AT A GLANCE

All you need to know about the aluminium composite panel with a honeycomb core English
 THE PRODUCT
AT A GLANCE ALUCORE® is an aluminium sandwich-type panel with high
• high rigidity with low weight rigidity and extremely low weight. In contrast to conventional
• visually appealing, even surfaces honeycomb composite panels, the system components, i.e.
• good air-borne sound insulation the “aluminium core” and the coil-coated “aluminium cover
• different thicknesses and formats sheets” are bonded in a continuous process. The advantages
• particularly well-suited as carrier material are product quality and surface evenness; the material
for the most differing surfaces and coatings does not become brittle-hard but shows tough and resilient
• easy to process properties and an excellent peel strength. Following in the
• approvals for specific applications footsteps of the ALUCOBOND® trademark, ALUCORE® is
• short delivery times the ideal material for a host of applications in transport,
• cut to size on request architecture or industrial production.

DELIVERY PROGRAMME
All standard formats available from stock (Delivery within 2 weeks ex works)
honeycomb core

ALUCORE ® (both sides lacquered platinum white, protective foil on both sides)
cover sheets with lacquering
Standard thickness [mm] Standard width [mm] Standard length [mm]
6 1 250 2 500 / 6 250
6 1 500 6 250
10 1 250 2 500 / 6 250

d1 10 1 500 6 250
15 1 250 2 500 / 6 250
H 15 1 500 6 250
20 1 250 2 500

d2 20 1 500 6 250
25 1 250 2 500
25 1 500 6 250
Structure
H: total thickness (5.5 – 50 mm)
L: length (2000 – 9600 mm) Other thicknesses and formats on request

d1: thickness of Al cover sheet

(front side 0.5 / 1.0 mm) ALUCORE ® / ALUCORE ® A2 (one/both side(s) PVDF lacquered, one/both side(s) protective foil)
d2: thickness of Al cover sheet Standard thickness [mm] Standard width [mm] Standard length [mm]
(rear side 0.5 / 1.0 mm) 6 1 250 / 1 500 2 000 – 9 600
10 1 250 / 1 500 2 000 – 9 600
10.5 1 250 / 1 500 2 000 – 9 600
15 1 250 / 1 500 2 000 – 9 600
20 1 250 / 1 500 2 000 – 9 600
25 1 250 / 1 500 2 000 – 9 600

ALUCORE ® base (both sides mill finish, without protective foil)

Standard thickness [mm] Standard width [mm] Standard length [mm]
9.5 1 250 / 1 500 2 000 – 9 600
14 1 250 / 1 500 2 000 – 9 600

ALUCORE ® lite (both sides mill finish, without protective foil)

Standard thickness [mm] Standard width [mm] Standard length [mm]
The honeycomb core consists of
6 1 250 / 1 500 2 000 – 9 600
aluminium foils made of the alloy AlMn
10 1 250 / 1 500 2 000 – 9 600
(EN AW 3003)
Cell size b: approx. 6.3 – 12.7 mm. The
COLOURS AND SURFACES
cover sheets of the ALUCORE ® panels Further colours and surfaces on request.
consist of corrosion-resistant Peraluman
DIMENSIONAL TOLERANCES
alloys (AlMg) and may be used in a deco- Thickness: ± 0.2 mm (mill-finished | stove-lacquered)
rative or functional manner, depending Width: -0 / +4 mm
Lengths 2 000 – 4 000 mm: -0 / +4 mm
on the purpose of application. Lengths 4 001 – 9 000 mm: -0 / +6 mm
 APPROVALS AND FIRE CLASSIFICATION
Shipbuilding
Country Test according to ... Classification
EU* MED approval Modules B and D
US* (EC type approval certificate, steering wheel) Flame-retardant surface materials and flooring
US Coast Guard Approval with low flame-spread characteristics
(veneers and flooring)
global* IMO FTPC Part 1 Class C
Type approval certificate by DNV GL non-combustible

Rail vehicles
Germany DIN 5510 S5 / SR2 / ST2
EU EN 45545 HL3 (for R1, R7, R17)
France NF F 16-101 Class F0
NF P 92-501 Class M1

Building construction
EU EN 13501-1 Class A2-s1, d0 (ALUCORE ® A2)
Class B-s1, d0
* Also applies to ALUCORE ® lite

RIGIDITY COMPARED WITH THICKNESS CHARACTERISTIC PEEL STRENGTH ACCORDING

AND WEIGHT TO DIN 53295

Weight [kg/m 2] Comparison characteristic peel strength according to DIN 53295 [%]

4.9 15.2 500

40 13
10.5
30
7
20 4.8
22 20 25 400
10 6 10 15

20000
40000 300
60000
80000
100000 200
120000
140000
160000
100
180000
200000
220000
Rigidity [kNcm 2/m] Thickness [mm] 0
ALUCORE ® with tough Conventional honeycomb
ALUCORE ® Solid aluminium Chipboard Sheet steel and resilient adhesive system panels with brittle-hard
adhesive system
SHIPBUILDING

In the shipbuilding industry, ALUCORE®

plays an important role due to fire-
protection standards and the necessary
weight reduction.

Thanks to its very light weight combined

with its economic workability, the compo-
site panel is used – particularly in the inte-
rior of the ship – for the ceilings, walls or
furniture and in the outer area for balcony
partitioning. In all the applications, the
material offers optimum strength values
at the same time.

Economic – balcony partitioning using ALUCORE ®

INTERIOR CONSTRUCTION

Whether for cleanrooms, partitions, light-weight containers,

cabins for machine tools, wind tunnels, lifting platforms,
lifts, etc., ALUCORE ® is the ideal material for industrial
applications.

For example, using large-format, curtain wall ALUCORE® panels,

it is possible to create an individual interior design in stairways
and public areas, fast building systems in hat-profile construc-
tion can be implemented, or ground areas can be fitted with
assembly systems for control rooms, navigating bridges and
platforms. The honeycomb panels are also excellently suited as
a carrier material for HPL, veneers, foils or paint.

Simple processing using commercially available tools on site and

the possibility of a flexible adaptation of the modular dimension
and fixation method offer the construction workers the greatest
possible comfort.

Individual – interior construction using ALUCORE ®

 ARCHITECTURE

Unique, mechanical properties, paired

with excellent processing and aesthetic
features make ALUCORE® the preferred
material in facade cladding and roofing
for planners, architects and designers.

With this decorative construction mate-

rial with its even surface and high rigidity,
innovative mounting systems for wall
cladding and roofing can be implemented
in a technically flawless manner.

Even applications with very demanding

technical requirements, e.g. large self-
supporting roofs or elements that are
exposed to extremely high wind loads,
can be constructed using A LUCORE®.
In comparison w ith other materials,
ALUCORE® therefore has a high rigidity
and an extremely low weight and offers
decisive advantages due to the high tensile
strength of the cover sheets.

Stable – large, self-supporting roof with ALUCORE ® cladding

RAIL AND TRANSPORT VEHICLE CONSTRUCTION

Today’s strict economic and ecological conditions demand

the implementation of sustainable structural materials in
the field of transport that are lightweight, stable and fully
recyclable.

In rail and transport vehicle construction, particularly the light

weight and the high rigidity speak in favour of using ALUCORE®.
Due to the lightweight construction, the CO2 emission can be
significantly reduced and at the same time, there is less burden on
the congested and restricted rail and road networks. ALUCORE®
is recyclable, i.e. the panels are fed back into the material cycle
and used for producing new material.

ALUCORE® composite panels are excellently suited for special

interior cladding, as well as for wall cladding and roofing in rail
vehicle construction, for superstructures for lorries, for cabins,
doors and flap systems.

Light weight – rail vehicle interior construction in ALUCORE ®

PROCESSING

CUTTING MILLING DRILLING FOLDING BENDING PRESS FORMING

JOINTING, FIXING EDGE COVERING LAMINATING LACQUERING, PRINTING GLUEING

SPRAYING

APPLICATION EXAMPLES
INTERIOR CLADDING CLAMPED SUSPENDED SUSPENDED
for vertical panel layout for horizontal panel layout

INTERESTING DETAILS
ENVIRONMENT / RECYCLING / QUALITY INSTALLATION
During the life cycle of ALUCORE® panels, no substances con- To avoid possible ref lection differences (does not apply
taining CFC are set free at any time. ALUCORE® can be fully to solid colours), we recommend installing the panels in
recycled, i.e. the panels are fed back into the material cycle and the same direction as marked on the protective peel-off
used in the production of new material. For 3A Composites foil. Colour variations may occur between panels originating
GmbH, effective, continuous environmental protection is a from different production batches. To ensure colour consis-
main priority. It is of utmost importance to preserve natural tency, the total requirement for a project should be placed in
resources in order to ensure a livable tomorrow for future one order.
generations. It commits itself to continuous self-improvement
programmes for environmental protection, many of which go PROTECTIVE FOIL / CLEANING / MAINTENANCE
above and beyond government regulations. It is also in this We recommend removing the protective foil as soon as pos-
area that 3A Composites GmbH strives to be a leader in its sible after the installation. Due to UV radiation, it may occur
field. We were one of the first companies to develop our own that residual glue sticks to the surface of the panels. Do not
environmental management system which is regularly audited mark the protective foils and panel surfaces with ink (markers),
by independent auditors. The certification according to EN adhesive tape or labels. The solvents or softeners could damage
ISO 14001 speaks for itself. the lacquered surface. Make sure to remove the protective foil
as soon as possible after installation, as prolonged exposure
STORAGE / HANDLING to the elements could make the foil difficult to remove. The
Make sure to protect ALUCORE® panels against rain, any frequency of cleaning depends on the design and on the degree
wetness penetrating the pallets and the formation of conden- of soiling resulting therefrom.
sation. It is recommended to store a maximum of 6 pallets of
identical size stacked on top of each other. Storage exceeding WARRANTY
6 months should be avoided, otherwise it could be difficult to ALUCORE® stands for high quality and longevity. Warranties
remove the protective foils. When stacking the panels, noth- according to the product specification and approved field of
ing should be placed in between them, as this could produce application can be obtained upon request.
marks on the panels.
ALUCORE ® FOR TRANSPORT, INDUSTRY AND ARCHITECTURE
Light-weight containers, cabins for machine tools, wind Planners, architects and designers appreciate and favour
tunnels, cleanroom claddings, partitions, ship furniture, ALUCORE® because it combines mechanical properties such
lifts... ALUCORE® provides an enormous variety of industrial as the tensile strength of the cover sheets with outstanding
applications. We offer back-up service for builders and con- processing and aesthetic features. Since it is clean and easily
struction companies even in the planning phase by providing fabricated with perfect details, a great variety of applications,
samples, detailed technical information and individual testing e.g. for façade cladding and roofing, is possible with the
procedures. Our ultimate aim is total customer satisfaction use of ordinary tools. ALUCORE® is also increasingly used
through efficiency and economy. in interior design. The flat, decorative and rigid material is
ideal for innovative fastening systems for ceiling and wall
In view of the strict financial and ecological restrictions, the claddings in the interior and in the outer area.
transport industry is increasingly calling for materials which
are light, stable and fully recyclable. ALUCORE® completely Owing to the variety of possible alternative surfaces and
fulfills these requirements. The honeycomb composite panels, colours, designers have a vast range of options. Another plus
for example, are preferred in the exterior and interior of ships point is that the panels are highly suitable for lacquering. All
because composite panels for walls, doors and ceilings are standard and special colours comply with the standards of
easily processed and offer optimum strength. ALUCORE® com- the European Coil Coating Association (ECCA).
posite panels are highly suitable for use in rail and transport
vehicles such as special interior cladding, walls and ceilings,
superstructures for lorries as well as doors and flap systems.

TECHNICAL DATA
ALUCORE ® / ALUCORE ® A2 ALUCORE ® lite
Standard thickness [mm] Unit 6 10 10.5 15 20 25 6 10
Cover sheet thickness, front side [mm] 1.0 0.5
Cover sheet thickness, rear side [mm] 0.5 0.5 1.0 1.0 1.0 1.0 0.5
Weight [kg/m²] 4.7 5.0 6.3 6.7 7.0 7.3 3.4 3.6

Technical properties
Section modulus W [cm³/m] 2.5 4.5 8.63 13.1 18.1 23.1 2.5 4.5
Rigidity E∙J [kNcm²/m] 7 100 21 900 34 800 75 500 138 900 221 600 5 800 17 300
Alloy of cover sheet EN AW-5005A (AIMg1)
EN AW-5005A (AIMg1) EN AW 5005A
(accord. to EN 485-2 / EN 1396:2007) H28 / H48
H22 / H42 (AIMg1)
(H22 / H42)
Modulus of elasticity E [N/mm²] 70 000 70 000
Tensile strength of cover sheets Rm [N/mm²] ≥ 125 ≥ 185 (125) ≥ 125
0.2% Proof stress R p0,2 [N/mm²] ≥ 80 ≥ 160 (80) ≥ 80
Elongation A 50 [%] ≥5 ≥ 2 (5) ≥5
2.4 mm/m at 100º C
Linear thermal expansion α 2.4 mm/m at 100º C temperature difference
temperature difference

Core
Bare compressive strength [N/mm²] approx. 2.5 approx. 2.6
[inch] 3/8 3/8
Cell size
[mm] (9.5) (9.5)

Surface
both sides polyester platinum white
Lacquering or fluoropolymer lacquer (e.g. PVDF),
one or both sides
both sides mill finish
Brilliance (standard) [%] 25 – 40
Hardness (pencil hardness) HB-F

Acoustical properties
Sound absorption factor αs 0.05 0.05
Air-borne sound insulation index
Rw [dB] 21 21 21 22 23 25 approx. 20
(accord. to ISO 717-1, ISO 140-3)

Thermal properties
Thermal conductivity (depends on total
λ [W/mK] 0.95 1.35 1.42 1.78 2.25 2.70 0.90 1.30
panel thickness incl. cover sheets)
Thermal resistance R [m²K/W] 0.0063 0.0074 0.0074 0.0084 0.0089 0.0093 0.006 0.008
Heat transition coefficient U [W/m²K] 5.67 5.64 5.64 5.61 5.59 5.58
Temperature resistance [ºC] -40 to +80 -40 to +80
Boundless possibilities.

09/2020  ALUCORE® EN

3A Composites GmbH
Alusingenplatz 1
78224 Singen, Germany
Phone +49 7731 - 941 2254
[email protected]
www.transport-industry.com