ALUCORE® is an innovative aluminium composite panel consisting of two aluminium cover sheets and a honeycomb core of aluminium.
Boasting the globally recognised ALUCOBOND® trademark, ALUCORE® is also a composite material that can be used for a wide variety of applications from the transport industry to architecture, and has fantastic properties such as extraordinary flatness, a large variety of colours, and high formability.
The product’s aluminium honeycomb core gives the composite panel a high rigidity and an extremely low weight. ALUCORE® therefore has a definite advantage when it comes to projects with high demands on material stiffness – such as façade cladding or roofing where it will be exposed to an extremely high wind load, or for large self-supporting roofs.
ALUCORE® – the first lightweight panel that is a bond for life!
Following in the footsteps of the world-wide established ALUCOBOND® trademark, ALUCORE® is also a composite material for a variety of applications in transport industry and architecture, showing excellent product properties such as extraordinary flatness, large variety of colours and high formability.The aluminium honeycomb core gives the composite panel a high rigidity and an extremely low weight. ALUCORE® therefore provides the decisive advantage where very high demands are made on the material for applications such as façade cladding or roofing, e.g. if exposed to extremely high wind load and for large self-supporting roofs.ALUCORE® is the first lightweight panel that you, too, will absolutely insist as being: a bond for life.
Rivets – not penetrating the panelRivets generally must be anchored in the 1mm thick ALUCORE® cover sheets. Sections can be attached to ALUCORE® with commercially available rivets for aluminium constructions. After drilling a blind hole of the same diameter as the rivet shank, the rivets can be anchored in the cover sheet. As a rule, rivets with stainless steel mandrel are used.
For outdoor use please note:
- For outdoor use aluminium blind rivets that have been approved for construction with a 5 mm shaft diameter and an attachment head diameter of 11 or 14 mm are used.
- Please take the thermal expansion of the panel into account (2.4 mm/m/100°C). To avoid jamming, the hole in the panel must be large enough to allow for expansion.
- With the shaft of the rivet fitting closely to the edge of the hole, the attachment head must cover over 1 mm of the area surrounding the hole.
- Multi-step drills or sleeves having corresponding diameters are used for centrically drilling holes into the panel and the substructure and for centrically fitting the rivet.
- Rivet attachment jigs are used for fitting blind rivets without jamming allowing for a tolerance of 0.3 mm. Make sure to use rivet attachment jigs and rivets from the same manufacturer, as the height of the attachment head according to DIN 7337 may vary.
- The clamping thickness results from the thickness of the material to be riveted plus an additional value of 2 mm to ensure that the closing head is perfectly formed. In accordance with this clamping thickness the corresponding shaft length is determined in the tables provided by the rivet manufacturers.
Threaded fasteners for outdoor useFor outdoor use make sure to take the thermal expansion of the panel into account. To avoid jamming, the hole diameter in the panel must allow for the expansion. Fastening without jamming is possible using fascia screws made of stainless steel with sealing washer (Fig. 1) that have been approved for construction. The screws must be suitable for the corresponding substructure (please note the information given by the manufacturer). The screws should be tightened with a torque wrench or screwdriver so that the sealing washer is placed on the panel for sealing the bore hole without exerting pressure to the panel. Multi-step drills or sleeves having corresponding diameters are used for centrically drilling holes into the panel and the substructure and for centrically fitting the rivet. Important: Make sure to remove the protective foil prior to screwing.
Examples for threaded fastenersStud welding with tip ignition on mill-finished ALUCORE® surfaces Process:
- The capacitor battery is charged.
- A spring in the welding gun moves the stud (with tip) towards the work-piece.
- The tip comes into contact with the work-piece and thereby closes the circuit. The rapidly increasing current causes the ignition tip to melt instantaneously, thus initiating the electric arc.
- Stud and work-piece are welded together.
- When the stud touches the work-piece the electric arc is extinguished, the fusion zones on stud and work-piece are joined and solidify.