January 2007
2007 MASTER FORMAT™ SECTION 08 45 23
(previously section 08950)
INSULATED
TRANSLUCENT FIBERGLASS SANDWICH PANEL SYSTEM
PART 1
- GENERAL
1.1
SUMMARY
A.
Section includes the
insulated translucent sandwich panel system as shown and specified. Work
includes providing and installing:
1.
Flat (curved) factory
prefabricated structural insulated translucent sandwich panels.
2.
Aluminum installation system.
3.
Aluminum sill flashing.
B.
Related Sections:
1.
Structural
Steel/Concrete/Rough Carpentry: Section ________
2.
Masonry: Section ________
3.
Flashing & Sheet Metal:
Section ________
4.
Sealants: Section ________
5.
Glazing: Section ________
1.2
SUBMITTALS
A.
Submit manufacturer’s product data. Include construction details,
material descriptions, profiles and finishes of components.
B.
Submit shop drawings. Include elevations, details, dimensions and
attachments to other work.
C.
Submit manufacturer's color charts showing the full range of colors
available for factory finished aluminum.
1.
When requested, submit samples for each
exposed finish required, in same thickness and material indicated for the work
and in size indicated below. If finishes involve normal color variations,
include sample sets consisting of two or more units showing the full range of
variations expected.
a.
Sandwich panels: 14" x 28" units
b. Factory finished aluminum: 5” long sections
D.
Submit Installer Certificate, signed by installer, certifying compliance
with project qualification requirements.
E.
Submit product test reports from a qualified independent testing
agency indicating each type and class of panel system complies with the project
performance requirements, based on comprehensive testing of current products. Previously completed test reports will be
acceptable if for current manufacturer and indicative of products used on this
project.
1.
Test reports required are:
a. Flame Spread and Smoke Developed (UL 723)
– Submit UL Card
b. Burn Extent (ASTM D-635)
c. Color Difference (ASTM D-2244)
d. Abrasion/Erosion Resistance (ASTM D-4060)
e. Impact Strength (UL 972)
f. Bond Tensile Strength (ASTM C-297 after aging
by ASTM D-1037)
g. Bond Shear Strength (ASTM D-1002)
h. Beam Bending Strength (ASTM E-72)
i.
Insulation U-Factor
(NFRC-100)
j.
NFRC System Certification
k. Condensation
Resistance Factor (AAMA 1503)
l. Class 1 Fire
Approval (FM 4881) (Optional)
m. Blast Analysis and Testing of Translucent Sandwich Panels Demonstrating Equivalent Performance to 1/4" Laminated Glass per DoD UFC 4-010-01 (Optional)
F.
Submit current documentation
indicating regular, independent quality control monitoring under a nationally
recognized building code review and listing program.
1.3
QUALITY ASSURANCE
A.
Manufacturer's Qualifications
1.
Material and products shall
be manufactured by a company continuously and regularly employed in the
manufacture of specified materials for a period of at least ten (10)
consecutive years and which can show evidence of those materials being
satisfactorily used on at least six (6) projects of similar size, scope and
location. At least three (3) of the projects shall have been in successful use
for ten (10) years or longer.
2.
Panel system must be listed
by the International Code Council – Evaluation Service (ICC-ES) which
requires quality control inspections and fire, structural and water
infiltration testing of sandwich panel systems by an approved agency.
3.
Quality control inspections
and required testing shall be conducted at least once each year and shall
include manufacturing facilities, sandwich panel components and production
sandwich panels for conformance with “Acceptance Criteria for Sandwich
Panels” as regulated by the ICC-ES.
B.
Installer’s
Qualifications: Installation shall be by an experienced installer, which
has been in the business of installing specified panel systems for at least
five (5) consecutive years and can show
evidence of satisfactory completion of projects of similar size, scope and
type.
C.
Performance Requirements: The
manufacturer shall be responsible for the configuration and fabrication of the
complete panel system.
1.
When requested, include structural
analysis data signed and sealed by the qualified professional engineer responsible
for their preparation.
1.4
DELIVERY STORAGE AND HANDLING
A.
Deliver panel system, components and materials in manufacturer's
standard protective packaging.
B.
Store panels on the long
edge, several inches above the ground, blocked and under cover in accordance
with manufacturer's storage and handling instructions.
1.5
WARRANTY
A.
Submit manufacturer's and installer's written warranty agreeing to
repair or replace panel system work which fails in materials or workmanship
within one (1) year of the date of delivery. Failure of materials or
workmanship shall include leakage, excessive deflection, deterioration of
finish on metal in excess of normal weathering and defects in accessories,
insulated translucent sandwich panels and other components of the work.
(Contact local representative for extended warranty periods.)
PART
2 - PRODUCTS
2.1
MANUFACTURER
A.
Kalwall Corporation, tel:
(800) 258-9777 – fax: (603) 627-7905 – email: info@kalwall.com
2.2
PANEL COMPONENTS
A.
Face Sheets
1.
Translucent faces:
Manufactured from glass fiber reinforced thermoset resins, formulated
specifically for architectural use.
a. Thermoplastic (e.g. polycarbonate, acrylic) faces
are not acceptable.
2.
Flammability of interior face
sheets:
a.
Flamespread: Underwriters
Laboratories (UL) listed, which requires periodic unannounced retesting, with
flamespread rating no greater than 50 (20) and smoke developed no greater than
250 (200) when tested in accordance with UL 723.
b.
Burn extent by ASTM D-635
shall be no greater than 1”.
c.
Face sheets shall not deform,
deflect or drip when subjected to fire or flame.
d.
Face sheets shall not
delaminate when exposed to 200°F for 30 minutes per IBC and NBC (300°F
for 25 minutes per UBC and SBC).
3.
Weatherability of exterior
face sheets:
a.
Color stability: Full
thickness of the exterior face sheet shall not change color more than 3.0 CIE
Units DELTA E by ASTM D-2244 after 5 years outdoor South Florida weathering at
5 degrees facing south, determined by the average of at least three (3) white
samples with and without a protective film or coating to ensure long-term color
stability. Color stability shall be unaffected by abrasion or scratching.
b.
Erosion barrier: Exterior
face shall have a permanent glass erosion barrier embedded beneath the surface
to provide long-term resistance to reinforcing fiber exposure. Exterior face
surface loss shall not exceed .7 mils and 40 mgs when tested in accordance with
ASTM D-4060 employing CS17 abrasive wheels at a head load of 500 grams for 1000
cycles. Sacrificial surface films or coatings are not acceptable erosion
barriers.
4.
Appearance:
a. Exterior face sheets: Smooth, 0.070” thick
and _______ in color.
b. Interior face sheets: Smooth, 0.045” thick
and _______ in color.
c. Face sheets shall not vary more than +/- 10% in
thickness and be uniform in color.
5.
Strength: Exterior face sheet
shall be uniform in strength, impenetrable by hand held pencil and repel an
impact equal to 70 (230) ft. lbs. without fracture or tear when impacted by a
3-1/4” diameter, 5 lb. free-falling ball per UL 972.
B.
Grid Core
1.
Thermally broken (aluminum)
I-beam grid core shall be of 6063-T6 or 6005-T5 alloy and temper with
provisions for mechanical interlocking of muntin-mullion and perimeter. Width
of I- beam shall be no less than 7/16”. The I-beam grid shall be
machined to tolerances of not greater than +/- .002”.
2.
Thermal break: Minimum
1”.
C.
Laminate Adhesive
1.
Heat and pressure resin type
adhesive engineered for structural sandwich panel use, with minimum 25-years
field use. Adhesive shall pass testing requirements specified by the
International Code Council
“Acceptance Criteria for Sandwich Panel Adhesives.”
2.
Minimum tensile strength of
750 PSI when the panel assembly is tested by ASTM C-297 after two (2) exposures
to six (6) cycles each of the aging conditions prescribed by ASTM D-1037.
3.
Minimum shear strength of the
panel adhesive by ASTM D-1002 after exposure to five (5) separate conditions:
a. 50% Relative Humidity at 73° F: 540 PSI
b. 182° F: 100 PSI
c. Accelerated Aging by ASTM D-1037 at room
temperature: 800 PSI
d. Accelerated Aging by ASTM D-1037 at 182° F:
250 PSI
e. 500 Hour Oxygen Bomb by ASTM D-572: 1400 PSI
2.3
PANEL CONSTRUCTION
A.
Provide sandwich panels of
flat fiberglass reinforced translucent face sheets laminated to a grid
core of mechanically interlocking thermally broken (aluminum) I-beams. The
adhesive bonding line shall be straight, cover the entire width of the I-beam
and have a neat sharp edge.
1.
Thickness: 2-3/4”
2.
Light transmission: ________.
3.
Solar heat gain coefficient:
________.
4.
U-factor by NFRC certified
laboratory:(0.23, 0.14, 0.10, 0.05) thermally broken [OR (0.53, 0.29, 0.22, 0.18) aluminum I-beam].
a. Complete insulated panel system shall have NFRC
certified U-factor of ________.
5.
Grid pattern: Nominal
12” x 24” (8” x 20”, 12” x 12”, other)
shoji (reverse shoji, square, staggered)..
B.
Panels shall deflect no more
than 1.9” at 30 psf in 10’-0” span without a supporting frame
by ASTM E-72.
C.
Panels shall withstand
1200ºF fire for minimum one (1) hour without collapse or exterior flaming.
D.
Thermally broken panels:
1.
Minimum Condensation
Resistance Factor of 80 by AAMA 1503 measured on the bond line.
2.
Minimum CRF of 90 at center
of grid cell.
E.
(OPTIONAL) Panel system
shall be a Factory Mutual (FM) tested and approved Class 1 wall system in
accordance with FM 4881.
F.
(OPTIONAL) Panels shall demonstrate performance equivalent to 1/4" laminated glass under blast loading as specified in DoD UFC 4-010-01.
2.4
BATTENS AND PERIMETER CLOSURE
SYSTEM
A.
Closure system: Extruded
aluminum 6063-T6 and 6063-T5 alloy and temper clamp-tite screw type closure
system.
1.
(Optional) Thermally broken
perimeter system shall have a urethane bridge.
2.
(Optional) Perimeter system
shall be factory prefabricated “Superbreak” as shown on drawings.
3.
(Optional) Curved closure
system may be roll formed.
B.
Sealing tape: Manufacturer's standard, pre-applied to closure system at
the factory under controlled conditions.
C.
Fasteners: 300 series
stainless steel screws for aluminum closures, excluding final fasteners to the
building.
D.
Finish: Exposed aluminum to
be manufacturer’s factory applied finish that meets the performance
requirements of AAMA 2604. (Mill)
1. Color ________ (selected from manufacturer's standard colors).
PART
3 - EXECUTION
3.1
EXAMINATION
A.
Examine substrates, supporting structure and installation conditions.
Do not proceed with panel
erection until unsatisfactory conditions have been corrected.
3.2
PREPARATION
A.
Metal Protection:
1.
Where aluminum will contact dissimilar metals, protect against galvanic
action by painting contact surfaces with primer or by applying sealant or tape
recommended by manufacturer for this purpose.
3.2 PREPARATION
(continued)
2.
Where aluminum will contact concrete or masonry, protect against
corrosion by painting contact surfaces with bituminous paint or method
recommended by manufacturer.
3.
Where aluminum will contact pressure-treated wood, separate dissimilar
materials by methods recommended by manufacturer.
3.3
INSTALLATION
A.
Install the panel system in accordance with the manufacturer's
installation recommendations and approved shop drawings.
1.
Anchor component parts securely in place by permanent mechanical
attachment system.
2.
Accommodate thermal and mechanical movements.
3.
Set perimeter framing in a full bed of sealant compound, or with joint
fillers or gaskets to provide weather-tight construction.
B.
Install joint sealants at perimeter
joints and within the panel system in accordance with manufacturer's
installation instructions.
3.4
CLEANING
A.
Clean the panel system inside and outside, immediately after
installation, according to manufacturer's written recommendations.
END OF SECTION
08 45 23