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HomeMy WebLinkAboutProject Monitoring Railing Change.930 King St.20220119930 King Street Project Monitoring: Changes to roof deck railing Description provided about drainage: The drainage will remain the exact same as before. We analyzed it closer and worked through a solution we are comfortable with. The glass will be attached using standoffs along the inside face of the curb. With heat tape along the cricket on the back side, snow shouldn’t lay against the glass, which was the concern previously. C U S T O M E R P R O D U C T I O N Q U A L I T Y G U I D E L I N E S - L A M I N A T I O N A N D I N T E R L A Y E R S - C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A English Introduction Definitions ….........……………………. pp. 3-8 EVA Plastic material Thermoplastic material Thermosetting material Laminated glass Laminated safety glass Decorative laminated glass Solar control laminated glass Optical properties .………………… pp. 9-10 Ultraviolet rays Infrared rays Haze Mechanical properties ..………… pp. 11-12 Cross-linking Shrinkage Instructions for use ..…………….. pp. 13-15 Storage and handling Use of rolls Use by date Product imperfections Lamination process ………………. pp. 16-28 Guidelines Oven types Vacuum system TK laminating ovens Equipment check Thermal Mapping Laminated glass testing Production control Glass preparation Area of working Glass washing Production line design Accelerated glass cooling Laminating cycle steps Process conditions Laminating cycle …...…...………………………... pp. 29-36 Lamination area scheme Recipes Management of holding time Correction of holding time Autoclave glass lamination Recipes Building safety certifications ………………….. pp. 37-38 Impact resistance Resistance to manual attack Technical data ...…...………………………………... pp. 39-43 Properties of laminated glass Transmittance data Shear and Young Modulus Post-lamination problems .…………………….. pp. 44-50 Tips and tricks Cleaner edges (EVA leakage) Edge-Stress Delamination Air bubbles Spider-web air bubbles Dark dots Haze Locations and contacts ..………………………… pp. 51-52 A number of vocabularies and topics related to the glass and lamination sector have been collected in the following pages: each one comes with a description and other comments. Below is a summary classified into macro categories: S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Confidential 1 of 52 Technical information and data in this guide should be considered representative and not used for design purposes. Introduction STRATO® is a thermosetting product and it will provide good performance and stability in finished products only if it is processed in the laminating oven in the correct way paying close attention to temperature, time, heating homogeneity and quality of the laminating equipment. These are the four critical points of lamination and it must be kept in mind that laminating a thermoset film is very different from laminating a thermoplastic film (e.g. PVB). S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A storage and handling documentation of use of rolls initial check of laminating equipment initial testing of laminated safety glass products factory production control – batch inspection, oven checks lamination-process guidelines It is important that the STRATO® customer understands the importance of following the quality and process guidelines listed in this guide: Before going into detail on the points listed above, it is good to understand some basic technical notions to improve the knowledge about the innovative materials offered by STRATO®. Confidential 2 of 52 It does not undergo the delamination process, which means a reduction or potentially a total loss of adhesion between the glass panes and the interlayer. EVA (Ethylene Vinyl Acetate) It is not a hygroscopic material, so it is more resistant to moisture than PVB, which suffers from a high degree of water vapour absorption. Its storage does not require climatic cabins with controlled temperature and humidity. As a result, there are cost savings in terms of logistics and operations. The STRATO® EVA film, produced by Satinal Spa, is a thermosetting plastic material with excellent thermomechanical properties, which confer it durability and stability beyond any thermoplastic (e.g. PVB). S T R A T O ® | G L A S S I N T E R L A Y E R S It has excellent acoustic insulation properties - soundproofing - in the high frequency range. It guarantees high adhesion to glass and inserts of different materials. It has a high resistance to high temperatures and UV rays. It has excellent optical properties and a low light reflection effect. It is perfect to be applied in buildings located in sunny areas where solar control is essential for energy saving. STRATO® has achieved the certifications of durability and resistance to humidity, high temperatures and solar radiation according to European standard UNI EN ISO 12543-4:2011 and American standard ANSI Z97.1-2015. Request our certifications by sending an email to customer@satinal.it C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Highlights Definitions 3 of 52 S T R A T O ® | G L A S S I N T E R L A Y E R S thermoplastics materials (e.g. PVB) thermosetting materials (e.g. EVA) Plastics is a family of artificial materials characterized by a particular macromolecular structure. These materials are subject to permanent alterations in their shape when certain conditions of pressure and temperature occur. Plastics are divided into: Plastic material Thermosetting material (e.g. EVA) As the temperature increases, thermosetting materials turn into rigid, insoluble and infusible materials. They react to heat first by softening, then they harden again thanks to a three-dimensional cross-linking process. They do not return to their soft/melted state when heated again. Thermosetting materials can be shaped combining the effect of heat and pressure. The stiffness of the STRATO® EVA film gives the laminated glass the characteristic of keeping it in position even after a glass breakage, avoiding instant collapse and guaranteeing the safety of people and goods until it is restored. According to the peel test, STRATO® has an adhesion to glass higher than 150 N/cm. Thermoplastic material (e.g. PVB) Thermoplastic materials (PVB), react to heat by softening and therefore acquiring a ductility that allows the modeling to create the finished products. Each time the material is heated, it melts again, softening and returning to its malleable state. C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Highlights 4 of 52 Definitions Glass EVA film Glass Laminated glass S T R A T O ® | G L A S S I N T E R L A Y E R S Originally made in 1903 by the French chemist Benedictus, the laminated glass consists of two or more panes of flat or curved glass, glued together by one or more layers of transparent or coloured plastic material. Laminated glass is used as safety glass in the architecture and building sector, because it prevents people or things from falling and in addition it plays a key role in energy saving in case of solar control glass or interlayers. In addition to the plastic interlayer, it can be possible to add different inserts (fabric, wire mesh, coloured PET, etc.) to obtain decorative laminated glass to be used as furniture elements for interior design. C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A 5 of 52 Definitions Laminated safety glass S T R A T O ® | G L A S S I N T E R L A Y E R S protection from injury class 2(B)2 - UNI EN 12600 protection from falls class 1(B)1 - UNI EN 12600 protection against break-ins and vandalism from class P1 to class P8A - UNI EN 356 bulletproof from class BR1 to class BR7 - UNI EN 1063 When the laminated glass is hit by a foreign object, the breakage remains on the impact point. The EVA interlayer applied between the two glasses retains the splinters, reducing the risk of cuts. It also absorbs the residual energy of the object avoiding its passage. According to its performance, the laminated glass is classified by European standards with different levels of safety: Decorative laminated glass The scheme reported in the UNI 7697/15 standard summarizes and identifies cases, damages  and the types of glass to be used in areas of potential risk. Glass has always been employed in the building construction industry, often limited to doors and windows, but today it is experiencing a real revival. From walls to stairs, from balustrades to the furnishing elements of offices, shops and residential buildings, nowadays this material is a must for a contemporary, minimal and elegant design. In addition to the classic transparent, frosted, black and white finishings, it is possible to insert - between the STRATO® EVA interlayer and glass - materials such as fabrics, wire mesh, marble, etc. to achieve chromatic and decorative effects with surprising and innovative aesthetic results always in line with the latest trends. C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A 6 of 52 Definitions Polyester (printed, colored, solar control coated or metallic) Polycarbonate Acrylic Silk and fabrics Paper Photographs Stone and wood panels Natural materials (leaves, grass, etc.) Perforated sheets and wire mesh Plastic Electroluminescent inserts Liquid Crystal Inserts (Smart Glass) LED STRATO® offers creative and versatile possibilities with high value added thanks to its compatibility with different inserts and supports. For example: S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Highlights 7 of 52 Definitions An EVA film enhanced with nanoparticle technology, such as STRATO® FRESCO, gives laminated safety glass more efficient solar heat control properties than monolithic transparent glass and traditional laminated glass with transparent EVA film. Laminated glass with STRATO® FRESCO (solar control) allows a specific part of the solar energy radiation to pass through and provides good lighting and avoids overheating. They can replace Low-E (Low-E) glass because they reduce heat transmission, with the advantage of having a resistant and safety glass easy to handle. They also represent a cheaper solution in terms of storage processing, handling and purchasing. Selectivity ratio between the light transmission of a glass and its solar factor. The closer the ratio is to 2, the more selective the glass is, so it offers better performance. Solar factor (FS) expresses the total amount of energy (i.e. heat) passing through the glass. Light transmission (TL) expresses the amount of visible light transmitted through the glass. Light reflection (RL) expresses the amount of light reflected from the glass. Thermal transmittance is the amount of average heat flow per square metre of surface area that passes through a structure that delimits two rooms at different temperatures. The unit of measurement of thermal transmittance is W/m2 K. STRATO® Fresco absorbs UV rays and infrared energy (NIR), allowing maximum visible light transmission. Request the data sheet sending an email to customer@satinal.it Solar control laminated glass S T R A T O ® | G L A S S I N T E R L A Y E R S Solar control glass Indoor temperature C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Cool environment Float glass Highlights Hot environment r a diatio n radiation No greenhouse effect Greenhouse effect heat 8 of 52 Definitions UV(C), at its shortest wavelength (100 - 280 nm), is the most dangerous radiation but fortunately it does not reach the earth's surface because it is absorbed into the atmosphere by the ozone layer. UV(B) is the second radiation for wavelength (280 - 315 nm) and it is almost completely blocked by the glass used for conventional window construction. UV(A) is the radiation at wavelengths between 315 - 380 nm and generally it is considered the most important energy in glazing and coatings. It is responsible for about 95% of the ultraviolet radiation that reaches the earth's surface all year round, even on cloudy days. It is unhealthy for people and it is also the main cause of discoloration of furniture and furnishings or goods on display in shop windows. UV rays are a kind of radiation invisible to the human eye. They represent the portion of the electromagnetic spectrum located between X-rays and visible light at a wavelength between 100 - 380 nm. This energy radiated by the sun is divided into three categories: Ultraviolet rays (UV) In order to minimise the risk caused by the UV radiation, it is recommended to use laminated glass with STRATO® EVA film. The insertion of STRATO® interlayers between two glass panes ensures the maximum protection from UV rays by blocking more than 99% of their transmission, while maintaining high visible light transmission (> 90%). UV(C)UV(B)UV(A)VISIBLE LIGHT INFRARED RAYS 100 nm 280 nm 315 nm 380 nm 700 nm Wavelength S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Optical properties X-RAYS MICROWAVES 1050 nm 10 cm0,1 pm 9 of 52 SUN S T R A T O ® | G L A S S I N T E R L A Y E R S Haze is an optical effect usually associated with high-gloss surfaces. It is a problem that can affect the quality of the appearance of glass. The cloudy/opaque effect may appear or it could be perceived as a very thin film of dust on the glass that cannot be removed; this confers a milky appearance to the glass reducing the quality of its overall visual appearance whereas it should be clear and transparent. In the case of clear architectural materials, it is usually more appropriate to use transparent glass with a low Haze percentage and a high light transmission. Haze STRATO® Extra Chiaro has a Haze value less than 0.5% while STRATO® Plus less than 0.3%. Infrared rays are electromagnetic waves whose wavelength is greater than 700 nanometres (nm), which is the value that delimits the transition from the visible to the invisible light spectrum. When infrared rays reach a window, they are not blocked by the standard monolithic or laminated glass. By entering inside a room, they help to increase the temperature of the room because they turn into heat hitting solid objects (greenhouse effect). Infrared Rays (IR) Request the data sheet sending an email to customer@satinal.it C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Highlights 10 of 52 Optical properties S T R A T O ® | G L A S S I N T E R L A Y E R S The cross-linking is the process by which the EVA polymer chains meet a reaction that creates strong links between different chains. Cross-linking Chains A Chains B Chains C CROSS-LINKS The cross-linking of the molecules is chemically activated during the lamination process: the STRATO® EVA film changes permanently into a thermoset material at rising temperatures. It is an irreversible change, therefore there is no further mutation if exposed to high temperatures again. The cross-linking process is carried out to improve the elasticity, the stiffness, the clarity, the ageing properties, the heat and moisture resistance of the STRATO® EVA film. If STRATO® is successfully processed, its cross-linking rate should be higher than 90% (solvent extraction test). C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Highlights Mechanical properties 11 of 52 S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A The shrinkage rate is the volume loss or contraction of a material caused by a chemical or physical change in the material itself. The manufacturing process of STRATO® product range is carried out paying attention to every details, ensuring the lowest possible shrinkage effects of the EVA film, a feature that makes STRATO® standing out from most competing products available on the market. The low shrinkage rate of the STRATO® films guarantees a long-lasting stability of the laminated glass, thus allowing special inserts and fabrics to be laminated without any deformation of the materials inserted between the glass panes. Shrinkage rate STRATO® products have a shrinkage rate less than 5%. Satinal performed the shrinkage test (shrinkage test - 100°C/212°F for 20 minutes) on a sample of STRATO® EVA film and a sample of a competitors EVA film on the market. In the pictures below, you can easily see the differences: the STRATO® EVA film keeps its original shape, without significant deformation. On the other hand the competitors EVA film sample shows important distortions, changing completely its original shape. Highlights 1.Samples before shrinkage test 2.Samples after shrinkage test 12 of 52 Mechanical properties S T R A T O ® | G L A S S I N T E R L A Y E R S Instructions for use C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A STRATO® is an adhesive interlayer for laminating glass with architectural and design purposes. Furthermore, it can be used with inserts of different materials, such as fabrics, wire mesh, PET films, etc., but it is very important to carry out previous compatibility and ageing resistance tests. If these preliminary checks are not carried out, it may be possible to have problems after lamination, such as poor adhesion or discolouration. Our tip Satinal recommends a very careful and professional approach when using STRATO®, especially in combination with other inserts. When using STRATO® please proceed with the utmost caution and always test and verify the compatibility and performance according to the appropriate standards and test methods. Send an email to customer@satinal.it or call +39 031 870573 to schedule a compatibility test in the in-house S-Lab. 13 of 52 The storage area of STRATO® must be dust-free, cool (temperature between 0°C/32°F and 35°C/95°F), dry (relative humidity less than 60%), not exposed to direct sunlight or heat sources and in uncontaminated air (chemicals, smoke, drains, dust, etc.). It is necessary to prevent moisture settling on the STRATO® film. If there is a risk of condensation, the roll must be placed at room temperature for at least 24 hours before opening. As soon as the goods arrive at their destination, they must be immediately unloaded from the truck/container and stored in their original packaging to protect them from dust and/or other contamination. Never leave the goods lying in the forwarder cargo box/container or outside, even for a short period of time. Also the lay-up area of the laminated glass must be protected from dust or moisture coming in from the surrounding production area. The rolls of STRATO®, partially used, should be wrapped in PE film overnight and protected from moisture, dust and other potential contamination. Alternatively, it is recommended to re-pack them in their original packaging, or in a clean box. Storage and handling S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Use of rolls Is the first opening date recorded with the corresponding roll number for each new opened package? Are the roll numbers of the STRATO® film used recorded with the production date for each lamination project? If not, we recommend introducing this roll and batch identification system for traceability purposes. 14 of 52 Instructions for use Technical information and data in this guide should be considered representative and not used for design purposes. S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Please use STRATO® before the expiration date: within 1 year from the production date indicated on the label applied on the cardboard box; within 6 months from the opening of tinfoil paper. It is recommended to keep this label and record its expiry date. Using STRATO® after this date may decrease its performance and may cause problems of adhesion, delamination, etc. Use by date Product imperfections STRATO® film may have post-production imperfections. They are marked, if present, with a coloured sticker applied to the roll in the corresponding area. Satinal has set a maximum tolerance of 5 defects per single STRATO® EVA film roll. For each marker on the roll, 1 linear meter is added free of charge, in order to guarantee the highest quality on the total quantity ordered by the customer. The roll will be automatically rejected by Satinal Quality Control if there are more than 5 defects. Highlights 15 of 52 Instructions for use S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Lamination process guidelines The chart "Property differences under various processing conditions" on page 27, provides an approach to determine the right laminating cycle for your oven. It will be necessary to adjust the holding times according to the thickness of the glass and the temperature uniformity of the furnace used. STRATO® requires uniform temperature processing. Therefore the indicated temperatures must be uniform over the entire glass surface in order to obtain all the advantages of cross-linking from a quality product such as STRATO®. The type of oven is therefore a key factor for a high quality laminated glass: there are many companies offering ovens on the market, however some are poor in quality and performance. The main aspects to consider when purchasing a furnace are efficiency, energy consumption, cooling, quantity of load per tray, multi-tray or single tray, thermal uniformity control, vacuum systems, etc. Satinal uses TK ovens to perform all product tests. Highlights Oven types In order to get all the advantages of the cross-linking process of a quality product such as STRATO®, it is necessary to have a high degree of heat uniformity during the lamination process. Otherwise, it will be very difficult, inefficient and sometimes impossible to control the process. TK S.r.l. is specialized in the design and construction of laminating, tempering, chemical tempering and HST furnaces. TK laminating ovens are divided into three different types: convection heating (Lamijet Convection), infrared heating (Lamijet) and conduction heating (Breva). They are available in various sizes and can be customized. Lamination process 16 of 52 S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Depending on the manufacturer, each furnace has a different vacuum system. If the vacuum is not stable and/or weak, the quality of the laminated glass will be varying or poor. Vacuum system Our tip It is recommended to purchase medium-high quality ovens with efficient vacuum systems. False economies can be expensive. Highlights 17 of 52 Lamination process Contact TK technicians for a free advice. They will guide you in choosing the oven that best suits your production needs and installation space. Send your request by email to service@tkitaly.com or call us at +39 031870573 S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A TK's laminating furnaces are divided into three different types: TK laminating ovens 18 of 52 Lamination process Possibility of laminating EVA - PVB - SentryGlas without autoclave High flow rate hot air circulation heating system Rapid cooling system with fresh air circulation Maximum temperature uniformity with thermocouple control Vacuum circuit with highly efficient oil pumps Possibility to adjust the vacuum based on the type of materials 1. Convection heating | Lamijet Convection Possibility of laminating EVA - SentryGlas Heaters' supports with ceramic insulators Heaters placed above and below the working surface Vacuum circuits with high efficient and high capacity oil pumps (one for each working plane) for maximum process efficiency Available in various sizes and with one or more processing chambers Possibility to adjust the vacuum based on the type of materials 2. Infrared heating| Lamijet Possibility of laminating EVA - PVB - SentryGlas with laminating cycles in less than an hour Electric conduction heating system and fast curing Maximum temperature uniformity Temperature control over multiple independent zones Temperature regulation with thermocouple connected to a digital microprocessor Position photo-cell for automatic glass loading and unloading Fast cooling 3. Conduction heating| Breva Vacuum bag preparation - mapping and thermal verification Most laminating furnace control systems do not show the temperatures measured in or on the glass. Normally they only detect the temperatures inside the furnace: this is generally insufficient if you want to know exactly what is happening in terms of temperature in the glass and to have a guarantee of the correct cross-linking of the EVA film. It is recommended to map the temperatures inside the oven with calibrated instruments and thermocouples (at least +/- 1.5° C tolerance). The probes must be positioned on or inside the glass and then it must be placed in the silicone or PE (disposable) vacuum bag. Initial check of laminating equipment S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A at the beginning of the holding phase after 30 minutes of holding time melting: holding time between 85°C (185°F) and 95°C (203°F) cross-linking: holding time at temperatures between 105°C (221°F) and 150°C (302°F) In order to analyse the heat transmission inside the laminating furnace, it is recommended to take note of the temperatures during the holding times in the following specific phases: The holding phases are carried out during the melting and the cross-linking process of the EVA film, in particular: The laminated glass should measure at least 200x200 mm and have a minimum thickness of 4 mm in order to carry out the thermal check. Highlights 19 of 52 Lamination process Technical information and data in this guide should be considered representative and not used for design purposes. This thermal mapping is carried out during laminating cycles with a standard production glass load. The thermocouples must be placed in the centre and in every corner of the single tray used and always on or inside the laminated glass. Mapping is recommended if you are using a new furnace or a new program or product, and regularly every 3 - 4 months to ensure stability of performance. Does the vacuum system reach a residual pressure of less than 50 mbar during the entire cycle? If not, there may be a leak or problems with the vacuum pump. It is recommended to check the cross-linking rate obtained at the thermocouples during cycles at cross-linking temperatures between 105°C (221°F) and 150°C (302°F) in order to verify the process. Satinal and TK's technicians are specialized in glass lamination and they are at customers' disposal to support them in setting the start-up parameters and during the glass lamination process. S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Highlights 20 of 52 Technical information and data in this guide should be considered representative and not used for design purposes. Lamination process Some glasses can heat up differently than others due to dimensional, colour, coating and structure differences. This kind of change also depend on heating methods, e.g. IR radiation, targeted hot air, convection, direct heat, etc. - and of course on the type of vacuum bag. Through the thermal mapping process you should pay attention to identify the specific compensation factors required for the main glass combinations, dimensions and thicknesses. Sometimes it is necessary to consider seasonal factors as well. In some countries glass temperatures and room temperatures can change significantly between winter and summer. In addition it is important to seal the vacuum bag at the point where the thermocouple wire comes out. The lack of an hermetic sealing may cause damage to the vacuum pump over time and may not guarantee sufficient air leakage between the glass to be laminated. Therefore, it may be necessary to apply a sealant or gasket depending on the type of thermocouple and vacuum bag. S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Thermal mapping vacuum bag Teflon nets microperforated green scotch thermocutter USB datalogger Some accessories for laminating can be ordered from Satinal, including: Send an email to customer@satinal.it for more information. Highlights 21 of 52 Lamination process Laminated glass testing Glass laminated with STRATO® must be tested according to EN 14449 (CE marking). The process and materials used must be documented. When new glass inserts and/or new glass thicknesses are laminated, the laminating cycle must be adjusted in times and temperatures according to the type of material or thickness. The compatibility of the inserts with the EVA film must be tested with adhesion and durability tests according to EN 14449: high temperature resistance test (boiling test for 2 or 16 hours) and high humidity test. S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Depending on the type of product to be laminated and its specific application, further tests such as the measurement of adhesion and other physical properties should also be carried out 'after ageing'. For the application of sealants or adhesives to the edges of installed panels, the compatibility of the sealant to be used with STRATO® and the additional insert must be checked. In general, silicones or adhesives with a certain acid content can damage the EVA film, even ones that look neutral. Some manufacturers sometimes change the ingredients. It is recommended to carry out occasional tests in order to recheck compatibility. Please contact Satinal Customer Service to request a compatibility test. Send your request to customer@satinal.it Our tip Highlights 22 of 52 Lamination process It is necessary to test all products that will be exposed to the sun or to UV radiation. It is recommended to test these items with a double solar intensity radiation test of at least 1000 hours. It is recommended to increase the test duration and intensity for specific applications, such as outdoor open-edge glass installations, to estimate the visual and mechanical degradation of the glass. Moreover, you should also check the cleaners: it is recommended to avoid those based on acetic or citric acid which can damage interlayers such as STRATO® EVA film or PVB as well. S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A For structural safety glass applications such as balustrades, it is recommended to follow local specifications and requirements - also in terms of testing. Factory Production Control – batch inspection, oven checks once a month, perform the peel test on at least five STRATO® - Glass samples. once a month, perform the test at high temperature (2h or 16 h at 100°C/212°F, possibly in boiling water) on at least five STRATO®-glass samples. Production control is required in Europe for each type of laminated glass according to EN 14449 (CE marking). For instance: In addition, if there is a temperature difference of more than 15°C (59°F) - in the melting phase at 85°C (185°F) - or more than 10°C (50°F) - in the cross-linking phase between 105°C (221°F) and 150°C (302°F) - the temperature of the oven must be measured once a week for at least one cycle of each production batch. Satinal recommends thermal mapping of the furnace at least once a year. It might be necessary every 3 - 4 months, depending on the type of furnace used. Our tip Highlights 23 of 52 Lamination process Using roller devices, the glass is carried to the washing area. The glass panes are carefully cleaned and dried with automatic machines. Dry and clean glass panes are assembled with EVA film to create a sandwich. The assembled glass is inserted into a silicone bag for the lamination process. Glass preparation S T R A T O ® | G L A S S I N T E R L A Y E R S A preprocessing is required before the glass laminating cycle: The glass is cut to the required shapes and sizes according to customer specifications. C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Working area The area in which the glass is processed should be protected and sheltered by external factors. This will prevent the passage of air flows and provide protection from dust. It is recommended to clean the working area regularly. A clean working environment is necessary also for safety reasons. In general, it is recommended not to have the working area close to exits or entrances in order to avoid exposure to light and/or contaminated air. Our tip Next to the washing area, it is recommended to place the Lay-Up area: this is where the EVA film is applied to the glass, which will be laminated. 24 of 52 Lamination process S T R A T O ® | G L A S S I N T E R L A Y E R S In warmer countries it may be necessary to install an air conditioner in the Lay-Up area to ensure that temperatures always remain below 25°C (77°F) - 30°C (86°F). Even a simple air filter is a good solution. It is recommended that workers wear dust safety suits including a hood to prevent hair from falling onto the glass. In addition, gloves approved by the glass industry should always be worn. Glass and laminating film should no longer be touched with bare hands after the glass has passed through the washing area. C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Glass washing Washing glass is a very critical part of the manufacturing process. Some problems may occur due to poor washing or contamination of the washed glass. The water quality and the cleaning of the glass should be checked regularly to prevent small particles from remaining on the glass. Therefore, it is recommended to operate in a clean area and using ethanol or isopropanol-based glass cleaners. Always use clean, dust-free gloves when handling and washing glass. It is recommended to allow the detergent to fully evaporate before application (5 to 10 minutes). Production line design As far as possible a linear layout of the production is recommended; the furnace should also be loadable from the front and unloadable from the back. This solution is very efficient in terms of productivity and allows a reduction of the cooling time of the glass outside the furnace. This provides advantages in terms of energy efficiency and improved optical quality of the glass. Fast cooling of the glass STRATO® benefits from fast cooling, because this avoids slight recrystallization trends. Cooling can be accelerated by using industrial fans. In warmer countries, it may be necessary to insulate the cooling zone and install an air conditioning system (depending on the time of the year). The cooling speed should be at least 2°C/minute. 25 of 52 Lamination process S T R A T O ® | G L A S S I N T E R L A Y E R S The above processing parameters are intended as a guideline. Differences can be recorded from one laminating furnace to another and it is important to note that temperatures are measured on the glass by thermocouple, not only as furnace lamination parameters. C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Highlights 26 of 52 Lamination process After inserting the glass into the vacuum bags placed on the oven trays, the laminating process can start. It is based on setting a specific temperature cycle that depends on the thickness of the glass and on the type of film used. STRATO® requires homogeneous processing temperatures: they have to be uniform over the entire glass surface, in order to obtain all the advantages of the cross-linking process related to an high quality product such as STRATO®. It is recommended to measure the temperatures inside the furnace with calibrated instruments and to use the thermocouples inside the glass to detect the exact temperature to ensure the correct cross-linking of the STRATO® EVA film. The laminating process consists of 4 steps: Pre vacuum Melting Cross-linking Cooling down In this first phase, the glass assembled with the EVA interlayer is placed inside a silicone bag, which must be carefully sealed. The vacuum system allows to obtain the total vacuum inside the silicone bags ensuring the de-airing process and lamination. This phase lasts about 15 minutes at room temperature (about 25°C/77°F) and the vacuum in the bag must be at least - 0.8 bar. The temperature is steady between 80°C (176°F) and 90°C (194°F) and, in about 20 minutes, the melting phase of the EVA film takes place. Then the temperature increases to the cross-linking temperature. The EVA cross-linking starts at 105°C (221°F), a chemical process to obtain a high quality finished product. Over 105°C (221°F), the cross-linking process accelerates significantly, so it is suggested to reach at least 130°C (266°F) on the glass. At this specific temperature the curing time to obtain a cross-linking greater than 90% is about 45 minutes. See the chart on page 27 to estimate the exact holding time of the glass in the furnace at different cross-linking temperatures. The cooling phase begins at the end of the cross-linking process, which can be carried out with or without holding the vacuum in the silicon bag. The temperature falls rapidly until the glass is completely cooled. S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A 27 of 52 Lamination process Negative performance Positive performance Excellent performance (for indoor and outdoor) I = insufficient OK = good E = excellent ND = not determinedData legend: Colours legend: Over curing Property Differences Under Various Processing Conditions Technical information and data in this guide should be considered representative and not used for design purposes. 212 °F 221 °F 230 °F 239 °F 248 °F 257 °F 266 °F 275 °F 284 °F 302 °F glass 1/8" STRATO® .030 glass 1/8" glass 3 mm STRATO® 0,8 mm glass 3 mm S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A 28 of 52 Lamination process Lamination area scheme (convection/conduction/Infrared irradiation ovens) Layout of laminating line with convection/conduction/Infrared irradiation ovens L a y -u p a r e a F i l m s t o c k W a s h i n g a r e a F e e d e r A c c e l e r a t e d c o o l i n g a r e a F i n i s h e d g o o d s a r e a By increasing the thickness of the glass, the lamination cycle time also increases, because thicker glass takes longer time to heat up. The laminating cycle has to be verified by mechanical and optical tests to ensure that the correct EVA interlayers should be cooled as quickly as possible to minimise the Haze. It is important to follow the processing methods suggested by the manufacturer of the EVA film. cross-linking has been achieved. Poor transparency indicates insufficient cross-linking during lamination. S T R A T O ® | G L A S S I N T E R L A Y E R S Laminating cycle Recipe example - high temperature The above processing parameters are intended as a guideline. Differences can be recorded from one laminating furnace to another and it is important to note that temperatures are measured on the glass by thermocouple, not only as furnace lamination parameters.GLASS GLASS EVA FILM THERMOCOUPLE C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Highlights Pre vacuum Melting Sample structure: glass 3 mm (1/8") STRATO® 0,4 mm (.015) glass 3 mm (1/8") Temperatures: measured on glass *based on the thickness of the glass Oven type: Lamijet TK with vacuum bag Time (min) Temperature °C 80° C (176°F) / 20 min* 135°C (275°F) / 45 min* Cross-linking Cooling down 29 of 52 Pre-vuoto Fusione Reticolazione Raffreddamento Time (min) Temperature °C 60° C / 20 min 115° C / 120 min 115°C (239°F) / 120 min* T° decrease T° decrease S T R A T O ® | G L A S S I N T E R L A Y E R S Recipe example - standard temperature C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Pre vacuum Melting Cross-linking Cooling down 80°C (176°F) / 20 min* 130°C (266°F) / 60 min* Recipe example - low temperature Pre vacuum Melting Cross-linking Time (min) Temperature °C 80°C (176°F) / 20 min* for LCD lamination, Smart Glass and special inserts Cooling down Time increase Time increase 30 of 52 Laminating cycle Sample structure: glass 3 mm (1/8") STRATO® 0,4 mm (.015) glass 3 mm (1/8") Temperatures: measured on glass *based on the thickness of the glass Oven type: Lamijet TK with vacuum bag Sample structure: glass 3 mm (1/8") STRATO® 0,4 mm (.015) glass 3 mm (1/8") Temperatures: measured on glass *based on the thickness of the glass Oven type: Lamijet TK with vacuum bag S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Recipe example - lowest processing temperature Pre vacuum Melting Cross-linking Time (min) Temperature °C 80°C (176°F) / 20 min* 105°C (221°F) / 240 min* Cooling down Recipe example - Fast curing Pre vacuum Melting Cross-linking Cooling down Time (min) Temperature °C 85°C (185°F) / 20 min* 140°C (284°F) / 30 min* Time increase T° decrease T° decrease Time decrease 31 of 52 Laminating cycle Sample structure: glass 3 mm (1/8") STRATO® 0,4 mm (.015) glass 3 mm (1/8") Temperatures: measured on glass *based on the thickness of the glass Oven type: Lamijet TK with vacuum bag Sample structure: glass 3 mm (1/8") STRATO® 0,4 mm (.015) glass 3 mm (1/8") Temperatures: measured on glass *based on the thickness of the glass Oven type: Lamijet TK with vacuum bag S T R A T O ® | G L A S S I N T E R L A Y E R S Management of holding time Thicker glass requires longer holding times during the melting and cross-linking phases because it takes longer to reach the required temperature and to heat uniformly. The management and correction of the holding time depends on the heat transfer conditions in the laminating equipment (vacuum furnace or autoclave). It is recommended to determine the appropriate time correction for the equipment used by testing. The following data are intended as a first indication and refer to the temperatures to be measured on the glass: Glass Thickness (mm)Material STRATO® film 3 + 3 4 + 4 5 + 5 6 + 6 8 + 8 10 + 10 12 + 12 15 + 15 0.4 0.4 0.8 - 1.2 - 1.6 Pre Vacuum at room temperature Heating to 80 °C Holding time at 80°C Heating to 135°C Holding time at 135°C Cooling down to 50°C Natural or forced cooling with or without vacuum holding in the silicon bag 15 min 15 min 15 min 20 min 20 min 20 min 20 min 20 min 20 min 30 min 30 min 30 min 30 min 30 min 30 min 30 min 30 min 25 min 35 min 40 min 45 min 55 min 65 min 80 min 95 min Time (minutes)Cycle / Glass temp. C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A 0.8 - 1.2 0.8 - 1.2 - 1.6 32 of 52 Laminating cycle Technical information and data in this guide should be considered representative and not used for design purposes. The chart suggests a simple scheme to determine the correct laminating cycle. The holding time should be adjusted according to the thickness of the glass and the temperatures indicated should be uniform along its entire surface. The type of furnace is essential for the quality of the glass laminated with STRATO®. Highlights S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A 33 of 52 Technical information and data in this guide should be considered representative and not used for design purposes. Laminating cycle Glass Thickness (inches)Material STRATO® film 1/8"+1/8" 5/32"+5/32" 3/16"+3/16" 1/4"+1/4" 5/16"+5/16" 3/8"+3/8" 1/2"+1/2"5/8"+5/8" .015 .015 .030 - .045 - .060 Pre Vacuum at room temperature Heating to 176 °F Holding time at 176 °F Heating to 275 °F Holding time at 275 °F Cooling down to 122 °F Natural or forced cooling with or without vacuum holding in the silicon bag 15 min 15 min 15 min 20 min 20 min 20 min 20 min 20 min 20 min 30 min 30 min 30 min 30 min 30 min 30 min 30 min 30 min 25 min 35 min 40 min 45 min 55 min 65 min 80 min 95 min Time (minutes)Cycle / Glass temp. .030 - .045 .030 - .045 - .060 The chart suggests a simple scheme to determine the correct laminating cycle. The holding time should be adjusted according to the thickness of the glass and the temperatures indicated should be uniform along its entire surface. The type of furnace is essential for the quality of the glass laminated with STRATO®. Highlights S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A 34 of 52 Laminating cycle Radiation oven, good heat transfer: Convection oven, good heat transfer, autoclave: Convection oven, slow heat transfer: Thicker glass requires longer holding times. The time correction depends on the heat transfer conditions in the laminating equipment (vacuum furnace or autoclave). Glass laminators should determine the appropriate time correction for their equipment by testing. The following values are intended as guidelines and they refer to the total thickness of the glass higher than 6 mm. +3 minutes per mm additional glass thickness +2 minutes per mm additional glass thickness +3 minutes per mm additional glass thickness Examples: a) Radiation oven, good heat transfer, 12+12 mm: 18 mm additional glass thickness, time correction +54 minutes b) Convection oven, slow heat transfer, 10+10+10 mm: 24 mm additional glass thickness, time correction +72 minutes Corrections for other glass thicknesses Technical information and data in this guide should be considered representative and not used for design purposes. Corrections of holding time The curing times indicated in the table above (pages 32-33) are valid for the temperatures measured on the glass. They might be significantly different from the temperatures measured in other positions in the oven or autoclave and from the parameters to set into the oven. S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Autoclave lamination The transportation of glass sheets is handled from section to section using a pneumatically supported roller conveyor system. The first stage takes place in the loading area of the plates. Workpieces will be moved to a washing and drying area, consisting of an automatic washing machine with demineralised water. The sheets of interlayers are then laid between the glass sheets in an air-conditioned environment with controlled temperature and humidity, depending on the type of product desired. Any excess of EVA thermosetting film is then removed manually or by automatic cutting machines in relation to the final pane size. The assembled glass pane then passes through the lamination line which consists of one or more furnaces and calenders. Using specific machines, the glass is heated and then passes through the calender for de-airing purposes. This process is necessary to facilitate the deaeration process, eliminating as much air as possible between the EVA thermosetting film and the glass panes and to enable the adhesive properties of the interlayer. The pre-assembly phase with furnace and calender can be replaced by other processes such as "Vacuum Bag". After the pre-assembly phase, such as pressing rolls or Vacuum Bag, the glass is put into the autoclave to finish the cross-linking process. The steps of an autoclave cycle are: pressurization, heating, holding at high temperature, cooling and depressurization. 35 of 52 Laminating cycle Layout of laminating line with autoclave S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Two-stage laminating recipe example - Pre-lamination with oven or vacuum bag Time (min) Temperature °C Time (min) Temperature °C Sample structure: glass 3 mm (1/8") STRATO® 0,4 mm (.015) glass 3 mm (1/8") Temperatures: measured on glass *based on the thickness of the glass Oven type: Pre-heating oven with pressing rolls or vacuum bag Sample structure: glass 3 mm (1/8") STRATO® 0,4 mm (.015) glass 3 mm (1/8") Temperatures: measured on glass *based on the thickness of the glass Oven type: Autoclave Vacuum pressure (bar) Room T° / 15 min* 90°C (194°F) - 100°C (212°F) / 30 min * or passage through pressing rolls Recipe example - Autoclave lamination Vacuum pressure (bar) 135°C (275°F) / 45 min* Room T° 12 bar 12 bar 0 bar0 bar -1 bar -1 bar 0 bar 36 of 52 Laminating cycle S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Building safety certifications Safety concept, applied to laminated glass for the design of public and private structures, includes both injury prevention (to reduce the risk of injury) and protection against vandalism and/or burglary attempts. The glass is classified by its impact performance according to the following standards: European standard EN 12600 'Pendulum test - Impact test method and classification for flat glass' sets out the standards that a laminated glass must meet in order to be classified as 'laminated safety glass'. The standard requires glass to be classified in relation to the impact of a special tool (impactor of about 50 kg) falling from different heights: Class 1: if it withstands an impact from a drop height of 1200 mm Class 2: if it withstands an impact from a drop height of 450 mm Class 3: if it withstands an impact from a drop height of 190 mm The standard also determines classes according to the glass breaking mode: Class A: extended breakage with dispersion of sharp-edged shards Class B: several breakages but the fragments do not disperse Class C: the glass disintegrates generating small, harmless shards STRATO® (laminated glass sample 44.1) is certified according to UNI EN 12600:2004 class 1B1, which means it is resistant to an impact from a fall height of 1200 mm (protection from falling out) without dispersion of shards. It is also certified Class A (laminated glass sample 55.1) according to the American standard ANSI Z97.1-2015 and CPSC 16 CFR 1201, and the Canadian standard CAN/CGSB 12.1-2017. UNI EN 12600:2004 - Impact test and classification for flat glass (European Standard) The American market meets different requirements for laminated safety glass used for building and architectural purposes. They must comply with all applicable testing requirements of ANSI Z97.1-2015 (American National Standard Institute) and as specified by CPSC 16 CFR 1201 (Consumer Product Safety Commission). In this case, the classification of laminated safety glass has two categories: Class A (Category II) when it withstands the impact of a body falling from a height of 48 inches (~ 1220 mm) Class B (Category I) when it withstands the impact of a body falling from a height of 18 inches (~ 457 mm) Highlights ANSI Z97.1-2015 - Impact test (American standard) 37 of 52 European Standard EN 356 "Testing and classification of resistance against manual attack" describes the test methods for classifying glass according to its anti-burglary and anti-vandalism properties. The vandalism resistance performance is classified according to the drop test of a steel ball with a diameter of approx. 100 mm and a mass of approx. 4.11 kg. In this case, the classes are divided as follows: 3 impacts by a ball falling from 1500 mm 3 impacts by a ball falling from 3000 mm 3 impacts by a ball falling from 6000 mm 3 impacts by a ball falling from 9000 mm 3x3 impacts by a ball falling from 9000 mm S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A UNI EN 356:2002 - Manual attack resistance (European Standard) Test Class Description Ball P1A P2A P3A P4A P5A For burglary resistance, an axe test is used, according to which all three specimens used need a minimum number of strikes to create opening. The glass is divided into the following classes: 30-50 impacts from hammer followed by axe 51-70 impacts from hammer followed by axe > 70 impacts from hammer followed by axe Test Class Description Axe P6B P7B P8B STRATO® (laminated glass sample 44.2) is certified according to UNI EN 356:2002 class P1A, which means it is resistant to three impacts of a steel ball falling from 1500 mm. STRATO® has also passed the tests according to the European standard EN ISO 12543-4:2011 and the American standard ANSI Z97.1-2015 Section 5.4.3. concerning resistance to high temperature, humidity and irradiation. Please contact Satinal Customer Service to request other certifications related to durability and resistance tests. Send your request to customer@satinal.it Highlights 38 of 52 Building safety certifications S T R A T O ® | G L A S S I N T E R L A Y E R S Technical data C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Haze Light transmission UV Cut-off* > 150 N/cm < 0.3 % > 94 % > 91 % 36 dB 360 nm Peel-off test ASTM D1003-61 (1997) standard Solvent based extraction 5 mm glass + STRATO® 0.8 mm + 5 mm glass 3/16" glass + STRATO® .030 + 3/16" glass ISO 9050; EN 410; NFRC 300 Mechanical Optical Test methodValue -30°C (-22°F) 63°C (145,40°F) STRATO® Plus Adhesion with glass Haze Cross-linking rate Light transmission UV(A) - Rays transmission UV Cut-off* > 150 N/cm 0.4 % > 94 % > 90 % 36 dB 385 nm < 1% Peel-off test ASTM D1003-61 (1997) standard Solvent based extraction ISO 9050:2003; EN 410:2011; NFRC 300 5 mm glass + STRATO® 0.8 mm + 5 mm glass 3/16" glass + STRATO® .030 + 3/16" glass ISO 9050:2003; EN 410:2011; NFRC 300 Noise reduction Mechanical Optical Test methodValue Tg (glass transition temperature)-28°C (-18,4°F) Melting temperature 72°C (161,60°F) STRATO® Extra chiaro *to increase the UV Cut-off, it is necessary to use multiple layers of EVA *to increase the UV Cut-off, it is necessary to use multiple layers of EVA Properties of laminated glass with STRATO® EVA film UNI EN ISO 11357-3:2018 UNI EN ISO 11357-3:2018 39 of 52 Adhesion with glass Cross-linking rate Noise reduction Tg (glass transition temperature) Melting temperature Technical information and data in this guide should be considered representative and not used for design purposes. STRATO® PLUS has a UV cut-off at 360 nm compared to the traditional STRATO® EXTRA CHIARO that blocks 100% UV rays up to 385 nm. This feature provides a higher degree of transparency to meet the need for a completely natural and neutral looking glass. On the other hand STRATO® EXTRA CHIARO, a unique product of its kind, combines high visible light transmission with excellent protection against UV rays while preserving the natural colours of what you see through the glass. S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Transmittance data 100 NM 380 NM 700 NM 40 of 52 Technical data UV VISIBLE LIGHT INFRARED (HEAT) Tr a n s m i t t a n c e % Wavelength (nm)  Technical information and data in this guide should be considered representative and not used for design purposes. S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A The graph represents the transmittance at specific wavelengths of light. Compared to an EVA film with natural UV passage, STRATO® EXTRA CHIARO offers a complete protection by reducing the harmful effects of UV radiation. Plus Natural UVExtra chiaro 41 of 52 Technical data UV VISIBLE LIGHT 100 NM 380 NM Transmittance % Wavelength (nm) Technical information and data in this guide should be considered representative and not used for design purposes. The modulus of elasticity and the shear modulus express the behaviour of the laminated glass under different types of stress. The modulus of elasticity (Young Modulus) expresses the ratio between tension and deformation in the case of mono-axial loading conditions and in the case of "elastic" behaviour of the material. It is defined as the ratio between the applied stress and the resulting deformation. The shear modulus (Shear Modulus) expresses instead the tangential stress-strain ratio. Below are the results of tests for STRATO® EVA film characterization according to Appendix A of EN 16613:2019. This standard defines the mechanical properties of interlayer materials in order to be able to carry out calculations of the load resistance of laminated glass panes. The test was carried out on glass laminated samples with a length of 1100 mm and a width of 360 mm: two 8 mm float glass and one 0.8 mm STRATO® EVA interlayer. The tests were carried out in accordance with the configuration provided by ISO EN1288-3:2016 (4-point bending test). The samples were subjected to a constant load of 1150 N and the displacements were monitored in order to evaluate the lowering of the rubber between the support and the glass. S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Shear and Young Modulus Tangential modulus of elasticity G at different temperatures and for different load durations 42 of 52 Technical data Technical information and data in this guide should be considered representative and not used for design purposes. Time S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A The tables show the values of the tangential modulus of elasticity (Shear Modulus) and the elastic modulus (Young Modulus) measured at different loading times for the various temperatures considered. Load: 1150 N Test specifications: float glass 8 mm + STRATO® EVA film 0.8 mm + float glass 8 mm Loading duration G (MPa) 1 s 3 s 10 s 30 s 1 m 5 m 10 m 30 m 1 h 6 h 12 h 24 h Temperature °C 20 30 40 50 60 4,6 4,5 4,5 4,4 4,3 4,3 4,3 4,3 4,3 3,3 3,2 3,1 4,3 4,3 4,3 4,2 4,1 3,8 3,7 3,5 3,4 3,1 3,0 2,8 2,9 2,9 2,9 2,8 2,8 2,7 2,6 2,4 2,3 2,0 1,9 1,9 2,7 2,6 2,6 2,3 2,2 2,0 1,9 1,8 1,7 1,4 1,3 1,2 1,7 1,7 1,7 1,6 1,6 1,4 1,3 1,2 1,1 0,9 0,9 0,9 Shear Modulus G [MPa] of STRATO® EVA interlayer according to temperature and load time variations Loading duration E (MPa) 1 s 3 s 10 s 30 s 1 m 5 m 10 m 30 m 1 h 6 h 12 h 24 h Temperature °C 20 30 40 50 60 13,7 13,5 13,4 13,1 12,9 12,9 12,9 12,9 12,9 10,0 9,7 9,3 13,0 12,9 12,8 12,5 12,3 11,5 11,2 10,6 10,3 9,3 8,9 8,5 8,8 8,7 8,6 8,4 8,4 8,0 7,7 7,3 7,0 6,1 5,7 5,7 8,0 7,9 7,8 6,9 6,7 6,0 5,8 5,3 5,1 4,2 3,9 3,7 5,0 5,0 5,0 4,8 4,7 4,1 4,0 3,6 3,3 2,8 2,7 2,6 Young Modulus E [MPa] of STRATO® EVA interlayer according to temperature and load time variations 43 of 52 Technical data Technical information and data in this guide should be considered representative and not used for design purposes. S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A In order to perform an initial check of compatibility and resistance, Satinal offers to the possibility to run some tests in its internal Laboratory S-Lab - such as resistance to high temperatures and humidity, impact tests (in line with the criteria dictated by the UNI EN ISO 12543, 12600, 356, etc.), light transmission tests, adhesion to glass, cross-linking tests, etc. - on samples of laminated glass only with STRATO® or with the addition of inserts. Send your request to customer@satinal.it Highlights Glass lamination is a process to be carried out with care and attention: in order to obtain a high quality finished product, it is advisable to handle the STRATO® EVA film respecting the storage conditions and expiry times (1 year from the date of production indicated on the packaging and 6 months from the date of tinfoil paper opening). Moreover, when inserts are added to laminated glass, the compatibility of the material must be verified by adhesion tests, high temperature, high humidity and UV radiation resistance tests, especially for open-edge applications in outdoor environments Additional specific tests should be considered depending on the type of laminated glass and its application, including the measurement of adhesion and other physical properties even 'after ageing', accelerated under UV exposure. In case of structural glass applications, such as railings, it is recommended to follow the local specifications and requirements of the different countries, also in terms of testing. Occasionally, balustrades may be made with a combination of laminated and tempered glass to achieve a safer product. Where higher safety factors are required we also recommend the use of a stiff insert, such as transparent stiff sheets, polycarbonate or similar, in combination with STRATO®. It is recommended to proceed with the utmost caution when using STRATO®, due to the wide range of application it offers and to always check compatibility and performance in detail (in line with the appropriate standards and test methods), asking for Satinal Technical Support. Tips and tricks Post lamination problems 44 of 52 S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Defects may occur after the lamination process due to several reasons. In the following pages there are some of the most common problems and tips to solve them. EVA leakage from glass edges - cleaning process Tips for reducing EVA leakage from edges 0 bar 135°C (275°F)/ 45 min* 80°C (176°F) / 20 min* Pre vacuum Cooling down Melting Cross-linking Sample structure: glass 3 mm (1/8") STRATO® 0,4 mm (.015) glass 3 mm (1/8") Temperatures: measured on glass *based on the thickness of the glass Oven type: Lamijet TK with vacuum bag - 1 bar -1 bar Time (min) Temperature °C Vacuum pressure (bar) Below is the recipe of the standard lamination process It is possible to overcome the problem of EVA leakage from the edges by reducing the total vacuum holding time in the silicon bag, following the following recipes without reducing the level of EVA adhesion to the glass. Once the cross-linking temperature has been reached, the deaeration process should be completed and it is possible to reduce the vacuum pressure or switch off the vacuum pump. This process must be carried out by testing and must be adapted according to the performance of the laminating furnace. Each process and correction must be adjusted to find the best equilibrium point, according to each specific laminating machine. 45 of 52 Contact TK Technical Department to verify the correct setting of the working parameters. Send your request by email to service@tkitaly.com or call +39 031870573 Our tip Post lamination problems S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A 135°C (275°F) / 45 min* 80°C (176°F) / 20 min* Pre vacuum Cooling downMeltingCross-linking Example of lamination recipe with vacuum bag for EVA leakage reduction - 1 bar Time (min) Temperature °C Vacuum pressure (bar) - 1 bar 0 bar 0 bar 135°C (275°F) / 45 min* 80°C (176°F) / 20 min* Pre vacuum Cooling downMeltingCross-linking Sample structure: glass 3 mm (1/8") STRATO® 0,4 mm (.015) glass 3 mm (1/8") Temperatures: measured on glass *based on the thickness of the glass Oven type: Lamijet TK with vacuum bag Example of lamination recipe with vacuum bag for EVA leakage reduction - 1 bar 0 bar Vacuum pressure (bar) Time (min) Temperature °C - 1 bar 0 bar 46 of 52 Post lamination problems Sample structure: glass 3 mm (1/8") STRATO® 0,4 mm (.015) glass 3 mm (1/8") Temperatures: measured on glass *based on the thickness of the glass Oven type: Lamijet TK with vacuum bag Reduce vacuum time /pressure Reduce vacuum time /pressure In case of high glass thickness (>8 mm overall) the vacuum pressure on the glass can lead to edge deformation and misalignment of the sandwich to be laminated: they are subject to a higher stress which is a high risk because it increases the possibility of delamination and glass breakage. To avoid this problem, it is recommended to add spacers to the edges of the glass which will help to release the compressive force applied to the edges of the glass. use glass, wood or aluminium to make the spacers. on the edge of the spacer, attach a non-stick film material similar to Teflon to ensure that it does not stick to the edges of the laminated glass at the end of the processing. the height of the spacer should be equal to or slightly less than the total thickness of the assembled glass. apply the spacer directly to the edge of the laminated glass. Do not leave gaps. Apply the spacers on all sides. If this is not possible, we recommend you to apply the spacers on at least the 2 longest sides of the assembled glass. We suggest you try the following method: S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Edge-stress and/or laminated glass misalignment Our tip 47 of 52 Post lamination problems Vacuum bag Spacer made of glass/wood/aluminium marginally lower height than assembly Teflon/PTFE release film adhered to outer edge of space Channel fillerGlass assembly under lamination STRATO® EVA film Delamination occurs mainly in open-edge glass, exposed to hot and humid weather conditions. It usually occurs on the edge of a laminated glass pane or around a clamp, and it is more common in glass panes with a polyvinyl butyral interlayer (PVB is hygroscopic, absorbs moisture). Poor product quality Delamination is a reduction or, potentially, a total loss of the adhesive bond between the glass panes and the interlayer. Causes of this defect can be related to: Heat and humidity Chemical compatibility It is important to make sure that the correct type of structural silicone is used because it must be compatible with the interlayer. Wrong selection can lead to delamination. Cleaning Using low quality Eva film of unknown origin does not guarantee good adhesion performance over time. By choosing STRATO®, it is guaranteed that high quality raw materials and controlled production processes are used. Delamination If cleaners and primers, used to prepare the laminated glass prior to bonding with structural silicone, are not completely removed, they can cause the delamination of the adhesive interlayer. S T R A T O ® | G L A S S I N T E R L A Y E R S C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A 48 of 52 Post lamination problems leaks in the vacuum bag. malfunction of the vacuum pump. pre-vacuum or holding time phase in the melting phase are too short. the EVA film has a defect or has been left in the open air too long without protection from sunlight and humidity. The presence of small air bubbles in laminated glass can be caused by: S T R A T O ® | G L A S S I N T E R L A Y E R S Air bubbles Bubbles with a spider-web appearance The presence of grouped or scattered small bubbles with a spider web appearance indicates a too high temperature in the cross-linking process. Check the correct sealing of the oven vacuum bag, as well as any vacuum losses due to holes in the bag and the correct vacuum pump functioning. The vacuum in the bag must be at least - 0.8 bar. The pre-vacuum cycle is too short or it has power losses. During the first melting step, increase the holding time at 80°C (176°F) in order to let the Eva film melt in a homogeneous way and to allow a sufficient air evacuation between the glasses. Keep the EVA roll in a low humidity environment during long-term storage. Lower the heating temperature during the cross-linking phase and increase the holding time. C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Our tip Our tip 49 of 52 Post lamination problems S T R A T O ® | G L A S S I N T E R L A Y E R S Haze At the end of lamination, the glass is opaque with a slight haze that affects the clarity. The heating temperature is not high enough or the holding time is not long enough for the EVA film to complete the cross-linking process. Another cause could be exceeding the expiry date of the film, indicated by the manufacturer, or incorrect storage conditions. C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A During the cross-linking process, increase the temperature or holding time. We recommend storing the roll in its original packaging at a maximum temperature of 35°C (95°F) protected from heat, direct sunlight, dust and humidity to ensure the quality of the EVA film. At optimal storage conditions, the goods have a shelf life of one year, while consumption is recommended within six months after the tinfoil paper opening. Our tip Dark dots The temperature of the laminating oven is not homogeneous. There are probably temperature peaks. Probably the EVA film used is defective. Increase the holding time of the melting and cross-linking phases. Check the material before assembling the glass. Our tip 50 of 52 Post lamination problems S T R A T O ® | G L A S S I N T E R L A Y E R S Locations and contacts São Paulo | Brasil Miami | USA Erba | Italy Satinal headquarters Satinal Spa Via del Lavoro 1 22036 Erba (CO) | Italy customer@satinal.it Satinal USA Inc. 1717 N Bayshore drive Miami (FL) | USA customer@satinal.it Satinal do Brasil Ltda. Rua Paes Leme 215-17°andar sl 1704 Pinheiros (SP) | Brasil brasil@satinal.it Headquarters and manufacturing plant C O P Y R I G H T © 2 0 1 8 S A T I N A L S P A Operational Headquarters and Logistics center Operational Headquarters and Logistics center 51 of 52 S A T I N A L S P A , V I A D E L L A V O R O 1 , 2 2 0 3 6 E R B A (C O ) | I T A L Y EN 0520-0 52 of 52 Italy giuseppe@satinal.it Contact Russia russia@satinal.it Europe anna@satinal.it daniela@satinal.it North America domenico@satinal.it export@satinal.it Sales Orders, shipments, samples and product testing Italy customer@satinal.it Russia russia@satinal.it Other Countries sales@satinal.it Technical assistance STRATO® interlayers customer@satinal.it TK furnaces service@tkitaly.com South America brasil@satinal.it Middle East sales@satinal.it