Installation Considerations

Mating Duct Flanges

Mating duct flanges affect expansion joint design. Senior Flexonics Pathway Frame Systems SR2700, SR2800 and SR2900 are designed to completely eliminate mating flanges on the duct work. Other frame systems are designed to be welded to existing flanges, thereby decreasing installation time and corrosion problems associated with bolted designs. The design of duct flanges should be coordinated with the expansion joint manufacturer.

Installation Misalignment

Duct systems, which require fabric expansion joints, are often extremely large and therefore subject to substantial dimensional errors. It is possible that misalignment could exceed the expected thermal movement. A convenient solution to this problem is to design the expansion joint frame to absorb the duct misalignment. Note that the flexible element is installed in its neutral position, and retains full movement capability. Field drilled holes are the best way to assure proper fit up.

Adjacent Ducting Equipment

The expansion joint flange and liner designs can be affected by location of adjacent equipment such as fans, dampers, etc. Expansion joints must be designed so that they do not interfere with the operation of adjacent equipment during maximum movement conditions.

Painting & Finishing

A fabric expansion joint assembly, complete with attachment flanges, may require final painting after installation. The metal components, therefore, should be prime coated only by the manufacturer for protection during shipment, storage, and erection.

Expansion Joint Assembly

Senior Flexonics Pathway normally recommends the purchase of complete assemblies, ready for final assembly into the duct. The fabric element is attached to its flanges at the factory and its fit and assembly is the total responsibility of the expansion joint manufacturer.

Large expansion joints, requiring shipment in sections, must be factory pre-assembled, matched-marked, and packaged for easy assembly after storage. Complete instructions are included with each expansion joint and experienced filed service supervisors or installation crews are available if desired.

On-Site Installation Service

Senior Flexonics Pathway can provide on-site installation service, mobilize, and be at your job site within 24 hours. Using our trained factory personnel, we can assist you with installation supervision or complete the turnkey installation.

Senior Flexonics Pathway performs work in both union and non-union facilities.

• Installation Service
• Field Supervision
• Ducting System Inspection
• Field Training
• Plant Surveys

Splicing and Repairability

Pathway Flexon and Ultrachem materials can be easily spliced in the field during expansion joint installation. These materials are easily repaired in the event of damage after installation. The "Thermowelding" characteristics of these materials provide splicing and repair material strength equal to or greater than the basic material strength.

Flexspan Heat Seal Iron

Lightweight and portable for use at any plant location. Available for rent or purchase. May be operated easily by plant personnel.

Required Materials

Heat seal film is required and placed between the ends of the joint to be spliced. No chemical prep of the belt or mechanical abrasion is required prior to splicing.

Splice Verification

Sample material and splicing film is supplied to allow verification of iron operation at the joint location in your plant to assure leak proof splices.

Splicing Your Expansion Joint Belt

Joints may be spliced in the vertical or horizontal positions. The temperatures of the heat seal iron is electonically controlled and heat loss is minimized with the use of an insulated back up board.

Easy to Work With

No special tools or skills are required to perform the splice. The Installation Manual completely details the procedure.

The Completed Splice

In minutes the splice is completed. Compared to hours spent vulcanizing rubber expansion joint materials, not to mention the cost on the required factory technician, our products offers a practical and economic solution.

Permanently Repairable

Unlike fluoroelastomer materials, Ultrachem and Flexon expansion joint systems are repairable over the life of the product. Repairable not just with a mechanical patch but repairable without degrading the tensile strength of the joint. This contrasts with the inability to effectively revulcanize fluoroelastomer products after installation because of the "aging" inherent with fluoroelastomer and other rubber products.

Mechanical Damage

This expansion joint at a fossil fired plant was mechanically damaged accidentally. Normally the joint would have to be replaced at the next outage or shutdown depending on the extent of damage.

Tear Propagation

Ultrachem materials have greater tensile strength and will not continue to propagate holes or tears like rubber materials. This benefit allows you to run longer without the damage getting worse or generating catastrophic failure of the joint.

Heat Seal Repair

Using the procedures above, the joint may be repaired and will retain original tensile strengths. No special preparation is necessary. This repair can be easily made by plant personnel.

Field Repairability

The ability to repair your expansion joint materials with plant personnel gives the plant more independence to solve its own problems. Expansion joint replacement and repairs can now be performed in a fraction of the time and expense normally allocated for fluoroelastomer repairs.