Proceedings of the 2008 Pressure Vessels and Piping Conference

PVP 2008
July 27-31, 2008, Chicago, Ill, USA

PVP2008-61082
THE DESIGN OF FABRIC EXPANSION JOINT GAS SEAL MEMBRANES

David Peterson
Robert Broyles
Senior Flexonics Pathway Inc.
2400 Longhorn Industrial Drive
New Braunfels, Texas 78130
Telephone: (830) 629-8080
Email:dpeterson@pathwayb.com
Email:broylesb@pathwayb.com

ABSTRACT
Fabric expansion joints are commonly used in round and
rectangular ducting systems for accommodating differential
thermal expansion and containing internal pressure. Fabric
expansion joints are intended for sustained operation without
significant leakage. Failure of fabric expansion joints can lead
to plant shutdowns. The outer gas seal membrane is a structural
material most commonly made from woven fabric with an
elastomeric coating. The fibers in the fabric are comparatively
strong and flexible but not chemically resistant. The coating
protects the fibers from chemical attack and seals the woven
fabric to minimize leakage through the material. The fabric
material is typically clamped between metal frames attached to
the ducting. The orientation of the fibers with respect to the
frames is a critical design factor. Fabric expansion joints are
normally designed in accordance with the guidelines of the
Fluid Sealing Association Technical Handbook. The handbook
gives helpful information but does not provide analytical
methods for the mechanical design of gas seal membranes. The
intent of this paper is to provide analytical methods for
determining the movement capability and pressure capacity of
gas seal membranes. Test results and non-linear finite element
analysis are used to support the proposed methods.
INTRODUCTION
Fabric expansion joints are commonly used in round and
rectangular ducting systems for accommodating differential
thermal expansion and containing internal pressure. Fabric

expansion joints are intended to operate without significant

leakage for a long period of time. The outer gas seal membrane
or GSM can be made from metal foil or unreinforced
elastomeric material. However, it is most commonly made from
woven fabric with an elastomeric coating. The fibers in the
fabric are comparatively strong and flexible but not chemically
resistant. The coating protects the fibers from chemical attack
and seals the woven fabric to minimize leakage through the
material.
Fabric expansion joints are normally designed in accordance
with the guidelines of the Fluid Sealing Association (FSA)
Technical Handbook [1]. The handbook gives helpful
information but does not provide analytical methods for the
mechanical design of the GSM. The intent of this paper is to
provide methods for determining the movement capability and
pressure capacity of the GSM. This paper is based on the
following assumptions:
a. Pressure and movement are applied slowly.
b. Concurrent movements occur simultaneously.
c. The GSM does not flutter during operation.
d. Splices in the GSM are as strong as the base material.
e. Load induced deformations are small.
f. The GSM is woven fabric with an elastomeric coating.
NOMENCLATURE
D
GSM outside diameter (in)
Db Back up bar bolt diameter (in)

F
Fe
FL
Fp
Fpo
F1
F2
H
K
Lb
LL
LS
P
R
SF
Tb
Te
Wa
We
Wi
X
Xc
Xcm
Xe
Xem
X
Y
YL
Ym
YS
YT
YTL
YTS

S
L

xy

Tensile force on GSM (lbs/in)

Effective clamping force (lbs/in)
Force on GSM due to lateral movement (lbs/in)
Force on GSM due to pressure (lbs/in)
Force required to cause pull out (lbs/in)
Longitudinal pull out force (lbs/in)
Radial pull out force (lbs/in)
Frame standoff height from duct (in)
Stiffness of GSM (lbs/in/in)
Distance between back up bars bolts (in)
GSM long axis length (in)
GSM short axis length (in)
Pressure (lbs/in2)
Radius of GSM arch (in)
Safety factor
Back up bar bolt torque (in-lb)
Effective back up bar bolt torque (in-lb)
Width of GSM between backup bars (in)
Effective width of GSM between backup bars (in)
Installed distance between backup bars (in)
Axial movement (in)
Axial compression (in)
Maximum axial compression (in)
Axial extension (in)
Maximum axial extension (in)
Equivalent axial due to angular rotation (in)
Lateral movement (in)
Lateral movement along the long axis (in)
Maximum lateral movement (in)
Lateral movement along the short axis (in)
Equivalent lateral due to torsion (in)
Equiv lateral along the long axis due to torsion (in)
Equiv lateral along the short axis due to torsion (in)
Angular rotation (rad)
Angular rotation about the short axis (rad)
Angular rotation about the long axis (rad)
Angle of GSM at back up bar (rad)
Shear strain associated with x-y axis (in/in)
Normal strain (in/in)
Torsional rotation (rad)
Angle from x-y axis (deg)

FABRIC EXPANSION JOINTS

The basic elements of a fabric expansion joint are the
GSM, the frame, and the backup bars. The GSM is clamped to
the frame using backup bars and bolts. A gasket material is
often used to seal the GSM to the frame. The frame provides a
mounting surface and the necessary standoff height to keep the
GSM away from the gas stream. Depending on the duct shape,
the frame can be round or rectangular. Rectangular frames
normally have round corners. The GSM is wrapped around the
frame, spliced, and then clamped in place using the backup
bars. A typical fabric expansion joint is shown on Figure 1.

Figure 1 Fabric Expansion Joint

FIBER REINFORCEMENT
The GSM is reinforced with fibers that are woven at 90
degrees to one another. The resulting construction is similar to
the wire cloth used in window screens. The fibers in the length
or warp direction are essentially straight. The fibers in the width
or fill direction are woven in between the warp fibers. Because
of this, the material has greater breaking strength but less
elongation in the warp direction. While in the fill direction, the
material has less breaking strength but greater elongation.
Consequently, the mechanical properties are anisotropic (i.e.,
not the same in all directions).
The fiber orientation with respect to the axis of the
expansion joint is very important to know. When the fibers are
aligned with the longitudinal axis of the duct, the orientation is
described as orthogonal. When the fibers are rotated at 45
degrees to the longitudinal axis of the duct, the orientation is
described as bias. The two orientations are shown in Figure 2.

Figure 2 GSM Fiber Orientation

The selection of fiber orientation is based on both economics

and performance.

MOVEMENT CAPABILITY
For rectangular ductwork, the gas seal can be exposed to
seven types of movement as shown in Table 1.
No.
1
2
3
4
5
6
7

Type
Axial compression
Axial extension
Lateral EW
Lateral HW
Angular EW
Angular HW
Torsion

Normal strain varies with its direction relative to the applied

lateral movement. The angle of maximum normal strain is
found by setting the derivative equal to zero or

d
= xy [sin ( sin ) + cos sin ] = 0
d

Direction
Longitudinal
Longitudinal
Parallel to short side
Parallel to long side
About the long side axis
About the short side axis
About the longitudinal axis

(2)

sin 2 + cos sin = 0

cos sin = sin 2

cos = sin
Table 1 Rectangular Ductwork Movement Types

= 45 deg
For round ductwork, the gas seal can be exposed to five
types of movement as shown in Table 2.
No.
1
2
3
4
5

Type
Axial compression
Axial extension
Lateral
Angular
Torsion

Direction
Longitudinal
Longitudinal
Normal to longitudinal axis
About normal to longitudinal axis
About the longitudinal axis

Substituting = 45 deg in the Eq. 1 gives the maximum normal

strain or

Y
We

xy =

AXIAL MOVEMENTS
Axial movements are movements in the direction of the
longitudinal axis of the duct which either compress or extend
the expansion joint. In low pressure systems, axial compression
causes the GSM to fold and wrinkle. In higher pressure systems,
axial compression causes the GSM to bulge outward or inward.
Alternately, axial extension straightens the GSM and reduces
folds and bulging. Within limits, axial movements are not
detrimental to the performance of the GSM.

LATERAL MOVEMENT
Lateral movements are perpendicular to the longitudinal
axis of the duct. GSM surfaces perpendicular to the direction of
lateral movement simply tilt. However, GSM surfaces parallel
to the direction of lateral movement are exposed to pure shear
which causes shear strain in the GSM. To evaluate the effect of
the lateral movement, the magnitude of the shear strain must be
found and then converted to normal strain for comparison with
uniaxial tensile test data.
From Gere and Timoshenko [2], the normal strain based on
pure shear is given by

(3)

Assuming pure shear, the shear strain in the GSM is equal to

the lateral movement divided by the effective width of material
in shear or

Table 2 Round Ductwork Movement Types

= xy sin cos

xy

(4)

Without consideration for the effect of internal pressure or

axial movement, non-linear finite element analysis using
(tension only) membrane shell elements shows that the effective
width is given by

We = 2Wa Wi

(5)

By substitution, the shear strain is

xy =

Y
2 Wa Wi

(6)

Table 3 shows good correlation between the results of Equation

6 and FEA.
Y

2Wa - Wi

xy (Eqn 6)

xy (FEA)

3
3
3
3
3

12
11
10
9
8

0.250
0.231
0.214
0.200
0.188

0.247
0.232
0.209
0.198
0.184

(1)

Table 3 Comparison of Shear Strain Results

can be converted to equivalent axial movements. For round

expansion joints, the maximum equivalent axial movement is

From equation 3, the maximum normal strain is

Y
4 Wa 2 Wi

(7)

Non-linear finite element analysis using tension only

membrane shell elements shows that internal pressure stiffens
the GSM and increases the shear strain for a given lateral
movement. The maximum stiffening occurs when the pressure is
sufficient to maintain the GSM is the shape of a theoretical half
circular arch with the lateral movement applied. In this
condition, the shear strain increased by a maximum of 50
percent for any given lateral movement. Therefore, the
maximum normal strain with a conservative consideration for
the pressure stiffening effect is

1 .5 Y
4 Wa 2 Wi

(8)

Considering the effect of axial movement, the maximum normal

strain is

1 .5 Y
4 Wa 2( Wi X )

D
2

X =

For rectangular expansion joints, the maximum equivalent axial

movement which occurs at the corners is

X =

S L L L L S
+
2
2

YT =

3
3

12
11

Flat
0.247
0.232

T D
2

(12)

For rectangular expansion joints, the maximum equivalent

lateral movements are

(9)

Non-linear finite element analysis using (tension only)

membrane shell elements shows that these equations can also be
used for large diameter round expansion joints. As shown in
Table 4, the shear strain is essentially the same for flat and
round models. The maximum normal strain for round expansion
joints occurs at two locations 90 degrees from the direction of
the lateral movement.
We

(11)

TORSIONAL MOVEMENT
Torsional movement is rotation about the longitudinal axis
of the duct. Like lateral movement, torisional movement
exposes the GSM to pure shear. Torsional movements can be
converted to equivalent lateral movements. For round
expansion joints, the maximum equivalent lateral movement is

YTS =

T L L
2

(13)

YTL =

T LS
2

(14)

where X is compression and +X is extension.

(10)

xy (FEA)
200 in. Dia
0.248
0.230

CONCURRENT MOVEMENTS
When different types of movements occur simultaneously,
the movements are defined as concurrent and can be combined
for comparison to axial and lateral movement limits. The
maximum combined equivalent axial movements for round and
rectangular expansion joints are given by

100 in. Dia

0.251
0.236

Table 4 Shear Strain for Round Expansion Joints

All non-linear finite element analysis was performed using
Cosmos/M software [3], (tension only) shell elements, large
displacement formulation, and automatic step control.
ANGULAR MOVEMENT
Angular movements are rotations about axes perpendicular
to the longitudinal axis of the duct. Angular movements cause
axial extension and axial compression of the GSM which are
maximum at 90 deg to the axis of rotation. Angular movements

X cm = X c + X

(15)

X em = X e + X

(16)

The maximum combined equivalent lateral movement for round

expansion joints is given by

Ym = Y + YT

(17)

The maximum combined equivalent lateral movement for

rectangular expansion joints is given by

Ym = Greater of YS + YTS or YL + YTL

(18)

Figure 3 shows the directions of the equivalent lateral

movements

For a GSM installed with either orthogonal or bias fiber

orientation, the maximum radius of the circular arc can be
found from the standard mensuration equation as follows

R=

Wa
W + X em
for R i
2
W + X em
2Arcsin i

2R

(21)

An iterative method must be used to find R (Note: the Arcsin

function is in radians).

Figure 3 Equivalent Lateral Movements

PRESSURE CAPACITY
At higher pressures, the GSM in rectangular expansion
joints will bulge and assume the shape of a circular arc between
the backup bars within the movement limits given on the next
section. The reinforcing fibers resist the pressure force. Figure 4
represents a unit long segment from a GSM under pressure.

Round expansion joints with positive internal pressure

require a different approach because bulging of the GSM to
form a circular arc simultaneously increases the circumference.
If the GSM cannot elongate sufficiently in the circumferential
direction, the pressure load will be restrained fully in the
circumferential direction before the arch shape develops. From
the test data, orthogonal fiber orientation has very limited
elongation. If the GSM has orthogonal fiber orientation, the
pressure load is assumed to be carried entirely by the
circumferential fibers. Therefore, the unit tensile force on the
fibers is

F=

PD
2

(22)

If the GSM has bias fiber orientation, the assumption is that the
arch shape will fully develop and the unit tensile force on the
fibers will be the same as rectangular expansion joints or

F = PR

(23)

The force due to pressure must be limited so that the GSM

fibers do not break or the GSM does not pull out from under the
backup bars.
Figure 4 Unit long GSM segment
The equilibrium equation is

F
P
=
2R 2

(19)

MOVEMENT LIMITS
With positive internal pressure, the maximum axial
compression for this paper occurs when GSM material has the
shape of an outward half circular arch between the backup bars.
The GSM width required to produce that shape is

Wa =

Therefore, the unit tensile force on the fibers is

F = PR

(20)

(Wi X cm )
2

(24)

Therefore, the maximum axial compression is

The tensile force is directly proportional to the radius.

Therefore, the maximum tensile force occurs when the distance
between the backup bars is Wi + Xem.

X cm =

Wi 2 Wa
W

for 1 a

Wi 2

(25)

This limit prevents the GSM from folding over the backup bars.

With negative internal pressure, the maximum axial

compression for this paper occurs when GSM material has the
shape of an inward circular arch with a height equal to the
frame standoff height. The radius of the circular arch is taken
from standard mensuration equations as follows

R=

Wa
2RH H 2
2Arcsin

for 0 H R

factor for temperature is shown in Figure 5 for a commonly

used PTFE coated fiberglass material.

(26)

An iterative method must be used to find R (Note: the Arcsin

function is in radians).
The maximum axial compression is
Figure 5 GSM Temperature Factor

X cm = Wi 2 2RH H 2

for X cm 0

(27)

This limit assures that the GSM will not enter the flow stream
or come in contact with the flow liner.
Further limits on axial compression may be necessary if
excessive folding could be detrimental to performance. This
may be the case in low pressure high temperature applications
where folds can hinder natural convection and create hot spots
in the material.

Aging is the effect of higher temperature exposure over

prolonged periods of time which causes a reduction in breaking
strength. Aging is determined by exposing material specimens
to a specific temperature for different periods of time and then
performing tensile tests. The reduction factor for aging is shown
in Figure 6 for a commonly used PTFE coated fiberglass
material at 450 degF.

With a 1 inch safety margin, the maximum axial extension is

given by

X em = Wa Wi 1

(28)

This limit assures that the GSM will never be straight and tight
between the backup bars. Further limits on axial extension may
be necessary if other movements are present or because of the
internal pressure.
FORCE LIMITS
Limiting the force on the GSM is important for safe
operation. The allowable unit force is given by

Allowable Force =

Breaking Strength x Reduction Factors

Safety Factor

Strength reduction factors typically consider the effects of

temperature and aging.
Higher temperatures reduce the
breaking strength of GSM materials. The reduction factor for
temperature is determined by performing tensile tests at various
temperatures in accordance with ASTM D638. The reduction

Figure 6 GSM Aging Factor

Additional reduction factors may be applied to address the
detrimental effects of the media on the breaking strength of the
material.
Safety factors address expected variations in material
performance, installation, operation, and environment. Typical
safety factors for structural fabric materials range from 3 to 5.
Unless the GSM warp and fill directions for the finished
expansion joint can be specified in advance, using the breaking
strength for the fill direction is advisable.

STRAIN LIMITS
The maximum normal strain must be limited so that the
GSM is not damaged during the lateral movement cycles. The
strain limit is a function of the type of material and the
orientation of the reinforcing fibers. The strain limit is based on
GSM tensile testing performed in accordance with ASTM
D638. Test specimens are made with both orthogonal fiber
orientation and bias fiber orientation with respect to the applied
load. The specimens are mounted in a tensile test fixture. A
tensile load is applied slowly. The machine records load verses
elongation for each specimen. The load is applied until the
material breaks. Typical test results for a commonly used GSM
material are shown in Table 5.

Fiber Orientation
Orthogonal (warp)
Bias

Elongation (%)
3
30+

Table 5 Typical GSM Elongation

The maximum strain is at 45 degrees for lateral movement.
Therefore, the maximum strain for material installed with
orthogonal fiber orientation is actually in the bias direction of
the fabric. The maximum strain for material installed with bias
fiber orientation is in the orthogonal direction of the fabric.
The maximum elongation with orthogonal fiber orientation
is typically very small. For that reason, lateral and torsional
movements should not be applied when the GSM is installed
with bias fiber orientation.
The allowable strain is given by

Allowable Strain =

the force is sufficiently large to overcome the resisting backup

bar clamping force, the GSM will pull out resulting in
catastrophic failure. Therefore, the pull out forces which are
shown in Figure 7 should be limited.

Max. Elongation x Reduction Factors

Safety Factor x 100

Figure 7 GSM Pull Out Forces

The pull out force is based on the total force applied by the
GSM at the backup bars. The total force comes from both
pressure and lateral movement. As indicated above, the
longitudinal force due to pressure is

Fp = PR

The lateral and torsional movement of the expansion joint is

resisted by shearing strain in the GSM. As indicated previously,
the shearing strain results in a maximum normal strain at 45
degrees. Therefore, the force at the backup bar can be
determined from the maximum normal strain and the stiffness of
the GSM at 45 degrees. The stiffness can be found by tensile
testing GSM specimens with the fibers at 45 degrees from the
installed orientation. For a GSM installed orthogonally, the
tensile tests are performed in the bias direction. The stiffness at
45 degrees is

Elongation reduction factors are used to address possible

detrimental effects from chemical attack and higher
temperatures.
Safety factors address expected variations in material
performance, installation, operation, and environment. Typical
safety factors for structural fabric materials range from 3 to 5.
Unless the GSM warp and fill directions for the finished
expansion joint can be specified in advance, the elongation for
the warp direction should be used.

GSM PULL OUT

The GSM is clamped between the backup bars. Lateral
movement, torsional movement, and pressure create forces that
attempt to pull out the GSM from between the backup bars. If

(29)

K=

Applied Unit Load x 100

Elongation

(30)

The resulting longitudinal force is

FL = 0.707 K

(31)

The total longitudinal force on the GSM at the backup bar is

F = Fp + FL

(32)

Based on the geometry, the maximum unit pull out forces

generated by the GSM are determined as follows

 W + X em
= Arcsin i

2R

W + X em
F1 = F Cos = F 1 i

2R

F2 = F Sin =

(33)

centers. The back-up bars are 3/8 x 2 inch carbon steel flat bar
with full radius edges. The maximum pull out force (Fpo) is the
total force on the gage divided by the distance between the
back-up bar bolts (Lb). The test results are shown in Table 6.

F [Wi + X em ]
2R

(34)

(35)

Bolt Torque
(in-lbs)
276
540
804

Max. Pull Out Force

(lbs/in)
142
257
356

Observations
Pull out
Pull out
Pull out & Tearing

Table 6 GSM Pull Out Force Test Results

Pull out is resisted by the bolt clamping force and friction
between the backup bars and the GSM. The load required to
start moving the GSM out from between the backup bars is the
pullout force. For safe operation,

F1

Fpo
SF

(36)

Tearing occurred at a unit load well below the rated load

capacity of the GSM because the load on the GSM is not
uniformly distributed between the bolt locations. Figure 9
shows the movement pattern of the GSM under load. As
expected, the clamping force is highest at the bolt locations.

where SF is the safety factor to account for variations in

installation conditions and bolt clamping force. A minimum
safety factor of 1.5 is recommended.
The pull out force is determined from actual tests. The test
fixture is shown in Figure 8.

Figure 9 GSM Pull Out Movement

The approximate unit clamping force is given by

Clamping Force =

Tb
0 .2 L b D b

(37)

With positive internal pressure, the in-service clamping force is

reduced by the radial pull out force (F2). Therefore, the
effective clamping force is

Fc =

Te
Tb
=
2F2
0.2L b D b 0.2L b D b

(38)

Solving for the effective bolt torque gives

Te = Tb 0.4F2 L b D b

Figure 8 GSM Pull Out Test Fixture

Tests were performed using a GSM made from PTFE coated
fiberglass cloth with inch diameter plated bolts on 6 inch

(39)

The effective bolt torque should be used to find the maximum

pull out force (Fpo) from the test data.

BACKUP BARS
The backup bars hold the GSM on the frame. Under
pressure, the GSM wraps around the inside edge of the backup
bars. Consequently, a smooth edge and radius is important so
that the GSM coating will not be damaged during operation. It
is also important that the ends of the backup bar segments are
close together and not significantly mismatched. Finite element
analysis using truss and gap elements shows that there is no
significant load concentration in the GSM with a 3/16 inch or
larger backup bar radius.
APPLICATION RECOMMENDATIONS
Table 7 gives recommendation for GSM applications.
Duct Shape

Lateral or
Fiber Orientation
Torsional
Orthogonal
Bias
Movement
Round
Yes
Yes
No
No
Yes1
Yes
Rectangular
Yes
Yes
No
No
Yes
Yes
1
Not recommended for applications with high positive internal
pressure.
Table 7 Application Recommendations
REFERENCES
[1] Ducting Systems Non-Metallic Expansion Joint Technical
Handbook, 3rd Edition, Fluid Sealing Assoc., Wayne, Pa, 1997
[2] Gere, J. M. and Timoshenko, S. P., 1997, Mechanics of
Materials, 4th Edition, PWS Publishing, Boston, p. 521.
[3] Cosmos/M 2.95 software, Solid Works Corp., Concord,
Mass., 2005.