Installation
Manual
Rev. 3a, 11/30/2005
COR*Guard LLC – An innovative, cost-effective manufacturer of
fluoropolymer coated stainless steel duct, cleanroom furniture and other custom
products
INSTALLATION MANUAL TABLE OF CONTENTS
Prime*Guard™ Seal
Welded Rings
Attaching to
Non-Prime*Guard Ductwork
6. Adjusting the
Flange Height
Introduction
The purpose of this Manual is to provide information for the proper handling and assembly of COR*Guard’s™ Prime*Guard™ ductwork. By following these tried and proven methods the safety, the reliability, and the longevity of the system will be insured to function as it was originally designed. All Prime*Guard™ products are factory inspected and certified to meet all quality standards before being shipping from the factory. The installer is obligated though, to re-inspect and verify that all products are serviceable before being installed and put into commission. It is the responsibility of the owner to assure that the installer has followed inspection procedures, if the installation is sub-contracted.
System
Design: Prime*Guard™
ductwork is manufactured to meet or exceed all SMACNA requirements for Round
Industrial Duct. Depending on the duct
sizes and the pressure classification of the exhaust system, reinforcing angle
rings may be required. Refer to SMACNA
“Industrial Duct Construction Standards” for these reinforcing requirements to
maintain SMACNA compliance.
SMACNA: All ductwork shall be supported
in accordance with the latest version of guidelines established by SMACNA. During the installation process special care
must be taken not to damage the coating.
The inspection process should insure the reliability of the coating, but
if the coating is damaged during the installation process the system will fail
to work as designed. Do not penetrate
the coating for any reason, except in the case of approved COR*Guard™
modification systems. Do NOT use
“Tek” screws, rivets, or other related fasteners that penetrate any coated
surface on ductwork, unless specifically allowed by SMACNA or specifically
stated in COR*Guard™ procedures.
Remember, do NOT install any ductwork that has failed a visual or
electronic inspection until it has been repaired and re-inspected. All fittings, balancing dampers, blast gates,
drains, test ports, and other inline accessories must be provided by COR*Guard™
to maintain the proper system design and warranty.
Warranty: COR*Guard™ will warranty
products for quality and workmanship for one (1) year from the date of
commissioning. Field installations,
modifications, repairs, and other post-installation operations shall be
performed using factory-authorized procedures.
Prior to any field repairs or other modifications, notify COR*Guard™ to
receive a Field Modification Authorization (FMA) from an authorized COR*Guard™
representative. Failure to follow these
procedures or to notify COR*Guard™ may result in voiding the warranty.
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Receiving
Prime*Guard™ components are inspected and packaged at the factory to assure that they arrive in perfectly new condition. Products though, can be damaged while in transit to the delivery site. Any claim for damage, loss, or delay as a result of the freight company, MUST BE identified on the bill of lading and filed with the delivery company by the consignee. If this is not done, the loss will not be recognized as valid by the delivery company, and the cost will be borne by the consignee. The consignee is responsible for inspecting the shipment upon arrival for damages and completeness and noting any issues on the bill of lading before taking receipt of the shipment. It is then also the consignee’s responsibility to notify COR*Guard™ within 48 hours of receipt of any unsatisfactory product.
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Product Care
Once the product has arrived at the job-site, proper handling and storage of Prime*Guard™ duct is essential to its eventual successful installation. Handle and store Prime*Guard™ ductwork carefully to make sure the coating is not damaged in any way. All COR*Guard™ items are shipped from the factory with packaging designed to protect the coated duct from damage due to handling and other debris, but proper care must still be used to protect the coating.
When storage of the duct is required, it should be left in the factory-installed packaging to maintain its cleanliness and to protect the coating. Store the items in a location that protects them from damage by traffic and other debris. If possible, store all the items indoors where dirt and other debris cannot come into contact with the coating. However, if you must store the items outside, then the ductwork should be protected with waterproof materials to protect it from dirt, dust and other damaging elements.
If it is necessary to stack the items, place a barrier, such as plywood, between the layers. The open end of each duct section is the area most susceptible to damage of the coating. Although, the ends are wrapped in packaging care must be taken to avoid an object penetrating the packaging and damaging the coated surface. If the duct sections are stacked horizontally, do not overload the bottom layer and compress the round diameter into an oval. When moving Prime*Guard™ duct and fittings by hand, do not drag them along the ground, which could scrape and damage the coating. Remove the factory-installed packaging ONLY when the item is ready to be inspected and then installed. Although the items are made from a steel substrate, it must be kept in mind that the coating is relatively delicate and damage to it will compromise the entire system.
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Product Inspection
A clean work area is imperative for handling and inspecting
the Prime*Guard™ ductwork so that it maintains its serviceability once
installed. All work areas and employee
hands should be cleaned before handling the coated duct. The objective is to clean any dust, dirt, or
other contaminates from the duct pieces before proceeding with the inspections
and to keep the items in this cleaned condition until they are installed. Proceed with the project ONLY when the
conditions are satisfactory for beginning this step. If unsatisfactory conditions exist, make the
effort to correct the situation before proceeding.
All COR*Guard™ products are inspected and certified to meet
quality standards prior to leaving the factory.
The consignee and installer though, are responsible for re-inspecting
and verifying, just prior to installation, that all ductwork has been kept in a
serviceable condition. Leave all the
factory packaging in place until the items are ready to be inspected and then
install immediately thereafter. Handle
with the utmost care to avoid damaging the coating.
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Visual Inspection
Begin the inspection by visually looking for dents in the
metal. Check the flanges on each end to
assure that they are still in the proper shape.
Continue the visual inspection by next checking the coating. Look for areas, especially on the flanges,
where the coating may have been scuffed or scraped. Visually check to see if any foreign items
have become imbedded in the coating. Tag
or identify any areas that are damaged or appear questionable.
Electronic Inspections
Next, electronically inspect the coating using a spark
tester. Check that the setting on the
tester is correctly set for the given coating thickness. Sweep the entire coated surface with the
brushes of the wand to check for areas that no longer have the recommended
coating in place. Pay particular
attention to the “tagged” areas that may have been damaged, scraped or
scuffed. Tag or identify any points that
fail the spark test. Any point that
“sparks” constitutes a failure of that item for installation until the failure has
been corrected and retested.
Follow the spark test with an inspection of the coating
thickness. Make sure that the thickness
gauge is set for non-ferrous metal.
After properly “zeroing” the gauge, pick random points on the coated
surface to take readings. The average of
all the readings should be within the specified thickness. If one reading is significantly outside the
desired thickness, check several points close to that area to verify the actual
coating thickness in that region.
Identify any specific areas that are not acceptable. If the average thickness is outside the
specified thickness identify the item as unacceptable.
An item is acceptable for installation and service only when
it has passed both the visual inspection and the electronic inspections. COR*Guard recommends that the approved
section of duct be tagged in some visual manner to easily identify that it has
pass all the necessary inspections.
If an item has had the coating damaged enough to expose the
stainless steel, or if it fails a spark test, or it does not have the proper
coating thickness, the item is unacceptable for installation at that time. Tag or clearly mark any items that fail the
inspection tests so that these items do not inadvertently become
installed. Segregate these unacceptable
items in one area that is clearly identified as such. Contact COR*Guard’s Quality Control
department with the information regarding each item that has failed and why it
has failed the inspection. COR*Guard’s
personnel will discuss the appropriate measures that need to be taken for each
item. However, most “unacceptable” items
can be repaired in the field without necessitating a replacement part. Instructions for field repairs and a repair
kit from COR*Guard will be necessary though.
Any damaged duct that cannot be field repaired must be replaced or returned
to COR*Guard for factory repair. Take
tremendous care to protect the coating throughout the entire process of
inspection to insure excellent performance from the system.
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