Manual for the

construction of
ALP System ducts
la co n d u zio n e d ell'aria

UNI EN ISO 9002

CERT.N 9091 ALP0
ISO 9002
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
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 J UNCTION 24
8 - THREE-WAY WYE J UNCTION 25
9 - PROFILES 26
10 - ACCESSORIES 40
CONSTRUCTION SYSTEM - 5
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 ma teria ls a nd a ccessories
- 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
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
assembly
silicone application
aluminium tape application
profiles application
CONSTRUCTION SYSTEM - 7
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.
8 - CONSTRUCTION SYSTEM
40 20 40 40 20
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.
CONSTRUCTION SYSTEM - 9
h
1
2
3
70
20 50
70
2
0
90
b
Double 45 jack-plane
Reference measurements for
the double-blade jack-plane
Internal section b x h
Multiblock rule
FIRST CUT
Carry out the operations described by the figure.
10 - CONSTRUCTION SYSTEM
b
h
b
40
40
h + 90
5
6
4
20
b 90
b + 90
20 20 50
2
0
FOLLOWING CUTS
Internal section h
CONSTRUCTION SYSTEM - 11
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 the
same 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
4 3
5
12 - CONSTRUCTION SYSTEM
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 ma ke profile a pplica tion ea sier, when
sprea ding silicone keep it a t a dista nce of
a bout 4 0 / 5 0 mm from the end of the duct.
After ha ving a pplied profiles, a pply silicone
in the rema ining pa r ts.
4
0

5
0
m
m
4
0

5
0
m
m
2 m long pneumatic pistol for silicone (art. 609)
CONSTRUCTION SYSTEM - 13
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 ta pe sha ll be a pplied on clea n surfa ces.
N ever touch the a dhesive side of the ta pe.
1
2
3
OTHER METHODS FOR THE CONSTRUCTION OF A STRAIGHT DUCT
14 - CONSTRUCTION SYSTEM
40 20 40 20
1200
1200
20 20 40
1200
20 20
The sum total of 3 sides of the duct is equal or below 1080 mm.
The sum total of 2 sides of the duct is equal or below 1120 mm.
Every single side of the duct is equal or below 1160 mm.
CONSTRUCTION SYSTEM - 15
20 20 40 20 20 40
2
3
1
Pieghe
Pieghe
2 - Straight duct
Transition
Bends
Bends
16 - CONSTRUCTION SYSTEM
1 4 3
2 3
Mouth 1
20
Mouth 2
8
8
7
5
6
7
Mouth 2 Offset
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
1 2
3
150
X+150
1
5
0

5
0
X
6
0
0
HOW TO J OIN BRANCH PROFILES
CONSTRUCTION SYSTEM - 17
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 part
inclined 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 along
offset;
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
18 - CONSTRUCTION SYSTEM
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 ta nt to build elbows properly so a s to a void
the forma tion of turbolences a nd high flow resista nce.
art. 608
CONSTRUCTION SYSTEM - 19
5
20
4
2
1
1
.
2
0
0
3
h
6
h
b
h
b
h
2
0
Minimo 100 mm
5 =Internal radius
6 =External radius
N OTE:
If possible, a lwa ys use the overa ll width of
the pa nel for the construction of elbows.
Always leave a min. 1 0 0 mm neck between
the end of the radius and the entr y / exit of
the elbow.
Interna l Ra dius
h
<300 mm
310-600 mm
>600 mm
r
150 mm
250 mm
300 mm
MARKING
Carry out the operations described by the figure:
Minimum
1 0 0 mm
20 - CONSTRUCTION SYSTEM
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/B art. 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.
CONSTRUCTION SYSTEM - 21
THE BENDING OF COVERS
X
X
X
Side cur va ture
ra dius
<150 mm
150250 mm
>300 mm
20 mm
35 mm
50 mm
35 mm
50 mm
70 mm
Dista nce between bends
Int. cover Ext. cover
External cover Internal cover
art. 608
GLUING AND ASSEMBLY
External cover assembly Internal cover assembly
22 - CONSTRUCTION SYSTEM
ELBOW FINISHING
After having assembled the elbow, finish the duct. Carry out the same operations described for
the straight duct.
N OTE:
The a luminium ta pe sha ll be a pplied on clea n surfa ces.
N ever touch the a dhesive side of the ta pe.
Pressing Ma rking
Ta pe a pplica tion Silicone a pplica tion
CONSTRUCTION SYSTEM - 23
20
4
2
1
5
h
1
1
.
2
0
0
3
7
6
h
1
h
h
1
h
b
h
b
2
0
6 - Asymmetric
elbow
Interna l Ra dius
h
<300 mm
310-600 mm
>600 mm
r
150 mm
250 mm
300 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 previous
paragraph: "SYMMETRIC ELBOW".
Re
1 2
3
40
Ri
40 40
1 2 5 4 3
12
13
14
15
M
i
n
.

1
5
0

m
m
1
.
2
0
0
6 8 9 7 10 11
16
24 - CONSTRUCTION SYSTEM
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 junction
Transition
Asymmetric
elbow Two-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.
Carry out the operations described by the
figure:
CONSTRUCTION SYSTEM - 25
M
i
n
.

1
5
0

m
m
1 11 12 2
6
9 2 10
8
5
7
16
15
14
13
3 4
40 40
1
2
0
0
4
2
3
5
1
2
3
4
8 - Three-way
wye junction
Three-way wye junctions convey the air in
three different directions of the plant.
Carry out the operations described by the
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
4
1
2
3
6
6
7
5
26 - CONSTRUCTION SYSTEM
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
CONSTRUCTION SYSTEM - 27
art. 303
art. 206/ A
1
2
3
4
5
6
6
7
PROFILES APPLICATION
Invisible fla nge
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 exerting
a slight pressure with the special hammer
28 - CONSTRUCTION SYSTEM
USE OF PROFILES
Fla nge / slide-in cha nnel 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
CONSTRUCTION SYSTEM - 29
art. 303
art. 204/ B
art. 304/ B
art. 206/ B
USE OF PROFILES
Invisible fla nge joint
This type of joint occurs by applying
an adhesive gasket on one of the two
flanges for its hermetic seal.
30 - CONSTRUCTION SYSTEM
USE OF PROFILES
" F Profile" joint - Fire Da mper
art. 501
art. 307
art. 204/ A
CONSTRUCTION SYSTEM - 31
USE OF PROFILES
" F Profile" joint - Volume Control Da mper
art. 501
art. 307
art. 204/ A
32 - CONSTRUCTION SYSTEM
USE OF PROFILES
" F Profile" joint - Recta ngula r Silencer
art. 501
art. 307
art. 204/ A
M
I
N
:

6
0
0
M
I
N
:

6
0
0
USE OF PROFILES
" F Profile" joint - Electric ba tter y
CONSTRUCTION SYSTEM - 33
art. 501
art. 307
Galvanised
iron
Galvanised
iron
34 - CONSTRUCTION SYSTEM
USE OF PROFILES
" F Profile" joint - Air Ha ndling Unit
art. 501
art. 307
art. 204/ A
35 - CONSTRUCTION SYSTEM
USE OF PROFILES
" Cha ir Profile" joint - Air Ha ndling Unit
art. 205
art. 308
36 - CONSTRUCTION SYSTEM
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
CONSTRUCTION SYSTEM - 37
art. 312
USE OF PROFILES
Profile for Filter
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 the
length of the duct minus 8 0 mm so
a s to be a ble to a pply profiles a t
both ends.
38 - CONSTRUCTION SYSTEM
1
2
0
0
X
4
0
art. 306
art. 205 art. 301
art. 305
USE OF PROFILES
Construction of a duct by ma king use of a " Double F Profile"
a nd a " H Profile"
art. 306
art. 305
CONSTRUCTION SYSTEM - 39
USE OF PROFILES
Profile for Screen
N OTE:
It is recommended to use a 2 0 0 / 8 0 micron panels
for the construction of gooseneck to be insta lled
outdoor.
Cut profiles at an angle of 45.
art. 311
40 - CONSTRUCTION SYSTEM
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
8
0
0
1
2
0
0
8
0
0
1
2
0
0
4
0
0
0
8
0
0
2
4
0
0
8
0
0
4
0
0
0
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
CONSTRUCTION SYSTEM - 41
DUCT
SIDE
mm
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
Ta ble for the ca lcula tion of stiffening
Long Pitch 8 0 0 - 2 4 0 0 - 8 0 0
Shor t Pitch 8 0 0 - 1 2 0 0 - 1 2 0 0 - 8 0 0
M ethod A:
M ethod B:
M ethod A ex a mple:
Section Pressure
1000 x 1000 400 PA
M ethod B ex a mple:
Section Pressure
1300 x 550 1000 PA
42 - CONSTRUCTION SYSTEM
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 elbow
TURNING VANES
Legend for Turning va nes
L mm
Up to 300
300 500
500 1000
Over 1000
N o.
of va nes
0
1
2
3
W IDTH OF AN Y 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
5
0

m
m
A
B
A
B
A
+
B
+
A
+
B
+
7
0
m
m 50 mm
B
B
A
A
A
-
5
m
m
B
-
5
m
m
CONSTRUCTION SYSTEM - 43
FLEXIBLE DUCT CONNECTOR - QUICK CLUTCH SYSTEM
art. 505/ B
art. 505/ C
art. 505/ A
art. 309
art. 205
1
2
3
4
5 6
44 - CONSTRUCTION SYSTEM
ROUND TUBE FOR DIFFUSER AND FLEXIBLE DUCT
art. 405
art. 504
art. 606
art. 406
art. 407
CONSTRUCTION SYSTEM - 45
PLATE FOR TEMPERATURE CHECK
PLATE FOR HUMIDISTAT
art. 511
art. 511
46 - CONSTRUCTION SYSTEM
INSPECTION DOOR
art. 308
art. 512
art. 309
CONSTRUCTION SYSTEM - 47
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
200
MAX. 4000
MISCELLANEOUS HANGER SYSTEMS
48 - CONSTRUCTION SYSTEM
art. 507
To ceiling by means of PVC plates
- MAX duct section: 600x500 -
To wall by means of duct support
art. 514
To wall via steel hanger
art. 503
CONSTRUCTION SYSTEM - 49
ANCHORAGE SYSTEMS FOR OUTDOOR DUCTS
Anchorage
to steel beam
art. 503
Direct anchorage
to concrete basement
art. 503
100 mm
100 mm
N OTE:
Clea n a nd dr y before a pplying the product
Do not dilute the product with water or other substances
Curing time: a bout 4 8 hours
50 - CONSTRUCTION SYSTEM
PROTECTING LINING FOR OUTDOOR DUCTS
art. 515
CONSTRUCTION SYSTEM - 51
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
52 - CONSTRUCTION SYSTEM
HOW TO J OIN PANELS
la co n d u zio n e d ell'aria

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Copyright: thiscatalogueformspart of ALPstechnological property. Anyimitation, inwholeor inpart, of themethodof instructionadoptedwill beprosecutedbylaw.