January 2007
2007 MASTER FORMAT™ SECTION 08 45 23
(previously section 08950)
INSULATED
TRANSLUCENT FIBERGLASS SANDWICH PANEL UNIT SYSTEM
PART 1
- GENERAL
1.1
SUMMARY
A.
Section includes the
insulated translucent sandwich panel system and accessories, factory unitized,
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.
4.
Thermal break windows
(Optional)
5.
Screens (Optional)
6.
Louvers (Optional)
7.
Opaque panels (Optional)
B.
Related Sections:
1.
Structural
Steel/Concrete/Rough Carpentry: Section ________
2.
Masonry: Section ________
3.
Flashing and 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.
Performance for Windows
(AAMA/NWWDA 101/I.S.2) (Optional)
m.
Class 1 Fire Approval (FM
4881) (Optional)
n. 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 be 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
1200°F 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.
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 to be ________
(selected from manufacturer's standard colors).
2.5
WINDOWS (OPTIONAL)
A.
Windows shall be designed
specifically for inclusion in the translucent panel unit wall system and
factory unitized to panels.
1.
Windows shall be of the
following type(s):
a. Project-out bottom
b. Project-in top
c. Fixed lite
d. Egress
B.
Performance: Windows
shall pass requirements of AAMA/NWWDA 101/I.S.2
.
1.
F-C 55 and AP-C 55 windows
shall pass requirements at 82.5 psf uniform load with air infiltration at 1.57
psf of .09 cfm/ft and no water entry at 8.25 psf.
2.
F-HC 70 windows shall pass
requirements at uniform load of 105 psf, air infiltration at 6.24 psf of .01
cfm/ft and no water entry at 12 psf.
3.
AP-HC 70 windows shall pass
requirements at uniform load of 105 psf, air infiltration at 6.24 psf of .03
cfm/ft and no water entry at 10.5 psf.
4.
AP-HC 55 windows shall pass
requirements at uniform load of 82.5 psf, air infiltration at 6.24 psf of .03
cfm/ft and no water entry at 8.25 psf.
C.
Construction: All window
frame members shall be of heavy guage 6063-T5 extruded aluminum with a
thermal break. Frame sections shall be
coped and joined by stainless steel screws at each corner. All
joints exposed to the weather shall be
sealed with an elastic compound. All openings shall be double
weather-stripped using T-slot bulb
gaskets to insure minimum air infiltration.
1.
Operating sash shall be
hollow extruded design, mitered and joined with heavy reinforcing corners and
marine glazed using continuous wrap around extruded vinyl glazing channel to
reduce sound transmission and insure water tightness.
a.
AP-HC 55 sash shall be glazed
with an expanded EPDM closed cell sponge gasket to exterior,
with aluminum glazing bead and a driven EPDM
wedge gasket to the interior for rapid removal
and replacement.
2.
Fixed lites shall be inside
glazed with neoprene glazing splines for rapid removal and replacement.
D.
Hardware:
1.
Hinges on operating windows
shall be four (4) bar stainless steel with adjustable friction blocks.
2.
Locking hardware shall be of
cam lever design and shall be made of cast white bronze.
E.
Glazing:
1.
Commercial (C) windows shall
be glazed with ________ (1/4”, 5/8”, 7/8” single, double,
triple) (insulated) glass.
a.
(Optional) 5/8”
translucent panels with ________ U-factor and faces to match 2-3/4”
translucent
panels.
2.
Heavy commercial (HC) windows
shall be glazed with 1” double (triple) insulated glass.
a.
(Optional) 1”
translucent panels with ________ U-factor and faces to match 2-3/4”
translucent
panels.
3.
Refer to section 08800
– Glazing
F. Finish of exposed aluminum:
1.
Manufacturer’s factory
applied finish which meets the requirements of AAMA 2604. Color to be ________
(selected from manufacturer’s standards).
2.
Clear anodized (Optional)
3.
Mill (Optional)
G. Screens (Optional)
1.
Constructed of hollow box
extruded frame.
2.
Mitered with reinforcing
corners mechanically joined.
3.
Screens for project-out
windows shall be equipped with wickets for access to handles.
4.
Screen cloth shall be of
18-16 aluminum mesh and held in place by spline.
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.
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