PALSUN® Technical Guide Flat Solid Polycarbonate Sheet
Content 2 PALSUN® Product Range 3 Standard Dimensions 3 Colors 4 Physical Properties 5 Impact Strength 6 Optical Characteristics 7 Solar Transmission Properties 8 SolarSmart™ Technology 9 Thermal Characteristics 10 Protection from the Harmful Effects of UV Radiation 11 Acoustic Properties 11 Weather Resistance 12 Flammability 12 General Recommendations for Working With PALSUN® 13 Determination of Required Sheet Dimensions 14 Installation 18 Mechanical Fastening 22 General
PALSUN® Technical Guide PALSUN® Product Range Some of the products' features below can be combined. Please contact your Palram dealer for further information. Product Description Features & Applications PALTUF® UV stabilized, general purpose, flat solid polycarbonate sheet. Recommended for indoor use only. PALSUN® Flat solid polycarbonate sheet with UV protective layer on one side. Suitable for both exterior and indoor applications.
Colors Color Group Description Clear Transmits up to 90% natural daylight, resulting in high lighting within the structure. Low haze colors offering high clarity. Transparent Translucent Colors Clear Solar Gray Bronze Blue Green Red Smart Blue* Smart Green* Bluish Breeze* White Opal: Transmits 11-50% visible light with high light dispersion, produces mild and even lighting within the structure.
PALSUN® Technical Guide Physical Properties The following table displays physical properties of 3mm (0.12 inch) PALSUN and PALTUF sheets. Property Method** Conditions (U.S. Customary)* Units - SI (U.S. Customary)* Value (U.S. Customary)* g/cm3 (lb/ft3) 1.2 (75) Physical Density D-792 Water Absorption D-570 24 hr. @ 23°C % 0.15 Tensile strength at yield D-638 10 mm/min (0.4 in./min) MPa (psi) 62.5 (9,100) Tensile strength at break D-638 10 mm/min (0.4 in.
Impact Strength PALSUN sheets are manufactured from polycarbonate, the most versatile, toughest transparent thermoplastic. PALSUN has 200 times the impact strength of glass, offering excellent protection against riots and public disturbances, breaking & entering or acts of vandalism. PALSUN can endure attacks by rocks, clubs, hammers and thrown objects, and still to retain its original shape, maintain its integrity with minimal indentations to its surface.
PALSUN® Technical Guide Optical Characteristics Figure 2: Solar Transmittance of Clear 3mm PALSUN® UV 100 VISIBLE LIGHT INFRA-RED 90 % Solar Transmittance Ultraviolet (UV) Radiation Blocking - PALSUN sheets completely block out potentially harmful UV radiation and a significant portion of Infrared (IR) radiation. Over the visible light range, a typical 3 mm (0.125 inch) thick clear PALSUN sheet transmits about 89% (average) of incident light, as seen in the attached graph.
Solar Transmission Properties Solar energy transmission is an extremely important consideration with transparent materials. Geographic location and typical thermal/ optical properties of the specific glazing are the main factors influencing solar heat gain. Various types of PALSUN - textured, tinted, opal, diffused, and heat blocking SolarSmart™ sheets - can be used to deliver the exact quantity and quality of light desired.
PALSUN® Technical Guide SolarSmart™ Technology - Efficient Daylighting Enjoy light without heat. Promoting Energetic Efficiency and Well Being SolarSmart technology defies standard transmission of solar energy in transparent sheets and allows more versatile color and solar transmission specification per project. Unlike regular tints, SolarSmart sheets and panels admit more natural daylight while reflecting outwards Infrared radiation that creates heat.
Heat-Blocking with High Clarity by PALSUN® Breeze PALSUN glazing with Breeze tint transmits plenty of incident daylight (70%), while absorbing/blocking a large portion of the Infrared radiation, thus significantly reducing heat buildup within the structure. PALSUN Breeze also provides a clear view due to its high transparency, which is uncommon for heat-blocking products.
PALSUN® Technical Guide Protection from the Harmful Effects of UV Radiation Exposure to solar ultraviolet (UV) radiation is widely known as a major health concern by now. The adverse affects were once thought to be associated with solar UV radiation in the 280-315nm (UV-B) range. However, in recent years it has become apparent that exposure to UV-A (315-400nm) is also detrimental. In addition to skin cancer, premature aging has been associated with exposure to UV-A.
Weather Resistance Solar UV radiation attacks many polymeric materials. The rate of deterioration and crazing on the exterior surface will vary for different polymers. Further erosion is accelerated by water, dirt, air pollution, chemicals etc. The extent of attack depends on environmental factors such as location, altitude, local weather conditions, air pollution etc. The best initial indication is yellowing, followed by a significant reduction in light transmission and structural strength.
PALSUN® Technical Guide Flammability Classifications PALSUN and PALSUN FR are classified as appears in the following table, based on tests executed by certified independent testing laboratories. PALSUN® PALSUN® FR Standard Classification* Standard Classification* EN 13501 B, s1, d0 UL-94 V-0 NSP 92501, 4 M1(1 mm) ASTM D-2863-87 L.O.I. = 30 NSP 92501, 4 M2 (1.
Determination of Required Sheet Dimensions The information below is presented to assist in ordering the required dimensions. A Determination of Sheet Size Due to thermal expansion, PALSUN & PALTUF sheets have to be cut accurately at predetermined lengths smaller than the dimensions of the frame. At the end of the frame, clearance must be left for expansion. The following tables and diagram help calculate the required sheet dimensions.
PALSUN® Technical Guide PALSUN® Recommended Panel width - 4 sides clamped (Continued) Thickness 8mm 10mm 12mm 14mm 15mm 18mm Length / Width Ratio (b/a) Load kg/m2 50 75 100 125 150 175 200 50 75 100 125 150 175 200 50 75 100 125 150 175 200 50 75 100 125 150 175 200 50 75 100 125 150 175 200 50 75 100 125 150 175 200 Ratio 1:1 Ratio 1.25:1 Ratio 1.5:1 Ratio 1.
PALSUN® Recommended Panel Width for Curved Installation - Metric Maximum Recommended on Center Distance between Supporting Arches Thickness 4mm 5mm 6mm 8mm 10mm 12mm * See notes on next page 16 Maximum Recommended on Center Distance between Supporting Arches According to Wind/Snow Loads Below (mm) Sheet Curvature Radius 700 900 1100 1300 1500 1800 2000 2200 2800 4000 6000 900 1100 1300 1500 1800 2000 2200 2800 4000 6000 1100 1300 1500 1800 2000 2200 2800 4000 6000 1500 1800 2000 2200 2500 2800 40
PALSUN® Technical Guide PALSUN® Recommended Panel Width for Curved Installation - US Customary Maximum Recommended on Center Distance between Supporting Arches Thickness In. mm /32” 4mm /64 ” 5mm 1 /4” 6mm /16” 8mm /32” 10mm /2” 12mm 5 13 5 13 1 Sheet Curvature Radius Max. Recommended on Center Distance between Supporting Arches According to Wind/Snow Loads Below (in.) (mm) Uniform Wind/Snow Loads (psf ) In. Ft.
Installation Choice of the Frame PALSUN & PALTUF sheets can be mounted in most existing frames made of wood, rigid PVC, aluminum or other metals. It is recommended to use neoprene or EPDM packing (never use soft PVC) to secure the sheet in its frame, rather than fixing with screws. Butyl rubber sealing strip or silicone sealant (PALRAM has tested and recommends Dow Corning Q3-7098 or Q3-3793 and Novasil S 64) are also permissible.
PALSUN® Technical Guide PALSUN® Glazing GA-2004 Glazing Detail Designed by Checked by Date Date Approved by itay_s 18/09/201 Palram Ind. , Tech.
Glazing System Detail Designed by Checked by Approved by Date itay_s Glazing system 27 Hybrid Glazing System Detail 20 Date 13/01/2013 Edition Sheet 1/1
PALSUN® Technical Guide Oriented Glazing System Detail Designed by Checked by Date Approved by itay_s Date 03/05/2012 Palsun Oriented System-1 Edition Sheet 1/1 Wet Glazing Detail Designed by Checked by Approved by Date itay_s Date 15/01/2013 palsun wet glazing 1 Edition Sheet 1 21 /1
Glazing System Detail Mechanical Fastening PALSUN & PALTUF sheets can be fastened with nuts and bolts, providing that several points be kept in mind: Never use rivets, as they apply excessive force and could cause cracks in the sheets. Always drill a slightly over-sized hole by 2-3mm (3/32” - 1/8”) to compensate for thermal expansion. Never use soft PVC washers! Use neoprene and aluminum washers to distribute the load.
PALSUN® Technical Guide General Fabrication Guidelines Tools PALSUN sheets can be fabricated with standard power or hand tools for wood or metal, as long as they are well sharpened and have the clearance required for machining rigid plastics. Only speed regulated tools should be used. The highest possible speed that will not melt the sheet during processing, due to the heat buildup, will achieve the best results. High-Speed steel tools are adequate in most cases.
Generally Accepted Recommendations for Circular Blade Specifications Property Units Sign Value Clearance angle α 10 – 20° Rake angle γ 5 – 15° Alternate double-bevel angle (Alt. 1) α° 45° Alternate bevel angle (Alt. 2) β° 10 – 15° Cutting speed - m/min. (ft/min) 1,000 - 3,000 (3,300 - 10,000) Rate of feed mm/sec. (inch/sec.) Thin gauge: 1.5-2.5 mm tooth pitch (1/16” - 3/36” ) Teeth per mm (Teeth per inch) t 2.5 - 6 (10 - 12) Heavy gauge: 3.
PALSUN® Technical Guide Saw Blade Specifications for Cutting PALSUN up to 5mm Thickness Property Clearance angle Units Value mm (inch) 300 (12) No. of teeth in blade Thickness 96 mm (inch) Teeth angles 2.2 - 3.2 (3/32” - 1/8” ) Rake: 45° Clearance: 15° Alternating: Left - Right Tooth appearance Speed rpm 1800 - 2400 Saw Blade Specifications for Cutting PALSUN 6mm Thickness and Above Property Clearance angle Units Value mm (inch) 350 (14) No.
Recommended Band Saw blade Properties Property Sign Units Value Clearance angle α 10 – 20° Rake angle γ 5 – 15° Cutting speed Rate of feed m/min (ft/min) 1,000 - 6,000 (1,950 - 3,300) mm/sec (inch/sec) 20 (13/6) Thin gauge: 1.5-2.5 mm tooth pitch (1/16” - 3/36” ) t Teeth per mm (Teeth per in.) 1.5 - 2.0 (12 - 18) Heavy gauge: 3.2 - 12 mm tooth pitch (1/8” - 1/2” ) t Teeth per mm (Teeth per in.) 2.5 - 3.5 (7 - 10) Notes: 1.
PALSUN® Technical Guide Routing A versatile technique, enabling diversity of edge fabrications and trimming of PALSUN sheets, notably for parts too large or of irregular shape for a band saw. With sharp two-flute straight cutters, this technique can produce very smooth edges. The feed rate should be slow, to avoid excessive heat buildup and shattering. As a safety measure, when routing, always guide the sheet with a suitable jig.
Drilling General Indications Drill bits: Regular, new high-speed steel twist drills, or new carbide-tipped drills are suitable for drilling holes in PALSUN sheets of various thicknesses, as long as they are sharpened well. They are used mainly for bores up to 12 mm(1/2 “) diameter.
PALSUN® Technical Guide Drilling tips and recommendations Location: Locate holes no closer to the edges than 2 – 2.5 times the diameter of the pertinent hole, with a 10mm (0.4 inch) minimum. Precision: It is imperative to keep the sheet (or stack of sheets) firmly clamped to a stable workbench (or a similar base) to avoid fluttering during drilling. Cooling: Usually cooling is not required with regular drills.
Cleaning General Polycarbonate Cleaning Guidelines Never use abrasive or high alkaline cleaners on PALSUN sheets. Do not use cleaners on PALSUN sheets for an extended period of time. Rinse immediately with clean, cold water. Do not apply cleaners in direct sunlight. Never use sharp objects, wipers (squeegees) or razors on PALSUN sheets. Do not clean with gasoline. Always practice safety first and never step directly on PALSUN sheets.
PALSUN® Technical Guide Cold Forming Cold Curving 1. PALSUN sheets can be cold bent or curved, within their minimal permitted bending radius, without damaging their mechanical performance. The minimal permitted bending radius for a PALSUN sheet is a factor of their thickness and should be calculated in the following manner: 200 x sheet thickness (e.g. for a 5mm PALSUN sheet, 5 x 200 = 1000mm minimum cold bending radius).
3. Installation a. Cold bent polycarbonate is more sensitive to mechanical or chemical abuse in the vicinity of the bend. Therefore, Palram recommends a design that offers better protection for bent areas from any detrimental influence. b. Avoid putting additional strain on bent parts, like forcing a bent angle in or out to fit into an existing framework. Thermoforming Pre-Drying General Guidelines Nearly all types of PALSUN sheets are suitable for various thermoforming (TF) procedures.
PALSUN® Technical Guide Guidelines to the Heating Process Good quality thermoformed products can only be achieved through a careful and controlled heating process. All parts of the treated sheet should reach even, uniform temperature, achieved by a slow, controlled heating rate, avoiding sudden changes in air circulation and temperature. Such events may result in hot spots and possible distortions. Sheet edges must maintain the same forming temperature as the whole sheet.
PE Masking: When preparing for bending of regularly cladded sheets- peel off the masking on both sides of the sheet along the bend line for about 100 mm (4 in) on each side in TF prepared sheets. It is possible to process the sheet with the masking on, up to 5 mm (0.2 in) thickness. For sheets of 6 mm thickness or more the PE masking should be removed along the bending line, as described above. Always test a few samples before proceeding to production.
PALSUN® Technical Guide Fault and Remedies in Thermoforming Practice Vacuum Forming Free Blown Proposed Treatment Hot Line Bending Drape Forming Probable Cause Moisture content too high Pre-drying + + + + Working temp. too high Decrease working temp. + + + 3 Part overheated Decrease heating period + + 4 Mold under-heated Increase mold temp.
Printing PALSUN is suitable for all printing methods which are applicable to rigid sheets. It has been tested and approved by leading digital printer manufacturers, achieving excellent results in all parameters. Clear PALSUN sheets match the high clarity of other thermoplastic sheets, yet offer far better adhesion properties and ease of printing with no requirement for any further surface treatment.
PALSUN® Technical Guide Chemical Resistance PALSUN sheets are compatible with many materials and chemicals, show limited resistance to others, and are incompatible with a third group, with which contact may be devastating. The mechanism of chemical attack on polycarbonate sheets differs significantly from the mechanism of corrosion of metals. Corrosion of metals results in a gradual loss of surface material as a result of electrolytic action by the relevant chemicals.
Chemical Concentration %* Acetaldehyde Resistance N Acetic Acid 10 R Acetic Acid 25 (concentrated) LR (N) Chemical Concentration %* Butane Resistance R Butter R Butyl Acetate N Acetone N Butyl Alcohol (Butanol) R Acetylene R Butylene Glycol R Acrylonitrile N Butyric Acid Ajax Detergent R Calcium Chloride Allspice N Calcium Hypochlorite R Allyl Alcohol LR Calcium Nitrate R R Calcium Soap Fat R R Camphor Oil N R Carbolic Acid N R Carbon Bisulfite N Alum (Alu
PALSUN® Technical Guide Chemical Concentration %* Resistance Chemical Concentration %* Resistance 20 R Diamyl Phthalate N Kerosene Diesel Fuel R Lactic Acid Diethyl Ether (Ethyl Ether) N Lacquers and Thinners R Dimethyl Formaldehyde (DMF) N Laundry Detergents (Most) R Dimethyl Sulfoxide (DMSO) N Ligroin (Hydrocarbon Mixture) R Dinonyl Phthalate (plasticizer) LR Lime Solution (2%) or paste R Doctyl Phthalate (plasticizer) LR Liquors or Liqueurs R Dioxane N Linseed Oil R
Chemical Concentration Resistance Chemical %* Concentration %* Resistance Petroleum LR Sodium Sulfide Petroleum Ether LR Sodium Thiosulfate R Petroleum Oil (Refined) R Spindle Oil R Phenol Phosphoric Acid N Stannous Chloride R 10 R Starch R R Styrene 25 LR Sugar N Sulfur Dioxide (Gas) Phosphorous Oxychloride Phosphorous Pentoxide Phosphorous Trichloride Polyethylene R Sulfuric Acid Polyethylene Glycol R Sulfurous Acid Potassium Acetate LR Sulfuryl Chloride R Tapping O
PALSUN® Technical Guide Adhesives and Sealants Adhesives and sealants are a special class of substances often required during installation or fabrication of PALSUN. The guidelines for their use, appearing below, must be followed. 1. Use only sealants, adhesives, rubber packing, sealing strips & gaskets that are compatible with PALSUN and approved by Palram or its distributors.
All marketing materials and any content therewith provided by Palram® are provided solely for the purpose of supporting and enhancing the marketing of Palram® products. These materials are protected by Palram’s intellectual property rights and may not be used for any other purpose or in connection with the sale of products of any other manufacturer. These materials may not be transferred to or used by any third party without prior permission of Palram. PALRAM EUROPE LTD.
