ORALITE® 5900 High Intensity Prismatic Grade 5900-010 white

Product Description

ORALITE® 5900
High Intensity Prismatic Grade
Technical
Datasheet
2020/4
Page 1 of 4
ORAFOL Europe GmbH – Orafolstrasse 1 – D 16515 Oranienburg – Germany
[email protected] – www.orafol.com
Product Description
ORALITE® retroreflective films series 5900 High Intensity Prismatic Grade are highly reflective, weatherproof, self-adhesive
films with excellent corrosion and solvent resistance. The product was specifically developed for the manufacture of traffic
control, guidance, warning and information signs, which are intended for long term vertical outdoor use.
ORALITE® 5900 sheeting is composed of a UV stabilised acrylic front film. Its retroreflective system consists of sealed cells
of air backed microprisms, using total internal reflection. The distinct shape of the sealing pattern identifies the machine
direction and the manufacturer of the sheeting shown in Figure 1.
Retroreflectivity
ORALITE® 5900 exceeds the minimum performance requirements of DIN 67520:2008-11 (RA2; design C) and ASTM D4956
(type IV). The required minimum retroreflection values, shown in tables 1 and 2, are complied with when measured in
accordance with the corresponding specifications using CIE standard illuminant A, and the provisions of CIE No.54.2.
Colour
ORALITE® 5900 High Intensity Prismatic Grade sheeting is available in white (010), yellow (020), orange (035), red (030),
green (060), blue (050) and brown (080) as well as fluorescent yellow-green (029) and fluorescent yellow (037). The sheeting
conforms to the daytime colour requirements in tables 3 & 4 when measured in accordance with the corresponding
specifications, the provisions of CIE No. 15.2, & shall comply with the specifications of DIN 6171-1: 2011-11 & ASTM D4956
(type IV) .
Figure 1 – Sealing pattern and application directions
Adhesive
The adhesive consists of a solvent polyacrylate, permanent pressure sensitive adhesive specially formulated for the
application to metallic surfaces such as aluminium and zinc coated steel plate. The adhesive is protected by a release liner
made of polypropylene film, silicone coated on one side, 0,075 mm [0,003”] thickness.
Application/Processing
ORALITE® 5900 High Intensity Prismatic Grade was especially developed for traffic control applications. Surfaces to which
the material will be applied must be thoroughly cleaned from dust, grease or any contamination which could affect the
adhesion of the material. Freshly lacquered or painted surfaces should be completely cured. The compatibility of selected
lacquers and paints should be tested by the user, prior to application of the material. For other applications, the user is fully
responsible for evaluating the suitability of the product, and for any risks associated with that use.
ORALITE® 5900 in white colour can be screen or digitally printed or laminated with overlay films. The printed or laminated
sheeting will continue to meet the retroreflective values of the respective colour provided that ORAFOL’s application
guidelines are followed. The overlay films recommended are: ORALITE® 5061 Transparent film, ORALITE® 5090 Anti Dew
film and ORALITE® 5095 Anti Graffiti film. The screen printing ink recommended is ORALITE® 5018. A transparent coating is
not necessary.
The material can also be printed on the ORALITE® UV Traffic Sign Printer with the specially developed UV digital inks
ORALITE® 5019. For long-term vertical outdoor use, the printed material should be used in combination with ORALITE® 5061
Transparent film.
Please refer to the Practical Information #4.3 published by ORAFOL for full instructions, or contact your ORAFOL Reflective
Solutions Division representative for advice relating to the above.
Practical Information
ORALITE® Reflective Films of Class RA2, Grade C
for Road Safety
Document 4.3
2022/01
Page 1 of 6
ORAFOL Europe GmbH – Orafolstrasse 1 – D 16515 Oranienburg – Germany
[email protected] – www.orafol.com
1. Processing instructions for ORALITE® High Intensity Prismatic Grade Films
These processing instructions apply to the following ORALITE® High Intensity Prismatic Grade films, Reflection Class CUAP
R2, DIN 67520:2008-11 RA2, Design C, ASTM D4946-17 Type IV Sheeting and AASHTO M268 Type B.
ORALITE® 5900 High Intensity Prismatic Grade
ORALITE® 5910 High Intensity Prismatic Grade
ORALITE® 5930 Prismatic Construction Grade
ORALITE® 5931 Prismatic Construction Grade
ORALITE® 5960 High Intensity Prismatic Construction Grade
The basic composition of ORALITE® High Intensity Prismatic Grade film is illustrated below:
The information within this document is based on our knowledge, experience and application tests. Its purpose is to provide
suggestions and support to practitioners. Even though it is not possible to explain all aspects that need to be taken into
account, this guideline comprises a large number of useful tips for handling ORALITE® High Intensity Prismatic Grade films.
Specific knowledge and skills of sign producers are prerequisites for the processing of ORALITE® High Intensity Prismatic
Grade film. On account of the large number of conditions that may influence the processing, adhesive bonding and use of the
films, the sign producer should carefully consider the suitability and performance of the product for each intended use and
perform their own tests.
2. Storage and Transportation
ORALITE® High Intensity Prismatic Grade film should be stored in a
cool and dry, indoor area that is protected from direct sunlight.
Recommend temperatures for storage are from 18° C to 24° C
[65° F to 75° F] and air humidity of 40% to 60%.
Rolls should be stored in the original carton. The rolls have standard spacers [core plug] that prevent contact between the roll
surface and the carton and thus the formation of pressure marks and surface damage. Please make sure that partly
processed rolls are never stored without spacers.
When making the rolls available for processing, it is advisable to use a horizontal suspension system. If the rolls are stored
in a vertical, freestanding position, a negative influence on the film’s characteristics is not expected. It is crucial to place the
roll on the spacer so as to avoid breakage at the edges and contamination.
Blank or printed film sheets are supplied in cartons that have been specifically designed to the sheet dimensions. There are
50 sheets per carton. If the sheets are stored outside the carton, please make sure to put individual sheets on a flat and
stable support so that they do not adjoin or overlap at the edges. Sheets may be stacked. However, in order to limit the
weight load not more than 40 to 50 sheets should be stacked.
3. Printing
ORALITE® High Intensity Prismatic Grade films surface can be screen-printed with ORALITE® 5018 Screen Printing Ink or
digitally printed with ORALITE® 5019i UV Digital Printing Ink and the ORALITE® UV Traffic Sign Printer.
highly weather-resistant layer
prism layer
air layer
white sealing layer
adhesive layer
protective liner
Practical Information
ORALITE® Reflective Films of Class RA2, Grade C
for Road Safety
Document 4.3
2022/01
Page 2 of 6
ORAFOL Europe GmbH – Orafolstrasse 1 – D 16515 Oranienburg – Germany
[email protected] – www.orafol.com
3.1 Screen printing process
ORALITE® 5018 screen printing inks are a one-component, solvent based and quick drying inks. The resulting surface is
glossy and exceptionally weather resistant. After complete curing, the ink is extremely resistant to mechanical stresses such
as those caused by cleaning brushes, etc. The application of an additional clear topcoat is not necessary for these ink
systems.
ORALITE® 5018 Screen Printing Ink is available in the following transparent colours and opaque black:
Yellow (020)
Red (030)
Orange (035)
Blue (050)
Green (060)
Brown (080)
Grey (073)
Black (opaque) (070)
ORALITE® 5018 is supplied ready for printing in containers with a capacity of 800 ml, 2400 ml, one gallon and 5 litres. Before
application, the ink must be stirred and allowed to stand for at least 10 minutes to degas. Opened containers must be closed
tightly immediately after use. This helps prevent solvent evaporation, so that the ink remains suitable for future printing.
3.2 Preparation of the screen
It is recommended using polyester fabric with a mesh count of 61 to 64 [155 to 163 mesh] as printing screens. When such
screen and ORALITE® screen printing inks are used, ORAFOL guarantees that prints onto ORALITE® films permanent and
temporary traffic control products comply with the specifications for chromaticity and specific retroreflectivity provided that the
printing process is carried out correctly.
Manual printing tables or automatic printing systems may be used. The screen-printing table must be flat and mechanically
stable. Vacuum conveying is required for printing film sheets. The hardness or elasticity of squeegees has a decisive
influence on the printing result. Squeegee rubbers with Shore hardness of 65 to 75 are recommended. Checking and surface
grinding, if required, of the squeegees is crucial. The squeegees should be 7 to 10 cm [2.75 to 4 inches] wider than the
printing format.
3.3 Screen printing
Before starting the screen printing process, the screen, squeegee
and flood bar must be cleaned with a suitable solvent. In addition,
each film should be wiped with an anti-dust or anti-static cloth
prior to printing.
For printing, it is recommend maintaining a medium squeegee
speed of approximately 0.75 m/s [2.5 ft/s] and the squeegee
should be applied at an angle of 30° to the print surface.
The distance between the screen and the film surface should be set to about 10mm [0.375 inches]. If the distance is too
short, the screen does not come off the substrate neatly, which results in poor print quality. Excessive squeegee pressure
can result in smearing or blurred contours and edges. The ink containers must be closed immediately after use.
Optimum conditions for the printing process require an air temperature ranging from 20° C to 24° C and a humidity of 35% to
50%. Unfavourable ambient conditions may require the use of additives to adjust the ink for processing. To meet the required
specification values for colour and retroreflection, it is crucial to ensure that no more than 3% thinner or not more than 1.5%
retarder and not more than 0.5% print modifier are added to ORALITE® 5018 Screen Printing Ink. Humidity at or below 30%
can lead to unsatisfactory printing results and long term stability of prints and is not recommended or warranted.
Practical Information
ORALITE® Reflective Films of Class RA2, Grade C
for Road Safety
Document 4.3
2022/01
Page 3 of 6
ORAFOL Europe GmbH – Orafolstrasse 1 – D 16515 Oranienburg – Germany
[email protected] – www.orafol.com
3.4 Drying after screen printing
The drying time of the prints depends on the type of sheet or ink used, and specific local conditions such as the positioning of
the prints, ambient temperature, air humidity, etc.
To facilitate quick and economical processing of the sheets after printing, forced drying is recommended by means
of fans or drying in a convection oven at 40° C to 50° C [104° F to 122° F] is utilized.
Furthermore, forced drying prevents formation of cracks in the films after printing.
When using fans and drying at room temperature, we recommend that prints are individually placed on a rack or a similar
shelf system as pictured below. To ensure adequate air circulation, a distance of at least 5 cm [2 inches] should be kept
between the storage levels. Furthermore, it is recommended to use at least three or four fans for drying. The fans are best
arranged one above the other in a movable manner on a trolley that can be driven up to the sheets from a distance of 1 to 2
m [3 to 6 ft]. Immediately after printing, the fans should run at a higher speed for about 30 minutes, after that normal speed
for another 30 minutes should be sufficient.
The use of a heatable drying rack results in a temperature increase and thus a substantially reduced drying time.
Drying conditions can be further optimized by using convection
ovens. These closed systems permit a low-dust drying phase at
constant temperature, low air humidity and do not subject the
operator to solvent vapours.
The following drying times are general guidelines for ORALITE® 5018 Screen Printing Ink:
ORALITE® 5018 Screen Printing Ink
Drying
Condition Over printable Stackable
(max. 40 sheets) Notes
Temp. Time Temp. Time
Air Drying 20° C 60
minutes 20° C 3 to 4
hours
RH 40-
60%
Oven
Drying 60° C 5
minutes 60° C
30
minutes
In case the sheets are printed in an overlapping manner, please make sure that the lower ink layer is not fully cured yet and
that overprinting must take place within 12 hours after the first printing.
At an ambient temperature of 20° C [68° F] and an average relative air humidity of 40 to 60%, printed traffic signs can be
shipped after a drying time of 48 hours. Prints made with the two ink series are fully cured after approximately 8 days.
3.5 Storage and transportation of printed sheets and traffic signs
When the inks are cured (see Table above), printed sheets can be stored horizontally. Please note that the maximum
number of sheets stacked should not exceed 40 to 50 sheets. Prints on pre-laminated traffic sign substrates should be stored
vertically and separated by an intermediate layer of suitable paper or support film. A low pressure load is crucial.
Practical Information
ORALITE® Reflective Films of Class RA2, Grade C
for Road Safety
Document 4.3
2022/01
Page 4 of 6
ORAFOL Europe GmbH – Orafolstrasse 1 – D 16515 Oranienburg – Germany
[email protected] – www.orafol.com
3.6 UV digital printing
ORAFOL’s UV digital printing system, especially designed for but not limited to the manufacturing of traffic signs, consists of
ORALITE® UV Traffic Sign Printer using the supplied RIP software, ORALITE® 5019i UV Digital Printing Ink and our
recommended ORALITE® overlay films. Clear lamination after printing yields films with long term outdoor stability that meets
the requirements of reflection class RA2.
The printing process requires an air and material temperature between 20° C and 26° C as well as air humidity between 40 –
60 %. The room should be free from dust to prevent entrapment of dust during printing. The surface of the ORALITE®
reflective films requires cotton gloves to prevent contamination of the surface and to allow a flawless print image.
For further details on printing preparation, cleaning and care intervals please refer to the handbooks and documentations of
the ORALITE® UV Digital Traffic Sign Printer and the RIP software.
Lamination with clear protective laminates shall be done at a maximum temperature of 37°C [100F] and 0.6 m/min [2 ft./min]
to yield a good lay flatness and stress free laminated product.
4. Cutting, die cutting, plotting
ORALITE® High Intensity Prismatic Grade films can be cut by means of a commercial stack cutter. The holding-down clamp
should be set to very low pressure and, as an additional measure, the film should be protected from compression. It is
recommended to limit the stacking height to 40 to 50 sheets (see Storage and Transportation). Sealing cut edges of
ORALITE® High Intensity Prismatic Grade films is not required.
If ORALITE® High Intensity Prismatic Grade films are die-cut by means of steel strip tools, it is not recommended to place
several sheets on the platen at the same time.
Commercial cutting plotters with tangential blades, preferably of the flatbed type, should be used as plotter systems.
Tangential control ensures high-quality cut edges. The cutting depth can be adjusted, from starting a cut, to cutting through.
Systems with a pneumatically controlled die head, where the cutting pressure can be adjusted precisely in accordance with
the specific material used, are highly recommended. The use of drag-knife systems is not recommended. The respective
cutting or processing speed depends on the complexity of the cutting pattern and the applied cutting system.
For the manufacturing of traffic signs with ORALITE® High Intensity Prismatic Grade films in a small series and/or with
variable lettering, ORAFOL offers the ORALITE® 5061 Transparent Film series in all common traffic sign colors. For black
letterings, markings and symbols the ORALITE® 5081 Lettering Film is recommended. Additional laminates are the
ORALITE® 5090 Anti-Dew Film and ORALITE® 5095 Anti-Graffiti Film, as well as the transparent film of the series ORALITE®
5061 Transparent Film.
For the application of cut films ORAFOL offers the ORATAPE® MT95 transfer film or ORATAPE® MT72, LT72 and MT52
application tapes. The application can be done by film laminating machine or hand roller.
5. Adhesive bonding and laminating
In order to achieve proper adhesion of the films, the substrate must be dry and free of dust, oil, fats, silicon or other
contamination. If the substrate needs to be treated with a solvent, the next processing step cannot be carried out until the
solvent is completely evaporated. When films are adhered to metallic substrates, fine grinding of the surfaces is
advantageous.
ORALITE® High Intensity Prismatic Grade film series 5900, 5910, and 5930 have been optimized for application onto flat
substrates such as aluminum alloys or galvanized steel. ORALITE® High Intensity Prismatic Grade film series 5930 are also
suitable for bonding to polyolefinic substrates such as polyethylene and polypropylene. However, the installer should perform
own tests in each case.
Laminating should not be carried out at air and material temperatures of less than 15° C [60° F]. The optimum temperature is
about 21° C [70° F]. The films should be stored in the rooms in which they will be processed for at least 48 hours. Adequate
curing of the ink is a prerequisite for any further processing of printed reflective films as otherwise the evaporating solvent
may cause blistering and even tearing of the films. If you intend to use a film-laminating machine, a controllable unwinding
and winding motor is recommended. The upper roller should be rubber coated with Shore hardness 65 to 75. The optimum
roll gap should be adjusted over the entire width. A flatbed roll applicator is recommended for the lamination of larger webs.
Practical Information
ORALITE® Reflective Films of Class RA2, Grade C
for Road Safety
Document 4.3
2022/01
Page 5 of 6
ORAFOL Europe GmbH – Orafolstrasse 1 – D 16515 Oranienburg – Germany
[email protected] – www.orafol.com
If it is necessary to apply two pieces of prismatic sheeting
side by side (splicing), they must not overlap. Depending on
the format, the gap should be approximately 1 mm [0.04
inches]. Please make sure that a right side of the film web is
always bonded to a left side, thus ensuring the uniform
orientation of the film’s honeycomb structure (shown below).
honeycomb/cell structure (schematic)
ORALITE® High Intensity Prismatic Grade films comply with the relevant minimum reflective data in machine direction as well
as in transverse direction.
When a hand roller is used for lamination, the film must be placed on the sheet in such a way that it protrudes at least 5 mm
[0.25 inches] from the surface on all sides. It is recommended to proceed as follows to ensure the accurate positioning of the
sheet: In a first step, peel off 60 to 80 cm [24 to 32 inches] of the protective paper or film from the ORALITE® High Intensity
Prismatic Grade film. Align the sheet on the substrate and press down the area where the adhesive is exposed. Then get
hold of the folded-over protective paper underneath the sheet and slowly peel it off further, while pressing down the sheet
with the rubber hand roller. Finally, the edges of the traffic sign sheet should be trimmed with a sharp knife applied at a 30°
angle.
Caution! Before laminating any ORALITE® film to a substrate, please make sure it is dry!
6. Colour adjustment
If several film sheets or film webs of ORALITE® High Intensity Prismatic Grade films are to be bonded to a substrate, they
should be color-matched in daylight and when illuminated in retroreflection. It is preferable to use only films from the same
roll. If more than one roll is required, only material from the same production lot should be used.
7. Cleaning of the applied products
Surfaces should only be cleaned with clear water, water/isopropanol (80/20%) or diluted soap solution. Please do not use
any solvents, thinner or abrasive cleaning agents for the cleaning of reflective films! We also do not recommend the use of
power washers for cleaning of read signs.
8. Intermediate storage of traffic signs
ORAFOL recommends indoor storage of signfaces or finished signs in an upright vertical position, with 2 cm [1 inch] spacers
between the signs in an area protected from excessive moisture or overheating. Outdoor storage should be done in a vertical
position with 10 cm [4 inches] spacers between the signs. The spacers should not touch the reflective surface. If a wrapping
is done, the material used shall allow air circulation and be removed when wet.
9. Durability of traffic signs
The durability of the sign will depend upon substrate and sheeting selection, preparation, application, maintenance, and
exposure conditions. Lifetime statements in the technical data sheets and warranty documents refer to signs that were
produced and applied according to above recommendations, the application/processing described in the technical data sheet
and the warranty documents issued by ORAFOL. Sign failures caused by improper preparation, application or maintenance
are not the responsibility of ORAFOL. A reduced service life or sign failure might be caused by snow packing or any other
sign burial, improperly selected or prepared substrate, exposure to extreme atmospheric conditions in certain geographic
areas, mechanical abrasion, exposure to aggressive chemicals, non-vertical application, use of other than the recommended
ORAFOL products (inks, laminate films, lettering films etc.).
Machine direction
Transverse direction
Practical Information
ORALITE® Reflective Films of Class RA2, Grade C
for Road Safety
Document 4.3
2022/01
Page 6 of 6
ORAFOL Europe GmbH – Orafolstrasse 1 – D 16515 Oranienburg – Germany
[email protected] – www.orafol.com
These instructions apply to the following materials:
Microprismatic retroreflective films
ORALITE® 5910 High Intensity Prismatic Grade
ORALITE® 5900 High Intensity Prismatic Grade
ORALITE® 5930 Prismatic Construction Grade
ORALITE® 5931 Prismatic Construction Grade
ORALITE® 5960 High Intensity Prismatic Construction Grade
Colour laminates
ORALITE® 5061 Transparent Film
Clear protective laminates
ORALITE® 5061 Transparent Film (colour code 000)
ORALITE® 5090 Anti-Dew Film
ORALITE® 5095 Anti-Graffiti Film
Lettering materials
ORALITE® 5081 Lettering Film
Transfer materials
ORATAPE® MT 95
ORATAPE® MT 72
ORATAPE® LT 72
ORATAPE® MT 52
Inks
ORALITE® 5018 Screen Printing Ink
ORALITE® 5019i UV Digital Printing Ink
For further information on the above described materials, please visit www.orafol.com.
IMPORTANT NOTE
All ORAFOL products are subject to careful quality control throughout the entire manufacturing process, and it is ensured that
they are of merchantable quality and free from manufacturing defects. The information published is based on our analyses
and studies and does not constitute any warranted properties or any agreement as to quality. Due to the diverse possibilities
of use of ORAFOL products and the constant development of new applications, the buyer should carefully consider the
suitability and performance of the product for the respective purpose; it bears all risks associated with such use. No warranty
is given for purposes other than those listed in the Technical Data Sheet or for applications that are not processed in
accordance with ORAFOL’s processing instructions.
The durability of the end product depends upon a variety of factors, including but not limited to substrate selection and
preparation, compliance with the recommended application guidelines, geographical area, exposure conditions and
maintenance of the ORAFOL material and of the end product. Product defects caused by the substrate or improper surface
preparation do not lie within ORAFOL’s sphere of responsibility.
When using ORAFOL products, the pertinent national regulations are to be observed. ORAFOL recommends that you obtain
the current stipulations from your local authority and ensure that the product meets these requirements. Please contact
ORAFOL for further information.