5.1 INTRODUCTION The thermoinsulated panels of Corus-Kalpinis-Simos SA are produced according to the European Standard pren 14509 (CEN /TC128/SC110) REV 10/2001 (OCTOBER) "Self-supporting double skin metal faced insulating Sandwich panel Factory made products Specification" This standard which is under approval process by CEN (European Standardization Committee) defines in precision a series of specifications that the panels should follow. These specifications regard: ñ External surfaces (Metal sheets) ñ Completion materials (Polyurethane) As well as additional technical data of the final product such as: ñ Attributes, (mechanical thermo-insulating, soundproofing, humidity resistance, air sealed) ñ Dimensional tolerances ñ Categorization ñ Marking packaging ñ Tests 5.2 EXTERNAL SURFACES SHEETS The steel sheets that Corus-Kalpinis-Simos SA uses for the production of the thermo-insulated panels are exclusively galvanized manufactured prepainted sheets and follow the specifications below: 5.2.1 It regards the types of prepainted sheets: Polyester PVF2 (PVDF) Stelvetite Foodsafe (CES120Antistatic)-Satin Plastisol Steel quality: Type S280GD+Z275 according to EN 10147: 2000. Steel grade with minimum yield strengtht 280N/mm 2 and guaranteed minimum tensile strength 360 N/mm 2. Metal base thickness of 0.50mm and 0.55 mm. Substrate anticorrosion metal coating Galvatite (hot-dip zinc coating) of minimum guaranteed total mass of 275 gr/m 2. By order can also be used sheets grade S320GD+Z275 (EN 10147: 2000) with minimum yield strengtht 320N/mm 2 and guaranteed minimum tensile strength 390 N/mm 2. Also, by order sheets with thickness 0.60mm. 5.2.2 It regards the types of prepainted sheets: Colorcoat HPS 200 Scintilla Celestia Steel quality: Type S220GD+ZA255 according to EN 10326:2004. Steel grade with minimum yield strengtht 220N/mm 2 and guaranteed minimum tensile strength 300 N/mm 2. Metal base thickness 0.50mm. Substrate anticorrosion metal coating Galvalloy (Zn~95%, aluminium Al~5%) of total mass of 255 gr/m 2. The alloy has the same thickness as a 275gr/m 2 pure zinc coating, but its mass is less owing to the lower density of alumunium relative to pure zinc. 5.1
5.2.3 Final coating of organic paint The prepainted sheets with final surficial paint follow the standard EN 10169-1:2003 They are used for various things regarding the type, the thickness and the tolerance of the surficial protection. The technical characteristics and attributes of the organic paints, the thickness of the final layer of the paint of the external side of the sheets as well as the thickness of the internal in contact with polyurethane, are mentioned analytically in unit 2. 5.2.4 Tolerances The dimensional tolerances of all the steel sheets follow the standard EN 10143:1993. regarding the tolerances for the metal thickness including the thickness of the galvanism but not the thickness of the final surficial paint the following apply: Nominal thickness 0,40 mm >0,40 mm 0,60 mm >0,60 mm 0,80 mm Thickness tolerances for sheet s width 1200 mm >1200 mm 1500 mm ±0,05 mm ±0,06 mm ±0,07 mm ±0,06 mm ±0,07 mm ±0,08 mm 5.2.5 Steel standards Steel according to its chemical constitution, properties, and use, follow different standard bodies. The steel sheets used for the production of thermo-insulated panels follow the standards EN 10142:2000, EN 10214:1995, EN 10215:1995, EN 10147:2000 and EN 10143:1993 In the following table are reported the typical properties of the steel sheets and the metal coatings for corrosion protection. The data in bold are the steel sheets which Corus-Simos-Kalpinis uses. LOW-CARBON STEEL SHEET 10142 STRUCTURAL STEEL SHEET 10147 STEEL GRADE TENSILE YIELD STRENGTH STRENGTH max. (N/mm 2 ) max. (N/mm 2 ) STEEL GRADE YIELD STRENGTH max. (N/mm 2 ) TENSILE STRENGTH max. (N/mm 2 ) DX 51 D DX 52 D - 300 500 420 A minimum value of 140 N/mm 2 may be expected A minimum value of 270 N/mm 2 may be expected S 220 GD S 250 GD S 280 GD S 320 GD S 350 GD S 550 GD 220 250 280 320 350 550 300 330 360 390 420 560 HOT-DIPPED ZINC ZING COATINGS ( ) 10142 10147 TOTAL AMOUNT OF ZINC ON BOTH SURFACE (g/m 2 ) THICKNESS OF COATING ON ONE SURFACE (Ìm) OTHER METALLIC COATINGS ( ) 10214 (95% Zn - 5% Al) TOTAL AMOUNT OF ZINC ON BOTH SURFACE (g/m 2 ) THICKNESS OF COATING ON ONE SURFACE (Ìm) 100 140 200 225 275 350 100 140 200 225 275 350 7 10 14 16 19.5 25 200 255 300 200 255 300 15 20 23 5.2
5.3 COMPLETION MATERIALS THERMO-INSULATING MATERIAL POLYURETHANE The hard polyurethane foam (PUR) is produced in a line of continuous smelting through mixture of two basic chemical substances, isocyane and polyole. Pentane is used as bulging material which does not contain chloroflouocarbons and hydrochloroflouocarbons (CFC and HCFC) harmful ingredients for the ozon layer in the atmosphere. The hard bulged polyurethane foam follows the standard pren 13165. The special characteristics of the hard polyurethane foam make it one of the best insulating materials which gives excellent advantages. It combines thermoinsulation, load tolerance, air-sealing, endurance to hits as a core of thermal panel, small weight and easy maintenance. Especially for thermoinsulating panels the polyurethane maintenance is null. A special characteristic of the hard polyurethane foam that makes it the best thermoinsulating material in the industry of premanufactured thermoinsulating panels is that for a small period between the mixture of side materials and the total maturing of the final product it presents exceptionally big adhesiveness that allows to stick with easiness on the inside of the sheets without additional adhesive materials. The power of accretion of the hard polyurethane foam with the sheets is usually bigger than the tolerance in drawing and partition of the insulating material itself. The polyurethane insulation has great endurance in a big series of chemicals, resolvents and oily products. It does not favour the growth of funguses and it is unaffected to mold and microorganisms. Typical properties of rigid polyurethane foam PROPERTIES VALUE UNITS STANDARD DENSITY 40~42 kg/m 3 DIN EN ISO 845 CLOSED CELLS >95 % DIN ISO 4590 WATER ABSORPTION AFTER 24 HOURS 2.4 VOL % DIN 53 428 THERMAL CONDUCTIVITY AFTER 24 HOURS AT 23ÆC 19.8 mw/mk Hesto-instrument DIMENSIONAL STABILITY - 30ÆC + 80ÆC H -0.1 +0.8 W -0.1 +0.3 L -0.1 +0.5 % DIN 53 431 FLAMMABILITY µ1 / µ2 DIN 4102, part 1 5.4 PROPERTIES 5.4.1 Mechanical TABLE MINIMUM STRENGTH VALUES FOR INSULATED POLYURETHANE PANELS /mm 2 PANEL TYPE TENSILE COMPRESSION SHEAR SHEAR COEFFICENT RL 40 WL 40 WLC 40 0,08 2,90 RL 50 WL 50 WLC 50 0,09 3,00 RL 60 WL 60 WLC 60 0,08 3,10 RL 80 WL 80 WLC 80 2,70 RL 100 WL 100 WLC 100 0,06 0,09 2,50 5.3
5.4.2 Thermal PANEL TYPE RL 30 RL 40 RL 50 RL 60 RL 80 COEFFICIENT W/(m 2 K) 0,69 0,54 0,47 0,38 0,29 RESISTANCE (m 2 K)/W 1, 28 1,68 1,96 2,48 3,28 PANEL TYPE WL 40 WLC 40 WL 50 WLC 50 WL 60 WLC 60 WL 80 WLC 80 WLC 100 COEFFICIENT W/(m 2 K) 0,58 0,47 0,39 0,30 0,21 RESISTANCE (m 2 K)/W 1, 56 1,96 2,36 3,16 4,71 PANEL TYPE FL 80 FL 100 FL 120 FL 150 FL 180 COEFFICIENT W/(m 2 K) 0,26 0,21 0,18 0,14 0,11 RESISTANCE (m 2 K)/W 3,76 4,71 5,66 7,09 8,52 NOTE: Thermal conductivity as per DIN 52612 Ï=0,0025 W/(mK) 5.4.3. Sound-insulating attributes For the thermoinsulated panels of sandwich type, the soundproof contributor has almost the same value regardless of the type and thickness. According to the sound measurement tests, to which they were submitted in the room for tests of the National Organism for Material Measurment in Dormund Germany, the wall applications panels of type WL 60 and WLC 60, have sound proof contributor Rw=25dB. 5.4.4. Water tightness The achievement of water tightness of the composite panels type ECOPANEL is based on the special configuration of the joints for the RL type as well as for the WLC/WL types. According to the measurements of the DIFB institute (Germany) the water infiltration for: ñ Roof panel of RL type: null up to 3 lt. /m2.min, with wind of 12m/wind sec. (EN 089030.2/EN 86) ñ Wall panel of WLC type: null for 600 P (DIN 18055/EN 42) 5.4.5 Air tightness Correspondingly, the air tightness of the composite panels type ECOPANEL is based on the existence of a special foamy material in their joint. According to the measurements of the DIFB institute (Germany) the air infiltration for: ñ Roof panel of RL type: 0,00026 m3/h.m (DIN 18055/EN 42) ñ Wall panel of WLC type: 0,07 m3/h.m (600 P ) (DIN 18055/EN 42) 5.4
5.5 TOLERANCES 5.5.1 Dimensional W3 100 mm 100 mm WL D width measurement points ËÌÂ Ì ÙÚËÛË apple Ô W1 W3 h1 D 20mm 20mm 20mm d RL width measurement points ËÌÂ Ì ÙÚËÛË apple Ô e2 W1 W2 e1 Thickness D=Nominal thickness d=overall thickness D+h 1 +h 2 h 1 =40mm for all Ecopanel RL Tolerance: D 100mm ±2mm D>100mm ±3mm Tolerance: d 100mm ±3mm d>100mm ±4mm Tolerance ±1mm Width W 1 =1.022mm overall width Ecopanel WL W 2 =1.070,3mm overall width Ecopanel RL W 3 =1.000mm nominal width Ecopanel RL Î È WL e 1 =42,5mm e 2 =48,3mm { Side displacement inner - outer skin Tolerance ±3mm Tolerance ±3mm Tolerance ±3mm Tolerance ±3mm 5.5
5.5.2 Length L L = =MHKO LENGTH (mm) (mm) L 6.000 mm Tolerance ±4 mm 6.000 mm < L 12.000 mm Tolerance ±6 mm L 12.000 mm Tolerance ±8 mm for all Ecopanel RL - WL - WLC 5.5.3 Rectangularity S W3 S = 0,004 x W3 =4 mm for Ecopanel RL S = 0,005 x W3 =5 mm for Ecopane WL-WLC 5.6
5.5.4 Curvature 200 mm T T L 200 mm fq (+) fq s (-) fq = s - 40 TOMH SECTION T-T (KATA ATO ) T-T Ecopanel RL Ecopanel WL - WLC Fq = 0,01 x W3 (Nominal width) = 10mm Fq = 0,0085 x W3 (Nominal width) = 8.5mm 5.7
5.5.5 Flatness Lw2 Lw3 T Lw1 T WIDTH ATO MHKO LENGTH Lw1 Lw2 Lw3 fw1 fw2 fw3 d TOMH SECTION T-T (KATA MHKO ) T-T Ecopanel WL flat Ecopanel WL - WLC lined LW 200 mm fw 0,6 LW 200 mm fw 0,4 LW = 400 mm fw 1,0 LW = 400 mm fw 0,7 LW 700 mm fw 1,5 LW 700 mm fw 1,0 5.8