SUPPLY-AIR-CEILING

SUPPLY-AIR-CEILING
FOR OPERATING THEATRES

Series
AL-KO Supply-Air-Ceilings
System description
State-of-the-art solutions
I low germ number in the operating
area and in the supply air flow
I low germ sedimentation
I low air speeds in the working area
I low harmful gas concentration also
in the anaesthetics work area
I good screening of the operating area
in case of disturbances by opening
doors
I minimum requirements according
to DIN 1946/4 are exceeded by far
I examination according to DIN 4799
by the Hermann Rietschel Institute
of the TU Berlin
I contamination-proof sealing of the
operating theatre light fi xture
I low disinfection and maintenance
expenditure

Results of the inquiry concerning the degree of contamination

of a Supply-Air-Ceiling-System with Size 1.8 m x 2.4 m:

Degree of contamination (s) / Air velocity (m/s)

0.4 s
0.3 s
0.2 s
0.1 s
0.0 s
0.15 m/s

0.20 m/s

0.25 m/s

0.30 m/s

Degree of contamination
Degree of contamination (exponential)

Prof. Dr.-Ing. K. Fitzner University of Technology Berlin

H. Rietschel Institute of heating engineering and air-conditioning technology

Series
AL-KO Supply-Air-Ceilings
General explanation for series AL-KO Supply-Air-Ceilings

The AL-KO Supply-Air-Ceiling for operation theatres Type AL is a supply air

system with constant laminar flow for
all types of operating theatre. It is
characterised by particularly low germ
numbers in the operation field and low
harmful gas concentrations in the
working area of the operation team
with a high thermal comfort. The AL-KO
Supply-Air-Ceiling fulfils requirements
necessary for cleanroom technology.

The low, predominantly laminar air

velocity at the patients location must
be emphasised from the medical point
of view. The cooling down of the patient
is less than with turbulent flow systems.
The ceiling system is disinfectantresistant and consists of a large output field,
equipped with patented laminarisators.
These consist of aluminium frames
covered with flow-optimised special
profiles with minimised frame width,
covered with a tear-proof, monofilament
polyester tissue.

frames with clamping device, test

groove for the seal fi t examination and
measuring connecting pieces are well
accessible, easy to assemble and
exchange without special tools. The
maintenance work can be accomplished
within the AL-KO Supply-Air-Ceiling
without intervention into the room
ceiling. Easy connection to the duct
system by duct flanges.

Manually adjustable or dampers with

actuators are available as an option.
Supply air box and ceiling housing are
made of galvanised steel with disinfectThe laminarising effect practically
excludes a secondary air contamination. antresistant coating or of stainless
The support leadthrough is aerodynami- steel, material No. 1.4301. The AL-KO
cally designed, so that no wake areas or Supply-Air-Ceiling, type AL, also fulfils
the requirement of low germ numbers in
flow deflections occur. Installation
the operation area in spite of high thermal
tolerances of the ceiling and support
loads. The contamination degree of less
can be compensated at the same time.
The HEPA-filter units in stable mounting than 0.1 is substantially lower than the

minimum requirement of JJLS=0.67

according to DIN 1946/4 for operating
theatres of the type A, highly aseptic.
The examination according to DIN 4799
was accomplished by the Hermann Rietschel lnstitute for Heating and Air-Condition Technology of the Technical
University of Berlin. The outstanding
temporal particle reduction characteristic of the laminar flow system protects
the patient against air germs much
better than operating theatre supply
air systems with turbulent mixed flows.
Only the operating theatre supply air
ceiling with laminar displacement flow
offers protection, since the socalled
protection retention cannot prevent
particle entry from adjacent areas in operating theatres with several closed doors
or with open doors. It ensures low
contamination in the working field.

A further benefit in comparison to turbulent flow ceilings is the fact that the
germ sedimentation is much lower in
the laminar flow.

The AL-KO Supply-Air-Ceiling, type AL,

therefore ensures optimal protection
against infections for the patient.

64

22a

12

54

12

16

66 54

16

32
50

48
22b
20

18
30
26

18
30
26

50

28

14

48

20
28

24
10

22b

24
14
10

22a

Abstract of patent

Series
AL-KO Supply-Air-Ceilings
Central and decentralized systems

Decentral
Decentralized system with outside air
intake AHU, exhaust AHU and circulation AHU (as various options are
possible, only one schematic drawing
is shown)

Central
Centralized Air Handling Unit
within the technical room for
total supply of the OP-theatre

DESIGN CRITERIA FOR AL-KO SUPPLY-AIR-CEILINGS

Type AL-S

with vertical filters

Type AL-H
with horizontal filters

Type AL-PA
for pathology

AL-KO Supply-Air-Ceiling
type AL-S
AL-KO Supply-Air-Ceiling with vertical filters type AL-S

Smooth internal surfaces without corners and edges

Lamp shaft with maintenance plate for better sevice

Easy and safe maintenance of filters including test

procedure for tightness

Operation lamp for installation through OP-Ceiling

AL-KO Supply-Air-Ceiling
type AL-S
Technical data with sizes and dimensions type AL-S

View from below

Width B

Lamp opening
500 / 600

175

View from above

Size for damper or

duct connection

Size for damper or

duct connection

a
Length L

HEIGHT H = 400 MM
Item no.

Type

Scheme

Length

Width

Air-volume

Pressure loss

0.20 m/s

0.25 m/s

0.20

0.25

mm

mm

m3 / h

m3 / h

Pa

Pa

Weight
kg

Duct connection
St.

mm

mm

24124

2 400

1 200

2 074

2 592

186

233

170

873

263

24144

2 400

1 400

2 419

2 024

215

269

190

873

263

24184

2 400

1 800

3 110

3 888

212

265

235

568

263

30184

2 400

1 800

3 888

4 860

210

262

270

720

263

24244

2 400

2 400

4 147

5 184

202

253

295

30244

3 000

2 400

5 184

6 480

201

251

320

2
2
4
2

720
873
568
873

263
263
263
263

Options:
I Casing made out of galvanized
steel with painting (resistant
against disinfection) or stainless
steel 1.4301
Access
Panel

I Filter frame made out of reinforced

fiber material or galvanized steel

H 400

(H 300)

(b 161)

b 263

50

I Duct connections with or without

airtight dampers with actuators

HEIGHT H = 300 MM
Item no.

Type

Scheme

Length

Width

Air-volume

Pressure loss

0.20 m/s

0.25 m/s

0.20

0.25

mm

mm

m3 / h

m3 / h

Pa

Pa

Weight
kg

Duct connection
St.

mm

mm

24123

2 400

1 200

2 074

2 592

182

227

175

720

161

24143

2 400

1 400

2 419

2 024

210

262

195

720

161

24183

2 400

1 800

3 110

3 888

210

262

240

30183

3 000

1 800

3 888

4 860

210

263

280

24243

2 400

2 400

4 147

5 184

210

263

305

30243

3 000

2 400

5 184

6 480

204

255

330

4
2
4
2
2
4
4
4

568
720
720
873
720
873
720
873

161
161
161
161
161
161
161
161

AL-KO Supply-Air-Ceiling
type AL-S
Tendertext type AL-S
Supply-Air-Ceiling for operating theatres

Support leadthrough

Particularly suitable for generating a laminar clean air

flow, while avoiding secondary air contamination, for the
creation of a sterile operating area, complying with the
test report according to DIN 4799, for ceiling-flush
installation, in a flat design, consisting of:

Aerodynamically designed to avoid airflow disturbances

to a large extent and thus contamination, built in dead
centre into the air outlet, with tolerance compensation
for the support position.

Accessories
Ceiling housing
as a pressure box according to the over-pressure principle
to prevent leak air flows, housing ready for assembly,
suitable for transportation through normal doors
Material ceiling housing and filter frame:
Galvanised steel sheet with
disinfectantresistant coating
Stainless steel, material No. 1.4301

Duct connecting piece made of galvanised steel sheet

Galvanised airtight damper according to DIN 1946-4,
manually operated
Airtight damper with electrical servo motor
with spring return
Airtight damper with pneumatic servo motor
Pressure monitoring with remote display
Spare filters
Basic lighting

HEPA-filter
According to DIN EN 1822, class H13 with both-way handle
protection, on stable mounting frame with clamping device
and test groove for the filter seal fi t examination, complete
with pressure measuring connecting piece, Frame material:
Medium densified fibre board
Aluminium

Laminarisators
According to the European patent 0 355 517 B1, as largearea ceiling panels, whose good laminarising characteristics
almost exclude a secondary air contamination, consisting
of aluminium frames with minimised frame width, without
lee areas between the ceiling panels, with a monofilament
polyester tissue covering, flame and disinfectant-resistant,
colour white, simple disassembly of the air distribution
frame without tools.
= Optional, please select

10

Performance and dimensions

Supply air volume flow
Exit speed
Air resistance (Start)
Length x Width
Height
Weight
Number and dimensions of the filters
Number and dimensions of the connecting pieces

m3/h
m/s
Pa
mm
mm
kg
mm
mm

Delivery and assembly including all auxiliary material, as

well as accomplishment and recording of the acceptance
inspection according to DIN 1946 Bl. 4 paragraph 10.2.2
(Edition 03/99)
Manufacturer
Type

AL-KO THERM GmbH

AL-S

AL-KO Supply-Air-Ceiling
type AL-H
Supply-Air-Ceiling with horizontal filters type AL-H

Supply-Air-Ceiling AL-H with media supply

Typical design of AL-H with air guiding

curtains and media supply

Filter frame: stainless steele

Laminarisator with HEPA filter

HEPA filter

Closed laminarisator

11

AL-KO Supply-Air-Ceiling
type AL-H
Technical data with sizes and dimensions type AL-H
b
h

30

175

b
h

B
35

35

Partial delivery
d

Partial delivery

Cut A / B

35

35

35

TYPE AL-H
Scheme 1
Item
no.

Scheme 2+3

Scheme 4

Air-volume

Type

Length Width

Pressure loss
100 Pa
0.20

12

Lamp
opening

Weight

0.25

m/s

m/s

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

mm

m3/ h

m3/ h

mm

mm

kg

2626

415

175

800

520

340

800

415

504

710

2 660

2 660

5 095

6 370

618

508

315

2828

415

175

900

520

340

900

415

504

800

2 810

2 810

5 685

7 110

768

658

360

2929

415

175

1 000

520

340

1 000

415

669

710

2 960

2 960

6 310

7 885

618

508

400

3030

415

175

1 120

520

340

1 120

415

669

800

3 055

3 055

6 720

8 400

660

660

440

3232

415

175

1 250

520

340

1 250

415

834

710

3 265

3 265

7 675

9 595

636

564

520

Tendertext type AL-H

Supply-Air-Ceiling for operating theatres

Support leadthrough

Particularly suitable for generating a laminar clean air

flow, while avoiding secondary air contamination, for the
creation of a sterile operating area, complying with the
test report according to DIN 4799, for ceiling-flush
installation, in a flat design, consisting of:

Aerodynamically designed to avoid airflow disturbances

to a large extent and thus contamination, built in dead
centre into the air outlet, with tolerance compensation
for the support position.

Accessories
Ceiling housing
As a pressure box according to the over-pressure principle
to prevent leak air flows, housing ready for assembly,
suitable for transportation through normal doors.
Material ceiling housing and filter frame:
Galvanised steel sheet with disinfectantresistant coating
Stainless steel, material No. 1.4301

HEPA-filter
According to DIN EN 1822, class H13 with both-way handle
protection, on stable mounting frame with clamping device
and test groove for the filter seal fit examination, complete
with pressure measuring connecting piece.
Frame material:
Medium densified fibre board
Aluminium

Laminarisators
According to the European patent 0 355 517 B1, as largearea ceiling panels, whose good laminarising characteristics
almost exclude a secondary air contamination, consisting
of aluminium frames with minimised frame width, without
lee areas between the ceiling panels, with a monofilament
polyester tissue covering, flame and disinfectant-resistant,
colour white, simple disassembly of the air distribution
frame without tools.
= Optional, please select

Duct connecting piece made of galvanised steel sheet

Galvanised airtight damper according to
DIN 1946-4, manually operated
Airtight damper with electrical
servo motor with spring return
Airtight damper with pneumatic servo motor
Pressure monitoring with remote display
Spare filters
Basic lighting

Performance and dimensions

Supply air volume flow
Exit speed
Air resistance (Start)
Length x Width
Height
Weight
Number and dimensions of the filters
Number and dimensions of the connecting pieces

m3 /h
m/s
Pa
mm
mm
kg
mm
mm

Delivery and assembly including all auxiliary material, as

well as accomplishment and recording of the acceptance
inspection according to DIN 1946 Bl. 4 paragraph 10.2.2
(Edition 03/99)
Manufacturer
Type

AL-KO THERM GmbH

AL-H

13

AL-KO Supply-Air-Ceiling
type AL-PA

800

300

AL-KO Supply-Air-Ceiling for pathology and anatomy

type AL-PA

View from below

300

View from above

300

400

300

1800

14

Tendertext AL-PA
Description

Construction

The Supply-Air-Ceiling Type AL-PA ensure a continuous

laminar flow for the total area according to DIN1946-4
(March 1999). This warranties optimum working conditions as f.e. protection against infection and a better
thermal comfort. The particles and the amount of gas
will be reduced. Also the required values for MAKguidelines are ensured. The installation of the ceiling and the
fi tting of lighting devices can be done very easily.

Technical data
Air supply volume
Air velocity
Pressure loss
Value of contamination according to:
DIN 1946-4
Temperature difference

Air supply chamber made of galvanised steel with optimum disinfection surface and for concealed installation
Duct connection to the side or to the top
Diffusor for air intake on top
Patented laminarisator according to European patent
0.355.517 made of polyester fixed on aluminium profiles
Both sides of the chamber are equipped with lighting
system with glas cover and wired to a terminal box

Accessories and options

3

1 040 m /h
0,2 m/s
25 Pa
> 01
R - tZU <=3K

Air supply chamber made of stainless steel

Partly covered
Chamber for suspended installation
Air tight dampers according to DIN 1946 part 4
Lighting system included above the laminarisator

PATHOLOGY

15

Air guiding curtains

Air guiding curtains

Air curtains are stabilizing the laminar
flow, minimizing the entry of germs
and enlarging the entire zone. Curtains
are most efficient if the air supply field
is close to the curtain and the length
of the curtain is done accordingly.
Air curtains are mechanically strong,
resistant against desinfection liquids
and protected against scratches. Therefore special glass need to be used.

16

LS-VR

LS-VB

LS-VF

Air curtain 8 mm safety glass, for suspended

Air curtain 8 mm safety glass for suspended

Air curtain with 8 mm safety glass, fi xed at

installation, framed with aluminium profi les.

installation with profi le, gaps are sealed.

the Media Supply Elements gaps are sealed.

Media supply elements

Media supply elements

Media supply elements are foreseen
to provide electricity and medical gases.
They can further include lighting
systems, communication systems and
can be used for the installation of other
equipment as f.e. air curtains with
safety glass. Media elements can be
fixed on all four sides of the laminar
flow field.

SUPPLY-AIR-CEILING FOR OPERATION THEATRES

17

Separator for slubs

Separator
for slubs
Separators protecting the ducts and
the components against sedimentation
and provide better economic and
service operation of the entire air
handling system. There are various
solutions for ceiling and wall installation available.
Installation types RAC-A/E and RAC-D:

Wall installation type RAC-A

Ceiling installation type RAC-D

Construction type RAC-E

Construction type RAC-A

Construction type RAC-Z

DRAWINGS
1

2.5

A/B

A/B
25

18

20

Application AFL-A

25

16.5

17.5

16.5

25

Application AFL-E

A/B

Application AFL-Z

Lighting system

Lighting system
Typical installation of the lighting
system is done close around the laminar
flow ceiling. In this case the difference
of the luminous density in the field of
operation and the room has to be
considered accordingly. In the fi eld of
operation the the luminous power has
to be at least 1000 lux at the height
of 1 m above the surface. Better is
2000 lux. Accessory to avoid reflections
can be equipped. Components against
infrared influence are foreseen a standard.

763 lx
1291 lx

3m

2345 lx

2m

2506 lx
1m

2646 lx

0m
1m
2000 lx
2m
1500 lx
1000 lx
3m

2m

1m

0m

3m
1m

2m

3m

Intensity of illumination in lux

19

Air-handling-units for hygienic application

AT4 AHU for hygienic application

The VDI guideline 6022,
part 1 and 3
defines the hygienic requirements
for AHU with regard to:
I planning
I design
I operation
I service
I maintenance
according to highest technical
standard
represents a qualified hygienic
standard providing planning security
and avoidance of problems
AL-KO AHU comply to these
requirements.
We recommend a design check
(Institut fr Lufthygiene)

CONFORMITY
Complies with all national and European standards

0
-201
2007

20

General requirements of VDI 6022

for manufacturers of AHU:
I all materials must comply with health
requirements and prevent microbio
logical growth
I sandwich panel construction
I low condensation tendency
I smooth internal surfaces
I grooves easily cleanable
I bottom panel surface powder coated
or made in stainless steel
I all units and components are easily
accessible and equipped with lighting
where necessary and sight glasses
(possible to darken)

I continuous and complete condensatedrainage

I use of fans with access for cleaning
I sealing materials must be closed-cell
type and not absorb moisture, give out
odours or form a nutritive medium for
microorganisums
I hygienically appropriate manufacture,
transportation and intermediate
storage at the place of installation

21

Air-handling-units for hygienic application

AL-KO solutions
1

Construction
I Providing enough maintenance space
I Consideration of excellent air flow
conditions for connections and air
dampers
I The outside air dampers have to
be installed internally to avoid
condensation
I A drain pan under outside air filter
ensure better cleaning
I All relevant components are available
either fully powder coated or in stainless steel
I Various design for all applications with
AL-KO software Klima@Soft

22

Examples
I Place silencer immediately downstream the fan, eliminator always
behind cooler. Alternative: Fan and
cooler in the direction of air flow
I The use of a direct driven fan or a fan
with flat belt drive requires only filter
class F7 for the supply air
Not approved (e. g.)
I Filter or silencer downstream a
humidifier
I Cooling coil without eliminator

Housing construction
I Sandwich panels
I No condensation tendency (category
T3 / TB 3 or T2 / TB 2)
I Smooth internal surfaces without
corners and edges
I Powder coated panels or internal
panels in stainless steel
I Avoidance of corrosive tin-plated
panel surfaces with unprotected
cutting edges
I Door and panel seals are foamed
seamlessly, have a high density,
and are non-ageing
I All sections are easily accessible, have
the necessary lighting, access doors,
and sight glasses
I Possibility of cabling mainly outside
the casing: no additional dirty corners

Filter
Filter construction:
I Microbiological inert filter materials
I Only use of closed - cell type sealing
I Mechanically sufficiently stable
materials even during humidity
I Filter differential pressure control
optically or electrically as standard
I Use of quality filters with test
certificates

Sealing materials
All used materials
I have been tested extensively
I prevent microbacterial growth
I are resistant to disinfectants
I permit physical and chemical
disinfection

Fans
Prevention of belt wear through:
I use of direct driven fans (plug fans)
I use of flat belts for belt driven fans
Casing with water drainage and cleaning
access (from size 400 onwards)

Filter installation:
I Correct installation of filter to prevent
mechanical stress on the filter medium
I Filter maintenance with easy access by
using filter quick snap device
I Cleanable filter section optional with
drain pan

23

AL-KO THERM GmbH

Hauptstrae 248 - 250
89343 Jettingen-Scheppach
Phone

(+49) 82 25 / 39 - 176

Fax

(+49) 82 25 / 39 - 55 176

E-mail

ruediger.froehning@al-ko.de

www.al-ko.com