ACP Fabrication Guide

Our ACP Sheets feature weather-proof performance, superior flexibility and zero undulation. Using the right and expert-recommended Fabrication methods, fabricators can ensure the ACP Sheets be at their best.
The accompanying guide throws light on some of the significant Fabrication methods for ACP Sheets.

Saw CuttingGroovingFoldingRout and Return SystemBending with Press BrakeBending with Three Roll BenderRivet and BoltCNC Cutting

ACP Sheets can be cut effectively by panel saws or running saws. One should ensure that only carbide tip blade that has been designed particularly for Aluminium is used for ideal results.

Our ACP’s are compatible with CNC Routing Machine or Panel Saw for mass grooving production. For U-Grooving, leaving 0.2 to 0.4mm of the center material is important. Then again, for 90° bends, we suggest 110° of grooving angle only.

ACPs that have been transformed to grooved panels should be folded with a Folding Jig, Plate Punch or Press Brake. The grooved panels should only be folded up on a levelled table to secure straight line on folded corners.

ACPs can be easily installed by the Rout and Return method. ACPs must be folded to form a tray-type panel. A persistent 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 base thickness of 0.51mm of core material are seen to be left.

Then, the edges are folded subsequent to eliminating the corners to make 25mm deep “pan” or cassette. The panel units are stiffened by riveting the corners with aluminium angles.

The subsequent stage includes pre-punched aluminium cut angles being joined on the middle to the returned pan edges at roughly 305 mm. The clip angles help transfer the breeze 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 should be least 16mm wide to guarantee 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.

ACP sheets must be bent with a Press Brake that is matched with a top die for the ideal radius.

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

ACP must be grooved and cut at the bending edges prior to bending by a Three-roll Bender. The Three-roll Bender is ideal for larger bending radius.

While working with ACP’s, one should utilize aluminium blind rivets for junctions. In addition, stainless steel bolts and nuts should be utilized while fixing works must be progressed upon from the same direction.

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 : Composite Panel Thickness (mm)
ø : Hole Diameter (mm)

ACPs can be improved aesthetically by CNC cut designs. Use CNC cutters that are made particularly for aluminium.


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