• Cladding panels are a kind of material used to cover the exterior and interior surfaces of buildings and other uses.

• Filled metal panels are composite panels consisting of two layers of aluminum, including a filler.

• The aluminum panels consist of several layers whose thicknesses vary according to the customer's request.

1. Multiple sizes and lengths

2. Multicolours

3. Light weight on buildings, which reduces the cost of foundations

4. Ease of renewal and change of shape using metal constructions

5. Durable performance

6. Covered with a protective layer on the surface of the cladding to prevent damage to the surface during the process of storage, transportation and installation

7. Speed of implementation and installation

8. Acoustic insulation

9. Thermal insulation in building facades

10. Anti-flaking and easy to maintain

11. Resistant to various weather conditions

12. Saves on cost

13. Easy to clean and polish

14. Environmentally friendly

15. It gives an aesthetic shape to the building

16. Easy to cut and shape

17. Flexible, accepts bending and twisting

18. Cladding facades have a long-life span of up to 50 years.

19. The stability of the paint layer without changing the colour.

The width of the cladding panels is fixed: 1.25 or 1.50, and the width of the panel can reach 2 mm according to the customer's request and with special machines. The lengths can be controlled according to demand.

The most common sizes are the following:

• 1.25*3.20

• 1.25*4.50

• 1.25*5.80

• 1.50*3.50

• 1.50*4.20

• 1.50*5.80

As for the thicknesses of the panels differ according to the use and also according to the request of the customer, which are as follows:

2 mm, 3 mm, 4 mm, 5 mm, 6 mm, but the most common for external cladding is 4 mm thick.

1. Protective film

2. Coated aluminum sheet

3. Bonding film

4. Core material

5. Back coated aluminum sheet

• The outer surface of the cladding panels shall be protected with a self-adhesive protective film with a thickness of no less than 60 microns with the panels having a thickness of 4 mm to protect it from scratching and any possible damages during processing, storage and installation.

• The protective film bears the name of the panel manufacturer, the direction of the installation arrow, and the warranty period for the panels.

• Guarantee the external protection film against the sun from 45 days to 6 months after installation, according to the temperature to which the protection film is exposed and the quality of the film. The temperatures and climate in which the raw materials are used must be taken into account to determine the specific type and schedule for the project.

• There are two types of it that differ according to the base of the adhesive, namely:

Water-based adhesive acrylic film and rubber adhesive film.

ACRYLIC FILM WITH WATER BASE:

• The strength of the adhesion is determined according to the outer layer of the paint

• The sooner the protective film is removed from the panels (as soon as possible), the easier it will be to remove

• These types can be used for projects that require very quick and effortless removal

• The period of removal does not exceed 45 days

• It is possible that the sticky acrylic film will leave traces on the surface in case of delay in removing it (it leaves some traces on the board).

RUBBER ADHESIVE FILM:

• It is easy to stick to panels

• It has a high quality of adhesive

• The adhesive film can be removed from the rubber after a long period of up to 6 months in places with high temperatures

• The rubber adhesive film does not leave traces on the surface

There are many types of paints available to be used to paint aluminum coils for the manufacture of aluminum insulated panels (PVDF coating - FEVE coating - HDPE coating).

The coating layer is composed as follows:

Liquid Coating:

It is a liquid plastic material that can be applied as a continuous layer on many surfaces, including aluminum, for the purpose of protection and aesthetic appearance.

Powder Coating:

It is a layer of powder that is sprayed on the board to turn it into a solid, adherent, solid state on the surface of the board after passing through four stages:

1. Oxidation

2. Polymerization

3. Polymerization additives

4. Reticulation

- The final layer is called the Dry film

The coating consists of four main components:

1. Binder or Resin

2. Pigment and fillers

3. Solvents

4. Additives

The most famous major resins used in the paint industry are:

• Polyester

• Epoxy

• PVDF

• PVC

1. PVDF

One of its most important features is the degree of its granularity, that is, the ability to combine its granules into a group of grains (the bonding strength between its molecules is high). Its main chemistry is acrylic (20-30%) with polyvinyl difluoride (70-80%).

Composition of PVDF Coating:

The paint consists of two layers (base + color) if the color does not contain metallic pigments or if the pigment depends on mica rocks.

First Layer:

It is a metal corrosion resistant primer with a minimum thickness of 5 microns.

Second Layer:

1- It is the color approved by the customer, and its minimum thickness is 25 microns, so that the total thickness of the base and color is 30 microns as a minimum.

2- A third layer of transparent paint with a thickness of up to 10 microns is used if the color chosen by the customer contains mineral pigments. Therefore, the total thickness of the system consisting of 3 layers is 40 microns as a minimum.

2. FEVE Coating:

• Resin-based (FEVE) powder coatings provide exceptional weatherability, corrosion, chemical resistance and environmental benefits These powder coating resins do not require a solvent and thus eliminate VOCs within detectable limits.

• FEVE fluoropolymer-based coatings have excellent abrasion resistance and weatherability, which provides protection from UV rays, wind, rain, dirt and chemicals. This coating technology also provides long-term glossiness and color retention for 30 years or more due to its long life.

FEVE coating composition:

FEVE resins are copolymers with interchangeable perfluoro ethylene and vinyl ether repeat units. In contrast to pure fluoropolymers, FEVE resins range from high-performance polymers to high-performance resins for coatings.

3. HDPE Coating:

• High Efficiency Polyethylene (HDPE) resin is a thermoplastic made from ethylene polymers.

• Polymerization occurs under low pressure conditions with the support of catalysts.

• HDPE grades are used in a variety of processing technologies such as extrusion, blow molding, injection and rotational casting.

• High Density Polyethylene (HDPE) is the largest family of polyethylene products.

aluminum coil:

• Roll widths start from 1 meter, the standard size is 1.25 meters, and the maximum width that can be used is 2 meters (using high-efficiency machines).

• The lengths of the coils are determined according to the weight used (i.e., according to the weight that the machine can bear).

• Aluminum thickness is one of the factors that must be relied upon in determining the price, as the greater the thickness, the greater the resistance of the panels to weather factors and the pressures on them.

aluminum alloy:

• Aluminum ingot is a mixture of most of its components is pure aluminum with 99% of the alloy components and 1% is other additives that improve the quality of the alloy and according to the required use

• The additives are (silicon - iron - magnesium - manganese - phosphate - copper) and according to the nature of the alloy used (for example, additives in alloys that need ductility lag behind additions in alloys that need hardness).

• There are famous alloys in the field of aluminum plates, including alloy 1100, alloy class 3000 (3003-3105), and alloy class 5000.

ALLOY 1100 PURE ALUMINUM:

The XXX1 series of alloys are made of aluminum of 99% or more purity, electrically and heat conductive, good formability, and corrosion resistant.

ALLOY 3003 Aluminum-Manganese Alloy:

The main ingredient in the XXX3 series alloy is manganese, usually with a smaller amount of magnesium.

ALLOY 3105 aluminum-manganese alloy:

well formable and not heat treatable.

ALLOY 5005. Aluminum-Magnesium Alloy:

The main ingredient in XXX5 series alloys is magnesium. This alloy is strong, weldable and resistant to marine corrosion.

• It is a polyethylene polymer whose thickness is determined according to the thickness of aluminum and according to the total thickness of the panels to be produced. It is in the general case for producing 4 mm panels with two layers of aluminum 0.5 from the top and from the bottom. The preferred thickness is 50 microns 0.0050 mm.

The filler material for aluminum sheets is divided into several types, namely:

• Low Density Polyethylene

• Polyethylene alloy materials that pass the B. fire resistance test

• Metal materials in a large proportion mixed with a little polyethylene and organic materials, which are organic materials, which are non-combustible materials that pass the fire resistance test, class A2

• It is a filler of metallic materials with a large percentage of up to 95% mixed with a little polyethylene and organic materials, which is non-combustible and exceeds the A2 fire test and comes in the form of rolls.

• The main components of the filler 4% polyethylene 1% organic materials 95% mineral materials.

Aluminum plate: The back aluminum plate is no different from the front plate, it must match the front plate's alloy and thickness.

Paint layer: to preserve the aluminum plate, which is a protective paint layer.

Examples:

7-micron polyester coating on the backing aluminum plate that helps protect the ACP panels from potential corrosion problems that may come from the back side of the corrosive

PE Coating: PE Coating provides sufficient moisture protection as it is a widely used plastic material developed in a large number of grades such as HDPE, LDPE EVOH, etc.

2PET coating: PET coating provides an increase in the life of any building material for many years and keeping it new and certainly contributes to the safety of the building due to its high resistance to heat and electricity.

1- Extrusion machine:

The PE material is conveyed by feeding into the spiral cylinder of the extrusion machine when it is molten at high temperature, after extrusion process the thickness of the filler plate can be adjusted by T-mold.

2- Rolling mill:

The rolling mill is for cold pressing molding to obtain the core material for the subsequent compound.

3- jaw machine:

Single wall jaw machine with upper and lower sliding parts combined with high-precision magnetic powder tension control system to ensure the tension requirements of continuous production and stable transfer of color coating of aluminum coil to the composite machine unit.

4- Compound machine unit:

At the appropriate temperatures, the initial installation of the PE core plate with the upper and lower aluminum plates at the beginning, then setting the installed machine unit at the appropriate temperature, then the tractor pressing rolling and the final rolling are completed.

5- Cooling unit:

The composite board is cooled by the air intake used to adjust the training air of the training unit, which ensures that the board is cooled to the normal temperature in a stable pattern curve after passing the compound machine unit, meanwhile achieving the required temperature to cover the board with protective tape later.

6- Cut-to-length sensor:

After composite panel cooling, flattening and edge trimming, the cutting sensor with respect to length generates a feedback signal that signals the automatic shear tongs to move synchronously in the conveying direction and automatically return to the original position after cutting, so that the dimensional accuracy of the cutting is guaranteed.