DuctSox SkeleCore Pull-Tight Cable User manual

Publication: AMEN00417 2021-02-22
SkeleCore Pull-Tight Cable
Installation Manual
Language: English
Thank you for selecting a DuctSox SkeleCore Pull-Tight with Cable System. This installation manual will be helpful for
installing the system. The key to a successful SkeleCore Pull-Tight installation is using Tensioning Baskets to apply
tension to the fabric and to smooth the appearance. Sections of fabric will be labeled, assembled, bagged, and boxed
for shipping. Systems will include a drawing detail of the system identifying what is in each package and detailed
dimensions of support locations.
Overview
Inventory
Read through this guide thoroughly. Review the components that need to be assembled and installed. Review the
Engineering and Architectural drawings of the project while reading this guide, including the project-specic drawing
details provided by DuctSox.
Shipping/Receiving
In some cases the DuctSox support system is delivered to the job site ahead of the DuctSox fabric sections. Depending
on the size of a project or order, a DuctSox system will be shipped by common courier in a single brown box or several
boxes. Larger orders will be shipped in crates by a common freight courier. Each DuctSox length should be packaged
into individual plastic bags and labeled according to size and number of pieces. Other markings or labeling may also be
incorporated for larger or more complicated systems. Be sure you have determined all boxes are accounted for.
Unpacking
Inspect shipment carefully and make sure all components are accounted for by emptying packaging and examining
all contents. Note any missing or damaged pieces listed on the Bill of Lading and contact your courier and DuctSox
Representative.
Labeling
Each fabric section will have a tag near any zipper. The tag will include job number, ship date, diameter, section
number (if the total length is comprised of more than one fabric section), and total length.
Equipment Required:
• Drill
• Level
• Tape measure
• Marker or pencil
• Wrenches for cable clamps and eye bolts (5/16 in and 9/16 in)
• Flat (standard) screwdriver
• Cable cutter
• Rivet gun

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Component Details
Universal Ring (UR): Used at both
ends of each basket. Available in
diameters from 8 in to 60 in (2 in
increments) or 203 mm to 1524
mm (51 mm increments)
Component Details
UR Connector
Tension Basket Tube with Push Button: 28.5 in (724 mm) in length to
provide 30 in (762 mm) of spacing between rings. End of tube with push
button is shown.
Tension Basket
Tension Cable Lock

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1/8 in (3 mm) Cable Only
Component Details (continued)
Top Zipper Tension Clips
Hoops: Used at 5 ft (1524 mm) intervals in the interior of each
tensioned section. Available in diameters from 8 in to 60 in (2 in
increments) or 203 mm to 1524 mm (51 mm increments). Hoops
are factory installed.
Glider Attachment
Cable Intermediate Support
Top Zipper
Type 1 Kit
Gripple Turnbuckle Kit

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Installation Steps
1. Review materials in box, including the CAD drawing and installed location of the DuctSox
2. Prepare metal inlet collar for fabric connection
3. Mark placement and install cable. (3x1 or 4x2)
4. Install and assemble DuctSox components
5. Start up AHU
6. Balance airow
Step 1
Review materials in box, including the project-specic drawing and installed location of the DuctSox. The Project-Specic
Drawings detail the specic locations of Tensioning Baskets and Cable Stops using the Inlet Belt as the main reference point.
READ INSTRUCTIONS THOROUGHLY BEFORE BEGINNING.
Example Project-Specic Drawing Detail
Step 2
Prepare metal inlet collar for fabric connection.
• Conrm inlet air supply location.
• Conrm inlet air supply size.
• DuctSox inlets are manufactured 1/2 in (12 mm) larger than specied
to t over metal inlet collar.
• Metal collar length should be 6 in–10 in (150 cm to 250 cm) for
secure fabric attachment.
• Edge Guard (provided) should be installed on the edge of the metal
collar to reduce fabric wear from the metal edge.
Edge Guard
(Supplied)
6 in–10 in
(150 cm–250 cm)

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DuctSox®Installation Manual SkeleCore Pull-Tight Cable
The following details are used for Galvanized Cable styles.
1. Eyebolts must be fastened to the structure of the building (including knee braces) by
others. They must be fastened in correct locations according to suspension style (Shown in
each suspension style’s section).
2. Hook Gripple®Turnbuckles to the installed eyebolts.
3. Insert cable into the plastic end of the Gripple®Turnbuckle and push/pull it through
the opening on the side of the Gripple®Turnbuckle.
Note: To release the cable hold in the plastic button and slide the turnbuckle.
To lock the button twist the plastic until tight.
4. Tighten the cable to 100 lb (445 Newtons) tension by pulling the cable tight and then
twisting the turnbuckles. Clip extra cable when nished, leaving about 3 in (76 mm) of
cable extending through the side the Gripple Turnbuckle.

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Step 3
Mark Placement and Install Cable.
The following details about Type 1 and Type 2 Kits are used for SS and Impregnated Cable styles.
Type 1 and Type 2 Kits
Type 1 and Type 2 kits are for straight runs of cable:
• Type 1: 50 ft (15250 mm) or less
• Type 2: 50 ft to 100 ft (15250 mm to 30500 mm)
• For systems over 100 ft (30500 mm), a combination of the kits
should be used.
These kits include one 6 in (153 mm) turnbuckle (two for Type 2), two
eyebolts, two cable thimbles, and four cable clamps.
Eye bolts must be fastened into the structure of the building by others
(this could include knee braces).
Cable is fastened directly to an eyebolt with a thimble and two cable
clamps. Take the cable end and thread two cable clamps onto it. Now
hook the thimble onto the eyebolt. Next, thread the cable onto the
thimble and through the eyebolts (cable clamps are still on the cable).
Now thread the cable back into the cable clamps and tighten them.
Cable is then fastened directly to the turnbuckle with a thimble and two cable clamps. Slack in the cable is taken up by
the turnbuckle. If cable is still too loose after tightening the turnbuckle, loosen the cable, re-fasten cable to turnbuckle at a
tighter position, and re-tighten the turnbuckle. Do not over-tighten the turnbuckle, we recommend no more than 100 lbs (445
Newtons) of tensile force.
Intermediate Support Cable
Installed every 12.5 ft (3810 mm) or less to keep the DuctSox installed at a
consistent elevation (reduces sag of the cable).
Step 3 – 1 Row Style
Galvanized and SS

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Step 3
Determine placement of cable (both cable path and elevation). The cable
must be mounted 1.5 in (38 mm) above the 12:00 location of the DuctSox.
Intermediate Cable supports are spaced no more than 12.5 ft (3810 mm).
T’s
There should be roughly 12 in (305 mm) from sidewall of DuctSox to the
closest edge of any knee-bracing. Structure too close to the main run may
cause premature failure due to abrasion from the structure.
NOTE: Offset distance of branch knee-brace from main trunk is
approximately half of the main trunk diameter plus 12 in (305 mm).
Elbows
Extended straps on heels of elbows are provided for support to cable suspension (Figure A). Vertical elbows are also
supported by extended straps (Figure B).
Figure A Figure B
1.5 in (38 mm)
12 in (305 mm)
12 in (305 mm)

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STEP 4
Install Tensioning Baskets and Fabric. Tensioned Sections must be completed in succession moving away from the Inlet Belt.
Overview of Step 4:
A. Install fabric Inlet Belt onto metal collar
B. Install Tensioning Basket
C. Using Project-Specic Drawing, install the balance of Tensioning Baskets and fabric.
D. Tension fabric
E. Fitting considerations
A. Install fabric Inlet Belt onto metal collar.
DuctSox Inlet must be attached to the metal collar using screws (not included) through
plastic patches on the Inlet Belt. Be sure to locate the zipper start and seam at the
12:00 orientation for proper alignment.
B. Install rst section of DuctSox fabric and Tensioning Basket at Inlet Belt.
Rivet the UR Connector to the Universal Ring. This assembly may already be
completed for you by DuctSox factory.
Rivet the Tension Cable Lock to 12:00 of the Universal Ring (2x). Each one in opposite
directions.
Install the Universal Ring assembly on the cable (2x). (Through the fabric and zipper
where required.) The lever of the Cable Lock will point towards the section being
tensioned.
Finish the basket by connecting the two Universal Ring assemblies with the basket tube.
Inlet Patch
Tension Cable Lock Levers
Install Universal Ring Assembly on Cable Finish Basket with UR ConnectorTop zipper, open
NOTE: When the Tensioning Basket is assembled, the UR Connectors point
towards each other. The Tension Cable Lock Levers point in the same direction
towards the fabric section being tensioned (see drawing on page 8 for
clarication).
WARNING: If this is done incorrectly, the system WILL NOT TENSION.
UR Connectors

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DuctSox®Installation Manual SkeleCore Pull-Tight Cable
C. Using Project-Specic Drawings, identify placement of the balance of SkeleCore Pull-Tight Tensioning Baskets.
Tensioned Sections are dened as the areas between the Tensioned Baskets.
Twist and snap the Glider attachments of the DuctSox onto the cable (pliers may be helpful for installation and removal of
Gliders). Unzip ttings and slide them in place independently of the straight sections. Tensioning Baskets are installed at the
Inlet, Endcap, Elbows, Reducers, and intermediate points of longer sections. BE SURE TO REVIEW THE PROJECT-SPECIFIC
DRAWINGS FOR ALL EXACT LOCATIONS.
The Cable Stop is used to keep shorter sections of DuctSox under slight tension. Nuts are tightened to lock the stop at
locations where Gliders are to be locked in place (see Step 5). Locations of Cable Stops (if any) can found on the project-
specic drawings.
47’ (14.3m)
Total Example Length
Tensioned
Section
Tensioned Section
0 ft
Tension Cable Lock Levers
point TOWARDS the Tensioned Section.
IMPORTANT: Tension Cable Lock Levers
point TOWARDS the Tensioned Section.
Tension Cable Lock Levers point
TOWARDS the Tensioned Section.
40 ft (12.2 m) 47 ft (14.3 m)

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Attach the Tension Clips of the fabric to the Tensioning Basket. Complete the connection by zippering the duct to the Inlet
Belt.
To complete the rst Tensioned Section, repeat the process going in the other direction, after you zipper the two sections of
fabric together.
D. Tension Fabric.
The amount of take-up will vary based on the length of the Tensioned Section. As
tension is applied, wiggle your DuctSox to evenly distribute fabric tensioning over entire
length. Tension the fabric until the desired roundness and tautness of the fabric is
achieved.
NOTE: Make sure the lock lever is engaged prior to pulling back on basket.
Top Zipper, Closed
Tension Clips in System
Pull back on Tensioning Basket
After Tensioning
Before Tensioning
Top Zipper, Open
Lever Engaged INCORRECT

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If your section ends with an Endcap, follow these additional instructions.
IMPORTANT: Before installing the Endcap, insert a Hoop into the mesh ap of the
Endcap. Tuck the Hoop under the mesh. Cinch the rope tight and lock.
Take the Endcap and install it on the corresponding Tensioning Basket.
Hoop
Endcap

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E-1. Fitting Considerations: Reducer or Elbow.
Fitting is placed between two Tensioned Sections.
1. Reference the drawing to determine important dimensions for installation of Fitting Tensioning Baskets.
2. Install and tension the DuctSox section prior to (up stream) of the Fitting.
3. Measure and place the downstream Tensioning Basket.
4. Zip fabric tting in place after adjacent Tensioning Baskets are secured.
E-2. Fitting Considerations: Take-Offs.
1. The main section of a Take-Off is tensioned in-line with the sections before and after this tting. The section before a Take-
Off, the Take-Off, and the section after a Take-Off are one continuous tensioned section.
2. Install the Tensioning Basket at the branch of the Take-Off tting just as the Tensioning Basket at the Inlet was installed.
3. Please refer to the project-specic drawings for basket locations.
E-3. Fitting Considerations: Fitting-to-Fitting Connection
Fitting-to-tting connections will be detailed on the Project-Specic Drawings. Use these details for this installation.
Step 5
Start Up AHU. Turn on the AHU and inate the DuctSox System. Check Top Zippers and sections to ensure system is inating
properly. If lengths do not t properly, double check all eld measurements and compare to drawings. If all measurements are
correct, contact your DuctSox Representative to discuss options.
Failure to install DuctSox Systems correctly may void warranty.
Tensioning Basket
Reducer Illustrated View

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Step 6
Air Balancing. System must be balanced to design CFM and static pressure immediately after installation.
A zipper at the inlet location provides easy access to monitor airow.
If the fabric is uttering after balancing, please contact your DuctSox Representative immediately. Solutions to the uttering
include adjusting the Adjustable Flow Device (AFD), adding AFDs, or other solutions that would result in a less turbulent
airow.
Laundering Instructions
• Sedona-Xm, TufTex, Verona, DuraTex, Microbe-X, Rx, and Stat-X fabrics:
• Remove the DuctSox fabric from your system, being sure to unzip all sections. Take care in
recording where each section was installed.
• Remove the hoops from the DuctSox system by simply twisting the attachment sideways. Note:
the hoop attachment only slides one way.
• Turn soiled side out and soak in cold water for 30 minutes.
• Wash cold in gentle cycle.
• Rinse thoroughly (repeat cycle if rinse water is dirty or DuctSox are still soiled).
• Drip dry or no-heat tumble dry.

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16 www.ductsox.com Publication: AMEN00417 2021-02-22
CUSTOMER SERVICE
DUCTSOX WORLD HEADQUARTERS
4343 Chavenelle Road
Dubuque, Iowa 52002
563-588-5300
DuctSox®SkeleCore Pull-Tight Cable Installation Manual