In technical collaboration

with
U . S. A.

ALUMINIUM COMPOSITE PANELS

Index
Introduction: Group Harwal

P2

Interplast Company Ltd.

P3

Alupex: Aluminium Composite Panels

P 4/5

Application & Advantages

P6

Quality & Test Certificates

P 7/8

Approved & Completed Projects

P 9/17

Fabrication Guidelines

P 18

Accessories & Installation

P 19

Technical Specifications

P 20

Standard Guarantee

P 21

Ireland

USA

UK

Intuition... Innovation... Agility...

The GROUP HARWALs primary business is based on plastic & metal products, with over 60
years of experience in different processes and technologies. Plastic Compounds, Building
Materials, Pipe Line Systems, Housing Systems, Shelters, Electrical Products, Household
Items, Storage Containers, Garden Sheds, Plastic Disposables, Packaging Materials, Outdoor
Products, Refrigeration, Residential & Contract Furniture are just some of the products
manufactured by HARWAL under our wide spread manufacturing facilities in UAE, USA &
CIS countries.
With an annual conversion capacity of 200,000 metric tons of plastic and 20,000 tons of
aluminium & steel, the Group has come to the forefront of their respective industries.

The difference is...

... to perceive, create & swiftly deliver
Group Companies

UAE - KSA - FRANCE - UK - RUSSIA

UAE

UAE - OMAN - KSA - RUSSIA

UAE

NETHERLANDS

Harwal Containers Manufacturing LLC

ARMENIA

UAE

INTERPOLYMER

UAE

ENGINEERING

UAE - RUSSIA

UAE

ARMENIA

UAE

UAE

ARMENIA

USA

GERMANY

ARMENIA

INTERPLAST
innovatio n

is

o u r

Interplast was established in 1981 to manufacture PVC compounds and over the
years has developed an extensive range of compounds for different applications
such as sidings, pipe ttings, cable insulation, sheathing, containers, rigid and
exible proles as well as clear tubing. In 1983, Interplast diversied into nished
products with the introduction of DECODUCT Electrical Cable Management
Systems.

cu lt u re. . .

A MANUFACTURER 0F LEADING PRODUCTS SUCH AS:

Starting with UPVC Conduits, Trunking and Fittings, Interplast has since added
many new products to its electrical range. Major additions were Underground
Cable Protection Systems and a range of wiring devices marketed under the
tradenames of INTERGARD and EDISON respectively and a full range of metal
trunking and cable trays complete with accessories in co-operation with its sister
company TSSC.

Having realized that further diversification was needed to fulfill the companys
growth strategy, it expanded into flexible packaging and thermoformed products
for the food industry. These products are marketed under the trade names of
DECOPACK and DECOFORM.

Within its DECOPACK range, the company developed unique products such as
plastic and paper luxury shopping bags as well as multi layer lm for various
applications. To serve its growing European customer base, Interplast
established Interplast UK in the United Kingdom, followed by the opening of
Interplasts ofce in Paris, France.

Another significant development in recent years has been in the

area of Home Improvement products.

Interplast manufactures a range of PVC storage sheds, window

proles, door panels, PVC siding as well as fencing systems which
are sold throughout the world.

The Building Materials Division of Interplast is offering a new

product range ALUPEX Aluminium Composite Panel, Catering to

the architectural and construction industry.

ALUMINIUM COMPOSITE PANELS

Introduction
The Building Materials Division is providing innovative products for the
continuously expanding construction industry in the middle east. This
divisions primary goal is to develop & manufacture quality products required
for the modern building architecture.

The latest addition to our building materials product range is ALUPEX

Aluminium Composite Panels developed in technical collaboration with US

Polymers INC, U.S.A. ALUPEX , is the next generation solution for all types
of cladding and building surfaces. It is a unique and versatile cladding material
used in enhancing new trends of modern architecture.

ALUPEX is manufactured with state-of-the-art technology of multi-layer extrusion lamination where two skins of non-corrosive special grade
ALUMINIUM metal sheets are bonded on to the non-toxic Polyethylene thermoplastic or a fire retardant mineral core to form a sandwich panel.
The external skin surface is available in various finishes and colours made from fluoropolymer (PVDF) paint coatings.
Our in-house coating facility, equipped with advanced three-roller reversal precision coating machinery, is supported by a leading Europeon
paint manufacturer. The external surface is further protected by an easy-to-peel protective film. The internal skin surface is supplied with a
non-corrosive service coating to further enhance its protection from cement or galvanic corrosion after installation.
A fully integrated manufacturing facility with state-of-the-art coil coating facility and In-house testing laboratory is providing quality products
designed to meet the harsh weather conditions of the Gulf region.

ALUPEX- Aluminium Composite Panel Product Range

This product range of composite panels is lighter and superior in strength-to-weight ratio, suitable for
day-to-day use for external and internal wall claddings in modern architectural buildings to create
attractive & durable finishes with low maintenance.
This range is manufactured using a thermoplastic polyethylene core conforming to CLASS 1 (BS 476)
fire rating of British Standard and high performance Aluminium Alloys to ensure faster and easy
fabrication methods.
The external Aluminium surface of panels is coated with superior PVDF (Poly Vinylidene Difluoride)
paints to maintain consistent decorative finish of the building surface over extended period of time
even in harsh Gulf weather conditions.

A single person can carry a lightweight

Alupex panel off size 1200 x 2400 x 4mm
with ease, as shown above.

Panel Thickness:

3 mm, 4 mm & 6 mm

External Aluminium Skin Thickness:

0.5 mm

Internal Aluminium Skin Thickness:

0.5, 0.4 mm

Available Panel Widths:

1000, 1250 & 1500 mm

4

ALUMINIUM COMPOSITE PANELS

Fire Retardant Aluminium Composite Panels manufactured using a

non-combustible fire retardant mineral core conforming to CLASS 0
(BS476) fire rating of British Standard certified by European testing
laboratories.
This product range is manufactured using a high grade of Aluminium
Alloys (E.g. AL1100 or AL3003 or AL 3105) to ensure lower oxidation
and superior non-corrosive cladding system for high-end architectural
requirements in commercial and public buildings.
The external Aluminium surface is coated with 2 and/or 3 coats system
in PVDF (Poly Vinylidene Difluoride) paints using special purpose base
primer coatings to ensure superior performance under severe and harsh
weather conditions for extended periods.

Standard Panel Thickness:

4 mm, & 6mm

Standard External Aluminium Skin Thickness:

0.5 mm

Standard Internal Aluminium Skin Thickness:

0.5, 0.4 mm

Standard Panel Widths:

1000, 1250 & 1500 mm

A unique and revolutionary STONE finish Aluminium Composite Panels manufactured using latest coil coating technology . The top skin of
Aluminium is coated repeatedly with different colour patterns in PVDF, Polyester and Polyurethane to achieve a naturally look-alike marble,
granite and other stone patterns. The high gloss and consistent colour strengths are maintained by high temperature drying (up to 255C). An
additional topcoat of clear PVDF is used to maintain extended weathering performance for external cladding applications.

These look-alike stone skins are then subjected to conventional high-pressure extrusion lamination process to manufacture ALUPEX TONE
composite panels. There are various granite and marble finishes available identical to natural stones with higher strength-to weight ratio.
These panels are the best alternative to conventionally heavy granite & marble tiles.

Standard Panel Thickness:

3, 4 mm

Standard External Aluminium Skin Thickness:

0.5 mm

Standard Internal Aluminium Skin Thickness:

0.5, 0.4 & 0.3 mm

Standard Panel Widths:

1000, & 1250 mm

AX 37083
Coffee Brown

AX 37052
Colonial Cream

AX 37128
Imperial Red

AX 37251
Rosy Red
5

AX 37125
Tan Red

AX 37333
Black Sapphire

ALUMINIUM COMPOSITE PANELS

Applications

External Wall Cladding, Building Fascia and Facade Finishes

Curtain Walls and Internal Wall Finishes
Rooftop Edges, Parapet Walls and Wall Canopies
Spandrel, Column Covers and Beam Wraps
Balconies and Patio Wall Claddings
Partition and Ceiling Panels

Stairways, Elevators and Kiosk Panels

Advertising Display Sign Boards
Public and Commercial Display Walls
Poster Hoardings and Exhibition Rooms
Shop Sign Boards and Showroom Finishes
Machine Casings and Furniture Accessories

Advantages
Performance with lightness: A proven strength-to-weight ratio surpassing the solid Aluminium, steel or concrete material.
Surface with choice and longevity: Coated with specially formulated uoropolymer (PVDF) based paints in variety of colours &
decorative nishes and a life expectancy of upto 20 years.
High tolerance with elegance & beauty: A reliable surface performance to withstand extreme and harsh weather conditions of
the Gulf and of coastal areas to maintain its elegance and beauty.
Durability with consistency: Manufactured with a corrosion resistant system to provide durability against temperature uctuations,
moisture, chemicals and ultra violet exposures.
Quality with condence: High quality ensures atness without distortion, surface smoothness without deection, extra peel-off
resistance and high impact strength.
Saving energy for a healthier environment: Helps in generating a pseudo-insulation and barrier to reduce the heat and sound
transmission losses.
Easy installation and economical option: Can be formed in any shape, angle or curve with ordinary metal and wood working
machinery and can be installed using conventional accessories

comparison with other cladding materials

PROPERTIES

ALUPEX
4mm thick

Aluminium
3 mm thick

Steel
1.5mm thick

Granite
30mm thick

Weight (kg/m2)

5.40

7.93

11.44

81

Sound Insulation (dB)

25

15

structure based

Heat Transmission
Coefcient (kcal/m2h C)

5.14

6.4

7.3

structure based

Flatness

excellent

average

average

good

Weathering

excellent

average

average

good

Fabrication

easy

difficult

difficult

not possible

Maintenance

low

high

high

average

Installation

easy

extra care

difficult

difficult

Fire Properties

good

average

good

excellent

Large

Medium

Medium

not so large

Panel Size

(1.22m x 2.4m or longer)

Handling

easy

not so easy

not so easy

difficult

Overall Cost

low

high

high

very high

ALUMINIUM COMPOSITE PANELS

Quality & Test Certificates

Ireland

UK

USA

UAE

UK

ALUMINIUM COMPOSITE PANELS

Quality & Test Certificates

ALUMINIUM COMPOSITE PANELS

Project Approvals

ALUPEX Aluminium Composite Panel is approved by following leading Engineering Consultants:

1) WS Atkins & Partners Overseas
2) Lacasa Engineering Consultants
3) The Engineer
4) National Engineering Bureau
5) Art Consultants
6) Schuter Pecthold
7) Gulf International Consultants
8) Horizon Engineering Consultants
9) Adnan Saffarini Engineering Consultants
10) Mazaya Engineering Consultants
11) LEO Engineering Consultants
12) Al Nahda Engineering Consultants
13) Nutek Engineers & Architects

14)
15)
16)
17)
18)
19)
20)
21)
22)
23)
24)
25)

Mimar Emirates
Elit Consultants
QHC Architects and Engineers
Badri & Bensouda Consultants
Archon Group
CAB Consultants
Al Ajmi Engineering Consultants
Bu Humaid Engineering Consultants
Meecon ME
Al Asri Engineering Consultants
Arex Consultants
Emirates Design Consortium

Project: PPM Conrad Hotel

Consultant: WS Atkins & Partners Overseas

ALUMINIUM COMPOSITE PANELS

Project Approvals
Project: Iris Bay
Consultant: WS Atkins & Partners Overseas

RTA - Dubai Metro

Project: Skycourts
Consultant: Lacasa Engineering Consultants

10

ALUMINIUM COMPOSITE PANELS

Completed Projects
Project: Dubai Sports City

Consultant:
QHC Architects & Engineers

Project: RTA - Dubai Metro

UAE
UAE
Project: Dubai Sports City

Consultant:
QHC Architects & Engineers

Project: Dubai Sports City

UAE

Consultant:
QHC Architects & Engineers

UAE
11

ALUMINIUM COMPOSITE PANELS

Completed Projects
Consultant:
Adnan Saffarini Eng. Consultants

Consultant:
Mazaya Eng. Consultants

UAE
Consultant:
Mazaya Eng. Consultants

UAE

UAE
12

ALUMINIUM COMPOSITE PANELS

Completed Projects
Consultant:
Al Nahda Eng. Consultants

UAE
Contractor:
Tiger Contracting Company

UAE

UAE
13

ALUMINIUM COMPOSITE PANELS

Completed Projects
Consultant:
Gulf International Consultants

IRAN

UAE
Consultant:
Horizon Eng. Consultants

IRAN
Consultant:
LEO Eng. Consultants

UAE
14

UAE

ALUMINIUM COMPOSITE PANELS

Completed Projects
Consultant:
Nutek Engineers & Architects

Consultant:
Mimar Emirates

UAE

UAE
Consultant:
Elit Consultants

UAE
15

ALUMINIUM COMPOSITE PANELS

Completed Projects
Consultant:
Al Ajmi Eng. Consultants

Consultant:
Emirates Design Consortium

UAE

UAE

Consultant:
Meecon Middle East

Consultant:
Gulf International Consultants

UAE

UAE
16

ALUMINIUM COMPOSITE PANELS

Completed Projects
Consultant:
Badri & Bensouda Eng. Consultants

Consultant:
Archon Group

UAE

UAE

UAE

Consultant:
CAB Consultants

Consultant:
Bu Humaid Eng. Consultants

UAE

UAE
17

ALUMINIUM COMPOSITE PANELS

Fabrication Guidelines

ALUPEX can be formed in any shape, angle or curve with ordinary metal and wood working machinery to fulfil requirements of any cladding
and design manifestos. Folding, curving, bending, cutting, joining, fastening, drilling etc. can be adopted with simple, easy and economical
skills to shape any architectural design form with flexibility.

GROOVING - Routing a groove using a

JIGGING - Alupex panels can be cut to

BENDING - This can be done by using a

disk or end-milling cutter is much more

any shape and size by a contour cutting

folding table or break press where the

easier than making a groove in a wooden

process with water jets, profile milling

inside bending radius is approximately

substrate. Kindly ensure that 0.28mm of

machines, contour saws and jigsaws.

10 to 11 times of the panel thickness.

plastic core material remains at the base

For the mass production it is advisable to

of groove for flat and consistent bending

make a prototype. Please be aware that

at the groove during fabrication.

the spring-back effect in case of these

panels is higher than that with other solid
metal sheets.

SAWING - Alupex panels can be cut with

GLUEING

Adhesive

tape,

liquid

PUNCHING - These can be punched with

a circular, band or jigsaw similar to any

adhesive, double sided adhesive tapes

any

other wood cutting process.

etc. can be used on back surfaces.

machines with evenly grounded tools

Please note that these adhesives cannot

and narrowest cutting gap. Please note

be used for the inner plastic cores and

that an inappropriate punching can cause

also usage on the top painted surface is

an indentation on the top surface.

conventional

sheet

punching

not advisable.

900 BEND
8

mm
2 +0.2
-0.0
90o

450 BEND

900 BEND WITH RADIUS

r-2 mm

mm
2 +0.2
-0.0

14 mm

r-7 mm

r-2 mm
0.8 mm

1.5 mm

18

45

135o

0.8 mm

ALUMINIUM COMPOSITE PANELS

Accessories & Installation

1

ALUPEX

Sealant

Intermittent Aluminium 'L' angle

Aluminium Continuous 'L' angle

Anchor Bolt

Fastening Bolt

Aluminium 'L' Bracket

Concrete

Window Frame
9

8
7

4
3

5
6

Vertical fixing

Side Wall fixing

SLOPE

Fixing to parapet

Column cladding

A typical fabricated panel

19

Fixing to window frame

ALUMINIUM COMPOSITE PANELS

Technical Specifications
PHYSICAL PROPERTIES
Property Description
1

Result

Standard / Remarks

7.50 kg/m2
10.75 kg/m2

ASTM D792
ASTM D792

4.80 kg/m2
5.40 kg/m2
7.25 kg/m2

ASTM D792
ASTM D792
ASTM D792

Average Panel Weight - ALUPEX FR

a) 4mm thk.
b) 6mm thk.
Average Panel Weight - ALUPEX and ALUPEX TONE
a) 3mm thk.
b) 4mm thk.
c) 6mm thk.

MECHANICAL / THERMAL PROPERTIES

1

Tensile strength - Aluminium

2
3
4

Bond Strength
Shear Rigidity
Alupex Peel/Tearing Strength - 180
a) 3mm thk.
b) 4mm thk.
Bond Performance
48 hrs. of submersion in boiling water and
after 21 days of immersion in water at 90 F.
Temperature Resistance
(from -50 C to + 100 C)

6
7
8
9

Alum. Asso.

180 N/mm2

Deflection Temperature
Fire Retardant Classification
Sound Reduction 4mm

26.70 N/mm
2.52 KN/mm2

ASTM D903
ASTM C393

upto 18 kgm2
upto 23 kgm2

ASTM D903
ASTM D903

No Change

Passed

No Change

Passed

>300 C
Class 0 & Class 1
STC = 25 def

ASTM D648
BS 476 - Part 6 & 7
ASTM E 90 - 04

SURFACE COATING
1

Dry Film Thickness (based on colour)

20 to 35m

ECCA - T1 (1995)

2
3
4
5
6
7
8
9
10
11
12
13

Pencil Hardness
Adhesion
T bend Test
Specular Gloss
Reverse Impact
Mortar Resistance
Acid Pollutants
Salt Spray - 3000 hours
Humidity - 3000 hours 100% @ 95F
Acid Rain Test
Alkali Resistance
Abrasion / Falling Sand

HB - H
No Adhesion loss or Cracking
No Tape off/no Cracks - 1-T
20 - 30 (10 - 40%)
No Cracking or loss of Adhesion
No effect
No effect
Pass
Unaffected
15 Cycles minimum
No effect
Resist 65-85 Litres/mil.

ASTM D3363
ASTM D3359
ASTM D4145
ASTM D523
ASTM D2794
ASTM C267
ASTM D1308
ASTM B117
ASTM D 2247
Kesternich
Kesternich
ASTM D 968

WEATHERING PERFORMANCE - PVDF Topcoat

1
2

South Florida Exposure

UVB (313 bulbs)

Chalk Resistance

< 5 NBS Units Change

Passed, 3,000hrs.

ASTM D 2244
ASTM D822

Rating of 8 min.

ASTM D 659

20

ALUMINIUM COMPOSITE PANELS

STANDARD GUARANTEE

20

20

*UP TO

*UP TO

YEARS

YEARS

Interplast Co. Ltd. guarantees the performance of ALUPEX

Aluminium Composite Panels for a period upto 20 years* depending
on the type and class of the product.

This guarantee covers the companys limited liability, which does not
extend to cover any consequential injury, loss or damage

* T h e

p r o d u c t

g u a r a n t e e

i s

c o d d i t i o n a l

b a s e d

21

o n

t h e

p r o d u c t

&

p r o j e c t

* Subject to the terms & condition

This guarantee is valid, provided the Alumninium Composite Panels

are installed by a qualied and experienced contractor as per our
suggested installation guidlines and the material is not subjected to
abnormal and improper use.

c a t e g o r y .

ALUMINIUM COMPOSITE PANELS

NOTES

22

M/10/2009

www.alupex.net

INTERPLAST

COMPANY LIMITED

Home Improvement & Building Materials Division

P. O. Box: 4679, Sharjah, U.A.E. Tel: +971-6-539 55 77, Fax: +971-6-539 57 75
E- mail:int erp last @emirat es.net .ae

Designed & Printed by:

Manufactured by:

INTERPLAST UK. LTD.

INTERNATIONAL PLASTIC CENTRE LLC

15 High Street, Inverurie, Aberdeenshire AB51 3QA

Tel: (+44) 01467 629555, Fax: (+44) 01467 672191
email: Sales@interplast.co.uk

P. O. Box: 270982, Riyadh 11352, Saudi Arabia

Tel: +966 1 2267110, Fax: +966 1 2267885
email: ipc@atheer.net.sa