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THERMOSET FRP DUCT CONSTRUCTION MANUAL SHEET METAL AND AIR CONDITIONING CONTRACTORS’ NATIONAL ASSOCIATION, INC. This is a preview of "SMACNA 1546-1997". Click here to purchase the full version from the ANSI store.

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Page 1: THERMOSET FRP DUCT CONSTRUCTION MANUAL154… · mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. This is a preview of "SMACNA

THERMOSET FRPDUCT CONSTRUCTION

MANUAL

SHEET METAL AND AIR CONDITIONING CONTRACTORS’NATIONAL ASSOCIATION, INC.

This is a preview of "SMACNA 1546-1997". Click here to purchase the full version from the ANSI store.

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THERMOSET FRPDUCT CONSTRUCTION

MANUAL

FIRST EDITION -- JUNE, 1997

SHEET METAL AND AIR CONDITIONING CONTRACTORS’NATIONAL ASSOCIATION, INC.

4201 Lafayette Center DriveChantilly, VA 20151--1209

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THERMOSET FRPDUCT CONSTRUCTION

MANUALCOPYRIGHTE1997All Rights Reserved

by

SHEET METAL AND AIR CONDITIONING CONTRACTORS’NATIONAL ASSOCIATION, INC.

4201 Lafayette Center DriveChantilly, VA 20151--1209

Printed in the U.S.A.

FIRST EDITION -- JUNE, 1997Second Printing -- February, 2002

Except as allowed in the Notice to Users and in certain licensing contracts, no part of this book may bereproduced, stored in a retrievable system, or transmitted, in any form or by any means, electronic,

mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher.

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iiiThermoset FRP Duct Construction Manual First Edition

FOREWORD

The selection of fiberglass reinforced plastic (FRP) duct for use in corrosive environments is increasing. FRP duct isfrequently being selected for fume hood exhaust systems, for air pollution and odor control systems in facilities suchas waste water treatment plants, and other corrosive environments.

FRP ducts are routinely designed and manufactured to meet a systems unique requirements. This represents a majoradvantage over thermoplastic (PVC), metallic, and coated metallic ductwork. FRP ducts are manufactured using spe-cifically designed reinforcement systems, bonded together with thermosetting plastic resins. These resins are selectedfor their ability to resist specific chemicals known to be present in the corrosive environment in which the ductworkis to be installed.

Working with resin and FRP duct manufacturers, SMACNA contractors have researched the current and future poten-tial use of FRP duct and its physical properties. This effort resulted in an authoritative manual that SMACNA contrac-tors, architects, engineers, managers, and plant owners can rely upon for the proper selection, manufacture, and instal-lation of specifically tailored FRP duct systems. To establish these manufacturing and construction standards,SMACNA contracted with Dr. Joseph M. Plecnik of the Civil Engineering Department at California State University,Long Beach, to develop and test duct design procedures for the manufacture and installation of round and rectangularduct systems. Dr. Plecnik investigated round duct systems ranging from 4 to 72 inches (100 to 1800 mm) in diameterand rectangular duct systems ranging from 12 to 96 inches (300 to 2400 mm) in width and depth, operating at a staticpressure within a range from -30 to +30 in. wg (-7500 to +7500 Pa) and within a temperature range from ambient to180_F (82ºC).

By following the manufacturing, construction, and installation details specified in this manual, a contractor shouldbe able to develop a duct system that dependably meets the stated requirements of the customer. As with all products,there are limits to the successful use of FRP duct systems. It is imperative that the customer provide an accurate defini-tion of the corrosive environment in which the FRP duct system is to be installed. Proper selection of the thermosetresins and reinforcing material ensures that the customer receives a well designed duct system that meets his needsfor the foreseeable future.

Throughout the manual and its appendices, we have included the engineering design criteria and safety factors selectedto achieve a safe, and cost effective construction standard. This includes ample consideration of the manufacturingvariables that occur in a product built to meet the individual requirements of each application.

SMACNA is indebted to representatives from thermoset resin and FRP duct manufacturers, and the SMACNA con-tractors who, as members of the FRP Task Force, volunteered their time and effort to the development of this manual.SMACNA appreciates their dedication and willingness to share their knowledge and experience in the design, fabrica-tion, and installation of FRP duct systems.

SHEET METAL AND AIR CONDITIONING CONTRACTORS’NATIONAL ASSOCIATION, INC.

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ivThermoset FRP Duct Construction Manual First Edition

FRP TASK FORCE

Michael J. Daugharty, ChairmanHeating & Plumbing Engineers Inc.Colorado Springs, CO

Joseph J. Flannagan, Jr.Primary Plastics, Inc.Endwell, NY

Norman T. R. HeathornN.V. Heathorn, Inc.Oakland, CA

G. A. Navas, StaffSMACNA, Inc.Chantilly, VA

CONSULTANTS

Dr. Frank A. CassisAshland Chemical, Inc.Los Angeles, CA

Robert M. HahnXerxes CorporationAvon, OH

Le RodenbergIndustry ConsultantEscondido, CA

Joseph M. Plecnik, PhD, P.E.Cal State University, L.B.Long Beach, CA

Robert C. TalbotTechnical WriterWest Worthington, OH

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Thermoset FRP Duct Construction Manual First Edition v

NOTICE TO USERSOF THIS PUBLICATION

1. DISCLAIMER OF WARRANTIES

a) The Sheet Metal and Air Conditioning Contractor’s National Association (“SMACNA”) provides its product for informational pur-poses.

b) The product contains “Data” which is believed by SMACNA to be accurate and correct but the data, including all information, ideasand expressions therein, is provided strictly “AS IS”, with all faults. SMACNA makes no warranty either express or implied regardingthe Data and SMACNA EXPRESSLY DISCLAIMS ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESSFOR PARTICULAR PURPOSE.

c) By using the data contained in the product user accepts the Data “AS IS” and assumes all risk of loss, harm or injury that may resultfrom its use. User acknowledges that the Data is complex, subject to faults and requires verification by competentprofessionals, and thatmodification of parts of the Data by user may impact the results or other parts of the Data.

d) IN NO EVENT SHALL SMACNA BE LIABLE TO USER, OR ANY OTHER PERSON, FOR ANY INDIRECT, SPECIAL ORCONSEQUENTIAL DAMAGES ARISING, DIRECTLY OR INDIRECTLY, OUT OF OR RELATED TO USER’S USE OF SMAC-NA’S PRODUCT OR MODIFICATION OF DATA THEREIN. This limitation of liability applies even if SMACNA has been advisedof the possibility of such damages. IN NO EVENT SHALL SMACNA’S LIABILITY EXCEED THE AMOUNT PAID BY USERFOR ACCESS TO SMACNA’S PRODUCT OR $1,000.00, WHICHEVER IS GREATER, REGARDLESS OF LEGAL THEORY.

e) User by its use of SMACNA’s product acknowledges and accepts the foregoing limitation of liability and disclaimer of warranty andagrees to indemnify and hold harmless SMACNA from and against all injuries, claims, loss or damage arising, directly or indirectly, outof user’s access to or use of SMACNA’s product or the Data contained therein.

2. ACCEPTANCE

This document or publication is prepared for voluntary acceptance and use within the limitations of application defined herein, andotherwiseas thoseadopting it or applying it deem appropriate. It is not a safety standard. Its application for a specificproject is contingenton a designer or other authority defining a specific use. SMACNA has no power or authority to police or enforce compliance with thecontents of this document or publication and it has no role in any representations by other parties that specific components are, in fact, incompliance with it.

3. AMENDMENTS

The Association may, from time to time, issue formal interpretations or interim amendments, which can be of significance betweensuccessive editions.

4. PROPRIETARY PRODUCTS

SMACNA encourages technological development in the interest of improving the industry for the public benefit. SMACNA does not,however, endorse individual manufacturers or products.

5. FORMAL INTERPRETATION

a) A formal interpretation of the literal text herein or the intent of the technical committee or task force associated with the document orpublication is obtainable only on the basis of written petition, addressed to the Technical Resources Department and sent to the Associa-tion’s national office in Chantilly, Virginia. In the event that the petitioner has a substantive disagreement with the interpretation, anappeal may be filed with the Technical Resources Committee, which has technical oversight responsibility. The request mustpertain to aspecifically identified portion of the document that doesnot involvepublished textwhich provides the requested information. In consid-ering such requests, theAssociation will not review or judgeproductsor componentsas being in compliancewith thedocument orpubli-cation. Oral and written interpretations otherwise obtained from anyone affiliated with the Association are unofficial. This proceduredoes not prevent any committee or task force chairman, member of the committee or task force, or staff liaison from expressing an opin-ion on a provision within the document, provided that such person clearly states that the opinion is personal and does not represent anofficial act of the Association in any way, and it should not be relied on as such. The Board of Directors of SMACNA shall have finalauthority for interpretation of this standard with such rules or procedures as they may adopt for processing same.

b) SMACNA disclaims any liability for any personal injury, property damage, or other damage of any nature whatsoever, whether spe-cial, indirect, consequential or compensatory, direct or indirectly resulting from the publication, use of, or reliance upon this document.SMACNA makes no guaranty or warranty as to the accuracy or completeness of any information published herein.

6. APPLICATION

a) Any standards contained in this publication were developed using reliableengineering principlesand research plus consultation with,and information obtained from, manufacturers, users, testing laboratories, and others having specialized experience. They are subject torevision as further experienceand investigation may show is necessary or desirable.Construction and products which comply with theseStandards will not necessarily be acceptable if, when examined and tested, they are found to have other features which impair the result

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Thermoset FRP Duct Construction Manual First Editionvi

contemplated by these requirements. The Sheet Metal and Air Conditioning Contractors’ National Association and other contributorsassume no responsibility and accept no liability for the application of the principles or techniques contained in thispublication.Authori-ties considering adoption of any standards contained herein should review all federal, state, local, and contract regulations applicable tospecific installations.

b) In issuing and making this document available, SMACNA is not undertaking to render professional or other services for or on behalfof any person or entity. SMACNA is not undertaking to perform any duty owed to any person or entity to someone else. Any person ororganization using this document should rely on his, her or its own judgement or, as appropriate, seek the advice of a competent profes-sional in determining the exercise of reasonable care in any given circumstance.

7. REPRINT PERMISSION

Non-exclusive, royalty-free permission is granted to government and private sector specifying authorities to reproduce only anyconstruction details found herein in their specifications and contractdrawings prepared for receiptof bidson new construction and reno-vation work within the United States and its territories, provided that the material copied isunaltered in substance and that the reproducerassumes all liability for the specific application, including errors in reproduction.

8. THE SMACNA LOGO

The SMACNA logo is registered as a membership identification mark. The Association prescribes acceptable use of the logo and ex-pressly forbids the use of it to represent anything other than possession of membership. Possession of membership and use of the logo inno way constitutes or reflects SMACNA approval of any product, method, or component. Furthermore, compliance of any such itemwith standards published or recognized by SMACNA is not indicated by presence of the logo.

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TABLE OF CONTENTS

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TABLE OF CONTENTS

viiThermoset FRP Duct Construction Manual First Edition

FOREWORD iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRP TASK FORCE iv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONSULTANTS iv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NOTICE TO USERS OF THIS PUBLICATION v. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS vii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 1 INTRODUCTION 1.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 SCOPE 1.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 USES 1.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 WHAT IS FRP? 1.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 PURPOSE 1.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 CONTENTS 1.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 2 MATERIALS 2.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 INTRODUCTION 2.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 THERMOSET RESINS 2.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 MIXING AND CURING THERMOSETS 2.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 CATALYSTS, PROMOTERS, INHIBITORS, AND OTHER ADDITIVES 2.2. . . . . . . . . . . . .

2.5 MATERIALS HANDLING 2.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6 FLAME RETARDANCE AND SMOKE GENERATION 2.4. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7 ULTRAVIOLET STABILIZERS 2.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8 TYPES OF REINFORCEMENT 2.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 3 LAMINATE CONSTRUCTION 3.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 INTRODUCTION 3.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 CORROSION BARRIER RESIN 3.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 CORROSION BARRIER 3.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 STRUCTURAL LAYER 3.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 EXTERIOR SURFACE 3.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 POTENTIAL ADHESION PROBLEMS DURING LAMINATE CONSTRUCTION 3.3. . . . .

3.7 WALL THICKNESS TOLERANCE 3.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 MECHANICAL PROPERTIES 3.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9 SURFACE HARDNESS 3.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 APPEARANCE 3.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 4 FIELD JOINING PROCEDURES 4.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 INTRODUCTION 4.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 PREPARATION FOR JOINING DUCT 4.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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viii Thermoset FRP Duct Construction Manual First Edition

4.3 PREPARATION OF STRAPPING 4.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 MIXING RESIN 4.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 JOINING DUCT 4.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 INTERNAL JOINT LAMINATING PROCEDURE 4.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 CLEAN–UP 4.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 5 DESIGN OF ROUND FRP DUCT 5.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 DESIGN OF ROUND FRP DUCTS USING TYPES I AND II LAMINATES 5.1. . . . . . . . . .

5.2 DESIGN OF ROUND FRP DUCTS USING FILAMENT WOUND(TYPE X) LAMINATES 5.9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 6 DESIGN OF RECTANGULAR FRP DUCT 6.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 DESIGN OF RECTANGULAR FRP DUCTS USING TYPE I AND II LAMINATES 6.1. . . .

6.2 SELECTION OF STIFFENERS AND FLANGES FOR RECTANGULAR DUCTSYSTEMS 6.9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 7 REQUIREMENTS 7.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 TERMINOLOGY 7.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 CONTACT MOLDING 7.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 MATERIALS 7.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4 STORAGE 7.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5 STATIC ELECTRICITY 7.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.6 REINFORCEMENT 7.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.7 RAW EDGES 7.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8 JOINTS (WELDS OR BONDS) 7.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.9 LAMINATE CONSTRUCTION 7.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.10 DESIGN REQUIREMENTS 7.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.11 OVERLAP 7.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.12 RECTANGULAR DUCT CORNERS 7.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.13 BOND CONSTRUCTION 7.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.14 FLANGE REQUIREMENTS 7.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.15 STANDARD ELBOWS AND MITERED JOINTS 7.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.16 FITTING CONFIGURATION 7.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.17 DUCT HANGERS AND SUPPORTS 7.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.18 FUME HOODS 7.6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.19 DAMPERS 7.6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.20 ACCESS OPENINGS AND END CAPS 7.7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.21 DRAINS 7.7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.22 VENTILATOR HEADS AND LOUVERS 7.7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.23 FLEXIBLE CONNECTIONS 7.7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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ixThermoset FRP Duct Construction Manual First Edition

7.24 FLEXIBLE MATERIALS 7.7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.25 LINEAR COEFFICIENT OF THERMAL EXPANSION 7.7. . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.26 TOLERANCES 7.8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.27 DRAINAGE 7.8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.28 SPRINKLERS 7.8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.29 BURIED DUCT 7.8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.30 MANUFACTURER’S SHOP REVIEW 7.8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.31 INSPECTION 7.9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.32 HANDLING, SHIPPING, AND INSTALLATION 7.9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 8 QUALITY CONTROL AND SAFETY 8.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 QUALITY CONTROL 8.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 SAFETY 8.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3 HEALTH CONCERNS 8.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 9 FRP GUIDE SPECIFICATIONS 9.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1 GENERAL 9.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2 DRAWINGS 9.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.3 SEISMIC RESTRAINT PROVISIONS 9.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4 GUIDE SPECIFICATIONS 9.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIX A DEVELOPMENT OF THE TABLES A.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIX B CHEMICAL RESISTANCE OF FRP DUCT B.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIX C ALTERNATE ROUND DUCT DESIGN TABLES C.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIX D GLOSSARY D.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIX E REFERENCED DOCUMENTS E.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INDEX I.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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x Thermoset FRP Duct Construction Manual First Edition

TABLES

Table 5--1 Standard Composition of Type I Laminates 5.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 5--2 Standard Composition of Type II Laminates 5.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 5--3 Minimum Mechanical Properties of Types I and II Laminates 5.5. . . . . . . . . . . . . . . . . . . . . .

Table 5--4 Negative Pressure Ratings of Types I & II Laminates in in. wg 5.6. . . . . . . . . . . . . . . . . . . . .

Table 5--4M Negative Pressure Ratings of Types I & II Laminates in Pa 5.7. . . . . . . . . . . . . . . . . . . . . . .

Table 5--5 Minimum Flange Dimensions for Round Duct 5.8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 5--6 Filament Wound (Type X) Composite Laminates 5.10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 5--7 Minimum Mechanical Properties of Filament Wound (Type X) Laminates 5.11. . . . . . . . . .

Table 5--8 Minimum Bond Construction for Filament Wound (Type X) Laminates 5.11. . . . . . . . . . . . .

Table 5--9 Negative Pressure Ratings of Filament Wound (Type X) Laminates in in. wg 5.12. . . . . .

Table 5--9M Negative Pressure Ratings of Filament Wound (Type X) Laminates in Pa 5.13. . . . . . . . .

Table 6--1 Positive Design Pressure of 10 in. wg 6.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6--1M Positive Design Pressure of 2500 Pa 6.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6--2 Positive Design Pressure of 20 in. wg 6.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6--2M Positive Design Pressure of 5000 Pa 6.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6--3 Positive Design Pressure of 30 in. wg 6.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6--3M Positive Design Pressure of 7500 Pa 6.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6--4 Negative Design Pressure of 10 in. wg 6.6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6--4M Negative Design Pressure of 2500 Pa 6.6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6--5 Negative Design Pressure of 20 in. wg 6.7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6--5M Negative Design Pressure of 5000 Pa 6.7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6--6 Negative Design Pressure of 30 in. wg 6.8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6--6M Negative Design Pressure of 7500 Pa 6.8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6--7 Minimum Flange Dimensions for Rectangular Duct 6.14. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6--8 Maximum Allowable Stiffener Span in in. for Positive or Negative Pressureof 10 in. wg 6.16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6--8M Maximum Allowable Stiffener Span in mm for Positive or Negative Pressureof 2500 Pa 6.17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6--9 Maximum Allowable Stiffener Span in in. for Positive or Negative Pressureof 20 in. wg 6.20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6--9M Maximum Allowable Stiffener Span in mm for Positive or Negative Pressureof 5000 Pa 6.21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6--10 Maximum Allowable Stiffener Span in in. for Positive or Negative Pressureof 30 in. wg 6.24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6--10M Maximum Allowable Stiffener Span in mm for Positive or Negative Pressureof 7500 Pa 6.25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 7--1 Minimum Strap Sizes for Round Duct 7.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 7--2 Weight of FRP Laminates 7.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 7--3 Trapeze Angle Support Capacity 7.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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xiThermoset FRP Duct Construction Manual First Edition

Table 7--4 Hanger Rod (ATR) Capacity 7.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 7--5 Minimum Bond Widths 7.10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table A--1 Nominal Laminate Thickness (in.) Given Duct Diameter and Vacuum A.11. . . . . . . . . . . . .

Table A--1M Nominal Laminate Thickness (mm) Given Duct Diameter and Vacuum A.12. . . . . . . . . . .

Table A--2 Safety Factors Given Filament Wound Laminate Combination and Vacuum A.13. . . . . . .

Table A--2M Safety Factors Given Filament Wound Laminate Combination and Vacuum A.14. . . . . . .

Table A--3 Material Properties For Filament Wound Laminates Model In L–t Coordinates,Combination S–5 (for Round Duct) A.23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table A--4 Data for Each Lamina (Theta (Θ) Measured Clockwise from +Y Axis) A.23. . . . . . . . . . . .

Table A--5 Material Properties for Filament Wound Laminates Model In L–t Coordinates,Combination S–7 (for Round Duct) A.23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table A--6 Data for Each Lamina (Theta (Θ) Measured Clockwise from +Y Axis) A.24. . . . . . . . . . . .

Table A--7 Average Material Properties for All Rectangular Ducts A.24. . . . . . . . . . . . . . . . . . . . . . . . . .

Table B--1 Typical Chemical Resistance of Various Resins Used in FRP Duct B.11. . . . . . . . . . . . . . .

Table C--1 Negative Pressure Ratings of Types I & II Laminates in in. wg C.2. . . . . . . . . . . . . . . . . . . .

Table C--1M Negative Pressure Ratings of Types I & II Laminates in Pa C.3. . . . . . . . . . . . . . . . . . . . . .

Table C--2 Negative Pressure Ratings of Filament Wound (Type X) Laminates in in. wg C.6. . . . . . .

Table C–2M Negative Pressure Ratings of Filament Wound (Type X) Laminates in Pa C.7. . . . . . . . . .

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xii Thermoset FRP Duct Construction Manual First Edition

FIGURES

Figure 2--1 Gel Time vs. Catalyst Concentration at Various Temperatures 2.3. . . . . . . . . . . . . . . . . . . . .

Figure 3--1 Lay–up Sequence for FRP Duct – Types I, II, and X Laminates 3.2. . . . . . . . . . . . . . . . . . . .

Figure 4--1 Preparation of Strapping 4.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4--2 Application of Strapping 4.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4--3 Butt–and–Strap End–to–End Joint 4.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4--4 Bell–and–Spigot Joining Method 4.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4--5 Gel Time vs. Catalyst Concentration at Various Temperatures 4.4. . . . . . . . . . . . . . . . . . . . .

Figure 5--1 FRP Flange Details 5.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6--1 Corner Reinforcement Detail 6.10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6--2 Wood Stiffeners with FRP Bond 6.11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6--3 Construction of Transverse Stiffeners 6.12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6--4 Semi–Circular Foam Stiffeners with FRP Bond 6.13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6--5 FRP Flange Details 6.14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--1 Trapeze Angle with Hanger Rods 7.6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--2 Flange Cant 7.11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--3 Flange Tolerance Description 7.11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--4 Flange Offset 7.12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--5 Flange Attachment 7.12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--6 Weld Width and Thickness 7.13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--7 Bolt Tightening Sequence 7.13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--8 Square Throat Elbows 7.14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--9 Round or Rectangular Standard Elbow 7.14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--10 Round or Rectangular Angles 7.15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--11 Rectangular Tees 7.15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--12 Round or Rectangular Offsets 7.16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--13 Transition Elbows 7.16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--14 Five Segment Elbow 7.17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--15 Round / Square Reducers 7.17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--16 Round or Rectangular Eccentric Reducers 7.18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--17 Round Tees 7.18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--18 Conical Tees 7.19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--19 Conical Reducing Tees / Lateral 7.19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--20 Reducing Tees / Lateral 7.20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--21 Conical Laterals 7.20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--22 Tee / Lateral Crosses 7.21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--23 Round or Rectangular Wyes 7.21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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xiiiThermoset FRP Duct Construction Manual First Edition

Figure 7--24 Round or Rectangular Reducing Wyes 7.22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--25 Round or Rectangular Offsets 7.22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--26 Conical Tee Crosses 7.23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--27 Typical Louver Construction 7.23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure7--28 Duct Hangers – Horizontal 7.24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--29 Support for Vertical Duct 7.25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--30 Turning Vane Construction 7.26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--31 Typical Blast Gate 7.27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--32 Typical Butterfly Damper with Locking Device 7.28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--33 Gravity Back–Draft Damper for Vertical Duct 7.29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--34 Duct Openings 7.30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7--35 Typical Stackheads 7.31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure A--1 Cross Section of a 20” x 20” Duct A.15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure A--2 Cross Section of a 36” x 18” Duct A.15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure A--3 Vacuum / Pressure Test of FRP Duct A.17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CHAPTER 1

INTRODUCTION

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CHAPTER 1 INTRODUCTION

1.1Thermoset FRP Duct Construction Manual First Edition

1.1 SCOPE

This manual covers the physical properties, manufac-ture, construction, installation and methods of testingfiberglass reinforced thermosetting plastic duct, in-tended for air conveyance in corrosive environments,as manufactured by hand lay–up, spray–up, and fila-ment winding fabrication techniques.

S Round duct 4 to 72 in. (100 to 1800 mm) di-ameter

S Rectangular duct 12 to 96 in. (300 to 2400mm) diameter

S Static pressures –30 to +30 in. wg (–7500 to+7500 Pa)

S Temperature range ambient to 180ºF (82ºC)(Depending on resin selection)

1.2 USES

Fiberglass reinforced plastic (FRP) has been used forvarious types of process equipment, in the chemical,pulp and paper, power, mining, municipal sewer treat-ment, and water treatment (odor pollution abatement)as well as many other associated industries handlingcorrosive environments.

FRP process equipment of all shapes and sizes, such ascolumns, scrubbers, hoods, ducts, fans, and stacks aswell as piping, tanks, grating, mist eliminator blades,heat exchanger shells, tube sheets, and many othertypes of equipment are required for severely corrosiveapplications.

1.3 WHAT IS FRP?

FRP stands for “fiberglass reinforced plastic.” FRP isalso used to define fiber reinforced plastic (fibers otherthan glass). Terms used interchangeably with FRP arereinforced thermoset plastic (RTP) or glass reinforcedplastic (GRP), which is used in Europe and Australia.

1.3.1 Laminate

Laminate refers to the “composite material” that ismanufactured from a thermosetting resin matrix withlayers of reinforcement fibers. Typical techniques forthe fabrication of round and rectangular duct are handlay–up, spray–up, and filament winding. Hand lay–upand spray–up typically apply layers of chopped strandand woven fabric to build up structural layers over aform or mold. Filament winding applies a structural

layer of continuous fiber strands wrapped around a ro-tating mold or mandrel. The reinforcing fiber is im-pregnated with a catalyzed thermoset polyester or vi-nyl ester. It is then allowed to reach full cure to forma hard and dense composite laminate for corrosion ap-plications. Once cured (exceeding initial Barcol hard-ness), the formed laminates are removed from themolds and preconditioned for field assembly. At thispoint, the fabricated duct sections are inspected andapproved for shipment to the job site.

1.3.2 Thermoset Plastics

Thermosetting resins, once fully cured and hardened,cannot be reverted to their original liquid state. Thechemical reaction of thermoset resins is exothermic,where the liquid catalyzed resin heats up and continuesto increase in temperature to form a cured solid resinstate. This is the basic difference between “thermo-plastic” and “thermoset plastic.”

While both types of plastics find application through-out the air handling industry, the scope of this particu-lar manual will be confined to air handling systemsfabricated with thermoset plastic materials.

1.3.3 FRP Duct Use

The most common use for FRP duct is for corrosioncontrol in air pollution and odor abatement ventilationand exhaust systems. The corrosion resistance of FRPdepends on the selection of the proper generic type ofthermosetting resin to handle the corrosive applica-tion.

Corrosion resistant FRP is generally superior to carbonsteel, galvanized steel, lower grades of stainless steel,and different types of lined steel equipment.

This manual is primarily directed to the above air han-dling systems.

The FRP duct industry is a dynamic industry with newproducts, systems, and procedures evolving on a regu-lar basis. Resins and other products not covered by thismanual are not necessarily inappropriate for use in aspecific duct system. The contractor must ensure thatthe owner, design engineer, resin manufacturer, andduct manufacturer are all in agreement that the speci-fied FRP duct system will meet the owner’s corrosionresistance requirements.

1.4 PURPOSE

This manual proposes to accomplish the following ob-jectives:

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