E. Klink Assembly Guide

ENERGY OPTIMISING VENTILATION ASSEMBLY GUIDE A visual guide for metal workers, fitters, contract managers and technical designers on how to assemble and install classified E. Klink ventilation ducts.

2 A guide for quality conscious professionals ASSEMBLY GUIDE

3 Contents: Installation of rectangular, classified E. Klink ducts 4 Installation of circular, classified E. Klink ducts 15 Duct assembly with LS joints 21 Duct assembly with Gebhardt Stahl joints 38 Calculation of pipe lengths 57 Ordering rectangular components 59

Installation of rectangular, classified E. Klink ducts Suspension of rectangular duct • Distance between duct suspension – maximum 1500 mm. • Maximum duct length 1500 mm. • Gap width 20 mm. 4

Installation of rectangular, classified E. Klink ducts 5 Ducts > 1250 x 1000 Assembly joints: • Gebhardt Premium 30/40 • Max. distance the between duct joint and the suspension cannot exceed 70 ± 100 mm Duct support: E.g. Hilti MQ-41 Duct hanger: M10 threaded rod. Ducts ≤ 1250 x 1000 Assembly joints: • LS joint • Gebhardt Premium 20/30/40 • Max. distance between the duct joint and the suspension cannot exceed 70 ± 100 mm Duct support: E.g. Hilti MQ-21.5 Duct hanger: M10 threaded rod.

Installation of rectangular, classified E. Klink ducts Maximum distance between the hanger and duct side – 75 mm 6

Installation of rectangular, classified E. Klink ducts 7 Horizontal wall penetration • Backstop: Fire insulation mat, e.g. Rockwool EI 30 Conlit Fire Mat (≥ 70 kg/m³) • Fire sealant: Rockwool Conlit Seal 800. • Gap width 20 mm. Joint depth 10-15 mm.

Installation of rectangular, classified E. Klink ducts 8 Duct reinforcement • Gebhardt ø16 mm stiffener. • Stiffeners are placed in the middle of the wall. • Correct number of stiffeners and distance between stiffeners is determined based on duct size.

Installation of rectangular, classified E. Klink ducts 9 Duct reinforcement • Stiffeners are placed in the middle of the wall.

Installation of rectangular, classified E. Klink ducts 10 Wall penetration in plasterboard wall • If the duct does not cut a wall stud, the backstop can be butted up against the wall’s soundabsorbing batts. • Soundabsorbing batts in the wall can be advantageously done using hard batts. A better hold- down in the backstop is achieved.

Installation of rectangular, classified E. Klink ducts 11 Wall penetration in a plasterboard wall • If the duct cuts a wall stud, the wall must be reinforced according to the wall manufacturer’s instructions. • The backstop can be butted up against the wall’s soundabsorbing batts. • Soundabsorbing batts in the wall can be advantageously done using hard batts. A better holddown of the backstop is achieved.

Installation of rectangular, classified E. Klink ducts 12 Vertical floor penetration – ducts ≤ 1250 x 1000 • Sectional steel is installed to secure the duct. • Minimum size of sectional steel 40x40x40x3 • Gap width 20 mm. Gap depth 10-15 mm.

Installation of rectangular, classified E. Klink ducts 13 Vertical floor penetration • Backstop: Fire insulation mat, e.g. Rockwool EI 30 Conlit Fire Mat (≥ 70 kg/m³). • Fire sealant: Rockwool Conlit Seal 800. • Sectional steel is installed to secure the duct. • Gebhardt ø16 mm stiffener. • Stiffeners are placed in the middle of the wall. • Correct number and distance between stiffeners is determined based on duct size. • Gap width 20 mm. Gap depth 10-15 mm.

Installation of rectangular, classified E. Klink ducts 14 Vertical floor penetration – Ducts > 1250 x 1000 • Assembly rails: Gebhardt Premium 30/40. • Sectional steel is installed to secure the duct. • Minimum size of sectional steel 70x70x70x3. • Gap width 20 mm. Gap depth 10-15 mm.

Installation of circular, classified E. Klink ducts 15 Suspension of circular ducts – Ducts ≤ ø1000 • Distance between duct suspension. Maximum 2000 mm. • Maximum duct length 3000 mm. • Circular pipe hanger: M10 threaded rod. • Circular sectional bracket: E.g. Hilti MV-P.

Installation of circular, classified E. Klink ducts 16 Horizontal wall penetration • Backstop: Fire insulation mat, e.g. Rockwool EI 30 Conlit Fire Mat (≥ 70 kg/m³) • Fire sealant: Rockwool Conlit Seal 800. Gap width 20 mm. Gap depth 10-15 mm.

Installation of circular, classified E. Klink ducts 17 Wall penetration in a plasterboard wall • If the duct does not cut a wall stud, the backstop can be butted against the wall’s soundabsorbing batts. • Soundabsorbing batts in the wall can be advantageously done using hard batts. A better holddown in the backstop is achieved.

Installation of circular, classified E. Klink ducts 18 Wall penetration in a plasterboard wall • If the duct cuts a wall stud, the wall must be reinforced according to the wall manufacturer’s instructions. • The backstop can be butted up against the wall’s soundabsorbing batts. • Soundabsorbing batts in the wall can be advantageously done using hard batts. A better holddown in the backstop is achieved.

Installation of circular, classified E. Klink ducts 19 Vertical floor penetration • Backstop: Fire insulation mat, e.g. Rockwool EI 30 Conlit Fire Mat (≥ 70 kg/m³) • Fire sealant: Rockwool Conlit Seal 800. • Gap width 20 mm. Gap depth 10-15 mm.

20 Assembly of ventilation ducts Index: Assembly of LS joints 21 Assembly of Gebhardt joints 38

Assembly of ventilation ducts using LS joints How to perform an LS joint • 4 LS sectional frames. • 4 sectional corners. • Insert 2 corners in each of the longest sectional frames. • Then attach both short sectional frames to one of the long sectional frames. • Finally, the rectangular frame is terminated by putting the last long sectional frame in place. 21

22 Assembly of ventilation ducts using LS joints • The LS sectional frame has had sealant applied where the duct end is inserted.

Assembly of ventilation ducts using LS joints Assembly of sectional corners and LS sectional frames • Sectional corners are carefully pushed into the sectional frame. • If necessary, use a rubber mallet. 23

24 Assembly of ventilation ducts using LS joints How to attach the sectional frame to the duct • Place the duct in a vertical position. • Start by attaching the sectional frame in a corner. • Try to keep the sectional frame parallel with the duct side when fitting. • The sectional frame is hammered down over the duct end.

25 Assembly of ventilation ducts using LS joints The sectional frame is hammered all the way down • The sealant must enclose the duct end completely.

26 Assembly of ventilation ducts using LS joints How to attach the sectional frame to the duct • The LS sectional frame is attached with a clamping tool. • When working cut duct sections, a portable hand notcher is used. • The maximum distance between the attachment points must not exceed 80 mm.

27 Assembly of ventilation ducts using LS joints How to seal the sectional frame and duct • Sealant is applied in all four corners, in order to seal where the sectional frame meets the duct. Correct sealing in the corners is important for establishing the air tightness of the duct.

28 Assembly of ventilation ducts using LS joints Spread the sealant with a finger • The sealant is smoothed with a finger to achieve a proper seal of the corners on the LS sectional frame. • The sealant must be smoothed well over the edge by the corner assembly.

Assembly of ventilation ducts using LS joints 29 Sealant is applied in all corners of the LS section • Before laying sealant rupper, a short, small strip of sealant is applied in all four corners of the LS sectional frame.

30 Assembly of ventilation ducts using LS joints Correctly mounted sectional frame on the duct The image shows: • Correct insertion of sealing rubber. • The duct end is hammered all the way down. • Sealant encloses the duct end.

31 Assembly of ventilation ducts using LS joints Insertion of sealing rubber in the slot of the sectional frame • The sealing rubber is pressed down into the slot. • The sealing rubber must not be pulled. • Strips of sealant are pressed out in the corners. • Sealing rubber is cut at a 45° angle.

32 Assembly of ventilation ducts using LS joints How to finish the sealing rubber • Sealing rubber is cut at a 45° angle. • Cut off with an overlap of 5 mm. • The sealing rubber must not be pulled.

33 Assembly of ventilation ducts using LS joints Check the amount of sealant • The sealant must be visible on the back of the LS sectional frame.

34 Assembly of ventilation ducts using LS joints Before joining two ducts using LS joints • Check that both duct ends have had sealing rubber applied – before joining the ducts.

Assembly of ventilation ducts using LS joints Assembly of duct joints • C-profile sections are pushed over the ducts’ LS sectional frames. 35

36 Assembly of ventilation ducts using LS joints C-profile sections are mounted on all four sides of the assembled duct

Assembly of ventilation ducts using LS joints The C-profile sections can be locked • The C-profile sections on the duct sides can be locked with 2 self-tapping screws. • Thereby, the LS assembly does not slide if weight is applied on the ducts after assembly. 37

38 Assembly of ventilation ducts using Gebhardt joints How to make a Gebhardt joint • 4 Gebhardt sectional frames. • 4 sectional corners. • Insert 2 corners in each of the longest sectional frames. • Then attach both short sectional frames to one of the long sectional frames. • Finally, the rectangular frame is terminated by putting the last long sectional frame in place.

Assembly of ventilation ducts using Gebhardt joints • Butyl sealant is applied to the Gebhardt Premium sectional frame where the duct end is inserted. 39

40 Assembly of ventilation ducts using Gebhardt joints Assembly of sectional corners and Gebhardt sectional frames • Sectional corners are carefully pushed into the sectional frame. • If necessary, use a rubber mallet.

Assembly of ventilation ducts using Gebhardt joints 41 How to attach the sectional frame to the duct • Place the duct in a vertical position. • Start by attaching the sectional frame in a corner. • Try to keep the sectional frame parallel with the duct side when fitting. • The sectional frame is hammered down over the duct end.

42 Assembly of ventilation ducts using Gebhardt joints The sectional frame is hammered all the way down • The butyl sealant must enclose the duct end completely.

Assembly of ventilation ducts using Gebhardt joints 43 Correctly mounted sectional frame on the duct The image shows: • The duct end is hammered all the way down. • Sealing butyl encloses the duct end.

44 Assembly of ventilation ducts using Gebhardt joints How to attach the sectional frame to the duct • The Gebhardt Premium sectional frame is attached with a clinching machine. • When working with cut duct sections, the frame is screwed in place with self-tapping screws. • The maximum distance between the attachment points cannot exceed 80 mm.

Assembly of ventilation ducts using Gebhardt joints The sectional frame is prepared for the insertion of pop rivets • Holes are drilled in all four corners – 8 holes in total, as preparation for putting pop rivets in the sectional frame. • When working with cut duct sections, the frame is screwed in place with self-tapping screws. 45

46 Assembly of ventilation ducts using Gebhardt joints Pop rivets are inserted into the sectional frame • Pop rivets are inserted in all corners of the sectional frame – 8 pop rivets in total.

Assembly of ventilation ducts using Gebhardt joints • The pop rivet has now been put in a corner of the sectional frame. 47

48 Assembly of ventilation ducts using Gebhardt joints Sealing with sealant in the corners • Sealant is applied in all four corners, where the sectional frame meets the duct and the sectional corners get an optimum seal.

Assembly of ventilation ducts using Gebhardt joints Spread the sealant thoroughly with a finger • The sealant is distributed thoroughly, where the sectional frame meets the duct and the sectional corners to achieve an optimal seal. 49

50 Assembly of ventilation ducts using Gebhardt joints Applying and cutting off sealing rubber • The sealing rubber band is placed so that it is flush inside the duct. • Do not pull on the sealing tape. • The sealing tape must overlap in the corners. • The sealing tape is cut flush with the side of the sectional frame. • Sealing tape sizes: 20P flange – 15 x 4 mm. 30P flange – 20 x 4 mm. 40P flange – 25 x 4 mm.

Assembly of ventilation ducts using Gebhardt joints Before joining two ducts using Gebhardt joints • Check that only one duct end has had sealing tape applied before joining the ducts. 51

52 Assembly of ventilation ducts using Gebhardt joints The sectional frame is fitted with bolts in the corners • The four corners of the sectional frame are fitted with M8x25 bolts. • Tighten the corner bolts equally.

Assembly of ventilation ducts using Gebhardt joints Assembly of duct joints • Gebhardt profile sections are pushed over the ducts’ sectional frames. 53

54 Assembly of ventilation ducts using Gebhardt joints Sectional profiles are mounted on all four sides of the duct • Gebhardt sectional profiles are mounted on all four sides of the assembled duct.

Assembly of ventilation ducts using Gebhardt joints Gebhardt screw clamps as an alternative • As an alternative to Gebhardt profiles Gebhardt screw clamps can be used. • Screw clamps are fitted close to all the corners. • Maximum distance between the screw terminals should not exceed 250 mm. 55

56 Diagrams for ordering rectangular components Index: Calculating pipe lengths 57 Calculating T-pieces 58 Ordering ducts [LKR] 59 Ordering sharp bends [LBR] 60 Ordering curved bends [LBXR] 61 Ordering rect. reducers [LDR] 62 Ordering rect.-to-round reducers [LORU] 64 Ordering S-offsets [LBSR] 66 Ordering straight offsets [LKS] 67 Ordering angled branches [LAR] 68 Ordering straight branches [LT] 69 Ordering branch on circular ducts [LPSR] 70 Ordering T-pieces [LTTR] 71

57 Calculating pipe lengths Calculating pipe lengths for offset [RL] is calculated in the Lindab Vent Tools App. = 90°, 60°, 45°, 30° or 15°. α

58 Calculating T-pieces Calculating pipe lengths for T-pieces [L] is calculated in the Lindab Vent Tools App. = 90°, 60°, 45°, 30° or 15°. α

59 Ordering ducts [LKR] Standard length is 1500 mm. Assembly method: Klink LS [LS]: L ≤ 1000 mm Gebhardt Stahl [GS20]: 1000 > L ≤ 1600 mm Gebhardt Stahl [GS30]: L > 1600 mm Duct with side plate ≥ 1000 has stiffeners fitted. Order code: LKR-aaa-bbb-LLLL-xx/xx a [largest side] in mm b [smallest side] in mm L in mm xx/xx: assembly method, e.g. LS/GS20 xx/xx: assembly method/termination, e.g. LS/EB EB = end cover BB = tray cover

60 Ordering sharp bends [LBR] Number and placement of splitters [EN 1505] Width [a] Number of splitters Distance between splitters #1 #2 #3 > 400 ≤ 800 1 a/3 > 800 ≤ 1600 2 a/4 a/2 > 1600 ≤ 2000 3 a/8 a/3 a/2 Order code: LBR-aaa1-bbb-aaa2- αα-xx/xx-LL1- LL2 a1 [width1] b [height] a2 [width2] a = angle in degrees [°]. Standard angle 90° xx/xx: assembly method, e.g. LS/GS20 L1 and L2 are only indicated if legs on elbows are desired extended beyond the standard.

61 Ordering curved bends [LBXR] Number and placement of splitters [EN 1505] Width [a] Number of splitters Distance between splitters #1 #2 #3 > 400 ≤ 800 1 a/3 > 800 ≤ 1600 2 a/4 a/2 > 1600 ≤ 2000 3 a/8 a/3 a/2 Order code: LBXR-aaa1-bbb-aaa2- αα-xx/xx-LL1- LL2 a1 [width1] b [height] a2 [width2] a = angle in degrees [°]. xx/xx: assembly method, e.g. LS/GS20 L1 and L2 are only indicated if legs on elbows are desired extended beyond the standard.

62 Ordering rect. reducers [LDR] Order code: LDR-aaa-bbb-ccc-ddd-LLL-x-e-h-xx/xx c [small width] L [length] d [small height] x [type 1-6] a [large width] e and h are indicated for type 6 b [large height] xx/xx: assembly method, e.g. LS/GS30 Standard lengths: e and h ≤ 200: L=400 e or h > 200 and ≤ 300: L=600 e or h > 300 and ≤ 400: L=800 The transition piece is always viewed from the small end!

63 Ordering rect. reducers [LDR]

Ordering rect.-to-round reducers [LORU] 64 Standard lengths: e and h ≤ 200: L=400 e or h > 200 and ≤ 300: L=600 e or h > 300 and ≤ 400: L=800 The transition piece is always viewed from the circular end! Order code: LORU-aaa-bbb-ddd-LLL-x-e-h-xx/xx a [width] x [type 1-6] b [height] e and h are indicated for type 6 ød [diameter] xx/xx: assembly method, e.g. LS/NP L [length] If a union is used [MF], the total length measurement is [L] incl. union length.

Ordering rect.-to-round reducers [LORU] 65

66 Ordering S-offsets [LBSR] Standard lengths: S ≤ 200: L=400, S > 200 and ≤ 300: L=600, S > 300 and ≤ 400: L=800 Order code: LBSR-aaa1-bbb-aaa2- SSS-xx/xx-LLL a1 [width1] S = offset b [height] xx/xx: assembly method, e.g. LS/GS20 a2 [width2] L [total length]

Ordering straight offsets [LKS] 67 Standard lengths: S ≤ 200: L=400, S > 200 and ≤ 300: L=600, S > 300 and ≤ 400: L=800 Order code: LKS-aaa1-bbb-aaa2- SSS-xx/xx-LLL a1 [width1] S = offset b [height] xx/xx: assembly method, e.g. LS/GS20 a2 [width2] L [total length]

68 Ordering angled branches [LAR] Order code: LAR-aaa-bbb-xx-y a [width] b [height] xx: assembly method, e.g. LS/GS20 y: 1-4: bend to double hem [bf], e.g. 2+4 bf

69 Ordering straight branches [LT] Order code: LT-aaa-bbb-LLL-xx-y a [width] b [height] xx: assembly method, e.g. LS/GS20 y: 1-4: bend to double hem [bf], e.g. 2+4 bf L [length] Standard length equal to 100 mm

70 Ordering branch on circular ducts [LPSR] Order code: LPSR-aaa-bbb-DDD-LLL-xx a [width] L [length] Standard length equal to 100 mm b [height] xx: assembly method, e.g. LS/GS20 øD [pipe diameter]

71 Ordering T-pieces [LTTR] Order code: LTTR-aaa1-aaa2-aaa3-bbb-xx a1 [width1] b [height] a2 [width2] xx: assembly method, e.g. LS, GS20 etc. GS30 a3 [page plate3]

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