Palram PALFOA User Manual

www.palram.com

PALIGHT®

Flat Foamed PVC Sheet

CREATING
SOLUTIONS

Fabrication Guide

PALIGHT®

1

Contents

Subject Page Subject Page

Introduction to PALIGHT 1 Adhesive Bonding of PALIGHT 4

Features and Benefits 1 Heat Bending 5

Cutting 1 Thermoforming 5

Drilling 1 Heating Cycle 5

Milling 1 Processing Temperatures 5

Routing 1 Painting 6

Thermal Expansion / Contraction 2 Graphic Applications 7

Screwing and Nailing 2 Direct Digital Printing 8

Installation 2 Laminating 8

Exterior Signs 3 Chemical Resistance 11

Tips on Sign Installations with Posts 3 PSDS Information (Replaces MSDS) 15

Significant Items to be Considered 3 Recommended Uses and Restrictions 15

Screwed Joints 3 Further Information 15

Riveted Joints 3 Physical Properties Table 15

Frame Fastening of Flat PALIGHT Sheets 3

Hanging Signs 3

Some Foam PVC products manufactured by others may contain lead.
PALIGHT is manufactured without lead or any other heavy metal.

Fabrication Guide

Introduction to PALIGHT®

PALIGHT foamed PVC sheet is versatile, flexible, lightweight, and durable and is ideal for use digital or screen printing, fabrication,
and construction.
PALIGHT Premium Foam PVC exhibits the whitest color available and has been successfully tested and approved by digital flatbed
printer manufacturers worldwide. Printers and display buidlers will benefit from its consistent, smooth, and bright surface for
producing high quality displays.
PALIGHT is easily handled, cut and fabricated using conventional tools and equipment, and can be printed, painted or laminated.

Features and Benefits

 Ease of Fabrication

 Light Weight

 Chemical Resistant

 Superior Insulating Characteristics

 Moisture Resistant

 Great Flammability Ratings

 Heavy Metal Free

Cutting

Circular Saws

PALIGHT material up to 3 mm thick can be cut with a knife or blade.
For PALIGHT sheets 3 mm and thicker, carbide-tipped, triple chip, ground type circular saws can be used.
The following settings are recommended:

 Rake angle: 0 to 15

 Clearance angle: 10 to 20

 Cutting speed: 4,000 to 8,000 feet per minute

 Feed: 70 to 90 feet per minute

 Tooth pitch: 0.080” to 0.040”

 Band Saws

High speed steel blades normally recommended for wood or plastic can be used for PALIGHT material utilizing the following
guidelines.

 6 to 8 teeth per inch

 Cutting speed: 3,000 to 5,000 feet per minute

 Feed: up to 40 feet per minute

Saber Saws

Rough cut type blades ground for plastics can be used on PALIGHT sheets. Smooth metal-cutting blades are not
recommended.

Drilling

PALIGHT can be drilled with carbide-tipped bits using twist drills recommended for metals.
The following settings are recommended:

 Point angle: between 90 to 110

 Spiral angle: 30

 Relief angle: 10

 Cutting speed: 150 to 1,300 feet per minute

 Feed rate: 0.01 to 0.02 inches per revolution

The minimum distance from the edge should be 2 times the hole diameter. In an effort to reduce heat build up during drilling of
thicker PALIGHT sheets, it may be necessary to periodically remove the drill bit from the PALIGHT material.

2

PALIGHT®

Milling

PALIGHT can be milled by using standard milling machines of various types utilizing the following guidelines:

 Relief angle: 5 to 10

 Rake angle: -10 to 0

 Cutting speed: 3,000 to 3,500 feet per minute

 Cutting feed: 0.12 inches per revolution

Routing

PALIGHT material can be easily routed using multi-fluted carbide tools on standard woodworking
routers. Standard tools and machines can be utilized with no need to alter equipment. Adjust feed and
speed rates as needed to achieve the best edge finish on the PALIGHT parts.

Thermal Expansion / Contraction

As with most plastics, PALIGHT foamed PVC will expand and contract with an increase or reduction in temperature. This material
property is known as linear thermal expansion and contraction.
Since PALIGHT can be used in a wide variety of indoor and outdoor applications, linear thermal expansion and contraction may need
to be considered during the fabrication and installation of the material. It is important to take in to account the temperature at which
the PALIGHT material was fabricated as well as the temperature of the installation.
PALIGHT should not be used in applications or climatic conditions that exceed 140° F (ambient or surface temperature), at which
temperature the PALIGHT will soften and permanently deform. Dark colors are generally not recommended for outdoor use, as they
absorb heat and can easily exceed the maximum allowable temperature of 140° F.

PALIGHT Linear Expansion / Contraction

Quick Reference

Total Temp.

Change (∆)

20°F

40°F 0.071 0.089 0 .142 0. 178 4 mm 20 -28 in.

60°F 0 .107 0.13 3 0. 213 0.266 5 mm 31 - 43 in.

80°F 0 .142 0.17 8 0.284 0.355 6 mm 47 - 70 in.

100 °F 0. 178 0.222 0. 355 0.444

120 °F 0 .213 0.266 0.426 0.533

140 °F 0.249 0 . 311 0.497 0.622

Expansion / Contraction of Material at

Standard Lengths / Widths (in inches)

48 in. 60 in. 96 in. 120 in. 2 mm 6 - 8 in.

0.036 0.044 0.071 0.089 3 mm 12 -16 in.

Sheet Thickness Distance Between Fastening Points

Distances Between Fastening Points

for Screw and Rivet Joints

Screwing and Nailing

Any type of screw or nail can be used to fasten PALIGHT material. Power nailers and screw driving equipment are suggested. Inserting
the screw or nail in an elongated slot or an oversized hole is recommended so that the material can expand or contract if fluctuations
in temperature occur. For best results, use oversized washers or grommets in combination with screws.

Installation

PALIGHT is manufactured as an extruded foam PVC product with a directional grain running the entire length of the sheet. This
manufacturing process gives PALIGHT greater flexural strength in the direction of the extrusion. The grain of the PALIGHT should
always be installed perpendicular to the fastening point.

3

Fabrication Guide

25mm

Exterior Signs

PALIGHT, when used correctly and with basic mechanical fixing methods is suitable for exterior use. Using PALIGHT can provide an
excellent weatherproof sign substrate ready for screen printing, painting, or vinyl graphics.

Tips on Sign Installations with Posts

The following tips have been compiled to be used as a general guide for fixing PALIGHT for a minimum amount of breakage.
Unusual designs falling outside the examples given may require certain modifications when considering PALIGHT.

Significant Items to be Considered

1. Bolt holes should always be larger than the bolt shaft to allow for thermal expansion and contraction, thus eliminating the possible
stress at bolt fixing points. The use of washers spread the compressive load when bolts/nuts are tightened. Be sure not to over
tighten as this will weaken the connection.

2. Split timber posts are the best to use because the PALIGHT is supported evenly on both sides. If steel or aluminum poles are
used, nylon bolts and washers give the best results. Be certain not
to skimp on fasteners for these types of installation. They should be
evenly spaced and away from the top and bottom edges.

Screwed Joints

For the attachment of PALIGHT, basically all known through bolts are
acceptable. For outdoor mounting, it is recommended that the bolt
shank be passed through the PALIGHT in prepared holes or suitably
dimensioned slots that leave adequate clearance between the bolt
shank and the PALIGHT.

The screws should only be tightened firmly enough to allow the
sheet to expand and contract in all directions without warping or
buckling. Tapping screws or screws with form fitted passage of the shank through the sheet should be avoided, but are allowed for
interior uses with predictably low temperature variations.
The diameter of the hole or length of the slot should not be less than 2.5 times the shank diameter of the fastener. Disc washers
should be used to cover the holes or to bridge the slots and they should be large enough to ensure adequate load distribution.
Precise centering of the screws in holes and slots is essential to permit free movement of the sheet in all directions.

Frame Fastening of Flat PALIGHT Sheets

PALIGHT can be fastened utilizing various different framing materials such as, but not limited to, wood, aluminum, steel and vinyl.
Besides the inherent rigidity of PALIGHT sheets, which is dependent on thickness, all possible exterior stresses, e.g., wind pressure,
etc., must be taken into consideration in frame fastening. For appropriate mechanical and elastic property values the data sheet
should be consulted. Dimensional changes due to thermal expansion (or contraction) must be taken into consideration by leaving
sufficient clearance between the sheet edge and the frame.

Hanging Signs

PALIGHT may be successfully used as interior hanging signs. As PALIGHT is an extruded sheet product, thin gauges or large hanging
signs may require additional support. The addition of an aluminum or thick walled plastic “C” channel across the top, bottom, or
around the perimeter may be needed to alleviate any tendencies to warp. When the additions of supporting channels are not
an option, the method illustrated below may also be used to help prevent bowing. Holes should be located 2-1/2 times material
thickness from edge.

4