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

 

PRE-INSTALLATION INFORMATION.. 3

Introduction. 3

System Design. 3

SMACNA. 3

Warranty. 3

Receiving. 3

Product Care. 3

Product Inspection. 4

Visual Inspection. 4

Electronic Inspections. 4

FLANGE SYSTEMS. 5

Angle Rings. 5

Prime*Guard™ Unattached Rings. 5

Prime*Guard™ Attached Rings. 5

Prime*Guard™ Seal Welded Rings. 6

DUCT ASSEMBLY.. 7

Gasket 7

Hardware. 7

Connecting Sections. 8

Attaching to Non-Prime*Guard Ductwork. 10

FIELD MODIFICATIONS. 10

Shortening Duct in the Field. 10

1.         Disassembly. 10

2.         Measuring the Modification. 10

3.         Cutting the Duct 10

4.         Filing the Edges. 10

5.         Flange Tool 11

6.         Adjusting the Flange Height 11

7.         Flanging the Duct End. 11

8.         Inspect the Coating. 11

FIELD INSTALLED FLANGE. 12

FIELD INSTALLED NIPPLE. 13

NPT Nipple. 13

INSTALLING A TEST PORT. 13

3/8” Test Port 14

FIELD INSTALLED SADDLE TAP. 14

SPARK TEST PROCEDURE. 15

Spark Detector 15

COATING REPAIR.. 15

Precautions. 15

Preparing the Repair Area. 16

Sizing the Patch. 16

Applying the Patch. 16

1.         Heating the Area. 16

2.         Place the Patch. 16

3.         Flowing the Repair Patch: 16

Spark Test Inspection. 16

Technical Assistance. 16


PRE-INSTALLATION INFORMATION

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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Angle Rings

Prime*Guard™ ductwork is manufactured and should be installed according to SMACNA procedures for round industrial duct.  This is accomplished by bolting angle ring joint systems together in a specific and systematic process.  Please refer to the latest edition of SMACNA to review the standards for this process.  The diameter of the angle rings can range in size from 4” to 120”.  The specific design for the angle ring connection system varies depending on the diameter of the duct, the gage of the material, and the pressure requirements of the system. 

 

 


Figure #1:  Unattached angle rings

 

 

 

Prime*Guard™ Unattached Rings:                The standard joint design is an unattached angle ring and a retaining flange on the end of the duct.  The diameter of the duct, the gage of the metal, and the negative pressure rating will determine the range in which this design is appropriate.  Refer to the SMACNA manual or contact a COR*Guard representative for details.  Angle rings can be manufactured from material that is either black iron or 300 series stainless steel.  As shown in Figure #1, a gasket and fasteners complete the system.