ALP Tubulatura Ventilatii

Manual for the
construction of
ALP System ducts
ISO 9002
UNI EN ISO 9002
CERT.N° 9091 ALP0
la conduzione dell'aria
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 JUNCTION 24
8 - THREE-WAY WYE JUNCTION 25
9 - PROFILES 26
10 - ACCESSORIES 40
Equipment
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
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
6 - CONSTRUCTION SYSTEM
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
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.
art. 701/A
art. 602/A
4 m duct
The sum total of 4 sides of the duct is equal or below 1040 mm.
20 40 40 40 20
1200
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.
FIRST CUT
Carry out the operations described by the figure.
h
b
Internal section b x h
Double 45° jack-plane Multiblock rule

20
20 50
70 Reference measurements for

the double-blade jack-plane
90
70
1
2
FOLLOWING CUTS
Internal section h
20
20 20 20 50
b 90
b + 90
40
40
h + 90
6
5
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.
1
ASSEMBLY
When the glue is dry, close the duct. Follow

the general rules given here below:
• when joining panels, always start from the 2
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.
3 4
Assembly is completed by pressing the corners 5

by means of a stiff spatula (art. 704).
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.
40
÷5
0 mm
N.B.
To make profile application easier, when
spreading silicone keep it at a distance of
about 40 / 50 mm from the end of the duct.
After having applied profiles, apply silicone
in the remaining parts.
40
÷5
0 mm
2 m long pneumatic pistol for silicone (art. 609)
TAPE APPLICATION
Taping shall perform two functions:

• a technical function since it restores the
vapour barrier and avoids the formation of
1
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 shall be applied on clean surfaces.
• Never touch the adhesive side of the tape.
OTHER METHODS FOR THE CONSTRUCTION OF A STRAIGHT DUCT
20 40 40 20
1200
20 40 20
1200
Every single side of the duct is equal or below 1160 mm.
20 20
1200
2 - Straight duct
Transition
20 40 40 20 20 20
Bends
Pieghe
3
Bends
Pieghe
3 - Straight duct
Offset
Offset Mouth 2
Offsets are ducts intended to connect two
ducts placed on different axes.
Carry out the operations described by the

figure:
Mouth 2 Mouth 1 Offset
1 4 3
7
5
8
7
6
8
2 3
20
Mouth 1
To mark and cut lateral sides, follow the

procedure adopted for transitions. Assemble
and complete as usual.
4 - Standard branch
HOW TO JOIN 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 art. 701/B
Double 22.5° jack-plane
turbulences as well as the danger of high flow
X
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 duct’s dimensions 1 2 3
600
change.
50 150
For the construction, act as follows:

150
• mark 3 sides (1 - 2 - 3) of the branch at the X+150
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. 206/B
art. 204/B
art. 313 art. 304/B art. 303 art. 206/A
5 - Symmetric
elbow
art. 702/A
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
art. 702/B
covers.
Cover
art. 702/C
art. 608
art. 707
art. 603/A
Side
art. 603/B
N.B.
• It is important to build elbows properly so as to avoid
the formation of turbolences and high flow resistance.
MARKING
h b
Carry out the operations described by the figure:

h b
1
20
2
h
4 Internal Radius
h r
1.200
< 300 mm 150 mm

310-600 mm 250 mm
> 600 mm 300 mm
3
20 h
Minimum
6 100 mm100 mm
Minimo
NOTE:
• If possible, always use the overall width of 5 = Internal radius
the panel for the construction of elbows. 6 = External radius
• Always leave a min. 100 mm neck between
the end of the radius and the entry / exit of
the elbow.
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/A art. 702/B
Art.702/B
art. 702/C
Art.702/C
It is recommended to mark both the sides and the covers for a

perfect connection during assembly.
X
X
X
THE BENDING OF COVERS
Side curvature Distance between bends

radius Int. cover Ext. cover
< 150 mm 20 mm 35 mm
150÷250 mm 35 mm 50 mm
> 300 mm 50 mm 70 mm
X
art. 608
External cover Internal cover
GLUING AND ASSEMBLY
External cover assembly Internal cover assembly
X
X
ELBOW FINISHING
After having assembled the elbow, finish the duct. Carry out the same operations described for
the straight duct.
Pressing Marking
Tape application Silicone application
NOTE:
• The aluminium tape shall be applied on clean surfaces.
• Never touch the adhesive side of the tape.
6 - Asymmetric
elbow
b
Asymmetric elbows have an entry section h 1
which is different in size from the exit section.
MARKING
Carry out the operations described by the figure:

h b
1
20
2
1
h
Internal Radius
4
h r
1.200
< 300 mm 150 mm

5
310-600 mm 250 mm
> 600 mm 300 mm
20 h 3
1
h
How to position the centre to mark the external 6

radius: 7
• 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". h
7 - Two-way
wye junction Transition
Asymmetric
Two-way wye junctions convey the air in two elbow
different directions of the plant.
It is recommended to mark the three sides of the
1.200
duct all together so as to make assembly easier.

figure:
Min. 150 mm
15 40 40
16
14
13
Re
Ri
12
1 2 5 4 3 6 8 9 7 10 11
40
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
3
1 2
8 - Three-way
wye junction
Three-way wye junctions convey the air in
1200
three different directions of the plant.

figure:
Min. 150 mm
9 2 10 Asymmetric elbows
6
8
5
14
16
13
7
15
4 11 2 12 3 1
40 40
After having properly marked, cut

5
and prepare all lateral covers. It is
no use marking the upper cover of
4 1 - Lower cover
the duct; just follow the internal
2 - Transition cover/damper
borders of the lower cover you have 3 3 - External radius cover
already cut to copy it. 4 - Internal radius cover
After gluing, assemble the duct in 5 - Upper cover
2
the above mentioned order.
Complete as usual.
1 4
2
3
9 - Profiles
PROFILES APPLICATION
art. 205
Apply the corners on the duct to make it stiffer
and stronger.
1 3
How to glue the profile
6
7
6
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
PROFILES APPLICATION
Invisible flange
art. 206/A
How to apply the corner plates 2

on the duct corners.
1 3
art. 303
How to glue the profile
7
6
6 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
USE OF PROFILES
art. 301-302
art. 204/A
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. 304
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.
art. 303
art. 204/B
art. 304/B
art. 206/B
USE OF PROFILES
"F Profile" joint - Fire Damper
art. 501
art. 307
art. 204/A
USE OF PROFILES
"F Profile" joint - Volume Control Damper
art. 501
art. 307
art. 204/A
USE OF PROFILES
"F Profile" joint - Rectangular Silencer
art. 501
art. 307
art. 204/A
USE OF PROFILES
"F Profile" joint - Electric battery
art. 501
art. 307
Galvanised
MIN: 600
iron
Galvanised
MIN: 600
iron
USE OF PROFILES
"F Profile" joint - Air Handling Unit
art. 501
art. 307
art. 204/A
USE OF PROFILES
"Chair Profile" joint - Air Handling Unit
art. 308
art. 205
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. 309
art. 205 art. 309

art. 201
art. 205 art. 310
USE OF PROFILES
Profile for Filter
art. 312
USE OF PROFILES
Construction of a duct by making use of a "Double F Profile"

and a "H Profile"
When a duct is very large, it is built by joining panels through

"Double F Profile" (art. 306), instead of using 45° cut.
art. 306
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).
art. 305
N.B.
• Before cutting profiles, take the
length of the duct minus 80 mm so art. 306 art. 305
as to be able to apply profiles at
both ends.
art. 301 art. 205
12
00
X
40
USE OF PROFILES
Profile for Screen
Cut profiles at an angle of 45°.
art. 311
NOTE:
• It is recommended to use a 200/80 micron panels
for the construction of gooseneck to be installed
outdoor.
10 - Accessories
STIFFENING SYSTEM FOR DUCTS
art. 507
Bars shall be cut 4 mm less than the internal
section of the duct.
art. 506
art. 508
art. 514
Table for the calculation of stiffening
PRESSURE
PA PA PA PA PA PA PA PA PA PA PA
DUCT
SIDE 0-150 160-300 310-450 460-600 610-750 760-950 960-1000 1010-1250 1260-1500 1510-1750 1760-2000
mm
0 - 400
410 - 500 1 1 1 1 2
510 - 600 1 1 1 1 1 2
610 - 700 1 1 1 1 1 1 2
710 - 800 1 1 1 1 1 1 2 2 2
810 - 900 1 1 2 2 2 2 2 2 2
910 - 1000 1 1 1 1 2 2 2 2 2 2 2
1010 - 1100 1 1 1 2 2 2 2 2 2 2 2
1110 - 1200 1 1 1 2 2 2 2 2 2 2 2
1210 - 1300 1 1 1 2 2 2 2 2 2 2 2
1310 - 1400 1 1 1 2 2 2 2 2 2 2 2
1410 - 1500 2 2 2 2 2 2 2 2 2 2 2
1510 - 1600 2 2 2 2 2 2 2 2 2 2 2
1610 - 1700 2 2 2 2 2 2 2 2 2 2 2
1710 - 1800 2 2 2 2 2 2 2 2 2 2 2
1810 - 1900 2 2 2 2 2 2 2 2 2 2 2
1910 - 2000 2 2 2 2 2 2 2 2 2 2 2
Method A: Long Pitch 800 - 2400 - 800

Method B: Short Pitch 800 - 1200 - 1200 - 800
0
80
00
40 00
24
0
80
0
80 00
12
00
40
00
12
0
80
Method A example: Method B example:

Section Pressure Section Pressure
1000 x 1000 400 PA 1300 x 550 1000 PA
TURNING VANES Mark the outline of the vane-plate on the
side of the elbow
art. 510
art. 509
Glue the turning vanes on the sides
Assemble the turning vanes
Legend for Turning vanes
No. WIDTH OF ANY AIR FLOW AS A

L mm FRACTION OF "L"
of vanes (from the inside to the outside)
Up to 300 0 L
300 ÷ 500 1 1/3-2/3
500 ÷ 1000 2 1/6-1/3-1/2
Over 1000 3 1/12-1/6-1/4-1/2
FLEXIBLE DUCT CONNECTOR - QUICK CLUTCH SYSTEM
A
B
2
5 mm
A-
B
A
art. 505/B
m
1 5m
B-
art. 505/C
art. 505/A
A
50 mm
B B
3
4
A+
B+
A+
B+
70
mm
50 mm
5 6
art. 205 art. 309
ROUND TUBE FOR DIFFUSER AND FLEXIBLE DUCT
art. 606
art. 504
art. 406
art. 407
art. 405
PLATE FOR TEMPERATURE CHECK
art. 511
PLATE FOR HUMIDISTAT
art. 511
INSPECTION DOOR
art. 309
art. 512
art. 308
HANGER SYSTEMS
Traditional, by means of threaded bars and channels
MAX 4000
By means of self-adhesive duct support
art. 504
MAX 4000
By means of duct support
MAX 4000
art. 503
MISCELLANEOUS HANGER SYSTEMS
To ceiling by means of PVC plates
- MAX duct section: 600x500 -
200
MAX. 4000
art. 507
art. 514
To wall via steel hanger

To wall by means of duct support
art. 503
ANCHORAGE SYSTEMS FOR OUTDOOR DUCTS
art. 503
Anchorage
to steel beam
art. 503
Direct anchorage
to concrete basement
PROTECTING LINING FOR OUTDOOR DUCTS
100 mm
100 mm
art. 515
NOTE:
• Clean and dry before applying the product
• Do not dilute the product with water or other substances
• Curing time: about 48 hours
HOW TO JOIN 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
2
HOW TO JOIN PANELS
ED. 02/2000
la conduzione dell'aria
Via Vezze 62/68 - 24050 CALCINATE (BERGAMO) ITALY - Tel. ++39 035 4423600 - Fax ++39 035 4423601
e-mail: alp@alp.it - internet: http://www.alp.it
Copyright: this catalogue forms part of ALP’s technological property. Any imitation, in whole or in part, of the method of instruction adopted will be prosecuted by law.

ALP Tubulatura Ventilatii

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Manual for the

Technical - Commercial Department

THE CONSTRUCTION OF DUCTS 7

2 - STRAIGHT DUCT - TRANSITION 15

3 - STRAIGHT DUCT - OFFSET 16

7 - TWO-WAY WYE JUNCTION 24

8 - THREE-WAY WYE JUNCTION 25

Consumption materials and accessories

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

Carry out the operations described by the figure.

Double 45° jack-plane Multiblock rule

70 Reference measurements for

Before spreading the glue, eliminate any dust

When the glue is dry, close the duct. Follow

Assembly is completed by pressing the corners 5

A thin coat of silicone shall be applied in all

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

Taping shall perform two functions:

To apply the aluminium tape in a straight way,

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

Every single side of the duct is equal or below 1160 mm.

Carry out the operations described by the

Mouth 2 Mouth 1 Offset

To mark and cut lateral sides, follow the

Standard branches are ducts directly connected

To make assembly easy, their length shall never

For the construction, act as follows:

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

Carry out the operations described by the figure:

< 300 mm 150 mm

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

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

Side curvature Distance between bends

External cover Internal cover

GLUING AND ASSEMBLY

External cover assembly Internal cover assembly

Tape application Silicone application

which is different in size from the exit section.

Carry out the operations described by the figure:

< 300 mm 150 mm

How to position the centre to mark the external 6

Carry out the operations described by the

Carry out the operations described by the

After having properly marked, cut

How to glue the profile

How to glue the part the profile

How to assemble the profile by exerting a

How to apply the corner plates 2

How to glue the profile

How the assemble the profile by exerting

Flange / slide-in channel joint

Invisible flange joint

"F Profile" joint - Fire Damper

"F Profile" joint - Volume Control Damper

"F Profile" joint - Rectangular Silencer

"F Profile" joint - Electric battery

"F Profile" joint - Air Handling Unit

"Chair Profile" joint - Air Handling Unit

Profiles for Grilles

Two series of profiles may be used for

art. 205 art. 309

art. 205 art. 310

Profile for Filter

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