technical manual antares 01 02-2010€¦ · m9s4 m9s6. multiwall panel for vertical glazing...

TECHNICAL MANUAL

AANNTTAARREESS PPAANNEELL

VERSION 01 EDITION 02.2010

Technical Office

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TTEECCHHNNIICCAALL MMAANNUUAALL VVSS.. 0011 EEDD.. 0022--22001100 PPAAGG.. 22

SOMMARIO

ANTARES PANEL.................................................................................................................. 5

Specification ........................................................................................................................ 5

1 SYSTEM COMPONENTS ................................................................................................ 6

1.1 ANTARES panel ........................................................................................................................ 6

1.1.1 Standard dimensions .............................................................................................................. 6

1.2 Aluminium profiles ...................................................................................................................... 7

1.2.1 Upper and side aluminium profile ........................................................................................... 7

1.2.2 Simple lower aluminium profile ............................................................................................... 7

1.2.3 Lower aluminium profile with sill ............................................................................................. 8

1.2.4 Window profile ....................................................................................................................... 8

1.2.5 High upper profile ................................................................................................................... 9

1.3 Fixing hooks ..............................................................................................................................10

1.4 Aluminium hinge ........................................................................................................................10

1.5 Gaskets.....................................................................................................................................11

1.5.1 Perimeter gasket ...................................................................................................................11

1.5.2 Opening gasket .....................................................................................................................11

1.6 Opening brachet ........................................................................................................................11

2 SPAN CAPACITY AND LOAD RESISTANCE .................................................................. 12

Pressure load tables with two supports ..................................................................................................13

2.1 Depression load tables with two supports ..................................................................................14

2.2 Pressure load tables with fixing hooks .......................................................................................15

2.3 Depression load table with fixing hooks .....................................................................................16

3 PRE-INSTALLATION ................................................................................................... 17

3.1 Packaging and distribution.........................................................................................................17

3.2 Transportation ...........................................................................................................................17

3.3 Handling and storage ................................................................................................................17

3.4 Cutting and fabrication...............................................................................................................18

4 INSTALLATION INSTRUCTIONS ................................................................................. 19

4.1 Preliminary checks ....................................................................................................................19

4.2 Fixing of aluminium profiles .......................................................................................................19

4.3 Sealing and joining the aluminium profiles .................................................................................21

4.4 Construction of corners .............................................................................................................21

4.5 Panels longer than 7 m ..............................................................................................................22

4.6 Installation of panels ..................................................................................................................23

4.7 Installation of last panel .............................................................................................................24



4.8 Installation of opening vent ........................................................................................................ 25

4.9 Rubber gasket ........................................................................................................................... 26

4.10 Installation of fixing hooks ......................................................................................................... 26

4.11 Accessories .............................................................................................................................. 26

5 ASSEMBLING OF OPENING PARTS............................................................................. 27

5.1 Window dimensions .................................................................................................................. 27

5.2 Assembly of fixed frame ............................................................................................................ 27

5.3 Assembly of opening vent ......................................................................................................... 28



For further information or suggestions please contact: EMP ESTRUSIONE MATERIALI PLASTICI S.A. Via Lische, 11/13 Z.I. 3 6855 STABIO (SVIZZERA) T el: +41.(0)91.641.72.72 Fax: +41.(0)91.641.72.95 web: www.macrolux-emp.com IMPORTANT: the information contained in this brochure is provided to assist customers in the project phase and during installation. Although all reasonable care has been taken in its compilation, the company reserves the right to amend without notice. It is the customer’s responsibility to ensure that the product is fit for its intended purpose and that actual conditions of use are suitable. The customers must, in all cases of doubt or difficulty, consult EMP SA before proceeding.



ANTARES PANEL INTRODUCTION ANTARES is a modular panel suitable for the construction of vertical and pitched translucent glazings. Consisting of a multiwall polycarbonate panel called ANTARES 40MM, aluminium profiles, rubber gaskets and fixing hooks. The panel is complemented by a range of accessories, making it versatile, easy to install and resistant to weathering. The panel can be applied to all vertical and sloped walls with a pitch of less than 45°, related to vertical.

Specification Translucent glazing made up of ANTARES system comprising:

Multiwall polycarbonate panel, coextruded UV-protection on the outer surface, 4-

wall construction, 40 mm thickness, 3,7 kg/m² in weight, U-value 1,5 W/m² K, colours clear (other colours on request); edges closed with aluminium tape; dimensions: module 500 mm wide, length (to be defined); 10 year guarantee

Perimeter anodized aluminium profiles, silver finish minimum 15 micron (or raw profiles)

External seal in EPDM rubber Aluminium fixing hooks (if required)



1 SYSTEM COMPONENTS

1.1 ANTARES panel ANTARES is a multiwall polycarbonate panel with co-extruded UV-protection on the outer surface. ANATRES panel fit together by means of interlocking male-female couplings; in this way it is possible to close easily and quickly different types of openings (sheds, continuous vertical glazing, ...) also with opening elements with the same panel and with specific aluminium profiles.

1.1.1 Standard dimensions

Dimension Value Tolerance

Weight 3,7 kg/m2 ± 7 % Thickness (s) 40 mm - 1 mm + 0.6 mm

Rib’s space (As) 25.8 mm - 0.3 mm + 0.5 mm Width (L) 528 mm ± 3.0 mm

Module width (Lm) 500 mm ± 2.0 mm

Length standard 7000 mm special lengths on request

Maximum length 13.500 mm subject to transport restrictions

Thermal insulation 1,5 W/m2 K

Colours LT (1)

Clear (8005) Opal (8121)

74% 51%

UV protection Co-extruded on the outer surface (on both sides on request)

Guarantee 10 years against hailstone, yellowing, loss of light transmission

Temperature range (continuous use) -30°C +120°C

Coefficient of thermal expansion 0.065 mm/m °C (6.5×10-5 m/m K) Fire certification Please ask to our commercial offices

(1) Light transmission

UV protected side

L

Lm

s

As



1.2 Aluminium profiles

1.2.1 Upper and side aluminium profile

The upper and side aluminium profile serves to secure ANTARES panel; a lip holds the gasket in place and a special housing accommodates a connector plate at the profile joints. This profile can be fixed with screws both in vertical than in horizontal position (see dotted lines in the figure).

TECHNICAL DATA Length 5700 mm/6500 mm Aluminium alloy 6060 (UNI EN 573-3) Area 332 mm2 Weight 0,895 kg/m Anodizing 15 µ Tolerances UNI EN 755/9

1.2.2 Simple lower aluminium profile

The simple lower aluminium profile serves to secure ANTARES panel; a lip holds the gasket in place and a special housing accommodates a connector plate at the profile joints. This profile can be fixed with screws both in vertical than in horizontal position (see dotted lines in the figure).

TECHNICAL DATA Length 5700 mm/6500 mm Aluminium alloy 6060 (UNI EN 573-3) Area 242 mm2 Weight 0,655 kg/m Anodizing 15 µ Tolerances UNI EN 755/9



1.2.3 Lower aluminium profile with sill

The lower aluminium profile serves to secure ANTARES panel; an extruded sill channels water away from the building. A lip holds the gasket in place and a special housing accommodates a connector plate at the profile joints. This profile can be fixed with screws both in vertical than in horizontal position (see dotted lines in the figure).

TECHNICAL DATA Length 6500 mm Aluminium alloy 6060 (UNI EN 573-3) Area 393 mm2 Weight 1,062 kg/m Anodizing 15 µ Tolerances UNI EN 755/9

1.2.4 Window profile This profile is used to construct the opening frame which contains the ANTARES panel and the fixed frame which is fixed to the structure. In this way it is possible to construct windows which open outwards and are hinged at the top.




1.2.5 High upper profile This profile is made up of two elements joined together and it is used, replacing profile, in order to contain the upper part of panel when they have a length included between 7 m and 15 m. Two slots hold gaskets in place and a special housing accommodates a connector plate at the profile joints.


170

54

2

2

8.6

34.1

10.9

R0.5

R3

15.3

6

25.2

2.5

R0.5

R3

167

2

5.4

2.5

10.9

24.4

11.7

5R3

M9S4

M9S6



1.3 Fixing hooks The fixing hooks (aluminium or stainless steel ones) enable the panel to be fixed to the face of a load bearing structure in situations where a panel on its own would not support the weight. The hook must be placed between the load bearing structure and the panel so that it remains hidden. A hook must be fixed to every panel, corresponding with each longitudinal support. The maximum distance between supports should be calculated based on the required load (look at load tables). The hook should be fixed with the required number of screws (Ø 5 mm) suitable for the type of sub structure (wood screws for timber, self drilling or self tapping for steel, rawl-type plugs for concrete, etc).

1.4 Aluminium hinge

The aluminium hinge is used in the construction of the opening vent. It must be attached to the fixed frame with two screws Ph-AB, 4.2 mm x 13 mm long UNI 6955 and to the opening frame with two screws Ph 5 mm x10 mm long UNI 7687. A pin joins the two parts together.

TECHNICAL DATA Length 60 mm Holes for screws 3 holes 6 mm Aluminium alloy 6005 (UNI EN 573-3) Area 371 mm2 Weight 60 g/cad Tolerances UNI EN 755/9



1.5 Gaskets

1.5.1 Perimeter gasket The EPDM rubber gasket (compatible with polycarbonate) must be positioned on the outside of the upper, side, simple lower and sill profiles, in the special lip, to ensure that the system is perfectly watertight.

1.5.2 Opening gasket The opening gasket is used to seal the fixed frame and opening frame. The slot in the opening profile is designed to accommodate the gasket.

1.6 Opening brachet The brachets enable an angle of 90º to be constructed in the sub frame and opening frame, by pre-drilling the channel in the opening profile.



2 SPAN CAPACITY AND LOAD RESISTANCE The load tables are referred to the maximum resistance of ANTARES panel (breaking point), constructed with the accessories indicated and following the instructions contained in this manual. The load data differentiates between pressure and uplift. In calculating the external load bearing on the structure, the planner must verify both the climatic conditions of the place in which the building will be constructed, as well as the general and particular characteristics of the structure into which the polycarbonate is to be inserted. Aerodynamic peculiarities, such as valleys, involve multiplication factors of the external loads (for example on the lateral edges of the structure the wind load has an amplification factor 2, in the valleys snow loadings can be expected.) For these values please refer to the relevant regulations in force in the country involved. If the value at failure is used as a project parameter, then the appropriate safety coefficient should be calculated in line with regulations in force in the country and the project criteria. The estimation of actual loads, amplification factors and safety coefficients are responsibility of the planner.



Pressure load tables with two supports Three situations are considered: Failure of system is considered, i.e. the lowest value between the collapse of the

panel, failure of the frame or the panel springing out of its housing Limit of maximum deflection at 1/100 of span between supports Limit of maximum deflection at 1/50 of span between supports

Load

(N/m2) Maximum height corresponding to breakage

500 2750 mm 750 2350 mm

1000 2100 mm 1250 1950 mm 1500 1800 mm 1750 1700 mm 2000 1650 mm 2250 1550 mm 2500 1500 mm

Load

(N/m2) Maximum height corresponding to 1/100 deflection

500 1400 mm 750 1250 mm

1000 1150 mm 1250 1050 mm 1500 1000 mm 1750 950 mm 2000 900 mm 2250 850 mm 2500 800 mm

Load


500 1700 mm 750 1550 mm

1000 1450 mm 1250 1300 mm 1500 1250 mm 1750 1200 mm 2000 1150 mm 2250 1100 mm 2500 1050 mm



2.1 Depression load tables with two supports Three situations are considered: Failure of system is considered, i.e. the lowest value between the collapse of the


Load (N/m2) Maximum height corresponding to breakage

500 2750 mm 750 2350 mm

1000 2100 mm 1250 1950 mm 1500 1800 mm 1750 1700 mm 2000 1650 mm 2250 1550 mm 2500 1500 mm

Load


500 1400 mm 750 1250 mm

1000 1150 mm 1250 1050 mm 1500 1000 mm 1750 950 mm 2000 900 mm 2250 850 mm 2500 800 mm

Load


500 1700 mm 750 1550 mm

1000 1450 mm 1250 1300 mm 1500 1250 mm 1750 1200 mm 2000 1150 mm 2250 1100 mm 2500 1050 mm



2.2 Pressure load tables with fixing hooks Three situations are considered:

Failure of system is considered, i.e. the lowest value between the collapse of the panel, failure of the frame or the panel springing out of its housing

Limit of maximum deflection at 1/100 of span between supports Limit of maximum deflection at 1/50 of span between supports

Load


500 3200 mm 750 2900 mm

1000 2650 mm 1250 2400 mm 1500 2200 mm 1750 2000 mm 2000 1800 mm 2250 1650 mm 2500 1500 mm

Load


500 1700 mm 750 1500 mm

1000 1250 mm 1250 1050 mm 1500 900 mm 1750 750 mm 2000 --- 2250 --- 2500 ---

Load


500 2250 mm 750 2000 mm

1000 1650 mm 1250 1500 mm 1500 1400 mm 1750 1250 mm 2000 1150 mm 2250 1100 mm 2500 1000 mm



2.3 Depression load table with fixing hooks Three situations are considered: Failure of system is considered, i.e. the lowest value between the collapse of the


Load


500 2000 mm 750 1500 mm

1000 1100 mm 1250 800 mm 1500 --- 1750 --- 2000 ---

Load


500 1500 mm 750 1000 mm

1000 --- 1250 --- 1500 --- 1750 --- 2000 --- 2250 --- 2500 ---



3 PRE-INSTALLATION

3.1 Packaging and distribution Standard panels are supplied on pallets and covered securely with heavy-duty polythene film. In standard packaging there are nr. 50 panels of ANTARES panel. Non standard, specially produced panels will be placed on pallets at EMP’ s discretion. For special requirements (personalized packs and packaging necessary for unloading and handling in the warehouse) please discuss with our sales staff at the time of order.

3.2 Transportation The transportation of panels must be carried out on suitable vehicles so that panels and pallets can be placed completely flat, with straps and blocks being used to prevent movement and possibility of damage.

3.3 Handling and storage The handling and storage of panels is a delicate procedure in which damage can occur. It is therefore essential that the following instructions are carefully followed:

Extreme care must be taken when using fork lift trucks. Under no circumstances

must the forks lift the panels directly. Wooden pallets or other supports must be placed in between.

The distance of the forks must be such as to correctly distribute the loads. No more than three pallets should be stacked on top of each other. Always place

spacers or wooden strips between them to avoid possibility of damage to the contact surface (polystyrene, insulation).

Store panel at a slight angle to allow eventual condensation and water to escape. Store packs inside. Where this is not possible, protect with tarpaulin which ensures

correct ventilation and protection from sun. WHEN EXPOSED TO HIGH TEMPERATURES (PALLETS LEFT IN HOT SUN) THE

PROTECTIVE FILM ON THE SURFACE OF THE PANEL TENDS TO BECOME STICKY AND DIFFICULT TO REMOVE.



3.4 Cutting and fabrication

Referred to the total height (L), the height of ANTARES panel (H) must be: H = L – 35 mm This allow installation and leave space for thermal expansion. The panel can be cut with standard cutting equipment such as vertical and horizontal reciprocating-type saws. The cutting swarf can easily be removed with compressed air.

The transparent tape on standard sheets serves to keep the internal flutes clean from the dust normally present in warehouses and factories. This should be removed when cutting the panel and replaced if material is returned to stock. Before installing the panels, the ends should be closed with adhesive aluminium tape (full, breather or micro porous) to keep the flutes clean. The panel is subsequently inserted into the appropriate closure to prevent the tape from being washed away by the elements.

H =

L -

40

mm

L

H =

L -

35

mm

L



4 INSTALLATION INSTRUCTIONS

4.1 Preliminary checks

Check that the panels are stored correctly, in accordance with the instructions Check that the tolerances of panels and accessories are as specified Check that the product has no obvious defects. If necessary, inform EMP SA

before starting installation Make all necessary arrangements to ensure that safe working procedures are

adopted in line with regulations in force Ensure that the sub structure and kerbs which will support the aluminium

profiles is level and that relevant distances are correct. Clean levels and surfaces if necessary. This ensures the correct installation of the glazing panels.

4.2 Fixing of aluminium profiles The lower aluminium profiles with and without a sill, must be drilled with holes at the bottom to facilitate the egress of condensation or water which could penetrate. The distance between the centres should be about 330 mm. Elongated holes are better than circular ones, which tend to form a bubble.

In case of inclined solutions (with screws fixed in horizontal position), the hole must be drilled on the lower face, it means on the inclined base N.B.: the aluminium profile serves solely to secure the panels and has no structural function. The fixings must not be more than 500 mm apart.



Perimeter profiles are designed to be fixed both with horizontal than vertical screws. FIG. 1 1 - INSULATING GASKET 2 - BEARING STRUCTURE 3 - FIXING SCREW (MAXIMUM DISTANCE 500 MM) 4A - PROFILE 4B - PROFILE

The fixing method must be appropriate for the type of supporting structure and compatible with the aluminium of the containing profile. Self drilling screws for steel (check the thickness of the support and the maximum depth that can be drilled). Wood screws for timber. In this case the aluminium profile must be pre-drilled Rawl-type plugs for concrete (ensure that fixings do not impede on any reinforcement bars in concrete)

FIG. 1



4.3 Sealing and joining the aluminium profiles To improve air and water tightness and to compensate for small irregularities in the surface, insulating gaskets can be placed between the profile and the sub structure. Additionally, the inside of the lower and side profiles should be siliconed at the bottom, and the outside of the upper profile, between the profile and sub structure.

The profiles are joined by inserting a rectangular-shaped aluminium connector plate (20 mm x 2 mm) 200 mm long between the two profile ends to maintain alignment. Another aluminium connector plate is placed over the bottom of the joint and sealed with silicone. If the aluminium profiles are in contact with other metals, ensure that there are no formations which could contaminate them and cause them to corrode. If there are, take care to isolate the two metals adequately.

FIG. 2 1 - ALUMINIUM CONNECTOR PLATE 2 - SILICONE 3 - ALUMINIUM CONNECTOR PLATE 20X2 MM 4 - PROFILE

4.4 Construction of corners The corners are constructed by cutting the lips of the side profile so that they intersect the lower profile (with or without sill) and the upper profile. The inside of the corner joints must be sealed carefully with a bead of silicone to prevent infiltration of water. FIG. 3 1 - TO BE CUTTED 23X63 MM 2 - TO BE CUTTED 60X83 MM 3 - TO BE CUTTED 7X7 MM 4 - PROFILE 5 - PROFILE 6 - TO BE CUTTED 53X63 MM 7 - TO BE CUTTED 83X83 MM 8 - TO BE CUTTED 8X8 MM

FIG. 2

FIG. 3



4.5 Panels longer than 7 m In order to install panels longer than 7000 mm, the standard upper profile will be replaced by the special high upper profile that assure the right restraint of panels also with high thermal expansion. In this case the space required for thermal expansion of panels will be calculated related to their right lenght.

FIG. 4 1 - PROFILE 2 - PROFILE 3 –ANTARES PANEL 4 - BEARING STRUCTURE

FIG. 5 1 - PROFILE 2 - PROFILE 3 – ANTARES PANEL 4 - BEARING STRUCTURE 5 - FIXING SCREWS

FIG. 4

FIG. 5



4.6 Installation of panels

During installation of the panels, ensure that the UV-protected side is placed to the outside. It is identifiable by a coloured film bearing the product specification and an identification code hot stamped on the edge of the sheet . Insert the taped panel into the upper profile, alongside the previously installed panel, so that it touches the internal base of the upper profile.

Lower the panel to vertical position and slot into base. Lock the two panels together, starting from the top and working down the length of the panel. Best results can be achieved by inserting the male side into the aluminium profile so that eventually a rubber hammer can be used to help fit them together. Do not hit directly with the hammer but place a buffer in between to distribute the blow.

Do not use a lubricant unless it is guaranteed by the manufacturer to be polycarbonate compatible



4.7 Installation of last panel For the installation of the remaining panels, proceed as indicated until the space left is less than:

X < 500 mm

Cut the final panel to a width 30 mm less than the width indicated in the diagram:

X - 30 mm

Lift the penultimate panel A out momentarily and insert the cut panel B, pushing it right into the end of the closure.

Re-insert panel A and lock the two panels together into their final position.



4.8 Installation of opening vent Should openings be required at intervals between the fixed glazing, they should be inserted in the following manner.

In the desired position (1) (check that the opening of the vent and the opening mechanism do not interfere with the existing components) insert the fixed frame as you would install ANTARES panel (2), checking the level and alignment and adjusting as necessary. Fix the window securely to the aluminium profiles or supporting structures. Under no circumstances must the window be fixed to the polycarbonate panel alone. Continue to install other fixed ANTARES panel(3) until reaching the next opening or until completion of glazing.

Place the opening vent next to the fixed frame, fix the hinge housings (1) and insert the pivot (2) as shown. Follow the manufacturer’s instructions to position and fix the opening mechanisms. If this operation is not being carried out immediately, secure the vent with a temporary fixing which can be removed later on.

(1) (2)



4.9 Rubber gasket To ensure water tightness a rubber gasket must be placed on the external surface in the appropriate housing.

4.10 Installation of fixing hooks If necessary, whether due to the height or the weight of the panels, position additional supports in between. The panels must be secured with special steel fixing hooks. Once the panels have been correctly slotted together, position the fixing hook at the edge of the panel in its own housing. Fix the hook using screws appropriate for the type of sub structure. Four screws are required for each fixing hook.

PAY ATTENTION: using a lower number of screws, the load resistance of the system could be compromised

Fixing hooks must be placed on each panel, corresponding with all the purlins/side rails. The distance between the purlins/side rails must be checked in relation to the anticipated load – both in pression and uplift. The distance should be the minimum anticipated in the two situations.

4.11 Accessories Dependant upon the specific situation, check if upper or lower connecting flashings are required under the glazing. To seal correctly and ensure water-tightness between the aluminium profiles and existing structures, it is advised that a row of silicone be used.



5 ASSEMBLING OF OPENING PARTS

5.1 Window dimensions

Opening vents, which integrate perfectly with the existing fixture, can be constructed for ventilation. They have a double gasket and a vent which opens outwards (hinged at the top). The windows should not have more than 2-3 sqm of opening surface. For larger windows please contact our Technical Department.

Additional items required for the assembly of

the windows As well as the aluminium profile and the panels, which should always be taped at the ends, for each opening element the following items are necessary: N° 8 corner joining plates N° 2 or more aluminium hinges depending from

opening vent’s width opening gasket to fit opening profiles

5.2 Assembly of fixed frame To make the fixed frame two pairs of opening profiles must be mitre cut at 45° so that the slot containing the gasket is on the inside.

Size of cut on outside of fixed frame

Height of fixed frame (H): H = V – 35 mm Where: V = free space

Width of frame (L):

PAY ATTENTION: all lengths are in mm

PRODUCT N° 1 panel

N° 2 panels

N° 3 panels

N° 4 panels

N° 5 panels

ANTARES 40MM 730 1230 1730 2230 ---

H

L



5.3 Assembly of opening vent To construct the opening vent, mitre cut two pairs of opening profiles at a 45° angle so that the slot, containing the gasket, is on the outside.

Size of external cut on opening vent

Heigth (HA) / Width (La) opening vent:

Ha = H – 105 mm La = L – 105 mm

Where: H = height of fixed frame L = lenght of fixed frame

Height of panels (Hp) for opening frame:

Hp = H – 200 mm Where: H = height of fixed frame

Insert the gasket into all the profiles (both for fixed and opening frame). Prepare the holes for fixing the angle cleat as shown in the following diagram. (drawing referred to brachet). Construct the vent by inserting the polycarbonate panels and fixing the angle cleats in the profile channel.

Fix the two hinges to the upper part of the assembled vent, taking care to position them at the same distance from the edges so that the opening is straight. If the vent is wider than 2 metres it is advisable to fix a third hinge in the middle. The vent should be attached to the fixed frame in the workshop, once the fixed frame has been assembled, using the pin and the instructions provided with the hinge.

La

Ha

technical manual antares 01 02-2010€¦ · m9s4 m9s6. multiwall panel for vertical glazing...

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