Dsm100 alucobondfixedcassettesystemweb

Unit 1, 9-11 Rothwell Avenue, Rosedale, Auckland, 0632 PO Box 303-388, North Harbour, Auckland, 0751 Telephone (09) 926-2297 Facsimile (09) 926-1444 www.kaneba.co.nz

ALUCOBOND FIXED CASSETTE SYSTEM

If this is a printed or downloaded document please verify that it is the latest edition by comparing the content with the version published on www.kaneba.co.nz CONDITIONS APPLY

Kaneba Alucobond Fixed Cassette System objective and characteristics: The objective of the Kaneba Alucobond Fixed Cassette system is to: 1) safeguard people from injury caused by structural failure of the Alucobond, 2) ensure that the Alucobond remain an effective cladding throughout its serviceability life, 3) adequately resist penetration by and the accumulation of moisture from the outside of a building, and 4) make efficient use of construction materials and human energy to avoid adverse effects on the environment.

Characteristics: 1) An air barrier limiting airflow through the Alucobond fixed cassette system is required as part of the external wall construction.

2) Alucobond panel edges are unrestrained to allow controlled movement of the panels during thermal and seismic activity1.

3) Alucobond panel joints ranges between 10 and 20mm wide.

4) Under flashings forming part of the Alucobond Fixed Cassette system is rare due to the simple, yet effective joint construction of the Alucobond Fixed Cassette system.

1

Evidence shows that less restraint is better and more durable. Refer DSI107 Alucobond Edge Groove Integrity statement.

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DSM100 AlucobondFixedCassetteSystem

Contents 1 APPLICATION AND SCOPE ..............................................................................................................6 1.1 1.2 1.3 1.4 1.5

GENERAL ..................................................................................................................................................... 6 APPLICATION ................................................................................................................................................ 6 SCOPE......................................................................................................................................................... 7 DETAILS ...................................................................................................................................................... 7 SPECIFIC DESIGN ........................................................................................................................................... 7

2 PROJECT DESIGN ............................................................................................................................8 CLADDING............................................................................................................................................................ 8

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10

COMPLIANCE ................................................................................................................................................ 8 RESPONSIBILITY............................................................................................................................................. 9 CLEARANCES................................................................................................................................................. 9 MOISTURE MANAGEMENT .............................................................................................................................. 9 STRUCTURE ................................................................................................................................................ 10 WIND LOADING .......................................................................................................................................... 10 FIRE RATED WALLS AND SPREAD OF FLAME ....................................................................................................... 10 ENERGY EFFICIENCY...................................................................................................................................... 10 COMPATIBILITY OF MATERIALS ........................................................................................................................ 10 ALUCOBOND MATERIAL ............................................................................................................................... 11

3 FRAMING CONSTRUCTION ............................................................................................................ 12 3.1 3.2 3.3 3.4

GENERAL ................................................................................................................................................... 12 FRAMING CONSTRUCTION ............................................................................................................................. 12 TOLERANCES .............................................................................................................................................. 12 CURVED WALLS .......................................................................................................................................... 13

4 AIR BARRIER AND FLASHING INSTALLATION ............................................................................ 14 ASPECTS OF THE DETAILS PROVIDED IN THIS SPECIFICATION WILL BE COMPROMISED.............................................................. 14

4.1 4.2 4.3 4.4

AIR BARRIER AND BUILDING UNDERLAY ............................................................................................................ 14 RIGID AIR BARRIER ...................................................................................................................................... 14 BUILDING UNDERLAY SUPPORT........................................................................................................................ 14 FLASHINGS ................................................................................................................................................. 14

5 ALUCOBOND SYSTEM DESIGN..................................................................................................... 16 5.1 5.2 5.3 5.4

GENERAL ................................................................................................................................................... 16 DOCUMENTATION ....................................................................................................................................... 16 ALUCOBOND DESIGNER................................................................................................................................. 16 DESIGN PRINCIPLES ...................................................................................................................................... 16

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DSM100 AlucobondFixedCassetteSystem

5.5 5.6 5.7 5.8

SLOPES ON HORIZONTAL SURFACES .................................................................................................................. 16 VENTILATION SLOTS ..................................................................................................................................... 17 DISSIMILAR MATERIALS ................................................................................................................................ 17 SITE CHECK BEFORE MANUFACTURE ................................................................................................................. 17

6 FABRICATING ALUCOBOND PANELS .......................................................................................... 18 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12

GENERAL ................................................................................................................................................... 18 SAWING .................................................................................................................................................... 18 SHEARING .................................................................................................................................................. 19 DE-BURRING CUT EDGES ................................................................................................................................ 19 ROUTING FOR BENDING................................................................................................................................. 19 CURVING ................................................................................................................................................... 26 DRILLING ................................................................................................................................................... 27 PUNCHING ................................................................................................................................................. 27 JOINING .................................................................................................................................................... 27 HOT AIR WELDING...................................................................................................................................... 30 ADHESIVE BONDING ................................................................................................................................... 31 STIFFENING ALUCOBOND PANELS TO LIMIT DEFLECTION ....................................................................................... 32

7 7.0 INSTALLING ALUCOBOND PANELS ....................................................................................... 33 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8

HANDLING ................................................................................................................................................. 33 GENERAL ................................................................................................................................................... 33 DO NOT ALTER ............................................................................................................................................ 33 INSTALL ALUCOBOND PANELS ......................................................................................................................... 33 FASTENERS DURABILITY ................................................................................................................................ 33 FASTENERS – SIZE AND LAYOUT ....................................................................................................................... 34 TOLERANCES .............................................................................................................................................. 34 DEFECTIVE OR DAMAGED WORK ...................................................................................................................... 34

8 8.0 JUNCTION SEALANTS .............................................................................................................. 35 8.1 8.2 8.3 8.4 8.5 8.6 8.7

GENERAL ................................................................................................................................................... 35 JOINT WIDTHS ............................................................................................................................................ 35 JOINT PROFILES ........................................................................................................................................... 35 PREPARE SURFACES ...................................................................................................................................... 35 BACKING ROD / BOND BREAKER ...................................................................................................................... 36 JOINT FINISHING .......................................................................................................................................... 36 PROTECTIVE PEEL OFF FOIL ............................................................................................................................. 36

9 ACCEPTABLE VISUAL FINISHING LEVELS .................................................................................. 37 9.1 GENERAL ................................................................................................................................................... 37 9.2 PANEL AND SEALED JOINT SURFACES ................................................................................................................. 37 9.3 FLATNESS OF WALLS ..................................................................................................................................... 37 10 MAINTENANCE................................................................................................................................ 38 Page 4 of 56 Date printed: 24/03/2013 5:09 p.m.

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DSM100 AlucobondFixedCassetteSystem

11 PRODUCT INFORMATION .............................................................................................................. 39 11.1 11.2 11.3 11.4 11.5 11.6

MANUFACTURING AND CLASSIFICATION .......................................................................................................... 39 PRODUCT MASS ........................................................................................................................................ 39 SHEET SIZES .............................................................................................................................................. 39 DURABILITY .............................................................................................................................................. 39 RESISTANCE TO MOISTURE ........................................................................................................................... 39 RESISTANCE TO FIRE ................................................................................................................................... 40

12 NOTATIONS ON KANEBA ALUCOBOND TYPICAL DESIGN DETAILS ........................................ 41 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23)

S/S SCREWS BY KANEBA ............................................................................................................................ 42 PROPRIETARY SHIMS BY KANEBA ............................................................................................................... 44 AIR BARRIER (WALL UNDERLAY) .................................................................................................................... 45 ALUCOBOND BY KANEBA ........................................................................................................................... 45 SEALANT ON PEF ROD BY KANEBA.............................................................................................................. 46 FLASHING TAPE OR METAL FLASHING......................................................................................................... 46 FIRE SEALANT BY KANEBA .......................................................................................................................... 47 ALUCOBOND FIXING ANGLE BY KANEBA .................................................................................................... 47 FLASHING TAPE (WINDOW HEAD) .............................................................................................................. 47 WINDOW HEAD FLASHINGS ..................................................................................................................... 48 DRAINHOLES ........................................................................................................................................... 48 AIR SEAL.................................................................................................................................................. 48 PROPRIETARY SOAKERS BY KANEBA ......................................................................................................... 49 CONTINUOUS FIXING ANGLE BY KANEBA.................................................................................................. 49 VENTILATION SLOTS ................................................................................................................................ 49 ALUMINIUM ANGLE BY KANEBA .............................................................................................................. 50 CONTINUOUS BACK FLASHING ................................................................................................................. 50 STRUCTURAL PACKING ............................................................................................................................ 50 PANEL STIFFENERS BY KANEBA ................................................................................................................ 51 50MM TYP OFF STRUCTURE ...................................................................................................................... 51 FLASHING TAPE OF METAL FLASHING ....................................................................................................... 52 JOINT WIDTH .......................................................................................................................................... 52 TOP HAT CHANNEL BY KANEBA ................................................................................................................ 53

13 TYPICAL EDGE TREATMENTS OF ALUCOBOND ......................................................................... 54 14 DEFINITIONS ................................................................................................................................... 55

Highlighted text relates to Specific Engineering Design which falls outside the scope of this document. Contact Kaneba for support and alternative testing.

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DSM100 AlucobondFixedCassetteSystem

1 1.1

APPLICATION AND SCOPE General

Alucobond is manufactured by 3A Composites, a subsidiary of Schweiter Technologies AG. Alucobond (Far East) Pte Ltd based in Singapore is the regional support office for the Asia Pacific region.

Kaneba Ltd is the agent for distribution and support of Alucobond in New Zealand.

Kaneba merchandises Alucobond composite material and provides associated services such as building cladding system design, fabrication, installation and overseeing of third parties.

All correspondence in regards to Alucobond in New Zealand must be addressed to: Kaneba Ltd Unit 1 of 9 – 11 Rothwell Avenue, Rosedale PO Box 303 388, North Harbour Auckland 0751 PH: 09 926 2297 FX: 09 926 1444 E-mail: support@kaneba.co.nz 1.2

Application

Alucobond is a light-weight composite material consisting of two aluminium cover sheets heatbonded (laminated) to a core made of polyethylene. At least one of the cover sheets will be prefinished with a lacquer on its visible surface and covered with a peel off foil for protection during handling. Where project requirements dictate so proprietary additives are mixed with the polyethylene to make it less combustible. A less combustible version of Alucobond is referred to as Alucobond PLUS and the least combustible version is referred to as Alucobond A2.

Alucobond is a very durable cladding material requiring only minor maintenance at regular intervals. Alucobond sheets are readily identified by the Alucobond branding on the protective peel off foil it is supplied with and with batch markings including the name Alucobond on the reverse face of the sheets. Alucobond sheets are manufactured in 3mm, 4mm and 6mm thicknesses. 3 & 6mm thick sheets are only used in specific circumstances – 4mm thick sheets are usually used for Architectural applications.

For the purposes of this document reference to Alucobond will also provide for all instances where Alucobond PLUS or Alucobond A2 is required. When reference is made to one of the specific version of Alucobond it will be type faced in bold and italic. (Note: Alucobond PLUS satisfies all the requirements of the NZBC clauses for C Fire referred to on the Kaneba CodeMarkTM certificate and is Alucobond A2 therefore only required where a client may have a specific requirement.)

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DSM100 AlucobondFixedCassetteSystem

If you are a specifier or other responsible party for a project, ensure that the information in this document is appropriate for the application you are planning.

Note: If you are unsure if your intended design complies with this document contact Kaneba on 09 926 2297 or at support@kaneba.co.nz for advice.

If you are an installer, ensure that you follow the design, moisture management, associated details and material selection provided by the designer. All the details provided in this document must be read in conjunction with the designer’s specification and drawings.

Make sure your information is up to date when specifying or installing Alucobond products.

Ensure you have the most recent manual. If you’re not sure you do compare your version with the one published on www.kaneba.co.nz or ask Kaneba on 09 926 2297 or at support@kaneba.co.nz.

1.3

Scope

The scope of this specification is for the use of 4mm Alucobond for buildings which fall within the scope of New Zealand Building Code (NZBC) NZS3604:2011. This specification also covers Alucobond in cavity construction when used for buildings subject to specific design up to an ultimate limit state (ULS) wind pressure of 2.5kPa. This document is intended for use by architects, designers and specifiers who are involved in specifying Alucobond cladding.

1.4

Details

Various Alucobond details are provided in the Details section of this document. This specification and the details in CAD format are also available to download from the Kaneba website at www.kaneba.co.nz For consistency reference is made to various NZBC Acceptable Solutions. These Acceptable Solutions are not necessarily a requirement for the Alucobond cladding, and must be evaluated on a case by case basis.

1.5

Specific Design

For use of Alucobond outside the scope of this document, the architect, designer or engineer must undertake specific engineering design (SED). For advice on designs outside the scope of this specification ask Kaneba on 09 926 2297 or support@kaneba.co.nz.

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DSM100 AlucobondFixedCassetteSystem

2

PROJECT DESIGN

Project design is undertaken by the building designer. The designer referred to in this section is usually appointed by the building owner / developer and is responsible for the overall design of a building, including the Alucobond cladding.

2.1

Compliance

The Alucobond Fixed Cassette System’s compliance is considered an Alternative Solution as defined in the NZBC. There are two options for establishing compliance of Alucobond with the New Zealand Building Code: 1) Utilize the Kaneba Alucobond Cladding Systems CodeMark TM certificate as a means to easily obtain approval for the Alucobond cladding by proving compliance with the relevant clauses of the NZBC by: a. document your design to the requirements of this specification, b. reference this document and the detail sheets you used for easy verification, c. use the Masterspec Alucobond Specification 4251 A, and d. reference the Kaneba Cladding Systems CodeMarkTM certificate in your building consent application documentation.

OR 2) Where you want to develop custom details not covered in this document you will have to apply for building consent, subject to Building Consent Authority scrutiny in the usual manner by: a. undertaking specific design and detailing for areas not covered in the scope of this document. b. specifying Alucobond.

Note: 1) If you are unsure if your design complies with this document contact Kaneba on 09 926 2297 or at support@kaneba.co.nz for advice.

2) Where specific design is required in terms of section E2.3.2 of the NZBC, Kaneba may be able to provide supporting documentation for your details in the form of a test report to the requirements of E2/VM1 of the NZBC Acceptable solution ‘E2/AS1’ or NZS 4284.

All design and construction must comply with the requirements of the NZBC regulations and standards.

Alucobond is also suitable for projects outside the scope of NZS3604:2011 where design is generally to AS/NZS1170 with testing to AS/NZS4284

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DSM100 AlucobondFixedCassetteSystem

2.2

Responsibility

The specifier or other party responsible for the project must perform a risk matrix analysis to determine which construction method is to be used. The designer must also ensure that the information and details published in this specification are appropriate for the intended application and that additional detailing is performed for specific design of any areas that fall outside the scope of this specification. Designers should ensure that the intent of their design meets the requirements of the NZBC. All New Zealand Standards referenced in this document are current edition and must be complied with.

3A Composites (the manufacturer of Alucobond) conducts stringent quality checks to ensure that any Alucobond product supplied falls within their quality spectrum. It is the responsibility of the panel fabricator to ensure that the product meets fabrication quality checks and aesthetic requirements before installation. Kaneba will not be responsible for rectifying obvious aesthetic surface defects or defective fabrication subsequent to installation.

2.3

Clearances

The bottom edge of the Alucobond cladding must comply with NZBC Acceptable Solution ‘E2/AS1’ paragraph 9.1.3 Alucobond panels must overhang the bottom plate on a concrete slab by a minimum of 50mm as required by NZS 3604.

Alucobond panels must have a minimum clearance of 100mm from paved surfaces and 175mm from unpaved ground.

On roofs and enclosed balustrades the minimum clearance between the Alucobond and the other surface must be 35mm as required by NZBC Acceptable Solution ‘E2/AS1’ Figure 18 (Page 57) Do not install external Alucobond so that it may remain in contact with water or ground.

2.4

Moisture Management

It is the responsibility of the designer to identify moisture related risks associated with any particular building design.

Wall construction design must effectively manage moisture, considering both the interior and exterior environments of the building, particularly in buildings that have a higher risk of wind driven rain penetration, or that are artificially heated or cooled.

Wall openings, penetrations, junctions, connections, windows sills, heads and jambs, must incorporate appropriate flashings for waterproofing.

Other materials, components, and installation methods used to manage moisture in external walls, must comply with the requirements of relevant standards and the NZBC.

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DSM100 AlucobondFixedCassetteSystem

For further information in relation to designing for weather tightness, refer to BRANZ Ltd and the Department of Building and Housing (DBH) updates on the following websites respectively www.branz.co.nz and www.dbh.co.nz 2.5

Structure

Timber framing must comply with NZS 3604 for buildings or parts of buildings within the scope limitations of NZS 3604. Buildings or parts of buildings outside the scope of NZS 3604 must be as per specific design in accordance with NZS 3603 and AS/NZS 1170.

Where specific design is required, the framing must be of at least equivalent stiffness to the

framing provisions of NZS 3604. In all cases studs must be at minimum 600mm centres of buildings designed to NZS 3604 and a maximum of 400mm centres for specifically designed buildings.

2.6

Wind Loading

Alucobond is suitable for use in all New Zealand wind zones up to and including EH and defined in NZS 3604.

Alucobond panels may need stiffening members applied to limit deflection. The specification of these stiffeners must be determined by the panel fabricator during Shop Drawing preparation and may be subject to specific engineering.

A specific design is required for all situations where pressures are higher than specified in section 1.3.

2.7

Fire Rated Walls and Spread of Flame

Alucobond PLUS sheets have a lower combustibility index than Alucobond and can be used where spread of flame needs to be controlled outsidei or insideii buildings. Alucobond sheets cannot be used to achieve fire ratings.

Alucobond A2 can also be used; however cost and availability may be more restrictive than that for Alucobond PLUS. Refer to the Kaneba Alucobond CodeMarkTM certificate for its NZBC compliance.

2.8

Energy Efficiency

Please contact Kaneba at support@kaneba.co.nz for further information.

2.9

Compatibility of materials

It is the responsibility of the designer to consider the effects of compatibility of materials in the design of the building. Specific attention must be given to penetrations and intersects of Alucobond to other trades. Examples would include bituminous sealants in contact with modern sealants, treated timber weatherboard above aluminium based Alucobond panels, copper cladding above Alucobond, etc.

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DSM100 AlucobondFixedCassetteSystem

Refer NZBC Acceptable Solution ‘E2/AS1’ Table 20 “Material selection”, Table 21 “Compatibility of materials in contact” and Table 22 “Compatibility of materials subject to run-off”.

2.10

Alucobond material

Details in this manual apply to Alucobond material only. Alucobond has its own specific characteristics resulting from its unique specification in raw materials and manufacturing processes. Changing the brand of Aluminium Composite Material may affect the performance of the cladding system and may therefore result in failure to elements that would have performed properly if used with Alucobond.

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DSM100 AlucobondFixedCassetteSystem

3

FRAMING CONSTRUCTION

3.1

General

The Alucobond cladding forms part of the wall construction of a building. Framing construction refers to the structural frame / connection point where Alucobond panels will be fixed to.

Timber strapped concrete block walls will also be suitable for an Alucobond installation. The details in this specification are only suitable for timber-framed / strapped buildings. Other framing materials are outside the scope of this specification.

All framing must comply with the requirements of NZS 3604.

3.2

Framing Construction

Sufficient framing must be provided to support Alucobond panel edges. The framing does not need to be continuous, but must not exceed the minimum fixing requirement centres of 600mm.

The framing must be rigid and not rely on the Alucobond panels for stability.

All timber framing sizes and set-out must comply with NZS 3604 and be as specified in this specification. Use of timber framing must be in accordance with framing manufacturer’s specifications. 

When studs are spaced at 600mm centres maximum the nogs / dwangs must be provided at 800mm centres maximum.



When studs are spaced at 400mm centres maximum the nogs / dwangs may be provided at 1200mm centres.



An extra stud is required in internal corners.



For EH wind zone, specific engineering design projects or wind pressures above 1.5kPa studs must be spaced at 400mm centres maximum.



In case of a pre-determined Alucobond panel size and joint design consideration must be given to the Alucobond panel joint locations when determining the stud spacing of a wall.

3.3

Tolerances

In order to achieve dimensionally acceptable Alucobond installations it is imperative that framing is within NZS3604 acceptable tolerances.

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DSM100 AlucobondFixedCassetteSystem

Table 3.3 NZS3604:2011 Table 2.1 (Page 2 – 4) acceptable timber framing tolerances Item

Tolerances

Deviation from the position shown on plan for a building

15mm

Deviation from vertical

15mm per 2 storey height (5mm per 2.4m) 20mm

Deviation from vertical for buildings in excess of 2 full storeys

Relative displacement between loadbearing walls in adjacent 5mm storeys intended to be in vertical alignment Deviation from line in plan: (a) In any length up to 10m (b) In any length over 10m

5mm 10mm total

Deviation from horizontal: (a) In any length up to 10m (b) In any length over 10m

5mm 10mm total

Straightness of corners (where 2 walls meet at right angles) Other studs (gradual bow)

2mm in 2.4m in both studs 6mm in 2.4m

Wall framing: (a) At mid-height under 3m long horizontal straight edge (b) At mid-height under 1.3m long horizontal straight edge

6mm gradual bow 1.5mm out of line

Exceptions: Tolerances on existing structures that are refurbished need to be considered. Settling of buildings outside the scope of NZS 3604 may also not fit the above criteria.

3.4

Curved Walls

Alucobond panels can be used in a curved application. For further information ask Kaneba on 09 926 2297 or e-mail support@kaneba.co.nz

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DSM100 AlucobondFixedCassetteSystem

4

AIR BARRIER AND FLASHING INSTALLATION

The design of the Alucobond Fixed Cassette System relies on and requires an air barrier to be provided to limit air movement through the wall construction. Without an air barrier the moisture management and structural aspects of the details provided in this specification will be compromised.

4.1

Air Barrier and Building Underlay

The Alucobond Fixed Cassette System has been designed to require an air barrier which complies with the requirements of NZBC Acceptable Solution ‘E2/AS1’. The Acceptable Solution requires external walls to have barriers to airflow, in the form of: a) Interior linings with all joints stopped for wind zones up to Very High, or b) Rigid underlays for buildings in Extra High wind zones, or c) Where walls are not lined, such as attic spaces at gable ends, an air barrier complying with NZBC ‘E2/AS1” Table 23, fixed to framing prior to fixing the Alucobond, and d) For attached garages, underlays to NZBC ‘E2/AS1” Paragraph 9.1.3.4.

Building underlay must be provided as per the requirements of the NZBC Acceptable Solution ‘E2/AS1’ ‘External Moisture’ and NZS 3604. The building underlay must comply with Table 23 of ‘E2/AS1’. The building underlay must be fixed in accordance with ‘E2/AS1’, NZS 3604 and the underlay manufacturer’s recommendations.

Also refer sections ‘E2/AS1” paragraphs 9.1.4, 9.1.5, 9.1.6, 9.1.7.

4.2

Rigid Air Barrier

For EH wind zone and specific design projects where the wind pressures are higher than 1.5kPa (ULS), a Rigid Air Barrier must be used.

4.3

Building underlay support

Flexible wall underlay must be supported to avoid the underlay being pushed into the cladding cavity space by for example by wall insulation. Relevant options of providing restraint given in ‘E2/AS1”: a) 75mm galvanized mesh or wire galvanized in accordance with AS/NZS 4534, or b) Polypropylene tape or galvanized wire at 300mm centres fixed horizontally and drawn taught c) Vertical battens at 300mm centres maximum.

Edges of building underlay must be secured to ensure no loose flaps intrude into the cavity space.

4.4

Flashings

All wall openings, penetrations, intersections, connections, window sills, heads and jambs must be flashed prior to Alucobond installation.

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DSM100 AlucobondFixedCassetteSystem

The building underlay must be appropriately incorporated with penetration and junction flashings.

Materials must be lapped in such a way that water tracks down to the exterior face of the building underlay. Kaneba will assume no responsibility for water infiltration within the wall due to poor installation of flashing or building underlay. The selected flashing material must comply with the durability requirements of table 20 on the NZBC Acceptable Solution ‘E2/AS1’

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DSM100 AlucobondFixedCassetteSystem

5

ALUCOBOND SYSTEM DESIGN

5.1

General

Alucobond System design must be performed by the Alucobond fabricator, and encompasses the evaluation of an architectural concept presented by the project designer, and presenting that concept in actual constructible details incorporating verified site specific elements and dimensions.

Contact Kaneba on (09) 926 2297 or support@kaneba.co.nz for further information.

5.2

Documentation

The Alucobond System design for a job must be properly documented in a format of Shop Drawings prior to attendance to site and verified by the issue of For Fabrication and Installation drawings before production commences.

5.3

Alucobond Designer

The Alucobond Designer must prepare a design covering the following aspects: 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13)

5.4

Design Calculations Fully dimensioned elevations of all Alucobond elements (Minimum scale 1:50) Complete details of construction, connections and all support systems (minimum scale 1:10) Dimensions of all typical elements and of any special sizes and shapes Provision for the deflection and/or drainage of moisture Jointing details and method of fixing between individual elements and between the Alucobond installation and adjacent work, including adjustment Adjustment and fixings to ensure accurate alignment of composite cladding Sealant types and full size sections of all sealants and backing rods Provision for thermal movement Provision for seismic movement and movement under wind loads Sequence of installation Co-ordination requirements with other work A schedule of materials, finishes, componentry, hardware and fittings

Design Principles

Refer the Alucobond detail section of this document and supplementary notes for guidance on the Alucobond design.

5.5

Slopes on horizontal surfaces

The top of a parapet must always have a slope exceeding 5째 to prevent ponding of moisture.

Where a slope abuts a vertical surface like a sill meets a window the slope must not be less than 10째.

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DSM100 AlucobondFixedCassetteSystem

5.6

Ventilation Slots

All Alucobond panels installed with a drained and ventilated cavity must provide for ventilation.

When the ventilation slots are incorporated with the Alucobond panel design 3 x 20mm ventilation slots at 50mm centres must be provided and the openings must be kept clear and unobstructed to allow free drainage and ventilation of cavities. The ventilation provision must have an opening area of at least 1000mm2/m length. For walls in excess of two storeys high separate drained ventilated compartments are required.

5.7

Dissimilar Materials

All elements and accessories must be compatible on the electrochemical scale of metals, so that no excessive levels of sacrificial corrosion will occur. All elements and accessories must be of an appropriate quality, ensuring that no reduction in structural integrity or weather tightness occurs during the design life of the panel system.

5.8

Site Check before manufacture

Check substrates for alignment, whether concrete, timber or steel framing, before commencing panel design. Notify the Contract Administrator in writing of any unacceptable conditions.

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DSM100 AlucobondFixedCassetteSystem

6

FABRICATING ALUCOBOND PANELS

6.1

General

Care must be taken when handling Alucobond panels. The protective peel off foil does not provide significant impact and scratch resistance. The foil also does not provide protection from solvents of any kind.

Do not carry Alucobond panels on the flat, carry on edge (in the vertical position); to avoid excessive bending that may result in permanent deformation of panels and / or stress marks.

All Alucobond cladding panels must be fabricated and assembled to the best standard of workmanship under experienced factory supervision and control.

6.2

Sawing

The use of coolants or lubricants is not required when sawing.

Alucobond is manufactured with any one of several high quality finishes. To limit damage to the finish it is best to move the saw blade rather than the Alucobond material. Saw cutting can be accomplished with the following cutting equipment.  Table saws are not recommended for cutting sheets larger than 1250mm x 1250mm in size.  Panel saws provide an effective method of cutting. These saws, whether standard equipment or custom made, perform well and have the added advantage of space savings. If a panel saw is to be used as production equipment, an industrial model should be used in order to obtain adequate cutting tolerances and provide reliability in production. (These saws are also referred to as wall saws.)  Multiple operations Rip/V-grooving Saws are capable of performing more than one operation with a single pass through the machinery. This equipment can make multiple saw cuts (sizing the panel) and V-grooves (rout) with a single instruction. (These machines are also referred to as CNC workstations)  Portable saws are an effective method of cutting panels on a small scale. For accuracy and reliability this equipment must also be industrial type. (Festool provides a good range of these saws.)  Reciprocating saws work well for cut-outs. Care should be taken when using this equipment to prevent damage to the Alucobond surface.

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DSM100 AlucobondFixedCassetteSystem

6.3

Shearing

Alucobond can be sheared. A slight roll-down of the aluminium cover sheet on the impact side may occur. (Reference figure 1) This roll-down is often referred to as the “edge zone.� In this area, the polyethylene core is compressed and can lead to increased stress between the core and the aluminium cover sheet. Due to the additional stress, shearing should be avoided when the edge of the panel is exposed to the environment.

When shearing Alucobond, markings on the material may be caused by the shearing equipment hold down pads. In order to limit these markings, the hold down on the shear should be fitted with a shock-absorbing rubber pad which will limit damage to the Alucobond material.

6.4

De-burring cut edges

For finishing work, after sawing the Alucobond metal files can be used. The proper filing direction is length-wise along the edge.

A custom de-burring tool can also be used to clean up panel edges.

6.5

Routing for bending

Alucobond can be accurately folded by hand after a simple routing operation is done on the unexposed (back) cover skin. Approved methods of routing Alucobond sheets are the following: (Either method should use high quality industrial equipment.)

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DSM100 AlucobondFixedCassetteSystem

ďƒ˜ Industrial quality hand router. This method is relatively slow and is only recommended for curved components or modification of panels where accuracy is not critical.

Special custom cutters for Alucobond are available. These cutters have been specifically developed for Alucobond material and will produce the required configuration for proper rout tolerances. Commercially available 90deg wood working routing cutters, available from your local hardware store, may be modified to provide approximately the same function as the custom cutters, provided the tip is flattened to a minimum of 1.6mm

ďƒ˜ Portable circular saw with a custom blade. For fabrication on a small scale where accuracy is not critical a portable saw fitted with a special blade is suitable. A quality industrial saw fitted with a custom V routing blade and an experienced operator will produce the required tolerances.

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DSM100 AlucobondFixedCassetteSystem

ďƒ˜ Panel saw fitted with a custom routing blade. For fabrication on a large scale where accuracy is important these saws are effective. A quality industrial saw with a custom V routing blade and an experienced operator will produce the required tolerances. ďƒ˜ Multiple operations Rip/V-grooving Saws are capable of performing more than one operation with a single pass through the machinery. This equipment can make multiple saw cuts (sizing the panel) and V-grooves (rout) with a single instruction. (Referred to also as CNC workstations) The advantages of these machines are high accuracy in V routing positions, consistent duplicating of repeatable components and consistency in grooving depth (measured between the external surface and the valley of the rout.)

The depth of the V rout is critical. As a rule of thumb, the exterior aluminium skin should be visible through the polyethylene core at the valley of the rout; this visual appearance should be consistent along the entire length of the rout. (Reference figure 4.) Extreme care should be taken not to remove all the polyethylene or cut into the exterior aluminium skin during the routing process. (This causes defects like a) inconsistent folding of panel edges, b) and weakening of the panel edge.)

Slight variations in grooving depth may occur due to thickness changes in the Alucobond sheet. This problem is avoidable when using a Multiple Operations Rip/V-grooving Machines which do not rely on the thickness of the Alucobond sheet to maintain a consistent cover of polyethylene over the exterior aluminium skin. A consistent grooving depth ensures a good smooth line when the edge is folded.

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DSM100 AlucobondFixedCassetteSystem

Figure 4 indicates the finished rout required to develop a quality bend.

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DSM100 AlucobondFixedCassetteSystem

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DSM100 AlucobondFixedCassetteSystem

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DSM100 AlucobondFixedCassetteSystem

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DSM100 AlucobondFixedCassetteSystem

6.6

Curving

The minimum bending radius for 4mm Alucobond (and Alucobond PLUS) without routing the back skin is 15 times the thickness of the panel being curved. 4mm Alucobond is therefore 60mm.

Alucobond can be cold formed in a pyramid roller or a press brake. The process is similar to forming solid aluminium; however due to the sensitive surface, care should be taken to ensure rollers are clean, smooth and free of defects to avoid damage to the surface finish. ďƒ˜ Pyramid roller. Do not pinch the Alucobond between the rollers. Roll the panel 3° to 5° tighter to allow for a small amount of springback that will occur. Once the Alucobond sheet is curved it will remain curved. There will be a flat end at each of the ends of the rolled Alucobond sheet of approximately 50mm, depending on the specific rolling machine.

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DSM100 AlucobondFixedCassetteSystem

ďƒ˜ Press brake. When forming with a press brake, use a top die (tublar) with the radius desired and open the bottom die (jaws) approximately two times the thickness of the material plus film wider than the top die. The lower die should always have a protective pad of not less than 3mm. The radius of the top die will be the approximate inside radius of the finished panel.

6.7

Drilling

Alucobond can be drilled with twist drills usually used for aluminium and plastics.

6.8

Punching

The punching of flat-formed parts from Alucobond is performed the same way as for solid aluminium sheet, using evenly ground tools and the narrowest possible cutting gap. Be sure to punch through the Alucobond material to completely serrate the polyethylene core material. As with shearing, a slight roll down may occur.

6.9

Joining

Material acceptable to join to Alucobond sheets are: a) b) c) d)

Aluminium Plastic Stainless steel (in areas protected from elements and in frequently rain-washed areas) Plated or coated steel with cadmium, zinc or aluminium

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DSM100 AlucobondFixedCassetteSystem

Materials not suitable to join to Alucobond sheets are: a) b) c) d) e)

Copper Brass Bronze Iron Raw steel

Unsuitable materials cause corrosion of joining surfaces due to electrolysis of dissimilar materials. Avoid these materials therefore. Where joining is required separate these materials from Alucobond with an electrically insulating intermediary layer.

When joining elements are to be anodized, assemble the materials after the anodizing process.

Proper consideration should be given to the thermal expansion characteristics of Alucobond when using any of the joining techniques. ďƒ˜ Threaded fasteners are an easy way to join Alucobond to an extruded profile. This method allows disassembly. Use the largest possible flat washer to minimize surface pressure and eliminate possible compression due to cold flow of the core material. Arrange attachment screws at least 2.5 x the diameter of the fastener from the edge of the Alucobond sheet as shown in Figure 16.

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DSM100 AlucobondFixedCassetteSystem

ďƒ˜ Rivets can be used to join Alucobond sheets together or to extruded profiles. Blind rivets provide the advantages of labour saving, one-sided working of the material, and the reduced potential of surface damage.

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DSM100 AlucobondFixedCassetteSystem

Place the closing or set-head of the side of the aluminium extrusion profile or sheet metal. When conditions do not permit this or when two pieces of Alucobond material are to be joined together, use rivets with special wide closing heads as shown in Figure 19 or with tightly fitting washers.

When blind rivets are subjected to tensile strength tests, the head tends to ‘unbutton’ from the Alucobond material, or pull through the hole. Since this would cause localised tearing of the Alucobond material, use the largest possible rivet head for connections that will experience loading.

Aluminium alloys such as 5032 and 5154 are suitable rivet material. Due to stress corrosion, alloy 5056 should not be used if the temperature of the manufactured part is expected to rise over 60deg C. Rivet connections are well suited for parts that may be subjected to impact or vibration.

6.10

Hot air welding

Hot air welding has proven an effective method for joining thermoplastic materials. Handheld, electrically heated, hot-air welding tools are used to heat the Alucobond core material and the welding rod (low density, UV stable PE) to their melting temperature. This allows the two components to fuse together. The strength of the welded core material is not sufficient to withstand structural loading. The weld is however very effective to exclude moisture from entering the panel and providing stability in the panel for moving and transportation shortly after welding took place.

To ensure a sound weld, the correct diameter rod must be used. For 4m Alucobond use a 5mm rod. Rod shapes other than round and diameters greater than 5mm are not suitable for this procedure. Temperature settings used should be approximately 260deg C. Both the core material and the rod must be sanded to remove any surface contaminants before welding.

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DSM100 AlucobondFixedCassetteSystem

Figure 20 illustrates the process for V and corner seam hot air welds. Although this process can be used to join two pieces of Alucobond material, the joint created must be reinforced with structural cleats like aluminium.

When offering up two pieces of Alucobond to be joined by welding it is important to continuously tape the edges together otherwise the unsecured edge will flair open and cause unevenness along the length of the welded edge because of the temporary melting and expansion of the core material. Also allow for settling after the welding process. If welded at 90° the panels will pull towards the weld a further 5°.

All welds must be supported by gluing in cleats along the length of the weld.

Use Permabond structural adhesive or Simson Panel Tac HM. Consideration must be given to the viability of hot air welding if Alucobond panels with surface finishes with gloss levels in excess of 30% are used because it may show up unsightly.

6.11

Adhesive bonding

Most adhesives and sealing compounds do not adhere to the polyethylene core material. It is therefore important to bond to the aluminium skin of the Alucobond material.

To achieve reliable bonding it is important to follow the adhesive recommendations.

manufacturer’s

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DSM100 AlucobondFixedCassetteSystem

Table 6.11 Scenario Glue Alucobond plates together

Limitations   

Characteristics 

Tight tolerances Curing time < 10 minutes Not suitable for adhering dissimilar materials.

Glue Alucobond plates together Glue Alucobond plates together Cleats to support welding Hot air welding support without cleats

Adhesive to use

 

Require flat surfaces with maximum gap fill of glue <1mm Fumes Surface preparation

Permabond TA 246 Structural Adhesive + # 46 Initiator for use with TA246

  

Require flat surface Require precision cleats Need to be able to roll

3M Double Sided Tape

No flat surface available but need to handle quickly

No space for cleats

3M Double Sided Tape + Simson Panel Tac Simson Panel Tac

 Cleats  24 hour curing time 24 hour curing time

Simson Panel Tac

Consideration must be given to the viability of cleat adhesion if Alucobond panels with surface finishes with gloss levels in excess of 30% are used because it may show up unsightly.

High strength contact adhesives can be used where the surfaces are flat and panels are not complex allowing good pressure to be applied.

6.12

Stiffening Alucobond panels to limit deflection

Proprietary folded composite sheet, or aluminium extrusions, structurally glued to the back of panels are used where the design so requires.

Where bonding of panel members are required, the components must be bonded with 3M VHB double sided tape combined with Simson® Panel Tack HM adhesive. Application of bonding systems shall be in strict conformity with the manufacturer’s specification.

1) Refer 3M VHB Tapes product information.

2) Refer Simson® Panel Tack HM product information and SKG test report.

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DSM100 AlucobondFixedCassetteSystem

7

7.0 INSTALLING ALUCOBOND PANELS

7.1

Handling

It is recommended to wear protective gloves to avoid cutting of hands on sharp panel edges.

For larger panels and on windy days use more than one person to carry a panel if no mechanical means are available. (Because of the relatively light weight of panels a single person could carry it; however if it is quite a panel face area in excess of 1.3m2 a single person can easily be brought off balance by wind gusts.)

Care must be taken when handling Alucobond panels. The protective peel off foil does not provide significant impact and scratch resistance.

Do not carry Alucobond panels on the flat, carry on edge (in the vertical position) to avoid excessive bending that may result in permanent deformation of panels and / or stress marks.

Store Alucobond panels on site in a manner that will avoid damage and secure panels in a manner that will protect it from movement. Movement may be caused by wind, vibration, people, etc.

7.2

General

Framing moisture contents must not exceed the maximum limit specified on NZS 3602 prior to Alucobond panel installation. Every endeavour must be made to keep framing dry once sheet fixing commences.

Check substrate for alignment, whether concrete, timber or steel framing, before commencing cladding installation. Notify the Contract Administrator in writing of any unacceptable conditions.

7.3

Do not alter

No cutting, trimming or welding of component parts are permitted during installation. It may damage the finish, decrease the strength or result in visual imperfections or failure in performance of the Alucobond design. Return any component parts that require alteration to the factory for correction or replacement with new parts.

7.4

Install Alucobond panels

All components and panels must be installed in accordance with the â&#x20AC;&#x153;For Fabrication and Installation (FFI)â&#x20AC;? drawings and stated design parameters (including joint size and design modules). Co-ordinate with other trades impacting on the Alucobond installation, including window, door and building underlay installations.

7.5

Fasteners Durability

Fasteners must meet the minimum durability requirements of the NZBC. The fixing requirements are the same as that of NZS 3604 which specifies the requirements for fixings to be used in relation to the exposure conditions.

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DSM100 AlucobondFixedCassetteSystem

Exposure conditions for Zone C outside sea spray zone and Zone B and Geothermal hot spots: Grade 304 or Grade 316 stainless steel.

Zone D: Grade 316 stainless steel.

Also refer to the NZBC Acceptable Solution ‘E2/AS1’ table 20 and 21 for information regarding the selection of suitable fixings and their compatibility with other materials and Table 24 ‘Fixing selection for wall claddings’ 7.6

Fasteners – Size and layout

The amount of fixings, their positioning, gauge and length must be that shown on the job specific Shop Drawings and For Fabrication and Installation drawings.

7.7

Tolerances

Permissible vertical and horizontal misalignment of abutting ends of Alucobond panels ≤ 2mm.

Ensure the maximum deviation for vertical members to be 3mm maximum in a 5.2m run and to be 5mm maximum in an 11m run.

Ensure the maximum deviation for horizontal members to be 3mm maximum in an 8.5m run.

Ensure the maximum offset from true alignment between the abutting members does not exceed 1mm.

Ensure the tolerance of width of the joints between two panels is a maximum of 2mm 7.8

Defective or damaged work

Repair damaged or marked elements. Replace damaged or marked elements where repair is not viable or where the repair work does not deliver a satisfactory visual finish at normal viewing distance with the naked eye.

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DSM100 AlucobondFixedCassetteSystem

8

8.0 JUNCTION SEALANTS

8.1

General

The purposes of junction sealants are to: a) provide protection to the Alucobond sheet folds, edges and fixings for increased durability, b) provide a better visual finish by covering the fixings and sheet edges in the panel joints, c) improve moisture management of the Alucobond Fixed Cassette system.

Where joints between individual Alucobond panels’ are sealed an appropriately tested sealant like Sika AT Façade must be used. Sealants to be supplied & applied in accordance with manufacturer’s recommendations.

It is imperative that the Alucobond protective peel off foil remains on the Alucobond panels during application of the sealant and afterwards until the sealant is sufficiently cured. Removing the foil before the sealant is cured may result in the sealant failure from excessive movement caused by thermal movement in the Alucobond panels.

Do not wipe sealant on the Alucobond protective peel off foil during application of the sealant.

Any spillage of sealant or other solvents must be cleaned off immediately.

Do not install any component parts that are defective in any way, including warped, bowed, dented and broken.

Do not use adhesive tape, film, papers, or sprayed protective coatings, or masking tape, which may become bonded to the Alucobond panel surface after exposure to the elements.

8.2

Joint Widths

Joint widths between Alucobond panels may vary depending on the amount of thermal movement that need to be accommodated in the system or to obtain a certain look. Joint widths referred to on the Shop Drawings and For Fabrication and Installation (FFI) Drawings are the joint width present on a panel installation before the protective peel off foil is removed at a temperature of 20deg C out of direct sunlight.

8.3

Joint profiles

Joint profiles may vary in shape and are not all designed to be suitable for performance under movement.

8.4

Prepare surfaces

Clean Alucobond surfaces with an approved solvent where sealant needs to bond to the Alucobond. Ensure no spillage on the panel or protective peel off foil surface and clean off any spillage immediately should it occur. Mask adjoining surfaces, install backing rod or breaker tape and apply sealant in accordance with the FFI drawings, sealant profiles and sealant manufacturer’s instructions.

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DSM100 AlucobondFixedCassetteSystem

8.5

Backing rod / Bond breaker

A suitable bond breaker tape must support the sealant to enable to sealant to perform properly.

Refer to detail section for further information.

8.6

Joint finishing

Sealant joints may be tooled off to have a concave profile or in some instances joint profiles may be tooled off to be flat. Refer to that is indicated on the Shop Drawings.

8.7

Protective peel off foil

Remove the protective peel off foil once the sealant has cured. The peel off foil usually needs to remain on the panels at least three days before removing it. Apply a pressure test to the sealant joint to determine if the sealant has cured before removing the peel off foil.

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DSM100 AlucobondFixedCassetteSystem

9

ACCEPTABLE VISUAL FINISHING LEVELS

9.1

General

When inspecting the Alucobond installation for an acceptable level of visual finish the following criteria applies.

9.2

Panel and sealed joint surfaces

Surfaces are acceptable where the normal person cannot identify defects at a normal viewing distance. (Normal viewing distance may vary â&#x20AC;&#x201C; on a building fascia normal viewing will be from standing beside the building approximately 30m away; for a ground level wall panel viewing distance will be not necessarily be right by the panel but where people will normally stand viewing the panels. At a building entry normal viewing distance may therefore be as close as 1m.)

9.3

Flatness of walls

Surfaces are acceptable where no change in line or level can be detected for the normal person when viewing installations from their normal viewing planes.

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DSM100 AlucobondFixedCassetteSystem

10

MAINTENANCE

It is the responsibility of the specifier / designer to determine normal maintenance requirements to comply with NZBC Acceptable Solution B2/AS1. The extent and nature of maintenance will depend on the geographical location and exposure of the building. As a guide, it is recommended that basic normal maintenance tasks shall include but not be limited to: 

Washing down exterior surfaces every 6 – 12 months. (Do not use a high pressure water blaster to wash down the cladding.)



Maintaining the exterior envelope and connections including joints, penetrations, flashings and sealant that may provide a means of moisture entry beyond the exterior cladding.



Pruning back vegetation that is close to or touching the building.

Inspection for leaks White water stains around drain holes / ventilation holes and water dripping from drain holes / ventilation holes in an Alucobond installation after rain showers is an indication that water is entering the system and investigation is necessary.

Refer to www.kaneba.co.nz/AlucobondMaintenance.html for further maintenance information.

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DSM100 AlucobondFixedCassetteSystem

11

PRODUCT INFORMATION

11.1

Manufacturing and classification

Alucobond is a light-weight composite material consisting of two aluminium cover sheets heatbonded (laminated) to a core made of polyethylene. At least one of the cover sheets will be prefinished with a lacquer on its visible surface and covered with a peel off foil for protection during handling. Where project requirements dictate so proprietary additives are mixed with the polyethylene to make it less combustible. The less combustible version of Alucobond is referred to as Alucobond PLUS. Alucobond is a very durable cladding material requiring only minor maintenance. Alucobond sheets are readily identified by the Alucobond branding on the protective peel off foil it is supplied with and with batch markings including the name Alucobond on the reverse face of the sheets. Alucobond sheets are manufactured in 3mm, 4mm and 6mm thicknesses. 3 & 6mm thick sheets are only used in specific circumstances â&#x20AC;&#x201C; 4mm thick sheets are usually used for Architectural applications.

For Material Safety Data sheets contact Kaneba on 09 926 2297 11.2

Product Mass

4mm Alucobond sheets have a mass of 5.5kg / m2 and 4mm Alucobond PLUS sheets have a mass of 7.6kg / m 2.

Alucobond is classified as a Light Weight Wall Cladding (not exceeding 30kg/m 2) in accordance with NZS 3604.

11.3

Sheet sizes

Alucobond sheets are manufactured to order in lengths up to 8000mm. Widths are also available in 1000mm, 1250mm, 1500mm and 1575mm all nominally, all subject to minimum order quantities per colour and width and manufacturing lead times apply.

All sheet dimensions are nominal and edges may need trimming to provide a consistent and presentable finish.

11.4

Durability

Alucobond, when installed and maintained as per the technical specification, will meet the durability requirements for claddings as required in the NZBC durability clause B2.3.1 (b)iii.

11.5

Resistance to moisture

Alucobond is impermeable and had excellent resistance to moisture. It is not recommended to submerse Alucobond under water for extended periods of time or to use it as a gutter.

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DSM100 AlucobondFixedCassetteSystem

11.6

Resistance to fire

Alucobond PLUS is less combustible that Alucobond. For applications where spread of flame needs to be limited Alucobond PLUS has the following characteristics: For exterior applications Alucobond PLUS meets all the criteria of the NFPA 285 and UBC 269 â&#x20AC;&#x201C; Method of test for the evaluation of flammability characteristics of exterior, non-load bearing wall assemblies containing combustible components using the intermediate-scale, multi-story test apparatus.

For interior applications Alucobond PLUS testing under ISO 9705 â&#x20AC;&#x201C; 1st edition 1993 produced the following results: FIGRA RC (W/s)

0.427

THR RC (MJ)

170,45

SMOGRA value (m2/s2)

1,385

TSP RC (m2)

550,1

Time to flash over (s)

No flash over

For interior application Alucobond PLUS is considered a Group 1S material.

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DSM100 AlucobondFixedCassetteSystem

12

NOTATIONS ON KANEBA ALUCOBOND TYPICAL DESIGN DETAILS

The purpose of these notations is to elaborate on the details depicting how the Alucobond Fixed Cassette System. These clarifications must not be relied upon as project specific design information. Each project is subject to KANEBA scrutiny on its own merits and site specific requirements.

There are a range of methods to fix Alucobond to buildings including the Fixed Cassette System and Suspended Cassette System. Each system has its own merits and may not necessarily be suitable as the best option for a specific building.

The designs of the Alucobond systems provide part of the external cladding and rely on an air barrier to effectively manage external moisture. The air barrier may include Air Seals around windows, a rigid air barrier or alternatively to the rigid air barrier a sealed plasterboard lining.

The details shown include a range of components. As a provider of part of the external cladding KANEBA do not necessary provide all the components.

Each notation may be affected by other nations in this document. The whole document should therefore be considered when reading a specific notation.

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DSM100 AlucobondFixedCassetteSystem

1) S/S SCREWS BY KANEBA a) PURPOSE: To attach Alucobond panels to a building structure b) This item should be read with Table N1. c) Screws are normally positioned where the Alucobond panel perimeter coincides with studs or nogs. (Two screws located in close proximity may be sufficient to increase distances between screw fixings, subject to deflection limits in Alucobond panel edges.) d) High wind loading exceeding 2.5kPa ULS resulting in suction on panels may require fixings at more frequent intervals, and is therefore subject to Specific Engineering Design.

Timber framing construction may have to consider the panel configuration also. e) Where fixings are designed to connect an Alucobond panel (subjected to positive pressure) to a structure, the fixing must be combined with shimming. f) Screw lengths and gauge varies dependant on the shimming depth or if required by Specific Engineering Design. g) Where screws connect into an Alucobond fixing angle fixing centres must not exceed 600mm centres. h) Where fixing into 1.6mm aluminium use tec screws.

Factors affecting screw length selection:  Shimming thickness  Thickness of building underlay (Wrap or RAB)  Substrate fixed into (Concrete, steel, timber)  Shear movement Factors affecting screw gauge selection:  Screw length  Shimming thickness  Shear movement Factors affecting screw type selection:  Visually exposed screws usually Pan Head  Screws in joints usually counter sunk  Exposure to elements Factors affecting screw centres:  Wind loading on building  Panel sizes  Timber framing  Screw length and guage

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DSM100 AlucobondFixedCassetteSystem

TABLE N1 â&#x20AC;&#x201C; Alucobond Fixed Cassette System Fixings and shimming Screw Size

Guage

Diameter (mm)

Minimum embedment into framing

Length

Length

(Inches)

(mm)

Maximum shimming

mm

Over flexible building underlay

Over 6mm RAB

8g

4.17

2

50

30

15

9

10g

4.88

2½

63

35

23

17

10g

4.88

3

75

35

35

29

Screws must be full threaded, 304 or 316 Stainless Steel Fixings into horizontal panel joints: a) Alucobond panels must be fixed where the Alucobond panel edge joint coincides with a stud. b) As a minimum there must be two separate connection points to studs for a single horizontal Alucobond panel edge. c) Where continuous framing is available behind a horizontal Alucobond panel edge the minimum amount of fixings must be no less than the number of studs above or below the continuous framing. d) Where no framing is available to fix the Alucobond panel edge to (like at inter storey joints or at bases of walls) panel stiffeners must be provided in close proximity to the panel edge to limit deflection of the panel edge between fixings. (See item 19) Fixings into vertical Alucobond panel joints: a) Alucobond panels must be fixed where the Alucobond panel edge joint coincides with a nog / dwang. b) Where the Alucobond panel joint falls on a stud fixings must be no less than 600mm apart and there must be at least two connection points per Alucobond panel edge. c) Where an Alucobond panel edge does not fall on a stud or a nog / dwang no fixings are required, provided that the panel face height does not exceed 800mm. Where the fixings in this instance exceeds 800mm c/c into the framing panel stiffeners must be provided spanning between the closes fixings to the left and to the right of the vertical panel joint. (See item 19) Shims must be made from a non-absorbent material like high impact plastic or ACM material.

Shims must not be stacked in excess of three units. (It may compromise shear strength and may be subject to slippage.)

Out of tolerance structures: a) Where Alucobond panel fixing flanges are offset from the structure in excess to what is provided for in this table packing must be provided to the requirements of NZS 3604 to bring shimming within limits of this table. Also see item 18. b) Alucobond fixing flanges must not be closer than 5mm from the building underlay.

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DSM100 AlucobondFixedCassetteSystem

2) PROPRIETARY SHIMS BY KANEBA a) PURPOSE: To take up minor tolerances that may exist in the timber structure so that the Alucobond panel system can be installed in a straight line without being affected by an inconsistent wall frame AND to offset the Alucobond panels from the wall underlay to ensure sufficient airflow and drainage cavity for the drained and ventilated cavity design. b) When installing Alucobond by means of the Fixed Cassette System the exposed Alucobond surface is usually 50mm offset from the building underlay / structure it is fixed to. Theoretically this leaves a 16mm space between the Alucobond fixing flange and the building underlay / structure. The 16mm space is required to accommodate structural tolerances and to provide a cavity for the Alucobond system to manage airflow and moisture and separate the Alucobond cladding panels from the building underlay. To structurally secure the Alucobond panel, shims are used to provide a stable surface for the Alucobond panels to rest against. c) Due to construction tolerances in the structure shimming thicknesses vary. Shimming must be in accordance with Table N1. d) Where the distance between the Alucobond fixing flange and the building underlay / structure exceeds 35mm refer to item 18 of these notes. an option is to first structurally fix packing like 17mm thick x 100mm wide treated plywood into the building structure and then shim the remaining gap. e) Where packing is provided it must be sized and positioned in a manner that is structurally secure to allow sufficient embedment for the screws used during Alucobond installation.

(Packing must therefore always be backed by solid timber to allow fixings to have sufficient embedment as per Table N1.) f) Steps in building framing can be framed out in the wet area with a minimum of H3.2 treated timber into the building structure, all in accordance with the provisions of ‘NZS 3604’. Care must be taken not to expose the Alucobond to potential runoff from the treated timber.

Factors affecting shimming:  Construction tolerances  Ventilation cavities

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DSM100 AlucobondFixedCassetteSystem

3) AIR BARRIER (Wall Underlay) a) PURPOSE: To manage external moisture the Alucobond Cladding relies on an Air Barrier to limit the flow of air through the Cladding System. The structural calculations of the Alucobond are also based on a wall with an air barrier. b) NZBC Acceptable Solution ‘E2/AS1’ ‘External Moisture’ does not require the building underlay to be the Air Barrier because in some instances the air barrier may be formed by the plasterboard lining on the inside of the wall. Kaneba recommends that the building underlay is also specified as the Air Barrier – because it can be visually inspected during the Alucobond Site Check and installation process. c) The Air Barrier may be formed from a rigid backer board (like fibre cement board) or from a flexible material like building wrap. d) When a wind loading exceeds 1.5kPa rigid backer board will be required as per NZBC ‘E2/AS1’. e) See section 4 of the Alucobond Fixed Cassette System manual for more information.

Factors affecting air barrier type selection:  Wind loading on the building  Client / designer / builder preference

4) ALUCOBOND BY KANEBA a) PURPOSE: Primary cladding material. b) Alucobond cladding is available in various colours. c) Core material can be Polyethylene, PLUS or A2 Factors affecting Alucobond core selection:  Where external spread of flame needs to be limited Factors affecting Alucobond surface finish selection:  Client / designer preference  Availability  Light Reflectivity. Building Consent Authorities may have limitations  Building location. Subject to resource consent / look.

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DSM100 AlucobondFixedCassetteSystem

5) SEALANT ON PEF ROD BY KANEBA a) PURPOSE: To contribute to weather tightness, to protect the sheet edges from the elements and to hide screw fixings. b) Sealant joints vary in width to accommodate different degrees of thermal movement and because of construction tolerances of the Alucobond and other trades. c) Sealant joints must not be less than 5mm wide d) Sealed joints between other trades and Alucobond may appear wavy. This is usually because Alucobond panels are installed in straight lines, but trades like fibre cement usually nail their material to a structure without adjustment therefore following the line of the frames structure. e) A suitable primer must be used where sealant is applied to concrete or fibre cement surfaces. f) Sika AT Façade is an approved sealant for Alucobond surfaces.

Factors affecting sealant type:  Greenstar requirements  Durability and adhesion testing  Compatibility with adjoining surfaces  Combustibility of the sealant type Factors affecting sealant joint widths:  Alucobond panel sizes  Screw head sizes  Alucobond surface finish / colour  Number of Alucobond panels / length of a sequence of panels  Exposure of panels around joints to the sun

6) FLASHING TAPE OR METAL FLASHING a) PURPOSE: To seal off the edge of the Alucobond to the building underlay. (Note the building underlay may not be the air barrier.) The flashing may be required to act as a fire stop and to manage external moisture. b) Flashings can be flexible flashing tape, aluminium, coloursteel or plastic.

Factors affecting flashing type selection:  Visual appearance.  Exposure to the elements (UV...)  Combustibility.

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DSM100 AlucobondFixedCassetteSystem

7) FIRE SEALANT BY KANEBA a) PURPOSE: Intumescent fire seal to obstruct movement of smoke in the cladding cavity in case of a fire. b) Contributes to the weather tightness seal of the Alucobond to the building underlay. c) Fuller Firecryl is an approved sealant for this purpose.

Factors affecting sealant selection:  Visual appearance.  Exposure to the elements (UV...)  Combustibility.

8) ALUCOBOND FIXING ANGLE BY KANEBA a) PURPOSE: To provide an intermediary fixing connection between the structure and the Alucobond panel. b) Fixing angles may be solid aluminium or ACM. c) The fixing angles at window heads must be continuous or butted together to close the cavity above the head flashing. Window head fixing angles must also be spaced off the building. d) Fixing angles on window jambs must be continuous to provide a drainage channel along the window. e) The aluminium surface of a fixing angle fixed against concrete must be separated from the concrete surface by a non-reactive layer. ACM fixing angles may be covered with their protective peel off foil.

Factors affecting fixing angle selection:  Wind loading on the Alucobond panel system.  Space constraints  Compatibility with other materials

9) FLASHING TAPE (WINDOW HEAD) a) PURPOSE: To seal off the head flashing against the building underlay. (Note the building underlay may not be the air barrier.)

Factors affecting Flashing tape selection:  Compatibility with adjoining surfaces  Acceptance by the project designer

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DSM100 AlucobondFixedCassetteSystem

10) WINDOW HEAD FLASHINGS a) PURPOSE: To prohibit moisture from entering the window frame or the wall structure, and where moisture enters to allow moisture to escape from the cavity. b) Usually a proprietary flashing supplied and fitted by the window contractor. c) A had flashing is not a requirement of the Alucobond Fixed Cassette System, but usually required by the Building Consent Authority of the window manufacturer.

Factors affecting window head flashing selection:  Distance the window frame is protruding past the building underlay / structure.  Compatibility with adjoining surfaces.

11) DRAINHOLES a) PURPOSE: To allow moisture that may enter the Alucobond cladding to be let out. b) Drain Holes are located at the bottom edges of fascia panels and at the bottom edges of panels above windows. (Drain holes must be located at the lowest end of Alucobond panels to avoid moisture from accumulating in Alucobond panels.) c) Drain hole sizes may be 8mm diameter or 8mm x 20mm slotted. d) Drain holes must be substituted with ventilation slots 3mm x 20mm at 50mm centres where the panel height it is draining has a cavity height of more than 1500mm. e) Drainage holes / slots do not require any edge protection to maintain the Alucobond durability expectations.

Factors affecting drain hole sizes:  Vermin proofing  Construction debris blocking the holes  Ventilation requirements of the Alucobond system

12) AIR SEAL a) PURPOSE: To eliminate airflow between penetrations like windows and doors and the Air Barrier. b) The air seal can be PEF backing rod or expanding foam or sealant. c) Ensure that the air seal is compatible with other materials.

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DSM100 AlucobondFixedCassetteSystem

13) PROPRIETARY SOAKERS BY KANEBA a) PURPOSE: To divert moisture that may enter the Alucobond cladding to the drainage plain at the back of the Alucobond sheet. b) 0.5mm soakers 100 x 100. c) 0.9mm Aluminium proprietary soakers.

Factors affecting soaker selection:  Window sill to Alucobond detail.

14) CONTINUOUS FIXING ANGLE BY KANEBA a) PURPOSE: To provide an intermediary fixing between the structure and the Alucobond cladding. Also to close off the cavity to vermin. b) Formed of ACM. c) This item is sealed off by pressure against the roof flashing. d) Fixings self-seal through the Alucobond core material from which the angle is formed. e) Where gaps bigger than 5mm will exist use a compatible sealant as a gap filler.

15) VENTILATION SLOTS a) PURPOSE: Ventilation slots provide air circulation and may provide drainage of moisture to the Alucobond cladding. b) Ventilation slots of 3 x 20mm @ 50mm c/c provides an opening area of 1000m2/m of cladding. c) At the bottom of walls drainage slots must provide a total opening area of 1000mm2 / m of wall and be positioned to allow a minimum drip edge to the wall cladding of 10mm at the base of the wall. d) Drainage holes / slots do not require any edge protection to maintain the Alucobond durability expectations.

Factors affecting ventilation slot requirement / calculation:  Wall height  Vermin  Pressure equalization of the Alucobond cladding cavities  Offset of cladding from air barrier – see item 20

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DSM100 AlucobondFixedCassetteSystem

16) ALUMINIUM ANGLE BY KANEBA a) PURPOSE: To provide stability for panels exceeding width limits in a wind zone. b) Angle is sealed against the building underlay to prevent vermin entering.

 

Factors : Alucobond panel width Wind loading on building

17) CONTINUOUS BACK FLASHING a) PURPOSE: To provide drainage for panels exceeding width limits in a wind zone.

18) STRUCTURAL PACKING a) PURPOSE: To adjust structural tolerances in the wall frame that cannot be accommodated with shimming. (Reasons for packing may be steps in the building façade, out of tolerance wall frames.) b) Packers can be fixed in accordance with the requirements of cavity battens. These packers must be a minimum H3.1 treated in accordance with NZS 3640 (Chemical preservation of rough sawn timber) to comply with the durability requirements of B2/AS1. c) These packers must be at least as wide as the width of the studs and nogs / dwangs or other timber members provided specifically for the support of the Alucobond cladding. d) An option is to first structurally fix packing like 17mm thick x 100mm wide treated plywood into the building structure and then shim the remaining gap as described in item 2 of these notes. e) Where packing is provided it must be sized and positioned in a manner that is structurally secure to allow sufficient embedment for the screws used during Alucobond installation.

(Packing must therefore always be backed by solid timber to allow fixings to have sufficient embedment as per Table N1.) f) Steps in building framing can be framed out in the wet area with a minimum of H3.2 treated timber into the building structure, all in accordance with the provisions of ‘NZS 3604’. Care must be taken not to expose the Alucobond to potential runoff from the treated timber.

Factors :  Wall size  Fixings to be S/S if in a sea spray zone.

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DSM100 AlucobondFixedCassetteSystem

19) PANEL STIFFENERS BY KANEBA a) PURPOSE: To limit deflection in Alucobond panels. b) Stiffeners are not required where the Alucobond panel can perform suitably within permissible deflection limits. Stiffeners are usually required where: i) Fixing positions on panel edges are limited. (Eg.at base of panels.) ii) Wind loadings on walls will exceed permissible deflection limits. iii) Visual requirements. (Eg. to make soffit panels appear flatter.) c) The need for stiffeners is usually determined during Shop Drawing preparation. d) Stiffeners may be formed from solid aluminium extrusions or Alucobond sheet material formed into a “top Hat” shape. e) Stiffeners are adhered to the back surfaces of Alucobond panels with 3M VHB tape and Simson Panel Tac structural adhesive.

    

Factors affecting stiffener selection and frequency: Wind loading on the building Alucobond thickness Soffit applications where the requirement is purely visual Alucobond edge fold dimensions Alucobond panel sizes

20) 50mm TYP OFF STRUCTURE a) PURPOSE: Indicates nominal offset of panel surface from structure. b) This distance may vary between 40mm and 100mm, based on the design requirements for a job, subject to proper packing (described in item 18) and shimming described in item 2. c) Window head returns must be considered when reducing the distance.

  

Factors affecting the offset from the structure: Visual look Expected tolerance of a building structure Actual construction tolerances

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DSM100 AlucobondFixedCassetteSystem

21) FLASHING TAPE OF METAL FLASHING a) PURPOSE: Closing off cavity when compartmentalizing Alucobond claddings b) This flashing may be flexible or metal.

  

Factors affecting the choice of flashing: Durability Complexity of the joint Compatibility of flashing with other surfaces

22) JOINT WIDTH a) PURPOSE: Accommodating thermal movement b) Design joint widths vary based on panel sizes and surface finishes, and are limited between 12 – 15mm, with adjustments in panel sizes and colours. c) Minimum joint widths are usually governed by the screw head sizes in the joints. d) Alucobond thermal expansion is approximately 2.4mm / m per 100deg Celsius change in temperature of the panel surface.

(Please note that the Alucobond panel surface temperature can be significantly higher than the air temperature.) e) Sealed joint widths are usually no less than nominally 12mm wide for Alucobond panels with a surface finish with a high Light Reflectivity Value (LRV) and can be up to 20mm wide for Alucobond surface finishes with a low LRV. f) Panel joint widths are documented in its theoretical installation dimensions. When installed Alucobond panels with low LRV values will show more movement on the joint widths. g) Joints narrower than 12mm joints are less accommodating to the visual effect of construction tolerances and also accommodate less movement in the system.

  

Factors affecting the joint with: Visual look Thermal movement Construction tolerances

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DSM100 AlucobondFixedCassetteSystem

23) TOP HAT CHANNEL BY KANEBA a) PURPOSE: Providing edge support to Alucobond panel b) Applies to Alucobond surfaces in excess of 300mm that may be stepped upon. (Note: It is not recommended to step on Alucobond panels. We do however make provision for the unlikely event of this abuse occurring.) c) The design allows for edge support to the Alucobond panel so that the stress is transferred to the top hat section and then the structure rather than it being applied to the joint fixings. d) Where the panel size between top hats exceeds 1200mm additional supports must be provided at centres not exceeding 1200mm.

  

Factors affecting the use if this profile: Safeguard the Alucobond installation from potential abuse Width of sloping surfaces Client preference

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DSM100 AlucobondFixedCassetteSystem

13

TYPICAL EDGE TREATMENTS OF ALUCOBOND

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DSM100 AlucobondFixedCassetteSystem

14

Definitions

Wall underlay A building paper, synthetic material or rigid sheathing used as part of the wall cladding system to assist the control of moisture by ensuring moisture which occasionally penetrates the wall cladding is directed back to the exterior of the building. (E2/AS1 page 20) Alucobond sheets The form Alucobond is supplied in before it is fabricated into cladding panels.

Alucobond panels Alucobond sheets profiled into panels ready for installation on a building.

Oil can effect results from an undesirable coil condition in which the material appears dished. It can be caused in the cold rolling process if too much pressure is placed on the centre of the strip, overstretching and lengthening of the centre material. If the material is rolled, the bumps simply transfer to the other side or pop in and out like an oil can.

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DSM100 AlucobondFixedCassetteSystem

i

Omega Point Laboratories test report 15632 â&#x20AC;&#x201C; 105515

ii

Warringtonfiregent test report 14576A

iii

British Board of AgrĂŠment certificate No 05/4214 section 13.

Reference document incorporated in this manual Shop Drawing cover sheet Masterspec Alucobond fabrication guide (Alucobond USA) Permabond Simson Panel Tac

Date 22/2/2012 22/2/2012 22/2/2012

by Jan Jan Jan

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DSM100 AlucobondFixedCassetteSystem