HULABOND

Our aluminium composite panels offer

developers, specifiers and fabricators
so much more.

HBS offers fabricators so much more than any other distributor of aluminium
profiles. We have more backup, more products, more innovative inventory
practices and more technical support.
Only HBS sell a unique range of branded products. HulaBond is the biggest selling
aluminium composite panel in South Africa, NuKlip is the only branded shopfront
system in South Africa, Coastal is a range of sliding doors and windows that use
punching tools to dramatically improve productivity. HulaSign is available off the
shelf in white.

HulaBond is the largest selling aluminium composite panel in South Africa.

HULABOND

More convenience
It has never been easier to order standard HulaBond panels. HBS stocks
HulaBond 1250 x 3200 in silver, white and champaigne and is available in
Johannesburg, Cape Town, PE and Durban. For smaller jobs, where colour
matching is not critical, orders will take just 48 hours.
More colours
HulaBond is available in 24 colours which will satisfy anyones aesthetic needs.
The minimum order quantity for any colour is 1000 m2 - only 250 panels. More
colour less hassle!
More versatile
Most project specific requirements such as colour, width or length can be
delivered 9 weeks from order. We can manufacture up to 1500 x 5800 in 4mm
or 6mm thickness. Double sided panels and a Fire Retardant core are also
available. Minimum order quantity is only 1000m2.
More cost effective
HulaBond can be up to 40% cheaper than other imported composite panels.
Also there is no up front payment, no letter of credit or any other financial
commitment required. HulaBond is treated like any other HBS product so you
only pay after receipt of the product.
More sense
It makes more sense than ever to use HBS composite panel because it is more
convenient, and with more colours, is more versatile and cost effective.

1. FULL PRODUCT DESCRIPTION

HBS aluminium composite panels consist of two sheets of aluminium, bonded to a polyethylene core. The
panel is available in a range of metallic and non-metallic based PVDF paint nishes in both standard and
custom sizes
1.1 Product attributes
Lightweight and rigid
The composite structure of HulaBond panels provides high rigidity
at a fraction of the weight compared with the panels of single sheet
construction.

Flat surface
The painted sheet used in the construction of the HulaBond panel
undergoes a special tension levelling operation; ensuring panels are
superior in surface smoothness and sheet flatness.

Formability
Shaping of the HulaBond panel is a straightforward process. The panel
can be easily curved to tight radii using pyramid rollers or a brake press.
Folding of the panel can be accomplished by routing through one of the
aluminium cover sheets and most of the plastic core whereafter the panel
can be folded by hand or using a simple folding tool.

Machinability
The HulaBond aluminium composite panel is easily cut, punched, drilled and
machined using standard woodworking and metalworking equipment.

PVDF paint finish

The enduring paint finish imparts a weather resistant low maintenance
finish to the panel. Only UV stable, inorganic ceramic pigments are
used in order to ensure long-term colour retention.

Vibration damping
The polyethylene core of the HulaBond panel exhibits excellent
sound attenuation properties. The vibration loss factor on the panel is
approximately six times better than an equivalent solid aluminium sheet.

Technical assistance
The HulaBond product is fully supported. Further information and technical
assistance are provided to address requirements on specific products.

Recyclable
HulaBond is manufactured from fully recyclable materials. On separation
both the aluminium and polyethylene can be economically reprocessed.

1.2 Panel gauge

The standard panel thicknesses are 4 and 6mm. Other thicknesses can be manufactured on request to cater for
specic application.
1.3 Skin gauge 0.5mm
The skin gauge is 0.5mm.
1.4 Alloy
The standard alloy used is 1100 H18.
1.5 Panel Size
Special sizes and colours
The standard size for HulaBond is 1250X3200X4mm.
HulaBond can be manufactured up to 1500 wide and up to 5800 long X 4mm or 6mm thick. HulaBond is
available in 24 colours. Please note that minimum order quantities on special sizes and colours are 1000m2.
Stocking
We endeavor to keep stock of silver HulaBond which is equivalent to 6 months sales and stock of white and
champagne HulaBond which is equivalent to 3 months sales on our shelves in Johannesburg, Cape Town and
Durban.
Stock is replenished monthly based on demand and it is unlikely that smaller non project orders cannot be
fullled.
The purpose of keeping stock on the shelf is to supply smaller projects or where colour matching is not critical
as colours differ from batch to batch. Please remember that for colour consistency you are advised to place
complete orders for any specic project to ensure a high standard of colour matching.
Lead times on project orders
The estimated lead time on project orders is 8 weeks which is comprised of the following:

Manufacturing
Transport to harbor and loading on ship
Sea freight
Customs clearance and delivery

2 weeks
1 week
4 weeks
1 week

We manufacture 3 million m2 per year so it is highly unlikely that manufacturing lead times will be longer than
estimated above. Lead times will be quoted per order.

IMPORTANT INSTRUCTIONS

Within 4 Months
Please install panels in the same facade according to
the indicated direction.

Please store panels in a cool and at place before

fabrication and installation.

WARNING
Please remove the protective lm within 4 months
after installation.

Colour variation may happen to the panel of same

color code but different batch of production,
please contact us to check before fabrication and
installation.

2. PRODUCT SPECIFICATIONS
2.1 General properties
Panel construction
(a) The HulaBond aluminium composite panel consists of skins of aluminium, which are coated with
PVDF paint, bonded to a polyethylene core.

PVDF paint
Aluminium Sheet
Pretreatment film
Adhesive

Polyethylene Sheet

Adhesive
Pretreatment film
Aluminium Sheet
Anti corrosive primer

Dimensional tolerances
W

Length (L)
Width (W)
Flatness (F)
Gauge (G)
Squareness (S)

2mm
2mm
0.5% of span
0.2MM
S1 S2 5mm

F
6

Thermal Expansion
It is the two aluminium cover sheets which determine the thermal expansion properties of
HulaBond in the length and width dimensions. This thermal expansion necessitates a close
examination of:
Possible consequences of thermal movements
Location of expansion joint
Restrained parts in which elastic buckling may occur at relatively low stress levels.
For a uniform increase in temperature T an unrestrained HulaBond panel will increase in width
and length by an amount;
e=LT
Where

e = increase in span length L

L = span length
coefficient of linear thermal expansion which for HulaBond = 2.4mm per 100C
temperature change. A value of 0.000024/C should be used in the equation.
temperature change in C

Under normal circumstances, an allowance should be made during the installation of HulaBond to
accommodate temperature fluctuations over the range 20C to +80C. This is equivalent to an
unrestrained change in length of 1.2mm per 1m span of panel.

2.2 Load deflection properties

The nature of wind flow around a building is complex and a theoretical prediction must be done
with care. Small variations in shape, surface roughness or in wind direction can cause significant
changes in the flow and hence in the magnitude and distribution of the resulting pressures on the
building.
Factors such as the scale and intensity of wind turbulence, the size of the building, the nature of
the surrounding buildings and topographical features have a profound influence. However, for the
great majority of buildings with conventional shapes, it is sufficient and more convenient to use
the detailed procedures given in SABS 0160-1989. The General Procedures and Loadings to be
adopted in the Design of Buildings
Wind is a dynamic phenomenon. The fluctuations in the wind forces results in a dynamic responses
of the building where the magnitude of this response will depend upon factors such as the
turbulence of the wind and the size, shape, weight, stiffness and dampening characteristics of the
building and building elements.
However, for the majority of buildings the dynamic response effects are small and a static wind
loading in which the wind forces are based on a peak gust speed will suffice. It should also
be noted that wind-induced vibration of light, flexible roof structures or claddings could lead
to loosening of fasteners and on occasions to fatigue failure, eventualities which can be easily
prevented through good design.

Fixing Geometry
The performance of the panel in a wind load environment is highly dependant upon the xing geometry selected,
the length of the spans involved, the degree of support and the type of support used. The majority of installations
closely approximate one of three xing
geometries. They are: single-span,
double span and plate

Single-span
Single-span loading considers
the case of a panel of short span
length (L) simply supported along
each long edge. The support
spacing in this model is equal to
the panel short span length (L). The
load configuration is represented
schematically above.

Double-span
Double-span loading considers the
scenario in which a rigidly fastened
stiffener has been attached at the
mid length/width position of the
panel, effectively reducing the
panel by a line of symmetry into two
smaller panel modules. The loading
conguration for each module in
then that of a panel, which is simply
supported along the one long edge
and rigidly fastened along the long
edge corresponding to the midpanel position of the stiffener. This
load conguration is represented
schematically above.

Plate
Plate load considers the scenario in
which the panel is simply supported
along all four edges. Te cover
sheet stress and panel deflection,
for a panel simply supported along
all four edges can be determined
from the single-span properties by
applying a correction factor, which
allows for the additional support.
This correction factor is a function
of the panel aspect ratio (a/b). The
influence of the additional support
along the short panel length is
greatest for panel aspect ratio
close to one and decreases with
increasing aspect ratio.
8

a
L

Limit states design criteria

The installer should ensure that, for every panel module, the design wind load on the module does not give rise
to a deection in the panel, which exceeds any one of the following limit states:
Limit state 1
A panel deection, which exceeds a user, dened limit based purely on visual considerations. Exceeding this limit
state, although not posing any substantial risks of failure, may under adverse windload conditions, give rise to
visually unacceptable deections of the panel.
Limit state 2
A panel deection which gives rise to a stress in the aluminium cover sheets which exceeds a limiting value.
Exceeding this limiting value may lead to the permanent deformation of the panel surface.
Limit state 3
A panel deection, which gives rise to a displacement in the panel edge, which exceeds a limiting value. Exceeding
this limiting state may result in the panel popping out or becoming detached from its xing.

Limit State 1, Calculation of maximum panel deflection

Single and double span configurations
For a uni-directional span (single and double span congurations),
deection in the panel under uniform wind loading conditions
can be determined from:

HulaBond Design Aid Chart

Plate Conguration Correction Factors
1

0.9

d=K PL

4
0.8

El
Where

d =
P =
L =
El =

midspan deection (mm)

wind pressure (kN/m2)
panel support spacing (mm)
modus of rigidity*
El 120 x 103 Nmm2/mm (3mm panel)
El 230 x 103 Nmm2/mm (4mm panel)
El 570x 103 Nmm2/mm (6mm panel)

K = coefcient of restraint
Single-span K1 = 13 x 10-6
Double-span K1 = 5,4 x 10-6
1

*The modulus of rigidity (El) for specied panel conguration has been determined

Correction Factors (kd ks)

ks
0.7

kd

0.6

0.5

0.4

0.3

0.2

1.5

2.5

3.5

Panel Aspect Ratio (a/b)

Correction Factors ks

Correction Factors kd

using software package CLASS Composite Laminate Analysis System available form
ASM International. Values of modules of rigidity calculated using this package closely
agree with those published for panels of similar construction and also with results obtained from tests conducted by independent consultants.

Plate configuration
For a panel simply supported on all its edges (plate conguration) the maximum panel deection can be
determined by applying a correction factor to the maximum deection determined for the single span scenario
dp = kdds
Where

dp = maximum panel deection (plate conguration) (mm)

ds =Maximum panel deection (single-span conguration) (mm)
kd = correct factor which is a function of the panel aspect ratio a/b. Values of K can be read from the
graph once a/b is known.
9

Limit state 2. Calculation of maximum panel outer cover sheet stress.

Maximum allowable outer cover sheet banding stress
It is the spaced aluminium cover sheets, which determine the bending strength of the panel. The core,
which acts as a shearweb in much the same way as the webs of an I-beam, can be disregarded when
calculating the bending tension.
For design purposes, a maximum bending stress failure criterion is used, where failure is deemed to
have occurred of the stress in the cover sheet resulting from an applied ending moment is raised beyond
the 0.2% proof strength of the aluminium alloy. A 1.75 safety factor is then applied to give a maximum
permissible design bending stress for the panel. The 0.2% yield limit (Sy) and the maximum permissible
design stress in the aluminium outer cover sheet (Sd) for the panel are:
Sy = 170 N/mm2
Sd = 97 N/mm2
Tests conducted by independent consultants* indicate that the panel performance under short term
load cycling, simulating 3 second gust wind buffeting conditions, exceed that determined from static
loading conditions. It is therefore the maximum permissible design stress (Sd) determine under static load
conditions, which determines the upper performance limit of the HBS aluminium composite panel.

Single and double span configurations

The actual stress developed in the cover sheet as a result of an applied bending moment to the panel
is given by

Sa =

Mb
Z

Where

Sa = actual stress in cover sheet

Mb = bending moment*
Z = selection modulus#

(N/mm2)
(N)
(mm2)

Z = 1.06 x 10 -3 mm2 (3mm panel)

Z = 1.54 x 10 -3 mm2 (4mm panel)
Z = 2.53 x 10 -3 mm2 (6mm panel)

*The maximum bending moment Mb for both single-span and double-span configurations, is for an
evenly applied load, given by:
M b = 125 x 10-9 PL 2
Where

P = wind pressure (kN/m2)

L = supporting spacing (mm)

# The section modulus of the panel Z can be calculated using:

Z = (tt3 - t3c )L
6tt
Where

10

tt = total panel thickness (mm)

tc = thickness of polyethylene core (mm)

Plate configuration
For a panel simply supported along the edges (plate
configuration), the maximum outer cover sheet stress
can be determined b7 applying a correction factor to the
maximum outer cover sheet stress determined for the
single span scenario.

Where
SP = maximum outer cover sheet stress (N/
mm2) (Plate configuration)
SS = maximum outer cover sheet stress (N/
mm2) (Single-span configuration)
KS = correct factor which is a function of
the panel aspect ratio a/b. Values of
K ca be read from the graph once a/b
is known

0.9

0.8

Correction Factors (kd ks)

SP = KS SS

HulaBond Design Aid Chart

Plate Conguration Correction Factors

ks
0.7

kd

0.6

0.5

0.4

0.3

0.2

1.5

2.5

3.5

Panel Aspect Ratio (a/b)

Correction Factors ks

Correction Factors kd

Limit State 3. Calculation of maximum panel edge displacement

It is possible to calculate the panel edge displacement resulting from an applied wind load as a function
of panel support spacing and panel mid-point deflection using the following occasion, which assumes
the panel displacement profile closely approximates that of a parabola.
2
2
2
2
D = ax x + a + ln x+ xa + a - L

Alternatively, it is possible to ascertain the maximum edge

displacement (D) by reading off the dimensionless edge
displacement (D) corresponding to the dimensionless
mid-span panel deflection (D) from the following
graph:

HulaBond Design Aid Chart

Edge Displacement vs Panel Deection
0.16

0.14

Dimensions Edge Displacement (D)

Where:
D = maximum edge displacement (one end
fixed) (mm)
x = 0.5L
a = L2/8d
L = Supporting spacing (mm)
d = maximum panel deflection (m)
ln = natural Logarithm

0.12

0.1

0.08

0.06

0.04

0.02

Equations:
L = L/Unit support spacing
d = d/L
D = D/L
Where:

L =
d =
D =
L =
d =
D=

dimensionless support spacing

dimensionless mid-span panel deection
dimensionless edge displacement
actual support spacing
actual mid-span panel deflection
actual edge displacement

0.05

0.1

0.15

0.2

0.25

Dimensionless Mid-Span Deection (d)

Edge displacement
one side only

Edge displacement
equal both sides

11

Edge displacement
It is the installers responsibility to ensure that the maximum likely edge displacement in the panel for a
given fixing configuration will not lead to failure. However, to assist, the limitations of the two popular
fixing methods, the double top hat and the adhesively bonded joint using an approved flexible silicone
glazing sealant, are examined in more details.
Double top-hat
Where a double top-hat section has been used, the amount of displacement, which can be accommodated
before there is risk of the panel popping out of the fixing, is determined by the amount of overlap
between panel and the land fastening.

d
s
Dmax

Tape
L
d

= panel support spacing (mm)

= panel mid-span panel
deflection (mm)
s
= panel arch length (mm)
Dmax = overlap (mm)

Step 1. Calculate the maximum dimensionless edge displacement (Dmax) which can be accommodated
by the fixing. This is the ratio of the overlap (Dmax) to the support spacing (L).
Dmax = D max
L
Step 2. Determine from the graph (displacement one side only curve) the value of dimensions mid-span
panel deflection (d) corresponding to the value of dimensionless edge displacement (DMax)
calculated in step 1.
Step 3. Convert to the value of dimensionless mid-span panel deflection (d) into an actual mid-span
panel deflection (d) by multiplying the dimensionless mid-span panel deflection by the support
spacing (L).
d = dL
Step 4. Confirm using the wind load deflection design Aid Charts provided that the limit panel deflection
calculated in step 3 is not exceeded.
Note: To determine the maximum edge displacement for a given panel geometry and wind load reverse
the above procedure.
12

Silicone Lap Joint

Where panels have been
fastened using a silicone sealant,
the amount of displacement
which can be accommodated
is that which results either
cohesive failure (failure in the
bond between adhesive and
adherent) or in adhesive failure
(failure within the adhesive). In
this instance, the criterion, which
will determine whether failure
will take place, is not only a
function of the geometry of xing
(sealant thickness and bead
width) but also the adhesive
strength, shear modulus and
shear strength of the sealant
used.

Double sided adhesive foam tape

Silicone sealant
S = panel arch length (mm)
w = silicone sealant bead width
= silicone sealant bead thickness

For single span and plate

conguration xing geometries the edge displacement generated is distributed equally between adjacent
xings, however, where panels have been xed using a double span geometry, no displacement takes place at
the mid- span xing but is accommodated entirely at the panel edge.
The fabricator should ensure that the stress generated within the silicone joint fall within the acceptable limits.
This is usually accomplished by ensuring that the combined edge displacement, which may result from both
thermal expansion and wind load deection of the panel, falls within rule of thumb limits of joint movement
capability, which have been provided by the supplier of silicone sealant.
Step 1. Calculate the maximum dimensionless edge displacement (Dmax) which can be accommodated
by the joint without exceeding the endurance limits of the sealant. This is a function of both the
thickness of the bead of silicone (t) and the grade of silicone used. A typical high performance structural
glazing silicone sealant is able to accommodate up to +-50% joint movement. For a 6mm silicone
bead, this is sufcient to accommodate a displacement in the panel of up to +- 3mm. However,
before proceeding, exact limits of D should be determined from the supplier of the silicone sealant.
The maximum dimensionless edge displacement (Dmax) which can be accommodated by the joint is the actual
edge displacement, which can be accommodated by (D), divided by the panel support spacing (L).
Step 2. Determine from the graph the value of dimensionless mid-span panel deection (d) corresponding to
the value of dimensionless edge displacement (D) calculated in Step 1. Where the panel is xed using
a single span or plate conguration mode information should be read from the edge displacement
equal both sides data curve, whereas information should be read from the edge displacement one
side only if panel has been xed in the double span mode.
Step 3. Convert the value of dimensionless mid-span panel deection (d) into an actual mid-span panel
deection (d) by multiplying the dimensionless mid span panel deection by the support spacing (L).
d = dL
Step 4. Conrm using the load deection design aid charts that the limiting panel deection calculated in Step
3 is not exceeded. (See attached aid design charts)
Note: To determine the maximum edge displacement for a given panel geometry and wind load,
reverse the above procedure.
13

Design Aid Charts

The following design aid charts are available to
assist your engineers to select and optimise the
use of HulaBond for the installation at hand.

HulaBond Design Aid Chart

Customised Analysis
100

80

Outer Cover Sheet Stress N/mm2

Double Span Design Aid Charts

- determination of maximum panel deflection
- determination of panel outer cover sheet
stress
- determination of panel edge displacement

90

Maximum Panel Deection (mm)

Single Span Design Aid Charts

- determination of maximum panel deflection
- determination of panel outer cover sheet
stress
- determination of panel edge displacement

4mm Panel Plate

Conguration
Aspect Ratio 1.5
Wind Load 1500
N/M2

70
60
50
40
30
20

Plate Configuration Design Aid Charts

- determination of maximum deflection
- determination of outer cover sheet stress
- determination of edge displacement

10
0
500

600

700

800

900

1000

1100

1200

Support Spacing (mm)

COVER SHEET DEFLECTION
STRESS LIMIT
PANEL DEFLECTION

4mm Panel Plate

Conguration
Panel Deection vs Support Spacing Aspect Ratio 1.4
Deection

4mm Panel Plate

Conguration
Panel Deection vs Support Spacing Aspect Ratio 1.4
Stress

HulaBond Design Aid Chart

HulaBond Design Aid Chart

120

160
150

110

140

100

120

Outer Cover Sheet Stress (N/mm2)

Maximum Panel Deection (mm)

130

110
100
90
80
70
60
50
40

90
80
70
60
50
40
30

30

20

20

10

10
0
500

600

700

800

900

1000

1100

1200

0
500

600

700

Support Spacing (mm)

500 N/m2

1000 N/m2

1500 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

Stress Limit

14

800

900

1000

1100

1200

Support Spacing (mm)

500 N/m2

1000 N/m2

1500 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

Max. Cover Sheet Stress

4mm Panel Plate

Conguration
Panel Deection vs Support Spacing Aspect Ratio 2.0
Stress

4mm Panel Plate

Conguration
Panel Deection vs Support Spacing Aspect Ratio 2.0
Deection

HulaBond Design Aid Chart

HulaBond Design Aid Chart

120

160
150

110

140

100

Outer Cover Sheet Stress (N/mm2)

Maximum Panel Deection (mm)

130
120
110
100
90
80
70
60
50
40
30

90
80
70
60
50
40
30
20

20

10

10
0

0
500

600

700

800

900

1000

1100

1200

500

600

700

Support Spacing (mm)

800

900

1000

1100

1200

Support Spacing (mm)

500 N/m2

1000 N/m2

1500 N/m2

500 N/m2

1000 N/m2

1500 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

Stress Limit

Max. Cover Sheet Stress

4mm Panel Plate

Conguration
Panel Deection vs Support Spacing Aspect Ratio 3.0
Deection

4mm Panel Plate

Conguration
Panel Deection vs Support Spacing Aspect Ratio 3.0
Stress

HulaBond Design Aid Chart

HulaBond Design Aid Chart

120

160
150

110

140

100

Outer Cover Sheet Stress (N/mm2)

Maximum Panel Deection (mm)

130
120
110
100
90
80
70
60
50
40
30

90
80
70
60
50
40
30
20

20

10

10
0

0
500

600

700

800

900

1000

1100

1200

500

600

700

Support Spacing (mm)

800

900

1000

1100

1200

Support Spacing (mm)

500 N/m2

1000 N/m2

1500 N/m2

500 N/m2

1000 N/m2

1500 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

Stress Limit

Max. Cover Sheet Stress

15

HulaBond Design Aid Chart

Panel Deection vs Support Spacing

4mm Panel Plate

Conguration
Panel Deection vs Support Spacing Aspect Ratio 2.5
Stress

4mm Panel Plate

Conguration
Aspect Ratio 2.5
Deection

HulaBond Design Aid Chart

120

160
150

110

140
100

Outer Cover Sheet Stress (N/mm2)

Maximum Panel Deection (mm)

130
120
110
100
90
80
70
60
50
40
30

90
80
70
60
50
40
30
20

20
10

10

0
500

700

600

800

900

1000

1100

500

1200

600

700

800

900

1000

1100

1200

Support Spacing (mm)

Support Spacing (mm)

500 N/m2

1000 N/m2

1500 N/m2

500 N/m2

1000 N/m2

1500 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

Max. Cover Sheet Stress

Stress Limit

4mm Panel Plate

Conguration
Panel Deection vs Support Spacing Aspect Ratio 1.0
Stress

4mm Panel Plate

Conguration
Panel Deection vs Support Spacing Aspect Ratio 1.0
Deection

HulaBond Design Aid Chart

HulaBond Design Aid Chart

120

160
150

110

140

100

Outer Cover Sheet Stress (N/mm2)

Maximum Panel Deection (mm)

130
120
110
100
90
80
70
60
50
40
30

90
80
70
60
50
40
30
20

20

10

10
0

0
500

600

700

800

900

1000

1100

1200

500

600

700

Support Spacing (mm)

900

1000

1100

1200

500 N/m2

1000 N/m2

1500 N/m2

500 N/m2

1000 N/m2

1500 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

Stress Limit

16

800

Support Spacing (mm)

Max. Cover Sheet Stress

HulaBond Design Aid Chart

Panel Deection vs Support Spacing

4mm Panel Plate

HulaBond Design Aid Chart

Single Span

Panel Deection vs Support Spacing

Deection

4mm Panel Plate

Single Span
Deection

120

160
150

110

140
100

Outer Cover Sheet Stress (N/mm2)

Maximum Panel Deection (mm)

130
120
110
100
90
80
70
60
50
40
30

90
80
70
60
50
40
30
20

20
10

10
0

0
500

600

700

800

900

1000

1100

500

1200

600

700

Support Spacing (mm)

800

900

1000

1100

1200

Support Spacing (mm)

500 N/m2

1000 N/m2

1500 N/m2

500 N/m2

1000 N/m2

1500 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

Stress Limit

Max. Cover Sheet Stress

HulaBond Design Aid Chart

Panel Deection vs Support Spacing

4mm Panel Plate

HulaBond Design Aid Chart

Double Span

Panel Deection vs Support Spacing

Deection

4mm Panel Plate

Double Span
Deection

120

160
150

110

140
100

Outer Cover Sheet Stress (N/mm2)

Maximum Panel Deection (mm)

130
120
110
100
90
80
70
60
50
40
30

90
80
70
60
50
40
30
20

20
10

10

0
500

600

700

800

900

1000

1100

1200

500

600

700

800

900

1000

1100

1200

Support Spacing (mm)

Support Spacing (mm)

500 N/m2

1000 N/m2

1500 N/m2

500 N/m2

1000 N/m2

1500 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

Stress Limit

Max. Cover Sheet Stress

17

HulaBond Design Aid Chart

Panel Deection vs Support Spacing

6mm Panel Plate

HulaBond Design Aid Chart

Double Span

Panel Deection vs Support Spacing

Deection

4mm Panel Plate

Single Span
Deection

120

160
150

110

140
100

Outer Cover Sheet Stress (N/mm2)

Maximum Panel Deection (mm)

130
120
110
100
90
80
70
60
50
40
30

90
80
70
60
50
40
30
20

20
10

10
0

0
500

600

700

800

900

1000

1100

500

1200

600

700

800

900

1000

1100

1200

Support Spacing (mm)

Support Spacing (mm)

500 N/m2

1000 N/m2

1500 N/m2

500 N/m2

1000 N/m2

1500 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

Max. Cover Sheet Stress

Stress Limit

HulaBond Design Aid Chart

Panel Deection vs Support Spacing

4mm Panel Plate

HulaBond Design Aid Chart

Single Span

Panel Deection vs Support Spacing

Deection

6mm Panel Plate

Single Span
Stress

120

160
150

110

140
100

Outer Cover Sheet Stress (N/mm2)

Maximum Panel Deection (mm)

130
120
110
100
90
80
70
60
50
40
30

90
80
70
60
50
40
30
20

20
10

10
0

0
500

600

700

800

900

1000

1100

1200

500

600

700

900

1000

1100

1200

Support Spacing (mm)

Support Spacing (mm)

500 N/m2

1000 N/m2

1500 N/m2

500 N/m2

1000 N/m2

1500 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

Stress Limit

18

800

Max. Cover Sheet Stress

HulaBond Design Aid Chart

Panel Deection vs Support Spacing

6mm Panel Plate

Conguration
Panel Deection vs Support Spacing Aspect Ratio 1.0
Stress

6mm Panel Plate

Conguration
Aspect Ratio 1.0
Deection

HulaBond Design Aid Chart

120

160
150

110

140
100

Outer Cover Sheet Stress (N/mm2)

Maximum Panel Deection (mm)

130
120
110
100
90
80
70
60
50
40
30

90
80
70
60
50
40
30
20

20
10

10
0

0
500

600

700

800

900

1000

1100

500

1200

600

700

800

900

1000

1100

1200

Support Spacing (mm)

Support Spacing (mm)

500 N/m2

1000 N/m2

1500 N/m2

500 N/m2

1000 N/m2

1500 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

Max. Cover Sheet Stress

Stress Limit

HulaBond Design Aid Chart

Panel Deection vs Support Spacing

6mm Panel Plate

Conguration
Aspect Ratio 1.4
Deection

6mm Panel Plate

Conguration
Panel Deection vs Support Spacing Aspect Ratio 1.4
Stress

HulaBond Design Aid Chart

120

160
150

110

140
100

Outer Cover Sheet Stress (N/mm2)

Maximum Panel Deection (mm)

130
120
110
100
90
80
70
60
50
40
30

90
80
70
60
50
40
30
20

20
10

10
0

0
500

600

700

800

900

1000

1100

1200

500

600

700

800

900

1000

1100

1200

Support Spacing (mm)

Support Spacing (mm)

500 N/m2

1000 N/m2

1500 N/m2

500 N/m2

1000 N/m2

1500 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

Stress Limit

Max. Cover Sheet Stress

19

HulaBond Design Aid Chart

Panel Deection vs Support Spacing

6mm Panel Plate

Conguration
Panel Deection vs Support Spacing Aspect Ratio 2.0
Stress

6mm Panel Plate

Conguration
Aspect Ratio 2.0
Deection

HulaBond Design Aid Chart

120

160
150

110

140
100

Outer Cover Sheet Stress (N/mm2)

Maximum Panel Deection (mm)

130
120
110
100
90
80
70
60
50
40
30

90
80
70
60
50
40
30
20

20
10

10
0

0
500

600

700

800

900

1000

1100

500

1200

600

700

800

900

1000

1100

1200

Support Spacing (mm)

Support Spacing (mm)

500 N/m2

1000 N/m2

1500 N/m2

500 N/m2

1000 N/m2

1500 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

Max. Cover Sheet Stress

Stress Limit

HulaBond Design Aid Chart

Panel Deection vs Support Spacing

6mm Panel Plate

Conguration
Aspect Ratio 2.5
Deection

6mm Panel Plate

Conguration
Panel Deection vs Support Spacing Aspect Ratio 2.5
Stress

HulaBond Design Aid Chart

120

160
150

110

140
100

Outer Cover Sheet Stress (N/mm2)

Maximum Panel Deection (mm)

130
120
110
100
90
80
70
60
50
40
30

90
80
70
60
50
40
30
20

20
10

10
0

0
500

600

700

800

900

1000

1100

1200

500

600

700

900

1000

1100

1200

Support Spacing (mm)

Support Spacing (mm)

500 N/m2

1000 N/m2

1500 N/m2

500 N/m2

1000 N/m2

1500 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

Stress Limit

20

800

Max. Cover Sheet Stress

HulaBond Design Aid Chart

Panel Deection vs Support Spacing

6mm Panel Plate

Conguration
Panel Deection vs Support Spacing Aspect Ratio 3.0
Stress

6mm Panel Plate

Conguration
Aspect Ratio 3.0
Deection

HulaBond Design Aid Chart

120

160
150

110

140
100

Outer Cover Sheet Stress (N/mm2)

Maximum Panel Deection (mm)

130
120
110
100
90
80
70
60
50
40
30

90
80
70
60
50
40
30
20

20
10

10
0

0
500

600

700

800

900

1000

1100

1200

500

600

700

800

900

1000

1100

1200

Support Spacing (mm)

Support Spacing (mm)

500 N/m2

1000 N/m2

1500 N/m2

500 N/m2

1000 N/m2

1500 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

2000 N/m2

2500 N/m2

3000 N/m2

Stress Limit

Max. Cover Sheet Stress

21

3. SURFACE FINISHES
3.1 Painted
PVDF paint nish
HulaBond is available in 24 colours. Customised colours are available subject to enquiry. Paints are
prepared using resins, which are blended with modifying resins and inorganic, ceramic pigments to
provide a coating of considerable durability. The coatings applied to the HulaBond panel are:

Resistant to degradation by ultraviolet light

Resistant to colour change
Resistant to chalking
Resistant to erosion
Resistant to dirt pick-up
Resistant to fungal growth
Flexible, allowing post-coating forming
Low in maintenance costs for the life of the building

PVDF paint tests

Samples of the coil coated product used in the manufacture of HBS aluminium composite panels are
subject to the following tests:

Hot acetic acid salt spray

Pencil hardness
Film thickness
Reverse thickness
Adhesion (T-bend and tape)
Cross hatch
Humidity

(ASTM
(ASTM
(ASTM
(ASTM
(ASTM
(ASTM
(ASTM

B287)
D3363)
D1400)
D2794)
D1737)
D3359)
D2247)

3.2 Maintenance general

Rain washing is usually sufficient. Panels not exposed to rain should be cleaned every 6 months
using a mild neutral household detergent with a cloth or soft brush. More regular cleaning would be
advised for panels in heavily polluted industrial areas or panels on the coast.

22

4. MANUFACTURING AND INSTALLATION INFORMATION

4.1 HulaBond profile identification full size details

4.9

55.0

39.0

Cover
AXE0017 - 6.0m
52.0

85.0

40.0

30.9

30.0

52.0

Top Hat
AXE0001 - 6.0m

Top Hat
AXE0002 - 6.0m

28.0

30.0

30.0

14.0

13.5

8.0
14.0

14.0

20.5

4.0

Corner
AXE0007 - 6.0m

End
AXE0005 - 6.0m

End Link
AXE0006 - 6.0m
Balustrade
AXE0004 - 6.0m

8.0

25.5

Connector
AXE0008 - 6.0m

50.8x25.4x3.18mm
ALC018M - 6.0m

31.75x31.75x3.18mm
AL023M - 6.0m

25.4x25.4x1.52mm
ALD007M - 6.0m

23

4.2 HulaBond expressed grid fixing details overview

Out

Insulation if required

All fixings to be
confirmed by facade
engineer

Alternative

Number of fixings and brackets per panel

dependent on windload and panel sizes
Consult your facade engineer

All fixings to
be confirmed
by facade
engineer

Nominal 70

Insulation If Required

ALC018M

Nominal 70

AXE0003

AXE0017

Detail A

24

AXE0001
AXE0002

AXE0001
AXE0002

Blind rivets

Detail B
Alternative

Out

ALC018M

AXE0017

Insulation if required

4.3 HulaBond expressed grid fixing details full size details

All fixings to be confirmed

by facade engineer
AXE0003

AXE0001
AXE0002

Blind rivets

AXE0017

Detail A
Insulation if required

ALC018M

AXE0001
AXE0002

Detail B
Alternative

AXE0017

25

Out

4.4 HulaBond expressed grid fixing details full size details

Alternative

26

Out

ALC018M

4.5 HulaBond flush grid fixing details overview

G
AL023M

Last bracket pair < 50mm from stiffener tube

F
H
Expansion Joint

Number of fixings and brackets per panel

dependent on windload and panel sizes
Consult your facade engineer

AL023M

Flat plate sleeve splice

AR300M
50mm X 25
Stiffener tube
Folded 1mm
sheet over
panel junction

Insulation If Required
ALC018M

AR300M
AL023M

Expansion Joint

AXE0003

AR300M

AR300M

AL023M

AL023M

25.0

31.8

ALC018

31.8

All fixings
to be confirmed
by facade
engineer

100 Nominal

12.0

12.0

Detail E

Detail F
Alternative

27

4.6 HulaBond flush grid fixing details full size details

AXE0003

31.8

AR300M

25.0

AL023M

12.0

Detail E
ALC018M

AR300M

AL023M

12.0
Silicone and
polycord between
panels

28

Detail F
Alternative

4.7 HulaBond flush grid fixing details full size details

Insulation If Required

Silicone and
polycord between
panels

AL023M

29

4.8 HulaBond flush grid fixing details full size details

100 Nominal

Last bracket pair < 50mm from stiffener tube

ALC018M

AL023M

Flat plate sleeve splice

31.8

AR300M
50mm X 25
Stiffener tube

Folded 1mm sheet

over panel junction

AR300M
AL023M

Expansion Joint

30

AL023M

75.0

Fixing brackets
staggered in pairs

50.0

60.0

50.0

31.8
Number of brackets depends on Windload typically < 500mm

Fixing brackets
staggered in pairs

50.0

50.0

4.9 HulaBond flush grid fixing details

31.8

ALD007M

31

4.10 Rivets
Riveting of HulaBond panels
The information provided in this section is for guidance only. Where rivets are used for the structural fastening of
the HulaBond panel, we strongly recommend that future information is obtained from the manufacturers of the
rivet system used and that this be followed up with pre-production testing of the intended joint conguration.
Ultimately, it is the installers responsibility to ensure that the rivet system and joint geometry used, fully meet
the requirements of the task to be accomplished.
As a rule, riveted joints are used where welding is uneconomic or impossible or where the materials to be joined
are too thin. Riveting of HulaBond is also frequently used in combination with other xing systems, for example,
to provide clinching during hot air welding and to provide a temporary fastening during cure of an adhesive
bond.
A distinction can be made between solid riveting and blind or pop riveting. Solid riveting assumes there is
access to both sides of the assembly to be joined, so that rivets can be closed through use of a dolly or snap
tool. In instances where it is not possible to use solid rivets, the blind riveting system provides a practical
solution. Because access to both sides of the join is invariably limited, our focus is primarily on the use of blind
riveting systems.

Rivet systems
According to the type of closing head, the customary blind riveting process can be grouped under rivets
with break-off-shanks and those with pull/push-through-shanks. Rivets are available in a wide variety of
head shapes. Countersunk rivets should not be used in contact with the HulaBond panel. Some of the most
commonly used riveting systems are shown below:

Pop
blind rivet

Gesipa
blind rivet

Large flange
rivet

Fero
blind rivet

Chobert
blind rivet

Avdel
blind rivet

Tubtara
blind rivet (nut)

Sealed
rivet

Arrangements of rivets
Rivets can be positioned individually or rows or set over an area. Joints can be made by lap or butt. Lap and
single riveted butt joints have a tendency to bulge when subjected to a load, a disadvantage that can be
overcome through use of a double butt riveting technique.

Lap riveting
32

Butt riveting

Edge spacing
With too small edge spacing the edge may bulge or breakout. With too large edge spacing, the edge
may curl up.

Rivet diameter
It is hardly possible to give a general ruling on the choice of rivet diameter and rivet spacing. However, an
attempt has been made to provide guidelines, which optimise the rivet diameter d to sheet thickness s so
as to take full advantage of the maximum permissible shear strength of the rivet and the maximum permissible
pressure on the wall of the holes in the parts to be joined. Where possible, a large head rivet should be used
so as to avoid compression of the comparatively soft HBS aluminium composite panel.
Rivet shank length
For clinching a rivet successfully, the shank length must exceed the length of the rivet hole. Too short a shank
length may result in too small a head, insufcient clamping and possible loosening, whereas too long a shank
length may result in extended closure time, and lateral buckling of the rivet. Further information on selection of
an appropriate shank length should be obtained from your rivet supplier.
Riveted joint strength calculations
Where aluminium rivet are used, the transmission of load is largely through resistance to shear, and with aluminium
structural components, through the walls of the hole. The installer should check rivet strength requirements with
his rivet supplier.
Bearing pressure
Caution is recommended with thin and soft materials, since the edge of the hole can become upset or buckled
when subjected to a high load. Head shapes, which hold down the edge of the hole rmly, must be used,
or washers and cover strips must be provided. The permissible pressure at the hole wall is dened by the
permissible tensile stress of the joint components.
Workshop data

Marking off
Only lead or wax pencils should be used. Scribers acting on the surface panel may give rise to shallow ssures
which in subsequent use, especially with structural parts subjected to dynamic loading, can cause fractures. Use
of centre punches is acceptable only when the mark is drilled out.
Hole Clearance
The maximum permissible clearance, which depends upon rivet diameter, must not be exceeded. Greater play
causes unnecessary work of clinching and can make the strong, tightly-closed tting of the hole unreliable, or
with greater clamping lengths may even lead to bending of the shank. The maximum play between rivet shank
and rivet hole diameter is 0.1mm.
Rivet Hole
Rivet Holes are either punched and drilled or predrilled and reamed. Both ends must be cleanly deburred.
33

Surface treatment
Before assembly, the components must be thoroughly cleaned and cut edges smoothly deburred. Where
required, a zinc chromate primer should be applied to improve corrosion resistance and provide protection
from friction and notch effects.
Tacking
In order to prevent slipping or distortion of the parts to be riveted they should be held together at intervals by
tacking bolts or clamps. To keep tacking time to a minimum, it is advantageous to use quick gripping devices.
Riveting sequence
With long riveted seams stretching of the sheet due to upsetting occurs. In order that this stretching is evenly
distributed, rivets should be set using a sequence similar to that shown below. See diagram 1

Removal of faulty rivets

Under no circumstances must the rivet head be chiselled off and the shank punched out. The primary rivet head
is to be drilled as accurately as possible down to sheet level where after the residue of the head should be
carefully knocked away and the shank removed with a punch or pulled through from the reverse side.

Prevention of Contact Corrosion

Galvanic action can take place when aluminium is joined to an appreciably more noble metal, and the joint
exposed to moisture. The moisture acts as an electrolyte to form an electrical couple in which the aluminium,
as the less noble metal is prone to attack. The degree of attack depends upon the electrolyte and the type and
size of materials, which are in combination.
A couple can also form in an aluminium assembly where moisture has penetrated a crevice. In this way, more
oxygen can diffuse into moistened edge zone than into the interior zone thus giving rise to a potential difference,
the less aerated inner zone being always less noble than the more aerated outer zone, the former becoming
susceptible to attack.
In order to prevent contact corrosion suitable measures should be taken. Avoid pairing aluminium with more
noble metals. Minimise the relative area of the more noble material. Increase the electrical resistance and
electrical path length between contacting surfaces by treating with a zinc-chromate primer and application of
an insulation layer.

The insulating or sealing material used, must not absorb moisture, must be sufciently pressure proof. Painting
is adequate for simple cases. Zinc-chromate primers, bitumen paints, wash primers and rubber-chloride lacquers
are particularly suitable.
The use of copper, lead or mercury bearing paints and lacquers and application of graphite bearing lubricants/
greases are to be avoided.

34

5. FABRICATION
5.1 Routing and folding

2 mm

2 mm

2 mm min

0.8 mm
min

r = 2 - 3 mm

2 mm min

1.5 mm
min

0.8 mm
min

= 12mm for = 3-4mm

18mm for = 6-8mm

= 10mm for = 3-4mm

15mm for = 6-8mm

r = 2 - 3 mm

r=

Conventional, off-the-shelf equipment can be used including: universal, vertical and horizontal routing
machines.
To avoid pressure marks on the HulaBond surface when chucking the work pieces, wooded or plastic shims
should be used.
The most suitable cutters for both aluminium and HulaBond panels are high-speed steel or carbide tipped
cutters which have a wide tooth spacing, radiused and small grooves and small lip angles. These produce
perfect cuts under the following conditions:
High-speed steel (HHS) cutters:
Cutting speed max.
3000 m/min.
Feed max.
25m/min.
Carbide tipper (CT) cutters:
Cutting speed max.
Feed max.

5000 m/min.
30m/min.

The very simple method of routing makes the shaping ability of the HulaBond one of its major features. The
system allows shapes of various kinds and sizes to be formed out of the panel. A v-shaped groove is formed in
the panel allowing it to be bent without the use of a brake press.

35

5.2 Shearing
The shearing of HulaBond can easily be done using rotary shears or
a guillotine. It is however difcult to avoid light markings caused by
the rollers, or a slight drawing of the aluminium cover sheets on the
impact side caused by rolling over of the core material. To prevent
damage to the HulaBond panel, the hold down on the shear should
be tted with a shock-absorbing rubber pad.

5.3 Punching
Punching at-formed parts from an HulaBond is performed in the same
way as solid aluminium sheet, using the narrowest possible cutting gap
and evenly ground tools.

5.4 Planing and filing of edges

When using a jig saw on HulaBond, swarf is often left behind on the
edges of the sheet. For removing this swarf and nishing off the edges,
plane cutting les work best. Files with screenlike perforated roots, or
tools with very coarse or rasp-like cut are recommended for ling.
Through these perforations the swarf will be removed from the tool
surface.
The le prole should be from slightly to fully rounded. The proper
ling direction is lengthways along the edge. When clamping a sheet
of HulaBond between jaws, a shim of wood or plastic will protect the
surface against damage.

5.5 Drilling
The drilling of HulaBond can be achieved with twist drills normally used
for aluminium and plastic on machines common for metals.
Drill material: High-speed steel (HSS)
Tool geometry: Lip angle: 100 degrees 140 degrees
or spot facing cutter with centre-point.
Angle of twist 30 45 degrees
Working conditions: Cutting speed: 50 300 m/min.
Feed: 0.02 0.5 mm/rev.
By using high-speed, low feed, occasional raising of the drill and blowing with compressed air, the swarf will
be rapidly removed.

36

5.6 Cutting/sawing
A ne tooth tungsten-carbide tipped (CT) saw blade is the most suitable for cutting
HulaBond aluminium composite panel. E.g. A 60 tooth on 250mm diameter.

5.7 Curving/folding
Using the standard 1100-H18, HulaBond can be curved to the following minimum radii:
Panel thickness
4mm
6mm
Radius
175mm
275mm

6. INSTALLATION TIPS
1. Care must be taken to avoid damage of the panels during installation.
2. The plastic protective film must be left on during installation with only enough removed to allow
for fixing the panel in position. The protective film must only be removed once all wet trades are
off site.
3. Care must be taken to install all panels facing the same direction as per the direction indicators
on the panels
4. Allowance must be made for thermal expansion and contraction. See details under product
specification.
5. Check spanning capabilities with HBS technical staff prior to installation.
6. When using silicone, care must be taken to ensure that the surfaces being bonded are suitably
cleaned, (see manufacturer's instructions) to ensure maximum adhesion.

37

7. SILICONE BUILDING SEALANTS

7.1 Silicone building
Silicones are man made materials in which organic and inorganic substances are chemically combined The
elements silicon is present in sufcient amounts to affect the properties of the materials measurably.
There is a whole family of nished silicone products amongst the sealant family. A characteristic of silicone is its
resistance to heat, cold, chemicals and weathering, which makes it extremely widely used as a sealant, within
not only the building and glazing eld but also in general industry.
Silicone sealants are available in one-component and two-component form. In the one component form, they
are supplied in squeeze tubes, or in 310ml caulking cartridges which are used in a hand operated caulking
gun. The two-component sealants are less widely used because of their expensive application equipment and
reduced versatility.
The commercially available one-part silicone sealant is toothpaste-like in consistency and on being extruded
from the container, combines with moisture vapour to form a resilient rubber seal, which is virtually unaffected by
weathering and the elements. Naturally the drier the conditions (Highveld winter) the longer the sealant will take
to cure. (During curing temperature plays almost no part, however excessive heat may cause bubbles to occur
in the silicone, negating the manufacturers warranty. Please adhere to silicone manufacturers guidelines).
To cater for the various surfaces found within the building and construction industry, silicone sealants are available
in a wide range of colours. There are two basic types of curing systems available, the older acid curing system,
(acetoxy) and the neutral system, which tends to be a little softer and offers better movement capacity.
Acetoxy type
The consistency of this product allows it to be applied over a wide temperature range, allowing application in
any kind of weather.
Acetic acid is given off on exposure to the air which can cause irritation if working too close or in conned
spaces. Most acetoxy type sealants will develop a skin within 10 15 minutes.
The sealant will not sag or slump. NB: If used in conjunction with copper, e.g.: a fascia, there will be very limited
adhesion, possibly incomplete curing, due to the acetic acid.
Some typical properties
These are not intended for preparation of specications, but are used merely as a guide.
Weathering exposure after 10 hrs (In Atlas weatherometer,
change in hardness and colour)

None

Tack Free Time (at 25 degrees Celsius)

1 Hour

Movement capability in service

25%

Working time, minutes (Dependant on R.H, factor)

10-15

Ozone Resistance

Excellent

U.V. Resistance

Excellent

Elastic Recovery

100 degrees

Service Temperature range

-60C to approx 230C

38

Typical uses
This type of sealant is particularly effective for glazing butt and lap joints, all glass vision systems, curtain
walls and other glass, plastic and metal assemblies. It may be factory applied as the primer or as a secondary
seal in the components which are erected in situ before receiving the primary seal.
Limitations
Acetoxy type silicone sealants should not be applied to: concrete, marble, limestone, lead and lead
surfaces, galvanised iron and copper.
To surfaces which may bleed oils or solvents: - they include impregnated wood, curtain rubbers, or tapers
(e.g. Neoprene)
In totally conned spaces, as the sealant requires atmospheric moisture to cure.
To surfaces which will be painted, as a paint lm does not stretch with the extension of sealant. The paint
will not adhere strongly to the sealant.
If used with mill nish aluminium, extensive cleaning and priming must be done.
Joint design
A thin bead silicone sealant will accommodate more movement than a thick bead. The thin bead is therefore
more desirable. The ideal ratio of a joint width to depth is 2:1. Closed cell polyethylene is the recommended
bond breaker. The use of this bond breaker prevents undesirable three-sided adhesion.
Small curtain wall panels should allow a minimum width of 4 times the expected movement. If plastic is
involved, the coefcient of thermal expansion is greater and therefore necessitates larger joint dimensions.
In that case the neutral curing sealant or lower modulus product should be used.

8. PRODUCT TESTS
8.1 Tests
The following tests have been performed on the HulaBond Composite Panel.
1. Surface Fire Index

SABS 0177

2. Toxicity Index of Materials

Nes 713

3. Thermal Resistance (Winter conditions)

SABS

4. Thermal Resistance (Summer conditions)

SABS

5. Resistance to impact by hail

ASTM E822

6. Flexural properties

ASTM C393

7. Flatwise tensile properties

ASTM C297

8. Climbing drum peel test

ASTM D1781

9. Flatwise plane shear tests

ASTM C273
39

9. PHYSICAL PROPERTIES (4mm and 6mm HulaBond panels)

Standard 4mm panel

Non standard 6mm panel

Weight
Mass per unit area (kg/m 2)
5.51
2
Density (kg/m )
1380
Mechanical Properties of panel
Section Modulus - (cm 2/m)
1.54
Modulus of rigidity (EI) (kNm 2/m)
0.23
Minimum curving radius (mm)
175
Properties of aluminium outer cover sheet
Alloy
1100-H18
UTS (N/mm 2 Max.)
220
0.2% Proof strength (N/mm 2 Min.)
170
Elongation (in 50mm)
2% Min.
Max. permissable outer cover sheet stress
97
2
Modulus of elasticity (N/mm )
70000
Properties of polyethylene core
Shear Modulus (N/mm 2) (ASTM C273)
308
Core shear stress at failure (N/mm2) (ASTM C393)
1.90
Bond integrity
Flatwise plane shear (N/mm 2) (ASTM C273)
15.9
Flatwise tensile strength (N/mm 2) (ASTM 297)
13.0
Climbing drum peel strength (Nmm/mm) (ASTM D1781)
172
Thermal properties
Thermal resistance (Calc.) (m 2K/W)
0.0097
Coefficient of linear-thermal expansion mm/mk
0.024
Surface fire properties
Surface re index test on nishing materials (SABS 0177-111)
Spread of ame index
Nil
Heat contribution index
Nil
Smoke emission index
0.16
Surface re index
0.05
Class
1
Toxicity index on materials for air-conditioning ductwork (NES 713)
Smoke toxicity index (core only)
2 (low toxicity)

7.38
1230
2.53
0.57
275
1100-H18
220
170
2% Min.
97
70000
308
1.90
15.9
13.0
172
0.0172
0.024

Nil
Nil
0.16
0.05
1
2 (low toxicity)

Note smoke toxicity between:

0 and 3 indicates a low smoke toxicity
3 and 5 indicates an intermediate smoke toxicity.
Above 5 indicates a high smoke toxicity
Impact properties
Resistance to impact by hail (ASTM E822)
Stone diameter (mm)
25
50
75

40

Depth of Indentation
Velocity (m/s)
4mm panel (mm)
30.12
0.5
36.23
2.5
50.51
11.5

10. TYPICAL HULABOND REACTION TO CHEMICAL SPILLAGE

Chemicals

Concentration

HulaBond

Petrol, Gasoline

Concentrated

No change

Water

Concentrated

No change

Germicide

Concentrated

No change

Acid of vinegar

10%

No change

Ethanol

25%

No change

Ethanol

95%

No change

Parafn/Diesel oil

Concentrated

No change

Caustic potash sol.

10%

No change

Sea water (NaCI)

3.5%

No change

Soda Iye (NaOH)

10%

No change

Sodium carbonate

10%

No change

Hydrochloric acid

10%

No change

Nitric acid

10%

Colour change

Sulphuric acid

10%

No change

Typical washing agent

5%

No change

11. HULABOND SURFACE COATING PROPERTIES

Property
Coating thickness
Gloss
Pencil Hardness
Flexibility (T-bend)
Adhesion
Abrasion resistance
Mortar resistance
Humidity resistance
Boiling water resistance
Salt spray resistance
Acid resistance
Alkali resistance
Chalk resistance

ASTM
CNS8406
D523-89
D33633-74
D4145-83
D3359-87
D968-81
D605.2-90
D714-87
D3359-B
D117-94
D1308-87
D1308-87
D4214-89

Criteria
m
At 60
No Cracking
100C 2 hours
Falling sand 20 liters/mil
Test 7.7.2 / 24 hours
At 35C
Blister-10 Scribe-8

Result
>25.0
20 - 75
2H
2T no rift
No adhesion loss
50-80 KTR no crack
24 hours. Pat test
3000 hours. No blister
Passed
3000 hours. No blister
Passed
Passed
Max. chalk = rating of 8
41

SOLID COLOUR SERIES

42

04 Pure White

08 Ivory White

09 Deep Blue

10 Green

11 Red

13 Yellow

14 Black

15 Light Blue

1003 Milk White

1006 Grey

1014 Dark Green

1017 Finland Green

1020 Orange

1046 Grass Green

1052 Pink

As a result of printing processes, this colour chart is not an exact replica of actual product colours.

HulaBond Aluminium Composite Panel

METALLIC COLOUR SERIES

01 Glossy Silver

02 Silver Grey

03 Champagne Gold

05 Gold

06 Jade Green

07 Metallic Grey

18G Gold Brushed

18S Silver Brushed

1034 Copper

As a result of printing processes, this colour chart is not an exact replica of actual product colours.

43

NUKLIP

HULABOND

COASTAL

ARM 30176

Jhb (011) 626 3332 / 3337

Durban (031) 564 7350
Cape Town (021) 552 5884
PE (041) 403 1400