Working with Duraplate® Fabrication Guidelines

Working with DuraPlate® Fabrication Guidelines

TABLE OF CONTENTS

Introduction 1

Product Description 2-7

DuraPlate Panel Specifications 2 DuraPlate Panel Attributes 3-5 Finishes and Coatings 6 Product Tolerances 6 Shipping and Packaging 7

Cutting and Machining 8-11

Shearing 8 Sawing 8 Punching 9 Drilling 10 Routing 11 Water Jet 11

Assembling 12-13

Shiplap Joints 12 Logistic Joints 12 Rivet Fasteners 12 Bolt & Nut Fasteners 12 Screw Fasteners 12 Adhesive Bonding 13 Caulking 13

Forming 14

Cleaning 15

Panel Repair 15

Material Safety Data Sheet 16-18 NOTES, CAUTIONS and WARNINGS

This manual contains Notes and Cautions in reference to working with DuraPlate material.

Notes: Provide additional information or highlights important tips throughout the manual.

Cautions: Provide notification of situations that can cause damage to machinery and tools.

Warnings: Provide alerts to situations that can cause personal injury or death.

WORKING WITH DuraPlate

Safety and Handling

Wabash National recommends safe working practices at all times. Assuring full compliance with all environmental, health, and safety laws and applicable standards and to avoid jeopardizing the environment or individual safety.

Wear appropriate personal protective equipment:

• Always wear approved eye protection around machinery and when working with DuraPlate, as well as proper ear and foot safety equipment.

• To protect hands and arms from scrapes or cuts, wear heavy abrasion-resistant gloves, as well as cut-resistant arm guards when handling DuraPlate panels.

• Wear proper respiratory protection when working in areas with high concentrations of dust, chips, and/or heat from certain fabricating operations. A half face or full face respirator, or dust mask, is recommended for any use that may cause dust or fumes.

• In situations where there is a possibility of accidental head contact, head protection should be worn. Hard hats can protect from impact as well as penetration or electrical hazards.

When using other tools and equipment in association with DuraPlate, safety is very important. Follow the manufacturer’s safety guidelines when performing any function. Use the correct tools and equipment, and use them properly. Additionally, properly maintaining tools and equipment regularly will enhance safety.

WARNING: The steel used in DuraPlate is thin and can be very sharp. When manually lifting or maneuvering a standard size DuraPlate sheet, it is advised to use at least two people. Doing so may prevent the possibility of injury, or damaging or scratching the panel.

WARNING: Do not attempt to weld DuraPlate material under any circumstances. Attempts to weld the product may result in product delamination, product failure and/or fire. Heat applied to the panel must be carefully considered and applied with caution. DuraPlate products are designed to perform in temperature ranges of -50ºF to +190ºF. INTRODUCTION

These fabrication guidelines have been developed as a resource to help designers, engineers, researchers and fabricators understand DuraPlate panel technology. The contents of this document serve as guidelines to working with DuraPlate in the most efficient and effective manner. It provides data and information to aid in current uses, new technology, as well as research and development.

Wabash first introduced DuraPlate in 1996, for use in semi-trailer sidewalls. Today, our composite materials are used in a wide range of products and markets, with multiple new offerings and materials in development.

Staffed with experts to aid in the integration of DuraPlate composite material in many applications, Wabash has extensive research and development capabilities to provide testing data to support specific customer applications. With a strong belief in protecting the Intellectual Property (IP) of Wabash National Corporation and that of its customers, a mutual nondisclosure agreement (MNDA) is used early in discussions with potential customers.

Headquartered in Lafayette, Indiana, Wabash National Corporation (NYSE: WNC) is a diversified manufacturer and North America’s leading producer of semi-trailers and liquid transportation systems. Established in 1985, the company specializes in the design and production of dry freight vans, refrigerated vans, platform trailers, intermodal equipment, liquid tank trailers, engineered products, and composite products.

Contact information: 866-877-5062 [email protected] wabashnational.com

1 PRODUCT DESCRIPTION

DuraPlate is an engineered steel and plastic composite material that has proven performance in the most demanding applications. This composite panel is comprised of two external sheets of high strength galvanized steel that are thermally Polyester Baked-on Paint bonded to each side of a high density polyethylene core. Rust Inhibiting Baked-on Primer Zinc Coating: G-90 Hot-Dip First fabricated in 1996, DuraPlate’s original application was for semi-trailers because of its strength and durability. Today, the 80,000-psi Yield Full-Hard Steel DuraPlate semi-trailer is the leader in the trucking industry, with Special Proprietary Primer Coating more than 500,000 produced in North America. The versatility Adhesive Film of DuraPlate has allowed innovation and progression into other markets, and has successfully replaced standard materials for Foamed-Plastic Core Material products, including truck bodies, swing and overhead doors, cargo trailers and portable storage units.

DuraPlate is well suited and accommodating to many products and applications because of its excellent strength-to-weight ratio and superior performance.

DuraPlate Panel Specifications DuraPlate panels are produced in a continuous process to standard specifications in a dedicated state-of-the-art production facility. The standard weights, measurements and properties of DuraPlate are provided below. Wabash National has the flexibility to provide custom specifications upon request with minimum quantity requirements.

Standard Specifications Panel Thicknesses General Steel Galvanized 80,000 psi yield Polyester baked-on finish 2.5 mm Core High-density polyethylene 4.0 mm Panel Thickness 2.5 mm (.098 in) 6.0 mm 4 mm (.157 in) 7.5 mm 6 mm (.236 in) 7.5 mm (.295 in) 10.0 mm 10.0 mm (.394 in) 13.0 mm (.511 in) 13.0 mm Widths 48 in 49 in

Length 130 in (standard)

2 DuraPlate Panel Attributes: 2.5–4.0 mm Thickness Product Attributes Typical engineering properties for DuraPlate® composite material, using a high-density polyethylene core between two sheets of steel. (1)

2.5 mm (.013”) 4.0 mm (.013”) 4.0 mm (.016”)

U.S. METRIC U.S. METRIC U.S. METRIC

Thickness 0.098 in 2.5 mm 0.157 in 4.0 mm 0.158 in 4.0 mm

Maximum Width 48 in 1,219 mm 48 in 1,219 mm 49 in 1,245 mm

Maximum Length 130 in 3,302 mm 130 in 3,302 mm 130 in 3,302 mm

(2) Weight 1.408 lb/ft² 6.874 g/m² 1.602 lb/ft² 7.822 g/m² 1.828 lb/ft² 8.925 g/m²

1,335 1 X 10³ 4,040 45.7 X 10³ 4,718 53.3 X 10³ Stiffness (EI) 4 4 4 lbf▪in²/in MPa▪cm /m lb▪in²/in MPa▪cm /m lb▪in²/in MPa▪cm /m

Tensile Yield of 80,000 lb/in² 551.6 MPa 80,000 lb/in² 551.6 MPa 80,000 lb/in² 551.6 MPa Laminate

Puncture Resistance 1,238 lbf 5,507 N 1,287 lbf 5,725 N 1,636 lbf 7,277 N 0.5 in Diameter Ball

Puncture Resistance 3,529 lbf 15,698 N 3,004 lbf 13,362 N 3,369 lbf 14,986 N 6 in Spade

Coefficient of Thermal Expansion at Low 86.071 154.93 74.071 133.33 78.071 140.53 Temperature µin/in▪ºF µm/m▪ºC µin/in▪ºF µm/m▪ºC µin/in▪ºF µm/m▪ºC (3) (ASTM E831-06) Coefficient of Thermal Expansion at High 252.218 453.99 246.218 443.19 249.218 448.59 Temperature µin/in▪ºF µm/m▪ºC µin/in▪ºF µm/m▪ºC µin/in▪ºF µm/m▪ºC (3) (ASTM E831-06)

Corrosion Pass Pass Pass (4) (ASTM B117) 1,000 hrs 1,000 hrs 1,000 hrs

Acoustical Properties 26 STC 27 STC 28 STC (ASTM E90-04)

Surface Burning (5)(6) Class B Class B Class B (ASTM E84)

.048 .087 ..082 R-value .845 x 10¯² K- 1.532 x 10¯² 1.440 x 10¯² Hr-ft²-deg Hr-ft²-deg Hr-ft²-deg m²/W K-m²/W K-m²/W (ASTM C177) F/BTU F/BTU. F/BTU

(1) All properties based on 0.013 and .016 in., 80 ksi steel skin material. (2) Weights based on 20% foam core. (3) Coefficient of Linear Thermal Expansion (CLTE) extrapolated from tests on 6 mm, 7.5 mm, and 13 mm. (4) Pass without blisters or creep. (5) Class B rating represents Flame Spread Index 26-75; Smoke Developed Index ≤ 450. (6)(6) Can achieve achieve a Class a Class A rating A rating by capping by capping off edges offof panels edges to ofcapture panels core to. capture core. ©2008 Wabash National Corporation. All rights reserved. No portion of these materials may be reproduced, stored, or transmitted without prior approval from Wabash National. Wabash National reserves the right to make changes at any time without notice, as we continuously improve our products. This document does not provide a warranty; but rather, is an effort to explain the characteristics of DuraPlate® material, as we deem to be accurate. Wabash National shall not have any responsibility or liability for any damages resulting from such use. DuraPlate® is a registered trademark owned by Wabash National, L.P. 3

Revision C, Jul. 2014 Wabash National Corporation 765.771.5300 1000 Sagamore Pkwy S. Lafayette, IN 47905 http://www.wabashnational.com http://www.duraplateproducts.com DuraPlate Panel Attributes: 6.0–7.5 mm Thickness Product Attributes Typical engineering properties for DuraPlate® composite material, using a high-density polyethylene core between two sheets of steel. (1)

6.0 mm (.016”) 7.5 mm (.013”) 7.5 mm (.016”)

U.S. METRIC U.S. METRIC U.S. METRIC

Thickness 0.236 in 6.0 mm 0.295 in 7.5 mm 0.295 in 7.5 mm

Maximum Width 49 in 1,245 mm 49 in 1,245 mm 49 in 1,245 mm

Maximum Length 130 in 3,302 mm 130 in 3,302 mm 130 in 3,302 mm

(2) Weight 2.065 lb/ft² 10.082 g/m² 2.328 lb/ft² 11.366 g/m² 3.348 lb/ft² 16.346 g/m²

11,712 132.2 X 10³ 16,340 184.4 X 10³ 19,269 217.5 X 10³ Stiffness (EI) 4 4 4 lb▪in²/in MPa▪cm /m lb▪in²/in MPa▪cm /m lb▪in²/in MPa▪cm /m

Tensile Yield of 80,000 lb/in² 551.6 MPa 80,000 lb/in² 551.6 MPa 80,000 lb/in² 551.6 MPa Laminate

Puncture Resistance 1,855 lbf 8,251 N 1,878 lbf 8,353 N 2,175 lbf 9,675 N 0.5 in Diameter Ball

Puncture Resistance 5,500 lbf 24,465 N 4,794 lbf 21323 N 6,237 lbf 27,744 N 6 in Spade

Coefficient of Thermal Expansion at Low 68.583 123.45 62.67 112.8 61.4667 110.64 Temperature µin/in▪ºF µm/m▪ºC µin/in▪ºF µm/m▪ºC µin/in▪ºF µm/m▪ºC (3) (ASTM E831-06) Coefficient of Thermal Expansion at High 244.522 440.14 239.5 431.1 241.0 433.80 Temperature µin/in▪ºF µm/m▪ºC µin/in▪ºF µm/m▪ºC µin/in▪ºF µm/m▪ºC (3) (ASTM E831-06)

Corrosion Pass Pass Pass (4) (ASTM B117) 1,000 hrs 1,000 hrs 1,000 hrs

Acoustical Properties 26 STC 27 STC 27 STC (ASTM E90-04)

Surface Burning (5) Class B Class A Class A (ASTM E84)

.137 .163 .162 R-value 2.414 x 10¯² 2.344 x 10¯² 2.855 x 10¯² Hr-ft²-deg Hr-ft²-deg Hr-ft²-deg K-m²/W K-m²/W K-m²/W (ASTM C177) F/BTU F/BTU. F/BTU

(1) All properties based on 0.013 and .016 in., 80 ksi steel skin material. (2) Weights based on 20% foam core. (3) Approximate transition temperature for which the Coefficient of Linear Thermal Expansion (CLTE) begins to change significantly: 6 mm = 131ºF; 7.5 mm = 113ºF; 13 mm = 108ºF (4) Pass without blisters or creep. (5) Class B rating represents Flame Spread Index 26-75. Smoke Developed Index ≤ 450. Class A rating represents Flame Spread Index ≤ 25.

©2008 Wabash National Corporation. All rights reserved. No portion of these materials may be reproduced, stored, or transmitted without prior approval from Wabash National. Wabash National reserves the right to make changes at any time without notice, as we continuously improve our products. This document does not provide a warranty; but rather, is an effort to explain the characteristics of DuraPlate® material, as we deem to be accurate. Wabash National shall not have any responsibility or liability for any damages resulting from such use. DuraPlate® is a registered trademark owned by Wabash National, L.P. 4

Revision C, Jul. 2014 Wabash National Corporation 765.771.5300 1000 Sagamore Pkwy S. Lafayette, IN 47905 http://www.wabashnational.com http://www.duraplateproducts.com DuraPlate Panel Attributes: 10.0–13.0 mm Thickness Product Attributes Typical engineering properties for DuraPlate® composite material, using a high-density polyethylene core between two sheets of steel. (1)

10.0 mm (.016”) 12.9 mm (.013”) 13.0 mm (.016”)

U.S. METRIC U.S. METRIC U.S. METRIC

Thickness 0.394 in 10.0 mm 0.510 in 12.9 mm 0.510 in 12.954 mm

Maximum Width 49 in 1,245 mm 49 in 1,245 mm 49 in 1,245 mm

Maximum Length 130 in 3,302 mm 130 in 3,302 mm 130 in 3,302 mm

(2) Weight 2.818 lb/ft² 13.76 kg/m² 3.125 lb/ft² 15.26 kg/m² 3.348 lb/ft² 16.35 kg/m²

35,733 403.3 X 10³ 56,748 640 X 10³ 65,053 734.2 X 10³ Stiffness (EI) 4 4 4 lb▪in²/in MPa▪cm /m lb▪in²/in MPa▪cm /m lb▪in²/in MPa▪cm /m

Tensile Yield of 80,000 lb/in² 551.6 MPa 80,000 lb/in² 551.6 MPa 80,000 lb/in² 551.6 MPa Laminate

Puncture Resistance 2464 lbf 10960 N 2,581 lbf 9,675 N 2,752 lbf 12,242 N 0.5 in Diameter Ball

Puncture Resistance 8213 lbf 36533 N 6,226 lbf 23,337 N 8,502 lbf 37,819 N 6 in Spade

Coefficient of Thermal Expansion at Low 59.042 106.28 53.34262 96.017 56.6167 101.91 Temperature µin/in▪ºF µm/m▪ºC µin/in▪ºF µm/m▪ºC µin/in▪ºF µm/m▪ºC (3) (ASTM E831-06) Coefficient of Thermal Expansion at High 235.945 424.70 233.3134 419.96 230.889 415.6 Temperature µin/in▪ºF µm/m▪ºC µin/in▪ºF µm/m▪ºC µin/in▪ºF µm/m▪ºC (3) (ASTM E831-06)

Corrosion Pass Pass Pass (4) (ASTM B117) 1,000 hrs 1,000 hrs 1,000 hrs

Acoustical Properties 27.5 STC 27 STC 28 STC (ASTM E90-04)

Surface Burning (5) Class A Class A Class A (ASTM E84)

.191 .217 .219 R-value 3.366 x 10¯² 3.824 x 10¯² 3.859 x 10¯² Hr-ft²-deg Hr-ft²-deg Hr-ft²-deg K-m²/W K-m²/W K-m²/W (ASTM C177) F/BTU F/BTU. F/BTU

(1) All properties based on 0.013 and .016 in., 80 ksi steel skin material. (2) Weights based on 20% foamed core. (3) Approximate transition temperature for which the Coefficient of Linear Thermal Expansion (CLTE) begins to change significantly: 6 mm = 131ºF; 7.5 mm = 113ºF; 13 mm = 108ºF (4) Pass without blisters or creep. (5) Class B rating represents Flame Spread Index 26-75. Smoke Developed Index ≤ 450. Class A rating represents Flame Spread Index ≤ 25.

Revision C, Jul. 2014 Wabash National Corporation 765.771.5300 1000 Sagamore Pkwy S. Lafayette, IN 47905 http://www.wabashnational.com http://www.duraplateproducts.com Finishes and Coatings STANDARD STEEL DuraPlate finishes and coatings offer excellent aesthetics and performance. COATINGS

Standard galvanized coating for panel skins is G40 (interior) and G90 (exterior), G40 interior depending on application and placement of the panel. G90 exterior The coating process begins with the cleaning of the metal surface to remove any mill- related contaminants. Further treatments are applied to improve paint adherence and product performance. The surface is then primed and the finish coat is applied via a roll-coating process for superior coverage.

The polyester coil coatings offer durability and are highly resistant to surface marking, marring and staining. The coating is resistant to humidity, as well as to salts and corrosives. The polyester coating also offers superior surface hardness while retaining flexibility. The surface is also enhanced to resist any chalking or fading due to UV exposure. Surface contaminants may be easily cleaned with mild solutions or conventional detergents.

Standard DuraPlate panels are white and have an superior-quality finish. Paint needed to match our standard white coil coated polyester paint can be purchased from Custom Aerosol (www.custom-aerosol.com) using paint code ADS 3HW76160 to match PPG coil coated paint code #3HW76160.

Note: The coil coated paint dry film thickness is 1.0-1.25 mils thick so sometimes matching may be diffucult because of the higher dry film thickness one gets when spray painting with a wet paint. A flattener may be needed to get the same gloss level.

For more information on the technical properties of standard PPG Truform Coating, go to www.ppg.com.

Product Tolerances PANEL FLATNESS Wabash National has built a solid reputation by producing high- PANEL SQUARENESS quality products. DuraPlate products are manufactured utilizing state-of-the-art equipment in a continuous panel process, resulting in nominal variation to production tolerances. Disclaimer: These are typical tolerances. See final print for your product tolerances.

Thickness: PANEL LENGTH The tolerance for thickness, regardless of core depth, is +/- .020”. PANEL WIDTH

Length: The length tolerance of a finished panel is +/- 0.125”. EDGE ALIGNMENT Width: PANEL THICKNESS Width tolerance of a panel is +0.25” / -0” for logistics edge. For shiplap seam panels, width tolerance is +/-.062”.

Squareness: Diagonal measurements on the face of the panel may not differ by more than 0.1875”.

Skin Alignment: Tolerance for a finished panel is -0.0625”, +0.03125”.

Flatness: Camber or lateral bow is 0.016” per 8’. and transverse bow is 0” +/- 0.125” in 49”.

6 Shipping and Packaging Standard packaging is designed to protect the panels during material movement and shipment. DuraPlate products are custom packaged based on the nature of the contents and the destination of the order.

Fork lifts used in transporting products must be capable of safely carrying the load. The approximate maximum weight of a load is 5,000 lbs. It is recommended that pallets should be approached with a forklift from the long axis. Caution should always be taken not to misjudge the center point of the lift. Heavy contact between the lift and the pallet may result in damage to the edges of the product. This is especially true for shiplap products, in which the steel edges are susceptible to bending and deforming. If it is necessary to load or unload a pallet from the narrow edge of the pallet, the load should be placed on a firm, flat surface as soon as possible and the forklift then repositioned to pick up the load from the long edge as soon as possible.

DuraPlate products pass a quality inspection prior to leaving the manufacturing facility. Most domestic shipments are placed on a flatbed or in a conventional van trailer. International shipments are either loaded into containers at the DuraPlate manufacturing site or shipped to a designated location for loading into containers. All necessary international paperwork accompanies the shipment.

Wabash Composites has carefully screened various carriers and can provide preferred shippers. Packaging and shipping charges may accompany an order, based on order quantity as well as any specialized packaging requirements.

Note: Products are subject to damage if not handled properly by shippers or customer staff.

7 CUTTING AND MACHINING

Shearing Shearing of DuraPlate panels is best accomplished by using a hydraulic bow-tie shear.CUTTING Although a mechanical AND shearMACHINING may be used, the hydraulic unit provides a smoother, cleaner cut. The higher impact speed of the mechanicalShearing shear tends to tear or break the DuraPlate product, whereas the slowerShearing impact ofspeed DuraPlate of a panelshydraulic is best shear accomplished is less aggressive, by using a hydraulicproviding a better cut.bow-tie shear. Although a mechanical shear may be used, the hydraulic unit provides a smoother, cleaner cut. The higher impact speed of the mechanical shear tends to tear or break the DuraPlate product, whereas Use of a shearthe slower tends impact to wipe speed the of galvanizeda hydraulic shear coating is less from aggressive, the steel providing and a smear it ontobetter the cut. cut edge. This aids in corrosion prevention. When shearing less than 1” from a panel, a wrap-around effect, in which the short sectionUse beingof a shear removed tends to folds wipe overthe galvanized the shear coating blade, from is likelythe steel to andoccur. For these instances,smear it onto a thesaw, cut router, edge. This or wateraids in corrosionjet is recommended. prevention. When shearing less than 1” from a panel, a wrap-around effect, in which the short section SHEARING DURAPLATE: BLADE CLEARANCE being removed folds over the shear blade, is likely to occur. For these Proper bladeinstances, gap is a important saw, router orwhen water shearing jet is recommended. DuraPlate. On non- Center Blade set at 0.001” composite metal materials, the blade gap would typically be set up to Center Blade ends at 0.002” 10% of the thickness of the material; however, this rule of thumb does Proper blade gap is important when shearing DuraPlate. On non-composite SHEARING DuraPlate: metal materials, the blade gap would typically be set up to 10% of the * Use these settings only when shearing not hold true for DuraPlate. Since the core offers virtually no resistance BLADE CLEARANCE to the shear,thickness the clearance of the material; used however,within thethis manufacturingrule of thumb does process not hold istrue DuraPlate, not on steel only. 0.001” - 0.002”.for DuraPlate. The centerSince the of core the offersblade virtually is set atno 0.001”resistance and to thethe shear, ends Center Blade set at 0.001” the clearance used within the manufacturing process is 0.001”-0.002”. at 0.002”. Although these clearances work well with DuraPlate, they Center Blade ends at 0.002” The center of the blade is set at 0.001” and the ends at 0.002”. Although CAUTION: Excessive pressure should notthese be used clearances on steel work alone. well with Setting DuraPlate, blade they clearances should not bebased used onon * Use theseon settingsthe panel only will result in the width steelof the alone. panel Setting rather blade than clearances the combined based on widththe width of ofthe the steel panel skins when shearingmarring DuraPlate, the finish or denting will result ratherin wrapping than the combinedthe lower width skin of over the steelthe lowerskins will shear. result Gibsin wrapping should the not on steelthe only.panel. be set at thelower manufacturer’s skin over the lower recommendations. shear. Gibs should be set at the manufacturer’s recommendations. There are other precautionary factors to consider. Any panel movement There are other precautionary factors to consider. Any panel movement or or shiftingshifting during during fabrication fabrication may may cause cause damage damage toto the the panel. panel. Use Use of lower of lower pressurepressure pneumatic pneumatic hold hold downs, or or a plywooda plywood shim shim between between the hold the down hold downand and the the panel, panel, may mayprevent prevent damage. damage. When changing When or changing rotating blades, or it rotating blades,is important it is importantto thoroughly to clean thoroughly both the blades clean andboth the the machine blades before and CAUTION: Excessive the machinereinstalling. before Withreinstalling. such tight Withclearances, such anytight debris clearances, will prevent any obtaining debris pressure on the panel will preventproper obtaining blade clearance. proper blade Also, care clearance. should be Also, taken care to avoid should any damage be will result in marring to the surface of the panels by ensuring that the work area, shear bed, and taken to avoid any damage to the surface of the panels by ensuring that the finish or denting conveyors are clean and free of cutting debris. the work area, shear bed, and conveyors are clean and free of cutting the panel. debris. Sawing Sawing Certain applications, such as lower volume production, out-of-position cuts, Certain applications,or cuts removing such less as thanlower 1” willvolume best be production, served by use out-of-position of a saw. cuts, or cuts removing less than 1” will best be served by use of a saw. A reciprocating saw may be used for rough cuts. Finish cutting using a reciprocating saw is not recommended. A sabre saw must have a A reciprocatinghigh quality saw metalmay beblade. used Cuts for started rough from cuts. an edge Finish require cutting no special using a reciprocatingpreparation. saw is However, not reccommended. for cuts starting inside A sabre the perimeter,saw must a havestarter a hole high qualityshould metal be blade.drilled. Cuts started from an edge require no special preparation. However, for cuts starting inside the perimeter, a starter hole shouldMaintaining be drilled. a sharp blade will produce a clean cut at the edges. A 40-tooth carbide tip blade is recommended. Maintaining a sharp blade will produce a clean cut at the edges. A 40 If painted, the surface coat may chip when a saw is used. To minimize this tooth carbidechipping, tip blade tape applied is recommended. along the edges to be cut is recommended. The taped edge will minimize chipping and reduce the potential for scratches If painted,caused the surface by the saw.coat may chip when a saw is used. To minimize this chipping, tape applied along the edges to be cut is recommended. The taped Useedge of awill saw minimize will wipe some chipping of the andgalvanized reduce coating the potential onto the cut for edge scratches causedto aid in preventingby the saw. corrosion. Wabash Composites recommends using a Milwaukee metal cutting saw Model #6370-20 with #48-40-4515 (or 4520) 42-tooth metal cutting blade for best results.

8 Sawing cont. Use of a saw will wipe some of the galvanized coating onto the cut edge to aid in preventing corrosion. The DuraPlate Products Group recommends using a Milwaukee metal cutting saw Model # 6370-20 for the best results.

Punching CertainPunching applications may require the panels to be punched. Punching offers aCertain cost effective applications method may require for creating the panels holes, to be considering punched. Punching equipment availability.offers Additionala cost effective attributes method offor punchingcreating holes, include considering speed, reduction in scratchesequipment caused availability. by drill Additionalshavings, attributesand the abilityof punching to create include a variety of shapedspeed, holes. reduction Specific in scratches tooling is caused required by drill to ensureshavings, a qualityand the punch is created.ability It to is create recommended a variety of to shaped use a holes. TiN coating Specific on tooling the punch is required tip to reduceto wear ensure and a qualitygalling. punch A hollow is created. or concave It is recommended tip has proven to use to a aid and guide theTiN punchcoating throughon the punch the material.tip to reduce Use wear of anda concave galling. tipA hollow will also increaseor toolingconcave life. tip has proven to aid and guide the punch through the material. Use of a concave tip will also increase tooling life.

To ensureTo ensure proper proper cutting cutting of the of thelower lower steel steel skin, skin, care care must must be taken to ensureto ensure the dies the remaindies remain sharp sharp and and tolerances tolerances are are kept kept tight. tight. As As the the punch punchcontacts contacts the upper the upper steel steel skin, skin, the the plastic plastic core core deforms deforms underunder pressurepressure and creates and creates a hydraulic a hydraulic force force on onthe the lower lower skin, skin, forcing forcing thethe lower skinlower through skin through the die.the die. This This is unique is unique to to composite composite materials.materials. As As such, thesuch, dies the must dies mustbe maintained be maintained in goodin good condition condition or or holehole qualityquality will suffer.will suffer. It should It should also alsobe notedbe noted that that the the top top cutting cutting surfacesurface of of the die shouldthe die be should flush withbe flush the diewith holderthe die toholder prevent to prevent any markingsany markings on the paint. onAlignment the paint. ofAlignment the punch of the to punch the die to isthe also die critical;is also critical; otherwise, distortionotherwise, of the distortionhole may of be the created. hole may While be created. a close While punch a close to die punch to die clearance is crucial, the punch or die may chip if they clearance is crucial, the punch or die may chip if they come in contact. come in contact. The chipped die will cause more hanging chads The chippedand additional die will side cause loading more of hanging the punch. chads With andproper additional alignment side and loadingsharp of the dies, punch. chads With and burrs proper are alignmentkept to a minimum. and sharp dies, chads and burrs are kept to a minimum. Stripping force is also an important consideration. Failure to ensure Strippingthe forcedie is clearis also will an result important in poor punchconsideration. quality. The Failure punch tomust ensure the die is clearenter will the dieresult to ain sufficient poor punch depth quality. to ensure The the punch slug is mustclear ofenter the the die to adie sufficient before the depth next panelto ensure is punched. the slug A slight is clear depression, of the die or dimple,before the next paneloccurs is punched.where the punch A slight contacts depression, the upper or steel dimple, skin. occursThis conical where the punchshape contacts increases the the upper friction steel between skin. the This sides conical of the shape punch increases and the frictionthe between metal, thereby the sides raising of the the punchamount andof force the necessarymetal, thereby, to strip raisingor pull the metal. After the punch is retracted, the plastic relaxes back the amount of force necessary to strip or pull the metal. After the into the plastic core around the hole area, resulting in a hole slightly punch smalleris retracted, than the the diameter plastic ofrelaxes the punch. back into the plastic core around the hole area, resulting a hole slightly smaller than the diameter of the punch.The occurrence when the diameter of the hole shrinks slightly after punching is referred to as “spring back.” In some cases, the The occurrenceshrinkage whenwill increase the diameter the force ofrequired the hole to insert shrinks rivets, slightly bolts afteror punchingscrews. is referred To prevent to asthis, “spring a larger back”. hole may In besome punched. cases, Other the shrinkage options will increaseare to doublethe force cycle required punch the to productinsert rivets, after the bolts, spring or backscrews. is To preventcomplete, this, a larger or to drillhole out may the bepunched punched. hole. Other options are to double cycle punch the product after the spring back is complete, or to drill outThe the unique punched composition hole. of DuraPlate allows the user to ignore certain standard punching rules. For example, the rule of thumb that a hole cannot be punched when its diameter is less than the The uniquethickness composition of material of does DuraPlate not apply. allows This isthe true user because to ignore the core certain standardprovides punching minimal rules. resistance For example, to the punch. the rule Further, of thumb the rule that that a hole cannot10% be punched part thickness when equals its diameter punch clearance is less than to die the clearance thickness is not of materialapplicable. does not apply. This is true because the core provides minimal resistance to the punch. Further, the rule that 10% part thickness equals Avoidpunch any clearance panel movement to die clearance or shifting isduring not applicable. fabrication. Too much pressure on the panel will result in marring the finish or denting 11 the panel. Pneumatic hold downs set to the proper pressure or a plywood shim will minimize potential damage to the panel.

9 Drilling DRILLING INFORMATION Drilling of DuraPlate is an option that is frequently used to create or Bit: R5 sharpened to 118º enlarge holes. Drill Speed: 2500 RPM Coated drill bits have proven to perform better than standard jobber bits. Most standard bits have a black coating that is cheap to apply, but is also porous. This results in buildup on the bit causing it to overheat. The recommended bit for DuraPlate applications has a tip coating that resists buildup.

Areas of concern while drilling DuraPlate should be noted. Negative results may occur if drill bit is dull or spindle RPM is too high. The recommended drill bit has a sharper point angle. The standard drill bit used is a R5 bit, sharpened to 118º.

For best hole quality, drill pressure should be regulated and constant. Drill RPM should be set at 2500 RPM. Excessive speed and/or pressure can also result in overheating the core and reduced bit life. Controlled feed rate and pressure will produce a clean hole and reduce burrs. This may be regulated by use of an air pressure regulator valve, flow control valve and/or shock absorber.

In cases where an automatic feed drilling machine is used, care should be taken to reduce the impact the drill bit makes as it comes in contact with the DuraPlate and to control the feed rate. Excessive feed rates as well as a moderately hard impact with the drill bit to the DuraPlate could result in poor quality, including holes out of specification, hole distortion, burrs left around the hole and/or chipped drill bits. To control impact and speed of the drill box as it moves towards the DuraPlate, it is recommended to use a pneumatic flow control valve and an adjustable shock absorber on the drill.

Care should be taken to minimize drill shavings buildup on the drill bit. The shavings on the bit will scratch the paint of the DuraPlate if allowed to gather. Shavings should be removed as they accumulate. One method used with success for manual drilling has been to wrap the upper half of the bit with tape, preventing the material from adhering to the grooves, thereby keeping the drill bit free of shavings.

The drill bit chuck should never come into contact with the DuraPlate surface because it will damage the finish. Furthermore, in a stacked drilling process, the materials should be clamped tightly together to avoid shaving accumulation between the objects being drilled. Failure to do this will result in marred surfaces, poor quality of the drilled hole, and holes drilled outside of specifications. Unlike punching, there is no deformation of the surface around the hole inherent to the process. The hole can be drilled to size for the rivet, bolt or screw, since there is no spring back with drilled holes.

10 Routing Routing offers a high speed process to mark the DuraPlate for drilling or sawing,Routing or to cut a panel. The router may also be used to score a panel for bending or forming. In this instance, scoring a panel refers Routing offers a high-speed process to mark the DuraPlate for drilling or to cutting the surface steel from one surface side of the panel and 90º90 -° - 105105º° sawing, or to cut a panel. The router may also be used to score a panel the majority of the core, creating a groove. It is recommended that for bending or forming. In this instance, scoring a panel refers to cutting a minimumthe surface of 1/32” steel offrom core one is surface left for side strength of the paneland stability,and the majority and the of remainingthe core, steel creating skin kept a groove. intact. It isThis recommended also aids in that keeping a minimum the bend of 1/32” radiusof constant core is left and for smooth.strength and stability, and the remaining steel skin kept intact. This also aids in keeping the bend radius constant and smooth. ApplicationPossible will routing determine tool: Amana the bit #45749 speed, from depth, Tools andToday. type of bit DuraPlateDURAPLA TEPanel PANEL .047”.047” selected. The desired dimensions and geometry of the formed radius will determineApplication the will width determine and thedepth bit speed, of the depth cut. and type of bit selected. The desired dimensions and geometry of the formed radius will determine Waterthe Jet width and depth of the cut. A water jet cutter is an effective tool to cut DuraPlate. Water jet applicationsWater Jetuse a jet of water at high velocity and pressure. Additives, such as garnet, can assist in this process. A water jet cutter is an effective tool to cut DuraPlate. Water jet applications use a jet of water at high velocity and pressure. Additives, Cuts started from an edge require no special preparation. However, such as garnet, can assist in this process. for cuts starting inside the perimeter, a water jet starter hole should be drilled.Cuts started from an edge require no special preparation. However, for cuts starting inside the perimeter, a water jet starter hole should be drilled. The following parameters have produced good results and are intended to serveThe as following a starting parameters point, noting have produced that different good results water and jets are may intended respondto serve to different as a starting parameters. point, noting that different water jets may respond to different parameters. Cutting speed is 45” per minute on 13.0 mm DuraPlate and 50” per minuteCutting on 6 speedmm panels. is 45” per Use minute 60,000 on 13.0lbs pressure mm DuraPlate for either and 50” thickness. per minute The wateron 6 mmjet usespanels. 3/4 Use lbs 60,000 per minute lbs of pressureto accomplish for either the thickness. cuts. A The water jet uses 3/4 lbs per minute to accomplish the cuts. A skimmer may skimmer may be required to remove floating core material that builds be required to remove floating core material that builds up on the surface. up on the surface. Pump obstruction may result if the build-up is not Pump obstruction may result if the buildup is not removed. SPEED FOR CUTTING DuraPlate removed. SPEED FOR CUTTING DURAPLATE The kerf of the cut is ~.065” for 13.0 mm and 6.0 mm. The edge is ~90º 13.013.0 mm mm = = 45” 45” per per min min The kerfto theof theDuraPlate cut is surface.~.065” The for steel13.0 does mm notand roll 6.0 as mm. found The with edge shearing is 6.06.0 mm mm = = 50” 50” per per min min ~90º orto punching, the DuraPlate consequently, surface. no The wiping steel of doesthe galvanized not roll as coating found occurs. with shearingTherefore, or punching, it is recommended consequently, that edgesno wiping not be of left the exposed. galvanized coating occurs. Therefore, it is recommended that edges not be left exposed.The painted surface of the panel adjacent to the cut is abraded ~.018” on both sides of the cut. The painted surface of the panel adjacent to the cut is abraded ~.018” on both sides of the cut.

11 ASSEMBLINGASSEMBLING ShiplapASSEMBLING Joints ShiplapASSEMBLINGShiplap Joints jointsJoints have exposed edges of steel 1” wider than the core. TheseShiplap steel joints edges have may exposed be joined edges by of overlapping, steel 1” wider by varyingthan the the core. inside ShiplapShiplap joints Jointshave exposed edges of steel 1” wider than the core. These steel andThese outside steel edges panel mayskins. be Forjoined some by applications, overlapping, oneby varying shiplap the edge inside may edgesShiplap may be joints joined have by overlapping,exposed edges by varyingof steel the1” widerinside thanand outsidethe core. panel beand sheared outside off panel so that skins. there For issome one flushapplications, edge, (e.g. one for shiplap the start edge of may a skins.These For some steel applications,edges may be one joined shiplap by overlapping,edge may be bysheared varying off the so insidethat there wallbe sheared assembly). off so that there is one flush edge, (e.g. for the start of a is oneand flush outside edge panel(e.g., forskins. the Forstart some of a applications,wall assembly). one shiplap edge may wall assembly). be sheared off so that there is one flush edge, (e.g. for the start of a The shiplap may or may not have an offset. With an offset along the The shiplapwall assembly). may or may not have an offset. With an offset along the length of a lengthThe shiplap of a panel,may or when may notjoined have to anthe offset. opposite With shiplap, an offset a smoother along the panel, when joined to the opposite shiplap, a smoother surface is created. surfacelength of is acreated. panel, when joined to the opposite shiplap, a smoother The shiplap may or may not have an offset. With an offset along the surface is created. length of a panel, when joined to the opposite shiplap, a smoother Logistic Joints surface is created. LogisticTheLogistic flush Joints Joints edge with logistics panel allows for two panels to come close The flushtoThe each flush edge other edge with without logisticswith logistics touching. panel panel allows Designed allows for two for for panels two use panels primarilyto come to comewithinclose toclose the each Logistic Joints ShiplapBonded Joint Shiplap Joint othertransportationto without each othertouching. without industry, Designed touching. logistic for usepanels Designed primarily are usedfor within use in conjunctiontheprimarily transportation within with the The flush edge with logistics panel allows for two panels to come close Shiplap Joint industry,logistictransportation logistic strips. panels Anindustry, innerare used andlogistic in outer conjunction panels logistic are with stripused logistic joins in conjunction adjacent strips. An panels. with inner to each other without touching. Designed for use primarily within the and outerThroughlogistic logistic strips. the stripuse An ofjoins inner logistic adjacent and strips, outer panels. panelslogistic Through are strip held joins the secure use adjacent of and logistic fixed,panels. strips, and Shiplap Joint transportation industry, logistic panels are used in conjunction with panelscargoThrough are heldcan the besecure useheld of and free logistic fixed, from strips, movementand cargo panels canwith are be heldcargo held secure freetie-downs. from and fixed,movement and logistic strips. An inner and outer logistic strip joins adjacent panels. with cargocargo tie-downs.can be held free from movement with cargo tie-downs. Through the use of logistic strips, panels are held secure and fixed, and An offset may or may not be produced along the length of the panel to cargo can be held free from movement with cargo tie-downs. An offsetprovideAn offset may a or maysmooth, may or not may flat be not surface.produced be produced along thealong length the oflength the panel of the to panel provide to a provide a smooth, flat surface. smooth,An offsetflat surface. may or may not be produced along the length of the panel to Rivet Fasteners provide a smooth, flat surface. RivetingRivet Fasteners panels is a popular method to assemble components. This methodRiveting ispanels well establishedis a popular and method cost-effective to assemble with components. predictable results. This RivetRivet Fasteners Fasteners method is well established and cost-effective with predictable results. RivetingRiveting panels panels is a popular is a popular method method to assemble to assemble components. components. This method This When selecting the type of rivet, surface material should be taken into is wellmethod established is well and established cost-effective and cost-effectivewith predictable with results. predictable Rivets canresults. be consideration.When selecting Both the typesolid of and rivet, tubular surface rivets material are commonly should be used taken as intowell aluminum buck rivets or pull rivets. asconsideration. blind rivet applications Both solid and for interiortubular surfaces.rivets are commonlyRivet patterns used are as either well When selecting the type of rivet, surface material should be taken into punchedas blind rivet or drilled applications as the situationfor interior requires. surfaces. 3/16” Rivet or patterns 1/4” holes are are either Logistic Joint Whenconsideration. selecting the typeBoth of solid rivet, and surface tubular material rivets shouldare commonly be taken used into as well consideredpunched or standard,drilled as althoughthe situation variations requires. are 3/16”available or 1/4” based holes on theare LogisticLogistic Joint Joint consideration.as blind rivet Both applications solid and tubular for interior rivets surfaces.are commonly Rivet used patterns as well are as either blind project.considered Two standard, rows of although1/4” rivets variations on 1 ½” centersare available is standard based practiceon the in Logistic Joint rivet applicationspunched or drilledfor interior as the surfaces. situation Rivet requires. patterns 3/16” are either or 1/4” punched holes are or semi-trailerproject. Two manufacturing. rows of 1/4” rivets on 1 ½” centers is standard practice in drilledconsidered as the situation standard, requires. although 3/16” variations or 1/4” holes are areavailable considered based standard, on the semi-trailer manufacturing. althoughproject. variations Two rows are available of 1/4” rivetsbased on on 1 the ½” project. centers Two is standard rows of 1/4”practice rivets in Bolts and Nut Fasteners semi-trailer manufacturing. on 1 ½”ThisBolts centers method and Nutis isstandard tested,Fasteners cost-effective,practice in semi-trailer and predictable. manufacturing. BoltsThis method are usually is tested, used tocost-effective, mount the panel and predictable. to the frame in an Bolts and Nut Fasteners application.Bolts are usually Rivets used and to bonding mount the are panelmore tocommonly the frame used in an when This method is tested, cost-effective, and predictable. Boltsjoiningapplication. and Nut panels Fasteners Rivets together. and bonding are more commonly used when Bolts are usually used to mount the panel to the frame in an joining panels together. This methodapplication. is tested, Rivets cost-effective and bonding and are predictable. more commonly Bolts areused usually when used to As with rivets, holes are punched or drilled and are prepared to accept mountjoining the panel panels to thetogether. frame in an application. Rivets and bonding are more commonlystandardAs with used rivets, bolts. when holes Choice joining are of panelspunched bolts together.is basedor drilled on requirements.and are prepared to accept standard bolts. Choice of bolts is based on requirements. As with rivets, holes are punched or drilled and are prepared to accept As withstandard rivets, holesbolts. areChoice punched of bolts or drilled is based and on are requirements. prepared to accept standard bolts.Screw Choice Fasteners of bolts is based on requirements. Fastened Joint UseScrew of screwsFasteners for assembly has advantages not found in either rivets or Fastened Joint boltUse ofand screws nut applications. for assembly The has core advantages material not acts found as a lock in either nut to rivets aid inor Screw Fasteners Fastened Joint stabilizingbolt and nut and applications. holding the The screw core in material place. This acts prevents as a lock slippage nut to aid due in Fastened Joint ScrewUse Fasteners of screws for assembly has advantages not found in either rivets or tostabilizing vibration, and expansion holding thethrough screw heat, in place. or contraction This prevents through slippage cold, due of bolt and nut applications. The core material acts as a lock nut to aid in Use oftheto screws vibration, metal forskin assemblyexpansion or the screw. has through advantages heat, ornot contraction found in either through rivets cold, or bolt of and stabilizing and holding the screw in place. This prevents slippage due nut applications.the metal skin The or core the materialscrew. acts as a lock nut to aid in stabilizing and to vibration, expansion through heat, or contraction through cold, of holdingSelf-starting the screw screws,in place. such This as prevents sheet metal slippage screws, due tomay vibration, be used expansion for the metal skin or the screw. throughfastening.Self-starting heat, or Allen,contraction screws, hex, such and through as torque sheet cold screwsmetal of the screws,are metal commonly skinmay or be the usedused screw. infor fasteningfastening. panels, Allen, hex,with andfinal torque selection screws based are on commonly requirements. used in Self-starting screws, such as sheet metal screws, may be used for Self-startingfastening screws, panels, such with as final sheet selection metal screws, based onmay requirements. be used for fastening. Allen,fastening. hex and torque Allen, screws hex, and are torque commonly screws used are in commonly fastening panels,used in with final selectionfastening based panels, on requirements. with final selection based on requirements.

12 Adhesive Bonding Bonding through the use of adhesive materials is a common method to Adhesive Bonding adhere and fasten panels. Bonding is most commonly used in shiplap panel applications.Bonding through the use of adhesive materials is a common method to adhere and fasten panels. Bonding is most commonly used in shiplap panel applications. Adhesives have been researched to determine those which have the best adhesive factors, Adhesiveswhile permitting have been researchedthe skins to determine expand thoseand contractthat have thein response to externalbest heat adhesive and factors, cooling while cycles permitting without the deformingskins to expand the and skin. The flexibility, wearability,contract in responseand strength to external of heatthe andbond cooling are cyclescritical without to all applications. deforming. The flexibility, wearability and strength of the bond are critical to all applications. (Suggested adhesives: Methacrylate adhesives such as Sika 3100 Series or LORD Maxlok T6.) Test first All surfaces shouldto ensure be cleanedadhesive worksprior for to your application application. of adhesive or bonding agent. Wiping down surfaces with an alcohol rag typically is sufficient when usingAll surfaces the recommended should be cleaned adhesives. prior to application Adhesive of the should adhesive be applied accordinglyor bonding to the agent. manufacturer’s Wiping down recommendation.surfaces with an alcohol This rag may be accomplished typicallyby flattening is sufficient and spreadingwhen using the the recommended adhesion with adhesives. a putty knife. Using a clampingAdhesive fixture should beor appliedplacing accordingly a heavy objectto the manufacturer’s on the bonded recommendation. Using a clamping fixture or placing a heavy joint area to holdobject the pieces on the bondedin place joint is recommended.area to hold the pieces Care in shouldplace is also be taken to protectrecommended. the panels Uniformfrom any clamping marring pressure or damage. is a must forCardboard a good or other cushionbond. material Care shouldmay bealso used be taken between to protect the the heavypanels fromobject any or clamps and the panelmarring surfaces. or damage. Cardboard or other cushion material may be used between the heavy object or clamps and the panel surfaces. Caulking Caulking Caulking and sealing applications are most commonly utilized to provide a weatherproof seam.Caulking and sealing applications are most commonly utilized to provide a weatherproof seam.

A sealing applicationA sealing is usedapplication behind is used riveted behind or riveted bolted or boltedseams, seams, along along a frame or base rail,a or frame when or basejoining rail, dissimilaror when joining metals, dissimilar as a barriermetals, asor a spacer. barrier Sealing applicationsor spacer. are often Sealing in theapplications form of are a oftenfoam in tape the form or gasket. of a foam tape or gasket.

13 15 FORMING DuraPlateFORMING panels may be bent or folded based on application and need, but specific methods are required. Using a router or water jet cutter, one skin and core material may be removed, leaving the opposite DuraPlate panels may be bent or folded based on application and need, 90 - 105 90º -° 105º° skin intact.but specific It is essentialmethods arethat required. the cutter Using leave a router a minimum or water jet of cutter,1/32” of core materialone skin andadhering core material to the may remaining be removed, skin toleaving provide the opposite strength. skin The desiredintact. dimensions It is essential and that geometry the cutter of leave the formeda minimum radius 1/32” will of coredetermine the widthmaterial and adhering depth toof thethe remaining cut. A broader skin to provide cut of strength.skin and The core desired will producedimensions a larger and radius geometry bend. of Narrowthe formed cuts radius will willresult determine in tighter the widthcorners. and depth of the cut. A broader cut of skin and core will produce a larger The skinradius may bend. be eitherNarrow manually cuts will result or mechanically in tighter corners. bent to the shape DuraPlateDURAPLATE PANEL Panel .047” chosen. If done manually, a wooden block or baffle may be utilized to protectThe the skin surface may be if either light manually hammering or mechanically is necessary bent to tofinish the shape the fold. If chosen. If done manually, a wooden block or baffle may be utilized to a mechanical press is used, care should be taken to ensure that there is protect the surface if light hammering is necessary to finish the fold. pressureIf a mechanical sufficient topress complete is used, thecare fold should or bendbe taken without to ensure exerting there istoo muchpressure pressure. sufficient to complete the fold or bend without exerting too much pressure. It must be noted that once bent or formed, the skin will tend to hold a memoryIt must of be the noted shape. that once It may bent be or re-straightened formed, the skin backwill tend into to visual hold alignment,a memory but of the the surface shape. Itmay may be be damagedre-straightened in the back process. into visual Also, repeatedalignment, bending but ofthe the surface metal may may be damagedresult in skinin the failure. process. Also, repeated bending of the metal may result in skin failure.

90º90°

14 CLEANING

DuraPlate panels have an automotive-quality finish that resists corrosion and is designed to maintain its appearance for many years in normal conditions. Routine washing is required to clean dirt, debris and harmful irritants. Cleaning panels regularly will restore the panels to original appearance and enhance longevity.

The recommended cleaning process is power washing. A pressure washer should be utilized for large areas of panel surface. However, smaller cleaning applications or smaller panels may be washed by hand. Do not use organic or corrosive cleaning agents, as they may cause damage to the finish coating. A mild detergent formula, similar to those used in washing cars, is recommended. Pressure washing should not exceed 2,000 psi. Care should be taken if decals and graphics are present to avoid edges from lifting or curling. As with any finish, use of abrasive cleaning pads will result in marring the finish and should be avoided. If a brush or cleaning pad is required, a soft bristle brush is recommended. Spray perpendicular to the panel at 8” or greater from the panel. Keep wand in motion. Heat can build up and delaminate steel skin from core. PANEL REPAIR

Panels may become damaged, regardless of strength and durability. The scope and extent of the damage determines the repair process. Common repairs include fillers, self-adhesive patches or full panel replacement.

If the skin is torn, but the surface has not suffered any visible delamination, removal of burrs and application of automotive body filler will suffice. Follow the filler manufacturer’s recommendations and then touch up the painted surface. If the delamination has progressed beyond a minor repair, it may be necessary to cut out the affected portion of the panel and replace it with self-adhesive patches. This is not a structural repair but will prevent further delamination. If the damage is extensive, a full panel replacement may be required.

For more information regarding how to repair DuraPlate, please contact Wabash Composites.

866-877-5062 [email protected] wabashnational.com

15 Material Safety Data Sheet: DuraPlate

Section I Product Identification

Manufacturer: Wabash National Corporation 3000 E. Main St. Lafayette, IN 47905 866-877-5062

Emergency Phone Number: 765-771-5300 To be used only in the event of chemical emergencies involving a spill, leak, fire or exposure accidents.

Trade Name: DuraPlate

Synonyms: Polyethylene / Steel Laminated Panel

Section II Material Identification and Information

Ingredients: Percent (%) Occupational Exp. Limits (OSHA) (CAS #) (By wt.)1 (mg/m3)

Polyethylene: 37 – 69 10.0 Total2 (9002-88-4) 5.0 Resp.2

Galvanized Steel: 63 – 31 15.0 Total2

Section III Physical Properties

Appearance and Odor: Composite sheet material, odorless

Melting Point: Polyethylene 110-130o C (230-266o F) Steel 427-482o C (800-900o F)

Sp. Gravity: Polyethylene 0.7 g/cc Steel 7.9 g/cc

Solubility: Insoluble in water

16 Material Safety Data Sheet: DuraPlate

Section IV Reactivity Data

Auto Ignition: 260-410o C (500-770o F) depending on polyethylene blend

Extinguishing Media: Water, foam, CO2, dry chemical powder

Special Fire Fighting Procedure: Toxic gases may form upon combustion. Respiratory protection is recommended.

Thermal Decomposition: May produce carbon monoxide, carbon dioxide, organic vapors

Section V Fire and Explosion Data

Stability: Stable

Incompatibility: None known

Decomposition Products: Reference: “Thermal decomposition,” Section IV

Conditions to Avoid: None known

Section VI Health Hazard Data

These products are not considered to be a health hazard in the form in which they are sold (sheet, panel). However, if these products are abraded, melted, welded, cut or processed in any manner that causes release of fumes or dusts, hazardous levels of fumes or dusts may be generated from these materials or constituents of these materials.

Effects of Overexposure:

Acute: Physical irritation of the eyes may result from overexposure to high concentrations of dust or chips from certain fabricating operations.

Chronic: Repeated long-term inhalation of high concentrations of respirable dust may cause inflammation of the upper and lower respiratory tract.

Special Precautions: Avoid prolonged inhalation of high dust concentrations and ingestion of material. Wash hands before eating, drinking or smoking. Wear proper eye and respiratory protection when working in areas of high dust concentrations.

Emergency and First Aid Procedures: For dust contact with eyes, wash immediately under water for at least 15 minutes. For dust inhalation exposure, remove to fresh air. Contact a physician.

17 Material Safety Data Sheet: DuraPlate

Section VII Storage, Handling and Disposal Data

Waste Disposal: Care must be taken when using or disposing of material debris to prevent environmental contamination. Dispose of the debris in accordance with the Clean Air Act, the Clean Water Act, the Resource Conservation and Recovery Act and all state or local laws/regulations regarding disposal.

Storage and Handling Precautions: Store in a flat, dry area. Handle carefully to avoid scratching product finish. Caution should be taken to avoid sharp edges.

Section VIII Personal Protection Data

Primary Routes of Entry: Inhalation and ingestion of dust concentrations.

Respiratory Protection: An approved NIOSH/MSHA respirator must be used when engineering controls cannot be implemented to control dust concentrations. Reference OSHA 1910.134 for specific requirements.

Ventilation: Local exhaust. Reference OSHA 1910.94 for specific requirements.

Eye: Eye protection must be worn when working in dust concentrations and during sawing or other operations that might cause flying debris. Reference OSHA 1910.133 for specific requirements.

Protective Glove: Gloves should be used to prevent cuts or scrapes.

1 Concentration of ingredients depends upon the thickness of the material.

2 These products are not considered to be a health hazard in the form in which they are sold (sheet, panel). However, if these products are abraded, melted, welded, cut or processed in any manner that causes release of fumes or dusts, hazardous levels of fumes or dust may be generated from these materials or constituents of these materials. Dust from these materials is regulated as particulate, N.O.S.

18 NOTES

19 Thank you for your consideration of DuraPlate for your application.

The Wabash National team is ready to discuss your specific composite requirements and address any fabrication questions you may have.

wabashnational.com [email protected] 866-877-5062

©2019 Wabash National Corporation. All rights reserved. No portion of these materials may be reproduced, stored, or transmitted without prior approval from Wabash National. Wabash National reserves the right to make changes at any time without notice, as we continuously improve our products. This document has been developed to serve as a fabrication guideline to assist those in working with DuraPlate in the most efficient and effective manner. It is not exhaustive of what DuraPlate is capable of accomplishing. This document does not provide a warranty, and Wabash National shall not have any responsibility or liability for any damages resulting from such use. DuraPlate is a registered trademark owned by Wabash National, L.P.

WCP 0013 2.19