AH FM 4 Part1 AirDuctFabManuals 2007
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Transcript of AH FM 4 Part1 AirDuctFabManuals 2007
Max
10 Fa
b M
anual
Mach
ine A
dju
stmen
ts Manual
1", 1
1/2 "
, & 2"
Air D
uct B
oard
Knauf Insulation Air Duct Fabrication Manual for 1", 11/2", and 2"
Knauf Air Duct Fabrication Manual
References...................................................................................... 2
Introduction...................................................................................... 3
Modular.Duct.Construction.............................................................. 6
Tools.and.Equipment....................................................................... 7
Hand.Fabrication........................................................................... 10
Machine.Fabrication...................................................................... 14
Closure.......................................................................................... 22
90.Degree.Elbows......................................................................... 27
Stacked.Elbows............................................................................. 31
Tees............................................................................................... 33
End.Caps....................................................................................... 35
Reducers....................................................................................... 36
Offsets........................................................................................... 43
Tap-ins,.Diffusers/Grilles,.Access.Doors,..Equipment.Connections................................................................ 48
Fire.Damper.Installation................................................................ 53
Reinforcement............................................................................... 54
Hangers.and.Supports................................................................... 60
Damage.Repair............................................................................. 63
Job.Inspection.Check.List.............................................................. 65
Table of Contents
1
.2
References
This.manual.presents.methods.of.fabrication,.closure,.reinforce-ment,.and.installation.of.fiber.glass.duct.systems.in.terms.intended.to.be.clearly.understood.by.the.duct.systems.contractor.and..fabricator..It.is.based.on.industry.standards.which.are.documented.in.greater.detail.in.the.following:
.(1)..Fibrous Glass Duct Construction Standard,.Low.Velocity.Systems—2.inches.W..G..Maximum.Static.Pressure.
.(2)..Fibrous Glass Duct Construction Standard With 1½" Duct Board,.Supplement.to.NAIMA.Fibrous.Glass.Duct.Construction.Standard..NAIMA
.(3)..Fibrous Glass Residential Duct Construction Standards,.De-sign,.Fabrication.and.Installation.Techniques.for.the.Residential.HVAC.Duct.Contractor:.NAIMA.
.(4)..Fibrous Glass Duct Construction Standards—.6th.Edition,.1992:.Sheet.Metal.and.Air.Conditioning.Contractors.National.Association..(SMACNA).
The.information.contained.herein.is.intended.to.provide.sufficient.guidance.for.the.correct.fabrication.and.installation.of.most.low.pressure.fiber.glass.duct.systems.in.both.residential.and.commer-cial.applications..When.system.design.parameters.are.such.that.fabrication.and/or.installation.considerations.appear.to.be.beyond.the.scope.of.this.manual,.the.reader.should.consult.the.NAIMA.publications.listed.above,.as.well.as.the.local.Knauf.Insulation.sales.representative.
The.procedures.shown.herein.will.enable.a.completed.duct.system.to.conform.to.National.Fire.Protection.Association.Requirements.90A.and.90B.as.well.as.UL.181.Class.1.air.duct.criteria.
Fabricators.and.installers.should.also.refer.to.local.codes.and.ordinances.for.additional.specific.requirements.that.may.apply.to.ducted.heating.and.air.conditioning.systems.
Knauf.Insulation.recommends.a.careful.review.of.this.manual.to.become.fully.acquainted.with.the.fabrication.techniques.discussed..The.use.of.these.practices.will.result.in.less.time.and.material.wasted.in.fabricating.and.installing.duct.systems.Knauf.Insulation.provides.updated.information.as.needed.to.supplement.the.information.in.this.manual,.so.that.it.will.remain.a.valuable.reference.source.for.the.fabrication.of.Knauf.Air.Duct.Board.
Knauf Air Duct Fabrication Manual �
Knauf Air Duct Fabrication Manual
Knauf Air Duct Fabrication Manual 26_27
Knauf Air Duct Fabrication Manual
Knauf.Insulation.presents.this.manual.to.provide.an.in-depth.overview.of.fabrication.techniques.using.Knauf.Air.Duct.Board..This.manual.addresses.the.principles.of.Modular.Duct.Construc-tion.(MDC).applied.to.the.fabrication.of.straight.runs,.elbows,.tees,.reducers,.offsets,.tap-ins,.and.other.connections..Other.topics.such.as.reinforcement,.hangers,.and.damage.repair.are.also.presented,.making.this.manual.a.comprehensive.shop.reference.
Techniques.reviewed.include.both.hand.fabrication.and.the.use.of.grooving.machines..“Modified.Shiplap”.and.“V-groove”.construction.are.both.presented..Techniques.are.applicable.for.Knauf.EI-475.Air.Duct.Board.and.Air.Duct.Board-M.as.well.as.heavy-duty.EI-800.Air.Duct.Board.and.Air.Duct.Board-M.
Knauf.Insulation.recommends.that.the.fabricator.use.the.modi-fied.shiplap.method,.as.it.provides.for.a.stronger.corner.joint.that.squares.up.easily..Also,.using.modified.shiplap.construction.enables.all.longitudinal.and.circumferential.joints.to.be.compatible..Tap-in.joints.are.the.same.as.section.joints,.and.fittings.can.be.added.to.any.section.of.duct,.eliminating.one.circumferential.joint..Therefore,.for.overall.ease.of.fabrication,.Knauf.Insulation.recommends.the.fabricator.use.the.modified.shiplap.rather.than.V-groove.method.of.fabrication..In.the.case.of.2".Air.Duct.Board,.however,.either.method.could.be.used..This.is.because.machine.tools.are.currently.only.available.in.the.V-groove.configuration.while.hand.tools.are.available.for.shiplap.fabrication..Also,.2".Air.Duct.Board.is.currently.available.only.with.a.butt.edge..Therefore,.especially.for.circumferential.joints,.the.fabricator.must.manually.put.male.and.female.shiplaps.on.opposite.sides.of.the.board.after.grooving.longitudinal.cuts.
Introduction
2_�
.4
Features and Benefits
System Cost Savings
•. Knauf.Air.Duct.Board.is.usually.about.10%.lower.in.installed.cost.than.conventionally.fabricated.and.uninsulated.sheet.metal.duct,.and.40%.less.than.insulated.sheet.metal.duct.
•. Shop.productivity.with.Knauf.Air.Duct.Board.averages.twice.that.of.sheet.metal.
•. Field.man-hours.to.install.Knauf.Air.Duct.Board.average.25%.to.30%.less.than.sheet.metal.
•. Machines,.tools,.and.shop.space.required.to.fabricate.fiber.glass.duct.involve.much.less.investment.than.for.sheet.metal.
System Reliability and Durability
•. Knauf.Air.Duct.Board.complies.with.strict.flexural.rigidity.speci-fications,.ensuring.long.term.system.integrity.
•. Reinforcement.systems.described.in.this.manual.have.been.tested.at.1½.times.design.pressure.for.50,000.cycles.in.dy-namic.testing,.and.2½.times.design.pressure.in.static.testing.
•. Fiber.glass.duct.board.has.achieved.over.40.years.of.success-ful.field.application.experience.
•. Fiber.glass.duct.system.fabrication.and.installation.are.fully.documented.by.practical,.accepted.industry.standards.
System Air Tightness
•. Fiber.glass.duct.systems.are.classified.for.leakage.as..Class.6.by.SMACNA.(Sheet.Metal.and.Air.Conditioning.Contractors.National.Association)..Rectangular.sheet.metal.ducts.cannot.meet.this.air.tightness.level.without.every.joint.being.sealed.
•. Closure.systems.described.in.this.manual.have.been.tested.for.integrity.in.accordance.with.UL.181.A.procedures.
System Safety
•. Fiber.glass.duct.systems.are.UL.181.Class.1.listed.•. Fiber.glass.duct.systems.function.safely.at.operating.tempera-
tures up to 250˚F.•. Hanging.and.support.systems.as.described.in.this.manual.will.
support.three.times.the.weight.of.the.duct.board.
System Performance
•. Fiber.glass.duct.systems.are.thermally.efficient...C-values:.0.23.for.1".duct.board;.0.15.for.1½".duct.board;.0.125.for.2".duct.board.
•. Fiber.glass.duct.systems.are.acoustically.efficient,.providing.sound.attenuation.properties.approximately.equal.to.those.achieved.by.lining.sheet.metal.ducts.with.1",.3.0.pcf.duct.liner.
•. Knauf.Air.Duct.Board.friction.loss.coefficients.are.approximate-ly.equal.to.those.of.mat.faced.duct.liner,.and.better.than.those.of.textile.duct.liner.
•. For.additional.technical.information,.consult.the.Air.Duct.Board.Data.Sheet.or.your.Knauf.Insulation.sales.representative.
Summary of Benefits
Knauf.duct.systems.are—•. Essentially.air-tight.(SMACNA.Class.6).•. Thermally.efficient..Insulation.thickness.is..
factory.controlled.•. Acoustically.efficient,.with.excellent.sound..
attenuation.•. Lower.installed.cost.than.lined,.wrapped,.or.bare.sheet.metal.
Knauf Air Duct Board
Knauf Air Duct Fabrication Manual �
Knauf Air Duct Fabrication Manual
Knauf Air Duct Fabrication Manual 26_27
Knauf Air Duct Fabrication Manual
4_�
Technical data
Flexural Rigidity (El)
When.tested.in.accordance.with.North.American.Insulation.Manu-facturers.Association.(NAIMA).Test.Method.AHS-100-74,.flexural.rigidity.of.Knauf.Air.Duct.Board.shall.not.be.less.than.the.following:. Type.EI-475. 475.psi.per.inch.of.width.
Type.El-800. 800.psi.per.inch.of.width
Maximum Static Pressure
2".W.G..(500.Pa),.positive.or.negative.
Maximum Air Velocity in Duct
5,000.FPM.(25.4.m/s).
Temperature
250˚F (121°C) maximum inside duct, continuous operation; .150˚F (66°C) maximum external duct surface temperature.
Maximum Allowable Deflection1 ⁄100.of.duct.span.
Maximum Allowable Stress
In.steel.members.used.for.reinforcement.or.support:..22,000.psi.(152.mPa).
Board Fatigue
No.significant.deformation.of.duct.sections.after.50,000.cycles.at.3.to.4.cycles.per.minute.from.natural.sag.to.11 ⁄2.times.operating.pressure.
Water Vapor Sorption
Water.vapor.sorption.of.the.board.will.not.exceed.5%.by.weight.under conditions of 120˚F (49°C) dry bulb at 95% R.H. for .96.hours.duration,.when.tested.in.accordance.with.ASTM.C.1104.
Corrosiveness
Non-corrosive.in.contact.with.galvanized.steel,.copper.or.alumi-num.when.compared.to.control.specimen.in.contact.with.sterile.cotton.when.tested.in.accordance.with.ASTM.C.665.
Closure
When.fabricated.and.installed.in.accordance.with.Knauf.Insulation.Class.1.Air.Duct.Listing,.the.air.duct.board.system.shall.conform.to.Underwriters.Laboratories.Standard.UL.181.
Fire Safety Standards
National.Fire.Protection.Association.(NFPA).Standards.90A,.90B,.and.UL.181.
Restrictions
Fibrous.glass.duct.systems.should.not.be.used.in.the.following.applications:. A.. .Kitchen.or.fume.exhaust.ducts,.or.to.convey.solids,.liquids.
or.corrosive.gasses.. B.. Installation.in.concrete.or.buried.below.grade.. C.. Outdoors.. D.. .As.casings.and/or.housings.of.built-up.equipment... E.. .Immediately.adjacent.to.high-temperature.electric.heating.
coils.without.radiation.protection..Refer.to.NFPA.Standard.90A.for.proper.design.
. F.. .For.vertical.risers.(more.than.two.stories.in.height).in.air.duct.systems..
. G.. .With.equipment.of.any.type.which.does.not.include..automatic.maximum.temperature.controls.
. H.. With.coal.or.wood.fueled.equipment.
. I.. .In.variable.air.volume.systems.on.the.high.pressure.side.unless.reinforced.to.withstand.the.full.fan.pressure.
. J.. .As.penetrations.in.construction.where.fire.dampers.are.required,.except.as.shown.on.page.53.with.the.fire.damper.installed.in.a.sheet.metal.sleeve.extending.through.the.wall.
Moisture Control
The.following.precautions.should.be.taken.to.avoid.soaking.the.duct.board.with.liquid.water:. 1.. .When.using.either.evaporative.coolers.or.humidifiers,.the.
immediate.area.around.the.device.introducing.water.into.the.system.should.be.protected.by.using.a.drip.pan.and..a.protective.sheet.metal.sleeve.
. 2... .Both.supply.and.return.outlets.of.duct.systems.running.through.non-conditioned.space.and.used.for.cooling.only.must.be.tightly.closed.to.prevent.accumulation.of.con-densed.water.vapor.in.the.duct.system.during.the.heating.season.
. 3.. .Fibrous.glass.duct.materials.that.have.become.wet.at.the.job-site.before.or.during.installation.should.not.be.installed..Duct.systems.which,.in.service,.are.found.to.be.wet.should.be.replaced..Consult.the.local.Knauf.sales..representative.for.further.information.
Microbial Growth
Will.not.support.or.promote.the.growth.of.mold.or.fungus..when.tested.in.accordance.with.UL.181.or.standard.practices.ASTM.G.21.and.G.22.
Knauf Air Duct Systems
.6
Modular.Duct.Construction.(MDC).enables.the.fabricator.and.contractor.to.standardize.all.shop.fabrication.proce-dures.by.utilizing.the.full.four-foot.completed.fiber.glass.duct.section,.or.module,.for.all.fittings.as.well.as.straight..sections..By.utilizing.MDC.the.following..benefits.can.be.realized:A.. Increased.productivity.B.. .Improved.quality.of.workmanship..C.. .Minimized.number.of.circumferential.joints.D.. .Simplified.fabrication.of.fittings.in.the.shop.
and.on.the.job.site.
The.principles.of.MDC.are:.A.. .Modified.shiplap.joints.should.be.used.
rather.than.V-groove.B.. .The.male.end.of.the.duct.is.always.installed.
toward.the.air.handling.unit.C.. .Most.fittings.can.be.fabricated.from..
completed.four-foot.modules.D.. .All.sweep.and.radius.type.fittings..
are.eliminated.E.. .Branch.ducts.are.tapped.into.an..
existing.shiplap.wherever.possible.F.. .Integrity.of.four-foot.modules..
should.be.maintained.insofar.as.possible.during.installation.
G.. .When.a.four-foot.module.has.to..be.field-cut,.the.unused.piece.should..be.utilized.as.soon.as.possible.
H.. .Blueprints.should.be.modified.to..accommodate.the.MDC.principle.
Modular Duct Construction
Typical.Sheet.Metal.Layout
MDC.Layout
Knauf Air Duct Fabrication Manual 7
Knauf Air Duct Fabrication Manual
Knauf Air Duct Fabrication Manual 26_27
Knauf Air Duct Fabrication Manual
6_7
Use.of.the.correct.tools.and.equipment.will.speed.fabrication.of.Knauf.Air.Duct.Board,.ensuring.proper.construction.of.duct.modules.and.a.neat,.professional.job..The.necessary.tools.can.be.obtained.from.several.sources,.and.many.can.easily.be.made.by.the.fabricator.himself.
Hand Fabrication Tools:All.hand.fabrication.tools.listed.below..for.1",.11 ⁄2",.and.2".duct.board,.are.available.from.the.sources.listed.accompanying.each.tool.description..2".shiplap.tools.are.only.available.from.Amcraft..at.this.time.Modified Shiplap Tool—Used.to.make.a.modified.shiplap,.either.left.or.right.hand.90˚ V-Groove Tool—Used to make 90˚corner cuts when using the.V-groove.method.of.fabrication.End Cutoff Tool—Used.to.make.the.rabbit.cut.and.closure.flap.Female Shiplap Tool—Used.to.form.the.female.shiplap.and.rabbit.for.seating.the.edges.of.the.duct.board.These.hand.fabrication.tools.are.available.from:•. Amcraft.Inc.,.. Toledo,.OH.43612.. 419-729-7900•. Glass.Master.Corp.,. Carrollton,.TX.75006.. 800-874-9135•. Malco.Products,.Inc.,. Annandale,.MN.55302.. 800-328-3530T-Square—Provides.a.straight.edge.for.marking.cut.lines.or.for.guiding.cutting.tools,.as.well.as.measuring.angles.Angle Tool—Provides.a.straight.edge.at.angles.of.221 ⁄2˚or 15˚ for.marking.cut.lines.or.for.guiding.cutting.tools.when.fabricating.fittings with 45˚or 30˚miter angles.The.T-Square.and.Angle.Tool.are.available.from:•. Amcraft.Inc.,.. Toledo,.OH.43612.. 419-729-7900•. Glass.Master.Corp.,. Carrollton,.TX.75006.. 800-874-9135•. Malco.Products,.Inc.,. Annandale,.MN.55302.. 800-328-3530
Tools and Equipment
Modified.Shiplap.Tool.(Righthand),.Modified.Shiplap.Tool.(Lefthand)
End Cutoff Tool, 90° V-Groove Tool, Female Shiplap Tool.
T-Square
Angle.Tool
.8
Angle Finder (Saw Guide)—Used.to.mark.cut.lines.when.fabri-cating fittings having miter angles other than 30˚, 45˚, or 90˚. .Can.be.purchased.at.any.hardware.store.
Cuts-All Tool—Cuts.both.male.and.female.shiplap.grooves..Especially.useful.for.making.fittings.from.MDC.modules.in.the.shop.or.on.the.job.site..Available.from:•. Amcraft.Inc.,.. Toledo,.OH.43612.. 419-729-7900•. Glass.Master.Corp.,. Carrollton,.TX.75006.. 800-874-9135•. Malco.Products,.Inc.,. Annandale,.MN.55302.. 800-328-3530
Round Hole Cutter—Cuts.circular.holes.for.taps.ranging.in.size.from.4".to.20".diameter..Has.a.replaceable.blade..Should.be.used.instead.of.a.knife.whenever.making.round.tap-ins..Available.from:•. Amcraft.Inc.,.. Toledo,.OH.43612.. 419-729-7900•. Glass.Master.Corp.,. Carrollton,.TX.75006.. 800-874-9135•. Malco.Products,.Inc.,. Annandale,.MN.55302.. 800-328-3530
Male/Female Shiplap Tools—Cut.male.and.female.shiplap.grooves,.duplicating.cuts.made.by.the.Cuts-All.Tool..Constructed.from.heavy.gauge.metal..Available.from:•. Amcraft.Inc.,.. Toledo,.OH.43612.. 419-729-7900•. Glass.Master.Corp.,. Carrollton,.TX.75006.. 800-874-9135•. Malco.Products,.Inc.,. Annandale,.MN.55302.. 800-328-3530
120˚ Table—Used.for.folding.and.closing.longitudinal.joints.of.four-foot.duct.modules..When.the.module.is.stapled.and.taped.while held at a 120˚angle, it will recover to form 90˚square cor-ners..Can.be.made.by.the.fabricator.
Tools and Equipment
Cuts-All
Angle.Finder.(Saw.Guide)
Round.Hole.Cutter
120˚ Table
Male/Female.Shiplap.Tools
120˚
4'
16" 24"
Knauf Air Duct Fabrication Manual �
Knauf Air Duct Fabrication Manual
Knauf Air Duct Fabrication Manual 26_27
Knauf Air Duct Fabrication Manual
8_�
AccessoriesLuna (Standard) Vane Cutter—This.tool.makes.crescent-shaped.cut-outs.in.the.duct.board.for.installation.of.molded..fiber.glass.turning.vanes..Available.from.Amcraft,.Inc...Toledo,.OH.43612419-729-7900.
Molded fiber glass stock.is.available.from.which.turning.vanes.of.desired.lengths.may.be.cut..Available.from:•. Duro-Dyne.Corp.. Farmingdale,.NY.11735. 800-899-3876.•. Mina.Corp...
San.Francisco,.CA.. 94188. 415-822-7800.•. Cain.Manufacturing.Co.,. Pelham,.AL.35124. 800-554-0342.
Sheet Metal Turning Vanes, Dampers, and
Other Accessories
Sheet.metal.accessories.for.duct.work.such.as.turning.vanes,.splitters,.dampers,.access.doors.and.miscellaneous.hardware.kits,.are.available.from.your.local.distributor.or.from.some.of.the.sources.listed.for.hand.tools..Duro-Dyne.Corp..publishes.a.catalog.that.includes.all.of.these.accessories,.including.their.“Glasline”.products.made.especially.for.fiber.glass.duct.board.applications..Cain.manufacturing.also.publishes.a.catalog.describing.their.hardware.and.accessory.items.
Tools and Equipment
Luna.(Standard).Vane.Cutter
Sheet.Metal.Turning.Vanes
Splitters.and.Dampers
Access.Doors
Molded.Fiber.Glass.Turning.Vane.Stock
.10
It.is.very.important.to.measure.and.lay.out.the.proper.dimensions.before.cutting.the.duct.board.
Most.fabrication.is.done.using.the.Centerline.Method,.where.lines.are.drawn.on.the.duct.board.to.locate.the.centerlines.of.grooves.which.form.corner.breaks.and.the.closure.flap..Location.of.each.line.is.determined.by.the.inside.duct.dimensions.
When.laying.out.a.duct.module,.an.allowance.is.added.to.each.in-side.dimension..This.compensates.for.the.widths.of.corner.breaks.and.closure.flap..The.sum.of.these.allowances.is.added.to.the.inside.duct.perimeter.(2x.height.plus.2x.width).to.determine.total.“stretch-out,”.the.total.length.of.duct.board.required.to.fabricate.a.module.of.the.desired.inside.dimensions..This.allowance.depends.on.the.fabrication.method,.equipment,.tooling,.and.thickness.of.air.duct.board.being.used.
The.four.basic.ways.to.fabricate.a.duct.module.are.shown.at.right..One-piece.construction.is.fastest.and.easiest..Modules.can.be.made.from.one.piece.of.duct.board.when.the.sum.of.the.interior.dimensions.of.the.module.plus.the.add-on.allowance.does.not.exceed.the.width.of.the.board..Two-piece.“U”,.two-piece.“L”,.and.four-piece.construction.may.be.used.to.fabricate.large.ducts,.and.to.make.use.of.“drop-off”.pieces.of.duct.board..It.should.be.noted.that.an.additional.longitudinal.stapling.and.taping.operation.is.required.when.using.two-piece.construction,.and.that.a.total.of.four.such.longitudinal.closures.are.necessary.with.four-piece.construction.
Note: The.staple.flaps.can.also.be.on.the.“U”.piece,.rather.than.the.filler.cap.as.shown.here..This.allows.a.smaller.“drop-off”.board.width.to.be.utilized.
Hand Fabrication of 1", 11/2", and 2" Duct Board
One-Piece
Two-Piece.“U”
Two-Piece.“L”
Four-Piece
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10_11
There.are.two.methods.of.forming.corners:.Modified.Shiplap.and.V-Groove..V-Groove.is.a.simple.way.to.form.straight.duct.sec-tions,.but.does.not.offer.the.flexibility.needed.in.preparing.fittings,.branches.or.other.modifications..Therefore,.Knauf.recommends.that.fabricators.use.the.Modified.Shiplap.method.
Example: 14" x 6" One-Piece
Hand Fabrication of 1" Duct Board
96.or.120.(typical)
14.+.13 ⁄4" 14.+.13 ⁄4" 11 ⁄2"6.+.13 ⁄4" 6.+.13 ⁄8"
14.+.13 ⁄4" 14.+.13 ⁄4" 11 ⁄2"6.+.13 ⁄4" 6.+.13 ⁄8"
Modified.Shiplap
V-Groove
One-Piece.Shiplap
14.+.13 ⁄4" 14.+.13 ⁄4" 11 ⁄2"6.+.13 ⁄4" 6.+.13 ⁄8"
One-Piece.V-Groove
.12
Hand Fabrication of 1" Duct Board: Center Line Method
Cutting the Board:In.many.instances,.the.required.duct.size.plus.add-on.allowance.exceeds.the.maximum.board.size,.or.there.is.drop-off.from.previ-ously.cut.sheets.that.can.be.utilized.to.reduce.scrap.waste.
These.circumstances.necessitate.use.of.one.of.the.construction.techniques.other.than.one-piece..In.cases.of.these.alternate.methods,.it.is.important.to.remember.that,.as.the.number.of.pieces.of.duct.board.used.to.fabricate.a.module.increases,.so.does.the.add-on.allowance.(see.table.below).
ConstructionMethod
Add-OnAllowance
One-Piece 8"Two-Piece.“U” 9¼"Two-Piece.“L” 9¼"
Four-Piece 11½"
Examples:
14" x 6" Two-Piece “U”
14" x 6" Two-Piece “L”
14" x 6" Four-Piece
(Even.though.Four-Piece.Duct.is.possible.to.construct,.it.is.important.to.consider.the.increased.labor.involved.before.using.this.method.on.a.job.)
14.+.1¾" 14.+.13 ⁄4"6.+.1¾" 6.+.4"
14.+.13 ⁄4" 14.+.13 ⁄4"6.+.13 ⁄4" 6.+.4"
Two-Piece.“U”
14.+.13 ⁄4" 14.+.13 ⁄4"6.+.13 ⁄8" 1½" 1½"6.+.13 ⁄8"
14.+.13 ⁄4" 14.+.13 ⁄4"6.+.13 ⁄8" 1½" 1½"6.+.13 ⁄8"
Two-Piece.“L”
14.+.13 ⁄4" 14.+.13 ⁄4"6.+.4" 6.+.4"
Four.Piece
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The.techniques.and.cuts.necessary.to.fabricate.duct.sections.from.11 ⁄2".thick.duct.board.are.the.same.as.for.1".board..However,.due.to.the.extra.thickness,.the.stretch-out.allowance.increases,.and.tools.for.11 ⁄2".thickness.are.required..Therefore,.new.calcula-tions.must.be.made.when.laying.out.11 ⁄2".duct.board.modules.or.fittings,.as.shown.below.
Stretch-out, 11/2" duct board
ConstructionMethod
Add-OnAllowance
One-Piece 12"Two-Piece."U" 13 1 ⁄2"Two-Piece."L" 13"
Four-Piece 16"
Example:
14" x 6" One-Piece
14" x 6" Two-Piece “U”
14" x 6" Two-Piece “L”
14" x 6" Four-Piece
(Even.though.Four-Piece.Duct.is.possible.to.construct,.it.is.important.to.consider.the.increased.labor.involved.before.using.this.method.on.a.job.)
14.+.23 ⁄4" 14.+.23 ⁄4"6.+.23 ⁄4" 2"6+21 ⁄8"
Two-Piece.“U”
14 + 23 ⁄4" 14.+.23 ⁄4"6.+.23 ⁄4"
14.+.23 ⁄4" 14.+.23 ⁄4"6.+.23 ⁄4" 2"6+21 ⁄8"
2"
2"
2" 6+21 ⁄8"
Four-Piece
14 + 21 ⁄2" 14.+.23 ⁄4"6.+.51 ⁄2" 6+51 ⁄2"
Four-Piece
14.+.23 ⁄4" 14.+.23 ⁄4"6.+.23 ⁄4" 6+51 ⁄2"
14 + 23 ⁄4" 14.+.23 ⁄4"6.+.23 ⁄4" 6+51 ⁄2"
Two-Piece.“L”
Hand Fabrication of 11/2" Duct Board: Center Line Method
2".Flap
2".Flap
2".Flap 2".Flap
14.+.23 ⁄4" 14.+.23 ⁄4"6.+.23 ⁄4" 2"6+21 ⁄8"
.14
Hand/Machine Fabrication of 2" Duct Board: Center Line Method
The.techniques.and.cuts.necessary.to.fabricate.duct.sections..from.2".thick.duct.board.are.the.same.as.for.1".board..However,.due.to.the.extra.thickness,.the.stretch-out.allowance.increases,.and.tools.for.2".thickness.are.required..Therefore,.new.calcula-tions.must.be.made.when.laying.out.2".duct.board.modules.or.fittings,.as.shown.below.
Stretch-out, 2" duct board
ConstructionMethod
Add-OnAllowance
One-Piece 16"Two-Piece.“U” 181 ⁄2"Two-Piece.“L” 18"
Four-Piece 23"
Example:
14" x 6" One-Piece
14" x 6" Two-Piece “U”
14" x 6" Two-Piece “L”
14" x 6" Four-Piece
(Even.though.Four-Piece.Duct.is.possible.to.construct,.it.is.important.to.consider.the.increased.labor.involved.before.using.this.method.on.a.job.)
14.+.31 ⁄2" 14.+.31 ⁄2"6.+.31 ⁄2" 3"
3"3"
6.+.23 ⁄4"
14.+.31 ⁄2" 14.+.31 ⁄2"6.+.31 ⁄2" 6.+.8"
14.+.31 ⁄2"6.+.23 ⁄4" 6.+.23 ⁄4"14.+.31 ⁄2"
Two-Piece.“L”
14.+.31 ⁄2"6.+.8" 6.+.8"14.+.31 ⁄2"
Four-Piece
Two-Piece.“U”
One-Piece.(Standard.tooling)
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When.using.a.Glass.Master.grooving.machine,.there.are.two.methods.for.setting.up.the.cutting.tools:.Standard.tooling.and.Preferred.tooling.
Knauf.recommends.using.the.Modified.Shiplap.method,.with.Preferred.tooling,.for.machine.grooving..There.are.two.main.advantages.gained.through.the.use.of.Preferred.tooling:
(1)..Better.control.of.depth.and.accuracy.of.cuts,.which.results.in.a.clean.longitudinal.staple.flap..This.is.because.the.flap.is.always.cut.closest.to.the.side.frame.of.the.grooving.machine.where.the.tool.bars.and.rollers.are.supported.
(2)..Because.the.female.shiplap.edge.enters.the.closure.machine.first,.a.neater.closure.is.obtained.
With.Standard.tooling,.the.typical.set-up.for.a.one-piece.duct.is:
1 2 3 4 5 SCO
so.the.closure.flap.is.being.cut.by.the.#5.tool.at.the.right-hand.side.of.the.board.as.it.goes.through.the.machine.*
With.Preferred.tooling,.the.typical.machine.set-up.for.a.one-piece.duct.is:
8(A) 3(B) 2(C) 3(D) R1(E) SCO
so.the.closure.flap.is.being.cut.by.the.#8.tool.at.the.left-hand.side.of.the.board.**.With.this.tooling.set-up,.the.duct.board.should.always.be.fed.into.the.grooving.machine.female.shiplap.edge.first.
Example:
14" x 6" One-Piece Duct
*Always.put.the.wide.dimension.first.when.setting.up.the.machine.tools.with.Standard.tooling.**Always.put.the.narrow.dimension.first.when.setting.up.the.machine.tools.with.Preferred.tooling.
Machine Fabrication of Duct Board
One-Piece.(Standard.tooling)
. 14". . 6". . 14". . 6"1. . 2. . 3. .. 4. . 5. SCO
Preferred.Tooling
. 6". . 14". . 6". . 14"A. . B. . C. . D. . E. SCO.
.16
Tool Name And
Designation Function
1.(F). Left.Hand.Female.Shiplap
R-1(E). Right.Hand.Female.Shiplap
2(C),.4. Right.Hand.Modified.Shiplap
3(B)(D). hLeft.Hand.Modified.Shiplap
5.(G). Right.Hand.Closure.Flap
6. Left.Hand.Female... Shiplap.with.Cutoff
7. Right.Hand.Female.. Shiplap.with.Cutoff
8(A). Left.Hand.Closure.Flap
9. Left.Hand.Male.Shiplap
0. Right.Hand.Male.Shiplap
SCO. Straight.Cutoff... (Used.with.R-1.Tool... to.make.same.cut.as.#7.tool)
All.Glass.Master.machine.grooving.tools.have.numbered.plates.corresponding.to.the.location.and.width.of.the.actual.cutting.portion.of.the.tool..Thus,.to.set.up.the.grooving.machine,..the.interior.dimension.of.the.duct.is.measured.between.the.numbered.plates.on.the.tools;.the.widths.of.the.plates.represent.the.necessary.add-on.allowances.
Tools for Max10 Ten-Sided Duct:
Grooving.tools.are.available.for.machine.fabrication.of.ten-sided.fi-ber.glass.duct..Sections.of.ten-.sided.duct.up.to.ten.feet.long.or.up.to.31".nominal.inside.diameter.can.be.fabricated.from.one.piece.of.standard.48".x.120".x.1”.Knauf.Air.Duct.Board..Larger.diameters.can.be.fabricated.using.two.piece.construction.
See.Knauf.MAX10.Fabrication.Manual.for.further.details.
Machine Fabrication of Duct Board
1.(F)
R1.(E)
2(C)
3(B)(D)
4
5.(G)
6
7
8(A)
9
0
SCO
90˚V
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Example:
14" x 6" One-Piece Duct
Example:
14" x 6" Two-Piece ÒUÓ Duct
Example:
14" x 6" Two-Piece ÒLÓ Duct
Example:
14" x 6" Four-Piece Duct
(Even.though.Four-Piece.Duct.is.possible.to.construct,.it.is.important.to.consider.the.increased.labor.involved.before.using.this.method.on.a.job..Additionally,.tape.and.staples.will.cost.four.times.more.with.this.method.then.one-piece.fabrication.)
Note: Separate.sets.of.tools.are.required.for.each.thickness.
Machine Fabrication of 1", 11/2" and 2" Air Duct Board Using Standard Tooling
One-Piece.(Standard.tooling)
. 14". . 6". . 14". . 6"1. . 2. . 3. . 4. . 5. SCO
Two-Piece.“U”
. 14". . 6". . 14". . . 6"1. . 2. . 3. . 4. 8. . 5. SCO
Two-Piece.“L”
. 14". . 6". . . . 14". . 6"1. . 2. . 5. SCO. 1. . 2. . 5. SCO
Four-Piece
. 14". . . 6". . . . 14". . . 6"1. . 7. 8. . 5. SCO. 1. . 7. 8. . 5. SCO
.18
Machine Fabrication of 1", 11/2" and 2" AIr Duct Board Using Preferred Tooling
Example:
14" x 6" One-Piece
Example:
14" x 6" Two-Piece ÒUÓ
Example:
14" x 6" Two-Piece ÒLÓ
Machine Fabrication of 11/2" and 2" Duct Board:
As.with.hand.fabrication.of.11⁄2".and.2".thick.duct.board,.allowanc-es.must.be.made.to.accommodate.the.thicker.board..The.grooving.machine.must.be.reset.to.allow.the.thicker.board.to.pass.through.the.rollers..(As.noted,.some.grooving.machines.will.not.cut.11⁄2".or.2".duct.board.).Tools.designed.specifically.for.fabrication.of.11⁄2".or.2".duct.board.must.be.used.to.make.the.deeper,.wider.cuts.required..The.11⁄2".tools.are.numbered,.and.the.width.of.the.plates.on.the.tools.allows.for.the.proper.add-on.allowance..At.this.time,.2" tools are all 90° V-Groove and have tabs on top of the tool.
Two-Piece.“U”.(Preferred.Tooling)
. 6". . 14". . 6". . . . 14". . .8. . 3. . 2. . 5. SCO. 1. . R1. SCO
Two-Piece.“L”.(Preferred.Tooling)
. 6". . 14". . . . 6". . 14". .8. . 3. . R1. SCO. 8. . 3. . R1. SCO.
One-Piece.(Preferred.Tooling)
. 6". . 14". . 6". . 14".8. . 3. . 2. . 3. . R1. SCO.
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Knauf Air Duct Board Length Selection, 1" Board, One-Piece Duct (Dimensions in inches)
Width ofDuct
Depth of Duct
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 286 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 767 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 788 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 809 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82
10 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 8411 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 8612 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 8813 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 9014 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 9215 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 9416 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 9617 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 9818 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 10019 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 10220 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 10421 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 10622 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 10823 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 11024 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 11225 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 11426 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 11627 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 11828 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 12029 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 12030 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 12031 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 12032 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 12033 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 12034 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 12035 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 12036 92 94 96 98 100 102 104 106 108 110 112 114 116 118 12037 94 96 98 100 102 104 106 108 110 112 114 116 118 12038 96 98 100 102 104 106 108 110 112 114 116 118 12039 98 100 102 104 106 108 110 112 114 116 118 12040 100 102 104 106 108 110 112 114 116 118 12041 102 104 106 108 110 112 114 116 118 12042 104 106 108 110 112 114 116 118 12043 106 108 110 112 114 116 118 12044 108 110 112 114 116 118 12045 110 112 114 116 118 12046 112 114 116 118 12047 114 116 118 12048 116 118 12049 118 12050 120
*This.chart.includes.a.13 ⁄8".width.flap..For.1.11⁄2".flap,.add.1⁄8".
.20
Widthof Duct
Depth of Duct
6 7 8 9 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 486 36 38 40 42 44 48 52 56 60 64 68 72 76 80 84 88 92 96 100 104 108 112 116 1207 38 40 42 44 46 50 54 58 62 66 70 74 78 82 86 90 94 98 102 106 110 114 1188 40 42 44 46 48 52 56 60 64 68 72 76 80 84 88 92 96 100 104 108 112 116 1209 42 44 46 48 50 54 58 62 66 70 74 78 82 86 90 94 98 102 106 110 114 118
10 44 46 48 50 52 56 60 64 68 72 76 80 84 88 92 96 100 104 108 112 116 12012 48 50 52 54 56 60 64 68 72 76 80 84 88 92 96 100 104 108 112 116 12014 52 54 56 58 60 64 68 72 76 80 84 88 92 96 100 104 108 112 116 12016 56 58 60 62 64 68 72 76 80 84 88 92 96 100 104 108 112 116 12018 60 62 64 66 68 72 76 80 84 88 92 96 100 104 108 112 116 12020 64 66 68 70 72 76 80 84 88 92 96 100 104 108 112 116 12022 68 70 72 74 76 80 84 88 92 96 100 104 108 112 116 12024 72 74 76 78 80 84 88 92 96 100 104 108 112 116 12026 76 78 80 82 84 88 92 96 100 104 108 112 116 12028 80 82 84 86 88 92 96 100 104 108 112 116 12030 84 86 88 90 92 96 100 104 108 112 116 12032 88 90 92 94 96 100 104 108 112 116 12034 92 94 96 98 100 104 108 112 116 12036 96 98 100 102 104 108 112 116 12038 100 102 104 106 108 112 116 12040 104 106 108 110 112 116 12042 108 110 112 114 116 12044 112 114 116 118 12046 116 118 120
48 120
Knauf Air Duct Board Length Selection, 11/2" Board, One-Piece Duct (Dimensions in inches)
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Knauf Air Duct Board Length Selection, 2" Board, One-Piece Duct (Dimensions in inches)
Widthof
Duct
Depth of Duct
6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46
6 40 44 48 52 56 60 64 68 72 76 80 84 88 92 96 100 104 108 112 116 120
8 44 48 52 56 60 64 68 72 76 80 84 88 92 96 100 104 108 112 116 120
10 48 52 56 60 64 68 72 76 80 84 88 92 96 100 104 108 112 116 120
12 52 56 60 64 68 72 76 80 84 88 92 96 100 104 108 112 116 120
14 56 60 64 68 72 76 80 84 88 92 96 100 104 108 112 116 120
16 60 64 68 72 76 80 84 88 92 96 100 104 108 112 116 120
18 64 68 72 76 80 84 88 92 96 100 104 108 112 116 120
20 68 72 76 80 84 88 92 96 100 104 108 112 116 120
22 72 76 80 84 88 92 96 100 104 108 112 116 120
24 76 80 84 88 92 96 100 104 108 112 116 120
26 80 84 88 92 96 100 104 108 112 116 120
28 84 88 92 96 100 104 108 112 116 120
30 88 92 96 100 104 108 112 116 120
32 92 96 100 104 108 112 116 120
34 96 100 104 108 112 116 120
36 100 104 108 112 116 120
38 104 108 112 116 120
40 108 112 116 120
42 112 116 120
44 116 120
46 120
.22
Closure.materials.and.methods.used.with.Knauf.Air.Duct.Board.are.key.elements.in.providing.air-tight,.structurally.sound.longitudi-nal.and.circumferential.joints.
Closure.systems.for.use.with.all.fiber.glass.duct.systems.are.required.by.model.codes.and.project.specifications.to.conform.to.Underwriters.Laboratories,.Inc..UL.181.Class.1.and..UL.181A.requirements..Three.types.of.listed.closures.are.available:. (1).Pressure-sensitive.aluminum.foil.tape;. (2).Heat-sealable.aluminum.foil/scrim.tape;. (3).Mastic.and.fiber.glass.fabric.systems.
Note: If.the.closure.used.is.not.one.of.the.approved.systems.and.if..application.is.not.in.accordance.with.stated.procedures,.Knauf.Insulation.assumes.no.liability.for.duct.system.performance...Use.of.a.non-listed.closure.voids.the.Class.1.rating..Consult.the.installation.instructions.enclosed.in.each.package.of.duct.board.
Surface Preparation:To.ensure.proper.adhesion.of.closure.materials,.the.foil.facing.of.the.duct.board.must.be.clean,.dry,.and.free.from.dust,.dirt,.grease,.oil.or.moisture.before.application..Observe.all.recommendations..of.closure.material.manufacturers.
Shelf Life:Shelf.life.and.long.term.storage.requirements.often.apply.to.closure.tapes.and.mastics..Consult.manufacturers’.recommenda-tions.and.ensure.compliance.with.these.requirements.before.using.these.materials.
Closure of Fiber Glass Duct Joints
Fiber.Glass.Fabric.and.Mastic
Pressure-Sensitive.Aluminum.Foil.Tape
Heat-Sealable.Tape
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Preparing Joints and Seams: Longitudinal.seams.of.duct.modules.are.prepared.as.follows:(1).Fold.the.grooved.duct.board.to.form.the.module,.making.
certain.that.both.ends.are.flush.and.male/female.shiplaps.firmly seated. (This is best done using the 120˚ Angle Table shown.on.page.7.)
(2).Staple.the.longitudinal.flap.using.1 ⁄2".(minimum).outward.clinching.staples.2".on.centers.
(3).Apply.approved.closure.over.the.longitudinal.staple.flap.ac-cording.to.the.procedures.shown.on.the.following.three.pages.
Seams and Joints Without Staple Flaps (Butt Joints):Cross.tabs.of.approved.closure.material.(tape),.8".(minimum)..long.and.12".(maximum).on.centers,.must.be.used.to.secure.seams.and.joints.in.position.when.staple.flaps.are.not.present..There.must.be.at.least.one.cross.tab.on.each.side.of.the.duct.
Closure of Fiber Glass Duct Joints
Center.tape.over.edge.of.flap,1".(min.).overlap
1 ⁄2".outward.clinch.staples,
2".on.centerApprox..2".on.center
12".(max.) 8".(min.),centered..over.joint
Centered.over.joint
Cross.tab
Butt.joint
Tape.closure.joint..with.staple.flap
.24
Application Above 50°F:Tape.must.be.of.approved.type,.21 ⁄2".(min.).wide..Position.tape.along.edge.of.staple.flap.so.there.will.be.1".(min.).overlap..Press.tape.in.place,.being.careful.to.avoid.wrinkles..Rub.tape.thoroughly.with.a.squeegee.until.the.scrim.reinforcement.of.the.duct.board.facing.can.be.seen.through.the.tape..Take.care.not.to.puncture.or.tear.the.duct.board.facing,.especially.around.staples.
Application Below 5O°F:Ensure that the temperature of the tape is above 50˚F. If neces-sary,.place.in.a.warm.area.to.improve.initial.adhesive.tack..Pre-heat.the.area.to.be.taped.using.a.heating.iron.capable.of.maintaining a plate temperature of at least 400˚F. Position the tape.over.the.joint.and.press.in.place..Pass.the.iron.two.or.three.times.over.the.taped.areas.using.a.rapid.ironing.motion,.then.rub.the.tape.firmly.with.a.squeegee.
Note: Tape.should.not.be.applied.to.surface.of.duct.board.when.the.tem-perature of the board surface is below 32˚F due to the possibility of.entrapping.ice.crystals.which,.upon.melting,.will.cause.tape.to.loosen..Heat.surface.first.to.drive.off.moisture.
Closure with Pressure-Sensitive Aluminum Foil Tapes
Application below 50°F
Application above 50°F
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ApplicationTape.must.be.of.an.approved.type,.21 ⁄2".(minimum).wide..Position.the.tape.along.edge.of.the.staple.flap.to.overlap.at.least.one.inch.on.both.sides..Press.the.tape.in.place.with.an.iron.which.can maintain a plate temperature of between 55O˚F and 600˚F, working.until.the.heat.indicator.dots.on.the.tape.have.darkened,.showing.that.the.adhesive.has.been.activated..Complete.the.bond.with.a.second.pass.of.the.iron..Do.not.use.a.heat.gun;.heat.and.pressure.are.both.required.to.effect.a.seal..Allow.the.joint.to.cool.before.stressing.it..Be.sure.tape.edges.are.sealed..Take.care.not.to.puncture.or.tear.the.duct.board.facing,.especially.around.staples.
Note: Staples.may.be.omitted.when.an.automatic.closure.machine.such.as.the.Glass.Master.Closemaster.is.used..Iron.temperature.must be set at 650˚F. Continuous production may require periodic pauses to allow sealing iron temperature to recover to the 650˚F minimum.
Closure with Heat-Sealable Tape
Closure.Machine
Sealing.Iron
.26
Application:Brush.a.thin.coat.of.approved.mastic.about.31 ⁄2".wide.over.the.center.of.the.stapled.seam..With.the.brush,.press.the.3".wide.(min.).fiber.glass.fabric.firmly.into.the.mastic..Apply.a.second.coat.of.mastic.over.the.fabric,.working.until.the.scrim.is.filled..Follow.instructions.of.the.mastic.manufacturer.regarding.rate.of.applica-tion,.ventilation.requirements,.and.time.needed.for.the.joint.to.cure.before.subjecting.it.to.stress.
Note: This.closure.method.must.be.used.for.mechanical.connections.of.fiber.glass.duct.to.sheet.metal,.except.when.duct.operating.pressure.is.below.1".W.G..With.operating.pressures.less.than.1",.pressure-sensitive.tape.closures.may.be.used..For.details.regard-ing.connections.of.fiber.glass.duct.to.equipment.and.other.sheet.metal.accessories,.see.page.52.
Closure with Fiber Glass Fabric and Mastic
Fiber.Glass.Fabric.Application
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�0° Elbows
Throatless Elbow from MDC Module:Before.fabricating.this.fitting,.it.is.important.to.consider.the.configu-ration.of.the.shiplaps..For.Standard.tooling,.the.board.should.be.grooved.with.the.cheeks.as.the.first.and.third.panels.(e.g.,.12".x.8".x.12".x.8")..For.Preferred.tooling,.the.board.should.be.grooved.with.the.cheeks.as.the.second.and.fourth.panels.(e.g.,.8".x.12".x.8".x.12")..Following.this.practice.will.result.in.the.shiplaps.not.having.to.be.replaced.
To.fabricate.stacked.elbows,.see.page.31.
Step 1:.Measure.inside.width.dimension.of.tap-in.(A).and.add.for.board.thickness.as.follows:
Duct Board
1" 11/2" 2"l.D..+.11/2". l.D..+.21 ⁄4" l.D..+.3"
Measure.this.distance.back.from.female.end.of.module.(B)..Mark.a.perpendicular.line.
Step 2: Cut.facing.and.fiber.glass.with.knife.on.solid.line..Slit.facing.only.along.seams.to.female.edge..(dashed.lines).
Step 3:.Remove.section;.save.for.use.as.end.cap.
Step 4:.Install.any.sheet.metal.accessories.needed.(eg.,.turning.vanes).*
Step 5:.Reverse cut section 180˚ and install as end cap using 8" cross.tabs..Tape.seams.**
Step 6:.If.installation.is.in.field,.insert.tap-in.duct;.staple.and.tape.seams.**
*Gauge.of.sheet.metal.accessories.in.fiber.glass.duct.systems.is.dependent.on.duct.size.and.other.parameters..Refer.to.NAlMA.Fibrous.Glass.Duct.Construction.Standard.for.details.
**Refer.to.Closure.Section,.pages.22-26.
Step.1
Step.2.and.3
Step.4,.5.and.6
A BID
.28
�0º Elbows
Throatless Elbow from Flat:Before.fabricating.this.fitting,.it.is.important.to.consider.the.configu-ration.of.the.shiplaps..For.Standard.tooling,.the.board.should.be.grooved.with.the.cheeks.as.the.first.and.third.panels.(e.g.,.12".x.8".x.12".x.8")..For.Preferred.tooling,.the.board.should.be.grooved.with.the.cheeks.as.the.second.and.fourth.panels.(e.g.,.8".x.12".x.8".x.12")..Following.this.practice.will.result.in.the.shiplaps.not.having.to.be.replaced.
To.fabricate.stacked.elbows,.see.page.31.
Step 1:.Using.inside.duct.width.(ID).and.board.thickness,.measure.tap-in.distance.(see.below).back.from.female.edge.and.mark.line.
Duct Board
1" 11/2" 2"l.D..+.11/2" l.D..+.21/4" l.D..+.3"
Step 2:.Make.knife.cut.along.line,.slit.facings.along.seam.
Step 3:.Remove.section..Save.for.use.as.end.cap..Fold,.staple.and.tape.seams.**
Step 4:.Install.any.sheet.metal.accessories.required,.such.as.turning.vanes.(e.g.,.turning.vanes).*
Step 5:.Install.end.cap,.using.8".cross.tabs.over.cap.and.duct,.then.tape.all.seams.**
Step 6:.If.installation.is.in.the.field,.insert.next.4-foot.module.
*Gauge.of.sheet.metal.accessories.in.fiber.glass.duct.systems.is.dependent.on.duct.size.and.other.parameters..Refer.to.NAIMA.Fibrous.Glass.Duct.Construction.Standard.for.details.
**Refer.to.Closure.Section,.pages.22-26.
ID
ID.+.:11 ⁄2".(for.1".board)11 ⁄4".(for.11 ⁄2".board)3".(for.2".board)
Step.1
Step.2
Step.3
Step.4,.5.and.6
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�0º Elbows
Installing Fiber Glass Turning Vanes:Step 1:.Fabricate.elbow.in.the.flat.through.Step.2,.page.28.
Step 2:.Draw.diagonals.on.(A).and.(C).from.the.edges.of.the.cut.out.panel.to.the.opposite.corner.of.the.section.
Step 3:.Measure.5".from.throat.along.this.line;.make.first.mark.
Step 4:.Make.each.succeeding.mark.on.3".centers,.then.make.cuts.with.Luna.(Standard).Vane.Cutter.
Step 5:.Remove.crescent.shaped.wedges.
Step 6:.Cut.turning.vanes.to.I.D..+.11 ⁄2".(for.1",.11 ⁄2".and.2".duct.board).and.install.in.top.section.
Note: Approved.duct.adhesive.applied.in.the.cut-outs.will.improve.elbow.integrity.
Step 7:.Fold.up.duct,.inserting.vanes.in.cuts.along.section.C.
Step 8:.Install.end.cap,.using.8".cross.tabs..Tape.all.seams.(see.Closure.Section,.pages.22-26).
ABCD
ABCD
ABCD
Step.1
Step.2.and.3
Step.4.and.5
Step.6.and.7
Step.8
3 3 33
5
.30
�0° Elbows—1", 11/2" and 2" Air Duct Board
A
A
(A)
(B)
B
B
Throat.Dim.
Plug.Size
.+.
Add-on
Throated Elbow From MDC Module
(where specific heel dimension is required):
Step 1:.Measure.throat.dimension.from.male.end.of.module,.then.draw.vertical.line.on.side.panel.of.duct..From.that.line,.measure.duct.I.D..plus.add-on.for.board.thickness.as.follows:
Duct Board
1" 11/2" 2"l.D..+.11 ⁄2" l.D..+.21 ⁄4" l.D..+.3"
Draw.line.on.top,.bottom,.and.opposite.side.of.module.
Step 2:.Cut.top,.bottom,.and.side.of.module.along.the.dotted.line.using.the.M/F.tool,.making.the.female.cut.on.section.(A)..Blade.will.offset.into.the.duct.same.direction.as.plug.
Step 3:.Make.knife.cut.through.facing.and.board.on.first.line.drawn..Slit.only.the.facing.along.top.and.bottom.edge.from.this.cut.back.to.shiplap.cuts.
Step 4:.Separate.sections.(A).and.(B)..Flip.section.(A).over.(note.reference.points.at.right).
Step 5:.Install.turning.vanes.*
Step 6:.Join.two.duct.sections..Close.by.applying.8".cross.tabs.across.sections.on.all.sides,.then.tape.over.all.seams.(see.Closure.Section,.pages.22-26).
*Gauge.of.sheet.metal.accessories.in.fiber.glass.duct.systems.is.dependent.on.duct.size.and.other.parameters..Refer.to.NAIMA.Fibrous.Glass.Duct.Construction.Standard.
for.details.
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Knauf Air Duct Fabrication Manual
�0_�1
�0° Stacked Elbows
Stacked:
For.stacked.elbows,.the.panel.configurations.are.reversed.from.those.shown.on.pages.27.and.28..This.allows.the.shiplap.to.be.in.position.to.accept.the.male.end.of.the.next.module.without.requir-ing.additional.hand.fabrication.to.replace.the.shiplaps.
Example 1:
8" x 12" Standard Tooling
Always.put.wide.dimension.first.when.making.stacked.elbows.using.Standard.tooling.
Example 2:
8" x 12" Preferred Tooling
Always.put.narrow.dimension.first.when.making.stacked.elbows.using.Preferred.tooling.
12. 8. 12. 8
8. 12. 8. 12
Example.1
Example.2
.32
�0° Elbows
Three-Piece 90º Elbow From MDC Module 1", 11/2", 2":
Step 1:.Measure.the.throat.minus.3".
Step 2:.Use.Angle.Tool.(see.page.6),.and.draw.221 ⁄2˚.line.across.duct,.add.4".and.return.221 ⁄2˚.line.back.across.duct..Continue.that.line.down.that.side..Repeat.on.other.two.sides..Cut.221 ⁄2˚.lines.with.M/F.Tool.then.use.knife.to.make.miter.cuts.on.other.sides.of.module.
Step 3: Rotate center section 180˚.
Step 4:.Join.duct.sections,.using.8".cross.tabs,.then.tape.all.seams.(see.Closure.Section,.pages.22-26).
Note:This.fitting.will.have.higher.dynamic.pressure.loss.than.a..90˚ elbow with turning vanes.
Step.1.and.2
Step.3
Step.4
221 ⁄2˚
221 ⁄2˚
Throat.-3"
4"
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Tees From MDC Module
Step 1:.Measure.inside.width.dimension.(I.D.).of.tap-in.sections..Back.from.female.end.of.module,.measure.I.D..plus.add-on.for.board.thickness.as.follows:
Duct Board
1" 11/2" 2"l.D..+.11 ⁄2" l.D..+.21 ⁄4" l.D..+.3"
Draw.lines.on.both.sides.of.module.at.this.point.
Step 2:.Make.knife.cut.along.lines..Slit.facing.to.female.end.of.module.on.top.and.bottom.edges..Remove.sections.and.discard.
Step 3:.Install.sheet.metal.accessories.such.as..turning.vanes.*
Step 4:.Fabricate.an.end.cap.with.four.female.shiplap.edges.(see.page.35,.Type.1)..Tape.in.place.using.8".cross.tabs.**
Step 5:.If.installation.is.in.the.field,.connect.branches.to.trunk,.staple.and.tape.all.seams.**.
*Gauge.of.sheet.metal.accessories.in.fiber.glass.duct.systems.is.dependent.on.duct.size.and.other.parameters..Refer.to.NAIMA.Fibrous Glass Duct Construction Standard.for.details.
**See.Closure.Section,.pages.22-26.
ID.+Add-on
ID.+Add-on
Step.1
Step.2
Step.3
Discard
Step.4
Step.5
.34
This.connection.should.always.be.made.using.the.male.shiplap.end.of.a.duct.section,.to.prevent.the.tap-in.from.being.pushed.too.far.into.the.trunk.duct.(or.from.being.properly.seated.in..the.opening).
1...Cut.a.hole.in.the.trunk.duct.which.is.2".larger.in.each.dimen-sion.than.the.inside.dimensions.of.the.branch.duct.section..This.hole.should.start.1".from.the.bottom.of.the.trunk.duct.(see.drawing)..Remove.the.wedge-shaped.piece.from.bottom..panel.to.receive.male.shiplap..See.Joint.Detail.
2...Slit.all.four.corners.of.the.aluminum.foil.facing.at.the.male.shiplap.end,.to.provide.four.stapling.flaps..Fold.these.flaps.back.90º..Push.the.branch.duct.into.the.hole.in.the.main.duct.so.that.the.male.shiplap.is.firmly.seated.in.the.hole..Check.for.proper.alignment.
3...Staple.and.tape.seams.(refer.to.Closure.Section,.pages.22-26).
Tees From MDC Module—2" Air Duct Board
B.+.2"Joint.Detail
A
B.+.2"Opening.in.Main.Duct
AB
Main.Duct
Main.Duct
Tap-in.Duct
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�4_��
Type 1:Use.when.female.shiplap.without.stapling.flap.is.present.on.end.of.module.or.fitting.and.end.cap.will.not.have.staple.flaps.
Step 1: Measure.end.cap.to.fit.within.shoulder.of.female.shiplap.using.I.D..plus.add-on.for.board.thickness.as.follows:
Duct Board
1" 11/2" 2"l.D..+.11 ⁄2" l.D..+.21 ⁄4" l.D..+.3"
Form.with.straight.knife.cuts,.all.four.sides.
Step 2: Tape.end.cap.to.module.with.8".cross.tabs,.then.staple.and.tape.all.four.sides.*
Type 2:Use.when.female.shiplap.without.stapling.flap.is.present.on.end.of.module.or.fitting.and.end.cap.will.have.staple.flaps.
Step 1: Measure.endings,.including.add-ons.as.listed.in.the.table.in.Step.1.above,.to.fit.within.shoulder.of.female.shiplap.and.provide.at least 11⁄2" staple flap. Form with straight knife cuts, all four sides, being.careful.not.to.cut.off.the.staple.flap.
Step 2: Staple.and.tape,.folding.(not.cutting).at.corners.*
Type 3:Use.when.female.shiplap.with.stapling.flaps.is.present.on.end.of.module.or.fitting.
Step 1: Measure.end.cap.to.fit.within.shoulder.of.female.shiplap..Form.with.square.knife.cuts,.all.four.sides.
Step 2: Staple.and.tape,.folding.(not.cutting).at.corners.*
*See.Closure.Section,.pages.22-26.
End Caps
Type.1
Type.2
Type3
Female.Shiplap
B.+Add-on
A.+.Add-on
B.+Add-on
A.+.Add-on
B.+Add-on
A.+.Add-on
Female.Shiplap
Staple.Flap
Female.Shiplap,Staple.Flap
BA
BA
B
A
.36
Reducers—1", 11/2" and 2" Air Duct Board
When fabricating reducers, remember:1.. Measurements.should.be.made.along.the.female.factory-
molded.shiplap.edge.of.the.duct,.not.on.the.interior.dimension.part.
2.. The.length.of.reduction.should.be.made.on.a.6:1.ratio,.but.with.a.minimum.reduction.length.of.24"..That.is,.for.each.inch.of.reduction,.measure.back.6",.but.no.less.than.24".total.
3.. Any.shiplap.edge.removed.must.be.re-cut.4.. Reducers.are.easily.made.in.the.flat.before.folding.and.sealing.
the.duct..However;.folding.up.the.board.helps.the.fabricator.to.visualize.the.finished.configuration.before.making.cuts.
Note:To.help.orient.the.board.properly,.examples.shown.were.machine.fabricated.using.Standard.tooling.(see.page.17).
One-Way Reducer:Step 1:.Measure.4".on.panels.(A).and.(C).
Step 2:.Make.knife.cut.through.insulation.and.facing.along.solid..diagonal.lines.on.panels.(A).and.(C),.with.minimum.reducer.length.24"..Remove.wedge-shaped.pieces.of.insulation.and.clean.facing.
Step 3:.Replace.shiplaps.on.diagonal.cuts.of.panels.(A).and.(C).with.Female.Shiplap.Tool..Trim.facing.to.form.11 ⁄2".(min.).staple.flap.
Step 4:.Fold.up.duct,.staple.and.tape.seams.(see.Closure.Sec-tion,.pages.22-26).
24".(min.)
ABCD
ABCD
A
B
C
D
ABCD
10".x.6".to.6".x.6"
Step.1
Step.2
Step.3
Step.4
4"4"
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�6_�7
Reducers—1", 11/2" and 2" Air Duct Board
One-Way Reducer:This.is.the.easiest.reducer.to.fabricate..By.grooving.the.board.with.cheek.panels.second.and.fourth,.shiplaps.do.not.have.to.be.replaced.
Step 1..Measure.4".on.panels.(B).and.(D).
Step 2. Make.knife.cut.through.insulation.and.facing.along.solid.diagonal.lines.on.panels.(B).and.(D),.with.minimum.reducer.length.24".
Step 3..Remove.wedge-shaped.pieces.of.insulation,.and.trim.facing.to.form.a.11 ⁄2".staple.flap.
Step 4..Fold.up.duct..Staple.and.tape.seams.(see.Closure.Section,.pages.22-26).
ABCD
ABCD
A
B
C
D
ABCD
6".x.10".to.6".x.6"
Step.1
Step.2
Step.3
Step.4
4"4"
24".(min.)
.38
Two-Way Reducer with Bottom Flat: Step 1:.Measure.4".in.on.panels.(A).and.(C)..Measure.4".on.panels.(B).and.(D).
Step 2:.Using.knife,.on.panels.(A).and.(C).cut.through.facing.and.fiber.glass.along.solid.diagonal.lines..On.panels.(B).and.(D),.cut.through.fiber.glass.only—do.not.cut.through.facing—along.dotted.diagonal.lines..Make.cuts.to.6:1.ratio.for.reducer.length.with.minimum.reducer.length.24".
Step 3:.Strip.out.wedge-shaped.pieces.of.insulation.and.clean.facing..Replace.shiplaps.using.female.shiplap.tool.on.panels.(A).and.(C)..Trim.up.all.three.staple.flaps.(11 ⁄2".min..width).
Step 4:.Fold.up.duct..Staple.and.tape.seams.(see.Closure.Sec-tion,.pages.22-26).
Reducers—1", 11/2" and 2" Air Duct Board
ABCD
ABCD
A
BC
D
ABCD
14".x.12".to.10".x.8"
Step.1
Step.2
Step.4
4" 4" 4" 4"
Step.3
24"..(min.)
Side
Top
Knauf Air Duct Fabrication Manual ��
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Reducers—1", 11/2" and 2" Air Duct Board
Centerline Reducer with Bottom Flat: Step 1: Measure.half.of.width.reduction.required.from.both.sides.on.panels.(A).and.(C).(2")..On.panels.(B).and.(D),.measure.full.height.reduction.required.(4").
Step 2:.Make.knife.cuts.through.insulation.only.on.panels.(B).and.(D).(dotted.diagonal.line),.and.through.fiber.glass.and.facing.on.panels.(A).and.(C).(solid.diagonal.lines)..Make.cuts.to.6:1.ratio.for.reducer.length.with.minimum.reducer.length.24".
Step 3:.Strip.out.wedge-shaped.pieces.of.insulation..Replace.all.shiplaps and trim all staple flaps to 11⁄2" (min. width).
Step 4: Fold.up.duct..Staple.and.tape.all.seams..(see.Closure.Section,.pages.22-26).
ABCD
ABCD
A
BC
D
ABCD
14".x.12".to.10".x.8"
Step.1
Step.2
Step.4
4" 2" 2" 2"4" 2"
Step.3
Top
Side
24"..(min.)
.40
Focal Reducer:Step 1: Measure.half.of.required.reduction.from.both.sides.of..all.panels.
Step 2: Make.knife.cuts.through.insulation.and.facing.on.panels.(A).and.(C).(solid.diagonal.lines)..Make.knife.cuts.through.fiber.glass.only—do.not.cut.through.facing—.on.panels.(B).and.(D).(dotted.diagonal.lines)..Make.cuts.to.6:1.ratio.for.reducer.length.with.minimum.reducer.length.24".
Step 3: Strip.out.wedge-shaped.pieces.of.insulation..Replace.all.shiplaps..Trim.up.staple.flaps.to.11 ⁄2".(min.).width.
Step 4: Fold.duct..Staple.and.tape.seams.(see.Closure.Section,.pages.22-26).
Reducers—1", 11/2" and 2" Air Duct Board
ABCD
ABCD
A
B
C
D
ABCD
14".x.12".to.10".x.8"
Step.1
Step.2
Step.4
2" 2"2" 2" 2" 2"2" 2"
Step.3
Top
Side
24"..(min.)
2"
Knauf Air Duct Fabrication Manual 41
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40_41
Reducers—1", 11/2" and 2" Air Duct Board
Simple Reducers From MDC Module:
Using Cuts-All tool
Step 1:.Measure.in.4".on.top.and.bottom.of.module.
Step 2: Slit.facing.only.with.knife.to.allow.easier.passage.of.Cuts-All.tool.
Step 3: Cut.module.along.diagonal.lines.with.Cuts-All.tool..Offset.of.blade.goes.to.the.center.of.duct..Minimum.reducer.length.is.24".
Step 4:.Strip.wedge-shaped.pieces.of.insulation.from.facing.
Step 5: Trim.staple.flaps.to.11 ⁄2".(min.).width..Fold.panel..Staple.and.tape.(see.Closure.Section,.pages.22-26).
Note:If.reduction.is.made.in.square-edged.panel,.add.half.the.board.thickness.to.the.changed.dimension.
10".x.6".to.6".x.6"
Step.1 Step.2
Step.3 Step.4
Step.5
4"
4"24"(min.)
ShiplapPanel
Slit.Facing.Only
ShiplapPanel
.42
Reducers—1", 11/2" and 2" Air Duct Board
Two-Way Reducer with Bottom Flat:Step 1: Measure.width.reduction.of.2".on.top.and.bottom.of.duct,.height.reduction.of.3".+.1 ⁄2".for.female.shiplap.allowance.on.square-edged.sides.
Step 2: Slit.facing.only.on.top.and.bottom.with.knife.to.allow.easier.passage.of.Cuts-All.tool.
Step 3:.Cut.board.with.Cuts-All.tool.on.top.and.bottom.
Step 4: On.top,.slit.facing.along.edge.with.knife,.remove.wedge.of.insulation.with.facing.
Step 5: On.bottom,.strip.out.wedge.piece.of.insulation,.leaving.facing.intact.
Step 6:.Peel.back.facing.from.top.of.side.panel.next.to.cut.made.with.Cuts-All.tool..Make.knife.cut.for.height.reduction..On.opposite.side.panel,.make.knife.cut.through.insulation.and.facing.for.height.reduction.
Step 7: Strip.out.wedge-shaped.pieces.of.insulation,.leaving..facing.intact..Trim.up.facing.for.staple.flaps.
Step 8: Fold.duct,.staple.and.tape.flaps.(see.Closure.Section,.pages.22-26).
Note:If.reduction.is.made.in.square-edged.panel,.add.half.the.board.thickness.to.the.changed.dimension.
Step.2Step.1
Step.4Step.3
Step.6Step.5
Step.8Step.7
16".x.8".to.14".x.5"
2"
2"24"(min.)
ShiplapPanel
Slit.Facing.Only
ShiplapPanel
31 ⁄2"31 ⁄2"
2"
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Offsets—1", 11/2", and 2" Air Duct Board
30º Offset:Step 1:.Find.the.amount.of.offset.needed.by.field.measurement..(Example:.7.inches.)
Step 2: Determine.a.starting.point.from.one.end.of.the.four..foot.MDC.module.using.field.measurement..Using.the.Angle.tool.(page 6), draw a line on a 15˚ angle across the module.
Step 3: Measure.a.length.double.the.offset.dimension..(in example, 7" x 2 = 14"). Draw a second 15˚ angle line at .this.point.
Step 4: Using.the.knife,.cut.through.all.four.sides.of.the.module..(Optional:.diagonal.cuts.may.be.made.with.the.Cuts-All.or.M/F.tool.).When.cutting.cheek.panels,.hold.knife.so.the.blade.angle.matches.the.angle.of.diagonal.cuts.on.top.and.bottom.of.module..Separate.module.into.three.sections.
Step 5: Rotate center section 180˚. Join sections together using 8".cross.tabs..Tape.all.seams.(see.Closure.Section,.pages.22-26).
Step.2
Step.3
Step.5
Step.4
Option:.Cuts-All.or.M/F
Step.6
Parallel.Planes
15°
90°
90° 15°14"
14"
.44
Offsets—1", 11/2", and 2" Air Duct Board
Easy Way Offset:
Basic values:
X = offset dimension
(Example: 7 inches)
Y = length of offset
(Example: 2 feet)
Step 1:.Determine.a.starting.point.from.one.end.of.the.four-foot.MDC.module..Make.a.mark.at.this.point.(1).
Step 2:.At.opposite.end.of.module,.measure.distance.X.(example:.7").from.edge.of.duct.and.draw.a.line.parallel.to.edge.of.duct.
Step 3:.From.point.(1).measure.Y.length.(example:.2.feet).and.mark.point.(2).
Step 4:.From.point.(1),.rotate.the.tape.measure.until.Y.length..(2.feet).intersects.the.line.drawn.in.Step.2..Mark.this.point.(3).
Step 5:.Draw.line.connecting.points.(2).and.(3).and.extending.to.opposite.side.of.module.at.point.(4).
Step 6:.From.point.(4),.measure.back.Y.length.and.mark.point.(5)..Draw.a.line.connecting.points.(5).and.(1).
Step 7:.Cut.through.all.four.sides.of.module.with.knife.(option:.use.Cuts-All.or.M/F.tool.on.cheek.panels)..Hold.knife.so.blade.angle.matches.the.angle.of.cuts.connecting.points.(2)-(4).and.(5)-(1)..Separate.module.into.three.pieces.
Step 8: Rotate center section 180˚. Join sections together using .8".cross.tabs..Tape.all.seams.(see.Closure.Section,.pages.22-26).
Step.1,.2.and.3
Step.4
Step.5,.6.and.7
Cuts-All.or.M/F.tool.optional.on.cheek.panels
Y.(2')
X.(7")
(2)
(1)
Y
(2)
(1)
(3)
(2)
(1)
(3)(4)
(4)
(5)
90°
Parallel.Planes
90°
Step.8
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Air Duct Board
44_4�
Offsets—1", 11/2", and 2" Air Duct Board
Using Offset Template:Several.types.of.templates.are.available.to.aid.in.fabricating.offsets.of.any.angle..The.template.shown.on.this.page.is.available.from.National.Duct.Systems,.Carrollton,.Texas.214-242-7727.
Step 1:.Determine.the.offset.amount.in.inches..Then,.set.a.length.for.the.offset..(Example:.14".offset,.2.foot.section.)
Step 2: Divide.offset.in.inches.by.length.in.feet..(Example:.14 ⁄2.=.7.(this.is.called.7.on.12.pitch).
Step 3: On.template,.find.the.corresponding.line.under.“PITCH.ON/12"..Read.to.left.on.same.line.to.determine.the.offset.loss.for.every.foot.of.offset.length..(Example:.7.on.12.pitch.gives.an.offset.loss.of.17 ⁄8".for.every.foot.of.offset.length.)
Step 4:.Multiply.the.offset.loss.times.the.length.of.the.offset,.and.add.this.figure.to.the.length..(Example:.17 ⁄8".x.2'.=.3 3 ⁄4".)
Step 5: Determine.a.starting.point.from.one.end.of.the.4-foot.module..Draw.a.line.using.the.“PITCH.ON/12”.angIe.(Example:.7.on.12).from.the.template.
Step 6: Measure.the.offset.length.plus.loss,.then.draw.the.same.angle.at.that.point.(Example:.24".+.3 3 ⁄4".=.27 3 ⁄4")
Step 7: Cut.through.all.four.sides.of.the.duct.on.two.parallel..planes.with.knife.held.so.blade.angle.aligns.with.cuffing.planes...(Optional:.Use.Cuts-All.or.M/F.Tool.on.angled.cuts).
Step 8: Separate.module.into.three.sections..Rotate.center.sec-tion 180˚. Join sections together using 8" cross tabs and tape all seams.(see.Closure.Section,.pages.22-26).
Step.1,.4.and.5
Step.7
Step.8
Parallel.Planes
2'
14"
Option:.Cuts-All.or.M/F
Step.6
27 3 ⁄4"
.46
Two Way Offset:By.combining.the.30.Degree.and.Easy.Way.Offset.methods.(pages.43.and.44),.a.two.way.offset.is.easily.fabricated.from.the.MDC.module..This.module.is.16".x.10"..Offset.16".dimension.10".and.10".dimension.6".
Step 1: Using the Angle tool (page 6) draw line A-B on a 15˚ angle.across.the.16".side.of.the.module.starting.about.12".from.the.left.end.and.angling.toward.the.right..When.establishing.start-ing.point,.allow.for.the.offset.angle.at.the.other.end.
Step 2: Measure.along.the.edge.of.the.duct.twice.the.offset.dimension.for.the.16".side.(20")..Draw.parallel.line.C-D.20".from.it.
Step 3: Rotate.the.module.so.the.16".dimension.with.the.angled.lines.faces.you.and.the.10".side.is.on.the.top..Draw.a.line.parallel.to.the.edge.of.the.module,.6".from.the.near.top.edge.
Step 4:.Place.the.end.of.the.tape.measure.at.point.B.and.find.point.E,.which.is.20".from.point.B.on.the.line.drawn.6".from.the.edge.of.the.module...As.in.the.Easy.Way.Offset.(page.44),.draw.a.line.from.point.D.through.point.E.and.extending.to.the.edge.of.the.module..Draw.parallel.line.B-F.20".to.the.left.
Step 5: Turn.the.module.so.the.unmarked.16".dimension.is.on.top,.and.connect.the.diagonal.lines.so.that.they.define.two.parallel.planes.slicing.through.the.module.
Note:
If offset is the same both ways, use 15° on all 4 sides.
Offsets—1", 11/2", and 2" Air Duct Board
Step.1.and.2
15°
20"15°
12".Approx.
A
B
C
D
Step.3.and.4
15°
20"
6"
A
B
C
DE
F
Step.5
Parallel.Planes
Knauf Air Duct Fabrication Manual 47
Knauf Air Duct Fabrication Manual
Two Way Offset:Step 6: Stand.the.module.on.its.corner.and.sight.along.these.two.parallel.planes..Slit.the.facing.all.the.way.around.the.module.along.both lines. Maintaining both the 15˚ angle and the offset angle, cut the.module.into.three.sections.with.the.knife.aligned.with.these.angled.cutting.planes.
Step 7: Rotate the center section 180˚. Join sections together using 8".cross.tabs..Tape.all.seams.(see.Closure.Section,.pages.22-26).
Offsets—1", 11/2", and 2" Air Duct Board (continued)
Step.6
Step.7
6"
10"
10"
6"
16"
10"
10"
46_47
Round Taps:Step 1. Cut.hole.in.trunk.duct.using.round.hole.cutter.(page.7)..Do.not.cut.with.knife..Round.tap.may.be.made.in.any.panel.
Step 2. Insert.collar.(dove-tail.or.spin-in)..Complete.tap-in.per.instructions.of.round.duct.manufacturer.
Square Taps:Step 1. Cut.tap.opening.in.shiplapped.panel.of.trunk.duct,.making.straight.knife.cuts.through.board.and.facing.on.sides.of.opening,.and.through.facing.only.along.duct.edges..Opening.dimensions.are.tap.l.D..+.duct.board.thickness.
Step 2. Insert.male.shiplap.end.of.tap.in.opening..Staple.and.tape.flap.*
Note:Tap.of.less.than.full.height.often.requires.additional.reinforce-ment.of.trunk.duct..See.NAIMA.Fibrous.Glass.Duct.Construction.Standard,.Section.II..For.2".Air.Duct.Board,.see.“Tee.from.MDC.Module,”.pages.33-34.in.this.manual.
*See.Closure.Section,.pages.22-26.
Round.Tap
Square.Tap
Tap-Ins—1", 11/2", and 2" Air Duct Board
Tap-Ins—1", 11/2", and 2" Air Duct Board
Knauf Air Duct Fabrication Manual 4�
Knauf Air Duct Fabrication Manual
48_4�
Wide Mouth Tap:Two.wide.mouth.taps.can.be.fabricated.from.one.MDC.module.
Step 1: Draw a 45˚angled line across and through the center point.of.the.module..Draw.221 ⁄2˚.angled.lines.across.module.from.points where 45˚ line intersects module edges. This will establish three.cutting.planes.through.the.module.
Step 2: Cut.module.into.four.sections.with.knife,.aligning.blade.with.cutting.planes..Divide.into.two.pairs..Note:.Cuts-All.or.M/F.tool.may.be.used.to.make.cuts.on.cheek.panels.
Step 3: Rotate one section of each pair 180˚. Assemble each tap with.8".cross.tabs,.then.tape.all.around.*
Step 4: Cut.opening.in.trunk.duct.(tap.I.D..+.1".for.1".duct.board,.11 ⁄2".for.11 ⁄2".duct.board,.2".for.2".duct.board)..Insert.male.shiplap.end.of.tap.into.opening..Staple.and.tape.all.around.*
*See.Closure.Section,.pages.22-26.
Step.1
Wide.Mouth.Tap
Step..2
Step..3.and.4
Side Connection:Step 1. Cut.opening.(l.D..+.board.thickness).to.accept.male.shiplap.end.of.tap.in.side.of.trunk.duct..Full.height.tap..is.preferable.
Step 2. Attach.male.shiplap.staple.flap.of.tap.to.trunk.duct.(see.Closure.Section,.pages.22-26).
Step 3. Attach.frame.to.tap.with.sheet.metal.screws.and.square.washers..Install.diffuser.or.grille.in.accordance.with.manufacturer’s.instructions.
Bottom Connection:Step 1..Cut.opening.(I.D..+.duct.board.thickness).to.accept.male.shiplap.end.of.drop.in.bottom.of.trunk.duct.(may.be.shiplapped.or.straight.edged.panel).
Step 2..Attach.male.shiplap.staple.flap.of.drop.to.trunk.duct.(see.Closure.Section,.pages.22-26).
Step 3..Support.drop.and.diffuser.separately.if.combined.weight.is.in.excess.of.15.pounds,.using.hanger.wires.and.supports.(see.Hangers.and..Supports.Section,.pages.60-62).
*Gauge.of.sheet.metal.accessories.in.fiber.glass.duct.systems.is.dependent.on.duct.size.and.other.parameters..Refer.to.NAIMA.Fibrous.Glass.Duct.Construction.Standard.for.details.
Diffuser & Grille Connections—1", 11/2", and 2" Air Duct Board
Side.Connection
Bottom.Connection
Frame
Tap.=.I.D..+..Thickness.of.Duct.Board
�0_�1
Access Door, Flange on Door Frame:Step 1: Cut.opening.in.trunk.duct.to.accept.door.
Step 2: Frame.door.opening.with.sheet.metal.inside.trunk.duct.
Step 3: Install.door.with.steel.butt.hinges.or.window.type.sash.lock.
Access Door, Flange on Door:Step 1: Cut.opening.in.trunk.duct.to.accept.door.
Step.2:.Frame.door.opening.with.sheet.metal.around.door.open-ing.
Step 3: Install.door.with.screws.and.washers,.or.suitable.hardware.
For.further.details,.refer.to.NAIMA.Fibrous.Glass.Duct..Construction.Standard,.Section.II.
Access Doors—1", 11/2", and 2" Air Duct Board
1".x.1".x.1",.22.Gauge.-.for.1".Board
11⁄2" x 11⁄2" x 11⁄2",.22.Gauge.-.for.11⁄2".Board
2".x.2".x.2",.22.Gauge.-.for.2".Board
Z-Channel.around.opening
1".x.1".x.1",.22.Gauge.-.for.1".Board
11⁄2" x 11⁄2" x 11⁄2",.22.Gauge.-.for.11⁄2".Board
2".x.2".x.2",.22.Gauge.-.for.2".Board
Z-Channel.around.door
3",.22.Gauge.frame.inside.of.opening
1".x.1".x.1",.22.Gauge.-.for.1".Board
11⁄2" x 11⁄2" x 11⁄2",..22.Gauge.-.for.11⁄2".Board
2".x.2".x.2",.22.Gauge.-.for.2".Board
U-Channel.around.opening
Flange.on.Door.Frame
Flange.on.Door.Frame
2",.22.Gauge.frame,..outside.of.door
1".x.1".x.3",.22.Gauge.-.for.1".Board
11⁄2" x 11⁄2" x 31⁄2",.22.Gauge.-.for.11⁄2".Board
2".x.2".x.4",.22.Gauge.-.for.2".Board
U-Channel.frame.around.door.opening
Knauf Air Duct Fabrication Manual
Equipment Connections
When.fastening.fiber.glass.ducts.to.any.sheet.metal.equipment.or.accessories,.combinations.of.sheet.metal.screws,.washers,.pocket.clips,.S.clips.and.angles.may.be.used..Combinations.are.shown.at.the.right..Important:.After.securing.the.duct.sections.to.sheet.metal.equipment,.seal.all.joints..See.Closure.Section,.pages.22-26.
Note: When.operating.pressure.is.less.than.1".W.G..and.sheet.metal.surfaces.are.cleaned.carefully,.U.L..181A-P.listed.pressure-sensi-tive.tapes.may.be.used..For.pressures.over.1".but.not.more.than..2".W.G.,.a.U.L..181A-M.listed.glass.fabric.and.mastic.must.be.used.
22.Gauge.Pocket.Clip.with.Button.Punch.Snap.Lock
Washers
Sheet.Metal.Angle
Sheet.Metal.S.Clip
�2_��
Sheet.metal.sleeve.must.be.installed.through.rated.fire.wall..Check.local.codes.for.proper.sheet.metal.gauge.and.attachment.angle.
Note:Sealing.of.fibrous.glass.duct.board.to.sheet.metal.sleeve.must.be.made.with.a.U.L..181A-M.rated.glass.fabric.and.mastic..An.exception.is.when.operating.pressure.is.less.than.1".W.G..and.sheet.metal.surfaces.are.carefully.cleaned,.in.which.case.a.U.L..181A-P.rated.pressure.sensitive.aluminum.foil.tape.may.be.used..See.Closure.Section,.pages.22-26.
Fastener Schedule:.#10.plated.sheet.metal..screws,.1 ⁄4".longer.than.board.thickness,..with.21 ⁄2".square.galvanized.steel.washers,..12".(max.).on.centers
Fire Damper Installation
Rated.Fire.Wall
.1".x.1".x.1 ⁄8".Metal.angle
Sheet.Metal.Sleeve
Fibrous.Glass.Duct.Board
11 ⁄2".(nom.)
Sheet.Metal.Sleeve.through.fire.wall.as.specified.in.fire.damper.mfr's.insutructions
Fire.Damper
Closure
#10.x.11 ⁄4".sheet.metal.screws.and.21 ⁄2".square.washers,.12".(max.).O.C.,.to.attach.duct.board.to.sheet.metal.sleeve
Sheet.Metal..Screws:..see.fastener.schedule
Access.Door:.see.page.51
Knauf Air Duct Fabrication Manual
Reinforcement.is.often.necessary.for.supply.and.return.ducts.to.ensure.structural.integrity..Knauf.Insulation.recommends.either.the.Fasloop.or.Locking.Cap.Washer.system.for.reinforcing.supply.ducts..It.is.also.possible.to.combine.the.two.systems,.as.the.examples.show.
Locking Cap/Tie Rod Reinforcement:
Materials needed:
(1).Washers.with.0.150".hole,.21 ⁄2".x.21 ⁄2".x.0.020.(minimum).thickness,.beveled.edges.(away.from.facing).
(2).1 ⁄4".caps.with.spring.steel.or.stainless.steel.locking.inserts.
(3).Galvanized.wire,.12.gauge.(minimum).
Step 1: Cut.wire.to.duct.O.D.+7 ⁄16".
Step 2:.Place.first.locking.cap.over.end.of.wire.
Step 3:.Measure.in.31 ⁄2".from.female.edge.of.joint.
Step 4:.Slip.washer.over.wire,.insert.wire.through.bottom.of.duct.(with.beveled.edges.of.washer.away.from.facing).and.on.through.opposite.side.of.duct.
Step 5:.Slip.second.washer.over.wire.
Step 6: Push.on.second.locking.cap.
Step 7: Continue.reinforcement.according.to.table.on.page.56.
Positive Pressure Reinforcement
Locking.Cap
Step.1
Step.2
Step.3.and.4
Step.5.and.6
3 1⁄2"
�4_��
Fasloop/Tie-Rod Reinforcement
Materials needed:
(1). .Volcano.indented.washer,.21 ⁄2".x.21 ⁄2",.0.028".min..thickness,.beveled.edges.away.from.facing,.plain.or.with.adhesive.back.
(2). .Galvanized.wire,.minimum.12.gauge.
(3). .Fasloop.Bending.and.Cutting.Tool..(available.from.Malco.Products,.Inc.,..Annandale,.MN.55302.
. . 800-328-3530).
Step 1: Cut.wires.to.Duct.O.D..+.11 ⁄2".or.buy.preformed.wires.
Step 2: If.using.non-preformed.wires,.make.initial.bend.on.one.end.of.wires.using.Fasloop.tool.
Step 3: Measure.in.3 1 ⁄2".from.female.edge.of.joint.
Step 4: Insert.wire.through.washer.and.duct,.with.beveled.edges.of.washer.away.from.facing,.and.on.through.opposite.side.of.duct.
Step 5: Slip.second.washer.over.wire.
Step 6: Depress.duct.slightly.to.feed.wire.into.Fasloop.tool;.make.final.bend.in.wire.
Step 7: Continue.steps.above.for.additional.reinforcements.necessary.as.indicated.in.table.on.page.56.
For.more.information.on.reinforcement.of.fittings.in.positive.pres-sure.fiber.glass.air.duct.systems,.refer.to.NAIMA.Fibrous.Glass.Duct.Construction.Standard,.Section.IV.
Positive Pressure Reinforcement
Fasloop
Step.1
Step.2
Step.5.and.6
Step.3.and.4
O.D..+.1.1 ⁄2".
3 1⁄2"
Knauf Air Duct Fabrication Manual
Positive Pressure Reinforcement Schedule
Positive Pressure Reinforcement Schedule
StaticPressureIn. W.G.
DuctI.D.
Max.
1" Duct Board 11/2" Duct Board 2" Duct Board
Tie RodsAcross
Duct, 16"Centers
MaximumSpacingBetweenTie Rods
Tie RodsAcross
Duct, 16"Centers
MaximumSpacingBetweenTie Rods
Tie RodsAcross
Duct, 16"Centers
MaximumSpacingBetweenTie Rods
0-1⁄2 0-36 none none none none none none37-42 2 24" 2 48" 2 48"43-48 2 24" 2 48" 2 48"49-60 3 24" 3 48" 3 48"61-64 3 24" 3 24" 3 24"65-80 4 24" 4 24" 4 24"81-96 5 24" 5 24" 5 24"
Over.1⁄2to.1
0-24 none none none none none none25-30 1 24" 1 48" 1 48"31-32 1 24" 1 24" 1 24"33-36 2 24" 2 24" 2 24"37-48 2 24" 2 24" 2 24"49-64 3 24" 3 24" 3 24"65-80 4 24" 4 24" 4 24"81-96 5 24" 5 24" 5 24"
Over.1to.2
0-15 none none none none none none16-18 1 24" none none none none19-24 1 24" 1 48" 1 48"25-32 1 16" 1 24" 1 24"33-48 2 16" 2 24" 2 24"49-60 3 16" 3 24" 3 24"61-64 3 16" 3 16" 3 16"65-80 4 16" 4 16" 4 16"81-96 5 16" 5 16" 5 16"
For.2".Air.Duct.Board.Reinforcement.Schedule,.please.call.your.Knauf.Insulation.sales.representative.
�6_�7
Negative Pressure Reinforcement
Formed channel reinforcement:
Materials needed:
(1)..3".wide.formed.channel,.22.gauge.(see.table.on.page.58.for.height).
(2)..Sheet.metal.clips,.2".x.6".x.20.gauge,.with.turned.edges.
(3)..Sheet.metal.screws,.#10.x.11⁄2".for.1".duct.board,.#10.x.2".for.11⁄2".duct.board,.#10.x.21⁄2".for.2".duct.board.
Step 1: Affix.channel.to.male.shiplap.edge.at.the.circumferential.joint..See.table.on.page.58.for.proper.height.of.channel.and.spacing.
Step 2: Affix.retaining.clips.to.duct.interior.under.channels..Clips.must.be.no.more.than.16".apart.nor.16".from.longitudinal.edge.of.duct..Clips.should.be.spaced.from.the.center.line.of.the.duct.according.to.the.table.below:
Duct Transverse
Dimension No. of Clips
16"-32" 133"-48" 249"-64" 365"-80" 481"-96" 5
Step 3: Fasten.clips.using.two.sheet.metal.screws.
For.reinforcement.of.fittings.in.negative.pressure.fiber.glass.ducts.refer.to.NAIMA.Fibrous.Glass.Duct.Construction.Standard,.Section.IV.
Step 1 and 2
Step 3
Knauf Air Duct Fabrication Manual
Negative Pressure Reinforcement Schedule
Negative Pressure Reinforcement Schedule
StaticPressureIn. W.G.
DuctI.D.
Max.
1" Duct Board 11/2" Duct Board 2" Duct Board
ChannelSpacing
Channelgauge
Heightof
ChannelChannelSpacing
Channelgauge
Heightof
ChannelChannelSpacing
Channelgauge
Heightof
Channel0-1⁄2 0-30 * — — * — — * — —
31-36 24" 22 1" 48" 22 1" 48" 22 1"37-42 24" 22 1" 48" 22 1" 48" 22 1"43-48 24" 22 1" 48" 22 1" 48" 22 1"49-60 24" 22 1" 48" 22 11⁄2" 48" 22 11⁄2"61-72 24" 22 1" 24" 22 1" 24" 22 1"73-84 24" 22 1" 24" 22 1" 24" 22 1"85-96 24" 22 11⁄4" 24" 22 1" 24" 22 1"
Over.1⁄2to.1
0-24 * — — * — — * — —25-30 24" 22 1" 48" 22 1" 48" 22 1"31-36 24" 22 1" 24" 22 1" 24" 22 1"37-42 24" 22 1" 24" 22 1" 24" 22 1"43-48 24" 22 1" 24" 22 1" 24" 22 1"49-60 24" 22 1" 24" 22 1" 24" 22 1"61-72 24" 18 1" 24" 18 1" 24" 18 1"73-84 24" 18 11⁄4" 24" 18 11⁄4" 24" 18 11⁄4"85-96 24" 18 11⁄4" 24" 18 11⁄4" 24" 18 11⁄4"
Over.1to.2
0-15 * — — * — — * — —16-18 24" 22 1" * — — * — —19-24 24" 22 1" 24" 22 1" 24" 22 1"25-36 16" 22 1" 24" 22 1" 24" 22 1"37-48 16" 22 1" 24" 22 11⁄4" 24" 22 11⁄4"49-60 16" 22 1" 24" 22 11⁄4" 24" 22 11⁄4"61-72 16" 18 1" 16" 18 1" 16" 18 1"73-84 16" 18 11⁄4" 16" 18 11⁄4" 16" 18 11⁄4"85-96 16" 18 11⁄2" 16" 18 11⁄2" 16" 18 11⁄2"
*.Straight.ducts.of.these.dimensions.do.not.require.reinforcement..However,.some.fittings.of.these.dimensions.may.require.reinforcement.NOTE:.Ducts.of.48".maximum.width.and.over.require.use.of.anti-sag.devices..See.page.59.
�8_��
Anti-Sag Reinforcement:Large.ducts.experience.natural.sag.due.to.the.weight.of.the.duct.board.when.it.is.not.pressurized..Anti-sag.devices.should.be.in-stalled.across.spans.48".and.over.in.width..If.anti-sag.reinforcement.is.required,.hangers.must.be.located.within.12".of.reinforcement.
Materials needed:
Same.as.required.for.Fasloop.or.Locking.Cap.Washer.tie-rod.reinforcement, plus 1⁄2" diameter metal conduit.
Step 1: Cut.conduit.to.duct.I.D..height..Length.of.wire.should.be.duct.O.D..+.5 ⁄8".
Step 2: Measure.in.31 ⁄2".from.male.edge.of.shiplap.
Step 3:.Insert.wire.through.washer.and.duct.(with.beveled.edges.of.washer.away.from.facing).
Step 4: Thread.wire.through.plain.washer.on.duct.interior,.conduit,.and.another.plain.washer.
Step 5: Insert.wire.through.other.side.of.duct.
Step 6: Slip.appropriate.washer.over.wire,.and.terminate.wire.using.Locking.Cap.Washer.or.Fasloop.method,.as.shown.on.pages.54.and..55.respectively.
Reinforcement
Step 1, 2 and 3
Step 4 and 5
Step 6
Knauf Air Duct Fabrication Manual
Hangers for Horizontal Duct Runs:Straight.horizontal.runs.of.fiber.glass.ducts.should.be.supported.by.3".wide.x.1".high.hangers.at.intervals.as.shown.in.the.chart.at.the.right.
Note: 2".wide.by.11 ⁄2".high.hangers.spaced.at.4-foot.intervals.(maxi-mum).may.be.used.in.place.of.3".hangers.when.ducts.are.no.more.than.48".wide.by.24".deep.
Hanger Extensions:Hangers.must.be.increased.in.height.and.gauge.when.they.extend.beyond.the.sides.of.the.duct..See.table.below.
If Total Hanger Extension is not
Greater Than:
Minimum Channel Gauge
Minimum Channel Profile
6" 24 3".x.1.5"18" 22 3".x.2"30" 18 3".x.2"
Shown.at.right.are.recommended.configurations.for.hanging.straight.runs.of.fiber.glass.duct.
Note: Mounting.of.accessories:.When.mounting.equipment.such.as.dampers,.damper.operators.and.control.motors,.the.duct.system.shall.be.adequately.reinforced.and.supported.to.accommodate.the.additional.weight.of.the.equipment.without.damage.to.the.duct..Particularly.important.is.the.mounting.of.both.dampers.and.their.operators.on.the.same.sleeve.or.mounting.plate.
Hangers and Supports
Minimum.Hanger.Spacing,.Straight.Horizontal.Duct,.3".x.1".Channel
48444036322824201612
840
Inside
.Duc
t.Heig
ht.(In
ches
)Inside.Duct.Height.(Inches)
0. 8. 16. 24. 32. 40. 48. 56. 64. 72. 80. 88. 96.
Hanger.Strap
1".wide.(min.)..22.gauge
Hanger.Wire.
12.gauge.(min.)
6".(min.)
6.ft..max.
6.ft..max.
8.ft..max.
4.ft..max.
60_61
Hangers and Supports
Hanging Fiber Glass Duct Fittings Up To 48" Wide:
Elbows:
Install.hangers.12".(max.).off.each.side.of.throat..When.duct..is greater than 18" wide, install additional hanger at 45° angIe, .approximately 2⁄3 of the distance from throat to heel.
Branch Support:
If.trunk.duct.hanger.falls.where.branch.duct.is.located,.add.trunk.hangers.on.either.side.of.branch.duct..Do.not.exceed.maximum.hanger.spacing.(see.chart,.previous.page).
Tee Support:
If.tee.run-out.hanger.falls.where.trunk.duct.is.located,.add.run-out.hangers.on.either.side.of.trunk..Do.not.exceed.maximum.hanger.spacing.(see.chart,.previous.page).
Offsets (Flat Bottom):
If.angled.part.of.offset.is.greater.than.48".long,.install.hangers.under.angled.part..Do.not.exceed.maximum.hanger.spacing.(see.chart,.previous.page).
Transitions (Flat Bottom):
Locate.hangers.as.for.straight.duct..Use.spacing.(chart,.previous.page).for.largest.dimension.of.transition.
Offsets and Transitions:
(Sloping.Bottom.Surfaces):.When.inclined.portion.is.greater.than.48".long,.install.hangers.as.shown.in.detail.(right)..Do.not.exceed.maximum.spacing.per.chart,.previous.page.
Hanger.Rod
Centered.inside.duct.parallel.to.air.flowDuct
45°
12".max.
12".max.
12".max.
6".to.12"
6".to.12"
6".to.12"6".to.12"
#10.plated.sheet.metal.screws2 1 ⁄2".sq..washers
3".x.1".Channel.9".(min.).long
Knauf Air Duct Fabrication Manual
Vertical Riser Supports:Supports.should.be.used.when.riser.length.is.8.feet.or.more.and.should.be.installed.at.12.foot.(maximum).intervals..
Note: Risers.in.fiber.glass.duct.systems.may.not.exceed.2.stories.in.height.
Floor Mounted Support:
Step 1: Insert.sheet.metal.sleeve.inside.duct.where.duct.inter-sects.floor..Sleeve.should.be.the.same.dimensions.as.the.duct.I.D..and.have.a.length.equal.to.floor.thickness.+.4".
Step 2: Affix.1".x.1".x.1 ⁄8".angle.bars.to.floor.on.each.side.of.duct.
Step 3: Use.sheet.metal.screws.to.affix.duct.and.sheet.metal.collar.to.floor.angle.
Wall Mounted Support:
Step 1: Using.1".x.1".x.1 ⁄8".angle,.construct.wall.support.bracket.
Step 2: Fabricate.a.U-channel.to.reinforce.the.duct.at.point.where.it.will.pass.through.support.bracket..See.Reinforcement.Section.(pages.54-59).for.channel.dimensions.and.sheet.metal.gauge.
Step 3: Affix.reinforcement.channel.to.duct.with.sheet.metal.screws.and.square.washers.
Step 4: Insert.duct.section.with.reinforcement.channel.into.wall.support.bracket..Secure.reinforcement.channel.to.bracket.with.sheet.metal.screws.
Note: A.2".wide.sheet.metal.sleeve.inside.the.duct.and.screwed.through.it.to.the.wall.support.bracket.may.be.used.in.place.of.reinforcing.U-channel.around.outside.of.duct.
Hangers and Supports
Through.floor
Step.2
Step.2
Step.1
Along.wall
wall
Step.1
Step.3
Step.3
floor
floor
floor
62_6�
Repairing Minor Damage:Minor.damage.such.as.a.straight.slit.in.the.facing.may.be.repaired.by.applying.approved.closure.material.in.accordance.with.the.Closure.Section,.pages.22-26.
Repair.more.extensive.damage.as.follows:
Example 1:
When facing damage is up to 1⁄2" wide, apply approved closure material.so.that.it.extends.at.least.1".beyond.all.sides.of.the.damage.
Example 2:
When facing damage is more than 1⁄2" wide but less than the width.of.the.closure.tape,.smooth.facing.and.apply.a.double.layer.of.closure.material.so.the.second.layer.extends.at.least.1".beyond.all.edges.of.the.first.layer.
Note: Replace.tie.rod.or.channel.reinforcements.if.these.have.been.damaged,.lost,.or.removed.while.making.repairs..See.Reinforce-ment.Section.(pages.54-59).
Damage Repair
1".(min.).all.sides.of.damaged.area
1".(min.).beyond.edges.of.first.layer
Second.layer
First.layer
Example.2
Example.1
Knauf Air Duct Fabrication Manual
Damage Repair
Repairing Major Damage:Major.damage.extending.into.the.insulation.and.involving.some.loss.or.displacement.of.the.material.requires.removal.of.the.entire.damaged.area.and.insertion.of.a.duct.board.plug.
Example 1:
Step 1:.Remove.damaged.area..Piece.removed.must.be.at.least.6".x.6",.and.must.extend.no.closer.than.6".to.corners.of.duct..If.damage.extends.to.within.6".of.edge.of.duct,.cut.to.edges.of.dam-aged.panel.and.fabricate.a.plug.whose.end.cuts.match.those.of.the.damaged.piece.that.was.removed.
Step 2: Shiplap.all.four.sides.of.hole.in.duct.with.M/F.tool.
Step 3: Fabricate a plug to fit the hole with 11⁄2" (min.) staple flaps.on.all.four.sides.
Step 4: Apply.approved.closure.material.to.seal.plug.*
If.entire.panel.is.cracked,.creased.or.otherwise.severely.damaged,.repair.as.follows:
Step 1: Slit.facing.with.knife.along.both.sides.of.damaged.panel.and.remove.
Step 2: Fabricate.a.new.panel.and.reassemble.section..See.U-Style.technique,.pages.10.and.12-14.*
Example 2:
Replacing.panel.with.shiplapped.edges
Example 3:
Replacing.panel.with.straight-cut.edges
Note: Replace.tie.rod.or.channel.reinforcements.if.these.have.been.damaged,.lost,.or.removed.while.making.repairs..See.Reinforce-ment.Section.(pages.54-59).
*See.Closure.Section,.pages.22-26.
Example.1
Example.3
Example.2
64_6�
Project.Name.
Duct.System.Contractor.
Inspected.by.. Date
The inspector should have the following available:
•. Knauf.Air.Duct.Fabrication.Manual•. Knauf.MAX.10.Fabrication.Manual•. NAIMA.Fibrous.Glass.Duct.Construction.Standard•. Knauf.Installation.Instruction.Sheets•. Job.plans.and.specifications•. Measuring.tape
All.questions.should.be.answered."YES"..If.any."NO".answers.occur,.review.appropriate.sections.of.this.manual.for.corrective.guidance.
General Yes No1.. Is.system.installed.within.design.limitations?...............................................................................................................................................................□.. . . . . . . . . . □2.. Are.all.facing.tears.repaired.using.proper.materials? .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .□.. . . . . . . . . . □3.. Are.all.sheet.metal.accessory.items.galvanized?.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .□.. . . . . . . . . . □
Product Yes No4.. Is.the.El.rating.printed.on.the.facing? .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .□.. . . . . . . . . . □5.. Is.the.UL.label.present.on.most.modules.or.fittings?.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .□.. . . . . . . . . . □6.. Is.the.system.free.from.ballooning.or.condensation.that.could.indicate.duct.board.facing.delamination? .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .□.. . . . . . . . . . □
Fabrication Yes No7.. Are.8".(min.).cross.tabs.of.approved.closure.spaced.12".(max.).O.C..where.staples.are.not.used? .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .□.. . . . . . . . . . □8.. Is.the.system.completely.free.from.facing.tears.or.punctures,.or.(if.not).are.tears.and... punctures.correctly.repaired? .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .□.. . . . . . . . . . □.9.. Is.the.system.completely.free.from.areas.where.excessive.amounts.of.closure.material.may... have.been.applied.to.conceal.potential.problems?.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .□.. . . . . . . . . . □10.. Are.all.joints.tight,.free.from.bulges,.with.sealed.joints.showing.good.workmanship?.................................................................................................□.. . . . . . . . . . □11.. Have.offsets.been.used.to.avoid.obstructions,.rather.than.forcing.or.bending.a.straight.section?.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .□.. . . . . . . . . . □
Accessory Installation Yes No12.. Are.electric.heaters.properly.installed.with.interior.sheet.metal.sleeves,.screws.and.washers.on.16".centers,... and.are.they.separately.supported?.(See.NAIMA.Fibrous.Glass.Duct.Construction.Standard.).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .□.. . . . . . . . . . □13.. Are.motorized.damper.operators.mounted.on.the.same.sleeve.as.the.dampers.themselves?. (See.NAIMA.Fibrous.Glass.Duct.Construction.Standard.) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .□.. . . . . . . . . . □14. Do quadrants on manual volume dampers move a full 90°?.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .□.. . . . . . . . . . □15.. Are.sheet.metal.sleeves.present.in.fire.damper.installations,.properly.attached.to.duct.with.screws.and... square.washers.on.16".(min.).centers?.(See.NAIMA.Fibrous.Glass.Duct.Construction.Standard.).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .□.. . . . . . . . . . □16.. Are.grilles,.diffusers.and.registers.installed.in.accordance.with.NAIMA.Fibrous.Glass.Duct... Construction.Standard?.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .□.. . . . . . . . . . □17.. Are.unit.connections.made.in.accordance.with.NAIMA.Fibrous.Glass.Duct.Construction.Standard?.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .□.. . . . . . . . . . □
Contractor's Inspection Checklist
Knauf Air Duct Fabrication Manual
Closure Yes No18.. Are.all.system.joints.properly.closed?..........................................................................................................................................................................□.....................□19.. Are.closure.materials.of.listed.type,.as.shown.on.the.UL.instruction.sheet.in.the.duct.board.package?.....................................................................□.....................□20.. Are.staples.or.cross.tabs.properly.spaced.on.circumferential.joints?...........................................................................................................................□.....................□21.. Are.staples.of.correct.size.and.type,.spaced.at.recommended.intervals?...................................................................................................................□.....................□22.. Where.pressure-sensitive.tape.closures.are.made,.are.they.rubbed.down.firmly.so.staples. and.facing.scrim.show.through.clearly?.......................................................................................................................................................................□.....................□23.. Where.heat-activated.closure.material.is.used,.was.application.temperature.sufficient. (darkening.of.heat.indicator.dots.are.evidence.of.this)?...............................................................................................................................................□.....................□24.. If.glass.fabric.and.mastic.closure.materials.were.used,.is.the.mesh.of.the.fabric.filled.with.mastic?...........................................................................□.....................□
Reinforcement Yes No25.. Is.reinforcement.of.type.recommended?......................................................................................................................................................................□.....................□26.. Is.tie.rod.wire.12.gauge.or.heavier?.............................................................................................................................................................................□.....................□27.. Is.tie.rod.spacing.correct.according.to.duct.span,.board.El.number,.and.static.pressure.of.system?..........................................................................□.....................□28.. Are.tie.rod.washers.21⁄2" square and proper gauge by type?.....................................................................................................................................□.....................□29.. Are.beveled.edges.of.washers.away.from.duct.board.facing?.....................................................................................................................................□.....................□30.. Are.tie.rods.used.on.both.sides.of.butt.joints?..............................................................................................................................................................□.....................□31.. Is.wire.termination.as.recommended?..........................................................................................................................................................................□.....................□32.. Are.anti-sag.conduits.used.on.ducts.of.48".span.or.greater.to.support.top.panels?....................................................................................................□.....................□33. Do.tie.rods.run.straight.through.ducts.rather.than.at.angles?......................................................................................................................................□.....................□34.. Are.heels.of.tees,.elbows.and.end.caps.reinforced?....................................................................................................................................................□.....................□35.. Are.channel.sheet.metal.gauges,.dimensions,.and.spacing.correct?..........................................................................................................................□.....................□36.. On.supply.ducts,.is.reinforcement.on.female.shiplap?.................................................................................................................................................□.....................□37. On return ducts, are channel reinforcements attached with screws and 21⁄2" washers (or 2"x 6" clips)?...................................................................□.....................□38.. On.return.ducts,.are.reinforcements.on.male.shiplap?.................................................................................................................................................□.....................□
Hangers and Supports Yes No39.. Are.hanger.designs.in.accordance.with.NAIMA.Fibrous.Glass.Duct.Construction.Standard?.....................................................................................□.....................□40.. Are.hangers.installed.in.accordance.with.NAIMA.Fibrous.Glass.Duct.Construction.Standard?...................................................................................□.....................□41.. Are.accessories.that.add.weight.to.the.duct.system.separately.supported?................................................................................................................□.....................□42.. Are.vertical.risers.supported.on.12.foot.(max.).centers.and.no.more.than.two.stories.in.height?................................................................................□.....................□43. If.channel.reinforcement.is.used.as.hangers,.are.all.attachments.within.6".of.sides.of.duct?......................................................................................□.....................□44.. Are.fittings.supported.by.hangers.as.recommended.in.NAIMA.Fibrous.Glass.Duct.Construction.Standard?..............................................................□.....................□
66_67
NAIMA's Fiber Glass Duct Training VideotapeThis.two.hour.VHS.videotape.introduces.the.Fibrous.Glass.Duct.Board.System.and.depicts.tools.and.techniques.used.for.fabricating.straight.duct.modules.by.hand.or.machine..It.covers.approved.closure.methods.and.materials..Step-by-step.fabricating.techniques.are.shown.for.elbows,.tees,.reducers,.offsets,.and.tap-ins..By.show-ing.exactly.how.each.fitting.is.correctly.fabricated,.this.videotape.is.an.excellent.operator.training.resource..Call.the.NAIMA.Office.at.703-684-0084.to.obtain.a.copy.
Knauf Air Duct Fabrication Manual
At Knauf, we manufacture a wide variety of products that serve a common goal, helping to make the most of our planet’s energy resources. A family-owned global company, we understand and are committed to high standards in quality, performance and environ-mental responsibility. Every step we take today toward energy conservation helps ensure better lives for generations to come.
leed eligible Product Use of this product may help building projects meet green building standards as set by the Leadership in Energy and Environmental Design (LEED) Green Building Rating System. Credit 4.1 - 4.2 Recycled Content Credit 5.1 - 5.2 Regional Materials
NOTESKnauf Insulation GmbH complies with ISO 9002 in the prevention, detection and correction of problems in production and service areas.
Knauf Insulation GmbH One Knauf driveShelbyville, IN 46176
Sales and Marketing (800) 825-4434, ext. 8283
Technical Support (800) 825-4434, ext. 8212
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World Wide Web www.KnaufInsulation.com
©2006 Knauf Insulation GmbH.