Professional Documents
Culture Documents
ETEM S.A
url http://www.etalbond.com
Contents
Material description
● applications
Product information
● panel dimensions
● mechanical characteristics
● rigidity and weight
● flatness
● dimensional tolerances
● fire behaviour
● additional certifications
● efficiency and sustainability
● energy consumption and saving
-energy consumption for production
-energy conservation for maintenance, repair, refurbish or replacement
-energy saving by thermal insulation
● recycling
● reliable quality
● endurance
● thermal characteristics
- thermal expansion / contraction
Surface finishes
● coating type
● performance
● paint consistency
● coating direction
● paint durability
● optional coatings
● touch up paint
Prevention of panel edge corrosion
Panel handling
Protective film removal
Panel cleaning
Processing
● Cutting
-saw cutting
-machinery
-shear cutting
-machinery
● Routing
-vertical saw
-portable circular saw
-disk milling cutters
-hand operated router
-milling cutters for hand routing
-routing directions
-CNC router
● Bending
-press brake
-3-roll bender
-disk milling cutters
● Joining
-rivets and bolts with nuts
-screws and bolts
-structural adhesives
-double sided tape
Aluminium 0.50 mm
Polymeric or
Fire Resistive Core
Aluminium 0.50 mm
ii) Etalbond-FR is the Fire resistant version consisted of a non-combustible mineral filled core.
Aluminium
Thermoplastic or
Fire resistive core
Aluminium
Material Advantages
● Lightweight and rigid
● Flat surface
● Design flexibility
● Weather resistant
● Simple assembly and easy interface with other systems
Material Applications
The material is suitable for a wide variety of applications: wall cladding and facades, fire resistant structures,
roof edging and fascias, interior decoration, light supporting structures, exhibition stands, false ceilings,
machine coverings, signage.
Product information: etalbond and etalbond-FR is produced in the following standard dimensions.
● Standard dimensions
Thickness Width Sizes (mm) Length Surface Area Width Sizes Special Lengths
(mm) sizes (mm) (m2) (mm) UP to (mm)
3 1250, 1500 3200 4.0, 4.8 1250, 1500 4000
4 1250, 1500 3200 4.0, 4.8 1250, 1500 7000
6 1250, 1500 3200 4.0, 4.8 1250, 1500 7000
● mechanical characteristics
The mechanical properties of the etalbond panel is determined by the 0.5 mm thick aluminium 3105 /H44
face sheets.
Tensile strength, Rm ≥ 150 N/mm2 Panel characteristic properties:
Yield strength, Rp0.2 ≥ 120 N/mm2 Flexural strength, ≥ 85 MPa
Elongation, A50 ≥ 4 % Flexural modulus, ≥ 12.000 MPa
Modulus of Elasticity, E = 70.000 N/mm2
Panel Weight of Weight of Rigidity Moment of Section Equivalent Aluminium Equivalent Steel
thickness etalbond® etalbond-FR (ExJ) Inertia Modulus Aluminium Weight Steel Weight
(mm) Kg/m2 Kg/m2 kNm2 / m cm4 / m cm3 / m thickness Kgr /m2 thickness Kgr /m2
mm mm
3 4,6 - 0,125 0,159 1,25 2,7 7,3 1,9 14,8
4 5,5 7,6 0,240 0,310 1,75 3,3 8,9 2,4 18,7
6 7,4 11,2 0,590 0,751 2,75 4,5 12,2 3,2 25,0
5.6 kg
Etalbond 4 mm
8,9 kg
Aluminium 3,3 mm
● dimensional tolerances
Dimensional tolerances
Thickness ±0.20 mm
Width -0 / +1 mm
Lengths 1000 - 4001 mm -0 / +2 mm
Lengths 4001 - 7000 mm -0 / +10 mm
Diagonal Difference (max) 3.0 mm
Thickness ±0.05 mm
Bow Up to 3200 Max deviation from flatness = 9 mm
flatness 3201 - 7000 mm 0,003 x length (mm)
● fire behaviour
etalbond®, has obtained the following Approvals and Fire Classification
Country Test according to Classification
Germany DIN 4102, Teil 1 B2
Index 0
BS 476, Part 6
UK Class 1
BS 476, Part 7
meets therefore Class 0
France NFP 92-501 Class M1
Italy CSE RF 2/75/A, RF 3/77 Class 1
Austria ONORM 3800 teil 2 Class B2
GOCT 30244-94 G-2
GOCT 30402-96 B-1
Russia
GOCT 12.1.044-89 π. 4.18 D-2
GOCT 12.1.044-89 π. 4.18 T2
Switzerland VKF fire regulation Class 4.2
USA ASTM E84 Passed
etalbond®, -FR has obtained the following Approvals and Fire Classification
Country Test according to Classification
Austria ONORM 3800 Teil 2 B1, Q1, Tr1
Switzerland VKF fire Regulation Class 5.3
Germany DIN 4102, Teil 1 Class B1
EN 13501-1: 2002
EU - Euroclassification EN ISO 11925-2 B- s1, d0
EN 13823: 2002
ΓΟCT 30244-94 G-1
ΓΟCT 30402-96 B1
Ukraine
ΓΟCT 30444-97 ΡΠ1
ΓΟCT 12.1.044-89 Д2
USA ASTM E84 Passed
●additional certifications
Country Approval Body Certification
POLAND ITB Aprobata
UK BBA British Board of Agrèment Certificate
ITALY Ministry of Interior Homologation
SWITZERLAND VKF VKF Homologation
Ukrainian Certificate and Act of
UΚRΑΙΝΕ Ukraine State Certification Center
acceptance of certification works
● dimensional tolerances
Dimensional tolerances specifications
Thickness ± 0,2mm
Width - 0 / +2mm
Length - 0 / +4mm
Diagonal Differences Max 3mm
Etalbond as a versatile material adapts perfect to all building's contours and allows architects to create new
architecture. The perfect combination of formability, flatness, stability and weather resistance that characterizes
this material. Further due to its composite structure, Etalbond® can be shaped in a multitude of ways without
loosing its rigidity.
● Resistance to mechanical damage
In normal circumstances the etalbond and etalbond-FR have adequate rsistance to abrasion and scratching.
Hard body impacts may result in indentation damage to the outer skin of the products, but paint adhesion will
be maintained.
● Maintenance
Regular maintenance inspections should be carried out to ensure that both rainware and fixings are secure.
Cleaning of installation may be periodically necessary (especially in humid, marine or industrial environments)
both to restore its appearance and to remove potentially corrosive deposits. This can be done by hosing with
water, using a neutral detergent (see cleaning instructions).
Etalbond, etalbond –fr composite panels are used for Back ventilated building cladding. The external cladding
system using etalbond acts as a barrier against the elements while the formed ventilated space reduces the
heat transmission.
The air circulation between the etalbond cladding and the outer wall is
caused by air and temperature changes.
When the external temperature is hot the circulating air permits the
inner wall surfaces of the building to cool off. This way energy is saved
otherwise spent to cool the building.
When external temperature is cold, it prevents the heat loss from the
building interior and saves on the heating cost.
Cold and moisture from the building inside or from precipitation is dried out naturally.
Additionally the inherent corrosion and weather resistance of the panels make the material durable and long
lasting. This way etalbond®, etalbond-FR not only help building insulation and contribute to substantial
reduction in energy consumption for both heating and ventilation but also extend the durability life of the
building itself.
etalbond® or etalbond-FR panel by having better rigidity than solid aluminum metal it serves the same function
with much thinner aluminum sheets and thus less energy consumption (embodied energy). As a result,
etalbond® / FR save more than half of electricity required to produce a solid aluminum plate of equivalent
rigidity. The energy content in aluminium in composite panels drops even further by energy savings and
emission reduction due to low transportation weight of aluminium composite panels in the use phase.
Energy saving by thermal insulation Layer etalbond® and etalbond-FR are used for external or internal
cladding, the air space between the aluminium composite panel and backing building wall forms a thermal
insulation layer which increases the wall system's energy conservation performance. This energy saving can be
further increased by providing additional external insulation on the building.
case 1: Heat transmission through an actual wall
Etalbond 4mm
Back ventilated space 50mm
Building wall 100mm
Air space 50mm
Plaster wall 12mm
K= 1,8 Kcal/m2h ºC
Etalbond 4mm
Back ventilated space 50mm
Glass wool 50mm
Building wall 100mm
Air space 50mm
Plaster wall 12mm
K= 0,50 Kcal/m2h ºC
● Reliable Quality
Both etalbond® and etalbond-FR
panels are produced under the
proper control based on ISO 9001
quality assurance system.
incoming raw Materials. The additional product certifications and the related obligations by holding them active
and well in place are sound proofs of ETEM’S dedication to retain its reputation as a reliable partner who will
continue to supply its customers with high grade quality products in the best possible price.
The performance of the coating will depend upon its environment, locations and aspect face. It will retain a good
appearance for at least 20 years in non- corrosive environments and at least 12 years in severe industrial
environments given that the cleaning instructions given by ETEM are respected.
● thermal characteristic
- thermal expansion / contraction
The thermal characteristics of LDPE core is: λ pe = 0,29 W/m2 K
The etalbond panels can be used in a temperature range of -50 º C to +80 º C.
The measured thermal resistances of etalbond® and etalbond-FR panels are shown in the table below.
In a practical way etalbond and etalbond-FR cannot be considered as insulating panels by themselves. Etalbond
and etalbond-FR cladding can be combined though with properly selected thermal insulating materials to attain
the required by the local building codes insulation.
The thermal expansion coefficient is the amount the aluminium will change in dimension with a change in temperature. It is
the amount of strain due to thermal expansion per degree Kelvin (or Celcius).
The Etalbond®, etalbond-FR panels will expand or
contract in a rate similar to that of their aluminium skin. That
means that no relative movement between aluminium and
etalbond® or etalbond-FR cladding. In case the substructure is
made of steel and because its thermal expansion is less than
etalbond that of Aluminium a certain extend of movement is anticipated.
This movement is normally small 1 to 3 mm and must be
relieved by suitable adjustment such as proper spacing between
substructure panels.
In outside usage with panel connections provide at least a
2.1mm working play between rivet or screw diameter and the
drilled etalbond hole and a smaller play of about 0.1 mm on the
substructure to compensate for thermal expansion.
For etalbond joining use galvanized, stainless steel or aluminium, rivets, screws or bolts.
●When fastening etalbond with rivets or screws, use a step drill to ensure
coaxial hole drilling of panel and substructure. It is suggested to make trials
before starting actual work.
Flexible
●Always use Rivets or screws with heads larger than the etalbond drilled hole
Fixed connection diameter and also provide a working play (about 0.3 mm) between the
etalbond panel and the rivet or screw head.
Substructure configuration with Fixed and Flexible connections and Resisting Forces
Thermal expansion and contraction coefficients of linear expansion for different materials are shown in the table below.
Coefficient of linear
Substance Elongation /1 meter / 50°C temperature difference
expansion
Aluminum 24.0 x 10-6/°C 1.2 mm
Etalbond 24.0 x 10-6/°C 1.2 mm
Iron 11.4 x 10-6/°C 0.57 mm
Steel 12 x 10-6/°C 0.6 mm
Zinc 26.3 x 10-6/°C 1.32 mm
Titanium 8.5 x 10-6/°C 0.43 mm
Concrete 12 x 10-6/°C 0.6 mm
LDPe 100-200x 10-6/°C 5.0- 10.0 mm
Acrylic sheet 50-90x 10-6/°C 2.5 -4.5 mm
Τable showing the expansion in length of the Aluminium in mm
Temperature difference Length of panel
1m 2m 3m 4m 5m 6m 7m 8m
[ºK] Change in length in [mm]
- 30 -0,72 -1,44 -2,16 -2,88 -3,60 -4,32 -5,04 -5,76
- 20 -0,48 -0,96 -1,44 -1,92 -2,40 -2,38 -3,36 -3,84
- 10 -0,24 -0,48 -0,72 -0,96 -1,20 -1,44 -1,68 -1,92
0 0 0 0 0 0 0 0 0
10 0,24 0,48 0,72 0,96 1,20 1,44 1,68 1,92
20 0,48 0,96 1,44 1,92 2,40 2,88 3,36 3,84
30 0,72 1,44 2,16 2,88 3,60 4,32 5,04 5,76
40 0,96 1,92 2,88 3,84 4,80 5,76 6,72 7,68
50 1,20 2,40 3,60 4,80 6,00 7,20 8,40 9,60
60 1,44 2,88 4,32 5,76 7,20 8,64 10,08 11,52
70 1,68 3,36 5,04 6,72 8,40 10,08 11,76 13,44
80 1,92 3,84 5,76 7,68 9,60 11,52 13,44 15,36
If thermal expansion is inhibited, the resulted thermal distortions give rise to stresses that might damage the
structure. To absorb the thermal distortions , suitable adjustments should be put in place according to the initial
study which should be followed by the cladding constructor.
● Installation
It is strongly recommended to
install all panels in the same
direction as marked on the
protective peel-off-film to
avoid possible colour
reflection differences.
●To ensure colour consistency, It is imperative that the total requirement for a project should be placed in a
total order of one width.
In low elevation buildings it is suggested to clean from bottom up and rinse from top to bottom.
Always test clean small areas first to make sure that the mild soap used does not cause any problem on the
etalbond surface. Keep in mind that cleaners should not be used indiscriminately.
Do not use excessive and abrasive rubbing as may alter or change the surface glossiness.
Always rinse thoroughly with clean water after finishing with cleaning.
Avoid strong solvents or strong concentrations of other cleaners as they can damage the etalbond coated
surface.
Keep away abrasive cleaners from etalbond coated surface .
Remove rundown soapy waters as soon as possible.
Never use on etalbond coated surface any paint removers, aggressive alkali, acid or abrasive cleaners. Never
use strong organic solvents on etalbond.
Follow manufacturer’s recommendations for diluting cleaners.
Etalbond Maintenance:
Clean regularly etalbond coated surfaces found in cities, as once per year. This way the dust and fume
accumulation will not get considerable and the cleaning will be easier. In severe Urban and Industrial areas
thorough cleaning is necessary twice per year or for stains originated from tree sap, chimney fumes,
insecticides, SO2 etc...
The finish should be washed gently with a mild solution of soap or mild detergent and lukewarm water (1/3 cup
mild detergent per gallon of lukewarm water).
Using a soft cloth or sponge, gently wash the coated surface to loosen dirt and grim and rinse well with clean
water.
To minimize streaking, wash from bottom to top. An adequate rinse should be assured to cleanse the finish and
also further dilute the solution. To prevent water spotting, thoroughly dry with cellulose sponge.
Avoid the use of abrasive cleaners, squeegees and/or other cleaning implements that may mar or gouge the
coating.
Etem recommends AAMA’s “Voluntary Guide Specification for Cleaning and Maintenance of Painted Aluminium
Extrusions and Curtainwall Panels”, Publication 610.1-79 as a suitable reference.
Forklift unloading:
When loading or unloading etalbond panels with the use of a forklift, make sure that the lifts are set to their
maximum distance apart and located centrally between the pallets. Pallets should be unloaded one by one and
placed on even ground.
Crane unloading:
When unloading the panels lifting slings will be required. Make sure that that lifting slings are in place, in good
condition, located with protection to the bottom panel and that package is balanced. Ensure that no people are
below the pallet during a lifting operation.
Lifting equipment:
ETEM recommends the use of approved types of lifting or suction equipment or panel clamps for the safe and
easy installation of etalbond panels.
Surface finishes
● coating type
etalbond® and etalbond-FR are available in a wide range of metallic or solid, standard and non- standard coil
coated colors applied on pretreated aluminium substrates. These high performance finishes are especially
suited for cladding applications and provide outstanding exterior durability, good formability, excellent color and
gloss resistance, good adhesion and corrosion resistance.
- Upper face: The coating finish could be either PVDF 3C system, PVDF 2C or very high durability
Polyester.
The PVDF-2C coating finish (contains 70% Kynar 500® PVDF or Hylar
5000® resins) is a 2-coat High performance fluoropolymer, Ideal for
normal environments and include both metallic and opaque finishes.
The total paint thickness is in excess of 25 microns. Meets ECCA
performance requirements and AAMA’s 2604.
Very High durable polyester paint on the other side could be an alternative if lesser performance in terms of
durability and overall performance is acceptable. This type of paint satisfies AAMA 2604 and AAMA 2603
guidelines (voluntary specification, performance requirements and test procedures for High performing organic
coatings on aluminium extrusions).
● paint consistency
-The whole coated process is rigorously controlled and monitored on a continuous basis to ensure a high quality
on the applied paint system.
-Nevertheless for large projects we recommend the placing of a global order to avoid different paint batches
which could result in possible slight shade differences due to paint line adjustments.
● coating direction and colour difference – Install panels in the same direction as marked on the protective film
and the back of the panel to avoid, colour shading due to the random orientation of metallic flakes (metallic
and special colours) and the mixing of coil coating paint directionality in solid colours.
● paint durability
The performance of the pvdf coating will depend upon its environmental, location and aspect face. It will retain
a good appearance for at least 20 years in non-corrosive environments and at least 12 years in severe
industrial environments given that ETEM proposed cleaning procedures on a yearly basis are followed and
documented.
● Touch up pain For covering up small scratches there are available in most etalbond pvdf (duranar) touch up
paints by using small brushes . Please be aware that brushed spots may not match completely the original
finish in appearance, as the two systems differ as original paint is furnace cured while the touch up is naturally
cured. Please make a test prior to any touch up application or overspray and follow the instructions provided by
the paint supplier.
● prevention of edge corrosion if etalbond panels are used in a corrosive environment corrosion start
developing little by little at the cut edges (exposed edges) and tends to advance its way through resulting in the
gradual detachment of aluminium face from the core material. To avoid corrosion on the panel edges it is
strongly recommended to protect the edges (some manners are shown below) or by covering the edges with
suitable aluminium profiles.
Compatibility To prevent electro-chemical corrosion direct contact with copper or water run-off from copper
installations, or direct contact with lead in coastal environments, should be avoided. Fixing devices must be of,
or compatible with aluminium. Precautions must also be taken (e.g by using a strip sealant) to prevent direct
contact with timber preserved with copper or fluoride compounds or treated with a fire retardant.
● Recycling
It is well known that aluminium is 100% recycled without quality loss. In recycling terms the
aluminium record is by far unbeatable.
70% of all Aluminium manufactured the last 100 years is still in use today. To this record it should
be added the fact that recycling aluminium today consumes only 5% of the original amount of
energy for producing primary aluminium from bauxite ore.
During etalbond® manufacturing the scrap produced is systematically reduced and recycled (both
aluminium and plastic core) to keep an environment friendly operation, fact that emphasizes Etem’s
concern for resource conservation and environmental responsibility.
● Workability
One of the most important features of etalbond is its great workability. It can be cut by using a multitude of
machinery , it can be folded after grooving, it can be bent with a press break or a 3-roll bender and also the core
material can be welded with hot melt adhesive.
● Cutting
Existing machinery and tooling used for woodworking and metal can be used for the saw cutting of etalbond®.
Below an indicative list of saw cutting equipment with nominal values for tool geometry and working conditions
is supplied for easy reference.
Prior to processing large quantities trial saw cuttings should be done to evaluate both the tool working
conditions and the recommended cutting speeds.
For markings the use of a soft pencil is adequate. Hard marking tools should be avoided as they can fracture
the Aluminium surface.
The chips formed during saw cutting should be taken away with compressed air.
Due to the nature of etalbond® material it is best to move the saw blade than the material as no scratch will
remain on the panel.
etalbond® can be cut to any shape with a jig saw and if circular shaped, by using an auxiliary circular cutting
tool.
If good saw cutting practices are applied and recommendations followed the result should be clean cuts with
little burr. If despite following the recommendations ragged cuts are produced check the following causes; poor
tool support, tool vibration, blunt cutting edges, high frictional heat at the cutting edge.
As etalbond® has low thermal conductivity it cannot be cooled easily with compressed air or any other means.
Thus it is recommended to select the tool geometry and cutting conditions in such a manner so as to minimize
the frictional forces developed at the cutting point and keep the resulting heat at a low level.
Vertical Panel For higher productivity vertical panel saws are used.
unit in automatic
mode
Pneumatic locking of
the saw carriage
Pneumatic locking of
CNC machine the beam carriage
CNC Machine
etalbond® can be
easily sheared by
using rotary shears
or guillotine shears
with advanced
cutting technology.
A conventional
Portable Circular
Saw can be used
for cutting
etalbond® quickly
and accurately. It
should be
combined with a
guide rail, in order
to ensure straight
line cutting.
All circular saws can be adjusted in two ways: For depth of cut (top) and for angle of cut (bottom). Reducing the
depth of cut allows to cut grooves and slots across the face of a panel. Adjusting the angle makes bevel cuts
possible, usually up to 45°. Always unplug the saw when making either adjustment. Reference nominal values
for tool geometry and working conditions are as per the following:
Milling cutters are cutting tools used in milling machines. They remove material by
their movement within the machine or directly
from the cutters shape.
For etalbond we suggest the use of a milling
bit with helix flutes (deep helical grooves)
running up the cutter. The tooth cuts the
panel, and chips of its material are pulled up
the flute by the rotation of the cutter. Milling
cutters may have from one to many teeth, with
2, 3 and 4 being most common. The more
teeth a cutter has, the more rapidly it can
remove material. Why helical? Because if the flutes were straight, the whole tooth would impact the etalbond at
once, causing vibration and reducing accuracy and damaging surface quality. Setting the flutes at an angle
allows the tooth to enter the material gradually, reducing vibration. Typically, finishing cutters have a higher rake
angle (tighter helix) to give a better finish.
Jig saws are handy tools for cutting etalbond. The most important part of the saw
ιs the blade. Blades are classified by the number
of teeth they have.
In case burr occurs on the cut edges, or the edges need to be rounded, a common hand-
held scraper can be used after cutting for smoothing out.
Routing:
etalbond® can be routed by using conventional equipment (horizontal and
vertical routing machines). For accurate and precise manual folding of the
etalbond® composite panels, resulting in a good finish, we route the rear side of
the panels and extract the aluminium sheet and a part of polyethylene or fire
resistant core. Normally the panel is grooved and folded 35mm from the edge.
1) Vertical panel saw, equipped with special shaped routing saw blades:
The equipment needed is the same vertical saw used for the cutting, but with a
special shaped routing saw blade and a relevant equipment for adjusting the
routing thickness. horizontal or even angular on the axes of the panel- routing can
be made provided that etalbond® panels are placed in a suitable position. These
equipment should always operate with the use of a chip collector to avoid dust.
2) Circular saw, with a suitable routing disk can be used only for limited number of
processings. Note that special care should be given on the stability of the portable
circular saw during processing of the material, as well as the precision of the
routings with the help of the chosen guided system.
3) Hand operated or Portable Plunge Router with routing bits and combined with
suitable guides are able to cut or route etalbond®
panels in many different contours and shapes. As in
CNC, machines, these routers use rotating milling
cutters or special routing bits -carbide tipped cutter- the
hand operated router can be used for a limited number
of processes.
When a V-groove is bent at 90°angle the bending radius of the final product will
be 2-3.5 mmR and the element will elongate by 0.5 to 1mm.
In general the folding radius is determined by the shape and depth of the groove.
It is advisable that several trials are made before start, to insure the required
folding radii in etalbond cassettes.
For processing small quantities of panels a router and trimmer can be used.
Technical characteristics:
Material: carbide
Νo of teeth: 2 - 4
Feeding speed: 3 - 5 m/min
RPM: 20 000 - 30 000
For processing large volumes of V-grooving as standard industrial production, a circular saw and a grooving
cutter are needed along with a lifter.
Punching – notching
Drilling
Etalbond can be drilled with standard twist drills used for aluminium and plastics on machinery common for
metals. Holes can be made on etalbond with a hand drill or a drill press with a drill bit or circle cutter.
Drill Bit specifications: Twist drill, High speed steel (HSS)
Tool geometry
Tip angle: 100 -140 or counter –bore grind with centre-point
Cutting speed: 160 -980 rpm
Chips removal during drilling process can be obtained by using a high rpm low feed and by occasionally lifting
up the drill.
Bending
Etalbond panels can be bended by the following methods.
Bending with press brake: etalbond can be bend with a press brake. The minimum bendable radius for a
Protective
90º Bending is as follows:
film Etalbond can be brake formed from flat up to 90º to form a right angle.
It has been determined that etalbond (4mm) panels can be bent 90º at
a min inside radius of 19 mm (by using a hydraulic brake press with an
open air bend bottom die with an inside opening of 50 mm and an
edge minimum distance of lmin= 5 x t (panel thickness) = 20mm (for 4
etalbond mm).
To avoid damage of aluminium skin It is recommended that the center
l of the die be filled with rubber up the top edges.
As with any fabrication technique it is strongly recommended to make
trial bends with scrap material first before any actual fabrication is
undertaken.
A roll bending machine –mainly three or four roll machines- allows a larger
ending radius than in press brake. It should be ensured though that the feeder rolls
do not press too tight and distort the composite material. The minimum bendable
limit depends on the machine type used and the length of bender.
Joining techniques
standard processes used in metal and plastics industry can also be utilized for joining etalbond. If etalbond is
to be joined to extrusion profiles or structural framing then taping screws, rivets, bolts /nuts can be used.
Structural adhesives and double faced high strength tapes can also be used in conjunction with mechanical
fastenings.
Tapping screws
When joining etalbond for outdoor use, the thermal expansion of etalbond should be taken into account.
To avoid the development of thermal stresses, the hole diameter in the panel must allow for
the expansion.
Fastening without thermal obstructions is possible by using stainless steel screws with
sealing washer that are been approved for construction. These screws should be suited for
the certain substructure.
It is preferable that the screws are tightened with a torque wrench or screwdriver and the
sealing washer is used on the panel for both sealing the drilled hole and protecting the panel
surface from excess pressure.
Only aluminium, stainless steel and plastic can be directly connected to etalbond without
special precautions.
Shown above a 304 steel tapping screw for aluminium composite panels:
Easier fastening with "no walking" on the panel at the start of the installation Torque wrench
Rivets, bolts/nut
Etalbond panels can also be fastened together or joined to aluminium extruded
elements with inox or aluminium blind rivets or bolts.
If blind rivets are to be used make use of Special wide closing heads or tightly
fitting washers for the protection of etalbond surface. The suggested rivet shaft
diameter should be 5mm while the rivet head diameter should be from 11 to 14
mm.
The thermal expansion of the aluminium panel should be taken into consideration
for this and to avoid problems the hole on the panel should always be larger than
the rivet shaft to allow for expansion.
Either multistep drills or hole gauges having corresponding diameters and
allowing for a tolerance of 0.3 mm ( please always make a test prior to any
application as many factors can influence correct riveting) should be used for
fitting the rivet on center. It is important to always remove the protective film from the affected region prior to
riveting.
Component 1: Etalbond
Component 2: sub-structure
Component 3: stepped drill
Attention: This step should be taken by exerting maximum care when drilling in
order to avoid stresses.
Component 1: Etalbond
Component 2: Sub-structure
Blind rivet and riveting tool form a system. Always use tools that rivet manufacturer
recommends. Attention should be paid to the proper mouthpiece that corresponds to
the appropriate rivet diameter.
If the mouthpiece is too large then a fin from the rivet collar will be drawn into the mouthpiece or the entire
mandrel will be drawn through the rivet collar.
When using threaded fasteners or bolts caution should be taken not to over tighten the fastener.
Riveted joints have high strength and endurance and are well suited for joints which may be subjected to
frequent jolting and vibration.
It is recommended to use a large head with a washer to allow for a better load transmission.
Rivet Failure mechanisms: It is of importance to know the mechanisms of failure of this important jointing
mechanism in riveting of similar or dissimilar materials.
A rivet joint may fail as a result of a number of mechanisms shown below.
Rivets are initially sized with nominal diameters between 1.2 x √t and 1.4x√t (where t= plate thickness).
Removal of an installed Rivet. Several times there is need for removing an installed rivet. The recommended
steps are shown below.
SCREWS:
Where connections with screws are concerned the same technical requirements apply as with rivet connections.
In selecting screw material, care should be exercised to ensure that the connectors do not corrode. For this
Aluminium or Stainless steel screws are used. Aluminium or Stainless steel screws are installed through pre
drilled holes.
SCREW TYPES: The following type of screws can be used with Etalbond
……………………………………………………………………………………………………………………………………………………………………….
……………………………………………………………………………………………………………………………………………………………………….
Galvanized or Stainless steel or Aluminium bolts, nuts and washers should be used to avoid metal corrosion (
between dissimilar metals).
When Bolts are used for joining Etalbond extra precaution should be taken not to deform the Aluminium skin of
Etalbond as a result of over torquing.
To be on the safe side use lock nuts or double nuts with washers to prevent the nut from loosening over the
time.
A manual Torque wrench which incorporates a gauge or other method to indicate the amount of torque
transferred to the nut or bolt is recommended when tightening a bolt to Etalbond panels.
σε = Fε / t x D
where,
σε Max stress (kgr/mm2)
Fε Tensile force (kgr)
t Etalbond thickness (mm)
D Hole diameter (mm)
Always make hole allowances for avoiding jamming due to thermal expansion of aluminium (observe always
fastening guidelines in riveting and bolting).
Important note: Make sure that protective film is removed prior to screwing, riveting or bolting.
Taking mechanical fastening into account, additionally for low tensile or transversal strength requirements and
elastic connections one component polyurethane adhesives are effective.
Yet a wide variety of commercial adhesives for joining and assembling etalbond can also be used except those
which may corrode the aluminium substrate. Vinyl acetate type adhesives corrode aluminium.
For high strength and elastic connections for inside uses we recommend the usage of either SIKAFLEX 252,
SIKAFLEX 11FC, SIKA Bond –T2 or Prosyflex 3000 by Tremco.
Important note: 1) Please follow manufacturer’s instructions regarding the application and use of adhesives.
2) adhesives do not adhere to plastic core and the etalbond cut edges.
Νοtes on adhesives:
Prior to any adhesion work clean carefully the area to be adhered.
Select most appropriate adhesive that ensures adhesion integrity in the atmospheric conditions where it is
applied.
Always pretest adhesives before fabrication and installation and subject the samples to possible working
temperatures to observe possible distortions due to shrinkage of adhesive or deflections due to different
thermal expansion rates of the joined components.
One of the major advantages of thermoplastic substances is their heat weldability. The
thermoplastic material when heated sufficiently temporarily changes from a solid to a semi-solid
state enabling separate sheets or panels to be fused together and return to a solid upon cooling
providing a watertight, permanent bond. At the end a scraper blade is used to shave the remaining
welding material and get a smooth seam as soon as it has cooled down. Thus, a joining is
created.
The hot air welding it is useful in joining also etalbond panels making use of the welding
ability of polyethylene core. For this to obtain, the etalbond parts should have chamfered
edges to the corresponding angle of the finished part allowing an exposed polyethylene
surface on the welded side. A plastic rod of same properties as polyethylene core should be
utilized together with a hot air welder having a pressing apparatus.
Hot melt systems can be used to join etalbond given that the surfaces envolved are properly abraided and
cleaned. Only properly designed hot melts for aluminium bonding are to be used. Please follow manufacturer’s
directions for proper use.
●Single folded Cassette - This option is consisted of using aluminium (thickness 2 to 2.5 mm) or galvanized
steel (thickness 1.5 mm) as substructure elements combined with aluminium angles for the support of
etalbond in boxes. The aluminium angles are attached on the metallic substructure by the use of self taping
stainless steel fasteners or screws [use at least two fasteners per angle] while on the etalbond or etalbond-fr
side the attachment is performed by using Aluminium rivets Φ5 (two per connection). Below a cassette
construction and Mounting scheme of single folded cassettes is shown on the next page.
Corner cut out
Edge
Side folding
Sides folding
(single folded
Back side
cassette)
V-grooving
Aluminium
support angles Single
(30x30x3)mm Backfolded
side
Corner Back side cassette
attached to the
joining
Back side perimeter of attachment
to
Aluminium single folded substructure
angles in cassette
2mm
When all single folded cassettes have been fastened in place, the
formed scotias (Gap or separation openings) are covered with
etalbond strips bonded in place
Aluminium Angle
Adhesive
Etalbond Etalbond
back side back side
Etalbond
ebo
coated
face
Attachement concept of etalbond, etalbond–fr single folded cassette with scotia covering (Gap covering) with
etalbond strip
ETEM has available and proposes for usage the VARIO system as a reliable yet economic fixing system for the
attachment of Etalbond double folded cassettes (Additional information for this system, can be found on ETEMs
ventilated facade systems technical catalog).
1. etalbond
2. T-main
profile
3. fixing
Bracket
4.thermo-
insulation
pad
5. anchor/
Dubel
6. rivet
4.8x12
7.thermal
insulation
Horizontal section: VARIO fixing system etalbond double folded riveted on T-profile
2] PLAIN Etalbond sheets: - Etalbond panels could be used in Plain sheets only under the condition that care has
been taken that the edges of the material are protected against the elements (humidity, toxic rain, pollution).
This edge protection can be done by covering the exposed aluminium at the edges.
ETEM offers a number of special Aluminium profiles for mounting plain etalbond sheets and designed to offer
the necessary edge protection against corrosion. Below is a table of special profiles for use with etalbond plain
sheets with the respective drawings for mounting.
Special profiles for use with etalbond Drawings of Mounting Flat panels with special profiles and adhesive strips
plain panels
Galvanized steel
Aluminium Angle
50x50x4
Substructure
Substructure
Double face adhesion strip
Substructure
Etalbond panel
Etalbond panel
Double face adhesive
Special profiles for use with etalbond Drawings of Mounting Flat panels with special profiles and adhesive strips
plain panels
Profiles
3420, 3421
In visible fixing as is the rivet or screw fixing the smooth façade of the
etalbond cladding will be punched and the screw or rivet heads will be
observed from a distance. In practice though and when the façade is
observed from a distance no noticeable surface disruption is obvious.
There are several patterns that can be followed to make the rivet or
screw fixing option more attractive. Some of those patterns are shown
below.
BRAVO system
1. etalbond
2. hanger
3. main
profile
4. fixing
bracket
5. thermo-
insulation
pad
6. self drilling
screw
4.8x32
7. rivet
4.2x12
8. anchor/
Dubel
9. thermal
insulation
● Ensure that etalbond® pallets are safely fastened on the track-bed and handled carefully during transport
and unloading.
● Ensure that pallets are carefully examined upon delivery for any shape deformation, damage to the plastic
wrapping or any moisture presence (etalbond® panels which are wet must be dried to avoid formation of
dust spots or corrosion forming). Any damage should be reported immediately (by putting a notice on CMR)
and confirmed by the forwarding agent or inform insurance company.
STORAGE
●Store etalbond® pallets in horizontal position in dry areas with controlled temperature and avoid any
condensation forming (when cold panels are set to warmer rooms).
●Store same format etalbond® pallets stacked with a max of 4 pallets on top of each other with the heavier
pallets always at the bottom.
●Do not store etalbond® panels standing vertically.
●Storage exceeding 6 months should be avoided
PANEL LIFT
● Individual etalbond® panels must be lifted off the pallet by two people holding all four corners.
● Avoid panels to be drawn over each other.
● Wear gloves as personal protection and to avoid markings on the panels.
GENERAL PRECAUTIONS
●Do not mark with ink or stick tapes or labels on the protective film of the panels, in order to avoid
penetration of solvents or plasticizers.
● Arrows (printed on the protective film and on the back side of the panel) must follow the same direction,
when the panels are installed on the building, to avoid variations in colour perception.
● Protective film must be removed the soonest possible after installation on building.
Important Notice:
Care has been taken all information contained in this processing manual to be reliable and ensure accuracy from
information available at the time of printing.
ETEM cannot guarantee nor have any responsibility for the technical information provided herein which should be treated as
a general guide.
ETEM does not accept responsibility for any loss as a result of any company or person relying only on the material in this
publication or for any mistakes or misprints.
The use of any such information provided is the clear responsibility of the technical and professional user.
Due to continuous development and new knowledge, ETEM reserves the right to change technical information without prior
notice.
ETEM s.a
4 Iroon Polytechniou str., 190 18 Magoula Attikis, Greece
Tel: +30 210 4898 605, +30 210 5558 402
Fax: +30 210 4898 500
http://www.etalbond.com
Email: info@etalbond.com
STEELEMET S.A
119A llienci blvd., Sofia, 1220 Bulgaria
Tel: +35 92 92 19 111
Fax: +35 92 92 19 160
http:// www.steelmet.bg
email: info@stmet.com
ETEM S.C.G
Cara Dusana bb, Industrijska zona Nova Pazova
Tel: +381 22 32 80 20
Fax: +381 22 32 8019
e-mail: office@etemscg.co.yu
TEPRO METAL
Kreuzstrasse 20,
40210 Dusseldorf, Germany
Tel: +49 21 1179281-18
Fax: +49 21 1179281-95
e-mail:criemann@teprometal.vionet.gr
GENECOS
Rue de Passy,
75016 Paris, France
Tel: +33 1 45270754
Fax: +33 1 45270708
e-mail: genecos@genecos.vionet.gr
METAL AGENCIES
Suite 4, Cobb House 2-4 Oyster Lane,
Byfleet Surrey KT14 7DU, United Kingdom
Tel: +44 1932 331111
Fax: +44 1932 331190
e-mail: sales@metalagencies.com
ALUBUILD S.R.L.
Via C. Carra 64 z.i Corte Tegge
42100 Reggio Emilia, Italy
Tel: +39 0522 941218
e-mail: pa.guidetti@alubuild.it