In technical collaboration with U . S. A.

ALUMINIUM COMPOSITE PANELS

Index Introduction: Group Harwal

P2

Interplast Company Ltd.

P3

Alupex: Aluminium Composite Panels

P 4/5

Application & Advantages

P6

Quality & Test Certificates

P 7/8

Approved & Completed Projects

P 9/17

Fabrication Guidelines

P 18

Accessories & Installation

P 19

Technical Specifications

P 20

Standard Guarantee

P 21

Ireland

USA

UK

1

Intuition... Innovation... Agility... The GROUP HARWAL’s primary business is based on plastic & metal products, with over 60 years of experience in different processes and technologies. Plastic Compounds, Building Materials, Pipe Line Systems, Housing Systems, Shelters, Electrical Products, Household Items, Storage Containers, Garden Sheds, Plastic Disposables, Packaging Materials, Outdoor Products, Refrigeration, Residential & Contract Furniture are just some of the products manufactured by HARWAL under our wide spread manufacturing facilities in UAE, USA & CIS countries. With an annual conversion capacity of 200,000 metric tons of plastic and 20,000 tons of aluminium & steel, the Group has come to the forefront of their respective industries.

The difference is... ... to perceive, create & swiftly deliver Group Companies

UAE - KSA - FRANCE - UK - RUSSIA

UAE

UAE - OMAN - KSA - RUSSIA

UAE

NETHERLANDS

Harwal Containers Manufacturing LLC

ARMENIA

UAE

INTERPOLYMER

UAE

ENGINEERING

UAE - RUSSIA

UAE

ARMENIA

UAE

UAE

ARMENIA

USA

GERMANY

ARMENIA

2

INTERPLAST innovatio n

is

o u r

Interplast was established in 1981 to manufacture PVC compounds and over the years has developed an extensive range of compounds for different applications such as sidings, pipe fittings, cable insulation, sheathing, containers, rigid and flexible profiles as well as clear tubing. In 1983, Interplast diversified into finished products with the introduction of DECODUCT Electrical Cable Management Systems.

cu lt u re. . .

A MANUFACTURER 0F LEADING PRODUCTS SUCH AS:

Starting with UPVC Conduits, Trunking and Fittings, Interplast has since added many new products to its electrical range. Major additions were Underground Cable Protection Systems and a range of wiring devices marketed under the tradenames of INTERGARD and EDISON respectively and a full range of metal trunking and cable trays complete with accessories in co-operation with its sister company TSSC.

Having realized that further diversification was needed to fulfill the company’s growth strategy, it expanded into flexible packaging and thermoformed products for the food industry. These products are marketed under the trade names of DECOPACK and DECOFORM.

Within its DECOPACK range, the company developed unique products such as plastic and paper luxury shopping bags as well as multi layer film for various applications. To serve its growing European customer base, Interplast established Interplast UK in the United Kingdom, followed by the opening of Interplast’s office in Paris, France.

Another significant development in recent years has been in the area of Home Improvement products.

Interplast manufactures a range of PVC storage sheds, window profiles, door panels, PVC siding as well as fencing systems which are sold throughout the world.

The Building Materials Division of Interplast is offering a new ® product range ALUPEX Aluminium Composite Panel, Catering to the architectural and construction industry.

3

ALUMINIUM COMPOSITE PANELS

Introduction The Building Materials Division is providing innovative products for the continuously expanding construction industry in the middle east. This division’s primary goal is to develop & manufacture quality products required for the modern building architecture.

The latest addition to our building material’s product range is ALUPEX

®

Aluminium Composite Panels developed in technical collaboration with US ®

Polymers INC, U.S.A. ALUPEX , is the next generation solution for all types of cladding and building surfaces. It is a unique and versatile cladding material used in enhancing new trends of modern architecture. ®

ALUPEX is manufactured with state-of-the-art technology of multi-layer extrusion lamination where two skins of non-corrosive special grade ALUMINIUM metal sheets are bonded on to the non-toxic Polyethylene thermoplastic or a fire retardant mineral core to form a sandwich panel. The external skin surface is available in various finishes and colours made from fluoropolymer (PVDF) paint coatings. Our in-house coating facility, equipped with advanced three-roller reversal precision coating machinery, is supported by a leading Europeon paint manufacturer. The external surface is further protected by an easy-to-peel protective film. The internal skin surface is supplied with a non-corrosive service coating to further enhance its protection from cement or galvanic corrosion after installation. A fully integrated manufacturing facility with state-of-the-art coil coating facility and In-house testing laboratory is providing quality products designed to meet the harsh weather conditions of the Gulf region.

ALUPEX®- Aluminium Composite Panel Product Range

This product range of composite panels is lighter and superior in strength-to-weight ratio, suitable for day-to-day use for external and internal wall claddings in modern architectural buildings to create attractive & durable finishes with low maintenance. This range is manufactured using a thermoplastic polyethylene core conforming to CLASS 1 (BS 476) fire rating of British Standard and high performance Aluminium Alloys to ensure faster and easy fabrication methods. The external Aluminium surface of panels is coated with superior PVDF (Poly Vinylidene Difluoride) paints to maintain consistent decorative finish of the building surface over extended period of time even in harsh Gulf weather conditions.

A single person can carry a lightweight Alupex panel off size 1200 x 2400 x 4mm with ease, as shown above.

Panel Thickness:

3 mm, 4 mm & 6 mm

External Aluminium Skin Thickness:

0.5 mm

Internal Aluminium Skin Thickness:

0.5, 0.4 mm

Available Panel Widths:

1000, 1250 & 1500 mm 4

ALUMINIUM COMPOSITE PANELS

Fire Retardant Aluminium Composite Panels manufactured using a non-combustible fire retardant mineral core conforming to CLASS 0 (BS476) fire rating of British Standard certified by European testing laboratories. This product range is manufactured using a high grade of Aluminium Alloys (E.g. AL1100 or AL3003 or AL 3105) to ensure lower oxidation and superior non-corrosive cladding system for high-end architectural requirements in commercial and public buildings. The external Aluminium surface is coated with 2 and/or 3 coats system in PVDF (Poly Vinylidene Difluoride) paints using special purpose base primer coatings to ensure superior performance under severe and harsh weather conditions for extended periods.

Standard Panel Thickness:

4 mm, & 6mm

Standard External Aluminium Skin Thickness:

0.5 mm

Standard Internal Aluminium Skin Thickness:

0.5, 0.4 mm

Standard Panel Widths:

1000, 1250 & 1500 mm

A unique and revolutionary STONE finish Aluminium Composite Panels manufactured using latest coil coating technology . The top skin of Aluminium is coated repeatedly with different colour patterns in PVDF, Polyester and Polyurethane to achieve a naturally look-alike marble, granite and other stone patterns. The high gloss and consistent colour strengths are maintained by high temperature drying (up to 255˚C). An additional topcoat of clear PVDF is used to maintain extended weathering performance for external cladding applications. ®

These look-alike stone skins are then subjected to conventional high-pressure extrusion lamination process to manufacture ALUPEX TONE composite panels. There are various granite and marble finishes available identical to natural stones with higher strength-to weight ratio. These panels are the best alternative to conventionally heavy granite & marble tiles.

Standard Panel Thickness:

3, 4 mm

Standard External Aluminium Skin Thickness:

0.5 mm

Standard Internal Aluminium Skin Thickness:

0.5, 0.4 & 0.3 mm

Standard Panel Widths:

1000, & 1250 mm

AX 37083 Coffee Brown

AX 37052 Colonial Cream

AX 37128 Imperial Red

AX 37251 Rosy Red 5

AX 37125 Tan Red

AX 37333 Black Sapphire

ALUMINIUM COMPOSITE PANELS

Applications

• External Wall Cladding, Building Fascia and Facade Finishes • Curtain Walls and Internal Wall Finishes • Rooftop Edges, Parapet Walls and Wall Canopies • Spandrel, Column Covers and Beam Wraps • Balconies and Patio Wall Claddings • Partition and Ceiling Panels

• Stairways, Elevators and Kiosk Panels • Advertising Display Sign Boards • Public and Commercial Display Walls • Poster Hoardings and Exhibition Rooms • Shop Sign Boards and Showroom Finishes • Machine Casings and Furniture Accessories

Advantages Performance with lightness: A proven strength-to-weight ratio surpassing the solid Aluminium, steel or concrete material. Surface with choice and longevity: Coated with specially formulated fluoropolymer (PVDF) based paints in variety of colours & decorative finishes and a life expectancy of upto 20 years. High tolerance with elegance & beauty: A reliable surface performance to withstand extreme and harsh weather conditions of the Gulf and of coastal areas to maintain its elegance and beauty. Durability with consistency: Manufactured with a corrosion resistant system to provide durability against temperature fluctuations, moisture, chemicals and ultra violet exposures. Quality with confidence: High quality ensures flatness without distortion, surface smoothness without deflection, extra peel-off resistance and high impact strength. Saving energy for a healthier environment: Helps in generating a pseudo-insulation and barrier to reduce the heat and sound transmission losses. Easy installation and economical option: Can be formed in any shape, angle or curve with ordinary metal and wood working machinery and can be installed using conventional accessories

comparison with other cladding materials ®

PROPERTIES

ALUPEX 4mm thick

Aluminium 3 mm thick

Steel 1.5mm thick

Granite 30mm thick

Weight (kg/m2)

5.40

7.93

11.44

81

Sound Insulation (dB)

25

15

5

structure based

Heat Transmission Coefficient (kcal/m2h C)

5.14

6.4

7.3

structure based

Flatness

excellent

average

average

good

Weathering

excellent

average

average

good

Fabrication

easy

difficult

difficult

not possible

Maintenance

low

high

high

average

Installation

easy

extra care

difficult

difficult

Fire Properties

good

average

good

excellent

Large

Medium

Medium

not so large

Panel Size

(1.22m x 2.4m or longer)

Handling

easy

not so easy

not so easy

difficult

Overall Cost

low

high

high

very high

6

ALUMINIUM COMPOSITE PANELS

Quality & Test Certificates

Ireland

UK

USA

7

UAE

UK

ALUMINIUM COMPOSITE PANELS

Quality & Test Certificates

8

ALUMINIUM COMPOSITE PANELS

Project Approvals ®

ALUPEX Aluminium Composite Panel is approved by following leading Engineering Consultants: 1) WS Atkins & Partners Overseas 2) Lacasa Engineering Consultants 3) The Engineer 4) National Engineering Bureau 5) Art Consultants 6) Schuter Pecthold 7) Gulf International Consultants 8) Horizon Engineering Consultants 9) Adnan Saffarini Engineering Consultants 10) Mazaya Engineering Consultants 11) LEO Engineering Consultants 12) Al Nahda Engineering Consultants 13) Nutek Engineers & Architects

14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24) 25)

Mimar Emirates Elit Consultants QHC Architects and Engineers Badri & Bensouda Consultants Archon Group CAB Consultants Al Ajmi Engineering Consultants Bu Humaid Engineering Consultants Meecon ME Al Asri Engineering Consultants Arex Consultants Emirates Design Consortium

Project: PPM Conrad Hotel Consultant: WS Atkins & Partners Overseas

9

ALUMINIUM COMPOSITE PANELS

Project Approvals Project: Iris Bay Consultant: WS Atkins & Partners Overseas

RTA - Dubai Metro

Project: Skycourts Consultant: Lacasa Engineering Consultants

10

ALUMINIUM COMPOSITE PANELS

Completed Projects Project: Dubai Sports City

Consultant: QHC Architects & Engineers

Project: RTA - Dubai Metro

UAE UAE Project: Dubai Sports City

Consultant: QHC Architects & Engineers

Project: Dubai Sports City

UAE

Consultant: QHC Architects & Engineers

UAE 11

ALUMINIUM COMPOSITE PANELS

Completed Projects Consultant: Adnan Saffarini Eng. Consultants

Consultant: Mazaya Eng. Consultants

UAE Consultant: Mazaya Eng. Consultants

UAE

UAE 12

ALUMINIUM COMPOSITE PANELS

Completed Projects Consultant: Al Nahda Eng. Consultants

UAE Contractor: Tiger Contracting Company

UAE

UAE 13

ALUMINIUM COMPOSITE PANELS

Completed Projects Consultant: Gulf International Consultants

IRAN

UAE Consultant: Horizon Eng. Consultants

IRAN Consultant: LEO Eng. Consultants

UAE 14

UAE

ALUMINIUM COMPOSITE PANELS

Completed Projects Consultant: Nutek Engineers & Architects

Consultant: Mimar Emirates

UAE

UAE Consultant: Elit Consultants

UAE 15

ALUMINIUM COMPOSITE PANELS

Completed Projects Consultant: Al Ajmi Eng. Consultants

Consultant: Emirates Design Consortium

UAE

UAE

Consultant: Meecon Middle East

Consultant: Gulf International Consultants

UAE

UAE 16

ALUMINIUM COMPOSITE PANELS

Completed Projects Consultant: Badri & Bensouda Eng. Consultants

Consultant: Archon Group

UAE

UAE

UAE

Consultant: CAB Consultants

Consultant: Bu Humaid Eng. Consultants

UAE

UAE 17

ALUMINIUM COMPOSITE PANELS

Fabrication Guidelines ®

ALUPEX can be formed in any shape, angle or curve with ordinary metal and wood working machinery to fulfil requirements of any cladding and design manifestos. Folding, curving, bending, cutting, joining, fastening, drilling etc. can be adopted with simple, easy and economical skills to shape any architectural design form with flexibility.

GROOVING - Routing a groove using a

JIGGING - Alupex panels can be cut to

BENDING - This can be done by using a

disk or end-milling cutter is much more

any shape and size by a contour cutting

folding table or break press where the

easier than making a groove in a wooden

process with water jets, profile milling

inside bending radius is approximately

substrate. Kindly ensure that 0.28mm of

machines, contour saws and jigsaws.

10 to 11 times of the panel thickness.

plastic core material remains at the base

For the mass production it is advisable to

of groove for flat and consistent bending

make a prototype. Please be aware that

at the groove during fabrication.

the spring-back effect in case of these panels is higher than that with other solid metal sheets.

SAWING - Alupex panels can be cut with

GLUEING

-

Adhesive

tape,

liquid

PUNCHING - These can be punched with

a circular, band or jigsaw similar to any

adhesive, double sided adhesive tapes

any

other wood cutting process.

etc. can be used on back surfaces.

machines with evenly grounded tools

Please note that these adhesives cannot

and narrowest cutting gap. Please note

be used for the inner plastic cores and

that an inappropriate punching can cause

also usage on the top painted surface is

an indentation on the top surface.

conventional

sheet

punching

not advisable.

900 BEND ø8

ø8

ø8

mm 2 +0.2 -0.0 90o

450 BEND

900 BEND WITH RADIUS

r-2 mm

mm 2 +0.2 -0.0

14 mm

r-7 mm

r-2 mm 0.8 mm

r

1.5 mm

18

45

135o

r

0.8 mm

o

r

ALUMINIUM COMPOSITE PANELS

Accessories & Installation 1

ALUPEX ®

2

Sealant

3

Intermittent Aluminium 'L' angle

4

Aluminium Continuous 'L' angle

5

Anchor Bolt

6

Fastening Bolt

7

Aluminium 'L' Bracket

8

Concrete

9

Window Frame 9

8 7

4 3

5 6

2

Vertical fixing

1

Side Wall fixing

SLOPE

Fixing to parapet

Column cladding

A typical fabricated panel

19

Fixing to window frame

ALUMINIUM COMPOSITE PANELS

Technical Specifications PHYSICAL PROPERTIES Property Description 1

2

Result

Standard / Remarks

7.50 kg/m2 10.75 kg/m2

ASTM D792 ASTM D792

4.80 kg/m2 5.40 kg/m2 7.25 kg/m2

ASTM D792 ASTM D792 ASTM D792

®

Average Panel Weight - ALUPEX FR a) 4mm thk. b) 6mm thk. Average Panel Weight - ALUPEX® and ALUPEX® TONE a) 3mm thk. b) 4mm thk. c) 6mm thk.

MECHANICAL / THERMAL PROPERTIES 1

Tensile strength - Aluminium

2 3 4

Bond Strength Shear Rigidity Alupex Peel/Tearing Strength - 180˚ a) 3mm thk. b) 4mm thk. Bond Performance 48 hrs. of submersion in boiling water and after 21 days of immersion in water at 90˚ F. Temperature Resistance (from -50˚ C to + 100˚ C)

5

6 7 8 9

Alum. Asso.

180 N/mm2

Deflection Temperature Fire Retardant Classification Sound Reduction 4mm

2

26.70 N/mm 2.52 KN/mm2

ASTM D903 ASTM C393

upto 18 kgm2 upto 23 kgm2

ASTM D903 ASTM D903

No Change

Passed

No Change

Passed

>300˚ C Class 0 & Class 1 STC = 25 def

ASTM D648 BS 476 - Part 6 & 7 ASTM E 90 - 04

SURFACE COATING 1

Dry Film Thickness (based on colour)

20 to 35µm

ECCA - T1 (1995)

2 3 4 5 6 7 8 9 10 11 12 13

Pencil Hardness Adhesion T bend Test Specular Gloss Reverse Impact Mortar Resistance Acid Pollutants Salt Spray - 3000 hours Humidity - 3000 hours 100% @ 95˚F Acid Rain Test Alkali Resistance Abrasion / Falling Sand

HB - H No Adhesion loss or Cracking No Tape off/no Cracks - 1-T 20˚ - 30˚ (10 - 40%) No Cracking or loss of Adhesion No effect No effect Pass Unaffected 15 Cycles minimum No effect Resist 65-85 Litres/mil.

ASTM D3363 ASTM D3359 ASTM D4145 ASTM D523 ASTM D2794 ASTM C267 ASTM D1308 ASTM B117 ASTM D 2247 Kesternich Kesternich ASTM D 968

WEATHERING PERFORMANCE - PVDF Topcoat 1 2

South Florida Exposure UVB (313 bulbs)

3

Chalk Resistance

< 5 NBS Units Change Passed, 3,000hrs.

ASTM D 2244 ASTM D822

Rating of 8 min.

ASTM D 659

20

ALUMINIUM COMPOSITE PANELS

STANDARD GUARANTEE

20

20

*UP TO

*UP TO

YEARS

YEARS

Interplast Co. Ltd. guarantees the performance of ALUPEX® Aluminium Composite Panels for a period upto 20 years* depending on the type and class of the product.

This guarantee covers the company’s limited liability, which does not extend to cover any consequential injury, loss or damage

* T h e

p r o d u c t

g u a r a n t e e

i s

c o d d i t i o n a l

b a s e d

21

o n

t h e

p r o d u c t

&

p r o j e c t

* Subject to the terms & condition

This guarantee is valid, provided the Alumninium Composite Panels are installed by a qualified and experienced contractor as per our suggested installation guidlines and the material is not subjected to abnormal and improper use.

c a t e g o r y .

ALUMINIUM COMPOSITE PANELS

NOTES

22

M/10/2009

www.alupex.net

INTERPLAST

COMPANY LIMITED

Home Improvement & Building Materials Division P. O. Box: 4679, Sharjah, U.A.E. Tel: +971-6-539 55 77, Fax: +971-6-539 57 75 E- mail:int erp last @emirat es.net .ae

Designed & Printed by:

Manufactured by:

INTERPLAST UK. LTD.

INTERNATIONAL PLASTIC CENTRE LLC

15 High Street, Inverurie, Aberdeenshire AB51 3QA Tel: (+44) 01467 629555, Fax: (+44) 01467 672191 email: [email protected]

P. O. Box: 270982, Riyadh 11352, Saudi Arabia Tel: +966 1 2267110, Fax: +966 1 2267885 email: [email protected]