Wa0006.
Wa0006.
1.1 Introduction
The conductors and insulation of cables are protected from external agencies (mechanical
damage and chemical attack) either by an integral protective sheath enclosing the cable or
by a protective enclosure forming part of the wiring system into which the cable is drawn
or laid, for example, a pipe-work system (conduit) or trunking and a ductwork system.
Wiring enclosures are structures consisting of an area in which insulated electrical
conductors (cables) are contained. The main purpose of cable enclosures application are
to provide a mechanical protection of electrical cable, easy for rewiring or modification of
circuit, flexibility and tidy looking.
This chapter discusses and elaborates more about conduits, their types, sizes, advantages
and disadvantages, installation techniques and finally some learning outcome review
questions.
Figure 1.2 Light gauge conduit (plain ended with lug-grip fittings)
Figure 1.5 (a) flexible metallic conduit and (b) Flexible non-metallic conduit
Cutting Procedure
1. Secure the material to be cut in a vise or other holding devise to avoid vibration
whichmay snap the blade (see figure 1.15)
2. To make an accurate cut, use a triangular file to make a notch for guiding the first
strokes of the saw. (figure 1.16)
Figure 1.16 conduit marking out
3. Steady the saw by holding the handle with the right/left hand and the frame with
the left/right.
4. Hold the blade parallel to the work surface and cut on the push stroke, being
careful not to bear down too hard.
5. Draw the blade back using no pressure each time.
6. Saw at a rate not to exceed 40 to 50 strokes perminute.
Care Of Saws
1. Store blades in a dry place and apply a light coat of oil when not in use. This will
keep theblades from rusting.
2. Never use a metal cutting saw to cut through woods.
3. Do not force the saw if it binds. Use a wedge to spread the cut.
4. Replace damaged saw handles with new ones immediately when needed.
5. To keep saw teeth in top condition, touch up the teeth with a file occasionally.
6. Always loosen the blade tension on a hacksaw when not in use.
7. Always remove the nested saw blade from the handle for storage.
To use a pipe cutter, place the conduit in the vise as described above for cutting with a
hacksaw. Put the cutter over the conduit and adjust it until the cutting wheel makes
contact at the point of the cut (Figure 1.17)
Tighten the cutter just enough to score the pipe on the first turn. Then, screw the
handle in about one-fourth of a turn for each turn around the conduit until the cut is
complete. Cutting oil can be used to ease the cutting action. Rigid-steel conduit is cut
the same way.
Cutting PVC Conduits
PVC conduit is easily cut using a junior hack saw (figure 1.18) because pipe cutters
may flatten the end of the pipe. Pipe cutters also leave a ridge on the inside of the pipe
that is very hard to remove. Any roughness of cut and burrs should be removed with
the aid of knife blade or simply by wiping with a cloth.
Flexible metallic and nonmetallic conduit should also be cut with a hacksaw at a 90°
angle. Cutting any type of conduit leaves a sharp edge or burrs on the inside of it that
must be removed by reaming.
Reaming conduits
To ream rigid-steel conduit, use the reamer shown in Figure 1.19. A rat-tail file does a
good job on any type of conduit. Use pliers, such as needle-nose or side-cutting pliers,
to ream EMT that has been cut with a hacksaw.
The important thing is to remove any sharp edge or burrs inside the conduit that might
cut the insulation when the conductors are pulled into it.
Threading Conduit
Once rigid-steel conduit is cut, it must be threaded for use with threaded couplings,
locknuts, and bushings. The thread is cut using stocks and dies rotating them in the
clockwise direction while pushing against the end of the conduit.
The dies used for threading smaller sizes of conduit are usually hand-driven (Figure
1.20). The handle may be solidly attached to the die, or the die assembly may be a
ratchet-type.
Figure 1.20Stocks and dies
Threading Procedure
Before threading the conduit, inspect the dies to see that they are sharp and free from
nicks and wear. Next, insert the conduit into the vise, place the guide end of the pipe
threader on the conduit, and push the threading dies against the conduit with the heel
of your hand (Figure 1.21).
With pressure against the threader, take three or four short, clockwise strokes
downward to start the threads. Continue the threading with clockwise strokes, mixed
with a reverse stroke every now and then, until two or three threads extend beyond the
die. To reverse the threader, pull the ratchet lock out and turn it a half turn. The
reverse turns keep the threads and dies clean and free of bits of metal.
Figure 1.26 positioning of a conduit and try square in the bending machine
iii. Using a set square, line up the 70cm mark with the front edge of the bending
machine former making sure that the conduit is touching and parallel with the set
square.
iv. Bend the conduit to 90 degree by pulling the bender handle toward you. Use a
firm and steady motion to avoid kinks or crimps in the conduit.
Figure .1.28. Bending a conduit
Check to make sure your bend is the right angle (90 0) by either holding it up to the wall, door
frame, window frame, work bench or by using a set square. You can also hold it to a surface
you know is level to check it.
Figure 1.36 (a) three point saddle. (b) Four point saddle
Opposite
Sine= … … … … … … … … … … … … … … …(1.1)
hypotenuse
In this case:
30 30
Sine= Hypotenuse=
hypotenuse sine 22.5
Hypotenuse=78 mm
Figure 1.40 (a) to (d) illustrates the application of the formula.
Solid 1 16
or 1.5 22
Stranded 2.5 30
4 43
6 58
10 105
16 145
25 217
16 145
Note: The inner radius of a conduit bend should be not less than 2.5 times the outside
diameter of the conduit.
ii. Multiply the cable factor by the number of conductors, to give the sum of the cable
factors.
iii. Identify the appropriate part of the conduit factor table given by the length of run and
number of bends. (For straight runs of conduit less than 3m in length, the conduit
factors are given in Table 12C. For conduit runs in excess of 3 m or incorporating
bends, the conduit factors are given in Table 12D, see Table 1.3 of this chapter.)
iv. The correct size of conduit to accommodate the cables is that conduit which has a
factor equal to or greater than the sum of the cable factors.
Example 1.2.1
Six 2.5mm2PVC insulated cables are to be run in a conduit containing two bends between
boxes 10 m apart. Determine the minimum size of conduit to contain these cables.
Solution:
From Table 12C, shown in Table 1.2of this chapter:-
The factor for one 2.5mm2 cable = 30
The sum of the cable factors = 6 x 30 = 180
From Table 12D shown in Table 1.3:-
A 25 mm conduit, 10 m long andcontaining two bends, has a factor of 260.
A 20 mm conduit containingtwo bends only has a factor of 141 which is less than 180, the
sum ofthe cable factors, therefore, 25 mm conduit is the minimum size tocontain these cables.
Example 1.2.2
Ten 1.0mm2PVC insulated cables are to be drawn into a plastic conduitwhich is 6 m long
between boxes and contains one bend. A 4.0 mm PVCinsulated CPC is also included.
Determine the minimum size of conduit tocontain these conductors.
Solution:
From Table 12C, and shown in Table 1.4The factor for one 1.0 mm cable = 16
The factor for one 4.0 mm cable = 43
The sum of the cable factors = (10 x 16) + (1 x 43) = 203
From Table 12D shown in Table 4.6, a 20 mm conduit, 6 m long and containingone bend, has
a factor of 233. A 16 mm conduit containing onebend only has a factor of 143 which is less
than 203, the sum of thecable factors and, therefore, 20 mm conduit is the minimum size to
containthese cables.
Table 1.3 Conduit cable factors for runs incorporating bends.
Table 12D Cable factors for runs incorporating bends and long straight runs
Conduit diameter, mm
Length 16 20 25 32 16 20 25 32 16 20 25 32 16 20 25 32 16 20 25 32
Of
Run
(m) Straight One bend Two bends Three bends Four bends
1
Covered
1.5
by
2
2.5 Tables
3
A and B
3.5
4
4.5
5
6
7
8
9
10
Aditional factors:
For 38mmϕ use …………1.4 x (32mm factor)
For 58mmϕ use ………… 2.6 x (32mm factor)
For 63mmϕ use ………… 4.2 x (32mm factor)
Space factor
This is the ration (in percentage) of the sum of the overral cross-sectional area of all cables
(including insulation) to the internal cross-sectional area of the conduit where,
(csa of all cables)
Space factor = ×100 % … … … … … … … … ..(1.2)
(Internal csa of conduit )
The maximum permissible conduit space factor is 40%. In other words, the area of the cables
must not exceed 40% of the internal cross-sectional area of a conduit. The 60% empty-space
requirement is intended to enable the dissipation of the heat produced by the current-carrying
conductors grouped inside the conduit.
Apendix 12 of the IEE Regulations gives tables showing how to calculate the maxmum
number of cables allowed in certain size of conduit.
Table 12A and 12B of the IEE Regulations, refers to straight conduit length of 3m of less.
Table 12A and 12D refers to longer runs including bends and sets.
Table 1.4 Straight Conduit cable factors.
Table 12A straight conduit length of 3m or less
Type of conductor Conductor Cross-sectional Factor
2
area (mm )
Solid 1 22
1.5 27
2.5 39
Stranded 1.5 31
2.5 43
4 58
6 88
10 149
Table 12B
Conduit diameter (mm) Cable factor
16 290
20 460
25 800
32 1400
Example;
Calculate a suitable conduit size which can be used to accommodate the following cables;
4 x 1.5 mm2 solid cables
4 x 1.5mm2 stranded cables
2 x 2.5mm2 stranded cables
Solution:
i. Find the cable factors and multiply by the number of cables:
Installing Conductors
Nearly all types of wire may be used in conduit installation; however, the most common type
used is moisture-resistant thermoplastic. To determine the length of wire to be installed, add
the length of conduit and the length of wire to be left in the boxes for connections (usually 10
to 15cm for each outgoing wire). If the conductors are to be connected into the breaker panel
add conductor lengths, in cm, equal to the length and width of the breaker panel.
The general procedure for installing conductors in conduit is the same for all types of conduit.
Conductors are installed by pulling them through the conduit. The pulling is done with a
special tool called a fish tape (Figure1.46).A fish tape is a thin, flexible metal tape with a
hook on one end. The tape is usually packaged on some type of reel. The tape is used to pull
wires through conduit or through openings in walls. For conduit use, the tape is inserted in
one conduit opening and worked through to the next opening. The wires to be drawn through
the conduit are bent around the hook on the fish tape.
Figure 1.46 Fish wires
All conduit installations must be erected first beforeany wiring is installed (IEE
Regulation 522–080–02).
CHAPTER 2
2.0 CABLE TRUNKING
2.1Introduction
A trunk is a rectangular section enclosure usually made of plastic, polyvinyl chloride (PVC.)
or metal sheet having one removable side.Where large number of cables follow the same
route or where cable sizes are large a trunking system will be used instead of a very large
conduit or multiple run of smaller conduits. It is available in two ranges, ordinary wiring
trunking and bus-bar trunking. The ordinary system is further available in either metal or
PVC. Trunking is usually supplied in length of 3 to 4 metres but longer length is available.
A cable tray is also a cable carrier that is used at some situations such ascommercial and
industrial constructione.g when making power distributions at a power room etc. In this
chapter we shall therefore discuss both trunking and tray systems of cable carriage.
2.2.0 Erecting PVC trunking
The main areas in which PVC trunking is used are domestic and office premises. All
necessary fitting are available to complete any shape of run with little difficulty. The
accessories are usually secured to the lengths of Trunking with a PVC solvent adhesive or
screwing.PVC. Trunking is available in categories that are mini-trunking (mainly for use in
domestic or small and special installation), Multi-compartment trunking and skirting
trunking.
PVC mini- Trunking
This isvery smallPVCtrunking,ideal for surface wiring in commercial installations such as
offices for carrying small cables such as computer cables,internal telephone cables etc.The
trunking can also be used in domestic when it seems to be convenient.The trunking is
screwed directly to a wall and there are various trunking sizes up toa minimum size of 16mm
by 10mm denoted as16x10mm.
When a trunking needs to pass through a corner,say,90 ° a smart cutting design should be
made.
Preparation and installation procedures
The preparationprocess involves the following stages:
a. Identify the required size of the mini-trunking piece(s)
b. Anticipate the number and nature of corners each trunking should pass
c. Gether useful tools,equipments and materials required in the whole process
d. Indicate markings on the trunking for bending or cutting purposes.Be very precise to
avoid undesirable material destruction
e. Cut or bend the trunking in the required shapes and corners e.g. 90° angle of bend etc
f. Collect the processed trunking pieces for fitting or installing on wall or
board.However,you must have drilled the board or wall before installlation starts.
Useful tools,equipments and materials as from starting to the ending of the task are try
square,pen or pencil,hacksaw,work bench,drilling machine,set of screw
drivers,fischers and screws
Fig.2.1
Multi-Compartment Trunking
Where an installation comprises a mixture of low-voltage and very low voltage circuits such
as mains lighting and power, fire alarm and telecommunication circuits, they must be
separated or segregated to preventelectrical contact (IEE Regulation 528.1). For the purpose
of these regulations various circuits are identified by one of two bands as follows:
Band one cables which are for telephone, radio, bell, call and intruder alarm circuits,
emergency circuits for fire alarm and emergency lighting.
Band two cables which are for mains voltage circuits.
Preparation and installation procedures
The preparationprocess involves the following stages:
a. Identify the required size of the multi compartment trunking piece(s).Be concious of
the cable bands you have
b. Anticipate the number and nature of corners each trunking should pass
c. Gether useful tools,equipments and materials required in the whole process
d. Indicate markings on the trunking for bending or cutting purposes.Be very precise to
avoid undesirable material destruction
e. Cut or bend the trunking in the required shapes and corners e.g. 90° angle of bend etc
f. Collect the processed trunking pieces for fitting or installing on wall or
board.However,you must have drilled the board or wall before installlation starts.
Useful tools,equipments and materials as from starting to the ending of the task are try
square,pen or pencil,hacksaw,work bench,drilling machine,set of screw
drivers,fischers and screws
Fig.2.2
Skirting Trunking
This is widely used in offices where a lot of socket outlets are required. The trunking is run
around the bottom of the wall and socket outlets accessories can be placed at various intervals
along the trunking.
Preparation and installation procedures
The preparationprocess involves the following stages:
a. Identify the required size of the multi compartment trunking piece(s).Be concious of
the socket outlets to incorporate
b. Anticipate the number and nature of corners each trunking should pass
c. Gether useful tools,equipments and materials required in the whole process
d. Indicate markings on the trunking for bending or cutting purposes.Be very precise to
avoid undesirable material destruction
e. Cut or bend the trunking in the required shapes and corners e.g. 90° angle of bend etc
f. Collect the processed trunking pieces for fitting or installing on wall or
board.However,you must have drilled the board or wall before installlation starts.
Useful tools,equipments and materials as from starting to the ending of the task are try
square,pen or pencil,hacksaw,work bench,drilling machine,set of screw
drivers,switched-sockets,fischers and screws.Cable laying and termination should
automatically be the last stape in the task.
Fig.2.3
Busbar Trunking
This system of trunking has solid conductors of Copper or Aluminium fixed inside it.This
type of trunking is basically devided into two types namely :
i.Rising mains busbar trunking and
ii.Overhead or Tap-On basbar trunking
The rising mains busbar trunking
The rising mains busbar trunking is normally for supplying mains to each floor of a multi
storey building and is usually mounted vertically as shown in figure 2.5.
.
Figure 2.6 A typical Overhead busbar trunking.
Preparation and installation procedures
The preparationprocess involves the following stages:
e. Identify the required size of the basbar piece(s).
f. Anticipate the number and nature of tap-on points required
g. Gether useful tools,equipments and materials required in the whole process
h. Indicate markings on the basbar for any required process.Be very precise to avoid
undesirable material destruction
i. Collect the processed basbar pieces for fitting or installing with the trusses support etc
Useful tools,equipments and materials as from starting to the ending of the task are try
square,pen or pencil,hacksaw,tray,set of spanners,screw drivers,bolts and nuts,
supporting brackets and screws.Cable laying and termination should automatically be
the last stape in the task.
Trunking Fittings
These are trunking joinery parts available in various shapes and sizes.The fittings are for
making conduit corners, lengthening conduits, providing multi outlets etc.Typical trunking
fittings are tee piece, four way box, bend etc.Both PVC and metallic conduit fittings are
available and are normally not mixed of their category in their application.This means that
PVC fittings should be used for PVC trunking and metallic fittings for metallic trunking
only.Some of these fittings are straight piece,flat bend piece,flat tee piece,flat four way
piece,reducer piece,straight couple piece,etc. as shown inFigure 2.7
Cable ladder
This is another cable carrier channel. Cable ladders are manufactured for
installation of power cable in the heavy cable distributions at power stations, and
main power system of buildings,as shown in figure 2.8. This type of ladder is
produced in 2.5 metres of length. The ladders are in most cases made of stainless
steel, steel or galvanized steel. They are found in white, grey or orange in colour.
Ladder fittings available are flat bend piece, straightpiece, flat tee piece, flat four
way piece, reducerpiece, straight couple piece, etc.
Figure 2.8 Cabble ladder
Mathematically , s . f =
∑ of cross−sectional areaof cables ×100 % …. (2.1)
Internal cross−sectional area of trunking
Practically we are asked to lay cables that should not cover more than 45% of the conduit
cross-sectional area.Normally cable manufacturers give diameter and even cross-sectional
area of cables (including insulation).The cross-sectional area of a single cable can therefore
be multiplied by a number of conductors to obtain the area of the trunking to be occupied
which should not be more than 45% of the entire trunking space.IEEE has given specific
tables to compute for suitable trunking size with given cable size.Table 12E and 12F are
used for this purpose.
Example 1
A trunking is required to carry the following:
40 conductors of 2.5 sq.mm solid core cables
10 conductors of 4.0 sq.mm single core cables and
5 conductors of 6.0 sq.mm single core cables.Calculate a suitable trunking size.
Solution
Using cable factors from table 12E we obtain total cable factor being:
(40x10.2) +(10x15.2) +(5x22.9) ¿408+152+114.5¿674.5
From table 12F the smallest trunking with a factor exceeding or equal to 674.5 is75mm by
25mm and its factor being 738.
Example 2
A trunking is required to carry the following cables:
80 conductors of 2.5 sq.mm solid core cables
20 conductors of 4.0 sq.mm single core cables
20 conductors of 6.0 sq.mm single core cables
Calculate the smallest trunking size allowed.
Solution
Using cable factors from table 12E we obtain total cable factor being:
(80x10.2) +(20x15.2) +(20x22.9) ¿816+304+458¿1578
From table 12F the trunking with a factor equal to or exceeding 1578 is 100mm by 50mm
which has a factor of 2091.
There are many advantages of using a trunking instead of using multiple conduits. Some of
the advantages being:
i. trunking is lighter
ii. It is cheaper
iii. It is quicker and easier to install
iv. It is easier to add more cables or to add more trunking to the system
v. Installing the wires is easier as the wires are laid instead of being drawn in
vi. Multi-compartment trunking is available to operate services e.g. to install
telephone cables and fire alarm cables in the same trunking.
Trunking can be for both indoors and outdoors, ranging from domestic, commercial and
industrial purpose. Many applications includes decorative skirting in homes, lighting
fixtures in restaurants and departments store.
Cable trays
Cable tray is a sheet-steel channel with multiple holes.The most common finish is hot-dipped
galvanized but PVC-coated tray is also available.In the industrial or commercial installations,
a cable tray system is used to support insulated electric cables used for power distribution and
communication. Cable trays are used as an alternative to open wiring or electrical conduit
systems, and are commonly used for cable management in commercial and industrial
construction. See figure 2.9.
Figure 2.9 typical cable tray.
They are especially useful in situations where changes to a wiring system are anticipated,
since new cables can be installed by laying them in the tray, instead of pulling them through a
pipe. Cables laid on tray must be secured with cable ties through the tray holes.
Cable tray fittings available are straight piece, flat bend,flat tee, flat four way, reducer piece,
straight coupler,angle coupler tray, etc
CHAPTER 3
3.0 DUCTING WIRING SYSTEM
3.1 INTRODUCTION
Cables need to be protected especially when they are run in non-protective area where cables
need to be secured. Cable enclosures are necessarily to be learnt because it develops and
underpins the security awareness when dealing with cables. Ducts are among the cable
enclosures which protects cables from being damaged. Cables are damaged mostly from
different pressures. When weather changes to an extreme then is easy to damage cables.
During the winter when earth’s surface area is fully of fell down ice may cause cables to
absorb wet which ultimately causes the cable cores insulation to puncture ( short
circuit).Likewise when extreme heat is generated within the cable itself or by another
source ,causes the insulation as well to puncture(short circuit between cores).Therefore
protection by means of electrical enclosures against mechanical pressure must be avoided for
use and shelf life
3.3 Ducts Standard sizes for Electrical, Telephone and communication system
3.3.1Space factor
This is a ratio (%) of the sum of the overall cross sectional area of cables (including
insulation) to the internal cross-sectional area of ducts and must not exceed 35%.1.2
GENERAL
The following outside diameters are for reference only and will vary depending on cable
manufacturer.
D=√4Ca/ π k ………………………………………………………………...
(3.2)
Examples
1. Calculate the minimum size of duct, if two cores of 35mm 2
cable are required to be installed and the fill factor 40%
Solution:
D=√4Ca/ π k
=√4 x 2 x 35/ π x 0.4
=√280/ π x 0.4
=222.9299mm
2. When the required size for duct is 350mm, and the fill factor
is 35%, what is the total area of cables? Give the standard
number of cores equivalent to the area.
Solution:
Ca= π k D2/4
=3.14 x 0.35 x 3502/4
=33,656.875mm
One natural threat is the weather and some culminates. In some continents including Europe,
have the wettest winter up 6mm of winter rainfall fall and in Asia and Africa face extreme
hot temperatures. Water, high temperature and electricity do not mix – flood and other
weather conditions damages substations, due to ineffective cable sealing, can result in power
outages and cause serious disruption to consumers, businesses and industry. Although we
cannot control the weather, we can contain the flood.
Cable duct seals are simple, fast and safe to install providing an effective cable seal against
water ingress (2.5 bar pressure), gas migration and fire spread (4 hour rating) into electrical
substations in the water utility industry.
Cable duct seals provide assured long term protection of water utility assets with a 50 year
accelerated age test – effectively sealing substation cables against flood water dangers.
Furthermore, the cable seal resists gases including methane, hydrogen sulphide (H2S) and
chlorine. The Cable duct seals can effectively seal single or multiple cables entering vertical
or horizontal cable ducts. Thereare duct seals which replace polyurethane expanding foam for
compliance with regulations and the requirement for gas tight seals – expanding foam should
not be used for critical applications where duct sealing is required to prevent the ingress of
harmful or flammable gases, liquids or smoke.See figure (3.1)
Figure 3.1 Cable duct sealing
General Requirements
S1.0
Because of the use of adhesives, gaskets, tape systems, or combination of these to close
openings are important in the surface of the ductwork and field-erected plenums and casings
through which air leakage would occur or the use of continuous welds.
S1.1
The prudent selection and application of sealing methods by fabricators and installers,
giving due consideration to the designated pressure class, pressure mode (positive or
negative), chemical compatibility of the closure system, potential movement of mating parts,
workmanship, amount and type of handling, cleanliness of surfaces, product shelf life, curing
time, and manufacturer-identified exposure limitations.
S1.2
That where distinctions are made between seams and joints, a seam is defined as joining of
two longitudinally (in the direction of airflow) oriented edges of 1.8 duct surface materials
occurring between two joints. Helical (spiral) lock seams are exempt from sealant
requirements. All other duct wall connections are deemed to be joints. Joints include but are
not limited to girth joints, branch and sub-branch intersections, so-called duct collar tap-ins,
fitting subsections, louver and air terminal connections to ducts, access door and access panel
frames and jambs, and duct, plenum, and casing abutments to building structures
S1.3
The sealing requirements do not contain provisions to:
a. resist chemical attack;
b. be dielectrically isolated;
c. be waterproof, weatherproof, or ultraviolet ray resistant;
d. withstand temperatures higher than 120°F (48°C) or lower than 40°F (4.4°C);
e. contain atomic radiation or serve in other safety-related construction;
f. be electrically grounded;
g. maintain leakage integrity at pressures in excess of their duct classification;
h. be underground below the water table;
i. be submerged in liquid;
j. withstand continuous vibration visible to the naked eye;
k. be totally leak-free within an encapsulating vapour barrier; and
l. create closure in portions of the building structure used as ducts, such as ceiling
plenums, shafts, or pressurized compartments;
m. the requirements to seal apply to both positive and negative pressure modes of
operation
n. Externally insulated ducts located outside of buildings shall be sealed before being
insulated, as though they were inside. If air leak sites in ducts located outside of
buildings are exposed to weather, they shall receive exterior duct sealant.
Ducts must be sufficiently airtight to ensure economical and quiet performance of the system.
It must be recognized that airtightness in ducts cannot, and need not, be absolute (as it must
be in a electrical piping system). Codes normally require that ducts be reasonably airtight.
Concerns for energy conservation, humidity control, space temperature control, room air
movement, ventilation, maintenance, etc., necessitate regulating leakage by prescriptive
measures in construction standards. Leakage is largely a function of static pressure and the
amount of leakage in a system is significantly related to system size. Adequate airtightness
can normally be ensured by a) selecting a static pressure, construction class suitable for the
operating condition, and b) sealing the ductwork properly.
Some sealants can adversely affect the release function of breakaway connections to fire
dampers; consult the damper manufacturer for installation restrictions.
3.7.1 Leakage
Apparent differences of about ten percent between fan delivery and sum of airflow
measurements at terminals do not necessarily mean poor sealing and excess leakage.
Potential accuracy of flow measurements should be evaluated.
Otherwise, open access doors, unmade connections, missing end caps, or other oversights
contribute to such discrepancies. When air terminals are at great distances from fans (over
500 feet (152m)), more effective sealing is probably required to avoid diminished system
performance.
Schools, shopping centers, airports, and other buildings may use exposed ductwork. Selecting
sealing systems for such ducts may involve more attention to the final appearance of the duct
system than with ducts in concealed spaces.
Certain types of paint may form reliable seals, particularly for small cracks and holes. Further
research and confirmation is needed in this area.
Systems must control connector length and notch depth on rectangular duct ends to facilitate
sealing. Failure to do so will compromise seal effectiveness. Round duct joints are normally
easier to seal than other types. However, with proper attention to joint selection,
workmanship, and sealant application, almost any joint can achieve low leakage. The mere
presence of sealant at a connection, however, does not ensure low leakage. Applying sealant
in a spiral lock-seam can result in poor seam closure and less satisfactory control. No single
sealant is the best for all applications. Selecting the most appropriate sealant depends
primarily on the basic joint design and on application conditions such as joint position,
clearances, direction of air pressure in service, etc.
3.7.2 Liquids
Many manufacturers produce liquid sealants specifically for ducts. They have the consistency
of heavy syrup and can be applied either by brush or with a cartridge gun or powered pump.
Liquid sealants normally contain 30 to 60 percent volatile solvents; therefore, they shrink
considerably when drying. They are recommended for slip-type joints where the sealant fills
a small space between the overlapping pieces of metal. Where metal clearances exceed 1/16
inch (1.6 mm), several applications may be necessary to fill the voids caused by shrinkage or
runout of the sealant. These sealants are normally brushed on to round slip joints and pumped
into rectangular slip joints. See figure 3.5
3.7.3 Mastics
Heavy mastic sealants are more suitable as fillets, in grooves, or between flanges. Mastics
must have excellent adhesion and elasticity. Although not marketed specifically for
ductwork, high quality curtain wall sealants have been used for this application. Oil-base
caulking and glazing compounds should not be used.
3.7.4 Gaskets
Durable materials such as soft elastomer butyl or extruded forms of sealants should be used
in flanged joints. For ease of application, gaskets should have adhesive backing or otherwise
be tacky enough to adhere to the metal during joint assembly. The choice of open cell or
closed cell rubber gaskets depends on the amount and frequency of compression and on the
elastic memory.
3.7.5 Tapes
Nothing in this standard is intended to unconditionally prohibit the use of pressure sensitive
tapes. The shelf life of tapes may be difficult to identify. It may be only six months or one
year. Although initial adhesion may appear satisfactory, the aging characteristics of these
tapes in service are questionable. They tend to lose adhesion progressively at edges or from
exposures to air pressure, flexure, the drying effects at the holes or cracks being sealed, etc.
The tape’s adhesive may be chemically incompatible with the substrate, as is apparently the
case with certain non-metal flexible ducts. Application over uncured sealant may have
failures related to the release of volatile solvents. Sea air may have different effects on
rubber, acrylic and silicone-based adhesives.
Tapes of a gum-like consistency with one or two removable waxed liners have become
popular for some applications. They are generally known as the peel and seal variety and
have been used between flanges and on the exterior of ducts. Such tapes are typically of
thicknesses several times that of tapes traditionally known as the pressure sensitive type.
Some may have mesh reinforcement. Others may have metal or non-metal backing on one
surface.
3.7.6 Heat Applied Materials
Hot melt and thermally activated sealants are less widely known but are used for ductwork.
The hot melt type is normally a shop application. Thermally activated types use heat to either
shrink-fit closures or to expand compounds within joint systems.
3.8 InstallationProcedures
1. Pull the product pipe off of the reel, cut it to theproper length, square it off and then de-
burr theend of the pipe. If you are using SecondaryContained(SC) piping, cut back the scuff
guard layerto the sump wall (approximately 22.86cm in dispensersumps - tank sump
dimensions may vary) andcut back the SC layer 11.43cm.
2. Install the ducted-style pipe entry boots in thesump wall per the ducted entry boot or the
ductedbulkhead boot installation instructions depending.
Figure 3.6: Ducted Entry Boot Connection
3. Pull the ducting and cut it to the proper length, butdon’t attach it to any entry boots at this
time.
Note: If you’re working with two pieces of ducting that need to beconnected, use the
deducted entry boot (Figure 2). Use the F connector by placing it between the two pieces of
ducting and
then tightening the band clamps down into the ducting.
Caution: Do not over-tighten the band clamps.
4. Make sure your ducting has been squared off andall burrs have been removed. Insert duct
bushing(Figure 3) inside the ducting (Figure 4).
Figure 3.8: Duct Bushing
The ducting system allows primary or secondarily contained pipe to be easily retracted and
then reinstalled. This ducting acts as a conduit for the pipe to run through and should not be
used as an additional containment layer. The ducting can be air tested to check system
integrity and fire protection association codes should be adhered to prevent from severe
injury, death, and serious property damage or any environmental contamination.
. All components of this systemshould be installed according to the manufacturer’s
specifications so that the system’s integrity isnot compromised. Test the complete system
after installation accordingly. Failure to properly verify operation could lead toenvironmental
contamination.
5. Insert the duct seal (Figure 3.8) into the first valleybehind the bushing (Figure 3.9).
Figure 3.10: F Connector
CHAPTER QUESTIONS
1. What is ducting system?
2. What do you understand by the following terms in relation to cable ducts :
a. Tapes
b. Shelf life of sealant
c. Gasket
d. Liquid
e. Leakage
3. List down at least ten (10) sealing requirements in relation to construction and installation
standards.
4. Find the minimum size of duct, if four (4) core of armoured cable each having diameter of
32.0mm and a fill factor of 35% are provided?
5. What are the performance requirements for all ducts?
6. List down the standard size of armoured cable as from 1mm2 up to 185mm2.
7……… is the space factor for duct.