Installer: please read all the instructions and familiarize yourself with the materials before starting the bonding procedure. Your shipment will include a bond kit with the following materials included.
A package of the Material Safety Data Sheets is enclosed. Familiarize yourself with the material you are handling and if necessary notify all safety people.
The following wet material is included: Resin, Thixotropic Resin Putty, and Catalyst.
The following dry material is included: Surfacing Veil (Fiberglass, Nexus or Halar depending on the specifications), Fiberglass Mat, Brushes and Roller.
The installer will need to supply the following to complete installation: acetone for clean up, saber saw with fine tooth blade, grinder with 24 grit replacement pad, safety glasses. Protective clothing, dust mask and paper to protect the floor.
1.Use a tape measure to mark off the length of the duct to be cut. Take a flexible flat strip of material and wrap around the duct surface and align the ends of the strip. Then draw a line completely around the duct.
2. tooth bimetal blade or a circular saw with an abrasive blade. Cut the duct on the mark being careful to make a straight cut. Align the duct ends to check for fit. Make sure there is no more than a 1/8" gap between ends. Using a grinder with a 24 grit replacement sanding pad, smooth out any rough edges.
3.Using a grinder, with 24 grit replacement sanding pads, sand the ends of the outside surface of the duct back 4" each to remove any paint of get coat. Use a cloth to remove any loose dust from the bonding surface.
4.The resin provided is promoted to cure at 70°F. Different temperatures and humidity can effect cure time. Test the resin at 3% catalyst and make adjustments to 2% or 4% to compensate for different conditions.
spread the putty over the gap to fill the seam. Be careful to provide as smooth a surface as possible on the inside and outside of the duct. If necessary, wipe excess putty from the inside of the duct with a clean rag.
5.Coat all exposed fibers on the end of the cut surface with catalyzed resin.
7.While waiting for the putty to cure, cut the surfacing veil to overlap the circumference by at least 2". Cut the fiberglass mat to width and length as shown in Figure 1. Make sure you have all material cut and ready before starting the bonding process.
6.Align duct ends and secure to prevent movement during bonding. Add 3%, by volume of catalyst to resin putty. Mix only as much putty as can be used within a 15 minute period. Using a putty knife,
8.Mix 3% catalyst by volume to resin. Make sure to only mix as much resin as can be used within 15 minutes
9.First, using a brush, wet out the duct joint surface and apply the surfacing veil. Work out all air bubbles in veil with either the brush of roller.
10.Next, using a clean dry surface, lay the first layer fiberglass mat and work in resin with brush. Carefully pick up the piece and wrap around the duct surface. On larger diameters you may want to do this in sections.
11.Roll out all air bubbles and make sure all fibers are completely saturated with the resin. Lay up subsequent layers per the diameter as shown in Table 1. The joint should be at least as thick as the duct or fittings being joined.
TABLE 1 STANDARD LAMINATE COMPOSITION TYPE 1
Nominal
Thickness
Sequences of Plies
in.
[Notes (1) (2)]
1
2
3
4
5
6
7
8
9
0.125
V
M
M
M
.....
.....
.....
.....
.....
0.18
V
M
M
M
M
.....
.....
.....
.....
0.23
V
M
M
M
M
M
.....
.....
.....
0.27
V
M
M
M
M
M
M
.....
.....
0.31
V
M
M
M
M
M
M
M
.....
0.35
V
M
M
M
M
M
M
M
M
NOTES: (1) Nominal Thickness is calculated as follows:
V= 10 mil surface mat(veil) - 0.010 in/ply
M- 1½ oz/sq. ft. mat - 0.043 in./ply
(2)This information is based on historical data and may not reflect all laminates made today. Laminates made today are often thinner and have a higher glass contentt than noted in the Table. The Table should be used for establishing minimum glass plies per nominal laminate thickness. Ply thicknesses should be based on design basis laminates.
13.An alternative bonding procedure may be specified for the duct 20" and larger to be wrapped on the inside to eliminate any seams. This will require the inside surface to be sanded back far enough to provide a good bonding surface for the lay-up. One layer of 1 ½ oz./sq. ft mat 4" wide saturated with catalyzed resin should be applied first followed by 1 layer of surfacing veil 4 ½" wide as the final layer. Make sure the surfacing veil covers the mat. Roll out all air bubbles and make sure all glass fibers and sanded areas are coated with resin. After the resin starts to gel make sure you apply a final coat of resin with a paraffin wax to complete the cure of the resin. An alternative is that a liquid paraffin wax solution can be brushed on after to complete the resin cure.
12.After the resin starts to gel, apply a final coat of catalyzed resin " hot coat " to the top surface and any uncoated sanded area. Make sure the part is hard before trying to move. The finished field joint should look like this picture.
DISPOSE OF WASTE MATERIAL PROPERLY. CHECK ANY LOCAL REGULATION THAT MAY APPLY.
Composites USA, Inc.
One Peninsula Drive, North East, MD USA 21901
Tel: 1-410-287-2700 Fax: 1-410-287-5222
www.compositesusa.com
