Working with DuraPlate®
Fabrication Guidelines
NOTES, CAUTIONS and WARNINGS
This manual contains Notes and Cautions in reference to working with DuraPlate material.
Notes: Provide additional information or highlights important tips throughout the manual.
Cautions: Provide notification of situations that can cause damage to machinery and tools.
Warnings: Provide alerts to situations that can cause personal injury or death.
WORKING WITH DuraPlate
Safety and Handling
Wabash National recommends safe working practices at all times. Assuring full compliance with all environmental,
health, and safety laws and applicable standards and to avoid jeopardizing the environment or individual safety.
Wear appropriate personal protective equipment:
• Always wear approved eye protection around machinery and when working with DuraPlate, as well as proper ear and
foot safety equipment.
• To protect hands and arms from scrapes or cuts, wear heavy abrasion-resistant gloves, as well as cut-resistant arm
guards when handling DuraPlate panels.
• Wear proper respiratory protection when working in areas with high concentrations of dust, chips, and/or heat from
certain fabricating operations. A half face or full face respirator, or dust mask, is recommended for any use that may
cause dust or fumes.
• In situations where there is a possibility of accidental head contact, head protection should be worn. Hard hats can
protect from impact as well as penetration or electrical hazards.
When using other tools and equipment in association with DuraPlate, safety is very important. Follow the manufacturer’s
safety guidelines when performing any function. Use the correct tools and equipment, and use them properly.
Additionally, properly maintaining tools and equipment regularly will enhance safety.
The DuraPlate Material Safety Data Sheet (MSDS) is provided at the end of this manual.
WARNING: The steel used in DuraPlate is thin and can be very sharp. When manually lifting
or maneuvering a standard size DuraPlate sheet, it is advised to use at least two people.
Doing so may prevent the possibility of injury, or damaging or scratching the panel.
WARNING: Do not attempt to weld DuraPlate material under any circumstances. Attempts
to weld the product may result in product delamination, product failure and/or fire. Heat
applied to the panel must be carefully considered and applied with caution. DuraPlate
products are designed to perform in temperature ranges of -50ºF to +190ºF.
TABLE OF CONTENTS
Introduction 1
Product Description 2-7
DuraPlate Panel Specifications 2
DuraPlate Panel Attributes 3-5
Finishes and Coatings 6
Product Tolerances 6
Shipping and Packaging 7
Cutting and Machining 8-11
Shearing 8
Sawing 8
Punching 9
Drilling 10
Routing 11
Water Jet 11
Assembling 12-13
Shiplap Joints 12
Logistic Joints 12
Rivet Fasteners 12
Bolt & Nut Fasteners 12
Screw Fasteners 12
Adhesive Bonding 13
Caulking 13
Forming 14
Cleaning 15
Panel Repair 15
Material Safety Data Sheet 16-18
NTRODUCTION
NTRODUCTION
ese fabrication guidelines have been developed as a resource
assist designers, engineers, researchers, and fabricators to
NTRODUCTION
INTRODUCTION
ese
fabrication
guidelines
have been developed
as a of
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derstand
DuraPlate
panel technology.
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this
assist designers,
engineers, to
researchers,
and DuraPlate
fabricatorsinto
cument
serve
as fabrication
guidelines
working
with
These
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as this
a resource to
ese
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as a of
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DuraPlate
technology.
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contents
ederstand
most efficient
and panel
effective
manner.
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provides
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help
designers,
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and
fabricators
understand
assist designers,
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and DuraPlate
fabricatorsinto
cument
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working
with
ormationserve
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aid
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uses,
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ofefficient
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ormationserve
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aid
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in current
e
most
efficient
and
effective manner.
It provides
data and
uses, new technology,
as well as research
and development.
search
and
development.
abash National has the experience of being a leading
ormation to aid in current uses, new technology, as well as
anufacturer Wabash
of transportation
in North
America.
Composites, aequipment
division of Wabash
National
Corporation,
search
and development.
abash
National
hasthe
thecompany
experience
of being in
a leading
tablished
inwas
1985,
specializes
the
design
established in 2008 to develop new markets and products
anufacturer
ofof
transportation
equipment
inpanel
North
America.
for
our
proven
DuraPlate®
composite
technology
and other
d production
dry
freight
vans,
refrigerated
vans,
flatbed
abash
National
has
the
experience
of
being
a
leading
tablished
1985,
the
company
specializes
inbodies
the design
composite
materials.
DuraPlate
was
first
introduced
in 1996 for use
ailers,
dropindeck
trailers,
dump
trailers,
truck
and
anufacturer
transportation
equipment
in North
America.
d production
of
dry freight
vans,
refrigerated
vans,
flatbed
inofsemi-trailer
sidewalls.
Today,
our composite
materials
termodal
equipment.
The
DuraPlate
composite
panel
is are used in a
wide
range
products
and
markets,
with
multiple
new offerings and
tablished
indeck
1985,
theofcompany
specializes
inbodies
the
design
ailers,
drop
trailers,
dump
trailers,
truck
and
e of the many
innovative
core products that the company
materials
development.
d production
of dryinfreight
vans, refrigerated
flatbed
termodal
equipment.
The DuraPlate
compositevans,
panel
is
anufactures.
ailers,
drop
deckinnovative
trailers, dump
trailers, truck
bodies
and
e of the
many
core
products
that
the
company
Staffed with business development specialists and engineers to aid in
termodal
equipment.
The
DuraPlate
composite
panel
is applications,
anufactures.
integration
of DuraPlate
material
in many
e DuraPlatethe
Products
Group
(DPG),composite
was formed
in early
e of the many
innovative
core
products
that
the
company
Wabashbusiness
Composites
has
extensive
research
and development
08 as a strategic
unit
within
Wabash
National
anufactures.
capabilities
to
provide
testingwas
data formed
to supportinspecific
e
DuraPlate
Products
Group
(DPG),
early customer
orporation. applications.
Their responsibility
is the
successful
application
With
a
strong
belief
in
protecting
the
Intellectual
08
as a strategic
business unit
Wabash
National
DuraPlate
Panel
technology
in within
various
industries.
The
Property
(IP)
of
Wabash
National
Corporation
and
that
e DuraPlate Their
Products
Group (DPG),
was
formed in
early of its
orporation.
responsibility
is
successful
application
uraPlate Products
Group
strives
tothe
continuously
improve
customers,
a mutual
nondisclosure
agreement
(MNDA)its
is used early
08
as a strategic
business
unit
Wabash
National
DuraPlate
technology
in within
various
industries.
The
in
discussions
with potential
customers.
oducts
andPanel
processes.
orporation.
Their responsibility
successfulimprove
application
uraPlate Products
Group strives is
tothe
continuously
its
DuraPlate
Panel
technology
in various
industries.
The Corporation
Headquartered
in Lafayette,
Indiana,
Wabash National
oducts
and
processes.
affed with Business Development Specialists and Engineers to
(NYSE: Group
WNC) isstrives
a diversified
manufacturer and
North America’s
uraPlate Products
to continuously
improve
its
d in the integration
of DuraPlate
composite
material
in many
leading
producer
of semi-trailers
and liquid
transportation
systems.
oductswith
andBusiness
processes.
affed
Development
Specialists
and
Engineers
to
plications, the
DuraPlate
Products
Groupspecializes
also hasinextensive
Established
in 1985,
the company
the design and
dsearch
in theand
integration
of DuraPlate
composite
material
in many
production of drycapabilities
freight vans, to
refrigerated
vans,
platform
development
provide
testing
datatrailers,
affed
with Business
Development
Specialists
and
Engineers
to
plications,
the
DuraPlate
Products
Group
also
has
extensive
intermodal
equipment,
liquid tank trailers,
tanks, engineered
support specific
customer
applications.
With frac
a strong
belief
dsearch
in theand
integration
of
DuraPlate
composite
material
in
many
development
capabilities
to
provide
testing
data
products,
and composite
products.
protecting the
Intellectual
Property
(IP) of Wabash National
plications,
the DuraPlate
Products
GroupWith
also has
extensive
support
specific
customer
applications.
a strong
belief
orporation and that of its clients a mutual nondisclosure
search
and
development
capabilities
to
provide
testing
data
protecting
the Intellectual
Property
(IP) of Wabash
National
reement
(MNDA)
is used early
in discussions
with potential
Contact
information:
support specific
customer
applications.
With
a strong belief
orporation
and
that
of
its
clients
a
mutual
nondisclosure
ents.
protecting
the
Property
(IP) of Wabash
National
reement
(MNDA)
usedSt.
early
in discussions
with potential
3000Intellectual
E.isMain
orporation
and
that
of
its
clients
a
mutual
nondisclosure
ents.
IN 47905
e DuraPlateLafayette,
Products Group
encourages questions or
reement (MNDA) is used early in discussions with potential
mments at 866-877-5062
any time.
ents.
e DuraPlate Products Group encourages questions or
mments at [email protected]
any time.
ontact information
is as follows:
e DuraPlatewabashcomposites.com
Products Group encourages questions or
00 Sagamore Pkwy S.
mments
at any time.
ontact
information
fayette,
IN 47905 is as follows:
00 Sagamore
65)
771-5300 Pkwy S.
ontact
information
fayette,
IN 47905 is as follows:
mail:
[email protected]
00 Sagamore
65)
771-5300 Pkwy S.
ebsite:
www.duraplateproducts.com
fayette,
IN 47905
mail:
[email protected]
65)
771-5300
ebsite: www.duraplateproducts.com
mail: [email protected]
ebsite: www.duraplateproducts.com
1
PRODUCT DESCRIPTION
PRODUCT DESCRIPTION
DuraPlate is an engineered steel and plastic composite
material that has proven performance in the most demanding
applications. This composite panel is comprised of two external
DuraPlate, is an engineered steel and plastic composite material that
sheets of high strength galvanized steel that are thermally
has proven
in the
applications.
bondedsuccess
to each side
of most
a high demanding
density polyethylene
core. This composite
panel is comprised of two external sheets of high strength galvanized
steel First
which
are thermally
to each
side
of a highwas
density
fabricated
in 1996,bonded
DuraPlate’s
original
application
for
polyethylene
core.
semi-trailers
because of its strength and durability. Today, the
DuraPlate semi-trailer is the leader in the trucking industry, with
more than 500,000
produced
in North
America.
The versatility
First fabricated
in 1996,
DuraPlate’s
original
application
was for semiof DuraPlate
hasitsallowed
innovation
and progression
trailers
because of
strength
and durability.
Today,into
theother
DuraPlate
markets, and has successfully replaced standard materials for
semi-trailer is the leader in the trucking industry, with more than
products, including truck bodies, swing and overhead doors,
360,000
produced in North America. The versatility of DuraPlate
cargo trailers and portable storage units.
has allowed innovation and progression into other markets, and has
successfully
replaced
standard
materials for products
including truckDuraPlate
is well suited
and accommodating
to many products
bodies,
swing
and
overhead
doors,
cargo
trailers
and
portable storage
and applications because of its excellent strength-to-weight
units.ratio and superior performance.
DuraPlate
Panel Specifications
DuraPlate
is well-suited
and accommodating to many products and
applications
because
of
its excellent
toprocess
weight ratio and
DuraPlate panels are produced
in a strength
continuous
superior
performance.
to standard
specifications in a dedicated state-of-the-art
production facility. The standard weights, measurements
and properties
of DuraPlate are provided below. Wabash
DuraPlate
Panel Specifications
Composites
has
flexibility in
to a
provide
customprocess
specifications
DuraPlate panels arethe
produced
continuous
to standard
upon
request
with
minimum
quantity
requirements.
specifications in a dedicated state-of-the-art production facility.
The standard weights, measurements, and properties of DuraPlate
are provided. The DuraPlate Products Group has the flexibility to
provide custom specifications upon request, with minimum quantity
requirements.
Standard Specifications
Panel Thicknesses
Panel Thicknesses
General Steel Galvanized
Standard Specifications
80,000 psi yield
Polyester baked-on finish
General
Core Core
Panel
Thickness Panel Thickness
Widths
Widths Lengths
.
Lengths Steel Galvanized
80,000-psi yield
High-density
polyethylene
Polyester baked-on finish
2.5High-density
mm (.098 in)polyethylene
2.5 mm (.098 in)
4 mm (.157 in)
4 mm (.157 in)
6 mm
(.236
in) in)
6 mm
(.236
7.57.5
mm
(.295
in) in)
mm (.295
13.0
mm
(.511
in) in)
13.0 mm (.511
48 in
4849
inin
496inft (standard)
24 ft (max.)
2.5
4.0
6.0
7.5
13.0
6 ft (standard)
24 ft (max)
2
5
DuraPlate Panel Attributes: 2.5–4.0 mm Thickness
Product Attributes
Typical engineering properties for DuraPlate® composite material, using a high-density polyethylene core between two sheets of steel. (1)
2.5 mm (.013”)
4.0 mm (.013”)
4.0 mm (.016”)
U.S.
METRIC
U.S.
METRIC
U.S.
METRIC
0.098 in
2.5 mm
0.157 in
4.0 mm
0.158 in
4.0 mm
Maximum Width
48 in
1,219 mm
48 in
1,219 mm
49 in
1,245 mm
Maximum Length
288 in
7,315 mm
288 in
7,315 mm
288 in
7,315 mm
(2)
1.408 lb/ft²
6.874 g/m²
1.602 lb/ft²
7.822 g/m²
1.828 lb/ft²
8.925 g/m²
1,335
lb▪in²/in
132.2 X 10³
4
MPa▪cm /m
4,040
lb▪in²/in
217.5 X 10³
4
MPa▪cm /m
4,718
lb▪in²/in
734.2 X 10³
4
MPa▪cm /m
80,000 lb/in²
551.6 MPa
80,000 lb/in²
551.6 MPa
80,000 lb/in²
551.6 MPa
Puncture Resistance
0.5 in Diameter Ball
1,238 lbf
5,507 N
1,287 lbf
5,725 N
1,636 lbf
7,277 N
Puncture Resistance
6 in Spade
3,529 lbf
15,698 N
3,004 lbf
13,362 N
3,369 lbf
14,986 N
Coefficient of Thermal
Expansion at Low
Temperature
(3)
(ASTM E831-06)
86.071
µin/in▪ºF
154.93
µm/m▪ºC
74.071
µin/in▪ºF
133.33
µm/m▪ºC
78.071
µin/in▪ºF
140.53
µm/m▪ºC
Coefficient of Thermal
Expansion at High
Temperature
(3)
(ASTM E831-06)
252.218
µin/in▪ºF
453.99
µm/m▪ºC
246.218
µin/in▪ºF
443.19
µm/m▪ºC
249.218
µin/in▪ºF
448.59
µm/m▪ºC
Corrosion
(4)
(ASTM B117)
Pass
1,000 hrs
Pass
1,000 hrs
Pass
1,000 hrs
Acoustical Properties
(ASTM E90-04)
26 STC
27 STC
28 STC
Surface Burning
(5)(6)
(ASTM E84)
Class B
Class B
Class B
Thickness
Weight
Stiffness (EI)
Tensile Yield of
Laminate
R-value
(ASTM C177)
(1)
(2)
(3)
(4)
(5)
(6)
.048
Hr-ft²-deg
F/BTU
.845 x 10¯² Km²/W
.087
Hr-ft²-deg
F/BTU.
1.532 x 10¯²
K-m²/W
..082
Hr-ft²-deg
F/BTU
1.440 x 10¯²
K-m²/W
All properties based on 0.013 and .016 in., 80 ksi steel skin material.
Weights based on 20% foam core.
Coefficient of Linear Thermal Expansion (CLTE) extrapolated from tests on 6 mm, 7.5 mm, and 13 mm.
Pass without blisters or creep.
Class B rating represents Flame Spread Index 26-75; Smoke Developed Index ≤ 450.
Can achieve
a Class
A rating
by capping
off edges of
to capture
core.to capture core.
Can
achieve
a Class
A rating
by capping
offpanels
edges
of panels
©2008 Wabash National Corporation. All rights reserved. No portion of these materials may be reproduced, stored, or transmitted without prior approval from Wabash National.
Wabash National reserves the right to make changes at any time without notice, as we continuously improve our products. This document does not provide a warranty; but
rather, is an effort to explain the characteristics of DuraPlate® material, as we deem to be accurate. Wabash National shall not have any responsibility or liability for any
damages resulting from such use. DuraPlate® is a registered trademark owned by Wabash National, L.P.
Revision C, Jul. 2014
3
Wabash National Corporation
1000 Sagamore Pkwy S. Lafayette, IN 47905
765.771.5300
DuraPlate Panel Attributes: 6.0–7.5 mm Thickness
Product Attributes
Typical engineering properties for DuraPlate® composite material, using a high-density polyethylene core between two sheets of steel. (1)
6.0 mm (.016”)
7.5 mm (.013”)
7.5 mm (.016”)
U.S.
METRIC
U.S.
METRIC
U.S.
METRIC
0.236 in
6.0 mm
0.295 in
7.5 mm
0.295 in
7.5 mm
Maximum Width
49 in
1,245 mm
49 in
1,245 mm
49 in
1,245 mm
Maximum Length
288 in
7,315 mm
288 in
7,315 mm
288 in
7,315 mm
(2)
2.065 lb/ft²
10.08 g/m²
2.025 lb/ft²
9.887 g/m²
2.253 lb/ft²
11.00 g/m²
11,712
lb▪in²/in
132.2 X 10³
4
MPa▪cm /m
16,340
lb▪in²/in
184.4 X 10³
4
MPa▪cm /m
19269
lb▪in²/in
217.5 X 10³
4
MPa▪cm /m
80,000 lb/in²
551.6 MPa
80,000 lb/in²
551.6 MPa
80,000 lb/in²
551.6 MPa
Puncture Resistance
0.5 in Diameter Ball
1,855 lbf
8,251 N
1,878 lbf
8,353 N
2,175 lbf
9,675 N
Puncture Resistance
6 in Spade
5,500 lbf
24,465 N
4,794 lbf
21323 N
6,237 lbf
27,744 N
Coefficient of Thermal
Expansion at Low
Temperature
(3)
(ASTM E831-06)
68.583
µin/in▪ºF
123.45
µm/m▪ºC
62.67
µin/in▪ºF
112.8
µm/m▪ºC
61.4667
µin/in▪ºF
110.64
µm/m▪ºC
Coefficient of Thermal
Expansion at High
Temperature
(3)
(ASTM E831-06)
244.522
µin/in▪ºF
440.14
µm/m▪ºC
239.5
µin/in▪ºF
431.1
µm/m▪ºC
241.0
µin/in▪ºF
433.80
µm/m▪ºC
Corrosion
(4)
(ASTM B117)
Pass
1,000 hrs
Pass
1,000 hrs
Pass
1,000 hrs
Acoustical Properties
(ASTM E90-04)
26 STC
27 STC
27 STC
Surface Burning
(5)
(ASTM E84)
Class B
Class A
Class A
Thickness
Weight
Stiffness (EI)
Tensile Yield of
Laminate
R-value
(ASTM C177)
(1)
(2)
(3)
(4)
(5)
.137
Hr-ft²-deg
F/BTU
2.414 x 10¯²
K-m²/W
.163
Hr-ft²-deg
F/BTU.
2.344 x 10¯²
K-m²/W
.162
Hr-ft²-deg
F/BTU
2.855 x 10¯²
K-m²/W
All properties based on 0.013 and .016 in., 80 ksi steel skin material.
Weights based on 20% foam core.
Approximate transition temperature for which the Coefficient of Linear Thermal Expansion (CLTE) begins to change significantly: 6 mm = 131ºF;
7.5 mm = 113ºF; 13 mm = 108ºF
Pass without blisters or creep.
Class B rating represents Flame Spread Index 26-75. Smoke Developed Index ≤ 450. Class A rating represents Flame Spread Index ≤ 25.
©2008 Wabash National Corporation. All rights reserved. No portion of these materials may be reproduced, stored, or transmitted without prior approval from Wabash National.
Wabash National reserves the right to make changes at any time without notice, as we continuously improve our products. This document does not provide a warranty; but
rather, is an effort to explain the characteristics of DuraPlate® material, as we deem to be accurate. Wabash National shall not have any responsibility or liability for any
damages resulting from such use. DuraPlate® is a registered trademark owned by Wabash National, L.P.
Revision C, Jul. 2014
4
Wabash National Corporation
1000 Sagamore Pkwy S. Lafayette, IN 47905
765.771.5300
DuraPlate Panel Attributes: 10.0–13.0 mm Thickness
Product Attributes
Typical engineering properties for DuraPlate® composite material, using a high-density polyethylene core between two sheets of steel. (1)
10.0 mm (.016”)
12.9 mm (.013”)
13.0 mm (.016”)
U.S.
METRIC
U.S.
METRIC
U.S.
METRIC
0.394 in
10.0 mm
0.510 in
12.9 mm
0.510 in
12.954 mm
Maximum Width
49 in
1,245 mm
49 in
1,245 mm
49 in
1,245 mm
Maximum Length
288 in
7,315 mm
288 in
7,315 mm
288 in
7,315 mm
(2)
2.818 lb/ft²
13.76 g/m²
3.125 lb/ft²
15.26 g/m²
3.348 lb/ft²
16.35 g/m²
35,733
lb▪in²/in
403.3 X 10³
4
MPa▪cm /m
19,269
lb▪in²/in
217.5 X 10³
4
MPa▪cm /m
65,053
lb▪in²/in
734.2 X 10³
4
MPa▪cm /m
80,000 lb/in²
551.6 MPa
80,000 lb/in²
551.6 MPa
80,000 lb/in²
551.6 MPa
Puncture Resistance
0.5 in Diameter Ball
2464 lbf
10960 N
2,175 lbf
9,675 N
2,752 lbf
12,242 N
Puncture Resistance
6 in Spade
8213 lbf
36533 N
6,237 lbf
27,744 N
8,502 lbf
37,819 N
Coefficient of Thermal
Expansion at Low
Temperature
(3)
(ASTM E831-06)
59.042
µin/in▪ºF
106.28
µm/m▪ºC
61.4667
µin/in▪ºF
110.64
µm/m▪ºC
56.6167
µin/in▪ºF
101.91
µm/m▪ºC
Coefficient of Thermal
Expansion at High
Temperature
(3)
(ASTM E831-06)
235.945
µin/in▪ºF
424.70
µm/m▪ºC
241.0
µin/in▪ºF
433.80
µm/m▪ºC
230.889
µin/in▪ºF
415.6
µm/m▪ºC
Corrosion
(4)
(ASTM B117)
Pass
1,000 hrs
Pass
1,000 hrs
Pass
1,000 hrs
Acoustical Properties
(ASTM E90-04)
27.5 STC
27 STC
28 STC
Class A
Class A
Class A
Thickness
Weight
Stiffness (EI)
Tensile Yield of
Laminate
Surface Burning
(5)
(ASTM E84)
R-value
(ASTM C177)
(1)
(2)
(3)
(4)
(5)
.191
Hr-ft²-deg
F/BTU
3.366 x 10¯²
K-m²/W
.162
Hr-ft²-deg
F/BTU.
2.855 x 10¯²
K-m²/W
.219
Hr-ft²-deg
F/BTU
3.859 x 10¯²
K-m²/W
All properties based on 0.013 and .016 in., 80 ksi steel skin material.
Weights based on 20% foamed core.
Approximate transition temperature for which the Coefficient of Linear Thermal Expansion (CLTE) begins to change significantly: 6 mm = 131ºF;
7.5 mm = 113ºF; 13 mm = 108ºF
Pass without blisters or creep.
Class B rating represents Flame Spread Index 26-75. Smoke Developed Index ≤ 450. Class A rating represents Flame Spread Index ≤ 25.
©2008 Wabash National Corporation. All rights reserved. No portion of these materials may be reproduced, stored, or transmitted without prior approval from Wabash National.
Wabash National reserves the right to make changes at any time without notice, as we continuously improve our products. This document does not provide a warranty; but
rather, is an effort to explain the characteristics of DuraPlate® material, as we deem to be accurate. Wabash National shall not have any responsibility or liability for any
damages resulting from such use. DuraPlate® is a registered trademark owned by Wabash National, L.P.
Revision C, Jul. 2014
5
Wabash National Corporation
1000 Sagamore Pkwy S. Lafayette, IN 47905
765.771.5300
Finishes and Coatings
STANDARD STEEL COATINGS
DuraPlate finishes and coatings offer excellent aesthetics and performance.
G40 interior
Standard galvanized coating for panel skins is G40 (interior) and G90 (exterior),
depending on application and placement of the panel.
G90 exterior
The coating process begins with the cleaning of the metal surface to remove
any mill-related contaminants. Further treatments are applied to improve paint
adherence and product performance. The surface is then primed and the finish
coat is applied via a roll-coating process for superior coverage.
The polyester coil coatings offer durability and are highly resistant to surface
marking, marring and staining. The coating is resistant to humidity, as well as to
salts and corrosives. The polyester coating also offers superior surface hardness
while retaining flexibility. The surface is also enhanced to resist any chalking or
fading due to UV exposure. Surface contaminants may be easily cleaned with
mild solutions or conventional detergents.
Standard DuraPlate panels are white and have an automotive-quality finish.
Custom colors and glosses are available with minimum order requirements.
For more information on the technical properties of standard PPG Truform
Coating, go to www.ppg.com.
Product Tolerances
PANEL FLATNESS
Wabash National has built a solid reputation by producing highquality products. DuraPlate products are manufactured utilizing
state-of-the-art equipment in a continuous panel process, resulting in
nominal variation to production tolerances.
PANEL SQUARENESS
Thickness:
The tolerance for thickness, regardless of core depth, is +/- .020”.
PANEL LENGTH
PANEL WIDTH
Length:
The length tolerance of a finished panel is +/- 0.125”.
Width:
EDGE ALIGNMENT
Width tolerance of a panel is +0.25” / -0” for logistics edge. For
shiplap edge, width tolerance is +0.125” / -0”.
Squareness:
Diagonal measurements on the face of the panel may not differ by
more than 0.1875”.
Skin Alignment:
Tolerance for a finished panel is -0.0625”, +0.03125”.
Flatness:
Camber or lateral bow is 0”+/- 0.016”
and transverse bow is 0” +/- 0.125” in 49”.
6
PANEL THICKNESS
and Packaging
andtoPackaging
packaging isShipping
designed
protect the panels during material
Standard
packaging
is designed to
protect
the panels
during
and shipment. DuraPlate products
are
custom
packaged
material
movement
and
shipment.
DuraPlate
products
he nature of the contents and the destination of the are
order.
custom packaged based on the nature of the contents and the
destination of the order.
sed in transporting products must be capable of safely
lifts used in transporting
products
must
e load. TheFork
approximate
maximum
weight
ofbea capable
load isof
safely carrying the load. The approximate maximum weight of
It is recommended that pallets should be approached with
a load is 5,000 lbs. It is recommended that pallets should be
rom the long
axis. Caution
should
always
be taken
approached
with a forklift
from the
long axis.
Caution not
should
e the center
point
thenotlift.
Heavy the
contact
between
the
always
be of
taken
to misjudge
center point
of the lift.
contact
between the
lift and
the pallet
may product.
result in
e pallet mayHeavy
result
in damage
to the
edges
of the
to the edges of the product. This is especially true for
ecially true damage
for shiplap
products, in which the steel edges
shiplap products, in which the steel edges are susceptible to
tible to bending
and
deforming.
If necessary
it is necessary
tounload
load aor
bending and deforming. If it is
to load or
allet from the
the
should
palletnarrow
from the edge
narrow of
edge
of pallet,
the pallet,the
the load
load should
be
placed
on a firm,
surface
as soon asand
possible
the forklift
on a firm, flat
surface
as flat
soon
as possible
theand
forklift
then repositioned to pick up the load from the long edge as
itioned to pick
up the load from the long edge as soon as
soon as possible.
DuraPlate products pass a quality inspection prior to leaving the
manufacturing
Most domestic
shipments
placed on
products pass
a qualityfacility.
inspection
prior to
leavingarethe
a flatbed or in a conventional van trailer. International shipments
ring facility.
Most domestic shipments are placed on a
are either loaded into containers at the DuraPlate manufacturing
in a conventional
van trailer.
International
shipments
site or shipped
to a designated
location for
loading into will
All at
necessary
international
paperwork accompanies
oaded into containers.
containers
the DuraPlate
manufacturing
site
the
shipment.
to a designated location for loading into containers. All
nternational
paperwork
willhas
accompany
the shipment.
Wabash
Composites
carefully screened
various carriers
and can provide preferred shippers. Packaging and shipping
chargeshas
maycarefully
accompany
an order, based
on order
quantity
as
Products Group
screened
various
carriers
and
well
as
any
specialized
packaging
requirements.
e preferred shippers. Packaging and shipping charges may
y an order, based on order quantity as well as any specialized
requirements.
Note: Products are subject to damage if not handled
properly by shippers or customer staff.
Note: That products are subject to damage if not
handled properly by shippers or a customer’s staff.
7
CUTTING AND MACHINING
Shearing
Shearing of DuraPlate panels is best accomplished by using a hydraulic
bow-tie shear. Although a mechanical shear may be used, the hydraulic
unit provides a smoother, cleaner cut. The higher impact speed of the
Shearing
mechanical
shear tends to tear or break the DuraPlate product, whereas
Shearing
Shearing
of
DuraPlate
best
accomplished
by
the slower
impact
speed
ofpanels
a panels
hydraulic
shear
is less aggressive,
providing
Shearing
of DuraPlate
is isbest
accomplished
by using
usingaahydraulic
hydraulic
bow-tie
shear.
Although
a
mechanical
shear
may
be
used,
the hydraulic
a better
cut. shear. Although a mechanical shear may be used,
bow-tie
the hydraulic
CUTTING
AND
CUTTING
ANDMACHINING
MACHINING
unit provides a smoother, cleaner cut. The higher impact speed of the
unit provides
a smoother, cleaner cut. The higher impact speed of the
mechanical shear tends to tear or break the DuraPlate product, whereas
shear
to
tear
or break shear
the
DuraPlate
product,
whereas
Use ofmechanical
a shear
tends
totends
wipe
the
coating
from
the steel
and a
the slower impact
speed
of galvanized
a hydraulic
is less
aggressive,
providing
the
slower
impact
speed
of
a
hydraulic
shear
is
less
aggressive,
providing
smear it onto
the
better
cut.cut edge. This aids in corrosion prevention. When
a better
cut. 1” from a panel, a wrap-around effect, in which the
shearing
less than
Use being
of a shear
tends tofolds
wipe over
the galvanized
coating
from
the steel
short section
removed
the shear
blade,
is likely
to and
occur.
smear
it onto
cut
edge. the
This
aids in corrosion
prevention.
When
shearing
Use of
a shear
tends
torouter,
wipe
from the
steel
and
For these
instances,
a the
saw,
or galvanized
water
jet iscoating
recommended.
less
than 1”
from
panel, aThis
wrap-around
effect, in which
the shortWhen
section
smear
it onto
the
cuta edge.
aids in corrosion
prevention.
beingless
removed
folds
overathe
shearablade,
is likely toeffect,
occur. in
Forwhich
these the
shearing
than
1”
from
panel,
wrap-around
Proper blade
gap isaimportant
when
shearing
DuraPlate. On nonsaw,removed
router or
water
is recommended.
shortinstances,
section being
folds jet
over
the shear blade, is likely to occur.
composite
metal
materials,
the blade
gap
would
typically be set up to
For these instances, a saw, router, or water jet is recommended.
10% of theProper
thickness
of the
material;
however,
rule ofOn
thumb
does
blade gap
is important
when
shearingthis
DuraPlate.
non-composite
metalfor
materials,
the blade
gapthe
would
typically
set up tono
10%
of the
not hold true
DuraPlate.
Since
core
offersbe
virtually
resistance
Proper
blade gap
is important
whenthis
shearing
DuraPlate. not
On hold
non-true
thickness
of the material;
rule of thumb doesprocess
to thecomposite
shear,
themetal
clearance
usedhowever,
within
the
manufacturing
is to
materials,
the
blade
gap
would
typically
be
set
up
for DuraPlate.
Since the
core
offers
virtually
no 0.001”
resistance
to the
shear,
0.001”
0.002”.
The
center
of
the
blade
is
set
at
and
the
ends
10% the
of the
thickness
the the
material;
however,
this rule
of thumb does
clearance
usedof
within
manufacturing
process
is 0.001”-0.002”.
at 0.002”.
Although
these
clearances
work
well
with
DuraPlate,
they
not hold
true
for
DuraPlate.
Since
the
core
offers
virtually
no Although
resistance
The center of the blade is set at 0.001” and the ends at 0.002”.
shouldtonot
be
used
on
steel
alone.
Setting
blade
clearances
based
the
shear,
the
clearance
used
within
the
manufacturing
process
is
these clearances work well with DuraPlate, they should not be usedon
on
the width
of -the
panel
rather
than
of of
the
skins
steel
alone.
Setting
blade
clearances
based
onwidth
the
width
thesteel
panel
0.001”
0.002”.
The
center
of the
the combined
blade
is set
at 0.001”
and
the ends
will result
in wrapping
thethese
lowerclearances
skinofover
the lower
shear.
Gibs
should
rather
than
the combined
width
thework
steel
skins
will
result
in wrapping
at 0.002”.
Although
well with
DuraPlate,
theythe
lower
skin
shear.
Gibs
shouldblade
be setclearances
at the manufacturer’s
be setshould
at the
manufacturer’s
recommendations.
not
be over
usedthe
onlower
steel
alone.
Setting
based on
recommendations.
the width
of the panel rather than the combined width of the steel skins
will
result
in
wrapping thefactors
lower skin
over the lower
shear. movement
Gibs should
There are other precautionary
to consider.
Any panel
There are other precautionary factors to consider. Any panel movement or
be
set
at
the
manufacturer’s
recommendations.
or shifting during fabrication may cause damage to the panel. Use of
SHEARING DURAPLATE: BLADE CLEARANCE
Center Blade set at 0.001”
Center Blade ends at 0.002”
SHEARING DURAPLATE: BLADE CLEARANCE
BLADE
CLEARANCE
Center
Blade
set
at 0.001”
DuraPlate,
not on
steel
only.
SHEARING DuraPlate:
* Use these
settings only when shearing
Center
set
at 0.001”
Center
BladeBlade
ends at
0.002”
Blade only
endswhen
at 0.002”
* UseCenter
these settings
shearingpressure
CAUTION:
Excessive
DuraPlate,
on steel
* Usenot
these
only
on settings
theonly.
panel
will result in
when shearing
DuraPlate,
marring
the finish or denting
not on steel
only.
the
panel.
CAUTION: Excessive pressure
on the panel will result in
marring the finish or denting
the panel.
shifting during fabrication may cause damage to the panel. Use of lower
lower pressure
pneumatic
downs,oror
a plywood
between
pressure
pneumatichold
hold downs,
a plywood
shimshim
between
the holdthe
down
Thereand
are
other
precautionary
factors
to
consider.
Any
panel movement
hold down
and
the
panel,
prevent
damage.
When
or it
the
panel,
may may
prevent
damage.
When
changing
orchanging
rotating
blades,
or shifting
during
fabrication
may
cause
to the
the
panel.
Use
of
is important
to thoroughly
both
thedamage
blades
machine
before
rotating
blades,
it is important
toclean
thoroughly
clean and
both
the
blades
and
lower
pressure
pneumatic
hold
downs,
or
a
plywood
shim
between
reinstalling.
such tight With
clearances,
debris
will prevent
obtaining
the machine
before With
reinstalling.
such any
tight
clearances,
any
debristhe
hold proper
down blade
and the
panel,
may
prevent
damage.
When
changing
Also, care
should beAlso,
takencare
to avoid
any damage
will prevent obtainingclearance.
proper blade
clearance.
should
be or
to the
surfaceitofisthe
panels byto
ensuring
that the
workboth
area,the
shear
bed, and
rotating
blades,
important
thoroughly
clean
blades
and
taken to avoid any damage to the surface of the panels by ensuring that
conveyorsbefore
are clean
and free of With
cuttingsuch
debris.
the machine
reinstalling.
tight clearances, any debris
the work area, shear bed, and conveyors are clean and free of cutting
will prevent obtaining proper blade clearance. Also, care should be
debris.taken to avoid any damage to the surface of the panels by ensuring that
Sawing
the work area, shear bed, and conveyors are clean and free of cutting
Sawing
Certain applications, such as lower volume production, out-of-position cuts,
debris.
or cuts removing
1” will
best be
served by use
of a saw.
Certain applications,
suchless
as than
lower
volume
production,
out-of-position
cuts, or
cuts removing less than 1” will best be served by use of a saw.
Sawing
A reciprocating saw may be used for rough cuts. Finish cutting using
Certain applications, such as lower volume production, out-of-position
a reciprocating saw is not recommended. A sabre saw must have a
A reciprocating
saw
may beless
used
forstarted
rough
cuts.
Finish
cutting
using
cuts,high
or cuts
removing
than
1”
willfrom
best
beedge
served
by use
of
a saw.
quality
metal blade.
Cuts
an
require
no special
a reciprocating
saw isHowever,
not reccommended.
A sabre
saw musta have
preparation.
for cuts starting inside
the perimeter,
starterahole
A
reciprocating
saw
may
be
used
for
rough
cuts.
Finish
cutting
using
high quality
metal
should
be blade.
drilled. Cuts started from an edge require no special
a
reciprocating
saw
is
not
reccommended.
A
sabre
saw
must
have
preparation. However, for cuts starting inside the perimeter, a startera
high Maintaining
quality
metal
blade.
Cuts
ancut
edge
require
a sharp
blade
will started
producefrom
a clean
at the
edges.no
A special
40-tooth
hole should
be drilled.
carbide tipHowever,
blade is recommended.
preparation.
for cuts starting inside the perimeter, a starter
hole
should
be
drilled.
Maintaining a sharp blade will produce a clean cut at the edges. A 40
If painted, the surface coat may chip when a saw is used. To minimize this
tooth carbide
tip blade
is recommended.
chipping,
tape applied
along the edges to be cut is recommended. The
Maintaining a sharp blade will produce a clean cut at the edges. A 40
edge will minimize chipping and reduce the potential for scratches
toothtaped
carbide
tip blade is recommended.
If painted,caused
the surface
coat may chip when a saw is used. To minimize
by the saw.
this chipping,
tape
applied
along
thechip
edges
to be cutisisused.
recommended.
If painted,
surface
coat
may
when a saw
To cut
minimize
Use
of the
awill
saw
will wipe
some
of the and
galvanized
coating
onto the
The taped
edge
minimize
chipping
reduce
the
potential
foredge
this chipping,
tape
applied
along
the
edges
to
be
cut
is
recommended.
to aid in preventing corrosion. Wabash Composites recommends using a
scratches
caused
by
the
saw.
The taped edge will minimize chipping and reduce the potential for
Milwaukee metal cutting saw Model #6370-20 for best results.
scratches caused by the saw.
8
CAUTION: Excessive
pressure on the panel
will result in marring
the finish or denting
the panel.
Sawing cont.
Use of a saw will wipe some of the galvanized coating onto the cut
edge to aid in preventing corrosion. The DuraPlate Products Group
recommends using a Milwaukee metal cutting saw Model # 6370-20
for the best results.
Punching
Punching
CertainCertain
applications
may may
require
thethe
panels
totobebepunched.
Punching
applications
require
panels
punched. Punching
offers aoffers
costaeffective
method
for for
creating
holes,
cost effective
method
creating
holes,considering
considering equipment
equipment
availability.
Additional
attributes ofinclude
punching
include
availability.
Additional
attributes
of punching
speed,
reduction
speed,caused
reduction
scratches
caused
drill
shavings,
and the
in scratches
by indrill
shavings,
andby
the
ability
to create
a variety
ability
to create
a variety
of shaped
holes. to
Specific
tooling
is required
of shaped
holes.
Specific
tooling
is required
ensure
a quality
punch
to ensure
quality punch isto
created.
It is coating
recommended
use a tip to
is created.
It is arecommended
use a TiN
on thetopunch
coating
on the punch
tip to reduce
wear and
galling.
A hollow
reduceTiN
wear
and galling.
A hollow
or concave
tip has
proven
to aid and
or concave tip has proven to aid and guide the punch through the
guide the punch through the material. Use of a concave tip will also
material. Use of a concave tip will also increase tooling life.
increase tooling life.
To ensure proper cutting of the lower steel skin, care must be taken
To ensure
proper
cutting
of the
lower
skin, care
must
be taken
to ensure
the
dies remain
sharp
andsteel
tolerances
are kept
tight.
As the
to ensure
thecontacts
dies remain
sharp
andskin,
tolerances
arecore
kept
tight. under
As the
punch
the upper
steel
the plastic
deforms
punch pressure
contactsand
thecreates
upper asteel
skin, force
the plastic
core deforms
under
hydraulic
on the lower
skin, forcing
the
lower
through
the die. This
is unique
tolower
composite
As
pressure
andskin
creates
a hydraulic
force
on the
skin,materials.
forcing the
such,through
the dies the
mustdie.
be maintained
in good
condition ormaterials.
hole quality As
lower skin
This is unique
to composite
will dies
suffer.
It should
also be noted
thecondition
top cuttingor
surface
of
such, the
must
be maintained
in that
good
hole quality
the
die
should
be
flush
with
the
die
holder
to
prevent
any
markings
will suffer. It should also be noted that the top cutting surface of the
on the
theholder
punch to
to the
die is any
also markings
critical; on the
die should
bepaint.
flushAlignment
with theofdie
prevent
otherwise, distortion of the hole may be created. While a close
paint. Alignment of the punch to the die is also critical; otherwise,
punch to die clearance is crucial, the punch or die may chip if they
distortion
of the hole may be created. While a close punch to die
come in contact. The chipped die will cause more hanging chads
clearance
is
crucial, the
may chip
they come
in contact.
and additional
side punch
loadingor
of die
the punch.
Withif proper
alignment
and
The chipped
die will
cause
hanging
and additional side
sharp dies,
chads
and more
burrs are
kept tochads
a minimum.
loading of the punch. With proper alignment and sharp dies, chads and
burrs are
kept to
a minimum.
Stripping
force
is also an important consideration. Failure to ensure
the die is clear will result in poor punch quality. The punch must
enter
the die
to a an
sufficient
depthconsideration.
to ensure the slug
is cleartoofensure
the
Stripping
force
is also
important
Failure
the
die
before
the
next
panel
is
punched.
A
slight
depression,
or
dimple,
die is clear will result in poor punch quality. The punch must enter the
wheredepth
the punch
contacts
upper
steel of
skin.
die to aoccurs
sufficient
to ensure
thethe
slug
is clear
theThis
dieconical
before the
shape
increases
the
friction
between
the
sides
of
the
punch
and
next panel is punched. A slight depression, or dimple, occurs
where
the metal, thereby raising the amount of force necessary to strip or
the punch contacts the upper steel skin. This conical shape increases the
pull the metal. After the punch is retracted, the plastic relaxes back
frictioninto
between
the sides of the punch and the metal, thereby, raising
the plastic core around the hole area, resulting in a hole slightly
the amount
of
force
strip
or pull the metal. After the
smaller than thenecessary
diameter oftothe
punch.
punch is retracted, the plastic relaxes back into the plastic core around
the hole
area,
resulting
a hole
slightly smaller
than
the diameter
of the
The
occurrence
when
the diameter
of the hole
shrinks
slightly
punch.after punching is referred to as “spring back.” In some cases, the
shrinkage will increase the force required to insert rivets, bolts or
screws. Towhen
prevent
this,
a larger of
hole
may
be shrinks
punched.slightly
Other options
The occurrence
the
diameter
the
hole
after
are
to
double
cycle
punch
the
product
after
the
spring
back
punching is referred to as “spring back”. In some cases, the isshrinkage
complete,
to drill
out the punched
will increase
the or
force
required
to inserthole.
rivets, bolts, or screws. To
prevent this, a larger hole may be punched. Other options are to
The unique composition of DuraPlate allows the user to ignore
double cycle punch the product after the spring back is complete, or to
certain standard punching rules. For example, the rule of thumb
drill out
the punched hole.
that a hole cannot be punched when its diameter is less than the
thickness of material does not apply. This is true because the core
The unique
composition
of DuraPlate
allows Further,
the userthe
torule
ignore
provides
minimal resistance
to the punch.
that certain
standard
punching
rules.equals
For example,
the ruletoof
thatisanot
hole
10%
part thickness
punch clearance
diethumb
clearance
cannotapplicable.
be punched when its diameter is less than the thickness of
material does not apply. This is true because the core provides minimal
Avoid
movement
or the
shifting
fabrication.
Too much
resistance
toany
thepanel
punch.
Further,
ruleduring
that 10%
part thickness
pressure
on
the
panel
will
result
in
marring
the
finish
or
denting
equals punch clearance to die clearance is not applicable.
the panel. Pneumatic hold downs set to the proper pressure or a
plywood shim will minimize potential damage to the panel.
9
11
Drilling
DRILLING INFORMATION
Drilling of DuraPlate is an option that is frequently used to create or
enlarge holes.
Bit: R5 sharpened to 118º
Coated drill bits have proven to perform better than standard jobber
bits. Most standard bits have a black coating that is cheap to apply, but
is also porous. This results in buildup on the bit causing it to overheat.
The recommended bit for DuraPlate applications has a tip coating that
resists buildup.
Areas of concern while drilling DuraPlate should be noted. Negative
results may occur if drill bit is dull or spindle RPM is too high. The
recommended drill bit has a sharper point angle. The standard drill bit
used is a R5 bit, sharpened to 118º.
For best hole quality, drill pressure should be regulated and constant.
Drill RPM should be set at 2500 RPM. Excessive speed and/or pressure
can also result in overheating the core and reduced bit life. Controlled
feed rate and pressure will produce a clean hole and reduce burrs. This
may be regulated by use of an air pressure regulator valve, flow control
valve and/or shock absorber.
In cases where an automatic feed drilling machine is used, care should
be taken to reduce the impact the drill bit makes as it comes in contact
with the DuraPlate and to control the feed rate. Excessive feed rates
as well as a moderately hard impact with the drill bit to the DuraPlate
could result in poor quality, including holes out of specification, hole
distortion, burrs left around the hole and/or chipped drill bits. To control
impact and speed of the drill box as it moves towards the DuraPlate,
it is recommended to use a pneumatic flow control valve and an
adjustable shock absorber on the drill.
Care should be taken to minimize drill shavings buildup on the drill
bit. The shavings on the bit will scratch the paint of the DuraPlate if
allowed to gather. Shavings should be removed as they accumulate.
One method used with success for manual drilling has been to wrap the
upper half of the bit with tape, preventing the material from adhering to
the grooves, thereby keeping the drill bit free of shavings.
The drill bit chuck should never come into contact with the DuraPlate
surface because it will damage the finish. Furthermore, in a stacked
drilling process, the materials should be clamped tightly together to
avoid shaving accumulation between the objects being drilled. Failure
to do this will result in marred surfaces, poor quality of the drilled hole,
and holes drilled outside of specifications. Unlike punching, there is no
deformation of the surface around the hole inherent to the process. The
hole can be drilled to size for the rivet, bolt or screw, since there is no
spring back with drilled holes.
10
Drill Speed: 2500 RPM
Routing
Routing offers a high speed process to mark the DuraPlate for drilling
or sawing,
or to cut a panel. The router may also be used to score a
Routing
panel for bending or forming. In this instance, scoring a panel refers
Routing
a high-speed
process
to markside
the DuraPlate
for drilling
to cutting
theoffers
surface
steel from
one surface
of the panel
and or
sawing, or to cut a panel. The router may also be used to score a panel
the majority of the core, creating a groove. It is recommended that
for bending or forming. In this instance, scoring a panel refers to cutting
a minimum
of 1/32” of core is left for strength and stability, and the
the surface steel from one surface side of the panel and the majority of
remaining
steel
skin kept
intact.It is
This
also aids inthat
keeping
the bend
the core, creating
a groove.
recommended
a minimum
of 1/32”
radiusofconstant
and
smooth.
core is left for strength and stability, and the remaining steel skin kept
90 ° - 105 °
intact. This also aids in keeping the bend radius constant and smooth.
Application will determine the bit speed, depth, and type of bit
Application
will determine
the bitand
speed,
depth and
typeformed
of bit selected.
selected.
The desired
dimensions
geometry
of the
radius
The desired
dimensions
and
geometry
of the
will determine
the
width and
depth
of the
cut.formed radius will determine
DURAPLATE PANEL
.047”
the width and depth of the cut.
Water Jet
A water
jet cutter
Water
Jet is an effective tool to cut DuraPlate. Water jet
applications use a jet of water at high velocity and pressure. Additives,
A water
jet can
cutter
is an in
effective
tool to cut DuraPlate. Water jet
such as
garnet,
assist
this process.
applications use a jet of water at high velocity and pressure. Additives,
such as garnet, can assist in this process.
Cuts started from an edge require no special preparation. However,
for cuts
starting
the
perimeter,
water jet
starter hole
should
Cuts
startedinside
from an
edge
require noa special
preparation.
However,
forbe
drilled.
cuts starting inside the perimeter, a water jet starter hole should be drilled.
The following
parameters
have
produced
andare
areintended
intended
The following
parameters
have
producedgood
good results
results and
to serve
as a starting
point,
noting
that
waterjets
jets
may
to serve
as a starting
point,
noting
thatdifferent
different water
may
respond to
different
parameters.
respond
to different
parameters.
Cutting
speed
is 45”
minute
13.0mm
mm DuraPlate
DuraPlate and
per
minute
Cutting
speed
is 45”
per per
minute
onon13.0
and50”
50”
per
onon
6 mm
panels.
Use 60,000
lbs of pressure
for either
thickness.
The
minute
6 mm
panels.
Use 60,000
lbs pressure
for either
thickness.
water jet uses 3/4 lbs per minute to accomplish the cuts. A skimmer may
The water
jet uses 3/4 lbs per minute to accomplish the cuts. A
be required to remove floating core material that builds up on the surface.
skimmer may be required to remove floating core material that builds
Pump obstruction may result if the buildup is not removed.
up on the surface. Pump obstruction may result if the build-up is not
removed.
The kerf of the cut is ~.065” for 13.0 mm and 6.0 mm. The edge is ~90º
to the DuraPlate surface. The steel does not roll as found with shearing
The kerf
of the cutconsequently,
is ~.065” for
mm
andgalvanized
6.0 mm. coating
The edge
is
or punching,
no 13.0
wiping
of the
occurs.
~90º Therefore,
to the DuraPlate
surface. The
not
as found with
it is recommended
that steel
edgesdoes
not be
leftroll
exposed.
shearing or punching, consequently, no wiping of the galvanized
Theoccurs.
painted Therefore,
surface of the
adjacent to the
cutedges
is abraded
~.018”
coating
it ispanel
recommended
that
not be
left on
both sides of the cut.
exposed.
SPEED
CUTTING
DuraPlate
SPEED
FORFOR
CUTTING
DURAPLATE
13.0mm
mm==45”
45”per
permin
min
13.0
6.0mm
mm==50”
50”per
permin
min
6.0
The painted surface of the panel adjacent to the cut is abraded ~.018”
on both sides of the cut.
13
11
ASSEMBLING
ASSEMBLING
ASSEMBLING
Shiplap Joints
ASSEMBLING
Shiplap
Jointshave exposed edges of steel 1” wider than the core.
Shiplap
joints
Shiplap
Joints
Shiplap
joints
havemay
exposed
edges
steel 1” wider
than thethe
core.
These
steel
edges
be joined
byofoverlapping,
by varying
inside
Shiplap
Shiplap
joints Joints
have exposed edges of steel 1” wider than the core. These steel
These
steel edges
beFor
joined
byapplications,
overlapping, one
by varying
inside
and
outside
panelmay
skins.
some
shiplapthe
edge
may
Shiplap
joints
have
exposed
edges
of
steel
1”
wider
than
the
core.
edges may be joined by overlapping, by varying the inside and outside panel
andsheared
outsideoff
panel
skins.
Forissome
applications,
onefor
shiplap
edgeofmay
be
so that
there
one flush
edge, (e.g.
the start
a
steel applications,
edges may beone
joined
by overlapping,
varying
skins.These
For some
shiplap
edge may beby
sheared
offthe
so inside
that there
be sheared
off so that there is one flush edge, (e.g. for the start of a
wall
assembly).
outside
panelfor
skins.
For some
applications,
is oneand
flush
edge (e.g.,
the start
of a wall
assembly).one shiplap edge may
wall assembly).
be sheared off so that there is one flush edge, (e.g. for the start of a
The shiplap may or may not have an offset. With an offset along the
wall assembly).
The shiplap
may or may not have an offset. With an offset along the length of a
The shiplap
may orwhen
may not
have
With
an offset
along the
length
of a panel,
joined
to an
theoffset.
opposite
shiplap,
a smoother
panel, when joined to the opposite shiplap, a smoother surface is created.
length of
panel, when joined to the opposite shiplap, a smoother
surface
is acreated.
The shiplap may or may not have an offset. With an offset along the
surface is created.
length of a panel, when joined to the opposite shiplap, a smoother
Logistic Joints
surface
is created.
Logistic
Joints
Logistic
The
flushJoints
edge with logistics panel allows for two panels to come close
Theeach
flush
edge
with logistics
allows
two
toclose
come
The flush
edge
withwithout
logistics
panel panel
allows
for twofor
panels
to
come
toclose
each
to
other
touching.
Designed
for
usepanels
primarily
within
the
Logistic Joints
each other
without
touching.
Designed
for
use
primarily
within
otherto
without
touching.
Designed
for use
primarily
within
the
transportation
transportation
industry,
logistic
panels
are used
in conjunction
withthe
The flush edge with logistics panel allows for two panels to come close
transportation
industry,
logistic
panels
arewith
usedlogistic
in conjunction
with
logistic
strips.
An
inner
and
logistic
strip
joins
adjacent
panels.
industry,
logistic
panels
are used
inouter
conjunction
strips. An
inner
to each other without touching. Designed for use primarily within the
logistic
strips.
Anof
inner
andstrips,
outer
logistic
strip
joins
adjacent
panels.
Through
the strip
use
logistic
panels
are
held
secure
fixed,
and
and outer
logistic
joins
adjacent
panels.
Through
the
use
ofand
logistic
strips,
transportation industry, logistic panels are used in conjunction with
Through
use
logistic
panels
are
andmovement
fixed, and
cargo
canthe
be
heldof
free
fromstrips,
movement
with
cargo
tie-downs.
panels
are held
secure
and
fixed,
and
cargo
can
beheld
heldsecure
free
from
logistic strips. An inner and outer logistic strip joins adjacent panels.
cargo tie-downs.
can be held free from movement with cargo tie-downs.
with cargo
Through the use of logistic strips, panels are held secure and fixed, and
An offset may or may not be produced along the length of the panel to
cargo can be held free from movement with cargo tie-downs.
An offset
may
ornot
may
be produced
along
the of
length
of thetopanel
to a
provide
smooth,
flat
surface.
An offset
mayaor
may
benot
produced
along the
length
the panel
provide
provide
a smooth, flat surface.
smooth,
flat
surface.
An offset may or may not be produced along the length of the panel to
Rivet Fasteners
provide a smooth, flat surface.
Rivet Fasteners
Riveting
panels is a popular method to assemble components. This
Riveting
panels
is a popularand
method
to assemble
This
is
well established
cost-effective
withcomponents.
predictable results.
Rivetmethod
Fasteners
Rivet Fasteners
method is well established and cost-effective with predictable results.
Riveting
panels
is a popular
method
to assemble
components.
This is
Riveting
panels
is a popular
method
to assemble
components.
This method
When selecting the type of rivet, surface material should be taken into
method is well
and
cost-effective
predictable results.
well established
and established
cost-effective
with
predictable with
results.
When selectingBoth
the type
rivet,
surface
material
should beused
taken
consideration.
solidof
and
tubular
rivets
are commonly
as into
well
consideration.
Both solid and
tubular surfaces.
rivets are commonly
used
aseither
well
as
blind rivet applications
for interior
Rivet patterns
are
selecting
theof
type
of surface
rivet, surface
material
beinto
taken into
WhenWhen
selecting
the type
rivet,
material
shouldshould
be taken
as blind rivet
applications
for interior
surfaces.
Rivet
areare
either
punched
or drilled
as the situation
requires.
3/16”
orpatterns
1/4” holes
consideration.
Both and
solidtubular
and tubular
rivets
are commonly
used
consideration.
Both solid
rivets are
commonly
used as
wellas
aswell
blind
punched orstandard,
drilled as although
the situation
requires.
or 1/4”
holes
are
considered
variations
are 3/16”
available
based
on the
as blind rivetfor
applications
for interior
Rivet
patterns
are or
either
rivet applications
interior surfaces.
Rivet surfaces.
patterns are
either
punched
considered
standard,
are available
based practice
on the in
project.
Two
rows of although
1/4” rivetsvariations
on 1 ½” centers
is standard
or drilled
as the situation
requires.
or 1/4” holes
are
drilledpunched
as the situation
requires.
3/16” or 1/4”
holes 3/16”
are considered
standard,
project. Twomanufacturing.
rows of 1/4” rivets on 1 ½” centers is standard practice in
semi-trailer
considered
standard,
although
variations
are available
based
on the
although
variations
are available
based
on the project.
Two rows
of 1/4”
rivets on
semi-trailer manufacturing.
Two
rows of
1/4” rivets
on 1 ½” centers
is standard practice in
1 ½” project.
centers
is
standard
practice
in
semi-trailer
manufacturing.
Bolts and Nut Fasteners
semi-trailer manufacturing.
Boltsmethod
and Nut
Fasteners
This
is tested,
cost-effective, and predictable.
This method
is tested,
cost-effective,
and predictable.
Bolts
are usually
used to
mount the panel
to the frame in an
and
Nut
Fasteners
BoltsBolts
andare
Nut
Fasteners
Bolts
usually
used
mount the
the frameused
in an
application.
Rivets
andtobonding
arepanel
more to
commonly
when
This method is tested, cost-effective, and predictable.
application.
Rivets
and bondingand
are more commonly
used
whenused to
joining
panels
together.
This method
tested,
cost-effective
are
Bolts areisusually
used
to mount the predictable.
panel to theBolts
frame
inusually
an
joining
panels
together.
mount
the
panel
to
the
frame
in
an
application.
Rivets
and
bonding
are more
application. Rivets and bonding are more commonly used when
As with
rivets,
holes
are panels
punched
or drilled and are prepared to accept
commonly
used
when
joining
together.
joining panels together.
As with rivets,
areofpunched
or drilled
and are prepared to accept
standard
bolts.holes
Choice
bolts is based
on requirements.
standard
bolts. are
Choice
of bolts
is based
requirements.
As with
holes
punched
or drilled
andon
are
prepared
to accept
standard
As rivets,
with rivets,
holes
are punched
or drilled
and
are prepared
to accept
bolts.standard
Choice ofbolts.
boltsChoice
is based
requirements.
of on
bolts
is based on requirements.
Screw Fasteners
Screw
Fasteners
Use of screws
for assembly has advantages not found in either rivets or
Use
of
screws
for assemblyThe
hascore
advantages
in either
rivets
or
bolt
and
nut applications.
materialnot
actsfound
as a lock
nut to
aid in
Screw
Fasteners
Screw
Fasteners
bolt and nut
applications.
core
actsprevents
as a lockslippage
nut to aid
in
stabilizing
and
holding theThe
screw
inmaterial
place. This
due
Use
of screws
for assembly
has advantages
not found
in either
rivets
or
Use of
screws
for
assembly
advantages
notcontraction
found
in either
rivetscold,
or
bolt
stabilizing
and
holdinghas
the
screwheat,
in place.
This prevents
slippage
due
to
vibration,
expansion
through
or
through
of and
bolt and nutThe
applications.
Theacts
coreasmaterial
acts
as
a in
lock
nut to aid
in
nut applications.
core
material
a
lock
nut
to
aid
stabilizing
and
to vibration,
expansion
through heat, or contraction through cold, of
the
metal skin
or the screw.
stabilizing
and holding
theprevents
screw inslippage
place. This
slippage
due
holding
screw
place.
This
dueprevents
to vibration,
expansion
thethe
metal
skininor
the screw.
to vibration,
expansionthrough
throughcold
heat,
or
contraction
through
cold, of
through
heat,
or
contraction
of
the
metal
skin
or
the
screw.
Self-starting screws, such as sheet metal screws, may be used for
the metal skin or the screw.
Self-startingAllen,
screws,
sheet screws
metal screws,
may be used
used in
for
fastening.
hex,such
andas
torque
are commonly
Self-starting
screws,
such
asand
sheet
metal
screws,
may
be usedused
for fastening.
fastening.
Allen,
hex,
torque
screws
areon
commonly
in
fastening
panels,
with
final
selection
based
requirements.
screws, such
ascommonly
sheet metal
screws,
may bepanels,
used for
Allen,Self-starting
hex and torque
are
used
in fastening
with final
fastening
panels,screws
with final
selection based
on
requirements.
fastening.
Allen,
hex, and torque screws are commonly used in
selection
based on
requirements.
fastening panels, with final selection based on requirements.
12
Shiplap
Joint
Shiplap
Joint
Shiplap Joint
Shiplap Joint
Logistic Joint
Logistic
Joint
Logistic
Joint
Logistic Joint
Fastened Joint
Fastened Joint
Fastened Joint
Fastened Joint
sive Bonding
ng through the use of adhesive materials is a common method to
Adhesive Bonding
e and fasten panels. Bonding is most commonly used in shiplap
Bonding through the use of adhesive materials is a common
applications.
method to adhere and fasten panels. Bonding is most commonly
used in shiplap panel applications.
sives have been researched to determine those which have the best
ive factors, Adhesives
while permitting
the skins to
todetermine
expand those
and contract
in
have been researched
that have the
nse to external
andfactors,
cooling
cycles
without
theand
skin.
bestheat
adhesive
while
permitting
the deforming
skins to expand
contract in response
to external
cooling
without
exibility, wearability,
and strength
of heat
the and
bond
are cycles
critical
to all
deforming. The flexibility, wearability and strength of the bond are
ations.
critical to all applications.
urfaces should
be cleaned prior to application of adhesive or
All surfaces should be cleaned prior to application of the adhesive
ng agent. or
Wiping
with
an alcohol
typically
is
bondingdown
agent.surfaces
Wiping down
surfaces
with anrag
alcohol
rag
ent when using
theis recommended
adhesives.
Adhesive
should be
typically
sufficient when using
the recommended
adhesives.
Adhesive
should
be applied accordingly
to the manufacturer’s
ed accordingly
to the
manufacturer’s
recommendation.
This may
Thisspreading
may be accomplished
by flattening
complished recommendation.
by flattening and
the adhesion
with aand
putty
spreadingfixture
the adhesion
with a aputty
knife.
Usingon
a clamping
Using a clamping
or placing
heavy
object
the bonded
fixture or placing a heavy object on the bonded joint area to hold
area to holdthe
thepieces
pieces
in place is recommended. Care should also
in place is recommended. Care should also be taken
ken to protect
the
panels
fromfrom
anyany
marring
Cardboard
to protect the panels
marringorordamage.
damage. Cardboard
or
her cushionother
material
may
be may
usedbebetween
the the
heavy
or
cushion
material
used between
heavyobject
object or
s and the panel
surfaces.
clamps
and the panel surfaces.
Caulking
ing
Caulking
and sealingare
applications
are most commonly
utilized
to
ng and sealing
applications
most commonly
utilized to
provide
provide a weatherproof seam.
therproof seam.
A sealing application is used behind riveted or bolted seams, along
ling application
is orused
riveted
bolted metals,
seams,as along
a frame
base behind
rail, or when
joiningordissimilar
a barriera
or base rail,ororspacer.
whenSealing
joiningapplications
dissimilarare
metals,
asthe
a barrier
spacer.
often in
form of aorfoam
tape
g applications
are often in the form of a foam tape or gasket.
or gasket.
13
15
FORMING
Forming
DuraPlate panels may be bent or folded based on application and need,
but specific methods are required. Using a router or water jet cutter,
one skin
and core
material
removed,
leaving
the opposite
DuraPlate
panels
may bemay
bentbe
or folded
based
on application
and need,
skin intact.
It
is
essential
that
the
cutter
leave
a
minimum
1/32” of
but specific methods are required. Using a router or water jetofcutter,
core material
adhering
to
the
remaining
skin
to
provide
strength.
one skin and core material may be removed, leaving the opposite skinThe
desired
dimensions
andthat
geometry
ofleave
the formed
radius
will
determine
intact.
It is essential
the cutter
a minimum
1/32”
of core
the width
and
depth to
ofthe
theremaining
cut. A broader
cut of strength.
skin andThe
core
will
material
adhering
skin to provide
desired
dimensions
geometry
the formed
radius
determine
the width
produce
a largerand
radius
bend.of Narrow
cuts
will will
result
in tighter
corners.
90 ° - 105 °
and depth of the cut. A broader cut of skin and core will produce a larger
radius
bend.
Narrowmanually
cuts will result
in tighter corners.
The skin
may
be either
or mechanically
bent to the shape
chosen. If done manually, a wooden block or baffle may be utilized to
The skin may be either manually or mechanically bent to the shape
protect
the surface if light hammering is necessary to finish the fold. If
chosen. If done manually, a wooden block or baffle may be utilized to
a mechanical press is used, care should be taken to ensure that there is
protect the surface if light hammering is necessary to finish the fold.
pressure
sufficient to
complete
or bend
without
exerting
If a mechanical
press
is used,the
carefold
should
be taken
to ensure
there istoo
muchpressure
pressure.
sufficient to complete the fold or bend without exerting too
DURAPLATE PANEL
.047”
much pressure.
It must be noted that once bent or formed, the skin will tend to hold
a memory
shape.
It may
beorre-straightened
into
It mustofbethe
noted
that once
bent
formed, the skin back
will tend
tovisual
hold
a memory
thesurface
shape. Itmay
maybe
bedamaged
re-straightened
into visual
alignment,
butofthe
in theback
process.
Also,
alignment,
but of
thethe
surface
may
be damaged
in thefailure.
process. Also,
repeated
bending
metal
may
result in skin
repeated bending of the metal may result in skin failure.
90°
16
14
Cleaning
DuraPlate panels have an automotive-quality finish that resists
corrosion and is designed to maintain its appearance for many
years in normal conditions. Routine washing is required to clean
dirt, debris and harmful irritants. Cleaning panels regularly will
restore the panels to original appearance and enhance longevity.
The recommended cleaning process is power washing. A pressure
washer should be utilized for large areas of panel surface. However,
smaller cleaning applications or smaller panels may be washed
by hand. Do not use organic or corrosive cleaning agents, as they
may cause damage to the finish coating. A mild detergent formula,
similar to those used in washing cars, is recommended. Pressure
washing should not exceed 2,000 psi. Care should be taken if
decals and graphics are present to avoid edges from lifting or
curling. As with any finish, use of abrasive cleaning pads will result
in marring the finish and should be avoided. If a brush or cleaning
pad is required, a soft bristle brush is recommended.
PANEL REPAIR
Panels may become damaged, regardless of strength and
durability. The scope and extent of the damage determines the
repair process. Common repairs include fillers, self-adhesive
patches or full panel replacement.
If the skin is torn, but the surface has not suffered any visible
delamination, removal of burrs and application of automotive body
filler will suffice. Follow the filler manufacturer’s recommendations
and then touch up the painted surface. If the delamination has
progressed beyond a minor repair, it may be necessary to cut out
the affected portion of the panel and replace it with self-adhesive
patches. This is not a structural repair but will prevent further
delamination. If the damage is extensive, a full panel replacement
may be required.
For more information regarding how to repair
DuraPlate, please contact Wabash Composites.
3000 E. Main St.
Lafayette, IN 47905
866-877-5062
[email protected]
wabashcomposites.com
15
Material Safety Data Sheet: DuraPlate®
Section I Product Identification
Manufacturer:
Wabash National Corporation
3000 E. Main St.
Lafayette, IN 47905
866-877-5062
Emergency Phone Number:
765-771-5300
To be used only in the event of chemical emergencies involving
a spill, leak, fire or exposure accidents.
Trade Name:
DuraPlate®
Synonyms:
Polyethylene / Steel Laminated Panel
Section II Material Identification and Information
Ingredients:
(CAS #)
Percent (%)
(By wt.)1
Occupational Exp. Limits (OSHA)
(mg/m3)
Polyethylene:
37 – 69
(9002-88-4)
10.0 Total2
5.0 Resp.2
Galvanized Steel:
63 – 31
15.0 Total2
Section III Physical Properties
Appearance and Odor: Composite sheet material, odorless
Melting Point: Polyethylene Steel
110-130o C (230-266o F)
427-482o C (800-900o F)
Sp. Gravity: Polyethylene Steel 0.7 g/cc
7.9 g/cc
Solubility: Insoluble in water
16
Material Safety Data Sheet: DuraPlate®
Section IV Reactivity Data
Auto Ignition: 260-410o C (500-770o F) depending on polyethylene blend
Extinguishing Media: Water, foam, CO2, dry chemical powder
Special Fire Fighting Procedure: Toxic gases may form upon combustion. Respiratory protection is
recommended.
Thermal Decomposition: May produce carbon monoxide, carbon dioxide, organic vapors
Section V Fire and Explosion Data
Stability: Stable
Incompatibility: None known
Decomposition Products: Reference: “Thermal decomposition,” Section IV
Conditions to Avoid: None known
Section VI Health Hazard Data
These products are not considered to be a health hazard in the form in which they are sold (sheet, panel).
However, if these products are abraded, melted, welded, cut or processed in any manner that causes release
of fumes or dusts, hazardous levels of fumes or dusts may be generated from these materials or constituents
of these materials.
Effects of Overexposure:
Acute: Physical irritation of the eyes may result from overexposure to high
concentrations of dust or chips from certain fabricating operations.
Chronic: Repeated long-term inhalation of high concentrations of respirable
dust may cause inflammation of the upper and lower respiratory tract.
Special Precautions: Avoid prolonged inhalation of high dust concentrations and ingestion
of material.
Wash hands before eating, drinking or smoking.
Wear proper eye and respiratory protection when working in areas of
high dust concentrations.
Emergency and First Aid Procedures: For dust contact with eyes, wash immediately under water for at least
15 minutes.
For dust inhalation exposure, remove to fresh air.
Contact a physician.
17
Material Safety Data Sheet: DuraPlate®
Section VII Storage, Handling and Disposal Data
Waste Disposal: Care must be taken when using or disposing of material
debris to prevent environmental contamination. Dispose
of the debris in accordance with the Clean Air Act,
the Clean Water Act, the Resource Conservation and
Recovery Act and all state or local laws/regulations
regarding disposal.
Storage and Handling Precautions: Store in a flat, dry area.
Handle carefully to avoid scratching product finish.
Caution should be taken to avoid sharp edges.
Section VIII Personal Protection Data
Primary Routes of Entry: Inhalation and ingestion of dust concentrations.
Respiratory Protection: An approved NIOSH/MSHA respirator must be used
when engineering controls cannot be implemented to
control dust concentrations. Reference OSHA 1910.134
for specific requirements.
Ventilation: Local exhaust. Reference OSHA 1910.94 for specific
requirements.
Eye:
Eye protection must be worn when working in dust
concentrations and during sawing or other operations
that might cause flying debris. Reference OSHA
1910.133 for specific requirements.
Protective Glove: Gloves should be used to prevent cuts or scrapes.
1 Concentration of ingredients depends upon the thickness of the material.
2 These products are not considered to be a health hazard in the form in which they are sold
(sheet, panel). However, if these products are abraded, melted, welded, cut or processed in
any manner that causes release of fumes or dusts, hazardous levels of fumes or dust may be
generated from these materials or constituents of these materials. Dust from these materials
is regulated as particulate, N.O.S.
18
Notes
19
Thank you for your consideration of DuraPlate for your application.
For further information, please contact Wabash Composites. Wabash
Composites is staffed with Business Development Specialists and
Engineers who are available to address any concern, whether it is a
question concerning DuraPlate, or a complex fabrication question.
3000 E. Main St.
Lafayette, IN 47905
wabashcomposites.com
[email protected]
866-877-5062
©2014 Wabash National Corporation. All rights reserved. No portion of these materials may be reproduced, stored, or transmitted without prior approval
from Wabash National. Wabash National reserves the right to make changes at any time without notice, as we continuously improve our products. This
document has been developed to serve as a fabrication guideline to assist those in working with DuraPlate® in the most efficient and effective manner.
It is not exhaustive of what DuraPlate® is capable of accomplishing. This document does not provide a warranty, and Wabash National shall not have
any responsibility or liability for any damages resulting from such use. DuraPlate® is a registered trademark owned by Wabash National, L.P.
Revision: WCP 0001 12.14