Manufacturing And Installation of Aluminum Composite Panels

Views: 234     Author: Julong     Publish Time: 2023-11-23      Origin: aluminum panel systems manufacturer


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Manufacturing And Installation of Aluminum Composite Panels

Aluminum composite panels can be manufactured in several ways. Cold composite and heat composite techniques are two types of composite methods for plastic core panels and two-sided aluminum panels, respectively. However, we will discuss how Julong manufactures its ACP sheets while maintaining a high level of quality.

1. Aluminum Panel Sheet Manufacturing Process

1.1 Cleanliness

The first step in the production of composite aluminum sheets is to clean the aluminum coil. The surface of aluminum coils is coated with lubricants and anti-oxidants as part of the manufacturing process, and some dirt will adhere during transit, affecting adhesion and necessitating cleaning. While passing the coil through a series of tanks, we degrease, deoxidize, and chromatize it.

1.2 Degreasing

Degreasing is the removal of oil and other impurities from a surface. Deoxidizing is used to remove the water from the coil, and aromatization is used to create the abrasive surface. An abrasive surface is required for good primer adhesion on aluminum surfaces.

1.3 Inclusion of a Protective Layer

After cleaning and chemical treatment, a dense chemical protective layer forms on the surface of the aluminum coil; this chemical film can increase the oxidation resistance of the aluminum coil and extend the life of the paint film. To make the core, the grains are melted into a sheet. The adhesive sheet (purchased from DuPont) is applied to both sides of the core.

1.4 PVDF/FEVE Coating

Julong fed the cleaned aluminum coil to a coater, which coated the aluminum coil's outside surface with a high-performance fluorocarbon resin. The aluminum composite sheet panels receive two coats of paint and primer. We use paints from reputable manufacturers such as Nippon, Spectrum, PPG, Monopol, and Akzonobel, and the customization of shades is done in-house. The topcoat is a weather-resistant fluorocarbon resin coating called polyvinylidene fluoride (PVDF). Its high UV resistance and contamination resistance keep the surface of the coated aluminum coil looking good. Fluorocarbon coatings are typically applied to aluminum coils via roll coating and dried at high temperatures. There are three layers of paint, and each coat must be baked at 240 °C for 45 seconds to dry.

1.5 Including the Top and Bottom Layers

Coils are placed on top and bottom of the core to create a sandwich panel. Induction roller heating is used to laminate the aluminum coil to the core. Our ACP has been brought to normal operating temperature with the help of a cooling tower and is now ready for use. The ACP sheet can now be protected with a protective film. After installation, the self-adhesive protection film can be removed. A protective layer is applied to the surface of the coating to prevent damage during future processing, transportation, and installation. The protective film also includes installation instructions for ACP sheets and ACP cladding.

1.6 Choosing the Correct Size

Finally, the ACP board and sheets are customized in length. Julong, on the other hand, uses pallet packaging to protect sheets during shipping. Loading the sheets into trucks while ensuring that the ACP is delivered to the retailer, architects, and facade consultants We maintain consistent communication throughout the transportation process.

2. A Guide to ACP Sheet Installation

With the popularity of aluminum composite panels, we can see that the processing performance of aluminum composite panels is extremely strong, and structural qualities, whether aesthetic or functional, have been evident from the past to the present. Many people, however, are unaware of what the staff should be aware of before constructing aluminum composite panels.

Allow experienced aluminum composite panel manufacturer Julong to quickly explain what needs to be done prior to installation for everyone.

2.1 Interior vs. Exterior Aluminum Composite Panel Installation

The Julong aluminum composite panel is available in three thicknesses for wall cladding: 3mm, 4mm, and 6mm. While 3mm and 4mm can be used on both the inside and outside of a building, 6mm can only be used on the outside of high-rise buildings. Only in this manner can the quality of the ACP cladding be determined.

2.2 Measuring

Check, measure, and modify the horizontal and vertical connectors before construction to reduce the error of aluminum composite panel installation. The first, and perhaps most crucial, step in installing a panel is determining its size. The measurement's precision is critical. Even minor mistakes in this phase can derail the entire process.

2.3 Imitation

Once the size of the panels has been correctly assessed, your provider can fabricate the boards. Fabrication necessitates several procedures, machinery, and expert assistance. Routing and folding are two important steps among them. Aluminum composite panels can be routed using standard routing machines and globally developed vertical panel saws, which include hand panel routers with various types of routing blades. The floor or base should be flat and free of unwanted particles (we recommend using a vacuum cleaner) to minimize denting or bending of ACP sheets. It is recommended that the sheet be routed entirely from the bottom side to minimize long-term property concerns on coated surfaces. The reverse bending of the routed area is frequently prohibited.

The following are some of the tools needed for routing and folding:

For small-scale processing, a manual router with a v-groove blade can be used, whereas a table circular saw or CNC router is required for large-scale processing.

ACP sheet cutting, or sawing, is a simple procedure that can be completed with common commercial metal equipment.

Julong ACP panels of any thickness can be easily punched by sheet metal punching machines.

Because it can be cut with a shear without chipping, the Julong ACP sheet is ideal for shearing.

Julong aluminum composite panels can be easily bent and shaped using a three-roll press machine and a press brake machine.

Twist drills, which are typically used for metals and plastics, can easily drill Julong ACP.

The same rivets used in aluminum structures can be used to connect Julong ACPs or other materials. Because they prevent corrosion on the edges, aluminum blind rivets with SS (Stainless Steel) screws are recommended for outdoor use and high-humidity environments.

When using the pasting technique to attach ACP sheets when thermal expansion is predicted, we recommend using only flexible and weather-resistant adhesive. The flexibility of the adhesive should be between 300 and 350%. The adhesive will have a minimum thickness of 3mm and will be conical in form. It is advised to use glue guns while applying glue.

2.4 Waterproofing

Waterproofing is an important part of the ACP panel installation process. Before installing the aluminum composite panels, the weather barrier that will protect the structure must be erected. A primer should be applied to the framings in this phase, and then the barrier should be used to seal the cladding materials.

2.5 Mounting System

Fabricators use a mounting technique to ensure that the ACP cladding is straight. Once the mounting system is in place, the cladding boards are installed in a predetermined order. A variety of factors influence the order, including the significance of shaped sections and corners.