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Insulation System The Kingspan US Units October 2018 The Kingspan KoolDuct System Training Manual Phenolic Ductwork Fabrication Installation Guidelines...
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Bayonet Cleat Storage and handling Tiger Clip coupling system The KoolDuct panel Connection to duct system components KoolDuct System operational limits Connections with Tiger Unit Information required for fabrication Connection of Inspection doors Fabrication procedure Cutting: Machines and Hand tools Assembly: Tiger Clips Chapter 4 –...
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System The Kingspan Training Manual Chapter 1 Introduction...
The Delivery Partner and/or KoolDuct fabricators shall have full regard to Kingspan’s Technical Support Documentation for the KoolDuct System and shall ensure that in any design and any erection of using the Kingspan KoolDuct System, the guidelines in the Technical Support Documentation are followed by it and any sub-contractors engaged to design and/or assemble the ductwork.
System The Kingspan Health and Safety Kingspan KoolDuct panels are chemically inert and safe to use. Wear gloves when handling and cutting the product: particles of the glass fibre reinforced facings can be irritating to the skin. Use suitable protective clothing (e.g. long-sleeved garments).
OUTSIDE STORAGE Where storage inside a building is not possible, Kingspan KoolDuct panels and ductwork sections shall be stored clear of the ground protected and secured against all weather, including wind, rain, and sunlight, by an opaque light coloured weatherproof material suitable for the climate in which it is to be stored.
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The Kingspan System KoolDuct Panel Printed foil facing shall be kept inside ductwork 154 ¾” (12.89 ft) Factory applied aluminum facings Silver Black (NOTE: The black faced KoolDuct is NOT part of the UL listed duct system) KoolDuct Panel Dimensions USA and North ”...
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Enclosed car park extract systems • Pressurisation systems for protected staircase, lobby, corridors • Conveyance of solid particles • Chemical or fume exhaust systems (please check compatibility with Kingspan) • For use with extreme heat above 185°F (85° C) •...
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System The Kingspan Information Required for Fabrication and Installation Information to be provided by the designer for the fabrication and installation of KoolDuct pre-insulated ductwork Comprehensive ductwork layout drawings indicating: GENERAL • Ductwork sizes • Routing of the ductwork system •...
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System The Kingspan Basic KoolDuct Fabrication Procedure 1. TRACING 2. CUTTING 3. ASSEMBLY: • with Tiger Clips (for pressure classes up to 1000 Pascal) or • with Adhesive (for pressure classes up to 750 Pascal) 4. TAPING 5. REINFORCING 6. COUPLING/JOINING 7.
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The Kingspan System Machine Cutting Specific training to be provided by the manufacturer of the machine Straight cutting machine CNC machine...
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The Kingspan System Cutting - Jack Planes for ” (22 mm) Panels, R-6 # 511 - Jack Plane, two blades at 45° Blades set ” less than Panel thickness To Set the Cut Height: A) Unloose big screw (1) on the back...
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System The Kingspan Cutting - Jack Planes for 1 ” (30 mm) Panels, R-8 # 516 - Jack Plane, two blades Blades set ” less than Panel thickness # 513U, 514U, 515U - Small Jack Planes, one blade Cut 1 ”...
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The Kingspan System Assembly option 1 - Tiger Clips # 364 ALL duct sections MUST be assembled with Tiger Clips or Adhesive Example 2: Duct 18” x 12”, at 4 in.w.g. Example 1: Duct 18” x 12”, at 2 in.w.g.
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System The Kingspan Assembly option 2 – Adhesive # 212 (or spray) ALL duct sections MUST be assembled with adhesive or Tiger Clips Adhesive for pressure classes up to 3 in.w.g. • Shake well • Protect board from over spray •...
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The Kingspan Sealing – Extended Silicone Tool # 444 ALL ductwork sections MUST be sealed with sealant compliant with the UL Listed KoolDuct System Suggested silicone coverage and application • For low pressure applications up to 2 in.w.g. (500 Pa): Minimum ”...
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The Kingspan System Training Manual Chapter 2 Rectangular Duct Construction...
System The Kingspan Straight Duct - Cutting METHOD 1 Cutting along the panel length ” or ” or ” or ” or ” or ” ” ” ” ” H + W + H + W + (7” R-6) or (9 ½“ R-8) •...
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System The Kingspan Straight Duct - Cutting METHOD 2 Cutting along the panel length ” or ” or ” or ” or ” or ” or ” ” ” ” ” ” 47 ¼ “ • ” R-6: The sum of 3 sides less than 42” (2H + W or 2W + H) •...
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System The Kingspan Straight Duct - Cutting METHOD 3 Cutting along the panel length ” or ” or ” or ” or ” or ” or ” ” ” ” ” ” 47 ¼ “ 47 ¼ “ • ” R-6: The sum of 2 sides less than 43 ¾“ (W + H) •...
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The Kingspan System Straight Duct - Cutting METHOD 4 Cutting along the panel length ” or ” or ” or ” or ” or ” or ” or ” or ” ” ” ” ” ” ” ” 47 ¼ ”...
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The Kingspan System Straight Duct - Cutting METHODS 5-8 Cutting along the panel width • ” R-6: Width or Height more than 45 ½ “ • 1 ” R-8: Width or Height more than 44 “ Panel length 154 ¾ “...
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System The Kingspan Panel joint Tiger Clips on external side Adhesive Tape • Bevelled edges of the two panels to be jointed • Adhesive on all bevel joints • Tiger clips at a maximum of 10” centres, along the external side •...
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The Kingspan System Multiple Duct Design Application: Alternative fabrication method for large ductwork with w and or h >1200mm. Likely to require less reinforcement than Methods 5-8. Circular/Rectangular holes min 8” Flange and foam Seal exposed foam in opening with UL Tape...
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System The Kingspan End Cap Option 1: Short Duct or Plenum Option 2: Long Duct > 40” Adhesive # 212 Cut End Cap at 45 degrees Cut End Cap at 45 Degrees. Assembly with Adhesive or Tiger Clips Apply sealant around...
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System The Kingspan Transition Concentric transition Eccentric transition θ max. 22.5°(D ≥ 2.5 x A) θ max. 22.5°(D ≥ 2.5 x A) Splitters are required for angles greater than 22.5° . Note: SMACNA recommended max. angles for diverging/converging transitions are...
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The Kingspan System Eccentric Transition Minimum Neck size: 100 mm Crease Outside Crease Inside Cover 2xTH 2xTH ” 12” 22” 12” 22” Crease Outside 4” Crease Lines Crease Inside Min 4” 18” 22” 18” • Dimensions in inches • D minimum = 2.5 x (18”-12”) = 2.5 x 6” = 15”...
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System The Kingspan Concentric Transition Minimum Neck size: 100 mm Crease Outside Crease Inside Crease Inside Crease Outside Cover 22” 12” Min 4” Crease Outside Crease Lines 3” Min 4” Crease Inside 18” • Dimensions in inches • D minimum = 2.5 x 3” = 7 ½ ”...
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System The Kingspan Double Offset Minimum Neck size: 4”...
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System The Kingspan Take-Off Straight Branch Angle Branch Boot Branch Boot Branch (Flanged Connection) (Un-flanged Connection) Boot Branch 6 ¾” # 512, # 519 Jack Plane 22.5º 4” 2 ½ “ 4” 2” Jack Plane 22.5º 45.0° 5 ¾ “...
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System The Kingspan Small Take-Off – Un-flanged Connection Duct side up to 24”, and Low Pressure up to 2 in.w.g. SUGGESTED TIGER CLIP PLACEMEMENT Opening No. Tiger w or h Clip per Side 4”-6” 7”-12” 13”-20” 21”-24”...
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System The Kingspan Large Take-Off – Flanged Connection Duct side larger than 24”, Pressure up to 4 in.w.g. Mechanical fix: • 75mm (3”) from corners • 300mm (12”) maximum intervals “F” Profile Take-off inside dim. – 6 mm Screws/rivets: minimum 2 per side, located at 300mm (12”) max spacing Suggested blind rivets with aluminum body: •...
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System The Kingspan Boot Branch with round fitting Silicone bead around exterior circumference Large round fitting – Flanged Connection Mechanical Fix required for diam. larger than 12” and/or Pressure > 2 in.w.g. Seal all around with Silicone Mechanical Fix for diam. larger than 12”...
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System The Kingspan Round Fitting for Round Diffusers and Flexible Ducts Mechanical Fix required for diam. larger than 12” and/or Pressure > 2 in.w.g. Round metal fitting with folding Round take off tabs spigot with spiral tube Silicone bead Seal exposed...
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System The Kingspan Grille / Register / Diffuser Installation with Aluminum Profile “U” Profile Clip Clip “U” Profile Grille / Grille / Diffuser Diffuser...
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System The Kingspan Square Elbow With Turning Vanes Turning Vanes required when either duct dimension greater than 8” (3 ½”) 1) The elbow top and bottom sides are cut in a 90° “L” shape 2) For the Turning Vane assembly, please follow (1 ¼”)
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System The Kingspan Symmetric Radius Elbow NECK Splitter 24” = W 1/3 W = 8” SR=16” ER=32” 8” = IR 1/3 W 4” Min = 8” 24” = W 8” = IR 4” Min SPLITTER for Short radius elbows Elbow side (inches) Splitters...
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System The Kingspan Asymmetric Radius Elbow NECK Splitter 18” = W2 ER=32” 1/3 W2 = 6” SR=16” 8” = IR 2” 6” 1/3 W1 4” Min = 8” 24” = W1 8” = IR 4” Min ER minus IR 1 minus...
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System The Kingspan Symmetric/Asymmetric Radius Elbow Ends of panels cut square (90° ) Inner strip exterior surface crimped ” panel: every 3”, or ” panel :every 4” (min. 8” radius) 45°taper edges toward air stream Ends of panels cut square (90° )
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System The Kingspan Elbow assembly with Tiger Clips – # 364 Can be used instead of the Adhesive for duct assembly Max TC Spacing 2” MAXIMUM TIGER CLIPS SPACING Pressure Duct Size (Elbow, Max Spacing Application Tee, etc.) 0 to 4 in.w.g.
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The Kingspan System Symmetric Elbow with Templates Use the Elbow Template with side required Asymmetric Elbow with Templates 1 - Use the Elbow Template with smaller 2 - Use the Elbow Template with bigger side side to trace the lines AB and BC...
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The Kingspan System Elbow, 45 Deg Throat, Radius Heel Alternative Elbow Design* Splitter SPLITTER Elbow side (inches) Splitters Position 0 – 20” 20” – 32” 32” – 64” W/4 W/2 Over 64” W/8 W/3 W/2 Splitter not required in angles less than 45° :...
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System The Kingspan Elbow, 45 Deg Throat, Radius Heel Alternative Elbow Design # 512, 519 Jack Plane 22.5 degrees Clamp Blades set ” less than Panel thickness Rule 2 ½” 2 ¾” ” ” Cut 1: Setup tool Neck size +2 ¾“...
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The Kingspan System Dynamic Branch – “Y” branch with radius elbow 20” NECK Min 4” ER = 32” 24” 1/3 = 8” 2xTH 8” = IR Min 4” 2” = 6” 16” 18” 8” = IR 6” Min 4” 3 minus •...
System The Kingspan Assembly Procedure • Place 1 on the table • Join section 2 and section 3 to 1 • Install section 4 • Install section 5 • Install section 6...
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System The Kingspan Dynamic Branch – Tee Branch (external sides flushed)
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The Kingspan System Dynamic Branch – Tee Branch (internal sides flushed)
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System The Kingspan Training Manual Chapter 3 Coupling Systems for joining ductwork sections...
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System The Kingspan 4-Bolt Flange – # 380-385 Assembly 1) Cut flange 20mm (¾ “) short of the duct 2) For any Duct size: Add Tiger Units, internal dimensions: one each side of each corner, i.e. h - 20 mm (h –...
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System The Kingspan 4-Bolt Flange – # 380-385 Assembly 6) 4-Bolt flange bonded to the duct. 7) Screws Use mallet to carefully apply the flange in its final position. Suggested screws: • Diameter 4mm ( ”) Tiger Unit 4-Bolt flange...
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System The Kingspan 4 Bolt Flange – # 380-385 Coupling Clip (not supplied by Kingspan) • Attach gasket to one flange face. Attach in G-Clamp (not supplied by Kingspan) one piece working around the corners. • The preferred gasket shall be # 242 polyurethane ”...
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System The Kingspan Aluminum Grip Flange System ” R-6 ” R-8 Grip Flange for Bayonet External Grip # 312 Internal Grip External U Grip U Grip Flange ” # 315 LKDA 311 Internal Grip for 1 ” h “Chair” Grip Flange...
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System The Kingspan Grip Flange System – ” (22mm), R-6 May be used with pressure up to 2 in.w.g. (or Tiger Clip when possible) Must be used with static pressure > 2 in.w.g. (or 4-Bolt flange) Bayonet Cleat # 321...
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System The Kingspan Grip Flange System – 1 ” (30 mm), R-8 May be used with pressure up to 2 in.w.g. (or Tiger Clip when possible). Must be used with static pressure > 2 in.w.g. (or 4-Bolt flange) Bayonet Cleat # 321...
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System The Kingspan Grip Flange Assembly Features: • Positive air-tight joint on panels of varying thickness (¾” to 1” and 1 ” to 1 ”) • No need of adhesive or rivets. • Strengthen the ends of the duct • Aerodynamic...
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System The Kingspan Duct-to-Duct Coupling Aluminum Grip with Bayonet Cleat Grip Flange Gasket # 242 (PU ” x ” ) One piece of self-adhesive gasket with overlap Note: Kool Clamp # 453 and WD-40 can assist with Bayonet application. Nylon Cap # 281 for visibly mounted...
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Aluminum tape is applied on both ends of the duct segments. STEP 2 Apply a continuous bead of Kingspan approved silicone to one end of one segment. STEP 3 The two duct segments are joined together. Tiger Clips (# 364)
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System The Kingspan Aluminum Flange Profiles for Connection To Duct System Components “F” STRUCTURAL FLANGE # 332 “F” GRIP FLANGE # 311 + 313 “h” GRIP FLANGE # 311 + 314 “h” STRUCTURAL FLANGE # 333 “U” STRUCTURAL FLANGE # 334 “U”...
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System The Kingspan Structural Aluminum Profiles (Alternative to Grip for 7/8” R-6 KoolDuct only) Structural U Profile # 334 Internal dim. – 1/8” Adhesive inside each profile EXAMPLE: STRUCTURAL FLANGE Aluminum Tape on corners Prior to insertion of the Structural flanges, the...
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System The Kingspan Connection To Duct System Components Gasket Gasket KoolDuct KoolDuct KoolDuct KoolDuct fitted with Fitted with fitted with Fitted with F Profile U Profile h Profile U Profile Rivet Rivet “S” slip when suitable Flanged Connection Spigotted Connection...
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Profile U Profile NOTE: The installation of fire dampers and their connection to ductwork fabricated from the Kingspan KoolDuct system should always be in accordance with the building regulations Rivets: minimum 2 per side, located at 300mm (12”) max spacing Suggested blind rivets with aluminum body: •...
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System The Kingspan Alternative Connection With Tiger Unit # 363 Low Pressure only ≤1 in.w.g. UL TAPE FIRST TIGER UNIT After connection : KoolDuct • Apply UL tape over Tiger Units • Seal with sealant DETAILED VIEW For VCD dimensions (w and h) ≤ 24”...
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System The Kingspan Connection of Inspection Doors Option 1: KoolDuct door Option 2: Pre fabricated door Connect safety restraints to access panels located in riser ducts. Seal the frame with Silicone Pre Fabricated Door KoolDuct Door...
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System The Kingspan Training Manual Chapter 4 Duct Reinforcement...
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For ductworks larger than those covered by the Schedule of duct reinforcement in this manual, the Multiple Duct method of construction can be used, in this case each one of the multiple smaller ductworks shall be reinforced independently. Alternatively, reinforcements shall be designed to suit the applications, please contact Kingspan Insulation for details...
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System The Kingspan Reinforcement System Always install reinforcement for both Positive and Negative Pressure Speed Clip Reinforcement Disc #353 (capped inlock washer) KoolDuct Panel Outer tube (Negative Pressure) Reinforcement Disc #353 = Internal duct dim. Inner tube (Positive Pressure) = External duct dim. + ½ “...
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System The Kingspan Reinforcement System Always install reinforcement for both Positive and Negative Pressure REINFORCING BARS SELECTION – POSITIVE PRESSURE Aluminum Tube Max Length 10 mm (3/8”) OD 2134 mm (84”) Threaded Rod Max Length 8 mm (5/16”) 2134 mm (84”) REINFORCING BARS SELECTION –...
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System The Kingspan Reinforcement Application Reinforcing Bars Add reinforcement for each duct segment, based on duct size and pressure. Both straight ductwork and fittings (e.g. elbows, transitions, etc.) shall be included in the reinforcement procedure. Flanged Joint when required Reinforcements...
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3@24" 79 - 80 47 1/4" 1 BAR CENTERED Over 2000 Consult with Kingspan NOTES 1@36" Reinforcing Bars shall be placed at a maximum of 36" centers, and Aluminium Grip: FIRST and LAST bar at MAX 18" FROM JOINT One Reinforcing Bar centered equal distance between joints 1 BAR CENTERED 1@24"...
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79 - 80 47 1/4" 1 BAR CENTERED 2 BARS CENTERED Over 2000 Consult with Kingspan NOTES 1@36" Reinforcing Bars shall be placed at a maximum of 36" centers, and 4-Bolt Flange: FIRST and LAST bar at MAX 36" FROM JOINT...
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System The Kingspan KoolDuct ” (R-6) - Schedule of Duct Reinforcement Tiger Clip Coupling Max Duct Pos Pressure Duct Dimension Static Pressure Positive and Negative segment only length 1/2 in.w.g. 1 in.w.g. 2 in.w.g. 3 in.w.g. 4 in.w.g. 4 - 8 154 3/4"...
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3@24" 79 - 80 47 1/4" 1 BAR CENTERED Over 2000 Consult with Kingspan NOTES 1@36" Reinforcing Bars shall be placed at a maximum of 36" centers, and Aluminium Grip: FIRST and LAST bar at MAX 18" FROM JOINT One Reinforcing Bar centered equal distance between joints 1 BAR CENTERED 1@24"...
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79 - 80 47 1/4" 1 BAR CENTERED 2 BARS CENTERED Over 2000 Consult with Kingspan NOTES 1@36" Reinforcing Bars shall be placed at a maximum of 36" centers, and 4-Bolt Flange: FIRST and LAST bar at MAX 36" FROM JOINT...
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System The Kingspan KoolDuct 1 " (R-8) - Schedule of Duct Reinforcement Tiger Clip Coupling Max Duct Pos Pressure Duct Dimension Static Pressure Positive and Negative segment only length 1/2 in.w.g. 1 in.w.g. 2 in.w.g. 3 in.w.g. 4 in.w.g. 4 - 8 154 3/4"...
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The Kingspan System Duct Reinforcement Examples Example A: ”, R-6 KoolDuct Ductwork section size: 40” (w) x 20” (h) Ductwork section length: 100” Pressure: 1 in.w.g. Reinforcements Reinforcements R-6 with 4-Bolt flange : R-6 with Grip flange and bayonet joint: Side 40”: 1@36”, bar max 36”...
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System The Kingspan Non-standard reinforcement Where the standard reinforcing bars cannot be installed: • top of a large square elbow • where a large branch takes off from a large duct • large end cap. Non-standard reinforcement options : •...
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System The Kingspan Training Manual Chapter 5 Hangers and Supports...
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See tables Weight of KoolDuct. Hangers and Supports – Components All components, such as volume control dampers, flexible ducts etc. should be fully and independently supported, with their weight neutralised by supports and not loading the KoolDuct system...
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System The Kingspan Horizontal Ductwork - Max Spacing Between Supports Ductwork Longer Maximum Spacing Between Supports Inside Dimension - w or h (inches) <47” 13 feet from 47” to 80” 6 feet >80” Special Analysis Required Note: Closer spacing may be required due to limitations of the building structure or to achieve the necessary duct rigidity Horizontal Ductwork –...
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The Kingspan Hangers and Supports – Hanging Duct Fittings The KoolDuct System is light weight, so duct support and hangers do not have to be as robust nor as numerous as with sheet metal ducts. It is the responsibility of the registered fabricator/installer to determine both spacing and placement of supports.
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At max 300mm (12”) spacing Option 1 KoolDuct Strut channel Tiger Supports at every corner of the duct Threaded bar Option 2 Note that the couplings of ductwork fabricated from the Kingspan KoolDuct system are NOT designed to take the vertical load of ductwork.
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System The Kingspan Hangers and Supports – Vertical Ductwork Brackets/supports should be installed to bases of vertically orientated ductwork when possible. WEIGHT OF KOOLDUCT The weight of the ductwork section shall always be independently determined by the Trained Fabricator / Installer, and the appropriate gauge of supports and hanger...
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System The Kingspan Hangers and Supports – Weight of KoolDuct ” R-6 7/8" R-6 KoolDuct Weight in [lbs per foot length] depending on width / height Duct connecting joint : 4 BOLT FLANGE Width (inch) 8" 12" 16" 20" 24"...
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System The Kingspan Hangers and Supports – Weight of KoolDuct 1 ” R-8 1 3/16" R-8 KoolDuct Weight in [lbs per foot length] depending on width / height Duct connecting joint : 4 BOLT FLANGE Width (inch) 8" 12" 16"...
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System The Kingspan Training Manual Chapter 6 Maintenance and External Ductwork...
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System The Kingspan Cleaning KoolDuct KoolDuct ductwork shall be cleaned in accordance to the Guide of Good Practice HVCA TR/19 or NADCA. Dry Cleaning and non-abrasive methods only : Dry Cleaning Method Energy Source Method of Removing Deposit Mechanical Rotary Brushing (A)
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A hole is also drilled into the ductwork to allow the insertion of the measuring probe. With ductwork fabricated from the KoolDuct system, a protective metal plate needs to be installed inside the ductwork using adhesive/sealant before the sensor / controller is fixed to the outside KoolDuct ductwork wall, so that the insulating panel is protected by the sandwich type of installation - mounting plate outside KoolDuct, metal plate inside KoolDuct.
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System The Kingspan Damage Repair Superficial damage can be repaired with UL tape only More substantial damage can be cut out and replaced. Silicone # 231G Add Tiger Clips #364 Aluminum Tape Aluminum Tape...
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The chosen finish shall be installed in accordance with the manufacturer’s instructions Note that all external couplings must be fully sealed. Painting Kingspan KoolDuct System can be painted for decorative purposes with paint that it is compatible with aluminum. Please bear in mind the project specification with regards to fire performance requirements of the duct when selecting the paint.
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System The Kingspan Training Manual Appendixes...
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The Kingspan KoolDuct System Kingspan Insulation, The Kingspan KoolDuct System - Fabrication Manual Kingspan Insulation, The Kingspan KoolDuct System - A Specifier’s Guide Kingspan Insulation, The Kingspan KoolDuct System – Technical Data Sheet Kingspan Insulation,Technical Note, Ductwork Commissioning And Testing HVAC Ductwork ASHRAE Handbook, HVAC Systems, Chapter 18 “Duct Construction”, 2008...
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