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Longevity of Duct Tape in Residential Air Distribution Systems: 1-D, 2-D, and 3-D Joints
Abstract
This paper addresses the effectiveness of using duct tape in sealing residential air distribution systems through two laboratory longevity tests. The first test involved the aging of common “core-to-collar joints” of flexible duct to sheet metal collars, and sheet metal “collar-to-plenum joints” exposed to continuous 200°F (93°C) circulating air. The second test consisted of baking duct tape specimens in a constant 212°F (100°C) oven following the UL 181BFX “Temperature Test” requirements. The study concluded that the duct tape performance in sealing joints depends on the joint's space dimensions; it gets worse as the number of dimensions required to describe the joint increases (1-D to 3-D). This is essentially caused by the shrinkage of the duct tape backing that results in the peeling of its rubber-based adhesive off the sheet metal fixture. The baking test results showed that the failure in the duct tape joints could be attributed to the combination type of the duct tape and the material it is applied to.
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Duct leakage is a major source of energy loss in residential buildings. Most duct leakage occurs at the connections to registers, plenums, or branches in the duct system. At each of these connections, a method of sealing the duct system is required. Typical sealing methods include tapes or mastics applied around the joints in the system. Field examinations of duct systems have shown that taped seals tend to fail over extended periods of time. The Lawrence Berkeley National Laboratory has been testing sealant longevity for several years. The accelerated test method developed by LBNL is being used as a basis for an ASTM Standard under sub-committee E6.41. LBNL tests found that typical duct tape (i.e., fabric backed tapes with rubber adhesives) fails more rapidly than all other duct sealants. LBNL has also tested advanced tape products being developed by major manufacturers. The results of these tests showed that the major weaknesses of the tapes that fail are the use of natural rubber adhesives and the mechanical properties of the backing.
Duct leakage has been identified as a major source of energy loss in residential buildings. Most duct leakage occurs at the connections to registers, plenums or branches in the duct system. At each of these connections a method of sealing the duct system is required. Typical sealing methods include tapes or mastics applied around the joints in the system. Field examinations of duct systems have shown that these seals tend to fail over time periods ranging from days to years. We have used several test methods over the last few years to evaluate the longevity of duct sealants when subjected to temperatures and pressures representative of those found in the field. Traditional cloth duct tapes have been found to significantly under-perform other sealants and have been banned from receiving duct tightness credits in California's energy code (California Energy Commission 1998). Our accelerated testing apparatus has been redesigned since its first usage for improved performance. The methodology is currently under consideration by the American Society for Testing and Materials (ASTM) as a potential new test method. This report will summarize the set of measurements to date, review the status of the test apparatus and test method, and summarize the applications of these results to codes and standards.
Can Duct Tape Take the Heat?
- M H Sherman
- I S Walker
Sherman, M.H. and Walker, I.S. 1998. " Can Duct Tape Take the Heat? ", Home Energy
Magazine, Vol. 14, No. 4, pp.14-19, July/August 1998, Berkeley, CA. LBNL 41434.
Sizing and Technology Transfer in Residential Thermal Distribution Systems: Part II – Residential Thermal Distribution Systems Phase VI Final Report. LBNL-42691
- Leakage Diagnostics
- Sealant Longevity
Leakage Diagnostics, Sealant Longevity, Sizing and Technology Transfer in Residential
Thermal Distribution Systems: Part II – Residential Thermal Distribution Systems Phase
VI Final Report. LBNL-42691, Lawrence Berkeley National Laboratory, Berkeley, CA.