Multiwall Polycarbonate Standing-Seam Technical Guide · SUNPAL is an advanced multiwall polycarbonate panel system that combines smart design, light transmission, high thermal insulation

Creating New Solutions for over 40 Years

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SUNPAL®Multiwall Polycarbonate

Standing-Seam

Architectural System Technical Guide

2 | SUNPAL® Technical Guide

Contents Page

Introduction 3

Panel Specification 4

Colors and Solar Transmissions 5

Thermal Insulation Properties 5

Typical Physical Properties 5

System Components Definition 6

A) Joiners 6

B) Fasteners 6

C) Sealing & end cap Strips 6

D) Alu Span-Bar 7

System Components List 8

Installation Data 11

Roof structure 11

Assembled System Width 11

Purlin Design - Recommended spans 11

Rafter Design - Recommended Spans 11

Installation Instructions 12

Assembly Details 15

Cladding Details 16

Roofing Details 20

SUNPAL® Technical Guide | 3

Introduction

SUNPAL is an advanced multiwall polycarbonate panel system that combines smart design, light transmission, high

thermal insulation and strength. It offers a lightweight, expansion-free and leak-proof design that withstands very high

loads. The system’s many advantages make it ideal for long term installations in various design projects. As architectural

glazing system, SUNPAL is applied in a variety of roofing and cladding uses, in flat or curved designs.

SUNPAL is a self fastening system, based on extruded Sunlite panels of 8mm, 10mm, 18mm and 20mm thickness.

The panels join together by polycarbonate or aluminum joiners which are sealed at the ends by End-caps.

T-Fasteners fix the system to the structure by clamping, without any penetration through the panels.

Aluminum Sealing Strip closes the panel lower end to prevent dirt from entering the flutes, and provide efficient drainage.

U-Profile (PC / aluminum) or Al F-Profile seals the upper end of the panel. Aluminum F-Profile fits to the panel side edges, to

interface with the structure for a completely framed installation.


Panel Specification

SUNPAL panels are of multiwall structure, available with thicknesses of 8mm, 10mm, 18mm and 20mm. Standard SUNPAL

panels have UV protection on both sides (specific order can be produced with UV protection on one side only). Maximum

panel length is 11.99 (typical stoke length).

Panel Data Drawing

SU

NP

AL

® 8

/60

0 L

ite

Width: 600mm

Height: 23.5mm

Height with PC-Joiner: 33mm

Weight: 1.10 Kg/m, 1.83 Kg/m²

Min. cold bending radius: 2.0m

SU

NP

AL

® 8

/60

0 Width: 600mm

Height: 23.5mm




SU

NP

AL

® 1

0/6

00 Width: 600mm

Height: 25.5mm




SU

NP

AL

18

/10

00 Width: 1000mm

Height: 33.5mm




SU

NP

AL

® 2

0/1

00

0

Width: 1000mm

Height: 35.5mm





Colors and Solar Transmissions

Color LT SHGC SC Color LT SHGC SC

SU

NP

AL

® 8

/60

00

Clear 65% 0.63 0.72

SU

NP

AL

® 1

0/6

00

Clear 65% 0.63 0.72

Bronze 25% 0.40 0.46 Bronze 25% 0.40 0.46

White Opal 26% 0.37 0.43 White Opal 26% 0.37 0.43

White Ice 50% 0.56 0.64 White Ice 50% 0.56 0.64

Solar Ice 20% 0.28 0.32 Solar Ice 20% 0.28 0.32

Solar Grey 30% 0.45 0.52 Solar Grey 30% 0.45 0.52

Solar Control Grey 20% 0.30 0.34 Solar Control Grey 20% 0.30 0.34

Green 50% 0.56 0.64 Green 50% 0.56 0.64

Blue 50% 0.60 0.69 Blue 50% 0.60 0.69

Red 20% 0.52 0.60 Red 20% 0.52 0.60

Color LT SHGC SC Color LT SHGC SC

SU

NP

AL

® 1

8/1

00

0

Clear 50% 0.54 0.62

SU

NP

AL

® 2

0/1

00

0

Clear 50% 0.54 0.62

Bronze 20% 0.35 0.39 Bronze 20% 0.35 0.39

White Opal 20% 0.30 0.34 White Opal 20% 0.30 0.34

White Ice 40% 0.48 0.55 White Ice 40% 0.48 0.55

Solar Ice 15% 0.23 0.26 Solar Ice 15% 0.23 0.26

Solar Grey 30% 0.44 0.51 Solar Grey 30% 0.44 0.51

Solar Control Grey 15% 0.25 0.29 Solar Control Grey 15% 0.25 0.29

Green 38% 0.46 0.53 Green 38% 0.46 0.53

Blue 36% 0.50 0.57 Blue 36% 0.50 0.57

Red 15% 0.44 0.50 Red 15% 0.44 0.50

LT (Light Transmission) = The percentage of incident visible light that passes through an object.

SHGC (Solar Heat Gain Coefficient) = The percentage of incident solar radiation transmitted by an object, which includes the direct solar transmission and the part of the solar absorption radiated inward.

SC (Shading Coefficient) = The amount of the sun’s heat transmitted through a given window compared with that of a standard 1/8- inch-thick single pane of glass under the same conditions.

Thermal Insulation Properties

Property SUNPAL® 8/600 Lite SUNPAL® 8/600 SUNPAL® 10/600 SUNPAL® 18-20 /1000

U-Value [Watts/m²·°C] 2.45 2.45 2.10 1.50

R-Value [m²·°C/ Watt] 0.41 0.41 0.47 0.67

Typical Physical Properties

Property Method** Conditions Units Value

Density D-792 g/cm³ 1.2

Heat deflection temperature (HDT) D-648 Load: 1.82 MP °C 130

Service Temperature - Short term °C -50 to +120

Service Temperature - Long term °C -50 to +100

Coefficient of linear thermal eaxpansion D-696 cm/cm °C 6.5 x 10

Tensile strength at yield D-638 10 mm/min MPa 62

Elongation at break D-638 10 mm/min % >80

Impact falling dart ISO 6603/1 J 40-400

Thermal expansion/contraction rate mm/m 3

*ASTM method except where noted otherwise


System Components Definition

The SUNPAL system is generally defined by the panel type. All the other components are selected to match this panel.

A) Joiners

The Joiners (PC or aluminum) fit all panel types. The choice between them is generally by the application -

PC Joiner or Alu Joiner ‘R’ for roofing (or any situation where the seam is external); Alu-Joiner ‘C’ for cladding

(hidden seam).

PC-Joiner (part 02) is 22mm high by 39mm wide, extruded polycarbonate colored to match the panels.

Maximum length is 11990mm, with weight of 160gr/m. The PC-Joiner should overhang about 100mm beyond the last

fastener.

End-Cap for PC-Joiner (part 03) is a clear acrylic cap, designed to plug the PC-Joiner ends. This end-cap prevents water

and dirt from entering the joiner, it helps to reinforce the joiner ends, and provides harmonic finished appearance to the

systems ends.

Alu Joiner ‘R’ (part 12) is 40mm wide and 22mm high, mill-finish extruded aluminum. Maximum length is 6000mm. The

Alu-Joiner ‘R’ should overhang about 150mm beyond the last fastener.

End-Cap for Alu Joiner ‘R’ (part 13) is a mill-finished aluminum plate, designed to close the Alu Joiner ‘R’ ends. This end-cap

is fixed by inserting two screws into the joiner.

Alu Joiner ‘C’ (part 04) is 39mm wide by 54mm high, extruded aluminum with mill finish. Maximum length is 6000mm. The

Alu-Joiner should overhang about 250mm beyond the last fastener.

End-Cap for Alu Joiner ‘C’ (part 05) is a mill-finish aluminum plate, designed to close the Alu-Joiner ends. This end-cap is

fixed by inserting two screws into the joiner.

B) Fasteners

T–Fastener (part 08) - SUNPAL roofing system is attached to the supporting structure by the T-Fasteners. These

are stainless steel concealed clips that are fixed onto the structure with screws. The fasteners have four different

sizes to match each panel type. For installing SUNPAL system onto wooden structure, the T-Fasteners are fixed

with Wooden Screws (part 12). For metal structure, Metal Screws (part 13) are used. As standard, each fastener is fixed with two

screws. For high wind areas, using three screws per fastener is recommended.

T-Stopper (part 09) - To prevent “travelling” of the panels, it is recommended to fix one T-Stopper at a certain fixing point along

each Joiner. This will be the only longitudinal fixed point, while all other fixings are floating. It is a T-Fastener with added stopper

plate, which fits into slit in the attaching panels (prepared on spot).

C) Sealing & end cap Strips

The Alu Sealing Strips (part 06) are mill-finished aluminum profiles in four sizes, to match each type of

panel. Maximum length is 6000mm (stock length). These are used as a closure for the panels end (usually

the lower), to prevent penetration of dirt end moisture, and provide efficient drainage. U-Profile is used for

sealing the panel’s upper end, to prevent penetration of moisture and dirt.

PC U-Profiles (part 07) are made of polycarbonate, and have two types to suite 8mm and 10mm panels. Their maximum length

is 12mm (stock length).


Alu U-Profile (part 16) is an aluminum profile mill finished, with two types of sizes to suit 18mm and 20mm panels. Their

maximum length is 6000mm (stock length).

Alu F-Profiles (part 11) are available at four sizes to match each panel type. These are aluminum profiles mill finished, with

maximum length of 6000mm (stock length). The F-Profiles are used generally as a side fixing detail, also possible as an upper-

end closure.

D) Alu Span-Bar (part 10)

This is an aluminum profile that can be used as a rafter on a structure frame. It can be straight or curved (by rolling),

and designed to perform both as a rafter and a fastener (no T – Bar Fasteners required in Span-Bar applications).

The Span-Bar has four sizes to match each panel type, and its maximum length is 6000mm.


System Components List

# Component Drawing Specification Stock Length / Quantity

0200 PC Joiner (8-20mm) Panel matched 12m

0300 End-Cap for PC Joiner (8-20mm) Natural clear 200 per box

1200 Alu Joiner ‘R’ (8-20mm) Mill finish 6m

1300 End-Cap for Alu Joiner ‘R’ (8-20mm) Mill finish

0808 T-Fastener (8 mm) Stainless steel 200 per box




0908 T-Stopper (8 mm) Stainless steel 50 per box





0920 T-Stopper (20mm) Stainless steel 50 per box

1400 Metal Screw (8-20mm) Self-Drilling 500 per box

1500 Wood Screw (8-20mm) Tapping 500 per box

0608 Alu Sealing strip (8mm) Mill finish 6m

0610 Alu Sealing strip (10 mm) Mill finish 6m



0708 PC U-Profile (8mm) Clear 6m

0710 PC U-Profile (10mm) Clear 6m

1618 Alu U-Profile (18mm) Mill finish 6m

1620 Alu U-Profile (20mm) Mill finish 6m



1108 Alu F-Profile (8mm) Mill finish 6m




0400 Alu Joiner ‘C’ (8-20mm) Mill finish 6m

0500 End-Cap for Alu Joiner ‘C’ (8-20mm) Mill finish 6m

1008 Alu span-bar (8mm) Mill finish 6m

1010 Alu span-bar (10mm) Mill finish 6m

1018 Alu Span-Bar (18mm) Mill finish 6m

1020 Alu Span-Bar (20mm) Mill finish 6m


Installation Data

Roof structure SUNPAL system fits for both rafter and purlin construction. The recommended minimum roof slope for SUNPAL

applications is 5%. For lower slopes rafter design is recommended.

Assembled System Width

SUNPAL® 8/600 and 10/600 SUNPAL® 18/1000 and 20/1000

Purlin Design - Recommended spansfor wind load of 1kPa (mm)

Polycarbonate Joiner Aluminum Joiner - R Aluminum Joiner - C

Panel Type Panel Width Mid-Span End-Span Mid-Span End-Span Mid-Span End-Span

SUNPAL Lite 8 mm 600 900 700 1,300 950 1,500 1,100

SUNPAL 8 mm 600 1050 825 1,400 1,000 1,600 1,200

SUNPAL 10 mm 600 1,250 950 1,600 1,200 1,800 1,400

SUNPAL 18/20 mm 1,000 1,350 1,000 1,600 1,200 1,800 1,400

Rafter Design - Recommended SpansWith max. intervals of T-Fasteners along rafters for wind load of 1kPa(mm)

Polycarbonate Joiner Aluminum Joiner - R Aluminum Joiner - C

Panel Type Rafter CentersInternal

Fasteners

Fasteners at

Rafter Ends

Internal

Fasteners

Fasteners at

Rafter Ends

Internal

Fasteners

Fasteners at

Rafter Ends

SUNPAL Lite 8 mm 602 900 700 1,300 950 1,500 1,100

SUNPAL 8 mm 602 1050 825 1,400 1,000 1,600 1,200

SUNPAL 10 mm 602 1,250 950 1,600 1,200 1,800 1,400

SUNPAL 18/20 mm 1,002 1,350 1,000 1,600 1,200 1,800 1,400

Note 1: The above spans are specified for wind loads of 1000 Pa (21 psf ) in roofing applications. For vertical or internal applications, contact your local SUNPAL distributor.

Note 2: In curved applications, Aluminum Joiners will have to be pre-rolled, while Polycarbonate Joiners can be cold curved to the roofing radius.

1002mm602mm


1. Cut to size

Cut panels to length allowing for an overhang of no more than 100mm at each end. We recommend a penetration of minimum

50mm into the gutter!

Use a circular saw or hand saw with fine tooth blades for easier and better cutting.

2. Slit for Alu Sealing-Strip

Using a small cutting disc (2 mm thick), prepare 18 mm deep horizontal cuts at each end of the panel teeth. This cut should be

in parallel to the panel top face, but without injuring the panel surface.

Since it needs precision, it is highly recommended to perform this action before assembly.

Cut to SizeA Slit for AIu Sealing StripB Remove Inner MaskingC

Fix Sealing StripG Fix Side FlashingsI

AssembleEFix T-Bar FastenersD Remove Outer MaskingF

Fix Joiner End-CapsH

Installation Instructions


3. Remove cutting chips

Using a vacuum cleaner or an air compressor with blow gun – blow out any “swarf” or loose particles from inside the panel

(ensuring both ends of panel are free of the plastic envelope/ sleeve).

4. Position first panel

For symmetric installation - determine the layout of the first panel, starting in the centre of the structure (this can be determined

by dividing the structure width x 2 and adding half the width of the panel).

For “side to side” installation - Set-up the first panel, fitted to the side flashing.

5. Remove inner Masking

Remove the protective foil from the internal face only. Keep this side away from the roof purlins until final positioning of the

panel, to avoid scratching.

6. Fix T-Stopper

At the top purlin (100mm from end of sheet for rafter only) place a T-Stopper up against panel and fix into place using hex head

fixings provided.

For curved application on arched structure, the T-Stopper should fix as the mid fastener at the top of the arch.

On wall application the T-Stopper should fix at the opposite to the expansion allowance.

7. Fix T-Fasteners

Along panel on remaining purlins (see span table for rafter design), place T fasteners against panel and fix into place using hex

head fixings provided (2 fixings for standard, 3 fixings for high wind areas and cyclonic regions).

8. Position next panel

Remove protective film from underside of second panel and place against T fasteners.

9. Locking the 2 panels together

Using a rubber mallet, start to fix the Joiner, locking the 2 panels together by striking with short intervals (5-10cm) along the

joiner. Start at the bottom end, and work your way up the roof (ensure that the joiner overhangs the panel ends by 13mm,

where the aluminum sealing strip will be installed later).

10. Aluminum Joiner

If using Aluminum Joiners ‘R’, before installing, drill 7mm diameter holes through the joiner sides along the line provided,

1000mm centers and install as per step 9.

After locking, fix M6 bolt through holes pre-drilled previously through aluminum joiner with lock nut and tighten (making

sure it’s firm. Do not over tighten).

11. Remove outer Masking

Remove the protective foil from the panel’s external face shortly after installation.

Delaying foil removal can make it very difficult to remove later (on hot days remove top protective film straight away to prevent

film from bonding with the panel).


12. Repeat steps 5 to 9 (or 11) until all panels are in place except for end panels.

13. Determine width of end panels required. Using a circular saw (fitted with fine tooth blade) or jigsaw cut the end panels to

width.

14. Along the cut edge of the SUNPAL panel, push on the aluminum F section (cut to size) so that it is firmly secured.

15. Lift the end panel into place and repeat step 9 (or 9-11). The aluminum F section should be hard up against last rafter or

end of purlins (note: if fixing to metal purlins, make sure the ends of the purlins are closed off ).

16. Fix the F-Section to the rafter or end of purlin using tek screws.

17. Start installing the U-Profile at the panel top end by pushing on. It is designed to be a tight fit so start by pushing one

end on and slowly tap it until it is firmly inserted. PC U-Profile (for SUNPAL 8-10mm) is to tap by hand, for Al U-Profile (SUNPAL

18-20mm) use a rubber mallet.

18. Start installing the Al Sealing Strip at the panel bottom end by pushing it on. It is designed to be a tight fit so start by

pushing one end on and using a mallet slowly tap it until it is firmly inserted. These sealing strips are necessary to prevent

penetration of dirt end moisture.

19. Joiner End-cap fixing

Insert Joiner End-cap in both joiner ends.

The End-cap for PC Joiner is pushed into place. The End-cap for Alu Joiner is fit with screws. There is no need to use silicone

sealants or adhesives of any kind.

20. Side flashings

These are used on both sides of the structure, as a fastener as well as a flashing.

They are fit either for full width or cut to size panels. Purpose made flashings are required in some situations. End-cap should fit

to these flashings on both ends.

Notes:

SUNPAL system does not require using silicones or adhesives for parts interface. For sealing of flashing assemblies Use

only PALRAM approved accessories, silicones, sealing tape, closure fixtures etc.

For cleaning SUNPAL multi panels use a pressure cleaner and allow natural drying. Do not use cloth/ sponge/ chamois or

similar, doing this can scratch the panels and harm their performance.


Assembly Details

Legend

01 Panel

02 PC Joiner

03 End-Cap for PC Joiner

04 Alu Joiner ‘C’

05 End-Cap for Alu Joiner ‘C’

06 Alu Sealing Strip

07 PC U-Profile

08 T-Fastener

09 T-Stopper

10 Alu Span-Bar

11 Alu F-Profile

12 Alu Joiner ‘R’

13 End-Cap for Aluminum Joiner ‘R’

14 Metal Screw

15 Wood Screw

16 Alu U-Profile

8

4

1

2

3

6

5 7 9

10

14

11

15

12

16

13


Cladding Detail 1: Cladding Base Note: Set T-stopper (09)

at the opposite to allow

for expansion at this end.

Cladding Detail 2: Cladding Base - Hidden Seams


Cladding Detail 3: Corner Details

Cladding Detail 4: Panels Cladding Joint

Note: Set T-stopper (09)




Cladding Detail 5: Parallel Apron Flashings

Cladding Detail 6: Parallel Apron Flashings - Hidden Seams


Cladding Detail 7: Cladding Top Flashings

Cladding Detail 8: Cladding Top Flashing - Hidden Seams

Note: Set T-stopper (09)




Roofing Detail 1: Apron Flashing

Roofing Detail 2: Eave

Note: For information on allowed

overhang please refer to “a) Joiners”

section on page 6.


Roofing Detail 3: Barge Details

Roofing Detail 4: Parallel Apron Flashing


Roofing Detail 5: Ridge Flashing

Roofing Detail 6: Hip Flashing


Roofing Detail 8: Overlap Panels

Roofing Detail 7: Valley Gutter Note: For information on

allowed overhang please

refer to “a) Joiners” section

on page 6.


©2008 PALRAM Industries Ltd.

HYG Technology is a trademark of PALRAM Industries Ltd.

EUROPE

.PALRAM EUROPE LTD

Tel (44) 1302 380776

Fax (44) 1302 380788

[email protected]

PALRAM UK

Tel (44) 1302 380738

Fax (44) 1302 380739

[email protected]

ISRAEL

PALRAM ISRAEL

Tel (972) 4 8459 900

Fax (972) 4 8459 980

[email protected]

USA

PALRAM AMERICAS

Tel 610 285 9918

Fax 610 285 9928

[email protected]

THE STANDARDS INSTITUTION OF ISRAELTT

07

.08

- 69

13

7

Inasmuch as PALRAM Industries has no control over the use to which others may put the material, it does not guarantee that the same results

as those described herein will be obtained. Each user of the material should make his own tests to determine the material's suitability for his

own particular use. Statements concerning possible or suggested uses of the materials described herein are not to be construed as constituting

a license under any PALRAM Industries patent covering such use or as recommendations for use of such materials in the infringement of any

patent. PALRAM Industries or its distributors cannot be held responsible for any losses incurred through incorrect installation of the material. In

accordance with our company policy of continual product development you are advised to check with your local PALRAM Industries supplier to

.ensure that you have obtained the most up to date information

Manufacturer’s Lifetime Warranty

SUNPAL panels are guaranteed for water leak-proof performance for 25 years. SUNPAL panels bear a limited lifetime warranty not

to lose more than 8% of light transmission for 15 years and no more than 1% per year thereafter, when measured according to

ASTM D1003-77. SUNPAL panels are warranted for up to 10 years from the date of purchase not to break or fail as a result of impact

by hail measuring up to 20mm in diameter, in speed of up to 21m/s.

Note: these warranties will apply only if the panels are installed and maintained according to PALRAM specifications and installa-

tion instructions.

Multiwall Polycarbonate Standing-Seam Technical Guide · SUNPAL is an advanced multiwall polycarbonate panel system that combines smart design, light transmission, high thermal insulation

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