Section 4 Appendices

Contents

Appendix 1: Summary of specification data-ALPOLIC/fr 66

Appendix 2: Optional coatings 71
Appendix 3: Perforated panel 73
Appendix 4: Impact test with iron plummet 76
Appendix 5: Panel strength 77
Appendix 6: Strength of joining hole 82
Appendix 7: Modified non-penetrating rivet 83
Appendix 8: Examples of complicated panels 85
Appendix 9: Touch-up coating method 94
Appendix 10: Example of practical cleaning method 95

66
Appendix 1: Summary of specification data-ALPOLIC®/fr

1. General
ALPOLIC®/fr is an aluminum composite material (ACM) with a non-combustible mineral-filled core,
used as an exterior and interior cladding and roof covering on new buildings and retrofit applications.
The material is manufactured by Mitsubishi Chemical Functional Products, Inc., and furnished by
approved dealers or distributors.

Note: This summary of specification data is about ALPOLIC/fr. If you need specifications of
ALPOLIC composed of polyethylene core and mainly used for signage, contact local distributors or
our office.

2. Product composition
ALPOLIC/fr is composed of a non-combustible mineral-filled core sandwiched between two skins of
0.5mm thick aluminum alloy (3105-H14):

Composition Skin material: 0.5mm thick aluminum alloy (3105-H14)

Core material: Non-combustible mineral filled core

The surface is finished with a high-performance Lumiflon-based fluorocarbon coating as standard, and
the back is a wash coating or service coating. ALPOLIC/fr is available in four finishes: Solid Colors,
Metallic Colors, Sparkling Colors and Stone-Timber-Metal Series. In these finishes, Lumiflon-based
fluorocarbon paints are applied in manufacturer’s continuous coil coating lines.

The back of ALPOLIC/fr, which will face the structural wall or steel when it is installed as a cladding
panel, has a polyester-based wash coating or a service coating to protect it from possible corrosion
problems.

The surface is protected with a self-adhesive peel-off protective film consisting of two polyethylene
layers of white and black. According to weathering tests under normal outdoor conditions, the
protective film will withstand six months’ exposure without losing its original peel-off characteristic or
causing stains or other damages.

3. Product dimension and tolerance

(1) Panel thickness: 3 mm, 4 mm and 6 mm
(2) Panel size: Width = 965, 1270 and 1575 mm
Length = less than 7200 mm
Note: Custom width can be accepted between 914 mm and 1575 mm subject to minimum quantity.
Please contact local distributors or our office.

67
(3) Product tolerance
Width: ±2.0 mm
Length: ±4.0 mm
Thickness: ±0.2 mm in 3 and 4 mm thick, ±0.3 mm in 6 mm thick
Bow: Maximum 0.5% (5mm/m) of the length or width
Square-ness (diagonal difference):
Maximum 5.0 mm
Surface defect: The surface shall not have any irregularities such as roughness, buckling and
other imperfections in accordance with our visual inspection rules. ALPOLIC/fr
is supplied with a cut edge and without aluminum sheet displacement or core
protrusion.

4. Principal properties
(1) Panel weight:
Unit 3mm 4mm 6mm
2
Panel weight kg/m 6.0 7.6 10.9

(2) Thermal expansion: 24×10-6 /°C

(3) Mechanical properties of Aluminum Composite Material (ACM):

Unit 3mm 4mm 6mm
2
Tensile strength (ASTM E8) MPa or N/mm 61 49 29
2
0.2% proof stress (ASTM E8) MPa or N/mm 53 44 26
Elongation (ASTM E8) % 4 5 2
2
Flexural elasticity, E (ASTM C393) GPa or kN/mm 49.0 39.8 29.1
2
Flexural rigidity, E×I, (ASTM C393) kNmm /mm 72 137 347

(4) Mechanical properties of aluminum alloy (3105-H14):

0.2% proof stress (ASTM E8): 152 MPa or N/mm2
Flexural elasticity (ASTM E8): 70 GPa or kN/mm2

(5) Deflection temperature: 115°C in 3mm, 116°C in 4mm and 109°C in 6mm

(6) Sound transmission loss (ASTM E413):

Thickness 4mm 6mm
STC (Standard Transmission Class) 26 26

5. Summary of fire tests

Extensive fire tests have been performed in accordance with standards in various countries.
ALPOLIC/fr has passed the following fire tests around the world:

68
Table 4-1 Fire tests for general and external cladding material
Country Test standard ALPOLIC/fr Results &
specimen classification
United BS476 Part 7 4mm, 6mm Class 1
Kingdom BS476 Part 6 4mm, 6mm Class 0
Germany DIN4102 Part 1 4mm, 6mm Class B1
USA NFPA 259-93 British Thermal Unit 4mm Passed
ASTM D1781-76 Climbing Drum Peel 4mm, 6mm Passed
Test
ASTM E84, Steiner Tunnel Test 4mm, 6mm Class A / Class 1
ASTM E-108, Modified 4mm Passed
UBC 26-9 & NFPA 285, ISMA Test 4mm, 6mm Passed
(Intermediate Scale Multi-story
Apparatus)
Canada CAN/ULC-S 134-92, Full-scale Exterior 4mm Passed
Wall Fire Test
China GB8625, GB8626 & GB8627 4mm Class B1
Japan Heat Release Test for Non-combustible 4mm, 6mm Passed. Certificate
Material (ISO 5660-1) No. NE-0001

Table 4-2 Fire tests for other categories

Category Country Test Standard ALPOLIC/fr Results &
specimen classification
Fire resistant USA ASTM E119, 1-hr Fire Rating and 2-hr 4mm Passed
rating wall Fire Rating
Roof USA ASTM E108, Fire Test for Roof Covering 4mm Passed Class A
material
Interior USA UBC 26-3, Interior Room Corner Test 4mm Passed
material
Combustion Toxicity Test, New York State 4mm Passed
Uniform Fire Prevention and Building
Code
Japan Heat Release Test for Non-combustible 3, 4, 6mm Passed. Certificate
Material (ISO 5660-1) & Toxicity Gas No. NE-209
Test

6. Paint finish
(1) Coating system
The surface is finished with Lumiflon-based fluorocarbon coating as standard; the back is a wash
coating or service coating. ALPOLIC/fr is available in four finishes: Solid Colors, Metallic Colors,
Sparkling Colors and Stone-Timber-Metal Series. In these finishes, Lumiflon-based fluorocarbon
paints are applied in the manufacturer’s coil coating lines. The coating system of each finish is:

69
A. “Solid Colors” are a two-coat two-bake system.
The total dry film thickness is 25 microns (0.98 mils) minimum and consists of a conversion
coating, an inhibitive primer and a Lumiflon-based fluorocarbon coating.
B. “Metallic Colors” and “Sparkling Colors” are a three-coat three-bake system.
The thickness is 32 microns (1.26 mils) minimum and consists of a conversion coating, an
inhibitive primer, a Lumiflon-based metallic coating and clear coating.
C. “Stone-Timber-Metal Series” is coated with a unique image transfer process.
The thickness is 45 microns (1.77 mils) minimum and consists of a conversion coating, an
inhibitive primer and a Lumiflon-based fluorocarbon coating including the image transfer layer.

Note 1: Lumiflon-based fluorocarbon coating has a coating warranty for 10 years.

Note 2: ALPOLIC/fr is finished with Lumiflon-based fluorocarbon paint as standard, but polyester
and other coatings are also available as an option.

(2) Color and gloss

Standard colors are provided in the Color Chart. Custom colors are available for all finishes upon
request subject to respective minimum quantities. The standard gloss is 30% for Solid and Metallic
Colors, and 15-80% for Sparkling Colors and for Stone-Timber-Metal Series. Custom gloss is
available between 15 and 80% in all colors upon request subject to minimum quantities. Please contact
local distributors or our office for custom color requests.

(3) Coating performance

The Lumiflon-based fluorocarbon coating meets the following criteria:

Table 4-3 General properties

Dry film property Test method Criteria
Gloss (60°) ASTM D523-89 15 to 80%
Formability (T-bend) NCCA 11-19 2T, no cracking
ASTM D1737-62
Reverse impact-crosshatch NCCA 11-5 No pick off
Hardness-pencil ASTM D3363-92a H
Adhesion
Dry ASTM D3359, method 8 No pick off
Wet 37.8°C, 24 hrs. No pick off
Boiling water 100°C, 20 min. No pick off
Abrasive resistance ASTM D968-93 40 liters/mil
(Falling sand)
Chemical resistance:
Muriatic acid, 10%HCl, 72hrs ASTM D1308-87 No change
Sulphuric acid, 20%H2SO4, 18hrs ASTM D1308-87 No change
Sodium hydroxide, 20%NaOH, 1hr ASTM D1308-87 No change
Mortar, pat test, 24hrs AAMA No change
Detergent, 3% solution, 38ºC, 72hrs ASTM D2248-93 No change

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Table 4-4 Weatherability
Dry film property Test method Criteria
Weather-o-meter test
Colour retention: ASTM D2244-93 Maximum 5 units after 4000 hrs.
Gloss retention: ASTM D523-89 70% after 4000 hrs.
Chalk resistance: ASTM D4214-89 Maximum 8 units after 4000 hrs.
Salt spray resistance: ASTM B117-90 Blister-10, scribe-8, after 3000
hrs, 35°C salt fog
Humidity-thermal ASTM D2246-87 No blister, no cracking
After 15 cycles of 38ºC 100%RH
for 24hrs and -23ºC for 20hrs
Humidity resistance: ASTM D2247-94 No change
After 3000 hrs, 100%RH, 35°C

71
Appendix 2: Optional coatings

ALPOLIC/fr and ALPOLIC have a coating finish of Lumiflon-based fluorocarbon paints as standard,
but we can supply ALPOLIC/fr and ALPOLIC coated with the following distinctive paints as an
option.

Table 4-5 Paint options

Coating type Characteristics Suitable application
Conductive fluorocarbon Electrically-conductive Interior walls and partitions in
coating (3×107-8 ohms) factory
PVDF-based fluorocarbon Ultra-weather-ability Outdoor (external wall cladding,
coating roof covering)
Polyester coating Matte finish Interior and light outdoor
applications
High cross-link polyester High hardness (4H) Internal lining of tunnels and
coating High reflectivity (80%) underpass

1. Conductive fluorocarbon coating

ALPOLIC/fr coated with conductive fluorocarbon paint is used on interior walls, partitions and
ceilings of clean rooms and warehouses. With an electrically-conductive surface, the panel also has
high rigidity and fire safety. The conductive paint can be applied on both sides of the panel, if
necessary.
Principal coating performance:
(1) Pencil hardness: 3H
(2) Surface electric resistance: 3×107-8 ohms
(3) Chemical resistance:
Sulfuric acid, 5%H2SO4: No change
Sodium hydroxide, 1%NaOH: No change

2. PVDF-based fluorocarbon coating

PVDF-based fluorocarbon coating has ultra-weatherability. The coating resists long-term
exposure to outdoor conditions. Solid (enamel) and metallic finishes are available. The paints
are applied in ALPOLIC’s continuous coil coating lines. Contact local distributors or our
office for details.
Matte finish: Due to the different hardening
3. Polyester coating speed between the outer and inner layers of
Matte finish is available with polyester coatings, the paint, microscopic wrinkles emerge over
although polyester coatings have less weather-ability the entire surface. The wrinkled surface
results in a matte appearance due to irregular
than fluorocarbon coatings. Matte finish is produced
light reflection.
with a new coating technology in which microscopic
wrinkles emerge over the entire surface during baking

72
in the coil coating line. Matte finish is available with solid (enamel), metallic and timber-patterned
products.

4. High cross-link polyester coating

The high cross-link polyester coating permits high surface hardness of 4H as well as sufficient surface
reflectivity of 80%. Therefore, it is suitable for an area where the panel might be scratched during
maintenance work, such as an internal lining of tunnels and pedestrian’s underpass. The paint is
applied in the manufacturer’s continuous coil coating lines, which ensures uniform coating quality of
the product.

Principal coating performance:

(1) Coating system: Two-coat two-bake system, total dry film thickness is 30 microns minimum
(2) Pencil hardness: 4H with ASTM D522-88
(3) Surface reflectivity: 80% in diffuse reflection (white color)

73
Appendix 3: Perforated panel

Perforated panels of ALPOLIC/fr and ALPOLIC have a pattern of holes at regular intervals. This
provides ventilation and permits vision through the panel, making it suitable for balconies, staircases,
partitions and ceilings.

1. Panel size
Maximum width: 1270mm (55”)
Maximum length: Approx. 3000mm (118”)
Practical examples of sizes: 1000×300mm, 1000×500mm, 1000×700mm, 1000×1000mm

2. Perforation process Turret puncher

As introduced in Section 3, “3. Processing method”, we normally
use a turret puncher for perforation of ALPOLIC/fr and ALPOLIC.
Suitable clearance between punch and die is 0.1mm or smaller
(material thickness × 2%). A small droop will appear at the
punched edge.

3. Examples of perforation pattern

The typical hole-arrangement of circle-shaped holes is as follows:
Direction Pattern Hole Interval Perforation
diameter (W) ratio
Square 20mm 40mm 19.6%

60° Zigzag 5mm 10mm 22.6%

6mm 10mm 32.6%
7mm 10mm 44.4%
W 7mm 12mm 30.8%
8mm 12mm 40.2%
8mm 16mm 22.6%
10mm 15mm 40.2%
15mm 25mm 32.6%
Note: Perforation ratio is % of the total area that is perforated.

4. Panel strength:
Panel strength is lessened after perforation. Namely, the permissible load of ALPOLICs becomes
smaller dependent on the perforation ratio (perforated area per total area). The following charts show
the maximum limit of uniformly-distributed load, like a wind load, without causing permanent
deformation. As shown in the chart, 20%-perforated ALPOLIC loses one half the original strength.

74
Fig. 4-1 Maximum wind load of perforated ALPOLIC

ALPOLIC 3mm, 4-side simply supported ALPOLIC 3mm, 4-side fixed

6 6
1000×300mm 1000×300mm

Maximum wind load (kPa)

Maximum wind load (kPa)

5 5
1000×500mm 1000×500mm
4 4
1000×700mm 1000×700mm
3 3

2 2
1000×1000mm
1 1
1000×1000mm
0 0
0% 10% 20% 30% 40% 0% 10% 20% 30% 40%
Perforation ratio (%) Perforation ratio (%)

ALPOLIC 4mm, 4-side simply supported ALPOLIC 4mm, 4-side fixed

6 6
1000×300mm 1000×700mm 1000×300mm
Maximum wind load (kPa)

Maximum wind load (kPa)

5 1000×700mm 5
1000×500mm 1000×500mm
4 4

3 3
1000×1000mm 1000×1000mm
2 2

1 1

0 0
0% 10% 20% 30% 40% 0% 10% 20% 30% 40%
Perforation ratio (%) Perforation ratio (%)

ALPOLIC 6mm, 4-side simply supported ALPOLIC 6mm, 4-side fixed

6 6
1000×300mm 1000×500mm
Maximum wind load (kPa)
Maximum wind load (kPa)

5 5
1000×700mm 1000×700mm
1000×500mm
4 4

3 3
1000×1000mm 1000×1000mm
2 2

1 1

0 0
0% 10% 20% 30% 40% 0% 10% 20% 30% 40%
Perforation ratio (%) Perforation ratio (%)

Note 1: The above charts are applicable to both ALPOLIC/fr and ALPOLIC.
Note 2: The above maximum load includes the safety factor of 1.25.

75
5. Notes on perforated panels
(1) Effective surfaces are protected with protective films. Remove protective film immediately after
installation.
(2) Align the coating direction in the case of Metallic, Sparkling Colors and Stone-Timber-Metal
Finishes, to avoid color difference due to coating direction.
(3) Use aluminum or stainless steel rivets or screws for joining. If aluminum skin has contact with
other metals in a humid atmosphere, corrosion of the aluminum might be accelerated by galvanic
corrosion.
(4) When re-coating ALPOLIC Perforated Panel, use air-curing type paint and dry it at 90°C or lower,
to prevent the core material from overheating.

76
Appendix 4: Impact test with iron plummet

We conducted this test in order to check the impact resistance of ALPOLIC in comparison to other
building materials. As the test result shows, ALPOLIC panels never crack, break or fracture by the
impact of an iron plummet.

1. Testing method
(1) Testing standard: JIS A 5703 “Plastic laminated or printed boards for inside use”
(2) Specimen: 450×900 mm, placed in a specimen holder shown below.
(3) Iron plummet: 1 kg weight shown below
(4) Procedures: Drop the iron plummet onto a specimen from 1 or 2 meters height.
(5) Evaluation: After the test, the specimen is evaluated on the following items:
a. Break or fracture by impact
b. Deformation of the entire area (H)
c. Deformation of the dropping point (h)
Specimen holder 1 kg iron plummet Evaluation of deformation
380
400 400
26mmR 60
400

h H

2. Test result
Material Thickness Weight Fracture Deformation H & h (mm)
(mm) (kg/m2)
1 2 3 4

3 4.6 No
ALPOLIC 4 5.5 No
6 7.4 No
2 5.4 No
Aluminum sheet
3 8.1 No
Steel sheet 1.0 7.9 No
Veneer 15 7.5 No
Gypsum board 12 8.9 Yes/Both (1m) Not available
Calcium silicate board 8 10.3 Yes/Both (2m)
Acrylic sheet 3 3.6 Yes/Both (1m) Not available

Dropping height :1m :2m Deformation H: h:

Note: In the “Fracture” column shown in the table, “Both” indicates that fracture was found both in
front and back. “Not available” means that it is impossible to measure the deformation value due to
fracture.

77
Appendix 5: Panel strength

1. General calculation method

(1) Calculation to check the possibility of permanent deformation
In order to check that ALPOLIC panels can withstand the wind load condition, we calculate the
maximum stress that may arise in aluminium skins of ALPOLIC with the design wind load. We use
the following equation for this purpose. In our calculation, we use the same equation and parameters
for both ALPOLIC/fr and ALPOLIC, because we ignore the role of the core in this calculation.

Stress = B·w·b2 / t2
Stress: Stress that may arise in aluminum skin, in MPa or N/mm2
b: Panel width or height, whichever is shorter, in mm
B: Coefficient dependent on a/b ratio (panel width/height) and supporting condition,
as shown in Table 4-6.
w: Wind pressure, in MPa, 10-3kPa or N/mm2
t2 : Square of apparent thickness of ALPOLIC, given in the following table:

ALPOLIC t2 0.2% proof stress

Thickness (mm2) (MPa or N/mm2)
3mm 6.33 152
4mm 9.25 152
6mm 15.17 152

If the stress value calculated with the equation is not larger than 0.2% proof stress above, aluminium
skins withstand the wind load and the permanent deformation will not occur. A suitable safety factor
should be taken into account herein.

(2) Maximum deflection

The maximum deflection of ALPOLIC panel can be calculated with the following equation:

Deflection = A·w·b4 / EAPtAP3

Deflection: Deflection that may appear in ALPOLIC panel, in mm
b: Panel width or height, whichever shorter side
A: Coefficient dependent on a/b ratio (panel width/height) and supporting condition,
as shown in Table 4-7.
w: Wind pressure in MPa, 10-3kPa or N/mm2
EAP: Flexural elasticity of ALPOLIC, shown below
tAP: Thickness of ALPOLIC

78
 ALPOLIC EAP EAPtAP3
Thickness (N/mm2) (N·mm)
3mm 49.0×103 1323×103
4mm 39.8×103 2546×103
6mm 29.1×103 6287×103

Table 4-6 Coefficient B to calculate the stress

Support condition Equation and B value
2-side simply supported
Stress = 0.75·w·b2 / t2
and 2-side free b

2-side fixed and 2-side

Stress = 0.5·w·b2 / t2
free b

4-side simply supported

a Stress = B·w·b2 / t2
b
a/b 1 1.2 1.4 1.6 1.8 2.0 3.0

B 0.2874 0.3762 0.4530 0.5172 0.5688 0.6102 0.7134

4-side fixed
a Stress = B·w·b2 / t2
b
a/b 1 1.2 1.4 1.6 1.8 2.0 >2.0

B 0.3078 0.3834 0.4356 0.4680 0.4872 0.4974 0.5000

Table 4-7 Coefficient A to calculate the deflection

Support condition Equation and A value
2-side simply supported
Deflection = 0.156·w·b4 / (EAP·tAP3)
and 2-side free b

2-side fixed and 2-side

Deflection = 0.0313·w·b4 / (EAP·tAP3)
free b

4-side simply supported

a Deflection = A·w·b4 / (EAP·tAP3)
b
a/b 1 1.2 1.4 1.6 1.8 2.0 3.0 >3.0

A 0.044 0.062 0.077 0.0906 0.1017 0.1110 0.1335 0.1422

4-side fixed
a Deflection = A·w·b4 / (EAP·tAP3)
b
a/b 1 1.2 1.4 1.6 1.8 2.0 >2.0

A 0.0138 0.0188 0.0226 0.0251 0.0267 0.0277 0.0284

79
2. Calculation results of stress
The following tables are calculated results of stress on the following cases.
Table 4-8 ALPOLIC 3mm, 4-side simply supported and 4-side fixed
Table 4-9 ALPOLIC 4mm, 4-side simply supported and 4-side fixed
Table 4-10 ALPOLIC 6mm, 4-side simply supported and 4-side fixed
If you need exact calculations, calculations entailing stiffener, and calculations of deflection, please
contact local distributors or our office. The calculation requires the following parameters: (A) Wind
load, (B) ALPOLIC thickness, (C) Supporting condition, (D) ALPOLIC panel size.

Table 4-8 ALPOLIC 3mm

Supporting condition: 4-side simply supported

Maximum stress (N/mm2)
w, kPa Panel width Panel length (a) in mm
(kg/m2) (b) in mm 900 1200 1500 1800 2100 2400 2700 3000 >3000
1.0 600 28 35 38 41 43 43 43 43 43
(102) 900 37 55 68 78 82 87 91 96 96
1200 55 65 90 110 126 139 145 151 171 >
1500 68 90 102 134 161 > 184 > 202 > 217 > 267 >
1.5 600 41 52 56 61 64 64 64 64 64
(153) 900 55 82 103 117 124 130 137 144 144
1200 82 98 135 166 > 190 > 208 > 217 > 226 > 256 >
1500 103 135 153 > 201 > 242 > 276 > 303 > 325 > 400 >
2.0 600 55 69 75 81 85 85 85 85 85
(204) 900 74 109 137 156 > 165 > 174 > 183 > 192 > 192 >
1200 109 131 180 > 221 > 253 > 278 > 289 > 301 > 341 >
1500 137 180 > 204 > 267 > 322 > 368 > 404 > 434 > 533 >

Supporting condition: 4-side fixed

Maximum stress (N/mm2)
w, kPa Panel width Panel length (a) in mm
(kg/m2) (b) in mm 900 1200 1500 1800 2100 2400 2700 3000 >3000
1.0 600 26 28 28 28 28 28 28 28 28
(102) 900 39 53 61 64 64 64 64 64 64
1200 53 70 90 103 110 113 114 114 114
1500 61 90 109 136 155 > 166 > 173 > 177 > 178 >
1.5 600 39 42 43 43 43 43 43 43 43
(153) 900 59 80 91 95 96 96 96 96 96
1200 80 105 135 154 > 165 > 170 > 171 > 171 > 171 >
1500 91 135 164 > 204 > 232 > 250 > 260 > 265 > 267 >
2.0 600 51 57 57 57 57 57 57 57 57
(204) 900 79 107 121 127 128 128 128 128 128
1200 107 140 180 > 206 > 219 > 226 > 227 > 227 > 227 >
1500 121 180 > 219 > 273 > 310 > 333 > 346 > 354 > 355 >
How to read the table: “>” indicates that the maximum stress becomes larger than 0.2% proof stress of
aluminum skin (152 N/mm2). Stiffener will be required in this range. In other ranges where calculated stress is
lower than 152 N/mm2, the panel will withstand without stiffener. Take into account a safety factor.

80
Table 4-9 ALPOLIC 4mm

Supporting condition: 4-side simply supported

Maximum stress (N/mm2)
w, kPa Panel width Panel length (a) in mm
(kg/m2) (b) in mm 900 1200 1500 1800 2100 2400 2700 3000 >3000
1.0 600 19 24 26 28 29 29 29 29 29
(102) 900 25 37 47 53 56 59 62 66 66
1200 37 45 62 76 87 95 99 103 117
1500 47 62 70 92 110 126 138 148 182 >
1.5 600 28 36 39 42 44 44 44 44 44
(153) 900 38 56 70 80 85 89 94 99 99
1200 56 67 92 113 130 142 149 155 > 175 >
1500 70 92 105 137 165 > 189 > 208 > 223 > 274 >
2.0 600 38 47 52 56 58 58 58 58 58
(204) 900 50 75 94 107 113 119 125 131 131
1200 75 89 123 151 173 > 190 > 198 > 206 > 234 >
1500 94 123 140 183 > 220 > 252 > 277 > 297 > 365 >
2.5 600 47 59 64 69 73 73 73 73 73
(255) 900 63 93 117 134 141 149 156 > 164 > 164 >
1200 93 112 154 > 189 > 216 > 237 > 248 > 258 > 292 >
1500 117 154 > 175 > 229 > 275 > 315 > 346 > 371 > 456 >
3.0 600 57 71 77 83 88 88 88 88 88
(306) 900 76 112 141 160 > 169 > 178 > 187 > 197 > 197 >
1200 112 134 185 > 227 > 260 > 285 > 297 > 309 > 350 >
1500 141 185 > 210 > 275 > 331 > 377 > 415 > 445 > 547 >

Supporting condition: 4-side fixed

Maximum stress (N/mm2)
w, kPa Panel width Panel length (a) in mm
(kg/m2) (b) in mm 900 1200 1500 1800 2100 2400 2700 3000 >3000
1.0 600 18 19 19 19 19 19 19 19 19
(102) 900 27 37 42 44 44 44 44 44 44
1200 37 48 62 70 75 77 78 78 78
1500 42 62 75 93 106 114 119 121 122
1.5 600 26 29 29 29 29 29 29 29 29
(153) 900 40 55 62 65 66 66 66 66 66
1200 55 72 93 106 113 116 117 117 117
1500 62 93 112 140 159 > 171 > 178 > 181 > 182 >
2.0 600 35 39 39 39 39 39 39 39 39
(204) 900 54 73 83 87 88 88 88 88 88
1200 73 96 123 141 150 155 > 156 > 156 > 156 >
1500 83 123 150 187 > 212 > 228 > 237 > 242 > 243 >
2.5 600 44 48 49 49 49 49 49 49 49
(255) 900 67 91 104 109 109 109 109 109 109
1200 91 120 154 > 176 > 188 > 194 > 195 > 195 > 195 >
1500 104 154 > 187 > 233 > 265 > 285 > 296 > 302 > 304 >
3.0 600 53 58 58 58 58 58 58 58 58
(306) 900 81 110 125 131 131 131 131 131 131
1200 110 144 185 > 211 > 225 > 232 > 234 > 234 > 234 >
1500 125 185 > 225 > 280 > 318 > 342 > 356 > 363 > 365 >
How to read the table: “>” indicates that the maximum stress becomes larger than 0.2% proof stress of
aluminum skin (152 N/mm2). Stiffener will be required in this range. In other ranges where calculated stress is
lower than 152 N/mm2, the panel will withstand without stiffener. Take into account a safety factor.

81
Table 4-10 ALPOLIC 6mm

Supporting condition: 4-side simply supported

Maximum stress (N/mm2)
w, kPa Panel width Panel length (a) in mm
(kg/m2) (b) in mm 900 1200 1500 1800 2100 2400 2700 3000 >3000
1.0 600 12 14 16 17 18 18 18 18 18
(102) 900 15 23 29 33 34 36 38 40 40
1200 23 27 38 46 53 58 60 63 71
1500 29 38 43 56 67 77 84 91 111
1.5 600 17 22 24 25 27 27 27 27 27
(153) 900 23 34 43 49 52 54 57 60 60
1200 34 41 56 69 79 87 91 94 107
1500 43 56 64 84 101 115 127 136 167 >
2.0 600 23 29 31 34 36 36 36 36 36
(204) 900 31 46 57 65 69 73 76 80 80
1200 46 55 75 92 106 116 121 126 142
1500 57 75 85 112 134 153 > 169 > 181 > 222 >
2.5 600 29 36 39 42 44 44 44 44 44
(255) 900 38 57 71 81 86 91 95 100 100
1200 57 68 94 115 132 145 151 157 > 178 >
1500 71 94 107 139 168 > 192 > 211 > 226 > 278 >
3.0 600 35 43 47 51 53 53 53 53 53
(306) 900 46 68 86 98 103 109 114 120 120
1200 68 82 113 138 158 > 174 > 181 > 188 > 214 >
1500 86 113 128 167 > 202 > 230 > 253 > 272 > 334 >

Supporting condition: 4-side fixed

Maximum stress (N/mm2)
w, kPa Panel width Panel length (a) in mm
(kg/m2) (b) in mm 900 1200 1500 1800 2100 2400 2700 3000 >3000
1.0 600 11 12 12 12 12 12 12 12 12
(102) 900 16 22 25 27 27 27 27 27 27
1200 22 29 38 43 46 47 47 47 47
1500 25 38 46 57 65 69 72 74 74
1.5 600 16 18 18 18 18 18 18 18 18
(153) 900 25 33 38 40 40 40 40 40 40
1200 33 44 56 64 69 71 71 71 71
1500 38 56 68 85 97 104 108 111 111
2.0 600 21 24 24 24 24 24 24 24 24
(204) 900 33 45 51 53 53 53 53 53 53
1200 45 58 75 86 92 94 95 95 95
1500 51 75 91 114 129 139 145 148 148
2.5 600 27 30 30 30 30 30 30 30 30
(255) 900 41 56 63 66 67 67 67 67 67
1200 56 73 94 107 114 118 119 119 119
1500 63 94 114 142 162 > 174 > 181 > 184 > 185 >
3.0 600 32 35 36 36 36 36 36 36 36
(306) 900 49 67 76 80 80 80 80 80 80
1200 67 88 113 129 137 142 142 142 142
1500 76 113 137 171 > 194 > 208 > 217 > 221 > 222 >
How to read the table: “>” indicates that the maximum stress becomes larger than 0.2% proof stress of
aluminum skin (152 N/mm2). Stiffener will be required in this range. In other ranges where calculated stress is
lower than 152 N/mm2, the panel will withstand without stiffener. Take into account a safety factor.

82
Appendix 6: Strength of joining hole

Rivets, bolt/nuts and tapping screws are quite often used for joining between ALPOLIC panels and
aluminum profiles. When a tensile force loads on the joining point, stress will be placed on the joining
hole of the ALPOLIC panel. In order to evaluate the maximum elastic limit of the joining hole, we
performed the following tensile test.
ALPOLIC

1. Test method:
Do tensile tests with 5mm and 10mm holes (D) that are located
different distances from edge (e). Determine the maximum
elastic limits by means of stress-strain curve.

2. Test result:
The following table shows the maximum elastic limits.
Hole Hole center e/D Maximum elastic stress, (S) Max. tensile force (F)
diameter (D) to edge (e) MPa or N/mm2 in N
in mm in mm 3mm 4mm 6mm 3mm 4mm 6mm
5 1 21 23 18 320 430 530
5 10 2 48 44 38 720 880 1150
15 3 55 46 40 820 920 1210
10 1 20 21 17 590 820 1000
10 20 2 38 33 25 1150 1330 1530
30 3 39 38 25 1170 1530 1470

3. How to use the above data:

To utilize the above data, we convert the above value to meet our particular case with the equation:

F=S×t×D
S: Maximum elastic stress in MPa or N/mm2
F: Maximum tensile force in N
t: Thickness of ALPOLIC in mm
D: Diameter of hole in mm

Calculation example:
Premise: ALPOLIC 3mm, D = 4mm, e = 8mm,
Result: F = S × t × D = 48×3×4 = 576 N per joining point (Take a safety factor).

According to the above table, a sufficient hole-strength cannot be expected, if the position is quite near
the edge. In order to ensure a reasonable strength of joining hole, the distance from hole-center to edge
(e) should be larger than twice the hole-diameter (D). Namely, we should keep e > 2×D.

83
Appendix 7: Modified non-penetrating rivet

1. General
The modified non-penetrating rivet method offers a new fixing method of ALPOLIC panels. This
fixing method is an alternative to adhesives and double-sided tapes, but this non-penetrating rivet,
unlike adhesives or double-sided tapes, functions as mechanical fixing. Therefore, the non-penetrating
rivet is suitable for areas where a reliable fixing is required even in the event of fire or other accidents.

It is important that this rivet is not usable on all ALPOLIC panels, but usable only on the low-gloss
finishes, because the trail of concealed rivet is visible from the front, if the surface is glossy. This
modified non-penetrating rivet is suitable only to the following ALPOLIC products.

ALPOLIC thickness Applicable gloss level

4mm, 6mm Low-gloss only (30% gloss or less)
3mm Matte finish only (polyester coating)

2. Installation method
SD-52-SW-SMH-MK
(1) Rivet Head of
Use the rivet, SD-52-SW-SMH-MK, mandrel
(4mm) shown in the diagram.
Shell
Mandrel 2.6mm 9.2mm 4.2mm diameter
(2) Aluminum profile
Although many shapes are applicable, the aluminum profile must allow the following fixing height
and must have projections, as shown in the diagram to prevent lifting of the aluminum skin.
Projections
Suitable fixing height and depth
ALPOLIC thickness Height, mm Depth, mm
3mm 7.5 2.5
4mm 7.5 3.0 Height
6mm 6.0 3.5 Depth

(3) Riveting procedures

Refer to Fig. 4-2 and 4-3 below.

4. Design strength
Use the following pulling strength for design as a net value. It includes a processing factor of 1.3, but
it does not include a safety factor. Divide it by the safety factor, if necessary. Keep the distance from
the rivet center to the edge at least 20mm to ensure this strength.

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ALPOLIC thickness Design strength/piece
4mm, 6mm 330 N
3mm 160 N

Fig. 4-2 Riveting procedures

1. Make a 4.5mm hole in the aluminum 2. Adhere the profile to ALPOLIC with 3. Make a 4.3mm hole in ALPOLIC.
profile. adhesive. Use Cemedine Super X or Use a drill with a stopper to give the
equivalent. specified depth.
Drill
Aluminum Adhesive Drill with
profile stopper
Stopper

4. Remove scraps and chips around the 5. Set the rivet 6. Pull the mandrel to fasten.
hole. Pneumatic
riveter
Vacuum or blow

7. Finish

Fig. 4-3 Improper installation

Inclined setting Scraps remain Hole is shallow

85
Appendix 8: Examples of complicated panels

We sometimes encounter unusual designs including 3-dimensional shapes. Mostly, the required
quantity is only several pieces, but we wish to fabricate the ALPOLIC panels in such a manner that
they achieve long-lasting performance with satisfactory appearance. Examples of these panels are
attached here for your reference. If you have similar difficulties in an actual project, please contact
local distributors or our office. We would like to study together.

The attached examples are based on those panels produced for actual projects. We scaled down the
panel size by 1/2 to 1/5 for transportation. Please correct the dimensions so as to fit to your case.

Example 1 Outside angle panel of coping

A corner panel of coping that is located on top of buildings
Example 2: Outside angle panel of sunshade (cornice)
A corner panel of a sunshade above an entrance or window
Example 3: Outside angle panel with water drip
A corner panel with a water drip that is normally located at the lower portion of
buildings
Example 4: Inside angle panel for recessed windows
Recessed windows sometimes require this type of panel, depending on the position of
the vertical and horizontal joints.
Example 5: Three-dimensional curved panel
This is a convex panel with a flat return (folded edge). This panel is applicable when
the curve radius is larger than 1300mmR in 4mm thick ALPOLIC.

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Example 1: Outside angel panel of coping

Completed panel Section detail

200
20

100
80

15
50

10 30

Elevations and plan

Aluminum flange
(large)

Aluminum flange
(small)

87
 A-A’ detail B-B’ detail C-C’ detail

30

Support plate,
Aluminum flange aluminum 1.2mmt
(large)

30
D-D’ detail

Drain hole
50
30 Water gutter, adhered
40
with 3M’s VHB tape

40
Drainage through
gutter and hole

Cut & groove

738
22
22 199 198 198 99 Cut
1 1 22
Groove
Notch
48
44
22 22 78
40

22 199 477
Coating 22
direction
45.15deg 45.15deg
49
2
A 98

32

65

A detail Theoretical line

Actual grooving line

Position actual grooving center line

1.0 1.0 1.0mm inner than the theoretical line to
compensate elongation after folding
45.15deg 45.15deg

2
2

88
Example 2: Outside angle panel of sunshade (cornice)

Completed panel

Elevations

A-A’ detail

30
Aluminum flange
(large)

B-B’ detail

Aluminum flange 28
(small)

C-C’ detail
3

Aluminum angle
20x20

Aluminum angle 20x20

D-D’ detail

30

Water gutter, aluminum sheet,

adhered with 3M’s VHB tape 40
Drainage through gutter and hole

89
 Cut & groove

740
22 149 49 200 200 49 49 22
5 5

45deg 45deg 49 Cut

Groove
5 Notch

22 22
204
Coating
direction 392
45.6deg 45.6deg
A 38
2
68
B 2
38
45.6deg 45.6deg 49

22
200 48 48 150

A detail B detail
Theoretical line
2
Actual groove line
2

1.0 1.0 45.6deg 45.6deg

45.6deg 1.0 1.0
45.6deg
Actual groove line
2
2 Theoretical line

Position actual grooving center line

1.0mm inner than the theoretical line to
compensate elongation after folding

90
 Example 3: Outside angle panel with water drip

Completed panel Section detail

280

A-A’ detail 70
Support plate (ALPOLIC),
adhere with 3M’s VHB tape

Trim and touchup

the edges

Cut & groove

350
22 118 188 22 Cut
Groove
22 Notch

Coating
278 400
direction

68

32

68 68

91
 Example 4: Inside angle panel for recessed windows

Completed panel Application example

Inside angle panel

for recessed window

A-A’ detail Support plate (ALPOLIC),

adhere with 3M’s VHB tape

Trim and touchup

the edges
Cut & groove

Main panel

321
22 277 22 Cut
22 22 Groove
Notch

Coating
139 direction

Supplementary panel

321 277 321

100 100
45deg
78 78
79
45deg

22 22
Coating 45deg 45deg
59 direction 78

59 22 79 139 22 22

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Example 5: Three-dimensional curving panel

This panel is applicable when the curving radius is larger than 1300mmR in 4mm thick ALPOLIC. We use a
regular 3-roll bending machine.

Front view Application example

25mm or less

3-dimensional
curving panel

Flat panel
1300mmR
or larger 3-dimensional
curving panel

Elevation and plan Section

20 15 190

190

1300R

93
 Cut & groove

Flat panel 3-dimensional curving panel

245 293
1051R
24 24 24 245 24
1075R 197

24 24
18

Coating 188 236 Coating

direction 188 254
direction

1265R
1289R

24
24
3 25 3 Slit, w=3, @=25
24 50 24
24 24 Slit, w=3, @=50
241
289
Cut
Groove
Notch
Bending work
Bend ALPOLIC panel and filling board together

Filling board

ALPOLIC

94
Appendix 9: Touch-up coating method

It is one of the advantages of Lumiflon paint that the coated surface can be re-coated at room
temperature. This manual refers to a typical touch-up (repair) coating method of ALPOLIC panels
coated with Lumiflon-based fluorocarbon paint. An air-cured type of Lumiflon-based fluorocarbon
paint, called “Bonflon #2000” is used as touch-up paint.

1. Touch-up paint (1 kg set) consists of:

1. Main agent, hardener and solvent
Main agent: 0.93 kg
Hardener: 0.07 kg
Solvent is not enclosed in the package. If you need solvent to dilute and
adjust the viscosity of the paint, procure it locally. Refer to the bottom note
Solvent is not enclosed. for suitable solvents.

2. Surface preparation 2. Wipe off dust and stains with a soft rag. Polish the relevant area with
sandpaper #320-400 mildly. Remove oils and fats with IPA (isopropyl
alcohol), ethyl alcohol or N-hexane diluted to 50% with water.
Note: Do not use solvents for surface preparation.

3. Cover the surrounding area, if necessary.

3. Mask Note: Do not use PVC tapes. Gloss increase may occur.

4. Stir the main agent to homogenize the pigments. Pour an appropriate

quantity of the main agent into a beaker.

5. Add an appropriate quantity of hardener and solvent. Mix them well and
4. Stir and pour maintain for 30 min before use. The mixing ratio is as follows:
Main agent : Hardener = 93 : 7 (=13 : 1)
Solvent: 20-40% to adjust the viscosity

6. Apply the paint with brush or spray. Approximately 1 hr will be required

for the surface to dry at 20°C.
5. Mix
Note: Use the mixture within 6hrs (at 20°C). Do not apply below 10°C.

General Notes:
1. Re-coated surface shows a slightly different appearance, especially in
metallic colors, due to the coating method difference.
2. Do not expose paint to direct sunshine for extended periods.
3. Store the paints away from direct flame and excessive heat. Keep airtight
6. Paint apply
and away from moisture.
4. Suitable solvents: xylene, butyl acetate, MIBK (metyl iso-butyl ketone),
and thinners for urethane/acrylic-urethane paints are suitable. As these are
strong organic solvents that are inflammable and intoxicating, follow the
manufacturer’s instructions. Most commercially popular paint thinners are
not suitable.

95
Appendix 10: Example of practical cleaning method

Cleaners and detergents are normally local products. A cleaner or a detergent widely available in one
country may not be available in another country. This method is an example of practical cleaning
method suitable for Lumiflon-based fluorocarbon coating. The cleaner called “Magiclean” is a
household cleaner from Kao Corp and widely available in East and Southeast Asian countries.
“Sharpshooter” is a versatile cleaner from 3M and available worldwide.

1. Light surface soiling

Firstly, try a water rinse using a soft sponge with modest pressure to remove the soiling (stain). If the
soiling remains after drying, then use dilute Magiclean.

1. Add cleaner to water 2. Apply the solution and spread 3. Dry with a squeegee and wipe
off with a wet cloth
Water 5 liters Magiclean Hold for 1 min
50-250 ml

Dilute Magiclean to 1-5% (50-250ml Spread the solution around ALPOLIC Dry with squeegee and finally wipe
Magiclean to 5 liters water). surface. Use soft towel or sponge. the surface with wet towel containing
Magiclean is a household cleaner Wait for about 1 minute, the foam clean water.
with pH 8 from Kao Corp. will be blackened.

2. Medium to heavy surface soiling

Use undiluted Sharpshooter or 50%Magiclean. As Sharpshooter is an alkali (pH12) and Magiclean is a
weak alkali (pH8), we require a water rinse after using these cleaners. Also, eye protection is
necessary to handle these solutions. Follow the manufacturer’s safety instructions.

1. Use undiluted Sharpshooter or 2. Apply undiluted Sharpshooter or 3. Rinse with a wet cloth
50% Magiclean 50% Magiclean with sprayer, soft containing clean water.
cloth or sponge.

Use undiluted Sharpshooter, or dilute Apply the solution on ALPOLIC with Rinse with a wet cloth soaked in
Magiclean by 50% (100ml sprayer, towel, or sponge. Slight clean water.
Magiclean to 100ml water). rubbing is required to remove heavy
surface soiling. Use a soft towel.

96