FIRE RETARDENT ALUMINUM COMPOSITE PANEL (A2, ALUMIUNM CORE)
ALUMINUM COMPOSITE PANEL WITH CORRUGATED CORE:
The WELLBOND is a newly developed composite panels which can be used in place of conventional PE, and FR core panels. This is also applicable in place of Honey comb and solid cladding sheets.
The main advantages are:
- Light weight compared to Solid sheet, PE and FR core
- Noncombustible Aluminum core
- Easy to fabricate compared to honey comb
- More strength because of the corrugated core
- Cost effective
- More sound and heat insulation
- 100% Recycling
The WELLBOND is offered in a wide variety of PVDF colors suitable for interior and exterior applications like wall cladding, roofing facades. WELLBOND also replaces the brick walls. Because of the good sound and thermal insulation, the WELLBOND replaces the gypsum board partition and brick walls. WELLBOND is also used as a clean room panel and in Automotive Industries.
Two sheets of aluminum sandwiching a corrugated Aluminum core formed in a continuous lamination process. The core material shall be free of voids and/or air spaces and not contain foamed insulation material.
Exterior / Surface panel is Aluminum Sheet Coated with PVDF and interior/ rear side or back side of Panel will be available Mill Finish / Polyester Service Coat / Chromate.
Aluminum Alloy Sheets:
Alloy: AA3000 Series (PVDF Painted material)
Core material: AA3000 Series
TYPICAL COMPOSITION OF ALUMINUM COMPOSITE PANEL (DIAGRAMATIC REPRESENTATION)
Aluminum Coil alloy (3003 Series) coated with KYNAR® 500 based Polyvinylidene Fluoride (PVDF utilizing with minimum 70% KDF resin).
PVDF Coating system offers Two or Three Layer coating depending on color selection such as Metallic colors and Normal RAL Colors. Metallic Colors are normally Three (3) coat system consisting Primer, Color and Clear Top coat. Normal RAL colors usually have Two coat system composed of inhibitive Primer and Color Coat; in conformance with the following general requirements of AAMA 2605.
Generally, we are manufacturing WELLBOND-AL with various options of color coating, basically we have Four different types of colors such as: Solid / Enamel Colors, Metallic Colors, Natural Finishes (Stone & Timber) and Sparkling Colors.
PVDF: Kynar 500/ Hylar 5000 resin (Fluro Carbon Paint) is the most common coating for the composite panels; coating is available in various colors & finishes. Typical PVDF Coating – ECCA (European Coil Coating Association Standard and ASTM)
WELLBOND is available in various dimensions however our standard Product is 4mm x 1220mm x2440mm.
The other available sizes are as follows:
- Dimensional / Standard Size (Rounded)
Thickness: 6mm ±0.3mm and 4mm ±0.2mm
Width: +/- 2.0 mmLength: +/- 3.0 mm
- Panel Bow: Maximum 0.8% of any 1828mm (72”) panel dimension.
- Squareness: 5mm
- Maximum deviation from panel flatness shall be 3mm in 1500mm on panel in any direction for assembled units. (Non-accumulative – No Oil Canning)
- Panel Dimensions: Field fabrication shall be allowed where necessary but shall be kept to an absolute minimum. All fabrication shall be done under controlled shop conditions when possible.
- Panel lines, breaks, and angles shall be sharp, true, and surfaces free from warp and buckle.
PRODUCT PERFORMANCE (PHYSICAL PROPERTIES)
The Top PVDF coated Aluminum skin and the bottom service coated bottom skin bonded on the core together with an adhesive. This thermosetting adhesive being processed in high temperature (about 150ºC), so there shall be neither adhesive failure of the bond a) between the core and the skin nor b) cohesive failure of the core itself. Bond integrity tested, in accordance with ASTM D1781 (simulating resistance to panel de-lamination), below the following values:
Peel Strength: 215 mmN /mm
COMPARISON WITH OTHER BUILDING MATERIALS
SOUND TRANSMISSION LOSS:
WELLBOND is having high sound insulation property per unit compared to metal sheets like Aluminum solid sheet and Plywood. Our panels are tested for Sound Transmission loss according to ASTM E413.
WELLBOND-AL is having an approximate Deflection Temperature of 120°C.This characteristic proves the property of WELLBOND-AL to resist boiling water. Kindly note that; recommended heating temperature of and duration for heating the Panels.
- Heating less than 30 Minutes Max Temperature 90°C
- Heating more than 30 Minutes Max Temperature 70°C
Properties of Skin
WELLBOND is normally made with Aluminum Alloy3003-H14 and other grades of Alloy 3000 are available as per customer requirement. General sheet metal work requiring greater strength than is provided by 1000 series alloys; profiled building sheet (roofing ceiling and siding); insulation panels; hollowware; food and chemical handling and storage equipment. 3003 is readily welded by the TIG and MIG processes.
Mechanical properties of WELLBOND:
WELLBOND has the following mechanical properties as average:
We can bend the WELLBOND in a Press Break or 3 roll Bending machines. Normally the smallest radius which we can apply to bend the panel without wrinkles at the radial surface of panel is termed as the bend radius. In 3 roll machine the bending diameter depends on the roll diameter, length and type of machine.
For WELLBOND the diameter is about 300 mm.
Compared to solid materials, the WELLBOND panel have a lower thermal conductivity the table below shows the thermal conductivity comparison of different materials.
WELLBOND panels reduce the Heat transfer from the outer air to the inner air. The air gap between the Panel and the wall increases the thermal insulation. The “U” Value of a WELLBOND cladding system is given below:
Results of Reaction to Fire Tests
The Panels used for the external cladding must withstand the wind load. This wind load will cause deflection of the panels and if the deflection is small the panel will not deform.
The permanent deformation of the panel is calculated by 0.2% Proof Stress (yield stress) divided by the safety factor. In the calculation we are assuming that the total strength of the panel is the strength of the Aluminum skins. If the calculated 2% proof stress is greater than the permissible, normally the panel is strengthened by giving additional stiffeners. The other factors affecting the strength of the panel are:
- Panel thickness, width and length
- Supporting conditions.
- Wind load
Bending Resistance: Calculation DEFELECTION OF PANELS:
F Load in N
Q Surface load in N/mm
L Span between bearings in mm
FM Maximum deflection
E*I Bending resistance in N mm
WIND LOAD: For WELLBOND 4mm 0.5 mm top skin, 0.3mm Core and 0.5mm bottom skin
For WELLBOND 6mm 0.8 mm top skin, 0.3mm Core and 0.5mm bottom skin
WELLBOND panels can be easily fabricated by the mechanical processing like saw cutting, bending, grooving drilling etc. The shear cutting is not recommended for the WELLBOND panels, all other conventional type fabrication method can be adopted for the processing of the WELLBOND RIVETING
RESISTANCE TO NATURAL FORCES
The WELLBOND panel has very good fungi and frost resistance. And since the panel is connected to the earth through the sub structure, if a lightning strikes a WELLBOND panel the electricity will be discharged to the earth through the substructure.
MATERIAL TEST REPORTS:
- SGS TEST REPORT for Regular and B1 ACP
- THOMAS BELL-WRIGHT TEST REPORT for B1(KT-B1351) core
- CORE MATERIAL DETAILS FROM KEOCT COMPANY(KT-B1351)
The data in these leaflets are general information and WELLBOND has the right to change due to product changes, improvements and other factors, as per EOS – 7630.