Metawell Klimadecke 1

processing and design tips

contents

Contents

Edge forms 2

•Edgedesigns 2

•Borderfinishes 4

Riveting 5

•Specifications 5

•Sourceofsupply 5

Sawing 6

•Specifications 6

•Toolparameters 6

•Sourceofsupply 6

Milling and drilling 7

•Specifications 7

•Toolparameters 7

• Slitcutter 7

• Router 8

• Prismaticcutter 8

Bonding 9

•Specifications 9

•Sourceofsupply 9

Forming 10

•Metawell 10

•MetawellAluflex 11

Individual colouring 12

•Painting 12

•Coating 13

page

®

®

Modifications and errors reserved 2

EdgEfoRMS

Edge designs Metawell®offersotherpossibilitiesforedgefinishesthansheetmetal,whichisduetoitsspecificpanelstructure.Moresignificantcharacteristicscanbecreatedattheedgeofasandwichpanelbyuseofanapplication-matchingedgedesign:

•opticaladjustmentoftheedgetotheapplication•increaseoftheelement‘sstiffnessintheedgeareas•reductionoftheriskofinjuriescausedbysharpmetaledges•reductionofassemblyworkby„automatic“fittinge.g.byintegrateddrillholesforconnectors•concealedattachmentofprofilesandfittingsatthebackofanedgefinish

Inordertoobtainanattractiveedgethepanelhastobemechanicallyprocessed.Thereforethepanelismilledthroughbacksheetandcorrugationtothecoversheet.Themillinggeometryisdependendonthefinaledgeformandthemachiningtools.InviewoftherequestednarrowtolerancesfordoublefoldingsandfoldingsatthecornerstherelevantpanelsshouldbeprocessedwithCNC-workstationsonly.oncethepanelsaremilled,thefoldingitselfcanbedoneeitherbyhandorwithsimpleedgingaids.Likethisflat(milled)panels,thattakelessspaceduringtransport,canbesenttotheassemblysitewheretheyarefurtherprocessedandfolded.onlypa-nelswithacoversheetthicknessofmin.0.8mmcanbemilledandfolded.Themax.foldinganglewithsinglemillingis135°.

NoteItisstronglyrecommendedtomakeapreliminarytestoraskforprocessedsamplestojudgethetechnicalandopticalsuitabilityofthechosenedgedesign.Pleasecon-tacttheplantforanyfurthertechnicalquestions.

Edge design KR-90Use: ceilingelements,liningsTool: CNC-workstation,verticalsaw,hand-tool(limited)Particularity: foldingradiiof2.5and4mmcanalsoberealizedwith coil-coatedpanels

Edge design KR-120Use: ceilingelementsTool: CNC-workstation,verticalsaw,hand-tool(limited)Particularity: foldingradiiof2.5and4mmcanalsoberealizedwith coil-coatedpanels

designKR-120(120°-folding)Radii:2.5and4mm

designKR-90(90°folding)Radii:0.5-2.5and4mm

Edge forms

Modifications and errors reserved 3

Edge design BKUse: ceilingelements,linings,doors,coversTool: CNC-workstationParticularity: canalsoberealizedwithcoil-coatedpanelsdesignBK(sheetcoverededge)

Radius:approx.1mm

Edge design EP/SUse: ceilingelements,liningsTool: rotaryjarsParticularity: ideallysuitedforcoil-coatedpanels(nocuttings)

designEP/S(hammershearcutedge)

Edge design EP/DUse: gaplessceilings,bigjoint-lesssurfacesTool: CNC-workstationParticularity: perfectlysuitedforsubsequentsealing/jointing

Edge design KBUse: structuralpartsTool: edgingbankParticularity: foldingwithoutpreparatorymilling,nocuttingofcoversheets, onlyforapplicationswithnovisualdemandsNote: bendingonlypossibleright-angledtocorrugation

designEP/d(coversheetpressed)

designKB(edgingbank)

Edge forms

Modifications and errors reserved 4

BesidesfoldingsmanyotherborderfinishesarepossiblewithMetawell®panels.Whenchoosinganappropriatefinishthefollowingaspectsshouldbeconsidered:

•opticalrequirements(design,typeofsurface) •generalconstructionalconditions(flushconnectiontothepanelsurface, fixingofaccessoriesorconnectionwithotherelements) •Ambiantparameters(temperature,pressure,affectingmedia) •Loadonthebordersduringoperation(mechanicstress,thermalloads, typeofelement–mobileorfixedmounting) •Requirementswithregardtotightness •Productioneffortsandquantity(singleproduction,project-wise production,serialproduction,availabletoolsanddevices)

ThecombinationofMetawell®panelswithotherelementsormaterialsispossibleandhasbeendonesuccessfullyforyearsinconsiderationoftherelevantindividualconditions.forinteriorconstructions,forinstance,postformingedgeswithglued-inwood,plasticoraluminiumprofilesandHPL-surfacescanberealized.

Inordertohaveadefinedbaseitmaybenecessarytomachinethepanels,e.g.tomillthecorrugationoffalongtheedgesandtofillthemwithfoamorinsertedplasticribbonsbeforeapplyingthefinaledgeending.Thispreparationismainlynecessarywhenedgebandingsorinjection-moldedbordersarewanted.furthertechnicalquestionsregardingtheseborderfinishescanbediscussedwiththeplant.

Plasticbeading

Edgeprofile

gluedinsert

Postformingedge

Tongue-and-groovesystem

Edge-banding

Border finishes

Edgecap

Injection-moldededge

Edge forms

Modifications and errors reserved 5

Metawell®panelscanbeconnectedtoeachotherortoothermaterialsbyconventionalrivets.Therivets‘lengthanddiameterdependmainlyonthecombinationofthecomponentsinvolved.

ThecorestructureofMetawell®alsoallowsconcealedrivetingononeside.Theuseofblindrivetsenablesthevisiblesurfacestobemechanicallysecuredwithoutdetractingfromtheirvisualappearance.Suchmethodsareused,forinstance,ininteriorconstructionsandfaçadetechnology.

MountingblindrivetnutsandscrewsintoMetawell®ispossible.Whenpiercingthroughcompletelytheyprovideincreasedresistanceagainstbendingmomentssincethebacksheetholdstheblindrivetnutandwithstandsdeformation.Blindrivetnutsshouldhaveatleastfourturnsofthread.

Therivet‘sextractionstrengthdependsonthecombinationofmaterialsandadditionalfactors,thedeterminationofwhichmightmakeatestnecessary.Therivets‘mechanicalparameterscanbefoundintherelevantsupplier‘sproductiondescription.

•TitgemeyergmbH,d-49084osnabrueckhttp://www.titgemeyer.deBlindrivets,blindrivetnuts

•BoellhoffgmbH,d-33622Bielefeldhttp://www.boellhoff.deBlindrivets,blindrivetnuts

•gesipagmbH,d-64546Moerfelden-Walldorfhttp://www.gesipa.comBlindrivets,blindrivetnuts

Specifications

Blindrivet–concealedfixing

Blindrivet-throughgoing

Blindrivet–rivetingindoublepanel

Blindrivetnut-throughgoing

Blindrivetnut-concealed

Blindrivetscrew

Riveting

RIvETINg

Source of supply

Modifications and errors reserved 6

Specifications Metawell®canbeworkedwithcircular,jigandbandsawswithconventionalsawblades:dihedralsawbladesshouldnotbeused,however,sincetheteethmaybecomeentangledbetweenthecoversheetandthecorrugationproducinganuncleancut.flattrapezoidalteethwithanegativetoothpositionandhardmetalcuttingedgeshaveprovenidealwhenusingcircularsaws.

Aformat-cuttingslidingtableortheuseofverticalsawsisadvantageouswhenprocessinglargepanels.foroptimumresults,werecommendtheuseofendstops.Sawinginpackstorationalizeprocessingispossible.

Thefixationofthepanelsandthesuitabilityofthesuctiondevice(e.g.ATEXdirecti-ve,volumeflow,etc.)shouldbeconsideredparticullarly.

groovesthatallowsubsequentedgingwithoutthehelpofafoldingmachinecanalsobeintroducedintothepanelsbyusingcircularorverticalsaws.forthis,however,inadditiontotheuseofaprismaticmillcutter,arollermustalsobeusedtopressdownthepaneltoensureadefinedcuttingdepth.

Preliminarytestswithsuitablesamplesarerecommended.

verticalsaw(panelsaw)

NegativeflattrapezoidaltoothLeitz-circularsawblade

Sawtype Circularsaw Bandsaw CNC-sawblade

Sawblade 80teeth/d=250mm 14teeth/1“ d=160mm

feed 10m/min 20m/min 10m/min

speed 3500-6500U/min - 12.000U/min

Source of supply LeitzgmbH&Co.Kghttp://www.leitz.org

Sawing

SAWINg

Tool parameters

differentdimensionsatLeitz-circularsawbladeswithneg.fZ/TR.

Modifications and errors reserved 7

Specifications Metawell®panelscanbeprocessedwithhandtoolsandmachinetools.

Wood-workingtoolsareideal,especiallyifequippedwiththerelevantprotectiondeviceagainst

metalcuttings,sinceprocessingMetawell®ismorecloselyrelatedtoprocessingwoodthanto

processingmetal.Thisrefersparticularlyintermsofthelargesurfacearea,theclampingtech-

niques,thefeedspeedandthelackofrequirementforcoolantsandlubricants.Inaddition,the

usabilityoftheexistingsuctiondevicemustbecheckedinadvance.Inaddition,theusabilityof

theexistingsuctiondevice(e.g.ATEX,volumeflow,etc.)hastobecheckedinadvance.

generallywedistinguishbetweenthefollowingtypesofprocessing,forwhichdifferenttypes

ofmachinesortoolsarerequired:

•Millingcontours

(bothcoversheetsandthecorrugationareremoved)

-handtool -endmillwithrouter

-machine -CNC-workstationwithrouter

•Millinggrooves

(onecoversheetandthecorrugationareremoved)

-handtool -panelrouter(limitedapplications)

-machine-CNC-workstationwithprismaticcutter

-verticalsawwithprismaticcutter(limitedapplications)

•Millingoutthecorrugation

(thecorrugationisremovedonthepanelsidesonly)

-handtool -trimmerwithslitcutter

-machine -CNC-workstationwithslitcutter

•drilling

handtool -drillingmachineorrouter

machine -CNC-workstationwithdrillerorrouter

Thetoolparameterslistedbelowarebasedonlong-termexperience.Inviewofthemanydif-

ferenttoolsandmachinesavailableitishighlyrecommendabletomakesomeprocessingtrials

withthetoolsandmachinesthatwillbeusedlateron.

Milling and drilling

MILLINgANddRILL INg

ToolsSlitcutter

(removingthecorrugationatthesides)

Slitcutter(removingthecorrugation

atthesides)

Typegroovingcutter22.5x4(millingdepthmax.8mmperoperationalstep)

T-groovingcutter45x8,2(hastobegroundtothe

requestedwidth)

speed 10.000min-1 10.000min-1

feed 5m/min 5m/min

SupplierHoffmanngmbH

http://www.hoffmann-tools.comLeitzgmbH&Co.Kghttp://www.leitz.org

Slit cutter

Removingthecorrugation(slitcutter)

Tool parameters

Modifications and errors reserved 8

Prismatic cutter

Milledgrooveforfolding(prismaticcutter)

ToolsCNCv-groovecutter(0.5mmfoldingradius)

CNCv-groovecutter(2.5mmfoldingradius)

CNCv-groovecutter(approx.4mmfolding

radius)

Typev-groovecutter(withchangingblades)

v-groovecutter(withchangingblades)

v-groovecutter(withchangingblades)

speedmax.

10.000min-1max.

10.000min-1max.

6.200min-1

feed 6m/min 6m/min 5m/min

SupplierLeitzgmbH&Co.Kghttp://www.leitz.org

LeitzgmbH&Co.Kghttp://www.leitz.org

LeitzgmbH&Co.Kghttp://www.leitz.org

Milling and drilling

Router

Millingcontours(router)

ToolRouter8mm

(millcuttingofcontours)

Endmill4mm(Innercorners,bottomholesanddrillholes)

Type

vHMcontourmiller8x30x80mm

solidcarbidecontourcutter,oneblade,righthandtwist,right-cutting,TiAlN-coating

vHMcontourmiller4x15x40mm

solidcarbidecontourcutter,oneblade,righthandtwist,right-cutting,TiAlN-coating

speed18.000min-1to30.000min-1

8.000min-1to30.000min-1

feed5m/min

to10m/min0,5m/minto10m/min

SupplierREXIMgmbH

http://www.rexim.deREXIMgmbH

http://www.rexim.de

Notedependingontherequiredradiiandtheavailablesurfaceofthepanel,theappropriatemillingtoolshavetobedefined.

Potentialrestrictionsandinstructionsoftherelevantsuppliershavetobeobserved.

Modifications and errors reserved 9

Specifications Bondingistheconnectiontechniquebestsuitedtothenatureofasandwichpanel:

•Theuniformstressdistributionoverthewholeofthebondedsurfaceensuresstaticanddynamicrigidity.Bondingacrossthewholesurfaceprovidesbettervibrationdampeningthanrivetedorscrewedconnections.•Theuseofbondingensuresthatthesurfacesremainsmechanicallyandvisually unimpaired.•Adhesivesareparticularlypopularforlightconstructionssinceverythincomponentscanbefixedtoeachotherwithoutaproblem.•Adhesivescanalsoserveassealantagainstfluids.•Whenconnectingdifferentmetals,theadhesive‘sinsulatingeffectspreventthe build-upoflocaleffectsandtheformationofcontactcorrosion.•Agreatvarietyofcontactadhesives(constructionalglues),surfaceadhesivesand adhesivestripsareavailableonthemarketandhaveprovedtheirperformancein themostdifferentapplicationsforyears.

Adhesivesarenormallymagneticallyneutralandprovideelectricalandthermalinsulation.SincetheindividuallayersofMetawell®panelsarebondedtoeachotherandthereforealreadyoptimallypreparedforbondingatthefactory,onlylittleadditionaltimeandexpenseisrequiredforthisconnectiontechnique.

Thechoiceofthebestadhesionsystemforaparticularapplicationdependsonthematerialsbeingjoinedandtherequirementsthathavetobemet.Thetraditionalgluingsystemsofferagreatchoicewithregardtostrength,adhesion,lifetime,processingconditionsandfurthertechnologicalcharacteristics.

Pleasecontactourfactoryortheadhesivemanufacturertodeterminethebestsuitableadhesionsystem.

SikadeutschlandgmbHhttp://www.sika.comSystems:SikaflexandSikaTack

3MdeutschlandgmbHwww.3mdeutschland.de

Source of supply

Bonding

Bonding

Modifications and errors reserved 10

Metawell® Metawell®panels,ase.g.thepaneltypeAluCC08-02-05/H6whichisfrequentlyusedininteriorconstructions,canbeplasticallyshapedaroundoneaxiswithappropriatedevices.Theformingprocesscreatestensilestraininonecoversheetofthepanelandcrushingstrainintheoppositecoversheet.Theloadingdirectionhasalsoaninfluenceonthepanel,whichisduetothefactthatthecoreofMetawell®panelsisacorrugatedsheet:

•Whenbendingparalleltothecorrugationtops,thecoversheetwhichisundercrushingstrainmaybucklebetweenthecorrugationpeak.Thereforeonlylargebendingradiicanberealizedinthatdirection.Mostlyitisadvantageoustouseathickercoversheet.

•Bendingperpendicularlytothecorrugationtopsisconsiderablyeasier.Thebehaviourisdependentonthecoversheets(tensilestrength,thickness)aswellasonthecorrugation.Toonarrowbendingsmayleadtoopticalimpairmentsbecausethecoversheetsdeformabitmorebetweenthecorrugation.

•Theplasticdeformationofthepanelsleadtoinherenttensionsinthepanelswhichmayhaveaneffectonthefurtherprocessingsteps.Particularlyaftersubsequentcuttinginherenttensionscouldbecomenoticeableintheformofdistortions.

NoteInordertodetermineappropriateworkingparametersitisrecommendedtomakebendingtrialswithsuitablesamples.Inviewoftheproblemofinherenttensionsthemodelsampleshouldbeasclosetotherealelementaspossible.Thisrefersinparticulartomechanicprocessingstepsafterthebendingprocesssuchaschangingcontours,makingcut-outsorinsertingslots.

formedMetawell®panels

foRMINg

Forming

Modifications and errors reserved 11

Metawell®Aluflexconsistsofathincorrugatedaluminiumsheetthatisgluedtooneflatcoversheet.Thismakesforapanelthatisveryflexibleinonedirectionbutrigidintheother,whichisidealforformedstructures.

Forming parallel to the corrugation ThankstoitsspecialstructureMetawell®Aluflexcanbeveryeasilytransformedaroundtheaxisparalleltothecorrugationtops,withsmallerbendingradii(e.g.forMetawell®Aluflex05-02/H4.7smallerthan200mm)evenplastically(seefig.1).Thebendingparametershavetobedeterminedcase-wisetomakesurethatbothbendingradiiandbendinganglecanbereproduced.Inordertocompensatethespring-backeffectofthematerial,the´over-bending‘isveryimportant.Therigidityaroundthisbendingaxisisrelativelysmall.Itmaybenecessarytoadditionallystiffentheelemente.g.bygluingametalsheetorothersurfacematerialtothecorrugationinordertoobtainatwo-dimensionallyformed„panel“.Withthisbendingtechniqueradiiof30mmandmorecaneasilyberealizedwithMetawell®Aluflex05-02/H4.7.

Forming perpendicularly to the corrugation Anytransformationperpendicularlytothecorrugationmakesthestructuralelementconsiderablystiffersothatitcanfrequentlybemounteddirectly(e.g.forcurvedceilingliningsinrailvehicles).Particularlyadvantageousistohavethecorrugationexposedtotheoutside(fig.2).Metawell®Aluflex05-02/H4.7isthussuitableforbendingradiiofmorethanapprox.100mm.Withsmallerradiithecorrugationtendstobe„pulledflat“andthecorrugationisseenthroughthecoversheet.Isthebendingdonewiththecorrugationontheinnerside,highermin.bendingradiiarerequestedtoavoidthatthecorrugatedsheetbuckles.

NoteItisstronglyrecommendedtomaketrialswithsuitablesamplesinordertodeterminetheworkingparametersase.g.theoverbendingangle.

Metawell® Aluflex

fig.1:Transformationparalleltothecorrugationtops

fig.2:Transformationperpendicularlytothecorrugation

fig3:formedstructures

Forming

Modifications and errors reserved 12

Painting ThankstotheirevensurfacesMetawell®panelsareparticularlysuitedasdesignmaterialforsurfacesthathavetomeethighdemandsregardingtheirvisualeffect.Withthemultiplepossibilitiestherearesomeimportantaspectswhichhavetobeconsidered:•Themaximumtemperaturethepanelscanbeexposedtois100°C.Higher workingtemperaturesmightbetolerableforspecialpaintprocedures,butmust beverifiedbytheplant.•Toreceiveanopticallyevensurfacetheminimumthicknessofthecoversheet (visibleside)shouldnotbelessthan0.8mm.•Thetypeofpaintingisdependendonvariousparameters,butalsoonthetotal quantityandthegeometryofthepanelsthathavetobepainted.

Bascially,therearethreedifferentpaintingtechniques:

• Coil-Coating Certaincoloursareavailableexstock.Specialcolourscanbesuppliedwithbigger purchasequantities.

• Powder-coating Newtechniquesallowpowder-coatingforbiggerordervolumes.Ifnecessary, pleasecontacttheusdirectly.

• Spray painting Spraypaintingoffersamaximumflexibilityregardingsurfacedesign.Paintsystem, thicknessandnumberoflayersaswellasmanyothercharacteristicscanbe individuallyadjustedtotheapplication.

Metawell®panelswithaprimeredtopsheetcannormallybelacqueredwitha coatingvarnishdirectlyafterremovaloftheprotectionfoiloraftercleaning thesurfacefromoilanddirtwithoutanyadditionalpretreatment.

Working steps with spray painting Paintpreparationandpaintingshouldbeperformedinthefollowingsteps (steps1to3canbeomittedifprimeredpanelsareused): 1.Roughenorsandthesurface. 2.Primerthepanels,usingprimerorpaintbase. 3.Applyalayeroffillersasvapourdiffusionbarrierifthepanelisforexterioruse. Commerciallyavailableprimersformetalsurfacestendtobewatersensitiveand mustbesealedwithsuchacoating. 4.Applyamin.30μmlayerofcoatingvarnish.Whencoloursarecritical (e.g.RAL9016)pleasecheckwiththepaintsupplier. 5.Ifneededthecoatingvarnishcanalsobecoveredwithaclearcoat.

Therelevantpaintmanufacturer‘sprocessinginstructionsmustbeobservedwhenselectingandprocessingthepaintsystem.Painttrialswiththepreferredpaintsystemarehighlyrecommendedbeforeuse.

Individual colouring

INdIvIdUALCoLoURINg

Modifications and errors reserved 13

Coating BecauseofitsflatsurfaceMetawell®panelsareanidealsubstrateforavarietyofcoatings.However,basicaspectshavetobeconsidered:

•Themaximumtemperaturethepanelscanbeexposedtois100°C.Higher workingtemperaturesmaybepossibleonrequest.•Whenselectingacoatingthedifferentexpansioncoefficientsofpanelsand coatingmaterialmustbetakenintoaccount.

Preliminarytestsshouldalwaysbecarriedouttocheckthesuitabilityoftheselectedcombinedsystem.

Filler and plaster coatingsInprinciple,anyfillerssuitableformetalsubstrates,suchasthoseusedintheautomobileindustry,aresuitableforfillingMetawell®panels.Preparingthepaneledgesbyappropriatemeasures(e.g.pressingdownthecoversheet)helpstoavoidsharpjointsandimprovestheadhesionofthefillerconsiderably.Therewiththeriskofcracksisenormouslyreduced,too.Separateworkinginstructionsregardingsmoothingandplasteringworksforinteriorconstructionsareavailableonrequest.

Foil coatingTherearethreemethodstoapplydecorativefoilsonMetawell®panels:1.Laminatingwithself-adhesivefoils,e.g.forlabellinganddecorativepurposes2.foillaminationusingtransferadhesivefoils(doublesidedadhesivefoils)3.foillaminationusingapaint-onorspray-onsurfaceadhesive

Themostappropriatefoilandcoatingtechniqueshouldbechosenwithrespecttothefinalambiantparametersthesystempanel-glue-foilwillbeexposedto.Hereparticularlyclimaticinfluenceshavetobeconsideredandpossiblypreliminarytestsshouldbemade.

High pressure laminatesWhenapplyingHPLthechoiceofanappropriategluingsystemisparticularlyimportant.dependendonthefinalplaceofuseofthepanelitmustbeexaminedifadouble-sidedcoatingofthepanelwithlaminateandbackpullisnecessaryinordertoavoiddeformationscausedbythedifferentmaterialextensionofthetwopanelsides.TheprocessinginstructionsofthesuppliersofbothgluingsystemandHPLmustbestrictlyobserved.

Other coatingsPleasecontactthefactoryforadvicebeforecoatingwithanyothermaterialsuchase.g.wood,glass,tiles,stoneetc.

Noteforsurfaceswithcarpets,asismainlyusedforfloorsandplatforms,Metawell®panelswithahighercompressivestrengthareavailable.

Individual colouring