ACP Fabrication Guide

ACP Fabrication Guide

Aludecor ACPs feature weather-proof performance, superior flexibility and zero undulation. By applying the correct and expert-recommended Fabrication techniques, Fabricators can make sure that Aludecor ACP sheets be at their best!
The following guide sheds light on the correct Fabrication Methods for Aludecor ACPs.

Saw Cutting

Aludecor ACP sheets can be cut easily by panel saws or running saws. One must make sure that only carbide tip blade that has been designed especially for Aluminium is used for optimum results.

Grooving

Aludecor ACPs are compatible with CNC Routing Machine or Panel Saw for mass grooving production. For U-Grooving, leaving 0.2 to 0.4mm of the core material is necessary. On the other hand, for 90° bends, we recommend 110° of grooving angle only.

Folding

Aludecor ACPs that have been transformed to grooved panels must be folded with a Folding Jig, Plate Punch or Press Brake. The grooved panels should only be folded up on a flat table to secure straight line on folded corners.
Figures shown below shows common type of bending of ACP.

Rout and Return System

Aludecor ACPs can be easily installed by the Rout and Return method. The ACPs must be folded to form a tray-type panel. A continuous V-shaped routed groove is created along the entire panel perimeter at a distance of 25 mm from the panel edge. After routing, only a face skin and a minimum thickness of 0.51mm of core material are seen to be left.

Next, the edges are folded after removing the corners in order to create 25mm deep “pan” or cassette. The panel units are stiffened by riveting the corners with aluminium angles.

The next step involves pre-punched aluminium clip angles being attached on the centre to the returned pan edges at approximately 305 mm. The clip angles help transfer the wind load on the panel into the structural supports. To allow for sequential installation, clips are staggered from one panel to the next.


ACP Installation Rout and Return

Rout and Return joints must be minimum 16mm wide to ensure smooth thermal movement. Aluminium clip angles at fastener connection points must acquire slotted holes for natural thermal movement. The Rout and Return joints are, at last, caulk sealed for superior protection against moisture and air.
If required Pasting system method of installation can be used shown below.


Aludecor ACP Paste Installation

Bending with Press Brake

Aludecor ACP sheets must be bent with a Press Brake that is paired with a top die for the desired radius.

Pres Bending Process under Pressure

l min = d x 5
r min = t x 15
t: Aludecor Panel Thickness
Ideal Mould Width (n) = (2xt) + (Roll Radius) + (Foil Thickness) +15 mm

Bending with Three Roll Bender

Aludecor ACPs must be grooved and slit at the curving edges before bending by a Three-roll Bender. The Three-roll Bender is ideal for larger bending radius.

Rivet and Bolt:

When working with Aludecor ACPs, one must use aluminium blind rivets for junctions. Besides, stainless steel bolts and nuts must be used while fixing works must be progressed upon from the same direction.

Forces that the composite panel is exposed to at points of connection


The Rivet and possible Diameter Measures/Edge Distance Measures

Fmax=σ x s x ø
Fmax : Stress Force (N)
σ : Elastic Stress (N/mm²)
s : Aludecor Composite Panel Thickness (mm)
ø : Hole Diameter (mm)

CNC Cutting

Aludecor ACPs can be enhanced aesthetically by CNC cut designs. Use CNC cutters that are made especially for aluminium.

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