Recommended Practices for Properly Installing Flexible Duct

Presented to

HVACR & Mechanical Instructor Workshop

by

ATCO Rubber Products, Inc.

and the

Air Diffusion Council

March 23, 2011

Air Diffusion Council

19 Active Members that manufacture flexible ducting in the US & Canada. 50+ Associate Members that supply materials to the flexible duct and HVAC industry. 30+ years promoting and furthering the interest of the general public in the areas of safety, quality, efficiency, and energy conservation.

Mission Statement of The Air Diffusion Council

The purpose for which the Air Diffusion Council was formed, as stated in its Certification of Incorporation, is to promote and further the interests of manufacturers of air distribution equipment, more specifically, flexible air ducts and related products, and the interests of the general public in the areas of safety, quality, efficiency and energy conservation, and to this end, develop programs approved and supported by the membership that legally promote and further these interests, such as: To encourage, assist and support the maintenance and development of credible and effective industry standards for the installation, use and performance of flexible duct products; to promote the use of those standards by various code bodies, government agencies; architects, engineers, heating and air conditioning contractors, etc. so that the best interests of the public may be served. To collect and disseminate lawful information of value to members of the Council, the general public and others and to act as a clearing house for all such information, as well as providing a means by which the interests of the individual members of the Council can be protected, defended, supported more vigorously and effectively in legal association with others who share those interests.
ADC Bylaws, Article 1, Section 2 (1996)

ADC
Flexible Duct Performance & Installation Standards (5th Edition)

The Greenbook of Flex

Provides information about

Characteristics of flexible duct

Testing, Listing, Reporting, and Certifying

Installation Requirements Typical Accessories General Commentary

Flexible Duct General Information

Available R-Values
R 4.2 R 6.0 R 8.0

Standard Length
25 Linear Feet

Diameter Range
2 12 (in 1 increments) 14 22 (in 2 increments)

Packaged in Compressed Form

Carton Bag

Flexible Duct Types

(Non-Metallic Ducts)

Insulated Non Porous Inner Core Various types of Outer Vapor Barriers

Insulated Perforated Porous Inner Core Various types of Outer Vapor Barriers

Uninsulated

Flexible Duct Types

(Metallic Ducts)

Insulated Metallic Inner Core Various types of Outer Vapor Barriers

Uninsulated

How To Identify the Duct

UL Listed Air Duct
No Length Limitations Identified by a Square or Rectangular shaped UL Label that states UL Listed Air Duct

Tested to all UL tests

UL Listed Air Connector

Length restricted to 14 feet maximum Identified by a Round Shaped UL Label that states UL Listed Air Connector, Not for use in lengths greater than 14 feet

Limited UL testing

What makes a good flexible duct installation? Key Points Design the flexible duct system per the requirements of ACCA Manual D. Use the flexible duct manufacturers air friction loss data to size the ducts whenever possible, otherwise use the chart in ACCA Manual D. Use the minimum length of flexible ducting needed to make the connections (Install fully extended). Keep bends greater than or equal to 1 duct diameter. Minimize sagging and snaking of the duct runs. Properly seal the flexible duct connections. Properly support the flexible ducting.

Key Point #1 Design the flexible duct system per the requirements of ACCA Manual D.

Typical Supply & Return System

(Uses Flex Duct & Duct Board Mixing Boxes)

From ACCA Manual D

Representative Laboratory Test Set-Up Demo

Represents a typical up-flow supply system for an approximate 1100 ft2 dwelling sized following the procedures in ACCA Manual D. Actual delivery was measured using an ALNOR Balometer.

Key Point #2
Use the flexible duct manufacturers air friction loss data to size the ducts whenever possible, otherwise use the chart in ACCA Manual D.

Typical Duct Air Friction Calculator

250 CFM at 0.2 WC/100 140 CFM = 400 FPM in 8 Duct

Typical Air Friction Loss Chart

Key Point #3
Use the minimum length of flexible duct needed to make the connections. Install ducts extended to their fullest length without compression.

When in doubt, stretchhh ittt outtt

Longitudinal Compression of Flexible Duct

Compression causes increased pressure drop: 15% = approximate 2 times 30% = approximate 4 times 45% = approximate 6 to 8 times

The moral of the story:

Ducts should be fully extended before and during installation. System has optimum air flow - Minimizes pressure drop - Maximizes savings

Key Point #4
Keep bends greater than or equal to one (1) duct diameter. Minimize sagging and snaking of the duct runs.
Goals: 1. Make it easy for the air to change direction. 2. Reduce overall equivalent feet of the duct run.

So how do bends actually affect the air flow?

90 = 20 equiv. ft.

45 = 10 equiv. ft.

180 offset = 40 equiv. ft.

Examples
If duct is 8 feet long then the total equivalent length = 28 feet.

For this installation the total equivalent length is nearly twice at approximately 50 feet.
Entrance & exit losses intentionally ignored for this demonstration.

The total pressure drop for any duct run equals the sum of the fitting (or bend) pressure drops and the pressure drop of the straight duct section.

Entrance fitting = Total duct length = 2 x 45 bends (2 x 10) = 1 x 90 bend (1 x 20) = Exit fitting = Total Equivalent Length =

35 ft. 14 ft. 20 ft. 20 ft. 35 ft. 124 ft.

Key Point #5
Properly seal the flexible duct connections.

Goals: 1. Do we really need to cool the attic or the crawl space?

Proper Flexible Duct Connections

For non-metallic ducts, fittings shall be beaded and have a minimum of 2 inches collar length.

Sleeves used to connect 2 flex duct pieces together shall be a minimum of 4 inches in length and beaded on each end.

Use tapes or mastics listed to the UL181B Standard and marked UL181BFX for tape and UL181B-M for mastic. If non-metallic straps are used, the straps should be listed to the UL181B Standard and marked UL181B-C. Maximum pressure is limited to 6 inches W.C. with non-metallic straps.

or

The right way to get from here to there!!!!!!!

Installation Tools& Materials

Tape (UL 181B-FX listed & labeled) Mastic (UL 181B-M listed & labeled) Non-Metallic (Plastic) Clamps (UL 181B-C listed & labeled) Metallic clamps (worm-gear type) Sheet metal connecting collar (minimum 4 length with beads each end) Sheet metal screws (ONLY Used With Metallic Inner Cores) Duct Hanging Material (Straps / Webbing) 1-1/2 minimum width Duct Cutting Tools (Knife, scissors, wire cutters, etc) Duct Clamp Tensioning Tool

Flexible Duct Connection (Non-Metallic)

Using tape and fasteners to make connection
Cut completely through duct and wire Fold back vapor barrier and insulation Slide 1 of core over fitting and bead Seal core to collar with 2 wraps of duct tape Secure connection with clamp placed over the core and tape, past the bead Pull vapor barrier and insulation back over the core Tape barrier with 2 wraps of duct tape

Flexible Duct Splice (Non-Metallic)

Using tape and fasteners to make splice
Cut completely through duct and wire Fold back vapor barrier and insulation on both ends Slide 1 of each core over connecting collar and beads Seal cores to collar with 2 wraps of duct tape Secure each connection with clamp placed over the core and tape, past the bead Pull vapor barrier and insulation back over the core and overlap Tape barrier with 2 wraps of duct tape

Flexible Duct Connection (Non-Metallic)

Using mastic and fasteners to make connection
Cut completely through duct and wire Fold back vapor barrier and insulation Apply mastic uniformly to the outside surface of collar Slide 1 of core over collar and past the bead Secure connection with clamp placed over the core and past the bead Pull vapor barrier and insulation back over the core and fitting Tape barrier with 2 wraps of duct tape

Flexible Duct Splice (Non-Metallic)

Using mastic and fasteners to make splice
Cut completely through duct and wire Fold back vapor barrier and insulation on both ends Apply mastic uniformly to both ends of the connecting collar Slide 1 of each core over connecting collar and beads Secure each connection with clamp placed over the core, past the beads Pull vapor barrier and insulation back over the core and overlap Tape barrier with 2 wraps of duct tape

Flexible Duct Connection (Metallic)

Using tape or mastic and screws to make a connection
Cut completely through duct and trim edge Fold back vapor barrier and insulation When using mastic, apply uniformly to collar Slide 1 of core over fitting Secure connection with #8 sheet metal screws spaced equally around circumference. Use 3 screws for diameters under 12 and 5 for diameters 12 and over When using tape (press. < 4), seal core to collar with 2 wraps of duct tape Pull vapor barrier and insulation back over the core Tape barrier with 2 wraps of duct tape

Flexible Duct Splice (Metallic)

Using tape or mastic and sheet metal screws to make splice
Cut completely through duct and trim edge Fold back vapor barrier and insulation on both ends When using mastic, apply uniformly both ends of the connecting collar Slide 1 of core over connecting collar Secure cores with #8 sheet metal screws spaced equally around circumference. Use 3 screws for diameters under 12 and 5 for diameters 12 and over When using tape (press. <4), seal cores together with 2 wraps of duct tape Pull vapor barrier and insulation back over the cores and overlap Tape barrier with 2 wraps of duct tape

Key Point #6
Properly support the flexible ducting. Goals: 1. Never use wire or other materials less than 1-1/2 2. Minimal compression of insulation = better R-Value 3. Less sag or snaking of duct = better air flow

What material should I use to support flexible duct?

Per NFPA 90A and 90B, supplementary material used with air ducts shall meet the requirements of Class 1 when tested to UL 723 (Surface Burn Characteristic Testing), i.e. 25 Flame Spread & 50 smoke developed maximum. Per ADC, any strapping material in contact with the flexible duct shall be 1-1/2 inch wide minimum and be applied at intervals not to exceed 4 feet (6 feet for vertical supports). Sag should not exceed inch per foot of support spacing.

Additional Points on Supporting Flex Duct

Ceiling joists or truss supports used to support flexible duct

Added supports before and after tight bends

Added support to avoid damage by fitting

Select the proper duct R-value for the job & the codes!

3rd Party Verification

R-4.2

R-6.0

R-8.0

Thermal Performance

- 30%

- 47%

1 4 7 *

2 5 8 0

3 6 9 #

The End
Visit ATCO at www.atcoflex.com Visit ADC at www.flexibleduct.org