CONTENTS

Packaging, Transport and Unloading Storage; Protective Film Processing; Rear Ventilation - General; Module Bar Linear Faade Elements for Horizontal Installation on steel box section walls Linear Faade Elements for Vertical Installation on steel box section walls Linear Faade Elements for Horizontal Installation on Concrete or Masonry Linear Module Bar Linear Faade Elements for Vertical Installation on Concrete or Masonry Installing Pflaum Linear Faade Elements Joint Design Corner Design for Horizontal Linear Elements Corner Design with Corner Plates for Horizontal and Vertical Linear Elements Base Design for Horizontal Linear Elements Parapet Design for Horizontal Linear Elements Edge part Design Faade Gap for Horizontal Linear Elements Drop Profile and Parapet Profile Designs Replacing Damaged Elements Visual Inspections; Cleaning and Retouching Other Information

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3 4 5 6 7 8 9 10 11-13 13-14 15 16 17 18 19-20 20 21 22 23-24 24

Packaging, Transport and Unloading

A protective film is fitted to linear faade 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: Pack Width: Pack Length: Pack Weight: max. 710 mm 1020 mm for construction widths of 200 350 mm 1120 mm for construction widths of 350 -400 mm max. 14.0 m max. 4.0 to

Check all packs upon delivery to ensure that they are complete and undamaged. The recipient must sign the haulers 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 Crane Only Unloading with Forklift or Crane

Belt or Chain

Wooden Box

Linear Elements

Total Weight approx. 2000 kg Total Weight approx. 950 kg

Unloading with Crane Only Unloading with Forklift or Crane

Traverse Steel Belt Belt or Chain

Total Weight approx. 1700 kg

Total Weight approx. 4000 kg

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.

Processing
The linear faade 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 faade elements, care should be taken to ensure that expansion is within prescribed limits(see NORM B2221). Linear elements may only be fastened centrally to prevent slipping during vertical installation.

Rear Ventilation - General

In accordance with NORM B 2219, the free ventilation crosssection must be at least 200cm/m and no more than 500cm/m depending on the height of the cladding. The air inlets and outlets must have a free cross-section of at least 150cm/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
Clamping profile as underlay plate

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.

Linear Faade 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.

Using the Module Bar on Box Sections

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.

Clamping profile

Clamping profile as underlay plate X=Rear Ventilation Opening

Rear Ventilation

Linear Faade 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 Uprofile and then riveted into the flange.

Using the Module Bar on Box sections with Insulation

Clamping profile

A-A

X=Rear Ventilation Opening

Rear Ventilation

Linear Faade 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 280cm/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 200cm/m for construction widths of 300mm and 235cm/m for construction widths of 200mm.

Clamping Profile

Variants Vertical installation of linear elements directly on the steel box wall using fastening clips or steel substructure. The centre of the linear faade 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.

Fastening Clip

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

Linear Faade 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 faade 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 faade 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).

Levelling Stirrup

Length X: A: 89 mm B: 119 mm C: 149 mm D: 179 mm

Installing Pflaum Linear Levelling Stirrups and Module Bars on Concrete or Masonry Type: A 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.

Type: B

Type: C

Type: D

Levelling Stirrup Distance max. 600 mm

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 faade, 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.

Using the Module Bar with a Levelling Stirrup

Clamping Profile

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

Clamping profile as underlay plate X=Rear Ventilation Opening

Rear Ventilation

Installation Surface Tolerances The maximum tolerance for a length of 2990 mm (standard length of a module bar) is +/- 1 mm

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

Linear Faade 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.
Fixing Profile

Rear Ventilation The linear module bar facilitates a rear ventilation area of 280cm/m. However, this can be increased to 500cm/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 200cm/m. The module bar can be notched at 105cm/m with 200 mm BBR and 70cm/m with 300 mm BBR.
min. 200 cm/m Rear Ventilation Opening

Clamping Profile

A drilled module bar can also be used.

Fixing Profile

Clamping Profile

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).

Rear Ventilation with drilled Module Bar

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Installing Pflaum Linear Faade Elements

Transport When transporting the faade 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.

Clamping Profile

Horizontal Installation Pflaum linear faade 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 faade elements are secured using the clamping profiles on each module bar as follows: Building height:
0 m to 8 m 8 m to 20 m over 20 m every fifth element row every fourth element row every third element row

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

11

Vertical Installation Pflaum linear faade 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 faade 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 faade elements.

Installing Pflaum Linear Elements without a Module Bar It is possible to install Pflaum linear faade 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

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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.

13

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.

Z=333

Z=200

Z=166

Horizontal Gaps Vertical Installation

Rear Ventilation Rear Ventilation

Rear Ventilation

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Corner Design for Horizontal Linear Elements

Corner Design with Notched Linear Faade 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.

Fixing Profile

Internal Corner Design for Horizontal Linear Faade Elements

15

Corner Design with Corner Plates for Horizontal Linear Elements

Corner Design with Corner Plates for Vertical Linear Elements

16

Base Design for Horizontal Linear Elements

17

Parapet Design for Horizontal Linear Elements

18

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.

19

Edge part Design

Faade Gap for Horizontal Linear Elements

20

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.

x bend folded joint

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 NORM 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.

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Replacing Damaged Elements

Procedure Point 1 Cut through the damaged linear elements as far up as possible along the entire length of the element.
cut

Damaged Linear Element

Point 2 Now cut the exposed module bar diagonally on both sides as shown in the diagram.

cut out

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.

Cut 1mm strip and rivet in place

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.

Tilt both elements upwards and then swing back down

Silicone sealant

New Linear Element

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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.

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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 m 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 40m. 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.

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Notes

25

PFLAUM & SHNE BAUSYSTEME GES.M.B.H.

HEADOFFICE, ADMINISTRATION, PRODUCTION Pflaum & Shne Bausysteme GmbH Ganglgutstrasse 89 A-4050 Traun Tel: +43-7229-64584 Fax: +43-7229-64584-43 e-mail: office@pflaum.at homepage: www.pflaum.at OFFICE VIENNA Pflaum & Shne Bausysteme GmbH Favoritenstrasse 130/2/3 A-1100 Wien Tel: +43-1-6066500 Fax: +43-1-6066710 Mobil: +43-664-4041869 PFLAUM CHINA Pflaum China Marketing and Technical Organisation Room 3G, No. 1066 Summit Centre Yanan West Road 200052, Shanghai, China Tel: +86-21-523954-56/ -57/ -35 or -36 Fax: +86-21-523954-37 or -5622 e-mail: china@pflaum.com.cn PFLAUM CZECH REPUBLIC Helpro Prazsk 80 CZ-64200 Brno Tel: +420-5-47224850 Fax: +420-5-47224849 e-mail: helpro-pflaumcz@telecom.cz homepage: www.pflaum.cz PFLAUM FRANCE Pflaum France 25 Boulevard Wilson F-67000 Strasbourg Tel: +33-388-143939 Fax: +33-388-750399 e-mail: pflaumfrance@wanadoo.fr PFLAUM GERMANY NORTH Pro-M Industrievertretungen GmbH Lindhooper Strasse 54-56 D-27283 Verden Tel: +49-4231-959-200 Fax: +49-4231-959-201 e-mail: pro-m@web.de PFLAUM GERMANY SOUTH Profiltec Bausysteme GmbH Stauffenbergstrasse 35-37 D-74523 Schwbisch Hall Tel: +49-791-94616-0 Fax: +49-791-94616-16 e-mail: info@profiltec-gmbh.de

PFLAUM HUNGARY Hajd Team Kft. Gerle u. 1. H-8000 Szkesfehrvr Tel & Fax: +36-22-330606 e-mail: iroda@hajduteam.hu homepage: www.hajduteam.hu PFLAUM IRELAND ERL-Engineering Research Ltd. Unit 7 Waterway House Crag Crescent Clondalkin Industrial Estate IRL-Dublin 22 Tel: +353-1-4138399 Fax: +353-1-4138702 e-mail: info@erl.ie homepage: www.erl.ie PFLAUM ITALY Promoclad Via G. Boccardo 26 I-00191 Roma Tel: +39-06-3335468 Fax: +39-06-3335468 e-mail: promoclad@fastwebnet.it PFLAUM LITHUANIA UAB Laivorita Subaciaus str. 79a LT-2014 Vilnius Tel & Fax: +370-5-2600902 Tel & Fax: +370-5-2600863 e-mail: laivorita@is.lt homepage: www.laivorita.lt PFLAUM NETHERLANDS Pflaum Bouwsystemen BV Postbus 210 NL-7600 AE Almelo Tel: +31-546-486400 Fax: +31-546-486406 e-mail: verkoop@pflaum-bouwsystemen.nl homepage: www.pflaum-bouwsystemen.nl PFLAUM POLAND Pflaum & Shne Bausysteme GmbH Przedstawicielstwo w Polsce ul. Partyzantw 22 PL-43 - 300 Bielsko - Biaa Tel: +48-33-8228447 Tel & Fax: +48-33-8122570 e-mail: office@pflaum.at homepage: www.pflaum.pl

PFLAUM SERBIA Armat Inzenjering d.o.o. Beograd YU Business Center Bulevar Mihaila Pupina 10A/VP11 11070 Novi Beograd SCG-Srbija i Crna Gora Tel: +381-11-311 7850 Fax: 381-11-311-7852 e-mail: armat@EUnet.yu PFLAUM SLOVAKIA Pflaum SK s.r.o. Agtov 1 SK-84101 Bratislava Tel: +421-2-64531792 Fax: +421-2-64531793 e-mail: pflaum@orangemail.sk homepage: www.pflaum.sk PFLAUM SLOVENIA Armat d.o.o. entjan Kocevarjeva ulica 2 SLO-8000 Novo mesto Tel: +386-7-3933-402 / -408 Fax: +386-7-3933-419 e-mail: armat@armat.si homepage: www.armat.si PFLAUM UNITED KINGDOM ERL Construction Elements Limited Willestrew Park / Lamerton / Tavistock GB-Devon PL 19 8PZ Tel: +44-1822-870455 Fax: +44-1822-870523 e-mail: info@erlconel.co.uk PFLAUM UKRAINE Fasteh Ltd ul. Barenboima 1 UA-01013 Kiev Tel: +380-44-259-55-05 Fax: +380-44-259-59-26 e-mail: fasteh@fasteh.kiev.ua homepage: www.fasteh.kiev.ua

www.pflaum.at

ea-mk-g2-st Technische nderungen, Irrtmer und Druckfehler vorbehalten. Stand Februar 2005

eigen)art linz