etalbond®, / FR

Technical and Processing Manual

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

Fixing systems and classification / Panel assembly in architectural cladding

Material description
etalbond® is a is a technologically advanced and innovative Aluminium composite panel suitable for
exterior cladding of new buildings and retrofit applications. It is consisted of a core firmly bonded between fine
aluminium facing and backing sheets, and it is available in two versions:

Aluminium 0.50 mm

Polymeric or
Fire Resistive Core

Aluminium 0.50 mm

i) Etalbond-pe which is a standard version of etalbond® consisted of a non-toxic polyethylene core.

ii) Etalbond-FR is the Fire resistant version consisted of a non-combustible mineral filled core.

Combined effect of Composite Material:

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

● rigidity and weight

The composite structure of etalbond® / etalbond® -FR provide an impressive strength-to-weight ratio
advantage compared with other solid materials and makes etalbond® a preferred material of choice, easy to
transport and handle in the warehouse and on project site. The combination of high rigidity and high strength
make the panels retain their shape and remain flat, even when exposed to extreme temperature changes.

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

Equivalent Rigidity in relation to thickness and weight

5.6 kg
Etalbond 4 mm

8,9 kg
Aluminium 3,3 mm

Steel 2,4 mm 18,7 kg

RIGIDITY kNm2/m WEIGHT kg/m2

between etalbond® and solid materials

etalbond® /FR Thickness 3 mm 4 mm 6 mm

Technical and
Physical properties Symbol Unit
Moment of Inertia I [cm4 /m] 0,159 0,310 0,751
Section modulus Z [cm³/m] 1.25 1.75 2.75
Rigidity E·J [kNm²/m] 0,125 0,240 0,59
Aluminium Alloy 3105
Linear Thermal
2.4 mm/m at 100ºC temperature difference
Expansion of Aluminium
● flatness
Etalbond® and Etalbond® -FR are very flat, compared to solid metal
sheets. Solid aluminum sheet, for example, has a slight distortion
stemming from its rolling process: buckles, edge waves and overall warping
are common. Composite panels flatness stems from the laminating
process itself in which most of such distortions are eliminated.

● 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

GOCT 30244-94 G-1

GOCT 30402-96 B-1
Russia
GOCT 12.1.044-89 D2
GOCT 12.1.044-89 T2

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

Lengthwise Flatness tolerance Max Bow

3200 mm 9 mm
> 3200 mm 0,003 x Length (mm)

Widthwise Flatness tolerance Max Bow

1000 mm 4 mm
1250 mm 5 mm
1500 mm 6 mm

Aluminium Coil Thickness tolerances

Width
Thickness

1250 mm 1251 -1600 mm

0,5 mm
± 0,04 ± 0,05

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).

● Efficiency and sustainability

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.

This way the building is protected from increased and rapid

temperature fluctuations providing both hydrothermal and insulation
protection to the building.

The back ventilated façade system in principle works as follows.

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.

● Energy Consumption and Saving

Energy consumption for production
It is well documented that aluminum metal acquires large amount of electricity to be produced. To produce 1 kg
of primary aluminium it takes 170 MJ (at some countries 227 MJ/Kg) of energy while recycling aluminium only
'costs' about 10 MJ/kg.
Since aluminium typically is a mixture of the two, the energy content is taken as 100 MJ/kg

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 conservation for maintenance, repair, refurbish or replacement

Further the durability and simplicity in maintenance, repair, refurbish or replace of etalbond®, etalbond-FR
conserves recurring embodied energy and resources during the life cycle of the building, where they are used.

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

case 2: Heat transmission through a wall with thermal insulation

(Rockwool)

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.

Performed periodic production and

quality control monitoring and
inspections of the etalbond® and
etalbond-FR products by well
esteemed third parties like BBA
ensure both the products’ quality
stability of the production process
and inspection control of the

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.

● endurance and durability

Under normal conditions the product will perform effectively as a cladding with an ultimate life of at least 40
years.
The aluminium substrate is durable and will perform satisfactorily in all normal atmospheric conditions including
marine and industrial ( if cleaning procedures set by ETEM are followed), but excluding the immediate vicinity of,
and down wind from, sources of abnormal corrosive contaminants, such as chemical works, cement works,
copper foundries.

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.

etalbond® /FR Thickness 3 mm 4 mm 6 mm

Thermal resistance Symbol unit
etalbond® λ etalbond W/m2 K 0,0873 0,0981 0,0949
etalbond® -FR λ etalbond-FR W/m2 K - 0,0293 0,0270

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.

-thermal expansion / contraction

The linear thermal expansion coefficient of both etalbond® and etalbond-FR panels is the same as of aluminium cover sheet.
Linear thermal expansion means the product will expand in all directions and this needs to be allowed for in design
calculations. The calculation is:
→ given factor x 10-6 x length x change in temperature °C.

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.

●In fastening, either a substructure (fixing) system or a panel observe that

there must be one fixed point (anchored at concrete or reinforced concrete
base) or a panel riveted or screwed on substructure.
Fixed
Fixed points allow free expansion in all directions and are capable to
withstand both wind and cladding weight loads. Ideally are located on the
upper side (or middle) of the wall for fixing system and either middle or upper
side when it relates to the panel. The rest of the fastening points are flexible Flexible
Flexible connection (movable) points.

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.

● Colour variations will occur between panels from

i) different production batches and
ii) panels coming from different widths

●To ensure colour consistency, It is imperative that the total requirement for a project should be placed in a
total order of one width.

● Panel Protective foil

Protective film guarantees panel finish protection during packaging, transportation, shaping and installation.
The film must remain on the panels for a short time and should be removed as soon as possible after the panel
has been put in position (film should be removed within 1 month after installation). Arrows that are marked on
the film show the direction of coating and should be taken into account during shaping and installation of the
panels.

Always observe closely the following rules regarding protective film.

-To avoid residuals of adhesive on to the surface of the panels due to UV radiation, it is recommended to
remove the protective film as soon as possible after the installation.
-The protective films and the panel surfaces should not come in contact with any kind of inks, adhesive
tapes or stickers, as the lacquered surfaces could be damaged by the included solvents or plasticizers.
- Make sure to remove the protective film as soon as possible after installation as weathering for a longer
period could make the film removal difficult if not impossible (as a rule of thump, the protective film should not
remain -on panels put in position on a building- longer than 30 days).

● Etalbond Cleaning and maintenance

Cleaning methods:
Removal of light surface soil: An initial step recommended is the rinse cleaning with forceful water starting from
the top to down the building wall.
Low water volume with moderate pressure is a good practice to start with in order to dislodge excess dust, soil
and fumes from the etalbond surface.
Next light rubbing of the etalbond surface with soft sponges or soft rags dipped in water with a mild detergent
soap should take place.
The washing should be performed by applying uniform pressure, cleaning first with a horizontal motion and
when finished the cleaning should be repeated with a vertical motion. Follow with a thorough rinsing with clean
water.
This way the panel surface will be cleaned adequately and uniformly.
Rundown of cleaner to the lower part of the buildings should be minimized and these areas should be kept wet
and next adequately rinsed to lessen stains from the unavoidable rundown.

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.

Removal of heavy surface soil, accumulated dust and heavy fumes

In this case some type of mild solvent such as Isopropyl alcohol, ethanol or N-hexane may be needed to remove
caulking compounds, grease or sealant.
Stronger solvents may be detrimental to the coated surface.
To prevent any damage to the finish these solvents should be spot-tested at a small invisible area. Remaining
residues should be washed with mild soap and rinsed with water.

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.

■ Transportation and Handling:

■ Etalbond panels should be handled with care in order not to damage the high quality material surface.
■ Despite of the hardness of the coating and the presence of the protection film the self weight of the
etalbond stack is always a potential mechanism of damage.
■ Etalbond panels should be handled carefully. Long sheets will sag under their own weight thus when lifted
at ends should be supported at additional points, lengthwise.
■ The etalbond panels should be secured against slippage during transport. Never pull or push panels over
the edge during loading or unloading situations as there is the potential to scratch the coated surface.
Instead the panels should be lifted by holding them from both ends.
■ Transport protection films must not be exposed to direct sunshine or to heat for periods longer than 15
Days.

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.

■ Storage of Etalbond Panels

■Etalbond panels should be kept stored in dry and well ventilated areas under normal
temperatures.
■Protect etalbond and etalbond-FR pallets during storage against rain, penetration of
moisture and condensation.
■Only pallets of identical size should be stacked, with a maximum of 4 pallets stacked on
top of each other.
■When Etalbond has to be stacked in high piles use intermediate layers of wood or plastic
and protected against humidity.
■The right storage of Etalbond panels or pallets is on horizontal racks. Flat storage protects Etalbond panels
from warping. Caution should be paid that the precoated surface is protected from any potential scratching.
It is suggested to do not unpack etalbond pallettes until use. After unpacking, restore remaining panels
horizontally into the palette. Do not store Etalbond in dusty places.

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.

PVDF 3C system (3coat finish)

The PVDF 3C thermoplastic coating system is a fluoropolymer 3-

coat, 3-bake system and includes both metallic and opaque
finishes. The total dry film thickness is 30- 32 µm (microns) and
consists of a conversion coat, an inhibitive primer, a metallic or
solid color coat and a fluorocarbon-based clear coat.

Advantages: Suited aggressive environments - increased acid rain

resistance - offers superior UV resistance - Provides increased abrasion resistance -Meets or exceeds the
performance requirements set by ECCA and AAMA 2605.

PVDF 2C system (2coat finish)

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 Durability Polyester [VHDPol]

Etalbond is also available in a 2-coat very high durability polyester

exquisite finishes providing an ultra high durability topcoat, based
on a special polyester resin, and using a wide palette of the most
durable pigments at a substantially lower cost to pvdf.
Etalbond products are continually developing, evolving and
improving as new markets for coil products are steadily growing.
Advantages: increased flexibility - outstanding heat resistance -
good corrosion resistance - meets or exceeds the performance requirements set by ECCA - Lower cost per
square meter
● performance
Pvdf fluorocarbon paint is a high quality coating which combines good formability, high surface durability and it
is resistant to weathering and solar radiation.
Precoated aluminium is coil coated mostly with this type of finish and its paint performance complies with the
‘specifications for coated coil for exterior building applications and the AAMA 2605 (voluntary specification,
performance requirements and test procedures for Superior performing organic coatings on aluminium
extrusions).

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.

Reverse coil side

An inhibitive primer is applied to give enhanced corrosion resistance in usage -from alkali attack when in
contact with cement or galvanic corrosion from steel- and to avoid damage when in contact with the top coat.
Appropriate markings related to the product as time of production, colour, batch number and direction arrows
are printed for tracking purposes.

● 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.

Recommended Edge protection

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.

● Processing etalbond® / etalbond® -FR

Processing of etalbond® can be done with a wide variety of tools and machinery used for aluminium or wood
ranging from inexpensive hand-held tools to state-of-the-art CNC machines.

● 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.

Circular saw Band saw Fret or jig saw

Blade material High- speed steel Hardened spring steel HSS

Blade or Band Geometry
Tooth Geometry
Tooth Pitch
First working orthogonal
clearance anqle.'a'
Contact Angle, V
Max Cutting speed, V
Max Feed speed, 's'
(HSS) or Carbide
ti d (CT)
Blade thickness: 2 to 4mm thickness: 0.8 to 1.2 mm thickness: 1.0 to 1.2 mm
Blade shall be thinner width: 15 to 25 mm width: 5 to 15 mm
between hub and outside
diameter to prevent
Space width and round groove Hook teeth Alternating or wavy
tooth setting
HSS: 10 to 20 mm CT Blade: 10 to 12 4 to 12 mm 1.2 to 3 mm
HSS: 10, CT blade: 15 35 -
DSS: 25, positive (cww) CT blade: 10, 3 to 5 -
HSS: 3 000 m/min iti CT blade: 5 000 3 000 m/min 200 m/min
HSS: 25 m/min CT / blade:
i 30 m/min 25 m/min 10 m/min
Required Machinery:
Usually good quality vertical panel saws or CNC cutters are used. Portable circular saws can be used on small
projects provided they are equipped with a system of guides so as to ensure straight line cuttings. In general
cutting of etalbond® can be done using one of the following conventional woodworking tools:

Straight-Line Cutting Curved-Line Cutting

Vertical Panel Circular Saw 9

CNC Cutter 9 9
Guillotine Shearing Machine 9
Portable Circular Saw 9
Portable Jigsaw 9
Milling cutters 9
Portable Plunge Router 9 9

Vertical Panel For higher productivity vertical panel saws are used.

90º rotation of the

saw

unit in automatic
mode

Pneumatic locking of
the saw carriage

Pneumatic locking of
CNC machine the beam carriage

CNC Machine

A state-of-the-art way to cut etalbond® panels in size is the

use of an automated CNC machine. To achieve the cut, these
machines use rotating milling cutters.

CNC machines can produce all kinds of linear and curvilinear

cuttings in one pass following exactly a given CAD drawing.

Guillotine Shearing Machine

etalbond® can be
easily sheared by
using rotary shears
or guillotine shears
with advanced
cutting technology.

The most suitable

cutting method for
large panels is by
square cutting. The
tolerance between the shearing blades must be regulated to prevent excessive edge rounding of the upper side
of the panel. Depending on the thickness of etalbond® the clearance and the rake angle of the shear should
be as per the following:

etalbond® thickness Clearance Contact (Rake) Angle

3mm 0,04mm 1°
4mm 0,04mm 1°30’
6mm 0,2mm 2°30’
Portable Circular Saw

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:

Diameter of Saw: 8” – 12”

No. of teeth: Maximum Available
Blade material: Carbide Tipped
Blade geometry: Thickness: 2mm to 4mm
(the blade should be tapered towards the center of the disc to prevent jamming)
Tooth geometry: Trapezoid
Tooth pitch: 10mm - 12mm
Clearance angle, α: 15o
Rake angle, γ: 10o, positive
Maximum cutting speed, ν: 5000 m/min
Maximum feed speed, s: 30m/min

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.

The higher the number of teeth the smoother

the finished cut. The material of the blade is
made also effects performance. High Steel (HSS)
blades or Cobalt steel blades( which are harder
than HSS) are used and last longer.

Cutting etalbond® panel to size

A sheet of etalbond® can be cut to an unlimited variety of shapes and sizes.

Finishing cut surfaces

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.

For routing the following mechanical equipment can be used.

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.

In Hand operated tools the stability of the tool and the

guide-system considerably affect the quality of the
routing.

V- Grooving etalbond® panels and Folding

Work directions: For shaped elements with radius between

2 to 3mm proceed as follows. First a V-shaped or rectangular groove is routed by
a milling cutter on the inside of the fold, ensuring 0.3 to 0.5 mm of core material
is left on the lower cladding sheet. The shape of the groove and its respective
depth determines the folding radius. Note that smooth bending (shape forming
of elements) cannot be obtained without uniform thickness of polyethylene
remaining.

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.

As such the original panel should be cut shorter by that proportion.

For even sharper edges (down to 45o degrees) a V-groove

of 135o should be made. The base of the groove should always be flat and about
2 to 3mm wide.

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.

Technical characteristics of carbide saw-tip:

Outside diameter: 305 mmΦ
Νο οf teeth: 24
RPM: 3 000 to 5 000
Feeding speed: 5 m/min
Material: carbide

90º groove cutter

Corner Cut outs:

The use of Composite panels for cladding purposes in relation to the support system used, requires the
construction of box-type shapes, known as cassettes. The construction of a cassette includes the sizing, routing,
corner cut outs for the folding and the joining of the corner elements.

Punching – notching

The punching of flat etalbond parts is performed exactly the

same way as in the aluminium sheets by using evenly cut
ground tools and the smallest possible cutting gap. Punching
with a press for notching and cutting out causes shear droop in
the aluminium surface. To reduce aluminium edge roundness
work the clearance of punch and die to be minimal (panel
thickness x 0.05).

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.

Etalbond thickness Traverse (widthwise) Bending Parallel (lengthwise) Bending

3 mm 38 mm 50 mm
4 mm 38 mm 50 mm
6 mm 50 mm 80 mm
The spring back effect is larger then in solid metals and should be taken into consideration in the process.
Bending with roll bending machine:

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.

In general Rmin = 15 x panel thickness

Etalbond thickness Rmin

3mm 45 mm
4mm 60 mm
6mm 90 mm
As with any fabrication technique it is strongly recommended to make trial bends with scrap material first before
any actual fabrication is undertaken.

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.

CREATING A SLIDING POINT via BLIND or CUP RIVET

by creating a sliding point it makes it possible to compensate for thermal
deformation. This way no thermal stresses are developed on the Etalbond element
due to riveted connections.

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

Special mouthpiece for riveting tongs

as rivet gauge with a specified tolerance
of approximate 0.3 mm

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.

Requirements of a good riveted connection:

The requirement of a good riveted connection is selecting the right material, the appropriate connecting device,
the geometric configuration, the proper sealing washer, the clamping area, the diameter of the blind rivet and
the hole of the rivet. All the above are very important items to establish a strong and durable connection but
several common errors should also be avoided when establishing a riveted connection (as shown below).

i) clamping area too thick

(snap head not fully developed)

ii) clamping set too thin for the set of components

(snap head not fully developed)

iii) components are far apart, therefore

formation of metal collar is impossible

iv) Drilled hole is too large, therefore metal

collar support too small

v) Blind rivet snap head is not in contact with

the component 1 and therefore no snap
head can be formed.
Fastening guidelines for riveting and Bolting
Allow a minimal spacing of 15 mm to position the rivet
from the etalbond panel edges.
To compensate for thermal expansion the drilled hole
should be at least 2mm larger than the rivet diameter.
In fastening with rivets there should be one fixed point at
the middle of the etalbond work piece.
The other fastening points should be made flexible with
sufficient hole play. Rivets head should always must be
large enough to cover the bore hole over 1 mm in the
panel.

A junction hole of 3 mm drilled on etalbond and at a

sufficient distance ( e >2D where e=distance from panel
edge and D= hole diameter) from panel edge can
practically withstand a load of 320N.
If instead a junction hole is positioned near a panel edge
then it will not show sufficient strength.

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.

- Shearing through one section of the rivet ( single shear)

- Due to double shear
- Compressive bearing failure of the rivet
- Shearing of the materials being joined
- Tearing of the materials between the rivets

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.

1. It is recommended that a small center drill be

use to provide a guide for a larger drill.

2. Using a high strength drill of a diameter equal in

size to the rivet spindle drill to depth of lock.

3. Drive out the rivet spindle using steel drift pin of

proper size.
4. Drill nearly through the head of the rivet using a
Drill the same size as the rivet shank.

5. Break off rivet head using drift pin as a pry.

6. Drive out the remaining sleeve with a drift pin

having the same size as the rivet shank.

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

1, 2: Wood and Parker screws made of

Aluminium or Stainless steel with
Aluminium washer and neoprene
gaskets can be used to fasten
Etalbond panels to Aluminium /
Stainless steel substructure and to join
Aluminium panels to one another.

……………………………………………………………………………………………………………………………………………………………………….

3, 4, 5: Self- tapping screws of stainless steel

with Aluminium or Stainless steel and
neoprene gasket to fix Etalbond panels
to the steel and Aluminium elements
and to the substructure.

……………………………………………………………………………………………………………………………………………………………………….

6, 7: Self-drilling screws made of Stainless

steel or Aluminium can be used for
fastening Etalbond to the Substructure.
● Bolts: Bolts can be also used to join two Etalbond panels or Etalbond panel to metallic elements.

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.

Stainless steel bolt with

washers

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.

Using screws, rivets, bolts :

When etalbond joining take place by using screws, rivets
or bolts in actuality a tensile force is applied on the
junction. The resulting stress is exerted on the inside of
the hole. The maximum stress is given by the formula

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.

Adhesives and Double face tape for fastening

Adhesives can be used along with double face tape (3M-VHB) for fastening etalbond temporary on flat surfaces
such as wall, ceiling, furniture, coverings etc.
As no structural adhesive is accompanied by a warranty for its durability it is a common practice and a
requirement imposed by building code agencies the use of mechanical fastening as well.

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.

Suitable adhesives for adhering etalbond® on different substrates

Substrate
Adhesive type Metal Wood Plaster Board Styrene foam
Epoxy * * * *
Acrylate * * *
Chloroprene * * *
Silicone * * *
Cyano acrylate * * *

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.

Hot air Welding

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.

Preparation and requirements for a welding joint

●Before folding and welding etalbond grooves have to drawn onto the panels by appropriate
milling cutters.
●A required welding temperature about 265º C ± 5º C should maintained during the whole Process.
●The applied pressure to the nozzle shoe during the process should be about 3 Kg*.
●The welding rode should be low density polyethylene type 1800-h in black colour and a diameter 3-4 mm.

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.

X Wrong √ Reinforced with Correct

Adhesive and
Hot Air Al Angle

Attachment Concepts, Fixing systems and classification

Etalbond and etalbond-fr can be attached on a building in several ways. A few of those attachment ways are
shown herewithin for conceptual purposes.

1] - Route and return

●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

Self tapping screw

Adhesive

Attachement concept of etalbond, Aluminium

etalbond–fr single folded cassette Rivet or Galvanized steel
with scotia covering with etalbond substructure
strip
● Double folded cassette – This option instead of one turn (single folded cassette) has two turns (double or Z-
shaped folded cassette ). Below is depicted the formation and installation scheme of a double folded cassette
on the substructure by using rivets or self tapping screws.

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).

VARIO Fixing system

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

Etalbond flat panel

l

Substructure

Etalbond flat panel

Substructure
Double face adhesion strip

Etalbond panel Etalbond panel

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.

A suggested riveting or screw pattern is shown with suggested min

distances of applying the rivets or screws.

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.

ETEM strongly recommends that

special care should be taken to
protect the edges of etalbond from
exposure to the environmental
elements

Visible fixing with rivets or screws Edge retention

ETEM strongly recommends to

protect the edges of etalbond
from exposure to the
environmental elements

Secret fixing Mechanical fixing with structural adhesive bonding.

Additionally, fixing methods can be combine to create a multitude of interesting design patterns.
3] Hanged Cassettes: This attachment method requires the cassettes (or trays) to be suspended on the
vertical carriers of the related substructure system. ETEM proposes the BRAVO Fixing system (it comes with a
variety of accessories) for this purpose. Additional information on the system can be found on ETEM
ventilated facade systems technical catalog.

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

Horizontal section: BRAVO system

Hanged cassette
 General Rules and Precautions applicable for etalbond.

COLOURS: Limitations, Variations, Consistency

●The colour reproduction on etalbond colour chart is subjected to printing limitations.

●Colour varation may occur between panels originated from different production batches.
●To ensure colour consistency the total requirement for a project must be come from one batch and one
width.

PALLET: LOAD, TRANSPORTATION, DELIVERY

● 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

ETEM S.A-/Northern Greece

Thessaloniki: 6th km Thessaloniki- Athens National Road, 570 09 Kalochori, Greece
Tel: +30 2310 790 323, +30 2310 790 330
Fax: +30 2310 753 416

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

STEELEMET Romania S.A

42nd Drumul intretarlare, 3rd sector, 73644 Bucharest, Romania
Tel: +40 21 2090570,
Fax: +40 21 2561464
e-mail: salesal@steelmet.ro

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

ETEM SYSTEMS llc.

67 Peremogy blvd., 03062 Kyiv, Ukraine
Tel /Fax: +38 044 206 1079
http: // www.etem.com.ua
e-mail:info@etem.com.ua

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