Signbond Aluminium

Composite Product and

Fabrication Guide
ISO9001:2008 ISO14001:2004

1. Products
SIGNAGE GRADE
Aluminium Composite Panel

Signage Grade
Aluminium
Composite Panel

DIGITAL PRINTING
Aluminium Composite Panel

2-METER WIDTH
Aluminium Composite Panel

EMBOSSED
Aluminium Composite Panel

SIGNAGE GRADE
Aluminium Composite Panel

Signbond Signage Grade Panel Technical Data

Panel thickness

Using a specially developed Polyester paint, Signbond Aluminium Composite comes with a
high glossy surface.The Aluminium Sheets on our 3mm panel are .2mm thick which makes for
an extremely flat, flawless and light weight panel. Signbond Aluminium Composite provides a
perfect surface for screenprinting, spray painting or applying vinyl adhesive.

Raw Materials
Basic aluminium: high-strength aluminium alloy.
Plastic core: no-toxic low density polyethylene.

4mm

6mm

(mm)

0.18

0.21

0.3

0.3

Weight

(kg/m )

2.55

3.51

4.75

6.39

Section Modulus

(cm3/m)

0.43

0.68

1.11

1.59

Rigidity (POssonratio =0.3)

E.I

(KNcm3/m)

276

701

1620

3487

Modulus of Elasticity

(N/mm2)
_135
Rm:>

Tensile Strength of Aluminium

(N/mm2)

0.2% Proof Stress

(N/mm2)

_ 100
p0.2:>

Rp0.2:110-175

Elongation

(%)

A50>72%

A50>3%

Rm:145w-185

2.0mm/m (100c temperature difference)

Thermal Resistance

(m K/m)

0.0036

0.0069

0.0113

0.0180

Heat Transition Coefficient

(w/m k)

5.72

5.61

5.5

5.3

Range of Application

Product Specifications

3mm

Thickness of Aluminium layers

Linear Thermal Expansion

Surface coating: Polyester.

2mm

-50~+80

*This specification provides technical data to the best of our knowledge at the time of publishing.
Due to our inability to control conditions of use and application, we are unable to make any
recommendations or suggestions. Mulford International Inc any of their suppliers assume any
liability for use of information presented.

Thickness: 2mm, 3mm, 4mm.

Width: 1220mm, 1500mm, 2000mm.
Panel length: up to 5800mm, Recommended: 2440mm, 3050mm, 3660mm, 4000mm.
Aluminium thickness: 0.18mm-0.5mm, depending on overall thickness and sheet
size.
Method of Processing and Construction
Method of processing: blade cutting, edge plane, CNC cutting & moulding, drilling,
punching, arc rolling or arc pressing, grooving & flanging.
Method of construction: bonding, chucking, riveting or bolting by Aluminium sections.

Special Excellence
Smooth Surface, Rich Texture,Various Colour: We can provide RAL and Pantone
colours, including high gloss, matt gloss, brushed, mirror, wooden finished board and
customized to your needs.
Various Designs and length: Width is from 1000mm to 2000mm.
Length can be customized to your requirements beyond the standard
size.
Simple Processing, Many Applications: It can be processed to
various forms and treatments such as cutting, bending, punching,
sticking and painting can be applied.

Signbond Signage Grade Panel Weather-resist Parameter

Time

Colour Variation

Chalking

ECCA/T3 ASTMD-2244-89

ASTMD-659-86
Index 1 - 10

5 year

7 year

10 year

High adhesive intensity: The American DuPont technology

insures the board does not distort, or strip away cockle, shelling
during the cutting and bending.
Environment friendly: It is a green building material, no radiation
or other pollution.
Superior weather-resistance: Surface treatment with high-grade
ultraviolet-resistant polyester paint (ECCA) request.

E3 = Very Good
E4 = Good
E5 = Satisfactory
Index 10 = No Chalking
Index 1 = Strong Chalking

DIGITAL PRINTING
Aluminium Composite Panel
Signbond Digital Aluminium Composite has been developed with a special coating
for digital flat bed printing. Signbond Digital ACM has a smooth flat white surface that
provides for excellent ink adhesion. Furthermore, Signbond Digital ACM comes with
an easy peel release liner, and is perfect for high-end digital print applications.
Product Features
Aluminium alloy: 3000 series aluminium alloy.
Coating: special coating for digital printing.
Material of core: high pressure and low density polyethylene.
Film: special film for digital printing.
Method of Processing and Construction

Special Advantages that Distinguish this product from other Advertising Panels

Surface Preparation: film sticking, screen printing and flat printing; Range of
processing temperature: -30c~70c.

Superior dimension precision: excellent tolerance in length, width, thickness,

diagonal and angularity.

Method of Processing: blade cutting, edge plane, NC cutting & moulding, drilling,
punching, arc rolling or arc pressing, grooving & flanging.

Convenient and diversified processing options.

Method of Construction: bonding, chucking, riveting or bolting by aluminium

sections.
Product Specifications
Thickness: 2mm, 3mm and 4mm.
Width: 1220mm, 1500mm and 2000mm.
Length: Maximum is up to 5800mm for convenient transportation,
Recommended: 2440mm, 3050mm, 3660mm and 4000mm.

Excellent physical properties: high surface flatness, hardness, rigidity and strength,
and low area density.
Excellent chemical properties: excellent chemical stability, such as high performance
of acid, alkali, oil and salt resistance.
Diversified Specifications: the max width can be made up to 2000mm, and the max
length can be up to 5800mm; with the aid of section assembly of Signbond digital
printing composite panel, the large scale overall section assembly for sections of any
size can be realized.
Long service life.
Highly Economical: convenient for flat transportation, processing, and moulding; low
expenses in transportation, construction and management.
Highly environment-friendly: this product is in conformity with CE Certification as
well as RoHS Certification and is recyclable.

2-METRE WIDTH
Aluminium Composite Panel

EMBOSSED
Aluminium Composite Panel

Signbond Aluminium Composite Sheets are now available as a 2 metre wide sheet.
Our new wide sheets are available in both sign and digital grades to give our customers
more design freedom, while reducing installation time and loss of production.

Both concave and convex panels will bring a strong three-dimensional feel.
Embossed aluminium panels are available with different colour choices.
Raw Materials

Raw Materials
Basic aluminium: high-strength aluminium alloy.
Plastic core: non-toxic low density polyethylene.
Surface coating: Polyester and Digital.

Basic aluminium: embossed high-strength

aluminium alloy.
Plastic core: no-toxic low density
polyethylene.
Surface coating: Polyester.

Product Description
Thickness: 3mm-6mm.

Product Description

Length: 2440mm, 3050mm, 4000mm.

Thickness: 3mm, 4mm.

Aluminium thickness: 0.3-0.5mm.

Width: 1220mm, 1500mm.

Coating: Polyester and FEVE.

Length: 2440mm, 3050mm, 4050mm.

Application
Building exterior & interior curtain walls.
Restoration of buildings.
Decoration of interior walls, ceilings,
bathrooms, kitchens, balconies, and
shop door decorations.
Display platforms and signboards.

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2. Storage and Handling

3. Processing

2a. Packaging

3a. Cutting

Signbond comes standard with a clear protective film, designed to be removed just
before installation to offer protection from surface damage.

There are many different methods in which cutting can be accomplished. This guide
focuses on four primary cutting methods:
Saw Cutting, Router Cutting, Shearing and Punching.

Signbond material should always be stored in a cool dry area where temperatures are
relatively stable. Excessive temperature fluctuations may cause condensation to form on
the stored sheets possibly resulting in permanent damage. Do not allow moisture to reach
stored material and storage exceeding 6 months should be avoided.

2b. Handling
Signbond panels should be handled carefully. When removing the panels from storage
all panels must be lifted off the pallet by two people holding all four corners. When
removing panels from a pallet / stack never drag the panel and ensure they dont slide
over a rough surface to avoid panel damage.
Individually carry the panels vertically and wear gloves to avoid making any marks on them.

2c. Storage
Vertical stacking of Signbond material is not recommended so to prevent warping or
bending, store Signbond panels horizontally.
Avoid stacking Signbond of different sizes together as the surface or panel can be
damaged by the edges of the smaller pieces.
Store the pallets so that they are protected against any wetness penetrating due to rain
and spray water and avoid any condensation forming (e.g. when transporting cold panels
to warmer rooms: think dry atmosphere).

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Saw Cutting: Sawing Signbond panel is an easy process that can be done with ordinary
commercial metal and woodworking equipment. Prior to processing large quantities, trial saw
cuttings should be done to evaluate both the tool working conditions and the recommended
cutting speeds. For marking the panels the use of a soft pencil is adequate.
It is recommended that the swarf formed during cutting should be vacuumed away
with compressed air.
The Signbond substrate is manufactured with a polyester paint finish and care should
be taken during the saw operation. It is best to move the saw blade rather than the
material when sizing the panels.
Routing: The substrate can be cut to size using either portable commercial or
automated routing equipment. Bits should be carbide tipped and kept sharp.
Shearing: The substrate can be easily sheared. However, a slight roll-down of the aluminium
cover sheet may occur on the impact side.This roll-down area is often referred to as the
edge zone. In this area, the polyethylene core is compressed and can lead to increased stress
between the core and the aluminium cover sheet. Due to this additional stress, shearing should
be avoided when the edge of the panel is exposed to the environment. When shearing the
substrate, light markings on the material may be caused by the hold down pads. In order to
avoid these markings, the hold down on the shear should be fitted with a shock-absorbing
rubber pad to prevent damage to the substrate.
Punching: Signbond panels of any thickness can be punched with conventional sheet
punching machines. For clean cuts use evenly ground tools and the narrowest possible
cutting gap. This punching method also causes a slight drawing of the panel cover sheet.

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3b. Router Bending and Folding Technique

3d. Fastening

The Signbond composite panels can be shaped by means of a simple processing

technique such as routing and folding. This allows for a variety of individual shaping and
design to be manufactured.

Joining / fixing technique: Signbond panel can be joined by means of standard

processes used in metal and plastics technology. If Signbond panel is to be joined to
structural parts of metals other than aluminium, or if fasteners (e.g. bolts, screws) are to be
used, the following material guidelines should be observed:

A V-shaped or rectangular grooves are routed on the rear of the panels with disk or
end milling cutters, whereby the aluminium cover sheet at the front and part of the
polyethylene core are retained.

1.  Fasteners and structural parts made of aluminium, plastic or stainless steel should be
suitable for the assembly with Signbond panel.

The small thickness of the remaining material then allows folding by hand. A brake press
is not required. The groove shape determines the radius of the bend. The grooves can be
produced with both a panel saw or with routing device. The routing and folding technique
can be used for composite panels of all standard surfaces.

2.  When using other materials please insert insulating washers etc. or apply protective
coating to prevent corrosion.

The convincing advantages of the routing and folding techniques are:

4. The minimum gap depends on the expected expansion of the panel.

Minimum investment.
Simple operating technique.
Folding need not be done in the workshop, it can be done on site; this means low
transport and storage costs.
Low-cost manufacture of preformed decorative elements, advertising boards, large
signboards and many more are possible.
Versatile formability.
Good economy.
Shapes are not restricted by machine dimensions.

3c. Drilling
Signbond material can be drilled with twist drills usually used for aluminium and plastics,
and on drilling machines customarily used for metals.

3.  Thermal expansion of the panel needs to be taken into for outdoor use of
Signbond panel to avoid jamming or deformation.
5.  The linear thermal expansion of Signbond panel is determined by the aluminium cover
sheets. At a temperature difference of 100 DcG the longitudinal deformation is 2.4
mm/m.
Threaded Fasteners: Threaded fasteners will allow the removal of the panel if needed
in future. Placement of the threaded fasteners should not be less than .75 from the edge of
the sheet.
It is not recommended to torque fasteners due to the cold flow of the core material, one
turn past finger tight is common practice.
To avoid jamming, the hole diameter in the panel must allow for the expansion.
It is always recommended to trial various joining techniques to ensure success.
Riveting: Signbond panels can be fastened together or joined to other materials with
rivets common to aluminium constructions. Countersink rivets do not allow for panel
expansion and are therefore unsuitable for outdoor use.
When riveting Signbond panel expansion of the needs to be taken into account when
riveting for outdoor use.

Working Specifications
Drill bit:

Twist drill, high speed steel.

Tip Angle:

100-140 degrees, or counter-bore grind with centering tip.

Cutting speed: 164 RPM to 984 RPM.

Quick removal of chips can be achieved by a high RPM, slow feed speed and
occasional lifting of the bit.

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3e. Adhesives
For interior design purposes, high strength contact adhesives that do not require lengthy
setting times can be used. Where moderate cure times are acceptable, construction
adhesives and silicones can be used to obtain a stronger bond than with contact adhesives.
Care must be taken in the selection of an adhesive regarding the thermal expansion of
the materials to be joined. Where significant thermal expansion can occur (i.e. exterior
applications) adhesives should be of medium or low modulus materials to allow for
movement without shear or loss of bond.

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5. Cleaning
3e. Adhesives continued
When using an adhesive to hold dissimilar materials, select one that will allow thermal
differential movement without shearing. Use a low modulus sealant where greater amounts
of movement are expected (i.e., plastics to Signbond material), and medium modulus
sealants if minimum movement is expected (i.e., bonding aluminium to Signbond material).

Signbond should be regularly cleaned following the method below. The surface of the
panel will commonly accumulate dust, dirt and other airborne particles. In the case of
panels used externally, various hydrocarbons from airborne exhausts are also likely to need
removal. It is also possible that surfaces could be contaminated with synthetic hydrocarbons
from other exhausts such as synthetic grease, oil, hydraulic fluids, lubricants or stains from
vegetation like plant or animal matter.

3f. Tapes / Velcro tapes

Cleaning Method

Double-sided tapes (such as the 3M Isotac products or acrylic foam) can be used for
interior design applications with low tensile or transversal strength requirements. Velcro
tapes are available for detachable joints.

We recommend a 4-step cleaning method:

1. Flush Signbond with water from a hose.
2. Wipe lightly with a soft cloth.
3. Use pressure washer.

4. Thermal Expansion
All the materials used in construction and sign making will expand when exposed to high
temperatures and shrink when temperature falls down.
Each material has its own thermal expansion rate. In metric system it is measured in mm/
m/100DC and shows how many millimetres one meter long material will expand when
temperature changes 100 degrees Celsius.
For example for steel and concrete rate is around 1,2mm and for PVC it is 5,2mm. When
different materials are fixed together it is always necessary to take into account their
expansion rates and exposure of those materials to different temperatures.

4.  Use detergent in a power wash or with a soft cloth for hand wiping and flush
with water.

Material Compatibility
Signbond is an extremely durable material that has been designed to withstand significant
exposure to environmental conditions. It is unlikely to be compromised by any cleaning
process that would conceivably be used on the material. However, in the interests of
maintaining the finish of the material, it is recommended to select products with a pH of 10
or less and which do not contain bleaches, ammonia or caustic ingredients such as sodium
hydroxide, potassium hydroxide or sodium metasillicate. It is also recommended that you
avoid abrasive materials or tools such as scouring powders, fibre pads or brushes.

Sometimes it may happen that substrate on which Signbond is designed to be installed is

rigidly fixed without taking thermal expansion into consideration. In this case this substrate
can bow and deflect causing subsequent bowing of Signbond fixed to this substrate.

Signbond Thermal Expansion

Signbond consists of 2 aluminium layers bonded to polyethylene core. Thermal expansion
of Signbond is determined by properties of aluminium skins. Thermal deflection of
aluminium is 2,4 mm/m/100DC. So, panel 2440mm long with 100DC temperature
fluctuation will expand 5,86mm and its length will become 2445,86m under new
temperature conditions. The same time if 2 edges of the panel are fixed tension in
Aluminium skins will lead to panel bowing. Bowing deflection in this case will be 73,2mm.
It is very important to make sure that when installation is done in the conditions where
essential temperature fluctuations are expected fixings shall be designed to allow free
thermal expansion of the panels.

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For further information please contact your local branch

Melbourne + Sydney + Brisbane + Adelaide + Perth + Newcastle
Auckland + Wellington + Christchurch + Hamilton
Phone Australia 1300 685 3673 Phone New Zealand 0800 685 3673
www.mulfordplastics.com