethylene, soft, Type: 1800-hColour: black, diameter: 3-4 mmThe outer layer (oxide layer) of the weldingrod should be removed with emery clothimmediately before welding. Please chamferthe starting end of the rod to approx. 45°.

TemperatureThe following air temperature is required forhot-air welding:ALUCOBOND®: 265°C +/- 5°CThe temperature must be continuouslyadjustable and is measured with a mercurythermometer or bimetal measuring unit 5 mmfrom the nozzle point. To measure the temper-ature, please take off the rapid welding nozzle.

Contact PressureThe required pressure to the nozzle shoe(rapid welding nozzle) should be approx. 3 kp.

Hot-air welding setsWe recommend that the Leister hot-air welding set, Type DIODE PID, be used in connection with the ventilator, Type MINOR.

Skimming the welding seamA scraper blade or knife is used at a very flatangle 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 ALUCOBOND® with PE core only)

Manufacturer / Suppliers:

Hot-air welding sets, temperature measuring devices, crescent-shapedknives and welding rodHeißlufttechnik Flocke GmbHLeister-Vertrieb Phone +49 2 12 38 260 - 0Fax +49 2 12 31 23 24www.heisslufttechnik.deLeister Process TechnologiesPhone +41 2123 74 - 74Fax +41 2123 74 - 16www.leister.comWelding rodKetterer + Liebherr GmbH & Co KG Phone +49 7 61 4 78 14 - 0 Fax +49 7 61 4 78 14 - 90www.ketterer-liebherr.deMilling cutters (not available ex stock)KWO Werkzeuge GmbHPhone +49 73 269642 - 0Fax +49 73 269642 - 10www.kwo.de

1

2

4

adjacent

Crescent shaped knife

3

Grooving with milling cutter

For t = 3mm Code No. 79805For t = 4mm Code No. 79806For t = 6mm Code No. 79807

r = 2 to 3 mm

t

r

Metal adhesives / Universal adhesivesFor indoor use, trade fair/exhibition standstructures and machines, most metal or universal adhesives are suitable.

Tapes / Velcro tapesDouble-sided tapes (such as the 3M-VHB highcapacity jointing systems) can be used for theabove applications with low tensile or trans-versal strength requirements. Velcro tapes areavailable for detachable joints, for exampleSCOTCHMATE or tapes marketed under theDual Lock trademark. Both products are also available from 3M Deutschland GmbHPhone +49 21 31 14 - 0Fax +49 21 31 14 - 26 49www.3m.com

19

Clamp connections incorporating aluminium or plastics are particularly suitable for ALUCOBOND®. They generally consist of twoparts with the clamping effect achieved bybolting.Various designs of clamping elements areused for display and store fitting purposes (no outdoor use). Suppliers:“Klemetric” system:KlemProducts®Gesellschaft für Werbemittel mbHPhone +49 89 857 72 80Fax +49 89 895 83 48www.klemproducts.de“Voluma” system:MERO Raumstruktur GmbH & Co.KGAusstellungssystemePhone +49 931 66 70 - 571Fax +49 931 66 70 - 189www.mero.deAny suitable connection or shock-resistant framecan easily be made with aluminium sections.The inevitable tolerances signify differentretention forces. A uniform and solid fit of thesections is obtained by pressing the sectionsides together prior to inserting the panels.Butt joint, corner and edge sections are available for panels of 3, 4 and 6mm. Please ask for our stock list. For fascia cladding applications special aluminium sections are provided for clampconnections.For further information on ALUCOBOND®

special sections and types for fascia claddingsplease ask for the respective documentation.

Adhesive sealing compoundsFor high-strength and elastic connections werecommend the following one-componentadhesive sealing compound:Sika Bond-T2 (polyurethane base) Sika GmbH Phone +49 71 25 9 40 - 0 Fax +49 71 25 9 40 - 321www.sika.deFor outdoor use, this adhesive can be used forfastening parts of minor static importance.

Important:Please observe the manufacturer’s instructionsregarding the application and use of adhe-sives/tapes.Adhesives and sealing compounds do notadhere to the ALUCOBOND® plastic core (cut edges).Laminating of ALUCOBOND® panels to othermaterials may result in deformation of thelaminates (differing expansion/bimetal effect).

Glueing

Clamp connections“Klemetric” system

“Voluma” system

20

Lacquering of mill-finished ALUCOBOND® surfaces

21

Surfacetreatment

Customer requirements for special colourshades of ALUCOBOND® composite panels are met in small amounts at our plant by overlacquering standard stove-lacquered ALUCOBOND® surfaces or mill-finished surfaces.

The composition of lacquer coating for ALUCOBOND® is basically the same as thosefor mill-finished aluminium surfaces. However,it is advisable to be familiar with coating systems and materials as well as workingmethods for aluminium.

Please note:

• For general information on painting, lacquering and coating of aluminium werecommend the leaflets on ”02, 03, 012,015 surfaces” issued by

Gesamtverband der Aluminiumindustrie e. V.Phone +4921147960Fax +49 2114796408www.aluinfo.de

Please note:• The maximum permissible temperatureof the material (ALUCOBOND® panels)must not exceed 70°C when applyingfast-drying methods. During the dryingprocess at high temperatures the ALUCOBOND® panels must be posi-tioned with great care to preventdeforming.

• ALUCOBOND® cut edges should not be incontact with organic solvents for a pro-longed period of time to avoid weakeningthe bond.

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

22

23

Cleaning and Maintenance

Surfacesof stove-lacquered

Non-suitable cleaning agentsPlease do not use any strong alkaline cleaningagents such as potassium hydroxide, sodiumcarbonate or caustic soda, any strong acidicproducts or highly abrasive cleaning agentssuch as Vim, Ajax or Imi, or any cleaningagents that corrode paint.

Cleaning agents

A list of neutral cleaning agents for organicallycoated aluminium components can beobtained from

Gesamtverband der Aluminiumindustrie e. V.Phone +492114796 - 0Fax +49 2114796 - 408www.aluinfo.de

Please observe the manufacturer’s cleaning andsafety instructions!

For further information, e.g. addresses ofapproved cleaning companies, please contact

Gütegemeinschaft für die Reinigung vonMetallfassaden e.V. (GRM)Phone +49 9 11 20 44 41 Fax +49 9 11 22 67 55www.grm-online.de

Cleaning

Annual cleaning is recommended. The surfacesshould be cleaned either manually using a softbrush or by means of a high-pressure cleaner(max. 50 bar) with clean water. If necessary, amild cleaning agent (pH 6-7) may be added, upto max. 10%. For details please contact yoursupplier (GRM - Gütegemeinschaft für dieReinigung von Metallfassaden e.V.). Cleaningshould take place from top to bottom. Aftercleaning, rinse with clean water to remove anycleaning agent residue.Generally, we recommend trying out the clean-ing agent on an unobtrusive part of the object tobe cleaned to check whether the surfaceappearance is affected.

Do not clean surfaces heated by the sun(>40°C) as the quick drying process maycause blemishes.

Expert and regular cleaning not only maintainsthe aesthetic and representative finish ofstove-lacquered surfaces, but also preservestheir value and service life by removing dirtand aggressive deposits that are not washedaway by rainwater.

Annual inspection

The inspection of roofing and walls should takeplace at least once a year. This will depend onlocal environmental conditions.

General instructions

• Remove leaves, grass and other objects.• Remove- any parts clogging the roof gutter to avoid overflow;- any accumulation of dirt from wall areas that are inaccessible for rainwater(e.g. roofing).

These areas not only impair the physicalappearance of the building but can also resultin a premature deterioration of the coating.• Make sure to check the condition of jointsealers, holders/supports and decorativeparts on the building to prevent any waterpenetrating.

• Make sure to inspect local defects (e.g.scratches) which could result in a prematuredeterioration of the coating or corrosion ofthe substrate.

Once the building has been completed, particular attention should be paid to holders/supports, coating defects, boreholes,deformations caused by rivets, as well as tothe general basic cleaning.

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Panel-Thickness: Standard Unit 3 mm 4 mm 6 mm

Thickness of Aluminium Layers [mm] 0.50Weight [kg/m2] 4.5 5.5 7.3Width [mm] 1000 / 1250 / 1500

Technical properties:Section modulus W DIN 53293 [cm3/m] 1.25 1.75 2.75Rigidity (Poisson’s ratio µ = 0,3) E·I DIN 53293 [kNcm2/m] 1250 2400 5900Alloy EN 573-3 EN AW-5005A (AlMg1)Temper of Aluminium Layers EN 515 H22/H42Modulus of Elasticity EN 1999 1-1 [N/mm2] 70’000Tensile Strength of Aluminium EN 485-2 [N/mm2] Rm � 1300.2% Proof Stress EN 485-2 [N/mm2] Rp0.2 � 90Elongation EN 485-2 [%] A50 � 5Linear Thermal Expansion EN 1999 1-1 2.4 mm/m at 100°C temperature difference

Core:Polyethylene, Type LDPE [g/cm3] 0.92

Surface :Lacquering Coil Coating

Fluorocarbon based (e.g. PVdF)Gloss (initial value) EN 13523-2 [%] 30 - 80Pencil Hardness EN 13523-4 HB - F

Acoustical Properties:Sound Absorption Factor �s ISO 354 0.05Sound Transmission Loss Rw ISO 717-1 [dB] 25 26 27Loss Factor d EN ISO 6721 0.0072 0.0087 0.0138

Thermal properties:Thermal Resistance R DIN 52612 [m2K/W] 0.0069 0.0103 0.0172Heat Transition Coefficient U DIN 4108 [W/m2K] 5.65 5.54 5.34Temperature Resistance [°C] - 50 ... + 80

Standard Data sheet

25

Standard Data sheet

plus

Panel-Thickness: Standard Unit 3mm 4mm

Thickness of Aluminium Layers [mm] 0.50Weight [kg/m2] 5.9 7.6Width [mm] 1250 / 1500

Technical poperties:Section Modulu W DIN 53293 [cm3/m] 1.25 1.75Rigidity (Poisson’s ratio µ = 0,3) E·I DIN 53293 [kNcm2/m] 1250 2400Alloy EN 573-3 EN AW-5005A (AlMg1)Temper of Aluminium Layers EN 515 H22/H42Modulus of Elasticity EN 1999 1-1 [N/mm2] 70.000Tensile Strength of Aluminium EN 485-2 [N/mm2] Rm � 1300.2% Proof Stress EN 485-2 [N/mm2] Rp0.2 � 90Elongation EN 485-2 [%] A50 � 5Linear Thermal Expansion EN 1999 1-1 2.4 mm/m at 100°C temperature difference

Core:Mineral filled polymer

Surface:Lacquering Coil Coating

Fluorocarbon based (e.g. PVdF)Gloss (initial value) EN 13523-2 [%] 30 - 80Pencil Hardness EN 13523-4 HB - F

Acoustical Properties:Sound Absorption Factor �s ISO 354 0.05Sound Transmission Loss Rw ASTM E90 [dB] STC: 30 OITC: 24

Thermal properties:Thermal Resistance R ASTM C518 [m2K/W] 0.007 0.009Temperature Resistance [°C] - 50 ... + 80

26

Panel-Thickness: Standard Unit 3 mm 4 mm

Thickness of Aluminium Layers [mm] 0.50Weight [kg/m2] 5.9 7.6Width [mm] 1250 / 1500

Technical properties:Section modulus W DIN 53293 [cm3/m] 1.25 1.75Rigidity E·I DIN 53293 [kNcm2/m] 1250 2400Alloy EN 573-3 EN AW-5005A (AlMg1)Temper of Aluminium Layers EN 515 H22/H42Modulus of Elasticity EN 1999 1-1 [N/mm2] 70’000Tensile Strength of Aluminium EN 485-2 [N/mm2] Rm � 1300.2% Proof Stress EN 485-2 [N/mm2] Rp0.2 � 90Elongation EN 485-2 [%] A50 � 5Linear Thermal Expansion EN 1999 1-1 2.4 mm/m at 100°C temperature difference

Core:Mineral compound, polymer bonded

Surface:Lacquering Coil Coating

Fluorocarbon based (e.g. PVdF)Gloss (initial value) EN 13523-2 [%] 30 - 80Pencil Hardness EN 13523-4 HB - F

Acoustical Properties:Sound Absorption Factor �s ISO 354 0.05Sound Transmission Loss Rw ISO 717-1 [dB] 27 27Loss Factor d EN ISO 6721 0.004 0.005

Thermal properties:Thermal Resistance R DIN 52612 [m2K/W] 0.002 0.003Thermal conductivity � DIN 52612 [W/mK] 1.5 1.33Heat Transition Coefficient U DIN 4108 [W/m2K] 5.81 5.78Temperature Resistance [°C] - 50 ... + 80

Standard Data sheet

A2

Informations(Please request)

ALUCOBOND® Information folder

ALUCOBOND® CD-ROM (Examples for fascia claddings)

ALUCOBOND® CD-ROM with addresses of suppliers for:machines – tools – accessories – profiles/profile systems

ALUCOBOND® Documentation filewith examples for fascia claddings and texts for tendering incl. CD ROM

27

Original samples with standard surfaces

Samples

www.alucobond.com

2/08/2010 Processing GB3A Composites GmbH

D-78224 Singen, GermanyPhone+49 (0) 7731 80 23 47Fax +49 (0) 7731 80 28 45info.eu@alucobond.com