This Online Learning Seminar is available
through a professional courtesy provided
by:
THERMOPLASTIC TECHNOLOGY
IN ARCHITECTURAL RAILING SYSTEMS
AVCON
1451 Rt. 37 West
Toms River, NJ 08755
Telephone 1-800-24-AVCON
Fax 732-286-0526
E-mail:[email protected]
Internet: http://www.AVCONRAIL.com
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© 2004 AVCON. The material contained in this course was researched, assembled, and produced by
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directed to the program instructor.
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Slide 1 of 52
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Thermoplastic Technology in Construction
Thermoplastic Technology in Construction
Presented By:
Klint Stanley, National Sales Manager
AVCON
Toms River, NJ 08755
Description:
Course is designed to provide information on the use and
application of Thermoplastics in architectural railing systems
AIA/CES Info:
Provider No. J624 – Course No. AEC014; LUs – 1.0
MCE Info:
Contact your respective governmental licensing & regulatory
agency.
Expiration date:
May 15, 2005
This program is registered with AIA/CES for continuing professional registration. As such, it does not include content that may be
deemed on construed to be an approval or endorsement by the AIA or AEC Daily Corporation of any material or construction or any
method or manner of handling, using, distributing or dealing in any material or product. Question related to specific materials,
methods and services should be directed to the program instructor.
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Thermoplastic Technology in Construction
How to use this Online Learning Course
•
Read and review the material contained in this seminar.
•
Each slide may contain additional Instructor comments. To view these
comments, double-click on the
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to scroll through the text.
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To view this presentation, use the previous/next keys on each slide or the up
and down arrow keys on your keyboard.
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Within this course is a code word that you will be required to enter in order to
proceed with the online examination. Please be sure to write down this code
word so that you have it available for the test.
•
To receive a certificate indicating course completion, refer to the instructions
at the end of the seminar.
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For additional information and post-seminar assistance, click on any of the
logos and icons within a page or any of the links at the top of each page.
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Thermoplastic Technology in Construction
Learning Objectives
At the end of this seminar, participants will have a better understanding of:
•
Basic architectural railing design considerations
•
Use of structural thermoplastic material in construction
•
Design capabilities of structural thermoplastic in railing systems
•
How to specify structural thermoplastic railing systems
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Slide 4 of 52
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Thermoplastic Technology in Construction
Structural Thermoplastic Technology
•
Whether seeking which railing material to use in the design of a new building
or replacing an existing system, several factors warrant consideration.
•
First, and most basic, a strong system that meets national building codes is
essential.
•
Color and style are important items.
•
Next decide if cost is the major factor. While wanting the best value, if
maintenance costs are excessive and if replacement is frequent, then what
appears to be the cheapest rail, simply is not.
•
Does the system we select meets structural codes when new, will it maintain
that strength over time?
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Slide 5 of 52
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Thermoplastic Technology in Construction
Structural Thermoplastic Technology
•
For years one of the most problematic items of building maintenance has been
the railing system used to protect its occupants.
•
The condition of the railing is a major factor in the building's appearance and
in potential liability. Railings must be constantly maintained and corrosion is
an ever present enemy.
•
Are there materials and systems that could postpone the inevitable
replacement?
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Slide 6 of 52
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Thermoplastic Technology in Construction
Structural Thermoplastic Technology
•
Who of us, though, cannot remember the time when an item made of plastic
was not thought of as cheap. Now, however, some of the most expensive
products you can buy are made of plastics .
•
But what about strength, can an "upscale appearance" using plastic railing
be maintained. Why, when safety is a paramount concern and the potential
for liability is so excessive, would plastic be selected?
•
It's because after a thorough investigation of thermoplastic technology,
coupled with the most valuable test of all, "real and everyday use," the
superior performance of structural thermoplastic railing has been proven.
•
The educated design professional, after learning what can be done with
today's technologically advanced structural plastic, will only specify an
engineered thermoplastic. They are calling on the manufacturer for
maintenance-free products.
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Slide 7 of 52
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Thermoplastic Technology in Construction
Structural Thermoplastic Technology
•
Strength. The liability associated with any railing can be greatly reduced by
specifying and using a rail system that exceeds building codes, and, more
importantly, maintains that strength over time.
•
The natural corrosion and oxidation that occurs when screws and dissimilar
metals and materials, including concrete, are combined in the presence of
salt and other chemicals will render many railing systems unsafe and
dangerous.
•
A railing that may have met code when installed, may not in a short period
of time. Without any compromise in safety, structural thermoplastic when
properly fabricated can complement the aesthetic appeal of your design,
eliminate maintenance, and keep the exceptional strength it is designed
with.
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Slide 8 of 52
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Thermoplastic Technology in Construction
Structural Thermoplastic Technology
•
Plastics are NOT created equal. There are thousands of plastic recipes, known
in the industry as compounds. The right plastic for the right job is an industry
in itself.
•
Do not confuse knowledge of plumbing pipe and plastic patio furniture, glued
together, with the modern world of thermoplastic. After all you cannot use
plastic sandwich wrap to side a house and you cannot use PVC plumbing pipe
and fittings to build a structural railing system.
•
The idea to use plumbing pipe with fittings (i.e., crosses, tees, elbows, etc.) is
great if you want to run water through it, but it was never designed to be
structural.
•
Enter into the equation a new family of plastics. You think nothing of all these
late model cars, with body side moldings and rocker panels in just about any
color, and even high impact bumpers on the most expensive of cars.
•
Special thermoplastics, designed with scientific polymers, compounds, and
plastic alloys can provide materials that are non-corrosive, durable, attractive,
and maintenance free.
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Slide 9 of 52
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Thermoplastic Technology in Construction
Structural Thermoplastic Technology
•
Design professionals are learning fast that there is little need to specify metals
when thermoplastics can meet their design criteria and in addition, offer
substantial savings in maintenance and replacement costs.
•
Unlike some mechanical or component systems, thermoplastic railing can be
shaped in the smoothest of radii or sharpest of bends. If you doubt the
strength, durability, and cosmetics of structural thermoplastic railing systems,
take a trip to Walt Disney World, Six Flags, Universal, Holiday Inns, Sheraton,
and many condominium projects just to name a few, and you will see major
examples of structural "Plastic" railing at work in the most demanding of
situations.
•
So when you are considering what type of railing to use when building,
designing, or replacing your railing, do not forget that you have an intelligent
alternative...structural thermoplastics.
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Slide 10 of 52
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Thermoplastic Technology in Construction
What are Thermoplastics
•
Thermoplastics are materials that are capable of softening or fusing when
heated and then returning to a rigid state when cooled.
•
Thermoplastics come in a variety of types. Each type of material performs
differently and has qualities that make it better suited for certain uses.
The type of thermoplastic that is selected for use should depend on the
application.
– An engine compartment may require a product that will perform
under high mechanical and thermal loads.
– Products that are exposed to the environment may require a material
with properties that include impact and weather resistance.
– Products that are used in laboratories or clean rooms may require
special qualities such as chemical or static resistance.
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Slide 11 of 52
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Thermoplastic Technology in Construction
Structural Thermoplastics in Construction
•
Plastics have become common component in the building and construction
industry.
•
Several advantages of plastic over more traditional exterior building material
including reduced maintenance:
– Common problems with wood:
• Moisture absorption.
• Insects.
• Require frequent repainting or staining.
• Not permitted in many project types.
– Common problems with metals:
• Rust.
• Dents and scratches.
• Costly maintenance.
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Slide 12 of 52
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Thermoplastic Technology in Construction
Engineering Grade Plastics
•
The focus of this course will be on engineering grade plastics. Engineering
Grade plastics are all-purpose plastics and have uses that include; building
construction, car manufacturing computer & TV monitors, compact disk cases,
and packaging material just to name a few.
•
Three common types of Engineering Grade plastics include:
– Polyvinyl Chloride (PVC).
– Acrylonitrile/Butadiene/Styrene (ABS).
– Acrylonitrile/Styrene/Acrylate (ASA).
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Thermoplastic Technology in Construction
Engineering Grade Qualities
•
PVC:
– Limited color stability in continuous exterior exposures in light colors; No
color stability in dark colors.
– Chalking.
– Readily available, inexpensive product, good stiffness.
– Good chemical resistance.
•
ABS:
–
–
–
–
–
Readily available product.
Easy to extrude or mold.
Lacks stiffness.
Limited color fastness.
Will become brittle after exposure to UV and environment.
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Slide 14 of 52
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Thermoplastic Technology in Construction
Engineering Grade Qualities
•
ASA:
– High thermal stability.
• Dimensional stability.
• Higher heat deflection point.
– Good Chemical Resistance.
– Resistance to weathering, aging and yellowing.
– Higher cost.
•
Each of these types of engineering grade plastics also comes in a variety of
composites and blends formulated for specific uses.
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Thermoplastic Technology in Construction
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Thermoplastic Technology in Construction
ASA Architectural Qualities
•
There are a variety of material grades designed to meet a range of end use
applications by offering excellent:
–
–
–
–
–
–
Weatherability.
Impact resistance.
Color retention.
Heat resistance.
Flammability.
Ease of processing.
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Thermoplastic Technology in Construction
Weatherability
•
ASA has high weathering resistance because the elastomer component is
composed of an acrylate rubber. Compared with butadiene rubbers, e.g. as
used in impact resistant polystyrene and ABS, it has significantly higher
resistance to UV radiation and to attack by atmospheric oxygen.
•
When plastics are exposed to outdoor weathering, it is not only their
mechanical properties which can change. The combination of UV radiation,
atmospheric oxygen and heat often produces clearly visible yellowing too.
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Slide 18 of 52
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Thermoplastic Technology in Construction
Impact Resistance
•
Testing is in accordance with ASTM
Standards.
•
This test shows how both products
started out with similar values, but
once exposed to the elements, ABS
shows a steep, significant loss, where
ASA maintains its properties over
time.
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Slide 19 of 52
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Thermoplastic Technology in Construction
Color Retention
•
UV-Resistant ABS and PVC blends typically have a tendency to grey or yellow
when exposed to UV or exterior exposure.
•
ASA does not have the same tendency because the formulation of resins are
specifically designed for outdoor use and resisting UV rays.
•
ASA has higher pigment concentration compared to ABS or other plastics.
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Slide 20 of 52
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Thermoplastic Technology in Construction
Heat Resistance
•
Long Term heat exposure can
cause weakening in many
styrenic plastics. When
exposed for extended periods
of time to 90 degree F
temperatures, the mechanical
strength of the ABS products
decrease.
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Slide 21 of 52
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Thermoplastic Technology in Construction
Processing – Extruding
•
Resin (Plastic) in pellet or powder form is placed
into a hopper.
•
It then feeds into an extruder chamber where the
material is heated to the proper temperature, then
pushed through the machine by a large turning
screw-like mechanism.
•
The material exits through a die specifically
designed to give the plastic the required shape.
•
The plastic then enters through a series of down
stream equipment (Vacuum sizers and cooling
tanks), which sizes it to the required tolerances
and cools the extrusion.
•
At the end of the process the extrusion is cut to
the desired length and packaged for shipment.
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Slide 22 of 52
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Thermoplastic Technology in Construction
Processing – Co-Extrusion
•
Co-Extrusion is the blending and extruding of two or more resins creating a
cap (outside) and a substrate (inside).
– Two or more plastics are used.
•
Co-Extruding creates a superior product when compared to the performance
of each individual resin.
•
Benefits of co-extrusions include enhanced product performance and cost
effectiveness.
Machining and fabricating of co-extruded tubing
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Slide 23 of 52
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Thermoplastic Technology in Construction
Processing – Injection Molding
•
Resin is fed to the machine through the hopper. The resins enter the injection
barrel by gravity though the feed throat. Upon entrance into the barrel, the
resin is heated to the appropriate melting temperature.
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Slide 24 of 52
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Thermoplastic Technology in Construction
Processing – Injection Molding
•
The mold is the part of the machine that receives the plastic and shapes it
appropriately. The part is cooled to a temperature that allows the resin to
solidify and be cool to the touch. The mold plates are held together by
hydraulic or mechanical force. The part is ejected from the mold and
repeated.
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Slide 25 of 52
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Thermoplastic Technology in Construction
Architectural Railing Design Basics
•
Structural Design Issues:
– Steel reinforced thermoplastic railing systems should be designed to allow
for expansion and contraction.
– Railings are designed with an “Expansion Joint” in the top rail and an
internal color-coded sleeve.
– When the temperature is low and the product is in a contracted state, the
expansion joint will be open as designed and you will see the color coded
expansion sleeve.
– Basic mounting options include Flange Mount, Fascia Mount, Core Mount
and Weld Mount.
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Slide 26 of 52
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Thermoplastic Technology in Construction
Architectural Railing Design Basics
•
Safety:
– To stop people from falling; to
assist people on stairs, ramps, etc.
– Building codes published with
certain requirements on height,
size and design, and strength.
– Member spacing – Current building
codes specify that a 4 inch sphere
not be able to pass through any
part of the railing system.
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Slide 27 of 52
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Thermoplastic Technology in Construction
Architectural Railing Design Basics
•
Code Compliance:
– Structural Loads – Railing must be designed to meet or exceed structural load
requirements of the prevailing code authority. Testing must be in
accordance with ASTM Standards.
– ADA Compliance- Americans with Disabilities Act requires the diameter of
the handgrip portion of the handrail, if round, to be not less than 1 inch or
more than 1.5 inches. Certain states and municipalities may require a specific
size within this range.
– ADA standards also list specific load and height requirements that railings
and handrails must meet as well as clearance requirements on stairs, ramps,
and landings.
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Slide 28 of 52
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Thermoplastic Technology in Construction
Architectural Railing Design Basics
•
Sizing and Dimension:
– Structural components of railings (posts
and horizontal rails) are approximately 2
inches in diameter with a 5/16 inch wall
thickness. Vertical balusters are 1 inch in
diameter.
– Handrails are typically installed between
34 and 38 inches above finish grade. At 42
inch high guardrails, the handrail is
attached to the vertical supports in a
"floating application". Typical handrails
are 1-1/2 inches in diameter to comply
with ADA grasping requirements.
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Slide 29 of 52
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Thermoplastic Technology in Construction
Architectural Railing Design Basics
•
Installation Issues:
– Concrete: Railings can either be core mounted or flange mounted into
concrete. Minimum depth recommended for a core mount is 4 inches into
a 4 inch diameter hole. Flange mount can be accomplished by utilizing the
correct anchors. Minimum embedment is specified by anchor provider.
– Steel: Installation into steel can be accomplished in two ways. When it is
possible to drill a hole through the steel, a flange mount can be used with
a bolt and nut application. Alternately, the steel within the post can be
extended and welded to the steel.
– Wood: Either flange or fascia mounts may be used. 3/8 inch diameter lag
bolts are recommended in both mounting applications. The length of the
lag bolt is determined by the application. Proper “Blocking” is a
requirement when mounting into wood. Usually a double 2x piece of
wood is sufficient.
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Slide 30 of 52
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Thermoplastic Technology in Construction
Architectural Railing Applications
•
Commercial.
•
Residential.
•
Leisure/Entertainment.
•
Municipal Facilities.
•
Hotel/Motel.
•
Condominium.
•
Stadium.
•
Amusement Parks.
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Slide 31 of 52
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Thermoplastic Technology in Construction
Architectural Railing Applications - Thermoplastic
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Slide 32 of 52
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Thermoplastic Technology in Construction
Architectural Railing Applications - Thermoplastic
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Slide 33 of 52
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Thermoplastic Technology in Construction
Architectural Railing Applications - Thermoplastic
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Slide 34 of 52
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Thermoplastic Technology in Construction
Architectural Railing Applications - Thermoplastic
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Slide 35 of 52
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Thermoplastic Technology in Construction
Architectural Railing Applications - Thermoplastic
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Slide 36 of 52
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Thermoplastic Technology in Construction
Architectural Railing Applications - Thermoplastic
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Slide 37 of 52
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Thermoplastic Technology in Construction
Architectural Railing Applications - Thermoplastic
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Slide 38 of 52
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Thermoplastic Technology in Construction
Architectural Railing Applications - Thermoplastic
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Slide 39 of 52
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Thermoplastic Technology in Construction
Architectural Railing Applications - Thermoplastic
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Slide 40 of 52
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Thermoplastic Technology in Construction
Limitations of Plastic Railing Assemblies
•
Where not to use:
– Anywhere that code requires a non-combustible (Steel) rail.
• Fire Exit Stairwells.
–
Automotive Guardrail.
• 10,000 pound point load resistance is required.
– Extremely ornate railings.
• The costs involved in development of molds makes ornate railings not
cost effective.
Please remember the word CO-EXTRUSION. You will be required to enter it in
order to proceed with the online examination.
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Slide 41 of 52
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Thermoplastic Technology in Construction
Specifying Structural Thermoplastic Railings
•
Part 1 - General:
– Reference Standards/Building Codes/ADA.
– Structural/System Performance.
– Shop Drawings/Test Reports.
– Engineering and Certifications.
•
Part 2 - Products:
– Appropriate competitors.
– Using the right materials for the job.
– Performance criteria.
– Shop fabrication.
•
Part 3 - Execution:
– Examine surface to receive railings.
– Installation sequence.
– Installation requirements.
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Slide 42 of 52
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Thermoplastic Technology in Construction
Architectural Railings Overview
•
Use and application of railings.
– With safety being of utmost importance, railings are required to prevent
falling off a structure and to provide assistance when using ramps or stairs.
Typical applications include:
• Balconies and decks.
• Roof parapets.
• Stairs.
• Ramps.
• Retaining Walls.
• Surrounding Pools.
•
Aesthetics.
•
New polymer chemistry and technology is impacting how and where
thermoplastic railings can be used.
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Slide 43 of 52
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Thermoplastic Technology in Construction
Architectural Railings Overview
•
Available Railing Systems.
–
Light Duty – Residential:
• Mechanical Aluminum (screwed together).
• PVC Porch Rail.
• Wrought Iron.
• Wood.
–
Heavy Duty – Commercial:
• Welded Steel.
• Welded Aluminum.
• Steel Reinforced Thermoplastic.
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Slide 44 of 52
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Thermoplastic Technology in Construction
Architectural Railings Overview
•
Traditional Materials:
– Steel - Pro is strength; Con is rust and high maintenance cost.
– Aluminum - Pro is design flexibility and powder coating color variety; Con
is oxidation, corrosion, and limited coating life.
– Stainless Steel- Pros are strength and maintenance-freedom if the proper
grade is used; Cons are cost, no color selection, and rust if incorrect grade
is used.
– Wood - Pro is cost; Cons are deterioration and maintenance intensive.
– Wrought Iron - Pro is design flexibility; Cons are rust and maintenance
intensive.
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Slide 45 of 52
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Thermoplastic Technology in Construction
Architectural Railings Overview
•
Thermoplastics.
– PVC:
• Pros: strength and under certain conditions cost.
• Cons: lack of color retention and weatherability.
– ASA:
• Pros: weatherability and color retention.
• Cons: cost, moderate stiffness.
– ABS:
• Cons too flexible and brittle.
– ASA outer layer/PVC core:
• Pros: good impact, stiffness, cost competitive, weatherability, and
color retention.
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Slide 46 of 52
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Thermoplastic Technology in Construction
Commonly Asked Questions
•
Is Plastic Strong Enough?
– Plastic Railing is engineered and designed to meet and exceed applicable
building codes. Independent testing supports this. Additionally, properly
designed railing is a marriage between plastics and strategically placed
metal superstructures often creating structural strength far in excess of
conventional metal railing.
•
Will plastic fade?
– All materials such as paint or plastics will fade when subjected to certain
conditions such as ultra-violet light. Properly formulated plastics are
compounded so as not to be susceptible to fading. ASA (acrylics) are
commonly used in both paint and plastic formulations to stop fading.
Plastics in the ASA family are vastly superior to others, such as PVC, in the
areas or color retention and should be used when there will be exposure
to UV light.
•
Will plastic rust or corrode?
– No. Plastics are used to eliminate rusting, painting and corrosion. Plastic
does not rust. Internal connectors are plastic or stainless steel.
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Slide 47 of 52
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Thermoplastic Technology in Construction
Commonly Asked Questions
•
Will thermoplastic get brittle in the sun, like PVC pipe?
–
•
Will plastic scratch?
–
•
Plastics, like other materials used in railing, is not indestructible. However,
simple sanding and polishing can remove marks that may be forced into its
surface.
Will plastic burn?
–
•
ASA is not susceptible to brittleness like PVC. ASA will not turn yellow or
fade as does PVC.
Thermoplastics are self-extinguishing. An additional source of fuel is
required to support combustion.
Does plastic give off toxic fumes if burned?
–
All materials will give off some fumes if burning. The smoke produced
when railing is ignited is less toxic than that produced by burning wood.
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Slide 48 of 52
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Thermoplastic Technology in Construction
Commonly Asked Questions
•
Do chemicals affect plastic?
–
•
How are plastic connections made?
–
•
Some chemicals will affect any material known to man. Most chemicals that would
ever come in contact with railings will have little or no affect. This includes all
common household and commercial cleaners. Additionally, no glues are used.
Connections are all mechanical.
Typically, a load bearing bracket/support is attached to one side of every joint. The
adjoining rail member is placed over on onto that support and secured in place with
a stainless steel screw or pin.
How are plastic railings mounted?
–
The typical methods of mounting metal or wood railing apply. Four basic and
common methods exist:
• Using appropriate bolts or lags secured through a base plate attached to each
post.
• Coring an appropriate size hole to insert each post into. Once inserted selfexpanding grout secures the rail in place.
• Welding if the surface is metal.
• Bolting to the side or structural stringer, commonly known as Fascia Mounting.
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Slide 49 of 52
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Thermoplastic Technology in Construction
Commonly Asked Questions
•
How are plastic railings mounted?
– The typical methods of mounting metal or wood railing apply. Four basic
and common methods exist:
• Using appropriate bolts or lags secured through a base plate attached
to each post.
• Coring an appropriate size hole to insert each post into. Once inserted
self-expanding grout secures the rail in place.
• Welding if the surface is metal.
• Bolting to the side or structural stringer, commonly known as Fascia
Mounting.
•
Is the color all the way through the material?
– Yes.
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• About the Instructor
• About the Sponsor
• Seminar Discussion Forum
Thermoplastic Technology in Construction
Commonly Asked Questions
•
Can you bend the tubing?
–
Yes, tubing may be bent, twisted, and contorted to meet most designs.
No molded “fittings” are used that would compromise strength or the
ability to form radii or other bends.
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• About the Instructor
• About the Sponsor
• Seminar Discussion Forum
Thermoplastic Technology in Construction
Conclusion of This Module
•
AEC Daily Corporation is a Registered provider with the AIA
Continuing Education Systems. Credit earned on completion of this
program will be reported to CES Records for AIA members.
•
If you desire AIA/CES, CSI and/or state licensing continuing
education credits, please click on the button below to commence
your online examination. Upon successful (80% or better)
completion of the exam, please print your Certificate of
Completion.
•
For additional knowledge and post-seminar assistance, please
avail yourself to the Seminar Discussion Forum (click on the link
above and bookmark it in your browser).
•
If you have colleagues that might benefit from this seminar, please
let them know. Last, revisit AEC Daily web site and download
additional programs available at the Online Learning Center.
© 2004 AVCON. The material contained in
this course was researched, assembled,
and produced by AVCON and remains their
property. Questions or concerns about the
content of this course should be directed to
the program instructor.
Click Here To Take The Test
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