The Pocket Installer. Fiber Glass Duct Board Air Handling Systems

a a a a The Pocket Istaller Fiber Glass Duct Board Air Hadlig Systems A guide for the istallatio of SuperDuct RC ad Mat-Faced Micro-Aire air duct products $ 50 00

Table of Cotets Page Itroductio 2 4 Products ad Applicatios 6 16 Good Practice Recommedatios 13 Limitatios of Use 15 Modular Duct Costructio 18 26 Basic Fiber Glass Fittigs 22 Other Fiber Glass Fittigs 24 O-site Storage ad Hadlig 28 32 Abuse 31 Exposure to Water 31 Closures ad Assembly 34 44 Closures ad Code Compliace 34 Duct Board Closure System Selectio Guide 35 UL 181A Closure Summary 36 Field Assembly 40 Istallatio Tips ad Tools 46 50 Field Fabricatio Tools ad Materials 49 Reiforcemet 52 74 Geeral Iformatio 52 Tie Rod Reiforcemet 54 Tie Rod Reiforcemet Table 57 Negative Tie Rod Duct Reiforcemet 60 Tie Rod Reiforcemet Tips 61 Fittig Reiforcemet ad Assembly 66 Hagers, Coectios ad Accessories 76 90 Rectagular Duct Hagers 76 Special Hager Situatios 79 Equipmet Coectio Details 84 Accessories 87 Field Fabricatio of Fittigs 92 100 Usig the Cuts-All Tool 96 Repairs 98 Job Ispectio Checklist 102 106 Appedix 107 108 2012 Johs Maville 1

Itroductio The Pocket Istaller is a guide describig procedures for the istallatio of air duct systems maufactured from Johs Maville air duct products ad accessories. The Pocket Istaller is iteded for use by mechaics, foreme, project superitedets, ispectors ad other idividuals ivolved i the istallatio ad ispectio of fiber glass air hadlig systems. Alog with simple-fittig fabricatio ad field-prove istallatio techiques, The Pocket Istaller provides fast access to commoly used tables ad related referece sources. It also icludes a ispectio checklist, which is recommeded as a meas of gaiig familiarity with quality stadards for fiber glass duct systems. With its focus o field istallatio, The Pocket Istaller provides fabricatio details oly isofar as they relate to typical jobsite modificatios. Comprehesive fabricatio iformatio is preseted i the Fibrous Glass Duct Costructio Stadards published by NAIMA ad SMACNA ad other sources. Combied with proper plaig, reasoable care ad good workmaship, the iformatio i the followig pages will help the istaller provide attractive, low leakage ad log-lastig fiber glass duct systems. For more iformatio o products, istallatio procedures or referece materials, please cotact your local Johs Maville Territory Maager or air hadlig product distributor. Additioal Referece Sources The facig page lists sources cotaiig iformatio o fiber glass air hadlig system desig, fabricatio, ad istallatio specificatios. Whe requestig these sources, use the Johs Maville publicatio umber to esure correct idetificatio. Referece Note: The NAIMA Fibrous Glass Duct Costructio Stadard ad the SMACNA Fibrous Glass Duct Costructio Stadard 7th Editio are fuctioally iterchageable. However, the NAIMA Stadard cotais optioal methods of fabricatio compared to the SMACNA Stadard ad will serve as the primary techical referece throughout The Pocket Istaller. 2

Itroductio Duct Costructio Stadards NAIMA Fibrous Glass Duct Costructio Stadard Curret Editio (cotact your Johs Maville Regioal Sales Office or order directly from NAIMA; cotact iformatio is i the Appedix) SMACNA Fibrous Glass Duct Costructio Stadard 7th Editio, or later (order from SMACNA; cotact iformatio is i the Appedix) Mat-Faced Micro-Aire Duct Board Mat-Faced Micro-Aire Duct Board Product Iformatio Page Mat-Faced Micro-Aire Duct Board UL Fabricatio Sheet SuperDuct RC Air Hadlig System SuperDuct RC Air Duct Board Product Iformatio Page SuperSeal Coatig Products Product Iformatio Page SuperDuct RC Air Hadlig System UL Fabricatio Sheet SuperDuct RC Air Duct System Guide Spec AHS-135 AHS-30 AHS-200 AHS-202 AHS-204 AHS-220 3

Itroductio The physical ad chemical properties of the Air Hadlig Systems products listed herei represet typical, average values obtaied i accordace with accepted test methods ad are subject to ormal maufacturig variatios. They are supplied as a techical service ad are subject to chage without otice. Numerical flame spread ad smoke developed ratigs are ot iteded to reflect hazards preseted by these or ay other materials uder actual fire coditios. Check with the Regioal Sales Office earest you to esure curret iformatio. All Johs Maville products are sold subject to Johs Maville s stadard Terms ad Coditios icludig Limited Warraty ad Limitatio of Remedy. For a copy of the Johs Maville stadard Terms ad Coditios, Limited Warraty ad Limitatio of Remedy ad iformatio o other Johs Maville thermal isulatios ad systems, call (800) 654-3103. The Pocket Istaller is iteded as a guide oly; actual coditios ecoutered durig istallatio may vary from jobsite to jobsite. Johs Maville assumes o resposibility for quality of istallatio, field workmaship or job safety. Johs Maville Material Safety Data Sheets (MSDS) are available with specific product safety iformatio. For iformatio o other Johs Maville thermal isulatios ad systems, call the umber listed below or visit specjm.com. North America Sales Office, Isulatio Systems Easter Regio P.O. Box 158 Defiace, OH 43512 (800) 334-2399 Fax: (419) 784-7866 Wester Regio ad Caada P.O. Box 5108 Dever, CO 80217 (800) 368-4431 Fax: (303) 978-4661 4

5

Products ad Applicatios The istallatio procedures discussed i this guide apply to rectagular ad roud systems fabricated from these Johs Maville products: SuperDuct RC Air Duct Board Mat-Faced Micro-Aire Duct Board SuperDuct RC ad Mat-Faced Micro-Aire Wide Board Fiber Glass Duct Performace Advatages I compariso with traditioal sheet metal duct systems, duct systems fabricated from Johs Maville highperformace fiber glass duct products offer a umber of istallatio ad operatioal beefits whe properly utilized. Easy to hadle ad hag Easy to modify o the job Easy to assemble i sectios Fewer joits to seal High thermal efficiecy Extremely quiet air delivery No duct expasio, cotractio or vibratio oise Additioal SuperDuct RC Air Hadlig System Advatages SuperDuct RC Air Hadlig System offers performace characteristics that allow it to meet or exceed the performace of premium lied, sealed metal duct systems. Maufactured with a tough acrylic polymer coatig o the airstream surface, SuperDuct RC Air Hadlig System products provide: Improved resistace to microbial cotamiatio A fully cleaable airstream surface Airstream treatmet resists icursio of dust ad debris ito fiber glass structure Ehaced acoustical performace for quiet operatio Operatio limits to 6000 fpm, up to 2" w.c. A full system approach JM s compatible accessory products esure UL 181, Class 1, performace 6

Products ad Applicatios Wide Board SuperDuct RC Air Hadlig System ad Mat-Faced Micro-Aire Duct Board products are available i Johs Maville s exclusive 96" x 120" x 1" Wide Board size. Wide Board is used to fabricate oe-piece duct sectios eight feet log, reducig material hadlig ad offerig the opportuity to cut costly field joits by half. Duct rus assembled from Wide Board may be hug at eight-foot itervals for ay duct spa, reducig hagig cost. 7

Products ad Applicatios Mat-Faced Micro-Aire Duct Board A flat, rigid board used to fabricate rectagular duct sectios. Made from resi-boded glass fibers ad faced with foil-scrim-kraft (FSK). The airstream surface is coated with thermosettig black acrylic polymer formulated with a EPA-registered, atimicrobial aget. 8 Duct Board Loaders are available from Glass Master Corporatio; please see the Appedix for cotact iformatio.

Products ad Applicatios Mat-Faced Micro-Aire Duct Board Geeral Properties Thickess 1", 1 1 2", 2" R-value (75 F mea temp.) 4.3 (1"), 6.5 (1 1 2"), 8.3 (2") Air Velocity (Max.) 5000 fpm Operatig Temperature 250 F max. cotiuous Operatig Pressure -2" w.c. to +2" w.c. Applicatio HVAC air duct systems The followig table provides iformatio o stadard package availability for male/female Mat-Faced Micro-Aire Duct Board. Butt-edge (BE) products ad other ostadard cofiguratios are also available; however, restrictios may apply. Please cotact your local Johs Maville distributor or the earest Regioal Sales Office for more iformatio. Mat-Faced Micro-Aire Duct Board Availability Boards Per: Thickess Type Size Carto Pallet 1" 475 48" x 120" 6 44 48" x 96" 6 44 475 WB 96" x 120" NA 44 800 48" x 120" 6 44 1 1 2" 800 48" x 120" 4 30 2" 800 48" x 120" 3 22 9

Products ad Applicatios SuperDuct RC Air Hadlig System A flat, rigid board used to fabricate rectagular duct sectios. Made from resi-boded glass fibers ad faced with foil-scrim-kraft (FSK). The airstream surface is coated with thermosettig black acrylic polymer formulated with a EPA-registered, atimicrobial aget. System compoets iclude: SuperDuct RC Air Duct Board SuperSeal Coatig Products 10

Products ad Applicatios SuperDuct RC Air Hadlig System Geeral Properties Thickess 1", 1 1 2", 2" R-value (75 F mea temp.) 4.3 (1"), 6.5 (1 1 2"), 8.3 (2") Air Velocity 6000 fpm Service Temperature 250 F max. cotiuous Operatig Pressure Applicatio -2" w.c. to +2" w.c. All HVAC air distributio applicatios where maximum IAQ ad system performace are required 11

Products ad Applicatios Johs Maville Fiber Glass Duct System Performace Schedule JM fiber glass air duct products are suitable for all ormal HVAC applicatios, icludig: Operatig velocities to 6000 fpm for SuperDuct RC systems Operatig velocities to 5000 fpm for Mat-Faced Micro-Aire rectagular duct Operatig pressures to 2" w.c. Operatig pressures to egative 2" w.c. for retur air duct* Evaporative coolig system ducts Exhaust ducts for ocorrosive, ocombustible air Note: Iformatio o tested safety margis above specified operatig coditios is available upo request. *With proper reiforcemet. 12

Products ad Applicatios Good Practice Recommedatios 1. Whe detailig the job, use Modular Duct Costructio priciples rather tha stadard sheet metal procedures (see page 20). 2. Utilize appropriate fiber glass fabricatio tools for best results (see page 51). 3. Take reasoable care i the uloadig, hadlig ad storage of duct to avoid damage. 4. Ducts ready for istallatio should be stored vertically, o the female ed, off the floor, i a dry area to avoid water absorptio. Pallets are useful for this purpose. It may also be advatageous to bad the duct sectios together to prevet them from beig kocked dow or blow over (see pages 30 32). 5. Prior to hagig, preassemble as may sectios as ca be coveietly raised. 6. Where field modificatios of fittigs are ecessary, use a straight edge to guide your kife for straight ad smooth cuts. Note that scrim may ot be parallel with duct sectio eds. 7. Do ot eglect reiforcig of straight duct ad fittigs. Where shop-reiforced fittigs are modified i the field, reiforcemet must be reistalled to esure proper performace. 8. Check the operatig pressure desig ad the probability of surges to esure the right reiforcig schedule. If severe surges greater tha 125% of the specified reiforcemet are aticipated, cosider usig a relief damper or higher-pressure reiforcemet schedule. 9. Properly selected ad applied closures are absolutely essetial for a log-lastig istallatio. Closures bearig the UL 181A listig must be used, ad applicatio must comply with the tape maufacturer s istructios. See pages 36 41 for detailed iformatio o closures. 10. Repair all tears ad puctures (see pages 100 102). 13

Products ad Applicatios 8 10 4 13 5 6 7 2 12 8 9 3 6 11 11 6 Some Places to Use Fiber Glass Duct 1. Vertical risers if ot servig more tha two floors 2. Large duct up to 150" spa 3. Johs Maville fiber glass air duct board 4. Low pressure mais ad braches 5. Slot diffusers 6. Simple or complex fittigs 7. Fresh air duct except for 6' adjacet to the outside air ilet grill 8. Retur air duct 9. Toilet exhaust 10. Trasfer duct 11. Retur soud traps 12. Drops 13. Duct supplyig idoor swimmig pool areas 14

Products ad Applicatios Limitatios of Use Fiber glass ductwork should ot be used i the followig applicatios: For vertical risers servig more tha two floors I air duct systems operatig ormally above 250 F For kitche or corrosive fume exhaust ducts To covey solids or corrosive gases To build casigs or housigs Not closer tha 2" to electric heatig coils I systems supplyig hospital-sesitive areas such as surgical suites, materity wards, itesive care uits ad isolatio areas I equipmet rooms where severe mechaical abuse ca occur I low-clearace garages Outdoors For velocities or pressures beyod recommedatios Withi 6' of fresh air itakes or outside grills Bathroom exhaust exposed to subfreezig temperatures The above list of limitatios is based o published code restrictios ad good egieerig practice. 15

16 Notes

17

Modular Duct Costructio Modular Duct Costructio (MDC) is a cocept that represets oe of the most basic differeces betwee fiber glass ductwork ad sheet metal ductwork. The practice of MDC icorporates desig, layout, detailig, fabricatio ad istallatio. Shiplap Note: Modular Duct Costructio requires the use of shiplap duct groovig equipmet. MDC practice is ot compatible with vee-groove cuttig. The recommedatios that follow ca help you achieve the versatility, simplicity ad other advatages available through Modular Duct Costructio. Additioal iformatio about MDC is available through Johs Maville traiig programs. Please cotact your earest Johs Maville Regioal Sales Office for traiig availability. 1. Female ed of the duct (without staple flap) is always istalled away from the uit. Retur Air HVAC Uit Female Joit Supply Air Note: As opposed to sheet metal practice, fiber glass duct systems have o iterior lap" requirig airflow cosideratio. Flow 18

Modular Duct Costructio 2. MDC utilizes the shiplap groovig method to facilitate fittig assembly with o isulatio voids. A B C D Whe tappig ito a side pael, the top (A) ad bottom (C) duct paels have a shiplap joit, which allows the isertio of the male ed of the ext duct sectio. B A C D Note ormal airflow for shiplap costructio. 19

Modular Duct Costructio 3. Make fittigs from a full 4' or 8' Wide Board sectio. Almost all fittigs ca be made from a full sectio (or from two or more full sectios for very large fittigs) achievig a 47"* or 95" ceterlie fittig legth for ells, trasitios ad offsets. 47"* 47"* 90 Ell Trasitio 47"* 47"* Offset 45 Ell Board *Fittig Thickess Legth 1" 47" 1 1 2" 46 1 2" 2" 46" Wide Board Offset with Trasitio 95" 4. Holes for brach coectios are frequetly cut i the field. If ecessary, they may be cut through a circumferetial joit to maitai the advatage of fulllegth sectios. 20

Modular Duct Costructio 5. Trasitios should be made part of the ext full sectio dowstream from the brach. Sheet Metal Layout Fiber Glass Layout 6. Tees ad 90 ells are ofte shipped throatless to the field for fial cuttig ad assembly. Cut with M/F tool ad istall here Whe a throatless ell must be istalled at other tha its full 47"* or 95" legth: Cut Or off the upstream ed of the throatless ell with a Cuts-All (male/female) tool ad add the cut-off piece o the dowstream ed of the ell (if required for overall legth). add a partial sectio of straight duct upstream of the ell (usig the Cuts-All tool) ad add the remaiig piece to the dowstream opeig of the ell. *See page 22 for fittig legths for various board thickesses. 21

Modular Duct Costructio Basic Fiber Glass Fittigs The followig illustratios represet commo fiber glass fittigs. I additio, almost ay sheet metal style fittig ca be fabricated from duct board. Where joits are properly made ad correct reiforcemet provided, the fittig is suitable for use. Throatless Ell with Vaes 4' Throated Ell with Vaes Note shiplap edges. Throatless Tee with Adjustable Splitter Note shiplap edges. Note large washer assembly to cotrol rod. 22

Modular Duct Costructio Basic Fiber Glass Fittigs Trasitio Offset Note edges trimmed flush, female joit restored. Note cross tabs for stregth. Brach Tap Note staple flaps for staplig ad tapig brach to mai duct. 23

Modular Duct Costructio Other Fiber Glass Fittigs Large Ell with Ceter Cheek Note metal chaels. Rectagular to Roud Trasitio 24

Modular Duct Costructio Other Fiber Glass Fittigs 3 Gore Rectagular Ell For low-velocity applicatio. Beam Clearace Trasitio Offsettig Trasitio 25

26 Notes

27

O-site Storage ad Hadlig Fiber glass duct systems offer high performace ad easier istallatio, but sice they are lightweight, they have differet jobsite hadlig requiremets whe compared to bare sheet metal duct systems. Material hadlig, spottig ad protectio of products at the jobsite should be carefully plaed to reduce exposure to other trades ad to miimize extra hadlig. The result ca be less damage ad subsequetly lower costs. This sectio presets iformatio that will help i the critical area of storage ad hadlig. Compressio Packagig Straight duct sectios, i which the smaller dimesio is 12" or greater, ca be compressio-packaged for shipmet to the jobsite. Compressio packagig sigificatly reduces the volume of the product to ease trasportatio, hadlig ad site spottig. Compressio-packaged duct should be upacked immediately after it is spotted o the jobsite. Duct that is kept i compressed form for more tha seve days may require diagoal tie-wires to restore the rectagular shape. (See Istallatio Tips, page 48, for details.) 28

O-site Storage ad Hadlig Carts Use of carts is a efficiet meas for hadlig several duct sectios or budles of compressio-packaged duct at oe time. Carts ca help protect the duct, keep it off wet ad dirty floors ad save o costly material hadlig. While carts may vary i size ad type, good oes share certai commo characteristics: They They Carts usually ca be made by shop persoel with available materials. feature good idustrial-quality casters with a brake. serve the dual purpose of providig trasport as well as a work surface for closure, assembly, reiforcemet or other istallatio procedures. 29

O-site Storage ad Hadlig Moisture ad Wid Protectio Proper attetio to storage of fiber glass air duct products, whether fabricated or i the flat, is essetial to prevet damage. Idoor Storage. Idoor storage is highly recommeded ad uiversally preferred. Store duct i protected area. Near the ceter of the structure is usually best. Store duct off floor or where water caot collect. Tie dow duct sectios to colums or similar structure, or put strappig aroud large quatities of duct sectios to secure agaist high wids. Outdoor Storage. Outdoor storage is ot recommeded. I cases where it is uavoidable, the followig miimum precautios must be observed: Store duct off groud. Shield from wid as much as possible ad tie dow duct sectios to a fixed poit or put strappig aroud duct to keep idividual sectios from blowig away. Completely cover all of the duct (ot just the ope eds) with plastic sheetig ad/or other waterproof materials. Secure water shields agaist wid. 30

O-site Storage ad Hadlig Abuse I the evet that the material is damaged as a result of hadlig, storage or ay other abuse, it must be properly repaired or replaced. Mior Exteral Damage. Jobsite coditios, icludig abuse from other trades, cotribute to mior puctures or tears i the duct board facig. This type of damage is easily repaired usig approved UL 181A closure materials. (See Repairs, pages 100 102, for details.) Mior Iteral Damage. Tears or puctures to the airstream surface of Mat-Faced Micro-Aire duct board should be buttered" with Johs Maville SuperSeal HV coatig. Tears or puctures to the iteral coatig of SuperDuct RC Air Hadlig Systems should be recoated with SuperSeal coatig products to esure system itegrity. More extesive damage to fiber glass duct sectios from abusive cotact or prologed cotact with stadig water may require pael or complete sectio replacemet. (See Repairs, pages 100 102, for details, ad Exposure to Water below.) Exposure to Water Exposure to rai, sow or stadig water may cause structural damage to fiber glass duct isulatio products, icludig duct lier ad duct wrap. Whether or ot physical damage occurs is determied by the duratio ad frequecy of exposure. Elemets iclude: (1) quatity of water ivolved, (2) exposure period ad (3) umber of exposures. The greater the exposure to the elemets above, the higher the likelihood of damage. The typical physical failure mode that results from water damage is the delamiatio of the facig from the fiber glass wool. Saturatio of the kraft backig o the FSK duct facig is a immediate cause for rejectio of a duct sectio. A secodary water exposure risk is microbial cotamiatio. Note that this ca occur i ay material exhibitig accumulated moisture (liquid water), icludig bare metal. It is a kow fact that fugal spores ad other microbiological cotamiats require water for growth. Removal of the water source ad subsequet dryig of the isulatio ca prevet microbial growth. 31

O-site Storage ad Hadlig However, i cases with log water exposure duratio, the presece of water may lead to microbial growth. I case of either physical or microbial damage due to water saturatio, the duct sectios should be discarded ad replaced with ew dry sectios. Determiig Water Damage Prior to Istallatio. If water damage is suspected, stad duct sectio(s) i questio, female ed dow, o a clea, dry floor. If water drais visibly from the sectio, it has bee saturated ad should ot be istalled. Also, if a duct sectio exhibits physical softess whe compared to a sectio that was ot exposed to water, it should be replaced. Ay evidece of facig delamiatio, such as bubblig or wriklig ear the ceter of ay flat pael of a duct sectio, also idicates saturatio ad is a cause for rejectio. Istalled Ductwork. I rare istaces, roof damage, blowig sow, rai or plumbig failures may expose istalled fiber glass ductwork to a large volume of water. To test for saturatio, make a icisio i the bottom ceter of the duct ru. If water appears from the icisio, the exposed duct ru should be replaced. Evidece of facig delamiatio, as described above, also idicates eed for duct ru replacemet. 32

33

Closures ad Assembly Closures ad Code Compliace Strog permaet closures are absolutely essetial for the proper performace ad logevity of a fiber glass duct system. The use of uapproved closure material ca result i duct system failure. North America buildig codes require a miimum Class 1 duct system ratig. Duct systems fabricated from fiber glass duct board products are listed with Uderwriters Laboratories uder Stadard UL 181 to obtai a Class 1 ratig, whe used with closure systems listed uder Stadard UL 181A. Use of o-ul 181A closure materials, regardless of experiece or specificatio, voids the Class 1 ratig ad the Johs Maville product warraties. I other words, failure to use a UL 181A closure meas the system does ot comply with North America buildig code requiremets. UL 181A Closure Test Approved closures meet the requiremets of UL 181A, a compaio stadard to the duct board stadard. Closures for fiber glass duct board products, icludig Johs Maville SuperDuct RC Air Hadlig Systems ad Mat-Faced Micro-Aire Duct Boards, must be imprited with verificatio of UL 181A compliace. UL 181A closures comprise three distict types: UL UL UL 181A, Part I (P) Pressure-sesitive tapes 181A, Part II (H) Heat-applied tapes (thermal) 181A, Part III (M) Glass fabric ad mastic closure Note: Closures tested to UL 181B requiremets are ot acceptable for air duct board systems. 34

Closures ad Assembly Closure Selectio Guide Johs Maville icludes a basic fabricatio istructio page i each package of duct board. The three UL 181A closure types are idetified ad simple applicatio istructios are outlied. While all three types of UL 181A closures offer similar performace whe properly applied, each has differet performace rages, advatages ad disadvatages. A duct board closure system selectio chart is prited below for your coveiece. Complete closure applicatio istructios are available i the NAIMA Fibrous Glass Duct Costructio Stadards Maual. For product-specific, detailed istallatio recommedatios ad restrictios, please cotact the tape or mastic maufacturer directly. Duct Board Closure System Selectio Guide Heat Activated Pressure Sesitive Glass Fabric ad Mastic UL 181A-H UL 181A-P UL 181A-M Serves as duct Serves as duct board Serves as duct board board closure closure ad equipmet closure ad equipmet oly coectio seal to 1" w.c. coectio seal to 2" w.c. Not sesitive Foil facig must be Not sesitive to foilto foil-facig clea ad dry facig cotamiatio cotamiatio Applicatio at Caot be applied to Does ot dry well i cold ay temperature foil surface below 50 F or humid eviromets; must ot freeze before fully cured Joit fully cured Joit cures over time; Joit cure time varies; whe tape cools may be hadled after should ot be hadled to touch applicatio util mastic is dry ABI dots verify No visual bod No visual bod bod verificatio verificatio Ulimited shelf Limited shelf life Limited mastic shelf life life (temperature depedet) (cotaier seal ad temperature depedet) Low waste; ot Higher waste due to Low waste with careful tacky util heated self-stick or twistig applicatio No release paper Release paper poses Normally messy or cleaup mess waste ad slippig applicatio ad cleaup problem Requires 500 F Applied with a squeegee Applied with brush, to 650 F heat spatula, had, rags or iro for cost- a combiatio of these effective applicatio 35

Closures ad Assembly Limitatio of Liability Proper closure is critical for code compliace ad system logevity. If the closure system used is ot UL 181A listed ad if applicatio is ot i accordace with the tape maufacturer s stated procedures, the UL 181 air duct ratig ad all Johs Maville product warraties are void. Staples 1 2" or 9 16" outward-clich steel staples are required to secure all joits prior to closure tape or mastic applicatio. Staples must be firmly seated agaist the facig ad spaced at approximately 2" itervals. I certai applicatios, cross tabs may be substituted for staples, as show i this guide. Refer to the NAIMA Fibrous Glass Duct Costructio Stadards Maual for detailed iformatio. UL 181A Closure Summary UL 181A-H Heat-activated Closure Descriptio. Ay heat-activated closures that bear the UL 181A-H imprit may be used. These 3" wide, heat-applied, chemically boded closures are recommeded for all roud or rectagular ductwork except where makig coectios from fiber glass to metal duct or equipmet. Heat-activated (also kow as heat-seal or thermal) closures feature Automatic Bod Idicator (ABI) dots, which darke whe sufficiet heat ad pressure have bee applied to make the closure. 36

Closures ad Assembly Heat-activated Closure Applicatio. The iro used to apply thermally activated closure systems should be UL 181A-H approved ad be capable of maitaiig a surface temperature of 550 F to 650 F. Heat ad pressure should be applied util the gree ABI dots have darkeed. After heatig the closure, use the surface of the iro, a leather glove or other heat-resistat tool to press the closure ito the duct-facig scrim patter. Use a combiatio of heat ad pressure to rub the closure ito the facig for best results. Several types of iros are available for shop ad field applicatio of UL 181A-H closure. Please cotact your Johs Maville distributor for more iformatio. Note: Ope flame must ot be used o heat seal closures. Heat aloe is ot sufficiet to provide a good bod; physical pressure (typically applied by a smearig actio) is also ecessary. UL 181A-P Pressure-sesitive Tape Descriptio. Ay pressuresesitive tape imprited with the UL 181A-P label may be used. Follow the maufacturer s istallatio istructios to esure compliace with all warraties. Pressure-sesitive Tape Applicatio. The followig geeral iformatio applies oly to pressure-sesitive tapes. For specific storage, istallatio ad warraty iformatio, refer to the data sheets provided by the tape maufacturer. Shelf Life. Pressure-sesitive tapes ofte have storage requiremets ad shelf-life limitatios. The istaller should verify that these coditios have ot bee exceeded prior to use. 37

Closures ad Assembly Note: A geeral rule for shelf life is two years. Exposure to high heat may accelerate agig. Cosult the tape maufacturer for more detailed shelf-life iformatio. Surface Preparatio. I order to obtai satisfactory adhesio ad bodig, the surface o which the closure will be applied must be clea ad dry. Dust, dirt, oil, grease, moisture ad similar substaces may result i adhesio ad bodig failure whe preset. Ofte, wipig the applicatio surface with a clea, oil-free, lit-free rag or paper towel is sufficiet. However, for the best results o cotamiated or questioable surfaces, the cleaig recommedatios of the tape maufacturer should be cosulted. Applicatio Above 50 F. Usig 3" wide (miimum) tape, positio the tape alog the edge of the flap i a maer that will allow 1" miimum overlap o adjacet surfaces. While holdig the tape taut, press i place takig care to avoid wrikles ad folds. Rub tape firmly with a plastic squeegee util the facig reiforcemet (scrim patter) shows through the tape. Avoid excessive pressure o the squeegee that could cause the tape to be puctured at staple locatios. Applicatio Below 50 F. If tape has bee stored at temperatures less that 50 F, it should be coditioed prior to use by placemet i a warm eviromet i order to improve the iitial tack. Usig ay suitable heatig iro with the plate temperature set at 400 F (±25 F), preheat the area to be taped. Quickly positio the tape o the preheated area ad press i place. Pass the iro two or three times over the taped surface usig a rapid iroig" motio. Complete the bod by rubbig the tape firmly with the plastic squeegee util the facig reiforcemet shows through the tape. 38

Closures ad Assembly UL 181A-M Glass Fabric ad Mastic Descriptio. Required for sealig equipmet coectios where pressure will exceed 1" w.c.; glass fabric ad mastic also serves as a geeral closure. Glass Fabric ad Mastic Applicatio. Apply a thi, eve coat of mastic approximately 3" wide over the ceter of the joit. Press the 3" wide glass fabric ito the wet mastic. Apply a secod coat of mastic, usig care to fill the scrim patter i the glass fabric. Note: Glass fabric ad mastic joits should ot be stressed util the mastic has dried. Temperature ad humidity affect the speed of cure; cosult the mastic maufacturer s iformatio. 39

Closures ad Assembly Field Assembly 1. To prepare joit for field assembly: Slit the staple flap corer. Fold back staple flaps. Trim the corer diagoally Corer ready for (usig care ot to cut sectioalizig. ito the airstream surface) to allow easy joiig of sectios. 2. It will save time ad trouble if a clea work surface is available to assemble the duct. Preparatio ca be as simple as sweepig the floor. Do ot place the duct o abrasive work surfaces that will damage or cotamiate the facig. 40

Closures ad Assembly 3. Assemble as may sectios of duct as practical before hagig. Preassembly is best accomplished by temporarily stackig sectios with the male joit dow to esure tight joits. This procedure ca geerally be carried out o up to three stadard 4' sectios. 4. Whe assemblig sectios horizotally, agle the duct sectios together to staple ad tape oe side. The adhere the tape to oe sectio, use the roll as a hadle ad pull the duct sectios tightly together, leavig the tape piece as a cross tab. Staple ad tape together to fiish the coectio. 5. I some circumstaces, it is possible to faste trapeze hagers o oe side oly to facilitate the istallatio of log rus with miimum labor (see page 78 for hager detail). 6. Whe coectig duct i the air, the use of tape tabs, illustrated i item No. four, ca be very helpful, particularly o large size ducts. With a sigle hoist, three or four preassembled duct sectios ca be lifted. With two hoists, eight or more preassembled sectios ca be lifted. 7. Reiforcemet is preferable prior to hagig. 41

Closures ad Assembly Liftig Optios Sectioalizig Table Tape Roll 42

Closures ad Assembly Tight Clearace Coectios Where joits must be sealed after hagig ad where the clearace is miimal, use oe of the followig optios: Leave Apply the hager wires or straps log o oe side util the joit is sealed, the pull the duct up ito positio by raisig the hager chaels util it is level. a bead of Johs Maville SuperSeal HV sealat or approved water-based duct sealat to the iside of the male just uder the staple flap, ad a secod bead approximately 1 2" back from the female ed. Push the two duct sectios together ad press the staple flap dow i the tight clearace areas. Staple ad tape the accessible sides i the usual maer. Mastic Staple Flap 43

44 Notes

45

Istallatio Tips ad Tools The right tools ad proper job orgaizatio combie with good work practices to result i durable, attractive duct systems. The followig lists of tips ad tools ca help to improve both quality ad productivity. For additioal istallatio details, refer to sectios o Recommeded Closures (see page 36) ad Field Assembly (see page 42). 1. Provide each work crew with drawigs ad detail sheets idicatig which duct sectios ad fittigs were fabricated for each zoe or air hadlig uit. 2. Make certai that istallers uderstad the priciples of Modular Duct Costructio, especially if the origial blueprit was draw with sheet metal-style layout rather tha MDC layout (see page 20). 3. Provide all supplies required for proper istallatio to prevet field substitutio, icludig: Closure staples, tapes ad mastics as eeded Approved wire, washers, chael ad istallatio tools for reiforcemet ad hagig Equipmet coectio, fire dampers, collars ad other accessories desiged for use with fiber glass duct systems 4. Be sure istallatios crews: Limit Properly Assure Assemble Hag See damage ad properly repair ay damaged duct sectios (see pages 100 102) store fiber glass duct (see pages 30 32) tight joits i assembled duct the practical maximum umber of duct sectios for hagig ad support ducts i proper itervals Job Ispectio Checklist" o page 104 ad Field Fabricatio Tools ad Materials" o page 51 5. All seams should be i lie. Alteratig seams will ot ormally correct duct ru; twistig or rotatio of the duct ru is a idicatio that it was ot grooved square with the male/female edges or was improperly aliged durig closig 46

Istallatio Tips ad Tools 6. If the duct is racked over at a agle ad ca t be straighteed with the hagers, use a diagoal tie rod every two to four sectios to hold the duct square. 7. Whe staplig is required, the staples should be parallel or slightly agled with the seam. 8. Durig hagig, faste trapeze hagers o oe side oly to facilitate the istallatio of log rus with miimum labor (see page 43 for details). 9. To istall brach duct flat at top or bottom, measure I.D. plus 1 1 2"* for depth of opeig (see Figure 1). For brach istallatio i ceter, cut hole dimesio equal to brach I.D. plus 1"** (see Figure 2). I all cases, logitudial cut is brach I.D. width plus 1."** Figure 1 Figure 2 Brach Duct I.D. I.D. Mai Duct + Brach 1 1 2"* I.D. Duct I.D. + 1"** Mai Duct Staple ad Tape Brach Staple Flaps Staple ad Tape Brach Staple Flaps Board *Measure Thickess I.D. Plus: 1" 1 1 2" 1 1 2" 2 1 4" 2" 3" Board **Measure Thickess I.D. Plus: 1" 1" 1 1 2" 1 1 2" 2" 2" 47

Istallatio Tips ad Tools 10. For large brach ducts (over 30") provide two hagers withi the first four feet of the brach ru to elimiate strai where the brach coects to the mai duct. A" 4 Max. Note: Tie rods are required (as show i Example A") where brach opeig exceeds ureiforced spas as show i table o page 54. 11. O throatless ells, cut to legth ad attach leftover piece (or ext full sectio) to throat before hagig (see page 95). 12. Make certai that the fiber glass duct is properly closed ad correctly reiforced. Repair ay puctures ad tears i the facig material by usig the approved closure system (see page 100). 48

Istallatio Tips ad Tools Field Fabricatio Tools ad Materials Cuts-All Tool Had-groovig Tools Roud-hole Cutters Staple Gu UL 181A-H Closure Iros JM-tested Duct Adhesives Air Turig Vae Cutter Reiforcig Hardware 49

Istallatio Tips ad Tools Field Fabricatio Tools ad Materials Complete had fabricatio tool kits are available from Glass Master, Malco ad Amcraft (show). SuperDuct RC System Accessories JM SuperSeal Edge Treatmet ad SuperSeal HV sealat for repairs ad fittig fabricatio Air Turig Vae Istallatio i Ope Ells Markig elbow miter lie at 3" itervals from throat Usig air turig vae cutter to make cutouts i elbow cheek Isertig precut air turig vae legths Fiishig air turig vae istallatio 50

51

Reiforcemet Geeral Iformatio Proper system reiforcemet is critical to the logevity ad performace of fiber glass ducts. Johs Maville experiece idicates that reiforcemet is istalled most efficietly i the fabricatio shop. I situatios where shippig cosideratios make full shop reiforcemet impractical, cosider reiforcig fittigs i the shop ad straight duct sectios i the field. Ay field reiforcemet or fittig modificatios requirig reiforcemet chages must be i compliace with NAIMA or Johs Maville reiforcemet tables. Reiforcemet is always required whe pressures ad spas (maximum iside duct dimesios) exceed those listed below. For comprehesive reiforcig iformatio, refer to the NAIMA Fibrous Glass Duct Costructio Stadard. Maximum Ureiforced Spa Pressure (w.c.) Type 475 Type 800 0 1 2" 36" 36" ½ 1" 24" 24" 1 2" 15" 18" Note: I some cases, both the width ad depth of the duct must be reiforced, as illustrated below. (Tie rod method show.) 52

Reiforcemet Failure to reiforce properly ca create excessive deflectio of the duct, resultig i extra stress o the existig reiforcemet ad closure system. Proper Reiforcemet Improper Reiforcemet Reiforcemet requiremets are based o duct size (spa) ad iteral static pressure. All duct sectios ad fittigs that fall withi the spa/pressure coditios show o the tables cotaied i this sectio must be reiforced. Note that fittigs are cosidered to be duct sectios ad require reiforcemet wheever the straight duct is reiforced. See pages 68 76 for commo field-fittig reiforcemet details. 53

Reiforcemet Tie Rod Reiforcemet The most commoly used reiforcemet system utilizes iteral wires to limit deflectio of the duct surfaces (see photo, page 55). Cost effective ad reliable whe correctly istalled, the tie rod system is easily modified or istalled i duct or fittigs. Compoets of this system are listed below. Tie rod. 12 gauge (0.105") galvaized steel wire Washers. 2.5" x 2.5" galvaized steel with beveled edges, 0.028" thick ad ceter hole diameter that varies with termiatio Termiatio. The followig methods may be used to secure the tie rods: 1. Wire loop, such as Fasloop 2. Blid rivet sleeve 3. Sprig lockig caps 1. Wire Loop. The Fasloop bedig tool, or tool with equivalet performace, is used to make the 190º loop. Washers must be 0.028" miimum thickess with volcao-type ceters ad 9 gauge (0.150") ceter holes. Cautios: 1. No other loop cofiguratio or washer type is acceptable. 2. Cut required wire legths from budled straight wire; coiled wire is very difficult ad time cosumig to straighte adequately. 3. The wire must ot be a frictio fit i the ceter hole of the washer; the washer must move freely o the wire. Tie Rod Legth = Duct O.D. + 1 3 4" 54

Reiforcemet Wire Loop Termiatio 2. Blid Rivet Sleeve. Steel blid rivet sleeves are a acceptable alterate termiatio method oly if the sleeves are properly crushed oto the wire! Duct systems usig sleeve termiatio must be staticpressure tested followig istallatio to determie adequate crimp pressure. No tool is available for this type of termiatio, ad for this reaso Johs Maville does ot recommed the sleeves for static pressures exceedig 1" w.c. Washers must be 0.028" miimum thickess with 7 32" diameter ceter holes. Cautios: 1. NEVER use alumium sleeves. 2. Extreme care must be take to esure a complete crimp. 3. To esure secure sleeve crimps, each duct ru must be pressure tested after istallatio. Blid Rivet Sleeve Tie Rod Legth = Duct O.D. 55

Reiforcemet 3. Sprig Lockig Caps. Lockig caps (or buttos") must be 7 8" diameter with sprig steel or stailess steel locks, ad may be used i systems operatig at static pressures of 1" w.c. or less. Washers must be 0.028" miimum thickess, with 9 gauge (0.150") ceter holes. Cautios: 1. NEVER use caps with alumium or mild steel sprigs. 2. Extreme care must be take to esure correct wire legth. 3. The caps must be pressed completely oto the wire. 4. Sprig lockig caps are ot suitable for use o sloped paels, such as trasitios or reducers. Sprig Lockig Cap Tie Rod Legth = Duct O.D. + 7 16" 56

Reiforcemet Reiforcemet of Rectagular Fiber Glass Air Ducts Spacig show is applicable to both positive (supply) ad egative (retur) pressure duct systems. Static Pressure (i. w.c.) 0 thru 1 2" Ati-sag Support over 48" Number of Tie Rods Across Duct Dimesio Maximum (space 16" Maximum Logitudial Iside o ceter; Spacig Betwee Tie Rods Duct refer to (refer to dimesio A dimesio Dimesio o page 60) C o (I.D.) (i.) page 60) Type 475 Type 800 0 36 Not Required Not Required 37 42 2 24" 48" 43 48 2 49 60 3 61 64 3 24" 65 80 4 81 96 5 Over 1 2" thru 1" Over 1" thru 2" Ati-sag Support over 48" Ati-sag Support over 48" 0 24 Not Required Not Required 25 30 1 24" 48" 31 32 1 24" 33 36 2 37 48 2 49 64 3 65 80 4 81 96 5 0 15 Not Required Not Required 16 18 1 24" Not Required 19 24 1 24" 24" 25 32 1 16" 33 48 2 49 60 3 61 64 3 16" 65 80 4 81 96 5 57

Reiforcemet Basic Positioig of Tie Rods Positive Pressure Ducts Figure 1 Basic Tie Rod Detail (ot to scale) 4 5 3 2 1 Female Joit Male Joit A A 4" A A C C C C B Wire 48" Where tie rods are required, as idicated i the tie rod reiforcemet table, the first rows of tie rod (for positive pressure duct) shall be placed 4" from the female edge of the trasverse joit (at Poit A i Figures 1 ad 2). Subsequet locatio of rows of tie rods, either 48", 24" or 16" apart as required by the reiforcemet table, shall be determied by measurig from this poit. 1. Facig: This must be lapped over the facig o the female shiplap ad stapled approximately 2" o ceter. 2. Tape: Refer to Closure ad Assembly tab for recommedatios. 3. Staple: Outward-clich type 1 2" or 9 16" steel staples approximately 2" o ceters, placed alog staplig flap at the joit as required. 4. Washer: 2 1 2" x 2 1 2" square, 0.028" miimum thickess galvaized steel with beveled edge, beaded reiforcig crater ad 0.150" hole. Beveled edge of washer tured away from the duct board facig. 5. Wire: 12-gauge (0.105") galvaized steel. 58

Reiforcemet 6. Ati-Sag Assembly: Large duct spas experiece atural sag whe ot pressurized. To miimize this, a ati-sag assembly is istalled o duct spas over 48" I.D. Coduit should be ½" diameter (miimum) galvaized steel (EMT), cut to the same legth as the iside duct dimesio, with additioal washers placed betwee the coduit eds ad the duct iterior. See detail i Figure 2 with ati-sag assembly located 4" from male ed of duct. Note: NAIMA Stadard calls for ati-sag support begiig at 48" I.D.; the differece from Figure 2 is ot a structural issue ad may be optioally used. Figure 2 Basic Ati-sag Tie Rod Detail (ot to scale) 4 5 3 2 4 5 1 Female Joit Male Joit Supply Duct Positive Pressure Spa over 48" D 4" A 4" A 6 C C C C C B D A. Maximum logitudial spacig betwee rows of tie rods if required by tie rod reiforcemet table to be 16", 24" or 48". B. Tie rods must be o more tha 16" o ceters across duct dimesio. C. 12-gauge (0.105") wire with 2 1 2" square washer. D. 12-gauge (0.105") wire with 1 2" coduit (EMT). See Figure 2 for details. Note: Proper-fittig reiforcemet may require chael ad/or metal agles i combiatio with tie rods. Refer to curret NAIMA Stadard for complete details. 59

Reiforcemet Negative Tie Rod Duct Reiforcemet Johs Maville Mat-Faced Micro-Aire Duct Board or SuperDuct RC systems that will be subject to egative pressure may be reiforced with the same tie rod schedule as show o page 59, with the modificatios listed below. IF THERE IS THE POSSIBILITY OF SURGES, REINFORCE TO THE EXPECTED SURGE PRESSURE ON NEGATIVE DUCT APPLICATIONS. Logitudial spacig of tie rods starts 4" from the male edge, as show i Figure 3. All tie rods used to reiforce egative pressure duct require 12-gauge (0.105") wire, 1 2" coduit ad four-washer assembly as show i Figure 3. Ductwork reiforced for egative pressure does ot require ati-sag supports. Materials A. Washer: 2 1 2" x 2 1 2" square, 0.028" miimum thickess galvaized steel with beveled edges ad 0.150" diameter hole; beveled edge of washer tured away from the duct board. B. Wire: 12-gauge (0.105") galvaized. C. Coduit: Should be 1 2" diameter galvaized steel (EMT), cut to the same legth as the iside duct dimesio. Additioal washers must be placed betwee the coduit eds ad the duct with edges tured away from board as show i Figure 3. Figure 3 4" Logitudial Spacig Specified B A C 60

Reiforcemet Tie Rod Reiforcemet Tips While fiber glass duct system reiforcemet is doe most efficietly i the shop eviromet, situatios may arise that call for reiforcemet to be istalled or modified i the field, such as: 1. Offsets fabricated from straight-duct modules 2. Icrease i fa pressure due to system desig or equipmet chages 3. Duct compressio packaged for shipmet to job 4. Tap-i requires duct joit to be altered 5. Reiforcemet icorrect from the shop Field Tie Rod Istallatio. To properly istall tie rod reiforcemet, observe the followig steps: 1. Sweep or clear a work area, preferably ear a wall. For fittig reiforcemet, a workbech, table or cart is desirable. 2. Select the proper reiforcemet schedule from the table o page 59. To do this, you must kow: Duct size (iside dimesios) System static pressure expressed i iches of water colum (w.c.) Board type, 475 or 800 For fittigs, the sizes of ay opeigs or duct-size chages Tip: To avoid cofusio ad repeated referece to the table, write the umber of wires per joit o a separate sheet of paper or make a sketch showig the joit with rods marked. 61

Reiforcemet Example: A duct sectio has bee field fabricated for the truk lie. Duct size is 48" x 20", static pressure (foud i pressure arrows or the fa pressure schedule o the blueprits) is +1.2" w.c. ad the duct board is Type 475. A. Referrig to the table o page 59 (highlighted below), select the static pressure from Colum 1, which will be i the Over 1" through 2" category (third block). B. Both duct dimesios must be cosidered idepedetly; for this example, begi with the 48" dimesio. Readig from Colum 2 (to the right of the selected pressure category), select Lie 5 (33 48"). C. Read the umber of tie rods required across the selected duct dimesio from Colum 3. D. From Colum 4, read the maximum logitudial spacig (refers to the legth of the joit, ormally 48" or 96" for Johs Maville Wide Board products) betwee tie rods required for Type 475 duct board. Over 1 2" Ati-sag Support over 48" 37 48 2 49 64 3 65 80 4 81 96 5 Over 1" thru 2" Ati-sag Support over 48" 0 15 Not Required Not Required 16 18 1 24" Not Required 19 24 1 24" 24" 25 32 1 16" 33 48 2 49 60 3 61 64 3 16" 65 80 4 81 96 5 62

Reiforcemet E. Repeat steps B through D for the 20" duct dimesio. Over 1 2" Ati-sag Support over 48" 37 48 2 49 64 3 65 80 4 81 96 5 Over 1" thru 2" Ati-sag Support over 48" 0 15 Not Required Not Required 16 18 1 24" Not Required 19 24 1 24" 24" 25 32 1 16" 33 48 2 49 60 3 61 64 3 16" 65 80 4 81 96 5 3. Mark the duct sectio(s) for tie-wire istallatio. Tip: Positio the duct with the female ed up o positive pressure (supply) ducts ad the male ed (with staple flap) up o egative pressure (retur) ducts. This will allow reiforcig to begi at 4" from the respective eds. Example: Usig the 48" x 20" duct sectio from the previous example: A. Place the duct o the floor with the female ed up. B. Begiig with the 48" side, make a mark o the ceter lie of the pael (24" iside or 25" outside). C. The table o page 59 shows that two wires will be required across the duct dimesio, spaced at 16" (maximum). Page 60, Figure 1 idicates that the two wires will be placed 4" from the female ed. Measure 8" o either side of the ceter lie mark ad 4" dow from the female to establish the marks for the first two wires. 63

Reiforcemet 48 duct side showig tie-rod istallatio template D. The table o page 59 idicates that wires are required at 16" itervals dow the legth of the cut sectio. Usig the marks at 4" from the female as the base, measure 16" maximum vertical spacig. Repeat markig process for the opposite side of the duct. Tip: Always use a template ad scratch-awl or similar sharp object to puch holes for the wires. E. The 20" duct dimesio will require oly oe wire o ceter (10" iside, 11" outside), begiig 4" from the female. F. The table o page 59 requires the logitudial iterval to be 24". Measure 24" from the mark 4" from the female, usig care to mark the hole i the ceter of the dimesio. Repeat the process for the opposite side of the duct. 64

Reiforcemet 4. Istall the wires i the duct sectio. 20" duct side showig tie-rod dimesios Tip: Cut all wires for the job before reiforcig, usig a jig to maitai a cosistet legth. Clamp a budle of wire securely ad cut with a bad or chop saw for large quatities of a commo legth. Warig: Wire legth should be determied by the formula show with the drawig o page 56. It is very importat that the wire legths vary by o more tha 1 4"! Tip: Usig the Fasloop bedig tool or tool with equivalet performace, pre-loop all wires o oe ed, ad istall oe washer with the bevel (ad volcao coe) toward the loop. Maufacture as may assemblies as possible at oe time. Tip: After isertig the wire assembly through the first side, reach iside the duct ad place the wires through the opposite holes (from iside to outside) to esure straight, parallel wires. 5. Positio the duct ear a wall so that the istalled washers ad loops will be firmly i place by the wall. Istall washers ad use the Fasloop tool to form the loops. Termiate all wire assemblies i this maer. Fiished reiforcemet of completed duct sectio 65

Reiforcemet Chael Reiforcemet A alterative reiforcemet method utilizes U" chael sectios made from various galvaized sheet metal gauges applied at specified itervals. For detailed iformatio o stadaloe chael reiforcemet, see the NAIMA Fibrous Glass Duct Costructio Stadard. Where tie rods caot be fasteed through to the opposite side, use chaels for reiforcig. See additioal fittig reiforcemet iformatio. Fittig Note: Some types ad sizes of fittigs ad lateral braches may require metal U" chael i additio to tie wire reiforcemet method. Refer to pages 70 71 for more iformatio. Cautio: Omissio of reiforcemet or substitutio of reiforcemet other tha illustrated i this book or the NAIMA or SMACNA Stadards will result i a duct system that may ot comply with buildig codes. Fittig Reiforcemet ad Assembly Reiforcemet Requiremets Fittigs must always be reiforced wheever the straightduct sectios of the same size require reiforcemet. I some cases, fittigs will require additioal or alterative reiforcemet as compared to straight duct. The followig pages illustrate Johs Maville-approved optios desiged to work with the procedures detailed i the NAIMA Fibrous Glass Duct Costructio Stadard. Use of adhesives does ot elimiate the eed for tie wires or other reiforcemet as called for i the NAIMA maual, except i the cases specifically oted. 66

Reiforcemet NAIMA/SMACNA Recommedatios The itroductio of the NAIMA Fibrous Glass Duct Costructio Stadard i 1989 dramatically chaged procedures for fabricatio ad assembly of duct ad fittigs i sizes or static pressures requirig reiforcemet. Use of metal corer agles has bee madated o 90 elbows, take-offs ad certai other fittig situatios to prevet potetial log-term leakage of the joits. Comprehesive iformatio o the use of metal iserts i duct reiforcemet ad assembly may be foud i the curret NAIMA ad SMACNA Fibrous Glass Duct Costructio Stadards. Johs Maville Adhesive Fittig Reiforcemet Recommedatios Johs Maville has tested ad approved specific costructio adhesive applicatios as a alterative to the NAIMA metal isert requiremets. The followig pages illustrate the correct use of adhesives o commo field fittigs ad joits. The use of adhesives is a optio o all JM rigid fiber glass duct products. Where adhesives are ot used, the fittig reiforcemet system described i the NAIMA Fibrous Glass Duct Costructio Stadard must be followed. I accordace with curret idustry practice, Johs Maville tests ad approves oly o-solvet based costructio adhesives, such as water-based or silicoe compouds. These products do ot geerate flammable vapors durig the curig process ad will meet the 25/50 flame spread/smoke developed criteria required for most applicatios. For a list of Johs Maville-approved adhesives, please cotact the Regioal Sales Office earest you or your local Johs Maville Territory Maager. Note: The NAIMA ad SMACNA Fibrous Glass Duct Costructio Stadards recogize the right of idividual duct board maufacturers to develop recommedatios which supersede those i the NAIMA Stadard. The Johs Maville adhesive recommedatios are applicable oly with SuperDuct RC Air Duct Board ad Mat-Faced Micro-Aire Duct Board. 67

Reiforcemet Partial Wrap-aroud Chael Reiforcemet Where reiforcemet is required but tie wires caot be fasteed to opposite sides of a duct sectio or fittig, it is ecessary to istall formed sheet metal chaels that partially wrap aroud the duct sectio or fittig at the required locatios. Note: Short-fittig throats are show for clarity; use of stadard MDC practice (see Tab 2) is recommeded wherever applicable. Also, tie wires have bee omitted from the followig drawigs for clarity but must be used i actual duct systems as the primary reiforcemet. 90º Elbow A 24" Maximum Allowable Spacig 6" Mi. Air Flow 24" O.D. Max. 4" Total Legth of Chael = Outside Duct Dimesio + 12" Tees A 24" Max. 24" O.D. Max. 68

Reiforcemet Ed Caps A 24 O.D. Max. 24" Max. Ed caps must be istalled per NAIMA fabricatio istructios. Detail A 3" x 1 1 2" Chael, 18-Gauge Galvaized 6" Plated No. 10 x 1 1 4" Sheet Metal Screw 1 1 2" 2 1 2" Sq. Washer Iside Duct Approved costructio adhesive must be applied liberally to the chael legs before istallatio of the chael. Whe chael fasteers are tighteed, adhesive should seep from uder the chael s edge. Note: Oly duct sectios that do ot exceed a outside dimesio (depth or width) of 24" are curretly tested ad approved for the adhesive method of chael securemet. For larger duct sectios, refer to the NAIMA Maual. 69

Reiforcemet Trasitios Trasitios, or ay fittig requirig reiforcemet of a sloped pael, must have the sloped pael washers firmly secured. The Johs Maville adhesive method is illustrated. Trasitio Reiforcemet, Slopig Sectio 5 1 4" Max. o Sloped Pael 24" Max. B 4" Max. Normal Tie Rod Termiatio o Straight Side Detail B 2 1 2" Sq. Washer Must be used o slopes. Adhesive must be applied to the uderside of the washer prior to istallatio o sloped paels. 70 Offsets Fabricatio of offsets i the field is a commo practice. Where static pressure ad duct size require reiforcemet of offsets i the field, tie wires are ofte required i additio to those called for i the table o page 59. The followig precautios should be take: 1. The offset should be carefully measured ad cut with a straight edge to esure a tight joit. 2. Flush or butt-edge joits should be used. 3. Approved costructio adhesive should be applied to the etire perimeter of oe side of the cut joit. Upo assembly of the joit, the adhesive should be firmly i cotact with both sides of the cut.

Reiforcemet Butt-edged Offset Reiforcemet 16" Max. Distace from Heel Joit to Tie Wire C 8" Max. Distace from Throat Joit to Tie Wire Max. Distace from Cheek Joit to Tie Wire 8" Female Shiplap Detail C Staight-edge Miter Cut Approx. 1 4" Dia. Bead of Adhesive Duct Board Note: The tie-wire spacigs show are maximum dimesios. Reduced dimesios should be used where applicable to keep the wires perpedicular with the duct surfaces. 71

Reiforcemet Sectioalizig Reiforced Duct ad Fittigs Whe istallig duct sectios ad fittigs that cotai reiforcemet, the NAIMA maual requires that sadwiched metal agles be used i may istaces to secure the joits. This is a ew requiremet ad demads alterate istallatio practices. To ease the trasitio to the ew reiforcemet stadard, Johs Maville has applied adhesive techology to reiforce the joits, elimiatig the eed for metal accessories i may cases. Please ote the followig: 1. The Johs Maville adhesive recommedatios apply oly to JM rigid fiber glass duct products. 2. Adhesive use is a optio oly. The reiforcemet methods detailed i the NAIMA Fibrous Glass Duct Costructio Stadards Maual are required wherever adhesives are ot used. 3. Use of adhesives as recommeded does ot elimiate the eed for use of tie wires or chael as required i the NAIMA maual or other sectios of The Pocket Istaller. Where Joit Reiforcemet is Required I ay situatio where a sloped or agled pael jois a flat or straight pael ad the duct is of sufficiet size or operatig pressure to require reiforcemet, the joit betwee those paels will require additioal reiforcemet. Agled Joits; Adhesive Required 72

Reiforcemet 90 Elbow Joit Adhesive Usage Oe of the most commo field fittigs is the 90 elbow. The JM adhesive-reiforcemet method illustrated also applies to tees or ay other fittig where a perpedicular duct takes off of a existig duct ad where joit height is the same. Adhesive Reiforcemet at Throat, 90 Elbows D 8" 8" H Detail D. Throat Reiforcemet Adhesive Adhesive, approx. 1 4" dia. bead extedig 8" (mi.) from both corers of throat alog depth ad width. Staple Flap 8" Mi. Adhesive 8" Mi. Whe duct dimesio H requires reiforcemet per reiforcig tables o page 59 (Type 475 or Type 800), adhesive is required as show i figure above. 73

Reiforcemet Note: Where reiforced duct height differs o take-offs, tap-is or ay 90 elbow, metal reiforcemet should be used as detailed i the NAIMA maual. To avoid the added cost ad complexity of the metal usage, cosider fabricatig all lateral (or vertical) rus of the same duct height (or width) ad the trasitioig to the required size further dow the ru. Trasitio Joit Adhesive Usage Where the sloped pael of a trasitio jois with a dowstream straight duct sectio ad where the ductwork requires reiforcemet, approved adhesives may be used to elimiate some metal reiforcemet. Trasitio Reiforcemet, Slopig Sectio 5 1 4" Max. o Sloped Pael 16" Max. 8" 4" Max. 8" Normal Tie Rod Termiatio o Straight Side See Detail D o page 75 for proper adhesive applicatio. 74

75

Hagers, Coectios ad Accessories Rectagular Duct Hagers Stadard Hagers Sheet metal chael sectios are ormally used to support rectagular fiber glass duct ad fittigs. Stadard chael width is 3", with the web depth ad metal gauge selected from Table 1, below. Hager spacig is determied from Table 2, page 79, ad varies by duct depth ad width. Note: JM Wide Board duct sectios of ay depth ad width may be supported o 8' ceters usig 3" hager chael with web ad metal gauge selected i accordace with Table 1. Table 1. Chael Selectio If Total Miimum Miimum Extesio is Chael Chael Not Greater Tha: Gauge Profile 6" 24 3" x 1.5" 18" 22 3" x 2" 30" 18 3" x 2" Hager Spacig ad Extesio, 3" Wide Chaels Maximum Hager Spacig See Table 2 E Total Hager Extesio (E + E ) See Table 1 E 3" 76

Hagers, Coectios ad Accessories Table 2. Maximum Hager Spacig by Duct Size, I.D. Maximum Hager Duct Size, Iches Spacig 48" wide or greater 4' Less tha 48" wide ad less tha 12" deep 6' Width betwee 24" ad 48" ad greater tha 24" deep 6' Less tha 48" wide ad depth betwee 12" ad 24" 8' Width 24" or less ad depth greater tha 12" 8' Wide Board ay width or depth 8' Use of 2" Wide Hagers 22-gauge, 2" x 1.5" chael may be substituted for 3" hagers where the duct width (ID) does ot exceed 48', ad the duct depth (ID) does ot exceed 24." Hager spacig itervals for 2" wide hagers may ot exceed 4'. Use of 2" Wide Hager Chaels 4 Ft. Max. 48" I.D. Max. E E + E 6" Max. 24" I.D. Max. E 77

Hagers, Coectios ad Accessories Hager Supports Hager chaels may be supported by ay of the followig systems: 1. 12-gauge (0.105") (miimum) galvaized steel wire (check local codes), secured through holes peetratig the hager chael eds 2. 1" x 22-gauge (0.030") (miimum) galvaized metal strap securely screwed, riveted or welded to the hager chael eds 3. 1 4" diameter threaded rod secured through holes i the hager chael eds. Note: The supports listed above may also be attached to reiforcig chaels i lieu of a separate hager chael where reiforcig chaels do ot exceed the maximum hager iterval. Horizotal Supports C B D C A A 6" Max. A. Chael B. Hager rod C. Hager strap D. 12-gauge (mi.) hager wire E. Reiforcig chael E 78

Hagers, Coectios ad Accessories Special Hager Situatios Hagig Fibrous Glass Duct Fittigs up to 48" i Width Elbow Support Required oly whe duct is greater tha 18" i width Two-thirds of the diagoal distace from throat to heel (approx.) 45 12" Max. Brach Support If truk duct hager falls where brach duct is located, add truk hagers o either side of brach duct. Do ot exceed maximum hager spacig (Table 2, page 79). Do Not Exceed Stadard Hager Spacig Stadard Truk Hager Spacig Brach 12" Max. 79

Hagers, Coectios ad Accessories Tee Support If a tee ru-out falls where truk duct is located, add ru-out hagers o either side of truk. Do ot exceed maximum hager spacig (Table 2, page 79). Ru-out Truk 12" Max. Offset Support (Flat Bottom Surface) Required oly whe agled portio of offset is greater tha 48" log. Additioal hagers may be required to comply with spacig. See Table 2, page 79. Do Not Exceed Stadard Spacig 6" to 12" 6" to 12" 80

Hagers, Coectios ad Accessories Trasitio Support (Flat Bottom Surface) Locate hagers as for straight duct. Note: Hager spacig may chage whe trasitio is from oe hager size to aother. Use closest spacig described by Table 2, page 79. Do Not Exceed Stadard Spacig Supportig Offsets ad Trasitios with Iclied Bottom Surfaces Required oly whe iclied portio of duct is greater tha 48". Hager is attached to duct per detail as show below. Additioal hagers may be required to comply with hager spacig per Table 2, page 79. 6" to 12" 6" to 12" 81

Hagers, Coectios ad Accessories Detail of Support at Iclied Bottom Surface 3" x 1" Chael 9" (Mi.) Log Hager Rod Cetered Iside Duct Parallel to Air Flow Duct 2 1 2" Sq. Washers #10 Plated Sheet Metal Screws 82

Hagers, Coectios ad Accessories Vertical Riser Supports Risers i fiber glass duct systems of 8' or loger require special support as show i the diagram below. The support systems do ot substitute for reiforcemet required by the Tie Rod Reiforcemet Table o page 59. Vertical riser support itervals should ot exceed 12' maximum itervals. A alterate method of riser support which uses floormouted attachmets is also illustrated. Johs Maville recommeds the use of a iteral metal sleeve i place of 2 1 2" square washers for ease of field istallatio. 2 1 2" square galvaized 0.028" miimum thickess washers are also acceptable, miimum oe per side, o 8" (max.) ceters. Note: Riser height is limited as stated i NFPA 90A for vertical risers i air duct systems servig more tha two stories. Chael per Hager Schedule, Page 78 #10 Plated Sheet Metal Screws 8" o.c., Miimum Oe per Side 3" Wide (Miimum) Sheet Metal Sleeve Iside Duct 1" x 1" x 1 8" Wall Support Agle 83

Hagers, Coectios ad Accessories Equipmet Coectio Details The followig figures illustrate some differet equipmet coectio details for use with fibrous glass duct. Additioal equipmet coectio details may be foud i the NAIMA Fibrous Glass Duct Costructio Stadard. I situatios where fiber glass duct is secured over a metal sleeve leavig the fiber glass wool exposed, the istaller should seal the duct board facig to the metal to elimiate leakage. Where the duct-system operatig pressure is less tha 1" w.c., UL 181A-P listed pressuresesitive tape should be used. Where the duct operatig pressure is 1" w.c. or greater, use glass fabric ad mastic that meet the requiremets of UL 181A-M (refer to Duct Board Closure System Selectio Guide, page 37). The type of equipmet determies which detail or details must be applied for the fabricatio of coectios. Flages ad collars o equipmet vary; select the detail that best meets the idividual job requiremet. Sheet Metal ad Equipmet Coectio Details Note: All mechaical coectios of fibrous glass duct to equipmet must be 12" (max.) o ceters. Figure 1. Closure Equipmet Flage #10 x 1 1 4"* Sheet Metal Screws, 12" (Max.) o.c., Mi. Two per Side Fibrous Glass Duct 84 22-gauge (0.030") Sheet Metal, 1" x 1" x 1"** Board *Sheet Metal Thickess Screws 1" #10 x 1 1 4" 1 1 2" #10 x 1 3 4" 2" #10 x 2 1 4" Board **Sheet Metal Thickess Chael 1" 1" x 1" x 1" 1 1 2" 1" x 1 1 2" x 1" 2" 1" x 2" x 1"

Hagers, Coectios ad Accessories Figure 2. Closure Equipmet Flage #10 x 1 1 4"* Sheet Metal Screws, 12" (Max.) o.c., Mi. Two per Side Fibrous Glass Duct 22-Gauge (0.030") Sheet Metal, Pocket Lock, 1" x 1" x 1"** Figure 3. #10 x 1 1 4"* Sheet Metal Screws, 6" (Max.) o.c., Mi. Two per Side Closure Equipmet Flage Screw, Blid Rivet Sleeve or Spot Weld to Equipmet Flage Fibrous Glass Duct Sheet Metal Sleeve, 22- Gauge (0.030"), Mi. 3" Wide Board *Sheet Metal Thickess Screws 1" #10 x 1 1 4" 1 1 2" #10 x 1 3 4" 2" #10 x 2 1 4" Board **Sheet Metal Thickess Chael 1" 1" x 1" x 1" 1 1 2" 1" x 1 1 2" x 1" 2" 1" x 2" x 1" 85

Hagers, Coectios ad Accessories Figure 4. Closure 2 1 2" Square Washers 12" Mi. o.c., Mi. Two per Side Equipmet Flage #10 x 1 1 4"* Sheet Metal Screws Fibrous Glass Duct 22-Gauge (0.030") Sheet Metal, 1" x 3"** Equipmet Coectig Flage Screw, Blid Rivet Sleeve or Spot Weld to Equipmet Flage Figure 5. #10 x 1 1 4"* Sheet Metal Screws, 12" (Max.) o.c., Mi. Two per Side 22-Gauge (0.030") Sheet Metal, 1" x 3" Closure Equipmet Flage 86 Use this coectio whe duct spa is greater tha 60" or static pressure is greater tha 1" w.c. Board *Sheet Metal Thickess Screws 1" #10 x 1 1 4" 1 1 2" #10 x 1 3 4" 2" #10 x 2 1 4" Fibrous Glass Duct **Equipmet Board Coectig Thickess Flage 1" 1" x 3" 1 1 2" 1 1 2" x 3" 2" 2" x 3"

Hagers, Coectios ad Accessories Accessories Typical Suggested Coectios for Istallatio of Accessories Additioal accessory coectio details may be foud i the NAIMA Fibrous Glass Duct Costructio Stadard. Sigle-blade Volume Damper Use 3 1 2" x 3 1 2" Moutig Washers Multi-Blade Volume Dampers 1. Isert damper assembly ad sleeve iside duct. 2. Put hager directly uder assembly. 3. Where damper motor ad operator are used, attach motor ad operator to a additioal outer sheet metal sleeve. 87

Hagers, Coectios ad Accessories Fire ad Smoke Dampers Cosult the SMACNA Fire Damper Guide ad the SMACNA Low-velocity Duct Costructio Stadard for details goverig the costructio of fire dampers ad placemet of fire dampers i walls. A. Metal sleeve for fire dampers should exted approximately 3" beyod each side of the wall to facilitate attachmet of duct sectios. B. Agles attached to sleeve but ot to wall. These are used o four sides of the duct ad they must lap the wall 1" miimum. C. #10 sheet metal screw ad 2 1 2" square beveled washers, 0.028" miimum thickess. Use at least oe per side, with a maximum iterval of 12". D. Tape closure to seal joit betwee duct ad sleeve. If duct operatig pressure is less tha 1" w.c., use UL 181A-P listed tape. If duct static pressure is 1" w.c. or greater, glass fabric ad mastic is required. E. Access door (see page 91) A E B D C C D B B A 1 1 2" Miimum Lap 88

Hagers, Coectios ad Accessories Duct Access Doors Widow-Type Sashlock Chael Frame Sheet Metal Screws Z-bar Fibrous Glass Pael Sheet Metal Reiforcig Plate Typical coceptual sketch; commercial access doors are also available. Moutig Diffuser Rectagular or square Where diffusers are less tha 150 sq. i. ad mouted directly i the wall of the duct, separate support is ot required. Refer to the NAIMA maual ad Johs Maville UL Fabricatio Istructios for other meas of diffuser support. Attach Like Brach Coectio Support Diffusers Idepedetly Chael Diffuser Screw Duct Diffuser 89

90 Notes

91

Field Fabricatio of Fittigs I geeral, shop fabricatio is substatially more efficiet tha field fabricatio. Field fabricatio should be avoided uless adequate, clea ad protected space as well as appropriate tools are available. Whe circumstaces require that fittigs be made i the field, the followig suggestios should be cosidered. Ells Start with a stadard closed 4' or 8' legth of duct. 1. Workig from the female ed, cut the throat rail 1 1 2"* loger tha the desired width I.D. Cut Foil Straight Cut Female Ope Width + 1 1 2"* Board *Cut Width Thickess Plus: 1" 1 1 2" 1 1 2" 2 1 4" 2" 3" 2. Istall preassembled vae assemblies with screws ad washers o 12" miimum ceters, miimum two screws per side, to hold i place. The cut piece becomes the heel. Fiber glass air turig vaes are recommeded i lieu of metal vaes ad ruers ad should be istalled by isertio ito the cheeks of the ell, ot with vae rail assemblies. 92

Field Fabricatio of Fittigs 3. Place 8" cross tabs o the heel piece o miimum 12" ceters (miimum oe tab per side). Fiish tapig the joit. If the upstream throat must be shorteed, cut off the male ed to provide the required heel legth with a male/female tool ad attach the leftover piece to the dowstream throat of the ell. Throat should be 4" or greater to allow secure closure. 4. Reiforce fittigs accordig to istructios i sectio begiig o page 68. Note: Stadard fiber glass air turig vaes (small crosssectio) are typically istalled 3" o ceter. Oe tie rod is required through the miter lie for every five vaes eve though the reiforcig schedule may ot require tie rods for that duct size ad static pressure. Air turig vae reiforcemet is ot a substitute for the duct or fittig reiforcemet. Trasitios Start with a stadard closed 4' or 8' legth of duct. Reduce size o the female ed; use the logest practical legth of chage to miimize pael loss. Width Reductio 1. For a width reductio, use a trasitio layout tool or straight-edge ruler to mark off the exact iches to be reduced from the outside of the duct (X"). 2. Determie legth (L) of cut alog duct sectio. Tip: Stadardize trasitio legth cuts (example: always make 2" reductio 18" dow duct sectio, but ever less tha six times the reductio). 3. Usig a straight edge, score the foil with a kife or tip of Cuts-All tool. Complete the cut with the Cuts-All tool makig a shiplap cut i the top ad bottom paels. 93

Field Fabricatio of Fittigs 18" X" Female 3 5 4 4. Ski glass away from facig ad leave facig as a staple flap. 5. Fold i edge ad staple flap. 6. Trim the remaiig edges to match the rail legth ad replace the female edge. Depth Reductio 1. For a depth reductio, mark off the iches to be reduced plus 1 2,"* from the outside of the duct. 2. Determie legth (L) of cut alog duct sectio. Tip: Stadardize trasitio legth cuts (example: always make 2" reductio 18" dow duct sectio, but ever less tha six times the reductio). 3. Usig a straight edge, make straight kife cuts i the side paels, leavig staple flaps for assembly. 4. Staple ad tape. 5. Trim the remaiig edges to match the rail legth ad replace the female edge. 18" X + 1 2"* 94 Board *Depth Reductio Thickess Plus: 1" 1 2" 1 1 2" 3 4" 2" 1"

Field Fabricatio of Fittigs Offsets 30 Oe-way Offset Use a stadard closed 4' or 8' legth of duct. 1. Mark the desired throat legth, allowig at least 4" for closure applicatio. 2. Usig a 15 sheet metal template or agle-fider, score the foil across the duct spa that will offset. Usig a straight edge, score vertical lies o the two adjacet faces of the sectio. Tur the duct over ad joi those marks by scorig the opposite spa, agai usig a straight edge. 3. Mark similar lies to produce a ceter piece twice the legth of the offset distace. 4. Usig the scored lies to guide your kife, carefully pull the kife through the duct sectio, maitaiig the 15 agle. Avoid a sawig motio for best results. 5. Rotate the ceter piece 180. Use cross tabs across the cuts i lieu of staple flaps (8" log, 12" o ceter, miimum oe per side) ad tape all joits. Make All Cuts Straight Through ad Hold 15 Agle 15 2X X = Iches of Offset (i.e., For a 6" Offset, Legth of Ceter Piece is 12") Rotate Ceter Piece 180 ad Assemble with Tape Tabs 95

Field Fabricatio of Fittigs Usig the Cuts-All Tool The versatile Cuts-All male/female (M/F) shiplap had tool is used to make male or female shiplaps o flat fiber glass board sheets or o closed duct modules. It elimiates butt joits by replacig them with a stroger, tighter shiplap cofiguratio. 1 2", 3 4", 1"* With a closed 4' sectio of duct, the Cuts-All tool, a straight kife ad a straight edge, early ay stadard fittig ca be field fabricated. The Cuts-All tool ca form the followig shiplap cuts: 1. Flat Male 2. Flat Female 7 8", 1 3 8", 1 7 8"* 7 8", 1 3 8", 1 7 8"* 1 2", 3 4", 1"* 3. Closed Male 4. Closed Female 5. Closed Trasitio 6. I-lie Elbows 96 * Dimesios for 1", 1½" ad 2" board thickesses, respectively.

Field Fabricatio of Fittigs 7. Multiple Cut. Use Cuts-All to cut sectio to legth, simultaeously providig male ad female eds. Ed Joits ad Tap-is Whe makig straight duct sectios or fittigs out of board without factory-molded shiplaps (scrap or drop-off pieces), male ad female ed joits or tap-is ca be shiplapped usig the appropriate ed of the Cuts-All tool. I.D. + 1"* Straight Kife Cuts Tap-i Duct Male Ed Straight Kife Cuts I.D. I.D. + 1"* Shiplap Slit Facig I.D. I.D. Width + 1"* I.D. Depth + 1 1 2"** Slit Facig I.D. Depth Straight Kife Cuts Top ad Sides Ed Cap I.D. Width Board *Cut I.D. Thickess Width Plus: 1" 1" 1 1 2" 1 1 2" 2" 2" Board **Cut I.D. Thickess Depth Plus: 1" 1 1 2" 1 1 2" 2 1 4" 2" 3" 97

Field Fabricatio of Fittigs Repairs Accidetal puctures or tears i the facig should be repaired to miimize leakage ad provide a eat appearace. Whe patchig SuperDuct RC Duct Board, use SuperSeal Edge Treatmet (follow directios o cotaier) or SuperSeal HV sealat o iterior joits before replacig patch or pael. If the damaged area is small, repair with approved closure system. Where larger areas of the facig have bee damaged, use the patch method. Sigificat damage of the facig ad duct material may require replacemet of the damaged duct wall. Patch Method. Obtai a suitable piece of facig for use as a patch ad apply with a miimum of 1" overlap o all edges. Cemet edges dow with a approved water-base duct adhesive ad the tape over lap with approved closure. 98

Field Fabricatio of Fittigs Pael Replacemet Method. Large areas of damage to facig ad duct wool require replacemet of the damaged pael area, as illustrated below. Damage to duct wall Cut out rectagular pael aroud damaged areas, utilizig Cuts-All tool to retai female joit. 99

Field Fabricatio of Fittigs Remove damaged pael ad use as patter for replacemet sectio. Isert replacemet pael, usig adhesive if fit is ot sug. (Note: All systems operatig at 2" w.c. or greater require adhesive.) Use approved closure to seal the replacemet pael i place. 100

101

Job Ispectio Checklist Materials Needed YES NO The Pocket Istaller ( ) ( ) NAIMA Fibrous Glass Duct Costructio Stadard, latest editio ( ) ( ) Maufacturer s recommedatios, where applicable ( ) ( ) Submittal drawigs ( ) ( ) Plas ad specificatios for job ( ) ( ) Measurig tape ( ) ( ) Approved closure materials for repair of ay opeigs required for proper ispectio. See pages 36 41. ( ) ( ) Geeral Is the fiber glass ductwork istalled uder the coditios permitted o page 16? ( ) ( ) Is the system operatig withi the desig limitatios for which it was reiforced? ( ) ( ) Have all tears or puctures of duct board facig bee repaired i accordace with practices outlied o pages 100 102? ( ) ( ) Are all sheet metal accessories fabricated of galvaized sheet metal? ( ) ( ) Product The type of the board must be idetified by pritig o the duct board facig. Is the board used i compliace with the egieer s specificatios? ( ) ( ) Check for UL label. Although each fiber glass board is labeled, each duct sectio may ot be sice there is oly oe label per board. ( ) ( ) Fabricatio ad Istallatio Are air turig vaes istalled i accordace with NAIMA stadards? (Pressig your had ito the cheek of the elbow will cofirm fiber glass vae usage.) ( ) ( ) Whe metal parts are attached, are 2 1 2" square (miimum) or JM-approved roud washers used o 12" (maximum) ceters? ( ) ( ) 102

Job Ispectio Checklist Whe staples ca t be used, are 8" cross tabs of approved closure beig used i place of the staples? (miimum oe per side, o 12" maximum ceters) ( ) ( ) Is system completely free of tears or puctures i the facig? Ay facig ad/or glass wool damage is easily repaired usig the techiques described o pages 100 102. ( ) ( ) Is the system free of areas of excessive closure usage? Check areas with several trasverse wraps or large areas of over-lapped tape to determie if they coceal icorrect fabricatio or repairs. ( ) ( ) Are all system joits tight, free from bulges, with taped joits showig evidece of good workmaship? ( ) ( ) Are all fittigs fabricated usig Modular Duct Costructio ad displayig evidece of good workmaship? ( ) ( ) Have offsets bee correctly fabricated ad istalled to prevet ductwork from bedig aroud obstructios? ( ) ( ) Metal to Glass Coectios ad Accessories Duct Heaters: Is iterior sleeve preset, properly attached with screws ad washers o 12" (maximum) ceters, with heater assembly separately hug or supported? (See NAIMA Maual, Sectio II for details.) ( ) ( ) Dampers: Where motorized dampers are used, is the sleeve exteded so that the operator is mouted o the same sleeve as the damper? Where maual volume dampers are used, does the quadrat move a full 90? See page 89 for typical examples. ( ) ( ) Fire Dampers: Is sheet metal sleeve preset, with duct properly attached with screws ad washers o 12" (maximum) ceters? (Fiber glass ducts must ot peetrate assemblies that are required to have fire dampers.) See page 90 for a typical example. ( ) ( ) Access Doors: Is istallatio i accordace with example o page 91 (or NAIMA Maual, Sectio II)? ( ) ( ) 103

Job Ispectio Checklist Grills, Diffusers ad Registers: Is the extra weight of the item separately supported ad ot depedet upo the duct system for support? (Exceptio: Registers ot greater tha 150 square iches i area may be attached to the duct usig metal chael, without additioal support.) See page 91 for a typical example. ( ) ( ) Uit Coectios: Are sheet metal screws ad washers used to secure ductwork to metal sleeve or flage? (Securig the duct without mechaical fasteers is isufficiet.) Is the correct closure used to seal the duct board facig to the metal sleeve or flage? See pages 86-88 for specific closure details. ( ) ( ) Closure Are all joits i the system properly sealed? ( ) ( ) Are all closure materials labeled to idicate compliace with UL 181A (UL 181A-P for pressure-sesitive taped, UL 181A-H for heat-sealed closures). See pages 36 41 for closure details. ( ) ( ) Are all glass fabric ad mastic closures utilizig mastics of a type listed o the UL istructio sheet (i each carto or pallet of duct board)? ( ) ( ) Are there staples or cross tabs, properly spaced, o the circumferetial joits? ( ) ( ) Are staples, if used, of the correct type ad size ad spaced i proper itervals as recommeded by the duct board maufacturer? ( ) ( ) Are all pressure-sesitive tape closures rubbed dow adequately, with staples or scrim i the facig clearly visible through the tape? ( ) ( ) If heat-sealable closure was used, was it applied correctly, as evideced by a darkeig of the ABI dot color? ( ) ( ) If glass fabric ad mastic are used, is the mesh of the glass fabric completely filled with mastic? ( ) ( ) 104

Job Ispectio Checklist Reiforcemet Is the reiforcemet system a JM (or NAIMA, if low pressure) recommeded type? ( ) ( ) Is tie-rod wire 12-gauge (or heavier) steel? ( ) ( ) Is tie rod spacig correct accordig to the duct spa, board type ad static pressure? ( ) ( ) Are tie-rod washers 2½" square (or proper diameter roud, as specified by JM) ad of the correct galvaized steel gauge, 0.028" miimum thickess with edges tured away from duct board facig to prevet cuttig ito it? ( ) ( ) If tie rods are used to reiforce a butt joit, are rods used o both sides of the joit? ( ) ( ) Is wire termiatio of a type documeted o pages 56 58? ( ) ( ) Do tie rods ru straight through the ducts ad ot at agles? ( ) ( ) Are heels of tees, elbows ad ed caps properly reiforced whe required by duct size, board type ad static pressure? (Tie wires, formed metal chael ad adhesives may be used aloe or i combiatio.) ( ) ( ) Whe adhesive is used, is it the correct type as specified by JM? ( ) ( ) Whe formed metal chael or agle is used, are sheet metal gauges, dimesios ad spacig correct? O supply ducts, is reiforcig member istalled o the female side of the shiplap? ( ) ( ) O retur ducts, are sheet metal chael reiforcemets attached with screws ad 2 1 2" square washers or 2" x 6" metal clips (see NAIMA Maual)? ( ) ( ) O retur ducts, is the reiforcig member attached to the male shiplap side of the joit? ( ) ( ) 105

Job Ispectio Checklist For the heels of tees, elbows, ed caps ad ay other fittigs where a pael faces a opeig o the opposite side, is correct reiforcig member (sheet metal chael, tie wires, adhesives or a combiatio of these) applied? ( ) ( ) Hagers ad Supports Are hagers istalled i accordace with pages 78 85? ( ) ( ) Are hager desigs i accordace with those show o pages 78 85? ( ) ( ) Are accessories that add weight to the duct system separately supported so as ot to stress the system? ( ) ( ) Are vertical risers limited to systems servig two stories ad supported o 12' (maximum) ceters? ( ) ( ) Are all fittigs supported by hagers i accordace with pages 78 85? ( ) ( ) 106

Appedix Additioal iformatio regardig products cotaied i The Pocket Istaller ad other Johs Maville thermal isulatios ad systems is available i a variety of electroic ad prit media. 717 17th St. Dever, CO 80202 specjm.com North America Sales Offices, Isulatio Systems Easter Regio P.O. Box 158 Defiace, OH 43512 (800) 334-2399 Fax: (419) 784-7866 Wester Regio ad Caada P.O. Box 5108 Dever, CO 80217 (800) 368-4431 Fax: (303) 978-4661 North America Isulatio Maufacturer s Associatio (NAIMA) (703) 684-0084 www.aima.org Sheet Metal ad Air Coditioig Cotractor s Natioal Associatio (SMACNA) (703) 803-2980 www.smaca.org Glass Master 2420 McIver Lae, Suite 101 Carrollto, TX 75006-6500 (800) 874-9135 Fax: (972) 484-5555 Amcraft P.O. Box 349 5144 Eterprise Blvd. Toledo, OH 43612 (419) 729-7900 (orders) Trademarks SuperDuct RC Air Hadlig System, Mat-Faced Micro-Aire Duct Board ad SuperSeal Coatig Products are registered trademarks of Johs Maville. Wide Board Duct Board is a trademark of Johs Maville. 107

108 Notes

a a a a JMCOM120130 717 17th St Dever, CO 80202 (800) 654-3103 specjm.com AHS-3 05/12 (Replaces 04/10) 2012 Johs Maville. Prited i USA.