CONTENTS PAGE

Packaging, Transport and Unloading 3

Storage; Protective Film 4

Processing; Rear Ventilation - General; Module Bar 5

Linear Façade Elements for Horizontal Installation on steel box section walls 6

Linear Façade Elements for Vertical Installation on steel box section walls 7

Linear Façade Elements for Horizontal Installation on Concrete or Masonry 8

Linear Module Bar 9

Linear Façade Elements for Vertical Installation on Concrete or Masonry 10

Installing Pflaum Linear Façade Elements 11-13

Joint Design 13-14

Corner Design for Horizontal Linear Elements 15

Corner Design with Corner Plates for Horizontal and Vertical Linear Elements 16

Base Design for Horizontal Linear Elements 17

Parapet Design for Horizontal Linear Elements 18

Edge part Design 19-20

Façade Gap for Horizontal Linear Elements 20

Drop Profile and Parapet Profile Designs 21

Replacing Damaged Elements 22

Visual Inspections; Cleaning and Retouching 23-24

Other Information 24

3

Linear Elements Wooden Box

Steel Belt

Packaging, Transport and Unloading A protective film is fitted to linear façade panels at our factory to protect the plastic-coated surfaces from damage during production, storage, transport and installation. Due to the edging on both sides of the elements, they are designed to be interlocking. Panels are delivered on special wooden pallets: Pack Height: max. 710 mm Pack Width: 1020 mm for construction widths of 200 – 350 mm 1120 mm for construction widths of 350 -400 mm

Pack Length: max. 14.0 m Pack Weight: max. 4.0 to

Check all packs upon delivery to ensure that they are

complete and undamaged. The recipient must sign the

hauler’s unloading report. All complaints must be noted on

this document and immediately notified to the relevant sales

office.

“TRANSPORT DAMAGE” will only be recognised where

the alleged damage is documented by means of a

photograph showing the goods on the truck and

confirmed on the delivery note. Unless these conditions are

met, all claims in relation to transport damage will be

rejected.

Unloading with Forklift or Crane

Unloading with Forklift or Crane

Unloading with Crane Only

Belt or Chain

Belt or Chain

Traverse

Total Weight approx. 2000 kg

Total Weight approx. 950 kg

Total Weight approx. 1700 kg

Total Weight approx. 4000 kg

Unloading with Crane Only

4

Storage

Panels must be stored on a slight incline to allow any accumulated water to run off. The factory-fitted transport packaging must be opened from the front face of the panels to ensure adequate ventilation. To prevent damage and crush marks to the linear panels, only stack palettes on top of each other and never stack packs on top of each other. When storing elements on an incline, care must be taken to prevent serious deformation (do not allow elements to bend or sag). PFLAUM linear elements must be suitably protected from rain, bad weather and dirt if they are to be stored temporarily in the open air. Fabric tarpaulins should be used for this purpose. Fabric tarpaulins are gas permeable and allow the rapid dispersion of any water which has been absorbed. The build-up of water between panels must be prevented because over time it can cause damage to the panels. PFLAUM linear elements must be stored indoors if longer interim periods are anticipated. Protective Film This film protects the panels from dirt and damage during transport and preparation. The protective film must be removed from the sandwich panels no later than 2 months after manufacture or after a maximum of 2 weeks exposure to the elements. Do not expose the panels to high temperatures. Do not expose the protective film to solvents in the form of thinners, adhesives, paints etc. Failure to observe this information can make it considerably more difficult to remove the protective film. Low temperatures make it easier to remove the film. Always remove the film in a smooth and continuous motion; never jerk the film. The protective film must be removed as soon as the sandwich element has been installed because the film becomes brittle because of the weather in a short period of time. At points where elements will overlap one another, e.g. door frames, the film must be removed prior to installation. Protective foil from the “EXQUISIT/METALLIC” colour ranges is marked with a series of arrows. These arrows indicate the direction in which the film should be peeled off.

5

Processing The linear façade elements consist of steel or aluminium plates. The panels are supplied with a high-quality coating and a protective film to minimise minor damage. If it is necessary to cut, punch or drill the panels, it is essential that cold-cutting techniques that do not produce sparks are used. All splinters

caused by drilling must be removed immediately. Never use grinders (Flex). When installing panels, make sure that the linear module bars are level and perfectly aligned against each other. When using long façade elements, care should be taken to ensure that expansion is within prescribed limits(see ÖNORM B2221). Linear elements may only be fastened centrally to prevent slipping during vertical installation.

Rear Ventilation - General In accordance with ÖNORM B 2219, the free ventilation cross-section must be at least 200cm²/m and no more than 500cm²/m depending on the height of the cladding. The air inlets and outlets must have a free cross-section of at least 150cm²/m. Ventilation slits must be included beneath the window seals for all external wall openings. Vent grilles must not restrict the minimum area for ventilation openings.

Module Bar PFLAUM linear panels can be installed on steel, concrete or wooden substructures using the module bars. These must be checked before commencing installation. For details on module bar distances, refer to Wind suction load values.

Clamping profile as underlay plate

MODULE BAR

6

Linear Façade Elements for Horizontal Installation on Steel Box Walls

Installation Preparations for Installation on Steel Box Walls

With this type of installation, care must be taken to ensure that the steel box wall is absolutely flat, even and aligned. This is especially important because the module bars are fastened directly to the web of the box wall. However, small uneven areas can be levelled out using underlay plates. If the foundation is not level, levelling profiles must be used. Installing Pflaum Linear Module Bars on Steel Box Walls

The module bars can be installed using steel tapping screws fastened directly to the box web. A maximum fastening

interval of 600 mm must be observed at all times. As a rule, two steel screws must be used for each fastening point or box web. The module bars must be perfectly aligned

both horizontally and vertically. If there is no box web available, the module bars must be riveted together using an underlay plate (clamp profile). Make sure that the element widths are precisely measured. Linear Façade Elements for Horizontal Installation on

Steel Box Walls with Additional Box Web Insulation

Installation Preparations for Installation on Steel Box

Walls

To improve thermal bridging in the web area of the box wall, additional insulation must be applied to the web (at least insulation sheets to block out footsteps) to a thickness of 3 – 4 cm. In order to do this, the levelling profile (U-profile) must be fastened directly to the box web near the module bar. A maximum fastening interval of 600 mm must be observed at all times. As a rule, two steel screws must be used for each fastening point or box web. The module bars must be perfectly aligned both horizontally and vertically in the U-profile and then riveted into the flange.

A-A

Clamping profile

Using the Module Bar on Box

Sections

Rear Ventilation

Clamping profile as

underlay plate

X=Rear Ventilation

Opening

A A

X=Rear Ventilation

Opening

Using the Module Bar on Box

sections with Insulation

Clamping

profile

Rear Ventilation

7

Linear Façade Elements for Vertical Installation on Steel Box Walls

The procedure for installing linear elements vertically is essentially the same as for installing elements horizontally although drilled module bars must be used to ensure adequate rear ventilation. A strong joint must be created in the central area of the linear element using a fixing profile to absorb the vertical forces exerted by the elements own weight. The number of fixing profiles to be used depends on the permitted static loading of the box sections and the length and weight of the linear elements. Rear Ventilation

The linear module provides a rear ventilation diameter of 280cm²/m when the box sections and linear elements are installed horizontally. When the box sections are installed horizontally and linear elements are installed vertically, the drilled linear module bars provide a rear ventilation diameter of 200cm²/m for construction widths of 300mm and 235cm²/m for construction widths of 200mm. Variants

Vertical installation of linear elements directly on the steel box wall using fastening clips or steel substructure. The centre of the linear façade element is attached with fasteners to the steel plate box wall or steel substructure. The fixation of the linear elements on the above and on the below area happens with fastening clips, therefore it is expandable. Insulation

Depending on the manufacturer and the material used, the insulation must be secured before it slumps and falls out of the box section.

Fastening Clip

Clamping Profile

8

Linear Façade Elements for Horizontal Installation on Concrete or Masonry

Preparations for Installation on Concrete or Masonry

Due to the common inaccuracies encountered in concrete constructions, the minimum and maximum façade alignments must be calculated when installing elements on concrete. As a result, levelling stirrups must be used: A laser levelling device with both horizontal and vertical measurement capabilities should be used to measure the concrete façade to ensure the flush installation of the module bars (e.g. HILTI PR15 rotation laser). The condition of the concrete or brickwork should be carefully inspected before installation work commences. The appropriate fastening (e.g. nail, dowel or anchor) should be selected for the levelling stirrup (authorisations, experiments). Installing Pflaum Linear Levelling Stirrups and Module

Bars on Concrete or Masonry

Linear Levelling Stirrup

Linear levelling stirrups must be fastened to the relevant building structure at intervals no greater than 600 mm

with two fasteners (according to static requirements). Make sure that the levelling stirrup is flush with the structure in order to be connected to the module bar. The levelling stirrup makes it possible to compensate for building tolerances of up to 3 cm.

Levelling Stirrup

Type: A Type: B

Type: C Type: D

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Length X:

A: 89 mm

B: 119 mm

C: 149 mm

D: 179 mm

9

Linear Module Bar The module bars must be fitted in perfect alignment

both vertically and horizontally and fastened on both sides to the levelling stirrups with tapping screws or rivets in accordance with the static requirements. When aligning the façade, a crimping plier should be used to connect the module bar to the levelling stirrup to aid the installation process. If there are no levelling stirrups in the joint area, the module bars must be riveted together with an underlay plate. Make

sure that the exact element width has been measured.

Installation Surface Tolerances The maximum tolerance for a length of 2990 mm (standard

length of a module bar) is +/- 1 mm

Installation Height Tolerances The maximum tolerance for the entire length of linear element when installing the module bar is +/- 1 mm.

Clamping Profile

Clamping profile as underlay plate

Rear Ventilation

X=Rear Ventilation

Opening

Using the Module Bar with a

Levelling Stirrup

Vertical Installation Tolerance

The maximum tolerance for a length of 2990 mm (standard length of a module bar) is 3 mm from the vertical.

10

Linear Façade Elements for Vertical Installation on Concrete or Masonry

The procedure for installing linear elements is essentially the same as the horizontal installation process. However, a strong joint must be created in the central area of the linear element using a fixing profile to absorb the horizontal forces exerted by the elements own weight. The type and number of fixing profiles to be used depends on the permitted static loading and the design of the fixing profiles as well as the length and weight of the linear elements. Rear Ventilation

The linear module bar facilitates a rear ventilation area of 280cm²/m. However, this can be increased to 500cm²/m using a levelling stirrup. The linear module bar is needed primarily when installing linear elements vertically in order to achieve the minimum rear ventilation area of 200cm²/m. The module bar can be notched at 105cm²/m with 200 mm BBR and 70cm²/m with 300 mm BBR. A drilled module bar can also be used. Insulation

Depending on the manufacturer and the material used, the insulation must be secured before it slumps and falls out. The insulation must be trimmed around the bracket (levelling stirrup).

Clamping Profile

Clamping Profile

Rear Ventilation with

drilled Module Bar

Fixing Profile

Fixing Profile

min. 200 cm²/m

Rear Ventilation Opening

11

Installing Pflaum Linear Façade Elements

Transport

When transporting the façade elements vertically or horizontally, care must be taken to ensure that they are always lifted on their edges to prevent the elements from breaking or buckling. Preparations for Installing Panels

Because the linear elements are interlocked in the packing unit it is necessary to realign the end edges to approximately 90°. This is done using tongs and stirrups. Stirrups can be provided on request. Clamp Profile

The clamp profile is used to secure the linear elements and is placed flush with the linear element overlap brackets and fixed to the module bar with rivets or screws. Horizontal Installation

Pflaum linear façade elements are installed on the module bar to allow for expansion: The module bar brackets must be checked to make sure that they are snugly fitted. Any tolerances should be balanced out equally on either side of the element. Depending on the height of the building, the linear façade elements are secured using the clamping profiles on each module bar as follows: Building height: 0 m to 8 m every fifth element row

8 m to 20 m every fourth element row over 20 m every third element row

In all cases, the last linear element must be secured in the parapet area.

Clamping Profile

Clamping Profile

12

Vertical Installation

Pflaum linear façade elements are attached to the module bars in such a way as to allow for expansion and then fastened to the overlap brackets using steel tapping screws and a centrally located fixing profile to prevent the façade elements from slipping. The fastening must be carried out so that the weight of the element is supported. As with the procedure for horizontal installation, the clamping profile must also be fitted to secure the linear façade elements. Installing Pflaum Linear Elements without a Module Bar

It is possible to install Pflaum linear façade elements without a module bar by placing them on existing structures such as wooden frames, Z-bars, box sections etc. However, care must be taken with this type of installation to ensure that the linear elements are rear ventilated. Particular attention must be paid to the scope for expansion of the linear elements. Experience has shown that a maximum length of 8m for steel plates and 5m aluminium plates should apply in order to ensure that the expansion of elements is absorbed by the substructure.

Rear Ventilation

Rear Ventilation

Rear

Ventilation

Fastening Clip

13

Linear Elements - Gaps

If elements are installed in areas subject to high winds, we recommend that small drops of silicone be applied to the gap at one metre intervals when installing the linear elements (see gap).

Joint Design The expansion potential of the linear elements should be taken into account when designing the joints between elements. For visual and technical reasons a gap width of 40-50mm is recommended. In this way the shadow profile can be taken from the module bar.

14

Gaps Larger than 50mm

If it is necessary to have larger gaps, it will be necessary to use double-sided module bars. When installing the gap profile, pay attention to the drainage of water around the base area. Horizontal Gaps – Vertical Installation

Z=333

Z=200

Z=166

Rear Ventilation

Rear Ventilation

Rear Ventilation

15

Corner Design for Horizontal Linear Elements

Corner Design with Notched Linear Façade Elements

Corner elements must be fastened at the clevis connector using a clamping profile and then screwed onto the module bar. In the case of corners larger than 500/500, a fixing profile must be fitted in the corner area. Internal Corner Design for Horizontal Linear Façade Elements

Fixing Profile

16

Corner Design with Corner Plates for Horizontal Linear Elements

Corner Design with Corner Plates for Vertical Linear Elements

17

Base Design for Horizontal Linear Elements

18

Parapet Design for Horizontal Linear Elements

19

Edge part Design

Window Terminations:

The protruding section of the drop profile at the top and bottom should be determined on the basis of the lateral window surrounds. This is necessary in order to slit the linear elements laterally. The ends of the drop profiles must be fitted with beading. For information on the joint formation, see the drop profile chapter.

20

Edge part Design

Façade Gap for Horizontal Linear Elements

21

Drop Profile Designs Drop Profile – Joint Design 1

As a rule, when the drop profile overlaps on one side, the drop profile flange should be cut diagonally depending on the thickness of the overlap to prevent loads in the overlap sections. A suitable sealant must be applied before overlapping the profiles. Drop Profile – Joint Design 2

In this design, the drop profile is placed flush against the underlay plate with an expansion gap and then sealed on both sides. Drop Profile – Joint Design 3

The simple folded joint is generally only used with large drop profile lengths. With this design the linear elements must be cut to facilitate the standing seam.

Parapet Profile Designs The parapet plating should be installed with a slight gradient towards the roof. Inset and retaining profiles should be used. These profiles are riveted onto the linear element. Depending on the design, the parapet cover should either be hooked into place or riveted directly onto the wall elements and fastened from above with stainless steel screws – for details on expansion see ÖNORM B2221. Parapet – Joint Design 1

As a rule, when the parapet plates overlap on one side, the beading flange should be cut diagonally depending on the thickness of the overlap to make it easy to open and overlap plates. A suitable sealant must be applied at the first overlap. Parapet – Joint Design 2

In this design, the parapet plate is placed flush against the underlay plate with an expansion gap and then sealed on both sides. Parapet – Joint Design 3

The simple folded joint is generally only used with large (wide) parapet lengths.

x bend folded joint

22

Replacing Damaged Elements

Procedure

Point 1

Cut through the damaged linear elements as far up as possible along the entire length of the element. Point 2

Now cut the exposed module bar diagonally on both sides as shown in the diagram. Point 3

First of all, a metal strip at least 1mm thick must be cut for each module bar. Then the linear element on top is placed in a vertical position again and the new strips are fixed in place at intervals of 4-5mm with rivets or screws. This should be tested by locking and unlocking the element. If this is not possible, readjust the metal strips. Point 4

Insert the new linear element and apply silicone to the rear web area as shown in the diagram. Mark the position of the module bar on the linear element. Swing the undamaged element up and lock both elements together before putting them back down. Only apply pressure to the area around the module bar.

Damaged Linear Element

Tilt both elements upwards

and then swing back down

cut

cut out

Cut 1mm strip and

rivet in place

Silicone sealant

New Linear Element

23

Visual Inspections Visual inspections must be carried out and logged annually on the building. If there faults or areas of damage are detected in the coating or other similar area, remedial action must be taken immediately (see Cleaning and Repairs Chapter). If you notice any corrosion damage to cut edges during the annual inspections, such damage must be repaired immediately by qualified personnel.

Cleaning Pflaum Linear Elements

If it is necessary to clean PFLAUM linear elements which are used either internally or externally, use a 5% soap solution. In the case of larger areas, steam degreasing is recommended. Afterwards, thoroughly rinse the area with clean water. Particularly difficult stains can be removed with white spirits. A special cleaning solution called “Pflaum Clear” is available on request. Retouching the Coating General

To manufacture the wide range of Pflaum colours, our steel plate production facilities use coating materials of varying qualities and paints from a variety of manufacturers. To order additional paint for repairs, you will need to quote the original order number for your panels. Paint for repairs is ready to apply using either a brush or roller. If, in exceptional circumstances, you need to thin the paint, you can use Butyl acetate or another equivalent thinner for cellulose paints. The surface quality achieved by repairing paintwork or covering over paint will not be the same as the quality of coil coated panels. Repairing Minor Damage to Coating (e.g. scratches)

Carefully remove any remaining paint residue around the scratch using fine grain sandpaper. Using a fine hairpin, carefully repair the damage. To ensure that the appearance of the surface is not excessively affected, make sure that only the damaged area is treated.

24

Retouching the Coating

Repairs to Large Areas of Coating

Panels can be cleaned using the procedure described in the chapter on cleaning PFLAUM linear elements. If there is no serious damage to the surface to be repaired and the base material is not exposed, the affected area should be treated directly using replacement paint from the manufacturer. Using a cross-like motion spray the paint onto the surface. repeat this motion twice until the paint is approx. 20 µm thick. In order to achieve this, some form of viscosity control (thinning) will be necessary. Again, Butyl acetate can be used as a thinner. Before starting work, test a small sample of the paint to check whether it will be necessary to sand the surface. The paints used are air-drying and are touch dry in 15 minutes and completely dry in about 24 hours. If there are areas of damage where the base material is exposed (possibly even with signs of corrosion), they should be carefully cleaned by sanding, brushing or sandblasting. After removing the dust left over from grinding, use a suitable 2 component epoxy metal primer to coat the surface to a thickness of approximately 40µm. This type of primer generally takes between 6-8 hours to dry. Afterwards, apply the repair paint evenly as described above.

Other Information When processing and using coated PFLAUM linear elements note the following: • Under extreme or unusual environmental conditions, even this

material may fail. Avoid exposing the sandwich elements to temperatures outside the limits set specifically for this material where the inspection will have to include the reshaped work pieces.

• Avoid exposing the elements to excessive quantities of

accumulated water or condensation when in use. • The cut edges must be given greater protection to prevent

corrosion – this can be achieved using suitable coatings or sealants.

These installation instructions are intended only as

recommendations.

25

Notes

L I N E A R F A S S A D E N S Y S T E MP F L A U M

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www.pflaum.at

P F L A U M & S Ö H N EB A U S Y S T E M E G E S . M . B . H .

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