PWS AND PWD

SANDWICH PANELS WITH EXPANDED POLYSTYRENE CORE

TECHNICAL CATALOGUE

w w w. ba l ex. e u

PWS and PWD

Sandwich panels with expanded polystyrene core August 2011

The content of his folder does not constitute a commercial offer in the understanding of the Civil Code regulations. Information included in this study demonstrates only sample solutions that require consultation and specification by the designer of a particular building according to individual clients needs. Balex Metal does not bear any responsibility in case of any technical irregularities or errors resulting from inappropriate application of information included in this paper.

TABLE OF CONTENTS
I. TECHNICAL SPECIFICATION OF THE ENCLOSURE MADE OF SANDWICH PANELS WITH EXPANDED POLYSTYRENE (EPS) CORE
1. General information Sandwich panel construction......................................................................................................................... 6 2. Technology of production ............................................................................................................................................................................ 6 3. Types of panels ................................................................................................................................................................................................. 6 4. Scope of application of the panels ............................................................................................................................................................ 7 5. Types of sandwich panel joints ................................................................................................................................................................... 8 6. PWS sandwich panel - wall type ................................................................................................................................................................ 9 7. PWD sandwich panel - roof type ............................................................................................................................................................... 9 8. General technical specification.................................................................................................................................................................10 9. Materials and facing coatings ...................................................................................................................................................................11 10. Facing profile scheme ................................................................................................................................................................................12 11. Profile type combinations ........................................................................................................................................................................13 12. Sample marking of PWS and PWD panels..........................................................................................................................................13 13. Facing colour scheme ................................................................................................................................................................................14 14. Strength issues .............................................................................................................................................................................................15 15. Thermal performance ................................................................................................................................................................................17 16. Fire safety .......................................................................................................................................................................................................19 17. Corrosion resistance ...................................................................................................................................................................................20 18. Noise reduction performance.................................................................................................................................................................20 19. Fasteners.........................................................................................................................................................................................................21 20. Lengthwise roof panel joining................................................................................................................................................................21 21. General assembly guidelines ..................................................................................................................................................................22 22. Transport guidelines ..................................................................................................................................................................................25 23. Certification documents ...........................................................................................................................................................................27

II. CONSTRUCTION AND ARCHITECTURE DETAILS OF THE ENCLOSURE MADE OF SANDWICH PANELS WITH EXPANDED POLYSTYRENE CORE
1. PWS Sandwich wall panels .........................................................................................................................................................................30 1.1. PWS01 PWS Wall panel - joint, types of profiles .........................................................................................................................30 1.2. PWS02 Panel fastening vertical panel arrangement .............................................................................................................31 1.3. PWS03 Supporting the panels on the ground beam or the foundations vertical panel arrangement ..............32 1.4. PWS04 Supporting the panels below the top of the ground beam or the foundations vertical panel arrangement............................................................................................................................................................33 1.5. PWS05 Supporting the panels on the ground beam or the foundations horizontal panel arrangement ........34 1.6. PWS06 Supporting the panels below the top of the ground beam or the foundations horizontal panel arrangement ......................................................................................................................................................35 1.7. PWS07 Joining the panels in the corner - horizontal or vertical panel arrangement - option I ..............................36 1.8. PWS08 Joining the panels in the corner - horizontal or vertical panel arrangement - option II ..............................37 1.9. PWS09 Joining the panels in the corner - horizontal or vertical panel arrangement - option III .............................38 1.10. PWS09/1 Joining the panels in the corner - horizontal or vertical panel arrangement ...........................................39 1.11. PWS10 Joining the panels in the corner - horizontal or vertical panel arrangement - option IV ..........................40 1.12. PWS11 Lengthwise panel joining - vertical panel arrangement .......................................................................................41 1.13. PWS12/1 Fastening the panels to the outermost support - horizontal panel arrangement - option I................42 1.14. PWS12/2 Fastening the panels to the outermost support - horizontal panel arrangement - option II .............43 1.15. PWS13 Fastening the panels to the outermost support - horizontal panel arrangement - option II..................44 1.16. PWS14 Joining the panels to the window strip - horizontal panel arrangement - option I ...................................45 1.17. PWS15 Joining the panels to the window strip - horizontal panel arrangement - option II (for panels of 75, 100 thickness) ....................................................................................................................................................46 1.18. PWS16 Joining the panels to the window strip vertical or horizontal panel arrangement option III ...........47 1.19. PWS17/1 Joining the panels to the PVC window - vertical or horizontal panel arrangement ...............................48 1.20. PWS17/2 Joining the panels to the PVC window - vertical or horizontal panel arrangement section X-X ...49 1.21. PWS18 Fastening the panels, sliding joint - vertical panel arrangement .......................................................................50 2. PWD Roof sandwich panels .......................................................................................................................................................................51 2.1. PWD01 PWD Roof panel - joint, types of profiles.......................................................................................................................51

2.2. PWD02-1 Fastening the panels to the purlins.............................................................................................................................52 2.3. PWD02-2 Fastening the panels to the purlins section X-X..................................................................................................53 2.4. PWD03 Panel endings in case of a monopitch roof .................................................................................................................54 2.5. PWD04-1 Gable-end roof edge .......................................................................................................................................................55 2.6. PWD04-2 Gable-end roof edge ........................................................................................................................................................56 2.7. PWD05 Joint of the panels with the PWS wall panel by the attic ........................................................................................57 2.8. PWD06 Joint of the panels at the roof ridge ...............................................................................................................................58 2.9. PWD07-1 Joint of the panels with the internal gutter option I Balex Metal ................................................................59 2.10. PWD07-2 Joint of the panels with the internal gutter - option II ......................................................................................60 2.11. PWD08-1 Joint of the panels with the prefabricated internal gutter - option I BALEX METAL ...............................61 2.12. PWD08-2 Joint of the panels with the prefabricated internal gutter - option II ..........................................................62 2.13. PWD09-1 Joint of the wall panel with the roof panel in the eaves of the roof .............................................................63 2.14. PWD09-2 Joint of the wall panel with the roof panel in the eaves of the roof - option II BALEX METAL ............64 2.15. PWD10-1 Lengthwise joining of the roof panels (L > 18m) ................................................................................................65 2.16. PWD10-2 Lengthwise joining of the roof panels (L > 18m) - section A-A .....................................................................66 2.17. PWD11-1 Joint of the panels with the prefabricated gutter at the attic - option I BALEX METAL ........................67 2.18. PWD11-2 Joint of the panels with the prefabricated gutter at the attic - option II ....................................................68 2.19. PWD11-3 Joint of the panels with the prefabricated gutter at the attic - option III BALEX METAL.......................69 2.20. PWD11-4 Joint of the panels with the prefabricated gutter at the attic option IV ..................................................70 2.21. PWD12/1 Roof ridge continuous skylight - longitudinal section ......................................................................................71 2.22. PWD12/2 Roof ridge continuous skylight cross- section .................................................................................................72 2.23. PWD13 Roof ridge skylight cross-section ...............................................................................................................................73 2.24. PWD14 Expansion gap ......................................................................................................................................................................74 2.25. PWD15/1 Installation of additional canopy roof at the wall - existing wall option ...................................................75 2.26. PWD15/2 Installation of additional canopy roof at the wall- basic option with the drip cap .................................76

I. TECHNICAL SPECIFICATION OF THE ENCLOSURE MADE OF SANDWICH PANELS WITH EXPANDED POLYSTYRENE CORE

1. GENERAL INFORMATION SANDWICH PANEL CONSTRUCTION

Balex Metal company provides a wide range of modern wall and roof sandwich panels with the expanded polystyrene core with the PWS and PWD trademark. The PWS and PWD sandwich panels consist of two stainless steel facings and a construction insulation core. The core, made of self-extinguishing expanded polystyrene class EPS CS (10) 80, is responsible for transferring shear stresses, maintaining fixed distance between facings and ensuring high thermal performance. The joining of the panel facings to the core with the use of single component glue characterises in high cohesion on the entire surface and long term parameter replicability. Milling of each expanded polystyrene core joint inside the sandwich panel results in their coupling and full thermal insulation, the core is solid and no delamination occurs. The facings of the panels are made of steel sheet S220GD, S250GD, S280GD of 0.50 to 0.60mm thickness, covered with organic and metallic coatings. A panel with single side facing made of coated sheet, used mainly for thermal insulation. The main function of the facing is transmission of the regular stress as well as protecting the facility from weather conditions. The construction of the panel makes it very light yet of high load-bearing capacity and stiffness allowing for larger support span (purlins, transoms). The range of PWS and PWD sandwich panel production comprises 6 thicknesses, 3 profiles and 25 colours, which allows for customisation of the elevation with balanced aesthetic and functionality values.

2. TECHNOLOGY OF PRODUCTION
The production process is continuous and performed on a fully automated assembly line The core is made of selfextinguishing expanded polystyrene class EPS CS (10) 80. The technological production process of sandwich panels with an expanded polystyrene core is based on fully automated feeding of the expanded polystyrene blocks, between two continuously moving steel tapes (with previously profiled edges and main outline). The high quality and replicability of PWS and PWD sandwich panel technical parameters were achieved through the use of the finest materials and constant control of all production stages.

3. TYPES OF PANELS
We offer two types of sandwich panels with polystyrene core: PWS wall panel of 1155 mm modular width (so called covering) allows for a quick installation of the construction with the use of eyelet fasteners. It may be double sided (coated sheet on both sides) and single sided (coated sheet on one side/unbleached paper with aluminium foil, coated with polyethylene of approx. 160g/m2 total basis weight, on the other. PWD roof panel (may also be used as a wall panel) 1100 mm modular width, trapezoidal surface shape, guarantees high load-bearing capacity for the transfer of service loads, as well as during installation. It is available as double sided (coated steel on both sides) and single sided (coated sheet on one side/unbleached paper with aluminium foil, coated with polyethylene of approx. 160g/m2 total basis weight, on the other). Due to trapezoidal surface shape the panel is capable of auto compensation of the thermal expansion.This shape allows for the use of panel in dark colours which characterize in high degree of sunlight energy absorption eliminating the risk of local bulging of the coating.

Table1. Types of sandwich panels Panel thickness [mm]

75 100 125 150 175 200

Panel type

Panel shape

Modular width 1155

PWS wall panel

PWD roof panel

75 / 91,50 100 / 116,50 125 / 141,50 150 / 166,50 175 / 191,50 200 / 216,50

Modular width 1100

Half-panel PWS wall panel

75 100 125 150 175 200

Modular width 1155

Laminated paper

Modular width 1100

Half-panel PWD roof panel 75 / 91,50 100 / 116,50 125 / 141,50 150 / 166,50 175 / 191,50 200 / 216,50

Laminated paper

Microventilation ducts

4. SCOPE OF APPLICATION OF THE PANELS

Sandwich panels are commonly used as building material for light enclosure of industrial, warehouse, sports and production halls, pavilions and commercial buildings, offices, social facilities, hangars, garages, workshops, administrative buildings, public use facilities, storage rooms, carrying freezers, cold stores (including food industry facilities). The wide range of colours and panel profiles allows for realisation of numerous facilities. The construction of the panels enables quick and simple installation in vertical or horizontal configuration regardless of weather conditions. Double-sided sandwich panels are to be used as wall, roof, ceiling elements. The single-sided are to be used only to make thermal insulation facings. The application of the panels should be in agreement with the technical design in regard to Polish standards, construction codes and the resolutions of the ITB Technical Approval. When using sandwich panels it is required to take into account decisions enclosed in the Ordinance of the Ministry of Spatial Economy and Construction in the matter of technical conditions to which buildings and their location should comply with (J. of L. No. 1/99, item. 140) taking into consideration fire classification for sandwich panels specified in this catalogue ( chapter Fire safety). Wind load and support spacing in the wall elements and roof coverings should not exceed the values specified in this catalogue. In respect to the acoustic values sandwich panels may be used in industrial, commercial facilities or of a similar profile in cases where the indicated individual acoustic requirements are not higher than those specified in this catalogue (Noise reduction performance). The panels may also be used for objects with no acoustic requirements. Use of the panels with structures increasing their acoustic insulation and/or limiting lateral sound transmission should be examined individually. Due to the heat and humidity characteristics the panels may be used in the scope compliant with the mentioned above ordinance in the matter of technical conditions.

5. TYPES OF SANDWICH PANEL JOINTS

The unique shape of the longitudinal joints with their optimal proportion between thickness of the feather and the depth of the groove in both of the facings on the inner as well as the outer side, substantially increased the fire resistance parameters of the PWS wall panels. In order to facilitate lengthwise joining of the panels and the gutter installation ( BALEX option) a factory undercut of the lower facing and the core has been introduced in the PWD roof panel as a standard. The distinctive element is also the specially milled joint improving thermal performance in the joint point and also facilitating the installation of the panels and their mutual pressure. Laboratory tests showed that in case of PWD panel the required pressure power is 4 times lower. For example to properly tighten the lock of the PWD 150 in a classical flat lock, the required pressure power is approx. 5 kN (~500 kg). In case of the same panel and the milled lock it is approx. 1,2 kN (~120 kg). In practice, it means that the panels lock under their own weight. The way of panel installation recommended by Balex Metal is presented in chapter 21.

PWS :

PWD :

6. PWS SANDWICH PANEL - WALL TYPE

1) joint fasteners

1 2 3 2 5 4

2) double-sided shape of the panel joint in the form of a double lock, increasing the joint tightness 3) self adhesive polyurethane tape (PUS) guarantying thermal insulation and joint tightness applied on the construction site 4) self -extinguishing expanded polystyrene core class EPS CS (10) 80 5) profiled external facing, provide pleasing aesthetic values

7. PWD SANDWICH PANEL ROOF TYPE

1) joint fasteners

1 6 5

7 2 4

2) self - drilling fastener or pop rivet 3) self adhesive polyurethane tape (PUS) guarantying thermal insulation and joint tightness applied at the construction site 4) self-extinguishing expanded polystyrene core class EPS CS (10) 80 5) unique custom milled joint, enabling easier installation and mutual pressing of the panels as well as improving thermal insulation (patent application no. W-114316) 6) trapezoidal profile of the facing improving the load-bearing capacity of the roof panel 7) chamber - water draining capillary groove

3 6

8. BASIC TECHNICAL SPECIFICATION

Table 2. Technical specification
Facing thickness [mm] Panel type standard ext. 1
75 100 125 PWS 150 175 200 75 100 125 PWD 150 175 200

custom made ext. 4 int.

Panel thickness [mm]

coated metal sheet + coated metal sheet Panel length L [m] min max 7 13,50 Panel mass [kg/m2] 10 10,00 10,39 2,00 17,004) 10,80 11,20 11,61 12,01 13,50 10,34 10,74 2,00 17,004) 11,15 11,55 11,96 12,36

coated metal sheet + laminate 3) Panel length L [m] min 8 max 9 6,00 8,00 2,00 9,00 10,00 6,00 8,00 2,00 9,00 10,00 Panel mass [kg/m2] 11 5,95 6,35 6,76 7,16 7,57 7,97 6,09 6,49 6,90 7,30 7,71 8,11

int. 3

5
75 100 125

0,50

0,50

0,50-0,60

150 175 200 75 100 125

0,50

0,50

0,50-0,60
150 175 200

1) minimum length of the panel with an undercut amounts to 4 m 2) mass indicator for PWS and PWD panels with a 0,50 mm thick sheet facing. In case of application of 0,60mm thick sheet facing it is required to increase the mass of one running metre of: - double-sided panel : PWS 1,57 kg, PWD 1,40 kg - single-sided panel: PWS 0,78 kg, PWD 0,70 kg 3) unbleached laminated paper with aluminium foil and polyethylene (approx. 160 g/m2) 4) after consultations there is a possibility of manufacturing longer panels up to 18 m

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9. MATERIALS AND FACING COATINGS

9.1. Material
STEEL S220GD,S250GD,S280GD (acc. to PN-EN 10346) increased parameter steel, galvanized on both sides permanently protected with anticorrosion coatings sheet thickness: 0,50; 0,60 mm coated with organic and metallic coatings PWS and PWD sandwich panels are coated by foil from external side; in PWS there is a possibility of coating by foil from both sides on customers demand

LAMINATE occurs only on the inner side of the sandwich panel unbleached laminated paper with aluminium foil and polyethylene (approx. 160 g/m2)

9.2. Coatings Standard offer

POLYESTER thickness of the coating 25 m for external use resistant to temperature changesand the weather conditions, good corrosion resistance colour scheme according to the Balex Metal colour palette. POLYESTER MATT PEARL thickness of the coating 35 m for external use resistant to temperature changesand the weather conditions, good corrosion resistance, ideal for industrial and commercial facility roof tops colour scheme according to the Balex Metal colour palette.

Offer on special demand

PVDF thickness of the coating 25 m good corrosion and mechanical damage resistance, long lasting and fade resistant colours (in temperature up to 110C), easy to form, with fairly hard surface, which greatly prevents the accumulation of dirt and loss of gloss recommended for external use (external facing of the building) colour scheme according to the Balex Metal colour palette. PCV(F) food safe thickness of the coating 120 m white colour foil, special increased hardness coating for use in food industry facilities and cool stores, washable and resistant to most cleaning detergents ALUZINC + Easyfilm metallic coating : 150 and 185 g/m2 basis weight for each side of the sheet thickness of the coating - 20 m (for 150 g/m2), 25 m (for 185 g/m2) double-sided thermally applied coating in a continuous process, additionally protected with a thin organic coating SPT (Special Protection Treatment), Easyfilm (environmentally friendly, thin organic layer which protects aluzinc coating against discoloration resistance to higher temperatures, high corrosive resistance, excellent heat and light reflection, good abrasive resistance.

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10. FACING PROFILE SCHEME

R = GROOVED

61

61

61

61

T = TRAPEZOIDAL

G = FLAT

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11. COMBINATIONS OF PROFILE TYPES

The table below presents possible types of external and internal facing profiles combination for particular types of panels. Table 3. Combinations of profile types
External facing

Panel type R 1
PWS PWD

Internal facing LAMINATED PAPER 5

T 3

G 4

R 6

T 7

12. EXAMPLE OF PWS AND PWD PANEL MARKING

PWS sandwich panel:

BALEX PWS 100.1155 zew. 0,50 SP 25 m 9006 - R / wew. 0,50 SP 25 m 9010 - G

PWS

100

1155
Modular width

Name of the Thickness panel

zew.
External facing

0,50
Metal sheet thickness

SP 25 m
Type of coating

9006 - R
Colour Type of profiles

wew.
Internal facing

0,50
Metal sheet thickness

SP 25 m
Type of coating

9010 - G
Colour Type of profiles

PWD sandwich panel:

BALEX PWD 100/118.1100-P/150 zew. 0,50 SP 25 m 3016 - T / wew. 0,50 SP 25 m 9010 - T

PWD
Name of the panel

100/118
Thickness

. 1100
Modular width

P/150
Overlap length

zew.
External facing

0,50
Metal sheet thickness

SP 25 m
Type of coating

3016 - T
Colour Type of profiles

wew.
Internal facing

0,50
Metal sheet thickness

SP 25 m
Type of coating

9010 - T
Colour Type of profiles

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13. FACING COLOUR SCHEME

Colour scheme according to the Balex Metal colour palette

Organic coatings
Polyester 25 m : 9010, 8012, Polyester Matt PEARL 35m: PVC(F) food safe PVDF: 9002, 7024, 9005, 7035, 9006, 6005, 9007, 6011, 3011, 6020, 3016, 5010, 5012, 1015, 8004, 1017, 8017, 1003

8637M, 8620M, 3301M, 7591M, 6490M, 9005M 9010 colours to be set

Metallic coatings
Aluzinc + Easyfilm AZ 150 ( 20 m ), AZ 185 ( 25 m )

Table 4. Classification of colours by relative brightness Symbol 9010 9002 7035 1015 6011 9006 9007 5012 1003 1017 9005 5010 6005 6020 7024 8017 8012 8004 3016 3011 Name white grey-white light-grey ivory reseda-green silver-metallic grey-aluminium light-blue signal-yellow sapphire-yellow black signal-blue dark-green fir-green graphite-grey chocolate-brown red-brown brick-red (including Rustika) coral-red red Group

very bright

bright

dark

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14. STRENGTH ISSUES

Table 5. Maximum load of very-bright- and bright-coloured single-span PWS wall panels with 0.50-mm-thick facing load towards the support
core thickness 75 100 125 150 175 200 load due to
bearing capacity rigidity bearing capacity rigidity bearing capacity rigidity bearing capacity rigidity bearing capacity rigidity bearing capacity rigidity

Maximum load, kN/m2, at the span of [m] 2,10 2,40 2,70 3,00 3,30 3,60 3,90 4,20 4,50 4,80 5,10 5,40 5,70 6,00
3,19 1,66 2,44 1,34 3,00 1,60 3,76 2,12 1,93 1,1 2,37 1,34 2,97 1,81 3,58 2,27 1,56 0,91 1,92 1,14 2,41 1,55 2,9 1,97 3,39 2,39 3,87 2,81 1,29 0,75 1,58 0,98 1,99 1,34 2,39 1,72 2,80 2,09 3,20 2,48 1,09 0,63 1,33 0,84 1,67 1,17 2,01 1,51 2,35 1,85 2,69 2,20 0,92 0,53 1,13 0,73 1,42 1,02 1,71 1,33 2,00 1,64 2,29 1,96 0,8 0,44 0,98 0,63 1,23 0,90 1,48 1,18 1,73 1,46 1,98 1,75 0,69 0,37 0,85 0,55 1,07 0,79 1,29 1,05 1,50 1,31 1,72 1,58 0,61 0,32 0,75 0,48 0,94 0,70 1,13 0,93 1,32 1,17 1,51 1,42 0,66 0,42 0,83 0,62 1,00 0,83 1,17 1,06 1,34 1,29 0,59 0,37 0,74 0,55 0,89 0,75 1,04 0,95 1,20 1,17 0,53 0,32 0,67 0,49 0,80 0,67 0,94 0,86 1,07 1,06 0,48 0,28 0,60 0,44 0,72 0,61 0,85 0,78 0,97 0,97

Table 6. Maximum load of very-bright- and bright-coloured multi-span PWS wall panels with 0.50-mm-thick facing load towards the support
core thickness 75 100 125 150 175 200 load due to
bearing capacity rigidity bearing capacity rigidity bearing capacity rigidity bearing capacity rigidity bearing capacity rigidity bearing capacity rigidity

Maximum load, kN/m2, at the span of [m] 2,10 2,40 2,70 3,00 3,30 3,60 3,90 4,20 4,50 4,80 5,10 5,40 5,70 6,00
2,89 1,83 2,49 1,54 3,49 1,71 4,45 2,22 2,18 1,32 3,06 1,47 3,90 1,92 4,75 2,38 1,75 1,14 2,72 1,28 3,47 1,69 4,22 2,09 4,99 2,51 5,76 2,92 1,27 0,99 2,21 1,13 3,12 1,49 3,80 1,86 4,49 2,23 5,18 2,60 1,62 1,01 2,42 1,33 3,39 1,66 4,07 2,00 4,70 2,34 1,22 0,90 1,82 1,20 2,53 1,50 3,35 1,81 4,30 2,12 1,40 1,08 1,94 1,36 2,56 1,64 3,27 1,93 1,10 0,98 1,51 1,24 1,99 1,50 2,54 1,76 1,21 1,13 1,58 1,38 2,01 1,62 1,28 1,27 1,62 1,49 1,32 1,38 -

Table 7. Maximum load of very-bright- and bright-coloured single-span PWS wall panels with 0,50-mm-thick facing load from the support
core thickness 75 load due to
bearing capacity rigidity (3) rigidity (2) bearing capacity

Maximum load, kN/m2, at the span of [m] 2,10 2,40 2,70 3,00 3,30 3,60 3,90 4,20 4,50 4,80 5,10 5,40 5,70 6,00
3,19 1,37 0,93 2,44 1,16 0,80 3,00 1,33 0,90 3,76 1,66 1,10 1,93 0,99 0,69 2,37 1,16 0,80 2,97 1,46 0,99 2,58 2,07 1,50 1,56 0,86 0,60 1,92 1,02 0,71 2,41 1,30 0,88 2,90 1,81 1,36 3,39 2,17 1,56 3,87 2,52 1,74 1,29 0,74 0,53 1,58 0,91 0,64 1,99 1,16 0,80 2,39 1,60 1,23 2,80 1,92 1,41 3,20 2,24 1,60 1,09 0,63 0,47 1,33 0,80 0,57 1,67 1,04 0,72 2,01 1,42 1,12 2,35 1,71 1,30 2,69 2,01 1,47 0,92 0,53 0,41 1,13 0,72 0,52 1,42 0,94 0,66 1,71 1,26 1,03 2,00 1,53 1,19 2,29 1,81 1,35 0,80 0,44 0,36 0,98 0,63 0,47 1,23 0,85 0,60 1,48 1,13 0,94 1,73 1,38 1,10 1,98 1,63 1,25 0,69 0,37 0,32 0,85 0,55 0,42 1,07 0,77 0,55 1,29 1,02 0,87 1,50 1,25 1,02 1,72 1,48 1,16 0,61 0,32 0,29 0,75 0,48 0,38 0,94 0,70 0,50 1,16 0,91 0,80 1,32 1,12 0,94 1,51 1,34 1,08 0,66 0,42 0,35 0,83 0,62 0,46 1,00 0,82 0,74 1,17 1,02 0,88 1,34 1,23 1,01 0,59 0,37 0,32 0,74 0,55 0,42 0,89 0,74 0,68 1,04 0,93 0,81 1,20 1,12 0,94 0,53 0,32 0,29 0,67 0,49 0,39 0,80 0,67 0,63 0,94 0,85 0,75 1,07 1,02 0,94 0,48 0,28 0,26 0,60 0,44 0,36 0,72 0,61 0,59 0,85 0,77 0,70 0,97 0,94 0,82

100

rigidity (3) rigidity (2) bearing capacity

125

rigidity (3) rigidity (2) bearing capacity

150

rigidity (3) rigidity (2) bearing capacity

175

rigidity (3) rigidity (2) bearing capacity

200

rigidity (3) rigidity (2)

rigidity (3) load permissible due to not exceeding the deflection of a panel fastened with 3 fasteners at the width rigidity (2) - load permissible due to not exceeding the deflection of a panel fastened with 2 fasteners at the width

Load per one fastener should not exceed 0,82 kN.

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Table 8. Maximum load of very-bright- and bright-coloured multi-span PWS wall panels with 0,50-mm-thick facing load from the support
core thickness 75 load due to
bearing capacity rigidity (3) rigidity (2) bearing capacity

Maximum load, kN/m2, at the span of [m] 2,10 2,40 2,70 3,00 3,30 3,60 3,90 4,20 4,50 4,80 5,10 5,40 5,70 6,00
2,89 1,48 1,11 2,49 1,25 0,93 3,49 1,39 1,03 4,45 1,80 1,35 2,18 1,08 0,80 3,06 1,20 0,89 3,90 1,56 1,16 4,75 1,89 1,44 1,75 0,93 0,69 2,72 1,04 0,77 3,47 1,37 1,02 4,22 1,69 1,28 4,99 1,99 1,52 5,76 2,27 1,74 1,27 0,81 0,59 2,21 0,92 0,68 3,12 1,21 0,90 3,80 1,52 1,15 4,49 1,79 1,36 5,18 2,05 1,57 1,62 0,83 0,61 2,42 1,08 0,80 3,39 1,37 1,04 4,07 1,62 1,23 4,70 1,87 1,42 1,22 0,74 0,54 1,82 0,98 0,72 2,53 1,25 0,95 3,35 1,48 1,13 4,30 1,71 1,30 1,40 0,88 0,65 1,94 1,15 0,87 2,56 1,36 1,03 3,27 1,57 1,19 1,10 0,80 0,59 1,51 1,06 0,80 1,99 1,25 0,95 2,54 1,45 1,10 1,21 0,97 0,73 1,58 1,16 0,88 2,01 1,34 1,02 1,28 1,08 0,82 1,62 1,25 0,94 1,32 1,16 0,88 -

100

rigidity (3) rigidity (2) bearing capacity

125

rigidity (3) rigidity (2) bearing capacity

150

rigidity (3) rigidity (2) bearing capacity

175

rigidity (3) rigidity (2) bearing capacity

200

rigidity (3) rigidity (2)

rigidity (3) - load permissible due to not exceeding the deflection of a panel mounted with 3 joints at the width rigidity (2) - load permissible due to not exceeding the deflection of a panel mounted with 2 joints at the width

Load per one joint should not exceed 0,82 kN. Table 9. Maximum load of very-bright- and bright-coloured single-span PWD roof panels with 0.50-mm-thick facing
core thickness 75 100 125 150 175 200 load due to
bearing capacity rigidity bearing capacity rigidity bearing capacity rigidity bearing capacity rigidity bearing capacity rigidity bearing capacity rigidity

Maximum load, kN/m2, at the span of [m] 2,10 2,40 2,70 3,00 3,30 3,60 3,90 4,20 4,50 4,80 5,10 5,40 5,70 6,00
2,01 1,91 1,76 1,52 2,46 1,82 3,16 2,41 1,56 1,23 2,18 1,52 2,81 2,04 3,43 2,56 1,41 1,00 1,97 1,28 2,52 1,74 3,08 2,21 3,64 2,68 4,20 3,15 1,28 0,82 1,79 1,09 2,30 1,50 2,80 1,92 3,31 2,34 3,82 2,77 1,17 0,68 1,64 0,93 2,10 1,30 2,57 1,68 3,03 2,07 3,50 2,45 1,08 0,57 1,51 0,80 1,94 1,14 2,37 1,48 2,80 1,83 3,23 2,19 1,01 0,47 1,40 0,69 1,80 1,00 2,20 1,31 2,60 1,63 3,00 1,96 0,94 0,39 1,31 0,60 1,68 0,88 2,06 1,16 2,43 1,46 2,80 1,76 0,84 0,33 1,23 0,52 1,58 0,77 1,93 1,04 2,28 1,31 2,63 1,59 1,15 0,45 1,49 0,68 1,81 0,93 2,14 1,18 2,47 1,44 1,03 0,40 1,40 0,61 1,71 0,83 2,02 1,06 2,33 1,30 0,92 0,35 1,26 0,54 1,60 0,75 1,92 0,96 2,21 1,18 0,83 0,30 1,13 0,48 1,44 0,67 1,75 0,87 2,07 0,98

With load working from the support, load per one fastener should not exceed 0,75 kN. Table 10. Maximum load of very-bright- and bright-coloured multi-span PWD roof panels with 0.50-mm-thick facing
core thickness 75 100 125 150 175 200 load due to
bearing capacity rigidity bearing capacity rigidity bearing capacity rigidity bearing capacity rigidity bearing capacity rigidity bearing capacity rigidity

Maximum load, kN/m2, at the span of [m] 2,10 2,40 2,70 3,00 3,30 3,60 3,90 4,20 4,50 4,80 5,10 5,40 5,70 6,00
1,85 2,26 1,60 1,90 2,29 2,04 2,97 2,57 1,40 1,63 2,01 1,76 2,61 2,23 3,21 2,70 1,25 1,41 1,79 1,54 2,32 1,96 2,86 2,38 3,40 2,81 3,95 3,23 1,12 1,23 1,61 1,36 2,09 1,74 2,58 2,12 3,06 2,50 3,56 2,89 1,02 1,08 1,46 1,22 1,90 1,56 2,34 1,90 2,78 2,25 3,23 2,60 0,93 0,96 1,34 1,09 1,74 1,40 2,14 1,72 2,55 2,04 2,93 2,36 0,77 0,85 1,23 0,98 1,60 1,27 1,97 1,56 2,35 1,85 2,72 2,15 0,65 0,76 1,14 0,89 1,48 1,16 1,83 1,42 2,17 1,70 2,52 1,97 0,55 0,68 0,91 0,81 1,34 1,06 1,70 1,31 2,02 1,56 2,35 1,81 0,47 0,62 0,77 0,74 1,13 0,97 1,54 1,20 1,89 1,44 2,20 1,67 0,41 0,56 0,66 0,68 0,96 0,89 1,30 1,11 1,68 1,33 2,06 1,55 0,57 0,62 0,83 0,82 1,12 1,03 1,44 1,23 1,79 1,44 0,50 0,57 0,73 0,76 0,97 0,95 1,25 1,15 1,55 1,34

With load working from the support, load per one fastener should not exceed 0,75 kN.

16

Table 11. Permissible span of single-span and multi-span PWD sandwich roof panels under tropical coat.
core thickness [mm] 100 125 150 175 200 Maximum span [m] 0oC 6,30 6,30 6,30 -5oC 5,10 5,70 6,30 -25oC 3,40 3,40 4,20 4,50

Notes on using tables:

- permissible load for one fastener should not exceed 1 kN - given permissible load and maximum span spacing apply to sandwich panels with light colour facings - the minimum in-between support width is 60mm and end supports width is 40mm - values given in tables do not apply to half panels with outer side steel coating and laminate on the inner side

15. THERMAL INSULATION

Table 12. The value of the heat transfer coefficient Uc determined with design value of the polyester heat transfer coefficient 10C, obl = 0,039 W/mK.
Item 1
1 2 3 PWS wall panels 4 5 6 7 8 9 PWD roof panels 10 11 12 150 175 200 0,26 0,22 0,20 150 175 200 75 100 125 0,25 0,22 0,19 0,54 0,41 0,32

Type of panel 2

Core thickness [mm] 3

75 100 125

UC [W/m2K] 4
0,50 0,38 0,30

17

Table 13. PWS panel insulating power for cooling facilities

Heat flux density [W/m2] Panel type Temperature difference t Item [K] 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

PWS 75

PWS 100

PWS 125

PWS 150
2

PWS 175

PWS 200

Heat transfer coefficient [W/m K] 0,47 2

4,70 7,05 9,40 11,75 14,10 16,45 18,80 21,15 23,50 25,85 28,20 30,55 32,90 35,25 37,60 39,95 42,30 44,65 47,00

0,36 3
3,60 5,40 7,20 9,00 10,80 12,60 14,40 16,20 18,00 19,80 21,60 23,40 25,20 27,00 28,80 30,80 32,40 34,20 36,00

0,29 4
2,90 4,35 5,80 7,25 8,70 10,15 11,60 13,05 14,50 15,95 17,40 18,85 20,30 21,75 23,20 24,65 26,10 27,55 29,00

0,25 5
2,50 3,75 5,00 6,25 7,50 8,75 10,00 11,25 12,50 13,75 15,00 16,25 17,50 18,75 20,00 21,25 22,50 23,75 25,00

0,21 6
2,10 3,15 4,20 5,25 6,30 7,35 8,40 9,45 10,50 11,55 12,60 13,65 14,70 15,75 16,80 17,85 18,90 19,95 21,00

0,18 7
1,79 2,69 2,58 4,48 5,37 6,27 7,16 8,06 8,95 9,85 10,74 11,64 12,53 13,43 14,32 15,22 16,11 17,01 17,90

The recommended scope of application

is marked with colour

ATTENTION!
a) Carrying freezer minimum temperature, for which the use of PWS expanded polystyrene panels is efficient, is -20 oC b) In the summer season the appropriately assumed outside temperature is 35oC c) In the winter season the appropriately assumed outside temperature is -20oC Example1: In order to check, which panels are suitable for carrying freezer with the inside temperature of -20oC t = 35 + | -20 | = 55 Check in line 10, with t = 55, which of the panels is 10 W/m2 flux density. The only possible choice: PWS 200 is in column 7. Example 2: In order to check, which panels are suitable for a division wall between two rooms, with -20oC inside temperature in one and 0oC in the other t = 0 + 20 = 20 Check in line 3, with t = 20, which of the panels is 10 W/m2 flux density. The result is that even PWS 75 panel found in column 2 fulfills the minimum insulation requirements. Units: 1oC = 1K Conversion from oC do K: K = 273,15oC

18

16. FIRE SAFETY

Walls made of PWS panels have received fire classification presented in the table below and have E60 fire integrity, provided that supporting structure of the fire resistance of at least R30 is used and the maximum spacing between the bearing elements in the case of walls is 3 m. In order to retain this fire integrity parameter, no heavy elements, such as installations, ventilation pipes, etc., can be suspended on the wall made of sandwich panels. In the case of roofing, the fire tightness is E30, provided that the supporting structure is applied. Table 14. Fire classification of PWS panels.
Types of panels 1
Balex PWS
1)

Panel thickness [mm] 2

100 to 200

Class of reaction to fire according to EN 13501-1:2004 3

B-s2, d01)

Classification according to the ITB 401/2005 manual

non-flammable, not dripping and not dropping off when exposed to fire

Provided that the panels are mounted directly to A1- or A2-class elements, the classification pertains to the method of joining the panels in the corner, in accordance to AT-15-4765/2007

Table 15. Fire resistance of walls made of PWS panels.

Fire resistance of non-bearing walls, in accordance with PN-B-02851-1:1997 4
E 60 -

Wall made of panels

Panel thickness [mm]

Degree of fire spread wg PN-90/B-02867 3

(NRO) NFS Non Fire Spreading (NRO) NFS Non Fire Spreading 1)

Fire resistance of non-bearing walls, in accordance with PN-EN 13501-2:2005 5

E60 / EW 60 -

1
BALEX PWS

2
75 100 to 200

BALEX single-sided panels

1)

75 to 200

Provided that the panels are mounted to the non-flammable surface, at least A2-s3,d0 class of reaction to fire

In the case of roof coverings, the fire tightness is E30, provided that the supporting structure is applied. Table 16. Fire resistance of roof coverings made of PWD panels.
Roof covering made of panels 1
BALEX PWD 125 do 200 BALEX single-sided panels 75 do 200

Panel thickness, mm 2
75, 100

Degree of fire spread ITB 401/2004 3

(NRO) NFS Non Fire Spreading

Resistance of roofing to outer fire according to EN 13501-5 4

BROOF (t1)

Fire resistance of loaded roof coverings according to PN-B-02851-1:1997 5

E 30 -

Fire resistance classification means that the fire integrity criterion for walls and roofs made of PWS and PWD panels
is met in at least the number of minutes specified after E. NRO means that the panel has been classified as an element that does not spread fire.

19

17. CORROSION RESISTANCE

The research conducted in the Warsaw Building Research Institute in the Department Of Durability And Protection Of Buildings showed that BALEX METAL PWS and PWD sandwich panels with expanded polystyrene core meet the EN ISO 12944-2 requirements in classes C1 to C3. PWS and PWD panels with facings covered with organic coatings SP 25 or SP 35 or PVDF 25 on the face side of the panel may be utilized in C1, C2, C3 corrosion class environment acc. to EN ISO 12944-2 standard. PWS and PWD panels with facings protected with AZ185 aluminium and zinc coating may be utilized in C1, C2, C3 corrosion class environment acc. to EN ISO 12944-2 standard. PWS and PWD panels with facings protected with AZ150 aluminium and zinc coating may be utilized in C1, C2 corrosion class environment acc. to EN ISO 12944-2 standard.

Corrosion classes and example of typical environments acc. to EN ISO 12944-2

C1 corrosion class indoors heated buildings with a clean atmosphere e.g. offices, shops, schools and hotels C2 corrosion class outdoors slightly polluted atmosphere, mainly countryside indoors not heated buildings with a possibility of condensation e.g. warehouses, sports halls C3 corrosion class outdoors urban and industrial atmospheres, medium pollution with sulphur oxide (IV), coastal area with low salinity indoors production rooms with high humidity and certain level of air pollution e.g. food industrial facilities, laundries, breweries, dairies.

18. NOISE REDUCTION PERFORMANCE

PWS and PWD sandwich panels are characterized by the following noise reduction parameters in the 75 mm to 200 mm core thickness scope. Table 17. Noise reduction index
Types of panels
Balex PWS Balex PWD

Core thickness [mm]

75 to 200 75 to 200

RW [dB]
>26 >23

RA1 [dB]
>24 >22

RA2 [dB]
>22 >20

NOTE: In the design process the given values should be decreased by 2 dB in accordance with PN-B-02151-3:1999 standard requirements RW - weighted noise reduction index RA1 - noise reduction assessment index RA2 - noise reduction assessment index Values of the indexes in table were calculated acc. to EN-ISO 717-1:1999 based on research acc. to EN 20140-3:1999. The above indexes mean that soundwise PWS and PWD sandwich panels may be used in following types of facilities: - enclosures of walls and roofs of industrial and sports halls, production and storage facilities, for constructing commercial, service and gastronomic pavilions, construction site back-up facilities, administration and social buildings if they meet individually settled acoustic requirements. - for construction of buildings that do not have to meet any acoustic requirements

20

19. FASTENERS
PWS and PWD sandwich panels are fastened to a steel construction with the use of self-drilling fasteners. Due to that it is possible to avoid initial drilling of holes in the panel and the construction. Moreover self-drilling fasteners increase the quality of the fastening and limit the number of used tools. In the case of self-drilling fasteners a new drilling bit is used as the fastener is to be used once only which influences the fastening durability. Fasteners are made of hardened carbon steel with anti-corrosion protective coating. All fasteners are equipped with cured EPDM gaskets. The application of EPDM increases the rigidity and tightness of the connection. ZD6 a fastener of drilling ability up to 6 mm, intended for cold-rolled steel bases ZD12 a fastener of drilling ability up to 12 mm, intended for hot-rolled steel bases ZD16 - a fastener of drilling ability up to 16 mm, intended for hot-rolled steel bases A fastener for wood and concrete intended for direct assembly in a wooden or concrete base. Before assembly, it is recommended to pre-drill the sandwich panel facing with a 5 mm drill. In the case of concrete base, it is necessary to pre-drill a hole of 5 mm diameter with a concrete drill. Self-drilling fastener intended for steel bases of thickness over 12 mm. Before the assembly it is necessary to pre-drill the sandwich panel and in the steel structure with a 5.8 mm drill.

20. FASTENING ROOF PANELS LENGTHWISE

Recommended roof inclination for PWD roof panels is:

>7 % - for panels fastened lengthwise or with roof skylights

>5 % - for continuous panels and without roof skylights

PWD panels have endings formed at the production stage that facilitate gutter assembly next to the eaves (BALEX option) or lengthwise panel fastening. A - standard 50 mm next to the eaves (BALEX variant) - standard 150 mm next to the overlap - max. 200 mm next to the overlap
Undercut thickness A[mm] 50 80 100 150 200 Minimum panel length Lmin[mm] 4000 4500 4600 4800 5000

L - Pane

l length

21

PWD panel is produced exclusively as Left:

21. GENERAL ASSEMBLY GUIDELINES

Before starting assembly it is recommended to verify the carrying construction in terms of precision of performance and its accordance with the design. PWS and PWD panels are secured against dirt and damage with a protective foil applied to facings in the production process. It is recommended to remove the protective foil from facings which are to form the internal side of the building, before fastening them to the construction. In the case of external facings the protective foil should be removed within 1 month from the date of production. It will prevent both the foil from binding permanently with protective varnish of facings and varnish from getting dirty while removing the foil.

Fig 1. For sandwich panel fastening it is recommended to use appropriate fasteners depending on type of carrying construction and panel core thickness. Types of fastening elements are specified in chapter FASTENERS. To fasten sandwich panels to a steel construction with thickness not exceeding 12 mm it is recommended to use selfdrilling fasteners made of hardened galvanized carbon steel. All fasteners are equipped with cured EPDM gaskets, which allows for long-term use with retention of the elasticity of the sealing element. In the case of steel base (> 12 mm thickness) or wood base special selfdrilling fasteners, with properly shaped working thread profile, are recommended. For screwing in fasteners use specialised power tools. Drivers should be equipped with a proper long join driving head and a penetration depth limiter, fig. 2. This guarantees appropriate assembly i.e. maintaining perpendicular location of a particular fastener in relation to a panel, minimised risk of damaging panels surface and tightness of the fastening fig. 3. It is possible to use universal drivers with standard short heads. However, tools of this type should be equipped with a penetration depth limiter. Optimal parameters of power tools for sandwich panel assembly are provided in the list below: power 600 - 750 W rotation 1500 - 2000 rpm. torque 600 - 700 Ncm

Fig 2. A power screwdriver with a limiter of the fastener driving depth

22

- too loose (undertightened) Fig 3. Proper tightening of fasteners

- correct

- too tight (overtightened)

After cutting and drilling it is necessary to remove all the metal chips and fillings which can cause discoloration of the facing surface. The tightness of the enclosure is obtained through the use of appropriate tapes and sealing foams. All facing sheet varnish damages that occurred during installation should be protected with touch-up paint.

PWD panel assembly example:

PWD panel

PUS sealing tape

Pop rivet

Ground beam 120x120

Support

Fastener PWD

PWS panel assembly example:

PUS sealing tape

PWS panel

Support

Fastener PWS

23

PWS panel assembly example:

Tightening belt Wall transom Hall frame pillar

Board

Board

Reference assembly drawing

Press the panel to the required crevice in the joining

FORCE DIRECTION Board

Hall frame pillar

Wall transom FORCE DIRECTION

Board

FORCE DIRECTION Board

Reference assembly drawing

24

22. TRANSPORT GUIDELINES

Recommended means of transport and its technical conditions:
Lorries with an open load-carrying body or an open trailer enabling loading long panels (up to 13,60 metres) from both sides of a car constitute the basic means of transport for sandwich panels. The following technical conditions are recommended for vehicles transporting sandwich panels: load-carrying body with canvas cover (CURTAIN type) load-carrying body longer than transported panels (a package of panels should be placed on the platform in its entire length). transport belts holding the load should be placed on a package of panels on each support (belt tension should not cause panels to deform)

Table 18. Way of sandwich panel packaging

Number of sandwich panels in a package Panel thickness [mm]
75 100 125 150 175 200

PWS/PWD - double-sided metal sheets PWS - with laminate [pcs]

14 10 8 7 6 5

PWD with laminate [pcs]

11 8 7 6 5 5

36 double-sided PWS 100.1155 wall panels with the length of 12 m is set as the example load (498.96 m2). The number of packages for the whole load is: the number of panels/the number of panels of particular thickness in a package = 36/10 = 3 packages x 10 pcs and 1 package 6 pcs Total load weight is: total panel surface x weight of 1m2 = 498.96 x 10.39 5184.19 kg Transport requirements regarding load: Load carrying body length min. 12.5m Load capacity min. 6,50 t

A truck-tractor with a covered trailer min 2,45 2,60 m wide is an optimal means of transport for the load specified above. The load is placed in two piles, two panel packages each.

Unloading, transport:
During loading and unloading extreme caution should be kept, one should avoid point supports as it may lead to damaging the facing of the lowest panel. In order to avoid this problem you should distribute the load over a greater surface area. You should also pay attention not to drag one panel along another one not to scratch it.

25

Panel storage:
Sandwich panels should be stored on ground beams, not less than 250mm over the ground. It is allowed to store two packages placed one on another at the most. It is recommended to store panels in airy rooms, at normal temperature, far away from acids, lye, salts and other corrosive substances. Storing uncovered panels is unacceptable. In case of storing panels under canvas cover for a short period of time (a fortnight at the most) you should ensure free air flow. If storing period is longer than 2 weeks panels should be placed in a well ventilated room and left uncovered as well as provided with free access to air in order for all layers to be ventilated. Not following these recommendations can lead to coating decolouration, so called white rust, permanent core damage as well as loss of warranty.

Minor repairs and maintenance:

All damage to coating caused during transport or assembly should be covered with touch up paint. Maintenance of sandwich panels consists in performing regular inspections and securing possible damages. During inspection close attention should be paid to uncovered edges and joints.

Notes concerning usage:

Sandwich wall panels with dark facings are characterized by high heat absorption capacity which can cause local deformation of facings surface in the period of high air temperatures. As a result allow for panels thermal motion and use panels of limited length. This effect does not have any influence on the properties of sandwich panels but the producer warns that clients purchase wall panels in those colours at their own risk and do not have rights to claim against the producer due to this fact. Local deformations in roof panel surface practically does not occur. Pursuant to the EN 14509 standard, it is assumed that sheets in dark colours heat to the temperature of 90C. Therefore, Balex Metal shall not be responsible for any damages caused by high temperature, which may result in changing the position of the facing in some places. Dark colours are defined in Item E.33 of the EN14509 standard.

26

23. CERTIFICATION DOCUMENTS

27

28

II. DETAILED CONSTRUCTION SOLUTIONS OF ENCLOSURES MADE OF PWS AND PWD SANDWICH PANELS WITH EXPANDED POLYSTYRENE CORE

29

1. PWS wall panel

1.1. PWS 01 PWS wall panel - joint, types of profiles
Modular width 1155

Recommended spacing of PWS fastening

Modular width 1155 Modular width 1155

Detail A

Detail B

PUS tape

TYPES OF PROFILES EXTERNAL FACINGS:

Modular width 1155 grooved

INTERNAL FACINGS:
Modular width 1155 grooved

Modular width 1155 flat

30

1.2. PWS 02 Panel fastening - vertical panel arrangement

Modular width 1155 Modular width 1155 Modular width 1155

1. PWS wall panel 2. LB 1 or LB 2 PWS wall panel fastener 3. PES 3x20 self adhesive sealing tape (recommended) 4. Wall transom acc. to construction design

31

1.3. PWS 03 Supporting the panels on the ground beam or the foundations vertical panel arrangement

1. PWS wall panel 2. OBR 100 flashing 3. OBR 101 flashing 4. LB 1 or LB 2 PWS wall panel fastener 5. LB 6 self drilling fastener or blind AL/Fe rivet approx. every 300 mm. 6. PUS 5x40 self- adhesive sealing tape 7. Butyl sealing tape (recommended ) 8. Panel joint sealant 9. Impregnated polyurethane seal 20 mm thick 10. Angle acc. to construction design 11. Damp proof insulation acc. to architecture design

32

1.4. PWS 04 Supporting panels below the top of the ground beam or the foundations vertical panel arrangement

1. PWS wall panel 2. OBR 100 flashing 3. OBR 101 flashing 4. LB 1 or LB 2 PWS wall panel fasteners 5. LB 6 self drilling fastener or blind AL/Fe rivet approx. every 300 mm. 6. PUS 5x40 self- adhesive sealing tape 7. Butyl sealing tape (recommended) 8. Panel joint sealant 9. Angle acc. to construction design 10. Damp proof insulation acc. to architecture design 11. Facing with approx. 10 mm width gap in case of increased thermal insulation requirements

33

1.5. PWS 05 Supporting the panels on the ground beam or the foundations horizontal panel arrangement

1. PWS wall panel 2. OBR 102 flashing 3. LB 1 or LB 2 PWS wall panel fasteners 4. PES 3x20 self- adhesive sealing tape (recommended) 5. Impregnated polyurethane seal 20 mm thick 6. Angle acc. to construction design 7. Damp proof insulation acc. to architecture design

34

approx. 23mm

1.6. PWS 06 Supporting the panels bellow the top of the ground beam or the foundations horizontal panel arrangement

1. PWS wall panel 2. OBR 102 flashing 3. LB 1 or LB 2 PWS wall panel fastener 4. PUS 5x40 self- adhesive sealing tape 5. PES 3x20 self- adhesive sealing tape (recommended) 6. Impregnated polyurethane seal 20 mm thick 7. Z profile acc. to construction design 8. Damp proof insulation acc. to architecture desig

approx. 23mm

35

1.7. PWS 07 Joining panels in the corner - horizontal or vertical panel arrangement - option I

min.10 1. PWS wall panel 2. OBR 104 flashing 3. OBR 05 flashing 4. LB 6 self drilling fastener or blind AL/Fe rivet approx. every 300 mm. 5. Polyurethane seal or assembly foam 6. Facing with approx. 10 mm width gap in case of increased thermal insulation requirements

36

1.8. PWS 08 Joining panels in the corner - horizontal or vertical panel arrangement - option II

min.50

min.10

1. PWS wall panel 2. OBR 104 flashing 3. OBR 05 or OBR 109 flashing 4. LB 6 selfdrilling fastener or blind rivet AL/Fe approx. every 300 mm 5. Polyurethane seal or assembly foam

37

1.9. PWS 09 Joining panels in the corner - horizontal or vertical panel arrangement - option III

min.50

min.10

1. PWS wall panel 2. OBR 103 flashing 3. OBR 104 flashing 4. LB 6 selfdrilling fastener or blind AL/Fe rivet approx. every 300 mm 5. LB 1 or LB 2 PWS wall panel fastener 6. PES 3x20 self-adhesive sealing tape (recommended) 7. Polyurethane seal or assembly foam 8. Pillar acc. to construction design 9. Transom acc. to construction design

38

1.10. PWS 09/1 Joining panels in the corner - horizontal or vertical panel arrangement

min.50

min.10

1. PWS wall panel 2. OBR 103 flashing 3. OBR 104 flashing 4. OBR 111 flashing 5. LB 6 selfdrilling fastener or blind AL/Fe rivet approx. every 300 mm 6. LB 1 or LB 2 PWS wall panel fastener 7. PES 3x20 self- adhesive sealing tape (recommended) 8. Polyurethane seal or assembly foam 9. Pillar acc. to construction design 10. Transom acc. to construction design

39

1.11. PWS 10 Joining panels in the corner - horizontal or vertical panel arrangement - option IV

min.50

min.10

1. PWS wall panel 2. OBR 103 flashing 3. LB 6 selfdrilling fastener or blind AL/Fe rivet approx. every 300 mm 4. LB 1 or LB 2 PWS wall panel fastener 5. PES 3x20 self- adhesive sealing tape (recommended) 6. Polyurethane seal or assembly foam 7. Pillar acc. to construction design

40

1.12. PWS 11 Lengthwise panel joining - vertical panel arrangement

1. PWS wall panel 2. OBR 100 flashing 3. LB 1 or LB 2 PWS wall panel fastener 4. Butyl sealing tape (recommended) 5. PES 3x20 self- adhesive sealing tape (recommended) 6. PUS 5x40 self- adhesive sealing tape 7. Panel joint sealant 8. Assembly foam 9. Impregnated polyurethane seal 20 mm thick 10. Transom acc. to construction design

min.30

41

1.13. PWS 12/1 Fastening panels to the outermost support - horizontal panel arrangement - option I

min.10

1. PWS wall panel 2. OBR105 flashing 3. LB 1 or LB 2 PWS wall panel fastener 4. LB 6 selfdrilling fastener or blind AL/Fe rivet approx. every 300 mm 5. PES 3x20 self-adhesive sealing tape (recommended) 6. Impregnated polyurethane seal (recommended) 9. Polyurethane seal or assembly foam 8. Pillar acc. to construction design

42

1.14. PWS 12/2 Fastening panels to the outermost support - horizontal panel arrangement - option II

min.10 1. PWS wall panel 2. OBR 110 flashing (item 4. fastener cuttings to be made during assembly) 3. OBR 111 flashing 4. LB 1 or LB 2 PWS wall panel fastener 5. LB 6 self drilling fastener approx. every 300 mm 6. PES 3x20 self-adhesive sealing tape (recommended) 7. Impregnated polyurethane seal (recommended) 8. Polyurethane seal or assembly foam 9. Pillar acc. to construction design

43

1.15. PWS 13 Fastening panels to the intermediate support - horizontal panel arrangement

1. PWS wall panel 2. LB 1 or LB 2 PWS wall panel fastener 3. PES 3x20 self-adhesive sealing tape (recommended) 4. Pillar acc. to construction design

44

1.16. PWS 14 Joining panels to the window strip - horizontal panel arrangement - option I

LONGITUDINAL SECTION

CROSS SECTION

outer side

1. PWS wall panel 2. OBR 104 flashing 3. OBR 106 flashing 4. OBR 100 flashing 5. Individual flashing 6. Individual flashing 7. LB 1 or LB 2 PWS wall panel fasteners 8. LB 6 selfdrilling fastener or blind AL/Fe rivet approx. every 300 mm 9. PUS 5x40 self-adhesive sealing tape 10. PES 3x20 self-adhesive sealing tape (recommended) 11. Butyl sealing tape 12. Panel joint sealant 13. Impregnated polyurethane seal 20 mm thick 14. Assembly foam 15. Transom acc. to construction design 16. Window mounting flat bar

min.30

45

1.17. PWS 15 Joining panels to the window strip - horizontal panel arrangement - option II (for panels of 75, 100 thickness)

LONGITUDIUNAL SECTION

CROSS SECTION

outer side

outer side

1. PWS wall panel 2. OBR 106 flashing 3. OBR 104 flashing 4. OBR 100 flashing 5. Individual flashing 6. Individual flashing 7. Individual flashing 8. LB 6 selfdrilling fastener or blind AL/Fe rivet approx. every 300 mm 9. LB 1 or LB 2 PWS wall panel fastener 10. Butyl sealing tape 11. PES 3x20 self- adhesive sealing tape (recommended) 12. PUS 5x40 self-adhesive sealing tape 13. Panel joint sealant 14. Assembly foam 15. Impregnated polyurethane seal 20 mm thick 16. Transom acc. to construction design 17. Window mounting flat bar

46

1.18. PWS 16 Joining panels to the window strip vertical or horizontal panel arrangement - option III

LONGITUDINAL SECTION

CROSS SECTION

outer side

1. PWS wall panel 2. OBR 104 flashing 3. OBR 107 flashing 4. Individual flashing 5. Individual flashing 6. LB 6 selfdrilling fastener or blind AL/Fe rivet approx. every 300 mm 7. LB 1 or LB 2 PWS wall panel fastener 8. PUS 5x40 self-adhesive sealing tape 9. PES 3x20 self-adhesive sealing tape (recommended) 10. Butyl sealing compound 11. Impregnated polyurethane seal 20 mm thick 12. Assembly foam 13. Transom acc. to construction design 14. Window mounting flat bar

min.30

47

1.19. PWS 17/1 Joining panels to the PCV window - vertical or horizontal panel arrangement

Modular width

Modular width

min.200

min.200

outer side 1. PWS wall panel 2. OBR 107 flashing 3. Impregnated polyurethane gasket or foam 4. PCV window

48

1.20. PWS 17/2 Joining panels to the PCV window - vertical or horizontal panel arrangement section X-X

outer side

1. PWS wall panel 2. OBR 107 flashing 3. LB 6 self drilling fastener or blind AL/Fe rivet approx. every 300 mm 4. Butyl sealing compound 5. Impregnated polyurethane seal 20 mm thick 6. PCV window

49

1.21. PWS 18 Fastening panels, sliding joint - vertical panel arrangement

5. Steel gasket (sh. 4x68x100)

G - thickness of the shelf of the angle bar (item 7)

1. PWS wall panel 2. M 6 screw with a counter nut 3. PES 3x20 self- adhesive sealing tape (recommended) 4. Cured EPDM gasket (recommended T19/3/6, 7 SFS) 5. Steel gasket (sh. 4x68x100) individual 6. Transom acc. to construction design 7. Angle acc. to construction design

50

Modular axis of the panel

2. PWD Roof sandwich panels

2.1. PWD01 Roof sandwich panels, joint, types of profiles
Modular width 1100

Modular width 1100

Modular width 1100

Special milled lock

PUS tape

TYPES OF PROFILES EXTERNAL FACING:

Modular width 1100

trapezoidal

INTERNAL FACING:
Modular width 1100

trapezoidal

51

2.2. PWD 02/1 Fastening panels to the purlins

Modular width 1100 Modular width 1100

1. PWS wall panel 2. PWD panel fastener 3. LB 6 selfdrilling fastener or blind AL/Fe rivet approx. every 300 mm 4. PES 3x20 self-adhesive sealing tape (recommended) 5. PUS 5x40 self-adhesive sealing tape 6. Purlin acc. to construction design

52

2.3. PWD 02/2 Fastening panels to the purlins - section X-X

ok. 300

1. PWS wall panel 2. PWD panel fastener 3. LB 6 selfdrilling fastener or blind AL/Fe rivet approx. every 300 mm 4. PES 3x20 self-adhesive sealing tape (recommended) 5. Purlin acc. to construction design

53

2.4. PWD 03 Panel flashing in case of a monopitch roof

300

a 2

00

Note: OBR 104/1 for an obtuse corner applied for 6 angle OBR 104/2 for an obtuse corner applied for 22 angle 1. PWD roof panel 2. OBR 53 flashing 3. OBR 104 flashing 4. LB 6 selfdrilling fastener or blind AL/Fe rivet approx. every 300 mm 5. TUP 18 sealing tape 6. TUN 18 sealing tape 7. Assembly foam or polyurethane seal

54

2.5. PWD 04/1 Gable-end roof edge

max 300

1. PWD roof panel 2. PWS wall panel 3. OBR 104 flashing 4. OBR 60 flashing 5. LB 6 self drilling fastener or blind AL/Fe rivet approx. every 300 mm 6. Assembly foam or polyurethane seal

55

2.6. PWD04/2 Gable-end roof edge

max 300

1. PWD roof panel 2. PWS wall panel 3. OBR 104 flashing 4. OBR 60 flashing 5. LB 6 selfdrilling fastener or blind AL/Fe rivet approx. every 300 mm 6. Assembly foam or polyurethane seal

56

2.7. PWD 05 Joint of the PWD panels with the PWS wall panel by the attic

1. PWD roof panel 2. PWS wall panel 3. OBR 112 flashing 4. Individual flashing 5. Individual flashing 6. PWD panel fastener 7. LB 6 self drilling fastener or blind AL/Fe rivet approx. every 300 mm (tight rivet on the external facing of the roof ) 8. PES 3x20 self-adhesive sealing tape (recommended) 10. Polyurethane seal or assembly foam 11. Angle fastened to the purlins acc. to construction design 12. Purlin acc. to construction design 13. Top facing 30 mm bend out

57

2.8. PWD 06 Joint of the panels at the roof ridge

1. PWD roof panel 2. OBR 53 or OBR 205 flashing 3. OBR 104 flashing 4. LB 6 selfdrilling fastener or blind AL/Fe rivet approx. every 300 mm 5. PWD panel fastener 6. TUP 18 sealing tape 7. TUN 18 sealing tape 8. PES 3x20 self-adhesive sealing tape (recommended) 9. Insulation material or assembly foam 10. Purlin acc. to construction design 11. OBR 65 flashing

58

2.9. PWD 07/1 Joint of the panels with the internal gutter - option I BALEX

1. PWD roof panel with an undercut core 2. Internal profile of the gutter 3. External profile of the gutter 4. LB 6 selfdrilling fastener approx. every 300 mm 5. PWD panel fastener 6. PES 3x20 self-adhesive sealing tape (recommended) 7. TUP 18 sealing tape 8. Heat-insulating material of the gutter 9. Purlin acc. to construction design

59

2.10. PWD 07/2 Joint of the panels with the internal gutter - option II

1. PWD roof panel with an undercut core 2. Internal profile of the gutter 3. External profile of the gutter 4. LB 6 selfdrilling fastener approx. every 300 mm 5. PWD panel fastener 6. PES 3x20 self-adhesive sealing tape (recommended) 7. Heat-insulating material of the gutter 8. Butyl sealing compound 9. Purlin acc. to construction design 10. Panel core with an approx. 30 mm undercut

60

2.11. PWD 08/1 Joint of the panels with the prefabricated internal gutter - option I - BALEX METAL

1. PWD roof panel 2. Prefabricated gutter acc. to architecture design (with a pitch) 3. Individual flashing 4. PWD panel fastener 5. LB 6 selfdrilling fastener approx. every 300 mm 6. PES 3x20 self-adhesive sealing tape (recommended) 7. Butyl sealing tape 8. TUP 18 sealing tape 9. Purlin acc. to construction design

61

2.12. PWD 08/2 Joint of the panels with the prefabricated internal gutter - option II

1. PWD roof panel 2. Prefabricated gutter acc. to architecture design (with a pitch) 3. Individual flashing 4. PWD panel fastener 5. LB 6 selfdrilling fastener approx. every 300 mm 6. PES 3x20 self-adhesive sealing tape (recommended) 7. Butyl sealing tape 8. Butyl sealing compound 9. Purlin acc. to construction design 10. Panel core with an approx. 30 mm undercut

62

2.13. PWD 09/1 Joint of the wall panel with the roof panel in the eaves of the roof option I

max 300

Note: OBR104/1 for an obtuse corner applied for 6 angle OBR104/2 for an obtuse corner applied for 22 angle 1. PWD roof panel 2. PWS wall panel 3. OBR 59 flashing 4. OBR 57 flashing 5. OBR 104 flashing 6. PWD and PWS panel fastener 7. Blind AL/Fe rivet or LB 6 selfdrilling fastener approx. every 300 mm 8. LB6 selfdrilling fastener 9. TUP 18 sealing tape 10. PES 3x20 self-adhesive sealing tape (recommended) 11. Butyl sealing compound 12. Assembly foam or polyurethane seal 13. Gutter stay 14. Gutter 15. Gutter hook 16. Wall transom acc. to construction design 17. Purlin acc. to construction design 18. Panel core with an approx. 30 mm undercut

63

2.14. PWD 09/2 Joint of the wall panel with the roof panel in the eaves of the roof - option II BALEX

max 300mm

Note: OBR104/1 for an obtuse corner applied for 6 angle OBR104/2 for an obtuse corner applied for 22 angle

1. PWD roof panel 2. PWS wall panel 3. OBR 62 flashing 4. OBR 104 flashing 5. OBR 59 flashing 6. LB 6 selfdrilling fastener 7. PWD and PWS panel fastener 8. Blind AL/Fe rivet or LB 6 selfdrilling fastener approx. every 300 mm 9. TUP 18 sealing tape 10. PES 3x20 self-adhesive sealing tape (recommended) 11. Assembly foam or polyurethane seal 12. Gutter stay 13. Gutter 14. Gutter hook 15. Wall transom acc. to construction design 16. Purlin acc. to construction design

64

2.15. PWD 10/1 Lengthwise joining of the roof panels (L > 18m)

A
Notes: 1. Standard undercut depth A = 150 mm 2. Maximum undercut depth A = 150 mm 3. Minimum length of the element with the undercut is 3500 mm 1. PWD roof panel 2. PWD panel fastener 3. Blind AL/Fe rivet or LB 6 selfdrilling fastener approx. every 300 mm 4. PES 3x20 self-adhesive sealing tape 5. Butyl sealing tape 6. Impregnated polyurethane seal or assembly foam 7. Section acc. to construction design 8. Purlin acc. to construction design

65

2.16. PWD 10/2 Lengthwise joining of the roof panels (L > 18m) - section A-A

A-A

1. PWD roof panel 2. PWD panel fastener 3. Blind AL/Fe rivet or LB 6 selfdrilling fastener approx. every 300 mm 4. Butyl sealing tapelaid on entire width of the

66

2.17. PWD 11/1 Joint of the panels with the prefabricated gutter at the attic - option I BALEX

1. PWD roof panel 2. PWS wall panel 3. Prefabricated gutter acc. to architecture design (with a pitch) 4. OBR 112 flashing 5. Individual flashing 6. Individual flashing 7. Blind AL/Fe rivet or LB 6 selfdrilling fastener approx. every 300 mm 8. PWD and PWS panel fastener (tight rivet on the ext. facing of the roof and gutter) 9. Butyl sealing tape 10. TUP 18 sealing tape 11. PES 3x20 self-adhesive sealing tape (recommended) 12. Purlin acc. to construction design

min. 40

67

2.18. PWD 11/2 Joint of the panels with the prefabricated gutter at the attic - option II

1. PWD roof panel 2. PWS wall panel 3. Prefabricated gutter acc. to architecture design (with a pitch) 4.OBR 112 flashing 5. Individual flashing 6. Individual flashing 7. Blind AL/Fe rivet or LB 6 selfdrilling fastener approx. every 300 mm 8. PWD and PWS panel fastener (tight rivet on the ext. facing of the roof and gutter) 9. Butyl sealing tape 10. PES 3x20 self- adhesive sealing tape (recommended) 11. Purlin acc. to construction design 12. Panel core with an approx. 30 mm undercut

68

min. 40

2.19. PWD 11/3 Joint of the panels with the prefabricated gutter at the attic - option III BALEX

Insulating panel of the thickness of G=40mm

1. PWD roof panel 2. PWS wall panel 3. Internal profile of the gutter 4. External profile of the gutter 5. OBR 112 flashing 6. Individual flashing 7. Blind AL/Fe rivet or LB 6 selfdrilling fastener approx. every 300 mm 8. PWD and PWS panel fastener (tight rivet on the ext. facing of the roof and gutter) 9. Butyl sealing tape 10. TUP 18 sealing tape 11. PES 3x20 self-adhesive sealing tape (recommended) 12. Heat-insulating material of the gutter 13. Purlin acc. to construction design

69

2.20. PWD 11/4 Joint of the panels with the prefabricated gutter at the attic option IV

Insulating panel of the thickness of G=40mm

1. PWD roof panel 2. PWS wall panel 3. Internal profile of the gutter 4. External profile of the gutter 5. OBR 112 flashing6. Individual flashing 7. Blind AL/Fe rivet or LB 6 selfdrilling fastener approx. every 300 mm 8. PWD and PWS panel fastener (tight rivet on the ext. facing of the roof and gutter) 9. Heat-insulating material of the gutter 10. Butyl sealing tape 11. PES 3x20 self- adhesive sealing tape (recommended) 12. Purlin acc. to construction design 13. Panel core with an approx. 30 mm undercut

70

2.21. PWD 12/1 Roof ridge continuous skylight - longitudinal section

1. PWD roof panel 2. Individual flashing 3. LB 6 selfdrilling fastener or blind AL/Fe rivet approx. every 300 mm (tight rivet on the external facing of the roof ) 4. PWD panel fastener 5. PES 3x20 self-adhesive sealing tape (recommended) 6. Polyurethane seal or assembly foam 7. Heat-insulating material of the skylight 8. Purlin + section acc. to construction design 9. Bent top facing

71

2.22. PWD 12/2 Roof ridge continuous skylight cross section

roof slope

1. PWD roof panel 2. Individual flashing 3. PWD panel fastener 4. LB 6 selfdrilling fastener 5. TUN 18 sealing tape 6. PES 3x20 self-adhesive sealing tape (recommended) 7. Heat-insulating material of the skylight 8. Polyurethane seal or assembly foam 9. Skylight base 10. Purlin + section acc. to construction design 11. OBR 65

72

2.23. PWD 13 Roof ridge skylight - cross section

roof slope

1. PWD roof panel 2. OBR 104 flashing 3. OBR 52 or OBR 205 flashing 4. Individual flashing to the ridge 5. PWD panel fastener 6. LB 6 self- drilling fastener every or blind AL/Fe rivet every 300 mm (tight rivet on ext. facing of the roof ) 7. Fastening blind Al./Fe rivet approx. every 1000 mm 8. Butyl sealing tape 9. PES 3x20 selfadhesive sealing tape (recommended) 10. Heat-insulating material or assembly foam 11. Skylight heat-insulating material 12. Polyurethane sealant or assembly foam 13. Skylight base 14. Purling + section acc. to construction design 15. OBR 65

73

2.24. PWD14 Expansion gap

1. PWD roof panel 2. OBR 64 flashing 3. Blind AL/Fe rivet or LB6 selfdrilling fastener approx. every 300 mm 4. Butyl sealing tape 5. Polyurethane sealant or assembly foam

74

2.25. PWD 15/1 Installation of additional roofing by the wall - existing wall option

1. PWD roof panel 2. PWS wall panel 3. Flashing OBR 76 4. Flashing OBR 104 5. PWD panel fastener 6. Blind AL/Fe rivet or LB6 self-drilling fastener every 300 mm. 7. TUN 18 Tape 8. TUP 18 Tape 9. PES 3x20 self adhesive sealing tape (recommended) 10. Butyl sealing compound 11. Polyurethane sealant or assembly foam 12. Wall transom 13. Purlin acc. to construction design 14. OBR 65

75

2.26. PWD 15/2 Installation of additional roofing by the wall - basic option with a drip cap

1. PWD roof panel 2. PWS wall panel 3. Flashing OBR 76 4. Flashing OBR 104 5. PWD panel fastener 6. Blind AL/Fe rivet or LB 6 self- drilling fastener every 300 mm 7. TUN 18 Tape 8. TUP 18 Tape 9. PES 3x20 self adhesive sealing tape (recommended) 10. Polyurethane sealant or assembly foam 11. Wall transom 12. Flat bar acc. to construction design 13. Purlin acc. to construction design 14. OBR 65

76

BALEX ME TAL Sp. z o.o. HEADQARTERS

ul. Wejherowska 12C 84-239 Bolszewo, Poland Infoline: 801 000 807 tel. +48 58 778 44 44 fax +48 58 778 44 48 kontakt@balex.eu www.balex.eu

Balex Metal Sp. z o.o. is a leading manufacturer of construction materials in Poland. The oer of the company includes complete solutions and steel roof and wall systems for residential, commercial and rural constructions. The products gained trust and appreciation in Poland, Belorussia, Russia, Lithuania, Latvia, Estonia, Ukraine, Czech Republic, Slovakia, Sweden, Norway and Finland. Consultancy and sale is being realized by own net of regional branches, cooperating distributors and a team of professional advisers.

BRANCH OFFICES
CZECH REPUBLIC UKRAINE LITHUANIA SLOVAKIA LATVIA BALEX METAL S.R.O. BALEX METAL TOV BALEX METAL UAB BALEX METAL SIA BALEX METAL Hradec Krlov Kiev Vilnius Bansk Bystrica Brocni Bolszewo Vzn 1097 M. Raskovoy, bud. 21 biuro 907, 02660 Savanoriu 174A Partiznska cesta 94, 974 01 Bansk Bystrica Liepnieku iela 10, Brocni, Saldus raj. LV-3851 ul. Wejherowska 12C, PL 84-239 tel. +420 495 543 267, fax +420 495 482 683 tel. +380 44 39 07 144, fax +380 44 39 07 145 tel./fax +421 48 419 75 27 tel. +371 638 65 886, fax +371 638 07 401 tel. +48 662 089 890, fax +48 58 778 44 55 tel. +370 527 30 299, fax +370 527 30 295

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Index 2011-08-08 03