HPL cladding for a flat-roof carport: sequence of steps.

1.1 Store panels on a pallet that is full-surface, flat and stable.

1.2 Place one cover panel on top and one underneath.

1.3 Store panels dry and protected from water, never outdoors.

Caution: Improper storage can cause lasting deviations from flatness.

1.4 On site, cover the panels with waterproof sheeting.

1.5 Remove the original packaging only immediately before processing.

1.6 Always lift panels upwards and carry them with two people. Do not slide them over each other or drag them over edges.

Tip: Avoid dirt between the panels. Always wear protective gloves.

2.1 For metallic, natural and wood decors, pay attention to the grain direction of the surface.

Caution: These decors have a surface colour with a direction. This matters for cutting.

2.2 Fit a carbide saw blade with trapezoidal flat tooth or alternate tooth.

Tip: For a 300 mm diameter blade: 72 teeth, 6,000 revolutions per minute, 30 mm protrusion above the top of the panel.

2.3 Saw the panel with a hand-held circular saw along the guide rail, feed approx. 6 to 10 metres per minute.

Caution: Always use sharp tools.

2.4 Break the cut edges by hand with a sanding block.

3.1 Place the panel on a hard, flat drilling surface so that nothing breaks out where the drill exits.

3.2 Drill with carbide drill bits with a 60 to 80 degree point angle.

Tip: Diameter 5 mm: 3,000 rpm. Diameter 8 mm: 2,000 rpm. Diameter 10 mm: 1,500 rpm.

3.3 When drilling near the edge, keep at least 25 mm from the panel edge.

4.1 Align the substructure flush and level.

4.2 Ventilate the construction so that the panels can always dry out.

Caution: Panels must not be exposed to standing moisture.

4.3 Have fixings made of non-corroding material ready: facade screws 5.5 mm or blind rivets 5.0 mm.

Tip: The facade screw has a Torx 20 drive and can be painted in the decor colour.

4.4 Alternatively take the balcony screw set M5: screw, polyamide washer, flat washer, spring washer and domed nut.

Tip: The length of the screw depends on the clamping thickness of panel and substructure.

4.5 Do not use countersunk screws.

5.1 Note: panels expand and shrink with humidity and temperature, twice as much across as along.

5.2 Drill the fixed point: drill diameter equal to the fixing, 6 mm for the facade screw.

5.3 Calculate the expansion allowance: greatest distance from the fixed point to the panel edge in metres times 2 gives the allowance in millimetres.

Tip: Example: 1.5 m times 2 gives 3 mm expansion allowance.

5.4 Drill the sliding points: diameter of the fixing plus expansion allowance, 8.5 mm or larger for the facade screw.

5.5 The centres of the holes in the substructure and in the panel must match: use a drilling template or step drill.

Caution: Always use the special gauge mouthpiece.

5.6 Keep the fixing spacing: for 8 mm panel thickness at most 625 mm (single-span panel) or 775 mm (double-span panel).

Caution: On a facade, structural requirements, applicable standards and local building regulations take precedence over the table.

6.1 Lay the joint tape (36 or 60 mm wide) on the supports at the butt joints.

Caution: The tape must extend under the fixing elements.

6.2 With two people, place the first panel on the substructure.

6.3 Fix the panel with facade screws, Torx 20.

6.4 Place the second panel at a distance from the first.

6.5 Leave the joint at least 8 mm wide, butt joints as wide as the panel thickness.

6.6 Place and fix panels 3 and 4 in the same way.

6.7 Peel off the protective film immediately after installation.

6.8 Done: the HPL cladding is installed.

7.1 Bond only when protected from weather and dust, in the workshop or on site.

7.2 Bond onto aluminium or planed timber structures.

7.3 All surfaces to be bonded must be clean, free of grease and dry.

7.4 Apply the adhesive and follow the adhesive manufacturer's processing recommendations.

Tip: Training by the adhesive manufacturer is recommended.

7.5 Place the panel on.

7.6 Note the profile width of the substructure: 80 to 100 mm for single-span panels, 40 mm for multi-span panels.

7.7 When bonding, note the maximum spacing of the vertical support profiles: 400 mm (single-span) or 500 mm (double-span) for 6 mm panel thickness, 500 mm for 8 mm panel thickness.

7.8 Observe the local building regulations and obtain a permit if necessary.

Caution: Local building regulations must be observed.