Die Oberfläche.
Transcription
Die Oberfläche.
Die Oberfläche. Resopal GmbH Hans-Böckler-Strasse 4 D-64823 Gross-Umstadt Tel.: +49 (0)6078 80 0 Email: info@resopal.de www.resopal.de TEC; 05/2015, fv, GB ➔ PROCESSING APPROPRIATE TO THE MATERIAL PERSPEKTIVEN RESOPAL® >2018 ➔ PROCESSING APPROPRIATE TO THE MATERIAL Die Oberfläche. Die Oberfläche. Resopal GmbH Hans-Böckler-Strasse 4 D-64823 Gross-Umstadt Tel.: +49 (0)6078 80 0 Email: info@resopal.de www.resopal.de TEC; 05/2015, fv, GB ➔ PROCESSING APPROPRIATE TO THE MATERIAL PERSPEKTIVEN RESOPAL® >2018 ➔ PROCESSING APPROPRIATE TO THE MATERIAL Die Oberfläche. Warranty This brochure has been prepared and checked to the best of our knowledge and belief. Nevertheless, we cannot accept any liability for the correct nature of its contents. Liability of the publisher Resopal GmbH and the brochure's editors is excluded in all cases of personal injury, property damage and purely financial loss resulting from use of the brochure. Image rights Illustrations are reproduced courtesy of the respective owners of the rights. If these cannot be identified, any claims arising will be settled within the framework of customary agreements. Subject to errors, changes and improvements! Contact List of suppliers Test reports and certificates RESOPAL® X-LINE RESOPLAN® The current collections, test reports, certificates, our list of suppliers and addresses to contact for the respective countries can be found on the Internet at: www.resopal.de or: 64 | 65 RESOPLAN® Contents RESOPLAN® – THE MATERIAL AND THE TECHNICAL SOLUTION Hospital building, Essen-Mitte, D-Essen; HDR TMK Planungsgesellschaft mbH, D-Düsseldorf; Photo: Udo Geisler Fotografie, D-Essen Residential building with three apartments, D-Sprockhövel; Architects BDA RDS PARTNER; Photo: Arne Thorben Damm PAGE 02 01. PRODUCT DESCRIPTION 04 02. VENTILATED CURTAIN WALL FACADES 06 03. STANDARDS AND GUIDELINES 08 04. HANDLING/CARE 09 05. GENERAL PROCESSING INSTRUCTIONS 10 06. GENERAL INSTALLATION INSTRUCTIONS AND GUIDELINES 11 07. VISIBLE ATTACHMENT with screws on a wooden substructure 15 08. VISIBLE ATTACHMENT with rivets on an aluminium substructure 20 09. CONCEALED ATTACHMENT with adhesives 26 10. CONCEALED ATTACHMENT with staple and anchor 32 11. WEATHER BOARDING with concealed screws 37 12. JOINTS AND CONNECTIONS BETWEEN PANELS 40 13. INDIVIDUAL APPLICATIONS 44 14. COMPOUND ELEMENTS 46 15. BALCONIES 46 16. RAILINGS 50 17. SCREENS 56 18. MOTIV IN RESOPLAN® 60 19. FIRE PROTECTION 62 20. TECHNICAL DATA/PRODUCT DATA 64 Club house, hockey club De Pelikaan, Schaap en Sturm Architects, NL-Roosendaal; Photo: Marcel Kentin, www.kentin.net/ 01 RESOPLAN® – THE MATERIAL AND THE TECHNICAL SOLUTION Ideas for facades, balconies and details Police training centre, D-Riesa-Poppitz; Photo: grit-doerre.de Facades are an important part of the world we live in. They give buildings a face. Their design can convey messages, blend with the environment or set highlights. Whichever - they have a decisive effect on the way in which we perceive the world around us and hence on our well-being. Whether for enhancing existing buildings or new buildings, highlighted, communicative or blending perfectly with the surroundings, individual or classically stylish, for complete facade designs or for focusing on details: the architectural requirements are multifarious - and Resopal can supply the materials needed to realize all creative requirements. RESOPLAN® and RESOPAL® X-LINE are the RESOPAL® products for outdoor use. Our job is to develop and manufacture products with which to design both interiors and exterieurs , enhance the quality of life in every respect and create materials that set and personalize the stage, convey a sense of well-being, value, character and enjoyment of life, while at the same time being almost unbeatable as regards processing, functionality and durability. Our attention focuses not only on the quality of life resulting from the use of our products, but also on our staff - both in general and during the work - and our contribution to protecting the environment through the durability of our materials, with environmentally friendly produc tion and disposal. That is why we developed our corporate philosophy Project M. For us, our central tenet since 2002 has been: "We take responsibility for our employees, their families and the future of the children." Project M entrusts each individual with responsibility to actively think ahead and become motivated in the common commitment to Resopal and the world in which we live. Identification with the company strengthens their commitment, increases our commercial success and secures our continued existence, today and in the future Project M places people at the centre point of all activities and defines our responsibility to the environment. Our concept with short, medium and long-term goals which continuously improves our commitment to the environment is a central element in Project M. It puts us in a position to consistently follow our chosen path of making a considerable contribution to the future protection of our environment. In this way, we establish the foundation for creating livable habitats for the future. RESOPAL® – the product ➔ is environment-friendly during production, use and in final disposal. ➔ consists of 65% paper and 35% water-based resins. The core paper is FSC- and/or PEFC-certified. An acrylic-based outer layer is used for the weather-resistant versions. ➔ effortlessly copes with the most demanding requirements and is extremely durable. The long useful life means that the wood has had ample time to regrow by the end of the product's useful life. ➔ is easily cleaned with minimum use of cleaning agents. ➔ is thermally recycled at the end of its useful life, thus helping to recover energy. RESOPLAN® for facades ➔ Building material classes B1/B2 as per DIN 4102 ➔ European class B-s2, d0/D-s2, d0 as per EN 13501 ➔ Approvals DIBt/KOMO/CSTB RESOPLAN® – the multifunctional board materials from Resopal with four decisive advantages: ➔ light ➔ weatherproof ➔ UV-resistant ➔ impact-proof RESOPLAN® boards have a very low weight per unit area. They are self-supporting and easily fitted, with visible or concealed attachment. The weatherproof laminate is resistant to corrosion and waterproof. RESOPLAN® boards for outdoor use are also lightfast. Resistant to UV light and colourfast on both sides, the colours do not fade even after decades. RESOPLAN® protects the building substance. Robust and dimensionally stable, the high-grade laminate can even withstand major impacts. RESOPLAN® X-LINE – for balcony and loggia claddings Balcony claddings are a particularly challenging aspect of facade design, as they must not only ensure protection against prying eyes, but also comply with the highest safety standards. The sophisticated facade panels and balcony claddings in top HPL quality leave nothing to be desired as regards their product properties, use and processing. ➔ Protection against falling in accordance with ETB guidelines St. Elisabeth nursery school, D-Neumarkt; Photo: Architectural office Joachim Breuer 02 | 03 01. PRODUCT DESCRIPTION RESOPLAN® – the multifunctional board material for outdoor use with long-term protection against weathering School, NL-Bergen; ZEEP Architects, NL-Amersfoort; Photo: Mark van den Boorn Photo: Fuenf6 GmbH, D-Nümbrecht RESOPLAN® offers made-to-measure solutions for a whole variety of architectural requirements. Different weatherproof RESOPLAN® versions are available for individual, coloured, patterned, integrative or eye-catching, matt or special-effect facade and building elements. ➔ The RESOPLAN® collection, comprises 40 "Plain Colours", ten "Woodgrains", eight "Materials" and two "Stones". ➔ RESOPLAN® Motif, gives facades an individual face with digital prints or screen prints. ➔ RESOPLAN® Effect, gives buildings lively facets due to the matt glossy surface texture of the design P010622 Ebony depending on the angle of light on the facade. RESOPLAN® is: ➔ weatherproof ➔ durable ➔ lightfast (as per EN 438-6) ➔ waterproof ➔ self-supporting ➔ robust and impact-resistant ➔ can be machined on wood-working machines ➔ rigid, due to the high modulus of elasticity ➔ easily installed ➔ low weight per unit area ➔ resistant to frost and hailstones ➔ non-droning ➔ non-rotting ➔ resistant to acid rain ➔ non-corrosive ➔ also available with barely flammable finish (European class B-s2, d0) Enduring protection for the building substance RESOPLAN® is used wherever the protective weatherproof cladding must also meet high standards as regards design. Their considerable mechanical strength makes them a durable high-quality product capable of withstanding mechanical stresses, such as knocks and bumps. Even in extreme climate conditions, RESOPLAN® remains dimensionally stable and weatherproof. Potential uses: ➔ Cladding for exterior walls ➔ Balcony claddings and screens ➔ Stairways, door and gate panels; surrounds on flat roofs, fascias ➔ Roof gutter and soffit shuttering ➔ Gable-end boards ➔ Dormer claddings ➔ Shuttering for supports ➔ Soundproofing panels ➔ Advertising media ➔ Doors 01. PRODUCT DESCRIPTION RESOPLAN® – the multifunctional board material for outdoor use with long-term protection against weathering Material description and composition RESOPLAN® belongs to the group of compact laminates for outdoor use as defined by DIN EN 438 Part 6 (Classification and specification of compact laminates for outdoor use), i.e. where they are exposed to the effects of sunlight, rain and frost. Protection against light and weather is assured by a suitable outer layer (coating) applied to both sides of the exterior. RESOPLAN® boards more than 5 mm thick display exceptional dimensional stability and are therefore self-supporting. The material owes its high rigidity to the high modulus of elasticity. RESOPLAN® is available in either building material classes B2 and B1 as per DIN 4102-1 or in European classes D and B as per EN 13501-1. Resistance of RESOPLAN® to airborne chemical stresses Air and rain contain natural and manmade additives, such as: • Carbon dioxide CO2: households, industry, motor vehicles • Sulphur dioxide SO2: households, industry • Nitrous gases e.g. NO2: industry • Hydrogen chloride HCl: industry, waste incineration RESOPLAN® therefore affords protection against the weather and is largely resistant to acid rain. This has been demonstrated in a 16-hour test with 10% hydrochloric acid which did not produce any visible changes in the RESOPLAN® material. Structure of RESOPLAN® A B C Protection against weathering Decor Dark solid core Environmental aspects ➔ RESOPLAN® effortlessly meets the highest demands; its longevity is the best and most efficient protection for the environment. ➔ RESOPLAN® produces few emissions and does not contain any VOCs. ➔ RESOPLAN® is environment-friendly during production, use and in final disposal. ➔ The environment and energy management system in accordance with ISO 14001/ISO 50001 ensures that: • environment aspects are taken into account even as the product is being developed • the energy required for the production process is minimized • water is used efficiently • waste is avoided and/or recycled • emissions are eliminated without harming the environment. ➔ RESOPLAN® contains roughly 65% paper (cellulose), which is made from wood, a regrowing raw material. In addition, it contains eco-friendly colour pigments and thermoset resins. ➔ RESOPLAN® is sustainable. The core paper is recycled, FSC- and/or PEFC-certified - not made from tropical wood! ➔ RESOPLAN® is not a hazardous substance within the meaning of the regulation on hazardous substances. ➔ It is not subject to any special requirements restricting machining. ➔ Even with barely flammable finish, RESOPLAN® does not contain any harmful halogens. ➔ RESOPLAN® is resistant to pests and mould. ➔ RESOPLAN® is easily cleaned with minimum use of cleaning agents. ➔ It is thermally recycled at the end of its useful life, thus helping to recover energy. Disposal ➔ RESOPLAN® is not dangerous; it is therefore not classified as special waste. ➔ RESOPLAN® waste is not subject to monitoring within the meaning of the German law on recycling materials for use as secondary raw materials (KrWG). ➔ RESOPLAN® is thermally recycled at the end of its useful life, thus helping to recover energy. ➔ Due to the high energy content (18-20 MJ/kg), waste from cutting must be thermally recycled in accordance with the law and may be incinerated in suitable systems, particularly as this does not lead to the production of harmful combustion products. According to §8 of the KrWG regulation, recycling as a secondary source of energy is equivalent to recycling as a secondary raw material if the waste has a calorific value of at least 11 MJ/kg. 04 | 05 02. VENTILATED CURTAIN WALL FACADES RESOPLAN® – the multifunctional board material for outdoor use with long-term protection against weathering All RESOPLAN® facade claddings are ventilated as a matter of principle. This ventilation must be suitably dimensioned in accordance with the regulations. Ventilated area: Height of building All heights Ventilation: Height of cladding All heights Ventilation space ≥ 20 mm Condensation is discharged through the ventilation. Ventilation area ≥ 50 cm2/m in accordance with DIN 18516 Care must be taken to ensure openings for ventilation at the upper and lower edges of the curtain wall, as well as around doors and windows. Details must be agreed in collaboration with the structural engineer and facade contractor. In addition to colours and decors, structural attachment of the RESOPLAN® panels also creates new options for cladding the facade. Almost boundless attention can now be paid to the details, as joints, enclosures for supports or pillars, visible and concealed attachments and plinth panelling make it possible to realize individual design ideas. Buildings can even be corrected. A distinction is essentially made between the following types of attachment: Visible attachment ➔ with screws on wooden substructures ➔ with rivets on aluminium substructures Concealed attachment ➔ with adhesives ➔ with staple and anchor Contact the manufacturer of the applicable substructure if you require more detailed information. The commonest types of attachment are presented in detail on the following pages. For all types of attachment, an official construction permit must be obtained and proof of stability presented for all buildings with a height of more than 8 m. Resopal GmbH holds the oldest official construction permit for HPL boards for outdoor use. The permit was granted in 1983 and has remained in force ever since without any noteworthy changes. Invitations to tender for ventilated curtain wall facades and repair of balconies Model invitations to tender have been prepared with the assistance of the FVHF (ventilated curtain wall facade association) to eliminate possible planning errors due to inadequate tender documents and simplify the procedure when inviting tenders for such facades and for repairing balconies. The invitations to tender for ventilated curtain wall facades and the repair of balconies, and the loggia descriptions, have been prepared on the basis of the principles for preparing work specifications pursuant to the German construction contract procedures VOB/A. They contain standard wording for the specification of frequently recurring technical aspects. Specifications in compliance with the "General technical specifications in construction contracts (ATV)" must be drawn up and freely worded for all other, more farreaching aspects. ADVANTAGES OF VENTILATED CURTAIN WALL FACADES RESOPLAN® – the multifunctional board material for outdoor use with long-term protection against weathering 1. The basic structure of a second sealing level with ventilated space has proved its value for centuries. 9. The surfaces, corners and edges of RESOPLAN® facades are optimally protected against high shock and impact stresses. 2. The optimum function of a ventilated exterior curtain wall is based on nature such as the protective wall of leaves in front of a ventilation space to keep out the rain. 10. The thermal insulation can be variously used in accordance with both the latest regulation on thermal protection and the extended conditions specific to the property. Thermal insulation is not required purely as protection against the weather. 3. As a rule, the load-bearing outer wall does not require any special pretreatment. Plastering is not necessary. 11. Dry materials under a ventilated facade cladding ensure calculable values for determination of the dew point and thickness of the insulation. Particularly advantageous calculated values are obtained by the second heat transmission resistance. 4. Each weather board reacts to climate and moisture by changing dimensions. Technically correct construction ensures that these are absorbed by the weather board and not transferred to the outer wall. 12. Repainting - with all the familiar problems of moisture migrating from the inside outwards - is not required on a ventilated facade cladding with fully finished weather boards. 5. Building materials react differently and sometimes even contradictorily to high or low temperatures and moisture. These reactions can be overcome without difficulty by installing ventilated cladding, particularly in conjunction with renovations. 13. Unlike the case with plastered exteriors, graffiti can also be removed from RESOPLAN® facades. 6. Even considerable structural tolerances can be overcome reliably with the aid of ventilated facade claddings, e.g. when refurbishing structures built using large slabs. 14. Ventilated curtain wall facades can be replaced at any point with identical colours. In addition, they offer optimum opportunities for attachment, e.g. for hooks or flowerpot holders. 7. Both the material and the component comply with regulatory fire protection requirements in accordance with the stipulated construction heights. 15. Carefully planned arrangements create optimum design possibilities based on arrangement, colour and construction. Corrections can even be made to the building in this way. 8. Equalization of moisture and insulation are assured in summer and winter, even when building conditions are unfavourable. 06 | 07 03. STANDARDS AND GUIDELINES RESOPLAN® – the multifunctional board material for outdoor use with long-term protection against weathering ISO 9001 Resopal GmbH was one of the first German HPL manufacturers to obtain certification according to ISO 9001. This gives you additional security and ensures a consistently high standard of quality for all RESOPLAN® products and services. Official construction permit RESOPLAN® first obtained general official construction approval from the Deutsches Institut für Bautechnik (German Construction Technology Institute), Berlin, almost 30 years ago. One special feature is that permitted tensile stresses for the various attachment areas are already listed in test certificate Z-33, 2-11, Annex 3. DIN standards and guidelines: • DIN 1052 Design of timber structures • DIN 1055 Action on structures - Part 4: Wind loads • DIN 4102 Fire behaviour of building materials and building components • DIN 4108 Thermal protection in buildings • DIN 4109 Sound insulation in buildings • DIN 4113 Aluminium constructions under predominantly static loading • DIN 18165 Fibre insulation materials • DIN 18202/DIN 18203 Tolerances in building construction • DIN 18338 Roofing work • DIN 18516-1 Cladding for external walls, ventilated at rear; Requirements, principles of testing • DIN 68365 Sawn timber for carpentry, quality conditions • DIN 68800 Wood preservation in buildings • Resopal GmbH - company regulations • State construction regulations • Guidelines governing the use of flammable materials in buildings (as valid for the federal state concerned) • Accident prevention regulations issued by the employers' liability insurance associations • DIN EN 438-6/7 Decorative high-pressure laminate (HPL) boards • DIN EN 485 Aluminium and aluminium alloys – Strips, sheets and panels • DIN 4074 Strength grading of wood • DIN EN 13830 Curtain walling • DIN 4108 Thermal protection and energy economy in buildings • DIN 13501 Fire classification of construction products and building elements • DIN 18351 German construction contract procedures (VOB) • DIN EN 10088 Stainless steels • DIN EN 62305 Protection against lightning • EnEV 2014 German Energy Saving Ordinance 2014 (Energieeinsparverordnung – EnEV) • Z-30 3-6 Products, connecting elements and building parts made of stainless steels • BS 6180 Barriers in and about buildings • EOTA TR 001 Determinations of impact resistance of panels and panel assemblies • CUAP Fastener of external wall claddings • ETAG Draft Guideline for European Technical Approval of kits for external wall claddings • FVHF-FOCUS® Technical publications by the FVHF e.V., Berlin 04. HANDLING/CARE of the RESOPLAN® boards Transport ➔ fully supported and flat ➔ on a sufficiently large and level pallet ➔ secured to prevent slipping ➔ protected against soiling, moisture and mechanical damage ➔ Pallets must lifted vertically, not pushed or pulled over the edges when loading and unloading The RESOPLAN® boards must be secured to sufficiently large, level and robust pallets so that they cannot slip during transport. The boards must be lifted off vertically to prevent damaging the surface when loading and unloading. On the lorry, the boards must be protected against moisture and soiling. RESOPLAN® boards are not hazardous goods within the meaning of transport regulations; special marking is therefore not required. Storage ➔ fully supported and flat ➔ on a sufficiently large and level pallet ➔ in closed spaces under normal climate conditions ➔ protected against soiling, moisture and mechanical damage ➔ Stacked pallets must always be covered and weighed down ➔ Stacked pallets must not be tightly wrapped in plastic sheeting - avoid formation of condensation The RESOPLAN® facade panels must be stored on a level, horizontal surface supporting their full area, in a closed space under normal climate conditions. They must be protected against soiling, moisture and mechanical damage. There must not be any impurities between the boards. When covering stacked RESOPLAN® pallets with plastic sheeting, for instance, care must be taken to prevent the formation of condensation. Handling ➔ Pallets must lifted vertically, not pushed or pulled ➔ Surface protected to prevent soiling Boards must always be lifted off vertically, not pulled. When processing the boards, care must be taken to ensure that the surface is absolutely clean, otherwise it may be damaged. Care and cleaning RESOPLAN® boards do not require any special care. Minor soiling can easily be removed with clear lukewarm water. More extensive soiling can be removed with soap or detergent solution. ➔ Always use non-abrasive household cleaning agents diluted in water ➔ Use a fine, clean cloth or sponge ➔ Always rinse with clear fresh water to prevent smears forming. The following cleaning agents must never be used ➔ abrasive cleaning agents (e.g. abrasive powder or emulsion) ➔ solvents and solvent-based cleaning agents (e.g acetone, naphtha, thinner, etc.) ➔ abrasive cleaning cloths or sponges (e.g. microfibre cloths, abrasive sponge, steel wool, etc.) ➔ high-pressure cleaners and steam jet cleaners Removal of graffiti The cleaning agent "MBE Anti Graffiti Spray" supplied by MBE GmbH is recommended to remove any sprayed graffiti on the RESOPLAN® facade. The RESOPLAN® surface can be cleaned effortlessly without damaging the panel when using this cleaning agent. It must subsequently be cleaned with soapy water and finally rinsed with clear fresh water. The processing instructions for the Anti Graffiti Spray must also be observed (available from the manufacturer). It is always advisable to test-clean a small patch of the area affected. The rest of the surface should not be cleaned until the efficacy and compatibility of the cleaning agent have been tested. 08 | 09 05. GENERAL PROCESSING INSTRUCTIONS for the RESOPLAN® boards Machining the RESOPLAN® boards RESOPLAN® is supplied as a cut-to-size board trimmed on all sides. Special squared blanks cut to size from the aforementioned formats are available from the factory. Since RESOPLAN® is easily machined with wood-working machines, fitted elements and drilled holes can be produced cost-efficiently both in a workshop and on the building site. Please note that, depending on the incident light, RESOPLAN® boards with plain decors may appear to look different on the facade / balcony. This should be taken into account in the planning and when cutting to size. Cutting For all sawing and cutting work, it is important to ensure that the inner corners of cut-outs and internal recesses are rounded. Saws + saw blades Carbide-tipped saw blades are used for cutting to size. Tooth spacing 10 to 15 mm, cutting speed 40 to 100 m/s, see table. Cost-effective results for producing a clean cut on both sides are obtained when using a marking saw. When using circular saw blades, the quality of the cut can be influenced by adjusting the angle of emergence (height adjustment). Contour cuts Contours can be cut with the aid of a compass saw. In this case, the RESOPLAN® board must be placed with the decor side facing down on a clean surface (possibly covered with protective felt). Particularly clean unchipped edges are obtained by using a manual or tablemounted routing machine. Drilling HSS bits are used to drill holes. Step drills are particularly advantageous on metal substructures. Note the diameter of the holes drilled in RESOPLAN® for the fixed point and sliding point. Planing Fitted boards can also be machined on site using an electric handheld planing machine (with carbide blade). Milling-cutting An unchipped edge can easily be produced by milling-cutting with wood-working machines when using carbide-tipped tools. Carbide-tipped circular saw blades Circumference Cutting speed V in m/s as a function of tool diameter and speed, e.g. on circular saws Board cutting Fitting cut Tool Bench-top circular saw Manual circular saw Cutting speed Speed Feed rate 50-100 m/s ~ 3000-6000 rpm 10-30 m/min 30-50 m/s 3000-4500 rpm Manual feed 6000 Operation for RESOPLAN® 80 100 120 76 95 114 72 90 108 68 85 102 96 64 80 90 60 75 84 56 70 78 52 65 72 48 60 66 44 55 60 40 50 54 36 45 48 32 40 42 28 35 36 24 30 30 20 25 24 16 20 18 12 15 12 8 10 6 4 5 5000 Average values for table 60 57 54 51 48 45 42 39 36 33 30 27 24 21 18 15 12 9 6 3 4000 »ü« 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 3000 »ü« 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 2000 "Overhang" As the overhang increases, the upper cut edge improves and the lower cut edge deteriorates, and vice versa. 0.3-0.5 mm trapezoidal flat tooth 400 380 360 340 320 300 280 260 240 220 200 180 160 140 120 100 80 60 40 20 1000 b c Angles: a = Clearance angle b = Wedge angle c = Rake angle 8°-12° (radial angle) Cutting speed V in m/s Tool diameter in mm a Speed of tool shaft (rpm) 06. GENERAL INSTALLATION INSTRUCTIONS AND GUIDELINES for RESOPLAN® Basic principles for installing RESOPLAN® Like every other material, RESOPLAN® is subject to the laws of physics. Depending on climatic effects, the material may undergo dimensional changes, but these should not cause any impairment if the processing and installation instructions are observed. Details regarding the execution are specified on the basis of the applicable construction law taking into account the position, height, type and use of the building, as well as the application (facade, balcony, detail). Regulations on fire protection and stability must be observed without fail, especially in the case of buildings over 8 m high. As a rule, the required spacing between attachments is defined by the structural engineer for the building concerned. Factors to be taken into account include the live loads according to DIN 1055, the permissible forces stipulated in the permits and, in the case of balconies, the data of the ETB test certificates. Depending on the agreement reached between customer and installation contractor, relevant standards and company regulations, such as those of the company supplying the substructure or mounting hardware, must also be observed. Installation aids Adequate freedom of movement must be ensured, as the mounting hardware is centred. A suitable drilling gauge can be used as an aid here. When securing the boards with rivets, a one-hand spring-loaded drilling gauge ensures that the drilling pattern is safely applied from the facade panels to the aluminium substructure. Step drills are more advantageous on metal substructures, as they make it possible to drill holes in the substructure and panel simultaneously. Rivet setting gauge for sliding points Drilling template Step drill (with adjustable stop collar) x1 ø x3 90ϒ x2 ø 10 | 11 06. GENERAL INSTALLATION INSTRUCTIONS AND GUIDELINES for RESOPLAN® Types of attachment visible ➔ screwed ➔ riveted concealed ➔ glued ➔ with staple and anchors RESOPLAN® mounting hardware Only approved mounting hardware which has been tested according to ETB may be used. ➔ RESOPLAN® can also be laid on aluminium substructures. ➔ Direct mounting without ventilation at the rear is not recommended. Drill holes in the panel for attachment ➔ Fixed-point hole for: RESOPLAN® screws = 5.2 mm dia. RESOPLAN® rivets = 5.2 mm dia. ➔ Sliding-point hole for: RESOPLAN® facade screws = 7.0 mm dia. RESOPLAN® rivets = 8.5 mm dia. plus rivet setting gauge = 0.3 mm (distance) ➔ RESOPLAN® balcony screws = 8.5 mm dia. ➔ Distance from edges: Holes must be drilled in RESOPLAN® so that visible attachments are at least 20 mm from the edge and concealed attachments at least 30 mm from the edge. ➔ Free overhangs: RESOPLAN® thickness 6 mm = max. 100 mm 8 mm = max. 150 mm 10 mm = max. 200 mm Larger overhangs can be realized by structural means. ➔ Spacing between attachment points: RESOPLAN® thickness 4 mm = max. 400 mm 6 mm = max. 600 mm 8 mm = max. 700 mm 10 mm = max. 800 mm or as specified in the proof of stability based on official construction permits and/or ETB test certificates. Position of the attachment points RESOPLAN® is normally secured invisibly with one fixed point (drawing 1) and several sliding points (drawing 2). Sectional drawing, fixed point (drawing 1) Countersunk screws must not be used! Sectional drawing, sliding point (drawing 2) 06. GENERAL INSTALLATION INSTRUCTIONS AND GUIDELINES for RESOPLAN® Fixed point The fixed point is located in the middle of the panel for two-field attachment and at the edge of the panel, in the middle zone, for single-field attachment (see drawings, two-field and single-field panels). The fixed point ensures uniform distribution of the shrinkage and transverse movement. Two-field panel Single-field panel +G + G 80 mm G + +G See spacing between attachment points See spacing between attachment points +G + G G + +G G+ +G + F G + +G G+ +G + G G + +G F + +G + G G + +G G+ +G + G G + +G G+ ~ 600 mm ≥ 20 mm ~ 600 mm ≥ 20 mm 1320 mm F = Fixed point 80 mm 80 mm G+ 80 mm ~ 600 mm ≥ 20 mm ≥ 20 mm ~ 660 mm G = Sliding points Sliding point The sliding point ensures adequate freedom of movement. 12 | 13 06. GENERAL INSTALLATION INSTRUCTIONS AND GUIDELINES for RESOPLAN® Bending radii Flexibility is a special advantage of RESOPLAN®. The information provided below is based on bending radii which can effectively be produced on site (without heating, i.e. at normal temperatures, by hand, wrapped round a curved substructure). The long edges must be cut without chipping! No point attachments on the transverse edges! When bending panels lengthwise, the transverse edges must be secured with top-hat or omega profiles as valid linear attachments. RESOPLAN® 6 mm 3050 mm Radius: 6000 mm RESOPLAN® 4 mm Radius: approx. 1000 mm RESOPLAN® 3 mm Radius: approx. 890 mm 07. VISIBLE ATTACHMENT with screws on a wooden substructure Wooden substructures must be protected in accordance with DIN 68800-2 (Wood preservation - Preventive constructional measures in buildings). 14 | 15 07. VISIBLE ATTACHMENT with screws on a wooden substructure Assembly screw with Torx seat and coloured head Approval: No. Z-33.2-11 Length: 35 mm thread for wood Holes for fixed points: 5.2 mm Holes for sliding points: 7.0 mm Coating: in the colours of the RESOPLAN® collection* Washer not required Packaging unit: 100 pieces Material: Material No. 1.4401 *Always state the required RESOPLAN® decor number when ordering. Edge attachment of RESOPLAN® at the join between panels Sufficiently wide joint-tape backing. Important: On wooden substructures, the joints must have "rain-proof" backing (1.2 mm thick EPDM tape with 10 mm overhang on both sides of the supporting laths). Central attachment using RESOPLAN® assembly screws on a wooden substructure with joint-tape backing 07. VISIBLE ATTACHMENT with screws on a wooden substructure Horizontal section 16 | 17 07. VISIBLE ATTACHMENT with screws on a wooden substructure Vertical section 07. VISIBLE ATTACHMENT with screws on a wooden substructure Horizontal section, outer corner Vertical section, window lintel with roller shutter enclosure Vertical section, window lintel with metal sheet 18 | 19 08. VISIBLE ATTACHMENT with rivets on an aluminium substructure Only officially approved mounting hardware may be used to secure RESOPLAN® (Z-33.2-11). 08. VISIBLE ATTACHMENT with rivets on an aluminium substructure Aluminium blind rivets Approval: Z-33.2.-11 in accordance with the "general construction permit" for securing RESOPLAN® to aluminium substructures. Execution: Blind rivets, aluminium / stainless shank with defined breaking point Rivet length: 18.0 mm Shank diameter: 5.0 mm Head diameter: 14.0 mm Riveting sleeve: AlMg 3/5 Rivet mandrel/shank breaking point: stainless steel A2 (1.4541) Coating: Two-pack lacquer, lightfast, available in the colours of the RESOPLAN® collection Boards: Holes for fixed points: 5.2 mm Holes for sliding points: 8.5 mm (rivets must be placed with a rivet setting gauge; distance = 0.3 mm) Aluminium substructures: Holes in aluminium substructures: 5.1 mm Blind rivets, aluminium / stainless shank with defined breaking point 20 | 21 08. VISIBLE ATTACHMENT with rivets on an aluminium substructure Horizontal section 08. VISIBLE ATTACHMENT with rivets on an aluminium substructure Vertical section 22 | 23 08. VISIBLE ATTACHMENT with rivets on an aluminium substructure Horizontal section, outer corner Vertical section, window lintel with roller shutter enclosure Vertical section, window lintel with metal sheet 08. VISIBLE ATTACHMENT with rivets on an aluminium substructure Thermal bridging on metal substructures Conventional metal substructures create local thermal bridges on the facade, with the result that the insulation must be made thicker so that the facade can achieve the required U-value. For structural reasons, the spacing between attachment points on the substructure must be reduced at the edge and corners of facades. These additional thermal bridges make it necessary to adjust the thickness of the insulation accordingly in these areas. If this is not done, homogeneous and uniform insulation of the facade will be impossible, resulting in areas with very different U-values within one and the same facade. To take account of this situation, some manufacturers of substructures also supply systems which are characterized by exceedingly low local thermal bridging effects. These systems have a wall bracket of glass fibre-reinforced polymer material. They permit homogeneous insulation of the complete facade and a major reduction in the thickness of the required insulation. This can have economic and in some cases also optical advantages. Further information on systems with exceedingly low thermal bridging effects can be obtained from the respective manufacturers of the substructure systems. List of suppliers at www.resopal.de or: Wall bracket, polymer material 24 | 25 09. CONCEALED ATTACHMENT with adhesives 09. CONCEALED ATTACHMENT with adhesives System description Adhesive systems for facades are designed to permit invisible attachment of the facade panels on wooden or aluminium substructures. Such systems comprise a permanently elastic adhesive, a double-sided adhesive mounting tape to secure the panels and corresponding products for pretreating both the rear RESOPLAN® panels and the substructure. Properties of the system ➔ One-pack ready-to-use adhesive ensuring safe and simple application ➔ Resistant to weathering and ageing ➔ Elastic connection permitting movements ➔ Aesthetic facade surfaces ➔ No dirt smears ➔ Manufacture in accordance with DIN ISO 9001 ➔ Stresses are uniformly distributed over the entire panel Application areas Attachment of ventilated facade panels on: ➔ Residential and commercial buildings ➔ Newly built and renovated buildings Minimum thickness: 8-12 mm Concealed adhesive attachment to aluminium substructures Adhesives can be used on buildings up to 22 m high according to the official construction permit No. Z-10.8-350 (adhesive from MBE) and Z-10.8-408 (adhesive from Sika). The adhesives used are high-quality air-curing elastic polyurethane (Sika) or MS polymer (MBE) adhesives. The adhesive manufacturer's product specification and processing instructions must be observed without fail. The aluminium substructure must comply with both DIN 1748-1 and the requirements of the official construction permit. 1 2 1 1 Application of adhesive 2 Adhesive tape 1 Concealed adhesive attachment to wooden substructures For wooden substructures, there are so far no official construction permits restricting the potential applications to areas not requiring official approval (buildings up to 8 m high). The substructure is made of spruce or fir, planed, with a maximum moisture content of 15% according to DIN 1052. The area to be glued must be untreated and free from surface treatment agents. 26 | 27 09. CONCEALED ATTACHMENT with adhesives Single-field Multi-field ≥ 100 mm ≥ 40 mm Processing of adhesive systems Processing conditions: ➔ Adhesive systems can be processed both in workshops and on site ➔ Processing in weather-proof and dust-proof conditions ➔ Air temperature must be not less than +5 °C and not more than +35 °C ➔ Relative humidity must not exceed 75% ➔ The temperature must not drop below +5 °C during the installation work and for a period of four hours thereafter ➔ The temperature of the components to be glued (substructure, RESOPLAN® panel) must be at least 3 °C above the dew point ➔ Adhesive attachment may only be undertaken by specially trained firms ➔ The work must be documented Pretreatment of the substructure: ➔ Carefully sand the aluminium bottom edge with abrasive felt ➔ Clean the substructure ➔ Uniformly apply one layer of primer over the complete surface ➔ Let primer evaporate (consider evaporation time) Pretreatment of the RESOPLAN® panel: ➔ Carefully sand the RESOPLAN® panel with abrasive felt ➔ Clean the surface to be glued ➔ Uniformly apply one layer of primer over the complete surface ➔ Let primer evaporate (consider evaporation time) ➔ After application, the primer must be protected against dust, dirt, etc. Bonding: ➔ Apply mounting tape to the entire length of the pretreated vertical substructure parallel to the edges (but do not remove the protective film) ➔ Application of adhesive: The adhesive is applied in the form of a triangular bead at least 6 mm away from the mounting tape and side edge of the profile ➔ Installation of the panel: peel the protective backing off the tape. Position the facade panel on the adhesive beads in the designated place so that the facade panel does not touch the mounting tape. Align the facade panel and press it firmly against the mounting tape. The position of the panel cannot be changed once it has been pressed against the mounting tape. The adhesive manufacturers' processing instructions must generally be taken into account! 09. CONCEALED ATTACHMENT with adhesives Horizontal section 28 | 29 09. CONCEALED ATTACHMENT with adhesives Vertical section 09. CONCEALED ATTACHMENT with adhesives Horizontal section, outer corner Window lintel with roller shutter enclosure Vertical section, window lintel with metal sheet 30 | 31 10. CONCEALED ATTACHMENT with staple and anchor 10. CONCEALED ATTACHMENT with staple and anchor System description RESOPLAN® panels can be secured invisibly using metal staples and undercut anchors on the rear side of the panel. According to European technical approval ETA-13/0137, attachment using the FZP II-T fischer Zykon-Panel Undercut Anchor is permitted for the RESOPLAN® F panels. RESOPLAN® suspended from substructure with FZP-II-T Advantages/benefits ➔ No mounting elements visible from the front ➔ Anchorage without pressure due to expansion ➔ No need to stamp a contour in the substructure ➔ Large panel sizes possible ➔ High retention forces ➔ Optimum long-term process ➔ High degree of prefabrication under workshop conditions ➔ Can be realized with customary aluminium substructures Application areas Attachment of ventilated facade panels for residential and commercial buildings. Panel sizes can be selected as required and must be secured with at least 4 anchor points. Thickness: 8, 10, 12 mm Preparation of drill holes / anchor assembly 32 | 33 10. CONCEALED ATTACHMENT with staple and anchor Horizontal section 10. CONCEALED ATTACHMENT with staple and anchor Vertical section 34 | 35 10. CONCEALED ATTACHMENT with staple and anchor Horizontal section, outer corner Vertical section, window lintel with metal sheet Horizontal section, reveal with metal sheet 11. WEATHER BOARDING with concealed screws Horizontal section Not approved for installation as weather boarding! Concealed attachment ➔ RESOPLAN® 8 mm ➔ Secured with the aid of stainless steel clips ➔ Wooden substructure: 50 x 35 mm and 100 x 35 mm in the area of the joint ➔ Dimensions: 3050 mm / 3650 mm x 200-300 mm ➔ Distance from substructure: max. 600 mm ➔ Installation from the bottom upwards ➔ Lowest clips supported with RESOPLAN® scraps ➔ Panel overlap approx. 25 mm ➔ Panel strips must always be formed with a fixed point during attachment ➔ Panel must be secured with an additional screw in the middle of the upper edge, alongside the assembly clip ➔ Last row secured to the upper edge with screws 36 | 37 11. WEATHER BOARDING with concealed screws Vertical section 11. WEATHER BOARDING with concealed screws Horizontal section, outer corner Horizontal section, inner corner 38 | 39 12. JOINTS AND CONNECTIONS BETWEEN PANELS for RESOPLAN® boards Horizontal joint ➔ The cut edge need not be sealed (coated). ➔ Rain-proof horizontal joint for wooden substructures with PVC or aluminium joint profile Important: Ensure the required freedom of movement (drawing 1)! ➔ Rain-proof horizontal joint with non-overlapping aluminium joint profile (drawing 2) ➔ Horizontal panel termination - e.g. under windowsills - with rain deflecting profile. Drawing 3 for wooden substructures ➔ Joint backed with beading (drawing 4) ➔ Open panel joints: permitted on aluminium substructures and with correct ventilation (drawing 5) ➔ Rain-proof horizontal joint with Z-profile (drawing 6) Note: The edge of the panel is not protected against UV light and may therefore change its colour with time. Drawing 1 Drawing 2 Drawing 3 Drawing 4 Drawing 5 Drawing 6 Inner and outer corners Figure 1 Figure 2 Outer corners Figure 1: Outer corner, butt-jointed, with 100 mm joint tape, angled, visible attachment on wooden substructure Figure 2: Outer corner, visible attachment with outer corner profile Figure 3 Figure 4 Inner corners Figure 3: Inner corner, butt-jointed, visible attachment on wooden substructure with 100 mm joint tape, angled Figure 4: Inner corner, visible attachment with inner corner profile 12. JOINTS AND CONNECTIONS BETWEEN PANELS for RESOPLAN® boards Wall connection: RESOPLAN®/compound heat insulation system Horizontal section, butt joint flush with the surface Horizontal section, inner corner 40 | 41 12. JOINTS AND CONNECTIONS BETWEEN PANELS for RESOPLAN® boards Vertical section, lintel Vertical section, windowsill connection Apartment building, D-Hamburg; photo: ©marcusbredt.de 42 | 43 13. INDIVIDUAL APPLICATIONS with RESOPLAN® 1 Gable 2 Dormer 3 Fascia board 4 Roof soffit 2 1 4 3 Total quality RESOPLAN® is easily processed and yields practical solutions affording durable protection against the effects of the weather, particularly on roofs. RESOPLAN® can be used for quick and easy cladding of: ➔ dormer windows, ➔ roof gutters and ➔ roof soffits. All the work can be undertaken with the tools and machines customary in the wood-working trade. Always well sealed RESOPLAN® used as: ➔ fascia board, ➔ surround on flat roofs, ➔ eaves gutter, ➔ gable-end board or ➔ attic storeys always ensures a perfect seal. The high-quality HPL laminate protects every nook and cranny of the masonry. Additional painting and other maintenance are unnecessary thanks to the durable decor surfacing on both sides and the RESOPLAN® protection against weathering. An aspect of great importance, particularly for roofs. RESOPLAN® as roof gutter and dormer cladding RESOPLAN® as gable-end soffit on wooden substructure, visible attachment 1 3 1 1 2 4 11 1 1 1: 2: 3: 4: RESOPLAN® Blind shuttering Roofing felt Vertical laths RESOPLAN® protection on angled gable-end board, wooden substructure, visible attachment 13. INDIVIDUAL APPLICATIONS with RESOPLAN® Attic storey with RESOPLAN® as a prefabricated roof edge element RESOPLAN® as fascia board and roof soffit RESOPLAN® as fascia board RESOPLAN®, 10 mm thick, as surround for a flat roof on wooden substructure, concealed attachment RESOPLAN® as roof soffit and wall cladding RESOPLAN®, 6 mm thick, as gable-end soffit on wooden substructure, visible attachment RESOPLAN® as fascia board RESOPLAN® as sandwich element, door and gate panels Variety of individual applications RESOPLAN® can also be used as a protective cladding ➔ for kiosks; garden sheds; as panelling in doors and gates; for fencing with metal or wood; ➔ as a single element filling the entire surface or as a sawn and individually profiled element. 44 | 45 14. COMPOUND ELEMENTS with RESOPLAN® RESOPLAN® compound elements comprise a substrate material with excellent thermal insulation properties to which RESOPLAN® panels have been laminated on both sides. Compound elements with RESOPLAN® surfacing have been manufactured for many years and successfully installed. The following points are decisive: ➔ A compound element must be dimensioned for the stresses encountered. ➔ Compound elements must be manufactured without tension. ➔ Compound elements must be installed in accordance with the manufacturer's instructions. Please contact the manufacturer of the compound elements for your individual solution. Balcony cladding, NL-Rotterdam 15. BALCONIES with RESOPLAN® RESOPLAN® is an ideal panel material for cladding balconies, loggias, covered walks, verandas and open galleries. It can also be used without difficulty as a screen and wind break in compliance with the following regulations and design principles: ➔ Protection against falling ➔ Construction law, state construction codes ➔ Regulations governing calculation ➔ Design principles ➔ Proof of stability ➔ Official construction permits ➔ Engineering design instructions ➔ Mounting hardware ➔ Fire protection Balcony panelling; G & S die Balkonbauer, D-Ahlen 15. BALCONIES with RESOPLAN® Hotel Ratschingserhof/Ahrntaler facade balconies Protection against falling Balcony railings and panelled protective surrounds serve to prevent people falling from a height. As a rule, such protection against falling is required for heights of more than 1 m. State construction codes contain divergent regulations which must also be observed. Their job is to secure the enclosed area or part-area so that people and objects acting on these components are not jeopardized by premature failure. In accordance with the ETB guideline "Components affording protection against falling", theoretical proofs may be replaced by tests. For the tests determining the load at rupture, a distinction is made between the soft impact as a bending test with static load (a1), the soft impact as pendulum impact test (a2) and the hard impact as collision test with a hard mass and high impact velocity (b). The component or parapet cladding is deemed to afford protection against falling as per § 3.2.1 of the ETB regulation if: ➔ the stability of the components is maintained, ➔ the component is not torn out of its anchorage, ➔ fragments cannot fall and injure people below, and ➔ the panel is not pierced by the specified loads. The suitability of RESOPLAN® as a cladding for balcony panellings has been demonstrated in various ETB tests. Construction law Protective surrounds The basic conditions for protective surrounds, such as parapet heights, horizontal and vertical spacings, are specified in the respective state construction codes. These must be taken into account in each case. Different requirements apply for private, public and commercial areas and must be observed accordingly. If necessary, more stringent requirements must be derived from the ordinance on workplaces. 46 | 47 15. BALCONIES with RESOPLAN® Basic conditions for balcony panellings in private and public areas H Height of parapet above the surface of the finished flooring, step-on edging, see table below e1 Max. vertical distance between handrail and panel = 120 mm e2 Max. vertical distance between surface of balcony slab and bottom edge of parapet cladding = 40 mm e3 Max. vertical distance between horizontally fitted cladding panels = 15 to 20 mm (refer also to the applicable state construction code) e4 Max. horizontal distance between parapet cladding and front edge of the balcony = 40 to 60 mm (refer also to the applicable state construction code) e5 Max. horizontal distance between vertically fitted cladding strips = 120 mm Minimum parapet heights above the surface of finished flooring of balconies (private sector; Germany) Height of fall (difference between surface of terrain and surface of finished flooring) from 0 to 12 m* over 12 m* Minimum height of parapet (H) 0.90 m** 1.10 m * The height may be reduced if necessary by technical equipment or the depth of the parapet. ** Except in Bremen The illustrations show a model test setup a1 Pressure cylinder a2 b Direction of fall Example of a bottom bracket Surface of finished OKflooring FFB H e2 e2 e2 H H e3 e1 e5 View of railing: horizontally divided cladding e1 View of railing: Cross-section e1 View of railing: vertically divided cladding e4 Standards and guidelines The applicable DIN standards and guidelines must be observed when installing protective surrounds for balconies, loggias, verandas, covered walkways, galleries and stairs, as well as when fitting screens and wind breaks. These include the following in particular: • DIN 1055 Action on structures • DIN 1045 Concrete, reinforced and prestressed concrete structures • DIN 4113 Aluminium constructions under predominantly static loading • DIN EN 1993 Design of steel structures • DIN EN 1090 Execution of steel structures and aluminium structures • DIN 4102 Fire behaviour of building materials and building components • DIN 4420 Service and working scaffolds • DIN 18202 Tolerances in building construction • DIN 55928 Protection of steel structures against corrosion by means of coatings • ETB guideline "Protective building parts to prevent falling" • Official construction permits for the dowels used • State construction codes • ATV DIN 18360 General technical specifications in construction contracts (ATV) - Metalwork • • • • • • Ordinance on workplaces Z-30 3-6 Products, connecting elements and building parts made of stainless steel Technical guideline of the metalworking trade: metal railings and surrounds The document "Technical guideline of the metalworking trade: metal railings and surrounds" contains instructions for the design, construction and installation of railings and protective surrounds which are governed by construction and labour law; in addition, it also provides aids for dimensioning. These also apply when refurbishing existing systems. Accident prevention regulations issued by the employers' liability insurance associations Guidelines governing the use of flammable materials in buildings (different interpretations in the respective state construction codes). DIN 18065 Stairs in buildings 15. BALCONIES with RESOPLAN® Elongation of panels Elongation is caused by external influences (temperature and humidity). For this reason, the joints between RESOPLAN® panels and the adjacent building parts must be at least 8 mm wide. Drain holes must be provided in the underside of edging strips. Mounting hardware Only mounting hardware made of corrosion-proof material may be used; the hardware must be compatible with RESOPLAN® and covered by the ETB guideline and/or official construction permit. The panels are secured to the railing structure without constraint. 1.) Aluminium blind rivets for metal substructures VVG blind rivet • Sleeve of VVG blind rivet made of aluminium alloy AlMg3 (EN AW-5019 as per DIN EN 573) • Rivet mandrel of stainless steel (material No. 1.4541) Dimensions of the blind rivet and breaking force of the rivet mandrel d =5 d = 14 Basic conditions for installation Head-breaking rivet mandrels ø 14 d1 1,75 L = 21 (18) POP blind rivet • Sleeve of POP blind rivet made of aluminium alloy AlMg3 (EN AW-5019 as per DIN EN 573) • Rivet ømandrel of steel dia. d1 = 2.64 mm (head-breaking rivet) • Rivet mandrel of stainless steel (shank-breaking rivet) ø5 1,0 ø5 1,75 3,5 UK Thickness of RESOPLAN® 6 mm 8 mm 10 mm Dimensions VVG blind rivet 5 x 18 mm 5 x 18 mm 5 x 21 mm Conceivable extreme position when constrained Breaking force of the rivet mandrel: 4.9 kN 5 x 18 head dia. D = 14 mm 5 x 21 head dia. D = 14 mm Dia. of hole in substructure: 5.1 mm Sliding point dia. 8.5 mm: Use of a drilling gauge ensures that the hole is centred in the substructure, thus ensuring sufficient freedom of movement for the sliding point of the RESOPLAN® panel. Installation without constraint is assured by using a supplementary gauge for rivets. Fixed point dia. 5.2 mm: The hole must be drilled in the substructure with a diameter of 5.1 mm. 2.) Set of balcony screws with cap nut Balcony screw M5 x L with washer, spring lock washer and cap nut of stainless steel. A polyamide shim is fitted between the RESOPLAN® panel and the substructure. Polyamide shim Spring lock washer Cap nut Diameter of hole RESOPLAN® RESOPLAN® balcony screw with coated head, for metal structures M5 DIN 9021 DIN 127 material No. 1.4301 DIN 1587 material No. 1.4301 Sliding point 8.5 mm Fixed point 5.2 mm 16,0 Ø8,5 L RESOPLAN® Thickness 6-10 mm M5 Polyamide shim Structural element Spring lock washer Cap nut 48 | 49 16. RAILINGS with RESOPLAN® General In the case of balcony railings, a distinction is made between type-tested railings and individual railings with structural analysis for the specific property. The advantage of a type-tested design over an individual design is that the type analysis applies nationwide, regardless of the property concerned. Balcony railings are made of steel, stainless steel or aluminium profiles which are either welded or connected to one another by means of corresponding mouldings using rivets or screws. The same regulations, standards and guidelines apply for all versions. In addition, balcony railings are distinguished according to the means by which they are secured to the structure: ➔ with false bearing ➔ with foot placed underneath ➔ with foot placed on top ➔ with foot at face end Balcony railing system with false bearing As a rule, railing systems with false bearing comprise an upper and lower load-bearing horizontal profile freely held between two reinforced concrete walls to which they are secured by means of wall brackets. The base in which they are anchored must be sufficiently strong. Such railing systems are mainly used in loggias 3 to 6 m long which are primarily found on buildings made from prefabricated reinforced concrete slabs. A vertical support is useful for very long railings. Balcony railing systems with foot placed underneath In such systems, the foot of the railing is secured to the reinforced concrete slab from below. Balcony railing system with false bearing Loggia railing with parapet cladding fitted from the outside and continuous edging strips A 8 2 2 3 + 5 5 3 1 1 4 + 6 A 1 RESOPLAN® 2 Upper guard rail 3 Newel post 4 Bottom guard rail 5 Edging strip 6 Continuous angle piece + 8 + 6 Section A Balcony railing systems with foot placed underneath with edging strip Railing with front-mounted parapet cladding and continuous horizontal transverse rails 2 B 2 3 3 1 B 7 7 7 Transverse rail 8 Wall bracket 9 Foot placed underneath 1 7 9 9 Section B 16. RAILINGS with RESOPLAN® Balcony railing systems with foot placed on top For the balcony railing shown here, the foot of the railing is secured to the top of the reinforced concrete slab. This is frequently encountered on rooftop verandas on which attachment from the face or underside is not possible on account of prevailing conditions. Balcony railing systems with foot at face end In this case, the foot of the railing is anchored in the balcony slab from the front. Anchorage in the balcony slab is difficult, as an appropriate distance from the edge must be maintained. Retroactive attachment from the front can normally only be realized with two dowels fitted side by side in balcony slabs with a "standard" thickness of 12 to 18cm. In new buildings, the foot of the railing can be secured to fitted elements (such as steel plates with cap screws, threaded sleeves embedded in the concrete, etc.) integrated into the face end of the balcony slab. Balcony railing systems with foot placed on top Railing with parapet cladding front-mounted on the outside and intermediate transverse rails C 2 3 2 6 6 3 1 1 6 C 5 5 Section C Balcony railing systems with foot at face end Railing with parapet cladding fitted from the inside and continuous edging strips D 2 2 3 4 4 1 3 1 4 D 7 7 Section D 1 RESOPLAN® 2 Upper guard rail 3 Newel post 4 Edging strip 5 Foot mounted on top 6 Transverse rail 7 Foot mounted at face end 50 | 51 16. RAILINGS with RESOPLAN® Attachment to continuous profiles This version allows different colours and decors to combined and optically arranged in aesthetic design. The parapet panels are secured directly to the continuous horizontal rails by means of balcony screws or rivets. The balcony screws can be supplied with coated heads. The horizontal rails are secured to the substructure (newel posts) in accordance with structural requirements. Execution ➔ Panel thickness: min. 6 mm (details see tables 1, 2 and 3) ➔ The parapet panel must be fitted without constraint so that it can expand correspondingly. ➔ One fixed point must be provided per panel. The fixed point must be located in the centre. ➔ The sliding point must be located in the panel for attachment with rivets and in the substructure for attachment with balcony screws. Version 1: Attachment with balcony screws Version 2: Attachment with rivets Fixed point: Fixed point: Sliding point: 0,3 mm 2 Sliding point: 2 1 0,3 mm 3 1 3 1 1 1 RESOPLAN®; 2 Balcony screw; 3 Blind rivet Parapet panel with continuous horizontal rails ➔ Limiting distances e1 ≤ 120 mm (refer also to the applicable construction code) e2 ≤ 40 mm (refer also to the applicable construction code) ➔ Free overhangs R R ≤ 75 mm The spans and distances between attachment points only apply in combination with the mounting elements specified in the ETB tests. Single-field panels e1 B B e2 R e2 R B A B R R e1 Horizontal e1 Vertical R A R R R Table 1 For the values stated in the following table, resistance to intermittent stresses has been proved for continuous rails in accordance with ETB requirements. Panel thickness 6 mm Type of attachment Rivet Screw 8 mm Rivet Screw 10 mm Rivet Screw Distance between attachment points B = 500 mm B = 500 mm A = 600 mm B = 550 mm B = 650 mm A = 800 mm B = 550 mm B = 800 mm A = 950 mm 16. RAILINGS with RESOPLAN® Multi-field panels R A A R R e2 R e2 R B B B R e1 Vertical, 8 mm e1 Vertical, 6 mm R A A R Table 2 For the values stated in the following table, resistance to intermittent stresses has been proved for continuous rails in accordance with ETB requirements. Panel thickness 6 mm Type of attachment Screw 8 mm Screw Horizontal, 8 mm e2 R e2 R A A A A R R e1 e1 Horizontal, 6 mm Distance between attachment points A = 800 mm B = 550 mm A = 1050 mm B = 850 mm R B R R B B R Table 3 For the values stated in the following table, resistance to intermittent stresses has been proved for continuous rails in accordance with ETB requirements. Panel thickness 6 mm Type of attachment Screw 8 mm Screw Distance between attachment points B = 550 mm A = 800 mm B = 850 mm A = 1050 mm 52 | 53 16. RAILINGS with RESOPLAN® Attachment to cover plates This version is recommended in order an impression of optically subdivided individual claddings. The cover plates are welded or screwed to the railing structure and the parapet panels attached to these directly using the approved connecting hardware (cf. table 4). Execution ➔ Panel thickness: min. 6 mm ➔ The parapet panel must be fitted without constraint so that it can expand correspondingly. 1 Panel secured with cover plates ➔ Limiting distances (refer also to the information on construction law, p. 46/47) e1 ≤ 120 mm (refer also to the applicable construction code) 1 Transverse rail e2 ≤ 40 mm (refer also to the applicable construction code) 2 Cover plate ➔ Free overhangs R: 3 Spring lock washer R1 ≤ 85 mm 4 Cap nut R2 = 20 mm 5 Post S2 = 40 mm 2 5 3 6 4 7 6 Polyamide shim 8 7 Screw 8 RESOPLAN® Multi-field panel R1 R1 e1 Single-field panel S2 S2 A A R2 R2 B B e2 B Table 4 For the values stated in the following table, resistance to intermittent stresses has been proved with cover plates in accordance with ETB requirements. Panel thickness 6 mm Type of attachment Distance between attachment points Cover plate, screwed 8 mm Cover plate, riveted Cover plate, screwed 10 mm Cover plate, riveted Cover plate, screwed B = 480 mm A = 600 mm B = 530 mm B = 630 mm A = 800 mm B = 530 mm B = 780 mm A = 950 mm 16. RAILINGS with RESOPLAN® Attachments with edging strips This version is recommended when a homogeneous, uniform appearance is required for the cladding. The parapet panels are secured indirectly on two or four sides by means of edging strips. They are retained via a corresponding rubber trim inside the edging strip. The edging strips are secured to the substructure in accordance with structural requirements. 1 3 P Execution ➔ Panel thickness: min. 6 mm, details see table 5. ➔ The parapet panel must be fitted without constraint so that it can expand correspondingly. Minimum clearance on three sides of the profile: 6 mm. ➔ The edging strip must be dimensioned in accordance with the rubber trim and thickness of the parapet panel. ➔ In the case of continuous panels edged on two sides (edging strip at top and bottom), we recommend the use of connecting plates or a metal H-profile in the area of the panel joint. ➔ Structural stability of the edging strips must be proved. Drain holes must be provided in the lower edging strips. Aluminium edging strip 2 1 RESOPLAN® parapet cladding t = 6 mm, 8 mm or 10 mm 2 Aluminium edging strip 3 Rubber trim Parapet panel edged on two sides ➔ Limiting distances (refer also to the information on construction law, p. 46/47) ➔ Profiled depth of aluminium edging strip: p ≥ 28 mm ➔ Panel width: B ≥ 1250 mm P e1 B e2 P A H t Table 5 For the values stated in the following table, resistance to intermittent stresses has been proved for edging strips in accordance with ETB requirements* Panel thickness 6/8 mm 6/8 mm 6/8 mm Span A 62 cm 76 cm 92 cm max. panel width B 125/365 cm 125 cm 125 cm * Test performed with aluminium edging strip 54 | 55 17. SCREENS with RESOPLAN® General Screens made from RESOPLAN® are used to shield individual areas of particularly long balcony systems and covered walkways. They are increasingly being used to ensure privacy, especially in residential buildings occupied by several households, apartment blocks, hospitals and hotels. As a rule, the screens are positioned perpendicular to the outer wall of the building and secured in various ways, just like normal claddings. Depending on the selected design, they range from the surface of the balcony slab to the underside of the floor on the next storey. As with the parapet claddings, a distinction is made between the following types of attachment: ➔ Attachment to continuous profiles ➔ Attachment to cover plates ➔ Attachment via edging strips Special features In addition to the aforementioned screens shielding individual parts of balconies, others in the form of screens or wind breaks can also be used to create a side wall on balconies. Since these side panels not only act as a wind break and screen, but also serve to prevent people falling, they can only be installed in combination with the railing used and the statically proved substructure. These panels must therefore be integrated into the structural analysis of the balcony railing. Screens on continuous profiles without serving to prevent people falling The substructure of hollow profiles must be realized in accordance with the structural analysis and anchored in the reinforced concrete slabs with correspondingly approved dowels or other fitted parts. The profiles must act as linear supports bearing the structural load in this case. The screens are secured with the same mounting hardware as the parapet panels. For distances between attachment points, refer to p. 52/53 Attachment to continuous profiles ➔ L: Variable, depending on height between floors ➔ R: Free overhangs of the screen for t = 6 mm: R ≤ 100 mm for t = 8 mm: R ≤ 150 mm for t = 10 mm: R ≤ 200 mm ➔ F: Clearance between screen and surface of the balcony. F can be selected as desired for screens which do not serve to prevent people falling. Refer to the section on construction law, p. 46/47, for screens which serve to prevent people falling. Table 6 Static system Single-field member Multi-field member max. span* t = 6 mm 600 700** t = 8 mm 700 900** * t = 10 mm 800 1100** Distances between attachment points must be derived from Z-33.2-11 for blind rivets on aluminium substructures ** Z-33.2-11 does not apply for the specified span. Load-bearing capacity must be proved separately. F L Spans have been calculated without restriction as regards sagging. R A A R 17. SCREENS with RESOPLAN® Screens on cover plates without serving to prevent people falling Cover plates must be secured to the substructure in accordance with the structural analysis. The cover plates must be anchored in the concrete slabs or masonry with correspondingly approved dowels or other fitted parts. The additional loads due to the screens must be taken into account for the railing construction. The screens are secured with the same mounting hardware as the parapet panels. • R: Free overhangs of the screen for t = 6 mm: R ≤ 10 mm for t = 8 mm: R ≤ 15 mm for t = 10 mm: R ≤ 20 mm • F: Clearance between screen and surface of the balcony. F R B H B F can be selected as desired for screens which do not serve to prevent people falling (refer to the section on construction law, p. 46/47). R A R Table 7 Static system max. span A and distances between attachm. points B* [mm] t = 6 mm t = 8 mm t = 10 mm Single-field member 500** 600 700 Multi-field member 500 700 800 * For blind rivets, distances between attachment points are calculated in accordance with Z-33.2-11. ** Distances between attachment points have been calculated without restriction as regards sagging. 56 | 57 17. SCREENS with RESOPLAN® Screens with edging strips, without serving to prevent people falling Edging strips must be secured to the substructure in accordance with the structural analysis. The additional loads due to the screens must be taken into account for the railing construction. ➔ H: Parapet height, railing (refer to the section on construction law, p. 46/47) ➔ L: Height of screen (max. L = height between floors) ➔ F: Clearance between screen and surface of the balcony. F F H H L L 1/ 4A F can be selected as desired for screens which do not serve to prevent people falling. Refer to the section on construction law, p. 46/47, for screens which serve to prevent people falling. Structural stability of the edging strips must be proved separately for horizontal loads (wind). A A Table 8 Max. length A* [mm] Ratio L/A = 1.0 Ratio L/A = 1.5 Ratio L/A = 2.0 Ratio L/A = 2.5 Panel thickness t = 6 mm t = 8 mm 900 1200 800 1100 700 1000 650 900 t = 10 mm 1500 1300 1200 1100 * Z-33.2-11 does not apply for this type of attachment; load-bearing capacity must be proved separately. Distances between attachment points have been calculated without restriction as regards sagging. A Balcony panelling; G & S die Balkonbauer, D-Ahlen 58 | 59 18. MOTIV IN RESOPLAN® The individual architectural board Design options with RESOPLAN® Individual perspectives for facades are opened up by MOTIV IN RESOPLAN®. Your design ideas can be implemented with the aid of the latest silk screen and digital printing techniques or by traditional methods (e.g. inlays). ➔ We will be pleased to advise you. Digital and screen printing Screen and digital printing bring flexibility und inexhaustible diversity into facade design. We print your high-resolution and ready-to-print data with light and heat resistant ink on a special paper and press them into RESOPLAN®. Each board a unique surface Drawings and paintings in UV-resistant colours on our special paper are permanently protected in RESOPLAN® and can therefore even be used as facade panels. The glass-clear melamine resin layer of the overlay offers permanent protection of the original against external influences. For use on the facade it is provided with a special UV weather protection. Inlay work Specially developed inlay techniques enable us to seamlessly combine decors from the RESOPAL® >2018 collection in one board. By means of templates, we produce inlays according to your requirements. ➔ Detailed information on MOTIV IN RESOPLAN® is available on request. Erich Kästner comprehensive school, D-Bochum; Photo: Michael Grosler Above: Building Bon Vie, Living-Social Welfare-Healthcare, NL-Culemborg; ZEEP Architecten, NL-Amersfoort; Photo: Marcel Kentin, www.kentin.net/ Below: School, ZEEP Architects, Photo: Mark van den Boorn, ZEEP Architects, NL-Amersfoort 60 | 61 19. RESOPLAN® FIRE PROTECTION RESOPLAN® Fire behaviour Preventive fire protection on the facade of buildings As the inventor of high-pressure laminate HPL, Resopal has devoted attention to the subject of "preventive fire precaution" from the very beginning. This applies above all for the weatherproof RESOPLAN® panel for outdoor use. The basis for external wall cladding applications is defined in the respective state construction codes and in such guidelines as those governing the "Use of flammable materials in buildings". B2 materials, with normal flammability according to DIN 4102, can therefore be used up to a building height of 8 m and B1 materials on high-rise buildings up to 22 m high (refer to the state construction codes). RESOPLAN® is classified as B2, normal flammability, in accordance with DIN 4102, Part 4, without further proof. The RESOPLAN®-F fire protection panel is officially approved (permit No. Z33.2- 11) and classified as a B1 building material (burns with difficulty). Provided that the fire department responsible for structural fire prevention has no objections in respect of fire protection, applications may be filed with the supreme construction authority for an extension of the application areas. Example: Balcony cladding with RESOPLAN®-F Large-scale fire tests on RESOPLAN® balcony claddings by the Leipzig Institute for Materials Research and Testing (MFPA) have shown that RESOPLAN®-F can be used on buildings up to a height of 35 m. No ageing processes The RESOPLAN®-F fire protection panel was specially developed for outdoor use. Although the product is permanently exposed to the weather, its fireproof finish is still fully functional several years later. In RESOPLAN®-F, the flame-retardant additives are integrated into the panel make-up. This was officially confirmed when tests were repeated after years' exposure to the weather. RESOPLAN® contains fire retarding agents which do not liberate any harmful halogens in the event of fire. International certificates Resopal attaches great importance to preventive fire protection in buildings. This commitment is documented by approvals, test certificates and test reports. Certificates for use of the fire resisting panel RESOPLAN®-F in buildings have been issued in the following countries: ➔ Germany ➔ France ➔ Ukraine ➔ Hungary ➔ Netherlands ➔ Russia Fire protection in Europe In Europe, laminate boards destined for use in construction are tested according to EN 13823 (SBI test, thermal stress due to a single burning item) and according to EN ISO 11925-2 (testing with a small burner - single-flame source test). The observed fire behaviour is stated in accordance with EN 13501-1. The RESOPLAN®-F fire resisting panel as classed as barely flammable according to EN 13501-1, European class B-s2, d0 (certificate of conformity 0766-CPR-277). 19. RESOPLAN® FIRE PROTECTION RESOPLAN® Bulkheads/fire barriers Special fire stopping systems, such as coated, horizontally running, stainless steel sheets, are used in Europe for ventilated facades on tall buildings to prevent fire spreading in the space provided for ventilation. In Germany, instructions for installing so-called "fire barriers" (special technical precautions to prevent fire in ventilated exterior wall claddings with cavities extending over several floors or which continue beyond fire break walls) have been published in the Sample List of Technical Building Regulations (MLTB) by the German Institute for Construction Technology (DIBt), edition dated September 2012, Annex 2.6/4. The MLTB distinguish between horizontal and vertical fire barriers. Horizontal fire barrier: "(...) On every second floor, horizontal fire barriers are required in the space provided for ventilation. The fire barriers must be installed between the wall and the cladding. If heat insulation is applied externally, installation between insulating material and cladding will suffice if the insulating material remains dimensionally stable in fire and has a melting point > 1,000 °C. (…)" ➔ In the arrangement shown here, the fire barriers are located above the windows on each alternate floor. They may also be arranged below the windows. Fire barrier Fire barrier Fire barrier Vertical fire barriers: "(...) The space provided for ventilation must not continue beyond the fire break wall. The space provided for ventilation must be filled with an insulating material which is at least as thick as the fire break wall, remains dimensionally stable in fire and has a melting point > 1,000 °C. (…)" Further information on the execution and arrangement of fire barriers, as well as exceptions (cases in which horizontal fire barriers are not required) can be found in the aforementioned "Sample List of Technical Building Regulations" (MLTB). 62 | 63 20. TECHNICAL DATA/PRODUCT DATA RESOPLAN® Properties Modulus of elasticity Lengthwise Crosswise Test method Unit EN ISO 178 N/mm N/mm2 14,000 10,000 Flexural strength Lengthwise Crosswise EN ISO 178 N/mm2 N/mm2 140 100 Tensile strength Lengthwise Crosswise EN ISO 527-2 N/mm2 N/mm2 100 70 Density ISO 1183 g/cm3 approx. 1.4 Dimensional stability at elevated temperature Lengthwise Crosswise DIN EN 438-2 % % approx. 0.2 approx. 0.4 Resistance to rapid changes of climate Appearance Flexural strength index Ds Bending module index Dm DIN EN 438-2 Degrees ≥4 ≥ 0.95 ≥ 0.95 Resistance to weathering (including lightfastness) Contrast Appearance Value 2 DIN EN 438-2 Degrees Lightfastness DIN EN 438-2 Grey scale (EN 20105-A02) 4-5 Coefficient of thermal expansion Lengthwise Crosswise DIN 51045 (+80/-20 °C) 1/K 1/K 0.9 • 10-5 1.6 • 10-5 Thermal conductivity DIN 52612 W/(m • k) approx. 0.3 Surface resistance (antistatic) DIN EN 61340-2-3 (no static charging) Ω 10-9-10-11 Water vapour diffusion resistance factor DIN 52615 approx. 17200 Fire behaviour RESOPLAN® RESOPLAN® F DIN 4102-1 DIN 4102-1 B2 B1 RESOPLAN® RESOPLAN® F EN 13501-1 EN 13501-1 D-s2, d0 B-s2, d0 Calorific value DIN 51900 MJ/kg ≥3 ≥4 approx. 20 Product data RESOPLAN® MOTIV IN RESOPLAN® RESOPLAN® Effect RESOPAL® X-LINE Format 3050 mm x 1320 mm 3650 mm x 1320 mm 2180 mm x 1020 mm 3050 mm x 1320 mm 3650 mm x 1320 mm 2180 mm x 1020 mm 3050 mm x 1320 mm 3050 mm x 1320 mm 3650 mm x 1320 mm 2180 mm x 1020 mm Thickness 6, 8, 10, 12 mm and 3 mm for composite elements (roughened on the rear) 6, 8, 10, 12 mm and 3 mm for composite elements (roughened on the rear) 6, 8, 10, 12 mm and 3 mm for composite elements (roughened on the rear) 6, 8, 10, 12 mm and 3 mm for composite elements (roughened on the rear) Rear side Same decor on both sides; all decors available as balcony panel with P00105 Pearl White rear P00160 Silver Grey Same decor and surface finish Same decor on both sides; all decors available as balcony panel with 154 Sugar White rear Surface 60 matt, dirt-repellent, good reflection values 60 matt, dirt-repellent, good reflection values ME (Mystic Effects), matt glossy surface texture for lively building facets 60 matt, dirt-repellent, good reflection values Warranty This brochure has been prepared and checked to the best of our knowledge and belief. Nevertheless, we cannot accept any liability for the correct nature of its contents. Liability of the publisher Resopal GmbH and the brochure's editors is excluded in all cases of personal injury, property damage and purely financial loss resulting from use of the brochure. Image rights Illustrations are reproduced courtesy of the respective owners of the rights. If these cannot be identified, any claims arising will be settled within the framework of customary agreements. Subject to errors, changes and improvements! Contact List of suppliers Test reports and certificates RESOPAL® X-LINE RESOPLAN® The current collections, test reports, certificates, our list of suppliers and addresses to contact for the respective countries can be found on the Internet at: www.resopal.de or: 64 | 65