SUNPAL Multiwall Polycarbonate Standing-Seam Architectural System

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SUNPAL®

Multiwall Polycarbonate

Standing-Seam

Architectural System

Technical Guide

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Contents Page

Introduction 3

Panel Speciﬁcation

4 Colors and Solar Transmissions

5 Thermal Insulation Properties

5 Typical Physical Properties

5 System Components Deﬁnition

6 A) Joiners

6 B) Fasteners

6 C) Sealing & end cap Strips

6 D) Alu Span-Bar

7 System Components List

8 Installation Data

11 Roof structure

11 Assembled System Width

11 Purlin Design - Recommended spans

11 Rafter Design - Recommended Spans

11 Installation Instructions

12 Assembly Details

15 Cladding Details

16

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X

_Introduction

SUNPAL is an advanced multiwall polycarbonate panel system that combines smart design, light transmission, high thermal insulation and strength. It offers a lightweight, expansion-free and leak-proof design that withstands very high loads. The system’s many advantages make it ideal for long term installations in various design projects. As architectural glazing system, SUNPAL is applied in a variety of roofing and cladding uses, in flat or curved designs.

SUNPAL is a self fastening system, based on extruded Sunlite panels of 8mm, 10mm, 18mm and 20mm thickness. The panels join together by polycarbonate or aluminum joiners which are sealed at the ends by End-caps. T-Fasteners ﬁx the system to the structure by clamping, without any penetration through the panels.

Aluminum Sealing Strip closes the panel lower end to prevent dirt from entering the flutes, and provide efficient drainage. U-Profile (PC / aluminum) or Al F-Profile seals the upper end of the panel. Aluminum F-Profile fits to the panel side edges, to interface with the structure for a completely framed installation.

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_{Panel Specification}

SUNPAL panels are of multiwall structure, available with thicknesses of 8mm, 10mm, 18mm and 20mm. Standard SUNPAL panels have UV protection on both sides (speciﬁc order can be produced with UV protection on one side only). Maximum panel length is 11.99 (typical stoke length).

Panel Data Drawing

SUNP

AL® 8/600 Lite

Width: 600mm

Height: 23.5mm

Height with PC-Joiner: 33mm

Weight: 1.10 Kg/m, 1.83 Kg/m²

Min. cold bending radius: 2.0m

SUNP

AL® 8/600

Width: 600mm

Height: 23.5mm

SUNP

AL® 10/600

Width: 600mm

Height: 25.5mm

SUNP

AL 18/1000

Width: 1000mm

Height: 33.5mm

SUNP

AL® 20/1000

Width: 1000mm

Height: 35.5mm

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_{Colors and Solar Transmissions}

Color LT SHGC SC Color LT SHGC SC SUNP AL® 8/6000 Clear 65% 0.63 0.72 SUNP AL® 10/600 Clear 65% 0.63 0.72 Bronze 25% 0.40 0.46 Bronze 25% 0.40 0.46

White Opal 26% 0.37 0.43 White Opal 26% 0.37 0.43

White Ice 50% 0.56 0.64 White Ice 50% 0.56 0.64

Solar Ice 20% 0.28 0.32 Solar Ice 20% 0.28 0.32

Solar Grey 30% 0.45 0.52 Solar Grey 30% 0.45 0.52

Solar Control Grey 20% 0.30 0.34 Solar Control Grey 20% 0.30 0.34

Green 50% 0.56 0.64 Green 50% 0.56 0.64 Blue 50% 0.60 0.69 Blue 50% 0.60 0.69 Red 20% 0.52 0.60 Red 20% 0.52 0.60 Color LT SHGC SC Color LT SHGC SC SUNP AL® 18/1000 Clear 50% 0.54 0.62 SUNP AL® 20/1000 Clear 50% 0.54 0.62 Bronze 20% 0.35 0.39 Bronze 20% 0.35 0.39

White Opal 20% 0.30 0.34 White Opal 20% 0.30 0.34

White Ice 40% 0.48 0.55 White Ice 40% 0.48 0.55

Solar Ice 15% 0.23 0.26 Solar Ice 15% 0.23 0.26

Solar Grey 30% 0.44 0.51 Solar Grey 30% 0.44 0.51

Solar Control Grey 15% 0.25 0.29 Solar Control Grey 15% 0.25 0.29

Green 38% 0.46 0.53 Green 38% 0.46 0.53

Blue 36% 0.50 0.57 Blue 36% 0.50 0.57

Red 15% 0.44 0.50 Red 15% 0.44 0.50

LT (Light Transmission) = The percentage of incident visible light that passes through an object.

SHGC (Solar Heat Gain Coeﬃcient) = The percentage of incident solar radiation transmitted by an object, which includes the direct solar transmission and the part of the solar absorption radiated inward. SC (Shading Coeﬃcient) = The amount of the sun’s heat transmitted through a given window compared with that of a standard 1/8- inch-thick single pane of glass under the same conditions.

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_{Thermal Insulation Properties}

Property SUNPAL® 8/600 Lite SUNPAL® 8/600 SUNPAL® 10/600 SUNPAL® 18-20 /1000

U-Value [Watts/m²·°C] 2.45 2.45 2.10 1.50

R-Value [m²·°C/ Watt] 0.41 0.41 0.47 0.67

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_{Typical Physical Properties}

Property Method** Conditions Units Value

Density D-792 g/cm³ 1.2

Heat deﬂection temperature (HDT) D-648 Load: 1.82 MP °C 130

Service Temperature - Short term °C -50 to +120

Service Temperature - Long term °C -50 to +100

Coeﬃcient of linear thermal eaxpansion D-696 cm/cm °C 6.5 x 10

Tensile strength at yield D-638 10 mm/min MPa 62

Elongation at break D-638 10 mm/min % >80

Impact falling dart ISO 6603/1 J 40-400

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_{System Components Definition}

The SUNPAL system is generally deﬁned by the panel type. All the other components are selected to match this panel.

A) Joiners

The Joiners (PC or aluminum) ﬁt all panel types. The choice between them is generally by the application - PC Joiner or Alu Joiner ‘R’ for rooﬁng (or any situation where the seam is external); Alu-Joiner ‘C’ for cladding (hidden seam).

PC-Joiner (part 02) is 22mm high by 39mm wide, extruded polycarbonate colored to match the panels. Maximum length is 11990mm, with weight of 160gr/m. The PC-Joiner should overhang about 100mm beyond the last fastener.

End-Cap for PC-Joiner (part 03) is a clear acrylic cap, designed to plug the PC-Joiner ends. This end-cap prevents water and dirt from entering the joiner, it helps to reinforce the joiner ends, and provides harmonic ﬁnished appearance to the systems ends.

Alu Joiner ‘R’ (part 12) is 40mm wide and 22mm high, mill-ﬁnish extruded aluminum. Maximum length is 6000mm. The Alu-Joiner ‘R’ should overhang about 150mm beyond the last fastener.

End-Cap for Alu Joiner ‘R’ (part 13) is a mill-ﬁnished aluminum plate, designed to close the Alu Joiner ‘R’ ends. This end-cap is ﬁxed by inserting two screws into the joiner.

Alu Joiner ‘C’ (part 04) is 39mm wide by 54mm high, extruded aluminum with mill ﬁnish. Maximum length is 6000mm. The Alu-Joiner should overhang about 250mm beyond the last fastener.

End-Cap for Alu Joiner ‘C’ (part 05) is a mill-ﬁnish aluminum plate, designed to close the Alu-Joiner ends. This end-cap is ﬁxed by inserting two screws into the joiner.

B) Fasteners

T–Fastener (part 08) - SUNPAL roofing system is attached to the supporting structure by the T-Fasteners. These are stainless steel concealed clips that are fixed onto the structure with screws. The fasteners have four different sizes to match each panel type. For installing SUNPAL system onto wooden structure, the T-Fasteners are fixed with Wooden Screws (part 12). For metal structure, Metal Screws (part 13) are used. As standard, each fastener is fixed with two screws. For high wind areas, using three screws per fastener is recommended.

T-Stopper (part 09) - To prevent “travelling” of the panels, it is recommended to fix one T-Stopper at a certain fixing point along each Joiner. This will be the only longitudinal fixed point, while all other fixings are floating. It is a T-Fastener with added stopper plate, which fits into slit in the attaching panels (prepared on spot).

C) Sealing & end cap Strips

The Alu Sealing Strips (part 06) are mill-finished aluminum profiles in four sizes, to match each type of panel. Maximum length is 6000mm (stock length). These are used as a closure for the panels end (usually the lower), to prevent penetration of dirt end moisture, and provide efficient drainage. U-Profile is used for sealing the panel’s upper end, to prevent penetration of moisture and dirt.

PC U-Proﬁles (part 07) are made of polycarbonate, and have two types to suite 8mm and 10mm panels. Their maximum length is 12mm (stock length).

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Alu U-Profile (part 16) is an aluminum profile mill finished, with two types of sizes to suit 18mm and 20mm panels. Their maximum length is 6000mm (stock length).

Alu F-Profiles (part 11) are available at four sizes to match each panel type. These are aluminum profiles mill finished, with maximum length of 6000mm (stock length). The F-Profiles are used generally as a side fixing detail, also possible as an upper-end closure.

D) Alu Span-Bar (part 10)

This is an aluminum proﬁle that can be used as a rafter on a structure frame. It can be straight or curved (by rolling), and designed to perform both as a rafter and a fastener (no T – Bar Fasteners required in Span-Bar applications). The Span-Bar has four sizes to match each panel type, and its maximum length is 6000mm.

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_{System Components List}

# Component Drawing Speciﬁcation Stock Length / Quantity

0200 PC Joiner (8-20mm) Panel matched 12m

0300 End-Cap for PC Joiner (8-20mm) Natural clear 200 per box

1200 Alu Joiner ‘R’ (8-20mm) Mill ﬁnish 6m

1300 End-Cap for Alu Joiner ‘R’ (8-20mm) Mill ﬁnish

0808 T-Fastener (8 mm) Stainless steel 200 per box

0908 T-Stopper (8 mm) Stainless steel 50 per box

0910 T-Stopper (10 mm) Stainless steel 50 per box

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0920 T-Stopper (20mm) Stainless steel 50 per box

1400 Metal Screw (8-20mm) Self-Drilling 500 per box

1500 Wood Screw (8-20mm) Tapping 500 per box

0608 Alu Sealing strip (8mm) Mill ﬁnish 6m

0610 Alu Sealing strip (10 mm) Mill ﬁnish 6m

0708 PC U-Proﬁle (8mm) Clear 6m

0710 PC U-Proﬁle (10mm) Clear 6m

1618 Alu U-Proﬁle (18mm) Mill ﬁnish 6m

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1108 Alu F-Proﬁle (8mm) Mill ﬁnish 6m

0400 Alu Joiner ‘C’ (8-20mm) Mill ﬁnish 6m

0500 End-Cap for Alu Joiner ‘C’ (8-20mm) Mill ﬁnish 6m

1008 Alu span-bar (8mm) Mill ﬁnish 6m

1010 Alu span-bar (10mm) Mill ﬁnish 6m

1018 Alu Span-Bar (18mm) Mill ﬁnish 6m

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_{Installation Data}

Roof structure

SUNPAL system ﬁts for both rafter and purlin construction. The recommended minimum roof slope for SUNPAL applications is 5%. For lower slopes rafter design is recommended.

Assembled System Width

SUNPAL® 8/600 and 10/600

SUNPAL® 18/1000 and 20/1000

Purlin Design - Recommended spans

for wind load of 1kPa (mm)

Polycarbonate Joiner Aluminum Joiner - R Aluminum Joiner - C Panel Type Panel Width Mid-Span End-Span Mid-Span End-Span Mid-Span End-Span

SUNPAL Lite 8 mm 600 900 700 1,300 950 1,500 1,100

SUNPAL 8 mm 600 1050 825 1,400 1,000 1,600 1,200

SUNPAL 10 mm 600 1,250 950 1,600 1,200 1,800 1,400

SUNPAL 18/20 mm 1,000 1,350 1,000 1,600 1,200 1,800 1,400

Rafter Design - Recommended Spans

With max. intervals of T-Fasteners along rafters for wind load of 1kPa(mm)

Polycarbonate Joiner Aluminum Joiner - R Aluminum Joiner - C Panel Type Rafter Centers Internal

Fasteners Fasteners at Rafter Ends Internal Fasteners Fasteners at Rafter Ends Internal Fasteners Fasteners at Rafter Ends SUNPAL Lite 8 mm 602 900 700 1,300 950 1,500 1,100 SUNPAL 8 mm 602 1050 825 1,400 1,000 1,600 1,200 SUNPAL 10 mm 602 1,250 950 1,600 1,200 1,800 1,400 SUNPAL 18/20 mm 1,002 1,350 1,000 1,600 1,200 1,800 1,400

Note 1: The above spans are speciﬁed for wind loads of 1000 Pa (21 psf ) in rooﬁng applications. For vertical or internal applications, contact your local SUNPAL distributor.

Note 2: In curved applications, Aluminum Joiners will have to be pre-rolled, while Polycarbonate Joiners can be cold curved to the rooﬁng radius.

1002mm 602mm

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1. Cut to size

Cut panels to length allowing for an overhang of no more than 100mm at each end. We recommend a penetration of minimum 50mm into the gutter!

Use a circular saw or hand saw with ﬁne tooth blades for easier and better cutting.

2. Slit for Alu Sealing-Strip

Using a small cutting disc (2 mm thick), prepare 18 mm deep horizontal cuts at each end of the panel teeth. This cut should be in parallel to the panel top face, but without injuring the panel surface.

Since it needs precision, it is highly recommended to perform this action before assembly.

Cut to Size

A

B

Slit for AIu Sealing Strip

C

Remove Inner Masking

Fix Sealing Strip

G

I

Fix Side Flashings

Assemble

E

Fix T-Bar Fasteners

D

F

Remove Outer Masking

Fix Joiner End-Caps

H

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3. Remove cutting chips

Using a vacuum cleaner or an air compressor with blow gun – blow out any “swarf” or loose particles from inside the panel (ensuring both ends of panel are free of the plastic envelope/ sleeve).

4. Position ﬁrst panel

For symmetric installation - determine the layout of the ﬁrst panel, starting in the centre of the structure (this can be determined by dividing the structure width x 2 and adding half the width of the panel).

For “side to side” installation - Set-up the first panel, fitted to the side flashing.

5. Remove inner Masking

Remove the protective foil from the internal face only. Keep this side away from the roof purlins until ﬁnal positioning of the panel, to avoid scratching.

6. Fix T-Stopper

At the top purlin (100mm from end of sheet for rafter only) place a T-Stopper up against panel and ﬁx into place using hex head ﬁxings provided.

For curved application on arched structure, the T-Stopper should ﬁx as the mid fastener at the top of the arch. On wall application the T-Stopper should ﬁx at the opposite to the expansion allowance.

7. Fix T-Fasteners

Along panel on remaining purlins (see span table for rafter design), place T fasteners against panel and fix into place using hex head fixings provided (2 fixings for standard, 3 fixings for high wind areas and cyclonic regions).

8. Position next panel

Remove protective ﬁlm from underside of second panel and place against T fasteners.

9. Locking the 2 panels together

Using a rubber mallet, start to ﬁx the Joiner, locking the 2 panels together by striking with short intervals (5-10cm) along the joiner. Start at the bottom end, and work your way up the roof (ensure that the joiner overhangs the panel ends by 13mm, where the aluminum sealing strip will be installed later).

10. Aluminum Joiner

If using Aluminum Joiners ‘R’, before installing, drill 7mm diameter holes through the joiner sides along the line provided, 1000mm centers and install as per step 9.

After locking, ﬁx M6 bolt through holes pre-drilled previously through aluminum joiner with lock nut and tighten (making sure it’s ﬁrm. Do not over tighten).

11. Remove outer Masking

Remove the protective foil from the panel’s external face shortly after installation.

Delaying foil removal can make it very difficult to remove later (on hot days remove top protective film straight away to prevent film from bonding with the panel).

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12. Repeat steps 5 to 9 (or 11) until all panels are in place except for end panels.

13. Determine width of end panels required. Using a circular saw (ﬁtted with ﬁne tooth blade) or jigsaw cut the end panels to width.

14. Along the cut edge of the SUNPAL panel, push on the aluminum F section (cut to size) so that it is ﬁrmly secured.

15. Lift the end panel into place and repeat step 9 (or 9-11).The aluminum F section should be hard up against last rafter or end of purlins (note: if ﬁxing to metal purlins, make sure the ends of the purlins are closed oﬀ ).

16. Fix the F-Sectionto the rafter or end of purlin using tek screws.

17. Start installing the U-Profileat the panel top end by pushing on. It is designed to be a tight fit so start by pushing one end on and slowly tap it until it is firmly inserted. PC U-Profile (for SUNPAL 8-10mm) is to tap by hand, for Al U-Profile (SUNPAL 18-20mm) use a rubber mallet.

18. Start installing the Al Sealing Stripat the panel bottom end by pushing it on. It is designed to be a tight ﬁt so start by pushing one end on and using a mallet slowly tap it until it is ﬁrmly inserted. These sealing strips are necessary to prevent penetration of dirt end moisture.

19. Joiner End-cap ﬁxing

Insert Joiner End-cap in both joiner ends.

The End-cap for PC Joiner is pushed into place. The End-cap for Alu Joiner is ﬁt with screws. There is no need to use silicone sealants or adhesives of any kind.

20. Side ﬂashings

These are used on both sides of the structure, as a fastener as well as a ﬂashing.

They are fit either for full width or cut to size panels. Purpose made flashings are required in some situations. End-cap should fit to these flashings on both ends.

Notes:

SUNPAL system does not require using silicones or adhesives for parts interface. For sealing of ﬂashing assemblies Use only PALRAM approved accessories, silicones, sealing tape, closure ﬁxtures etc.

For cleaning SUNPAL multi panels use a pressure cleaner and allow natural drying. Do not use cloth/ sponge/ chamois or similar, doing this can scratch the panels and harm their performance.

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_{Assembly Details}

Legend

01 Panel 02 PC Joiner

03 End-Cap for PC Joiner 04 Alu Joiner ‘C’

05 End-Cap for Alu Joiner ‘C’ 06 Alu Sealing Strip

07 PC U-Proﬁle 08 T-Fastener 09 T-Stopper 10 Alu Span-Bar 11 Alu F-Proﬁle 12 Alu Joiner ‘R’

13 End-Cap for Aluminum Joiner ‘R’ 14 Metal Screw 15 Wood Screw 16 Alu U-Proﬁle 8 4 1 2 3 6 5 7 9 10 14 11 15 12 16 13

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Cladding Detail 1: Cladding Base

Note: Set T-stopper (09) at the opposite to allow for expansion at this end.

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Cladding Detail 3: Corner Details

Cladding Detail 4: Panels Cladding Joint

Note: Set T-stopper (09) at the opposite to allow for expansion at this end.

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Cladding Detail 5: Parallel Apron Flashings

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Cladding Detail 7: Cladding Top Flashings

Cladding Detail 8: Cladding Top Flashing - Hidden Seams

Note: Set T-stopper (09)

at the opposite to allow for expansion at this end.

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Rooﬁng Detail 1: Apron Flashing

Rooﬁng Detail 2: Eave

Note: For information on allowed overhang please refer to “a) Joiners” section on page 6.

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Rooﬁng Detail 3: Barge Details

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Rooﬁng Detail 5: Ridge Flashing

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Rooﬁng Detail 8: Overlap Panels

Rooﬁng Detail 7: Valley Gutter

Note: For information on allowed overhang please refer to “a) Joiners” section on page 6.

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HYG Technology is a trademark of PALRAM Industries Ltd. EUROPE .PALRAM EUROPE LTD Tel X_{(44) 1302 380776} Fax X_{(44) 1302 380788} [email protected] PALRAM UK Tel X_{(44) 1302 380738} Fax X_{(44) 1302 380739} [email protected] ISRAEL PALRAM ISRAEL Tel X_{(972) 4 8459 900} Fax X_{(972) 4 8459 980} [email protected] USA PALRAM AMERICAS Tel X_{610 285 9918} Fax X_{610 285 9928} [email protected] 07.08 - 69137

Inasmuch as PALRAM Industries has no control over the use to which others may put the material, it does not guarantee that the same results as those described herein will be obtained. Each user of the material should make his own tests to determine the material's suitability for his own particular use. Statements concerning possible or suggested uses of the materials described herein are not to be construed as constituting a license under any PALRAM Industries patent covering such use or as recommendations for use of such materials in the infringement of any patent. PALRAM Industries or its distributors cannot be held responsible for any losses incurred through incorrect installation of the material. In accordance with our company policy of continual product development you are advised to check with your local PALRAM Industries supplier to

.ensure that you have obtained the most up to date information

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_{Manufacturer’s Lifetime Warranty}

SUNPAL panels are guaranteed for water leak-proof performance for 25 years. SUNPAL panels bear a limited lifetime warranty not to lose more than 8% of light transmission for 15 years and no more than 1% per year thereafter, when measured according to ASTM D1003-77. SUNPAL panels are warranted for up to 10 years from the date of purchase not to break or fail as a result of impact by hail measuring up to 20mm in diameter, in speed of up to 21m/s.

Note: these warranties will apply only if the panels are installed and maintained according to PALRAM speciﬁcations and installa-tion instrucinstalla-tions.