Fabric Expansion Joint

Represented by: THERMOFLO Equipment Company.
For assistance please call 918-252-9333

Represented by: THERMOFLO Equipment Company. For assistance please call 918-252-9333
-––[MANUFACTURING CAPABILITIES
& QUALITY ASSURANCE ]–-–
COMBINED FACILITIES
Manufacturing Floor Area 200,000 sq. feet (18580 sq. meters)
Total Land Area 31 acres (125,000 sq. meters)
Bridge Crane Capacity 40-ton max. (36,288 kq)
Maximum Hook Height 37 feet max. (11.28 meters)
Fork Lift Capacity 30,000 Ibs. (13,608 kg)
FABRICATION
Vulcanizing Presses Digital Controlled, Flat belt, corners
Welding Sub Arc, Arc, Pulse Arc, TIG, MIG, Core Wire, Resistance, Electroslag,
Tube Welding, Track Welding, Large Turn Tables, Rolls, and Positioners.
Plate Roll 1 1/2” Thickness (38.1 mm)
Angle Roll 5” x 5” x 1” (127 x 127 x 25 mm)
Press brakes 5 ton through 400 ton (4536 through 362,880 kg)
Radial Expanders 5 ton through 400 ton (4536 through 362,880 kg)
1/2 through 96” diameter (13 mm through 25 m)
Shear .003 through 1” (.08 through 2.5 mm)
Flame and Plasma Cutting 4-torch computer controlled water table
Abrasive Blasting 16’ x 16’ x 24’, recirculating system (4.9 x 4.9 x 7.3 m)
Painting and finishing equipment
BELLOWS FORMING
Expanding mandrel forming from 1/2” (10 mm) to 30’ (9.1 m) diameter
Large bellows of unlimited diameter can be made in sections
Roll forming to 14’ (4.27 m) diameter
Hydraulic forming, 1200 ton (1,088,640 kg) press for heavy wall and
specialized toroidal bellows
QUALITY ASSURANCE
Compliance Senior Flexonics Quality Assurance System has been certified
to ISO 9001 and is in with ASME Section VII, Division 1, ASME B31.1
and ASME B31.3, AWS B1.1, AISI, ASIC, Stoomwezen and T.U.V.
Section VIII (U Stamp)
Section III (N Stamp)
Section III (NPT Stamp)
TEST CAPABILITIES AND DESIGN VERIFICATION TESTS

Various Fabric Test Fixtures Dead Weight Testing
Elevated Temperature/Pressure Fabric Expansion Joint Cycle Testing Hardness Testing
Fabric Belt Oven Tester Ambient Temperature Bellows Fatigue Testing
Durometer Hardness Elevated Temperature Bellows Fatigue Testing
Specific Gravity Seismic Analysis of Fabricated Components
X-ray 300KV – 10 MA and 5 MA Magnetic Particle, Vibration Analysis of Fabricated Components
Dye Penetrant, Zyglo, Ultrasonic and Eddy Current Testing Shock Loading Performance Testing
Mass Spectrometer and Halogen Leak Detection Bellows Spring Rate Testing
Positive Material Identification (PMI) Expansion Joint Deflection Testing
Hydro Testing Bellows Torsion Testing
Cycle Testing Burst Testing
Spring Rate Testing
© Senior Flexonics Pathway, 2000

1 All Rights Reserved
Table of Contents
Manufacturing capabilities & Quality Assurance . . . . . 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Function of fabric expansion joint components . . . . . 4
Products, markets & applications . . . . . . . . . . . . . . . 5-6
Movement capabilities . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chimney seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operational & design considerations . . . . . . . . . . . 9-10
Cavity pillow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Options & accessories . . . . . . . . . . . . . . . . . . . . . . . . 12
Frame styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14
Installation considerations . . . . . . . . . . . . . . . . . . . . 15
Splicing and repairability . . . . . . . . . . . . . . . . . . . . . . 16
Flexon® product line . . . . . . . . . . . . . . . . . . . . . . . . . 17
Patented PTFE/FKM alloy provides
additional flexibility . . . . . . . . . . . . . . . . . . . . . . . 18
High temperature applications . . . . . . . . . . . . . . . 19-20
How to specify a fabric expansion joint . . . . . . . . 21-22
Elastomer Material Descriptions . . . . . . . . . . . . . . . . . 23
Thermal growth chart . . . . . . . . . . . . . . . . . . . . . . . . 24
Glossary of terms . . . . . . . . . . . . . . . . . . . . . . . . . 25-26
Power plant schematic . . . . . . . . . . . . . . . . . . . . . 27-28
Rectangular metal duct expansion joints . . . . . . . . . . 29
Ducting Expansion Joint Specification Sheet . . . . . . . 30
For high temperature applications see our literature covering

materials, designs, testing and options for this demanding service.
The brochure is entitled “Dextra™ Composite Expansion Joint,
Engineered Solutions for High Temperature Duct Applications”.
2
2
Introduction
Senior Flexonics Pathway, with origins dating to 1902,
pioneered development of the first fabric expansion joints
for flue gas ducting applications in 1964 as a practical
alternative to large round and rectangular metal expansion
joints. With superior flexibility to absorb the large motions
occurring in ducting systems, fabric expansion joints have
become the preferred product for these demanding
applications.
Since those early days, we have stayed at the forefront of

product design innovation and materials development
technology. As a member of the Fluid Sealing Association
(FSA) and the Expansion Joint Manufacturers Association
(EJMA), Senior Flexonics Pathway has set the highest
standards for furnishing engineered nonmetallic materials,
combined with proven frame designs to yield durability,
reliability and extended service life.
This design manual has been developed to provide

knowledgeable insight into the proper application of fabric
expansion joints. Useful design information, installation
instructions and engineering reference data have been
included to assist the reader in selecting a product that will
provide the best overall value through increased operating
efficiency, reduced maintenance and extended reliability.
Senior Flexonics Pathway provides the following services

to meet your special needs:
■ 48 hour shipment: Any catalog standard fabric
expansion joint can be fabricated and shipped in as

little as 48 hours, sometimes even faster.
■ On-Site Installation: Senior Flexonics Pathway can
mobilize an experienced field crew to perform turn-key

installations; or simply provide an experienced
Installation Specialist to advise your plant personnel.
■ Emergency Hotline: We understand that emergencies
usually don’t happen during business hours. Our

Emergency Hotline (830) 660-0337 is monitored
24 hours per day, every day, to provide immediate
contact with responsible and knowledgeable personnel.
3
-––[FUNCTION OF FABRIC EXPANSION

JOINT COMPONENTS]–-–
A
D
B H
C
F
E
A. GAS SEAL MEMBRANE particles which may be present in the gas stream. A liner is
The gas seal membrane is intended to withstand system also used to reduce flutter of the fabric element caused by
pressure and be resistant to chemical attack from the turbulence, to help control the accumulation of dust or ash
interior and the exterior. The gas seal must also have the in the expansion joint cavity, and to reduce the
flexibility to absorb thermal movements. Depending on temperature of the flexible element.
system temperature, it may require additional thermal
protection. F. ACCUMULATION BAG
An accumulation bag is intended to deter flyash from
B. INSULATING LAYERS building up in the expansion joint cavity. It is typically
The insulating layers provide a thermal barrier to ensure that used, in conjunction with a liner, in duct runs from boilers
the inside surface temperature of the gas seal membrane
to air clean-up equipment such as precipitators, scrubbers
does not exceed its maximum service temperature. The
and bag houses, or whenever high amounts of dust or ash
insulating layer can also reduce condensation caused by the
are present in the gas. A flyash barrier must be capable of
gas stream coming in contact with the “cool” surface of an
retaining its strength and flexibility while being exposed to
uninsulated gas seal membrane.
maximum system temperatures and media.
C. INSULATING RETAINER LAYER

This layer is provided to keep the insulating layers in place
G. FABRIC ATTACHMENT FLANGES
Fabric attachment flanges are required to connect the
in order to maintain thermal integrity. The retaining layer
flexible element to the ductwork. Properly designed,
must be capable of withstanding gas stream temperatures
they can be attached directly to the duct work and thus
and must be chemically compatible with system media.
eliminate the necessity for an adjoining duct flange.
D. BACK UP BARS Flanges can be designed with a “landing bar” duct
Back up bars, positioned at the flange attachment, use attachment which allows some installation misalignment
clamping pressure to create the fabric-to-duct seal and without affecting the flexible element. The flanges establish
restrain the fabric when it is subjected to the system the stand off height of the fabric, which is necessary to
pressure. The thickness and width of the back up bars achieve thermal integrity during all movement conditions.
should be sufficient to perform this function with the bolt The edges of the flanges in contact with the gas seal
spacing being used. The edges of the back up bars should membrane should also have a radius to prevent damage.
have a radius to preclude cutting of the fabric.
H. GASKET
E. METAL LINER OR BAFFLE Single ply fluoroplastic and fluoroelastoplastic belt designs
A liner is designed to protect the gas seal membrane and such as Ultrachem materials require flexible chemically
insulating layers of the flexible element from abrasive inert gaskets.
4
-––[PRODUCTS, MARKETS
& APPLICATIONS]–-–
MANUFACTURING CAPABILITY
We have the
unique ability to
react quickly to
support your
outage needs for
fabric expansion
joints. Senior
Flexonics
Pathway can
produce round, rectangular and custom shapes for every
application. We are well known worldwide for our
“Round the Clock” Service.
ULTRACHEM AND
FLEXON MATERIALS
Senior Flexonics
Pathway is the
FOSSIL FIRED POWER company that first
MARKET APPLICATIONS developed the use of
Applications range fluoropolymer (PTFE)
from the FD fan to the materials in expansion
primary air, tempering joint systems.
air, coal mill, boiler Specifically designed
flue duct joints, for a variety of wet and
economizer, air heater, dry corrosive applications, these materials will exceed
precipitator, baghouse, your system requirements.
fabric filter, ID fan,
scrubber, absorber,
reheater and stack
expansion joints.
ENGINEERING SERVICES
Senior Flexonics Pathway
supports its fabric
expansion joint products
with experienced field
engineers, On-Site service GAS TURBINE
installation, repair EXHAUST APPLICATIONS
services, and CAD Our fabric expansion joints are currently in service in
supported application peaking plants, on shipboard power systems, on co-
engineers to help you generation turbines, natural gas pipeline pump stations
solve your expansion and a variety of heat recovery.
joint problems.
5
WET SCRUBBER APPLICATIONS ECONOMIZER APPLICATIONS

There is no more Our fabric
demanding service for expansion joints
expansion joints than are ideally suited
wet scrubbers. Senior for this flyash
Flexonics Pathway can laden application.
provide the correct Flexible high
PTFE or FKM gas seal strength and
materials to handle lightweight fabric
this hostile belt elements in
environment. combination with our engineered frames offer longer life
and lower installed costs.
REFINERY MARKET
APPLICATIONS
Our products are installed at the CO boiler, exhaust gas
ducting, precipitator, fans, crude reheat units, and the
balance of the air and gas ducting.
CRUDE OIL REHEAT

DUCTING APPLICATION
More sensitive to downtime than most industries, our
refinery customers appreciate the high quality of our
fabric expansion joints. These joints were designed with
turned out angle flanges and a ‘flat belt’ design for easy
installation and access.
SPECIAL DESIGNS
PULP AND PAPER In addition to Senior Flexonics Pathway’s standard
MARKET APPLICATIONS configurations provided in this catalog, many specially
The corrosive engineered designs have been produced for the following
conditions applications:
around the ■ Heat Recovery Steam Generators (HRSG)
power and
recovery boilers
■ Circulating Fluid Bed Boilers (CFB)
as well as the ■ Cement Industry
duct joints to ■ Steel Industry
the fans,
precipitator,
■ Windtunnels, HVAC, etc.
scrubber, and stack are all locations where you will find ■ Selective Catalyst Reduction (SCR) Units
expansion joints.
6
-––[MOVEMENT
CAPABILITIES]–-–
The system thermal expansions are the differential
expansion/contraction of operating and/or excursion
temperatures and the minimum ambient temperature during
installation and shutdowns. The expansion joint engineer uses these
movements and temperatures to select the proper material and design for
each expansion joint. Senior Flexonics Pathway’s nonmetallic expansion
joints frequently can handle combined axial, lateral, angular and torsional
movements in a single assembly.
The expansion joint locations can often be optimized, reducing the total number required. Consideration should be
given for accessibility and belt replacement, for new ducting systems, it may be more economical for the duct fabricator
to provide a portion of the expansion joint frame.
Lateral Movement - The amount of duct movement occurring in either or both

of the two perpendicular planes to the longitudinal axis of the duct,
which moves the expansion joint flanges out of alignment.
Axial Compression/Extension - The dimensional shortening

(compression) or lengthening (extension) of the expansion joint
face-to-face dimension parallel to it’s longitudinal axis.
Torsional Deflection - The amount of twisting movement (in degrees)

occurring in the perpendicular planes to the longitudinal axis of
the duct system.
Angular Deflection - The amount of rotation (in degrees) of the duct

system which flexes the expansion joint flanges out of parallel position
with each other.
TYPICAL MOVEMENT CAPABILITIES BREACH OPENING

Belt Type Active Length 6” (152mm) 9” (229mm) 12” (305mm)
FACE-TO-FACE
Single Layer Axial Compression 2” (51mm) 3” (76mm) 4” (102mm)
Fabric Element Axial Extension 1/2” (13mm) 1/2” (13mm) 1/2” (13mm)
(Non-concurrent) Lateral 1” (25mm) 1 1/2” (38mm) 2” (51mm)
Axial Compression 1” (25mm) 1 1/2” (38mm) 2” (51mm) Set Back
Composite Belt
Axial Extension 1/4” (6mm) 1/4” (6mm) 1/4” (6mm) Active Length
(Concurrent)
Lateral 1/2” (13mm) 3/4” (19mm) 1” (25mm)
Integrally Flanged Axial Compression 2” (51mm) 3” (76mm) 4” (102mm) Active Length
Single Layer Axial Extension 1/2” (13mm) 1/2” (13mm) 1/2” (13mm)
(Concurrent) Lateral 1” (25mm) 1 1/2” (38mm) 2” (51mm)
Set
Notes: Back
1. Special considerations must be made when movements exceed those listed above or differ from nonconcurrent or concurrent
ratings. Consult with factory for these applications.
2. Breaching tolerances: Axial extension 1/4” (6mm), axial compression 1/2” (13mm), lateral + 1/4” (6mm). Exceeding these
tolerances will affect movement capabilities. Breach or
3. Lateral movement exceeding 3” (76mm) should utilize cold lateral offset (preset) to reduce the relative belt movement. F/F DOM
7
-––[SPECIAL APPLICATION
CHIMNEY GAS SEALS]–-–
THE PROBLEM
Numerous fossil-fueled utility chimneys built between the
years 1950 and 1970 used a rope packing design as a gas seal
between adjacent sections of brick liners. Should the rope
packing leak, flue gas may attack the less resistant concrete
chimneys causing leakage and chimney deterioration.
DESIGN SOLUTION
A fabric expansion joint has been designed to eliminate the need
for the original seals as well as provide for improved inspection
and maintenance. Features of the design include:
■ Lower installed cost due to lighter weight materials.
■ Gas seal membrane for long life
■ Easily repairable by heat sealing methods
■ Easily accessible
■ Unique frame design for easy access
■ Chimney air seal
THE PROBLEM
Penetration of flue gas ducts through the chimney liner and outer shell require an air tight seal
for a pressurized chimney annulus. Leaky seals allow the flue gases to enter the annulus and
attack the outer concrete structure shell.
DESIGN SOLUTION
A dual picture frame attached to the duct and the liner
(or shell) utilizing UltraChem™ Gas Seal Membrane is
installed to span between the two frames creating the
seal. Benefits of the design are:
■ Easily repairable by heat seal methods
■ Lower installed cost due to lighter weight materials
■ Easily accessible for inspection or repair
8
-––[OPERATIONAL & DESIGN

CONSIDERATIONS ]–-–
The following background information on the plant and detrimental to the design of the flexible element and
application can have significant influence to the design should be avoided.
life of the expansion joint.
■ Plant type PRESSURE & EXPANSION
■ Location of expansion
JOINT LEAKAGE
Fabric expansion joints are typically designed for low
■ Environmental conditions
pressure duct systems with maximum rating at +5 psig
■ Base or peak load plant for elastomeric and +3 psig for fluoroplastic and
■ Relevant history of existing and adjacent equipment fluoroelastoplastic belts.
FLOW MEDIA Fabric expansion joints are designed to be as leak tight

In defining system media, the designer should specify as practical. When an unusual amount of liquid is
the type of fuel, sulfur content, and any additives, present within the ducting, or leakage requirements are
cleaning agents or catalysts, which may be used in the specified, special caulking or gasket materials can
system. Ph in the vicinity of the expansion joint should be used when attaching the fabric element to attain the
be specified, if known, especially if the media is desired results. In industrial applications, minor leakage,
extremely acidic or caustic. detectable by soap bubble solution, is considered
acceptable.
The probability of condensation should be determined
by comparing dew point and normal operating When replacing a fabric element, leakage through bolt
temperatures. Even in systems which normally operate holes is minimized if holes are aligned and punched
quite hot, shutdowns and startups may produce in the field as opposed to prepunching the holes at
condensation resulting in excessive corrosion. This the factory. Backup bar bolts should be tightened to
condition can also occur on the outside of the steelwork 35 to 45 ft. lbs. (45-61 Nm) to ensure optimum
and should be considered. clamping pressure.
Abrasive components of the media such as flyash should MOVEMENTS

be identified. Flyash buildup within a flue gas duct Various movements resulting from thermal expansion
should be estimated, and the dead weight calculated to of the breeching, both Maximum Continuous System
determine the maximum load on an expansion joint Operating Temperature (MCSOT) and excursion
element. Plant operating procedures such as duct temperatures should be specified. Contractions of the
cleaning (wash-down or vacuuming) are also considered breeching due to cold winter shutdowns, mechanically
in the design. induced movements such as fan and equipment
vibrations, and structural deflections due to wind loads
TEMPERATURE and seismic events must also be specified.
Temperatures affect the selection of fabric expansion
joint materials. The following temperatures for the Movements in various directions should be analyzed to
system should be provided to the engineer. determine if they occur simultaneously or if they can
■ Normal operating temperature occur individually without a corresponding deflection in
■ Maximum continuous operating temperature another direction. The designer to make certain that the
expansion joint design is capable of absorbing a
■ Design temperature
combination of the total maximum movements should
■ Excursion temperatures and duration
specify maximum installation misalignment.
■ Ambient temperatures (the lowest, highest
and average) SYSTEM GEOMETRY/INSTALLATION
■ Dew point temperatures The geometry of the expansion joint system, including
Caution: Specifying a “design temperature” which duct size, orientation, material and attachments all have
includes excessive safety factors may actually be an effect on the selection of expansion joint frame
9
configuration. The installation of an expansion joint can or operating pressure oscillations. Both conditions can
be performed either internally or externally. Specific cause a premature failure and must be identified in the
frames are designed for each application depending on quotation/evaluation stage. This condition is commonly
preferences or accessibility. found adjacent to turning vanes, ID fan and stacks. This
pressure oscillation typically exists in ductwork locations
EXTERNAL ENVIRONMENT where the static pressure is very low ±1 to ±2” w.c (±25 to
Correct operation of high temperature expansion joints ±50 mm H2O).
requires that a portion of the system heat be dissipated to
the external environment. Abnormally hot ambient
INSTALLATION
conditions or an adjacent heat source, reflective surface,
CONSIDERATIONS
or duct insulation may create temperatures that exceed
The system designer must consider all installation
the limits of the gas seal membrane and should be
requirements such as mating duct flanges, adjacent
considered when designing the system.
ducting equipment, insulation, painting/ finishing, field
assembly, erection and necessary qualified supervision.
An external cover may be desirable to help protect
against failing objects or the accumulation of combustible
materials such as coal or saw dust. Covers should be RESPONSIBILITY
designed by the expansion joint manufacturer to ensure The system designer must evaluate whether the lines of
that proper air circulation requirements are satisfied. responsibility are clear between the ducting supplier,
erector, and the expansion joint supplier, and if they will
EXPANSION JOINT FLUTTER result in a system that meets specification requirements
The inherent flexibility of expansion joints can cause at an optimum overall cost. It is usually in the best
fatigue problems as a result of physical fluctuations interests of the end user to specify and/or order the
known as flutter. Flutter is a result of either flow induced expansion joints themselves.
10
-––[ CAVITY PILLOW ]–-–

CAVITY PILLOW STYLES
The Senior Flexonics Pathway cavity pillows serve three purposes, retarding the
intrusion of particulate, thermal protection, and resistance to pressure pulsation.
Our pillows are fabricated from selected insulation materials and wrapped with a
high temperature fabric, designed for the operating conditions. Standard pillows are
provided with “ears” or tabs that fasten under the belt and backup bars to hold the
pillow in place. The ears are designed to provide a memory to the
pillow such that it will return to an “as installed” uncompressed
state after plant cool down, during outages.
CAVITY ACCUMULATION PILLOW (CAP)

A cavity created between the structural steel frame/flanges and the
gas seal (fabric expansion joint) is designed to provide a standoff
Style - 1 between the fabric element and the flue gas. This cavity can fill
with particulate falling out of the flue gas. If these deposits are
allowed to buildup the expansion joint will fail to operate properly
and could become damaged. Senior Flexonics Pathway
recommends the use of an accumulation pillow designed to occupy
this “dead space”, preventing the deposits from entering and filling
this cavity. The cavity pillow in conjunction with a flow liner will
Style - 2 prevent the accumulation of particulate/fly ash. Many
maintenance managers view this option as a low cost insurance
policy that extends the service life of the expansion joint.
HIGH TEMPERATURE CAVITY Typical cavity pillow

INSULATION PILLOWS (CIP) construction consisting
Cavity Insulation Pillow (CIP) - A style CIP provides additional of layers of insulation
thermal protection to the belting material for high temperature encased in a protective
Style - 3 applications. high temp sleeve.
-––[ FLOW LINERS]–-–

Flow liners (baffles) are metal shields designed to provide protection for the fabric element and/or
cavity pillow from direct impingement of particulate or particulate accumulation. A liner is also
used to reduce flutter of the fabric element caused by turbulence, to help control the
accumulation of dust or ash in the expansion joint cavity, and to reduce the temperature of the Integral Liner
flexible element. Flow liners can be supplied on a variety of profiles (straight, airfoil, semi-airfoil
or telescoping) and materials. (Standard profile and material are straight 10 GA. A569 C.S.). Flow
liners fall into the following categories.
■ Integral liners are pre-manufactured parts of the expansion joint frame as on SR2700 and
SR2750 series frames.
Bolt-in Liner
■ Bolt-in liners are primarily used on integrally flanged style expansion joints as on our U1000
series, between the belt or expansion joint flange and the mating duct flange. Gaskets are
required on metal-to-metal and/or Teflon®-to-metal connections.
■ Weld-in liners spanning the breach opening can be either welded in the field to the duct
interior or can be supplied welded in factory to the expansion joint frame.
Weld-in Liner
11
-––[OPTIONS & ACCESSORIES]–-–

BRAIDED HOSE SEAL (BH)
Flexible stainless steel braided hose with enclosed ceramic insulation is often
specified for expansion joints in areas of high particulate loading. The hose is
secured between the flow liners to prevent particulate from entering the
expansion joint cavity. This accessory along with a cavity pillow works
well in cement plants.
TADPOLE GASKET TAPE (TG)

When using integral flange-type expansion joints in duct systems with
positive pressure operating conditions, Senior Flexonics Pathway
recommends the use of tadpole gasketing between the flexible element
flange and backup bars (as illustrated). This prevents the heads of the
erection bolts from abrading the outside cover of the flexible element.
This option also protects both flat and integrally flanged belts during large
TP lateral or compression movements.
FD
FLOW DEFLECTOR (FD)
In some expansion joint installations, an angle flow deflector is added to the design to
increase the service life of the joint. A flow deflector is used to prevent moisture and
particulate from sliding down vertical duct walls and being trapped in the expansion
joint cavity by the flow liner.
-––[FRAME STYLES]–-–
Senior Flexonics Pathway provides numerous frame designs for various applications. The integrally flanged U-belt
design has a very economical initial capital cost. The flat belt frame design has a lower replacement belt cost and
existing hardware can be reused. The following is a sample of several standard arrangements.
SR2400
Design applications where the ductwork flanges are present and a complete frame
assembly is preferred. This style works well for high temperature applications.
■ Complete drop-in assembly
■ Prefabricated standard frames reduce cost
■ Belting hardware accessible from outside
■ Best choice when adjacent structures or equipment cannot permit liner
SR2400 protrusion beyond attachment flange.

■ Accepts shop welded flow liner
■ Readily accepts eared pillow design
■ Used to fill large breech openings
■ Accommodates large lateral movements
■ Provides proper setback for belt protection
Senior Flexonics Pathway expansion joints are furnished assembled or unassembled.
12
SR2500
Complete drop-in assembly design which works well with low to moderate
temperature applications with low levels of particulate accumulation.
■ Economic frame using standard angle sizes
■ Accessibility to bolting hardware
■ Accepts shop welded flow liner
■ Designed for internal (SR2550) or external belt replacement (SR2500)

SR2500
■ Used frequently with fan applications
■ Studs or tack welded nuts are optional on belt flange
SR2600
Similar to the SR2500 style and is used where additional standoff is necessary or
SR2550
preferred. This design works well in low to moderate temperature applications with
low levels of particulate accumulation.
■ Economic frame using standard angle sizes
■ Fabric wrap design used to retrofit over existing metal expansion joints
(possible on-line installation)

■ Complete assembly drop-in design
■ Designed for internal (SR2650) or external belt replacement (SR2500)
■ Used frequently with fan applications
SR2600 ■ Accepts shop welded flow liner
■ Studs or tack welded nuts are optional on belt flange
SR2700
Used for low-to-high temperature applications with a cavity pillow, where high levels
SR2650 of particulate are present.
■ Accommodates both flanged and non-flanged ductwork
■ “Z” style with integral telescoping flow liners
■ Reduces particulate accumulation in frame cavity
■ Provides protection for belts and pillows
■ Complete accessibility to bolting hardware
■ Accepts eared pillow design
■ Tack welded nuts are optional
SR2700
SR2750
Similar to SR2700 with the exception of a single integral flow liner. This design
works well with lower particulate levels or vertical duct applications.
■ Accommodates both flanged and non-flanged ductwork
■ “Z” style integral upstream flow liner
■ Provides protection for belts and pillows
■ Complete accessibility to bolting hardware
SR2750
13
SR2800
This style frame is well suited for installation with field assembly over existing
expansion joints, and is utilized for all temperature ratings.
■ Economic frame utilizing standard prefabricated angle iron
■ Either welded or bolted frame can be utilized
■ Fabric wrap design can be used to retrofit over existing metal expansion
joints (possible on-line installation)

■ Accepts eared pillow design
SR2800
■ Facilitates field assembly and fit-up
SR2900
Best utilized where flanges are not present and field assembly is required or preferred.
■ Fabric wrap design used over existing metal expansion joints
(possible on-line installation)

■ Provides additional stiffener reinforcement to existing ductwork
■ Utilizes standard structural steel channels for economical design
SR2900 ■ Flanges act as duct stiffiners
U1000
The standard integrally flanged U-belt design is used for low to moderate temperatures
applications where duct flanges are present and particulate loading is minimal
■ Lowest initial cost due to reduced metal frame and fasteners cost
■ Molded corners provided for rectangular ductwork
■ Accommodates flanged ducting or equipment and utilized frequently for
U1000
fan applications
■ Minimal shipping costs
■ Standard 3” (75mm) high flange design
SLEEVES
Sleeves are primarily used for vibration in H.V.A.C. applications with minimal
pressures.
■ Least expensive design
■ Supplied endless or open ended for field-wrap of pipe penetration applications
■ Supplied with worm gear band clamps
■ For vibration applications
Sleeves ■ Provided with gaskets for Teflon® belt material
14
-––[INSTALLATION CONSIDERATIONS ]–-–

MATING DUCT FLANGES
B B
Mating duct flanges affect expansion joint design. Senior Flexonics Pathway Frame A
Systems SR2700, SR2800 and SR2900 are designed to completely eliminate mating A
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. F C
F C
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
D
could exceed the expected thermal movement. A convenient solution to this
D
problem is to design the expansion joint frame to absorb the duct misalignment. E E
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. Field Assembly Diagram
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
15
-––[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 PERMANENTLY REPAIRABLE

Lightweight and portable for use at any plant location. Unlike fluoroelastomer materials, Ultrachem and Flexon
Available for rent or purchase. May be operated easily expansion joint systems are repairable over the life of the
by plant personnel. product. Repairable not just with a mechanical patch but
repairable without degrading the tensile strength of the
REQUIRED joint. This contrasts with the inability to effectively
MATERIALS revulcanize fluoroelastomer products after installation
Heat seal film is required and because of the “aging” inherent with fluoroelastomer
placed between the ends of the and other rubber products.
joint to be spliced. No chemical
prep of the belt or mechanical MECHANICAL
abrasion is required prior to DAMAGE
splicing. This expansion joint at a fossil fired
plant was mechanically damaged
SPLICE accidentally. Normally the joint
VERIFICATION would have to be replaced at the
Sample material and splicing next outage or shutdown
film is supplied to allow depending on the extent of damage.
verification of iron operation at
the joint location in your plant TEAR PROPAGATION
to assure leak proof splices. Ultrachem materials have greater
tensile strength and will not
SPLICING YOUR continue to propagate holes or
EXPANSION tears like rubber materials. This
JOINT BELT benefit allows you to run longer
Joints may be spliced in the without the damage getting worse
vertical or horizontal positions. or generating catastrophic failure of the joint.
The temperatures of the heat
seal iron is electonically HEAT SEAL REPAIR
controlled and heat loss is Using the procedures above, the
minimized with the use of joint may be repaired and will
an insulated back up board. retain original tensile strengths.
No special preparation is
EASY TO necessary. This repair can be
WORK WITH easily made by plant personnel.
No special tools or skills are
required to perform the splice. FIELD
The Installation Manual REPAIRABILITY
completely details the The ability to repair your
procedure. expansion joint materials with
plant personnel gives the plant
THE COMPLETED SPLICE more independence to solve its
In minutes the splice is completed. Compared to hours own problems. Expansion joint
spent vulcanizing rubber expansion joint materials, not to replacement and repairs can now be performed in a
mention the cost on the required factory technician, our fraction of the time and expense normally allocated for
products offers a practical and economic solution. fluoroelastomer repairs.
16
-––[FLEXON PRODUCT LINE]–-–

Senior Flexonics Pathway manufactures a variety of composite belt configurations to meet the
varied needs of all our customers. Shown for illustration purposes is one of the premium grade
belt constructions for each rated continuous operating temperatures.
4 mil (0.1 mm) cast PTFE

corrosion resistant film
Multilayer reinforced
continuous filament
fiberglass yarn (Fill)
Wrapped to
maximize
flexibility and
tensile strength
Bundled and twisted

for flexibility
Woven to provide
extended life matrix
FLUORINATED ELASTOPLASTICS
Fluoroelastoplastics combine the corrosion resistance of a fluoroplastic with the flexibility
of a fluoroelastomer through the addition of FKM to the PTFE compound. Fluoroelastoplastic
materials have been used successfully in over 10,000 expansion joints worldwide, providing
exceptional performance even in the severe chemical environments found in flue gas
desulfurization plants (FGD), pulp and paper (recovery boilers), refuse derived fuels (RDF)
and smelters.
DARLYN® PRODUCT LINE

Senior Flexonics Pathway is an authorized fabricator of expansion joints utilizing Chemfab
Corporation’s DARLYN fabrics. These products were first introduced in 1983. The DARLYN
line of materials are fluorinatedelastoplastic alloys. Because of their thermal and chemical
capabilities, fluoroelastoplastic fiberglass reinforced, PTFE-coated and laminated belting materials
are being used extensively in expansion joint designs for all types of systems.
17
-––[PATENTED PTFE/FKM ALLOY

PROVIDES ADDITIONAL FLEXIBILITY ]–-–
Perfluoroplastic, due to its crystalline nature, is
inherently stiff which reduces the long term flex
endurance and life of PTFE fabric expansion joints.
To overcome this shortcoming, fluoroelastomer
(Viton®/Fluorel®) is blended into a patented alloy
which bathes the coated fiberglass matrix significantly
increasing the flexibility, tear resistance, tensile and shear
strength of DARLYN fabricated belts. This means longer
in-service life.
DARLYN can be easily identified by its lack of stiffness.

The uniformly distributed alloy coating is more
compliant than PTFE, filling the voids and impregnating
the woven structure. This pliable matrix maintains
consistent physical and chemical properties over a wide
range of temperatures and corrosive conditions
experienced in flue gas ductwork.
CONSISTENT COATING PROCESS

The DARLYN series of products are coated and cured over a dozen times in the patented process.
The multilayer alloy coating of PTFE and FKM completely surrounds the fiberglass foundation,
and then is multi-coated with PTFE. This unique procedure is a characteristic of the detailed
quality and consistency which guarantees the longevity of the DARLYN products.
DARLYN material is manufactured with 100% defect free, continuous, twisted multiple filament
fiberglass. This means that for the entire length of your DARLYN belting material the strands are
uncut, homogeneous and guaranteed the strongest fiberglass fibers possible. Numerous strands
are than grouped and twisted together maximizing the flex, tensile, shear and tear characteristics
of thousands of filaments. These glass yarns are then bathed with a protectant PTFE coating to
resist self-abrasion and friction during flexing, and chemical attack preventing acid from wicking
in service, which destroys conventional woven glass.
18
DARLYN 1100 CB & ULTRACHEM

CB or Chemical Barrier was developed for superior corrosion resistance. A multilayer PTFE cast
film is thermally and chemically welded to DARLYN 1100 and ULTRACHEM assuring an even
greater protection from corrosion due to exposure in the most extreme conditions. This
isotropic film (identical physical properties in all directions) is built up through multiple
operations assuring a uniform thickness, nonporous, chemically inert barrier. Further, when
combined with the DARLYN and ULTRACHEM isotropic fabric, the result is a uniform membrane
which can flex without stress concentrations, distributing the load equally throughout the belt.
HIGH TEMPERATURE APPLICATIONS

■ Superior strength retention, even after repeated flexing.
■ Fast, easy field splicing
■ Outstanding corrosion resistance
■ Less than 1/4 the weight of 100% fluoroelastomer fabrics, resulting in lower installed costs
ULTRACHEM fluoroplastic
coated fiberglass fabric
FLEXON-700 A composite belt designed
to provide continuous reliable service at
700°F (371°C). A tightly woven fiberglass
insulation is thermally bonded to the
FLEXON material. This composite design
provides insulating properties at elevated
temperatures and prevents separation of
the insulation.
4 mil PTFE film

60 oz (0.64 g/cm3)
laminated to
tightly woven fiberglass
ULTRACHEM cover ULTRACHEM Fluoroplastic coated
mat insulation laminated
fiberglass fabric with 4 mil (0.1 mm)
to the gas seal
PTFE film laminated to gas side
FLEXON-1000 A composite belt

designed to provide continuous reliable
service at 1000°F (538°C). A non-woven
fiberglass needle-mat insulation is bonded
to the ULTRACHEM material and encased
in aluminized coated fiberglass cloth.
5/8” (16 mm) thick
nonwoven fiberglass
insulation laminated
to the gas seal
19
ULTRACHEM Fluoroplastic coated

5/8” (16 mm) thick

nonwoven fiberglass
to the gas seal

designed to provide continuous
service at 1200°F (649°C), by the
addition of a 1/2” (13 mm) of ceramic
mat insulation to the FLEXON 1000.
Inconel® wire inserted silica cloth is
used as the encasement to replace 1/2” (13 mm)
ceramic mat
fiberglass in applications above insulation Inconel wire reinforced
1000°F (538°C). silica/ceramic fabric
encasement
ULTRACHEM Fluoroplastic coated


designed to provide continuous
service at elevated continuous
temperatures to 1500°F (816°C).
1” (25 mm) thick

ceramic mat insulation
5/8” (16 mm) thick

nonwoven fiberglass
Inconel wire reinforced Note: Designs are available to 2000°F (1090°C).
to the gas seal
silica/ceramic fabric
reinforcement encasement
20
-––[HOW TO SPECIFY A
SPECIAL
NOTE
The following STEP Maximum Continuous
instructions will help 2 System Operating
determine the correct Temperature (MCSOT°F)
part number. STEP Expansion joints can be manufactured and - This is the highest
Completion of the 1 shipped either assembly or unassembled select temperature at which the system
ducting expansion joint the option which best meets your requirements. normally operates. Excursion (upset)
specification sheet is A - Assembled – Ready for immediate installation temperatures and durations should
also helpful and enables be specified on the Ducting
Senior Flexonics U – Unassembled – Match marked and packaged to Expansion Joint Specification Sheet.
Pathway’s engineering minimize assembly at the jobsite. Complete assembly For applications exceeding 1200°F,
staff to verify that the instructions and manufacturing drawings included. please consult Senior Flexonics
correct design has been BA - Belt, Assembled - Fabric belt elements are provided Pathway’s engineering department.
selected. Factory holes, as a factory-spliced, endless loop, to fit existing frames.
back-up bars, nuts, and
BU - Belt, Unassembled - Fabric elements are prepared
bolts must be specified
for field splicing at the jobsite.
if required.
Operating Frame
Assembly MCSOT
Pressure Style
English U 450 12 SR2400

Metric U 232 305 SR2400
STEP Gas Seal Material - Leave this section

5 of the part number blank and Senior
Flexonics Pathway will make the
material selection.
STEP Select the letter code for the options and
6 accessories (CAP for Cavity Accumulation Pillow,
See material descriptions on Pages 17-20
CIP for Cavity Insulation Pillow, BH for Braided
Hose Seal, TG for Tadpole Gasket Tape, FD for
-––[FLEXON
Senior Flexonics
PRODUC
Pathway manufact
T LINE]–-–
ures a variety
. Shown for
of composite
-––[
illustratio
belt configura
PATisENT
n purposes
temperatures.
tions to meet
one of theED PTF
premium
ES ADD
the
grade E/FK
M ALLOY XIBILITY ]–-– EM
FLE
ITIONALYN 1100 CB develop
was is
ACH
ed for 1100 and
ULTRAC
ce. A multila
& ULTR superior corrosion resistan HEM assuring
yer PTFE
conditions.
This
cast
an even
ULTRACHE
fiberglass
film laminated
to gas
4
tic coated
M Fluoroplasmil PTFE
fabric with side
Flow Deflector, FWL for Field welded Liner, SWL for Shop
varied needs
of all our customers continuous operating
each rated
PROVID DARL
CB or to
due
lly and
e nature,
al Barrier
its crystallin
Chemic ally welded
term flex
chemic
to DARLYN
to exposur
e in the
most extreme
is built up
through
multiple
, when (16 mm)
thick
Welded Liner, BFL for Bolted Flange Liner)

plastic, long ns)
reduces the n due Further 5/8”
ons for Perfluoro is therma fiberglass
belt constructi stiff film
which corrosio joints.
expansion l properties in
on from
all directio inert barrier. membrane nonwovenlaminated
inherently fabric
protecti chemically is a uniform belt. insulation
life of PTFE (identical physica
and greater stomer nonporous, c fabric, the result out the to the gas
seal
4 mil cast PTFE film endurance c filming, fluoroela thickness, through
corrosion resistant e this shortcom
isotropi a uniform alloy HEM isotropi the load
equally
To overcom into a patented and ULTRAC
ns assuring
) is blended significantly distributing
trations,
®operatio
DARLYN
(Viton /Fluorel combin
®
with the s matrix
and shear
the coated
edfiberglas stress concen
withoute, tensile belt
which bathes which can flexresistanc
y, tear means longer composite
g the flexibilit belts. This IONSN-1200 A continuous
increasin fabricated APPLICAT FLEXO flexing. to provide
Multilayer reinforced
continuous
filament strength
of DARLYN ERATURE after repeated designed 1200°F (649°C), by the
(Fill) life. HIGH TEMP retention, even service at of ceramic
fiberglass yarn in-service (13 mm) d costs
■ Superio
r strength of a 1/2” g in lower installe 1000.
field splicing addition resultin to the FLEXON
■ Fast, easy
ce r fabrics, on is 1/2” (13
mm) reinforced
n resistan
fluoroelastomemat
insulati silica cloth Inconel wireic fabric
ding corrosio of 100% ®
wire inserted to replace ceramic
mat
silica/ceram
of stiffness. ■ Outstan 1/4 the weight Inconel ent insulation nt
by its lack encasem encaseme
identified is more
■ Less than
used as the tions above
Wrapped to can be easily in applica
DARLYN ed alloy coating impregnating fiberglass d
maximize ly distribut voids and . ite belt designe
flexibility and The uniform filling the s 1000°F (538°C) A compos
t than PTFE, matrix maintain wide
ic service at
tensile strength M fluoroplast FLEXON-700 ous reliable
PILLOW ]–-– ES]–-–
complian This pliable s over a
ULTRACHE fabric ss
structure. l propertie coated fiberglass to provide
continu
woven fibergla
the woven and chemica conditions
. A tightly to the
-––[CAVITY ESSORI
See pages
t physical 700°F (371°C) lly bonded
and twisted
consisten tures and corrosive on is therma ite design S & ACC
retarding the
Bundled
for flexibility
range of tempera gas ductwork.
in flue
experienced to provide
insulati
FLEXON
This compos
material.ULTRACHEM ies
ng propert
Fluoroplas
fabric with side
tic coated
at elevated
4 mil PTFE
CAVITY PILLOW
STYLES serve three purposes,
Pathway cavity
pillows to pressure
pulsation. -––[OPTION (BH) is often
s insulati fiberglass to gas on of Flexonics and resistance with a wrapped HOSE SEAL ceramic insulation The hose
is
Woven
provide s separati
laminated The Senior thermal protection, materials and hose with
enclosed
life matrix process. film
prevent particulate, pillows areED loading.
extended
patented tures and intrusion of from selected
insulation StandardBRAID steel braided
areas of high
particulate the
PROCESS times in the on, tempera are fabricated for the operating
conditions.
bars to hold the
Flexible stainless
joints in from entering
T COATING over a dozen s foundati on. ite belt Our pillows
fabric, designed belt and backup the
expansion
for to
particulate
liners to prevent with a cavity pillow
works
and cured s the fiberglas the insulati A compos high temperature that fasten
under the
designed to
provide a memory
specified
edthe flow
CONSISTEN are coated ely surround detailed
FLEXON-1500 ous “ears” or tabs
along
ristic of the The ears are between
uncompress
secured This accessory
theof flexibility
products FKM complet continu provided with “as installed”
11-12
OPLASTICSof a fluoroplas tic withseries is a characte tic coated to provide pillow in place. return to an joint cavity.
D ELAST The DARLYNd. Fluoroelas of PTFE and
toplastic procedure products. M Fluoroplasmil (0.1 mm) designed ous that it will expansion
alloy coating 4 continu pillow such outages. plants.
FLUORINATEcombine the corrosion FKM to the PTFE
resistance
multilayer This unique y of the DARLYN 4 mil PTFE
film ULTRACHE
fabric with gas side elevated . down, during well in cement
Thecompoun with PTFE.
e, providing to fiberglass to service at 1500°F (816°C) state after
plant cool with
of multi-coated
joints isworldwid es the longevit PTFE film
laminated
tures to PILLOW (CAP) TAPE (TG) joints in duct systems
Fluoroelastoplastics through the addition
laminated
filament
expansionand then gaswhich guarante g/cm )
3
multiple ULTRACHEM cover tempera ULATION frame/flanges and the GASKET expansion
tomer in over 10,000 ents found
in fluecy
consisten 60 oz (0.64 us, twisted
woven fiberglass strands are CAVITY ACCUM structural steel TADPOLE integral flange-type Pathway
, Senior Flexonicsflexible element
of a fluoroelas successfully quality and fuels (RDF)
continuo
defect free, tightlyinsulation material the between the a standoff
When using
chemical environm to provide conditions the
been used refuse derived with 100% belting laminated
plies are A cavity created joint) is designed This cavity can fill operating between of the
materials have ce even in
the severe
of your DARLYN
mat
Numerous positive pressure use of tadpole gasketing prevents the heads
manufactured
expansion
(recovery boilers),
seal (fabric gas.
to the gas possible. seal the flue are
exceptional
performan
pulp and paper material is entire length s fibers ristics of thick
1” (25 mm) insulation
gas
fabric element
and
gas. If these
deposits recommen
ds the
(as illustrated
). This
flexible element.
plants (FGD), DARLYN that for the t fiberglas and tear characte to mat Style - 1
between the
falling out
of the flue to operate
properly backup bars the outside
cover of the during large
desulfurization This means the stronges tensile, shear
ceramic
joint will fail flange and flanged belts
guaranteed
for various
fiberglass. ing the flex, nt PTFE coating with particulate expansion
erection bolts
from abrading
and integrally
smelters. homoge neous and maximiz with a protecta from wicking allowed to
buildup the Senior Flexonics
Pathway
to occupy both flat
and together ng acid also protects
uncut,
and twisted then bathed become damaged. n pillow designed This option ts.
Chemfab yarns are attack preventi ite belt and could an accumulatio and filling n movemen
joints utilizing s. These glass
than grouped chemical A compos mm) thick s the use of from entering
lateral or
compressio FD
DARLYNduring flexing, and 5/8” (16 the deposits will
® PRODUCT
LINE of expansion ds of filament FLEXON-1000 ous reliable reinforced recommend a flow liner
in 1983. The space”, preventing in conjunction with
fiberglass
continu Inconel wireic fabric
DARLYN Pathway is an authorized fabricator thousan
were first introduce
d and friction
ional woven
glass.
designed
to provide
. A non-wo
ven nonwoven
laminated this “dead pillow Many T P
self-abrasion and chemical insulation silica/ceram encasement
this cavity.
The cavity ly ash.
1000°F (538°C)
seal ent n of particulate/f a low cost insurance
Senior Flexonics These products of their thermal destroys convent
resist is bonded to the gas reinforcem
DARLYN fabrics. alloys. Because in service, which belting materials service at insulation prevent the
accumulatio
view this option
as
joint. to
Corporation’s delastoplastic ed and laminated needle-mat l and encased mm) thick Style - 2 e managers of the expansion to the design
are fluorinate , PTFE-coat fiberglass HEM materia
5/8” (16
fiberglass maintenanc
extends the
service life Typical cavity
(FD)
pillow
flow deflector
is added and
fiberglass reinforced for all types of systems. DEFLECTOR prevent moisture
pillow styles.
line of materials cloth. nonwoven policy that s, an angle is used to
fluoroelastoplastic joint designs to the ULTRACcoated fiberglass insulation
laminated
CAVITYFLOWexpansion jointconstruction installation consisting
A flow deflector being trapped in
the expansion
capabilities, in expansion ized to the gas
seal RATURE In some the joint.
of insulation
extensively lifeofoflayers and
in alumin 18 HIGH TEMPE PILLOWS (CIP) the service duct walls
are being used increase
provides additional down vertical
in a protective
encased
20 INSULATION - A style CIP from sliding
Pillow (CIP) temperature
particulate
for high temp sleeve.
liner.
high
Cavity Insulation to the belting material by the flow
joint cavity
thermal protection
17 .
applications
to 2000°F
(1090°C). Style - 3
STYLES]–-–
are available
Note: Designs
flanged U-belt
RS]–-–
19
-––[FRAME element and/or application
s. The integrally belt cost and
nt
-––[ FLOW LINE designed to
provide protection
for the fabric
accumulatio
n. A liner is
also
provides
numerous
for various
frame designs frame design has
The flat belt standard
a lower replaceme
arrangeme
nts.
metal shields or particulate the Pathway Integral Liner cost. of several
(baffles) are t of particulate Senior Flexonicsof economica
to help control l initial capital is a sample
Flow liners impingemen turbulence, the
from direct caused by has a very
the temperature The following frame
cavity pillow fabric element and to reduce design can be reused. a complete
flutter of the joint cavity, airfoil, semi-airfoil present and s.
used to reduce expansion of profiles existing hardware
(straight,
C.S.). Flow flanges are re application
n of dust or
ash in the on a variety 10 GA. A569 SR2400 s where the ductworkwell for high temperatu
accumulatio can be supplied are straight
Design application works
Flow liners and material This style
flexible element. (Standard profile and is preferred.
and materials. as on SR2700
assembly
drop-in assembly reduce cost
or telescoping) categories. joint frame ■ Complete frames
fall into the following of the expansion Bolt-in Liner ed standard outside permit liner
liners tured parts ■ Prefabricat accessible
from t cannot
liners are pre-manufac our U1000 or equipmen
■ Integral joints as on ■ Belting hardware adjacent structures
expansion Gaskets are
SR2750 series
frames. flanged style duct flange. ■ Best choice
when t flange.
used on integrally and the mating beyond attachmen
are primarily joint flange protrusion liner
■ Bolt-in liners expansion . SR2400 welded flow
the belt or etal connections the duct Accepts shop design
the field to
■
series, between tal and/or
Teflon-to-m
welded in eared pillow
metal-to-me can be either Readily accepts breech openings
required on
■
breach opening joint frame. Weld-in Liner ts

the the expansion ■ Used to fill large movemen
liners spanning factory to lateral
welded in dates large
for belt protection
■ Weld-in
can be supplied
■ Accommo
interior or proper setback
■ Provides 12
or unassembled.
assembled
furnished
joints are
11 Pathway expansion
Senior Flexonics
21
FABRIC EXPANSION JOINT ]–-–
STEP List the system operating pressure in STEP Frame Style - Select the appropriate frame style
3 inches water column, the pressure will be 4 (SR2400, SR2500, SR2550, SR2600, SR2650,
assumed to be positive unless a negative SR2700, SR2750, SR2800, SR2900, U1000, etc.)
number is listed. The maximum rated
operating pressure: ±83” wc (3 PSIG) for teflon belt For isometric view and detailed
±139” wc (5 PSIG) for elastomer. For higher description see pages 12-14
pressures please consult Senior Flexonics Pathway’s
engineering department. -––[OPTION
S & ACC
(BH)
ESSORIES
]–-–
ceramic insulation hose is

is often
SR2800
This style
frame is well
suited for
installation
with field
assembly
re ratings.
for all temperatu ed angle iron
over existing
installatio
SR2800 is well suited for all temperature ratings. iron
n with field
assembly
over existing
HOSE SEAL joints, and

is utilized prefabricat
BRAIDED steel braided hose with enclosed loading. The expansion
frame utilizing
standard This style
frame
and is utilized
for
prefabrica
ted angle
Flexible stainless
particulate
of high the can be utilized existing metal expansion joints, standard n
joints in areas
■ Economic
from entering bolted frame over expansion utilizing
can be utilized existing metal
expansio
expansion particulate welded or to retrofit c frame
specified for to prevent
a cavity pillow
works ■ Either
can be used ■ Economi
bolted frame to retrofit over
the flow liners along with wrap design ) welded or
secured between This accessory
■ Fabric
on-line installation
■ Either
can be used n)
joint cavity. wrap design
expansion joints (possible design ■ Fabric
on-line installatio
plants. eared pillow and fit-up joints (possiblepillow design
well in cement ■ Accepts
SR2800 field assembly ■ Accepts

eared and fit-up
Facilitates ■
TAPE (TG) joints in duct systems with nuts are optional protection s field assembly
GASKET Tack welded for belt
■ SR2800 ■ Facilitate
nuts are
optional n
TADPOLE flange-type
integral
expansion Pathway proper setback
Senior Flexonics ■ Provides ■ Tack welded for belt
protectio
When using flexible element proper setback
operating conditions, between the ■ Provides
positive pressure tadpole gasketing prevents the heads
of the
s the use of This is required
or preferred. .
recommend (as illustrated). flexible element. assembly or preferred
backup bars cover of the and field is required
flange and the outside during large
SR2900where flanges are not present metal expansion joints and field
assembly
from abrading flanged belts present n joints
erection bolts flat and integrally Best utilized used over
existing SR2900where flanges are not existing metal expansio
also protects both wrap design ) ductworkBest utilized over
This option . ■ Fabric
to existing design used
movements on-line installation reinforcement l design ■ Fabric wrap n) to existing
ductwork
lateral or compression (possible
F D additional stiffener for economica on-line installatio reinforcement economical design
TP ■ Provides steel channels (possible l stiffener for
structural
■ Utilizes
standard ■ Provides
additiona l steel channels
stiffiners structura
■ Flanges
act as duct ■ Utilizes
standard
stiffiners
design to SR2900 ■ Flanges
act as duct
added to the
TOR (FD) flow deflector is moisture and SR2900
temperatu
res
, an angle ures
FLOW DEFLEC joint installations deflector is
used to prevent
used for low
to moderate temperat
In some expansion life of the joint. A flow trapped in
the expansion design is loading is
minimal low to moderate
and being U1000 integrally flanged U-belt used for is minimal
service duct walls particulate design is e loading
increase the present and cost
from sliding
down vertical The standard flanges are
metal frame
and fasteners U1000 integrally flanged U-belt and particulat cost
particulate s where duct are present and fasteners
by the flow
liner. application due to reduced r ductwork The standard
for duct flanges metal frame
joint cavity initial cost for rectangula
frequently ns where
due to reduced y for
■ Lowest
t and utilized applicatio ar ductwork frequentl
corners provided equipmen initial cost for rectangul t and utilized
■ Molded ducting or ■ Lowest
provided
dates flanged corners or equipmen
■ Accommo ■ Molded ducting
s odates flanged
STYLES]–-–
fan application costs
■ Accomm
ns
U1000 ■ Minimal
shipping fan applicatio
design costs
flanged U-belt
-––[FRAME for various
applications
. The integrally
belt cost and
■ Standard
3” high flange U1000 ■ Minimal
■ Standard
shipping
3” high
flange design
frame designs a lower replacement

numerous design has
belt frame ts.
Pathway provides capital cost. The flat arrangemen s with minimal
Senior Flexonics initial of several standard application ns with
minimal
a very economical is a sample ES in H.V.A.C. applicatio
design has The following SLEEV used for vibration in H.V.A.C.
can be reused. frame
are primarily VES vibration
existing hardware and a complete Sleeves SLEE s used for
are present . n application
are primarily ns
SR2400 ductwork flanges applications of pipe penetratio Sleeves on applicatio
where the well for high
temperature pressures. design for field-wrap . of pipe penetrati
Design applications ■ Least expensive
This style works endless or
open ended pressures design field-wrap
preferred. clamps expensive ended for
assembly is ■ Supplied
gear band ■ Least
or open
drop-in assembly reduce cost with worm ■ Supplied
endless
gear band
clamps
■ Complete frames ■ Supplied s
d standard outside liner ■ application belt material with worm ns
■ Prefabricate
accessible from cannot permit For vibration for Teflon ■ Supplied
or equipment with gaskets

applicatio belt material
■ Belting hardware structures ■ Provided ■ For vibration for Teflon
when adjacent with gaskets
■ Best choice flange.Sleeves ■ Provided
beyond attachment
protrusion liner Sleeves
SR2400 welded flow
■ Accepts shop design
eared pillow
■ Readily accepts openings
large breech
■ Used to fill lateral movements
tes large
■ Accommoda belt protection
setback for
■ Provides proper
12
unassembled. 14 14
assembled or
joints are furnished
Pathway expansion
Senior Flexonics or unassembled.
assembled
furnished
joints are or unassembled.
Pathway expansion furnished
assembled
Senior Flexonics joints are
expansion
Pathway
Senior Flexonics
STEP The basic

8 part number
Duct Size is now
Belt Options Span complete.
Inside For a unassembled Flexon
Material Accessories F-F 1000CB material on a
Dimension SR2400 frame with a
cavity accumulation pillow
and a flow deflector 120
Flexon 1000 CAP - FD 14 120 x 96 inches wide by 96 inches
high with 14 inches active
length for maximum
Flexon 1000 CAP - FD 356 3048 x 2438 continuous operating
conditions of 450°F and
12 inches water column.
NOTES:
Torsion and angular movement capabilities may be obtained by
consulting Senior Flexonics Pathway's engineering department. Larger
spans are possible, depending on system pressures and movements,
and require consultation of Senior Flexonics Pathway's engineering
STEP List the Face to Face Dimension department. Non-standard face to face dimensions are available.
7 (distance between the mating duct Movements must be specified in the description accompanying the
flanges) in which the expansion joint part number. A significant difference exists between the movement
is to be installed. This dimension capabilities of round expansion joints and large rectangular joints (sides
should not be confused with the active length. exceeding 3’ length). This difference is due to the folding characteristics
of the fabric element, which vary depending on whether it is attached
to straight or curved flanges.
NT
-––[MOVEME ES]–-–
CAPABILITI
are the differential
thermal expansions and/or excursion during
The system of operating e
expansion/
contraction ambient temperatur uses these
es and the
minimum joint engineer design for
temperatur . The expansion material and
and shutdowns to select the proper c expansion
installation es nonmetalli
s and temperatur Flexonics Pathway’s torsional
movement angular and
joint. Senior axial, lateral, be
each expansion can handle combined ion should
Considerat
joints frequently required. fabricator
s in a single
assembly. total number l for the duct
movement reducing the more economica
be optimized, it may be
can often ducting systems,
joint locations t, for new
The expansion and belt replacemen frame.
accessibility joint both
given for of the expansion in either or
a portion occurring
to provide of duct movement duct,
l axis of the
- The amount to the longitudina
Lateral Movement lar planes out of alignment.
perpendicu joint flanges
of the two
the expansion
which moves
l shortening
dimensiona
ion - The joint
See page 7 for

Axial Compressi
(compressio
face-to-face
Torsional
occurring
on/Extens
Deflection
g (extension)
n) or lengthenin to it’s longitudina
dimension
parallel
- The amount
in the perpendicu
the duct system.
of the expansion
of twisting
lar planes
of rotation
l axis.
movement
to the longitudina
(in degrees)
(in degrees)
l axis of
of the duct
position
CAUTION
- The amount of parallel
flanges out
technical data.
Angular Deflection the expansion joint
flexes
system which OPENING
with each
other. BREACH O-FACE
ES FACE-T
Installation temperature and duct tolerances must be considered in

CAPABILITI 12” (305mm)
MOVEMENT6” (152mm) 9” (229mm)
TYPICAL Active Length 3” (76mm)
4” (102mm)
Belt Type n 2” (51mm) 1/2” (13mm)
Axial Compressio 1/2” (13mm)
Single Layer 1/2” (13mm) 2” (51mm) Set Back
Axial Extension 1 1/2” (38mm)
Fabric Element 1” (25mm) 2” (51mm)
Lateral 1 1/2” (38mm) Active Length
rrent) n 1” (25mm) 1/4” (6mm)
(Non-concu
1/4” (6mm)
determining installed face to face dimensions and movements.

1” (25mm)
Belt Axial Extension 3/4” (19mm) Active Length
Composite
1/2” (13mm) 4” (102mm)
) 3” (76mm)
(Concurrent Lateral
n 2” (51mm) 1/2” (13mm)
Integrally
Flanged 1/2” (13mm) 2” (51mm)
Axial Extension 1 1/2” (38mm) Set
Single Layer 1” (25mm) Back
) Lateral
(Concurrent or concurrent
nonconcurrent
or differ from
exceed those
listed above these Breach or
when movements (6mm). Exceeding F/F DOM
lateral + 1/4”
Notes: must be made applications. 1/2” (13mm),
considerations for these axial compression belt movement.
1. Special with factory 1/4” (6mm), the relative
ratings. Consult Axial extension to reduce
tolerances: offset (preset)
2. Breaching capabilities. cold lateral
will affect
movement should utilize
tolerances 3” (76mm)
exceeding
3. Lateral movement
22
-––[ELASTOMER MATERIAL
DESCRIPTIONS ]–-–
Ultraflex EV4® Fluoroelastomer and Elastomer Design Data

BELT CONSTRUCTION
■ Fluoroelastomer terpolymer material, ASTM FKM (Viton® B with a C Cure or Fluorel® FT2350)
per FSA-DSJ-401-94, Para. 3.1 (virgin FKM 68% by weight Flourine / 70% by weight FKM,
balance 30% by weight thermal type carbon black with calcium hydroxide. Magnesium
oxide and less than 5% by weight process aids).
■ Aramid / fiberglass reinforcing material treated to ensure a minimum 24 lbs. / lineal inch
Adhesion per ASTM D-413
■ Heavier FKM ply on gas slide providing optimum “unbalanced ply” design
■ Computer controlled belt press that guarantees optimum uniform pressure and heat
distribution over the entire material surface
F-VN-25 F-VF-25FSA F-VF-25N F-EP-25
.250" .250" .250" .125"

(6.35 mm) (6.35 mm) (6.35 mm) (3.18 mm)
Min. thick Min. thick Nom. thick Nom. thick
Gas Ply Gas Ply
FKM Aramid/Fiberglass Fiberglass
23
-––[THERMAL EXPANSION]–-– PRESSURE

EQUIVALENTS
CHART
In the selection of an expansion joint, one of the critical design factors is the thermal
expansion. To compute the linear expansion of a straight run of pipe or ducting, the
designer must select the material and determine the linear distance of the ductwork.
The linear expansion of the ductwork can be determined from the thermal growth chart
using the temperature change between ambient and the design temperature.
THERMAL GROWTH CHART

Temp. Temp. Carbon, 5 Cr Mo Austen, Ferritic
Monel Inconel 25CR
Degrees Degrees C MO, 3CR thru Stainless Stainless
400 600 20NI
F. C. MO Steel 9 Cr Mo 18 Steel Steel
-325 -198 -2.37 (-1.97) -2.22 (-1.85) -3.85 (-3.21) -2.04 (-1.70) -2.62 (-2.18) -3.00 (-2.50)
-300 -184 -2.24 (-1.87) -2.10 (-1.75) -3.62 (-3.02) -1.93 (-1.61) -2.50 (-2.08) -2.83 (-2.36)
-275 -171 -2.11 (-1.76) -1.98 (-1.65) -3.40 (-2.83) -1.81 (-1.51) -2.38 (-1.98) -2.66 (-2.22)
-250 -157 -1.98 (-1.65) -1.86 (-1.55) -3.17 (-2.64) -1.70 (-1.42) -2.26 (-1.88) -2.30 (-1.92) -2.49 (-2.07)
-225 -143 -1.84 (-1.53) -1.74 (-1.45) -2.95 (-2.46) -1.58 (-1.32) -2.14 (-1.78) -2.17 (-1.81) -2.32 (-1.93)
-200 -129 -1.71 (-1.42) -1.62 (-1.35) -2.72 (-2.27) -1.47 (-1.22) -2.03 (-1.69) -2.04 (-1.70) -2.15 (-1.79)
-175 -115 -1.58 (-1.32) -1.50 (-1.25) -2.49 (-2.07) -1.35 (-1.12) -1.91 (-1.59) -1.87 (-1.56) -1.98 (-1.65)
-150 -101 -1.45 (-1.21) -1.37 (-1.14) -2.27 (-1.89) -1.24 (-1.03) -1.79 (-1.49) -1.70 (-1.42) -1.81 (-1.51)
-125 -87 -1.30 (-1.08) -1.23 (-1.02) -2.01 (-1.67) -1.12 (-0.93) -1.59 (-1.32) -1.54 (-1.28) -1.60 (-1.33)
-100 -73 -1.15 (-0.96) -1.08 (-0.90) -1.75 (-1.46) -0.99 (-0.82) -1.38 (-1.15) -1.37 (-1.14) -1.39 (-1.16)
-75 -59 -1.00 (-0.83) -0.94 (-0.78) -1.50 (-1.25) -0.86 (-0.72) -1.18 (-0.98) -1.17 (-0.97) -1.19 (-0.99)
-50 -46 -0.84 (-0.70) -0.79 (-0.66) -1.24 (-1.03) -0.72 (-0.60) -0.98 (-0.82) -0.97 (-0.81) -0.98 (-0.82)
-25 -32 -0.67 (-0.56) -0.63 (-0.52) -0.98 (-0.82) -0.58 (-0.48) -0.77 (-0.64) -0.76 (-0.63) -0.76 (-0.63)
0 -18 -0.50 (-0.42) -0.46 (-0.38) -0.72 (-0.60) -0.43 (-0.36) -0.57 (-0.47) -0.56 (-0.47) -0.57 (-0.47)
25 -4 -0.32 (-0.27) -0.30 (-0.25) -0.46 (-0.38) -0.27 (-0.22) -0.37 (-0.31) -0.36 (-0.30) -0.37 (-0.31)
50 10 -0.14 (-0.12) -0.13 (-0.11) -0.21 (-0.17) -0.12 (-0.10) -0.16 (-0.13) -0.16 (-0.13) -0.16 (-0.13)
70 24 0.00 (0.00) 0 (0.00) 0.00 (0.00) 0.00 (0.00) 0.00 (0.00) 0.00 (0.00) 0.00 (0.00)
100 38 0.22 (0.18) 0.22 (0.18) 0.33 (0.27) 0.19 (0.16) 0.27 (0.22) 0.26 (0.22) 0.27 (0.22)
125 52 0.41 (0.34) 0.40 (0.33) 0.61 (0.51) 0.35 (0.29) 0.50 (0.42) 0.48 (0.40) 0.50 (0.42)
150 66 0.60 (0.50) 0.58 (0.48) 0.89 (0.74) 0.52 (0.43) 0.74 (0.62) 0.70 (0.58) 0.73 (0.61)
175 79 0.80 (0.67) 0.76 (0.63) 1.17 (0.97) 0.69 (0.57) 0.98 (0.82) 0.93 (0.77) 0.97 (0.81)
200 93 1.00 (0.83) 0.94 (0.78) 1.46 (1.22) 0.86 (0.72) 1.22 (1.02) 1.15 (0.96) 1.21 (1.01)
225 107 1.20 (1.00) 1.13 (0.94) 1.74 (1.45) 1.03 (0.86) 1.47 (1.22) 1.39 (1.16) 1.45 (1.21)
250 121 1.40 (1.17) 1.33 (1.11) 2.03 (1.69) 1.21 (1.01) 1.71 (1.42) 1.63 (1.36) 1.69 (1.41)
275 135 1.61 (1.34) 1.52 (1.27) 2.32 (1.93) 1.38 (1.15) 1.96 (1.63) 1.86 (1.55) 1.94 (1.62)
300 149 1.82 (1.52) 1.71 (1.42) 2.61 (2.17) 1.56 (1.30) 2.21 (1.84) 2.10 (1.75) 2.19 (1.82)
325 163 2.04 (1.70) 1.90 (1.58) 2.91 (2.42) 1.74 (1.45) 2.47 (2.06) 2.34 (1.95) 2.44 (2.03)
350 177 2.25 (1.87) 2.10 (1.75) 3.20 (2.67) 1.93 (1.61) 2.72 (2.27) 2.57 (2.14) 2.69 (2.24)
375 191 2.48 (2.07) 2.30 (1.92) 3.50 (2.92) 2.11 (1.76) 2.98 (2.48) 2.81 (2.34) 2.94 (2.45)
400 204 2.70 (2.25) 2.50 (2.08) 3.80 (3.17) 2.30 (1.92) 3.25 (2.71) 3.05 (2.54) 3.20 (2.67)
425 218 2.93 (2.44) 2.72 (2.27) 4.10 (3.42) 2.49 (2.07) 3.51 (2.92) 3.30 (2.75) 3.46 (2.88)
450 232 3.16 (2.63) 2.93 (2.44) 4.40 (3.67) 2.68 (2.23) 3.78 (3.15) 3.54 (2.95) 3.72 (3.10)
475 246 3.39 (2.82) 3.14 (2.62) 4.70 (3.92) 2.88 (2.40) 4.06 (3.38) 3.79 (3.16) 3.98 (3.32)
500 260 3.62 (3.02) 3.35 (2.79) 5.01 (4.17) 3.08 (2.57) 4.33 (3.61) 4.03 (3.36) 4.24 (3.53)
525 274 3.86 (3.22) 3.58 (2.98) 5.31 (4.42) 3.28 (2.73) 4.61 (3.84) 4.28 (3.57) 4.51 (3.76)
550 288 4.10 (3.42) 3.80 (3.17) 5.62 (4.68) 3.48 (2.90) 4.89 (4.07) 4.53 (3.77) 4.78 (3.98)
575 302 4.35 (3.62) 4.02 (3.35) 5.93 (4.94) 3.69 (3.07) 5.17 (4.31) 4.77 (3.97) 5.05 (4.21)
600 316 4.60 (3.83) 4.24 (3.53) 6.24 (5.20) 3.90 (3.25) 5.46 (4.55) 5.02 (4.18) 5.33 (4.44)
625 329 4.85 (4.04) 4.47 (3.72) 6.56 (5.46) 4.10 (3.42) 5.75 (4.79) 5.29 (4.41) 5.60 (4.66)
650 343 5.11 (4.26) 4.69 (3.91) 6.87 (5.72) 4.31 (3.59) 6.04 (5.03) 5.54 (4.61) 5.88 (4.90)
675 357 5.36 (4.46) 4.92 (4.10) 7.18 (5.98) 4.52 (3.77) 6.34 (5.28) 5.80 (4.83) 6.16 (5.13)
700 371 5.62 (4.68) 5.14 (4.28) 7.50 (6.25) 4.73 (3.94) 6.64 (5.53) 6.06 (5.05) 6.44 (5.36)
725 385 5.89 (4.91) 5.38 (4.48) 7.82 (6.51) 4.95 (4.12) 6.94 (5.78) 6.32 (5.26) 6.73 (5.61)
750 399 6.16 (5.13) 5.62 (4.68) 8.15 (6.79) 5.16 (4.30) 7.24 (6.03) 6.58 (5.48) 7.02 (5.85)
775 413 6.43 (5.36) 5.86 (4.88) 8.47 (7.06) 5.38 (4.48) 7.54 (6.28) 6.84 (5.70) 7.31 (6.09)
800 427 6.70 (5.58) 6.10 (5.08) 8.80 (7.33) 5.60 (4.66) 7.85 (6.54) 7.10 (5.91) 7.60 (6.33)
825 441 6.97 (5.81) 6.34 (5.28) 9.13 (7.61) 5.82 (4.85) 8.16 (6.80) 7.38 (6.15) 7.89 (6.57)
850 454 7.25 (6.04) 6.59 (5.49) 9.46 (7.88) 6.04 (5.03) 8.48 (7.06) 7.67 (6.39) 8.19 (6.82)
875 468 7.53 (6.27) 6.83 (5.69) 9.79 (8.16) 6.27 (5.22) 8.80 (7.33) 7.95 (6.62) 8.48 (7.06)
900 482 7.81 (6.51) 7.07 (5.89) 10.12 (8.43) 6.49 (5.41) 9.12 (7.60) 8.23 (6.86) 8.78 (7.31)
925 496 8.08 (6.73) 7.31 (6.09) 10.46 (8.71) 6.72 (5.60) 9.44 (7.86) 8.52 (7.10) 9.07 (7.56)
950 510 8.35 (6.96) 7.56 (6.30) 10.80 (9.00) 6.94 (5.78) 9.77 (8.14) 8.80 (7.33) 9.36 (7.80)
975 524 8.62 (7.18) 7.81 (6.51) 11.14 (9.28) 7.17 (5.97) 10.09 (8.40) 9.09 (7.57) 9.66 (8.05)
1000 538 8.89 (7.41) 8.06 (6.71) 11.48 (9.56) 7.40 (6.16) 10.42 (8.68) 9.37 (7.81) 9.95 (8.29)
1025 552 9.18 (7.65) 8.30 (6.91) 11.82 (9.85) 7.62 (6.35) 10.76 (8.96) 9.66 (8.05) 10.25 (8.54)
1050 566 9.46 (7.88) 8.55 (7.12) 12.16 (10.13) 7.85 (6.54) 11.09 (9.24) 9.94 (8.28) 10.54 (8.78)
1075 579 9.75 (8.12) 8.80 (7.33) 12.50 (10.41) 8.08 (6.73) 11.43 (9.52) 10.23 (8.52) 10.83 (9.02)
1100 593 10.04 (8.36) 9.05 (7.54) 12.84 (10.70) 8.31 (6.92) 11.77 (9.80) 10.51 (8.75) 11.12 (9.26)
1125 607 10.30 (8.58) 9.28 (7.73) 13.18 (10.98) 8.53 (7.11) 12.11 (10.09) 10.80 (9.00) 11.42 (9.51)
1150 621 10.57 (8.80) 9.52 (7.93) 13.52 (11.26) 8.75 (7.29) 12.45 (10.37) 11.09 (9.24) 11.72 (9.76)
1175 635 10.84 (9.03) 9.76 (8.13) 13.87 (11.55) 8.97 (7.47) 12.80 (10.66) 11.37 (9.47) 12.01 (10.00)
1200 649 11.10 (9.25) 10.00 (8.33) 14.20 (11.83) 9.19 (7.66) 13.15 (10.95) 11.66 (9.71) 12.31 (10.25)
1225 663 11.38 (9.48) 10.26 (8.55) 14.55 (12.12) 9.42 (7.85) 13.51 (11.25) 11.98 (9.98) 12.60 (10.50)
1250 677 11.66 (9.71) 10.53 (8.77) 14.88 (12.40) 9.65 (8.04) 13.86 (11.55) 12.29 (10.24) 12.89 (10.74)
1275 691 11.94 (9.95) 10.79 (8.99) 15.22 (12.68) 9.88 (8.23) 14.22 (11.85) 12.61 (10.50) 13.17 (10.97)
1300 704 12.22 (10.18) 11.06 (9.21) 15.56 (12.96) 10.11 (8.42) 14.58 (12.15) 12.93 (10.77) 13.46 (11.21)
1325 718 12.50 (10.41) 11.30 (9.41) 15.90 (13.24) 10.33 (8.60) 14.94 (12.45) 13.25 (11.04) 13.76 (11.46)
1350 732 12.78 (10.65) 11.55 (9.62) 16.24 (13.53) 10.56 (8.80) 15.30 (12.74) 13.56 (11.30) 14.05 (11.70)
1375 746 13.06 (10.88) 11.80 (9.83) 16.58 (13.81) 10.79 (8.99) 15.66 (13.04) 13.88 (11.56) 14.35 (11.95)
1400 760 13.34 (11.11) 12.05 (10.04) 16.92 (14.09) 11.01 (9.17) 16.02 (13.34) 14.20 (11.83) 14.65 (12.20)
The linear thermal growth or contraction between 70°F (24°C) and indicated temperature is in inches/100 feet (mm/m) of duct work.
24
-––[GLOSSARY OF TERMS]–-–
Cavity Pillow (Insulation Bag): Same as accumulation
pillow, except used for thermal barrier.
Clamping Bars: See back-up bars.
Composite Belt: An expansion joint in which the

various plies are constructed of different materials that are
not integrally bonded together. Normally made up of an
inside liner, thermal insulating barrier and an outer cover.
Other special plies may be included.
Concurrent Movement: Combination of two or more

types (axial and lateral) of movements.
Corners: Molded, formed, or radial belt corners of

rectangular expansion joints.
Design Pressure: The maximum pressure, both positive

or negative that is expected during normal operation,
Accumulation Pillow: A pillow fabricated using
insulation material, wrapped in a woven fabric, then not including periods of abnormal operation (see
placed in an expansion joint cavity. The purpose is to excursion pressure).
either retard the intrusion of particulate, thermal
protection, or to resist pressure pulsation. Design Temperature: The maximum or most severe
temperature expected during normal operation, not
Active Length (Live Length): The portion of the flexible including periods of abnormal operation caused by
seal that is free to move. equipment failure. (See excursion temperature)
Back-Up Bars: Metal bars used for the purpose of Excursion Pressure: The maximum pressure, both
clamping the fabric expansion joint to mating ductwork positive and negative, the system could reach during
flanges. abnormal conditions or equipment failure.
Baffle (Liner): A metal shield that is designed to protect Excursion Temperature: The maximum temperature
the expansion joint from the abrasive particles in the gas the system could reach. Excursion temperature should be
stream and to reduce the flutter caused by air turbulence defined by maximum temperatures and time duration.
in the gas stream and in some cases may be part of the
overall thermal protection system. Face-To-Face: See breach opening.
Belt Type (Flat Belt): An expansion joint in which the Field Assembly: A joint that is assembled at the job
flexible fabric portion of the joint is flat and is bolted or site due to its size (too large to ship) or the location of
clamped to metal flanges or frame. |the breach opening makes it more practical to install
in sections. On-site assembly is required for certain
Bolt-In Flow Liner: A baffle that is designed to be bolted frame styles.
to the breach flange. This design can be either single or
telescoping and requires the use of a gasket seal. Field Splice: See splice
Typically used on integrally flanged expansion joints.
Flanges: That part of an expansion joint used for
Belt: The flexible element of a nonmetallic expansion fastening the joint into the system ductwork.
joint.
Flow Direction: Direction of gas movement through
Breach Opening: The distance between the mating duct the system.
flanges in which the joint is to be installed.
Flow Liner: See baffle
25
Flutter: The repetitive oscillating movement of the Operating Pressure: The pressure or vacuum condition
expansion joint material due to fluctuation between which occurs during normal performance.
positive pressure and negative pressure or due to flow
induced pulsations. This phenomenon is detrimental to Operating Temperature: The gas temperature at which
expansion joints. the system generally will operate during normal
conditions.
Frame: The complete angle iron or plate frame to which
belt or bellows portion of the expansion joint is attached. Pre-Compression: Compressing the expansion joint
(shortening the manufactured F/F) so that in the cold
Flow Deflector: A metal baffle installed in the ductwork position the joint has a given amount of compression
adjacent to the expansion joint, that diverts the gas set into the joint. The purpose of pre-compression is
stream over the flow liner for the purpose of preventing to allow for unexpected or additional axial extension
the particulate in the flow stream for entering the and/or lateral movement.
expansion joint cavity. It also can be used to prevent
condensation from entering the expansion joint cavity. Pre-Set: Dimension that joints are deflected to insure
that desired movements will take place. See lateral offset
Gas Seal: The layer or specific ply of the expansion and manufactured F/F.
joint material that is designed to minimize or contain
the flue gas. Resultant Movement: The net effect of concurrent
movements.
Lateral Movement: The relating displacement of the two
ends or the expansion joint perpendicular to its Set Back (Stand Off Height): The distance the
longitudinal axis. The displacement movement usually expansion joint is set back from gas stream to allow for
caused by the thermal expansion of the ducting system lateral movement and to prevent the joint from
and measured in inches or millimeters. protruding into the gas flow.
Lateral Offset: The offset distance between two adjacent Shipping Bars: Braces that are located between the two
duct flanges or faces. Can be due to misalignment or, by expansion joint flanges to prevent over-compression or
design, to compensate for excessive displacement in the distortion during shipment and joint assembly or
opposite direction during cycling. (Cold lateral offset) installation. These braces must be removed after
installation.
Lifting Lugs: A lifting device that is attached to the
metal portion of the expansion joint for field handling Splice: Procedure for making endless boot or bellows
and erection. from open ended material. Splicing may be accomplished
by one or more of the following: cementing, bonding,
Manufactured F/F (Face to Face): The manufactured heat sealing, stitching, vulcanizing or mechanical
width of the joint measured between joint flange faces. fastening.
The joint may be set into a breach opening that is less
than the manufactured F/F of the joint to allow for axial Telescoping Liners (Overlapping Liners): Metal shields
extension. attached to each side of the expansion joint, that overlap
or telescope together under thermal movements.
Misalignment (Offset): The out of line condition that
exists between the adjacent faces of the breach or duct Thermal Barrier: A layer of insulating material designed
flanges during ductwork assembly. to reduce the surface temperature at the gas sealing layer
to a level compatible with its heat resistance capability.
Molded Corner Expansion Joint: A rectangular
integrally flanged expansion joint in which the corner Weld-In Liner: A liner that is designed to be welded to
is molded to form a continuous unspliced section. the existing duct wall. This design can be either single
or telescoping type.
Movements: The dimensional changes which the
expansion joint is required to absorb, such as those
resulting from thermal expansion or contraction.
26
-––[ TYPICAL BOILER
Boiler
Economizer
Particulate removal system

(e.g. electrostatic precipitator,
baghouse)
Primary air
[typ]
Coal mills
[typ]
Gas
recirculation
fan Air heater
F.D. fan
[typ]
Field survey technicians perform comprehensive inspection of

all expansion joints and provide a written and photograph
document to plan replacement based on existing and projected
life expectancy. Infrared analysis determines leaks even if the
expansion joints are lagged over. This methodical approach
reduces/eliminates the potential of unplanned forced outages and
accurately projects the scope and cost of outage work required.
27
DUCTING LAYOUT ]–-–
Stack
600-800°F (316-427°C) Particulate laden flue gas

(flow liner and cavity pillow recommended) CEM (continuous
emission monitor)
600-700°F (316-371°C) Clean air
300-350°F (149-177°C) Particulate laden flue gas

(flow liner and cavity pillow recommended)
280-330°F (138-166°C) Flue gas with minimal particulate
280-330°F (138-166°C) Flue gas with acidic condition

(corrosion resistant frame and belt recommended)
120-180°F (49-82°C) Flue gas at the acid dew point

(corrosion resistant frame and belt recommended)
Ambient clean air
Stack seal fan

Bypass duct
I.D. fan Flue gas desulfurization

[typ] equipment (e.g. spray
absorber, scrubber,
atomizer) [typ]
28
-––[RECTANGULAR METAL
DUCT EXPANSION JOINTS]–-–
Corspan
ROUND CORNER-FOR BEST FATIGUE CAMERA CORNER –

PERFORMANCE AND BEST VALUE NOT RECOMMENDED
Corspan recommends the round corner design for all Corspan does not recommend the use of camera corner
applications. This design results in the lowest corner construction for rectangular metal expansion joints of any
stress if fit up and welding of the corner seams are convolution profile. This is a method of assembly that
carefully controlled. allows all corner seam welding to be performed on the
outside of the corner in a very accessible area with welders
of lower skill level than would be required for a single
miter corner. However, this style corner results in deep
crevices at the corner that are corrosion initiators in
certain flue gas conditions. The design also results in
a reduction in movement capability.
SINGLE MITER CORNER –

CONVENTIONAL DESIGN
Corspan also recommends the single miter design
for corner construction. If a corner preference is not
specified, Corspan will use the single miter design for all
convolution profiles for lowest cost. This design allows
for maximum amount of motion possible for a given
convolution profile. The corner is a simple “picture
frame” construction.
DOUBLE MITER CORNER –

VALUE ADDED –
Flexon® is a registered trademark of Senior Flexonics Pathway
LOW CORNER FATIGUE Corspan® is a registered trademark of Senior Flexonics Pathway
The double miter corner design offers lower corner Ultrachem® is a registered trademark of Senior Flexonics Pathway
fatigue than the conventional single miter corner or Inconel® is a registered trademark of Inco Alloys
camera corner designs. Welds are positioned away from Viton® is a registered trademark of E.I. Dupont
the centerline of the corner and the highest stressed area Fluorel® is a registered trademark of 3M
of the bellows. Teflon® is a registered trademark of E.I. Dupont
29
DUCTING EXPANSION JOINT SPECIFICATION SHEET
CUSTOMER NAME INQUIRY NO. DATE
MAILING ADDRESS CITY STATE ZIP PROJECT NAME
NAME OF PERSON SUBMITTING DATA PHONE FAX NO. DELIVERY REQUIRED BY
TYPE OF PLANT FUEL SULFUR CONTENT
NO. OF PLANT CYCLES PER YEAR BASE LOAD PEAK LOAD DUCT SYSTEM
NEW EXISTING
EXPANSION JOINT GEOMETRIES

U1000 SERIES 2400 SERIES 2500 SERIES 2600 SERIES 2700 SERIES 2750 SERIES 2800 SERIES 2900 SERIES
ITEM OR TAG NUMBER
QUANTITY REQUIRED
EXPANSION JOINT LOCATION (FAN OUTLET, STACK, ETC.)
EXPANSION JOINT STYLE/SERIES
DUCT SIZE (INSIDE DIMENSION OR DIAMETER) IN IN MM MM

SIZE
BREACH OPENING (FACE TO FACE, SPAN) IN IN MM MM
FLOWING MEDIA (AIR, FLUE GAS, ETC.)
FLOW DIRECTION (UP, DOWN, HORIZONTAL, ANG. UP, ANG. DOWN)

GAS
FLOW VELOCITY FPS FPS M/S M/S
DUST LOAD PSF PSF Mg/M3 Mg/M3
NORMAL OPERATING “WC “WC

PRESS
DESIGN PRESSURE
MAXIMUM OPERATING “WC “WC MM H2O MM H2O
NORMAL OPERATING °F °F °C °C
TEMPERATURE
DESIGN °F °F °C °C
GAS TEMPERATURE
MAXIMUM UPSET EXCURSION °F °F °C °C
DURATION PER UPSET MIN MIN MIN MIN
AMBIENT (MINIMUM/MAXIMUM) °F / °F °F / °F °C / °C °C / °C
AXIAL COMPRESSION
MOVEMENTS
AXIAL EXTENSION
LATERAL OFFSET (PERPENDICULAR TO LONG SIDE)
LATERAL OFFSET (PERPENDICULAR TO SHORT SIDE)
OTHER (ANGULAR OR TORSIONAL) A/T DEG A/T DEG A/T DEG A/T DEG
DUCT MATERIAL (GAUGE OR THICKNESS)
INTERNAL LINER MATERIAL (GAUGE OR THICKNESS)

DUCT
FWL - FIELD WELDED
LINER ATTACHMENT SWL - SHOP WELDED
BFL - BOLTED FLANGED
CAVITY INSULATION PILLOW REQUIRED (YES OR NO)
RADIUS OR SQUARE CORNER R/S IN R/S IN R/S MM R/S MM

DESIGN
DUCT MATERIAL / THICKNESS MAT’L / IN. MAT’L / IN. MAT’L / MM MAT’L / MM
STAND OFF HEIGHT INCH INCH MM MM

NOTES:
Senior Flexonics Pathway

2400 Longhorn Industrial Dr.
New Braunfels, Texas 78130
Tel Int: 1 830 629 8080
www.flexonics.com Fax Int: 1 830 629 6899
1 800 854 2553 E-mail: sales@pathway.flexonics.com

Fabric Expansion Joint

Enviado por

Dados do documento

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Fabric Expansion Joint

Enviado por

Direitos autorais:

Formatos disponíveis

Represented by: THERMOFLO Equipment Company.

For assistance please call 918-252-9333

TEST CAPABILITIES AND DESIGN VERIFICATION TESTS

© Senior Flexonics Pathway, 2000

For high temperature applications see our literature covering

Since those early days, we have stayed at the forefront of

This design manual has been developed to provide

Senior Flexonics Pathway provides the following services

expansion joint can be fabricated and shipped in as

mobilize an experienced field crew to perform turn-key

usually don’t happen during business hours. Our

-––[FUNCTION OF FABRIC EXPANSION

C. INSULATING RETAINER LAYER

WET SCRUBBER APPLICATIONS ECONOMIZER APPLICATIONS

CRUDE OIL REHEAT

Lateral Movement - The amount of duct movement occurring in either or both

Axial Compression/Extension - The dimensional shortening

Torsional Deflection - The amount of twisting movement (in degrees)

Angular Deflection - The amount of rotation (in degrees) of the duct

TYPICAL MOVEMENT CAPABILITIES BREACH OPENING

-––[OPERATIONAL & DESIGN

FLOW MEDIA Fabric expansion joints are designed to be as leak tight

Abrasive components of the media such as flyash should MOVEMENTS

-––[ CAVITY PILLOW ]–-–

CAVITY ACCUMULATION PILLOW (CAP)

HIGH TEMPERATURE CAVITY Typical cavity pillow

-––[ FLOW LINERS]–-–

-––[OPTIONS & ACCESSORIES]–-–

TADPOLE GASKET TAPE (TG)

■ Prefabricated standard frames reduce cost

■ Belting hardware accessible from outside

■ Best choice when adjacent structures or equipment cannot permit liner

SR2400 protrusion beyond attachment flange.

■ Readily accepts eared pillow design

■ Used to fill large breech openings

■ Accommodates large lateral movements

■ Provides proper setback for belt protection

Senior Flexonics Pathway expansion joints are furnished assembled or unassembled.

■ Accessibility to bolting hardware

■ Accepts shop welded flow liner

■ Designed for internal (SR2550) or external belt replacement (SR2500)

■ Studs or tack welded nuts are optional on belt flange

(possible on-line installation)

■ Designed for internal (SR2650) or external belt replacement (SR2500)

■ Used frequently with fan applications

SR2600 ■ Accepts shop welded flow liner

■ Studs or tack welded nuts are optional on belt flange

■ “Z” style with integral telescoping flow liners

■ Reduces particulate accumulation in frame cavity

■ Provides protection for belts and pillows

■ Complete accessibility to bolting hardware

■ Accepts eared pillow design

■ Accommodates large lateral movements

■ Tack welded nuts are optional

■ Provides proper setback for belt protection

■ “Z” style integral upstream flow liner

■ Provides protection for belts and pillows

■ Complete accessibility to bolting hardware

■ Accommodates large lateral movements

■ Tack welded nuts are optional

■ Provides proper setback for belt protection

Senior Flexonics Pathway expansion joints are furnished assembled or unassembled.

■ Either welded or bolted frame can be utilized