The fabrication and installation of double-sided aluminum foil composite ducts involve several key steps that ensure the structural integrity, efficiency, and durability of the system. These steps are carefully planned and executed to meet industry standards and optimize material usage. Here's a detailed breakdown:
1. **Layout and Marking**
Before cutting begins, precise layout and marking are essential. The design is reviewed based on the dimensions of the sheet metal, and the layout is optimized to minimize waste and reduce the number of seams. Attention is given to aligning the patterns correctly, ensuring that the final product meets both functional and aesthetic requirements.
2. **Cutting and Forming**
For rectangular ducts, the four sides can be formed from a single sheet by making three 90-degree cuts and two 45-degree cuts. Alternatively, the duct can be constructed using two or more sheets, with edges trimmed and joined together. This method allows for greater flexibility in shaping complex duct configurations while maintaining dimensional accuracy.
3. **Joint Sealing and Taping**
Once the duct sections are assembled, the outer joints at the 45-degree corners are sealed using aluminum foil tape. Each side of the joint should be covered with at least 20 mm of tape to ensure airtightness. After sealing, the duct is checked using a square and a steel tape measure to verify verticality and diagonal alignment. The assembled sections are then placed vertically and allowed to cure until fully bonded.
4. **Flange Bonding and Final Assembly**
After the duct is shaped, flanges are bonded to both ends. The flatness and diagonal deviation of the flange faces are inspected to ensure they meet the required specifications. Once the duct is fully assembled, the inner corners of the duct and the flange joints are sealed with a high-quality sealant. This prevents exposure of the foam insulation and adhesive, enhancing the duct’s thermal performance and longevity. Before applying the sealant, all surfaces must be clean, free of grease, moisture, dust, and debris.
5. **Duct Reinforcement**
Reinforcement is critical for maintaining the shape and strength of the duct, especially in larger or longer sections. The number of reinforcement points and the spacing between them are determined based on standard guidelines, such as those outlined in Table 3.6.1. The flange joints themselves can act as natural reinforcement points, providing additional structural support where needed.
By following these detailed procedures, the installation of double-sided aluminum foil composite ducts ensures a high-quality, efficient, and long-lasting HVAC system. Each step contributes to the overall performance and reliability of the ductwork, making it an essential part of modern building construction.
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