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Fabrication

Manual

©2013 Rollfab Metal Products, Aluma-Kor is a registered trademark of Rollfab Metal Products

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INTRODUCTION Aluma-Kor aluminum composite material (ACM) is the building material of the future, which you will discover as soon as you fabricate it. Our ACM is as easy to fabricate as wood and requires no special tools with the exception of fabricating our Natural Metals products (Titanium, Stainless Steel). Our ACM can be curved, bent, routed, drilled, sawed, sheared, punched, trimmed and molded into complex shapes with conventional woodworking or metalworking tools. Aluma-Kor’s versatility makes it adaptable to many other standard systems that are available from a variety of vendors, including rout & return systems, glazed-in systems and creative custom systems. In addition, you can create complex assemblies with Aluma-Kor in combination with polyethylene welding and support systems attached with structural adhesives.

This "How To" Manual has been developed to assist fabricators with fabricating Aluma-Kor material in the most efficient and effective manner. The tips and suggestions contained in this manual are the result of many years of combined experience by fabricators in both the U.S. and abroad. These recommended suggestions and product data are based on information which is, in our opinion, reliable. However, since skill, judgment, and quality of equipment and tools are involved, and since conditions and methods of using Aluma-Kor material are beyond our control, the suggestions contained in this manual are provided with-out guarantee. We recommend that prospective users determine the suitability of both the material and suggestions before adopting them on a commercial scale.

ROLLFAB METAL PRODUCTS DOES NOT MAKE ANY WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING MERCHANTABILITY AND FITNESS FOR PURPOSE, WITH RESPECT TO ANY SAID SUGGESTIONS AND PRODUCT DATA. In no event shall Rollfab Metal Products, have any liability in any way related to or arising out of said suggestions and product data for direct, special, consequential or any other damages of any kind regardless whether such liability is based on breach of contract, negligence or other sort, or breach of any warranty, express or implied. Also, normal safety and health precautions practiced in any fabricating environment should be used when fabricating Aluma-Kor material. Goggles or other face protection, as well as hearing protection should always be worn. MSDS for Aluma-Kor materials are available through our Customer Service Department.

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TABLE OF CONTENTS

SECTION I: PRE-FABRICATION GUIDELINES

Material Receiving & Inventory Transporting & Handling Storing Material

SECTION II: FABRICATION GUIDELINES

Cutting Jointing or Edge Filing Routing Curving the Panels Punching Drilling

SECTION III: PANEL ASSEMBLY

Extrusions Joining

SECTION IV: Systems

Assembly Systems

SECTION V: TECHNICAL DATA

Data Chart

SECTION VI: MATERIAL & EQUIPMENT SOURCES

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Section I: Pre-Fabrication Guidelines Material Receiving & Inventory:

• Shipping damage and packaging issues should be noted on the bill of lading and immediately reported to manufacturer.

• Customers are responsible for filing freight claims with the shipping company WITHIN 24 HOURS of receiving materials. Failure to do so may result in forfeit of corrective actions. • Any defective material must be reported directly to the manufacturer.

Transporting & Handling: Aluma-Kor planks should be transported by means of a forklift with the proper length forks or extension in the original / sealed packaging until processing of the material is ready to begin. If a forklift is unavailable, planks may be lifted and carried by hand per the following guidelines.

BE SURE TO READ, UNDERSTAND AND FOLLOW ALL GUIDELINES. Manufacturer guidelines may vary depending upon specific application and project conditions. The manufacturer should be contacted with

questions regarding conditions which vary from the guidelines set forth. Standard carpentry knowledge is required and good construction practice for health, safety and welfare must be followed when fabricating

Aluma-Kor. Rollfab Metal Products offers these recommended guidelines based upon current product information and accepts no responsibility for the conditions and/or methods of fabrication.

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Storing Material: Aluma-Kor planks have a strippable protective film on the painted surface to protect the finished surface. The film should be left on the product until all fabrication and installation of the product has been completed. The protective film is designed to prevent minor abrasions to the finish surface. However, the product should still be handled very carefully to avoid scratches and denting which can penetrate through the film and damage the products finished surface.

• When handling product, clean work gloves should always be worn to protect hands from being cut on the sharp edges.

• DO NOT drag nor slide product at any time while handling it. Product must be directly lifted away from contacting surfaces to avoid damage to the painted surface. (see figure below)

Aluma-Kor product must be kept in a dry well-ventilated area away from exposure to all elements including natural and construction based during storage, failure to do so may result in damage to the finished surface and/or the core. Such damage is NOT covered under warranty.

Aluma-Kor product can be stored either horizontally or vertically per the following guidelines:

• Materials must be kept completely flat to prevent warping by means of palletizing or rack stands.

• Materials should be the same size when stacked as different sizes can cause scratching & denting.

• Materials stored vertically should be leaned into a structural rack on top of a rubber mat as shown below on the left, the right side image is incorrectly stacked.

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SECTION II: FABRICATION GUIDELINES

Cutting: Aluma-Kor material can be cut using various methods common to both the metal and woodworking industries. These methods include cutting with table saws, panel saws, multiple operation rip/V-grooving saws, portable saws, reciprocating and band saws, and routing and shearing equipment. No cutting lubricants, oils or coolants are required with any of these cutting operations.

Knife Cutting

Aluma-Kor material cannot be knife cut.

Saw Cutting

Aluma-Kor material is manufactured with any one of several high quality finishes. Care should be taken to protect the finish during any sawing operation. It is best to move the saw blade rather than the material when sizing the panels. Below are the saw cutting guidelines:

• Table Saws are not recommended for cutting sheets larger than 4' x 4' in size. Blades should be Carbide tipped or High Speed Steel designed for cutting nonferrous materials, ground thinner from the rim towards the center to prevent pinching. The blades should have angled or circular teeth, alternate beveled, triple ground with the tooth gap wall rounded. The chip angle should be 5 to 15 degrees with a clearance angle of 10 to 30 degrees and a tooth spacing of 3/16" to 1". Cutting speeds of 5,500 RPM and feeds of 16"/second are possible.

• Panel Saws provide an effective method of cutting Aluma-Kor Material. These saws, whether standard equipment or custom made, perform well and have the added advantage of space savings. Blades should be the same type used for table saws.

• Multiple Operation Rip/V-grooving Saws are used for high volume production operations. Blades should be the same type used for Table Saws.

• Portable Saws (circular) are also used effectively to cut Aluma-Kor. These saws should be production/industrial type equipment. Blades should be the same type used for table saws.

• Reciprocating Saws work well for making cutouts. Care should be taken with portable and reciprocating saws to prevent damage to the Aluma-Kor material surface. More than one sheet can be cut at a time by stacking panels. If center cutting (i.e. Letter cutouts) is required, a foam pad may be placed under the Aluma-Kor material with the reciprocating blade cutting into the foam. The sheets may be clamped or secured with double-faced tape for the cutting operation. When clamping between jaws, protect the panel surface against damage. Blades should be high speed steel, 03" to .047" thick, 3/16" to 9/16" wide, with hook or circular teeth with alternate angles, set or waved at a spacing of .010" to .250". Cutting feeds up to 4"/second are possible.

• Band Saws may be used to cut irregular shapes or curves. Blades should be tempered spring strip steel, .03" to .047" thick, 9/16" to 1" wide, with skip teeth designed for nonferrous and ferrous materials spaced at a minimum of 10 teeth per inch. Cutting speeds of 10,000 FPM at a cutting feed of 10"/second are possible.

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Shearing

Alum-Kor material can be easily sheared. However, a slight roll-down of the aluminum cover sheet may occur on the impact side. This “roll-down” area is often referred to as the “edge zone.” In this area, the polyethylene core is compressed and can lead to increased stress between the core and the aluminum cover sheet. Due to this additional stress, shearing should be avoided when the edge of the panel is exposed to the environment.

When shearing Aluma-Kor material, light markings may be caused on the material by the shears hold down pads during the shearing process. In order to avoid these markings, the hold down on the shear should be fitted with a shock-absorbing rubber pad to prevent damage to the Aluma-Kor material. (Reference Figure 1)

Jointing or Filing of Edges: Floor model woodworking jointers are effective for edge finishing. For finishing work, after contour cutting with a reciprocating saw (ordinary cutting files work best), the file profile should be from slightly to fully rounded. The proper filing direction is length-wise along the edge. Routing: Aluma-Kor Material can be cut to size using either portable commercial or automated routing equipment. Bits should be carbide tipped and kept sharp. Single or multiple flutes may be used. Aluma-Kor material can be accurately folded by hand after a simple routing operation is done on the back skin. This fabrication method is called Rout and Return. It is unique to composite panel fabrication. Do not use a press brake for tight folds of Aluma-Kor material. The material may be routed by using one of the two following methods.

1. Router

One procedure for routing our material is to use an industrial or commercial grade, hand-operated router. High production operations will find this method is relatively slow as the recommended feed rate is 6' to 10' per minute using carbide tipped cutters. Special custom cutters for ACM Material are available (Reference Section VI). These cutters have been specifically developed for Aluma-Kor material and will produce the required configuration for proper rout tolerances. Commercially available 90° wood working routing cutters, available from your local hardware store, may be modified to provide approximately the same function as the custom cutters, provided the tip is ground to a (or flattened to) 1/16" minimum at the point (Reference Figure 2). Keeping the router bit sharp will reduce heat build-up and the need to re-rout fused core material.

Figure 2 - Router Bits

Flat Rout

Figure 1 - Edge

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2. Circular Saw (custom blade) For fabrication of a large number of sheets that require routing, a portable table or circular saw fitted with a special blade is advisable (Reference Figure 3). This blade is often referred to as a "V" Routing Blade. These blades, used with a quality industrial saw, will produce the required tolerances at a much faster rate than hand routers (Reference Section VII). Many fabricators use a worm gear-driven industrial-quality saw, with a larger plastic base plate added for stability. The depth of the "V" rout is critical. As a rule of thumb, the exterior aluminum skin should not be visible through the polyethylene core at the valley of the rout; this visual appearance should be consistent along the entire length of the rout (Reference Figure 4). Extreme care should be taken not to touch the exterior aluminum skin with the router bit or saw blade. Slight variations can occur due to thickness changes in the Aluma-Kor material sheet; constant depth of the rout ensures a good smooth line when the edge is folded. The same guidelines should be used when routing with a "V" Routing Blade on a portable circular saw or with a portable router. Figure 3 indicates the finished rout required to develop a quality bend.

Figure 3 – Custom V-Groove Circular Saw Blade

Figure 4 – Rout Depth

Leave skin plus 1/32”-1/64” of polyethylene

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By routing one side only, Aluma-Kor material can be bent either upward or downward to create both an inside or outside corner as illustrated in Figure 5. An Aluma-Kor "panel" is easily fabricated by routing all four sides, notching the corners (shown in Figure 7 and Figure 8), and folding or returning each of the routed sides (Reference Figure 6). This type of fabrication is commonly referred to as "Rout and Return." Note that as a result of the slight radius produced when bending, your finished panel dimension will be 1/32" to 1/16" larger when folded. This is determined by the profile of the cutter used to make the rout. Trial cuts should be made prior to production to determine any necessary adjustments in layout dimensions. On the following page, two different methods of fabrication are illustrated showing how corners may be handled on the folded or "returned" leg of the "pan."

Figure 5 – Rout & Bend

Figure 6 – Rout and Return

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Standard rout fabrication utilizes a very small radius at the bends, this can be achieved by "V" routing and folding (Reference Figure 8).

Figure 7 – Square Corner

Figure 8 – Envelope Corner

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By using a flat head router bit, a larger radius can be achieved by “flat” routing. A flatter, wider cut will result in a smoother bend (Reference Figure 9).

Figure 9 – Small Radius “V” Routing

Figure 10 – Large Radius “Flat” Routing

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Curving: The minimum bending radius for 4 & 6 mm Aluma-Kor material without routing the back skin is fifteen times the thickness of the panel being curved (i.e., 4 mm = 60 mm (2.36") minimum radius, and 6 mm = 90 mm (3.54") minimum radius). Aluma-Kor material can be cold formed in a pyramid roller, a press brake or over a clamped pipe 3 mm only. The process is similar to the forming of aluminum; however, due to the sensitive surface, care should be taken to ensure rollers are clean, smooth and free of defects to avoid damage to the surface finish.

1. Pyramid Roller

As an extra precaution, a film should be used between the panel and the rollers to further protect the panel surface. Make sure that the rollers are clean and free of rust, pitting, dimples, and other potentially damaging surface discrepancies. Do not pinch the material between the rollers. Roll the panel 3° to 5° tighter to allow for a small amount of spring-back that will occur. Once the sheet is curved; however, it will remain curved (Reference Figure 11).

Figure 11 – Pyramid Roller Curving

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2. Press Brake

When forming with a press brake, use a top die (tubular) with the radius desired and open the bottom die (jaws) approximately two times the thickness of the material plus film wider than the top die. The lower die should always have a protective pad of not less than 1/8" film. Some adjustment of the lower jaws may be necessary to allow for varying bending properties between anodized and painted finished and for varying thicknesses. The radius of the top die will be the approximate inside radius of the finished panel (Reference Figure 12).

3. Bending Over a Clamped Pipe

When forming over a pipe of the proper diameter that is securely clamped to a work table. A hinged "leaf" attached to the end of the table will bend the material. The radius of the pipe should be just smaller than the inside radius of the finished panel (Reference Figure 13).

Figure 12 – Press Brake Radius Forming

Figure 13 – Clamped Pipe Radius Forming

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Punching: The punching of flat-formed parts from Aluma-Kor material is performed the same way as solid aluminum sheet, using evenly ground tools and the narrowest possible cutting gap. Be sure to punch through the material to completely serrate the polyethylene core material. As with shearing, a slight roll down may occur. Refer to the section on shearing for additional information. (Reference Figure 14)

Drilling:

Aluma-Kor material can be drilled with a commercial quality twist drill bit usually used for aluminum and plastics, and on drilling machines customarily used for metals. A countersink bit needs to be used when drilling holes for csk rivet application.

Working Specifications: Drill Bit: Twist drill, high-speed steel. Tip Angle: 100° to 140°, or counter-bore grind with centering tip. Cutting Speed: 164 RPM to 984 RPM.

Quick removal of chips, particularly the polyethylene, can be achieved by a process of high revolution, slow feed and occasional lifting of the drill bit. (Reference Figure 15)

Figure 14 – Hole Punching

Figure 15 – Hole Drilling

(15a) (15b)

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SECTION III: PANEL ASSEMBLY

Extrusions: There is one basic set of Aluma-Kor Extrusions available for purchase which is used for both our wet & dry systems, A1000 series & A2000 series (Reference Figures 16). Extrusions may be cut to length by means of a 10” Miter Saw or Wet Saw with an 80 tooth (min.) NON-FERROUS METALS blade (Reference Figure 17). If cutting the extrusions with a “dry saw” it is recommended to use “saw blade lubricant” (Reference Figure 18). This will help keep the blade cooler therefore extending the blades life and allowing for larger volume cutting.

Figure 16 – A1000 “Dry Seal” series

Figure 17 – Extrusion Saw Blade Figure 18 – Saw Blade Lubricants

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Joining: Use the following guidelines when other material elements come in direct contact with the surface of Aluma-Kor Materials:

1. Acceptable joining element materials: Aluminum Plastic Stainless steel Plated or coated steel with cadmium, zinc or aluminum

2. Unacceptable joining element materials: Copper Brass Bronze Iron Raw Steel

Unacceptable materials cause corrosion of joining surfaces due to electrolysis of dissimilar materials. Therefore, use "heavy" or "red" metals only with an electrically insulating intermediate layer. When joining elements are to be anodized, assemble the materials after the anodizing process. Proper consideration should be given to the thermal expansion characteristics of Aluma-Kor Material when using any of the joining techniques.

Threaded Fasteners: The easiest method of joining sheets of Aluma-Kor Material together or to an extrusion profile system is with machine screws or bolts (Reference Figure 19). This method allows the panel to be removed. Use the largest possible flat washer to minimize surface pressure and eliminate possible compression due to cold flow of the core material. Arrange attachment screws at least 2.5 x the diameter of the fastener from the edge of the sheet, as shown in Figure 20. It is not recommended to torque fasteners due to the cold flow of the core material. Two complete turns of the nut past finger tight is common practice (Reference Figure 21).

Figure 19 – Screw or Bolt Figure 20 – Screw Location

Figure 21 – Over Torque

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To countersink into Aluma-Kor Material without prior preparation, tighten the nut and washer onto the bolt and draw the head of the fastener into the cover sheet. Countersink washers can also be used. Either method is preferable in lieu of traditional countersinking as shown in Figure 22.

Rivets: Aluma-Kor Material can be fastened together, joined to aluminum extrusions, or other sheet metals with rivets common to aluminum construction. Blind rivets provide the advantages of labor savings, one-sided working of the material, and the reduced potential of surface damage. Semi-tubular, solid and other types of rivets can also be effective on a production basis. Place the closing or set-head on the side of the aluminum extrusion profile or sheet metal. When conditions do not permit this or when two pieces of Aluma-Kor Material are to be joined together, use rivets with special wide closing heads as shown in Figure 23 or with tightly fitting washers.

Figure 22 – Countersunk Screws

Figure 22 – Rivets

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When blind rivets are subjected to tensile strength tests, the head tends to "unbutton" from the Aluma-Kor Material, or pull through the hole. Since this would cause localized tearing of the material, use the largest possible rivet head for connections that will experience loading. Aluminum alloys such as 5032 and 5154 are suitable rivet material. Due to stress corrosion, alloy 5056 should not be used if the temperature of the manufactured part is expected to rise over 140° F (60° C). Rivet connections are well suited for parts that may be subjected to concussion or vibration. Colored plastic concealment caps are available for various types of blind and tubular rivets. Consult the rivet manufacturer for details. Follow the directions and determine suitability by pre-testing.

Hot Air Welding: Hot-air welding, although the process is labor intensive, has proven to be an effective method for joining thermoplastic materials together. Hand held, electrically heated, hot-air welding tools are used to heat the core material and the welding rod (low density, UV stabilized PE) to their melting temperature. This allows the two components to fuse together. However, the strength of the welded core material alone is not capable of withstanding structural loading. To insure a good weld, the correct diameter rod should be used. For both 4mm and 6 mm Aluma-Kor Material, use a 5 mm (3/16") diameter rod. Rod shapes other than round and diameters greater than 5 mm are not suitable for this procedure. Temperature settings used should be approximately 500° F. Both the PE core material and PE rod should be sanded to remove any surface contaminants. Figure 23 illustrates the process for "V" and corner seam hot-air welds. Although this process can be used to join two pieces of Aluma-Kor Material, the joint created should be reinforced with an aluminum cap sheet if significant load is anticipated on the panel.

SECTION IV: SYSTEMS

Figure 23 – Air Weld BARE ALUMINUM ADHERED TO THE ACM BACKSIDE

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Assembly Systems: There are currently two Aluma-Kor Assembly Systems available, A1000 Dry-Seal Series & A2000 Wet-Seal Series (Reference Figures 24 & 25). The Dry-Seal System is a “Drained & Back Ventilated Rainscreen”, which requires only minimal caulking to be applied (at window sills, etc) in order to maintain the systems weathering design criteria (Reference “The Rainscreen Principle” study available on the website). The Wet-Seal System is a “Route & Return” caulked Rainscreen, which is designed to keep moisture & air from entering the space between the Rainscreen and the building’s exterior wall entirely. Each system has its merit, however recent studies relative to the formation of mold between within the exterior envelope of building structures are leaning towards the advantages of using a ventilated Rainscreen system which allows air to flow within the envelope space between the back of the Rainscreen and the exterior skin of a building thereby forcing moisture to drain & dry out limiting the ability of mold fungus to grow.

Figure 24 – Series A1000 - Dry-Seal Figure 25 – Series A2000 – Wet-Seal

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SECTION V: TECHNICAL DATA

Property Units 4 MM PE 6 MM PE 4 MM FR 6 MM FR

Thickness Inch 0.15 0.236 0.15 0.236

Weight Lbs/Sf 1.15 1.53 1.56 2.15

Min. Bond Strength ASTM

D1781 lbs 377.5 377.5 150.6 150.6 Peak Peel Load ASTM

D1781 lbs 406.8 406.8 170.8 170.8

Peel Torque ASTM D1781 in-lb/in 60.7 60.7 21.94 21.94

Flatwise Shear ASTM D1002 lb/sq in. 1221 2055 92.8 70.8

Allowable Bend-Stress lb/sq in. 11500 11500 11500 11500

Coefficient of Expansion ASTM

E228 in/in/ degree F 1.31 x 10-5 1.31 x 10-5 1.31 x 10-5 1.31 x 10-5

Stiffness

ASTM D393 lb-sq in/in 1140 1896 1262 2450

Flexural Modulus ASTM

C393 lb/sq in 6.0 x 106 4.0 x 106 6.7 x 106 3.0 x 107

Moment of Inertia in4/in 1.89 x 104 4.58 x 104 1.89 x 104 4.58 x 104

Modulus of Elasticity PSI 9,951,636 9,951,636 9,951,636 9,951,636

Tensile Strength ASTM

E8 lb/ sq in 25,835 25,835 25,835 25,835

Yield Strength ASTM

E8 lb/ sq in 22,821 22,821 22,821 22,821

Flatwise Tensile ASTM

C297 lb/ sq in 951 953 315 291

"R" Thermal Resistance sq ft hr Degree F/BTU 0.051 0.086 0.026 0.04

Maximum Width 62 " 62 " 62 " 62 " 62 "

Maximum Length 243 " 243 " 243 " 243 " 243 "

Sound Transmission Coefficient ASTM E-90 26 Untested Untested Untested

Fire Performance ASTM E-84 Class A Class A Class A Class A

ASTM E-84 and NFPA 285 NFPA 285 Untested Untested Pass Pass

Burn Rate - ASTM D 635 yes/no No Ignition No Ignition No Ignition No Ignition

Ignition Temperature ASTM

1929 degrees C 390 C 390 C 430 C 440 C

Flame Spread Index ASTM E 84 0 0 0 0

Smoke development Index ASTM E 84 5 5 105 105

2009 Intl Building Code Classification Class A Class A Class A Class A

National Fire Protection Assoc. NFPA 5000 Class A Class A Class A Class A

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SECTION VI: MATERIAL & EQUIPMENT SOURCES

TWO-PART ADHESIVES

National Starch & Chemical Corp. Finderne Avenue Bridgewater, NJ 08807 (908) 685-5000 Dymax Corporation 51 Greenwoods Road Torrington, CT 06790 (203) 482-1010

STRUCTURAL SEALANT

Dow Corning Corporation Product Information P.O. Box 997 Midland, MI 48686 (517) 496-6000 GE Silicon Products 260 Hudson River Road Waterford, NY 12188 (800) 332-3390 Tremco Corporation 3735 Green Road Beachwood, OH 44122 (216) 292-5000 EPOXY Lord Corporation Industrial Adhesives Department 2000 West Grandview Boulevard Erie, PA 16514 (814) 868-3611 Essex Specialty Products, Inc. 1250 Harmon Road Aurbin Hills, MI 48326 (810) 391-6300 ROUTING BLADES Drake Corporation 1913 North Van Buren Street Huntingburg, IN 47542

MECHANICAL FASTENERS Pro-Fastening 8126 Zionsville Road Indianapolis, IN 46268 (800) 292-7550 COATINGS & PAINTS AKZO Nobel 6369 Old Peachtree Road Norcross, GA 30071 (770) 662-8464 Benjamin Moore & Company 2501 West North Avenue Melrose Park, IL 60160 (708) 343-3100 PPG Coatings One PPG Place Pittsburgh, PA 15272 (412) 434-3131 Valspar Industrial Coatings 701 South Shiloh Road Garland, TX 75042 (972) 276-5191 Sherwin Williams 10 Midland Building 101 Prospect Avenue Cleveland, OH 44115 (800) 331-7979 SEALANTS Dow Corning Corporation Product Information P.O. Box 997 Midland, MI 48686 (517) 496-6000 GE Silicon Products 260 Hudson River Road Waterford, NY 12188 (800) 332-3390 Tremco Corporation 3735 Green Road Beachwood, OH 44122 (216) 292-5000

ADHESIVE TAPES 3M Industrial Tape and Specialties Division 3M Center Building 220-7E-01 St. Paul, MN 55144 (800) 362-3550 Avery Dennison Specialty Tape Division 250 Chester Street Painesville, OH 44077 (216) 639-2600 Mactac Technical Products Division 4560 Darrow Road Stow, OH 44224 (800) 323-3439 Norton Performance Plastics Corporation One Sealants Park Granville, NY 12832 (800) 724-0883