technical manual - makrolon solid sheets · 2017-03-27 · technical manual . covestro deutschland...

Technical Manual

Covestro Deutschland AG

51365 LeverkusenGermany

Phone +49 214 6009 5555

E-mail [email protected] www.sheets.covestro.com

The manner in which you use and the purpose to which you put and utilize our products, technical assistance and informa-

tion (whether verbal, written or by way of production evaluations), including any suggested formulations and recommen-

dations, are beyond our control. Therefore, it is imperative that you test our products, technical assistance, information

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sarily been done by Covestro. Unless we otherwise agree in writing, all products are sold strictly pursuant to the terms of

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and shall not bind us. Nothing herein shall be construed as a recommendation to use any product in conflict with any claim

of any patent relative to any material or its use. No license is implied or in fact granted under the claims of any patent.

1. THE SOLID POLYCARBONATE SHEET 4

1.1 At a glance technical specification 5 1.2 Grades 6

2. STANDARD PRODUCT RANGE 10

3. CHARACTERISTICS 18

3.1 Impact strength 19 3.2 Light transmission 21 3.3 Temperature resistance 21 3.4 Fire behaviour 22 3.5 Noise insulation 23 3.6 Chemical resistance 26

4. MACHINING 28

4.1 General remarks 29 4.2 Sawing 31 4.3 Cutting and punching 33 4.4 Drilling 34 4.5 Milling 35 4.6 Laser cutting 35 4.7 Grinding 36

5. FORMING 38

5.1 Cold forming 39 5.2 Thermoforming 40

6. BONDING 50

6.1 Solvent-based adhesives 51 6.2 Adhesive bonding agents 52 6.3 Adhesive tape 53

7. FASTENING 54

7.1 Welding 55 7.2 Mechanical fastening 56

8. FINISHING 58

9. CLEANING 60

10. CURVED GLAZING 62

11. FLAT GLAZING 66

ANNEX 1: CHEMICAL RESISTANCE OF MAKROLON® 70

ANNEX 2: CHEMICAL RESISTANCE OF MAKROLON® AR 85

CONTENTS

1. THE SOLID POLYCARBONATE SHEET

1.1 At a glance technical specification

Each grade designation shows the type, colour, light transmission and additional properties of Makrolon® sheeting. Example: Makrolon® UV white 2130 can be read as follows …

Brand name Type Colour Properties Colour Approximate light transmission

Makrolon® GP: general purpose clear –: no special treatment 0: clear in percent

UV: UV-protected white 2: 2-sides UV-protected 1: white

AR: abrasion resistant bronze 7: 1 side abrasion resistant 2: orange

NR: non reflective grey 8: 2 sides abrasion resistant 3: red

FR: flame retardant umbra 4: violet

FG: food grade green 5: blue

blue 6: green

7: grey

8: brown/bronze

9: black

Makrolon® UV white 2 1 30

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1.2 Grades

Makrolon® GP – general purposeMakrolon® GP is the standard grade of the Makrolon® polycarbonate solid sheet range.

Makrolon® GP sheets are extremely break-resistant. Their impact resistance, which is 250 times higher than glass, provides perfect protection for people and objects. The material is resistant to extreme temperatures, and can be used under the most demanding conditions (from –100 °C to +120 °C). Its high transparency combined with the smooth surface makes it an attractive material for a wide variety of applications. Makrolon® GP sheets obtain good fire classifications in accordance with most national standards.

Makrolon® UV – UV-protectedMakrolon® UV sheets are extremely weather-resistant because the sheets are produced with a coextruded UV-protective layer. This layer comprises the same basic material as the sheet material and is homogeneously fused with it. No delamination of the layer is possible, even after years of exposure to the ele-ments or if the sheets are cold bent.

This system has been extensively tested both in artificial weathering tests as well as in natural weathering under extreme climatic conditions. It provides Mak-rolon® UV with high weather resistance and superior durability. Makrolon® UV sheets therefore come with a 10-year guarantee on weather resistance and transparency.

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For detailed information on the warranty, please check our warranty statement. This document is available from our distributors and on our website:www.sheets.covestro.com

Makrolon® AR – abrasion resistantMakrolon® AR stands for particularly hard-wearing UV-resistant sheets made from polycarbonate. Makrolon® AR offers comparable surface quality to glass and the outstanding impact strength of polycarbonate. The sheets are highly scratch-resistant due to their polysiloxane coating. Pronounced soiling, such as graffiti, can be removed effectively. Makrolon® AR also offers excellent UV resistance and shows superior resistance to chemicals.

Their high scratch resistance and impact strength make Makrolon® AR sheets the ideal choice for transparent noise barriers, glazing in schools, hospitals, prisons and psychiatric units, as well as for safety glazing in vehicle construc-tion, to name just a few examples. Their chemical resistance means they are ideal as sight glasses in machine guards.

The high resistance to scratches and abrasion on both sides gives Makrolon® AR a long service life. We give you a 10-year guarantee against breakage and a 5-year guarantee against delamination and weathering.

For detailed information on the warranty, please check our warranty statement. This document is available from our distributors and on our website:www.sheets.covestro.com

ThE SoLID PoLyCARboNATE ShEET

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Makrolon® NR – non reflectiveMakrolon® NR is a transparent sheet with a matt finish and improved UV resis-tance on one side. These sheets are ideal in signage applications and poster glazing.

Makrolon® FR – flame retardantMakrolon® FR sheets are specially produced for the US market from resins which have a classification according to UL-94 V0.

Makrolon® FG – food gradeMakrolon® FG sheets are produced from resins which are suitable for food con-tact applications. The material complies with the European directive 2002/74/EC and the American FDA regulations.

Makrolon® UV patternedMakrolon® UV patterned are clear transparent polycarbonate sheets with UV protection on both sides, and a patterned surface (Rh/P/GX).

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Material propertiesMakrolon® is synonymous with first-class sheets. The sheets are made from polycarbonate and available in solid and multi-wall format. Their versatility is such that they can be used in many applications and can withstand a wide tem-perature range.

Makrolon® sheets are renowned for good transparency, extremely high break resistance and impact strength, high dimensional behaviour stability and good electric insulation. They also obtain excellent fire ratings (see the specific data sheets for more detailed information).

Their consistency is thanks to outstanding raw materials from Covestro, the Covestro Sheet Europe extrusion know-how, our comprehensive quality man-agement system and production processes certified according to DIN ISO 9001/2.

All properties are determined in standard conditions (23 °C and 50 % relative humidity) at a thickness of 4 mm, unless otherwise mentioned.

2. STANDARD PRODUCT RANGE

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Properties Typical value Unit Test method

Mechanical

Density 1.20 g/cm3 ISO 1183-1

Tensile stress at yield > 60 MPa ISO 527-2/1B/50

Elongation at yield 6 % ISO 527-2/1B/50

Tensile strength > 60 MPa ISO 527-2/1B/50

Elongation at break > 70 % ISO 527-2/1B/50

Elastic modulus 2400 MPa ISO 527-2/1B/1

Limiting flexural stress ca. 90 MPa ISO 178

Impact strength

Charpyunnotched no break kJ/m² ISO 179/1fU

notched ca. 11 kJ/m² ISO 179/1eA

Izod

unnotched no break kJ/m² ISO 180

notched (3 mm) ca. 70 kJ/m² ISO 180/4A

notched (4 mm) ca. 11 kJ/m² ISO 180/1A

Ball indentation hardness H 358/30 130 MPa ISO 2039-1

Poisson’s ratio 0.40 — —

Scratch resistance/Taber abrasion as per 100 rev./5.4 N/CS 10F 30 – 40 % ASTM D1044 & ANSI Z26.1

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Optical

Light transmission in relation to thickness

3 mm (clear) 87– 88 % DIN 5036

5 mm (clear) 86 – 87 % DIN 5036

10 mm (clear) 82 – 83 % DIN 5036

15 mm (clear) 79 – 80 % DIN 5036

Reflection loss in the visible range (for each surface) ca. 5 % —

Total energy transmission (g) in relation to thickness

3 mm (clear) ca. 82 % DIN 67507

10 mm (clear) ca. 79 % DIN 67507

Absorption in the visible range in relation to thickness 3 mm (clear) ca. 4 % —

Refractive index 1.586 — ISO 489

Thermal

Coeff. of linear thermal expansion 0.065 mm/m °C DIN 53752-A

Thermal conductivity 0.20 W/m °C DIN 52612

Heat transfer coefficient (Ug) in relation to thickness

1 mm 5.8 W/m² K DIN 4701

3 mm 5.5 W/m² K DIN 4701

5 mm 5.2 W/m² K DIN 4701

10 mm 4.6 W/m² K DIN 4701

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STANDARD PRoDUCT RANGE


Thermal

Specific heat capacity 1.3 J/g K —

Calorific value 31 MJ/kg ISO 1928

Thermoforming temperature 190 – 210 °C —

Maximum surface temperature (IR radiator) ca. 220 °C —

Max. permanent service temperature without load ca. 120 °C —

Min. permanent service temperature without load ca. –100 °C —

Ignition temperature 570 °C DIN 51794

Vicat softening temperature 148 °C ISO 306 Method B50

Heat deflection temperature under load

Method A: 1.80 MPa 127 °C ISO 75-2

Method B: 0.45 MPa 139 °C ISO 75-2

Oxygen index (LOI) 27 % ISO 4589-2

Electrical

Dielectric strength 35 kV/mm IEC 60243-1

Volume resistivity 1016 Ω cm IEC 60093

Surface resistivity 1014 Ω IEC 60093

Dielectric constantat 10³ Hz 3.1 — IEC 60 250

at 106 Hz 3 — IEC 60 250

Dissipation factorat 10³ Hz 0.0005 — IEC 60 250

at 106 Hz 0.009 — IEC 60 250

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Acoustical

Weighted sound reduction index Rw in relation to thickness

4 mm 26 dB —

8 mm 30 dB —

10 mm 32 dB —

Behaviour towards water and air

Moisture absorptionafter storage in standard climate 0.15 % ISO 62-4

after storage in water at 23 °C 0.35 % ISO 62-1

Permeability to

water vapour 3.8 10-10 g cm/cm² DIN 53122

N2 1.1 10-13 g cm/cm² hPa DIN 53380

O2 7.5 10-19 g cm/cm² hPa DIN 53380

CO2 3.2 10-12 g cm/cm² hPa DIN 53380

air 2.6 10-13 g cm/cm² hPa DIN 53380

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STANDARD PRoDUCT RANGE

Properties UnitTest temperature in °C

-60 -40 -20 0 23 40 60 100 120

Temperature dependence of mechanical properties (single measured values, indicative)

Elongation at break % 52 51 70 81 95 104 110 120 122

Tensile strength MPa 93 87 81 79 67 63 57 45 38

Tensile stress at yield MPa 93 87 81 74 67 67 60 47 37

Elastic modulus MPa 2478 2417 2513 2436 2520 2420 2220 1840 1740

Notched impact strength

Charpy kJ/m² - 11.8 12.8 13.4 13.6 10.4 9.3 9 8.7

Izod kJ/m² - 10.0 10.4 11.0 10.7 14.4 8.1 13 12

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3.1 Impact strength

Makrolon® outperforms most other transparent materials on impact strength. It is almost unbreakable. Makrolon® solid sheets are up to 250 times more impact resistant than glass, and they have been tested in accordance with several stan-dards, complying with the most stringent regulations. Some typical results are listed in the tables below.

3. CHARACTERISTICS

Standard Material Thickness Classification Number

Vehicle glazing

Allgemeine Bauartgenehmigung (Germany) Makrolon AR 3 to 12 mm Class B D 2346

ECE R43 (Vehicles, Europe) Makrolon AR

3 mm 4 mm 5 mm 6 mm 8 mm 10 mm 12 mm

VIII/B/M VIII/B/M VIII/B/M VIII/B/M VIII/B/M VIII/B/M VIII/B/M

001830 001831 001832 001833 001834 001835 001836

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Standard Material Thickness Classification

Safety glazing

EN 356 (security glazing, resistance to manual attack)

Makrolon GP Makrolon UV Makrolon AR ≥ 4 mm EN356-P5A

EN 12600 Makrolon UV, patterned

5 mm 6 mm 8 mm10 mm12 mm

class 3 class 2 class 1class 1class 1

Machine guarding

EN 12415 Makrolon GPMakrolon AR

6 mm8 mm10 mm12 mm18 mm (Makrolon GP only)

A1, A2, B1A1, A2, B1, C1A1, A2, A3, B1, B2, C1, C2A1, A2, A3, B1, B2, B3, C1, C2A1, A2, A3, B1, B2, B3, C1, C2, C3

EN 12415 Makrolon GPMakrolon AR

6 mm8 mm10 mm12 mm

Ec = 478 NmEc = 680 NmEc = 1020 NmEc = 1125 Nm

Certificates are valid for a limited period. Please examine each document for validity.

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3.2 Light transmission

Makrolon® sheets have a light transmission value of up to 90 %, depending on the colour and thickness of the sheet (check the individual data sheets for more details). Coloured and/or translucent sheets reduce light intensity and heat, which results in pleasant room temperature and ambience. our opal white sheets offer improved light transmission, resulting in a more diffuse but bright-er light, ideal for working environments.

Makrolon® UV sheets absorb dangerous UV radiation (‹ 400 nm). These sheets are therefore ideal as skylights or in situations where protective glazing is need-ed to shelter materials sensitive to UV-light in factory units, museums or shop-ping centres.however, in most of the cases plant growth (except some special plants which need UV radiation) is not negatively influenced by Makrolon® multi UV sheets, as they transmit the relevant light spectrum (PAR = photo active radiation). This important property means the sheets are well suited for applications such as football stadiums.

3.3 Temperature resistance

Makrolon® sheets can be used at temperatures between –100 °C up to +120 °C. The stability of the sheets remains at a high level within this temperature range, which means they can be used where other transparent plastics will fail.In normal circumstances, the temperatures to which the sheets are exposed will be in the range of –15 °C up to +60 °C, which is well within the material’s toler-ances.

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ChARACTERISTICS

3.4 Fire behaviour

Makrolon® sheets meet stringent quality standards set by many different coun-tries for fire safety. The material does not cause flame propagation, but it cannot be considered as a fireproof material.

Its self-extinguishing properties allow the sheet to soften in the event of fire. It then tears open and shrinks back from the fire source without spreading the fire itself. Smoke and heat dissipate through the opening, thus leading to a drastic temperature reduction in the room and, more importantly, reduced load on the supporting structure. In effect, the sheet is acting as a heat extractor. Heat ex-tractors relieve the thermal load on a building in temperatures of 300 °C or more in a fully developed and growing fire. The benefit is prolonged fire resistance.

In DIN 18230, Part 1 ‘Fire safety in industrial building constructions’, roof and wall elements made of Makrolon® are included in the calculations as suitable heat extractors. The use of Makrolon® reduces the thermal load on the building and the fire resistance required of building components. This needs to be eval-uated with fire safety engineering methods as part of an overall fire safety con-cept for each specific building. Remember also to check local planning regula-tions to confirm that such a construction is allowed.

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Typical classifications (*) of Makrolon® sheets

3.5 Noise insulation

Excessive noise and continuous, disturbing noise are harmful. That is why the effect of noise needs to be kept down to a minimum. Sound pressure levels and sound reduction indexes are expressed in decibels (abbreviated as db).

The human ear perceives an increase of 10 db(A) as a doubling of the loudness, i. e. car traffic noise (70 dB) is twice as loud as the noise in the average office (60 db).

Makrolon® sheets reduce sound levels mainly via reflection of sound waves.

Country Standard Typical classification

Germany DIN 4102 B1–B2

France NF 92 501/505 M2

UK BS 476, part 7 class 1Y

Italy CSE RF 2/75/A & 3/77 class 1

Europe EN 13501-1 B-s1, B-s2(*) Depending on thickness, color and applications Makrolon sheets have a good fire performance in accordance with national fire regulations in many countries. Polycarbonate sheets may change their fire behavior due to ageing and weathering. For details, please check with the Technical Service Department.

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ChARACTERISTICS

Rw

For practical assessment of sound reduction, however, the “weighted sound reduction index”, Rw, is used. This takes account of the subjective effect of vari-ous frequencies.

Sound reduction index of single-sheet glazing

Makrolon® GP in mm Rw in dB

4 26

8 30

10 34

12 36

15 36

18 37

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Sound reduction index of double-sheet glazingA significant sound reduction can be obtained with two or more Makrolon® sol-id sheets sandwiching an air layer.

Data without guarantee. Needs to be approved in individual cases by the customer.

Makrolon® sheets are often used for noise barriers along roads.

GermanyIn accordance with ZTV LSW 06, road noise barrier walls must reduce traffic noise by at least 25 db (DLr). Transparent Makrolon® UV or Makrolon® AR (hard coated), with its thickness of 8 mm, exceeds the standard.

They must also display other characteristics, e. g. fire resistance etc., which are guaranteed by Makrolon®.

Makrolon® GP in mm

Air space in mm

Makrolon® GP in mm Rw in dB

4 50 4 31

4 150 4 39

6 30 6 32

10 30 10 40

10 60 10 45

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ChARACTERISTICS

3.6 Chemical resistance

The chemical resistance of Makrolon® depends on the concentration of the sub-stance with which it comes into contact, the temperature, the duration of con-tact and the internal tension level of the polycarbonate sheet due to fabrication etc. Several types of damage can arise, sometimes more than one at the same time.

Dissolving/SwellingLow-molecular, aromatic, halogenated and polar components migrate into the plastic. The damage can range from a sticky surface to complete dissolving.

Stress crackingSome chemicals migrate to a minor extent and in very low quantity into the surface, causing relaxation of tensions in the material. This results in unsightly stress cracking. because of increased notch occurrence, some mechanical properties are negatively influenced. Stress cracking is usually easy to see in transparent sheets.

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Molecular reductionSome properties of materials are determined by the molecular weight. If a sub-stance initiates a molecular reduction through a chemical reaction, the impact resistance and elastic properties of the material will be influenced. Electrical prop-erties are rarely influenced, while thermal properties are only slightly influenced by the molecular weight.

The table in annex 1 shows the resistance of Makrolon® to chemicals and sev-eral other substances. In the table in annex 2 you will find information about the resistance of Makrolon® AR.

Examples

Solvents/not resistant toDichlorine methane Chloroform Tetrahydro furane

Swelling agentsBenzene Chlorine benzene Acetone

Not influenced by/resistant to

diluted mineral acids, many organic acids, oxidising or reducing agents, neutral and acid salt solutions, many fats, waxes and oils

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ChARACTERISTICS

4. MACHINING

4.1 General remarks

ToolsMakrolon® sheets can be machined using the standard tools commonly used for metal and woodworking. We recommend carbide-tipped tools. Above all, it is important to use sharp cutting tools with the right geometry.

CoolingNo cooling is required during the normal machining of Makrolon® sheets. In the event of local overheating during machining – e. g. when drilling through very thick materials – we recommend cooling with water or oil-free compressed air.

oil emulsions and cutting oils should not be used when machining Makrolon® as these may contain additives to which Makrolon® is not resistant, resulting in stress crack formation.

Dimensional accuracyThe coefficient of linear expansion of Makrolon®, at 0.065 mm/m °C, is signifi-cantly higher than for metal or glass. For this reason, dimensions should always be checked at room temperature.

Remember that shrinkage of approx. 3 to 6 % depending on thickness occurs when the material is heated above the glass transition temperature (approx. 145 °C) for the first time.

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Protective maskingMakrolon® sheets are provided with a PE masking film to protect their smooth surfaces from damage during transport and fabrication.

The film should be left on the sheet during machining. Solar radiation and weath-ering may influence the properties of the film and make it very difficult to remove later on (possible formation of adhesive residues).

our standard protective masking film is not suitable for exposure to thermal loads, or thermoforming. The film should therefore be removed from the sheets before proc esses such as drying, hot line bending and/or thermoforming.

We have specially manufactured, unprinted grades of film that allow the sheets to be thermoformed with the protective masking left on.

MarkingMarking out of drill holes or edges to be cut should be done on the protective film, using either a soft pencil or felt-tip pen. Marking tools should not be used as the tracing mark has a notching effect, and a higher load at this point may cause the sheet to crack.

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Ribbon saw

Circular saw blade

4.2 Sawing

Hand sawsStandard hand saws may be used to cut Makrolon® sheets. A saw with fine spac-ing between the teeth should be used.

Circular sawsUsing a circular saw is the easiest way to cut Makrolon® sheets.

Experience has shown that carbide-tipped circular saw blades produce the cleanest cuts. The spacing varies from fine for thin sheets to coarse for thicker materials. Ensure that no shavings are left on the cutting surface as these could damage the protective film and scratch the Makrolon® sheets.

When handling sheets less than 1.5 mm thick use a thick underlay board or a pair of shears instead of a circular saw.

Ribbon saws Ribbon saws are ideal for curved cutting of formed parts or irregular shapes. To achieve a clean cut edge, it is important to work on a solid cutting surface. A wide spacing is required when working with thick materials.

For higher quality cut edges, circular saws or milling cutters achieve a better result than ribbon saws.

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MAChINING

Trouble-shootingFused cut edge: Check tool sharpness Check cutting speed and reduce if necessary Check rate of advance and reduce if necessary Cool if necessary

Notched cut edge: Check tool sharpness Check tool geometry Improve cutting surface (use an underlay if necessary)

Recommended angles for sawing Ribbon saw Circular saw

Clearance angle α 20 – 40° 10– 30°

Rake angle γ 0– 5° 5 –15°

Cutting speed v (m/sec) 10 –17 17– 50

Spacing t (mm) 1.5 – 3.5 2 –10

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0.5 mm 0.75 mm

Depending on sheet thickness, various different types of cutter are recommended for punching.

Clean cut edges – clearance between blade and supporting surface: 0.001– 0.03 mm

4.3 Cutting and punching

Makrolon® sheets up to 3 mm thick are easy to cut and punch, producing a good cut result. The thicker the sheet, the poorer the quality of the cut is likely to be, and the greater the risk of cracking.

Good results can be obtained using a sharp shearing tool with a wedge angle of max. 45°, with clearance between the tool and the cutting surface of 0.01 to 0.03 mm.

If you require smooth cut edges, Makrolon® sheets with a thickness of 1.5 mm or more should be sawn or milled.

When punching close-tolerance holes, allowance must be made for shrinkage if machining is to be followed by heat treatment of over 145 °C. This means that the hole should be measured approx. 5 % larger than actually required. The big-ger the hole and the thicker the sheet, the lower the tendency for the sheet to shrink. Good results are obtained using symmetrically ground shearing tools.

For punching/cutting Makrolon® sheets that are more than 1.5 mm thick, we recommend asymmetrically ground blades. To achieve right angles, blades ground on one side with a wedge angle of 30° should be used. Make sure that the base plate (polyamide or polyethylene hDPE with a high molecular weight) remains in place and is properly centred with the punching tool to ensure clean cut edges.

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MAChINING

Drills for Makrolon® sheets

4.4 Drilling

Standard drills used for metalworking are perfectly suitable for machining Mak-rolon® sheets. Make sure that the cutters on the drill are sharp. Cooling during drilling is generally not necessary.

When working with relatively large drilling depths we recommend using water or compressed air and/or regularly withdrawing the drill from the hole to reduce heat and remove shavings.

oil/water emulsions or cutting oils should not be used when drilling through Makrolon® sheets. Standard circle-cutting equipment (e. g. circle cutters or com-pass saws) is suitable for large-scale drilling. The drill holes should be smooth and as free as possible of notches or rough areas to ensure secure fastening.

Recommended angles for drilling

Clearance angle α 5 –15°

Rake angle γ 0 – 5°

Point angle 110 –130°

Helix angle β 19 – 40°

Cutting speed 15 – 30 m/min

Feed 0.1– 0.3 mm/rev

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4.5 Milling

Makrolon® sheets are easy to process using milling machines. The choice of milling machine depends on the type of machining required. Ensure that your tool has good chip clearance and sharp cutters.

4.6 Laser cutting

Various designs of laser can be used for the thermal cutting of Makrolon® sheets – with or without film. Lasers are particularly suitable for cutting complex con-tours. To achieve a bubble-free cut edge, the Makrolon® sheets need to be pre-dried after which it is recommended that they be conditioned.

Laser beam cutting of Makrolon® sheets that are more than 2 mm thick leads to colouring at the edges.

Recommended angles for milling

Clearance angle α 5 –10°

Rake angle γ 0 –10°

Cutting speed 100 – 500 m/min

Feed 0.1– 0.5 mm/rev

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MAChINING

4.7 Grinding

Makrolon® sheets can be ground either dry or wet using industrial abrasives to prepare for polishing. The contact pressure between the grinding tool and the workpiece should be kept low to avoid melting.

When grinding it is recommended that you use different grits in succession (e.g. in the sequence 150, 240 and 400).

PolishingMedium-density riding polishing wheels with a peripheral velocity of 20 to 30 m/s can be used to polish Makrolon® sheets with alkalifree polishing pastes.

A clean polishing wheel without polishing paste is then used to complete the polishing process.

Large-surface polishing should be avoided.

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5.1 Cold forming

Cold bendingAll Makrolon® sheets (with the exception of Makrolon® AR), with a minimum ra-dius of 150 times sheet thickness, can be subjected to cold bending.

Minimum radius ≥ 150 x sheet thickness.

Thermoforming is recommended for smaller radii.

Cold foldingMakrolon® sheets can be cold folded. To achieve good results, the following guide values should not be exceeded:

The relaxation immediately following the cold folding process means that the sheet has to be overstretched by approximately 25°. The internal and external stress levels take a few days to become balanced, with the parts only then tak-ing on their final shape.

5. FORMING

Sheet thickness in mm

Bending radius in mm

Maximum folding angle

1 to 2.5 2 90°

3 and 4 3 90°

5 and 6 4 60°

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bear in mind that cold folding places high stress on areas at the edge of the material.

Avoid the use of aggressive chemicals, particularly with cold folded and cold bent parts.

The use of cold folding should be restricted to thin Makrolon® sheets.

5.2 Thermoforming

Protective maskingMakrolon® sheets are provided with a PE masking film to protect the smooth surfaces from damage during transport and fabrication.

The film should be left on the sheet during machining. Solar radiation and weath-ering may influence the properties of the film and make it very difficult to remove later on (possible formation of adhesive residues).

Our standard protective masking film is not suitable for exposure to thermal loads or thermoforming, and should be removed from the sheets before pro-cesses such as drying, hot line bending and/or thermoforming.

We have specially manufactured, unprinted grades of film that allow the sheets to be fabricated with the protective masking left on.

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Pre-dryingMakrolon® sheets absorb only small amounts of moisture from their surround-ings. Nevertheless, we recommend drying the sheets prior to forming. Insuffi-cient pre-drying leads to the formation of bubbles during the heating process, impairing the optical quality of the finished part.

A circulating air oven should be set at a temperature of 120 to 125 °C to ensure thorough pre-drying. The drying times vary according to the thickness of the Makrolon® sheets.

Once the protective film has been removed, the sheets can be hung up in the oven or laid in a frame. Make sure that the sheets are spaced 20 to 30 mm apart to allow the air to circulate freely.

Sheet thickness in mm

Drying time at 125 °C in hours

1 1.5

2 4

3 7

4 12

5 18

6 22

8 30

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FoRMING

Hot folding

To reduce heating time and save energy when using the thermoforming ma-chine, pre-dried Makrolon® sheets should be kept in the drying oven until pro-cessing.

Makrolon® sheets that are cooled to room temperature after the drying process should be processed within a maximum of ten hours (depending on ambient conditions) unless re-dried.

When cutting the sheets it is important to remember that there will be one-off shrinkage upon initial heating to above the glass transition temperature of 145 °C.

Shrinkage values of max. 6 % for sheets up to 3 mm thick and of max. 3 % for thicker sheets can be expected.

Prior to thermoforming, Makrolon® sheets should be thoroughly cleaned using an anti-static detergent or ionised compressed air thus avoiding surface de-fects e.g. embedded particles of dust on the finished part.

Hot foldinghot folding is a relatively easy forming process for the production of uniaxially formed parts. The Makrolon® sheet simply requires local heating to 150 to 160 °C so that pre-drying is generally not required.

The Makrolon® sheet is heated using IR heaters or heating elements in a linear manner. As soon as the desired temperature is reached, the sheet is removed from the heating element, folded, placed in the mold and clamped into position. The desired shape should be fixed until the material becomes stiff.

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If using one-sided heating, the Makrolon® sheet must be turned over several times to guarantee even heating on both sides. With sheet thickness of 3 mm or more and when producing large numbers of units, we recommend simultane-ous heating of both sides using a sandwich heating appliance. by adjusting the heating width using the shields, various different bending radii can be achieved. however, do not fall below a minimum bending radius of three times the sheet thickness.

Local heating creates stresses in the finished part. Care should be taken when using chemicals with bent formed parts.

Heating the Makrolon® sheet To achieve compliant formed parts, the Makrolon® sheets should be heated evenly as part of a controlled process to a temperature of 175 to 205 °C. The best forming precision of the parts is achieved at the upper end of the forming temperature range. Given that the forming temperature is very high and Makro-lon® sheets cool quickly, it is better in practice to heat the sheets directly on the forming machine and not – as is frequently done with other thermoplastics for example – in separate circulating air ovens.

For heating the Makrolon® sheets we recommend IR heating systems, if possible two-sided, which can be heated up relatively quickly.

The advantage of two-sided heating lies in more even and quicker heating of the material. This enables shorter cycle times and is more economical. The heat-ing time increases in linear proportion to the thickness of the Makrolon® sheets and should be calculated by means of trials on the forming machine.

43

FoRMING

Heat source

Mold

Thermoforming using a male tool

To avoid any significant loss of heat at the sheet edges during the heating pro-cess or uneven cooling, which could create internal stresses and warping, we recommend that the clamping device be conditioned. To improve the thickness flow, the sheets may be hot formed with mechanical pre-stretching.

Cooling the finished partMakrolon® sheets cool quickly, with the result that the forming process must be rapid. At the same time, however, the high heat resistance means that short cooling cycles can be achieved. As soon as the formed part is dimensionally stable (at approx. 135 °C) it can be removed from the tool.

Male forming Simple, uniaxially formed parts with large radii of curvature can be stretch formed. The Makrolon® sheets are heated to the right temperature in a circulat-ing air oven and quickly transported to a tool heated to between 80 and 100 °C.

The sheet’s own weight or light pressure applied with gloves or cloth is enough to form the sheet over the male tool.

The sheets then need to be cooled in fresh air. Make sure there are no draughts, which can cause distortions or stresses in the formed part.

We recommend removing the protective film before heating the sheets in an oven.

44

Sketch of vents during thermoforming

Sketch of vents during thermoforming

Thermoforming toolsTo produce large numbers of units and/or to achieve optimum surface quality, use should be made of conditioned (120 to 130 °C) aluminium or steel tools with silk-matt surfaces. A mold angle of between 4 and 6° will facilitate the release process.When constructing forming molds, allowance should be made for shrinkage of 0.8 to 1 %. Provision should be made for sufficient and correctly placed vents with a diame ter of no more than 0.5 to 0.8 mm to avoid impressions on the molded part. To improve ventilation, the hole may be back-drilled with a larger drill. Special materials are available for producing porous forming tools without vents.

The radii should be measured as generously as possible and at least correspond to the wall thickness of the Makrolon® sheet to attain a higher level of stiffness and to avoid any dilution or wrinkle formation during forming.

Male and female toolsThe decision on whether to use a male or female tool depends on the applica-tion. To achieve a better surface quality on the outer side of the finished part, and to attain greater detail, use of a female tool is recommended.

Blowing or thermoforming without countermoldThis technique is used to form domes. Blowing without a countermold involves working with air pressure whilst the thermoforming process without a counter-mold is carried out in a vacuum. To produce perfect moldings, the sheets should be evenly heated. Avoid any draughts in the workshop that could lead to uneven heating. At a sheet temperature of approx. 135 °C, the part retains its desired shape and can be removed.

45

FoRMING

Other methodsother thermoforming methods involve combinations of the above processes.

High-pressure formingCompressed air is used to increase the atmospheric air pressure in a closed mold, stretching the softened sheet across the mold. This results in precise reproduction of detail and sharp edges.

Twin-sheet formingTwo heated sheets are placed between two female tools. Using compressed air, blow moldings are produced with a high degree of structural stiffness and light-weight construction. This method can be used to form and join two sheets dur-ing one process.

ConditioningMakrolon® sheets should be processed under optimum conditions as far as possible so avoiding high internal stress in the sheets, which could result in a need for subsequent heat treatment.

Conditioning means heating parts, keeping them at their temperature and then slowly cooling them again.

Internal stresses in Makrolon® sheets can be largely removed by conditioning in a hot cabinet. The parts are evenly heated to 120 to 130 °C and kept at this temperature on the basis of 1 hour per 3 mm of thickness. It is important that the parts are then cooled without any extreme temperature fluctuations, prefer-ably in an oven.

46

Tips for thermoforming

Problems Possible causes Solution Hot bending

Stretch forming

Thermo-forming

Blowing/ Thermo-forming without counter-mold

Bubbles in the sheetMoisture Pre-drying

Excess heating Reduce heating

Badly formed parts

Sheet too hot Reduce heating

Tool too cold Raise tool temperature

Part not released soon enough Shorten cooling cycle

Vacuum too fast Limit vacuum

Sharp edges Round off edges

Sheet surface too small Use larger sheets

Wave formation

Uneven heating Monitor hot areas and shadow areas

Too small a distance between molds

Min. distance = 2 x thickness

Vacuum too fast Limit vacuum

Sheet surface too large Distance between clamp & tool < 50 mm

47

FoRMING

Problems Possible causes Solution Hot bending

Stretch forming

Thermo-forming

Blowing/ Thermo-forming without counter-mold

Reduced or incomplete details

Insufficient vacuum Check for lack of tightness or add vents

Sheet temperature too low Increase heating

Molding sticks to mold

Tool too hot Reduce tool temperature

Part not released soon enough Release sooner

Release angle too small Release angle > 4 to 6°

Impressions

Mold surface too smooth Slightly matt tool

Sheet temperature too high Reduce heating time

Vents badly positioned Re-evaluate vent positioning

Surface defectsDust on sheet or mold Clean with ionised

compressed air

Vents badly positioned Re-evaluate vent positioning

Uneven finished parts

Tool/clamp too cold Increase pre-heating

Heating/cooling Check for draughts; check heating

Release too late Release sooner

48

6.1 Solvent-based adhesives

Warning! Solvents may be toxic or contain carcinogens. Always ensure good ventilation when working with solvents and follow the information contained in the safety data sheets provided by the manufacturer.

When bonding Makrolon® sheets the load should be evenly distributed across the entire adhesive coating. Please note that the join should not be subject to peel stress but only to shear or tension stress.

Solvent-based adhesives are the easiest and most economical way of bonding Makrolon® parts.

The addition of 8 % Makrolon® shavings gives an adhesive coating with lower evaporation speed and higher viscosity, which makes it easier to apply and handle the adhesive.

A further advantage of this adhesive coating is that the surfaces being bonded no longer have to fit together as well (gap filling) as when using pure solvent-based adhesive.

6. BONDING

Different bonded joints51

Important: The surfaces to be bonded should be thoroughly cleaned with a soft cloth

soaked in isopropyl alcohol to remove grease, dirt and other foreign bodies. The solvent-based adhesive should be applied as a thin layer to one of the

surfaces to be bonded (any excess of adhesive will result in a weak join). The surfaces should be laid on top of each other immediately and briefly

pressed together to ensure a good join. The adhered parts may be moved after just a few minutes, although – at

normal room temperature – maximum bonding strength is only achieved after a few days (slow release of adhesive from the adherent).

Do not use any solvent-based adhesives for flat joints on either side of Makrolon® AR. The scratch-resistant surface prevents the adhesive from bond-ing properly.

Solvent-based adhesives can also be used to bond Makrolon® to other thermo-plastic materials with dissolvable surfaces. These joins generally have a lower level of strength depending on the combined materials. If this is the case, it is better to use adhesion bonding agents.

6.2 Adhesive bonding agents

Please adhere to the general safety measures recommended by the manufac-turer. Makrolon® parts may be adhered to each other or to other materials using industrial adhesive bonding agents that are compatible with Makrolon®. In select-ing a bonding agent it is important to consider the following parameters: heat resistance, elasticity, appearance of adhesive coating, ease of processing etc.

52

Double-sided adhesive tape

Bonding with adhesive tape

Important: The surfaces to be bonded must be roughened and thoroughly cleaned to

improve adhesion. Adhesives that contain solvents or catalysts that are not compatible with

Makrolon® should not be used. Instructions provided by the manufacturer must be observed.

If using an adhesive bonding agent with Makrolon® AR, we advise conducting some tests first, as the material is not easily bonded.

6.3 Adhesive tape

Transparent, double-sided adhesive tape (acrylic based) may be used for rapid bonding. These tapes are elastic and adhere well to Makrolon®. They are par-ticularly suitable for bonding thin Makrolon® sheets to other plastics, glass or metal.

Tips for good bonding: Fold the sheet so that it is slightly wider than the adhesive tape. Clean this area with isopropyl alcohol. Carefully apply the adhesive tape. Use a roller to apply even pressure to remove any air bubbles and improve

adhesion.

53

boNDING

7.1 Welding

Welding is primarily used with opaque sheets. The optical quality resulting from welding is not ideal so this technique should only be used after careful consid-eration.If welding is selected, please note the following points: The Makrolon® work pieces and welding rod if applicable must be dried and

cleaned before welding to avoid blisters forming and to stop dirt from becoming trapped in the weld.

To eliminate the inner stresses caused by local heat expansion during welding, the work pieces should be conditioned after the welding process.

Hot air weldingThis type of welding is suitable for joining Makrolon® parts up to a maximum weld length of 300 mm. The internal stresses and resulting warpage are easily con-trolled using local heating.

An air quantity of 50 to 100 l/min and an air temperature of 350 to 400 °C, mea-sured 5 mm from the nozzle, is recommended. Extruded round or profile rods or even narrow strips cut from a Makrolon® sheet may be used as a welding rod.

Ultrasonic weldingMakrolon® sheets may be joined to each other using ultrasonic welding. Detailed information on ultrasonic welding equipment and the welding conditions should be requested from the relevant equipment manufacturer.

7. FASTENING

55

7.2 Mechanical fastening

holes drilled in Makrolon® sheets impair the strength of the sheets. bearing in mind the relatively high linear thermal expansion coefficient of Makrolon® com-pared with metal or glass, structural measures should be taken to ensure the Makrolon® part can move freely under temperature fluctuations.

Example:The table below shows the expansion of a sheet measuring 1 m in length under a temperature increase of 20 °C.

During fastening work make sure that the Makrolon® sheet is not excessively stressed by local pressure forces. Washers or profiled rubber/foam strips should be used to distribute the pressure.

MaterialLinear thermal expansion coefficient in mm/mK

Expansion at ∆ 20 °C in mm

Makrolon® 0.065 1.30

Aluminium 0.024 0.48

Steel 0.012 0.24

Glass 0.008 0.16

56

Fastening holes should always be drilled allowing for expansion and shrinkage. The allowance should be based on the sheet dimensions and the expected temperature fluctuations. With very large sheets it may even be necessary to drill oblong holes. The distance between the mid-point of the holes and the outer edge of the sheet must be at least twice the diameter of the hole and a minimum of 6 mm. The screws should only be tightened to a position that en-ables the Makrolon® sheet to expand or shrink freely when exposed to tem-perature stress. Distance: 2 x ø drilled hole, but › 6 mm.

Industrial screw taps may be used for thread-cutting in Makrolon®. There is a risk of cracking due to the notching effect. We advise only opting for this type of fastening if no other form – e. g. bonding, clamping or screwing through a clear-ance hole – is possible. Cutting oil must not under any circumstances be used on Makrolon®.

Metal threaded inserts can be sunk into Makrolon® and fastened using ultra-sonic welding. Protective plates for machinery may also be clamped into rubber profiles made from EPDM. Thin sheets may also be nailed, tacked or riveted, though these forms of fastening should only be used in exceptional cases.

Mechanical fastening: Distance a: 2 x ø drilled hole, but › 6 mm

Mechanical fastening

Avoid screws with beveled heads, which can cause cracking.

57

FASTENING

Decoratingbefore treating Makrolon® sheets – e.g. by coating, screen printing or thermoform-ing – we recommend removing any loose particles of dirt or dust adhering to the surface using ionised air (see section "Cleaning”).

The low surface adhesion of Makrolon® AR sheets makes decorating very dif-ficult. The matt side of Makrolon® NR is not suitable for printing.

Coating and printingonce cleaned, Makrolon® may be coated and printed without any other pre-treatment.

Care should be taken to ensure that the coatings and printing inks are chemi-cally compatible with Makrolon®. otherwise, the properties of Makrolon® may be impaired. Various manufacturers can provide suitable ink systems. The manu-facturer’s instructions should be followed at all times.

Hot embossingMakrolon® sheets may be heat embossed with embossing film.

8. FINISHING

59

Makrolon® has a pore-free surface to which it is difficult for dirt to adhere. Dusty parts can be wiped with water, a soft cloth or a sponge but should never be rubbed when dry!

For thorough cleaning, we recommend a non-abrasive detergent. Razor blades or other sharp tools, abrasive or strongly alkaline detergents, solvents, leaded benzine and carbon tetrachloride should not be used. The only way to achieve effective cleaning without streaks is to use a microfibre cloth that is simply dampened with water. In the case of a greater build-up of dirt or greasy stains in particular, benzene-free pure petroleum spirit (cleaner’s naphtha or light gasoline) may be applied.

Splashes of dye, grease or residual sealant etc. may be removed using a soft cloth soaked in ethyl alcohol, isopropyl alcohol or petroleum ether (boiling point 65 °C) and gentle rubbing prior to curing. Rust marks can be removed with a 10 % solution of oxalic acid.Mechanical systems involving e.g. rotating bristles, strippers etc. are not suit-able for use with Makrolon® – even if generous quantities of water are added to the brushes, the sheet surface may become scratched, with the exception of Makrolon® AR. It may be possible to remove or disguise smallish scratches that are not too deep using hot air polishing. This does not apply, however, to Mak-rolon® AR.

Makrolon® has good electrical insulation properties resulting in electrostatic charging and the attraction of dust particles. before treating Makrolon® sheets we recommend removing any loose particles of dirt or dust on the surface by blowing with ionised air. The particles cannot be removed using a normal com-pressed air gun or a cloth but will generally just be moved around.

9. CLEANING

61

From the following diagrams you can determine the optimum thickness of Makrolon UV solid sheet for curved glazing as a function of the radius (R), load (q) and width (b) (see diagrams on page 64 and 65). This data can be applied on tunnel vaults where the angle contained is greater than 30° and with a uniform distributed load.

The sheet must be secured on four sides, but allowance must be made for linear expansion. These calculations include a safety factor of 1.5. The dimensions are normally determined by the architect/designer.

The load (usually wind- or snowload) has to be determined according to local or national planning regulations applying to use of the site and the height of the installed glazing. This is usually done by the architect. The minimum radius to which Makrolon UV sheet can be cold bended is 150 times the sheet thickness.

The following calculations are valid if the sheet is clamped on all four sides, and if the recommended rabbet depth as mentioned in table 1 is respected. Further-more, sufficient clearance should be allowed for expansion of the Makrolon® sheet after installation.

10. CURVED GLAZING

a' and b' in mm

c in mm

f in mm

g in mm

≤ 500 2.5 12 3

750 3 16 4

1000 3.5 20 5

1500 4.5 22 6

2000 6 24 7

2500 7 26 8

3000 8 28 9

a and b: trimmed pane dimensions

a' and b': tight sizesc: edge clearance

f: rabbet depthg: sealant width

63

b

q

R [m]

0.40

0.50

0.751.001.251.50

0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.00

250

500

750

1000

1250

1500

1750

2000

2250

2500

b

q

R [m]

2.50

0.75

1.00

1.25

2.00

3.503.00

1.501.75

0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.00

250

500

750

1000

1250

1500

1750

2000

2250

2500

b

q

R [m]

2.50

0.50

0.75

1.00

2.001.50

0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.00

250

500

750

1000

1250

1500

1750

2000

2250

2500

b

q

R [m]

2.50

1.00

1.25

2.00

5.004.003.00

1.50

1.75

0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.00

250

500

750

1000

1250

1500

1750

2000

2250

2500

3 mm

5 mm

4 mm

6 mm

64

b

q

R [m]

4.00

1.50

2.00

3.50

6.005.00

2.50

3.00

0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.00

250

500

750

1000

1250

1500

1750

2000

2250

2500

b

qR [m]

6.00

4.00

4.50

8.0010.0012.00

7.00

3.50

5.00

0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.00

250

500

750

1000

1250

1500

1750

2000

2250

2500

b

qR [m]

6.00

3.00

4.00

8.0010.50

7.00

3.50

5.00

0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.00

250

500

750

1000

1250

1500

1750

2000

2250

25008 mm

12 mm

10 mm

65

CURVED GLAzING

The required sheet thickness of Makrolon® sheets depends on the area size of the sheet and of the load to which it may be subjected.

The dimensions are normally determined by the architect/designer. The load (usually wind- or snowload) has to be determined to comply with local or na-tional planning regulations on use of the site and depending on the height of the installed glazing. This is usually done by the architect.

The following table is valid if the recommended rabbet depth as mentioned in table 1 is respected. Furthermore, sufficient clearance should be allowed for expansion of the Makrolon® sheet after installation.

It is assumed the sheet is supported on four sides by standard aluminium pro-files; the edges of the sheet have been schematised as 40 % fully clamped (edge’s rotation not allowed) and 60 % simply supported (free rotating edges).

The calculation has been limited according to the following criteria (a limit is also represented by each single criterium): maximum allowed deflection equal to 5 % of the sheet’s shortest side maximum allowed deflection 50 mm maximum stress 15N/mm2.

The calculations are valid for vertical and horizontal glazing. For horizontal glaz-ing, the slope must be a minimum of 15°.

11. FLAT GLAZING

67

Widthin mm

Length in mm

load in kN/m2

0.25 0.5 0.75 1 1.25 1.5 2 3 4

500

1000 3 3 3 3 3 3 4 5 6

2000 3 4 4 4 5 5 5 6 6

3000 3 4 4 4 5 5 6 6 8

4000 3 4 4 5 5 5 6 8 8

5000 3 4 4 5 5 5 6 8 —

6000 3 4 4 5 5 5 6 8 —

750

1000 3 3 4 4 4 4 4 5 6

2000 4 4 5 5 6 6 8 10 10

3000 5 5 6 6 8 8 8 10 —

4000 5 6 6 8 8 8 8 10 —

5000 5 6 6 8 8 8 10 — —

6000 5 6 6 8 8 8 10 — —

1000

1000 4 4 4 4 4 4 5 6 8

2000 4 4 5 6 6 8 8 10 12

3000 5 6 8 8 8 10 10 12 15

4000 6 8 8 8 10 10 12 15 15

5000 6 8 10 10 10 12 12 15 15

6000 6 8 10 10 10 12 15 — —

68

Widthin mm

Length in mm

load in kN/m2

0.25 0.5 0.75 1 1.25 1.5 2 3 4

1250

2000 4 5 6 8 8 8 10 12 15

3000 6 8 10 10 10 12 15 15 —

4000 8 10 10 12 12 15 15 — —

5000 8 10 12 12 15 15 15 — —

6000 8 10 12 12 15 15 — — —

1500

2000 4 6 8 8 10 10 12 15 —

3000 8 10 12 12 15 15 15 — —

4000 10 12 12 15 15 15 — — —

5000 10 15 15 15 15 — — — —

6000 10 15 15 15 — — — — —

2000

2000 8 8 10 12 12 15 15 — —

3000 10 12 15 15 15 15 — — —

4000 15 15 15 15 — — — — —

5000 15 15 15 — — — — — —

6000 15 15 — — — — — — —

69

This table shows the resistance of Makrolon® to chemicals and several other substances.

The test results have been obtained on samples with low internal tensions, which have been stored for six months in the substance at a temperature of 20 °C, without any mechanical load.

Chemical resistance depends on the nature and concentration of substances, the temperature during the contact period, the duration of contact and the in-ternal tension of the tested specimen.

This means that our products can be resistant to a number of chemicals for short contacts, but are not resistant for periods of long exposure, as performed in these tests.

Therefore, we always recommend carrying out a test in the actual application conditions, if these differ from the test environment described above.

The tested substances have been chosen according to their significance in several areas. In a lot of cases it is possible to deduce reaction to other chemi-cally comparable substances, even if these have not been tested.

our UV-protected materials (Makrolon® UV) are slightly more sensitive to chem-icals in comparison to the unprotected materials, but in general the results shown in the table still comply.

ANNEX 1: CHEMICAL RESISTANCE OF MAKROLON®

71

1. Chemicals

Acetaldehyde

Acetic acid, up to 10 % solution

Acetone

Acetylene

Acrylonitril

Allylalcohol

Alum

Aluminum chloride, saturated aqueous solution

Aluminum oxalate

Aluminum sulphate, saturated aqueous solution

Ammonia

Ammoniacal liquor

Ammonium chloride, saturated aqueous solution

Ammonium nitrate, saturated aqueous solution

Ammonium sulphate, saturated aqueous solution

Ammonium sulphide, saturated aqueous solution

Amylo acetate

Aniline

Antimony chloride, saturated aqueous solution

Arsenic acid, 20 % solution

Benzaldehyde

Benzene

Benzoic acid

Benzyl alcohol

Borax, saturated aqueous solution

Boric acid

Bromic benzene

Bromine

Butane (liquid or gaseous)

Butyl acetate

Butanol

Butylene glycol

Butyric acid

Calcium chloride, saturated aqueous solution

Calcium hypochloride

Calcium nitrate, saturated aqueous solution

Legend:

resistant

partially resistant

not resistant

The results shown in the sec-tions 2 to 10, and especially the commercial products marked with ®, are based on a one-time test. Changes in composition made by the pro-ducers of these substances can influence the product properties.

72

Calcium-soap, fat/pure

Carbon acid, wet

Carbon monoxide

Chlorine benzene

Chlorine gas, dry

Chlorine gas, wet

Chlorine lime slurry

Chlorine lime, 2 % in water

Chloroform

Chrom alum, saturated aqueous solution

Chromic acid, 20 % in water

Citric acid

Copper sulphate, saturated aqueous solution

Cresol

Cupric chloride, saturated aqueous solution

Cuprous chloride, saturated aqueous solution

Cyclo hexane

Cyclo hexanol

Cyclo hexanone

Dekaline

Diamyl phthalate

Dibutyl phthalate (plasticizer)

Diethylene glykol

Diethylether

Diglycolic acid, saturated aqueous solution

Dimethyl formamide

Dinonyl phthalate (plasticizer)

Dioctyl phthalate (plasticizer)

Dioxane

Diphyl 5.3

Ether

Ethyl alcohol, 96 % pure

Ethyl amine

Ethyl bromide

Ethylene chlorhydrine

Ethylene chloride

73

ANNEX 1: ChEMICAL RESISTANCE oF MAkRoLoN

Legend:

resistant

partially resistant

not resistant

Ethylene glykol

Ferritrichloride, saturated aqueous solution

Ferro bisulphate

Formaline, 10 %

Formic acid, 30 %

Gasoline

Glycerine

Glycol

Heptane

Hexane

Hydrochloric acid, 20 %

Hydrochloric acid, conc.

Hydrofluoric acid, 5 %

Hydrofluoric acid, conc.

Hydrofluorosilicic acid, 30 %

Hydrogen peroxide, 30 %

Iodine

Isoamyl alcohol

Isopropyl alcohol

Lactic acid, 10 % in water

Lead tetraethylene, 10 % in gasoline

Lighting gas

Ligroin (hydrocarbon compound)

Lime milk, 30 % in water

Magnesium chloride, saturated aqueous solution

Magnesium sulphate, saturated aqueous solution

Manganous sulphate, saturated aqueous solution

Mercuro chloride, saturated aqueous solution

Mercury

Methacrylic acid-methyester (MMA)

Methane

Methanol

Methyl amine

Methyl ethyl ketone (MEK)

Methylene chloride

Nitric acid, 10 %

74

Nitric acid, 10 – 20 %

Nitric acid, 20 %

Nitric gas, dry

Nitrobenzene

Oxalic acid, 10 % in water

Oxygen

Ozone

Pentane

Perchloric acid, 10 % in water

Perchloric acid, concentrated

Perchloro ethylene

Perhydrol, 30 %

Petroleum

Petroleum ether

Petroleum spirit

Phenol

Phenyl ethyl alcohol

Phosphor trichloride

Phosphoric acid, conc.

Phosphoric oxichloride

Potassium aluminum sulpate, saturated aqueous solution

Potassium bichromate, saturated aqueous solution

Potassium bromide, saturated aqueous solution

Potassium carbonate, saturated aqueous solution

Potassium chloride, saturated aqueous solution

Potassium cyanide

Potassium hydroxide

Potassium metabisulphide, 4 % in water

Potassium nitrate, saturated aqueous solution

Potassium perchlorate, 10 % in water

Potassium permanganate, 10 % in water

Potassium persulphate, 10 % in water

Potassium rhodanide, saturated aqueous solution

Potassium sulphate, saturated aqueous solution

Propane gas

75


Legend:

resistant

partially resistant

not resistant

Propargyl alcohol

Propionic acid, 20 %

Propionic acid, conc.

Propyl alcohol

Pyridine

Resorcin oil solution, 1%

Carbon disulphide

Hydrogen sulphide

Soda

Sodium bicarbonate, saturated aqueous solution

Sodium bisulphate, saturated aqueous solution

Sodium bisulphide, saturated aqueous solution

Sodium carbonate, saturated aqueous solution

Sodium chlorate, saturated aqueous solution

Sodium chloride, saturated aqueous solution

Sodium hydroxide

Sodium hypochloride, 5 % in water

Sodium sulphate, saturated aqueous solution

Sodium sulphide, saturated aqueous solution

Styrene

Sublimate, saturated aqueous solution

Sulphur

Sulphur dioxide

Sulphuric acid, 50 %


Sulphuric acid, conc.

Sulphurous acid, 10 %

Sulphuryl chloride

Tartaric acid, 10 %

Tetrachlorocarbon

Tetrachloroethane

Tetrahydrofurane

Tetraline

Thiophene

Toluene

Trichloro acetic acid, 10 %

76

Trichloroethyl amine

Trichloroethyl phosphate (plasticizer)

Trichloroethylene

Tricresyl phosphate (plasticizer)

Urea, saturated aqueous solution

Water

Xylene

Zinc chloride, saturated aqueous solution

Zinc oxide

Zinc sulphate, saturated aqueous solution

Baktol®, 5 %

Carbolic acid

Chloroamine

DDT

Delegol®, 5 %

Dimamin T, 5 %

Hydrogen peroxide

Iodine tincture

Lysoform, 2 %

Maktol®

Merfen®, 2 %

Oktozon®, 1%

Perhydrol

Resorcinol solutions, 1%

Sagrotan®, 5 %

Spirit, pure

Sublimate

TB-Lysoform

Trosilin G extra®, 1.5 %

Zephirol®

2. Disinfectants

77


Legend:

resistant

partially resistant

not resistant

Blood plasma

Delial-Sunmilk®

Hydroplex

Iodine tincture

Klosterbalsam

Lanoline

Menthol, 90 % in alcohol

Nail polish

Nail polish remover

Odol-mouthwater®

Periston blood substitute®

Vaseline

Vick-Vaporub®

All-spice

Apple juice

Beef sebum

Beer

Beets sirup

Brandy, 38 %

Butter

Chocolate

Cinnamon

Clove

Cod-liver oil

Coffee

Common salt

Fish

Fruit juice

Fruit syrup (raspberry)

Gherkins

Grape sugar

3. Pharmaceutics, cosmetics 4. Nutrition

78

Grapefruit juice

Juniper berry

Lard

Linseed oil

Liquor

Maggi®

Margarine

Meat

Milk

Mineral water

Mustard

Nutmeg

Onion

Orange juice

Paprika

Pepper

Rum

Salad oil

Syrup

Sugar solution, saturated aqueous solution

Tea

Tobacco

Tomato juice

Tomato puree

Vanilla

Vegetable juice

Vegetable oils

Vinegar

Vodka

Water

Wine

Worcester sauce

79


Legend:

resistant

partially resistant

not resistant

Ajax®

Bleaching agent

Calgonit® dishwashing

Calgonit® rinsing agent

Calgonit D®, DM, DA, R

Calgonit S®, 1%

Dor®

Fewa®

Green soap

Horolith M®

Household soap

Impact®, 0.2 %

Into-Fensterklar®

Natril®

Omo®

P3 Asepto®

Pantex®, 2 %

Persil®

Pril®

Rapdosept®

Rei®

Riseptin®

Sidolin®

Siliconoil emulsion

Somat W® 731

Suwa®

Trosilin F® extra, 2 %

Tuba® carpet shampoo, conc.

WK 60® (Kron-Chemie)

Aral BG® 58

Baysilon® Silicone oil

BP Energol EM 100®

BP Energol HL 100®

5. Wash and cleaning agents

6. Technical oils and fat

80

BP H LR 65®

Brake fluid (ATE)

Cable isolation oil IG 1402

Cable isolation oil KH 190

Calciumsoap fat

Camphor oil

Castor oil

Cod-liver oil

Contact oil 61

Diesel oil

Drilling oil

Esso Estic 42-45®

Fish oil

Fuel oil

Hydraulic oil Vac HLP 16

Jet engine fuel JP 4 (Kp 97– 209 °C)

Lubricant based on nafta

Lubricant based on paraffin

Mobil DTE Oil-Light®

Mobil Special Oil 10 W 30®

Molikote®-Paste

Molikote®-Powder

Nato-Turbine oil 0-250

Paraffin oil

Polyran® MM 25 (lubricant)

Rape oil

Sewing machine oil

Shell Spirax 90 EP®

Shell Tellus 11-33®

Shell Tellus 33®

Silicone oil

Skydrol 500 A®

Sodium soap fat

Tanning oil Brunofix®

Texaco Regal Oil BRUO®

Texaco Regal Oil CRUO®

81


Legend:

resistant

partially resistant

not resistant

Thenocalor N

Turbo oil 29

Turpentine substitute

Valvoline WA 4-7

Varnish

Whale fat

All-purpose glue

Cellux-sticking foils®

Isolation tape

Perbunan C®

Plaster

Plasticiserfree glazing kit

Putty

Terostat®

Tesafilm®

Tesamoll®

7. Adhesives and joining media

Antistatik C, 5 %

Antistatikum 58

Arquad 18®, 50 %

Delu-Antistatiklösung®

Persoftal®, 2 %

8. Polish paste and anti-statics

82

Perspex Polish 3®

Plexiklar®

Polifac grinding paste®

Statexan AN®

Ballpoint paste Diplomat

Ballpoint paste Othello

Ballpoint paste V77 (Linz)

Geha stamping ink

Indian ink S

Indian ink T

Multi-Marker (Faber-Castell)

Pelikan Royal Blue 4001

Register-ink DIA type U rot

Visor-Pen 7 blau

Acid-containing combustion gasses

Basilit® UAK, 20 % in water (wood protection agent)

Battery acid

Blood

Castor oil

Cement

Cleaning gasoline

E 605®, 0.5 % (pesticide)

E 605®, conc.

Final-photo developer (normal use concentration)

Freon® TF (propellant)

Freon® T-WD 602 (propellant)

Frigen® 113, R113 (propellant)

Gasoline, normal

Gasoline, super

Green chrome oxide (polish paste)

Isolation tape

9. Inks

10. Miscellaneous

83


Legend:

resistant

partially resistant

not resistant

Kaltron® 113 MDR (propellant)

Kerosene

Lighting gas

Marlon®, 1% (moisturising agent)

Metasystox®, 0.5 % (pesticide)

Natural rubber

Nekal BX®, 2 % (moisturising agent)

Neutol® photo developer (normal use concentration)

Oleic acid, conc.

Orthozid® 50, 0.5 % (pesticide)

Plaster

PLK 4 (wood protection agent)

Polishing wax

Polyamide

Polyethylene

Polymer plasticizer

Polyvinylchloride (plasticizer free)

Polyvinylchloride, (containing plasticizer)

Sea water

Shell IP 4 (fuel)

Soap suds

Starch

Sweat, acid (pH 4.7)

sweat, alkaline (pH 9.5)

Tanigan® CLS, 30 %

Tanigan® CV

Tannic acid

Test fuel

84

General chemical propertiesThe chemical resistance of Makrolon® is generally related to the medium, the temperature, the effective period of time and level of stresses existing or ex-erted within the material.

The glass-like, chemically inert surface coating of Makrolon® AR enhances its resistance to chemicals. This only applies if the surfaces are undamaged (no scratching or scoring, for example). Differentiation can be made between the various types of damage, and it is perfectly possible for more than one to be in evidence at the same time.

Disintegration/Surface swellingLow molecular, aromatic, halogenated and polar components can migrate with-in the plastic. The resulting damage can range from a tacky surface to total disintegration.

Stress crackingSome chemicals can penetrate the surface to a small degree, causing weaken-ing of the tension of the material due to stress cracking. Stress cracking can be optically undesirable. Heavy stress concentration can significantly affect some of the material's properties. Stress cracking can generally be readily identified by inspection.

Molecular degradationSome of the material’s properties are due to the size of its molecules. If a medium creates a chemical reaction that causes reduction of the molecular weight, then the viscoplastic properties in particular will be affected. The molecular weight has virtually no effect on the electrical properties and very little effect on the thermal properties.

ANNEX 2: CHEMICAL RESISTANCE OF MAKROLON® AR

85

The table on the next page compares the resistance of Makrolon® and Makrolon® AR to chemicals and various other products.

The test results were obtained using unstressed components with no mechanical loading and at 20 °C, kept in the various agents for a period of six months.

Apart from the type of chemicals involved, the resistance also depends on their concentration, the temperature at the time of contact and the duration of contact, as well as the stress condition of the component.

Our products may have sufficient resistance to short-term contact with a range of chemi cals, to which they are not deemed resistant under the listed test condi-tions.

Examples

Solvent/not resistant toDichloromethane Chloroform Tetrahydrofuran

Swelling agentBenzol Chlorobenzene Acetone

Insoluble/resistant to

diluted mineral acids, many organic acids, oxidants and reducing agents, neutral and acidic salt solutions, many fats, waxes and oils

86

Therefore we recommend separate testing be carried out if the practical de-mands deviate from the test conditions stated above. When selecting test media, the most significant were taken from each field of application. In many cases conclusions can be drawn regarding chemically similar media that were not in fact tested.

In the case of damaged Makrolon® AR sheets, in the medium to long term the same results can be assumed as for non-coated (GP/UV) sheets.

It should generally be noted that the resistance tests using coolants were only carried out in respect of short-term properties. It is a fact that these substances can significantly reduce the retentiveness of Makrolon® in the medium to long term.

This must be taken into account, especially when considering machinery protec-tion and strict operator safety requirements.

The relevant guidelines and recommendations of the machinery manufacturer and the responsible authorities should also be observed.

We further refer to our Technical Information Makrolon® Machinery Protection (MF 1022).

For the products listed in columns 2 and 3, and in particular for products with ® trademarks, the test results relate to one-off testing.

Any changes in composition introduced by the manufacturer may affect the prod-uct’s properties.

87

ANNEX 2: ChEMICAL RESISTANCE oF MAkRoLoN AR

Legend:

resistant

partially resistant

not resistant

Medium Makrolon® Makrolon® AR

1. Solvent

Acetone

Ethylmethylketone

Methanol

Ethanol

2-Propanol

Toluene

Dichloromethane

Perchloroethylene

Benzine, normal

Petroleum ether

2. Anorganic substances

Sodium hydroxide

Ammonia solution

Hydrochloric acid, 20 %


88


3. Coolant (test period 7 days at 50 °C)

Aral® Emulsion 230 EP, conc.

Aral® Emulsion 230 EP, 5 %

Aral® Sarol 460 EP, conc.

Aral® Sarol 460 EP, 10 %





Esso® Kutwell 40, conc.

Esso® Kutwell 40, 10 %

Esso® cutting oil BS 30, conc.

Esso® cutting oil BS 30, 8 %

Esso® cutting oil BS EP 50, conc.

Esso® cutting oil BS EP 50, 10 %

Esso® cutting oil BS 60, conc.

89

ANNEX 2: ChEMICAL RESISTANCE oF MAkRoLoN AR


3. Coolant (test period 7 days at 50 °C)

Esso® cutting oil BS 60, 6 %

Wisura Tralustar, conc. —

Wisura Tralustar, 10 % —

Zeliot MS 250, conc. —

Zeliot MS 250, 20 %

Legend:

resistant

partially resistant

not resistant

90

MF0

261

– Fe

brua

ry 2

011

Covestro Deutschland AG

51365 LeverkusenGermany

Phone +49 214 6009 5555

E-mail [email protected] www.sheets.covestro.com

Makrolon®, Vivak®, Axpet®, bayloy® and bayblend® are registered trademarks of Covestro AG.

technical manual - makrolon solid sheets · 2017-03-27 · technical manual . covestro deutschland...

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