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Fabrication Guidelines 02 Contents Fabrication Guidelines 02 Contents Contents Product description 3 Unit 6, Site 2, Oak Business Units, Safety, Storage & Handling 4 Thorverton Road, Matford, Exeter, Devon, EX2, 8FS Visual Consistency & Sawing 5 Tel: +44 (0) 1392 823015 Saw Equipment 6 UK Manufacturing Site Unit 2 Millyard Way 7 Routing & Folding Eythorne, Dover, Kent, CT15 4NL Additional Manufacturer Information 8 Tel: +44 (0) 1392 823015 Corner Cutting & Bending 9 Joining Techniques 10-12 Tel: +1 718 841 9940 www.multipaneluk.co.uk Coating / Printing / Cleaning Alupanel 13-14 Thermal Expansion 15 Compensation of Thermal Expansion 16-17 Wind Load Calculation 18-21 Appendix 1 - Accessories Colour-matched screws & rivets Gaskets Adhesive systems Appendix 2 - Machine manufacturer Information ESKO, MECAPRO, TEKCEL, ZUND, AXYZ, ALUBENDER, SBC Automation Product Description 03 Product Description Alupanel is a high-performance composite material consisting of Protective Film two aluminium sheets bonded to PE Paint Finish an extruded thermoplastic core. Aluminium Skin As a result of this technology, we Adhesive Layer have created a perfectly flat and Polyethylene Core very formable material with an excellent strength-to-weight ratio. Alupanel is supplied with a face PE paint finish, available in the widest colour range on the market. The versatility of the panel makes it a perfect material for sign makers, designers, architects, fabricators and installers. Advantages include: - Exceptional rigidity - Outstanding strength to weight ratio - Simple to fabricate - Easy and quick to install However, since skill, judgment, In no event shall Multipanel UK - High resistance to and quality of equipment and tools Ltd, have any liability in any way atmospheric conditions are involved, and since conditions related to or arising out of said - Easy to maintain and methods of using Alupanel are suggestions and product data for beyond our control, the direct, special, consequential or This manual has been developed suggestions contained in this to assist fabricators and any other damages of any kind. manual are provided without installers to work with Alupanel in guarantee. We recommend that the most efficient manner prospective users determine the possible. The following suitability of both the material and recommendations and product recommendations before data are based on information adopting them on a commercial which is, in our opinion, reliable. scale. www.multipaneluk.co.uk UK Head Office Tel: +44 (0) 1392 823015 • USA Office Tel: +1 718 841 9940 04 Safety, Storage and Handling Safety, Storage and Handling Safety: Storage: Standard health and safety When storing unpacked Alupanel precautions should be adhered please observe the following to when fabricating Alupanel guidelines : Material. Goggles or other face protection, as well as hearing • To prevent warping or bending, protection and gloves should store horizontally. always be worn. An SDS for • Avoid stacking Alupanel of Alupanel is available from your different sizes together, as the local sales representative or surface or panel can be distributor. damaged by the edges of the smaller pieces. • Preferably, store them by size Packaging: in racks. Alupanel comes as standard with • If storing panels vertically by a clear protective film, designed to leaning them against a rack lay be removed just before installation a rubber mat underneath and to offer protection from surface lean the Alupanel closely damage. Although the protective against the fixed back. film is UV stabilised, it should be • Alupanel is packed in wooden removed as soon as possible after crates and can usually be installation, especially in the case stacked up to four crates high. of panels exposed to sunlight and • It is advisable to store Alupanel adverse weather. in a clean dry area with a minimum temperature of 15oC for a duration of 24 hours Handling: before use after which you will Alupanel should be handled with be able to start the processing care, especially when dealing requirements for each panel. with long lengths. It is advisable After Alupanel has been that a small team carry out the removed from the stack it handling. When removing panels must be protected from any from a pallet / stack never drag penetrating moisture. the panel, always lift clear above the remaining panels on the stack. This will require two or more operatives. Visual Consistency / Sawing 05 Visual Consistency & Sawing Visual consistency: highly recommended that material It is recommended that the swarf Each of our product types has from the same production batch formed during cutting should be special characteristics that can is used in order to maintain overall vacuumed away with compressed affect the visual consistency from visual consistency. air. batch to batch and even from panel to panel. It is important For these reasons the panels must Due to the nature of the Alupanel that these characteristics be be installed with the directional it is best to move the saw blade considered when planning how to arrows all aligned in the same rather than the material as no use and install Alupanel. direction. Batches should not be scratch will remain on the panel. mixed on a building face without If good saw cutting practices are Solid colours: first contacting Multipanel UK Ltd applied and recommendations The industry standard for for a confirmation that they are followed, the result should be allowable variation for panel to visually similar enough to be used clean cuts with little bur. If despite panel and batch to batch is Delta together. following the recommendations, E 1.0 or less in a hunter colour ragged cuts are produced check space. Brighter colours, such as Before fabrication, remember to the following causes; poor tool reds, yellows, blues, etc, which use a felt tip pen to draw arrows support, tool vibration, blunt tend to be less opaque and which to indicate the coating direction cutting edges, high frictional heat depend somewhat on film build on any small pieces that might at the cutting edge. (paint thickness) to achieve their be cut out from areas without the appearance, will be more likely directional arrows. As Alupanel has low thermal to exhibit more variation than conductivity it cannot be cooled subdued colours. Sawing: easily with compressed air or Sawing Alupanel is an easy any other means. Therefore it is Projects - same batch process that can be done with recommended to select the tool ordinary commercial metal and geometry and cutting conditions in Metallic colours: woodworking equipment. Saw such a manner so as to minimize The industry standard for colour blades and router bits are available the frictional forces developed variation with metallic is Delta E through independent distributors at the cutting point and keep the 2.5 or less, much larger than the who handle cutting tools. Prior resulting heat at a low level. standard for solid colours. to processing large quantities, trial saw cuttings should be done Directional project: to evaluate both the tool working In coating, the flakes will tend to conditions and the recommended align in one direction. This greatly cutting speeds. For marking the increases the directionality of the panels the use of a soft pencil panel’s appearance. is adequate. Hard marking tools should be avoided as they can Production Batches/Projects: fracture the Aluminium surface. When working on projects it is www.multipaneluk.co.uk UK Head Office Tel: +44 (0) 1392 823015 • USA Office Tel: +1 718 841 9940 06 Saw equipment Saw equipment Saw cutting can be accomplished with the following equipment: Panel Saws: Multiple Operation Rip/ Jig Saws: Panel saws provide an effective V-Grooving Saws: Jig saws work well for cut-outs. method of cutting. These saws, In high production operations, Care should be taken with whether standard equipment equipment that is capable of portable jig saws to prevent or custom made, perform well performing more than one damage to the Alupanel material and have the added advantage operation with a single pass surface. More than one sheet of space saving. If a panel saw through the machinery is can be cut at a time by stacking is to be used as production recommended. This equipment panels. equipment, an industrial model can make multiple saw cuts (sizing should be purchased in order to the panel) and V-Grooves (rout) at If centre cutting (i.e., letter cut- obtain adequate cutting tolerances the same time. outs) is required, a foam pad may and increase the longevity of the be placed under the material with equipment. Portable Circular Saws: the blade cutting into the foam. Cutting Alupanel with portable The sheets may be clamped or Table Saws: circular saws is another effective secured with double-sided tape Table saws are not recommended method. As mentioned, this for the cutting operation. When for large sheets. equipment should also be clamping between jaws, protect production/industrial standard the panel surface against damage. equipment. Working Method Cutting Blade/Band Tooth Max. Max. Material Geometry Geometry Cutting Speed Cutting Feed Circular Saws Carbide tipped or 20 x 35mm blades with Angle or circular tooth, 5500 RPM 40 mm/sec highspeed steel maximum number of alternate bevelled, triple carbide teeth available, ground. Tooth gap wall designed for cutting non- rounded. Chip angle: 5°to ferrous material. The blade 15°.Clearance angle:10°to should be ground thinner 30°. Tooth spacing: 4 from the rim towards the mm to 25 mm, fine spacing centre to prevent pinching. preferable. Band Saws Tempered spring Thickness: 0.8 mm to 1.2 Skip teeth, designed for 10000 RPM 25mm/sec strip steel. mm. Width: 15 mm to 25 nonferrous and ferrous mm. Use racket or straight materials (light metals and set. plastics). Tooth spacing: minimum 4 teeth per cm. Reciprocating High speed steel. Thickness: 0.8 mm to 1.2 Hook or circular tooth with 10 mm/sec saws mm.
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