ACP Fabrication - Viva Knowledge Center (VKC)

Viva’s ACPs are engineered and manufactured for easy fabrication and installation. Our products are highly tensile and flexible.
Information provided in this section is for preliminary reference.
Please consult with an expert or contact us for specific advice.

Methodology

ACP Cladding Methodology - VIVA

Edge Bending

Bending

Methods for Processing

Routing And Folding (Tray Formation)

One of the primary features of Aluminium Composite Panels is that they can be routed through conventional routing machines to internationally designed vertical panels saws -including hand panel routers with various kinds of routing blades. During routing, the floor/base should be flat & free from foreign particles (use vacuum cleaner) to avoid denting or bending of sheets. In normal conditions, during routing, the routed sheet plastic thickness should not be more than the ½ of one side aluminium skin thickness. The thickness of remaining PE/FR core should be uniform throughout the sheet to attain smooth finish folding or bending. The blade or tip of routing machine should be appropriate & in good condition for smooth grooving. The distance of groove from edge is min 25 mm. After routing cut the corner of sheet with sharp blade or wood chisel wider than corner to find very smooth corner joints. Fold the sheets gently with equal pressure to avoid deflection of panel, hump generation & achieving the smooth panel finish. It is suggested to route the sheet from bottom side only to avoid long term properties problem on coated surfaces. Generally reverse bending of routed area is not allowed.

Equipments used for Routing & Folding

For processing a small number of panels a manual router with a v-groove blade can be used. For processing large number a table circular saw or CNC router is needed.

1. Manual Router with “v” groove circular blade
The manual router consist of circular grooving blades that are commonly available on the market and are used for manual processing. If they are equipped with special routing bits (carbide tipped cutter) the hand operated router can be used for a limited number of processes. In this case the stability of the tool and the guide-system considerably affect the quality of the routing, the setting of the manual router is very important, it is highly dependent on operator skills. The router rpm should be 2400 to 5000.

 

 

 

 

 

 

2. Vertical Grooving Manual
These type routers are consist of a moving arm with a circular blade/bit. Fix the sheet on vertical supported plate, set the grooving depth by setting the wheel. The plate should be flat and free from dents to find uniform routing.

 

 

3. Automatic CNC Router (Horizontal Grooving)

This machine consists of a computer along with programming and automatic robotic arm. Set the depth & design of routing, and then select appropriate bit for routing angle.

After setting above process, fix the sheet on table with clamp & execute run command.

Routed Groove V Form

Cutting / Sawing

Sawing or cutting of ACP is an easy process that can be done with ordinary commercial metal equipment. Saw blades and router bits are available at independent distributors who handle cutting tools. Before processing large quantities, trial saw cuttings should be done to evaluate both the tool working conditions and the recommended cutting speeds 3000 to 5000 rpm. For marking the panels the use of a soft pencils us adequate. High-speed band and circular saws with cutting speeds of up 30 m/min are recommended. Depending on the panel thickness, saw blades with a 5 to 10 mm tooth pitch should be used. For circular saws, a tooth geometry with alternating flat/trapeze teeth and carbide tips is normally recommended to ensure that edges are free of burrs. Adjust the saw blade diameter (O) and number of teeth for the material to be processed as well as the type of saw and its speed. To ensure clean cutting edges without any chips, the panel material should always be clamped to ensure that it is vibration-free.

This particularly applies for thin panel thicknesses of 2 to 4 mm, both for individual panels and composites. When using jig saws, make sure the saw blades are sharp and are not straight-set (plastic, PVC). Manual feeding must be carried out slowly and evenly.

Router/Cutter Speed – 3000 to 5000 rpm

Single sheet feed speed-25 to 30 m/Minute

3-4 sheets (stacked) feed speed- 15-20 m/Minute

Punching

Viva ACP panel of any thickness can be punched easily using sheet metal punching machines. For burr free cuts use sharp tools & dies with minimum cutting clearance of 0.10 mm. For punching & shearing strength please refer to our grade wise technical data sheets. The distance from one hole to another hole will be 5 mm & minimum diameter of punch should be 5mm also.

During punching sheet may be deflected, so re-straitening may require. Do not remove the protective film before completion of process.

Perforated sheet (Multiple Punched)

Single Punch

Shearing

Viva ACP is highly suitable for cutting with shear without any chipping. The gap between upper & lower shear will be 0.1mm & angle 1° to 5°.

Drilling

Viva Aluminium Composite Panels can easily be bent and shaped by three roll press machine & press brake machine :

A. Three Roll System Press Machine:

This technique is very effective for bending of sheet, the rollers should be neat & clean to avoid dent & scratches on sheets.

Minimum Bending radius (r) =15*T  (T stands for thickness of Panel.)

B. Press Brake Method

When bending or forming with a press brake, use a top die with the radius desired for bending and open the bottom die (jaws) approximately two times the thickness of the material plus film wider than the top die. The lower die should always have a protective pad which should not less than 2mm. Some adjustment of the lower jaws is necessary to allow for varying bending properties. The radius of the top die will be the approximate inside radius of the finished panel.

Bending

Viva ACP material can be easily drilled with twist drills commonly used for metals & plastics.

The twist drill will be high speed steel with tip angle 100° to 140°.

Counter Sinking

A hole is to cut a conical hole into a Sheet/metal object. This process is normally used to create space for the head of a screw or bolt to sit flush with the surface of the material or to clean away burrs left from drilling and tapping. Counter sinking screw are allowed only for interior use.

Riveting

Viva ACPs can be fastened together or joined with other materials with rivets common to aluminium constructions. For exteriors use & high humidity areas it is suggested to use aluminium blind rivets with SS (Stainless Steel) screw which prevents corrosion on edges.

  1. The shaft diameter of blind rivet should be 5 to 6 mm and head diameter is 10 to 15 mm.
  2. B. Please take the thermal expansion of panel into account e 2.4mm/m/100 C to avoid deflection of panel the hole in the panel should be large enough to allow the expected according to sheet length.
  3. C. The Rivet head should cover minimum 1.5mm surrounding area.

Screwing

Commercially available, Façade grade approved stainless steel screws should be used for fastening. The screws should be tightened with screw drivers or wrench. The screw should consist of sealing washer. The tightening of screw should be done without exerting any pressure to the panel. If the screws are too tight it may result slight deflection on sheet and the panel have no longer possibility for thermal expansion.

Pasting

Where sheets are installed with pasting method and thermal expansion is expected, we recommend to use flexible & weather resistance glue only. The flexibility of glue should be approximate 300-350%. The glue thickness will generally be a minimum of 3mm and will be in conical shape. The glue will be applied with glue guns. If spacer is required then the glue height will be 2 times of spacer height. The double headed tape can also be of same thickness. Please also follow the instruction of glue or tape supplier. The surface should be free from foreign particle, contamination of chemicals & water.

Tray Installation

Viva ACP can be easily used by making tray; following instruction should be taken for installation.
1. Panels should be fabricated into tray with aluminium frame.
2. All joints should be protected with approved sealant.
3. Finished tray should be delivered to the site complete with components marking for easy identification and assembly.
4 Fasteners including screws, nuts, bolts, and other items are required for joining of panel should be non-magnetic stainless steel.
5. Rivets used for fastening the frames should be of aluminium, large flange head type with stainless steel mandrel.
6. All other fixing materials should be of aluminium or stainless steel.
7. Defective panels having warped, bowed, dents n scratch and broken must not be installed.
8. Supporting brackets should be designed to provide three-dimensional adjustments and accurate location of wall component.
9. All joints should be of specified widths. No two adjacent or perpendicular joints should have difference in width of more than 2.5 mm. Tolerance between adjacent panels across any joints should not exceed 1.5 mm locally.

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Skyway 601, 6th Floor, A – Wing
Marol Naka, Andheri – Kurla Rd, Andheri East,
Mumbai, Maharastra – 400059

1800-313-3770 (Toll Free)
info@viva.co.in

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Rishi Bhandari
Rishi Bhandari
02:59 13 Feb 20
The strength of team is defined by the individual team members. And VIVA is the place where every team member enjoy... the profession.Learning... Developing and converting into reality is our key to success."We lead.... Never follow "read more
Prashant Kumar
Prashant Kumar
16:09 12 Feb 20
Now days VIVA just not an ACP company it is a Brand.Quality and operation policy of the company is much stronger. And... always try to give zero defect material to market.Working environment is very healthy and friendly. Management of the company is very supportive.This is the right place where you can implement your skill and knowledge. And learn lots of new things and technologies.read more
harsh mehta
harsh mehta
15:09 12 Feb 20
Have been working for 3 years it's been an awesome time .feels good and home like working environment with supportive... management and staff .Direct personal relationship with company directors and quick response for any query and problems and with best approach towards future we are biggest ACP manufacturer in the industry.VIVA provides full after sales support and satisfaction to customer and it's employees.It's great to be a part of something great.read more
azher khatib
azher khatib
13:52 12 Feb 20
Quality Product !!!
Sudarshan Yadav
Sudarshan Yadav
13:33 12 Feb 20
Viva is one of the largest manufacture of ACP sheet in India. The company have huge range of Exterior and Interior wall... cladding product, like ACP, HPL, Metal series, Natural Stone series, Galaxy series and many more innovative products. This is the first company in India to manufature A2+ FR Grade ACP. The company can provide customoze colour and sizes also. Very soon company will provide 6feet sheets in wirth. Service of the company is excellent.read more
Faizer Ali Dastagir
Faizer Ali Dastagir
13:32 12 Feb 20
Viva Composite is the largest Manufacturer of Aluminium composite Panel in India having state of art plant... manufacturing wide range of shades and textures available in FR and Non FR Grades.Viva also offers exciting work environment for its employees.read more
Mayank Jain
Mayank Jain
07:56 02 May 18
Professional quality service and superb products for interiors as well as exteriors.. Very well versed technicians and... staff..read more
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