Processing

Architecture Display Transport Industry

2

Jointing / Fixing TechniqueRiveting see page 14

• using commercially available tools and blind rivets, fastening possible in 1 mmcover sheet

Screwing see pages 15 - 17

• with sheet metal screws, rivet bolts and nuts fastening possible in 1 mm cover sheet

Glueing see page 18

• adhesive sealing compounds Indoor use: • metal adhesives • double-sided adhesive tape

Surface Treatment

Lacquering see page 19

• overlacquering of ALUCORE® surfaces with suitable lacquer qualities

Screen printing see page 19

• on polyester lacquer surfaces with commercial screen printing inks

Laminating see page 19

• with self-adhesive foils

Processing at a

glanceCutting and Fabricating

Sawing see page 5

• vertical panel saw, circular saw or jig saw

Routing see page 6

• CNC machining centres and circular panel saws

Drilling see page 6

• drill bits with locating point for thin sheets • large holes with countersinks and counterbores

Pressing see page 6

• bending press

Bending see page 7

• roll bending machines • step-bending with bending press

Folding see pages 8 - 9

• routing and folding technique or with bending press

CNC-machining centres see page 10

• sawing• routing• drilling

Panel edgings see pages 11 - 13

• by folding cover sheets or using panel edging sections

Transport / Storage / Handling 4

Cutting and Fabricating 5 - 7

Folding Techniques 8 - 10

Edging 11 - 13

Jointing / Fixing Techniques 14 - 18

Surface Treatment 19

Cleaning and Maintenance 20

Technical Data Sheet 21

ALUCORE® Information 22

3

Page

Contents

TransportHandling

Storage

4

ALUCORE® is a prefabricated panelling material with lacquered, foil-laminated or mill-finished surfaces. These surfaces are protected by a special foilduring transport, storage and processing. Thefollowing points must be taken into considera-tion when storing and handling panels:

• Pallets must be handled carefully duringtransport and unloading. (Caution: do not move open pallets)

• Upon delivery, pallets must be examined forany damage due to moisture (ALUCORE® panels that have become wet must be dried toavoid the formation of spots or corrosion). Anydamage must be reported immediately andconfirmed by the forwarding agent.

• Store pallets so that they are protectedagainst wetness penetrating due to rain andspray water and avoid the formation of condensation (e.g. when transporting coldpanels into warm rooms).

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

• Individual panels must be lifted off the pallet by two people holding all four cornersand not drawn over each other. Carry panelsvertically. Wear gloves to avoid making anymarks on them.

• To avoid marks, do not place anythingbetween the panels when stacking them.

The following points should be observedas regards the ALUCORE® protective foil:

• Storage exceeding 6 months should beavoided.

• Strong fluctuations in temperature anddirect insolation also reduce long-term durability.

• Do not the foils with ink (markers), adhesivetape or labels. The solvents and softenerscould penetrate the foil and damage the lacquered surface.

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

• After assembly, the protective foil must beremoved as soon as possible since it is verydifficult to remove foils that have beenexposed to weather conditions for a long time.

• The protective foil should not be removed attemperatures below 10° C.

5

Jig saw blades For wood or plastics, e.g. T101 B (Bosch), tooth thickness 2.5 mm for precision cuts Carbide tipped (CT) saw blades

Blade geometry Tooth thickness approx. 2 - 4 mm,tapered to the side to prevent jamming

Tooth geometry trapeze tooth / flat tooth

Pitch t 10 - 12mmClearance angle � 15 °Rake angle � 10 ° positive

Maximum cutting speed v 5,000m/min

Maximum feed s 30m/min

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

Trapezoid/flat tooth saw blades, flat teeth 45° chamfered for burrfree edges

Saw blade Ø D = 300mm (for Striebig panel saw Standard II)

Number of teeth Z = 72 LEUCO- Best.Nr. 181724

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

Number of teeth Z = 60 LEUCO- Code No. 181726

Bore Ø d = 30mmTooth thickness 3.2 mmClearance angle 15 °Rake angle 10 ° positive

Manufacturer/Supplier: LeucoLedermann GmbH & Co.KGPhone +49 74 51 93 0Fax +49 74 51 93 270www.leuco.com

Sawing

Sketch showing edge geometry for professional resharpening:

andCutting

Fabricating

6

RoutingALUCORE® can be easily routed on conven-tional routing machines and CNC machiningcentres. To avoid pressure marks on the surface,please use plastic or wood vice jaws whenchucking the workpieces.High-speed steel or carbide tipped cutterssuitable for aluminium and ALUCORE® have awide tooth pitch, radiused and smoothgrooves and small lip angles. They produce perfect cuts, under the followingconditions:• High-speed steel (HSS) max. cutting speed 3,000m/min.max. feed 25m/min.

• Carbide tipped (CT) cuttersmax. cutting speed 5,000m/min. max. feed 30m/min.

Suitable end milling cutters for ALUCORE®:HSS end milling cutter, shank Ø 8 mm

Carbide tipped cutter Series F 113

Manufacturer / Supplier: GIS Gienger IndustrieservicePhone +49 74 61 16 20 20Fax +49 74 61 16 20 21www.gis-tec.de

DrillingALUCORE® can be drilled with twist drills normally used for aluminium and plastics onmachines common for metals. Drill material: High-speed steel (HSS) Tool geometry: Lip angle: 100 ° - 140 ° Drilling without burr is possible using the following drills: Spot facing cutter with centre-point. Angle of twist: 30 ° - 45 ° e.g. Extreme 2TM HSS-G metal drill DIN 338of De WALT, Idstein, Germany

Pressing / StampingALUCORE® composite panels can be pressed.The core is compressed without destroyingthe viscoplastic bonding system. This offersnew processing and application possibilities.For more information, please refer to the sep-arate leaflet “Pressing ALUCORE® compositepanels".

Upper die plate

Upper die plate

Lower die plate

Lower die plate

Adapter

Adapter

Die

Die

Support

Support

Flush joint with H section

Flush edging with lining section

Overlapping panel joint

Bending with a roll bending machineALUCORE® composite panels of 6 and 10mmthickness can be bent using three and four-rollbending machines with relatively close radii.The viscoplastic composite system enablesradii to be produced from 300mm with apanel thickness of 6 mm and from 700mmwith a panel thickness of 10mm. The mini-mum diameter of the rolls should be 150mm. The values for adjusting the rolls have to bedetermined by trial. The bending rolls must bethoroughly cleaned of swarf before processingALUCORE®.The surface should be protected from damageby affixing plastic strips of 1 - 2 mm thicknessduring processing.

Step-bending withbending presses ALUCORE® can be shaped using the step-bending process. The bending radius is deter-mined by the stamping depth t, the stampingdistance s and the panel thickness d.Please ask for details.

Bending with saw cutsALUCORE® can be bent by applying saw cutson the rear side of the panel. The requiredradius ra is determined by the tooth thickness s,the wall thickness b, the panel thickness dand the number of saw cuts.The saw cuts are carried out using the recommended saw blades. To obtain a finalthickness of 1.3mm, corresponding tracingrollers are attached to the saw blades of thevertical panel saws. Principally, bendingshould take place in the 1mm thick cover sheet.

7

t

s

Die plate

Plastic support

Die

d

sb

d

1,3

r a

8

Folding techniquefor individual shaping

Folding with the bending pressALUCORE® can be folded on bending pressesusing the tool geometry shown in the sketch. When measuring cuts, the material gain forthe corresponding thickness must be takeninto consideration when making 90° folds.

Routing and folding technique / producing corners and edges

and design

Panel Bending radius Material Foldingthickness outside gain height min.(mm) (mm) (mm) (mm)6 ~4 2.7 2010 ~9 5.0 2515 ~13 7.5 3520 ~16 8.5 5025 ~18 10.0 60

Die

Die plate

Polyethylenefilm

10°

1.5

� 85°

Corners and edges can be produced simply onALUCORE® panels using the routing and folding technique. With all versions, a grooveis routed on the rear of the panel into the 1mmthick cover sheet at the front. In version 1, as with ALUCOBOND®, a cutterdisk or forming cutter for V-grooves 90° isused in the appropriate width.

Tracing roller for exact groove-depth adjustment

Cutter disk for V-groove

ALUCORE®

Version 1

Tracing roller for exact groove-depth adjustment

Cutter disk for rectangular groove

ALUCORE®

Version 2

In version 2, the core of the panel is pre-cutusing special tools.The grooves can be produced with circularpanel saws and CNC machining centres.Normally, folding by hand is possible. If this isnot possible, we recommend the use of afolding machine.

Important:These are customized design tools to matchthe respective machine and can be ordered by the processor from the recommended manufacturers. Please state the tooth geometry, tool diameter, etc.

The auxiliary tracing rollers can be producedfrom the existing ALUCOBOND® tracingrollers for 4 or 6 mm thickness.

9

Machinery for routing and folding technique

Vertical panel saws ALUCOBOND® / ALUCORE®routing device (customized accessory) For V-shaped grooves of up to 10mm panelthickness and for rectangular groovesHolz-Her Vertical panel sawPK 1255 ALUCOBOND®

ArticleNo. 278.6133Striebig vertical panel saw Standard II for composite panels

Manufacturers / SuppliersReich Spezialmaschinen GmbH Phone +49 70 227020 www.holzher.de

Striebig AG Maschinenbau Phone +41 41 2 595353www.striebig.com

Other panel saws can subsequently be providedby the above manufacturers with an additionalrouting device. Please ask for details.

CNC machining centres

With large panel thicknesses such as 10mm,V-grooves cannot be produced with verticalpanel saws (cutter edge width max. 20mm).CNC machining centres are used for this purpose.Rectangular grooves can also be produced onCNC machining centres.Please ask for manufacturers of CNC machiningcentres.

10

Tools for routing and folding

Cutter disk for V-grooves 90°

End milling cutter for V-grooves 90°With cylindrical shank of the correspondingdiameter for all panel thicknesses.Customized design by KWO

Milling cutter for rectangular grooves for ALUCORE® 10mm with additional pre-cutter for ALUCORE® 15, 20 and 25 mmCustomized design by OERTLI. Please ask for details.

214

1924

2910

15

20

25

The following points must be taken intoconsideration: • The edges should not be bent back andfolded a second time.

• The width of the base cutter edge must be2mm.

• The grooves should basically be routed inthe 1mm thick cover sheet.

• After routing the remaining metal sheetmust be 0.6 +0.1 mm thick.

Supplier for cutter disks for rectangular grooves and for pre-cuttersOERTLI Werkzeuge AG Phone +4118637511Fax +41 1 8605929www.oertli.ch

For panel thicknesses of 6 and 10mm amilling cutter for 90° V-grooves with a cutteredge width of 20mm must be used on circular panel saws. Customized design by Speiser

up to10mm

Cutter disk for rectangular grooves

Tracing roller

Pre-cutter

Panel thicknesses

Groove widths

Supplier for end milling cutters KWO-Werkzeuge GmbH Phone +49732696420Fax +49 7326964210www.kwo.de

Supplier for cutter disks for V-grooves and special saw bladesSpeiser Werkzeugvertriebs-GmbH Phone +49745694490Fax +49 745694490www.speiser-werkzeugtechnik.de

Instead of the milling cutter for rectangulargrooves a special saw blade, as shown onpage 11, may also be used.

11

Producing edgings by folding the cover sheet

Routing the panel by means of a special saw bladeCarbide tipped saw blade, tooth geometry, trapeze tooth (customized design by Speiser) Bore ø d = 30mmSaw blade ø D = 244 ± 0.05mmNumber of teeth z = 40Tooth thickness = 3.2mmClearance angle = 15°Rake angle = 10° positiveWidth of base cutter at trapeze tooth = 2mmSupplier:Speiser Werkzeugvertriebs-GmbH Phone +49745694490Fax +49 745694490www.speiser-werkzeugtechnik.de

Depending on the saw blade diameter and thepanel thickness, a corresponding tracing roller,as with the routing and folding technique forALUCOBOND®, is required to keep the preciserouting depth (remaining sheet thickness 0.6+0.1mm). For the panel thickness the correspon-ding diameter is turned from the tracingrollers for ALUCOBOND®. After routing the panel, the honeycomb coreand the rear cover sheet are cut off using ajoint cutter. Routing the panel with a cutter disk forrectangular grooves A further possibility for preparing the paneledging for cover sheet folding is routing usinga cutter disk for rectangular grooves. For panelthicknesses of 15, 20 and 25mm a pre-cutteror a joint cutter is used to remove the remainingcore. Folding the edges of the cover sheets We recommend folding the edges of the coversheets with a folding machine as betterresults are obtained using this method.

TypesJoint cutterOscillating joint cutter Super CutType FSN 400 EReference No. 7 236 28CutterStraight formReference No. 6 39 03 117 01 5

Supplier:C. & E. Fein GmbHPhone +4971731830Fax +49 7173183800www.fein.de

ALUCORE® panel edgings

With 6 and 10mm thick ALUCORE® panelsrouting is generally carried out in the 1mmthick cover sheet.

Tracing roller Saw blade

ALUCORE®

Calculating the dimension to be cut Depending on the type of edging, the panelthickness is added to the final width or length,and the thickness of the cover sheet of 1 mmis then deducted.

Example:Desired final dimension 800 mm

+15 mm-1 mm

Dimension to be cut = 814 mm

Dimension to be set on the panel saw Dimension to be cut Example: 814 mmLess panel thickness -15 mmLess 1 mm thickness of cover sheet -1 mm= Dimension to be set = 798 mm

Dimension to be set

Dimension to be cut

Final dimension

Tracing roller

Special saw blade

Producing edgings by means of edge bands ALUCORE® edges can be closed decorativelyby filling them with melamine resin andapplying edge bands.

Producing edgings by filling and contour-cutting the edgesEdgings can also be produced by filling theALUCORE® edges with plastic material andsubsequently cutting the contour of the edgesby means of end milling cutters. With thismethod, the cover sheets can be routed visibly or the ALUCORE® edges are filled withplastic material protruding over the edges andthen cut or ground.

12

Prior to inserting the sections, a bondingagent is filled into the grooves to securethem. The bonding agent firmly fixes to thehoneycomb core and section teeth, thus preventing the sections from slipping out.

Bonding agentFix All CrystalPermanently elastic, transparent structuraladhesive Supplier:SOUDALPhone +49 214 690 40Fax +49 214 690 423www.soudal.com

Producing edgings using edging sections An optically attractive edging can be producedby routing the edges of ALUCORE® panels witha disk milling cutter and subsequently insertingedging sections.

Aluminium edging sections are availablefor all panel thicknesses. Please ask for details: Edging section ALUCORE®No. Panel thickness a41213 6mm41214 10mm41215 15mm41216 20mm41217 25mm

Cutting the grooveA disk milling cutter and a hand routingmachine or CNC machining centre are used tocut a groove into the core at the ALUCORE®edges:Carbide tipped disk milling cutter for groovesDiameter D = 40mmWidth of edge W = 2.5mmBore ø d = 6mm, Reference No. 37329Cutter mounted on a mandrel with ball bearingShank ø 6mm, Reference No. 37910Shank ø 8mm, Reference No. 37912For better guidance a second ball bearing isrequired:Ball bearing ø 19mm, Reference No. 00504Supplier:KWO-Werkzeuge GmbH Phone +49732696420Fax +49 7326964210www.kwo.de

2,510,4

a 2,5

ALUCORE® panel edgings

Disk milling cutter for grooves

Mandrel

Hand routing machine

13

Producing edgings using panel edging sections Depending on the type of application, edgingsections of various shapes can be attached tothe ends of the ALUCORE® panels. They arefixed to the panel by bonding, clamping or riv-eting to the cover sheet.

Examples

For sections please ask for details.

14

Fixing TechniqueJointing /

ALUCORE® can be joined by means of standard processes used in metal and plas-tics technology. If ALUCORE® is to be joinedto structural parts of metals other than alu-minium, or if fasteners (e.g. bolts, screws)are to be used, the following materialguidelines should be observed:

Fasteners and structural parts made of aluminium, plastic or stainless steel shouldbe suitable for assembly with ALUCORE®.

When using other materials please insertinsulating washers or apply protective acoating to prevent corrosion.

Please take the thermal expansion of thepanel into account for outdoor use of ALUCORE® to avoid jamming or deforma-tion.

The minimum gap depends on the expectedexpansion of the panel.

Please refer to processing recommendationsfor rivets and bolts for additional measuresto prevent jamming.

The linear thermal expansion of ALUCORE® isdetermined by the aluminium cover sheets.

At a temperature difference of 100°C the longitudinal deformation is 2.4mm/mlength/width.

Rivets - not penetrating the panelRivets generally must be anchored in the1mm thick ALUCORE® cover sheetsSections can be attached to ALUCORE® withcommercially available rivets for aluminium con-structions. After drilling a blind hole of thesame diameter as the rivet shank, the rivetscan be anchored in the cover sheet. As a rule,rivets with stainless steel mandrel are used.

Rivets - penetrating the panelALUCORE® panels can be joined together orfastened to other materials using rivet typescommercially available for aluminium construc-tions. For outdoor use and for use in areas ofhigh humidity, aluminium blind rivets withstainless steel mandrels are normally used toprevent ugly corrosive edges. When using alu-minium blind rivets with steel mandrels, themandrel should drop out after riveting (detachable version).Countersunk rivets are not suitable.

For outdoor use please note: • Use aluminium blind rivets that have beenapproved for construction with a 5mm shankdiameter and an attachment head diameter of11 or 14mm. • Please take the thermal expansion of thepanel into account (2.4 mm/m/100° C). To avoid jamming, the hole in the panel mustbe large enough to allow for expansion. • With the shank of the rivet fitting closely tothe edge of the hole, the attachment headmust cover over 1 mm of the area surroundingthe hole. • Multi-step drills or sleeves having corre-sponding diameters are used for centricallydrilling holes into the panel and the substruc-ture and for centrically fitting the rivet. • Rivet attachment jigs are used for fittingblind rivets without jamming allowing for atolerance of 0.3mm. Make sure to use rivetattachment jigs and rivets from the samemanufacturer, as the height of the attachmenthead according to DIN 7337 may vary. • The clamping thickness results from thethickness of the material to be riveted plus anadditional value of 2 mm to ensure that theclosing head is perfectly formed. In accor-dance with this clamping thickness the corre-sponding shaft length is determined in thetables provided by the rivet manufacturers. Important: During riveting, many factors may have aninfluence on the exact tolerance of the rivetsof 0.3 mm (e.g. rivet head tolerance). Wetherefore recommend that you make a test ona façade panel.Please always remove the protective foilaround the riveting area prior to riveting.

Blind rivet with panhead For ALUCORE® with a thicknessof 10mm or more

Expansion blind rivet For ALUCORE® with a thickness of 6 mm or more

Blind rivet with countersunk head

Distance min. 15 mm

15

Suppliers / Manufacturers:

Blind rivetsCommercially available or from GESIPA-Blindniettechnik GmbH Phone +49 61 059620Fax +49 61 05962287www.gesipa.comGebr. Titgemeyer GmbH & Co. KG Phone +49 541 58 220 Fax +49 541 58 22490www.titgemeyer.deVVG-Befestigungstechnik GmbH & Co. Phone +494321967171Fax +49 4321967196www.vvg-befestigungstechnik.de

Blind rivets lacquered MBE GmbH Phone +49 23 73174300 Fax +49 23 731743011www.mbe-gmbh.comSFS intec GmbH & Co. KG Phone +49 61 7170020Fax +49 61 71700246www.sfsintec.biz

Plastic covers for rivetsHA-WIKunststoffe GmbH&Co.KG Phone +49275437450Fax +49 27548119www.ha-wi.de

Multi-step drillsKWO-Werkzeuge GmbH Phone +49732696420Fax +49 7326964210www.kwo.de

Hole gauges Please refer to blind rivets lacquered: MBE GmbH

Rivet attachment jigs Appropriate rivet attachment jigs are availablefrom manufacturers or suppliers of rivets.

Blind rivet nuts and bolts are threaded elements performing the function of a blindrivet and a nut or bolt (screw). There are various types of rivet head andmaterials which can be selected depending onthe intended application. The blind rivet nuts orbolts are inserted in blind holes drilled in oneside of the ALUCORE® panel. Subsequent fittingwith a tool is fast and cost-effective.

Manufacturer/Supplier:

Rivet nuts/bolts and appropriate tools

Alfred HonselNieten- und Metallwarenfabrik GmbH & CoPhone +4923737550Fax +49 2373755600www.honsel.de

Böllhoff GmbHD-33649 Bielefeld, GermanyPhone +49521448205Fax +49 5214482350www.boellhoff.de

Gebr. Titgemeyer GmbH & Co. KG Phone +49 541 58220 Fax +49 541 5822490www.titgemeyer.de

Gesipa-Blindniettechnik GmbHPhone +4961059620Fax +49 6105962287www.gesipa.de

Due to the minimum shaft length of 11mmthese fixtures can only be used for a panelthickness of 15mm or more. As a rule, therivet must be anchored in the 1mm thickcover sheet.

Blind rivet nuts and bolts

Blind rivet nuts Blind rivet bolts

Screw thread

Bolt head

Rivet shaft

Rivet head

Rivet shaft with nut thread

Types of rivet head

Panhead

Countersunk head

Types of rivet head

Panhead

Countersunk head

Small countersunk head

Tool for rivet nuts / bolts

Flowdrill Process Flowdrills are polygonally ground carbide-tipped tools.The Flowdrill presses against the thin metallicmaterial with a relatively high rotationalspeed and axial pressure. The generated heatmakes the material soft enough to push theFlowdrill through the workpiece thus forminga hole. The material which is mainly displacedin process direction forms a bushing at thesame time. The length of the bush can be 3 to5 times the original material thickness.In the case of threaded fasteners higher pull-out strength can be obtained due to the largercontact area of the screws.

The “flat/short” Flowdrill type is used for ALUCORE®. These drills are suitable for thinmaterials and remove protruding material fromthe panel surface at the same time.

Threaded fasteners for outdoor use Please take the thermal expansion of thepanel into account when using threaded fasteners outdoors. To avoid jamming, thehole diameter in the panel must allow for theexpansion. Fastening without jamming is possible withfascia screws made of stainless steel withsealing washer that have been approved forconstruction. The screws must be suitable forthe corresponding substructure (please notethe information given by the manufacturer).The screws should be tightened with a torquewrench or screw driver so that the sealingwasher is placed on the panel for sealing thebore hole without exerting pressure onto thepanel.Multi-step drills or sleeves having correspon-ding diameters are used for centrically drillingholes into the panel and the substructure andfor centrically fitting the rivet.

Important: Please always remove the protective foil priorto screwing.

16

Suppliers / Manufacturers: Fascia screws EJOT Baubefestigungen GmbH Phone +4927529080Fax +49 2752908731www.ejot.de

Fascia screws, lacquered MBE GmbH Phone +492373174300Fax +49 23731743011www.mbe-gmbh.com

SFS intec GmbH & Co. KG Phone +49 61 7170020Fax +49 61 71700246www.sfsintec.biz

Multi-step drills (not available ex stock) KWO-Werkzeuge GmbH Phone +49732696420Fax +49 7326964210www.kwo.de

Hole gaugesplease refer to fascia screws lacquered:MBE GmbH

Threaded fasteners

Supplier for Flowdrill tools:

FlowdrillFließformwerkzeuge GmbHPhone +496201290910Fax +49 62012909115www.flowdrill.com

Distance min. 15 mm

Fascia screw, thread-cutting

Hexagon screw

Carriage bolt

Countersunk screw with distance sleeve

Examples of threaded fastener

Hole edges strengthened by inserts

17

Stud welding with tip ignition on mill-finished ALUCORE® surfacesBy applying a force without the use of auxil-iary material, studs and pin-type parts arewelded to the carrier material by means of anelectric arc. Capacitor-discharge stud welding with tip ignition is suitable for ALUCORE® for sheets ofa minimum thickness of 1 mm. Studs and pins are used for various types ofjoin.Stud diameter: 3-8mmMaterial: AlMg Alloy

Suppliers for stud welders and studs:

HBS Bolzenschweiß-SystemeGmbH & Co.KGPhone +49 8131 511 0Fax +49 8131 511 100www.hbs-info.com

Heinz SoyerBolzenschweißtechnik GmbHPhone +49 8153 88 50Fax +49 8153 80 30www.soyer.de

Further suppliers:www.schweissbolzen.dewww.i-vt.dewww.schmeck-schrauben.dewww.thomas-welding.com

Process:1. The capacitor battery is charged. 2. A spring in the welding gun moves the stud(with tip) towards the workpiece.

3. The tip comes into contact with the work-piece and thereby closes the circuit. Therapidly increasing current causes the igni-tion tip to melt instantaneously, thus initi-ating the electric arc.

4. Stud and workpiece are welded together. 5. When the stud touches the workpiece theelectric arc is extinguished, the fusionzones on stud and workpiece are joinedand solidify.

Owing to the highly dynamic process, theselection of the setting parameters is particu-larly important. The appropriate combinationof the mechanical properties of the springforce and the air gap and the setting parame-ters of the capacity and the charging voltageis decisive for obtaining repeatable results.

Stud welding offers the following advantages:• low thermal effect on stud and ALUCORE® panel

• fastening method without forming a hole,the panel is not weakened, sealed connection

• welding from one side without counter support

• suitable for cover sheets with a minimumthickness of 1 mm

• fast working cycle

Ignition Creating a fusion zone Welding

18

Tapes / velcro tapesDouble-sided tapes (such as the 3M-VHB highcapacity jointing systems) can be used for theabove applications with low tensile or transver-sal strength requirements. Velcro tapes areavailable for detachable joints, for exampleSCOTCHMATE or tapes marketed under theDual Lock trademark.

3M Deutschland GmbHPhone +49 21 31 14 0Fax +49 21 31 14 34 70www.3m.com

Adhesive sealing compoundsFor high-strength and elastic connections werecommend the following one-componentadhesive sealing compound:

Sika Bond-T2 (polyurethane base)Sika GmbH Phone +49 71 25 9 40 0 Fax +49 71 25 9 40 710www.sika.de

For outdoor use, this adhesive can be used forfastening parts of minor static importance.

Important:Please observe the manufacturer’s instructionsregarding the application and use of adhe-sives/tapes. Laminating one side of ALUCORE® panels toother materials may result in deformation ofthe laminates (differing expansion/bimetaleffect).

Glueing

Clamp connections

Klemetric system

Voluma system

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

Clamp connections incorporating aluminium orplastics are particularly suitable for ALUCORE®.They generally consist of two parts with theclamping effect achieved by bolting.Various designs of clamping element are usedfor display and store fitting purposes (no outdoor use).Supplier:Klemetric system :KlemProducts®Gesellschaft für Werbemittel mbHPhone +49 89 857 72 80Fax +49 89 895 83 48www.klemproducts.comVoluma system :MERO Raumstruktur GmbH & Co.KGAusstellungssystemePhone +49 931 66 70 571Fax +49 931 66 70 189www.mero.deIrus system :Irus-SystemPhone +49 77 02 36 85Fax +49 77 02 90 45www.irus-system.comAny suitable connection or shock-resistantframe can easily be made with aluminium sections. For fascia cladding applications special aluminium sections are provided for clampconnections.For further information on ALUCORE® specialsections and types for fascia claddings pleaseask for the respective documentation.

irus system

19

Surfacetreatment /

printing

Screen printing on ALUCORE® surfaces in polyester lacquer qualityStove-lacquered ALUCORE® panels are wellsuited for screen printing.Prior to printing, please make sure to removethe protective foil and clean the surface witha lintfree cloth moistened with ethyl or isopropyl alcohol. The alcohol must not bepoured directly onto the panel. The lacquercoat can be damaged by the use of methylatedspirit. About 10 to 15minutes should be leftbetween cleaning and printing. Practice has shown that even within a givenspecification of stove-lacquer paint and printing ink there may be variances, and inview of this it is recommended that in thecase of each particular application the adhesion properties of the selected printingink should be tested.

LaminatingALUCORE® can be laminated (manually or bymachine) with cast or calendered self- adhesive foils. The varnish does not come offwhen changing the foils.

Overlacquering of stove- lacquered ALUCORE® surfacesof polyester lacquer quality(panels not exposed to weather conditions)Aluminium treatment and priming carried outat the factory in a continuous process withcontinuous quality control is advantageous tothe overlacquering of the stove-lacqueredALUCORE® surface.

ALUCORE® overlacquering procedure• Pre-cleaning of the panels using methylated spirit

• Grinding the surfaces with wet abrasivepaper (grain size 360)

• Removing grinding dust with a lintfree clothmoistened with spirit

• For the top coat, please follow the instructions of the top coat supplier

Please note: • The maximum permissible temperatureof the material (ALUCORE® panels)must not exceed 70° C when applyingfast-drying methods. During the dryingprocess at high temperatures the ALUCORE® panels must be positionedwith great care to prevent deformation.

• ALUCORE® cut edges should not be in con-tact with organic solvents for a prolongedperiod of time to avoid weakening of thebond.

• ALUCORE® panels lacquered or overlac-quered at a later stage should not be bentor folded. The lacquer in the bends or foldsmay be damaged due to the low elasticityof the top coat.

• Please make a test prior to overlacqueringand follow the instructions of the lacquersuppliers.

Lacquering of mill-finish ALUCORE® surfacesThe composition of lacquer coating for mill-finish ALUCORE® is basically the same as formill-finish aluminium surfaces. However, it isadvisable to be familiar with coating systemsand materials as well as working methods foraluminium.

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

Gesamtverband der Aluminiumindustrie e.V.(GDA) www.aluinfo.de

Non-suitable cleaning agentsPlease do not use any powerful alkaline cleaning agents such as potassium hydroxide,soda, caustic soda or any powerful acidicproducts or heavily abrasive scouring agentssuch as Vim, Ajax, Imi or lacquer-dissolvingcleaning agents.

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Cleaning and maintenance

surfacesof stove-lacquered

Cleaning agents

A list of neutral cleaning agents for organicallycoated or anodized aluminium components isavailable at Gesamtverband der Aluminiumindustrie e. V. (GDA)Phone +492114796268Fax +49 2114796408www.aluinfo.de

Please observe the manufacturer’s cleaningand safety instructions!

For further information such as addresses ofapproved and recommended cleaning companies, please contactGütegemeinschaft für die Reinigung vonMetallfassaden e.V. (GRM)Phone +49 71 71 10 40 845 Fax +49 71 71 10 40 850www.grm-online.de

Expert and regular cleaning not only maintainsthe aesthetic and representative finish ofstove-lacquered surfaces but also maintainstheir quality through the removal of dirt andaggressive deposits. Cleaning intervals depend on local environ-mental conditions and the resulting amount ofsoiling. Surfaces should be cleaned either manually orwith a suitable cleaning device from top tobottom.Please do not use any abrasive pads on lac-quered surfaces. We recommend that thecleaning agent be tried on an unobtrusive partof the object to be cleaned to check whetherthe surface is affected.Do not clean hot surfaces (> 40° C) as the quick drying process may causeblemishes.

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Thickness: 6mm 10mm 15mm 20mm 25mm

Cover sheet thickness, front [mm] 1.0 1.0Cover sheet thickness, rear [mm] 0.5 1.0Weight [kg/m2] 4.7 5.0 6.7 7.0 7.3

Technical properties: Section modulus W [cm3/m] 2.5 4.5 13.1 18.1 23.1Rigidity E·I [kNcm2/m] 7,100 21,900 75,500 138,900 221,600Alloy of cover sheets Peraluman alloy (AlMg)Modulus of elasticity [N/mm2] 70,000

Surface: Coil coating systems:Standard lacquering: both sides platinum white Special polyester lacquerFor fascia application: Fluorocarbon based (e.g. PVDF)Gloss (initial value) [%] 30 - 80Pencil hardness HB - F

Acoustical properties: Sound absorption factor �s 0.05Airborne sound insulation index (according to ISO 717-1, ISO 140-3) Rw [dB] 21 21 22 23 25

Thermal properties: Thermal conductivity (regarding total thickness, incl. cover sheets) �* [W/mK] 0.95 1.35 1.78 2.25 2.70Thermal resistance R [m2K/W] 0.0063 0.0074 0.0084 0.0089 0.0093Linear heat transition coefficient 2.4 mm / m at 100°C temperature differenceTemperature resistance [°C] -40 up to +80

Technical Data Sheet

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Information(please ask for the additional documentation on)

ALUCORE® Product Information Folder

ALUCORE® The Colours

ALUCORE® Documentation File

ALUCORE® CD ROM

Original samples with standard surfaces

Samples

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2/09

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ALUC

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3A Composites GmbH78224 Singen, GermanyPhone +49 (0) 7731 80 34 40Fax +49 (0) 7731 80 38 03info.eu@alucore.com

www.alucore.com