LIDL Faade System
Regeldetails und Konstruktionsmerkmale
LIDL Faade System
Overview 3A Composites
LIDL Faade System
3A Composites Worldwide Presence 22 sites in 8 countries
EcuadorGuayaquilQuevedoSanto DomingoManta
BrasilSao Paulo
Singapore
Shanghai
SinsSingen (GER) Osnabrck (GER) Chelmsford (UK)
Glasgow (KY) Northvale (NJ)
Benton (KY) Statesville (NC)
St Louis
Product Market Unit (PMU) LocationsArchitectureDisplayCore MaterialsTransport & Industry
Mumbai
Core Materials
Display & Graphic Arts
Transport & Industry
Architecture
LIDL Faade System
Singen Site founded 1912 1800 employees Production:
> 200.000 t Rolled products > 40.000 t Extrusion > 15.000 t Components > 4.000 t Forged products
Constellium Singen GmbH
Amcor GmbH Foils and laminates > 1100 employees
3A Composites GmbH Composite panels > 300 employees
LIDL Faade System
ACSI Products
LIDL Faade System
Developed and established in 1968 by Alusuisse and BASF Production of ALUCOBOND since 1969 in Singen/Germany 1978 First subsidiary overseas (Benton, Kentucky/USA) 1979 Start-up of the first fire rated ALUCOBOND (SB1, 21) 1989 Production start of non-combustible ALUCOBOND A2 1994 Beginning of first continuous production of the
aluminium honeycomb panel ALUCORE 1995 Start of the first ACM recycling centre in Germany 1997 Start-up of production line in Shanghai 1999 Production start of fire rated ALUCOBOND Plus 2002 Start-up of production line in Brasil 2005 4. production line in Singen (width up to 2005 mm) 2007 First subsidiary in India
ALUCOBOND Success Story: From Pioneer to Synonym
LIDL Faade System
Aluminium-Composite Panels
LIDL Faade System
4% AluminiumTightness21% PolyethyleneTensile Resistance75% CelluloseStiffness
Composition of a beverage carton
Composite = Optimized Set of Properties
Composites
LIDL Faade System
Sandwich Technology
(1) Flange(2) Web
= Funktionality
Composites
LIDL Faade System
11.7 kg
18.7 kg
8.9 kg
5,5 kg ALUCOBOND 4 mm
Aluminium 3,3 mm
Steel 2.4 mm
Fibre cement 5.8 mm
Weight kg/m2 Stiffness E*J
Composites
LIDL Faade System
Fluorocarbon Lacquer System(e. g. PVDF)
Composition:0.5 mm AluminumPlastic or mineralcore material 0.5 mm Aluminum
Formats:Thickness 4 mm (3, 6 mm)Width 1575 mm
1000, 1250, 1500,max. 1750 mm (2050 mm)
Length 2000 - 8000 mm
Composite Materials
LIDL Faade System
ALUCOBONDNormally flammableEN 13501-1 D, s1, d2
ALUCOBOND PlusFlame resistantEN 13501-1 B, s1, d0
ALUCOBOND A2Non combustibleEN 13501-1 A2, s1, d0
Composite Materials
LIDL Faade System
Processing of Composite Panels
LIDL Faade System
Sawing Cutting Routing
Rout & Fold Pressing Rolling
CNC routing Drilling Perforation
ALUCOBOND Fabrication
LIDL Faade System
Verarbeitung - Sgen
Vertical panel saw
Hand saw
Jigg saw
Processing Cutting to size
LIDL Faade System
LEUCO Topline-Kreissgeblatt TFFa
Jigg saw blade for plastic
TC tipped circular saw blades, teeth: trapezoid/flat for ALUCOBOND Plus und ALUCOBOND A2
Tungsten carbide quality grade K01
Processing Cutting to size
LIDL Faade System
Cutter angle10positive
Cutter angle5negative
ALUCOBOND, DIBOND, ALUCORE Solid aluminium
Processing Cutting to size
LIDL Faade System
Examples
Processing Rout & Return
LIDL Faade System
distanceroller
Milling disk
Processing Rout & Return
LIDL Faade System
To fold / bend a long edge on an ALUCOBOND panel, which have been routed, it is recommended to use a folding tool.
ALUCOBOND
6,2
4,2
Platten-streifen
Folding Tool
LIDL Faade System
gaug
e
8 mm
Clearance for adhesive
2 mm
end thickness10 mm
Double return of ALUCOBOND 4 mm
Processing Rout & Return
LIDL Faade System
Determination of periphery and size of cuttingThe measures of periphery and routing are determined out of the drawing measurements (final measures). For each folding 1mm must be subtracted from the final measure.The size of cutting results from the sum of the routing measures.In any case the final measures should be tested before starting a production run. Afterwards the limit stops of the circular saw should be kept fix to obtain identical elements with the same sizes.
LIDL Faade System
indexable inserts (TC)ALUCOBOND Plus und A2
Disc Milling Cutters for Vertical Panel Saws
Milling Form-Cutters with Cylindrical Shank
Processing Rout & Return
LIDL Faade System
SawingRouting
Processing Rout & Return
LIDL Faade System
Panel saw with routerHand panel miller
Hand Routing Machine
CNC-centre
Processing Rout & Return
LIDL Faade System
Two-parts facia-corner
Processing Rout & Return
LIDL Faade System
Developed view
Processing Rout & Return
LIDL Faade System
Processing on panel saw
Processing Rout & Return
LIDL Faade System
Cutting on guillotine
www.edel-stanztec.de www.knuth.de
Processing Punching
LIDL Faade System
Serial punching machine MP 6000for ALUCOBOND cassettes
www.liechtblick.ch
Processing Punching
LIDL Faade System
Processing Punching
Developed view on ALUCOBOND cassette
LIDL Faade System
pilot point drill bit normal drill bit
EXTREME 2TM HSS-G metal drill bit DIN 338
Processing Drilling
LIDL Faade System
Single Flute Cutters for Cut to Size and Contour Cutting of ALUCOBOND on CNC- centers
www.gis-tec.dewww.bewe-online.com
Processing Drilling
LIDL Faade System
Outwards: parallel feedInwards: counter rotation
Outwards: counter rotationInwards: parallel feed
Inwards cut
Outwards cut
Single Flute Cutterspin to right
FeedFeed
Feed 5 m/min.Rotation speed 24.000 U/min.
SerieF 113
ALUCOBOND
ALUCOBOND plus
ALUCOBOND A2
Processing Drilling
www.gis-tec.de
LIDL Faade System
CD-ROM:Supplier list for Machines Tools Accessories Profile sections
LIDL Faade System
Aluminium Constructionsin Faades
LIDL Faade System
Guidelines for ventilated CladdingsDIN 18516www.fvhf.dewww.sfhf.chwww.oefhf.at
LIDL Faade System
De-aeration min. 50 cmper meter,i. e. min. 5 mm gap
Ventilated cladding
LIDL Faade System
Min. venting 20 mm
Local reduction by sub-structure to 5 mm
Continuous ventilation from bottom to top
Sliding console
Fix console
De-aeration min. 50 cmper meter,i. e. min. 5 mm gap
Ventilated cladding
LIDL Faade System
Thermal movement
LIDL Faade System
Surface temperatures of facades
-30
-20
-10
0
10
20
30
40
50
60
70
80
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24time of day [h]
T
e
m
p
e
r
a
t
u
r
e
[
C
]
Surface temperature
Surface temperature
Air temperature
Air temperature
SUMMER
WINTER
max. 75C
LIDL Faade System
Thermal Expansion of ALUCOBOND Panels_________________________________________________________________________________
The linear thermal expansion factor is to be taken in consideration: 2,4 mm/(m length 100 K)i.e. 2,4 mm expansion/contraction on every meter length/width at 100 degrees temperature differenceExample: supposed temperature at erection 20C
temperature difference t = 50K expected heat up of the panel max. 70C panel length 3 m
Calculation 1: 2,4mm 3(m) 0,5(t =50K) = 3,6 mm expansion of paneli.e.: on each of the opposite edges 1,8 mm movement must be allowed, if substructure isrestrained as e.g. mounting on wooden structure or substructure vertical to the panel expansionIf the aluminium substructure is parallel to panel expansion the temperature difference can bereduced to t = 10K in general (according DIBt-Approval Z-33.2-6), if the panel lays directly onthe substructure (e.g. ECOCLAD-system)
Calculation 2: 2,4mm 3(m) 0,1( t =10K) = 0,72 mm expansion of panel
Note: For ALUCOBOND on steel substructures 50% of the thermal movement must be allowed,since steel has a linear thermal expansion factor of 1,2 mm/(m 100 K), i.e. 50% of aluminium.
LIDL Faade System
Drill hole in panel
Drill hole in sub-structure
Drilling holes
Thermal Expansion of Aluminium
LIDL Faade System
Drilling device for centrically drilling
Thermal Expansion of Aluminium
LIDL Faade System
distance0,3 mm
Thermal Expansion of Aluminium
Riveting
Riveting device
LIDL Faade System
Thermal Expansion of Aluminium
Screws
LIDL Faade System
Fastener made of aluminium and/or stainless steelNo counter sank screwsfor exterior application!
Thermal Expansion of Aluminium
LIDL Faade System
Wind loads
LIDL Faade System
Wind loads
Eurocode 1, Part 2-1Wind actionsBS prEN 1991-2-1Chapt. 7.2.9 Internal pressure
LIDL Faade System
Wind loads
Ventilated rain screens:Cp, res = 0,5 Area of joints Cladding areaVertical barrier at the corner
0,75%
LIDL Faade System
Lidl Cladding Constructions
LIDL Faade System
SZ20 Facade System
Tongue-/groove Panels(Horizontal layout)
LIDL Faade System
15-20
44024
44025
S
Z
Basis
44026
LIDL Faade SystemKassettenprofile SZ 20
44024
44025
Hut-Profil35953
44026
LIDL Faade SystemReference details: Fixing on insulated concrete parts
5 mm Aluminium rivetwith stainless steel mandrelHead 11 mmRAL9006 coated
500
Approved manufacturerz. B.: Ejot, MBE, SFS, Wrth
2
0
Profile RAL 9006Powdercoated
Slot hole
LIDL Faade System
Reference details: Fixing on insulated concrete parts
Joint sealant
LIDL Faade System
Reference details: Fixing on insulated concrete parts
Joint sealant
LIDL Faade System
Reference details: Fixing on insulated concrete parts
Mineral Insulation(non combustible, A2, s1, d0)
Reinforcement, if required
LIDL Faade SystemCustomized solution: Fixing on brick wall
Slot hole3mm flange
LIDL Faade System
Protection foil
Panel reverse side
Reference details: Panel Layout
LIDL Faade System
Reference details: Typical grid of substructure
Permissible loads for anchors may requires more substructureWind load
Wind load
LIDL Faade System
Reference details: Typical fixing of substructure
sliding console(s)for wind load only(with slot holes)
1x fix console for wind load and dead load(e. g. in concrete or steel bar)
LIDL Faade System
Reference details: Typical fixing of substructure
f
i
x
s
l
i
d
i
n
g
LIDL Faade System
Tray panels with horizontal layout
SZ20 3000x1000x4
Load: -1,5 kN/m
LIDL Faade System
Technical Services
LIDL Faade System
thread freezone
Approved manufactures:z. B. Ejot, SFS
Reference details: Typical fastener to substructure
LIDL Faade System
perforated sheet or 5 mm slot
Reference details: bottom of faade
LIDL Faade System
Circular frame
Reference details: bargeboard
LIDL Faade System
20Circular frame
20
Reference details: ridge / eaves
LIDL Faade System
A A
Section B-B
Section A-A1-part corner
Reference details: facia corner
LIDL Faade SystemReference details: Renovation of Plus stores
LIDL Faade SystemReference details: Renovation of Plus stores
LIDL Faade SystemReference details: Renovation of Plus stores
LIDL Faade SystemReference details: Renovation of Plus stores
Counter plates
LIDL Faade SystemBad examples: Renovation of Plus stores
LIDL askes for a complete structural calculation (for all components)They send assessors for final acceptance of construction work
LIDL Faade SystemBad examples: Renovation of Plus stores
www.spaeter.de
LIDL Faade SystemBad examples: Renovation of Plus stores
LIDL Faade SystemBad examples: Renovation of Plus stores
LIDL Faade SystemBad examples: Renovation of Plus stores
LIDL Faade SystemBad examples: Renovation of Plus stores
LIDL Faade SystemBad examples: Renovation of Plus stores
LIDL Faade SystemBad examples: Renovation of Plus stores
?
LIDL Faade SystemBad examples: Renovation of Plus stores
?
LIDL Faade SystemBad examples: Renovation of Plus stores
LIDL Faade SystemBad examples: Renovation of Plus stores
f
i
x
LIDL Faade SystemBad examples: Renovation of Plus stores
LIDL Faade SystemBad examples: Renovation of Plus stores
Different level of fix consoles
LIDL Faade SystemBad examples: Renovation of Plus stores
Dist
ance
!?
LIDL Faade SystemBad examples: Renovation of Plus stores
lousy fabrication
LIDL Faade SystemBad examples: Renovation of Plus stores
Irregular distance of rivets < 500
LIDL Faade SystemBad examples: Renovation of Plus stores
Slot hole?!
LIDL Faade SystemBad examples: Renovation of Plus stores
LIDL Faade SystemBad examples: Renovation of Plus stores
LIDL Faade SystemBad examples: Renovation of Plus stores
LIDL Faade SystemBad examples: Renovation of Plus stores
LIDL Faade SystemBad examples: Renovation of Plus stores
LIDL Faade SystemBad examples: Renovation of Plus stores
LIDL Faade SystemBad examples: Renovation of Plus stores
LIDL Faade SystemBad examples: Renovation of Plus stores
LIDL Faade SystemBad examples: Renovation of Plus stores
LIDL Faade SystemBad examples: Renovation of Plus stores
LIDL Faade SystemBad examples: Renovation of Plus stores
LIDL Faade SystemBad examples: Renovation of Plus stores
LIDL Faade SystemBad examples: Renovation of Plus stores
LIDL Faade SystemBad examples: Renovation of Plus stores
LIDL Faade SystemBad examples: Renovation of Plus stores
LIDL Faade System
Questions?!
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