Hollow Sheets
VULCAN POLYCARBONATE SHEETS Product Catalogue
Product Range
VULCAN Product Range Product
Description
LiteGuide
For diffused and indirect visible light penetration with a matte appearance.
Solarshield
Reflects heat building NIR radiation. High visible light transmission
Ti-Lite
Exceptional heat blocking, minimum, indirect sunlight penetration. Metallic appearance.
Valuview
General Purpose Polycarbonate Sheet, with a choice of single or double layered UV coating.
VULCAN Product Colors Group
Description
Colors
Clear
Transmits up to 90% natural daylight, resulting in high lighting within the structure. Clear
Transparent
Translucent
High Transparency, low haze colors offering high clarity. Solar colors offer advanced heat blocking capabilities that reduces heat buildup while allowing a clear view through the sheet.
White Opal: Light diffuser included. Transmits 20-50% visible light with exceptional light dispersion, produces mild and even lighting within the structure. Metallic Colors: Low Transparency, high haze colors offering great shade and indirect light transmission.
ICE
Valuview Blue
Solar Blue
Solar Green
Metallic Silver
Metallic Blue
Valuview Green
Valuview Bronze
Metallic Green
Metallic Bronze
White Opal
*Colors shown above are a reproduction of the actual color. Only actual sample chips can accurately represent the colors. Please contact us or your local distributor to receive color samples.
1
VULCAN POLYCARBONATE SHEETS Product Catalogue
Technical Specifications
VULCAN HOLLOW SHEET TECHNICAL SPECIFICATIONS Dimensions Product
Thickness mm
in.
mm
in.
4
5/32
6
~1/4
Twin-Wall
Triple-Wall
Rib-Spacing
6
1/4
6
~1/4
8
5/16
10
~3/8
10
3/8
10
~3/8
10*
3/8
20
~13/16
mm
in.
1200 1220 1810 1830 2100 (1)
47.25 48 71.25 72 82.68 (1)
1210 16
5/8
20
Weight
Standard Widths
psf
mm
ft.
777
0.16
1300
0.27
1500
0.35
1220 2440 3050 3660 4270 4880 5487 5795 6100 9000 11800
6 8 10 12 14 16 18 19 20 29’ 39’
1700
0.35
1990
0.41
2670
0.55
47.65
~13/16
Lengths
g/m2
Colors
Clear
Blue Green Bronze Opal(2)
(1) 2100mm (82.68”) wide panels not avaialble in all thicknesses. (2) Special colors or properties upon request and subject to MOQ. Thermal No. of Layers
Value
Panel Thickness 4mm Twin-Wall 6mm 8mm 10mm 10 mm Triple-Wall 16 mm Optimal Service Temperature Range Maximum Service Temperature Minimum Service Temperature Heat Deflection Temperature (Load: 264 PSI) VICAT Softening Temperature (Load: 2.2 lbs.) Coefficient of Linear Thermal Expansion Thermal Conductivity (BTU-in/hr-ft2 - °F)
R-Factor U-Factor 1.49 0.67 1.62 0.62 1.72 0.58 1.89 0.53 2.08 0.47 2.36 0.42 -40° F to +248° F (- 40° C to ± 120° C) 270° F (132° C) - 103° F (-75° C) 275° F 300°F 3.6 x 10-5 in. / in.oF 1.45
Mechanical Tensile Strength At Yield (0.4 in. / min.) Tensile Strength At Break (0.4 in. / min.) Elongation At Yield (0.4 in. / min.) Elongation At Break (0.4 in. / min.) Tensile Modulus of Elasticity (0.4 in. / min.) Flexural Modulus (0.052 in. / min.) Flexural Strength At Yield Rockwell Hardness Density Specific Gravity
9,400 psi 8,800 psi 6% > 90% 350,000 psi 380,000 psi 14,500 psi 118 R Scale 75 lb/ft3 1.2 g/cc
2
Test Method
ASTM C-177
ASTM D648 ASTM D-1525 ASTM D-696 ASM C-177
ASTM D-638
ASTM D-790 ASTM D-790 ASTM D-785 ASTM D-792 ASTM D-792
VULCAN POLYCARBONATE SHEETS Product Catalogue
Installation & Fastening Preparations Prior to Installation
A. Ensure smaller thermal expansions by installing sheets - especially colored sheets - at ambient temperatures of 10-25 deg.°C (50-77 deg. °F). It is generally recommended to avoid installing sheets at colder or hotter temperatures. B. Peel off the protective film at both open ends of the sheet (the width sides) to about 80-100 mm (3.5-4 in.) from the edges of the sheet, to enable taping of the aluminum sealing tape. If a factory installed temporary seal is taped over the open ends, it should be removed prior to the installation of the aluminum tape. Tape the sealing tape straight along the open-end side, so it will cling well and evenly to both sides of the sheet, making sure that all the open ends of the rib channels are properly sealed. C. Peel off the masking along the edges of length sides, both sides of the sheet, for about 80-100 mm (3.5-4 in.) from the edges, preparing the sheet for the insertion into the connecting profiles or the glazing frame. D. Remove the underside masking just prior to the actual installation on the roof. Premature removal of protective film may result in damage to the sheet during handling. E. Remove the upside, exterior protective film as soon as the installation of the whole glazed area is completed, or very short time afterwards. Failing to do so, exposing the protective film to direct sunlight, may fuse it to the sheet’s face and cause difficulties in removal, due to deterioration of the film, and void the warranty.
U-protective end cap Figure a. Partial or Complete Removal of Protective Film Prior and after Installation
Figure b. Installation of Sealing Tape on Open Ends of Sheet
Figure c. Use U-protective end cap to cover the ends
F. Ensure the use of the proper type of sealing tape according to the application used, verifying that the prepared sheets are mounted correctly. Please note: In case of curved installation, where both open ends are situated at the bottom apply the ventilated tape on both ends. Take care to protect the sealing tapes at both ends from mechanical damage by inserting the edges into aluminium profiles, or cover them with polycarbonate U-shaped profiles (Fig-f). Figure e. H PROFILE – Connector between 2 sheets
U PROFILE – Caps off the sheet ends
Mid Sheet Fastening A. A wider sheet has to be fastened to the supporting structure by additional fastening along its width, as the connectors on both longitudinal sides are not enough to hold the sheet down, against the uplift force it has to withstand. B. Fastening is usually done by screws, inserted along the supporting internal purlins, spaced about 500mm (20in.) apart.
Figure d. Schematic Isometric View of Partial Roof Installation with Mid-sheet Fasteners
C. Along the edge purlin, the fastening screws should be inserted about 300 mm (12 in.) apart. D. A hole must be pre-drilled into each screw location. The diameter of that hole should be 2 mm larger than that of the screw, to allow for thermal expansion movements. In case of dark colored sheets predrill even larger holes, and use wider fastener washers. E. An electric screwdriver with an adjustable clutch should be used to tighten the screws. Avoid excess overtightening, which might induce undue internal stresses, causing premature failure and buckling of the sheet. Pay attention to insert the screws perpendicular to the material face, as inclined insertion could damage the sheet and/or result in leaks. 3
Self-drilling screw Figure g.
INCORRECT Excess overtightening
CORRECT
Figure h.
Figure i.
INCORRECT Non-perpendicular drilling and insertion. Figure j.
VULCAN POLYCARBONATE SHEETS Product Catalogue
Installation & Fastening Positioning the Sheets
A. VULCAN Hollow sheets should be installed with the rib channels are sloping downwards (Figs. 1a, 1c, 2). That orientation will reduce accumulation of dirt inside the sheet and ease gravity drainage of condensation moisture.
R
R
Figure 1b
Figure 1c
Figure 1a
B. Sheets should be installed with the adjoining edges connected by a glazing profile suited to the glazing system.
th tgh legn len
slo
pe
>5
%
C. For sheets installed in the flat, horizontal position, (roofs, overhead skylights), a minimum slope of 5% is imperative, with 10 percent and above preferable. Steeper slopes offer better rainwater drainage and self-cleaning, and lessen the risk of water and dirt infiltration through the connectors and fastening screws. They also help to diminish the visual effect of sheet deflection caused by loading.
wiid w dtthh ww ididt h
Figure 2
D. Length dimension is defined as parallel to the ribs, while width is perpendicular to the ribs.
Flat, two-sided clamped glazing
Arch Radius A. VULCAN Hollow sheets may be cold bent, or curved up to their minimum permitted radius, using polycarbonate’s natural properties, without need of a thermal process. Curving VULCAN Hollow sheet beyond this minimum permitted radius induces undue stresses and strains in the glazing sheet, causing premature failure and will void the warranty. Table 2. Permissible Cold Bending Radii for Arched Glazing Product
Twin wall
Triple wall
Thickness
mm 4 6 8 10 10 16
Minimal permissible cold bending radius
in. 5/32 1/4 5/16 3/8 3/8 5/8
mm 700 1,050 1,400 1,750 2,200 2,800
ft. 2.30 3.40 4.60 5.70 7.20 9.20
in. 28 41 55 69 87 110
B. Local building codes and standards in most countries provide details for required design loads, which should be consulted before installation. The information below is provided for general reference. Table 3. Conversion of Wind Velocity Values into Wind (or Static) Pressure Wind Velocity Static pressure
km/h m/sec kg/m2 psf
Moderate 20 6 2 0.4
Strong 40-60 11-17 8-17 2-4
4
Storm 80-100 22-28 30-50 6-10
Hurricane 120-140(+) 33-40 70-100(+) 14-20(+)
VULCAN POLYCARBONATE SHEETS Product Catalogue
Handling & Storage Handling and Storage
A. VULCAN Hollow sheets should be transported and stored horizontally, on a flat, sturdy
pallet whose dimensions are equal to or larger than the sheets themselves. The sheets must be secured and fastened to the pallet during transportation and handling on site. It is possible to stack the sheets with the longer sheets at the bottom and the shorter on top, leaving no unsupported overhang. B. While moving a pallet with a forklift, always use forks as long as the sheets’ width.
Shorter forks on a wider pallet may cause damage to the sheets. C. VULCAN Hollow sheets leave the factory in white and clear, watertight polyethylene
film on top. The PE film should be taken off as close to the actual time of installation as possible. Storage of the sheets should be in a covered, dry, ventilated place, away from direct sunlight and rain.
Figure k.
D. Avoid leaving the sheet pallet in the rain, even if still wrapped, for extended periods, as water may condense inside
the hollow core. Extended exposure to direct sunlight may cause heat buildup, softening the protective film, fusing it to the sheet face, making removal difficult or impossible. E. Avoid leaving the sheets stored unwrapped, with their ends open, for more than a few days, as dust may collect
inside the hollows. F. Important! Never cover the pallet with, or place on the pallet, materials that collect heat or are good heat conductors
(e.g. dark objects, metal profiles or pipes, steel sheets etc.) They may collect and deliver excess heat, and damage the sheets. G. When necessary to store the pallet in the open, cover it with a white opaque polyethylene sheet, cardboard, or any other
insulating material, taking care to cover the pallet completely.
Cutting A. VULCAN HOLLOW sheets can be cut with standard wood or metal workshop
equipment. Saw blades designed especially for plastic yield best results. A circular saw (fixed or portable, with small teeth suited for hardwood), rotating at high speed, band saw or a jigsaw (best for short, complex cuts) can all be used, taking care to advance the blade slowly. A hand and hacksaw may also be used for local cutting. B. Always support the sheet in the vicinity of the cut and clean (with compressed air
and/or by a vacuum cleaner) the dust and debris generated by the cutting. Running clean compressed air through the hollow channels, blowing away sawdust and shavings inside is a good practice.
Figure l.
C. Sheets of low and intermediate thickness, with modest dimensions, can be cut (taking the appropriate precautions)
with a short, thin, sharp blade. A special cutting-wire hand tool may also be used, to make lengthwise cuts. * More on cutting and sawing on page 3~5
Drilling A.
Drilling can be carried out with drill bits intended for metal. When predrilling for a fastening screw, the hole’s diameter should be 2 mm larger than that of the screw used. As when cutting, always support the sheet in the vicinity of the place being drilled, and clean away the sawdust and shavings, both on and inside the sheet.
B.
Special attention must be given to drill all the required holes perpendicular to the face of the sheet.
C.
Though drilling the sheet for fastening is a common way of installation, it is recommended to be used mostly in plain, economy-oriented projects, and used sparingly elsewhere.
5
90o
Figure L
VULCAN POLYCARBONATE SHEETS Product Catalogue
Sawing & Cutting Sawing & Cutting
A. A variety of power saws, either table mounted or portable can be used to saw VULCAN sheets.
Shearing or punching are also possible. Laser or water-jet cutting are less common but also possible techniques.
1. Table Mounted or Portable Circular Saws: These types of saw are widely used to saw VULCAN sheets. There are two major workshop types and one portable type: A Moving Table, Fixed Blade Bench Saw : is preferable for long, straight sawing. Radial Arm Saw : is generally used for “cross-cut” (width) or diagonal sawing. Portable Circular Saw : usaually restricted for use on site for straight cutting, is slower and not as accurate as table saws. This type of saw may be attached underneath a special bench to function as an on-site, limited operation fixed table saw.
Circular Saw Blades: Should be fine toothed hollow ground, or preferably carbide tipped, triple chipped (Alt 1 on next page) or alternate bevels (Alt 2 on next page), with minimal blade body contact with the cut material. Such blades can offer clean, good quality cut. Table 1: Generally Accepted Recommendations for Circular Blade Specifications: No. 1 2 3 4 5 6 7
Property Clearance angle α γ Rake angle Alternate double-bevel angle (Alt. 1) Alternate bevel angle (Alt. 2)
Value 10 – 20 o 5 – 15 o 45 o 10 - 15 o
α° β°
Cutting speed (m/min.) (ft/min) Rate of feed (mm/sec.) (in./sec.)
1000 – 3000 3300 - 10000 30 11/4
Thin gauge: (1.5-2.5 mm) Tooth pitch t (mm) (1/16”-3/32”) (Teeth per in.) Heavy gauge: (3.2-12 mm) tooth pitch t (mm) (1/8” - 1/2”) (Teeth per in.)
2.5 – 6.0 10 - 12 6.5 – 8.5 3-4
Notes: 1. 2 Possible alternatives (Alt 1, Alt 2 see next page) are supplied by different tools manufacturers as alternate beveled teeth for blades intended for cutting plastics, and both offer satisfactory cuts (line 3 in the table). 2. For sawing thin gauge sheets of less than 2mm thickness, It is recommended to batch together 10 - 15 such sheets, with a thicker (3-4mm) bottom sheet for support. 3. Shearing is a preferable option for cutting a single thin gauge sheet.
6
VULCAN POLYCARBONATE SHEETS Product Catalogue
Sawing & Cutting
t
B. Circular Saw Cutting Recommendations:
B
These recommendations are based on technical know-how, particular tests
A B
and vast practical experience accumulated during years of work. These recommendations are to be accepted only as general guidelines.
Table 2: Saw Blade Specifications for Cutting VULCAN up to 5mm Thickness. Diameter (mm / in.) No. of teeth in blade Thickness (mm / in.) Teeth angles Tooth appearance Speed
A
B
A
B
A
A
λ
Figure M1: Typical Circular Saw Blade (segment)
300 / 12 96 2.2 - 3.2 / 3/32 –1/8 Rake- 10 °, clearance 15 ° Alternating: Left –right
β
B-B
A-A
B
A
β
1800 – 2400 rpm
Figure M2: Alternate Teeth Configuration ALT 1
Table 3: Saw Blade Specifications for Cutting VULCAN 6 to 12 mm Thickness. Diameter (mm / in.) No. of teeth in blade Thickness (mm / in.) Teeth angles Tooth appearance Speed
B-B
350 / 14 108 2.2 - 3.2 / 3/32 –1/ Rake- 10 °, clearance 15 ° Alternating:
45
B
A-A A
1800 - 2400 - pm Figure M3: Alternate Teeth Configuration ALT 2
Notes: 1. Teeth shapes sketches are not to scale. They should be considered to serve only as an indication. 2. The VULCAN sheets should be placed on a firm flat base and clamped into position during sawing. 3. When sawing VULCAN sheet it is recommended to leave the protective PE film on. 4. If the cut sheet vibrates during sawing, cardboard sheet padding may be placed beneath it to absorb the vibrations. 5. When sawing thin gauge VULCAN sheets it is recommended not to cut single sheets by themselves, but saw a pack of 5-10 sheets at the time, clamped firmly together to a steady base. 6. Low to moderate feed rate should be used when the sheets approach the blad, or vice versa. A feed rate that is too high can cause gumming, splitting or breaking of the sheet edges.
7
VULCAN POLYCARBONATE SHEETS Product Catalogue
Sawing & Cutting
C. Sawing Tips: Chipping and gumming are among the most common problems when sawing. Chipping : Various sized chips are broken of on both edges of the sawing line, leaving the cut edges rough and uneven. Gumming: Chips and splinters from the advancing saw blade overheat during the sawing process, melt and create heaps of cooled down material in front of the blade and on both sides of the cut. The swarf sticks to the edges leaving an ugly, rough edge finish, difficult to clean. Gummed material may also stick to the blade itself and cause seizure. The same uncontrolled heat that creates gumming, may also induce undue internal stresses along the edges of the cut, necessitating annealing of the sheet.
Recommended Remedies: Choose the correct tooth size and pitch. Select a more appropriate saw speed. Lower the feed rate. Examine the sharpness of the blade. Examine the blade alignment. Cool the blade with compressed air when long cuts are required. Take frequent pauses during long production runs, to let the saw blade cool down. Begin sawing with the blade already running at the full recommended speed.
Nevertheless, if you decide to cut a few sheets together and breakage occurs, please check the following items: 1. Try cutting fewer sheets at a time. 2. Check blade condition: sharpness, uniformity and alignment. 3. Change the gap between the blade and the bed to a more suitable one.
Our experience shows that cutting quality can be checked in advance by a simple trial cutting of an 80g-paper sheet: Acceptable - if the paper is cut cleanly, without tearing or crumpling. Unacceptable - if cut results in the paper torn and crumpled.
8
Taipei Office Address: 10F-7, No.28,Sec.3,Ren Ai Rd., DaAn Dist. Taipei, Taiwan 10653 Phone(886)227091757 FAX(886)227556758 E-MAI L: info@vulcanplasticstw.com
VULCAN PLASTICS
Kaohsiung Office Address: No. 126, Sec. 2, Heti Rd., Gangshan Dist. Kaohsiung City, Taiwan 820 Phone (886) 7 6295690
FAX (886) 7 6295692
E-MAI L: info@vulcanplasticstw.com