Ultra Shield Exterior HPL > INSTALLATION TECHNIQUES

Rivet Method:

Rivets are used in a panel mounting application to secure two or more components together.  The rivet is easily installed with access only required from one side of the assembly.

These systems require substructure (50x25mm rectangular aluminum channel), 10x30 size SS screw, POP rivets etc.

1)  Creation of Aluminum structure: The aluminum substructure (standard specified) generally consists of vertical support profiles/hollow sections are mounted on the wall using rivets/angle brackets.

Considering dimensional behavior of laminate at relative humidity as well as effect of climatic temperature on metal sub-construction, there is need to make fixed points & sliding points to fix the panels.

 a) Fixed points: fixed points are used for uniform distribution & shrinkage movement. The diameter of the drill hole in Aica exterior clad must measure   5 to 6mm  

  b) Sliding point: The diameter of drill hole in Aica exterior cladding must be larger than the diameter of the fastening as per required expansion clearance. Thus is the shaft diameter of the fastening plus 2mm for every meter of cladding material from the fixed point. The head of the fastening must be big enough so that the hole in exterior clads is always covered

Procedure: Make 6mm thru hole from back side & 20mm from front side on aluminum rectangular channel for screw fixing with channel and wall. Then mark screw position on wall with the help of rectangular channel for wall plug fixing. While plug fixing, provide space approx. 450 to 600mm between two channels as well as between two fasteners. Keep minimum 15mm distance of channel alignment from floor, sides & ceiling of wall area. Fix all plugs (approx. 30mm) to the marked area. Fix all rectangular channels on the wall with the help of 10x30mm size screw.

2) Panel cladding:  Mark the holes in the aluminum triangular substructure as well as in laminate panel for the rivet fixing. Make the drill in the compact laminate for Rivet fixing. While marking, keep rivet space in-between 20-60mm distance from corner as well as maintain minimum 450 to 600mm space in-between two Rivet. Compact laminate is then fixed with Rivet using Rivet gun on aluminum substructure. Fix the other panels in same fashion with maintaining 3mm gap in-between two panels.

      Important note: Using rivets system, the mouth piece drilling on the center of the plate is opened with the same diameter as the rivet, other holes are opened 2-3 mm wider than the rivet diameters, thus enabling movement of clad panels in case of expansion. The placement of the holes should be minimum 20 mm & maximum 60mm distance from the plate edge and distance maximum 10 times of the material thickness

 

 

 

 

 

 

 

Adhesive system:

Adhesive system is simple system for rear ventilated facades and visible roof under faces.

These systems require 50x25mm rectangular aluminum channel, 10x30 size SS screw, PU sealant, VHB structural glazing tape, PU primer black etc.

PU sealant & VHB tape should have good quality and resistance to UV radiation (3M?? PU 540 sealant & 3M?? VHB?? G23F are preferable).

Process:

      A) Creation of aluminum structure: Make 6mm thru hole from back side & 20mm from front side on aluminum rectangular channel for screw fixing with channel and wall. Then mark screw position on wall with the help of rectangular channel for wall plug fixing. While plug fixing, provide space approx. 450 to 600mm between two channels as well as between two fasteners. Keep minimum 15mm distance of channel alignment from floor, sides & ceiling of wall area. Fix all plugs (approx. 30mm) to the marked area. Fix all rectangular channels with wall with the help of 10x30mm size screw.

B) Surface preparation and priming: Abrade (rough) both the bonding area (front side of the channel & backside of laminate surface) using either cleaning pad/scrubber/fine emery paper. Clean the roughed surfaces and apply black primer (recommended) on these bonding areas and allow drying to leave a tack free film. Kindly note, primer coating on laminate backside surface is to be done just before bonding but before sealant application on the frame to get better bonding results.

       C) VHB & Sealant application: Paste VHB tape & PU sealant on front side of framed aluminum channel. Always apply VHB tape before sealant as there is skin formation on sealant bead if exposed long in air. Apply the sealant as a triangular bead of 6-8mm base and height approx. 10-12mmmaway from the tape.

       D) Panel Cladding: Align the compact laminate & fix the same on channel with the help of VHB channel & PU sealant. Apply pressure with a rubber roller or by hand. Kindly ensure proper alignment of panel before pressurized for bonding. Enough pressure should be applied so that both surfaces fully contact the tape.  Fix other compact laminate in same fashion & maintain 3mm to 4mm gap between two compact laminate. Kindly note to achieve maximum bonding strength, minimum 24 hours is required for optimum curing after installation process.

 

 

 

 

 

Z-Clip Method:

A Z-clip system involves installing clads on the wall structure (lip-up) and strips/clips on the back of the panel (lip down). Once the panel is “dropped” into place, blocking at the top of the panel keeps the compact laminate from being removed.

This system required 50x25mm rectangular aluminum channel, Z- clip, 10x30 size SS screw, 8x6mm SS Screw etc.

Creation of aluminum structure using Z-clip: Make 6mm thru hole from back side & 20mm from front side on aluminum rectangular channel for screw fixing with channel and wall. Then mark screw position on wall with the help of rectangular channel for wall plug fixing. While plug fixing, provide space approx. 450 to 600mm between two channels as well as between two fasteners. Keep minimum 15mm distance of channel alignment from floor, sides & ceiling of wall area. Fix all plugs (approx.30mm) to the marked area. Fix all rectangular channels with wall with the help of 10x30mm size screw. Fix Z-clip on rectangular channel with the help of 8x6mm SS screw. Keep minimum 450 to 600mm space in-between two Z-clip .

Fix Z-clip on another side of exterior laminate in reverse fashion with the help of 8x6mm size SS screw.

Then with the help of Z-clip, slide or hang laminate panel on framed rectangular channel.

Fix all other laminate panels in same fashion with maintaining 3mm gap in-between two compact laminate.

Important note in all above three procedures: An efficient air circulation must be secured between Aica exterior wall cladding and the surface or the coating of the building. The blank grouting spaces allowed for ventilation between the plates should not be filled with any material. An efficient air circulation must be provided from the ground level of the plate to the top edge. A minimum of 50 cm2 space is required for every 1 meter width. If no air ventilation gap is reserved at the construction framework, deformation will occur on the exterior plates.

 

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