Step by step to a perfect cladding

Step by step to a perfect cladding
Fabrication guideline
Step by step
to a perfect cladding
Dedicated to your Success
Fabrication of Reynobond®
Product characteristics
Reynobond® applications
Reynobond® description
Recommendations before use
Storage, handling of panels and shipping of fabricated elements
Protective equipment
Precautions relating to the product
Preparation for machining - calculation of design dimensions
Corner cutting, notches, pre-drilled holes
Screw fastening
Continuous edge grip
Hot air welding
Panel reinforcement
Surface treatment
Post painting
Screen printing
Application of adhesives
Coating touch-ups
Information and service
Other information
Warning - Attention
Panel squarness is obligatory
Reynobond Natural Metals
Other fabrication- or transformation methods
Other assembly methods
Fabrication of Reynobond®
Product characteristics
Reynobond® applications
Reynobond® description
Reynobond® offers a flexible, durable solution in many areas
of activity. It combines ease of use with exceptional strength
and a high quality coil coated finish.
Reynobond® is a composite panel consisting of two
pre-coated aluminium sheets bonded onto both side
of a polyethylene core. Bonding of the aluminium and core
is achieved by both chemical and mechanical action, which
gives Reynobond® remarkable bond integrity.
An exceptionally flat, corrosion-resistant panel,
Reynobond® is easy to use. Reynobond® panels are simple
to fabricate* and can be used to make many different forms
with minimum investment.
Architectural uses
Reynobond® is suitable for outdoor and indoor architectural
applications in new buildings or refurbishment work.
Ideal for exterior cladding, Reynobond® adapts to your shapes and
colour requirements. For ventilated facades, Reynobond® panels
can be used as flat, bent or fabricated into cassettes.
A technical back-up team is available to assist users in optimising
dimensions and in the choice of fastening systems, profiles or other
accessories useful for installation.
Reynobond® for industry and transport
Reynobond®55 and Reynobond®33 also provide innovatory
solutions for industrial and transport engineers.
They can be used for rollers, cases, containers, machine protection
and enclosures, but especially for cladding on public transport
vehicles, trailers, trucks etc.
Reynobond for Corporate Identity Design (CID)
and Sign & Display applications
Reynobond® enables companies and organizations to display their
corporate identity, using a reliable process with multiple
Reynobond®33 is suited for display applications such as signage,
advertising panels, shop fittings, exhibition stands and light boxes.
Reynobond®33’s finish is ideal for screen printing*, post-painting
and the application of adhesives.
Two 0.5 mm thick pre-coated aluminium sheets.
3, 4 and 6 mm standard nominal panel thickness.
Weight and density of the panels (density):
3 mm - 4.59 kg/m2
4 mm - 5.51 kg/m2
4 mm (FR) - 7,5 kg/m2
6 mm - 7.36 kg/m2
Upper sheet finish:
PVDF* 70/30 or Duragloss®5000
These panels are particularly UV and weather resistant and come in
several standard colours. The range can be extended to any other
colours (RAL, NCS, etc.) subject to a minimum production quantity.
Lower sheet finish: protective primer.
Coil coated aluminium sheet
Thermo-adhesive film between
the aluminium sheets and the core
Polyethylene core
*cf. glossary
aluminium composite material
Two 0.3 mm thick pre-coated aluminium sheets.
2, 3 and 4 mm nominal standard panel thickness.
PVDF* 70/30 coatings
offer excellent resistance against aging and are at the present time
the most sophisticated in the building sector.
Panel weight (density):
2 mm - 2.90 kg/m2
3 mm - 3.80 kg/m2
4 mm - 4.75 kg/m2
are high-tech polymerbased coatings available in gloss ratings of
20 % to 80 %. These coatings are particularly suitable for metallic
Upper and lower sheet finishes polyester or Duragloss®3000.
Available in standard colours with 25 % to 80 % gloss rating.
This range can be extended to any other colours (RAL, NCS, etc.)
subject to a minimum production quantity.
Duragloss®3000 coatings
are high-tech polymer-based coatings and constitute an ideal base
for screen-printing*. Guaranteed 10 years under certain conditions
of use.
Paint Finishes
The Reynobond® panel is available in four types of coating:
PVDF* 70/30 coating, Duragloss®5000, Duragloss®3000
and polyester. Custom colour formulations in opaque,
metallic or mica finishes offer virtually the full range of colours
required for architectural uses.
Polyester coatings
offer a high UV and weather resistance and are suitable
for screen-printing, the application of adhesives and post-painting
using the liquid spray technique.
Diagram of the coil-coating line
1 Uncoiler
8 Primer oven
2 Stitcher
9 Air and water coolers
3 Entrance accumulators
10 Finish coater
4 Degreasing
11 Finish oven
5 Anticorrosion treatment
12 Air and water coolers
6 Dry in place oven
13 Exit accumulators
7 Primer coater
14 Recoiler
The aluminium sheets used to manufacture Reynobond®
composite panels are treated against corrosion and coil-coated
at our Merxheim plant.
Coil-coating is a continuous paint application process
that provides a coating uniformity that is exceptional,
both qualitatively and aesthetically.
*cf. glossary
Fabrication of Reynobond®
Product characteristics
Production tolerances
Reynobond® panels are produced to the following tolerances:
Thickness 3 and 4 mm: ± 0.1 mm
Width: - 0/+3 mm
Length ≤ 4000: - 0/+3 mm
Length > 4000 and < 6000 mm: - 0/+4 mm
Length ≥ 6000 mm: please consult us
Maximum difference between diagonals: 3 mm
Difference on superposition: ±1.5 mm
Protective film
The film protects the paint finish during fabrication and installation. It
should, however, be removed as soon as possible after installation
of the panel on site, especially in the case of panels exposed to
sunlight and weather. The protective film should only remain
temporarily on the panels. Arrows are printed on the film to indicate
the direction of coil-coating (important for metallic finishes).
Types of film:
Opaque film 70 µ thick with ultraviolet barrier is used on
Transparent film 35 µ thick is applied to Reynobond®33 for Sign &
Display applications.
A Cardboard placed on the pallet
H Agglomerated woodchip sides (packages of over 20 panels)
B Cardboard placed on the last panel
I Wooden blocks (packages of more than 20 panels)
C Agglomerated woodchip cover
J Cardboard sides (packages of more than 20 panels)
D Longitudinal banding + 4 cardboard corners per band
K Reynobond®
E Stacking planks
L Pallet
F Transverse banding + 4 cardboard corners per band
G Polyethylene film (packages of over 20 panels)
Fabrication of Reynobond®
Recommendations before use
Storage, handling of panels and ship-ping
of fabricated elements
Panels must be stored in a cool, dry area
We recommend to store the panels in the workshop
at approximately 18 °C for at least 24 hours before processing
operations begin.
The handling of Reynobond®
Panels requires a certain amount of care and it is therefore
recommended that they be supported at several points along their
length (the number of support points depending on the length
of the panel).
When storing panels temporarily between different phases
of fabrication, use polystyrene or foamwedges.
Bear in mind the ambient temperature during fabrication*.
Panels with outer coatings in darker colours absorb more heat than
lighter colours. Account must be taken of this when calculating
the temperature difference (about 20 °C more for a black panel
compared to a white or metallic panel).
Expansion is not the only tolerance factor to be taken into
consideration during design calculations: account must also be
taken of the tolerances of the support (masonry, structural steel)
and the installation tolerances (joinery, wall openings, etc.).
Essential precautions
Fabricated elements will be packaged in identical fashion in closed
crates with blocks between the elements. The latter will be placed
so as to avoid the elements coming into contact with each other
and moving inside the crate.
Precautions relating to the product
Protective equipment
Thermal expansion
Reynobond® panels may only be used at temperatures between
-50 °C and +80 °C and will thermally expand or contract in exactly
the same way as solid aluminium plate or sheet.
This thermal expansion must be born in mind when choosing the
fastening system and calculating dimensions and joint widths.
Reynobond® has a coefficient of expansion of 2.36 x 10-5 m/°C
(0.0236 mm/m/°C).
For a panel exposed to weather conditions with temperatures
varying between -20 °C in winter and +40 °C in summer,
we have a temperature difference of 60 °C.
Length of panel
Expansion for
a temperature
difference of 60 °C
Individual protective equipment should be worn
in accordance with the safety regulations in force
in the workshops.
However, we also recommend that you wear:
Gloves: for handling the panels at all stages.
Goggles: for the fabrication operations that produce swarf
(sawing, milling*, drilling*…).
Ear protection: when using very noisy machinery (panel saw…).
2,84 mm 4,26 mm 5,68 mm 8,52 mm
*cf. glossary
Fabrication of Reynobond®
Recommendations before fabrication
Direction of coil coating
Metallic and mica coatings have a reflective or pearlescent finish,
due to the millions of microscopic aluminium or mica particles
suspended in the paint mix.
These particles are oriented in the longitudinal direction during the
coil coating process.
During production, arrows and a production number are printed on
the back surface of the panels.
Directional arrows are also printed on the strippable protective film.
Consequently, it is important when fabricating and installing panels
with metallic or mica coatings to take this orientation into account.
Panel directionality must be maintained in order to avoid shading
differences between adjacent panels and must be taken into
account when making the optimisation calculations.
Before fabrication*, remember to use a felt tip pen to draw arrows to
indicate the coating direction on any small pieces that might be cut
out from areas without the directional arrows.
Coating orientation is, however, not the only factor of difference in
colours. All metallic and mica coatings are in fact subject to
variations in appearance between batches.
In this case, Alcoa strongly advises not mixing panels from different
batches on the same wall elevation in order to avoid shading
Contact with other materials
Only plastics, stainless steel, aluminium and zinc may be directly
assembled with Reynobond® without taking any special
precautions (as long as stainless steel or aluminium screw fasteners
are used).
In all other cases, it will be necessary to protect the contact surface
using a non-porous coating such as cadmium, zinc, aluminium,
chrome or organic varnishes. Direct contact between the aluminium
sheet covering the Reynobond® and heavy metals (e.g. copper,
brass, bronze, iron) creates a high risk of corrosion. If such materials
must be used for contact parts, they must be coated or separated
from the Reynobond® by electrically insulating inserts (e.g. plastic
mounting plates or washers…).
*cf. glossary
Fabrication of Reynobond®
Circular saw
Shearing machine
Vertical panel saw
The tools necessary for processing Reynobond®
may be chosen according to the criteria
and conditions detailed in the table below:
Milling machine
Routing machine
CNC flat milling machine
Punching machine
Drilling machine
Rivet gun
Vertical panel saw
The best saw which is suitable for large runs
of work and for better cutting accuracy.
Certain models may be fitted with a milling* device.
Circular saw
Particularly appropriate for use in a workshop or on site.
Simple to use, it cuts panels at high speed.
The use of a flat trapezoid toothed blade and a negative cutting
angle gives good results when cutting aluminium.
The blade may be either high speed steel (HSS)
or carbide tipped steel (MC).
The feed speed will be of about 20-25 m/min depending on the type
of high-speed steel or carbide blade.
Allows the cutting of complex shapes or small cut-outs.
It is not suited to sawing long straight lines.
The maximum feed speed can be up to 6 m/min and must be
adapted to the surface finish required.
When starting a run, it is advised that you make some prototypes
to check the quality of the finish. In this way, one or more
parameters can be varied to obtain a better result.
In all cases, it is desirable to eliminate any source of vibration
caused by the saw or by poor fastening of the part.
Shearing machine
Reynobond® may be cut with a shearing machine,
whether circular or guillotine shears.
If using guillotine shears, we recommend that flexible protective
inserts be placed between the holding block and the panel
to avoid a mark being left on the aluminium skin
when the guillotine comes down.
Remark : a slight turned down top skin may be left along the leading
edge of the sheared panel.
*cf. glossary
Fabrication of Reynobond®
Milling machine
All the conventional milling machines (universal, vertical or
horizontal) are commonly used on Reynobond®. However, we
recommend the use of protection on the locking device to avoid it
leaving marks where it was tightened on the panels.
The wide-spaced teeth, the rounded, smooth grooves
and the small cutting angle of the
high-speed steel or carbide-tipped milling cutters makes
this a suitable tool for machining Reynobond®.
Routing machine
Hand-held machines allow groove cuts* to be made on large
surface panels or milling along the edge (folded edge, edge insert).
The use of a guide rail or template allows better accuracy and good
repeatability of the operation.
CNC flat milling machine
All the Reynobond® machining operations can be performed on a
single machine: the numerically controlled flat milling machine.
Cutting, machining and drilling* operations etc. can be performed
very rapidly with a high degree of accuracy thanks to a multiple tool
holder head and of the reduction of handling of the panel between
The CNC milling machine is the most rational tool for machining
Reynobond® in large runs or where a high degree of accuracy is
Specific arc-shaped or elliptical cuts will be extremely accurate
and the finish will be perfect.
Any shape, any type of notch or indentation is possible.
Punching machine
The technique of cutting Reynobond® by punching is the same as
that used for aluminium sheet. It offers remarkably clean cuts
thanks to the high characteristics of the alloy used and the
lubricating function of the polyethylene core. The working clearance
between the die and the punch should be ± 0.15 mm.
The cleanness of the cut depends on the geometry of the tool and
the punch speed.
We recommend that you do a few experimental runs in order to find
the optimum setting.
Drilling machine
Reynobond® may be drilled with the same machines and the same
twist drill bits as those used for drilling* steel or aluminium sheets.
We recommend that the bit be removed regularly from the hole and
a blow gun* be used to remove swarf. If the quality of the finish is
poor after drilling, we recommend that you reduce the cutting
speed or feed speed. A few test runs will allow you to check the
quality of the finish.
Tapping of aluminium accessories
We recommend the use of special taps for aluminium.
Often the use of the finishing tap is enough.
These taps have wide, rounded, polished flutes presenting a wide
cutting angle. Progressive or spiral fluted taps offer the best swarf
evacuation, as do those whose threads are cut by staggered flutes.
When tapping using a fixed machine, the taps used will be those
used for machining aluminium in one pass.
*cf. glossary
To bore Reynobond®, a counterbore or a three-groove inserted
shank reamer may be used. The holes worked with the reamer will
be less out of round than those drilled with a two-lip drill bit.
To countersink cone screw heads, an angular milling cutter or
counterbore will be used.
Wood chisel
The wood chisel can be used for occasional jobs such as reworking
an edge or cutting out corners for short fabrication runs.
Metal file
A file can be used to trim the sharp edges left by machining
It can also be used to adjust dimensions, when cutting with a wood
chisel, for example.
Rivet gun
The rivet gun is an essential tool for making cassettes:
it is used to assemble the cassette after fabrication*.
All types of rivet gun are suitable, pneumatic or electric, even
mechanical for small runs.
The rivet gun is also an essential tool on site, for installing panels in a
riveted system, or for fixing frame profiles.
Blow gun*
A blow gun* is a very practical accessory for removing swarf and
filings from work surfaces and the panels machined. This tool does
require the installation of a compressed air system.
The cutting tools (milling cutters, drill bits, disks, blades)
suitable for the machining of Reynobond® panels are those
used for traditional machining of aluminium,
of the high-speed steel or carbide type.
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They will be chosen according to the type of machine-tool used:
Vertical panel saw
Circular saw
Milling machine
Routing machine
CNC flat milling machine
- depending on CNC model
*cf. glossary
Fabrication of Reynobond®
General fabrication* techniques
Reynobond® composite panels can be fabricated using extremely
simple techniques and machinery.
Standard or complex elements can be made with minimum
investment. However, the specific characteristics of the composite
material require certain precautions : read carefully chapter
"Recommendations before use",
paragraph "Handling of panels" page 7.
After fabrication, Reynobond® panels are easily shaped.
This stage of the process can be performed after delivery to the site,
which has the advantage of considerably reducing transport costs.
Fabrication brochures specific to each
of the systems recommended
by Alcoa Architectural Products Merxheim
are available on request.
Preparation for machining
calculation of design dimensions
Closed 90° fold - milling cutter with 3 mm flat surface
When milling for a fold, a thickness of 0.3 mm of polyethylene
should be left in the bottom of the groove, on top of the thickness
of the aluminium (see procedure in the Milling chapter*).
For a fold milled with a cutter with a flat surface of 3 mm, the fold
axis will be in the middle of the milled groove flat, therefore 0.8 mm
from the visible face. This, in the case of a closed 90° fold leads to
an oversize of 0.8 mm per angle.
In practise, we round this off to 1 mm for ease of calculation.
When making a closed fold with a milling cutter with a 3 mm
flat surface, the exterior finished dimension is increased
by about 1 mm.
Here we will present some fabrication techniques
with our recommendations. It is, however, essential
that you ensure that you have all the technical information
concerning the machines used and that you follow the
manufacturer’s operating instructions. The aim being to
carry out the fabrication operations on a finished material
without damaging it (scratches, knocks, twisting, etc.)
This so that the user receives finished, shaped elements
of irreproachable quality.
*cf. glossary
Fold and counterfold
In the case of a fold and a counterfold in the other direction, the
problem is different (always work on the reverse side of the panel,
whether the fold is open or closed).
In the case of an open fold, the fold axis is still in the middle of the
milled groove, but the fold is not formed around that axis, but
outwards, which causes the polyethylene to stretch. When an open
fold is added to a closed fold, by the
fold - counterfold upwards technique, the following occurs : When
an outward fold is made with a groove cutter with a 3 mm flat
surface, the finished exterior dimension is reduced by 1 mm.
Making two side folds on a
cassette – with a milling cutter
with a 3 mm flat surface:
The flat size of panels to be cut and milled must be calculated
and marked out before any machining work is begun.
This will allow fabrication within the best possible tolerances.
The tolerances generally accepted on fabricated elements
are ± 1 mm, when using a milling cutter with a 3 mm flat surface.
In all cases, a test run should be performed beforehand,
to work out the adjustments to be made to the dimensions.
Fabrication of Reynobond®
Measurements to be taken
Before any cutting is undertaken, it is necessary to calculate the flat
size of the elements taking into account the folding parameters and
the dimensional characteristics indicated in the paragraph above
"Preparation for machining", page 12.
Cutting panels:
Before starting a long run, we recommend that as a precaution,
you check with the blade and with a rule.
For the trimming of the panels, generally speaking,
the width of the blade is sufficient.
Remember that it is useful to check with a rule and to calibrate
measuring instruments regularly.
Panel saw
As for cutting with a circular saw, you must work on the reverse
of the panels (the side with the strippable protective film against
the saw frame). The stops will be placed to the left of the sawing
column so that the operator can hold the sawn pieces.
Trimming is quicker and easier than with a circular saw.
Now we detail this operation.
The first cut is made horizontally, at the upper edge*,
to get a straight edge. Then turn the panel so that the reference
edge* is resting on the carrying rollers. Make a vertical cut on the left
edge* of the panel. You now have a panel with straight edges,
a straight base and right angles. The panel is now ready to be cut
into the different pieces.
In some cases it may be possible to cut 4 to 5 panels or more
at the same time. Test runs should be performed before starting
Sawing methods and tools
Although it is possible to cut Reynobond® panels with a jigsaw, we
would only recommend its use for occasional work or specific cuts.
Circular saw
Reynobond® panels are cut in the same way
as solid aluminium plate.
Three basic precautions need to be taken:
The work area must be kept clean, an exhaust system must be
used and you would work on the reverse of the panel. This will
reduce the risk of scratching to a minimum. Moreover, when
working on a bench, wherever possible, the panel being fabricated
should be placed on polystyrene blocks and care should be taken
to ensure they do not get incrusted with swarf.
We recommend the use of guides whose length exceeds that of the
panel to be cut by 200 mm at each end. It is possible to cut several
panels at the same time. However, to guarantee the longevity of the
equipment, we do not recommend super-posing more than two
4 mm Reynobond® panels.
Cut on the upper edge*
Turn the panel round
Vertical cut
The panel is ready to be cut into pieces A, B, C…
*cf. glossary
Given the characteristics of the alloy used, Reynobond®
generally has few burrs. If a rough cut is made,
it may be trimmed with the tools conventionally used.
Outils cylindriques :
Measurements to be taken
Before any milling operations, it is necessary to calculate the flat
size of the elements taking into account the folding parameters and
the dimensional characteristics indicated in the paragraph above
"Preparation for machining", page 12.
Routing machine
CNC flat milling machine
Milling machine
Circular saw
Vertical panel saw
Milling* methods
The method used for milling* operations will depend on the tools
available and the job to be done:
Method 1)
Routing machine, milling machine and CNC
flat milling machine
We would remind you that you must always keep the front side
intact as well as a minimum thickness of polyethylene in the bottom
of the milling groove (polyethylene thickness is of 0.3 mm
for V-shaped groove, and 1 mm for a concave milled groove).
To achieve this, you must define a point 0.
We begin by placing the milling cutter in contact with the surface
to be milled, and using wedges or the depth adjustment wheel,
we subtract the value of the milling cut. Before beginning work
on the panel, it is prudent to check the adjustment of the router by
making a short milling cut. Do not hesitate to modify the milling
depth if necessary.
In the case of a V-shaped rout, the optimum thickness of the
polyethylene is 0.3 mm. If there is more than 0.5 mm the fold
will not close properly, and if there is less than 0.1 mm,
there is a risk of breaking the return on folding.
The table opposite gives some examples of values:
Reynobond® 55
Reynobond® 33
3 4 6 3 4 6 2 3 4 2 3 4
C Residual PE*
Value to be
2,2 3,2 5,2 1,5 2,5 4,5 1,4 2,4 3,4 0,7 1,7 2,7
*cf. glossary
Fabrication of Reynobond®
Circular tools
Method 2)
Panel saw
No specific settings are necessary: the milling depth is defined by
the tracer disk. On the other hand, it is essential that an extra panel
30 mm thick be placed on the base plane. This panel must be wider
and longer than the composite panel to be milled. The surface
condition and the flatness of this extra panel must be perfect.
The quality of the fabrication work depends on it.
We recommend the use of a gaboon latted board 20 mm thick with
a 10 mm thick plywood panel screwed onto it. It is on this plywood
surface that all the work will be done. This can be replaced at little
cost if it is inadvertently damaged.
For the milling of large Reynobond® panels, we recommend that
you make a large panel with support studs. These can be made
of off-cuts of Reynobond®. They will be screwed onto the panels,
which means they can be changed as they become worn.
It is a good idea to mark the point of impact of the cutter on the
suction hood of the saw. This allows a more accurate approach and
limits milling "overflow".
When milling very close to the edge, ensure that the tracer disk is in
contact with the panel.
An off-cut of the same thickness could be added.
Warning: do not use the stops intended for sawing when milling.
The milling axis is offset in relation to the left edge of a saw blade
cutting edge. As the machine is supplied with several stops, some
of them must be calibrated for sawing operations and others for
milling operations.
1 50 mm wide Reynobond® panel.
2 10 mm thick plywood panel.
3 20 mm thick gaboon latted board.
*cf. glossary
Rout and return
The rout and return technique consists of using shaped milling
cutters to make V-shaped or straight grooves* on the back of the
Reynobond® composite panel.
This allows, in most cases, the hand folding of the panels on site
without any need for a folding bench. A folding rule consisting of a U
or H-shaped profile with a lever can be used to make hand folding
easier. See paragraph «Folding», page 19.
The grooves can be made using a routing machine, a fixed panel
saw or a horizontal milling table.
Bending radii of between 2 and 10 mm inclusive can be obtained
depending on the choice of milling technique and the geometry of
the groove.
V-shaped groove
This allows a bending radius of at least 2 mm.
The angle of the groove may be 90° or 135°. Important : to ensure
that enough of the polyethylene core is removed in the case of a 90°
fold, you are advised to opt for a groove flat of 3 mm.
Other types of groove
A straight groove with a concave bottom allows folding radii of
between 7 mm and 10 mm, depending on the depth of the groove.
Try some experimental bends to check the bend.
The use of a step cutter will allow the removal of the polyethylene
core for plastic welding applications.
Whatever the shape of the groove, the front sheet must remain
intact and we recommend that you retain a minimum thickness of
polyethylene at the bottom of the groove.
This residual thickness of polyethylene is 0.3 mm for a V-shaped
groove. It will be between 0.5 mm and 1 mm inclusive for a straight
groove with concave bottom.
*cf. glossary
Fabrication of Reynobond®
Corner cutting, notches, pre-drilled holes
Two methods are commonly used for cutting out corners
to allow the forming of a cassette.
This technique is the most productive, with the corners being cut
out and the corner fastening holes being put in a single operation.
We have developed a punch that can be used on our KS,
KU and KH systems.
This tool is also suited to drilling* and notching
(also possible with a CNC machine).
Wood chisel
A sharp hammer blow to a wood chisel allows you to cut out the
small thickness at the bottom of a routing groove with no difficulty.
The wood chisel must be wider than the part to be cut out.
With a little experience, good clean joints can quickly be made.
*cf. glossary
Fabrication of Reynobond®
General recommendations
Generally speaking, it is essential to:
Fold the return leg back in one movement.
Close the fold 10 to 20° more than the desired angle before making
the exact angle.
This avoids a slight spring back effect.
Folding is done by hand using a tool you can make yourself.
Depending on the folds, the following techniques may be used :
Folding methods
Folding with a U or H jig:
U or H-shaped, it is fitted with a handle to facilitate the operation.
This jig is particularly suited to folding small pieces.
Folding with a folding bed
This is a jig fixed onto a base. The panel is placed vertically in the jig.
As the panel will tilt under its own weight,
not much effort is required.
This technique is particularly suited to the folding of returns,
especially for long lengths or small folding widths.
Other folds
Folds, counterfolds, abutted edges require a knack
that is acquired with experience.
Example of a bordered edge below.
*cf. glossary
Fabrication of Reynobond®
Bending by press brake
Bending on an universal
folding press with apron
after preliminary milling
only if numerically controlled
Caution when using:
When carrying out the work, check that the rollers are not exerting
too much pressure on the material.
To obtain the radius required progressively, it may be necessary to
put the panel through the machine several times.
Test runs can be used to determine the number of times and the
position of the cylinders.
The multi-layered structure of the Reynobond® panel causes a
spring back effect that is more pronounced than that of steel or
aluminium sheet.
Feeding into and removal from the rollers may cause flattened
sections at the ends of the panels. To eliminate this, it is a good idea
to leave 60 to 80 mm extra length depending on the diameter
of the rollers on either end of the panel, which can then be recut.
The use of a numerically controlled rollforming machine permits
special fabrication operations such as the shaping of elliptical parts
and also gives excellent repeatability.
Méthodes et outils de cintrage*
This operation consists of bending Reynobond® panels
in a conventional bender with three symmetrical polished cylinder
dia s lim m
m it
et ed
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of y
General recommendations
The techniques used for bending* Reynobond® are those generally
used for working steel or aluminium sheet. However, the specific
characteristics of the composite panel make certain precautions
Bending* techniques allow many different types of curved pieces to
be formed, including fascias, parapets, airplane wing type profiles,
cladding for posts and complex shapes (conical shapes).
When bending Reynobond®, the original protective film on the top
surface must be left on. Depending on the conditions in the
workshop, it is even advised that the protection be reinforced with
another self-adhesive film or the insertion of polyethylene or PVC
strips 1 to 2 mm thick.
These essential precautions avoid marking and scratching that may
only be discovered after installation, when the protective film is
removed. Depending on the tools available and the type of
application, one of the four following bending techniques will be
Before starting any work, see the chapter
"Recommendations before use",
paragraph "Storage and handling of panels", page 7.
*cf. glossary
Bending by press brake
Press brakes can also be used to bend Reynobond® panels by
applying the techniques and experience gained from working with
steel or aluminium sheet.
The bending operation is achieved by a die descending a given
distance. The bending radius and angle depend on the diameter
and travel of the upper punch as well as the width of the lower die.
For this type of bending, the Reynobond® panel will be protected by
placing a flexible sheet with a hardness of at least 60 shores and
thickness of 1.5 mm or more on either side of the panel.
This protective layer ensures that the panel is displaced into the
hollow of the lower die without marking it at the points of contact
of the upper punch and lower die.
We recommend a minimum bending radius of 15 times
the thickness of the panel.
PE : r mini = 15 x e
Bending with a folding press
For this type of bending, the panel is held between two fixed beams
on the folding bed. The folding apron bends the part of the panel
sticking out around the upper beam of the folding tool.
The bending radius depends on the radius of the interchangeable
folding tools which are fixed on the upper sheet holder.
It is possible to obtain large bending radii using a stretching
technique on a numerically controlled bending machine by
combining the descent of the tool with the panel feed. In this case it
is recommended that pads with protective shells be used to reduce
the risk of facets forming.
Extra protection must be used on the two outer surfaces of the
Reynobond® to avoid any marking occurring during the movements
in the stretching process. In all cases, one or more test bends will
need to be performed in order to find the optimum adjustment of
the feed and the depth of the pad descent. Here account must be
taken of a spring back phenomenon known to occur
in aluminium-polyethylene composite panels.
Bending after preliminary milling*
Radii between 2 and 10 mm inclusive may be achieved by the rout
and return technique.
This consists of making V-shaped or straight grooves using shaped
milling cutters on the reverse of the Reynobond® composite panel.
See paragraphs "Milling" and "Folding".
Intermediate radii of 10 to 60 mm can be achieved using a specific
machining technique.
This technique, known as "paring", consists of removing a strip of
the aluminium sheet on the back of the composite panel. The width
of this strip will be equal to the flat size of the radius to be obtained.
The depth must be determined by making prototypes to ensure that
this operation does not affect the appearance of the front
of the panel.
The use of this technique requires considerable experience
of fabrication and excellent knowledge of the properties of the
composite panel. In most cases, a reinforcement system will be
required to compensate for the loss of rigidity of the bent part
caused by this technique
General remark: Fully closed (360°) rotating parts can only be made
by rollforming.
*cf. glossary
Fabrication of Reynobond®
Riveting *
Example of corner riveting
for a cassette system
Reynobond® panels can be assembled using the same rivets
as aluminium.
The rivets are placed at least at 10 mm from the edge – and more
where the Reynobond® panels are used in a riveted façade system.
The length of the rivets will depend on the thickness of the materials
to be assembled. These values can be found in the supplier’s
technical data sheet.
The type of rivet used and its diameter will depend on the pressure
exerted on the Reynobond® panel.
The right choice will avoid any risk of flying of the rivets.
For safety reasons, when choosing the rivets, we recommend that
a factor of 3 be applied to the tensile strength and shear strengths
given by the supplier. For outdoor use, allow at least 2 mm working
clearance between the diameter of the rivet and the bore diameter
of the hole in the Reynobond® panel to allow for the linear expansion
of 0.0236 mm/m/°C. It is essential that a step drill be used to
achieve perfect coaxial drilling of the panel and the support.
See chapter "Recommendations before use", paragraph "Thermal
expansion", page 7.
We advise that you follow the manufacturer’s instructions
in all cases and try some experimental riveting before starting
Painted rivets are particularly suitable for assemblies with visible
rivets. For the choice of accessories, please contact our technical
Riveting without expansion
Riveting with expansion
*cf. glossary
Screw fastening
The simplest method of assembly is threaded fasteners (bolts)
with nuts. We recommend the use of large washers on both sides
of the panel in order to distribute the tightening loads.
Assembly without washers could cause creep and considerably
reduce the tightening performance.
Assembly using traditional cladding screws is possible without any
particular arrangements.
Assembly using countersunk head screws is performed after milling
or simply by tightening the screw (countersinking).
Remark : assembly using threaded fasteners does not allow for the
expansion of the panel and is therefore best suited for indoor use,
and on an aluminium support (same coefficient of expansion as
Reynobond® panel).
Continuous edge* grip
It is possible to assemble panels by continuous edge gripping using
aluminium or synthetic profiles. For Sign & Display applications,
the profiles used come in different shapes.
Depending on the shape of the profile, it may be possible, before
assembling, to tighten the flanges of the profiles using a press.
This improves the assembly’s pullout strength.
For outdoor or very large assemblies, we recommend extra
fastening using rivets (which will be hidden underneath the gripping
profile) so as to avoid the panels coming apart.
*cf. glossary
Fabrication of Reynobond®
General recommendations
Gluing is a way of achieving invisible assemblies between
Reynobond® panels, but also on a wide range of substrates such
as metals, plastics, composites or painted surfaces.
One and two-component adhesives, silicon mastic
and double-sided adhesive tapes can all be used.
In all cases, the applications must be evaluated on a case by case
basis by analysing the following criteria :
Mechanical stresses
The mechanical stresses to which the assemblies are subjected fall
into four main categories.
Maximum mechanical strength will be obtained when the joint
is subject to pull-off or shearing stresses ; peeling and splitting
stresses should be avoided as far as possible.
Surface condition:
Many surfaces that are difficult to glue (wood agglomerate board,
plaster…) can be treated with a primer to make them easier to glue.
Rough surfaces can be made smooth by abrasion.
On rough surfaces or to assemble two non-abutting parts, a thicker
layer of adhesive will be necessary to compensate for the
irregularities or fill the micro-pores (e.g. in wood) and provide a good
contact between the adhesive and the two substrates.
To compensate for an uneven surface, double-sided adhesive tape
may be used with a layer of foam of suitable thickness and flexibility.
Where problems of roughness and flatness occur together, we
recommend the use of a visco-elastic foam tape.
Certain materials (copper, brass, plasticized PVC) may require
a primer or induction to avoid interaction between the adhesive
and the substrate.
Influence of surface energy on adhesion
Adhesion is the result of the molecular attractive force between two
different materials, comparable to a magnetic force (Van der Waals
force). The attractive force is determined by the surface energy of
the material as well as by the nature of the adhesive used.
The higher the surface energy, the greater the molecular attraction
and the wetting power of the adhesive. The assembly will therefore
be stronger.
Optimum application temperature: between 21 °C and 38 °C.
We do not recommend applications at temperatures below 10 °C.
Special cases must be examined according to the product chosen.
Humidity: for good application, ensure that the surfaces are dry,
and free of condensation.
Migration of plasticizers
Plasticizers are added to PVC essentially in order to make the
material more flexible. When an adhesive is applied to a surface,
these plasticizers may migrate into the adhesive mass resulting in
the softening of the adhesive which loses all cohesion. A product
specially designed to resist plasticizers must therefore be selected.
Surface preparation:
All adhesives and mastics require surface preparation for the best
results. The aim is to eliminate from the surface all traces of paint,
rust, oil or dust.
The importance of this preparation depends on the performances
required of the glued joint and the operating cost.
As a rule, structural adhesives require thorough surface preparation
if the performances promised are to be achieved.
There are three techniques involved in preparing a surface:
Cleaning with solvents is valid only for removing grease, oil etc.
It is indispensable to use a hydrocarbonated solvent like heptane.
If there is a residue of detergents and/or humidity, an alcohol-based
solution such as isopropylic alcohol (IPA) or ethanol will be required.
Dry with a clean, non-fluffy cloth.
The mechanical treatment of surfaces by abrasion (sandblasting,
abrasive disks or strips or Scotch-briteTM) gives excellent results
for all materials that are thick enough not to be deformed. Cleaning
will be necessary following the abrasion treatment.
Chemical treatment
This is the best method for metal or glass surfaces. Each surface
requires a particular chemical solution (acid or alkaline).
In all cases, we recommend that you refer to the manufacturer’s
instructions and carry out preliminary tests.
Double-sided adhesive tape may be used.
The general recommendations for adhesives also apply.
Firm application pressure (about 1 kg/cm2) increases adhesion
and consequently holding power.
For this purpose, we advise use of a roller or scraper.
Invisible, removable fastening can be achieved by using Velcro®
or Dual LockTM - ScotchmateTM type fastening tape.
Fabrication of Reynobond®
Hot air welding *
General recommendations
This method is frequently used to assemble plastics and in
particular Reynobond® panels (on no account, does hot-air welding
apply to panel assembly).
The filler rod and the polyethylene core are welded together after
heating by a jet of hot air projected by an electrically
heated welding gun.
For good quality welding, you need:
Good preparation of the edges to be welded together.
Adequate filler rod quality.
A good welding speed.
Pressure evenly applied.
Clean hot air.
An appropriate temperature.
Welding by the to-and-fro method:
Hold the filler rod at a right angle whilst exerting regular pressure
on the rod, make to-and-fro B-B (non-circular) movements.
The filler rod and the edges to be welded must be heated i
n a similar way.
Welding using a high-speed nozzle
Principle : Normal hot air guns fitted with a removable high-speed
welding nozzle allow the edges to be welded and the filler rod to
be heated at the same time. This makes for better quality welding.
The filler rod is pushed by the constant pressure of the high-speed
nozzle, and is therefore pressed between the edges to be welded.
General method statement
Preparation of the edges to be welded:
Butt welding : the edges must be bevelled, Figures B.
Corner assembly : only one of the panels is bevelled.
T-assembly : remove the narrow strip of metal skin to free the areas
to be welded.
Welding of a fold : bevel the edges to be welded first of all using
a shaped milling cutter.
Figure A
Figures B
*cf. glossary
remember that welding can under no circumstances be applied to panel assembly.
Practical advice
The polyethylene core oxidizes relatively quickly once exposed to
the air. It must be welded at the most 24 hours after it is bevelled.
After it has cooled, it is possible to remove the welding flash
using a knife or scraper.
We recommend that this operation be carried out in a clean,
oil and water-free area.
Compressor pressure
The specific welding qualities of the filler rod are:
low density
0.9 g/cm3
Ø of rod
3, 4 and 5 mm
Immediately before welding, remove the outer layer of oxide from
the filler rod.
Bearing pressure
Welding speed
To-and-fro method
70 l/min
330 ±°5C
3 kp 20-30 cm/min
High-speed nozzle method
70 l/min
330 ±°5C
3 kp 50-80 cm/min
Panel reinforcement
Reynobond® panels can be stiffened by various means
to resist wind loads and reduce panel deflection. Stiffeners
are generally aluminium extrusions whose dimensions vary
according to the inertia required.
Adhered to the non-exposed back side of the panel
at regular intervals, these stiffeners act like miniature
beams. The wind load on the panel is transferred
to the stiffeners, which act as true support beams and guide
the thrust energy outwards towards the panel edge.
The fastenings used to attach the panel to the structural supports
must be placed at or close to the stiffener end locations. Thus the
loads are transferred from the panel to the stiffeners, then to the
supports, in the most direct manner possible. Stiffener spacing
is a design decision that involves a number of variables such as
stiffener strength, stiffener span, design wind load, allowable
specified deflection (namely 1/30th of the width of the panel),
panel thickness, fastener strength and support spacing.
Because the maximum panel deflection is at the geometric centre
of the panel, a stiffener should be placed there with the remaining
stiffeners extending laterally at equal spacing from that point.
For more information on stiffener spacing and design loads,
we advise you to contact our technical department which can carry
out static calculations.
Fabrication of Reynobond®
Surface treatment
General recommendations
Different qualities of coating can be post-painted. However,
we do not recommend post-painting of PVDF* 70/30 resins.
Different results are obtained with different colours or resins, even
from the same manufacturer.
Acrylic or two-component polyurethane air dry paints have been
successfully tested. In some cases the drying process can be
shortened by oven drying at a maximum of 70 °C.
Depending on the properties of the resins used in post-painting*,
sometimes whitening can be seen in the folded areas. We advise
that the elements be fabricated before post painting.
The polyethylene core of Reynobond® panels suffers from
prolonged contact with organic solvents.
The same applies to paints.
It is therefore recommended that some pre-testing be carried
out and that the paint manufacturers’ instructions are followed.
Screen printing* tests on Polyester coating
B.P. 3
Clean the surface with a blow gun or solvent.
component components
F- 01 450 Poncin
Mainstrasse 99
D- 90 451 Nürnberg
Treuchtlinger Strasse
D - 91 781
Weissenburg i. Bay
General method statement
Sand the surface with car body type glass paper using an eccentric
Ink reference
Thermo-Jet ®
Noristar® PG
Norilit NK N
Sorte P
Aqua-Jet KSF
Postfach 152
Marasoft MS
D-71730 Tamm
Ultraplus UVP
Colorstar CS
Adolfheim St. 11
Mattplast MG
D-74321 Bissingen
Polyplast PY
Marastar SR
Screen printing*
General recommendations
The compatibility and adherence of various inks have been
successfully tested (1). A clear protective coating is recommended
for permanent outdoor exposure.
*cf. glossary
(1) Caution!
Pre-testing is recommended to check ink or paint compatibility
with the Reynobond® panel coating before large-scale painting
is undertaken. Respect the manufacturer’s instructions.
Application of adhesives
General recommendations
Before application, ensure that the fabricated panels do not have
any dents in the surfaces to be treated and that they are free of dust
and grease.
Self-adhesive plastic films and photographs coated beforehand
with a suitable adhesive can be applied without difficulty.
The ambient temperature and that of the support must correspond
to that specified by the manufacturer for each type of film.
It should be noted that the minimum application temperature
is about 4 °C.
Method of applying the film to the support
Various methods may be employed depending on the size and
shape of the decoration to be applied.
The general rules given below must be respected in all cases:
Remove the strippable protective film at a 180° angle.
Apply the adhesive with a scraper starting from the centre
and moving out to the edges.
Remove the top protection.
Particular precautions after removal of the protective paper
Rivet heads
Around rivet heads, use a pin or a similar object (not knives or razor
blades) to free any trapped air.
Overlapping metallic joining elements
For a support joining element, use a razor blade as shown
in the drawing below.
Air bubbles
The last step consists of removing any air bubbles by pricking
the edge of the bubble with a needle and pushing the air out
with your thumb or a scraper.
Fabrication of Reynobond®
Coating touch-ups
Regular cleaning is strongly recommended. Frequency of
cleaning and the choice of the appropriate product will
depend on the geographic location of the building and
degree of soiling.
We recommend that a full-size sample be test-painted before
large-scale painting is undertaken.
Panels may occasionally be scratched during fabrication and
installation. Small scratches can be easily repaired with matching
air dry paint using an artist’s brush. Small dents may be repaired
with automotive type body filler before being post-painted.
Washing must be done in steps from the bottom upwards
according to the following rules:
Manual cleaning or using special machines (industrial cleaner, foam
machine etc.).
Ensure that pressure is moderate.
Use of appropriate detergents.
After cleaning, systematic and thorough rinsing of the surfaces
with clean water to remove the remains of the detergent.
The excess rinsing water must be wiped with a sponge, rubber
squeegee or chamois leather, to avoid streaking.
As stated previously, proper surface preparation, such as sanding
and the application of a primer may be required to achieve
satisfactory results. - see chapter "Surface treatment", paragraph
"Post-painting*", page 28.
Pots of touch-up paint in the architectural range of colours
are available on request.
For more details, see the paint manufacturer’s application
Never use products that dissolve the paint, namely:
High alkaline products such as potash or caustic soda.
Acid products.
Abrasive scouring agents.
*cf. glossary
Fabrication of Reynobond®
Information and service
For applications concerning Reynobond®, Alcoa Architectural
Products Merxheim is at your disposal to provide further information
on the following subjects:
Specification service
During the preliminary study and design stages of projects:
Our sales department provides answers to questions relating
to budgetary issues.
Our technical department will advise you about choice of products,
technical installation solutions, panel dimensional restrictions,
and will deal with special points.
Optimisation service
Panel production, optimisation of shapes according
to the restrictions imposed by our production methods.
Alcoa Architectural Products Merxheim has an on-site
demonstration workshop where a trainer presents the different
fabrication techniques as well as the machines and tools
indispensable for the processing of Reynobond®.
Fastening systems – extrusions and accessories:
In our technical documents we offer information and guidelines
about fastening systems.
Some of these systems are certified for façade cladding
applications (technical certificates) : please ask your usual contact
for further information.
Other information
For all other types of information concerning the characteristics
of the product and the colour ranges, please see the specific
documents available on request.
A list of experienced qualified fabricators is available.
On request, extra documents can be sent to you presenting
fabrication techniques and panel assembly methods.
Alcoa Architectural Products Merxheim can provide you
with the details of specific machines and tools.
*cf. glossary
Fabrication of Reynobond®
Warning - Attention
Panel squarness is obligatory
It’s absolutely obligatory to square the panels on the 4 sides
especially for panels which are fixed with visible fixing systems like
screwed SC/ST, riveted RV/RT or which are directly glued on site.
To obtain this squarness, it’s necessary to cut the panel only with
a sawing or milling solution and to cut minimum 10 mm on the four
side coming out of the Alcoa production (see page 14).
Reynobond Natural Metals
The fabrication methods described in this brochure are only valid
for the product Reynobond ACM (Aluminum Composite Material).
For the product range Reynobond Natural Metals family of Zinc,
Stainless steel, Copper or other metals skins, please consult
the Alcoa technical department.
Other fabrication- or transformation methods
For further information or advice about other fabrication or
transformation methods which are not described in this brochure,
please consult the Alcoa technical department (ex: perforation,
embossed, laser cutting, water jet cutting, Lettering cutting…).
Other assembly methods
For further information or advice about other assembly methods
which are not described in this brochure, please consult the Alcoa
technical department (ex: panels directly glued on site or screwed
This brochure has been drawn up based on the latest
information available at the time of publication.
Given the changes, improvements and other factors
affecting the product, Alcoa reserves the right to modify
or withdraw certain details without notice.
The fitness for the purpose and method of use mentioned
in this brochure, or any infringement of patent,
are the sole responsibility of the user.
All the diagrams and information contained
in this brochure are quoted for illustrative purposes only.
Fabrication of Reynobond®
Cylindrical shaping of a product by passing it through a suitably
arranged set of rollers (rollforming machine). Bending may be
achieved by several different processes, such as the press brake,
the rollforming machine, the rolling-crushing…
Shaping operation by folding, stamping, bending…
Blow gun
Device fitted on a flexible hose connected to a compressed air pipe,
allowing pressurised air to be used to clean surfaces and cavities
full of waste and dust.
Groove flat
Refers to a flat portion or a rectangular section, not very thick.
Groove cutting, routing
Operation to cut grooves in a piece.
Very precise machining of the inner surface of a rotating part,
to bring the latter to the design dimension.
Operation consisting of making, in solid material, a cylindrical hole
using a drill bit.
Edge of the panel.
Abutted edge
Assembly of two panels machined so that their joining together
does not leave the edges visible.
These two operations allow the two thicknesses of aluminium and
the thickness of polyethylene to be masked.
Bordered edge :
Folding over of a thickness of aluminium skin across the width
of the panel.
Hot air welding
The welding operation consists of assembling two parts by causing
them to melt at their edges, so as to obtain a regular, smooth and
very strong join.
PE is welded using a hot air source that melts it.
Machining operation consisting of removing material using a
rotating tool whose end contains sharp edges.
The machine is a milling machine, the tool is a milling cutter.
Abbreviation of «polyethylene»; used for the core of Reynobond®.
Painting of products that have already undergone an intermediate
treatment or shaping phase.
Operation consisting of cutting the metal by means of two tools,
one fitting onto the other : one is called the punch, the other the die.
Abbreviation of "polyvinylidene chloride", a resin that makes up
some of our paint coatings.
Assembly of two or more metal parts brought together, drilled and
with a rivet through them. The rivet is then clinched using a riveter.
Screen printing
Printing process which uses a screen made up of a mesh in which
ink is applied through the unobstructed holes in the mesh that
correspond to the picture to be printed.
Squareness of the corners of panels or parts of a frame.
trimming: Operation consisting of removing the burrs that form
during machining.
Photo Credits:
Airbus building B22 | Toulouse | France | Chaix & Morel | Laude
Friedling Graphique - Rixheim - 03 89 65 54 65 - Certifié Imprim’Vert
Alcoa Architectural Products
1, rue du Ballon
68500 Merxheim, France
Tel. +33 (0) 3 89 74 47 96
Fax +33 (0) 3 89 74 46 90
[email protected]
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