MAX TI 3.6 GB by sdsdfqw21

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									the max.

           /TI 3          Working with
            MAX Compact Laminates and
           MAX Compactforming Elements
Published so far in our       TI 1:      Tender Recommendations
Technical Information         TI 2:      Working with MAX Postforming Laminates (out of print)
Series are:                   TI 3:      Working with MAX Compact Laminates and
                                         MAX Compactforming Elements.
                              TI 4:      Cubicles made of MAX Compact Laminates and
                                         MAX Compactforming Elements.
                              TI 5:      Furnishing Objects with MAX Compact Laminates and
                                         MAX Compactforming Elements.
                              TI 6:      Properties, Fire Behaviour, Resistance and Chemicals, and
                                         Cleaning of MAX High-Pressure Laminates (HPL),
                                         MAX Compact Laminates (HPL), and Funder Star Favorit
                                         (Melamine-Faced Chipboard)
                              TI 7:      MAX EXTERIOR, for Balconies and Railings.
                              TI 8:      MAX Perforated Panels.
                              TI 9:      MAX Metal Laminates
                              TI 10:     Working with MAX High-Pressure Laminates (HPL)
                              TI 11:     Star Railings and Filler Panels made from MAX Compact
                                         Elements and MAX Compactforming Elements
                              TI 12:     MAX EXTERIOR, Façade and Wall Cladding
                              TI 14:     PU Safety Edges for Doors and Furniture Parts (out of print)
                          *   TI 15:     MAX Wall Protection System consisting of MAX Compact
                                         Laminates, MAX Compactforming Elements, and the MAX
                                         Wall Protection Profile
                              TI 16:     Tender Specifications for Cubicles and Shower Units made
                                         of MAX Compact Laminates.
                              TI 17:     EXTERIOR Recommendations for the Production of
                                         Compound Panels
                          *   TI 18:     MAX Alumax, MAX Aluphenol, MAX Alucompact.




                              Please file this
                              Technical Information brochure
                              in your MAX information folder under
                              Index Number 3

                              * = Changed from last issue




Technical Information 3                                              2
                          Contents




                          MAX Compact Laminates and the environment           4

                          Description of materials                           5
                          - MAX Compact Laminates (HPL)                      5
                          - MAX Compactforming Elements (HPL)                5
                          - Behaviour in fire                                 5
                          - Warranty                                         5

                          Test certificates                                    6

                          General information                                 7
                          - Transport and handling                            7
                          - Cleaning                                          7
                          - Storing and conditioning                          8
                          - Application and construction                      8

                          Machining                                           8

                          Constructional connections                         14

                          Fundamentals for large area claddings using
                          MAX Compact Laminates                              17

                          Mounting gluing for cladding                       18
                          - Working when gluing                              18

                          Gluing                                             19
                          - Gluing MAX Laminates and MAX Compact Laminates
                            to metal                                         20

                          Information on working with
                          MAX Compactforming Elements                        21

                          Installation of washbasins into a
                          MAX Compactforming Element                         21




Technical Information 3                                       3
                          MAX Compact
                          Laminates and
                          the environment


                          MAX Compact Laminates of all
                          thicknesses consist of lengths of
                          natural fibre - about 65% of the
                          weight - and synthetic resins
                          which are melted at high pressure
                          and high temperature and which
                          harden irreversibly. The precise,
                          controlled production processes
                          do not harm the environment. The
                          panels do not contain any organic
                          halogens (chlorine, fluorine,
                          bromine etc.)compounds such as
                          occur in propellant gases or PVC.
                          They contain neither asbestos nor
                          wood preservatives (fungicide,
                          pesticide etc.) and are free from
                          sulphur, mercury and cadmium as
                          well as other heavy metals. The
                          panels are highly resistant to
                          abrasion, do not affect food and
                          easy to clean. The shavings
                          which arise when machining
                          (cutting and milling) are not
                          hazardous to health.
                          Consequently, even with the
                          thermal disposal of waste -
                          assuming modern heating plants -
                          no environmental poisons such as
                          hydrochloric acid, organic chlorine
                          compounds or dioxins can arise.
                          At high combustion chamber
                          temperatures and appropriate
                          dwell times of the combustion
                          gases in the combustion
                          chamber, as well as an adequate
                          supply of oxygen, MAX Compact
                          Laminates break down into
                          carbon dioxide, nitrogen, water
                          and ashes.
                          Disposal on well-ordered
                          commercial landfills is not
                          problematic.
                          The country-specific rules and
                          regulations which apply to
                          disposal must always be
                          observed.




Technical Information 3                                         4
                                          Description of Material




MAX Compact Laminates (HPL)               MAX Compactforming                   Warranty
MAX Compact Laminates are                 Elements                             ISOVOLTA warrants the quality of
duromer high-pressure laminates           MAX Compactforming Elements          MAX Compact Laminates and
(HPL in accordance with EN 438            stand out due to the same good       MAX Compactforming Elements
Type CGS).                                qualities as MAX Compact             within the framework of the values
The dimensioning enables space-           Laminates.                           and test standards given in
saving application. They are              Bending options can be found in      Technical Information 6.
unbreakable and shockproof and            our current delivery programme.      However, it is expressly not liable
offer safe fixing options for                                                   for defects in the working,
construction elements.                                                         construction and installation as it
MAX Compact Laminates are                 Behaviour in fire                     has no influence over these. The
heat-, cold- and steam-resistant.         Normal quality MAX Compact           local regulations are to be
They do not oxidise. Thus, there          Panels (Type CGS in accordance       observed without fail. All details
is no corrosion. Standing water           with ON/EN 438) in thicknesses       correspond to the current state of
must be avoided when using.               from 2-20mm are combustion-          the technology. Suitability for
Excellent properties in use - like        resistant in accordance with         particular applications cannot be
easy cleaning, hygienic sealed            ÖNORM B 3800 Part 1                  confirmed in general.
surface, long working life and high       Construction material class B1,
resistance to chemicals (see              Q1 - low smoke emitting,
Technical Information 6) - are            Tr1 - non-drip Austrian Plastics
further advantages. The surfaces          Institute Test Report
are pleasant to touch.                    No.41312/99).
The material is physiologically
                                      *   In accordance with DIN 4102,
harmless and is not electrically          MAX Compact Laminates are B1
conductive.                               (Type CGF in accordance with
                                          EN 438) fire resistant for 6 to
                                          10mm thicknesses. Construction
                                          authority permit for Germany:
For the MAX Compact Laminates             Z-33.2-16.
types CGS and CGF, ONCERT             *   MAX Compact Laminates have a
confirms that the qualities in             low fire risk. They do not melt and
accordance with ON EN 438 are             drip in the event of fire and have
maintained world-wide.                    low smoke gas development (no
                                          halogens, hydrogen sulphide etc.).
                                          The flammability class in
                                          accordance with ÖNORM B 3800
                                          Part 1 is - for MAX
                                          Compactforming Elements,
                                          normal flammability (test
                                          certificate from the Austrian
                                          Plastics Institute No. 19659 / 85
                                          10 22).




Technical Information 3                                                         5
                              Test Certificates
                              (Status in 2001)




                              ■ Disinfectability of MAX                ■ Type CGF in accordance with
                              Laminates surfaces (Austrian             EN 438 tested in accordance with
                              Plastics Institute no. 29750/93          ÖNORM B 3800 Part 1 (in the
                              and the Hygiene Institute of the         thicknesses 2 - 10mm) B1 - Q1 -
                              University of Vienna                     TR1 Austrian Plastics Institute,
                              Test Report R38/97).                     No. 43328/00).

                              ■ Disinfection agent resistance          ■ Fire classification 5 (200°C).3
                              of MAX Laminates surfaces                EMPA Dübendorf, Switzerland
                              (Austrian Plastics Institute no.         No. 162844/45 of 12.6.96 for
                              37114/97).                               thicknesses from 4-15mm.

                          *   ■ Testing of MAX Laminates and           ■ Medical assessment of the
                              classification in accordance with         smoke gases in accordance with
                              the requirements of EN 438               DIN 4102 of 1 mm thick MAX
                              (Austrian Plastics Institute, no.        Laminates of types S and F in
                              37931/97)                                accordance with EN 438
                                                                       (Department for Hygiene and
                              ■ Test report with regard to             Occupational Medicine of the
                              harmlessness when used in                College of Technology, Aachen -
                              domestic areas                           Prof. Dr. Einbrodt on 26.3.86).
                              (Austrian Plastics Institute, no.
                              29750/93 11 18).                         ■ Test report of the ageing
                                                                   *   behaviour of MAX Bau Compact
                          *   ■ Harmlessness of the contact            Laminates
                              of MAX Compact Laminates with            (Austrian Plastics Institute, No.
                              foodstuffs.                              39886/1/98).
                              ISEGA-Aschaffenburg 14824 U 20.
                                                                       ■ Normal flammability of MAX
                          *   ■ Type CGS in accordance with            Compactforming Elements - B2
                              EN 438; Requirements in                  complying with ÖNORM B 3800,
                              accordance with ÖNORM B 3800             Part 1, (Austrian Plastics Institute
                              Part 1 (in the thicknesses 2 to 10       19659/85 10 22)
                              mm) Construction material
                              classes B1, Q1 and TR1 (Austrian         Please ask if test certificates are
                              Plastics Institute, no. 41312/99).       required for other countries.

                              ■ Type CGF in accordance with
                              EN 438 fulfils the requirements of
                              DIN 4102 Class B1, Fire resistant.
                              for 6 to 10 mm thicknesses.




Technical Information 3                                                 6
                          General
                          Information




                          Transport and Handling              *   ■ MAX Compact Laminates -
                                                                  also those for external use
                          ■ Handle the panels with care in        (EXTERIOR) - do not only react
                          order not to damage the edges           to temperature but also to
                          and surfaces of the high-quality        moisture and according to the
                          material.                               climate of the relevant place of
                          In spite of the excellent surface       storage or installation. If these
                          hardness, the stack weight of           two influencing factors affect just
                          MAX Compact Laminates is a              one side of the panel material
                          possible cause of damage due to         then - depending on the duration
                          scouring movements when                 of the effect - greater or lesser
                          transporting.                           deviations from being flat can
                          ■ MAX Compact Laminates                 occur. That is why we give
                          must be secured against slippage        information about rear ventilation,
                          during transport. When loading or       storage, stack covering etc.
                          unloading, the panels must be
                          lifted and not pushed or pulled
                          over the edge                           Cleaning
                          ■ Transport protection films
                          must always be removed from             Recommendations on this can be
                          both sides at the same time.            found in Technical Information 6.




Technical Information 3                                            7
Storing and Conditioning                      ■ Conditioning of the panel                  Panel longitudinal direction = Part
                                              material before working - in the             longitudinal direction.
■ MAX Compact Laminates must                  climate of the subsequent place              In practice, 2 mm/m has been
be stacked horizontally on flat, stable        of installation - is ideal. As this is       proved to be an adequate
supports and supporting panels.               rarely possible, the following               average for dimensional changes
The goods must lie completely flat.            applies:                                     caused by climate. Joints are to
                                              The period for adequate                      be provided between the
■ Cover plates must always be                 conditioning (workshops) must -              individual elements (larger drill
left on the stack. The top cover              depending on the panel thickness             holes when screwing through,
should be weighted down.                      - be assumed to be 10 to 20 days.            washers, large screw heads etc.).
                                              When working and constructing                Metal subconstructions change
                                              with the panels, thought must be             their dimensions with differences
                                              given to the possible dimensional            in temperature. The dimensions
                                              change of the panels. For                    of MAX Compact Laminates alter
                                              high pressure laminates (HPL) it             under the influence of changing
                                              is half as much lengthways as                relative humidity. These changes
                                          *   widthways. Due to this                       in dimension can be opposite to
                                              characteristic of the material,              each other.
                                              when connecting MAX Compact                  Wall claddings must always be
                               Figure 1
                                              Laminates to each other - doubles,           executed with sufficient rear
                                              corner connections etc. – care               ventilation.
                                              must be taken, without fail, that all
                                              elements which are to be
                                              connected to each other have the             Use and Construction
                                              same production direction. This
                                              means only connect lengthways                ■ During construction and
                                              with lengthways and widthways
                                                                                       *   installation, care must always be
                                              with widthways. For panel offcuts            taken that the material is not
                                              with double-sided plain-colours              exposed to standing water. This
                                              or non-directional decoration,               means that it must not stand
                                              therefore, the longitudinal                  continuously in water or, in other
                                              direction is to be marked on them.           words, the panel material must
                               Figure 2       Moving elements, such as doors               always be able to dry out again.
■ After removal of panels, PE                 for example, should always be cut            When it is very wet, e.g. for
films must again be completely                 out of the panel in the longitudinal         shower cubicles or similar
closed over the stack.                        direction.                                   employment, the mechanical
■ The same applies, in principle,                                                          corner connection must always be
for cut-panel stacks.                                                                      done together with a gluing
■ Compressed laminates shrink                                                              system which sets elastic and
when they lose moisture                       Thicknesses of the     Max. cross            waterproof.
■ Compressed laminates                        MAX Compact Panels dimensional change        ■ The same applies in principle
expand when they absorb                             4mm                0,25%
                                                                                           for MAX Compactforming
moisture                                                                                   Elements and MAX Compact-
                                                    6mm                0,2%                folding material. Due to the
                                                    12mm               0,15%               reformable structure of the
                                                                                           panels, particular care is
                                                                                           necessary when selecting the use
                                                                                           and type of working. Please
                                                                                           speak to our Application
                                                                                           Engineering department.




Technical Information 3                                                                     8
                                      Machining




MAX Compact Laminates,                                                                ■ Circular saws, hand-held
MAX Compactforming Elements                                                           circular saws:
and the panel types from the                                                          Saw blades with grouped
MAX EXTERIOR program can                                                              trapezoidal teeth and a straight
be machined with the same                                                             tooth face
carbide-tipped tools as                                                               FZ/TR are advantageous. See
MAX High Pressure Laminates.                                                          Figure 4 (e.g. Leitz).
If high tool life is required, then                                                   In order to achieve good cutting
diamond (PKD) fitted tools                                                             quality, MAX Compact Laminates
should be used.                                                                       should be fed as smoothly as
                                                                                      possible.
                                                                                      Cutting speeds:
                                                                           Figure 3   50-60m/sec. depending on tool
                                                                                      diameter and speed,
                                                                                      e.g. 4000 rpm.
                                                                                      Ø 250mm, 64 teeth.
                                                                                      Feed rate per tooth:
                                                                                      0.02 - 0.04mm
                                                                                      Feed rate: 6 - 10m/min, according
                                                                                      to thickness
                                                                 WZ/FA
                                                   WZ
                                                         Alternate tooth
                                       Alternate tooth
                                                             chamfered




                                                                HZ/FA
                                               FZ/TR
                                                           Hollow tooth
                                       Flat/trapezoid
                                                            chamfered
                                                tooth



                                                                           Figure 4




                                                                                      ■ Jigsaws:
                                                                                      Hardened saw blades with
                                                                                      medium toothing e.g. BOSCH
                                                                                      T127D or DF,
                                                                                      Slow feed rate - inadequate cut
                                                                                      quality because the cut is torn
                                                                                      out.
                                                                                      Grinding or milling and
                                                                                      chamfering is required for visible
                                                                                      edges.


                                                                           Figure 5




Technical Information 3                                                                9
■ CNC machining centre, table        ■ Table milling:
surface-miller:                      MAX Compact Laminates are
For shape and form milling of        milled with carbide-tipped tools;
curved parts when using carbide      preferably with carbide disposable
disposable insert panel millers      inserts (e.g. Leitz no. 1666)
(e.g. Leitz No. 357 Ø 9mm) or        For curves we recommend
with diamond-fitted tools. MAX        brazed profiling millers or radius
Compact Panels are engraved -        disposable insert heads.
e.g. numbers, letters, pictograms    For milling the rebates, it is
- or designs are milled with         recommended that 4-cutter
specially equipped base-cutting      disposable inserts with chamfered
millers.                             corners are used. Pre-cutters are
Compact Panels which are milled      then to be removed from the                                          Figure 7
(engraved) on one side can lose      milling heads.                         ■ Hand surface miller:
their symmetry and thus become       Cutting speed: 40-60m/sec.             Used for special jobs (e.g. recess
bent. Please take account of this    Feed rate: 5 - 10m/min.                for washstand, Trax coupling etc.)
in the supporting construction.      Feed rate per tooth:                   with carbide tools.
All millings in brown or black       0.2 - 0.4mm
cores are to be coated with white    e.g. speed 6000 rpm.,                  ■ Plastic edge miller:
oil in order to achieve even, rich   Ø 125mm, 2 cutters,                    Used with angled (45° or 60°)
colour tones.                        Feed rate 5m/min.                      carbide tools mainly for milling
                                     An even milled surface is              chamfers and „edge fractures“.
                                     obtained by mechanical feeding.

                                                                            ■ Electric hand plane with
                                                                            chamfering or mitring groove for
                                                                            milling chamfers.

                                                                            ■ Roughing or groove-cheek
                                                                            millers for routings on the surface.




                                                                 Figure 8



                                                                                                          Figure 6




Technical Information 3                                                     10
                                                                                                                    *   ■ The profile cutter head - Profi
                                                                                                                        Cut WE 610-1-5 - is a standard
                                                                                                                        product from Leitz, Figure 9.
                                                                    13
                                                                                                                        Variant 1 in Figure 10 should give
                                                                                              Ø145
                                                                                          (Profile centre)              advantages regarding tool wear
                                                                                                                        due to the low moulding depth.
                                                                                                                        Variant 2 in Figure 11 enables
                                              13
                                                                                                                        horizontal machining of the two




                                                                                                 (Profile centre)
                                                                                                                        parts which are to be joined.




                                                                                                        28
                                                                                                                        Both variants are produced at the
                                                                                                                        customer’s request.

                          Leitz standard miller                                                        Figure 9




                                                                                               Ø125
                                                                                5
                                  (max. 15)




                                                                                    1
                                  13


                                                    5




                                                                         153,6 x 22/23 x 30 Z2 DIA

                          Variant 1                                                              Figure 10


                                                                                                 Ø125
                                                                               4
                                                        (max. 15)


                                                                    4
                                                        13
                                               10




                                                                        174,5 x 26/34 x 30 Z2/2 DIA

                          Variant 2                                                              Figure 11




Technical Information 3                                                                                                 11
                                      ■ Drilling:
                                      Carbide-tipped fitting driller with
                                      centring piece and chamfered
                                      cutting tips for large diameter
                                      drillings (hinges, Trax coupling).
                                      Drills with precutters have not
                                      proved themselves; they become
                                      blunt too quickly and then rub
                                      instead of cutting.
                                      HSS helical drills for through drill
                                      holes should have a more steeply
                                      angled tip as is usual for metal
                          Figure 12   machining (≤ 90°).

                                      When using carbide-tipped drills,
                                      use pillar drilling machines -
                                      carbide metal tends to break off
                                      easily when drilling by hand.

                                      ■ Sanding the edges:
                                      With the usual machines - 100 to
                                      120 grain. Edges can also be
                                      worked by hand with sandpaper
                                      or a scraper. Even colouring of
                                      the brown or, if desired, black
                                      panel edges is obtained if they
                                      are coated with silicon-free oil
                                      (e.g. white oil).




                          Figure 13


                                      ■ Punched holes:
                                      Punch-quality MAX Compact
                                      Laminates up to a thickness of
                                      about 4 mm can be given round
                                      holes. Punched MAX Compact
                                      Laminates are used for noise-
                                      absorbing claddings.
                                      Special questions about this can
                                      be answered for you by our
                                      Application Engineering
                                      Department or our Technical
                                      Information 8.




Technical Information 3               12
                                                               ■ Forming edges:
                                                               No edge protection is necessary
                                                               for MAX Compact Laminates and
                                                           *   MAX Compactforming Elements.
                                                               For visible edges a great many
                                                               design possibilities are offered.


                           Figure 14           Figure 15




                           Figure 16           Figure 17




                           Figure 18           Figure 19




                           Figure 20           Figure 21
                                                               When using pieces of panel,
                                                               provide V-joints and expansion
                                                               clearances if necessary!




                                               Figure 22
                                                               Always curve internal corners in
                                                               order to avoid notching fractures!
                                                               Ri = 5mm.




                   wrong               right
                                               Figure 23


Technical Information 3                                        13
                                                   Constructional
                                                   Connections




Corner connection M = 1:2          Figure 24                                         Figure 25                                          Figure 26




                    connecting piece made
                    from MAX Compact




Corner connection M = 1:2          Figure 27       Corner connection in accordance   Figure 28       Thread cut in MAX Compact Panel.   Figure 29
                                                   with Leitz standard M = 1:2


                                               *   Corner connections must be                    *   When using the Fischer PA4 M6/
                                                   mechanically supported over the                   7.5mm screw plugs (Figure 26) it
                                                   entire length                                     is important to screw the threaded
                                                   (Figures 21 to 24) or milled with a               bolts in to a sufficient depth in
                                                   special mitring profile and glued                  order to achieve good
                                                   (Figure 25).                                      compression of the screw plug:
                                                   Important is the increasing of the                screw-in depth at least 6mm for
                                                   gluing surface and/or the                         PA4 M6 / 7.5mm
                                                   reinforcing of the connection.




Corner connection M = 1:2          Figure 30




Technical Information 3                                                                              14
                                                                              For blind-hole screwing vertical to
                                                                              the surface of the panel, please
                                                                              note:
                                                                              ■ Pre-drilling diameter (D) =
                                                                              Screw diameter minus about 1
                                                                              thread depth
                                                                              ■ Hole depth (a) = Panel
                                                                              thickness minus 1-1.5 mm
                                                                              ■ Screw-in depth = Hole depth
                                                                              minus 1 mm

                                                                              When screwing parallel to the
                          Figure 31                               Figure 32   surface of the panel, the following
■ Object hinge                        ■ Screw-on strap hinge (HETAL           is to be noted:
(Prämeta company) for doors           company) for doors made from            ■ The remaining thickness (b) of
made from MAX Compact                 MAX Compact Laminates.                  the MAX Compact Laminates
Laminates, door thicknesses                                                   must be at least 3 mm:
10-13mm.                              Obtainable via:                         ■ The diameter of drill holes
Single axis pivot.                    Hannelore Lohr                          parallel to the panel surface is to
Obtainable via:                       Elisabethstr. 36,                       be chosen so that no splitting of
Schachermayer Linz company,           A-2380 Perchtoldsdorf                   the MAX Compact Laminates
Vienna.                               Tel.: +43 1/869 86 52                   occurs when the screws are
                                      Fax.: +43 1/867 48 29                   screwed in.
                                                                              ■ For screwing parallel to the
                                      ■ Due to the - usually - lower          panel surface, self-tapping and
                                      material thickness, the                 chipboard screws are suitable.
                                      recommended method of fixing is          ■ In order to achieve appropriate
                                      through-screwing or through-            stability, a minimum screw-in
                                      riveting (blind rivets). The drill      depth of 25 mm is necessary.
                                      diameter is to be chosen so that it     ■ Screwings parallel to the panel
                                      is greater than the shank               surface must be avoided, without
                                      diameter of the fixing elements          fail, for MAX Compactforming
                                      (dimensional change).                   Elements.
                                      Correspondingly larger screw
                                      heads and swage heads for rivets        Trials to determine the correct
                                      or washers are to be used.              drill diameter are to be carried
                                                                              out in every case.




                                                           a                                               b
                                                    D


                                                                  Figure 33                               Figure 34




Technical Information 3                                                       15
                                                                           ■ When too small a drill
                                                                           diameter has been chosen,
                                                                           burring of the edge of the hole
                                                                           occurs.
                                                                           ■ In order to enable easy
                                                                           screwing in, it is advantageous to
                                                                           use plastic-coated screws.
                                                                           ■ Drill holes are to be cleared out.
                                                                           ■ Grease, oil or soap on the
                                                                           screws makes screwing in easier.
                                                                           ■ Hexagonal screws reduce the
                                                                           screwing-in „feel“ they are easily
                                                                           „over-screwed“.
                                                                           ■ When using the Fischer PA4
                                                                           M6/ 7.5 mm screw plug it is
                                                                           important to screw the threaded
                                                                           bolts in to a sufficient depth - at
                                                                           least 6 mm - in order to achieve
                                                                           good compression of the screw
                                                                           plug.


Screw type                 Screw       Pilot       Thread     Extraction     Remarks

                          diameter     hole        reach       value Nx

                                     diameter                (10 N = 1 kp)

Chipboard screw           3,5mm       3,0mm        8mm          3750          P
                                                                             SPAX

Chipboard screw           4,5mm       4,0mm        8mm          1670          P
                                                                             SPAX

Sheet metal screw         3,5mm       3,0mm        8mm          3240

Sheet metal screw         4,8mm       4,5mm        8mm          3730

Self-tapping                                                                 Fa. Würth
                            M4        3,7mm        8mm          3750
screw DIN 7500                                                               Fa. Bossard Austria

Machine screw               M4        3,2mm        8mm          3120         Pre-cut thread (8mm deep)

Machine screw               M6        4,8mm        8mm          6880         Pre-cut thread (8mm deep)

Brass straddling dowel      M6        8,0mm        6mm          4850                  A
                                                                             Fischer PA 4 / 7,5

Chipboard screw           4,0mm       2,5mm        19mm         1140         Chipboard

Wood screw                4,0mm       2,5mm        19mm         1800         Spruce


                                     Bending MAX                           important to pay attention to the
                                     Compact Laminates:                    expansion play. Curved panels
                                     It is possible to shape MAX           must have U-sections put on all
                                     Compact Laminates over, or with,      round. Point-fixing of the panels is
                                     a curved subconstruction.             not suitable. For constructional
                                     Radius for 6 mm thick panels          details we are pleased to receive
                                     ≥3000 mm                              your queries.
                                     Radius for 8 mm thick panels
                                     ≥3500 mm.
                                     For curved panels as well, it is




Technical Information 3                                                      16
                                                  Fundamentals for
                                                  large-area claddings
                                                  made from
                                                  MAX Compact Laminates

The centre point of the drill hole in
the subconstruction must coincide
with the centre point of the drill
hole in the MAX Compact
Laminate. The fasteners should
be positioned going outwards
from centre of the panel. Fixed
and sliding points must be
formed. Attention is to be paid to
adequate expansion clearance.
A rule of thumb for the required
expansion clearance is:
                                                  Sliding point                     Figure 35   Fixed point                      Figure 36
Element length or
Element width (in mm)
                        = Expansion clearance
        500




■ Sliding point                                   Laminate is always covered. The               ■ Fixed point
The diameter of the drill hole for                fastening is placed in such a way             Fixed points are used for even
sliding points in MAX Compact                     that the panel can move.                      distribution (halving) of the
Laminates must be drilled larger                  Rivets are put in place with                  expansion and shrinkage
than the diameter of the                          flexible mouth-pieces. The                     movements. The diameter of the
fastening, depending on the                       defined clearance allows                       drill hole in the MAX Compact
required expansion clearance.                     movement of the elements in the               Laminate is the same size as the
                                                  drill hole. Clearance 0.3 mm.                 diameter of the fastening
This is the shaft diameter of the
fastening plus at least 2 mm for                  Screws must not be over-
every meter of cladding material                  tightened. Do not use any
starting from the fixed point.                     countersunk screws - use
                                                  washers if necessary
The head of the fastening must                                                                  ■ Arrangement of fixed and
be large enough so that the drill                                                               sliding points for large-area
hole in the MAX Compact                                                                         cladding elements.
                                                     Fixed point                                   Sliding point

                                                                            50-80                                        50-80
    Flexible mouthpiece




                                                                            50-80                                        50-80

                                                             20        20                                     20    20


                                      Figure 37   Double-span panel                 Figure 38   Single-span panel                Figure 39




Technical Information 3                                                                          17
                                           Assembly gluing
                                           for claddings




                                           Wall claddings must always be            An alternative to secret,
                                           executed with adequate rear              mechanical fixing is gluing the
                                           ventilation.                             MAX Compact Laminates with the
                                           Dissimilar climates in front of and      SIKA Tack Panel gluing system
                                           behind the elements can lead to          which was specially developed for
                                           distortion.                              this by SIKA Plastiment. It works
                                                                                    on normal planed-wood or
                                                                                    aluminium subconstructions
                                                                                    Rear-ventilated wall claddings -
                                                                                    and many more - can be mounted
                                                                                    cleanly and easily.

                                                                                    ■ Fixing lines(vertical)in the
                                                                                    centre of the panel make a
                                                                                    significant contribution to level
                                                                                    positioning of the element.
                                                                                    The fixing distances can be found
                                                                                    in Technical Information 5 or we
                                                                                    are pleased to receive your
                                                                                    queries.


                                                                                    ■ Processing for gluing.
                                                                                    An aligned subconstruction made
                                                                                    from planed-wood (support
                                                                                    smoothing) or aluminium is
                                                                                    needed. Details as in Figure. The
                                                                                    panels are held in position with
                                                                                    double-sided adhesive tape and
                                                                                    are permanently glued with PUR
                                                                                    adhesive cement. Special working
                                                                                    instructions and training by the
                                                                                    adhesive suppliers are necessary.

Horizontal cut, vertical joint M = 1:2.5                                Figure 40




                                           Further details and variants of
                                           wall cladding with MAX Compact
                                           Laminates can be found in our
                                           Technical Information 5.




Technical Information 3                                                             18
                                      Gluing




Glued connections are to be           ■ For gluing decorated edging         2. Woodworking materials (rebate
made so that the dimensional          strips to one another, PUR glues      strips etc.) can also be glued on
changes of the MAX Compact            have proven themselves, e.g.          to well sanded decorative sides
Laminates and MAX Compact-            from Synthesa Kleiberit PU501.        with high quality PVAc glues.
forming Elements are not              Please pay attention to the colour    Prerequisite for this is that the
hindered.                             of the glued joint!                   material absorbs the glue
Only glue panels to each other                                              moisture in the bonding process.
which are in the same run             ■ Cyanoacrylate glue
direction and have the same           (superglue) for supporting            In every case, you must carry
conditioning as, otherwise,           mechanical connections.               out your own trials before
stresses occur. The amount of                                               starting the work.
swelling and shrinkage in MAX         ■ Acrylic adhesive tapes for          Please observe, without fail,
Compact Laminates is twice as         installations (e.g. from 3M: VHB      the recommendations of the
much widthways as lengthways. If      adhesive tape system                  glue manufacturer.
glued connections are frequently      Acrylic foam 4950 1mm thick or
subjected to impacts and knocks       4912F 2mm thick). When using
etc. then they should be              double-sided adhesive tapes, pay
supported by mechanical               particular attention to the
connections. The surfaces which       conditioning at the place of use as
are to be glued must be sanded        - due to the dimensional changes
and free of dust.                     of supports or the Compact
Among others, the following types     Laminates- uncontrollable
of glue are recommended by the        stresses can occur. The larger the
adhesive companies:                   area and thus the possible
                                      change of length, the thicker the
1. Gluing of                          adhesive tape has to be.
MAX High Pressure Laminates,
MAX Compact Laminates and
MAX Solid Colour Edgings to one       ■ Gluing with PUR cements, e.g.
another. Especially when gluing       Würth „Klebt und dichtet“ [Glues
Solid Colour Edgings to one           and Seals], Sikaflex 252,
another, the glue must be as          Teroson-Terostat 92, Henelit
colourless as possible. Gluing of     Pyrmoflex-S, Icema 145/454, etc.,
MAX High Pressure Laminates           have proven themselves. They
with metals and insulating            are used for the installation of
materials for connecting panels.      basins in MAX Compactforming
                                      Elements or for the gluing of
■ Reaction adhesives such as          claddings etc.(see Page 16).
polyurethane and epoxy glues.
Caution: Glue residue on the          ■ Gluing of Compact Laminates
panel surfaces etches them if it      with foams from Kleiberit
hardens. Not every glue can then      PU501 from Synthesa, and
be removed from the MAX panel.        Rexomet T3500 from Reichhold
If the glued joint is not elastic     Chemie.
then, especially when gluing
metals, stresses - and thus
formation of fractures - can arise.
See Page 18.




Technical Information 3                                                     19
                                           * Gluing MAX High Pressure
                                            Laminates and MAX Compact
                                            Laminates to metal



*   Internal use                            Suitable are high quality contact      ■ Summary
                                            glues or glues based on PUR,           Greater panel thicknesses permit
    ■ The problem here lies in the          silicon or MS polymers which           the gluing of metal elements with
    different reactions of the materials    bond elastic. It is to be noted that   low risk. The use of 1 mm thick
    which are to be glued to - on the       metal elements are usually not so      standard panels from store
    one hand - temperature and - on         flat as, for example, calibrated        requires great care when working
    the other hand - climatic               woodwork materials. This makes         but the risk always remains high.
    influences, i.e. temperature in          maximum surface contact                All other prerequisites for proper
    combination with air humidity.          between the glue, the MAX panel        working - like conditioning the
                                            and the metal support more             MAX panels to the expected
    ■ With thin panel material from 1       difficult and gluing faults can arise   climate at the place of installation,
    mm to 3 mm thick, the gluing            which can be starting points for       preparing the metal surfaces in
    should be done over the entire          fractures. Careful rolling on with     accordance with the information
    surface and should be done with         small hand rollers is                  from the glue manufacturer etc. -
    elastic bonding glues.                  recommended!                           are to be met. See Technical
    The thinner the panels used, the        Full-surface panel presses only        Information 10.
    greater the danger of tearing due       make sense for absolutely flat
    to arising stresses. This               elements or for thicker glue joints,
    particularly occurs if recesses         as is described in the following for
    have been made which have not           greater panel thicknesses.
    been done properly, i.e. not milled
    with smooth edges. Also, bad            ■ Panel thicknesses above 4
    adhesion of the glue at individual      mm are fixed with glue beading.
    places, or notches on the edges         The distances between these
    of the panels can be starting           vertical beads are:
    points for fractures.
    An important parameter for the          Panel     4mm      max. 100mm
    functional fixing of MAX High            thickness 5mm      max. 200mm
    Pressure Laminates on to metal                    6mm      max. 300mm
    supports is the thickness of the
    glue joint. For gluing over the         The thickness of the glue joint
    entire surface this should be           after pressing must be 2 - 2.5 mm.
    between 0.5mm and 1mm.




    Technical Information 3                                                        20
Information for                    Installation of
working with MAX                   washbasins
Compactforming                     into a MAX Compact-
Elements                           forming Element

MAX Compactforming Elements        ■ The simple solution:                     ■ The rational solution:
have a higher carrying capacity    Cut in and screw on an „Build-in
(rigidity) the higher the folded   washbasin“.
edges are. If the limbs are
shortened then they must not be
cut back below the size of:
Internal radius + Thickness +                 Gasket                                                      2-3mm
10mm.
This means that a piece which is
at least 10 mm wide must remain
after bending.                       Brass
                                     stradling                                                           PUR
Please note the tolerance            dowel                                                               glue
dimensions of MAX Compact-
                                     M6 nut
forming Elements; these can be
                                                                                Counterpiece,
found in the relevant delivery       M6 hex socket                              e.g. wooden wedge
programme.                           set screw

                                                                  Figure 41                               Figure 42




                                   ■ The economie solution:
                                   Mill out the Compactforming
                                   Element, screw-on the built-in
                                   washstand.
                                   For larger quantities, the milling
                                   out can be done with a template
                                   on the table miller.




                                                           PUR
                                                           glue




                                                                  Figure 43




Technical Information 3                                                       21
■ Installing a build-in wash basin
into a Compactforming Element.
This work procedure is described
below:




1. Draw the cut-out and cut out        3. Glue the basin in with PUR          5. Fine clean and finish off with a
with a miller.                         glue and screw in as in the            scraper and sandpaper.
                                       diagram.




                           Figure 44                              Figure 45                               Figure 46




2. Rebate from the underside of        4. Mill the projection of the          Build-in wash basins and
the Compactforming Element with        Compact Laminates flush on the          installation washstands can be
a rod miller or CNC machining          visible side with a manual             obtained from specialist sanitary
centre.                                surface miller (angled miller!).       ware dealers. The basin shown in
                                                                              the photographs is a Bijou basin
                                                                              from the Laufen company.
                                                                              The screw kit for screwing the
                                                                              basin on (brass expansion screw-
                                                                              plugs, set-screw - screw at least
                                                                              6.0 mm into the screw-plug - nut
                                                                              and washers) can be obtained
                                                                              from (among others):

                                                                              Hannelore Lohr
                                                                              Elisabethstr. 36,
                                                                              A-2380 Perchtoldsdorf
                                                                              Tel.: +43 1/869 86 52
                           Figure 47                              Figure 48
                                                                              Fax.: +43 1/867 48 29




Technical Information 3                                                       22
3-8/2001-213563GB.12




                       Aktiengesellschaft

                       Industriezentrum N.Ö. Süd
                       A-2355 Wiener Neudorf
                       Tel. +43 2236 605-0
                       Fax +43 2236 605-401
                       E-Mail: max@isovolta.com
                       www.isovolta.com

								
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