A look at Aluminium, Glass and Sealants commonly used in the shopfitting and joinery industry

1. CPCCSH2002A: Use Aluminium Sections for Fabrication
CPCCSH2003A: Apply and Install Sealant and Sealant Devices
LMFGG1001A: Complete a basic glass and glazing project

2. Section 1: Glass

3. Float Glass
Float Glass, often referred to as ‘standard ‘ or ‘annealed ‘glass, is made
by flowing molten glass, then allowing it to solidify, over a bed of molten
tin.
The glass is then heat treated, or annealed, to increase its strength and
stability.
Float glass is available in a range of finishes including
clear, tinted, reflective, patterned or opaque forms.

4. Tinted Glass
 Aesthetics
 Reduction in Heat Entry (solar gain)
 Reduction in Glare
 Improved privacy

5. Reflective Glass
 Reduces solar gain
 Mirror-effect on outside

6. Mirror
 Mirror is
manufactured by
coating float glass
with silver and
protective backing
coats. These coats
protect the silver
from abrasions and
damage.
 Separate sheets
with butchers paper
to protect surfaces

7. Laminated Glass
Laminated glass is
essentially two pieces of
float glass bonded together
with a vinyl film in between.
This film, otherwise known
as a polymeric interlayer,
provides added strength. It
also increases thermal and
acoustic insulation, and
prevents glass penetration
by holding all fragments
together when breakage
occurs.
http://www.rylock.com/images/anim_laminglass.gif

8. There are two types of laminated glass:
PVB and Resin laminated glass
 PVB laminated glass is two or more sheets of glass
which are bonded together with one or more layers
(PVB) under heat and pressure to form a single piece
 Resin laminated glass is manufactured by pouring
liquid resin into the cavity between two sheets of glass
which are held together until the resin cures.

9. Benefits of Laminated Glass
 Safety
 Security
 Sound Reduction
 Solar Energy Control
 UV Control
 Protection from Weather and Natural
Disasters
 Durability
 Low Visual distortion

10. Décor Patterned glass
 This is float glass which has a
pattern embossed into the glass
during manufacture. This is
done by passing the semi
molten glass through a set of
rollers prior to annealing.
 One side remains smooth and
one is textured.
 ‘Obscure’ glass and ‘slumped’
glass are all types of patterned
glass

11. Insulating glass units
 Also known as ‘double-glazed units’
where two or more panels of glass are
bonded to a metal or thermoplastic
spacer (TPS).
 Air or argon gas is used in the space
between the glass panes.
 Their primary benefit is insulation
(Acoustic and Thermal) and solar
control.
 Most types of glass can be incorporated
into an insulating glass unit.

12. 1. Glass
2. Air pocket
3. Metal spacer section
4. Rubber seal
5. Desiccant
6. Silicone Sealant

13. Toughened glass
Toughened or Tempered
glass, is float or patterned
glass which has been
heated to a high
temperature and then
rapidly cooled using air
jets.
This creates a glass in
which the centre is in
tension, while the surface
is in compression.

14. Benefits of Toughened Glass
 Strength
 Safety (shatters into small bits or ‘cuboids’)
Disadvantage
 Cannot be cut, drilled or polished once toughened.

15. Toughened Laminated Glass
This is the optimum in safety glass.
Each piece of glass is toughened to
provide superior structural strength
when compared to annealed glass.
These pieces are then bonded
together using either PVB or Resin
as the interlayer medium, to ensure
that if the glass breaks, the small
pieces are held together by the
interlayer.

16. Energy Efficiency in Glass
As homes are heavy users of energy, the Building Code
of Australia (BCA) now stipulates energy efficiency
regulations for all residential buildings so that new
homes will need less artificial heating and cooling.
The type of Glass used can have a major difference in
the amount of energy used in a home.
The window energy rating scheme or WERS provides a
way of rating certain windows and glass units on a
five star scale.
Heat gain and heat loss in glass are just some of the
considerations used in the rating.
To find out more, go to: http://www.wers.net/

17. Heat-gain in Glass

18. Heat-loss in Glass

19. Cutting Glass
Glass is a material that requires a particular method
of cutting, and if not followed correctly can result in
damage or injury.
Glass can be cut by:
 Hand - using tools which have specially ground
cutting wheels attached to a handle (other types
use a small industrial diamond).
 CNC machine - Computer controlled, using
similar cutting tools to that used by hand
 Water Jet – A mix of water and grit (sand) in a fine,
high pressure jet, blasting through the glass.

20. Before cutting any glass:
 Check the sizes of the glass to be cut
 Determine if any off-cuts can be used up first
 Determine the best method of cutting / breaking
 Clean off benches and cover with protection
 Select appropriate P.P.E.

21. Glass cutters
Good quality glass cutters have hollow handles that contain lubricant
(usually oil) for the wheel which is released when pressure is applied.

22. To cut Glass by hand:
 To cut glass, lay the glass on a clean, firm and flat surface that is
covered for protection (felt, blanket or carpet is satisfactory).
 Mark the cut size or shape on the face of the glass with a fine
point felt marker or white pencil.
 For best results use a well lubricated cutter to cut the glass. A
single score must be made on the surface with out any misses or
jumps. If the cut misses or jumps the score line can be joined
although there is no guarantee the glass will break successfully
along break line, it may run off.
 Once a cut line has been scored on the surface do not run the
cutting wheel over the same line as this can fracture the glass or
damage the cutting edge on the tool.
 Start the scoring at the edge of the glass and apply a firm even
pressure and draw the cutter across the face in a single stroke
until it runs off the opposite edge. You should be able to hear the
tool scoring the line.

23. To score the glass, hold the glass cutter between the
first and second finger, gripping the lower end firmly with
your thumb and fingers.
‘Thomas’ Grip cutter
Pistol Grip cutter

24. Start scoring right at the edge of the sheet

25. To make square or straight cuts hold a ‘T’ square or straight edge along
the set out to help guide the cutter, making allowances for the setback in
the tool, i.e. the distance from the cutter to the edge of the tool.
Apply a firm downward pressure on the guide and place the cutter
against the edge. Start the scoring at the furthest edge of the glass and
draw the cutter back toward you with a smooth even pressure.

26. Methods of ‘breaking’ glass
Smaller sections of the glass can be snapped by hand.
With your thumbs over the top and fingers underneath, snap the
glass with an upward pressure. Larger sheets can be snapped in
the same manner, by starting at the edge of the sheet and lifting
the sheet slightly, the cut will run along the score line.

27. Another way to break glass is to gently tap the glass directly
below the score line with a sharp object (the back edge of the
glass cutter is ideal) until a fracture starts. Care must be
taken to tap the glass directly below the score, this method
works best if there are no gaps in the score line.

28. Running Pliers can also be used.
They work by placing the pliers over the edge of the
glass with its marker in line with the score and applying
pressure on the handles. This creates a fracture and will
open up or “run” along the line.

29. Larger sheets can be broken by
snapping the sheet on the
cutting table.
- Place the scored glass near to
and parallel with the table's
edge but not overhanging. The
overhanging section of the
sheet must be supported.
- Place both hands evenly on
the edge of the sheet and apply
an even downward
pressure, the glass will snap
along the line.
- When cutting thicker glass
more pressure will be required.
- Lift the sheet slightly and
suddenly, but smoothly snap the
sheet down on the table, this
will cause the sheet to snap.

30. Apply an even, downward pressure, and the glass will snap along the line.

31. You can also break glass by placing a straight edge directly in line with
the score line beneath the glass and applying a gentle firm downward
pressure on either side. The glass will snap along the line.

32. Narrow slivers can be removed with special glass pliers with relieved jaws, by
levering down and pulling away from the score line. Smaller sections and the
jagged edges can be trimmed back to the score line with glass pliers or by
nibbling away the waste with the notches on the back of the glass cutter.

33. Caution:
 Always be careful around
glass, especially when
‘breaking’ the cut, or
injuries will occur!
 Always wear eye protection
as glass chips sometimes
break off, and cause major
damage to your sight!

34. Speed Cutters

35.  Speed cutters provide a fast and effective way of cutting glass parallel to
one edge.
 The base plate houses a number of grooved rollers at an angle, allowing
them to sit on the edge of the glass and move freely along the edge.
 The arm is fixed to the base plate at 90° and consists of an adjustable
cutter block and a fixed tape measure.

36. The cutter can be adjusted to the desired measurement along the arm.

37. Ensure that the wheels of the speed cutter are
properly located on the edge of the glass as
shown

38.  When using a speed cutter maintain one
hand on the base plate to retain its position
on the edge of the glass.
 The other hand holds the cutter arm and
applies a slight pressure as the speed
cutter is moved along the face of the glass
creating a score line.

39. Glass cutting machinery
 Off-site specially designed machines may be used to cut particular
shapes or designs from glass of varying thickness and types.
 CNC machines guide laser, plasma or water jet cutting heads that
can cut and shape glass to the finest detail and intricate shapes.

40. Water-jet cutting
Periodically clean off the glass

41. Glass edgers

42. Important points to remember when
handling and cutting glass
 Always wear safety glasses
 Wear gauntlets and gloves
 Never leave glass hanging over a bench
 Before moving around with glass, make
others aware of your intentions
 Keep oil cutters oiled! – ….duhh….
 Don’t go back over scored lines
 Always cut glass on a clean bench
 Check glass for scratches before cutting

43. Section 2:
Aluminium

44. Aluminium Properties
Aluminium is:
○ Corrosion resistant
○ Strong
○ Lightweight
○ Durable (long lasting)
○ Versatile
○ Environmentally sustainable

45. Aluminium Finishes
 Raw (or Mill)
 Brushed
 Polished
 Powder coated
 Painted
 Anodised

46. Aluminium Uses
• Window and Door sections (residential and
commercial)
• Shopfront sections
• Handles
• Decorative trims
• Angle trims
• Toilet partition sections
• Office fitments and shelving
• Showerscreen sections
• Wardrobes

47. Know your sections
Aluminium sections are designed to work easily
and efficiently, so it is important to choose
the right section for the task at hand.
To see more aluminium sections go to: http://www.awscommercial.com.au

48. Shopfront sections

49. Wardrobe sections

50. Residential window and door sections

51. Machining aluminium
Aluminium needs to be cut to length and
machined before it can be assembled.
Cutting, drilling, punching and milling, are all
types of aluminium machining processes, and can
be done via CNC machine, manual milling
machines, hydraulic punches, aluminium cut off
saws and even by hand with hacksaws, files and
drills etc.

52. Machining aluminium (cont.)
Cutting tools should be:
• lubricated
• sharp
• Tungsten

53. Manual Aluminium machinery

54. Aluminium Milling machine
(copy router)

55. CNC aluminium
machining centres

56. Joining aluminium
 Mechanical
 Fusion bonding
(welding)
 Proprietary
(snap-in / clip-in)
 Adhesive bonding

57. Mechanical Joining
•Screws
•Spigots
•Bolts
•Pop-rivets
•Corner stakes

58. Section 3:
Sealants
 Provide a barrier against moisture
and air penetration
 Conceal untidy gaps
 Can increase appearance
(aesthetics)
 Can also provide a means
of fixing (e.g. wrap around
showerscreen rubber)

59. Sealants Sealant Devices
 Rubber  Cover strips or
 Butyl tape plates
 Caulking  Strip or sheet
 Silicones membrane
 Waterproof paint  Flashings
around windows
 Putty
and doors etc.
 Sheet joining
beads etc.

60. Before using sealants ask yourself:
 Is it suitable for the job?
 Have I looked at the Material Safety
Data Sheet? (MSDS)
 Is there a better way to do this?
 What is the working time?
 How do I clean it up?
 Do I have all the tools required?
 Will it react with other materials?

61. Sealant applications:
Aluminium and glass

63. Sealant applications:
Aluminium and glass (cont.)
Correct application of glazing rubber into section

64. Sealant applications:
Aluminium and glass (cont.)
Wrap around gasket (shower screens and wardrobes etc.)

65. Sealant applications:
Timber and glass

66. Sealant applications:
Gap sealing / Caulking
Using tape to ensure a clean and tidy job.