Manuale Alp Gbr

8/12/2019 Manuale Alp Gbr

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Manual for theconstruction of

ALP System ducts

la conduzione dell'aria

UNI EN ISO 9002

CERT.N9091 ALP0

ISO 9002


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Introduction

Practical Manual

Dear collaborator,

this manual has been conceived and developed as a basic practical guide for ALP Technicians.

It is intended to fulfil two main requirements:

in the first place it shall be an easy practical handbook for those who approach the ALP system

for the first time and in the second place it shall be a practical manual for technical / operational

advice for those who actively work with our System.

We have tried to achieve the best result and to offer an overview - as detailed as possible -

about construction and assembly features of ALP products.

We would be pleased if you could give us tips or any kind of material useful for future editions.

Our sincere thanks to those who have contributed to the creation of this practical manual.

Technical - Commercial Department

CONSTRUCTION SYSTEM - 3


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Table of contents

EQUIPMENT PAG. 6

THE CONSTRUCTION OF DUCTS 7

1 - STRAIGHT DUCT 8

2 - STRAIGHT DUCT - TRANSITION 15

3 - STRAIGHT DUCT - OFFSET 16

4 - STANDARD BRANCH 17

5 - SYMMETRIC ELBOW 18

6 - ASYMMETRIC ELBOW 23

7 - TWO-WAY WYE JUNCTION 24

8 - THREE-WAY WYE JUNCTION 25

9 - PROFILES 26

10 - ACCESSORIES 40



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HOW TO ORGANIZE THE WORKSHOP

Here below you will find a list of basic tools, materials and accessories necessary for the

construction of ALP System ducts.

Equipment

- Work table 4000 x 1200 mm Art. 601

- Multiblock rule 4000 mm Art. 602 / A

- Multiblock rule 1200 mm Art. 602 / B

- Square 1200 mm Art. 603 / A

- Square 700 mm Art. 603 / B

- Rule 1200 mm Art. 604

- Compass - Large Art. 605

- Tool-kit case Art. 607

- Manual bending machine Art. 608

- Pneumatic pistol for silicone Art. 609

- Pneumatic glue spreader Art. 610

The equipment set may be completed by adding other tools described by the ALP General Catalogue.

Consumption materials and accessories

- Aluminium tape Art. 201

- Special glue Art. 202

- Silicone Art. 203

- Adhesive gasket Art. 204

- Corners in nylon-glass Art. 205

- Corner plates Art. 206/ A

- Corner covers Art. 206/ B

Profiles

Equipment

6 - CONSTRUCTION SYSTEM

art. 301 art. 302 art. 303 art. 304 art. 305 art. 306 art. 307

art. 308 art. 309 art. 310 art. 311 art. 312 art. 313


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The construction

of ducts

For the construction of ALP System ducts keep in mind as follows:

the measurements of ducts shall always be understood as internal measurements;

the marking of ducts shall always be based on internal measurements;

the procedure to be followed for construction is given here below:

marking - cutting

gluing

assemblysilicone application

aluminium tape application

profiles application



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1 - Straight duct

STRAIGHT DUCT WITH A 4 M CUTTING SYSTEM

Use the Double 45 jack-plane (art. 701/ A) and the Multiblock rule (art. 602/ A) for the

construction of straight ducts.


40 2040 4020

1200

art. 602/ A

art. 701/ A

4 m duct

The sum total of 4 sides of the duct is equal or below 1040 mm.

When the sum total of the sides the duct is composed of is either equal or below 1040 mm, it

will be possible to build a max. 4 m long duct by making use of a single panel.


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b

h

b

40

40

h + 90

56

4

20

b 90

b + 90

20 20 50

20

FOLLOWING CUTS

Internal section h


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GLUING

Before spreading the glue, eliminate any dust

residue which might hinder a perfect gluing.

The glue shall be spread in a uniform way on

both surfaces by completely covering the

foam.

ASSEMBLY

When the glue is dry, close the duct. Follow

the general rules given here below:

when joining panels, always start from thesame border so as to trim only the duct side

opposite the starting side;

always take the internal side of the duct as a

reference so as to perfectly join corners

check the perpendicularity of sides.

Assembly is completed by pressing the corners

by means of a stiff spatula (art. 704).

1

2

43

5


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SILICONE APPLICATION

A thin coat of silicone shall be applied in all

internal corners of the duct for its hermetic

seal. Prevent the air from coming into contact

with the insulating foam.

N.B.

To make profile application easier, when

spreading silicone keep it at a distance of

ab out 4 0 / 5 0 m m from the end of the duct.

After having applied profiles, apply silicone

in the remaining parts.

4050mm

4050mm

2 m long pneumatic pistol for silicone (art. 609)


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TAPE APPLICATION

Taping shall perform two functions:

a technical function since it restores the

vapour barrier and avoids the formation of

condensate in the foam;

an aesthetical function since it hides cut and

pressed parts from view.

To apply the aluminium tape in a straight way,

use the tape marker to mark along the edges

of the duct (art. 706).

Press by making use of a soft spatula (art. 705)

to avoid the formation of any air bubble which

might cause the tape to come off.

N.B.

The tape sha ll be a pplied on clea n surfaces.

N ever touch the adhesive side of the tape.

1

2

3


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20 2040 202040

2

3

1

Pieghe

Pieghe

2 - Straight duct

Transition

Bends

Bends


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1 4 3

2 3

Mouth 1

20

Mouth 2

8

8

7

5

6

7

Mouth 2Offset

Mouth 1 Offset

Offsets are ducts intended to connect two

ducts placed on different axes.

Carry out the operations described by the

figure:

To mark and cut lateral sides, follow the

procedure adopted for transitions. Assemble

and complete as usual.

3 - Straight duct

Offset


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1 2 3

150

X+150

150

50

X

600

HOW TO J OIN BRANCH PROFILES


Standard branches are ducts directly connected

to the main duct intended to deviate the air flow

without making use of two-way wye junctions.

To make assembly easy, their length shall never

exceed 600 mm. To avoid the formation of

turbulences as well as the danger of high flow

resistances, these branches shall have a partinclined at an angle of 45 and intended to let

the air in more easily. Its dimensions remain

constant (150 mm) even if the ducts dimensions

change.

For the construction, act as follows:

mark 3 sides (1 - 2 - 3) of the branch at the

same time;

cut the panel and leave sharp corners alongoffset;

make cuts on the cover by means of the

Double 22.5 jack-plane (art. 701/ B) so as

to bend the cover at an angle of 45.

art. 313 art. 304/ B art. 303 art. 206/ A

art. 701/ B

4 - Standard branch

Double 22.5 jack-plane

art. 206/ B

art. 204/ B


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Symmetric elbows have an entry section which is just the same

as the exit section.

To build elbows, use single-blade jack-planes (art. 702/ A -

702/ B - 702/ C), the compass (art. 707), the squares (art. 603/ A

- 603/ B) and the manual bending machine (art. 608).

From a building point of view, elbows are made of sides and

covers.

Cover

Side

5 - Symmetric

elbow

art. 702/ A

art. 702/ C

art. 707

art. 603/ A

art. 603/ B

art. 702/ B

N.B.

It is impor tant to build elbow s prope rly so a s to avoidthe formation of turbolences and high flow resistance.

art. 608


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5

20

4

2

1

1.2

00

3

h

6

hb

hb

h

20

Minimo 100 m

5 = Internal radius

6 = External radius

NOTE:

If possible, alw a ys use the overall w idth of

the pa nel for the construction of e lbow s.

Alwa ys leave a min. 10 0 mm neck betw een

the end of the rad ius a nd the entry / exit of

the elbow .

Internal Radius

h

600 mm

r

150 mm

250 mm300 mm

MARKING

Carry out the operations described by the figure:

Minimum

1 0 0 m m


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CUTTING

The single-blade jack-plane, free-hand used, shall always be pulled.

The two vertical lines on the front side of the jack-plane indicate the ends of the cut.

Art.702/A

Art.702/C

Art.702/Bart. 702/ A art. 702/ B

art. 702/ C

X

X

X

It is recommended to mark both the sides and the covers for a

perfect connection during assembly.


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THE BENDING OF COVERS

X

X

X

Side curvature

radius

300 mm

20 mm

35 mm

50 mm

35 mm

50 mm

70 mm

Distan ce betw een bend s

Int. cover Ex t. cover

External cover Internal cover

art. 608

GLUING AND ASSEMBLY

External cover assembly Internal cover assembly


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ELBOW FINISHING

After having assembled the elbow, finish the duct. Carry out the same operations described for

the straight duct.

NOTE:

The a luminium tap e sha ll be a pplied on clea n surfaces. N ever touch the adhesive side of the tape.

Pressing M a rk ing

Ta pe a pplica tion Silicone a pplica tion


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20

4

2

1

5

h1

1.2

00

3

7

6

h1

h

h1

h

b

h b

20

6 - Asymmetric

elbow

Internal Radius

h

600 mm

r

150 mm

250 mm300 mm

Asymmetric elbows have an entry section

which is different in size from the exit section.

MARKING

Carry out the operations described by the figure:

How to position the centre to mark the external

radius:

Calculate the width of the external radius

(Ir + h1) (6)

Start from the larger section (h) to mark the

external radius (7).

For the following operations see the previousparagraph: "SYMMETRIC ELBOW".


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Re

1 2

3

40

Ri

4040

1 2 5 4 3

12

13

14

15Min.

150m

m

1.2

00

6 8 9 7 10 11

16


After having spread the glue, assemble every single element in the following order. It is

important to cut the base of the damper at an angle of 45 so that the air goes in two different

directions. Put some aluminium tape to prevent the foam from coming into contact with the air.

1 - Transition cover/ damper

2 - External radius cover

3 - Internal radius cover

7 - Two-way

wye junctionTransition

Asymmetric

elbowTwo-way wye junctions convey the air in two

different directions of the plant.

It is recommended to mark the three sides of the

duct all together so as to make assembly easier.


figure:


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Min.

150mm

111 122

6

9 2 10

8

5

7

16

15

14

13

344040

1200

4

2

3

5

1

23

4

8 - Three-way

wye junction

Three-way wye junctions convey the air in

three different directions of the plant.


figure:

After having properly marked, cut

and prepare all lateral covers. It is

no use marking the upper cover of

the duct; just follow the internal

borders of the lower cover you have

already cut to copy it.

After gluing, assemble the duct in

the above mentioned order.

Complete as usual.

1 - Lower cover

2 - Transition cover/ damper

3 - External radius cover

4 - Internal radius cover

5 - Upper cover

Asymmetric elbows


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4

1

2

3

6

67

5


9 - Profiles

PROFILES APPLICATION

Apply the corners on the duct to make it stiffer

and stronger.

How to glue the profile

How to glue the part the profile

will be applied to

How to assemble the profile by exerting a

slight pressure through the special hammer

art. 205


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art. 303

art. 206/ A

1

2

3

4

5

6

6

7

PROFILES APPLICATION

Invisible flan ge

How to apply the corner plates

on the duct corners.

How to glue the profile

How to glue the part the profile

will be applied to

How the assemble the profile by exertinga slight pressure with the special hammer


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USE OF PROFILES

Flange / slide-in channel joint

This type of joint occurs by applying an

adhesive gasket on one of the two flanges for

its hermetic seal.

art. 301-302

art. 304

art. 204/ A


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art. 303

art. 204/ B

art. 304/ B

art. 206/ B

USE OF PROFILES

Invisible flange joint

This type of joint occurs by applying

an adhesive gasket on one of the two

flanges for its hermetic seal.


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USE OF PROFILES

"F Profile" joint - Fire Damper

art. 501

art. 307

art. 204/ A


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USE OF PROFILES

"F Profile" joint - Volume Control Damper

art. 501

art. 307

art. 204/ A


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USE OF PROFILES

"F Profile" joint - Rectang ular Silencer

art. 501

art. 307

art. 204/ A


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USE OF PROFILES

"F Profile" joint - A ir Ha ndling Unit

art. 501

art. 307

art. 204/ A


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USE OF PROFILES

"Cha ir Profile" joint - A ir Ha ndling Unit

art. 205

art. 308


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USE OF PROFILES

Profiles for Grilles

Two series of profiles may be used for

this type of application: "U Profile"

(art. 309) or "Profile for

Grille" (art. 310).

art. 205 art. 309

art. 309

art. 205 art. 310

art. 201


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art. 312

USE OF PROFILES

Profile for Filter


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When a duct is very large, it is built by joining panels through

"Double F Profile" (art. 306), instead of using 45 cut.

To extend the surface, panels are flat-joined by following an

analogous procedure. In this case the profile used is a "H Profile"

(art. 305).

N.B.

Before cutting profiles, ta ke thelength of the du ct minus 8 0 mm so

as to be able to apply profiles at

both ends.


1200

X

40

art. 306

art. 205art. 301

art. 305

USE OF PROFILES

Construction of a duct by making use of a "Double F Profile"

and a "H Profi le"

art. 306

art. 305


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USE OF PROFILES

Profile for Screen

NOTE:

It is recomm ended to use a 2 0 0 / 8 0 m icron panels

for the construction of gooseneck to be installedoutdoor.

Cut profiles at an angle of 45.

art. 311


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STIFFENING SYSTEM FOR DUCTS

Bars shall be cut 4 mm less than the internal

section of the duct.

10 - Accessories

art. 514

art. 508

art. 507

art. 506


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800

1200

800

1200

4000

800

2400

800

4000

1

1

1

1

1

2

2

2

2

2

2

1

1

1

1

1

1

1

2

2

2

2

2

2

1

1

1

2

2

2

2

2

2

2

2

2

2

1

1

2

2

2

2

2

2

2

2

2

2

2

2

1

1

1

1

2

2

2

2

2

2

2

2

2

2

2

2

1

1

1

1

2

2

2

2

2

2

2

2

2

2

2

2

1

1

1

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

1

1

1

2

2

2

2

2

2

2

2

2

2

2

2

1

1

1

1

1

2

2

2

2

2

2

1

1

1

2

2

2

2

2

2

2

2

2

2

2

2

2

PA

0-150

PA

310-450

PA

460-600

PA

610-750

PA

960-1000

PA

1010-1250

PA

1260-1500

PA

1760-2000

PA

760-950

PA

160-300

PA

1510-1750


DUCT

SIDEmm

PRESSURE

0 - 400

410 - 500

510 - 600

610 - 700

710 - 800

810 - 900

910 - 1000

1010 - 1100

1110 - 1200

1210 - 1300

1310 - 1400

1410 - 1500

1510 - 1600

1610 - 1700

1710 - 1800

1810 - 1900

1910 - 2000

Table for the calculation of stiffening

Lo ng Pi tch 8 0 0 - 2 4 0 0 - 8 0 0

Sh o r t Pi tch 8 0 0 - 1 2 0 0 - 1 2 0 0 - 8 0 0

M e th o d A:

Method B:

M e th o d A e x a m p le:Section Pressure

1000 x 1000 400 PA

Method B example:Section Pressure

1300 x 550 1000 PA


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art. 510

art. 509

L

Glue the turning vanes on the sides

Assemble the turning vanes

Mark the outline of the vane-plate on the

side of the elbowTURNING VANES

Legend for Turning vanes

L m m

Up to 300

300 500

500 1000

Over 1000

N o.of vanes

0

1

2

3

W IDTH O F ANY AIR FLOW AS A

FRACTION OF "L"

(from the inside to the outside)

L

1/ 3-2/ 3

1/ 6-1/ 3-1/ 2

1/ 12-1/ 6-1/ 4-1/ 2


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50mm

A

B

A

B

A+B+A+B+70mm 50 mm

B

B

A

A

A-5

mm

B-5

mm


FLEXIBLE DUCT CONNECTOR - QUICK CLUTCH SYSTEM

art. 505/ B

art. 505/ Cart. 505/ A

art. 309art. 205

1

2

34

5 6


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ROUND TUBE FOR DIFFUSER AND FLEXIBLE DUCT

art. 405

art. 504

art. 606

art. 406

art. 407


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PLATE FOR TEMPERATURE CHECK

PLATE FOR HUMIDISTAT

art. 511

art. 511


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INSPECTION DOOR

art. 308

art. 512

art. 309


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HANGER SYSTEMS

MAX 4000

MAX 4000

MAX 4000

Traditional, by means of threaded bars and channels

By means of self-adhesive duct support

By means of duct support

art. 504

art. 503


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ANCHORAGE SYSTEMS FOR OUTDOOR DUCTS

Anchorage

to steel beam

art. 503

Direct anchorage

to concrete basement

art. 503


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100 mm

100 mm

N O TE:

Clean and dry before apply ing the product

Do not dilute the product with water or other substances Cur ing time: about 48 hours


PROTECTING LINING FOR OUTDOOR DUCTS

art. 515


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HOW TO J OIN PANELS

If the pressure is not high or ducts are small or medium-sized you may join panel strips from

waste. Just make cuts at an angle of 45, glue the two parts and then apply the aluminium tape

on both ends of the panel.

Glue

Tape

1

2


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HOW TO JOIN PANELS


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