ACP Sheets offer robust performance and unparalleled brilliance when it comes to exterior and interior cladding. Fabrication plays a significant role in determining the longevity of ACPs in any exterior or interior installation.
AluWall ACP sheets are uber flexible and aesthetically superior. The following Expert recommended Fabrication techniques are sure to ensure that AluWall ACPs perform the best, always.
Saw Cutting
AluWall 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
AluWall ACP sheets 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
AluWall ACP sheets 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.
Rout and Return System
AluWall ACP sheets 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.
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.
Bending with Press Brake
AluWall ACP sheets must be bent with a Press Brake that is paired with a top die for the desired radius.
Bending with Three Roll Bender
AluWall ACP sheets 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 AluWall ACP sheets, 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.
CNC Cutting
AluWall ACP sheets can be enhanced aesthetically by CNC cut designs. Use CNC cutters that are made especially for aluminium.
