It is possible to process Valcan’s range of panels in both on site and off site situations depending on the project requirements, within this page we aim to provide guidance on tooling and processing applicable.

For off site fabrication Valcan can hire out suitable equipment to contractors, if this is of interest, please contact the team on +44(0)1278 428 245.

The settings and information contained within this page are offered for guidance only and do not constitute a guaranteed performance. Each machine will have its own characteristics and maximum performance guidelines as stated by the manufacturer which should be adhered to over and above the settings offered as guidance below.

Valcan have partnered with tools and accessories company Certifix Ltd and CNC tooling specialist company LKH Tools to ascertain best practice in this area. For beam saw cutting the blade will vary from machine to machine and therefore the below information is initial guidance only.

Certifix LtdLKH Tools
0161 672 33330115 666 0060
www.certifix.co.ukwww.lkhtools.co.uk

Vacuum hold down (where applicable) and extraction will make a huge difference to how the tools/blades will perform in the material. As with any tool/blade, these tools need a securely held material / component to achieve the correct results. Vibration will result in the premature failure of any tool/blade.

VitraDual and Vitrabond/A2

Off site CNC Cutting and Grooving

VitraDual

Drilling, cut outs and slotting work – dry, no coolant required. Tooling options for 4mm and 6mm diameter:

Tools Required:6mm Diameter – S1-6.0/6-12-50 MP Superior
Available from LKH tools
RPM:24,000 RPM
Max Plunge Rate:1.5 Meters Per Minute
Max Feed Rate:Start at 6 meters per minute, Increasing to a maximum of 12 Meters per Minute.
Max Depth:3mm single pass
Link to tool on LKH website
Tools Required:4mm Diameter – S1-4.0/6-6-50 MP Superior
Available from LKH tools
RPM:24,000 RPM
Max Plunge Rate:1.2 Meters Per Minute
Max Feed Rate:Start at 2 meters per minute, Increasing to a maximum of 4 Meters per Minute.
Max Depth:3mm single pass
Link to tool on LKH website

V Grooving using ball nose cutter – dry, no coolant required:

Tool Required:B1-10/10-22-55 MP B Superior
Available from LKH tools
RPM:24,000 RPM
Max Plunge Rate:1.5 Meters Per Minute
Max Feed Rate:Start at 3 meters per minute, Increasing to a maximum of 5-7 Meters per Minute.
Max Depth:1.9-2.1mm Single pass – Between 0.7-1.0mm of material should remain after grooving completed
Link to tool on LKH website

Vitrabond/A2

Drilling, cut outs and slotting work – dry, no coolant required. Tooling options for 4mm and 6mm diameter:

Tools Required:6mm Diameter – S1-6.0/6-8-50 PCD
Available from LKH tools
RPM:24,000 RPM
Max Plunge Rate:1.5 Meters Per Minute
Max Feed Rate:Start at 12 meters per minute, Increasing to a maximum of 18 Meters per Minute.
Max Depth:3mm single pass
Contact LKH Tools to discuss PCD tooling requirements
Tools Required:4mm Diameter – S1-4.0/6-6-50 MP Superior
Available from LKH tools
RPM:24,000 RPM
Max Plunge Rate:1.2 Meters Per Minute
Max Feed Rate:Start at 8 meters per minute, Increasing to a maximum of 12 Meters per Minute.
Max Depth:3mm single pass
Link to tool on LKH website

V Grooving using ball nose cutter – dry, no coolant required:

Tool Required:B2-10/10-10-50 PCD
Available from LKH tools
RPM:24,000 RPM
Max Plunge Rate:1.5 Meters Per Minute
Max Feed Rate:Start at 12 meters per minute, Increasing to a maximum of 18 Meters per Minute.
Max Depth:1.9-2.1mm Single pass Between 0.7-1.0mm of material should remain after grooving completed
Contact LKH Tools to discuss PCD tooling requirements

V Grooving using 92 degree V shaped tool – dry, no coolant required:

Tool Required:ACM 10/10-45-90 DLC
Available from LKH tools
RPM:24,000 RPM
Max Plunge Rate:1.5 Meters Per Minute
Max Feed Rate:Start at 12 meters per minute, Increasing to a maximum of 18 Meters per Minute.
Max Depth:1.9-2.1mm Single pass Between 0.7-1.0mm of material should remain after grooving completed
Link to tool on LKH website

Off site folding of VitraDual

It is possible to fold VitraDual without first grooving, we recommend that an internal radius of 2.5x material thickness (for example 7.5mm internal radius on 3.0mm panel) is used for best performance however, results can vary from machine to machine depending on fabricator specifics, we recommend that samples are produced by fabricators and signed off by Valcan prior to production commencement.

Should a fold need to be tighter than our guidance, it is recommended that the VitraDual panels are first grooved then folded to create a tighter radius as laid out above.

Note:- it is not possible to fold Vitrabond panels without grooving.

On site cutting and grooving

It is possible to cut VitraDual and Vitrabond/A2 panels on site using rail/plunge saws with suitable aluminium blade according to machine manufacturer and suitable extraction equipment should be used. Saws such as the Festool TS 55, Makita SP600J (others are available too) can be used for straight cuts. Saws such as the Festool TS 55, Makita SP600J (others are available too) can be used for straight cuts.

Grooves in panels can be achieved using the the Festool PF1200 or Makita CA5000ZJ with the manufacturers recommended blades installed. Grooving can also be achieved using hand routers.

For the Festool TS 55 saw the blade to be used is the HW 160×2.2×20 TF52 blade and part number 496306. For the Makita SP6000 the blade to be used is the B-09307 165x20mm 56T blade.

The panels to be cut or grooved on site should be placed face down on a clean and level surface, it is recommended that this be a MDF board. The cutting board should be swept of cutting swarf and grit between panels being cut/processing.

For cutting of VitraDual and Vitrabond/A2 panels, the blade should extend approximately 2mm past the sheet into the face of the MDF cutting board – with a suitable sharp blade, single pass should be achievable.

For grooving, the blade should leave between 0.7-1.0mm of material after processing – with a suitable sharp blade, clean groove should be achieved in a single pass.

Drilling of VitraDual and Vitrabond/A2

Drill panels 1 at a time using hardened steel bits. All panels should have a minimum of 1 fixed point per panel and the rest sliding points, the fixed point should be central as the panel dimensions allow.  

Drill bits for VitraDual and Vitrabond/A2 are available from our Vitrafix product range.

VFDB4.9-VD – Vitrafix Drill Bit, 4.9mm for VitraDual
VFDB7.0 – Vitrafix Drill Bit, 9.5mm for VitraDual

Larger floating hole size may be required under facade designers requirements, please call Valcan to discuss specific requirements.

Ceramapanel

Off site Cutting

Ceramapanel can be cut off site using a variety of tools including beam saws and CNC flat bed routers.

Please note that the Ceramapanel Natural+ and Painted range of boards will need any cut/drilled faces to be sealed with the Ceramapanel Edge Sealant, this is supplied FOC with the panel order, if extra is required please contact the Valcan team on +44(0)1278 428 245 to discuss your requirements. Ceramapanel Natural boards do not require sealing.

Quality Poly Crystalline Diamond (PCD) tools are recommended for cutting of fibre cement panels, these provide durability and long life as well as smoother, cleaner and more accurate cuts.

Below you will find details of CNC tools and saw blades suitable for processing Ceramapanel fibre cement panels.

For CNC cutting, a 6mm PCD bit can be used, no coolant is required, guidance on settings as follows. A good suitable extraction system will be required.

Tools Required:6mm Diameter – S1-6.0/6-14-50 PCD P – Fibre Cement Board
Available from LKH tools
RPM:24,000 RPM
Max Plunge Rate:Use ramp plunge – 1 Meter Per Minute – DO NOT USE FOR DRILLING
Max Feed Rate:Start at 1.2 meters per minute, Increasing to a maximum of 2 Meters per Minute.
Max Depth:12mm single pass
Contact LKH Tools to discuss PCD tooling requirements

For saw blade cutting, the blade should extend approximately 5mm below the panel and only 1 panel should be cut at once. As initial guidance, for a 300mm diameter blade, thickness would be 3.2mm with 6 cutting teeth and saw speed of 2000rpm, feed speed will depend on machine. The information for saw blades shown is guidance only and may vary from machine to machine, it is important that the operator of the saw has a good knowledge of the equipment and how the settings affect cutting of various materials.

On site cutting

On site cutting can be achieved using rail/plunge saws with suitable fibre cement blades according to the machine manufacturers guidance and suitable extraction equipment should be used. Saws such as the Festool TS 55, Makita SP600J (others are available too) can be used for straight cuts.

Certifix Ltd offer a range of PCD saw blades from both Dart and Makita:

Makita PCD Saw Blade for Fibre Cement
PCD Saw Blade for Fibre Cement, 160mm
PCD Saw Blade for Fibre Cement, 165mm

The panels to be cut on site should be placed on a clean and level surface, it is recommended that this be a MDF board. The cutting board should be swept of cutting grit and dirt between panels being cut/processing.

The blade should extend approximately 5mm past the sheet into the face of the MDF cutting board – with a suitable sharp blade, single pass should be achievable.

Drilling of Ceramapanel

Drill panels 1 at a time using hardened steel bits. All panels should have a minimum of 1 fixed point per panel and the rest sliding points, the fixed point should be central as the panel dimensions allow.  

Drill bits for Ceramapanel are available from our Vitrafix product range.

VFDB4.9 – Vitrafix Drill Bit, 4.9mm for Ceramapanel
VFDB9.5 – Vitrafix Drill Bit, 9.5mm for Ceramapanel

If a panel needs to have 2 fixed points by design, these fixed points should be located on separate carrier rails and located as near as possible to the horizontal central line as, if no central row of fixings are available, use the nearest row. If more than one rail is available behind panels, use the centre most rails for fixed points.

On panels with no centre rails, the standard T rails should be swapped out for two separate L rails to prevent fixings of adjacent panels to same carrier profile. Another alternative is to use a top-hat profile for fixing.

If you are looking to purchase any of the tooling or equipment listed on this page, please contact the Valcan team on on +44(0)1278 428 245 or enquiries@valcan.co.uk and we’ll be happy to assist with supply and support.