AH FM 4 Part1 AirDuctFabManuals 2007

1", 11/2", & 2" Air Duct Board Max10 Fab Manual
Machine Adjustments Manual
Knauf Insulation Air Duct Fabrication Manual for 1", 11/2", and 2"
Knauf Air Duct Fabrication Manual
Table of Contents
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
References
This.manual.presents.methods.of.fabrication,.closure,.reinforcement,.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). ibrous Glass Duct Construction Standard,.Low.Velocity. . F Systems2.inches.W..G..Maximum.Static.Pressure. F .(2). ibrous Glass Duct Construction Standard With 1" Duct . Board,.Supplement.to.NAIMA.Fibrous.Glass.Duct.Construction. Standard..NAIMA F .(3). ibrous Glass Residential Duct Construction Standards,.De. sign,.Fabrication.and.Installation.Techniques.for.the.Residential. HVAC.Duct.Contractor:.NAIMA. F .(4). ibrous 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.commercial.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.
2 .
Introduction
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.Construction.(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.modified.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.
Knauf Air Duct Fabrication Manual 26_27 Knauf Air Duct Fabrication Manual 2_
Knauf Air Duct Board

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.specifications,.ensuring.long.term.system.integrity. . Reinforcement.systems.described.in.this.manual.have.been. tested.at.1.times.design.pressure.for.50,000.cycles.in.dynamic.testing,.and.2.times.design.pressure.in.static.testing. . Fiber.glass.duct.board.has.achieved.over.40.years.of.successful.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.temperatures up to 250F. . 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.1".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.approximately.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.
4 .
Knauf Air Duct Systems

Technical data
Flexural Rigidity (El) When.tested.in.accordance.with.North.American.Insulation.Manufacturers.Association.(NAIMA).Test.Method.AHS-100-74,.flexural. rigidity.of.Knauf.Air.Duct.Board.shall.not.be.less.than.the.following: . Type.EI-475. Type.El-800. 475.psi.per.inch.of.width. 800.psi.per.inch.of.width Restrictions Fibrous.glass.duct.systems.should.not.be.used.in.the.following. applications: . . . . . A.. . itchen.or.fume.exhaust.ducts,.or.to.convey.solids,.liquids. K or.corrosive.gasses. B.. Installation.in.concrete.or.buried.below.grade. C.. Outdoors. D.. . s.casings.and/or.housings.of.built-up.equipment.. A E.. .mmediately.adjacent.to.high-temperature.electric.heating. I coils.without.radiation.protection..Refer.to.NFPA.Standard. 90A.for.proper.design. F.. . or.vertical.risers.(more.than.two.stories.in.height).in.air. F duct.systems.. G.. . ith.equipment.of.any.type.which.does.not.include.. W 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.. . s.penetrations.in.construction.where.fire.dampers.are. A required,.except.as.shown.on.page.53.with.the.fire.damper. installed.in.a.sheet.metal.sleeve.extending.through.the. wall.
Maximum Static Pressure 2".W.G..(500.Pa),.positive.or.negative. Maximum Air Velocity in Duct 5,000.FPM.(25.4.m/s). Temperature 250F (121C) maximum inside duct, continuous operation; . 150F (66C) maximum external duct surface temperature. Maximum Allowable Deflection 1 100.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.1 1 2.times.operating. pressure. Water Vapor Sorption Water.vapor.sorption.of.the.board.will.not.exceed.5%.by.weight. under conditions of 120F (49C) 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.aluminum.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.
. . . . .
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... . oth.supply.and.return.outlets.of.duct.systems.running. B through.non-conditioned.space.and.used.for.cooling.only. must.be.tightly.closed.to.prevent.accumulation.of.condensed.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.
Modular Duct Construction

Modular.Duct.Construction.(MDC).enables.the.fabricator. and.contractor.to.standardize.all.shop.fabrication.procedures.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.. B.. C.. D.. Increased.productivity. I .mproved.quality.of.workmanship.. M . inimized.number.of.circumferential.joints. S . implified.fabrication.of.fittings.in.the.shop. and.on.the.job.site.
The.principles.of.MDC.are:. A.. B.. C.. D.. E.. F.. M . odified.shiplap.joints.should.be.used. rather.than.V-groove. T . he.male.end.of.the.duct.is.always.installed. toward.the.air.handling.unit. M . ost.fittings.can.be.fabricated.from.. completed.four-foot.modules. A . ll.sweep.and.radius.type.fittings.. are.eliminated. B . ranch.ducts.are.tapped.into.an.. existing.shiplap.wherever.possible. I .ntegrity.of.four-foot.modules.. should.be.maintained.insofar.as.possible. during.installation. W . hen.a.four-foot.module.has.to.. be.field-cut,.the.unused.piece.should.. be.utilized.as.soon.as.possible. B . lueprints.should.be.modified.to.. accommodate.the.MDC.principle. Typical.Sheet.Metal.Layout
G..
H..
MDC.Layout
6 .
Tools and Equipment

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 ToolUsed.to.make.a.modified.shiplap,.either. left.or.right.hand. 90 V-Groove ToolUsed to make 90corner cuts when using the.V-groove.method.of.fabrication. End Cutoff ToolUsed.to.make.the.rabbit.cut.and.closure.flap. Female Shiplap ToolUsed.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 Carrollton,.TX.75006. 800-874-9135 Annandale,.MN.55302. 800-328-3530 T-Square End Cutoff Tool, 90 V-Groove Tool, Female Shiplap Tool. Modified.Shiplap.Tool.(Righthand),.Modified.Shiplap.Tool.(Lefthand)
. Glass.Master.Corp.,
. Malco.Products,.Inc.,
T-SquareProvides.a.straight.edge.for.marking.cut.lines.or.for. guiding.cutting.tools,.as.well.as.measuring.angles. Angle ToolProvides.a.straight.edge.at.angles.of.22 1 2or 15 for.marking.cut.lines.or.for.guiding.cutting.tools.when.fabricating. fittings with 45or 30miter angles. The.T-Square.and.Angle.Tool.are.available.from: . Amcraft.Inc.,. . . . . . . Toledo,.OH.43612. 419-729-7900 Carrollton,.TX.75006. 800-874-9135 Annandale,.MN.55302. 800-328-3530
. Malco.Products,.Inc., Angle.Tool
Knauf Air Duct Fabrication Manual 26_27 6_7 Knauf Air Duct Fabrication Manual 7
Tools and Equipment

Angle Finder (Saw Guide)Used.to.mark.cut.lines.when.fabricating fittings having miter angles other than 30, 45, or 90. . Can.be.purchased.at.any.hardware.store. Cuts-All ToolCuts.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 Carrollton,.TX.75006. 800-874-9135 Annandale,.MN.55302. 800-328-3530 Cuts-All
Angle.Finder.(Saw.Guide)
Round Hole CutterCuts.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 Carrollton,.TX.75006. 800-874-9135 Annandale,.MN.55302. 800-328-3530
. Malco.Products,.Inc., Round.Hole.Cutter
Male/Female Shiplap ToolsCut.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 Carrollton,.TX.75006. 800-874-9135 Annandale,.MN.55302. 800-328-3530 16" 4' 24" Male/Female.Shiplap.Tools
120 TableUsed.for.folding.and.closing.longitudinal.joints.of. four-foot.duct.modules..When.the.module.is.stapled.and.taped. while held at a 120angle, it will recover to form 90square corners..Can.be.made.by.the.fabricator.
120
8 .
120 Table
Tools and Equipment

Accessories
Luna (Standard) Vane CutterThis.tool.makes.crescentshaped.cut-outs.in.the.duct.board.for.installation.of.molded.. fiber.glass.turning.vanes..Available.from.Amcraft,.Inc... Toledo,.OH.43612 419-729-7900. 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. Sheet.Metal.Turning.Vanes Luna.(Standard).Vane.Cutter
. Mina.Corp... San.Francisco,.CA. . . . . 94188 415-822-7800. Pelham,.AL.35124 800-554-0342.
. Cain.Manufacturing.Co.,
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.
Splitters.and.Dampers
Molded.Fiber.Glass. Turning.Vane.Stock
Access.Doors
Hand Fabrication of 1", 11/2", and 2" Duct Board

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.inside.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.
One-Piece
Two-Piece.U
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.
Two-Piece.L
Four-Piece
1 .0
Hand Fabrication of 1" Duct Board

There.are.two.methods.of.forming.corners:.Modified.Shiplap.and. V-Groove..V-Groove.is.a.simple.way.to.form.straight.duct.sections,.but.does.not.offer.the.flexibility.needed.in.preparing.fittings,. branches.or.other.modifications..Therefore,.Knauf.recommends. that.fabricators.use.the.Modified.Shiplap.method.
Modified.Shiplap
V-Groove
Example: 14" x 6" One-Piece
96.or.120.(typical)
14.+.13 4"
6.+.13 4"
14.+.13 4"
6.+.13 8"
11 2"
14.+.13 4" One-Piece.Shiplap
6.+.13 4"
14.+.13 4"
6.+.13 8"
11 2"
14.+.13 4" One-Piece.V-Groove
6.+.13 4"
14.+.13 4"
6.+.13 8"
11 2"
Knauf AirAir Duct Fabrication Manual 10_11 Knauf Duct Fabrication Manual 11 26_27
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.previously.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). Construction Method One-Piece Two-Piece.U Two-Piece.L Four-Piece 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.) Add-On Allowance 8" 9" 9" 11" 14.+.1" Two-Piece.U 6.+.1" 14.+.13 4" 6.+.4"
14.+.13 4"
6.+.13 4"
14.+.13 4"
6.+.4"
14.+.13 4"
6.+.13 8"
1"
14.+.13 4"
6.+.13 8"
1"
14.+.13 4" Two-Piece.L
6.+.13 8"
1"
14.+.13 4"
6.+.13 8"
1"
14.+.13 4" Four.Piece
6.+.4"
14.+.13 4"
6.+.4"
1 .2
Hand Fabrication of 11/2" Duct Board: Center Line Method

The.techniques.and.cuts.necessary.to.fabricate.duct.sections.from. 1 1 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.1 1 2".thickness.are.required..Therefore,.new.calculations.must.be.made.when.laying.out.1 1 2".duct.board.modules.or. fittings,.as.shown.below. Stretch-out, 11/2" duct board Construction Method One-Piece Two-Piece."U" Two-Piece."L" Four-Piece Example: 14" x 6" One-Piece 14" x 6" Two-Piece U 14" x 6" Two-Piece L 14" x 6" Four-Piece (Even.though.Four-Piece.Duct.is.possible.to.construct,.it.is. important.to.consider.the.increased.labor.involved.before.using. this.method.on.a.job.) 14.+.2 3 4" 6.+.23 4" 14.+.23 4" 6+51 2" Add-On Allowance 12" 13 "
1 2
14.+.2 3 4"
6.+.23 4"
14.+.23 4"
6+21 8"
2"
14.+.2 3 4" Two-Piece.U
6.+.23 4"
14.+.23 4"
6+21 8"
2"
13" 16"
2".Flap
2".Flap
14 + 2 3 4"
Two-Piece.L
6.+.23 4"
14.+.23 4"
6+51 2"
14.+.2 3 4"
6.+.23 4"
2"
14.+.2 3 4"
6+21 8"
2"
14 + 2 3 4"
Four-Piece
6.+.23 4"
2"
14.+.2 3 4"
6+21 8"
2"
14 + 21 2"
Four-Piece
6.+.51 2" 2".Flap
14.+.2 3 4"
6+51 2" 2".Flap
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.calculations.must.be.made.when.laying.out.2".duct.board.modules.or. fittings,.as.shown.below. Stretch-out, 2" duct board Construction Method One-Piece Two-Piece.U Two-Piece.L Four-Piece Example: 14" x 6" One-Piece 14" x 6" Two-Piece U 14" x 6" Two-Piece L 14" x 6" Four-Piece (Even.though.Four-Piece.Duct.is.possible.to.construct,.it.is. important.to.consider.the.increased.labor.involved.before.using. this.method.on.a.job.) 14.+.31 2" Two-Piece.L 6.+.23 4" 3" 14.+.31 2" 6.+.23 4" 3" Add-On Allowance 16" 181 2" 18" 23" 14.+.31 2" Two-Piece.U 6.+.31 2" 14.+.31 2" 6.+.8"
14.+.31 2"
6.+.31 2"
14.+.31 2"
6.+.23 4"
3"
One-Piece.(Standard.tooling)
14.+.31 2" Four-Piece
6.+.8"
14.+.31 2"
6.+.8"
1 .4
Machine Fabrication of Duct Board

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).. etter.control.of.depth.and.accuracy.of.cuts,.which.results. B 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).. ecause.the.female.shiplap.edge.enters.the.closure.machine. B 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
. 1.
14". .
. 2.
6". .
. 3.
14". .
. 4.
6" .
5. SCO
. A.
6". .
. B.
14". .
. C.
6". .
. D.
14" .
E. SCO.
Preferred.Tooling
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

Tool Designation 1.(F). R-1(E). 2(C),.4. 3(B)(D). 5.(G). 6. . 7. . 8(A). 9. 0. SCO. . . Name And Function Left.Hand.Female.Shiplap Right.Hand.Female.Shiplap Right.Hand.Modified.Shiplap hLeft.Hand.Modified.Shiplap Right.Hand.Closure.Flap Left.Hand.Female.. Shiplap.with.Cutoff Right.Hand.Female. Shiplap.with.Cutoff Left.Hand.Closure.Flap Left.Hand.Male.Shiplap Right.Hand.Male.Shiplap Straight.Cutoff.. (Used.with.R-1.Tool.. to.make.same.cut.as.#7.tool) 3(B)(D) 2(C)
1.(F)
R1.(E)
5.(G)
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.fiber.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.
8(A)
SCO
90V
1 .6
Machine Fabrication of 1", 1 1/2" and 2" Air Duct Board Using Standard Tooling
Example: 14" x 6" One-Piece Duct 1.
. 14". .
. 2.
6". .
. 3.
14". .
. 4.
6" .
5. SCO
. 14". 1. .
. 2.
6". .
. 3.
14". .
. 4.
. 8.
6" .
5. SCO
Example: 14" x 6" Two-Piece U Duct Two-Piece.U
1.
. 14". .
. 2.
6". .
. . 5. SCO.
. 1.
14". .
. 2.
6" .
5. SCO
Two-Piece.L
1. Example: 14" x 6" Two-Piece L Duct
. 14". .
. . 7. 8.
6". .
. . 5. SCO.
. 1.
14". .
. . 7. 8.
6" .
5. SCO
Four-Piece
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 Preferred Tooling
Example: 14" x 6" One-Piece 8. . 6". . . 3. 14". . . 2. 6". . . 3. 14". .
R1. SCO.
One-Piece.(Preferred.Tooling)
Example: 14" x 6" Two-Piece U
8.
. 6". .
. 3.
14". .
. 2.
6". .
. . 5. SCO.
. 1.
14". .
. . R1. SCO
Two-Piece.U.(Preferred.Tooling)
Example: 14" x 6" Two-Piece L
8.
. 6". .
. 3.
14". .
. . R1. SCO.
. 8.
6". .
. 3.
14". .
. R1. SCO.
Two-Piece.L.(Preferred.Tooling) Machine Fabrication of 11/2 " and 2" Duct Board: As.with.hand.fabrication.of.11 2".and.2".thick.duct.board,.allowances.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.
1 .8
Knauf Air Duct Board Length Selection, 1" Board, One-Piece Duct
(Dimensions in inches)
Width of Duct 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
Depth of Duct 6 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 7 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 8 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 9 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 10 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 11 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 12 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 13 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 14 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 15 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 16 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 17 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 18 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 19 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 20 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 21 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 22 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 23 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 24 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 25 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 26 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 27 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 28 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120
*This.chart.includes.a.13 8".width.flap..For.1.11 2".flap,.add.1 8".
Knauf Air Duct Board Length Selection, 11/2" Board, One-Piece Duct
Width 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 48
Depth of Duct 6 36 38 40 42 44 48 52 56 60 64 68 72 76 80 84 88 92 96 100 104 108 112 116 120 7 38 40 42 44 46 50 54 58 62 66 70 74 78 82 86 90 94 98 102 106 110 114 118 8 40 42 44 46 48 52 56 60 64 68 72 76 80 84 88 92 96 100 104 108 112 116 120 9 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 96 100 104 108 112 116 120 12 48 50 52 54 56 60 64 68 72 76 80 84 88 92 96 100 104 108 112 116 120 14 52 54 56 58 60 64 68 72 76 80 84 88 92 96 100 104 108 112 116 120 16 56 58 60 62 64 68 72 76 80 84 88 92 96 100 104 108 112 116 120 18 60 62 64 66 68 72 76 80 84 88 92 96 100 104 108 112 116 120 20 64 66 68 70 72 76 80 84 88 92 96 100 104 108 112 116 120 22 68 70 72 74 76 80 84 88 92 96 100 104 108 112 116 120 24 72 74 76 78 80 84 88 92 96 100 104 108 112 116 120 26 76 78 80 82 84 88 92 96 100 104 108 112 116 120 28 80 82 84 86 88 92 96 100 104 108 112 116 120 30 84 86 88 90 92 96 100 104 108 112 116 120 32 88 90 92 94 96 100 104 108 112 116 120 34 92 94 96 98 100 104 108 112 116 120 36 96 98 100 102 104 108 112 116 120 38 100 102 104 106 108 112 116 120 40 104 106 108 110 112 116 120 42 108 110 112 114 116 120 44 112 114 116 118 120 46 116 118 120 48 120
2 .0
Knauf Air Duct Board Length Selection, 2" Board, One-Piece Duct
Width of Duct 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34
Depth of Duct 6 40 44 48 52 56 60 64 68 72 76 80 84 88 92 8 44 48 52 56 60 64 68 72 76 80 84 88 92 10 48 52 56 60 64 68 72 76 80 84 88 92 12 52 56 60 64 68 72 76 80 84 88 92 14 56 60 64 68 72 76 80 84 88 92 16 60 64 68 72 76 80 84 88 92 18 64 68 72 76 80 84 88 92 20 68 72 76 80 84 88 92 22 72 76 80 84 88 92 24 76 80 84 88 92 26 80 84 88 92 28 84 88 92 30 88 92 32 92 34 36 38 40 42 44 46
96 100 104 108 112 116 120
96 100 104 108 112 116 120
96 100 104 108 112 116 120
96 100 104 108 112 116 120
96 100 104 108 112 116 120
96 100 104 108 112 116 120
96 100 104 108 112 116 120
96 100 104 108 112 116 120
96 100 104 108 112 116 120
96 100 104 108 112 116 120
96 100 104 108 112 116 120
96 100 104 108 112 116 120
96 100 104 108 112 116 120
96 100 104 108 112 116 120
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
Closure of Fiber Glass Duct Joints

Closure.materials.and.methods.used.with.Knauf.Air.Duct.Board. are.key.elements.in.providing.air-tight,.structurally.sound.longitudinal.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. Pressure-Sensitive.Aluminum.Foil.Tape
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.recommendations.and.ensure.compliance.with.these.requirements.before.using. these.materials.
Heat-Sealable.Tape
Fiber.Glass.Fabric.and.Mastic
2 .2
Closure of Fiber Glass Duct Joints

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.according.to.the.procedures.shown.on.the.following.three.pages. Center.tape.over.edge.of.flap, 1".(min.).overlap
1 2
".outward.clinch.staples, 2".on.center Tape.closure.joint.. with.staple.flap
Approx..2".on.center
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. Cross.tab
Centered.over.joint 12".(max.) 8".(min.), centered.. over.joint
Butt.joint
Closure with Pressure-Sensitive Aluminum Foil Tapes

Application Above 50F:
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 5OF:

Ensure that the temperature of the tape is above 50F. If necessary,.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 400F. 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.temperature of the board surface is below 32F due to the possibility of.entrapping.ice.crystals.which,.upon.melting,.will.cause.tape.to. loosen..Heat.surface.first.to.drive.off.moisture.
Application above 50F
Application below 50F
2 .4
Closure with Heat-Sealable Tape

Application
Tape.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 55OF and 600F, 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 650F. Continuous production may require periodic pauses to allow sealing iron temperature to recover to the 650F minimum.
Sealing.Iron
Closure.Machine
Closure with Fiber Glass Fabric and Mastic

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.application,.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.regarding.connections.of.fiber.glass.duct.to.equipment.and.other.sheet. metal.accessories,.see.page.52.
Fiber.Glass.Fabric.Application
2 .6
0 Elbows
Throatless Elbow from MDC Module:
Before.fabricating.this.fitting,.it.is.important.to.consider.the.configuration.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:
ID
Step.1
Duct Board
1" l.D..+.1 / ".
1 2
1 1 /2" l.D..+.2 "

14
2" l.D..+.3"
Measure.this.distance.back.from.female.end.of.module.(B)..Mark.a. perpendicular.line. Step.2.and.3 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.4,.5.and.6
Knauf AirAir Duct Fabrication Manual 26_27 Knauf Duct Fabrication Manual 27
0 Elbows
Throatless Elbow from Flat:
Before.fabricating.this.fitting,.it.is.important.to.consider.the.configuration.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. ID
Step.1
ID.+.: 11 2".(for.1".board) 11 4".(for.11 2".board) 3".(for.2".board)
Duct Board
1" l.D..+.11/2" 1 1 /2" l.D..+.21/4" 2" l.D..+.3" Step.2
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.
Step.3
Step.4,.5.and.6
2 .8
0 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. Step.2.and.3 D C B A Step.1 D C B 3 A
5
3 3 3
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). Step.4.and.5
Step.6.and.7
Step.8
0 Elbows1", 11/2" and 2" Air Duct Board

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: (A)
.+.
(B)
Duct Board
1" l.D..+.11 2" 1 1 /2" l.D..+.21 4" 2" l.D..+.3"
Plu d-on Ad
g.S
ize
Throat. Dim.
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.
3 .0
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.requiring.additional.hand.fabrication.to.replace.the.shiplaps.
12. Example 1: 8" x 12" Standard Tooling Always.put.wide.dimension.first.when.making.stacked.elbows. using.Standard.tooling.
8.
12.
Example.1
8.
12.
8.
12
Example 2: 8" x 12" Preferred Tooling Always.put.narrow.dimension.first.when.making.stacked.elbows. using.Preferred.tooling. Example.2
0 Elbows
Three-Piece 90 Elbow From MDC Module 1", 1 1 / 2", 2":
Step 1:.Measure.the.throat.minus.3". Step 2:.Use.Angle.Tool.(see.page.6),.and.draw.22 1 2.line.across. duct,.add.4".and.return.22 1 2.line.back.across.duct..Continue.that. line.down.that.side..Repeat.on.other.two.sides..Cut.22 1 2.lines. with.M/F.Tool.then.use.knife.to.make.miter.cuts.on.other.sides.of. module. Step.1.and.2 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).
4" 221 2 221 2
Throat. -3"
Note:
This.fitting.will.have.higher.dynamic.pressure.loss.than.a.. 90 elbow with turning vanes.
Step.3
Step.4
3 .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:
ID.+ Add-on
ID.+ Add-on
Duct Board
1" l.D..+.11 2" 1 1 /2" l.D..+.21 4" 2" l.D..+.3" Step.1
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.
Discard Step.2
Step.3
Step.4
Step.5
Knauf AirAir Duct Fabrication Manual 2_ Knauf Duct Fabrication Manual 26_27
Tees From MDC Module2" Air Duct Board

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.dimension.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.90..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). Main.Duct B
B.+ .2"
Opening.in. Main.Duct
B.+.2"
Joint.Detail
Main.Duct
Tap-in.Duct
3 .4
End Caps
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: B.+ Add-on 1 1 /2"
1 2
Female. Shiplap
Duct Board
1" l.D..+.1 " 2" l.D..+.3" l.D..+.2 "
14
A.+.Add-on Type.1
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 112" 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.* Staple. Flap B.+ Add-on
Female. Shiplap
A B
A.+.Add-on Type.2
Type 3:
Use.when.female.shiplap.with.stapling.flaps.is.present.on.end.of. module.or.fitting. Female.Shiplap, 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.
Staple.Flap
B.+ Add-on
A B A.+.Add-on Type3
Reducers1", 11/2" and 2" Air Duct Board

When fabricating reducers, remember:
1.. Measurements.should.be.made.along.the.female.factorymolded.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. D C B A 24".(min.) Step.2 10".x.6".to.6".x.6"
Step.1
4"
4"
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.Section,.pages.22-26). D Step.4 C A D C B A
Step.3
3 .6

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). Step.2 Step.1 6".x.10".to.6".x.6"
4"
4"
A 24". (min.)
Step.3
B A Step.4 D C

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.onlydo.not.cut.through.facingalong.dotted. diagonal.lines..Make.cuts.to.6:1.ratio.for.reducer.length.with. minimum.reducer.length.24". Step.1 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.Section,.pages.22-26). D C B A 14".x.12".to.10".x.8"
4"
4"
4"
4"
A 24".. (min.)
Step.2
Step.3
Top
C Step.4
Side
3 .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 112" (min. width). Step 4: Fold.up.duct..Staple.and.tape.all.seams.. (see.Closure.Section,.pages.22-26). 14".x.12".to.10".x.8"
4" Step.1
2"
2"
4"
2"
2"
A 24".. (min.)
Step.2
Step.3
Top D A B C Step.4
Side

Focal Reducer:
Step 1: Measure.half.of.required.reduction.from.both.sides.of.. all.panels. D Step 2: Make.knife.cuts.through.insulation.and.facing.on.panels. (A).and.(C).(solid.diagonal.lines)..Make.knife.cuts.through.fiber. glass.onlydo.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). C B A 14".x.12".to.10".x.8"
2" Step.1
2" 2"
2"
2"
2" 2"
2"
A 24".. (min.)
Step.2
Step.3
Top A D Step.4 C B Side
4 .0

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. 4" Step 5: Trim.staple.flaps.to.11 2".(min.).width..Fold.panel..Staple. and.tape.(see.Closure.Section,.pages.22-26). Step.1 Step.2 10".x.6".to.6".x.6"
Shiplap Panel 4" 24" (min.)
Shiplap Panel Slit.Facing.Only
Note:
If.reduction.is.made.in.square-edged.panel,.add.half.the.board. thickness.to.the.changed.dimension.
Step.3
Step.4
Step.5

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. 31 2 " 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). Step.3 Step.4 Step.1 2" 16".x.8".to.14".x.5" Shiplap Panel 24" (min.) 31 2 " Shiplap Panel Slit.Facing. Only
2" Step.2
Note:
If.reduction.is.made.in.square-edged.panel,.add.half.the.board. thickness.to.the.changed.dimension.
Step.5
Step.6
4 .2
Step.7
Step.8
Offsets1", 11/2", and 2" Air Duct Board

30 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.2
15
14" 90 14"
90
15
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). Parallel. Planes
Step.3
Option:.Cuts-All.or.M/F
Step.4
Step.5
Step.6

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 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). (4) 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). (5) (4) (1) 90 Cuts-All.or.M/F.tool.optional.on. cheek.panels (3) (2) (1) Y (1) Y.(2') (3) (2) (2) X.(7")
Step.1,.2.and.3
90 Parallel.Planes Step.5,.6.and.7
Step.8
4 .4
Knauf Air Duct Fabrication Manual Air Duct Board

Using Offset Template:
Several.types.of.templates.are.available.to.aid.in.fabricating. offsets.of.any.angle..The.template.shown.on.this.page.is.available. from.National.Duct.Systems,.Carrollton,.Texas.214-242-7727. Step 1:.Determine.the.offset.amount.in.inches..Then,.set.a.length. for.the.offset..(Example:.14".offset,.2.foot.section.) Step 2: Divide.offset.in.inches.by.length.in.feet..(Example:.14 2.=.7. (this.is.called.7.on.12.pitch). Step 3: On.template,.find.the.corresponding.line.under.PITCH. ON/12"..Read.to.left.on.same.line.to.determine.the.offset.loss.for. every.foot.of.offset.length..(Example:.7.on.12.pitch.gives.an.offset. loss.of.1 7 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:.1 7 8".x.2'.=.3 3 4".) Step.6 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. Parallel.Planes 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.section 180. Join sections together using 8" cross tabs and tape all seams.(see.Closure.Section,.pages.22-26). Step.1,.4.and.5
2'
14"
27 3 4"
Option:.Cuts-All.or.M/F Step.7
Step.8

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.starting.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. Step.1.and.2 6" D D 15 B 15 A 20" C
12".Approx.
E 20" F B 15
Step.3.and.4
Note:
If offset is the same both ways, use 15 on all 4 sides. Parallel. Planes
Step.5
4 .6
Offsets1", 11/2", and 2" Air Duct Board (continued)

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).
10"
6"
10" Step.6
10"
10" 16" 6" Step.7
Knauf Air Duct Fabrication Manual 47 46_47
Tap-Ins1", 11/2", and 2" Air Duct Board

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.*
Round.Tap
Note:
Tap.of.less.than.full.height.often.requires.additional.reinforcement.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.
Square.Tap
Tap-Ins1", 11/2", and 2" Air Duct Board

Wide Mouth Tap:
Two.wide.mouth.taps.can.be.fabricated.from.one.MDC.module. Step 1: Draw a 45angled line across and through the center point.of.the.module..Draw.22 1 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.*
Wide.Mouth.Tap
Step.1
Step..2
Step..3.and.4
Knauf Air Duct Fabrication Manual 4 48_4
Diffuser & Grille Connections1", 11/2", and 2" Air Duct Board
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.manufacturers. instructions. Tap.=.I.D..+.. Thickness.of.Duct.Board Side.Connection Frame
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.
Bottom.Connection
Access Doors1", 11/2", and 2" Air Duct Board

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. 1".x.1".x.1",.22.Gauge.-.for.1".Board Flange.on.Door.Frame
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.opening. Step 3: Install.door.with.screws.and.washers,.or.suitable. hardware. For.further.details,.refer.to.NAIMA.Fibrous.Glass.Duct.. Construction.Standard,.Section.II. 1".x.1".x.1",.22.Gauge.-.for.1". Board 112" x 112" x 112",.. 22.Gauge.-.for.112".Board 2".x.2".x.2",.22.Gauge.-.for.2". Board U-Channel.around.opening
112" x 112" x 112",.22.Gauge.-.for.112".Board 2".x.2".x.2",.22.Gauge.-.for.2".Board Z-Channel.around.opening
3",.22.Gauge.frame. inside.of.opening
Flange.on.Door.Frame
2",.22.Gauge.frame,.. outside.of.door
1".x.1".x.1",.22.Gauge.-.for.1". Board 112" x 112" x 112",.22.Gauge. -.for.112".Board 2".x.2".x.2",.22.Gauge.-.for.2". Board Z-Channel.around.door
1".x.1".x.3",.22.Gauge.-.for.1".Board 112" x 112" x 312",.22.Gauge.-.for.112".Board 2".x.2".x.4",.22.Gauge.-.for.2".Board U-Channel.frame.around.door.opening
0_1
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-sensitive.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
Fire Damper Installation

Sheet.metal.sleeve.must.be.installed.through.rated.fire.wall.. Check.local.codes.for.proper.sheet.metal.gauge.and.attachment. angle.
Rated.Fire.Wall .1".x.1".x.1 8".Metal.angle Sheet.Metal.Sleeve
Fibrous.Glass. Duct.Board
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. Access.Door:. see.page.51
Sheet.Metal.. Screws:.. see.fastener. schedule
#10.x.11 4".sheet.metal. screws.and.21 2".square. washers,.12".(max.).O.C.,. to.attach.duct.board.to. sheet.metal.sleeve
Fastener Schedule:.#10.plated.sheet.metal.. screws,.1 4".longer.than.board.thickness,.. with.21 2".square.galvanized.steel.washers,.. 12".(max.).on.centers
Sheet.Metal.Sleeve. through.fire.wall.as. specified.in.fire.damper. mfr's.insutructions
Closure
11 2". (nom.) Fire. Damper
2_
Positive Pressure Reinforcement

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
Step.1
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. Step.5.and.6 Step.3.and.4 Step.2
3 12"
Positive Pressure Reinforcement

Fasloop/Tie-Rod Reinforcement
Materials needed: (1). . olcano.indented.washer,.2 1 2".x.2 1 2",.0.028".min.. V thickness,.beveled.edges.away.from.facing,.plain.or.with. adhesive.back. (2). (3). G . alvanized.wire,.minimum.12.gauge. F . asloop.Bending.and.Cutting.Tool.. (available.from.Malco.Products,.Inc.,.. Annandale,.MN.55302. 800-328-3530). Fasloop
. .
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.1 O.D..+.1.1 2".
Step.2 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.pressure.fiber.glass.air.duct.systems,.refer.to.NAIMA.Fibrous.Glass. Duct.Construction.Standard,.Section.IV.
3 12"
Step.3.and.4
Step.5.and.6
4_
Positive Pressure Reinforcement Schedule

Positive Pressure Reinforcement Schedule
1" Duct Board Static Pressure In. W.G. 0-12 Duct I.D. Max. 0-36 37-42 43-48 49-60 61-64 65-80 81-96 Over.12 to.1 0-24 25-30 31-32 33-36 37-48 49-64 65-80 81-96 Over.1 to.2 0-15 16-18 19-24 25-32 33-48 49-60 61-64 65-80 81-96 Tie Rods Across Duct, 16" Centers none 2 2 3 3 4 5 none 1 1 2 2 3 4 5 none 1 1 1 2 3 3 4 5 Maximum Spacing Between Tie Rods none 24" 24" 24" 24" 24" 24" none 24" 24" 24" 24" 24" 24" 24" none 24" 24" 16" 16" 16" 16" 16" 16" 1 1/2" Duct Board Tie Rods Across Duct, 16" Centers none 2 2 3 3 4 5 none 1 1 2 2 3 4 5 none none 1 1 2 3 3 4 5 Maximum Spacing Between Tie Rods none 48" 48" 48" 24" 24" 24" none 48" 24" 24" 24" 24" 24" 24" none none 48" 24" 24" 24" 16" 16" 16" 2" Duct Board Tie Rods Across Duct, 16" Centers none 2 2 3 3 4 5 none 1 1 2 2 3 4 5 none none 1 1 2 3 3 4 5 Maximum Spacing Between Tie Rods none 48" 48" 48" 24" 24" 24" none 48" 24" 24" 24" 24" 24" 24" none none 48" 24" 24" 24" 16" 16" 16"
For.2".Air.Duct.Board.Reinforcement.Schedule,.please.call.your.Knauf.Insulation.sales.representative.
Negative Pressure Reinforcement

Formed channel reinforcement:
Materials needed: (1).. ".wide.formed.channel,.22.gauge.(see.table.on.page.58.for. 3 height). (2).. heet.metal.clips,.2".x.6".x.20.gauge,.with.turned.edges. S (3).. heet.metal.screws,.#10.x.112".for.1".duct.board,.#10.x.2".for. S 112".duct.board,.#10.x.2 12".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 16"-32" 33"-48" 49"-64" 65"-80" 81"-96" No. of Clips 1 2 3 4 5 Step 1 and 2
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 3
6_7
Negative Pressure Reinforcement Schedule

Negative Pressure Reinforcement Schedule
1" Duct Board Static Pressure In. W.G. 0-12 Duct I.D. Max. 0-30 31-36 37-42 43-48 49-60 61-72 73-84 85-96 Over.12 to.1 0-24 25-30 31-36 37-42 43-48 49-60 61-72 73-84 85-96 Over.1 to.2 0-15 16-18 19-24 25-36 37-48 49-60 61-72 73-84 85-96 Channel Spacing * 24" 24" 24" 24" 24" 24" 24" * 24" 24" 24" 24" 24" 24" 24" 24" * 24" 24" 16" 16" 16" 16" 16" 16" Channel gauge 22 22 22 22 22 22 22 22 22 22 22 22 18 18 18 22 22 22 22 22 18 18 18 Height of Channel 1" 1" 1" 1" 1" 1" 1 1 4" 1" 1" 1" 1" 1" 1" 1"
14
1 1/2" Duct Board Channel Spacing * 48" 48" 48" 48" 24" 24" 24" * 48" 24" 24" 24" 24" 24" 24" 24" * * 24" 24" 24" 24" 16" 16" 16" Channel gauge 22 22 22 22 22 22 22 22 22 22 22 22 18 18 18 22 22 22 22 18 18 18 Height of Channel 1" 1" 1" 1"
12
2" Duct Board Channel Spacing * 48" 48" 48" 48" 24" 24" 24" * 48" 24" 24" 24" 24" 24" 24" 24" * * 24" 24" 24" 24" 16" 16" 16" Channel gauge 22 22 22 22 22 22 22 22 22 22 22 22 18 18 18 22 22 22 22 18 18 18 Height of Channel 1" 1" 1" 1 1 2 " 1" 1" 1" 1" 1" 1" 1" 1" 1" 1 1 4 " 1 1 4 " 1" 1" 1 1 4 " 1 1 4 " 1" 1 1 4 " 1 1 2 "
1" 1" 1" 1" 1" 1" 1" 1" 1" 1"
14
1 1 4" 1" 1" 1" 1" 1" 1" 1 1 4" 1 1 2"
1 1 4" 1" 1" 1"

14
1 1 4" 1" 1 1 4" 1 1 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.
Reinforcement
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.installed.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 12" 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.3 1 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.
Step 1, 2 and 3
Step 4 and 5
Step 6
8_
Hangers and Supports

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. Inside.Duct.Height.(Inches) 48 44 40 36 32 28 24 20 16 12 8 4 0 Minimum.Hanger.Spacing,.Straight.Horizontal.Duct,.3".x.1".Channel
6.ft..max.
4.ft..max.
Note:
2".wide.by.1 1 2".high.hangers.spaced.at.4-foot.intervals.(maximum).may.be.used.in.place.of.3".hangers.when.ducts.are.no. more.than.48".wide.by.24".deep.
8.ft..max.
Hanger Extensions:
Hangers.must.be.increased.in.height.and.gauge.when.they.extend. beyond.the.sides.of.the.duct..See.table.below.
6.ft..max. 0. 8. 16. 24. 32. 40. 48. 56. 64. 72. 80. 88. 96.
Inside.Duct.Height.(Inches) If Total Hanger Extension is not Greater Than: 6" 18" 30" Minimum Channel Gauge 24 22 18 Minimum Channel Profile 3".x.1.5" 3".x.2" 3".x.2" Hanger.Strap 1".wide.(min.).. 22.gauge Hanger.Wire. 12.gauge.(min.)
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.
6".(min.)

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 23 of the distance from throat to heel.
45
12".max.
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).
12".max.
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).
12".max.
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).
6".to.12"
Transitions (Flat Bottom): Locate.hangers.as.for.straight.duct..Use.spacing.(chart,.previous. page).for.largest.dimension.of.transition.
6".to.12"
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.
6".to.12"
6".to.12"
3".x.1".Channel. 9".(min.).long
Hanger.Rod Centered.inside.duct.parallel.to.air.flow Duct #10.plated.sheet.metal.screws
2 1 2".sq..washers
60_61

Vertical Riser Supports:
Supports.should.be.used.when.riser.length.is.8.feet.or.more.and. should.be.installed.at.12.foot.(maximum).intervals.. Through.floor
floor Step.2 floor
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.intersects.floor..Sleeve.should.be.the.same.dimensions.as.the.duct. I.D..and.have.a.length.equal.to.floor.thickness.+.4". Step.1 floor
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. Step.3
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.
Along.wall wall
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. Step.1 Step.2
Step.3
Damage Repair
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: 1".(min.).all.sides.of.damaged.area
Example 1: When facing damage is up to 12" wide, apply approved closure material.so.that.it.extends.at.least.1".beyond.all.sides.of.the. damage. Example.1 Example 2: When facing damage is more than 12" 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.
Second.layer First.layer 1".(min.).beyond.edges.of. first.layer
Note:
Replace.tie.rod.or.channel.reinforcements.if.these.have.been. damaged,.lost,.or.removed.while.making.repairs..See.Reinforcement.Section.(pages.54-59).
Example.2
62_6
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.damaged.panel.and.fabricate.a.plug.whose.end.cuts.match.those.of. the.damaged.piece.that.was.removed.
Example.1
Step 2: Shiplap.all.four.sides.of.hole.in.duct.with.M/F.tool.
Step 3: Fabricate a plug to fit the hole with 112" (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:
Example.2
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 Example.3
Note:
Replace.tie.rod.or.channel.reinforcements.if.these.have.been. damaged,.lost,.or.removed.while.making.repairs..See.Reinforcement.Section.(pages.54-59).
Contractor's Inspection Checklist

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
1.. 2.. 3..
. . . . . . . . . . Are.all.facing.tears.repaired.using.proper.materials? .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Are.all.sheet.metal.accessory.items.galvanized?.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Is.system.installed.within.design.limitations?...............................................................................................................................................................
Yes
No
Product
4.. 5.. 6..
. . . . . . . . . . Is.the.UL.label.present.on.most.modules.or.fittings?.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Is.the.system.free.from.ballooning.or.condensation.that.could.indicate.duct.board.facing.delamination? .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Is.the.El.rating.printed.on.the.facing? .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes
No
Fabrication
7.. 8.. . 9.. . 11..
Yes
Are.8".(min.).cross.tabs.of.approved.closure.spaced.12".(max.).O.C..where.staples.are.not.used? .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Is.the.system.completely.free.from.facing.tears.or.punctures,.or.(if.not).are.tears.and.. punctures.correctly.repaired? .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Is.the.system.completely.free.from.areas.where.excessive.amounts.of.closure.material.may.. have.been.applied.to.conceal.potential.problems?.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . .
No
. . . . . . . . . . .
10.. Are.all.joints.tight,.free.from.bulges,.with.sealed.joints.showing.good.workmanship?.................................................................................................
. . . . . . . . . . . . . . . . . . . . Have.offsets.been.used.to.avoid.obstructions,.rather.than.forcing.or.bending.a.straight.section?.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Yes No
Accessory Installation
12.. 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? . 14. (See.NAIMA.Fibrous.Glass.Duct.Construction.Standard.) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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?.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64_6
Closure
19.. 20.. 21.. . .
18.. Are.all.system.joints.properly.closed?..........................................................................................................................................................................
.................... Are.closure.materials.of.listed.type,.as.shown.on.the.UL.instruction.sheet.in.the.duct.board.package?..................................................................... .................... Are.staples.or.cross.tabs.properly.spaced.on.circumferential.joints?........................................................................................................................... .................... Are.staples.of.correct.size.and.type,.spaced.at.recommended.intervals?................................................................................................................... ....................

and.facing.scrim.show.through.clearly?....................................................................................................................................................................... (darkening.of.heat.indicator.dots.are.evidence.of.this)?...............................................................................................................................................
Yes
No
22.. Where.pressure-sensitive.tape.closures.are.made,.are.they.rubbed.down.firmly.so.staples 23.. Where.heat-activated.closure.material.is.used,.was.application.temperature.sufficient 24.. If.glass.fabric.and.mastic.closure.materials.were.used,.is.the.mesh.of.the.fabric.filled.with.mastic?...........................................................................
.................... .................... ....................

No
Reinforcement
26.. 27.. 28.. 29.. 30.. 31.. 32.. 33. 34.. 35.. 36.. 37. 38..
25.. Is.reinforcement.of.type.recommended?......................................................................................................................................................................
.................... Is.tie.rod.wire.12.gauge.or.heavier?............................................................................................................................................................................. .................... Is.tie.rod.spacing.correct.according.to.duct.span,.board.El.number,.and.static.pressure.of.system?.......................................................................... .................... Are.tie.rod.washers.2 12" square and proper gauge by type?..................................................................................................................................... .................... Are.beveled.edges.of.washers.away.from.duct.board.facing?..................................................................................................................................... .................... Are.tie.rods.used.on.both.sides.of.butt.joints?.............................................................................................................................................................. .................... Is.wire.termination.as.recommended?.......................................................................................................................................................................... .................... Are.anti-sag.conduits.used.on.ducts.of.48".span.or.greater.to.support.top.panels?.................................................................................................... .................... Do.tie.rods.run.straight.through.ducts.rather.than.at.angles?...................................................................................................................................... .................... Are.heels.of.tees,.elbows.and.end.caps.reinforced?.................................................................................................................................................... .................... Are.channel.sheet.metal.gauges,.dimensions,.and.spacing.correct?.......................................................................................................................... .................... On.supply.ducts,.is.reinforcement.on.female.shiplap?................................................................................................................................................. .................... On return ducts, are channel reinforcements attached with screws and 212" washers (or 2"x 6" clips)?................................................................... .................... On.return.ducts,.are.reinforcements.on.male.shiplap?................................................................................................................................................. .................... .................... Are.hangers.installed.in.accordance.with.NAIMA.Fibrous.Glass.Duct.Construction.Standard?.................................................................................. .................... . Are.accessories.that.add.weight.to.the.duct.system.separately.supported?................................................................................................................ .................... Are.vertical.risers.supported.on.12.foot.(max.).centers.and.no.more.than.two.stories.in.height?................................................................................ .................... If.channel.reinforcement.is.used.as.hangers,.are.all.attachments.within.6".of.sides.of.duct?...................................................................................... .................... Are.fittings.supported.by.hangers.as.recommended.in.NAIMA.Fibrous.Glass.Duct.Construction.Standard?.............................................................. ....................
Yes
Yes

40.. 41.. 42.. 43. 44..
No
39.. Are.hanger.designs.in.accordance.with.NAIMA.Fibrous.Glass.Duct.Construction.Standard?.....................................................................................
NAIMA's Fiber Glass Duct Training Videotape

This.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.showing.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.
66_67
Knauf Insulation GmbH One Knauf drive Shelbyville, IN 46176 Sales and Marketing Technical Support Customer Service Fax World Wide Web (800) 825-4434, ext. 8283 (800) 825-4434, ext. 8212 (866) 445-2365 (317) 398-3675 www.KnaufInsulation.com
2006 Knauf Insulation GmbH.
NOTES Knauf Insulation GmbH complies with ISO 9002 in the prevention, detection and correction of problems in production and service areas.
At Knauf, we manufacture a wide variety of products that serve a common goal, helping to make the most of our planets energy resources. A family-owned global company, we understand and are committed to high standards in quality, performance and environmental 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

AH FM 4 Part1 AirDuctFabManuals 2007

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1", 11/2", & 2" Air Duct Board Max10 Fab Manual

Machine Adjustments Manual

Knauf Air Duct Fabrication Manual

Knauf Air Duct Fabrication Manual

Knauf Air Duct Board

Knauf Air Duct Fabrication Manual

Knauf Air Duct Systems

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.

Modular Duct Construction

Knauf Air Duct Fabrication Manual

Tools and Equipment

Hand Fabrication Tools:

Tools and Equipment

Knauf Air Duct Fabrication Manual

Tools and Equipment

. Mina.Corp... San.Francisco,.CA. . . . . 94188 415-822-7800. Pelham,.AL.35124 800-554-0342.

Hand Fabrication of 1", 11/2", and 2" Duct Board

Knauf Air Duct Fabrication Manual

Hand Fabrication of 1" Duct Board

Example: 14" x 6" One-Piece

14.+.13 4" One-Piece.Shiplap

14.+.13 4" One-Piece.V-Groove

Hand Fabrication of 1" Duct Board: Center Line Method

14.+.13 4" Two-Piece.L

14.+.13 4" Four.Piece

Knauf Air Duct Fabrication Manual

Hand Fabrication of 11/2" Duct Board: Center Line Method

14.+.2 3 4" Two-Piece.U

6.+.51 2" 2".Flap

6+51 2" 2".Flap

Hand/Machine Fabrication of 2" Duct Board: Center Line Method

14.+.31 2" Four-Piece

Knauf Air Duct Fabrication Manual

Machine Fabrication of Duct Board

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

Machine Fabrication of Duct Board

Knauf Air Duct Fabrication Manual

Example: 14" x 6" Two-Piece U Duct Two-Piece.U

1. Example: 14" x 6" Two-Piece L Duct

Example: 14" x 6" Two-Piece U

Example: 14" x 6" Two-Piece L

Knauf Air Duct Fabrication Manual

*This.chart.includes.a.13 8".width.flap..For.1.11 2".flap,.add.1 8".

Knauf Air Duct Fabrication Manual

96 100 104 108 112 116 120

96 100 104 108 112 116 120

96 100 104 108 112 116 120

96 100 104 108 112 116 120

96 100 104 108 112 116 120

96 100 104 108 112 116 120

96 100 104 108 112 116 120

96 100 104 108 112 116 120

96 100 104 108 112 116 120

96 100 104 108 112 116 120

96 100 104 108 112 116 120

96 100 104 108 112 116 120

96 100 104 108 112 116 120

96 100 104 108 112 116 120

96 100 104 108 112 116 120

Closure of Fiber Glass Duct Joints

Knauf Air Duct Fabrication Manual

Closure of Fiber Glass Duct Joints

".outward.clinch.staples, 2".on.center Tape.closure.joint.. with.staple.flap

0 Elbows1", 11/2" and 2" Air Duct Board

Knauf Air Duct Fabrication Manual 4 48_4