ALP ROUND System User manual

Pre-insulated Circular Air Ducts
Fabrication Manual

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Fabrication Manual
Index
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•ALPROUNDSystem
- Technical Characteristics
• Straight ducts
•Elbows
- Making a 45° Elbows
• Reducers
- Making One-step Transition
• Joint systems
-Joint-flange
- Joint-neck
• Duct Support
- Specification of Use
- Straight ducts - Cut-to-length
-1-
p. 5
p. 6
p. 2
p. 2

Fabrication Manual
ALP ROUND SYSTEM - Aluminium Pre-insulated
Circular Air Ducts
IMPORTANT
Please refer to the last ALP ROUND Catalogue/Price List for a complete list of all available
pieces, accessories and materials.
Technical Characteristics
- Duct/Foam wall thickness: 25 mm
- Insulation foam density: 60 kg/m3
- External facing: aluminium foil 120 micron, embossed
- Internal facing: aluminium foil 120 micron, embossed
-Ductweight:
Diam. 200 mm 1,60 Kg/m
Diam. 300 mm 2,30 Kg/m
Diam. 400 mm 3,00 Kg/m
Diam. 500 mm 3,60 Kg/m
Diam. 600 mm 4,30 Kg/m
Specification of Use
- Operative Pressure: max 3.500 Pascal
- Sealing Class: Class B
- Air Velocity: max 30 m/sec
-2-

Straight Ducts
Straight ducts are supplied in two half-shells, to be assembled.
The procedure to assemble a Straight Duct is simple and fast.
Mark the “female” side of the half-shells, by using the tape-marker.
Mark it internally and externally.
These line-marks will guide you when applying the aluminium tape.
Apply the aluminium tape, following the line-marks.
Apply the aluminium tape internally ONLY and press it properly by
using the soft spatula.
Back-fold the aluminium tape, as shown in the picture.
Repeat the same operations as above also for the other half-shell.
Then, the two half-shells are ready for glueing
Apply the glue on both sides of the half-shells.
Wait the necessary time before assemblying the duct.
You can use ALPTAK glue or HYDRO-GLUE. Check the glue TDS to
know how long you have to wait.
Assemble the duct by joining the two half-shells.
Press the alu-tape internally, using the related tool,
and finish the duct applying the alu-tape externally.
Fabrication Manual
-3-

Straight Ducts - Cut-to-length
Fabrication Manual
Each section of straight duct is 4 m long. In case you need a shorter section of duct, we suggest to assemble
the complete 4 m duct and then to cut it to the right length.
Take a mesure from one end of the duct and mark the point.
Take a flexible strip, made of aluminium or carton-paper, and wrap the duct
around.
Position it at the right length, where you have marked before.
Following the rigid strip, mark the duct around using the marker in nylon.
Cut the duct following the line-mark.
Use the Round Cutter for an easy and
fast procedure.
-4-

Elbows
Fabrication Manual
Elbows are supplied in two half-shells, to be assembled.
The procedure to assemble an Elbow is simple and fast.
Mark one of the half-shells, by using the tape-
marker.
Mark it internally and externally.
These line-marks will guide you when applying
the aluminium tape.
Apply the glue on both sides of the half-shells.
Wait the necessary time before assemblying the duct.
You can use ALPTAK glue or HYDRO-GLUE. Check the glue TDS to
know how long you have to wait.
NOTE: Use the template to avoid spraying the glue inside the duct.
Assemble the duct by joining the two half-
shells.
Then apply the aluminium tape, internally and
externally, by following the line-marks.
Making a 45° Elbow
The Elbows have a reference mark in order to make easy and fast to cut them at 45°.
In order to make a 45° Elbow, it is necessary to assemble a 90° elbow first. Once the elbow has been
assembled, then you can proceed in cutting the Elbow into two 45° Elbows.
Cut the Elbow following the line-mark.
Use the Round Cutter for an easy and fast
procedure.
-5-

Reducers
Fabrication Manual
Reducers are supplied in two half-shells, to be assembled.
The procedure to assemble a Reducer is simple and fast.
Mark one of the half-shells, by using the tape-
marker.
Mark it internally and externally.
These line-marks will guide you when applying
the aluminium tape.
Apply the glue on both sides of the half-shells.
Wait the necessary time before assemblying the duct.
You can use ALPTAK glue or HYDRO-GLUE. Check the glue TDS to
know how long you have to wait.
NOTE: Use the template to avoid spraying the glue inside the duct.
Assemble the duct by joining the two half-
shells.
Then apply the aluminium tape, internally and
externally, by following the line-marks.
Making 1-step transition
A Reducer makes 2-step transition in the same piece:
- from 600 mm to 500 mm and then to 400 mm
- from 400 mm to 300 mm and then to 200 mm.
However, the Reducers have a reference mark in the middle to make easy and fast to cut them in half and
get 1-step transition.
In order to make 1-step transition, it is necessary to assemble completely the Reducer first. Once the
Reducer has been assembled, then you can proceed to cut it in the middle.
Cut the Reducer following the line-mark.
Use the Round Cutter for an easy and fast
procedure.
-6-

Joint Systems
Fabrication Manual
In ALP ROUND System n. 3 types of joints are available:
- 1 Joint-flange
- 2 Joint-neck – LONG
- 3 Joint-neck – SHORT
Joint-flange
The Joint-flange is made in ABS Plastic.
This Joint-flange is used to connect all ALP ROUND pieces.
The Joint-flange is available only for the following diameters:
- 200 mm - 300 mm - 400 mm
“Invisible” Joint-neck – LONG
The LONG Joint-neck is made in aluminium.
Thickness is 8/10 mm.
Length is 300 mm.
This Joint-neck is used to connect the Straight ducts.
“Invisible” Joint-neck – SHORT
The SHORT Joint-neck is made in aluminium.
Thickness is 8/10 mm.
Length is 90 mm.
This Joint-neck is used to connect Elbows, Reducers and
Shaped Pieces.
-7-

Joint-flange – How to Install
Fabrication Manual
Invisible Joint-neck (Long / Short) – How to Install
Apply PROFIX glue inside
the Joint-flange. Apply PROFIX glue also on the duct, within 2 cm from
the edge.
Install the Joint-flange on
the duct, without waiting
time.
Install the adehsive foam
gasket. Joint the ducts and fix them by using bolts & nuts.
Install the double-sided tape. Close the joint-neck Lift the wings. These wings
mark the middle of the neck.
Apply PROFIX glue on the
Joint-neck and insert the
neck inside the duct.
Apply PROFIX glue on the
other half of the Joint-neck
and join the two ducts.
Apply the aluminium tape,
just to cover the joint.
-8-

Supporting
Fabrication Manual
-9-
600
500
400
300
4 metres
Ring Type
FR - N° 2
6 mm
200
MaxGripple®WireDrop Rod - Diam.mm
SpacingHangersDuct Diameter
Example: Gripple®Wire