Elval Colour "Fabrication Manual For Etalbond"

FABRICATION MANUAL FOR CASSETTES Health and Safety Normal safety and health precautions practiced in any fabricating
environment should be used when fabricating ETALBOND and ETALBOND FR material. Gloves, steel toed boots, goggles, helmets, dust masks, and hearing protection, should always be worn. It is mandatory to wear googles and dust masks when working with ETALBOND FR material.
Product Description ETALBOND and ETALBOND FR are a sandwich type composite panel consisting of a non-toxic polyethelene core or a fire resistant core permanently bonded between two aluminium sheets. ETALBOND sheets are produced in core thickness of 2mm, 3mm and 5mm with an aluminium thickness of 0,50mm. Standard widths are 1250mm and 1500mm and standard lengths are 3200mm. The total thickness of ETALBOND is 3mm, 4mm and 6mm and the ETALBOND FR is 4mm and 6mm. The bonding of aluminium sheets with the core is realized with the simultaneous application of mechanical and chemical methods under high temperatures. The final stage of production results in a strong and exceptionally rigid and flat panel. ETALBOND is a technologically advanced product whose unique features fit in a variety of applications.
Figure 1
Aluminium skin Adhesive layer
LDPE or Fire Resistant core Adhesive layer
Aluminium skin
FABRICATION MANUAL FOR CASSETTES Edited: Sept. 12, 2011
Tolerances: ETALBOND and ETALBOND FR are manufactured to exact tolerances with state-of-the-art equipment. All dimensional tolerances must be in accordance with Appendix D of the Standard EN 14509. The thickness of the panels should have a tolerance of 0,15mm for panels 3 and 4mm thick, and 0,20mm for panels 6mm thick. The flatness should be visually flat with a maximum deviation of 0,60mm over 200mm. The panels should have an acceptable deviation of squareness 0,6% of the panel width. The panel length should be measured the center of the panel and should have a tolerance of 5mm for L 3000mm and 10mm for L > 3000mm. The panel width should be measured at 200mm from each edge of the panel and at the centerline. The acceptable tolerance for the width of the panel is 2mm. (See figure 1) ETALBOND and ETALBOND FR are manufactured to exact tolerances with state-of-the-art equipment. All dimensional tolerances must be in accordance with the manufacturer standards. Declared tolerances for ETALBOND , and ETALBOND FR:
Figure 2
(d1-d2) 3mm
d1
00 m
d2 .
_ L < 8000mm
t = 3, 4, 6mm Tolerance: +0,2mm _
L=2000-4000 Tolerance: -0/+4mm L=4001-6000 Tolerance: -0/+6mm L=6001-8000 Tolerance: -0/+10mm
Table 1. Acceptable tolerance of curvature

Length (mm) 1250 1500 Max Curvature (mm) 5 6 Length (mm) 3200 >3200 Max Curvature (mm) 9.6 0.003 x Length
< _ 15
le To
e nc ra
2m /+ 0 :-
Packaging The ETALBOND/ ETALBOND FR sheets are packaged and delivered on cushioned, wooden skids with three layer corrugated cardboard paper 4mm thick over on the top and under the bottom sheet. Each pallet is covered with a loose polyethylene wrap all around the ETALBOND/ ETALBOND FR sheets and wooden cross members are used for stiffness on the top and the bottom. The pallet is held together with steel strapping. (See figure 2)
Figure 3
Handling ETALBOND/ ETALBOND FR without stiffeners and edge forming should be handled with care. Long sheets will sag in the middle and should be supported correctly. A protective film with an ultraviolet barrier is placed on the panel to protect the finish during transportation, fabrication, and installation. There are arrow indications on the protective film, and the cassettes should always be cut and installed with the arrows in the same direction (See figure 3). Worktable surfaces should be clear of debris and metal shavings which may penetrate the film and scratch the panel surface. The etalbond panels should be secured against slippage during transport. Never pull or push panels over the edge during loading or unloading situations as there is the potential to scratch the coated surface. Instead the panels should be lifted by holding them from both ends. Transport protection films must not be exposed to direct sunshine or to heat for periods longer than 15 Days. It is recommended that the protective film be removed immediately after installation.
When loading or unloading etalbond panels with the use of a forklift, make sure that the lifts are set to their maximum distance apart and located centrally between the pallets. Pallets should be unloaded one by one and placed on even ground. When unloading the panels lifting slings will be required. Make sure that that lifting slings are in place, in good condition, located with protection to the bottom panel and that package is balanced. Ensure that no people are below the pallet during a lifting operation. ELVAL COLOUR recommends the use of approved types of lifting or suction equipment or panel clamps for the safe and easy installation of etalbond panels.
Figure 4
Storage of Panels Panels should be kept stored in dry and well ventilated areas under normal temperatures. Protect pallets during storage against rain, penetration of moisture and condensation. Only pallets of identical size should be stacked, with a maximum of 4 pallets stacked on top of each other. When ETALBOND/ ETALBOND FR has to be stacked in high piles use intermediate layers of wood or plastic and protected against humidity. The correct storage of panels or pallets is on horizontal racks. Flat storage protects panels from warping. Caution should be paid that the pre-coated surface is protected from any potential scratching. It is suggested not to unpack palettes until ready for use. After unpacking, restore remaining panels horizontally into the palette. Do not store ETALBOND/ ETALBOND FR in dusty places.
Shearing ETALBOND/ ETALBOND FR can be easily sheared with a punching machine or shearing machine. However, shearing should be avoided when the edge of the panel is exposed to the environment. A shock-absorbing rubber pad should be used when shearing ETALBOND in order to avoid damaging the surface of the panel. Sawing and Routing Existing machinery and tooling used for woodworking and metalworking can be used with ETALBOND/ ETALBOND FR. Prior to processing large quantities trial cuttings should be done to evaluate both the tool working tolerances and the recommended cutting speeds. Table saws are not recommended for dimensions larger than 1200mm x 1200mm. ETALBOND/ ETALBOND FR can be cut to any shape with a jig saw. It is recommended to select the tool geometry and cutting conditions in such a manner as to minimize the frictional forces developed when sawing and routing. ELVAL COLOUR recommends that you use a custom tool supplier. Line cuts ELVAL COLOUR recommends an 8 diameter saw blade with extra fine, carbide tipped, 60 tooth, combination rip and crosscut blades. Blades should be maintained and replaced according to the blade manufacturers specifications. Routed cuts A special circular saw blade should be used that produces a groove of 105 with a flat surface of 2mm for panels bent to 90. (See figure 4) Carbide blade teeth are recommended. Band saws and jig saws should be chosen according with the characteristics outlined in the chart below (See figure 5). Router bits should be used to machine the 105 V-groove in the ETALBOND/ ETALBOND FR panels. The bit should have an angle of 105 and a flat surface of 2mm necessary for creating the proper groove for bending 90 (See figure 6). Saw blades have a better capacity to machine the product while dissipating the heat generated at a more rapid rate. When routing the panels in a 105 V-groove a minimum of 0,3mm of core should remain (See figure 7). When routing the panels in a 135 V-groove a minimum of 0,5mm of core should remain (See figure 8). This technique is mandatory for ETALBOND and ETALBOND FR panels, and must be included in the quality inspection process. Automated panel saws can streamline the fabrication process and are available through equipment manufacturers and distributors.
Figure 5. Carbide tip saw blade for cutting non-ferrous metals
2mm
20
105
Table 2. List of recommended tools

Circular Saw Blade material Blade geometry Tooth geometry Tooth pitch (spacing) Clearance angle a Contact angle v Max. cutting speed Max. feed speed Carbide tip 8 or 14 diameter See fig. 4 See fig. 4 20 -5 5500 RPM 0,4 m/s Band Saw Tempered spring strip steel Thickness: 0,8-1,2mm Width: 15-25mm Skip teeth for cutting non-ferrous metals 2-3mm 35 3-5 3000 m/min 0,25 m/s Reciprocating Saw HSS Thickness: 0,8-1,2mm Width: 15-25mm Alternating or wavy tooth setting 2-3mm 200 m/min 0,10 m/s
Figure 6. Routing bit
90
2mm
Figure 7: Priciples of routing and bending
90 0.3mm
90
R=2-3mm 2-3mm
Routing groove 90 for bending up to a 90 corner
45 0.3mm
135
2-3mm
R=2-3mm
135 45 0.3mm
2-3mm
R=2-3mm
Figure 8: Routing the back of the panels
90
2mm - 3mm
0.3mm
Bending: When bending cassettes the final dimension of the cassette becomes 0,5mm to 1mm longer than the original dimension due to the elongation effect. Trial tests should be performed before production in order to determine any necessary adjustments (See figure 9). V-grooves are made on the same side of the panel for inside and outside returns. Panels can be easily folded by using jigs made from standard aluminium extrusions (See figures 10-12). Figure 9: Elongation effect
D-0,5mm
L-1mm
D-0,5mm
2mm - 3mm 4mm 0.3mm
0,5mm
Depth "D"
Panel Length "L"
Figure 10: Single lower return using aluminum jigs
Figure 11: Double lower return using aluminum jigs
10
Figure 12: Reverse upper return using aluminum jigs
11
Cassettes are formed by notching out the corner material and folding the edges of the panels 90 (See figures 13-14). Then the corners are fastened using aluminium plates with aluminium pop rivets 4-5mm in diameter.
Figure 13: Envelope corner cuts
Figure 14: Square corner cuts
12
Joinery Use the following guidelines when other elements come in direct contact with the surface of ETALBOND : 1. Acceptable joining element materials: Aluminum Plastic Stainless steel Plated or coated steel with cadmium, zinc or aluminum 2. Unacceptable joining element materials: Copper Brass Bronze Iron Raw Steel Unacceptable materials will cause corrosion of joining surfaces due to electrolysis. Therefore, the use of ferrous metals should always have an electrically insulating material between to avoid direct contact with the ETALBOND / ETALBOND FR. When joining elements are to be anodized, assemble the materials after the anodizing process. Proper consideration should be given to the thermal expansion characteristics of ETALBOND when using any of the joining techniques. Rivets Panels can be fastened together or joined to aluminum extrusion profiles or aluminium plates with aluminium or stainless steel rivets common to aluminum construction. Blind rivets provide the advantages of labor savings, one-sided working of the material, and the reduced potential of surface damage. Semi-tubular, solid and other types of rivets can also be effective on a production basis. Place the closing or set-head on the side of the aluminum extrusion profile or aluminium plate. When conditions do not permit this or when two pieces of ETALBOND are to be joined together, use rivets with special wide closing heads as shown in Figure 15 or with tightly fitting washers. When blind rivets are subjected to tensile strength tests, the head tends to "unbutton" from the ETALBOND / ETALBOND FR , or pull through the hole. Since this would cause localized tearing of the of ETALBOND / ETALBOND FR , use the largest possible rivet head for connections that will experience loading. All rivets used shall be SFS intec made of aluminium AlMg5 and mandren from A3 SS. Rivet connections are well suited for parts that may be subjected to concussion or vibration. Colored plastic concealment caps are available for various types of blind and tubular rivets. Consult the rivet manufacturer for details. Follow the directions and determine suitability by pre-testing.
13
Figure 15
Threaded Fasteners The easiest method of joining sheets of ETALBOND / ETALBOND FR together or to an extrusion profile erection system is with stainless steel machine screws or bolts (See Figure 16). This method allows the panel to be removed. Use the largest possible flat washer to minimize surface pressure and eliminate possible compression due to cold flow of the core material. Arrange attachment screws at least 2.5 x the diameter of the fastener from the edge of the sheet, as shown in Figure 17. It is not recommended to torque fasteners due to the cold flow of the core material. Two complete turns of the nut past finger tight is common practice (See Figure 18). Screws when used shall be SFS intec SS A3.
Figure 16 MIN. 3 TIMES DIAMETER
DIAMETER
Figure 17 MIN. 2,5 TIMES DIAMETER
14
Figure 18
EXCESSIVE TORQUE (NOT RECOMMENDED) To countersink into ETALBOND / ETALBOND FR without prior preparation, tighten the nut and washer onto the bolt and draw the head of the fastener into the cover sheet. Countersink washers can also be used. Either method is preferable in lieu of traditional countersinking as shown in Figure 19. Figure 19
Preferred
Preferred
Traditional (not recommended)
Panel Reinforcement ETALBOND/ ETALBOND FR panels can be stiffened by adding an aluminium extrusion to the back side of the cassette. Stiffeners act like purlins that are placed along the shortest dimension of the cassette. When wind loads are applied to the cassette the stiffeners transfer the load to the edge of the cassette. The back side of the cassette and the stiffener must be wiped clean with isopropyl alcohol before bonding the stiffener with the recommended adhesive to the back side of the cassette. The stiffener is then mechanically fastened to the cassette edge with stainless steel self-tapping screws 4,8 x 25mm and countersink washers(See figure 20).
15
Figure 20. Reinforcement with aluminium profile E-2264
32 16
22 55
4.7
E-2264
Adhesive bond
Recommended adhesives are: SIKATACK PANEL AGOMET VP 347 SIKAFLEX 252 SIKA FAST PROSYFLEX 3000
16
Figure 21. Profile reinforcement 30x30x1,5
Figure 22. Profile reinforcement 40x40x1,5
7,5 7,5
1,5 7,5 7,5
1,5
100
100
7,5 7,5 30 30
7,5 7,5 40 40
For cassettes with a 35mm depth use the aluminium profile reinforcement 30x30x1,5 bonded to the back of the cassette with recommended adhesives and fastened to the side of the cassette with two aluminium rivets 5 x 15.
For cassettes with a 50mm depth use the aluminium profile reinforcement 40x40x1,5 bonded to the back of the cassette with recommended adhesives and fastened to the side of the cassette with two aluminium rivets 5 x 15.
Figure 23. Profile reinforcement 20x30x2

2
7,5 7,5
100
7,5 7,5 30 20
For cassettes with a 35mm depth use the aluminium profile reinforcement 20x30x2 bonded to the back of the cassette with recommended adhesives and fastened to the side of the cassette with two aluminium rivets 5 x 15.
FABRICATION MANUAL FOR CASSETTES Edited: Sept. 12, 2011 17
Figure 23a. Reinforcement angles for standard cassettes
90
2
90
5 4 3
90
90
Routing the back of the Etalbond

1 90 5
2mm - 3mm
0.3mm
1. Etalbond 2. Reinforcement profile glued and fastened 3. Corner joint (for corner assembly without slot reinforcement) 4. Aluminium rivet 5. Routing
18
Figure 23b. Aluminium tubes for reinforced cassettes
90
90
5 4 3
90
90
Routing the back of the Etalbond

1 90 5
2mm - 3mm
0.3mm
1. Etalbond 2. Reinforcement profile glued and fastened 3. Corner joint (for corner assembly without slot reinforcement) 4. Aluminium rivet 5. Routing
19
Figure 24a. Corner clip for 35mm cassettes
Figure 24b. Corner clip for 35mm cassettes
Aluminium rivet (5x15) Aluminium plate min. thickness 2mm
Aluminium rivet (5x15)
Aluminium plate min. thickness 2mm

35
48
24
Simple return (35mm)
20
Double return (35mm)
Figure 25a. Corner clip for 50mm cassettes Aluminium rivet (5x15)
Figure 25b. Corner clip for 50mm cassettes
48
35
35
24
Note: Corner clips are made from min. 2mm thick aluminium alloy plate 5754. This clip should be fastened with two aluminium rivets 5 x15mm to the inside of the cassette.
20
Figure 25c. Table for slot details for 50mm cassettes
50
50
26
26
28
28
27
29
50mm cassette with double return Tongue width: 14mm 26a, 27a, 28a Tongue width: 12mm 26b, 27b, 28b Tongue width: 10mm 26c, 27c, 28c
50 mm cassette with single return Tongue width: 14mm 26a, 28a, 29a Tongue width: 12mm 26b, 28b, 29b Tongue width: 10mm 26c, 28c, 29c
21
Figure 26a. Slot detail for 50mm cassette with tongue width 14mm. Cassette with 40mm reverse return at the upper side of the cassette and envelope corner cut-outs.
Figure 27a. Slot detail for 50mm cassette with tongue width 14mm. Cassette with 20mm double return at the lower side of the cassette and envelope corner cut-outs.
500.5 500.5 15 40 15
5,3
19
31
15,9 90
69
19,10.2
31
min. 1000.5
21,3 15 200.2
min. 1000.5
19,10.2 14 200.2 10,20.2 21,3 69
100
69
400.2
31
69
5,3
15 500.5 20
15
44
17
5,3
48
480.5
90
400.2
10,20.2
14
22
Figure 28a. Slot detail for 50mm cassette with tongue width 14mm. Detail for slot in the middle of the cassette with openings for riveting the slot stiffener
Figure 29a. Slot detail for 50mm cassette with tongue width 14mm. Cassette with single return at the lower side and envelope corner cut-outs.
500.5 15 500.5 15 15 15
5,3
5,3 73 19,10.2 10,20.2
69
19,10.2 14
400.2
min. 1000.5
69
15
31
15
200.2
17
48
480.2
90
200.2
21,3
15
400.2
10,20.2
23
Figure 30 a. Slot stiffener for 50mm cassettes with a tongue width 14mm
440.5 36
7,5
14,1 15 25 5,1 15 69 15 140.2 200.2 15 7,5 22,5 3 340.5 15 31 9,1
91,50.5
The slot stiffener is made from min. 2mm thick aluminium alloy plate 5754. This stiffener should be fastened with four aluminium rivets 5 x 15mm to the inside of the cassette.
91,50.5
69
400.2
10,20.2
24
Figure 26b. Slot detail for 50mm cassette with a tongue width 12mm. Cassette with 40mm reverse return at the upper side of the cassette and envelope corner cut-outs.
Figure 27b. Slot detail for 50mm cassette with a tongue width 12mm. Cassette with 20mm double return at the lower side of the cassette and envelope corner cut-outs.
500.5
500.5 15 15
40
5,3
19 31
69
17,10.2 12 10,20.2
15,9
90
23,3 min. 1000.5 31 min. 1000.5 69 17 200.2 48 20 90 31
69
17,10.2 12 200.2
69
15 500.5
15
44
5,3
17
48
23,3
400.2
10,20.2
400.2
25
Figure 28b. Slot detail for 50mm cassette with a tongue width 12mm. Detail for slot in the middle of the cassette with openings for riveting the slot stiffener.
Figure 29b. Slot detail for 50mm cassette with a tongue width 12mm. Cassette with single return at the lower side and envelope corner cut-outs.
500.5 15 500.5 15 15 15
5,3
69
5,3
17,10.2 12 10,20.2
69
17,10.2 23,3 min. 1000.5 69 17 200.2 31 17 48 48 90 60 400.2 12 10,20.2
23,3 69
17 15
200.2
400.2
26
Figure 30b. Slot stiffener for 50mm cassettes with a tongue width 12mm
440.5 34
7,5
5 14,1
15
91,50.5
15
69
17 17,10.2 12 10,20.2 400.2 29 340.5
21,8 91,50.5 69 17 7,5 22,5 15
200.2 9,1
25 5,1
27
Figure 26c. Slot detail for 50mm cassette with a tongue width 10mm. Cassette with 40mm reverse return at the upper side of the cassette and envelope corner cut-outs.
Figure 27c. Slot detail for 50mm cassette with a tongue width 10mm. Cassette with 20mm double return at the lower side of the cassette and envelope corner cut-outs.
500.5
500.5 15 15
40
5,3 15,9
19
31
69
15,10.2 10 10,20.2
15,9 31
90
min. 100 0.5
25,3 min. 1000.5 69 19 200.2 31 15,9 48 20 17 480.5 90
69
15,10.2 10 10,20.2
25,3 69
15 500.5
15
44
5,3
200.2
400.2
400.2
28
Figure 28c. Slot detail for 50mm cassette with a tongue width 10mm. Detail for slot in the middle of the cassette with openings for riveting the slot stiffener.
Figure 29c. Slot detail for 50mm cassette with a tongue width 10mm. Cassette with single return at the lower side and envelope corner cut-outs.
500.5 15 500.5 15 15 15
5,3
5,3 15,9 69
15,10.2 10 10,20.2
69
15,10.2 10 25,3 min. 1000.5 400.2 19 10,20.2
25,3 69
19 15
200.2
15,9 48
17
480.5
90
200.2
31
400.2
29
Figure 30c. Slot stiffener for 50mm cassettes with a tongue width 10mm
5 7,5
440.5 34
15
91,50.5
69
19 15,10.2 10 10,20.2 400.2
23,8 91,50.5 69 19 7,5 51,5 5 340.5 22,5 15 29
25 5,1
200.2
30
Figure 25d. Table for slot details for 35mm cassettes
35
35
31
31
33
33
32
34
35mm cassette with double return Tongue width: 10mm 31a, 32a, 33a Tongue width: 12mm 31b, 32b, 33b Tongue width: 14mm 31c, 32c, 33c
35 mm cassette with single return Tongue width: 10mm 31a, 33a, 34a Tongue width: 12mm 31b, 33b, 34b Tongue width: 14mm 31c, 33c, 34c
31
Figure 31a. Slot detail for 35mm cassette with tongue width 10mm. Cassette with 40mm reverse return at the upper side of the cassette and envelope corner cut-outs.
Figure 32a. Slot detail for 35mm cassette with tongue width 10mm. Cassette with 20mm double return at the lower side of the cassette and envelope corner cut-outs.
350.5 12 350.5 12 12
40
4,3 35
42
21
79
15,10.2 10,20.2 10
min. 1000.5
min. 1000.5
10,3 79
400.2
12 200.2 12 51 33
90
20
33 12 12
12
42
200.2
10
79
15,10.2 10,20.2
10,3
400.2
79
32
Figure 33a. Slot detail for 35mm cassette with a tongue width 10mm. Detail for slot in the middle of the cassette with openings for riveting the slot stiffener
Figure 34a. Slot detail for 35mm cassette with a tongue width 10mm. Cassette with single return at the lower side and envelope corner cut-outs.
350.5 350.5 12 12 12 12 12
4,3 4,3 15,10.2 79 79 15,10.2 10,20.2 10 400.2 12 42 200.2 12 23 12 33 33 90 10,20.2 10
400.2
10,3 79 12 200.2
min. 1000.5
10,3 79
33
Figure 35a. Slot stiffener for 35mm cassettes with a tongue width 10mm
28,50.5 5 12 10
79
12 15,10.2 10,20.2 10 400.2 7,5 260.5 200.2 58,5 12 8,3
4,1
79
12
13,5
7,5
7,5
34
Figure 31b. Slot detail for 35mm cassette with tongue width 12mm. Cassette with 40mm reverse return at the upper side of the cassette and envelope corner cut-outs.
Figure 32b. Slot detail for 35mm cassette with tongue width 12mm. Cassette with 20mm double return at the lower side of the cassette and envelope corner cut-outs.
350.5 12 12 12
40
350.5
4,3 35 17,10.2 79 10,20.2 12 min. 1000.5
21
42 17,10.2 min. 100 0.5
8,3 79 200.2
400.2
12 12 51 33
90
200.2 20 33 12 42
12
12
12
79
10,20.2
8,3
400.2
79
35
Figure 33b. Slot detail for 35mm cassette with tongue width 12mm. Detail for slot in the middle of the cassette with openings for riveting the slot stiffener.
Figure 34b. Slot detail for 35mm cassette with tongue width 12mm. Cassette with single return at the lower side and envelope corner cut-outs.
350.5 12 12 12 12 350.5 12
4,3 4,3 79 17,10.2 10,20.2 12
79
17,10.2 10,20.2 12
400.2
min. 1000.5
8,3 79 200.2 12 90 33 33
8,3 79 12 200.2
23
12
12
42
400.2
36
Figure 35b. Slot stiffener for 35mm cassettes with tongue width 12mm
28,50.5 5 13,5 12 10
79
10,20.2 12
12 17,10.2 6,3 7,5 260.5
4,1
79
12
13,5
200.2 58,5
7,5 12
400.2
7,5
37
Figure 31c. Slot detail for 35mm cassette with tongue width 14mm. Cassette with 40mm reverse return at the upper side of the cassette and envelope corner cut-outs.
Figure 32c. Slot detail for 35mm cassette with tongue width 14mm. Cassette with 20mm double return at the lower side of the cassette and envelope corner cut-outs.
350.5 12 40 12 350.5 12
35
4,3 42 19,10.2 79 10,20.2 14 19,10.2 10,20.2 min. 1000.5 79 14 6,3 200.2 12 51 33 90 20 33 12 42 400.2
min. 1000.5
79
21
6,3 79 200.2 12
12
12
400.2
38
Figure 33c. Slot detail for 35mm cassette with tongue width 14mm. Detail for slot in the middle of the cassette with openings for riveting the slot stiffener.
Figure 34c. Slot detail for 35mm cassette with tongue width 14mm. Cassette with single return at the lower side and envelope corner cut-outs.
350.5 350.5 12 12 12 12 12
4,3 19,10.2 79 10,20.2 14
4,3 19,10.2 79 10,20.2 14
400.2
min. 1000.5
79
79
6,3 12 200.2
6,3 200.2 12 90 33 33
23
12
12
42
400.2
39
Figure 35c. Slot stiffener for 35mm cassettes with tongue width 14mm
28,50.5 5 10 12
12 19,10.2 10,20.2 14 4,3 12 200.2 12 7,5 260.5
4,1
79
79
13,5
7,5
58,5
400.2
7,5
40
Step by step pictorial how to fabricate cassettes It is recommended to leave a minimal space from the edge of the panel in order to ensure the squareness and geometry of the cut out shape.
2a
2b
41
Step by step pictorial how to fabricate cassettes
10a
Aluminium rivet (5x15)
10b
48
35
35
24
10c
Slot stiffener may be used instead of corner joint
11
42
Step by step pictorial how to fabricate cassettes
12
7,5
7,5
1,5 7,5 7,5
1,5
100
100
7,5 7,5 30 30
7,5 7,5 40 40
13 D 0,5mm D 0,5mm
L 1mm
L 1mm
W 1mm
W 1mm
43
Title Dimensions Core / Panel thickness Lower return Side slots Slot stiffener Profile reinforcement Corner clips
Etalbond cassette Type A Width-900mm, Length-1300mm, Depth-35mm LDPE / 4mm Single return see figure 32 4 0 E-2264 cut to 892mm and fastened at centerline see figure 20 4 see figure 24
900
40 E-2264
1
1300
33
100
44
100
35
Etalbond cassette Type B Width-1150mm, Length-2000mm, Depth-50mm LDPE / 4mm Single return see figure 27 5 on each side 0 4 on each side fastened between slots see figure 22 4 see figure 23
1150
12,96 48
40x40x1,5
= = 2000
1
100
45
100
50
Etalbond cassette Type C Width-1150mm, Length-1150mm, Depth-35mm LDPE / 4mm Double return see figure 31 3 on each side 0 2 on each side fastened between slots see figure 21 4 see figure 24
1150
15
30x30x1,5
1150
20
46
33
100
100
35
Etalbond cassette Type D Width-1250mm, Length-2700mm, Depth-50mm LDPE / 4mm Single return see figure 27 6 on each side 0 3 profile reinforcements (E-2264 cut at a length of 1242mm) equally spaced from the center see figure 20 4 see figure 23
1250
11,25
E-2264
= =
E-2264
1
2700
E-2264
48
100
100
50
47
Title Dimensions Core / Panel thickness Lower return Side slots Slot stiffener Profile reinforcement
Corner clips
Etalbond cassette Type E Width-1250mm, Length-2700mm, Depth-35mm LDPE / 4mm Single return see figure 32 6 on each side 6 on each side see figure 34 1 profile reinforcement (E-2264 cut to a length of 1242mm) bonded and fastened to the center of the cassette 4 profile reinforcements (20x30x2 cut at a length of 100mm) equally spaced, bonded and fastened to the lower return 0
1250
E-2264
1
2700
20x30x2
33
100
100
11 35
48
Corner clips
Etalbond cassette Type F Width-1250mm, Length-2700mm, Depth-35mm LDPE / 4mm Single return see figure 32 6 on each side 0 3 profile reinforcements (E-2264 cut to a length of 1242mm) bonded and fastened to the center of the cassette 1 profile reinforcement (20x30x2 cut at a length of 1242mm) bonded and fastened to the lower return 4 see figure 24
1250
11
E-2264 E-2264 E-2264 20x30x2
2700
33
100
100
35
49
Corner clips
Etalbond cassette Type G Width-1700mm, Length-900mm, Depth-50mm LDPE / 6mm Double return see figure 26 3 on each side 0 1 profile reinforcement (E-2264 cut to a length of 892mm) bonded and fastened vertically to the center of the cassette 2 profile reinforcements (20x30x2 cut at a length of 100mm) equally spaced bonded and fastened to the lower return 4 see figure 23
10
20x30x2
900
20
50
48
100
E-2264
100
50
1700
Etalbond cassette Type H Width-2200mm, Length-1300mm, Depth-50mm LDPE / 4mm Double return see figure 26 4 on each side 0 3 profile reinforcements (E-2264 cut to a length of 1292mm) bonded and fastened, equally spaced vertically from the center of the cassette 4 see figure 23
E-2264
E-2264
E-2264
1300
20
51
48
100
100
50
10
2200
Corner clips
Etalbond cassette Type I Width-1400mm, Length-2400mm, Depth-50mm LDPE / 4mm Single return see figure 27 6 on each side 0 3 profile reinforcements (E-2264 cut to a length of 1392mm) bonded and fastened, equally spaced horizontally from the center of the cassette 3 profile reinforcements (20x30x2 cut to a length of 1392mm) Bonded and fastened to the upper and lower return 4 see figure 23
20x30x2 E-2264
E-2264
2400
E-2264
48
100
20x30x2
100
10 50
1400
52
Corner clips
Etalbond cassette Type J Width-1400mm, Length-2400mm, Depth-50mm LDPE / 4mm Double return see figure 26 6 on each side 6 on each side 1 profile reinforcement (E-2264 cut to a length of 1392mm) bonded and fastened, in the center of the cassette 2 profile reinforcements (20x30x2 cut to a length of 1392mm) Bonded and fastened to the upper and lower return 4 see figure 23
20x30x2
E-2264
2400
20x30x2
20
48
100
100
10 50
1400
53
ETALBOND, ETALBOND FR, and ETALBOND LIGHT Product evaluation method: The European Standard or the European Technical Approval Guideline defining the minimal requirements is not available at this time. The draft European Guideline concerning kits for external wall cladding part 1 and part 2 may be used as one of the test reference documents. Available standards: Dimensional tolerances: According to manufacturers standards (see Table 1 and Figure 1). Characteristics of the material: Appendix A3 to Standard NF EN 14509, Appendices C3 and C4 of European Technical Approval Guideline no. 16. Mechanical properties of aluminium and aluminium alloy sheets, strips and plates according to Standard EN 485-2. Chemical composition of aluminium and aluminium alloy according to Standard EN 573. Specifications for coil coated aluminium and aluminium alloy sheets and strips according to Standard EN 1396. Consistency of self-inspection of production in the factory
1.0
Quality assurance operations For the metal sheets: acceptance certificate 3.1 A according to Standard EN 10204 Dimensional inspections (length, width) Functional inspections (flatness, squareness, straightness of edges)
Frequencies At each delivery
1.1
At each change and random sampling once per shift
1.2 1.3
Dimensional inspections of cassettes and of notches (making cassettes using panels) Inspection of visual appearance Peel resistance according to Standard ASTM D 1781 or D 1876 after heat conditioning (6 hours in boiling water test on samples at ambient temperature) unchanged performance. Certified characteristics Composition Thickness or mass per unit area Peel resistance according to Standard ASTM D 1781 or D 1876 after 24 hours.
Each panel Once a month
1.4
Once a week with recording
54
ETALBOND Control Checklist
Inspection procedure Thickness of the composite panel is within tolerance. (If the thickness is more than the tolerance the properties may be considered the same, However if the thickness is less than the tolerance there may be an issue regarding static performance) Length of the composite panel is within tolerance. (If the length is out of tolerance the material may still be used for production of cassettes as long as the productivity is not affected.) Width of the composite panel is within tolerance. (If the width is out of tolerance the material may still be used for production of cassettes as long as the productivity is not affected.) Squareness of the composite panel is within tolerance. (If the squareness is out of tolerance the material may still be used for production of cassettes as long as the productivity is not affected.) Flatness of the composite panel is within tolerance. (If the flatness is out of tolerance the material may not be suitable for the production of cassettes.) Visual appearance of the composite panel is free from bumps, scratches, and other visual imperfections. (If not, the panels may need to be recycled.) Monthly peel test according to Standard ASTM D 1781 or D 1876 after heat conditioning has passed. (If the test fails the supplier should be contacted immediately, and the panels of the same batch should not be used for the production of cassettes.) Weekly peel test according to Standard ASTM D 1781 or D 1876 has passed. (If the test fails the supplier should be contacted immediately, and the panels of the same batch should not be used for the production of cassettes.)
Yes
No
2 3 4 5 6
Quality Control Manager
Date:
55
Cassette Quality Control Checklist
Inspection procedure
Yes
No
Acceptance certificate 3.1 A was received from ELVAL COLOUR (If not, contact the supplier) Thickness of the cassette is within tolerance. (If the thickness is more than the tolerance the properties may be 2 considered the same, However if the thickness is less than the tolerance there may be an issue regarding static performance) Length of the cassette is within tolerance ( 1mm). 3 (If the length is out of tolerance the material may still be used for production of cassettes as long as the productivity is not affected.) Width of the cassette is within tolerance ( 1mm). 4 (If the width is out of tolerance the material may still be used for production of cassettes as long as the productivity is not affected.) Squareness of the cassette is within tolerance. 5 (If the squareness is out of tolerance the material may still be used for production of cassettes as long as the productivity is not affected.) Flatness of the cassette is within tolerance. 6 (If the flatness is out of tolerance the material may not be suitable for the production of cassettes.) Visual appearance of the cassette is free from bumps, scratches, and 7 other visual imperfections. (If not, the panels may need to be recycled.) Notches, slots, V-grooves, are in accordance with this fabrication 8 manual. (If not, the panel may not be suitable for the production of cassettes.) The core thickness after routing V-grooves should be verified at each shift change from a random sample. The core thickness should be 9 0,3mm with a tolerance ( 0,1mm). (If samples are not in tolerance the routing machinery needs to be recalibrated and the defective samples recycled.) Accessories, fasteners, rivets, and bonding adhesives are in accordance 10 with this fabrication manual. (If not, the cassette may not be suitable for building application.) 11 Annual audit from ELVAL COLOUR
Quality Control Manager
Date:
56

Elval Colour "Fabrication Manual For Etalbond"

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Elval Colour "Fabrication Manual For Etalbond"

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FABRICATION MANUAL FOR CASSETTES Health and Safety Normal safety and health precautions practiced in any fabricating

LDPE or Fire Resistant core Adhesive layer

FABRICATION MANUAL FOR CASSETTES Edited: Sept. 12, 2011

t = 3, 4, 6mm Tolerance: +0,2mm _

L=2000-4000 Tolerance: -0/+4mm L=4001-6000 Tolerance: -0/+6mm L=6001-8000 Tolerance: -0/+10mm

Table 1. Acceptable tolerance of curvature

FABRICATION MANUAL FOR CASSETTES Edited: Sept. 12, 2011

FABRICATION MANUAL FOR CASSETTES Edited: Sept. 12, 2011

FABRICATION MANUAL FOR CASSETTES Edited: Sept. 12, 2011

FABRICATION MANUAL FOR CASSETTES Edited: Sept. 12, 2011

Figure 5. Carbide tip saw blade for cutting non-ferrous metals

Table 2. List of recommended tools

Figure 6. Routing bit

FABRICATION MANUAL FOR CASSETTES Edited: Sept. 12, 2011

Figure 7: Priciples of routing and bending

FABRICATION MANUAL FOR CASSETTES Edited: Sept. 12, 2011

Figure 8: Routing the back of the panels

2mm - 3mm 4mm 0.3mm

Panel Length "L"

FABRICATION MANUAL FOR CASSETTES Edited: Sept. 12, 2011

Figure 10: Single lower return using aluminum jigs

FABRICATION MANUAL FOR CASSETTES Edited: Sept. 12, 2011

Figure 11: Double lower return using aluminum jigs

FABRICATION MANUAL FOR CASSETTES Edited: Sept. 12, 2011

Figure 12: Reverse upper return using aluminum jigs

FABRICATION MANUAL FOR CASSETTES Edited: Sept. 12, 2011

Figure 13: Envelope corner cuts

Figure 14: Square corner cuts

FABRICATION MANUAL FOR CASSETTES Edited: Sept. 12, 2011

FABRICATION MANUAL FOR CASSETTES Edited: Sept. 12, 2011

Figure 16 MIN. 3 TIMES DIAMETER

Figure 17 MIN. 2,5 TIMES DIAMETER

FABRICATION MANUAL FOR CASSETTES Edited: Sept. 12, 2011

Traditional (not recommended)

FABRICATION MANUAL FOR CASSETTES Edited: Sept. 12, 2011

Figure 20. Reinforcement with aluminium profile E-2264

FABRICATION MANUAL FOR CASSETTES Edited: Sept. 12, 2011

Figure 21. Profile reinforcement 30x30x1,5

Figure 22. Profile reinforcement 40x40x1,5

1,5 7,5 7,5

Figure 23. Profile reinforcement 20x30x2

Figure 23a. Reinforcement angles for standard cassettes

Routing the back of the Etalbond

FABRICATION MANUAL FOR CASSETTES Edited: Sept. 12, 2011

Figure 23b. Aluminium tubes for reinforced cassettes

Routing the back of the Etalbond

FABRICATION MANUAL FOR CASSETTES Edited: Sept. 12, 2011

Figure 24a. Corner clip for 35mm cassettes

Figure 24b. Corner clip for 35mm cassettes

Aluminium rivet (5x15) Aluminium plate min. thickness 2mm

Aluminium rivet (5x15)

Aluminium plate min. thickness 2mm

Simple return (35mm)

Double return (35mm)

Figure 25b. Corner clip for 50mm cassettes

Aluminium rivet (5x15) Aluminium plate min. thickness 2mm

Aluminium plate min. thickness 2mm

Simple return (50mm)

Double return (50mm)

FABRICATION MANUAL FOR CASSETTES Edited: Sept. 12, 2011

Figure 25c. Table for slot details for 50mm cassettes

FABRICATION MANUAL FOR CASSETTES Edited: Sept. 12, 2011

19,10.2 14 200.2 10,20.2 21,3 69