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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 26_27


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





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




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"





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





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

Knauf Air Duct Fabrication Manual 1�




12_1�

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" Four-Piece


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" Four-Piece


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)





14_1�

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


. 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





16_17

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


. 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.





18_1�

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)





20_21

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





22_2�

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





24_2�

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





26_27

�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





28_2�

�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.

Knauf Air Duct Fabrication Manual �1




�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"

Knauf Air Duct Fabrication Manual ��




�2_��

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





�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"

Knauf Air Duct Fabrication Manual �7




�6_�7


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).


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





�8_��


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).


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"





40_41


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


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"





42_4�

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


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




Air Duct Board

44_4�


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.


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



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.


Round.Tap

Square.Tap

Tap-Ins—1", 11/2", and 2" Air Duct Board

Tap-Ins—1", 11/2", and 2" Air Duct Board



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.*


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


Z-Channel.around.opening




Z-Channel.around.door

3",.22.Gauge.frame.inside.of.opening


11⁄2" x 11⁄2" x 11⁄2",..22.Gauge.-.for.11⁄2".Board


U-Channel.around.opening

Flange.on.Door.Frame

Flange.on.Door.Frame

2",.22.Gauge.frame,..outside.of.door




U-Channel.frame.around.door.opening


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


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"


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


Tie RodsAcross

Duct, 16"Centers


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


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


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


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


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.


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


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).


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


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.


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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©2006 Knauf Insulation GmbH.

Documents

AH FM 4 Part1 AirDuctFabManuals 2007