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application manual >> ductworK

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1 THERMAL INSULATION OF DUCTWORK 3» Measure surface dimension for insulating rectangular ducts 3

» InsulatingrectangularductswithArmaflex sheets 3

» Insulating rectangular ducts with self-adhesive Armaflexsheets 3

» InsulatingirregularflatshapeswithArmaflex sheets 4

» Insulating square to round sections with Armaflexsheets 4

» Insulatingstraightpartsofcircularductswith Armaflexsheets 5

» Insulating segmented bend of circular ducts Armaflexsheets 5

» InsulatingductbracketswithArmaflexDuct halt-round sections 7

»InsulatingductbracketswithArmaflextubes 7

»InsulatingductbracketsbyusingArmaflex sheet 8

2 LINING OF DUCTWORK FOR ACOUSTIC PURPOSES 9» Lining of ductwork 9

3 USEFUL HINTS 10»Sprayadhesion 10

»Makeatemplateforasegmentedductbend withArmflexsheet 10

» Makeatemplateforirregularshapes 10

4 REFERENCES » References In additiontothismanualArmacellprovides additional documents, freely available from www.armacell.com. 11

© ARMACELL ASIA LTD.

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APPLICATION MANUAL DUCTWORK

APPLICATION MANUAL DUCTWORK

MEASURE SURFACE DIMENSIONS FOR INSULATING RECTANGULAR DUCTS

MeasuresurfacedimensionsandcutArmaflexsheet to size. Note:Add5mmsothatmaterialisfittedundercompression.

a

c

ba = width of duct + 5mmb = length of duct + 5mm + thickness of insulationc = width of duct + 5mm + 2xthicknessofinsulation

INSULATING RECTANGULAR DUCTS WITH ARMAFLEX SHEET

Clean all surfaces using Armaflex cleaner to removegrease, oil, dirt etc. and cut sheets to size

SpreadathinfilmofadhesiveontothemetalsurfaceandthenontotheArmaflexsheet.

When the adhesive is tack dry (fingernail test) place Armaflexsheetinpositionandpressfirmlytoachievea good bond. Continue applying Armaflex adhesive tobothsurfaces,includingtheArmaflexedge,andallowtotackdrybeforepressingfirmlyintoposition.Note: Remember to roll the sheet down into positionalong the insulated edges.

1

3

2a2b

Insulate acc. to drawing, this is

especially important for external

duct work.

5mm

Thecutsheetsshouldbepositionedsothatthereisa5-10mmoverlap(forcompression).Donotapplyadhe-sive to this area.

Whenpressedtogetherthematerialisundercompres-sionandisnotstretched.Applyanadditionalwetsealalong the butt joints.

Note:Armaflexsheetof16mmthicknessorlesscanbewrapped around the ductwithout the need for cuttinginto4-pieces.However,caremustbe taken toensuretheupper surface is sloped toward theedges,withatleasta2°angle.Slopingof the topwillpreventpond-ing of water, particularly on exterior applications, andforms a watershed. This is best achieved if the material iswrappedaroundtheloweredges,buttheuppersideisfittedwithaseparatesheet.

INSULATING WITH SELF-ADHESIVE SHEET

Clean all surfaces using Armaflex cleaner to removegrease, oil, dirt etc. and cut sheets to size

Peelbackreleasepaper&lineupsheet.Pressfirmlytoactivate adhesive.

5mm

Alignmaterialandcontinuetocorrectly lineup,press-ingfirmlywhilstslowlyremovingreleasepaper.Atbuttjointsallow5mmoverlapforcompression.

Note:Keepthereleasepaperonthe5-10mmbuttjointoverlap.Therestofthereleasepapershallberemoved.

see Tip Section:Spray Adhesion

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1 - Insulating Ducts with Armaflex Sheet APPLICATION MANUAL DUCTWORK

© ARMACELL ASIA LTD.

APPLICATION MANUAL DUCTWORK 1 - Insulating Ducts with Armaflex Sheet

4 © ARMACELL ASIA LTD.

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INSULATING IRREGULAR FLAT SHAPES WITH ARMAFLEX SHEET

1. Trace all seams using standard drawing chalk.

2.CreateatemplatebypressingapieceofArmaflex onto the chalked duct seams.

3.Cut the shape of the resulting pattern out of the Armaflexsheet. Note: Add a minimum 5 mm to each measurement to allowforinstallationundercompression.

4.Apply all over Adhesive coverage both the duct surfaceandthecontactingArmaflexsurface. Allow theadhesivetotackdry.(seetip“spraytacking”).

5.Position and fix the Armaflex sheet. Add pressure usingaplasticcardtoprovideoptimaladhesionwith asmoothfinish.Avoidair/solventbubbles.

6.Measure and cut Armaflex sheet for the straight backstosize,adhereandsmoothoutwithaplastic cardtofinish.Avoidair/solventbubbles.

IF USING ARMAFLEx DUCT ShEETS (aluminium foil finished)

7. Before sealing all seams with self-adhesive aluminium foil tape, the seams and joints require a pre-cleanwithArmaflexcleaner.

8. Close all seams self-adhesivealuminiumfoiltape.

INSULATING SQUARE TO ROUND SECTIONS WITH ARMAFLEX SHEET

When covering square to round duct sections, it may be easier to create a template directly onto theArmaflexsheet as opposed to first transferring onto a piece ofcardboard.Thegeneralapproachisasinthefollowingprocedure:

1.Applychalkdirectlyontotheductworksection.

2.Press anArmaflex sheet of the required insulation thicknessfirmlyontothechalkededgestotransferan accurateimpressionontheArmaflexsheet. Beforecuttingtheresultingshapeaddanadditional 5mm(minimum)toallsidesoftheshapetoallowfor installationundercompression.

3.Apply the shaped Armaflex sheet to the ductwork surface as described in the section “Insulating irregularflatshapes”.

5

1 - Insulating Ducts with Armaflex Sheet APPLICATION MANUAL DUCTWORK

© ARMACELL ASIA LTD.

INSULATING SEGMENTED BEND OF CIRCULAR DUCTS WITH ARMAFLEX SHEET

1.Placethesegment/fishtailtemplateontothesurface of the laminated Armaflex surface. Mark out the required number of segments for the bend.

2.Cutthesegmentsusingasmallsharpknife. Note:Theexampleshownisfora2+2fabrication- two centre pieces, one starting and one finishing piece.

3.UsingArmaflexadhesiveapplyathin,evenlayerof adhesive to both edges of the segment. Multiple segments can be glued at one time, as shown.

4.Allowtheadhesivetotackdry(fingernailtest),fitthen pressthegluedseamstogetherfirmly.Note:Foreasy fixing,press togethereachendfirst, thenpress the centre section area last.

5.When all applicable fabrications have been fixed together,applyathinevenfilmofadhesivearoundall circumferential edges of the segments.

6.Position and line-up the centre seams, apply firm pressure around the glued seams to bond the segments together. Note: Ensure all fixing seam surfaceshaveadhesiveapplied. Allowadhesive to “touchdry”beforebondingtogether.

7. When all segments are glued together use a small sharpknifeandcutalongthecentrelineofthefab- riation.

INSULATING STRAIGHT PARTS OF CIRCULAR DUCTS WITH ARMAFLEX SHEET

For circular ducts larger than OD > 500mm please re-fer totheArmaflexapplicationmanual(page14)section“Armaflexadhesivevanditsuseonpipework>88.9mmO.D.”Followallwaystheprocedurerecommendedforver-ticalpipes.

1.Determinethecircumferenceofthepipe. Important:AlwaysmeasurewithastripofArmaflex of the thickness to be used for the insulation. Warning:Donotstretchthestrip. Note: Add a minimum 5mm to each measurement to allowforinstallationundercompression.

2.Cut Armaflex sheet to the required size - apply Armaflexadhesivetothecutsurfacesinathinlayer, allow to touch dry.

3. Press together at the ends and then in the middle. Close the entire seam starting from the middle. Note:Inordertopreventtheseamre-openingensure theadhesivehasbeenfullyappliedtotheedgesof the fixing seam and ensure the correct amount of adhesivehasbeenapplied.

Checktheopentimeofadhesivetoensureitisstillfit for use.

C + 5mm

see Tip Section:Chalking for simple template

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6 © ARMACELL ASIA LTD.

APPLICATION MANUAL DUCTWORK 1 - Insulating Ducts with Armaflex Sheet

8.Placethepre-fabricatedfittingcoverovertheducting bend.ApplyathincoatofArmaflexadhesivetothe mainfixingseams. Allow to tack dry. Fix the glued seam together, starting from both ends and working to the centre. Note: As an alternative, segments can be applied separately and then fixed, positioned, sealed and taped to finish, directly on the installed ducting on location.

9. If using Armaflex Duct (aluminium foil fin- ished):Tofinish,applymatchingself-adhesivetape on all seams and joining details. Note:Beforeapplyingthetape,ensuretheinsulation surface is clean and dry. Tip:Usingaplasticcardwhenapplying,canenhance thebondingstrengthofthetape.

10.On completion of the bend fabrication, continue to install the straight-line fabrications.Themain fixing seamsshouldbesecuredusingArmaflexAdhesive. The sheets should always be positioned so that thereisa5-10mmoverlap(forcompression).Donot applyadhesivetothisarea. Applyanadditionalwetsealalongallbuttjoints. Note: Allow additional circumferential excess in the sheet fabrications when using Armaflex Duct (pre-coveredsheet).

12.Thefixingofthestraight-linefabricationisthesame asforstandardArmaflexsheet. Note:Forverticalductworkall-overadhesivecover- age to the ductwork surface is required at all times. Forhorizontalductworkabove500mmindiameter, 1/4 adhesive coverage to ductwork surface is required. Tip: Where required, “turn away” the main fixing seam from view.

13.Pushstraight linefabricationsup-tothe“butt” joints of thebend,andwhereapplicableprovideanaddi- tional vapour seal (wet seal) usingArmaflex adhe- sive.Ensuretherearenogapsbetweenthejointing detailsbeforeapplyingtapeoradhesive. Tip:Onverticalapplications, toavoidthe insulation “slipping”, fix theArmaflex sheet to the surface of theductingbyapplying50mmofAdhesiveonboth the innerface of the insulation and metal surface usingabrush.Allow1-4minutesbeforepressingthe sheet to the ducting surface for a secure bond.

14.If using Armaflex Duct (aluminium foil fin- ished): To finish, cover over all seams and joints usingsmatchingself-adhesivetape. Tip:usingaplasticcardwhenapplyingcanenhance thebondingstrengthofthetape. Note:Additional vapour sealingof “butt” jointswith Armaflexadhesiveisonlyrequiredwheretheinside airtemperatureoftheductingisbelow+15°C.

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7© ARMACELL ASIA LTD.

1 - Insulating Ducts with Armaflex Sheet APPLICATION MANUAL DUCTWORK

INSULATING DUCT BRACKETS WITh ARMA-FLEx TUBES

“PICTURE FRAME” METhOD

Foracosteffectivesolutionwithahigh-endfinish,Armaflextube can be used to over-cover raised ductwork-connect-ing brackets.

Throat Length 45°cut

1.UsingunslitArmaflextubewithequalthicknessasthe attachedmainductbranch;splitwithasharpknifethe tube into two equal halves.

2. Measure the four insulated sides of the duct body.

3.Using a mitre box or theArmaflex template, cut the Armaflexasshownwitha45degreeangle.Fromthe throatmeasurement,determinethelengthofthefitting andcutanopposite45angleasshown.

4.Continue to cut the other 3 sides of the tube picture famefitting.

5.UsingArmaflexadhesive,applyathinevenfilmwitha brush to the three sets of 45 angles.

6.Allowtheadhesivetotouchdry,fixtheanglestogether, applyingfirmevenpressureforagoodbond.

7.PlacethepictureframeArmaflextubearoundtheduct- ing,applytheadhesivetothefinalanglecutsandbond tocompletethefixingofthepictureframe.

8.To finish, wet seal around the picture frame fitting cover.

INSULATING DUCT BRACKETS WITh ARMA-FLEx DUCT hALF-ROUND SECTIONS

“WRAP-AROUND” METhOD

1.Determine the actual circumference of the insulated ducting, using the Armaflex Duct bracket ma- terial. For large diameter ducts, itmay be necessary to joinmultiplebracketstrips togetherusingArmaflex adhesive. Note: The covers can be used to insulate over hanging bracketconnectionsandflanges.

2. The insulation surface shall be clean and dry before applyingtheself-adhesivebracket/flangecovers.

3. Remove from both edges the self-adhesive release strip.

4.Placeandfixdown thecover in the requiredstarting position.

5. Without stretching, continue to work the cover around itemstobeover-covered,applyingfirmpressuretothe self-adhesive area of the cover.

6.Continue to fully insulate over/around the required items.Whereapplicable,cutoutforthe“oilthread”that holdsthehangerinplace. Tip:Checktoseethatthecoverhascompletelybonded totheinsulationsurface.Applyfirmevenpressure.

7.Tofullycompletethevapourseal,applyself-adhesive aluminiumfoiltapetoallattachedseamsandjoints.Tip: using a plastic cardwhen applying can enhance the bondingstrengthofthetape.

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8 © ARMACELL ASIA LTD.

INSULATING DUCT BRACKETS BY USING AR-MAFLEx ShEETS

Single stripmethod - Four single stripsappliedtotheinsulation.

Three-sidedboxmethod -Built up sidestripswithover-coveringbodystrips.

Continuous single strip method - Com-pletesinglecontinuousstrip.

Inallsituations,thefabricatedArmaflexinsulationbracketcovers have the same thickness as the attached ductwork connections.Foracontinuousvapoursealedsystem,allinsulationcoversshallbesecurelyfixedandwetsealedwithArmaflexadhesive.

Note:On foil coveredArmaflexDuct, all exposedblackedges, seams and joints should be covered using match-ingself-adhesivefoiltape.

APPLICATION MANUAL DUCTWORK 1 - Insulating Ducts with Armaflex Sheet

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2 - Lining of ductwork for acoustic purposes APPLICATION MANUAL DUCTWORK

© ARMACELL ASIA LTD.

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LINING OF DUCTWORK

Armaflex can be used to internally line ductwork foracousticpurposes.Allgeneralrulesandrecommenda-tionsforworkingwithArmaflexremainvalid.

Thetemperatureoftheairandoftheinsulationshouldbe between 4°C and 38°C at the time of installation.

1.CleanallsurfacesusingArmaflexcleanertoremove grease, oil, dirt etc. before commencing installation.

2. Measure the internal duct dimensions and add an additional 5 mm to each dimension, cut Armaflex sheet to size.

3.CutArmaflexsheettosize.

4. Peel back enough release liner to start.

5. Square off sheet along an edge or corner. Press the sheettothesurfacetakingcarenottotrapanyair.

6.ReachbehindtheArmaflexsheetandpeellinerback whilepressingthesheettothesurface. ApplyfirmandevenpressuretoadheretheArmaflex sheet to the ductwork surface.

5mm

5mm

At all butt joints allow an additional 5 mm of material to enableinstallationundercompression.Thiswillpreventthepossibleopeningofseamsinhighairvelocities.

10 © ARMACELL ASIA LTD.

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APPLICATION MANUAL DUCTWORK 3 - Ductwork >> Useful hints

SPRAY ADHESION

Using Spray Adhesive when using Armaflex sheet on ductwork

Some full contact spray adhesives can be used in conjunction with Armaflex Duct sheets on ductworkoperating at above ambient temperatures. As withstandard Armaflex Adhesive, both the insulation sur-face and the ductwork surface should be covered usingalloveradhesivecoverage.Sprayadhesiveshouldbeappliedasaccordingtothemanufacturersrecommen-dations.

Armacell does not recommend any specific brand ofsprayadhesiveforuse.Ifinanydoubtregardingthesuit- ability of using a given spray adhesive for a given Armaflex Duct application, please contact our technicalsupportteam.

Important:Wherea specification states insulationmustachievea0ODP rating, thespayadhesiveshouldalsoconform to this requirement.

Note: Before applying any spray adhesive, please con-firmwiththesprayadhesivemanufacturerthattheadhe-siveissuitableforusethroughouttheexpectedoperating temperaturerangeoftheductwork.

CHALKING FOR SIMPLE TEMPLATES

Make a template for a segmented duct bend with Armaflex sheet

1.Determine the true circumference of the bend by using a strip ofArmaflex around the centre of the bend. Important: Always measure using a strip of pre- coveredArmaflexsheet-50mmwide-ofthethick- ness to be used for the insulation. Do not stretch thestrip. Note: If the segmented bend has raised seams, the Armaflexstripshouldbeplacedon topandaround this area.

2. Mark the circumference and add 10mm to the determining true length. This will be referred to as the “truecircumference”length.

3.Toproduceaquickpattern for thesegmentsbelow mark, using white chalk, one of the centre segments contained within the ducting bend.

4.Usingalongstripofpre-coveredArmaflexsheetpress animprintofthechalkedsurfaceontotheArmaflex. This can be used as the basis of the master template.

5.Cutouta“trial”segmentand,whererequired,make slight adjustments to the marking out. Place the trial segmentaroundtheductbendbeforecompletingthe mastercopy.Addadditionallengthtothemasteras required. Tip:Avoidmakingthefittingcovertootight.

Make a template for irregular shapes

1. Place a piece of card next to the insulated duct featureandtracetheshape.

2. Usingacraftknifecutthisshapefromthecard.

3. Usingthisasatemplatedrawtheshapedirectlyonto theArmaflexsheet.

4. Cuttheresultingshape

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4 - References APPLICATION MANUAL DUCTWORK

© ARMACELL ASIA LTD.

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OThER APPLICATION GUIDES

» ArmaflexApplicationmanual

ApplicationGuidesforArma-ChekSPlus, Arma-ChekT,Arma-ChekDandArma-ChekR

» SpecialApplicationAdviceforNH/Armaflex

» SpecialApplicationAdviceforHT/Armaflex

» ApplicationHintsforArmaflexUnderground

» ApplicationHintsforArmaflexTuffCoat

» ArmaflexApplicationGuideforPlasticpipes

» ArmaflexProtectR-90ApplicationGuide

» ApplicationGuideforArmaSoundIndustrialSystems

» Armaflex&Arma-Chekapplicationvideo

CALCULATION TOOLS

» Armafinish FR paint - Coverage Calculator

Arma-Chek T - Coverage Calculator

» keytec. ISO 15665 DeterminetherightArmaSoundIndustrialSystems

» keytec. Armaflex Underground Calculate the impact of insulation on the time until pipefreezingoccurs.

keytec. Arma-Chek R fishtail calulator Calculate the exact shape and measurements for fishtailsusedtocoverbendsinsulatedwithArmaflex

keytec. Unit converter metric / imperial Calculate the most common units from metric to imperialmeasurements

» ArmWin AS ArmwinAS is the technical calculation program to determineinsulationthicknessesrequiredtoprevent surface condensation and limit energy losses.

ItalsoallowsuserstocalculateU-values,heatflows andtemperaturechangesforpipes,ductsandtanks.

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REFERENCES

Inadditiontothismanual,Armacellprovidesthefollow-ing documents, freely available from www.armacell.com. These documents contain further detailed advice for specificapplications.

MECHANICAL PROTECTION AND OUTDOOR APPLICATIONS WITH ARMAFLEX

Explanation of the issues arising when installingArmaflexoutdoorsandevaluationofsolutionstoprotectArmaflexfrommechanicaldamage.

INSULATING COLD LINES WITH LINE TEMPERATURES BETWEEN -50°C TO -196°C (-58°F to -320°F)

Installation advice on issues arising when insulating low temperaturelinesbelow-40°C.

ARMAFLEX UNDERGROUND

Explanation of the theory underlying insulating under-ground pipes, including advice on insulating under-groundpipesusingArmaflexandalso includingacal-culationtooltocalculatetheimpactofinsulationonthetimeuntilpipefreezingoccurs.

TRACE hEATING

Explanation of the theory underlying insulating traceheatedpipes,includingadviceonselectingcorrectlydi-mensioned insulation tube.

ARMAFLEx ON RECTANGULAR & CIRCULAR DUCTWORK

Additional detailed installation advice when installing Armaflexontorectangularorcircularductwork.

ARMAFLEx IN CONCRETE

Installation advice when burying pipes insulated inArmaflexdirectlyinconcrete.

GLUING ARMAFLEx ONTO CELLULAR GLASS

InstallationadvicewheninstallingArmaflexdirectlyontoa cellular glass surface.

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Armacell Asia Limited ·Suite9-10·L25OfficeTowerLanghamPlace8ArgyleStreet·Mongkok·Kowloon·HongKongPhone+85225748420·Fax+85225748394www.armacell.com

Armacellprovidesthisinformationasatechnicalservice.TotheextenttheinformationisderivedfromsourcesotherthanArmacell,Armacellissubstantially,ifnotwholly,rely-ingupontheothersource(s)toprovideaccurateinformation.InformationprovidedasaresultofArmacell’sowntechnicalanalysisandtestingisaccuratetotheextentofourknowledgeandability,asofdateofprinting,usingeffectivestandardizedmethodsandprocedures.Eachuseroftheseproducts,orinformation,shouldperformtheirownteststodeterminethesafety,fitnessandsuitabilityoftheproducts,orcombinationofproducts,foranyforeseeablepurposes,applicationsandusesbytheuserandbyanythirdpartytowhichtheusermayconveytheproducts.SinceArmacellcannotcontroltheenduseofthisproduct,Armacelldoesnotguaranteethattheuserwillobtainthesameresultsaspublishedinthisdocument.Thedataandinformationareprovidedasatechnicalserviceandaresubjecttochangewithoutnotice.

© Armacell Asia Limited · Subject to alterations · 000-005-0311-EN(HK)

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TheArmaflexAssuranceSystem-yourpeace-of-mindassurancethatArmaflexismadetothestrictestquality,technicalperformanceandenvironmentallyfriendlystandards.

Prevents Moisture PermeationMulti-layeredclosedwallcellsprovideabuilt-invapourbarrierwhichcan’tbecompromisedbysurfacepunc-turesorrips-thisensuresthevapourbarrierstaysworking for the lifetime of the insulation system.

Provides Long Term Thermal PerformanceNon-wicking-NotransmissionofwatervapourispossiblethroughtheinsulationduetotheclosedcellnatureofArmaflex.MoisturewillnotmigratethroughprofessionallyinstalledArmaflex.

Long Term Durability Nofragilewatervapourbarrier-Thebuilt-invapourbarriercan’tbe“damaged”duringinstallationoroverthe lifetime of the insulation.

Avoids Thermal BridgingArmaflexisaseamlessinsulationsystem-thesesametechnicalpropertiesprovideasecuresystem.

Long Term Energy EfficiencyByminimisingtheingressofwatervapourintotheinsulationthemulti-layeredcellsinArmaflexpreventthe thermal conductivity from rising. Increased thermal conductivity can in the long term lead to increased energy costs and surface condensation.

Inhibits Growth of Mould• Minimisesmoisturepermeation,thefirstrequire- ment for mould growth• Minimisesthesecondrequirement:Nocellulosic vapourjacket,andthesmoothsurfacedoesn’ttrap dust

Formaldehyde FreeEnsuresthatArmaflexisalow-emittingproduct.ItisalsolowVOC.

Support Requirements of Health & IAQ (Indoor-Air-Quality)• Dust free and fibre free• Willnotemitanyparticlesorfibres-evenwhencut intoshapesandfittings • Nooutgassing-CFC&HCFCfreemanufacturing process

Supervised Quality StandardsISORegistrationensuresthatallArmacellmanufac-turing facilities consistently meet customer require-mentsbymanagingallprocesseswithongoingqualityassessments.

The Armaflex Assurance System