Support and Installation

CUSTOMIZING A DAB PANEL

DAB panels are sold as 2ft by 2ft panels but are extremely easy to modify using a DAB Patch Panel kit.  The Patch Panel kit includes extra materials needed to reseal your panel after it has been modified.

To modify the panel, simply mark the panel according to the size adjustments, cut the panel to size with scissors, and use the extra rails and hot glue to make new side rails.  It is recommended that length modifications be made by cutting “with” the pleats (in cutting along a pleat valley with a sharp knife).  This will make cutting and repairing the panel easiest.  Once the panel is cut, cut a length of rail material to the width of the panel and apply glue to the top and bottom of the rail in an “S-pattern” (NOT a straight line) as shown below.  Do NOT be shy with the amount of glue used.

If you need to cut perpendicular to the pleats (cutting across many pleats), when sealing the panel with a new rail, make sure to apply a generous bead of glue in a STRAIGHT line along the top and bottom.  It is recommended to glue the bottom of the rail on first, then apply glue to the top of the rail, after the bottom has cured, and press in place. 

Note the hot glue has an open time of a little under 1min.  You should work at a steady pace and keep pressure on the newly applied rails until they cure.  

Items needed:

  • DAB Panel Patch kit
  • Scissors or razor knife
  • Hot glue gun
  • Ruler
  • Marker

FITTING A DAB PANEL OVER INFRASTRUCTURE

One of the great features of DAB panels is the ability to cut them to fit over existing infrastructure when creating hot aisle containment solutions.  

As is shown in the video below, simply cut out the shape(s) you need, slice the panel to one edge (preferably along a pleat), fit the panel over the infrastructure and patch the rail and pleat with material from the DAB Panel Patch kit.

Items needed:

  • Panel Patch kit
  • Scissors
  • Ruler
  • Marker
  • Damp sponge

OPTIONS FOR COLD AISLE INSTALLATION

Installation of DAB panels for use as a Cold Aisle ceiling is very simple and requires only a few parts that can be purchased online. There are also containment vendors that make ceiling grids into which DAB panels can be placed.

To make a  grid, the following parts are required:

Optional items, depending on aisle construction and perferred fastening method include:

  • L-Channel Aluminum rail. 1 inch height by 3/16 inch thickness is recommended.  The width of the support leg should be at least 1 inch but can be asymmetric.  Online example: https://orangealuminum.com/a631000188/
  • T-slot Rail Fastener and Nut.  To secure the T and L bar rails to the 80/20 T-slot rail, one option is to use a t-nut.  Drill a hole in the T or L bar and fasten to the 80.20 using these nuts. Note, for the T bar, only one fastener is needed when connecting to the 80/20.  Online example: https://www.uline.com/Product/Detail/H-11989/T-Slot-Framing/Fasteners-for-T-Slot-Rail
  • Velcro Strips and Squares. An alternative to using t-nuts is to run a strip of velcro down the top of the 80/20 rail and use velcro squares on the ends of the T and L bars to fasten them. Long rolls of self-adhesive velcro are available online. Make sure to get strips that are not wider than one side of the 80/20 T-slot.  Online example: https://www.amazon.com/Length-Width-Strong-Adhesive-Fastener/dp/B06XQ5FTC2

Some examples of fastening methods.

AIR FLOW FLAP INSTALLATION AND USE

Air Flow Flap Installed in a ceiling grid

In cold aisle installations, the Air Flow Flap (AFF) is a required element.  The AFF must be installed ever 6-8 feet in the aisle to aid in the flow of hot air during a fire.  The AFF is very simple to install as it simply sits in the same grid as as DAB panel.  Simply shorten one DAB panel by 5 inches and place the AFF in-line with the DAB panel in the frame.  Use either strips of velcro to fasten the AFF to the T-bar or a simple screw and nut.  Either approach is applicable. The AFF also comes with integrated lighting which can be used as an alternate aisle lighting source.  One 24v power supply can be used to control up to 10 AFFs, allowing them to be chained together.  Switches and motion sensors are also available to control the lighting.Â