ALUCORE

Overview


Product Overview

Based on the principles of nature, ALUCORE® is an aluminium honeycomb core composite material with high rigidity and extremely low weight. It is designed for high wind load applications and/or where large unsupported spans are required.

ALUCORE® uses a viscoplastic adhesive bond which results in better peel strength and permits additional fabrication options such as bending.

ALUCORE® is manufactured in a continuous coil process and its Fluoropolymer  (PVDF or FEVE) or polyester stove – lacquered finish provides an extremely high weather resistant surface.

ALUCORE® is available in a wide range of dimensions and finishes.

 Benefits

  • Product quality
  • Does not become brittle-hard
  • Tough and resilient properties
  • Excellent peel strength
  • Ideal for a range of applications in transport and industrial production
  • Easy to process
  • Different thickness and formats

Applications

It is the combination of formability, flatness, stability and weather resistance that characterizes this material. Due to its composite structure, ALUCORE® can take on many different shapes. Its perfect formability does not affect its stability and flatness. The high rigidity of the panel remains.

Rail and Transport Vehicle Construction

Today’s strict economic conditions demand the implementation of sustainable structural materials in the field of transport that are lightweight, stable and fully recyclable.

ALUCORE® it all of the above and more, its excellently suited for special interior cladding, as well as for wall cladding and roofing in train construction, cabins, doors and trucks.

Interior Construction

Whether for clean rooms, partitions, light-weight containers, cabins for machine tools, lifting platforms, lifts, etc… ALUCORE® is the ideal material for industrial applications.

Simple processing using tools on site, the possibility of flexible adaption of the modular dimensions and fixation method offer the construction team streamlined installation.

Application Examples

Specifications


ALUCORE® is an aluminium sandwich-type panel with high rigidity and extremely low weight. In contrast to conventional honeycomb composite materials, the system components, i.e. the aluminium core and the coil-coated aluminium cover sheets are bonded in a continuous process.

The advantages are product quality and surface evenness. The material does not become brittle hard but shows tough and resilient properties and an excellent peel strength.

Following in the footsteps of the ALUCOBOND® trademark, ALUCORE® is the ideal material for a host of applications in transport, architecture or industrial production.

Alucore tech processAlucore tech procfess

The honeycomb core consists of aluminium foils made of the alloy AIMn (EN AW 3003) cell size b: approx. 6.3-12.7 mm.

The cover sheets of the panels consist of corrosion-resistant Peraluman alloys and may be used in a decorative or functional manner, depending on the purpose of application.

Technical Overview

Thickness 6mm 10mm 10.5mm 15mm 20mm 25mm 40mm
Aluminium Skin Thicknesses 1.00mm thick skin to front side
0.5mm thick skin to reverse face 1.00mm skins to reverse face
Mass                                (kg/m2) 4.9 5.3 6.4 7.0 7.4 7.8 7.5
Section Modulus Z  (mm3  103/m) 2.63 4.63 9.52 14.00 19.00 24.00 38.00
Moment Of Inertia  I (mm6 104/m) .0102 .0313 .0500 .1050 .1900 .3000 .7600
Rigidity             EI (kNm2/m) 0.71 2.19 3.50 7.55 13.90 22.17 58.52
Alloy Architectural / Facade Panels EN5005A  AlMg1 H42
Industrial / Transport Panels EN5745  AlMg3 H42
Modulus of Elasticity    E      (MPa) 70,000
Tensile Strength of Cover Sheets Architectural / Facade Panels = 125 MPa
Industrial / Transport Panels  = 220 MPa
0.2% Proof stress                ( MPa) Architectural / Facade Panels = 74 MPa
Industrial / Transport Panels = 130 MPa
Maximum Design Stress (Permissible) Architectural / Facade Panels = 48.5 MPa
Industrial / Transport Panels = 79 MPa
Linear Thermal Expansion 2.4 mm /m at 100oC temperature difference
Temperature Resistance -50  –  +80deg Celsius
Core cell size 6.3 mm 12.7 mm
Cell density 65 kg/m3 42 kg/m3
Bare compressive strength 2.5 – 4 MPa 1.5 MPa
Surface Finish Industrial / Transport – Coil coated Modified Polyester both sides  (Platinum White)
Architectural / Façade – Coil coated Fluoropolymer (PVDF or FEVE)
Panel widths 1250mm & 1500mm widths only
Panel Lengths From 2,000mm up to a maximum of 13,000mm
Industrial / Transport – Minimum of 500m2 per nominated length
Architectural / Façade – Minimum 1,000m2 per nominated length

Processing Methods

Tech & Installation


ALUCORE® is an aluminium sandwich-type panel with high rigidity and extremely low weight. In contrast to conventional honeycomb composite materials, the system components, i.e. the aluminium core and the coil-coated aluminium cover sheets are bonded in a continuous process.

The advantages are product quality and surface evenness. The material does not become brittle hard but shows tough and resilient properties and an excellent peel strength.

Following in the footsteps of the ALUCOBOND® trademark, ALUCORE® is the ideal material for a host of applications in transport, architecture or industrial production.

Alucore tech processAlucore tech procfess

The honeycomb core consists of aluminium foils made of the alloy AIMn (EN AW 3003) cell size b: approx. 6.3-12.7 mm.

The cover sheets of the panels consist of corrosion-resistant Peraluman alloys and may be used in a decorative or functional manner, depending on the purpose of application.

Wind Load and Permissible Panel Sizes

The diagrams below indicate the available ranges of panel thickness and permissible panel lengths at a given panel width (1250 or 1500mm), depending on the loads applied.

The tables apply to panels supported on four sizes (corners fixed). Dimensional values for other systems are available on request.

Loads and Panel Dimensions

Alucore Wind Loads

Rigidity compared with thickness and weight

Alucore Rigidity

Colour Chart


Colour Chart download

Solid & Metallic Colours

Anodized Look

Sustainability


Continuous environmental protection is a priority for ALUCOBOND®’s  manufacturer, 3A Composites. It focuses on preserving natural resources to ensure a liveable tomorrow for future generations.

3A Composites are leaders in environmental stewardship and are members of the German Association for Sustainable Construction (DGNB, World Green Building Council (WGBC), and The United States Green Building Council (USGBC).

With its commitment to continuous improvement programs for environmental protection, many of which go above and beyond government regulations, 3A Composites ensures they are the leaders in their field. One of the first companies to develop its own environmental management systems, the company has EN ISO 14001 certification and is regularly audited by independent auditors.

ALUCOBOND® can be used to obtain points towards LEED, BREEAM and Australian Green Building Council (AGBC) Green Star ratings.

Recycling/Recoverability

During the manufacturing process, all excess core material is recycled back into the manufacturing process and all scrap aluminium is sent back to aluminium processing plants for recycling. During the paint process, all fugitive volatile organic compounds (VOC’s) are captured, excess paint is recovered and used on the non visible surfaces of ALUCOBOND®, and all solvents used in the production process are collected and reused.

ALUCOBOND® is fully recyclable, each component including the core material and aluminium used in the manufacturing process, can be recycled and reused in the production of new materials.

Download Recycling for Future Generations Brochure here

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Locations

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