Fabric Joint Installation Manual - Flextech Industries

948 East Nusbaum PlaceClinton, MO 64735Phone: (660) 885-8899Fax: (660) 885-6852Website: www.flextech-ind.comwww.flextechdampers.comEmail: us.sales@flextech-ind.comSHIPPING, STORAGE, INSTALLATION & MAINTENANCE FORFLEXTECH DUCTING EXPANSION JOINTSThe installer and/or user has a responsibility to unload, store, and install FLEXTECH DUCTING EXPANSIONJOINTS in a manner which will not impair the quality built into the product and to operate the system within designconditions as set forth in the project specifications.SHIPPINGFLEXTECH takes special precautions in the packaging and loading of all ducting expansion joints shipped fromthe plant to assure safe and undamaged arrival at the destination. Care must be exercised by thoseresponsible for unloading to prevent any physical damage that can be caused by bumping, dragging, droppingor stacking for storage.The shipment should be inspected upon arrival for any physical damage to boxes, cartons, loose shipping bars,etc., that may have been caused during shipment and any damage noted should be reported to FLEXTECHimmediately so action can be taken to correct and claims can be filed against the delivering carrier.INSIDE STORAGE REQUIREMENTSInside storage is recommended for all Integral-Flanged flexible elements and the Belt-type flexible elements ofexpansion joints that must be shipped knocked-down due to overall size of the metal frames. These expansion jointcomponents should be:1. Stored in their original shipping containers.2. Stored in an area where they are protected from physical damage or abuse.3. Stored in an area where the temperature is normally 50 deg. F to 90 deg. F. DO NOT STORENEAR ANY HEAT SOURCES.4. Do not store expansion joints near any electrical equipment that may generate ozone.OUTSIDE STORAGE REQUIREMENTSOutside storage is acceptable for all fully shop assembled Belt-Type geometry expansion joints, metal framesof knocked down units, and all other metal components and should be:1. Stored at least one foot above ground in a dry area where flooding will not occur.2. Stacked no higher than four expansion joints high (as with shop assembled belt-type geometries)unless additional supports are added to carry the additional weight.3. Store in an area with sufficient space to prevent any physical damage or abuse when moving theexpansion joints or other construction materials from the storage area.4. Cover the expansion joints and other metal components with a tarpaulin or heavy plastic to protectthem from the weather and elements.5. Do not store the expansion joints near any electrical equipment that may generate ozone.Fabric Expansion Joint Installation Instructions - 1

INSTALLATIONThe following procedures are guidelines that will aid in the installation of FLEXTECH DUCTING EXPANSIONJOINTS. These installation procedures may have to be modified due to conditions at the job-site or because ofthe overall size of the expansion joint. No matter what the condition. It is always important to prevent damagedue to careless handling and to keep the expansion joint supported during installation.PRE-ERECTION REQUIREMENTS1. CHECK BREECH OPENING for misalignment and flange-to-flange dimensions to confirm theymeet with the project specifications and drawing. If the flanges are misaligned and exceed anerection tolerance of ± ¼” in all directions of the breach opening shown on the project drawings,contact FLEXTECH immediately for consultation.2. CHECK DUCT WORK FLANGES which should be smooth, flat, uniform, and parallel with all fieldwelds ground smooth on the flange faces.3. CLEAR WORK AREA of all sharp objects or protrusions.4. TRANSPORT EXPANSION JOINT to installation area along with associated hardware. Take carenot to damage the expansion joint flexible element or frames by careless handling duringtransportation.5. PROVIDE PROTECTION AGAINST WELD SPATTER at or around expansion joint installationarea. Shields or weld blankets should be used to protect the expansion joint flexible element fromany weld spatter or slag contact. All shields and weld blankets must be removed after all weldingaround the expansion joint area is completed.ERECTION OF BELT-TYPE GEOMETRY EXPANSION JOINTSFabric Expansion Joint Installation Instructions - 2

1. FLEXTECH BELT-TYPE SERIES expansion joints are normally shipped fully assembled whensize permits, with shipping bars holding the face-to-face dimension, which should remain in placeuntil after the installation is completed.2. On large BELT-TYPE SERIES expansion joints shipped knocked down due to size, the frames areshipped as rails with the flange face-to-face dimension held by steel shipping bars.3. Whenever practical, field assemble the expansion joint on the ground by welding the rail sectionstogether as shown on the FLEXTECH fabrication and installation drawing and install the endlessflexible element.4. When installing the flexible element, position the element in the metal frames and hold in placewith several bolts.5. Tighten the bolts in all radius corners first and then every fourth bolt down along the straight sides.When finished, install balance of bolts and torque all bolts to 35 to 40 foot pounds, going twicearound the periphery of each flange.6. Hoist assembled expansion joints with shipping bars in place and slide into prepared breachopening. FLEXTECH recommends using positioning bolts on 4’ – 0” centers on one flange only;so install these bolts and tighten down to hold expansion joint in position.7. FLEXTECH recommends that the other duct flange be tack welded to the duct section so that itcan be moved to butt up tight with the expansion joint flange. With no drilling in this flange anymisalignment of the ducting flanges can be handled by seal welding the two flanges where theymeet.8. Once the expansion joint is bolted on one side and duct flange has been moved in to meet theother flange, stitch weld around the outside periphery of both flanges and seal weld the inside asshown on FLEXTECH Fabrication and installation drawings. Extreme care should be exercised toprotect the expansion joint from weld splatter and slag during all field welding.9. After all welding is completed remove all shipping bars and welding shields or blankets.10. Do not directly insulate the expansion joint exterior as the flexible element must be allowed tomove freely. In the case of our insulated FC series fabric, the additional trapped heat may alsoform hot spots around the outer belt which could potentially result in pre-mature failure.INSPECTION AND MAINTENANCERegular maintenance programs are essential to provide optimum life expectance for flue duct expansion joints.A standard maintenance schedule should include:1. Inspection for any foreign debris (coal dust-fly ash) that may have accumulated on the external topleg of expansion joints located in horizontal duct work. Collection of debris can insulate theexternal cover, causing premature failure; as well as being a source of external combustion (coaldust) on the expansion joint.2. The accumulation of fly ash and unburned coal dust in the bottom cavity of expansion joints,located in horizontal ducting, should be removed on a regular basis. Fly ash packing in the jointcavity can severely inhibit the motion capabilities of the expansion joint and can cause prematurefailures. Especially when the fly ash packing has reached a cemented condition. Unburned coaldust in the bottom cavity can cause internal duct fires and damage the expansion joint.3. Duct work mating flanges and expansion joint hardware should be inspected for leaks allowing hotflue gas to damage the external cover of the expansion joint when exit gas temperatures exceedthe designed operating temperature of the flexible element.4. Actual duct movements should be observed and duct work support systems checked againstoriginal design criteria. Excessive ducting movements can cause damage or premature failure ofthe expansion joint. Consult FLEXTECH for specific recommendations.FLEXTECH Engineering Department has successfully provided thousands of expansion joints to many utilitiesand other major industrial users for numerous types of installations. Our success is measured by the repeatusers who have had excellent experience with FLEXTECH expansion joints and rely on FLEXTECH quality for“trouble-free” operation(s).When you need engineered excellence with proven field acceptance – Call FLEXTECH.Fabric Expansion Joint Installation Instructions - 3