Aluminium Profiles

Assembling and jointing the Al-SIP panels requires several different aluminium channel and angle profiles. These are readily available from your local aluminium or refrigeration panel supplier. The primary aluminium sections are shown below. For details on how panels are put together, refer to the sectional drawings found here.

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Base Channel - Used to fix the panels to the floor. Note that these should only be used for projects where condensation is not a concern as the channel is not thermally broken. For dwellings its advised to use x2 angle sections or alternatively cut the base channel into two to create a thermal break. Click here for section detail of how to install base channel.

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External Angle - Typically a 40 x 40mm angled section with a slight over-bend to the corner. This ensures a snug fit of the angle when riveted to an external corner.

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Internal Angle - Typically a 40 x 40mm angled section with a slight under-bend to the corner. This ensures a snug fit of the angle when riveted to an internal corner.

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90 Angle - Used to fix the panels to the floor when a thermal break is required. Click here for section detail of how to install angle to secure the base of panels.

Rivets 

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Sealed aluminium blind rivets are used to rivet the panels and extruded aluminium profiles together. Typically, 4.8mm rivets are used. Make sure that they are sealed rivets. Although its unlikely that standard rivets would allow water penetration, its best to not take any chances. One very useful tool to invest in is a riveting gun that attaches to a normal cordless drill. This will save a lot of frustration and time!

Sealants

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Butyl mastic sealant is a non-skinning, weatherproof, flexible sealant used in the outer expansion joint to provide a flexible, weather tight seal between panel joins.

Tools

 

Aluminium Saw Blade - The easiest and cleanest way to cut Al-SIP panels is with a suitable aluminium blade on a circular saw. The blade will easily cut through the aluminium skin(s) as well as the EPS foam core. Be sure to wear suitable eye and body protection to protect from aluminium shards.

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Rivet Gun for Drill - This is a very cheap and worthwhile investment. When you may have 1000+ rivets to fasten, you don’t want to be using a manual rivet gun…quite the workout. These very handy rivet guns fit into a cordless drill chuck and pull the rivet closed. Be careful to always reverse the drill after every rivet to eject the waste pin otherwise the unit will jam.

Foam Cutter with Sled - Another very useful investment if you are running electrical conduit for wiring between panels. The sled adapter allows you to easily and cleanly trench out the foam to make space for the conduit. Be careful not to inhale any fumes from the cutting of the EPS foam.