LIDL Faade System

Regeldetails und Konstruktionsmerkmale

LIDL Faade System
Overview 3A Composites
LIDL Faade System
3A Composites Worldwide Presence 22 sites in 8 countries
Ecuador
Guayaquil
Quevedo
Santo Domingo
Manta
Brasil
Sao Paulo
Singapore
Shanghai
Sins
Singen (GER)
Osnabrck (GER) Chelmsford (UK)
Glasgow (KY)
Northvale (NJ)
Benton (KY)
Statesville (NC)
St Louis
Product Market Unit (PMU) Locations
Architecture
Display
Core Materials
Transport & Industry
Mumbai
Core Materials
Display & Graphic Arts
Transport & Industry
Architecture
LIDL Faade System
Singen Site
founded 1912
1800 employees
Production:
> 200.000 t Rolled products
> 40.000 t Extrusion
> 15.000 t Components
> 4.000 t Forged products
ConstelliumSingen GmbH
Amcor GmbH
Foils and laminates
> 1100 employees
3A Composites GmbH
Composite panels
> 300 employees
LIDL Faade System
ACSI Products
LIDL Faade System
Developed and established in 1968 by Alusuisse and BASF
Production of ALUCOBOND

since 1969 in Singen/Germany
1978 First subsidiary overseas (Benton, Kentucky/USA)
1979 Start-up of the first fire rated ALUCOBOND

(SB1, 21)
1989 Production start of non-combustible ALUCOBOND

A2
1994 Beginning of first continuous production of the
aluminium honeycomb panel ALUCORE

1995 Start of the first ACM recycling centre in Germany
1997 Start-up of production line in Shanghai
1999 Production start of fire rated ALUCOBOND

Plus
2002 Start-up of production line in Brasil
2005 4. production line in Singen (width up to 2005 mm)
2007 First subsidiary in India
ALUCOBOND

Success Story: From Pioneer to Synonym

LIDL Faade System
Aluminium-Composite Panels
LIDL Faade System
4% Aluminium
Tightness
21% Polyethylene
Tensile Resistance
75% Cellulose
Stiffness
Composition of a beverage carton
Composite = Optimized Set of Properties
Composites
LIDL Faade System
Sandwich
Technology
(1) Flange
(2) Web
= Funktionality
Composites
LIDL Faade System
11.7 kg
18.7 kg
8.9 kg
5,5 kg
ALUCOBOND

4 mm
Aluminium 3,3 mm
Steel 2.4 mm
Fibre cement 5.8 mm
Weight kg/m2 Stiffness E*J
Composites
LIDL Faade System
Fluorocarbon Lacquer System
(e. g. PVDF)
Composition:
0.5 mm Aluminum
Plastic or mineral
core material 0.5 mm Aluminum
Formats:
Thickness 4 mm(3, 6 mm)
Width 1575 mm
1000, 1250, 1500,
max. 1750 mm (2050 mm)
Length 2000 - 8000 mm
Composite Materials
LIDL Faade System
ALUCOBOND

Normally flammable
EN 13501-1 D, s1, d2
ALUCOBOND

Plus
Flame resistant
EN 13501-1 B, s1, d0
ALUCOBOND

A2
Non combustible
EN 13501-1 A2, s1, d0
Composite Materials
LIDL Faade System
Processing of Composite Panels
LIDL Faade System
Sawing Cutting Routing
Rout & Fold Pressing Rolling
CNC routing Drilling
Perforation
ALUCOBOND

Fabrication
LIDL Faade System
Verarbeitung - Sgen
Vertical panel saw
Hand saw
Jigg saw
Processing Cutting to size
LIDL Faade System
LEUCO Topline-Kreissgeblatt TFFa
Jigg saw blade for plastic
TC tipped circular saw blades, teeth: trapezoid/flat
for ALUCOBOND Plus und ALUCOBOND A2
Tungsten carbide quality grade K01
Processing Cutting to size
LIDL Faade System
Cutter angle
10positive
Cutter angle
5negative
ALUCOBOND

, DIBOND

, ALUCORE

Solid aluminium
Processing Cutting to size
LIDL Faade System
Examples
Processing Rout & Return
LIDL Faade System
distance
roller
Milling disk
Processing Rout & Return
LIDL Faade System
To fold / bend a long edge on an ALUCOBOND panel, which have been
routed, it is recommended to use a folding tool.
ALUCOBOND

6,2
4,2
Platten-
streifen
Folding Tool
LIDL Faade System
g
a
u
g
e
8

m
m
Clearance for
adhesive
2 mm
end thickness
10 mm
Double return of ALUCOBOND 4 mm
Processing Rout & Return
LIDL Faade System
Determination of periphery and
size of cutting
The measures of periphery and
routing are determined out of the
drawing measurements (final
measures). For each folding 1mm
must be subtracted from the final
measure.
The size of cutting results from the
sum of the routing measures.
In any case the final measures should
be tested before starting a production
run. Afterwards the limit stops of the
circular saw should be kept fix to
obtain identical elements with the
same sizes.
LIDL Faade System
indexable inserts (TC)
ALUCOBOND

Plus und A2
Disc Milling Cutters for
Vertical Panel Saws
Milling Form-Cutters with Cylindrical Shank
Processing Rout & Return
LIDL Faade System
Sawing
Routing
Processing Rout & Return
LIDL Faade System
Panel saw with router
Hand panel miller
Hand Routing Machine
CNC-centre
Processing Rout & Return
LIDL Faade System
Two-parts facia-corner
Processing Rout & Return
LIDL Faade System
Developed view
Processing Rout & Return
LIDL Faade System
Processing on panel saw
Processing Rout & Return
LIDL Faade System
Cutting on guillotine
www.edel-stanztec.de www.knuth.de
Processing Punching
LIDL Faade System
Serial punching machine MP 6000
for ALUCOBOND

cassettes
www.liechtblick.ch
Processing Punching
LIDL Faade System
Processing Punching
Developed view on
ALUCOBOND

cassette
LIDL Faade System
pilot point drill bit normal drill bit
EXTREME 2TM HSS-G metal drill bit DIN 338
Processing Drilling
LIDL Faade System
Single Flute Cutters for Cut to Size and Contour
Cutting of ALUCOBOND

on CNC- centers
www.gis-tec.de
www.bewe-online.com
Processing Drilling
LIDL Faade System
Outwards: parallel feed
Inwards: counter rotation
Outwards: counter rotation
Inwards: parallel feed
Inwards
cut
Outwards
cut
Single Flute Cutter
spin to right
F
e
e
d
F
e
e
d
Feed 5 m/min.
Rotation speed 24.000 U/min.
Serie
F 113
ALUCOBOND

ALUCOBOND

plus
ALUCOBOND

A2
Processing Drilling
www.gis-tec.de
LIDL Faade System
CD-ROM:
Supplier list for
Machines
Tools
Accessories
Profile sections
LIDL Faade System
Aluminium Constructions
in Faades
LIDL Faade System
Guidelines for ventilated Claddings
DIN 18516
www.fvhf.de
www.sfhf.ch
www.oefhf.at
LIDL Faade System
De-aeration min. 50 cm
per meter,
i. e. min. 5 mm gap
Ventilated cladding
LIDL Faade System
Min. venting 20 mm
Local reduction
by sub-structure
to 5 mm
Continuous ventilation
from bottom to top
Sliding console
Fix console
De-aeration
min. 50 cm
per meter,
i. e. min. 5 mm
gap
Ventilated cladding
LIDL Faade System
Thermal movement
LIDL Faade System
Surface temperatures of facades
-30
-20
-10
0
10
20
30
40
50
60
70
80
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
time of day [h]
T
e
m
p
e
r
a
t
u
r
e

[

C
]
Surface temperature

Surface temperature

Air temperature

Air temperature
SUMMER
WINTER
max. 75C
LIDL Faade System
Thermal Expansion of ALUCOBOND

Panels
_________________________________________________________________________________
The linear thermal expansion factor is to be taken in consideration: 2,4 mm/(m length 100 K)
i.e. 2,4 mm expansion/contraction on every meter length/width at 100 degrees temperature difference
Example: supposed temperature at erection 20C
temperature difference t = 50K
expected heat up of the panel max. 70C
panel length 3 m
Calculation 1: 2,4mm 3(m) 0,5( t =50K) = 3,6 mm expansion of panel
i.e.: on each of the opposite edges 1,8 mm movement must be allowed, if substructure is
restrained as e.g. mounting on wooden structure or substructure vertical to the panel expansion
If the aluminium substructure is parallel to panel expansion the temperature difference can be
reduced to t = 10K in general (according DIBt-Approval Z-33.2-6), if the panel lays directly on
the substructure (e.g. ECOCLAD-system)
Calculation 2: 2,4mm 3(m) 0,1( t =10K) = 0,72 mm expansion of panel
Note: For ALUCOBOND

on steel substructures 50% of the thermal movement must be allowed,
since steel has a linear thermal expansion factor of 1,2 mm/(m 100 K), i.e. 50% of aluminium.
LIDL Faade System

Drill hole in panel
Drill hole
in sub-structure
Drilling holes
Thermal Expansion of Aluminium
LIDL Faade System
Drilling device for centrically drilling
Thermal Expansion of Aluminium
LIDL Faade System
distance
0,3 mm
Thermal Expansion of Aluminium
Riveting
Riveting
device
LIDL Faade System

Thermal Expansion of Aluminium

Screws
LIDL Faade System
Fastener made of aluminium and/or stainless steel
No counter sank screws
for exterior application!
Thermal Expansion of Aluminium
LIDL Faade System
Wind loads
LIDL Faade System
Wind loads
Eurocode 1, Part 2-1
Wind actions
BS prEN 1991-2-1
Chapt. 7.2.9 Internal pressure
LIDL Faade System
Wind loads
Ventilated rain screens:
C
p, res
= 0,5
Area of joints
Cladding area
Vertical barrier at the corner
0,75%
LIDL Faade System
Lidl Cladding Constructions
LIDL Faade System
SZ20 Facade System
Tongue-/groove Panels
(Horizontal layout)
LIDL Faade System
15-20
44024
44025
S
Z
Basis
44026
LIDL Faade System
Kassettenprofile SZ 20
44024
44025
Hut-Profil
35953
44026
LIDL Faade System
Reference details: Fixing on insulated concrete parts
5 mm Aluminium rivet
with stainless steel
mandrel
Head 11 mm
RAL9006 coated
500
Approved manufacturer
z. B.: Ejot, MBE, SFS, Wrth
2
0
Profile
RAL 9006
Powder
coated
Slot hole
LIDL Faade System
Reference details: Fixing on insulated concrete parts
Joint sealant
LIDL Faade System
Reference details: Fixing on insulated concrete parts
Joint sealant
LIDL Faade System
Reference details: Fixing on insulated concrete parts
Mineral Insulation
(non combustible, A2, s1, d0)
Reinforcement, if required
LIDL Faade System
Customized solution: Fixing on brick wall
Slot hole
3mm flange
LIDL Faade System
P
r
o
t
e
c
t
i
o
n
f
o
i
l
Panel reverse side
Reference details: Panel Layout
LIDL Faade System
Reference details: Typical grid of substructure
Permissible loads for anchors may requires more substructure
Wind load
Wind load
LIDL Faade System
Reference details: Typical fixing of substructure
sliding console(s)
for wind load only
(with slot holes)
1x fix console for wind load and dead load
(e. g. in concrete or steel bar)
LIDL Faade System
Reference details: Typical fixing of substructure
f
i
x
s
l
i
d
i
n
g
LIDL Faade System
Tray panels with horizontal layout
SZ20 3000x1000x4
Load: -1,5 kN/m
LIDL Faade System
Technical Services
LIDL Faade System
thread free
zone
Approved manufactures:
z. B. Ejot, SFS
Reference details: Typical fastener to substructure
LIDL Faade System
perforated sheet or 5 mm slot
Reference details: bottom of faade
LIDL Faade System
Circular frame
Reference details: bargeboard
LIDL Faade System
20
Circular frame
20
Reference details: ridge / eaves
LIDL Faade System
A A
Section B-B
Section A-A
1-part corner
Reference details: facia corner
LIDL Faade System
Reference details: Renovation of Plus stores
LIDL Faade System
Reference details: Renovation of Plus stores
LIDL Faade System
Reference details: Renovation of Plus stores
LIDL Faade System
Reference details: Renovation of Plus stores
Counter plates
LIDL Faade System
Bad examples: Renovation of Plus stores
LIDL askes for a complete structural calculation (for all components)
They send assessors for final acceptance of construction work
LIDL Faade System
Bad examples: Renovation of Plus stores
www.spaeter.de
LIDL Faade System
Bad examples: Renovation of Plus stores
LIDL Faade System
Bad examples: Renovation of Plus stores
LIDL Faade System
Bad examples: Renovation of Plus stores

LIDL Faade System

Bad examples: Renovation of Plus stores
LIDL Faade System
Bad examples: Renovation of Plus stores

LIDL Faade System

Bad examples: Renovation of Plus stores
?
LIDL Faade System
Bad examples: Renovation of Plus stores
?
LIDL Faade System
Bad examples: Renovation of Plus stores

LIDL Faade System

Bad examples: Renovation of Plus stores
f
i
x
LIDL Faade System
Bad examples: Renovation of Plus stores
LIDL Faade System
Bad examples: Renovation of Plus stores
Different level of fix consoles
LIDL Faade System
Bad examples: Renovation of Plus stores
D
i
s
t
a
n
c
e
!
?
LIDL Faade System
Bad examples: Renovation of Plus stores
lousy fabrication
LIDL Faade System
Bad examples: Renovation of Plus stores
Irregular distance of rivets < 500
LIDL Faade System
Bad examples: Renovation of Plus stores
Slot hole?!
LIDL Faade System
Bad examples: Renovation of Plus stores
LIDL Faade System
Bad examples: Renovation of Plus stores
LIDL Faade System
Bad examples: Renovation of Plus stores
LIDL Faade System
Bad examples: Renovation of Plus stores
LIDL Faade System
Bad examples: Renovation of Plus stores
LIDL Faade System
Bad examples: Renovation of Plus stores
LIDL Faade System
Bad examples: Renovation of Plus stores
LIDL Faade System
Bad examples: Renovation of Plus stores
LIDL Faade System
Bad examples: Renovation of Plus stores
LIDL Faade System
Bad examples: Renovation of Plus stores
LIDL Faade System
Bad examples: Renovation of Plus stores
LIDL Faade System
Bad examples: Renovation of Plus stores
LIDL Faade System
Bad examples: Renovation of Plus stores
LIDL Faade System
Bad examples: Renovation of Plus stores
LIDL Faade System
Bad examples: Renovation of Plus stores
LIDL Faade System
Questions?!