SFP Catalog 3 Fabric Exp Joints

Signature Not
Verified
Digitally signed by Tammie Gilligan

DN: cn=Tammie Gilligan, o=Senior
Flexonics Pathway, ou=Marketing,
c=US
Date: 2001.04.20 12:16:37 -06'00'
-[MANUFACTURING CAPABILITIES
& QUALITY ASSURANCE ]-
COMBINED FACILITIES
Manufacturing Floor Area
Total Land Area
Bridge Crane Capacity
Maximum Hook Height
Fork Lift Capacity
200,000 sq. feet (18580 sq. meters)

31 acres (125,000 sq. meters)
40-ton max. (36,288 kq)
37 feet max. (11.28 meters)
30,000 Ibs. (13,608 kg)
FABRICATION
Vulcanizing Presses
Welding
Digital Controlled, Flat belt, corners

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
Elevated Temperature/Pressure Fabric Expansion Joint Cycle Testing
Fabric Belt Oven Tester
Durometer Hardness
Specific Gravity
X-ray 300KV 10 MA and 5 MA Magnetic Particle,
Dye Penetrant, Zyglo, Ultrasonic and Eddy Current Testing
Mass Spectrometer and Halogen Leak Detection
Positive Material Identification (PMI)
Hydro Testing
Cycle Testing
Spring Rate Testing
Senior Flexonics Pathway, 2000

All Rights Reserved
Dead Weight Testing

Hardness Testing
Ambient Temperature Bellows Fatigue Testing
Elevated Temperature Bellows Fatigue Testing
Seismic Analysis of Fabricated Components
Vibration Analysis of Fabricated Components
Shock Loading Performance Testing
Bellows Spring Rate Testing
Expansion Joint Deflection Testing
Bellows Torsion Testing
Burst Testing
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 dont 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
The gas seal membrane is intended to withstand system
pressure and be resistant to chemical attack from the
interior and the exterior. The gas seal must also have the
flexibility to absorb thermal movements. Depending on
system temperature, it may require additional thermal
protection.
B. INSULATING LAYERS
The insulating layers provide a thermal barrier to ensure that
the inside surface temperature of the gas seal membrane
does not exceed its maximum service temperature. The
insulating layer can also reduce condensation caused by the
gas stream coming in contact with the cool surface of an
uninsulated gas seal membrane.
particles which may be present in the gas stream. 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 flexible element.
F. ACCUMULATION BAG
An accumulation bag is intended to deter flyash from
building up in the expansion joint cavity. It is typically
used, in conjunction with a liner, in duct runs from boilers
to air clean-up equipment such as precipitators, scrubbers
and bag houses, or whenever high amounts of dust or ash
are present in the gas. A flyash barrier must be capable of
retaining its strength and flexibility while being exposed to
maximum system temperatures and media.
C. INSULATING RETAINER LAYER

This layer is provided to keep the insulating layers in place
in order to maintain thermal integrity. The retaining layer
must be capable of withstanding gas stream temperatures
and must be chemically compatible with system media.
D. BACK UP BARS
Back up bars, positioned at the flange attachment, use
clamping pressure to create the fabric-to-duct seal and
restrain the fabric when it is subjected to the system
pressure. The thickness and width of the back up bars
should be sufficient to perform this function with the bolt
spacing being used. The edges of the back up bars should
have a radius to preclude cutting of the fabric.
G. FABRIC ATTACHMENT FLANGES

Fabric attachment flanges are required to connect the
flexible element to the ductwork. Properly designed,
they can be attached directly to the duct work and thus
eliminate the necessity for an adjoining duct flange.
Flanges can be designed with a landing bar duct
attachment which allows some installation misalignment
without affecting the flexible element. The flanges establish
the stand off height of the fabric, which is necessary to
achieve thermal integrity during all movement conditions.
The edges of the flanges in contact with the gas seal
membrane should also have a radius to prevent damage.
H. GASKET
E. METAL LINER OR BAFFLE
A liner is designed to protect the gas seal membrane and
insulating layers of the flexible element from abrasive
Single ply fluoroplastic and fluoroelastoplastic belt designs

such as Ultrachem materials require flexible chemically
inert gaskets.
-[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
FOSSIL FIRED POWER

MARKET APPLICATIONS
Applications range
from the FD fan to the
primary air, tempering
air, coal mill, boiler
flue duct joints,
economizer, air heater,
precipitator, baghouse,
fabric filter, ID fan,
scrubber, absorber,
reheater and stack
expansion joints.
Senior Flexonics
Pathway is the
company that first
developed the use of
fluoropolymer (PTFE)
materials in expansion
joint systems.
Specifically designed
for a variety of wet and
dry corrosive applications, these materials will exceed
your system requirements.
ENGINEERING SERVICES
Senior Flexonics Pathway
supports its fabric
expansion joint products
with experienced field
engineers, On-Site service
installation, repair
services, and CAD
supported application
engineers to help you
solve your expansion
joint problems.
GAS TURBINE
EXHAUST APPLICATIONS
Our fabric expansion joints are currently in service in
peaking plants, on shipboard power systems, on cogeneration turbines, natural gas pipeline pump stations
and a variety of heat recovery.
WET SCRUBBER APPLICATIONS

There is no more
demanding service for
expansion joints than
wet scrubbers. Senior
Flexonics Pathway can
provide the correct
PTFE or FKM gas seal
materials to handle
this hostile
environment.
ECONOMIZER APPLICATIONS
Our fabric
expansion joints
are ideally suited
for this flyash
laden application.
Flexible high
strength and
lightweight fabric
belt elements in
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
MARKET APPLICATIONS
The corrosive
conditions
around the
power and
recovery boilers
as well as the
duct joints to
the fans,
precipitator,
scrubber, and stack are all locations where you will find
expansion joints.
In addition to Senior Flexonics Pathways standard

configurations provided in this catalog, many specially
engineered designs have been produced for the following
applications:
Heat Recovery Steam Generators (HRSG)
Circulating Fluid Bed Boilers (CFB)
Cement Industry
Steel Industry
Windtunnels, HVAC, etc.
Selective Catalyst Reduction (SCR) Units
-[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 Pathways 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 its 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

Belt Type
Active Length
Single Layer
Fabric Element
(Non-concurrent)
Composite Belt
(Concurrent)
Integrally Flanged
6 (152mm)
9 (229mm)
12 (305mm)
Axial Compression
2 (51mm)
3 (76mm)
4 (102mm)
Axial Extension
1/2 (13mm)
1/2 (13mm)
1/2 (13mm)
Lateral
1 (25mm)
1 1/2 (38mm)
2 (51mm)
Axial Compression
1 (25mm)
1 1/2 (38mm)
2 (51mm)
Axial Extension
1/4 (6mm)
1/4 (6mm)
1/4 (6mm)
Lateral
1/2 (13mm)
3/4 (19mm)
1 (25mm)
Axial Compression
2 (51mm)
3 (76mm)
4 (102mm)
Single Layer
Axial Extension
1/2 (13mm)
1/2 (13mm)
1/2 (13mm)
(Concurrent)
Lateral
1 (25mm)
1 1/2 (38mm)
2 (51mm)
Notes:
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.
3. Lateral movement exceeding 3 (76mm) should utilize cold lateral offset (preset) to reduce the relative belt movement.
BREACH OPENING
FACE-TO-FACE
Set Back
Active Length
Active Length
Set
Back
Breach or
F/F DOM
-[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
-[OPERATIONAL & DESIGN

CONSIDERATIONS ]-
The following background information on the plant and
application can have significant influence to the design
life of the expansion joint.
Plant type
Location of expansion
Environmental conditions
Base or peak load plant
Relevant history of existing and adjacent equipment
FLOW MEDIA
In defining system media, the designer should specify
the type of fuel, sulfur content, and any additives,
cleaning agents or catalysts, which may be used in the
system. Ph in the vicinity of the expansion joint should
be specified, if known, especially if the media is
extremely acidic or caustic.
The probability of condensation should be determined
by comparing dew point and normal operating
temperatures. Even in systems which normally operate
quite hot, shutdowns and startups may produce
condensation resulting in excessive corrosion. This
condition can also occur on the outside of the steelwork
and should be considered.
Abrasive components of the media such as flyash should
be identified. Flyash buildup within a flue gas duct
should be estimated, and the dead weight calculated to
determine the maximum load on an expansion joint
element. Plant operating procedures such as duct
cleaning (wash-down or vacuuming) are also considered
in the design.
TEMPERATURE
Temperatures affect the selection of fabric expansion
joint materials. The following temperatures for the
system should be provided to the engineer.
Normal operating temperature
Maximum continuous operating temperature
Design temperature
Excursion temperatures and duration
Ambient temperatures (the lowest, highest

and average)
Dew point temperatures
Caution: Specifying a design temperature which

includes excessive safety factors may actually be
detrimental to the design of the flexible element and

should be avoided.
PRESSURE & EXPANSION

JOINT LEAKAGE
Fabric expansion joints are typically designed for low
pressure duct systems with maximum rating at +5 psig
for elastomeric and +3 psig for fluoroplastic and
fluoroelastoplastic belts.
Fabric expansion joints are designed to be as leak tight
as practical. When an unusual amount of liquid is
present within the ducting, or leakage requirements are
specified, special caulking or gasket materials can
be used when attaching the fabric element to attain the
desired results. In industrial applications, minor leakage,
detectable by soap bubble solution, is considered
acceptable.
When replacing a fabric element, leakage through bolt
holes is minimized if holes are aligned and punched
in the field as opposed to prepunching the holes at
the factory. Backup bar bolts should be tightened to
35 to 45 ft. lbs. (45-61 Nm) to ensure optimum
clamping pressure.
MOVEMENTS
Various movements resulting from thermal expansion
of the breeching, both Maximum Continuous System
Operating Temperature (MCSOT) and excursion
temperatures should be specified. Contractions of the
breeching due to cold winter shutdowns, mechanically
induced movements such as fan and equipment
vibrations, and structural deflections due to wind loads
and seismic events must also be specified.
Movements in various directions should be analyzed to
determine if they occur simultaneously or if they can
occur individually without a corresponding deflection in
another direction. The designer to make certain that the
expansion joint design is capable of absorbing a
combination of the total maximum movements should
specify maximum installation misalignment.
SYSTEM GEOMETRY/INSTALLATION
The geometry of the expansion joint system, including
duct size, orientation, material and attachments all have
an effect on the selection of expansion joint frame
configuration. The installation of an expansion joint can

be performed either internally or externally. Specific
frames are designed for each application depending on
preferences or accessibility.
or operating pressure oscillations. Both conditions can

cause a premature failure and must be identified in the
quotation/evaluation stage. This condition is commonly
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

requires that a portion of the system heat be dissipated to
the external environment. Abnormally hot ambient
conditions or an adjacent heat source, reflective surface,
or duct insulation may create temperatures that exceed
the limits of the gas seal membrane and should be
considered when designing the system.
50 mm H2O).
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
designed by the expansion joint manufacturer to ensure
that proper air circulation requirements are satisfied.
INSTALLATION
CONSIDERATIONS
The system designer must consider all installation
requirements such as mating duct flanges, adjacent
ducting equipment, insulation, painting/ finishing, field
assembly, erection and necessary qualified supervision.
RESPONSIBILITY
The system designer must evaluate whether the lines of
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

fatigue problems as a result of physical fluctuations
known as flutter. Flutter is a result of either flow induced
at an optimum overall cost. It is usually in the best

interests of the end user to specify and/or order the
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)

Style - 1
Style - 2
A cavity created between the structural steel frame/flanges and the

gas seal (fabric expansion joint) is designed to provide a standoff
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
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

INSULATION PILLOWS (CIP)
Style - 3
Cavity Insulation Pillow (CIP) - A style CIP provides additional

thermal protection to the belting material for high temperature
applications.
Typical cavity pillow

construction consisting
of layers of insulation
encased in a protective
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
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 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.
Integral Liner
Bolt-in Liner
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
lateral or compression movements.
TP
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
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
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
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
Designed for internal (SR2550) or external belt replacement (SR2500)
Used frequently with fan applications
Studs or tack welded nuts are optional on belt flange
SR2600
SR2550
SR2600
Similar to the SR2500 style and is used where additional standoff is necessary or
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
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
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
SR2650
SR2700
SR2750
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
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
Facilitates field assembly and fit-up
SR2800
SR2900
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
Flanges act as duct stiffiners
U1000
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
fan applications
Minimal shipping costs
Standard 3 (75mm) high flange design
SLEEVES
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
Provided with gaskets for Teflon belt material
14
-[INSTALLATION CONSIDERATIONS ]-
MATING DUCT FLANGES
Mating duct flanges affect expansion joint design. Senior Flexonics Pathway Frame
Systems SR2700, SR2800 and SR2900 are designed to completely eliminate mating
flanges on the duct work. Other frame systems are designed to be welded to
existing flanges, thereby decreasing installation time and corrosion problems
associated with bolted designs. The design of duct flanges should be coordinated
with the expansion joint manufacturer.
A
A
INSTALLATION MISALIGNMENT
Duct systems, which require fabric expansion joints, are often extremely large and
therefore subject to substantial dimensional errors. It is possible that misalignment
could exceed the expected thermal movement. A convenient solution to this
problem is to design the expansion joint frame to absorb the duct misalignment.
Note that the flexible element is installed in its neutral position, and retains full
movement capability. Field drilled holes are the best way to assure proper fit up.
D
D
E
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.
15
Installation Service
Field Supervision
Ducting System Inspection
Field Training
Plant Surveys
-[SPLICING AND REPAIRABILITY]-

Pathway Flexon and Ultrachem materials can be easily spliced in the field during expansion joint installation. These
materials are easily repaired in the event of damage after installation. The Thermowelding characteristics of these
materials provide splicing and repair material strength equal to or greater than the basic material strength.
FLEXSPAN HEAT SEAL IRON
PERMANENTLY REPAIRABLE
Lightweight and portable for use at any plant location.

Available for rent or purchase. May be operated easily
by plant personnel.
Unlike fluoroelastomer materials, Ultrachem and Flexon

expansion joint systems are repairable over the life of the
product. Repairable not just with a mechanical patch but
repairable without degrading the tensile strength of the
joint. This contrasts with the inability to effectively
revulcanize fluoroelastomer products after installation
because of the aging inherent with fluoroelastomer
and other rubber products.
REQUIRED
MATERIALS
Heat seal film is required and
placed between the ends of the
joint to be spliced. No chemical
prep of the belt or mechanical
abrasion is required prior to
splicing.
SPLICE
VERIFICATION
Sample material and splicing
film is supplied to allow
verification of iron operation at
the joint location in your plant
to assure leak proof splices.
SPLICING YOUR
EXPANSION
JOINT BELT
Joints may be spliced in the
vertical or horizontal positions.
The temperatures of the heat
seal iron is electonically
controlled and heat loss is
minimized with the use of
an insulated back up board.
EASY TO
WORK WITH
No special tools or skills are
required to perform the splice.
The Installation Manual
completely details the
procedure.
THE COMPLETED SPLICE

In minutes the splice is completed. Compared to hours
spent vulcanizing rubber expansion joint materials, not to
mention the cost on the required factory technician, our
products offers a practical and economic solution.
MECHANICAL
DAMAGE
This expansion joint at a fossil fired
plant was mechanically damaged
accidentally. Normally the joint
would have to be replaced at the
next outage or shutdown
depending on the extent of damage.
TEAR PROPAGATION
Ultrachem materials have greater
tensile strength and will not
continue to propagate holes or
tears like rubber materials. This
benefit allows you to run longer
without the damage getting worse
or generating catastrophic failure of the joint.
HEAT SEAL REPAIR

Using the procedures above, the
joint may be repaired and will
retain original tensile strengths.
No special preparation is
necessary. This repair can be
easily made by plant personnel.
FIELD
REPAIRABILITY
The ability to repair your
expansion joint materials with
plant personnel gives the plant
more independence to solve its
own problems. Expansion joint
replacement and repairs can now be performed in a
fraction of the time and expense normally allocated for
fluoroelastomer repairs.
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
Corporations 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
60 oz (0.64 g/cm3)
tightly woven fiberglass
mat insulation laminated
to the gas seal
4 mil PTFE film

laminated to
ULTRACHEM cover
FLEXON-700 A composite belt designed

to provide continuous reliable service at
700F (371C). 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.
ULTRACHEM Fluoroplastic coated

fiberglass fabric with 4 mil (0.1 mm)
PTFE film laminated to gas side
FLEXON-1000 A composite belt

designed to provide continuous reliable
service at 1000F (538C). 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

5/8 (16 mm) thick
nonwoven fiberglass
to the gas seal

designed to provide continuous
service at 1200F (649C), 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
fiberglass in applications above
1000F (538C).
1/2 (13 mm)

ceramic mat
insulation
Inconel wire reinforced

silica/ceramic fabric
encasement


designed to provide continuous
service at elevated continuous
temperatures to 1500F (816C).
1 (25 mm) thick
ceramic mat insulation
5/8 (16 mm) thick
nonwoven fiberglass
to the gas seal
Inconel wire reinforced

silica/ceramic fabric
reinforcement encasement
Note: Designs are available to 2000F (1090C).
20
-[HOW TO SPECIFY A
SPECIAL
NOTE
STEP
2
The following
instructions will help
determine the correct
part number.
Completion of the
ducting expansion joint
specification sheet is
also helpful and enables
Senior Flexonics
Pathways engineering
staff to verify that the
correct design has been
selected. Factory holes,
back-up bars, nuts, and
bolts must be specified
if required.
STEP
1
Expansion joints can be manufactured and

shipped either assembly or unassembled select
the option which best meets your requirements.
A - Assembled Ready for immediate installation

U Unassembled Match marked and packaged to
minimize assembly at the jobsite. Complete assembly
instructions and manufacturing drawings included.
BA - Belt, Assembled - Fabric belt elements are provided
as a factory-spliced, endless loop, to fit existing frames.
Maximum Continuous
System Operating
Temperature (MCSOTF)
- This is the highest
temperature at which the system
normally operates. Excursion (upset)
temperatures and durations should
be specified on the Ducting
Expansion Joint Specification Sheet.
For applications exceeding 1200F,
please consult Senior Flexonics
Pathways engineering department.
BU - Belt, Unassembled - Fabric elements are prepared

for field splicing at the jobsite.
Assembly
MCSOT
Operating
Pressure
Frame
Style
English
450
12
SR2400
Metric
232
305
SR2400
STEP
5
Gas Seal Material - Leave this section

of the part number blank and Senior
Flexonics Pathway will make the
material selection.
STEP
6
Select the letter code for the options and

accessories (CAP for Cavity Accumulation Pillow,
CIP for Cavity Insulation Pillow, BH for Braided
Hose Seal, TG for Tadpole Gasket Tape, FD for
Flow Deflector, FWL for Field welded Liner, SWL for Shop
Welded Liner, BFL for Bolted Flange Liner)
See material descriptions on Pages 17-20

T LINE]-
PRODUC
cast
the
yer PTFE
M ALLOY XIBILITY ]- EM
tions to meet
-[FLEXON
ce. A multila
belt configura
grade E/FK
FLE
an even
ACH
PTF
n resistan
premium
of composite
ED
& ULTR
one of the
r corrosio
HEM assuring
ures a variety
ITIONAL
n purposes
PATisENT
1100 CB developed for superio 1100 and ULTRAC conditions. This
-[
Pathway manufact
illustratio
ES ADD
was is
. Shown for
DARLYN al Barrier
DARLYN
Senior Flexonics
temperatures.
e nature,
multiple
most extreme
welded to
PROVID
of all our customers continuous operating
its crystallin chemically
Chemic
through
e in the
or to
flex
due
CB
varied needs
, when
is built up
to exposur
long term
plastic,
each rated
lly and
tic coated
M Fluoroplasmil PTFE
4
ULTRACHE
fabric with side
fiberglass
to gas
film laminated
(16 mm)
thick
5/8
ns)
Further
n due
fiberglass
Perfluoro
reduces the
is therma
joints.
all directio
corrosio
which
inert barrier.
membrane nonwovenlaminated
stiff film
expansion l properties in
on from
fabric
chemically
is a uniform
inherently
protecti
belt. insulation
seal
life of PTFE (identical physica
stomer
nonporous, c fabric, the result
and greater
out the
to the gas
ing, fluoroela
through
thickness,
endurance
c film
alloy
shortcom
equally
isotropi
HEM isotropi
a uniform
e this
the load
into a patented and ULTRAC
ns assuring
To overcom
is blended
distributing
significantly
operatio
)
DARLYN
trations,
s matrix
with the
edfiberglas
(Viton /Fluorel combin
and shear
stress concen
the coated
belt
withoute, tensile
flexresistanc
composite
which bathes which can
y, tear
means longer
IONSN-1200 A continuous
g the flexibilit
belts. This
increasin
fabricated
APPLICAT FLEXO
flexing. to provide
Multilayer reinforced
of DARLYN
filament
ERATURE after repeated designed 1200F (649C), by the
strength
continuous
(Fill)
of ceramic
life. HIGH TEMP retention, even
fiberglass yarn
d costs
service at
(13 mm)
in-service
r strength
1000.
of a 1/2 g in lower installe
Superio
addition resultin
FLEXON
splicing
the
to
field
ce
mm)
on
is
reinforced
r fabrics,
Fast, easy
1/2 (13
insulati
n resistan
Inconel wireic fabric
silica cloth
mat
fluoroelastomemat
ceramic
ding corrosio
wire inserted to replace
silica/ceram
of 100%
t
Inconel
of stiffness. Outstan 1/4 the weight
insulation
ent
encasemen
by its lack
encasem
Less than
identified
used as the
tions above
is more
can be easily
in applica
Wrapped to
d
DARLYN
ed alloy coating
fiberglass
impregnating
maximize
ly distribut
.
ite belt designe
voids and
s
The uniform
A compos
flexibility and
filling the
ic
1000F (538C)
service at
M fluoroplast
t than PTFE,
matrix maintain wide
tensile strength
FLEXON-700
ous reliable
ULTRACHE
ss
complian
fabric
This pliable
continu
s over a
structure.
coated fiberglass
woven fibergla
l propertie
to provide
the woven
. A tightly
and chemica
to the
conditions
t physical
700F (371C)
lly bonded
consisten
and corrosive
design
is therma
ite
twisted
tures
and
on
Bundled
tic coated
insulati
This compos
Fluoroplas
range of tempera gas ductwork.
for flexibility
material.ULTRACHEM ies
4 mil PTFE
at elevated
in flue
fabric with side
FLEXON
ng propert
experienced to provide
to gas on of
Woven
s insulati fiberglass
laminated
s separati
film
matrix
provide
life
prevent
process.
extended
patented
tures and
tempera
times in the
on,
PROCESS
on.
s foundati
ite belt
over a dozen
T COATING
the insulati
A compos
and cured
s the fiberglas
detailed
are coated
ous
ely surround
CONSISTEN
FLEXON-1500
flexibility
products
ristic of the
continu
theof
FKM complet
tic coated
series
tic with
is a characte
OPLASTICSof a fluoroplas
to provide
M Fluoroplasmil (0.1 mm)
of PTFE and
ous
toplastic
The DARLYNd. Fluoroelas
procedure
designed
D ELAST
products.
4
ULTRACHE
continu
resistance
film
alloy coating
fabric with gas side
This unique
elevated
.
4 mil PTFE
FLUORINATEcombine the corrosion FKM to the PTFE
to
multilayer
fiberglass
y of the DARLYN
with PTFE.
Thecompoun
to
service at
e, providing
laminated
1500F (816C)
of
laminated
es the longevit
PTFE film
filament
multi-coated
joints isworldwid
tures to
Fluoroelastoplastics through the addition
multiple ULTRACHEM cover
g/cm )
expansion
and then
gaswhich guarante
tempera
in fluecy
60 oz (0.64
tomer
us, twisted
in over 10,000
consisten
strands are
ents found
continuo
woven fiberglass
of a fluoroelas
successfully
quality and
material the
laminated
fuels (RDF)
defect free, tightlyinsulation
been used
chemical environm
belting
plies are
mat
with 100%
refuse derived
the severe
materials have
seal
Numerous
ce even in
of your DARLYN
manufactured
to the gas possible.
(recovery boilers),
thick
performan
ristics of
entire length
s fibers
material is
1 (25 mm) insulation
pulp and paper
exceptional
DARLYN
t fiberglas
mat
that for the
and tear characte to
plants (FGD),
ceramic
the stronges
This means
tensile, shear
desulfurization
guaranteed
fiberglass.
nt PTFE coating
ing the flex,
neous and
a protecta
wicking
maximiz
with
smelters.
from
homoge
and
together
ng acid
uncut,
then bathed
and twisted
Chemfab
yarns are
attack preventicomposite belt
A
mm) thick
chemical
than grouped
joints utilizing s. These glass
LINE
5/8 (16
ous reliable
reinforced
DARLYN during flexing, and
of expansion ds of filament
fiberglass
PRODUCT
FLEXON-1000
continu
Inconel wireic fabric
nonwoven
in 1983. The
d
thousan
ven
friction
glass.
provide
laminated
and
to
DARLYN Pathway is an authorized fabricator
silica/ceram encasement
insulation
. A non-wo
ional woven
were first introduce
and chemical
designed
self-abrasion
ent
seal
resist
their thermal destroys convent
reinforcem
to the gas
These products
of
is bonded
1000F (538C)
Senior Flexonics
which belting materials
service at
insulation
alloys. Because in service,
DARLYN fabrics.
mm) thick
ed and laminated
needle-mat
delastoplastic
Corporations
l and encased
5/8 (16
, PTFE-coat
fiberglass
fiberglass
are fluorinate
HEM materia
nonwoven
fiberglass reinforced for all types of systems.
cloth.
line of materials
laminated
to the ULTRACcoated fiberglass
insulation
fluoroelastoplastic
joint designs
seal
ized
capabilities,
to the gas
in expansion
in alumin
extensively
18
are being used
ons for
belt constructi
4 mil cast PTFE

film
corrosion resistant
17
Note: Designs
19
are available
to 2000F
(1090C).
20
See pages
11-12
for various
pillow styles.
-[CAVITY
ES]-
ESSORI
S & ACC
-[OPTION
Style - 3
STYLES]-
-[FRAME
flanged U-belt
s. The integrally belt cost and
nt
application
element and/or
for various
a lower replaceme
for the fabric
also
frame designs frame design has
nts.
n. A liner is
provide protection
numerous
arrangeme
accumulatio
provides
designed to
The flat belt
standard
Pathway
or particulate
Integral Liner cost.
metal shields
the
of several
l initial capital
(baffles) are
t of particulate
to help control
Senior Flexonicsof economica
is a sample
the
Flow liners
impingemen
turbulence,
frame
The following
has a very
the temperature
caused by
from direct
a complete
and to reduce design
can be reused.
cavity pillow
fabric element
present and
s.
airfoil, semi-airfoil
joint cavity,
flutter of the
(straight,
flanges are
existing hardware
expansion
re application
of profiles
used to reduce
C.S.). Flow
ash in the
SR2400 s where the ductworkwell for high temperatu
on a variety
10 GA. A569
n of dust or
are straight
can be supplied
accumulatio
works
Design application
and material
Flow liners
This style
(Standard profile
is preferred.
flexible element.
and
assembly
and materials.
as on SR2700
drop-in assembly reduce cost
or telescoping)
categories.
joint frame
Complete
frames
Liner
the following
expansion
standard
the
into
Bolt-in
ed
of
permit liner
fall
outside
liners
from
t cannot
Prefabricat
ctured parts
accessible
or equipmen
our U1000
liners are pre-manufa
Integral
joints as on
Belting hardware adjacent structures
expansion
when
frames.
Gaskets are
t flange.
flanged style
Best choice
SR2750 series
duct flange.
used on integrally
beyond attachmen
and the mating
are primarily
liner
protrusion
joint flange
.
Bolt-in liners
welded flow
SR2400
expansion
etal connections
the belt or
design
the duct
Accepts shop
Teflon-to-m
the field to
eared pillow
series, between
tal and/or
welded in
metal-to-me
Readily accepts breech openings
can be either
required on
Weld-in Liner
ts
joint frame.
breach opening
to fill large
movemen
the
expansion
Used
the
lateral
factory to
liners spanning
dates large
Weld-in
welded in
Accommo
for belt protection
can be supplied
proper setback
interior or
Provides
RS ]-
-[ FLOW LINE
11
21
PILLOW ]-
retarding the
is often
(BH)
is
ceramic insulation
Flexonics
wrapped
The hose
HOSE SEAL
enclosed
The Senior
thermal protection,
materials and
loading.
hose with
pillows areED
particulate,
insulation
particulate
the
StandardBRAID
steel braided
intrusion of
from selected
conditions.
stainless
areas of high
from entering
hold the
Flexible
are fabricated
joints in
bars to
for the operating
particulate
works
the
Our pillows
expansion
for to
belt and backup
fabric, designed
a memory
liners to prevent with a cavity pillow
specified
under the
provide
edthe flow
along
high temperature
that fasten
designed to
between
uncompress
ears or tabs
secured
The ears are
This accessory
as installed
provided with
joint cavity.
pillow in place.
return to an
expansion
that it will
outages.
plants.
pillow such
down, during
well in cement
plant cool
with
state after
TAPE (TG) joints in duct systems
PILLOW (CAP)
GASKET
ULATION frame/flanges and the
expansion
Pathway
TADPOLE integral flange-type
structural steel
, Senior Flexonicsflexible element
CAVITY ACCUM
a standoff
conditions
between the
the
to provide
When using
operating
between
of the
A cavity created
joint) is designed This cavity can fill
expansion
positive pressure use of tadpole gasketing prevents the heads
gas.
(fabric
flue
seal
the
are
gas
and
). This
ds the
deposits
flexible element.
recommen
fabric element
(as illustrated
gas. If these
cover of the
properly
between the
of the flue
backup bars
during large
to operate
Style - 1
the outside
falling out
flange and
joint will fail
flanged belts
with particulate
from abrading
expansion
Pathway
and integrally
erection bolts
buildup the
both flat
Senior Flexonics
allowed to
to occupy
also protects
become damaged.
n pillow designed
ts.
This option
and could
and filling
n movemen
an accumulatio
from entering
s the use of
FD
compressio
will
the deposits
recommend
lateral or
a flow liner
space, preventing in conjunction with
P
this dead
T
pillow
Many
ly ash.
The cavity
this cavity.
n of particulate/f a low cost insurance
accumulatio
as
to
prevent the
view this option
joint.
to the design
e managers
Style - 2
of the expansion
is added
maintenanc
(FD)
pillow
and
service life
flow deflector
Typical cavity
extends the
prevent moisture
s, an angle
DEFLECTOR
policy that
consisting
is used to
installation
the expansion
CAVITYFLOWexpansion jointconstruction
A flow deflector being trapped in
RATURE
of insulation
the joint.
In some
and
lifeofoflayers
duct walls
HIGH TEMPE PILLOWS (CIP)
the service
additional
in a protective
increase
down vertical
provides
encased
- A style CIP
from sliding
INSULATION
temperature
Pillow (CIP)
temp sleeve.
particulate
liner.
for high
high
by the flow
Cavity Insulation to the belting material
joint cavity
thermal protection
.
applications
STYLES serve three purposes,

pulsation.
pillows
to pressure
CAVITY PILLOW
Pathway cavity
with a
and resistance
Senior Flexonics
Pathway expansion
joints are
furnished
assembled
or unassembled.
12
FABRIC EXPANSION JOINT ]-

STEP
4
STEP
3
List the system operating pressure in

inches water column, the pressure will be
assumed to be positive unless a negative
number is listed. The maximum rated
operating pressure: 83 wc (3 PSIG) for teflon belt
139 wc (5 PSIG) for elastomer. For higher
pressures please consult Senior Flexonics Pathways
engineering department.
Frame Style - Select the appropriate frame style

(SR2400, SR2500, SR2550, SR2600, SR2650,
SR2700, SR2750, SR2800, SR2900, U1000, etc.)
For isometric view and detailed
description see pages 12-14
]-
ESSORIES
S & ACC
-[OPTION
(BH)
over existing
assembly
over existing
with field
assembly
installation
n with field
re ratings.
suited for
installatio
frame is well
for all temperatu ed angle iron
SR2800 is well suited for all temperature ratings. iron
This style
is utilized
prefabricat
for
frame
joints, and
ted angle
standard
This style
expansion
prefabrica
and is utilized
frame utilizing
n
standard
can be utilized existing metal expansion joints,
Economic
expansio
expansion
utilizing
over
bolted frame
c frame
can be utilized existing metal
to retrofit
welded or
Economi
Either
bolted frame to retrofit over
can be used
)
welded or
wrap design
Either
Fabric
can be used
on-line installation
n)
wrap design
Fabric
joints (possible
design
on-line installatio
eared pillow
Accepts
joints (possiblepillow design
and fit-up
eared
field assembly
and fit-up
Accepts
s field assembly
SR2800
Facilitate
optional
n
nuts are
protectio
for belt
Tack welded
Provides
integral
Senior Flexonics
When using
proper setback
flexible element
Provides
operating conditions,
between the
of the
positive pressure
tadpole gasketing prevents the heads
or preferred.
.
s the use of
This
is required
or preferred
recommend
(as illustrated).
flexible element.
assembly
is required
and field
backup bars
cover of the
large
assembly
flange and
the outside
during
and field
SR2900where flanges are not present metal expansion joints
flanged belts
from abrading
n joints
present
existing
erection bolts
flat and integrally
SR2900where flanges are not existing metal expansio
Best utilized
used over
protects both
design
also
wrap
ductworkBest utilized
over
)
Fabric
.
This option
to existing
design used
ductwork
movements
on-line installation reinforcement
n)
l design Fabric wrap
to existing
(possible
lateral or compression
for economica
F D additional stiffener
on-line installatio reinforcement economical design
steel channels
(possible
Provides
for
l stiffener
TP
structural
additiona
standard
l steel channels
Provides
Utilizes
structura
stiffiners
standard
act as duct
Utilizes
Flanges
stiffiners
SR2900
act as duct
design to
Flanges
added to the
(FD)
res
SR2900
TOR
deflector is
and
flow
temperatu
moisture
ures
angle
, an
to moderate
temperat
FLOW DEFLEC
used to prevent
joint installations
used for low
deflector is
the expansion
minimal
low to moderate
design is
trapped in
loading is
In some expansion life of the joint. A flow
used for
is minimal
and being
U1000 integrally flanged U-belt
particulate
design is
service
e loading
duct walls
cost
present and
increase the
down vertical
and fasteners
U1000 integrally flanged U-belt
and particulat
cost
The standard
flanges are
from sliding
metal frame
are present
s where duct
and fasteners
particulate
liner.
The standard
for
application
duct flanges
due to reduced
metal frame
r ductwork
by the flow
frequently
ns where
initial cost
y for
joint cavity
Lowest
for rectangula
due to reduced
applicatio
ar ductwork
frequentl
t and utilized
initial cost
equipmen
corners provided
for rectangul
t and utilized
Lowest
Molded
ducting or
provided
or equipmen
corners
dates flanged
ducting
Molded
Accommo
s
odates flanged
Accomm
fan application
costs
ns
shipping
fan applicatio
Minimal
U1000
design
costs
shipping
flanged U-belt
3 high flange
design
integrally
Minimal
U1000
The
Standard
.
flange
3 high
belt cost and
applications
Standard
for various
a lower replacement
frame designs
design has
numerous
ts.
belt frame
arrangemen
s with minimal
Pathway provides capital cost. The flat
minimal
application
of several standard
initial
Senior Flexonics
ns with
in H.V.A.C.
is a sample
ES
applicatio
a very economical
The following
SLEEV
design has
in H.V.A.C.
used for vibration
frame
can be reused.
VES
vibration
s
are primarily
and a complete
SLEE
used for
Sleeves
existing hardware
application
ns
.
are present
n
are primarily
applications
on applicatio
ductwork flanges
SR2400
of pipe penetratio Sleeves
pressures.
temperature
design
where the
.
for field-wrap
well for high
of pipe penetrati
Least expensive
pressures
Design applications
design
open ended
field-wrap
This style works
expensive
endless or
preferred.
ended for
clamps
Least
Supplied
or open
assembly is
gear band
clamps
endless
drop-in assembly reduce cost
with worm
Supplied
gear band
Complete
Supplied
s
frames
with worm
application
d standard
liner
belt material
outside
ns
Supplied
Prefabricate
For vibration
for Teflon
cannot permit
applicatio
accessible from
belt material
with gaskets
or equipment
For vibration
for Teflon
Provided
Belting hardware
structures
with gaskets
when adjacent
Provided
flange.Sleeves
Best choice
beyond attachment
protrusion
liner
Sleeves
SR2400
welded flow
Accepts shop
design
eared pillow
Readily accepts
openings
large breech
Used to fill
movements
lateral
tes large
Accommoda
belt protection
setback for
Provides proper
SR2800
is often
ceramic insulation hose is

HOSE SEAL
BRAIDED steel braided hose with enclosed
loading. The
particulate
the
of high
Flexible stainless
from entering
joints in areas
particulate
expansion
works
to prevent
specified for
a cavity pillow
the flow liners
along with
secured between
This accessory
joint cavity.
expansion
plants.
well in cement
SR2800
Facilitates
with
nuts are optional protection
TAPE (TG) joints in duct systems
Tack welded
for belt
GASKET
expansion
Pathway
proper setback
TADPOLE
flange-type
STYLES]-
-[FRAME
12
Senior Flexonics
Pathway expansion
joints are furnished
assembled or
14
unassembled.
Senior Flexonics
Pathway expansion
joints are
furnished
assembled
14
or unassembled.
Senior Flexonics
Pathway
expansion
joints are
furnished
assembled
or unassembled.
STEP
8
Belt
Material
Options
Accessories
Span
F-F
Duct Size
Inside
Dimension
Flexon 1000
CAP - FD
14
120 x 96
Flexon 1000
CAP - FD
356
3048 x 2438
The basic
part number
is now
complete.
For a unassembled Flexon
1000CB material on a
SR2400 frame with a
cavity accumulation pillow
and a flow deflector 120
inches wide by 96 inches
high with 14 inches active
length for maximum
continuous operating
conditions of 450F and
12 inches water column.
NOTES:
STEP
7
List the Face to Face Dimension

(distance between the mating duct
flanges) in which the expansion joint
is to be installed. This dimension
should not be confused with the active length.
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
department. Non-standard face to face dimensions are available.
Movements must be specified in the description accompanying the
part number. A significant difference exists between the movement
capabilities of round expansion joints and large rectangular joints (sides
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
See page 7 for

technical data.
are the differential

thermal expansions
and/or excursion during
The system
e
of operating
contraction
ambient temperatur
uses these
expansion/
minimum
joint engineer
es and the
design for
. The expansion
temperatur
material and
and shutdowns to select the proper
c expansion
es
installation
nonmetalli
torsional
s and temperatur Flexonics Pathways
movement
angular and
joint. Senior
axial, lateral,
be
each expansion can handle combined
ion should
Considerat
fabricator
required.
joints frequently
assembly.
l for the duct
total number
s in a single
reducing the
movement
more economica
it may be
be optimized,
can often
ducting systems,
t, for new
joint locations
The expansion
and belt replacemen frame.
both
joint
accessibility
expansion
given for
in either or
the
of
occurring
a portion
duct,
to provide
of duct movement
l axis of the
- The amount
to the longitudina
lar planes
Lateral Movement
out of alignment.
perpendicu
joint flanges
of the two
the expansion
which moves
l shortening
dimensiona
joint
ion - The
on/Extens
of the expansion
g (extension)
Axial Compressi
axis.
l
n) or lengthenin to its longitudina
(compressio
parallel
dimension
face-to-face
(in degrees)
movement
of twisting
l axis of
- The amount
to the longitudina
Deflection
lar planes
Torsional
in the perpendicu
occurring
the duct system.
of the duct
(in degrees)
position
of rotation
of parallel
- The amount
flanges out
Angular Deflection the expansion joint
flexes
OPENING
system which
BREACH O-FACE
other.
with each
ES
CAPABILITI
MOVEMENT6 (152mm) 9 (229mm)
TYPICAL
3 (76mm)
Active Length
Belt Type
Single Layer
n
Axial Compressio
Fabric Element
rrent)
(Non-concu
Composite
Belt
)
(Concurrent
Integrally
Flanged
Single Layer
)
(Concurrent
Axial Extension
Lateral
n
Axial Compressio
Axial Extension
Lateral
n
Axial Compressio
Axial Extension
Lateral
2 (51mm)
1/2 (13mm)
1 (25mm)
1 (25mm)
1/4 (6mm)
1/2 (13mm)
2 (51mm)
1/2 (13mm)
1 (25mm)
1/2 (13mm)
1 1/2 (38mm)
1 1/2 (38mm)
FACE-T
12 (305mm)
4 (102mm)
1/2 (13mm)
Set Back
2 (51mm)
2 (51mm)
1/4 (6mm)
3/4 (19mm)
3 (76mm)
1/2 (13mm)
1 1/2 (38mm)
Active Length
1/4 (6mm)
1 (25mm)
Active Length
4 (102mm)
1/2 (13mm)
2 (51mm)
Set
Back
or concurrent
nonconcurrent
or differ from
listed above
these
exceed those
(6mm). Exceeding
when movements
lateral + 1/4
Notes:
must be made applications.
1/2 (13mm),
considerations
for these
axial compression
belt movement.
1. Special
with factory
the relative
1/4 (6mm),
to reduce
ratings. Consult
Axial extension
offset (preset)
tolerances:
capabilities.
cold lateral
2. Breaching
movement
should utilize
will affect
3 (76mm)
tolerances
exceeding
3. Lateral movement
CAUTION
Installation temperature and duct tolerances must be considered in
determining installed face to face dimensions and movements.
Breach or
F/F DOM
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
.250"
(6.35 mm)
Min. thick
F-VF-25FSA
.250"
(6.35 mm)
Min. thick
F-VF-25N
.250"
(6.35 mm)
Nom. thick
Gas Ply
FKM
23
F-EP-25
.125"
(3.18 mm)
Nom. thick
Gas Ply
Aramid/Fiberglass
Fiberglass
-[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.
Degrees
F.
Temp.
Degrees
C.
-325
-300
-275
-250
-225
-200
-175
-150
-125
-100
-75
-50
-25
0
25
50
70
100
125
150
175
200
225
250
275
300
325
350
375
400
425
450
475
500
525
550
575
600
625
650
675
700
725
750
775
800
825
850
875
900
925
950
975
1000
1025
1050
1075
1100
1125
1150
1175
1200
1225
1250
1275
1300
1325
1350
1375
1400
-198
-184
-171
-157
-143
-129
-115
-101
-87
-73
-59
-46
-32
-18
-4
10
24
38
52
66
79
93
107
121
135
149
163
177
191
204
218
232
246
260
274
288
302
316
329
343
357
371
385
399
413
427
441
454
468
482
496
510
524
538
552
566
579
593
607
621
635
649
663
677
691
704
718
732
746
760
Carbon,
C MO, 3CR
MO Steel
-2.37
-2.24
-2.11
-1.98
-1.84
-1.71
-1.58
-1.45
-1.30
-1.15
-1.00
-0.84
-0.67
-0.50
-0.32
-0.14
0.00
0.22
0.41
0.60
0.80
1.00
1.20
1.40
1.61
1.82
2.04
2.25
2.48
2.70
2.93
3.16
3.39
3.62
3.86
4.10
4.35
4.60
4.85
5.11
5.36
5.62
5.89
6.16
6.43
6.70
6.97
7.25
7.53
7.81
8.08
8.35
8.62
8.89
9.18
9.46
9.75
10.04
10.30
10.57
10.84
11.10
11.38
11.66
11.94
12.22
12.50
12.78
13.06
13.34
(-1.97)
(-1.87)
(-1.76)
(-1.65)
(-1.53)
(-1.42)
(-1.32)
(-1.21)
(-1.08)
(-0.96)
(-0.83)
(-0.70)
(-0.56)
(-0.42)
(-0.27)
(-0.12)
(0.00)
(0.18)
(0.34)
(0.50)
(0.67)
(0.83)
(1.00)
(1.17)
(1.34)
(1.52)
(1.70)
(1.87)
(2.07)
(2.25)
(2.44)
(2.63)
(2.82)
(3.02)
(3.22)
(3.42)
(3.62)
(3.83)
(4.04)
(4.26)
(4.46)
(4.68)
(4.91)
(5.13)
(5.36)
(5.58)
(5.81)
(6.04)
(6.27)
(6.51)
(6.73)
(6.96)
(7.18)
(7.41)
(7.65)
(7.88)
(8.12)
(8.36)
(8.58)
(8.80)
(9.03)
(9.25)
(9.48)
(9.71)
(9.95)
(10.18)
(10.41)
(10.65)
(10.88)
(11.11)
5 Cr Mo
thru
9 Cr Mo 18
Austen,
Stainless
Steel
Ferritic
Stainless
Steel
-2.22 (-1.85)
-2.10 (-1.75)
-1.98 (-1.65)
-1.86 (-1.55)
-1.74 (-1.45)
-1.62 (-1.35)
-1.50 (-1.25)
-1.37 (-1.14)
-1.23 (-1.02)
-1.08 (-0.90)
-0.94 (-0.78)
-0.79 (-0.66)
-0.63 (-0.52)
-0.46 (-0.38)
-0.30 (-0.25)
-0.13 (-0.11)
0 (0.00)
0.22 (0.18)
0.40 (0.33)
0.58 (0.48)
0.76 (0.63)
0.94 (0.78)
1.13 (0.94)
1.33 (1.11)
1.52 (1.27)
1.71 (1.42)
1.90 (1.58)
2.10 (1.75)
2.30 (1.92)
2.50 (2.08)
2.72 (2.27)
2.93 (2.44)
3.14 (2.62)
3.35 (2.79)
3.58 (2.98)
3.80 (3.17)
4.02 (3.35)
4.24 (3.53)
4.47 (3.72)
4.69 (3.91)
4.92 (4.10)
5.14 (4.28)
5.38 (4.48)
5.62 (4.68)
5.86 (4.88)
6.10 (5.08)
6.34 (5.28)
6.59 (5.49)
6.83 (5.69)
7.07 (5.89)
7.31 (6.09)
7.56 (6.30)
7.81 (6.51)
8.06 (6.71)
8.30 (6.91)
8.55 (7.12)
8.80 (7.33)
9.05 (7.54)
9.28 (7.73)
9.52 (7.93)
9.76 (8.13)
10.00 (8.33)
10.26 (8.55)
10.53 (8.77)
10.79 (8.99)
11.06 (9.21)
11.30 (9.41)
11.55 (9.62)
11.80 (9.83)
12.05 (10.04)
-3.85
-3.62
-3.40
-3.17
-2.95
-2.72
-2.49
-2.27
-2.01
-1.75
-1.50
-1.24
-0.98
-0.72
-0.46
-0.21
0.00
0.33
0.61
0.89
1.17
1.46
1.74
2.03
2.32
2.61
2.91
3.20
3.50
3.80
4.10
4.40
4.70
5.01
5.31
5.62
5.93
6.24
6.56
6.87
7.18
7.50
7.82
8.15
8.47
8.80
9.13
9.46
9.79
10.12
10.46
10.80
11.14
11.48
11.82
12.16
12.50
12.84
13.18
13.52
13.87
14.20
14.55
14.88
15.22
15.56
15.90
16.24
16.58
16.92
-2.04
-1.93
-1.81
-1.70
-1.58
-1.47
-1.35
-1.24
-1.12
-0.99
-0.86
-0.72
-0.58
-0.43
-0.27
-0.12
0.00
0.19
0.35
0.52
0.69
0.86
1.03
1.21
1.38
1.56
1.74
1.93
2.11
2.30
2.49
2.68
2.88
3.08
3.28
3.48
3.69
3.90
4.10
4.31
4.52
4.73
4.95
5.16
5.38
5.60
5.82
6.04
6.27
6.49
6.72
6.94
7.17
7.40
7.62
7.85
8.08
8.31
8.53
8.75
8.97
9.19
9.42
9.65
9.88
10.11
10.33
10.56
10.79
11.01
(-3.21)
(-3.02)
(-2.83)
(-2.64)
(-2.46)
(-2.27)
(-2.07)
(-1.89)
(-1.67)
(-1.46)
(-1.25)
(-1.03)
(-0.82)
(-0.60)
(-0.38)
(-0.17)
(0.00)
(0.27)
(0.51)
(0.74)
(0.97)
(1.22)
(1.45)
(1.69)
(1.93)
(2.17)
(2.42)
(2.67)
(2.92)
(3.17)
(3.42)
(3.67)
(3.92)
(4.17)
(4.42)
(4.68)
(4.94)
(5.20)
(5.46)
(5.72)
(5.98)
(6.25)
(6.51)
(6.79)
(7.06)
(7.33)
(7.61)
(7.88)
(8.16)
(8.43)
(8.71)
(9.00)
(9.28)
(9.56)
(9.85)
(10.13)
(10.41)
(10.70)
(10.98)
(11.26)
(11.55)
(11.83)
(12.12)
(12.40)
(12.68)
(12.96)
(13.24)
(13.53)
(13.81)
(14.09)
(-1.70)
(-1.61)
(-1.51)
(-1.42)
(-1.32)
(-1.22)
(-1.12)
(-1.03)
(-0.93)
(-0.82)
(-0.72)
(-0.60)
(-0.48)
(-0.36)
(-0.22)
(-0.10)
(0.00)
(0.16)
(0.29)
(0.43)
(0.57)
(0.72)
(0.86)
(1.01)
(1.15)
(1.30)
(1.45)
(1.61)
(1.76)
(1.92)
(2.07)
(2.23)
(2.40)
(2.57)
(2.73)
(2.90)
(3.07)
(3.25)
(3.42)
(3.59)
(3.77)
(3.94)
(4.12)
(4.30)
(4.48)
(4.66)
(4.85)
(5.03)
(5.22)
(5.41)
(5.60)
(5.78)
(5.97)
(6.16)
(6.35)
(6.54)
(6.73)
(6.92)
(7.11)
(7.29)
(7.47)
(7.66)
(7.85)
(8.04)
(8.23)
(8.42)
(8.60)
(8.80)
(8.99)
(9.17)
Monel
400
-2.62
-2.50
-2.38
-2.26
-2.14
-2.03
-1.91
-1.79
-1.59
-1.38
-1.18
-0.98
-0.77
-0.57
-0.37
-0.16
0.00
0.27
0.50
0.74
0.98
1.22
1.47
1.71
1.96
2.21
2.47
2.72
2.98
3.25
3.51
3.78
4.06
4.33
4.61
4.89
5.17
5.46
5.75
6.04
6.34
6.64
6.94
7.24
7.54
7.85
8.16
8.48
8.80
9.12
9.44
9.77
10.09
10.42
10.76
11.09
11.43
11.77
12.11
12.45
12.80
13.15
13.51
13.86
14.22
14.58
14.94
15.30
15.66
16.02
(-2.18)
(-2.08)
(-1.98)
(-1.88)
(-1.78)
(-1.69)
(-1.59)
(-1.49)
(-1.32)
(-1.15)
(-0.98)
(-0.82)
(-0.64)
(-0.47)
(-0.31)
(-0.13)
(0.00)
(0.22)
(0.42)
(0.62)
(0.82)
(1.02)
(1.22)
(1.42)
(1.63)
(1.84)
(2.06)
(2.27)
(2.48)
(2.71)
(2.92)
(3.15)
(3.38)
(3.61)
(3.84)
(4.07)
(4.31)
(4.55)
(4.79)
(5.03)
(5.28)
(5.53)
(5.78)
(6.03)
(6.28)
(6.54)
(6.80)
(7.06)
(7.33)
(7.60)
(7.86)
(8.14)
(8.40)
(8.68)
(8.96)
(9.24)
(9.52)
(9.80)
(10.09)
(10.37)
(10.66)
(10.95)
(11.25)
(11.55)
(11.85)
(12.15)
(12.45)
(12.74)
(13.04)
(13.34)
Inconel
600
-2.30
-2.17
-2.04
-1.87
-1.70
-1.54
-1.37
-1.17
-0.97
-0.76
-0.56
-0.36
-0.16
0.00
0.26
0.48
0.70
0.93
1.15
1.39
1.63
1.86
2.10
2.34
2.57
2.81
3.05
3.30
3.54
3.79
4.03
4.28
4.53
4.77
5.02
5.29
5.54
5.80
6.06
6.32
6.58
6.84
7.10
7.38
7.67
7.95
8.23
8.52
8.80
9.09
9.37
9.66
9.94
10.23
10.51
10.80
11.09
11.37
11.66
11.98
12.29
12.61
12.93
13.25
13.56
13.88
14.20
(-1.92)
(-1.81)
(-1.70)
(-1.56)
(-1.42)
(-1.28)
(-1.14)
(-0.97)
(-0.81)
(-0.63)
(-0.47)
(-0.30)
(-0.13)
(0.00)
(0.22)
(0.40)
(0.58)
(0.77)
(0.96)
(1.16)
(1.36)
(1.55)
(1.75)
(1.95)
(2.14)
(2.34)
(2.54)
(2.75)
(2.95)
(3.16)
(3.36)
(3.57)
(3.77)
(3.97)
(4.18)
(4.41)
(4.61)
(4.83)
(5.05)
(5.26)
(5.48)
(5.70)
(5.91)
(6.15)
(6.39)
(6.62)
(6.86)
(7.10)
(7.33)
(7.57)
(7.81)
(8.05)
(8.28)
(8.52)
(8.75)
(9.00)
(9.24)
(9.47)
(9.71)
(9.98)
(10.24)
(10.50)
(10.77)
(11.04)
(11.30)
(11.56)
(11.83)
25CR
20NI
-3.00
-2.83
-2.66
-2.49
-2.32
-2.15
-1.98
-1.81
-1.60
-1.39
-1.19
-0.98
-0.76
-0.57
-0.37
-0.16
0.00
0.27
0.50
0.73
0.97
1.21
1.45
1.69
1.94
2.19
2.44
2.69
2.94
3.20
3.46
3.72
3.98
4.24
4.51
4.78
5.05
5.33
5.60
5.88
6.16
6.44
6.73
7.02
7.31
7.60
7.89
8.19
8.48
8.78
9.07
9.36
9.66
9.95
10.25
10.54
10.83
11.12
11.42
11.72
12.01
12.31
12.60
12.89
13.17
13.46
13.76
14.05
14.35
14.65
(-2.50)
(-2.36)
(-2.22)
(-2.07)
(-1.93)
(-1.79)
(-1.65)
(-1.51)
(-1.33)
(-1.16)
(-0.99)
(-0.82)
(-0.63)
(-0.47)
(-0.31)
(-0.13)
(0.00)
(0.22)
(0.42)
(0.61)
(0.81)
(1.01)
(1.21)
(1.41)
(1.62)
(1.82)
(2.03)
(2.24)
(2.45)
(2.67)
(2.88)
(3.10)
(3.32)
(3.53)
(3.76)
(3.98)
(4.21)
(4.44)
(4.66)
(4.90)
(5.13)
(5.36)
(5.61)
(5.85)
(6.09)
(6.33)
(6.57)
(6.82)
(7.06)
(7.31)
(7.56)
(7.80)
(8.05)
(8.29)
(8.54)
(8.78)
(9.02)
(9.26)
(9.51)
(9.76)
(10.00)
(10.25)
(10.50)
(10.74)
(10.97)
(11.21)
(11.46)
(11.70)
(11.95)
(12.20)
The linear thermal growth or contraction between 70F (24C) 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.
Accumulation Pillow: A pillow fabricated using

insulation material, wrapped in a woven fabric, then
placed in an expansion joint cavity. The purpose is to
either retard the intrusion of particulate, thermal
protection, or to resist pressure pulsation.
Design Pressure: The maximum pressure, both positive

or negative that is expected during normal operation,
not including periods of abnormal operation (see
excursion pressure).
Active Length (Live Length): The portion of the flexible

seal that is free to move.
Design Temperature: The maximum or most severe

temperature expected during normal operation, not
including periods of abnormal operation caused by
equipment failure. (See excursion temperature)
Back-Up Bars: Metal bars used for the purpose of

clamping the fabric expansion joint to mating ductwork
flanges.
Excursion Pressure: The maximum pressure, both

positive and negative, the system could reach during
abnormal conditions or equipment failure.
Baffle (Liner): A metal shield that is designed to protect

the expansion joint from the abrasive particles in the gas
stream and to reduce the flutter caused by air turbulence
in the gas stream and in some cases may be part of the
overall thermal protection system.
Excursion Temperature: The maximum temperature

the system could reach. Excursion temperature should be
defined by maximum temperatures and time duration.
Belt Type (Flat Belt): An expansion joint in which the

flexible fabric portion of the joint is flat and is bolted or
clamped to metal flanges or frame.
Field Assembly: A joint that is assembled at the job

site due to its size (too large to ship) or the location of
|the breach opening makes it more practical to install
in sections. On-site assembly is required for certain
frame styles.
Bolt-In Flow Liner: A baffle that is designed to be bolted

to the breach flange. This design can be either single or
telescoping and requires the use of a gasket seal.
Typically used on integrally flanged expansion joints.
Belt: The flexible element of a nonmetallic expansion
joint.
Breach Opening: The distance between the mating duct
flanges in which the joint is to be installed.
Face-To-Face: See breach opening.
Field Splice: See splice

Flanges: That part of an expansion joint used for
fastening the joint into the system ductwork.
Flow Direction: Direction of gas movement through
the system.
Flow Liner: See baffle
25
Flutter: The repetitive oscillating movement of the

expansion joint material due to fluctuation between
positive pressure and negative pressure or due to flow
induced pulsations. This phenomenon is detrimental to
expansion joints.
Frame: The complete angle iron or plate frame to which
belt or bellows portion of the expansion joint is attached.
Flow Deflector: A metal baffle installed in the ductwork
adjacent to the expansion joint, that diverts the gas
stream over the flow liner for the purpose of preventing
the particulate in the flow stream for entering the
expansion joint cavity. It also can be used to prevent
condensation from entering the expansion joint cavity.
Gas Seal: The layer or specific ply of the expansion
joint material that is designed to minimize or contain
the flue gas.
Lateral Movement: The relating displacement of the two
ends or the expansion joint perpendicular to its
longitudinal axis. The displacement movement usually
caused by the thermal expansion of the ducting system
and measured in inches or millimeters.
Lateral Offset: The offset distance between two adjacent
duct flanges or faces. Can be due to misalignment or, by
design, to compensate for excessive displacement in the
opposite direction during cycling. (Cold lateral offset)
Lifting Lugs: A lifting device that is attached to the
metal portion of the expansion joint for field handling
and erection.
Manufactured F/F (Face to Face): The manufactured
width of the joint measured between joint flange faces.
The joint may be set into a breach opening that is less
than the manufactured F/F of the joint to allow for axial
extension.
Misalignment (Offset): The out of line condition that
exists between the adjacent faces of the breach or duct
flanges during ductwork assembly.
Molded Corner Expansion Joint: A rectangular
integrally flanged expansion joint in which the corner
is molded to form a continuous unspliced section.
Operating Pressure: The pressure or vacuum condition

which occurs during normal performance.
Operating Temperature: The gas temperature at which
the system generally will operate during normal
conditions.
Pre-Compression: Compressing the expansion joint
(shortening the manufactured F/F) so that in the cold
position the joint has a given amount of compression
set into the joint. The purpose of pre-compression is
to allow for unexpected or additional axial extension
and/or lateral movement.
Pre-Set: Dimension that joints are deflected to insure
that desired movements will take place. See lateral offset
and manufactured F/F.
Resultant Movement: The net effect of concurrent
movements.
Set Back (Stand Off Height): The distance the
expansion joint is set back from gas stream to allow for
lateral movement and to prevent the joint from
protruding into the gas flow.
Shipping Bars: Braces that are located between the two
expansion joint flanges to prevent over-compression or
distortion during shipment and joint assembly or
installation. These braces must be removed after
installation.
Splice: Procedure for making endless boot or bellows
from open ended material. Splicing may be accomplished
by one or more of the following: cementing, bonding,
heat sealing, stitching, vulcanizing or mechanical
fastening.
Telescoping Liners (Overlapping Liners): Metal shields
attached to each side of the expansion joint, that overlap
or telescope together under thermal movements.
Thermal Barrier: A layer of insulating material designed
to reduce the surface temperature at the gas sealing layer
to a level compatible with its heat resistance capability.
Weld-In Liner: A liner that is designed to be welded to
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
600-800F (316-427C) Particulate laden flue gas

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

(flow liner and cavity pillow recommended)
280-330F (138-166C) Flue gas with minimal particulate
280-330F (138-166C) Flue gas with acidic condition
(corrosion resistant frame and belt recommended)
120-180F (49-82C) Flue gas at the acid dew point
(corrosion resistant frame and belt recommended)
Ambient clean air
Stack seal fan

Bypass duct
I.D. fan
[typ]
Flue gas desulfurization

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

PERFORMANCE AND BEST VALUE
CAMERA CORNER
NOT RECOMMENDED
Corspan recommends the round corner design for all

applications. This design results in the lowest corner
stress if fit up and welding of the corner seams are
carefully controlled.
Corspan does not recommend the use of camera corner

construction for rectangular metal expansion joints of any
convolution profile. This is a method of assembly that
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
LOW CORNER FATIGUE
The double miter corner design offers lower corner
fatigue than the conventional single miter corner or
camera corner designs. Welds are positioned away from
the centerline of the corner and the highest stressed area
of the bellows.
29
Flexon is a registered trademark of Senior Flexonics Pathway

Corspan is a registered trademark of Senior Flexonics Pathway
Ultrachem is a registered trademark of Senior Flexonics Pathway
Inconel is a registered trademark of Inco Alloys
Viton is a registered trademark of E.I. Dupont
Fluorel is a registered trademark of 3M
Teflon is a registered trademark of E.I. Dupont
DUCTING EXPANSION JOINT SPECIFICATION SHEET

INQUIRY NO.
CUSTOMER NAME
MAILING ADDRESS
CITY
NAME OF PERSON SUBMITTING DATA
STATE
DATE
PROJECT NAME
DELIVERY REQUIRED BY
FAX NO.
PHONE
TYPE OF PLANT
NO. OF PLANT CYCLES PER YEAR
ZIP
BASE LOAD
FUEL
SULFUR CONTENT
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.)
SIZE
EXPANSION JOINT STYLE/SERIES

DUCT SIZE (INSIDE DIMENSION OR DIAMETER)
IN
IN
MM
MM
BREACH OPENING (FACE TO FACE, SPAN)
IN
IN
MM
MM
FLOW VELOCITY
FPS
FPS
M/S
M/S
DUST LOAD
PSF
PSF
Mg/M3
Mg/M3
NORMAL OPERATING
WC
WC
MAXIMUM OPERATING
FLOW DIRECTION (UP, DOWN, HORIZONTAL, ANG. UP, ANG. DOWN)
PRESS
GAS
FLOWING MEDIA (AIR, FLUE GAS, ETC.)
TEMPERATURE
DESIGN PRESSURE
WC
WC
MM H2O
MM H2O
NORMAL OPERATING
DESIGN
MAXIMUM UPSET EXCURSION
MIN
MIN
MIN
MIN
GAS TEMPERATURE
DURATION PER UPSET

AMBIENT (MINIMUM/MAXIMUM)
F /
F /
C /
C /
MOVEMENTS
AXIAL COMPRESSION
AXIAL EXTENSION
LATERAL OFFSET (PERPENDICULAR TO LONG SIDE)
LATERAL OFFSET (PERPENDICULAR TO SHORT SIDE)
OTHER (ANGULAR OR TORSIONAL)
A/T
DEG A/T
R/S
IN R/S
DEG
A/T
DEG A/T
DEG
MM R/S
MM
DUCT MATERIAL (GAUGE OR THICKNESS)
DUCT
INTERNAL LINER MATERIAL (GAUGE OR THICKNESS)

FWL - FIELD WELDED
LINER ATTACHMENT
SWL - SHOP WELDED

BFL - BOLTED FLANGED
CAVITY INSULATION PILLOW REQUIRED (YES OR NO)
DESIGN
RADIUS OR SQUARE CORNER

DUCT MATERIAL / THICKNESS
STAND OFF HEIGHT
NOTES:
MATL /
IN.
INCH
IN R/S
MATL /
IN.
INCH
MATL /
MM
MM
MATL /
MM
MM
www.flexonics.com
1 800 854 2553
Senior Flexonics Pathway

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

SFP Catalog 3 Fabric Exp Joints

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Signature Not

Digitally signed by Tammie Gilligan

200,000 sq. feet (18580 sq. meters)

Digital Controlled, Flat belt, corners

TEST CAPABILITIES AND DESIGN VERIFICATION TESTS

Senior Flexonics Pathway, 2000

Dead Weight Testing

For high temperature applications see our literature covering

-[FUNCTION OF FABRIC EXPANSION

particles which may be present in the gas stream. A liner is

C. INSULATING RETAINER LAYER

G. FABRIC ATTACHMENT FLANGES

Single ply fluoroplastic and fluoroelastoplastic belt designs

FOSSIL FIRED POWER

WET SCRUBBER APPLICATIONS

CRUDE OIL REHEAT

In addition to Senior Flexonics Pathways standard

Heat Recovery Steam Generators (HRSG)

Circulating Fluid Bed Boilers (CFB)

Windtunnels, HVAC, etc.

Selective Catalyst Reduction (SCR) Units

TYPICAL MOVEMENT CAPABILITIES

Lower installed cost due to lighter weight materials.

Easily repairable by heat seal methods

Lower installed cost due to lighter weight materials

Easily accessible for inspection or repair

-[OPERATIONAL & DESIGN

Base or peak load plant

Relevant history of existing and adjacent equipment

Normal operating temperature

Maximum continuous operating temperature

Excursion temperatures and duration

Ambient temperatures (the lowest, highest

Caution: Specifying a design temperature which

detrimental to the design of the flexible element and

PRESSURE & EXPANSION

configuration. The installation of an expansion joint can

or operating pressure oscillations. Both conditions can

where the static pressure is very low 1 to 2 w.c (25 to

Correct operation of high temperature expansion joints

An external cover may be desirable to help protect

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

CAVITY ACCUMULATION PILLOW (CAP)

A cavity created between the structural steel frame/flanges and the

HIGH TEMPERATURE CAVITY

Cavity Insulation Pillow (CIP) - A style CIP provides additional

Typical cavity pillow

-[OPTIONS & ACCESSORIES]-

TADPOLE GASKET TAPE (TG)

FLOW DEFLECTOR (FD)

Senior Flexonics Pathway expansion joints are furnished assembled or unassembled.

Senior Flexonics Pathway expansion joints are furnished assembled or unassembled.

Senior Flexonics Pathway expansion joints are furnished assembled or unassembled.

Field Assembly Diagram

ADJACENT DUCTING EQUIPMENT

PAINTING & FINISHING

EXPANSION JOINT ASSEMBLY