1.

0 OBJECTIVE

To Outline The Work Method Of Installation Of Air Conditioning Ductworks (C/W),

Insulation, Ventilation Ductworks, Smoke Spill Exhaust System Ductwork, Kitchen
Exhaust Ductworks, Pressurization System Ductworks , Special Ductwork C/W
Thermal Insulation And Fire Rated Coated , Ductwork C/W Thermal Insulation And
Epoxy Coating. For IMU Project Cadangan Membina Sebuah Hospital Swasta 7
Tingkat Dengan 1 Tingkat Besmen Beserta Podium Tempat Letak Kereta 6 Tingkat as
Per Approved Shop Drawing.

2.0 SCOPE OF WORK

1. To supply, deliver, install, testing and commissioning, completion, handling

over, operational maintenance and servicing during defect liability period of
sheet metal ductwork in accordance with the contract documents.
2. To execute the work in accordance to the approved shop drawings.
3. To be responsible for the arrangement with authority representative to witness
the completed ductworks.
4. The air conditioning ductworks c/w insulation are installed at the Air Handling
Unit (AHU) & Fan Coil Unit (FCU) ducted for return, supply & fresh air supply
ductwork.
5. The general ventilation ductworks are installed at the mechanical rooms that
require sheet metal ducting and all toilets at every level.
6. The kitchen exhaust ductworks are installed at the kitchen areas.
7. The smoke spill ventilation ductwork c/w fire rated coating and fresh air
ductworks are installed at areas requiring smoke spill system.
8. Staircase and lift pressurization ductwork for pressurize air ductwork & by pass
ductwork c/w fire rated coating.
3.0 REFERENCES

a. Contract Document
b. ACMV Shop Drawing
c. Material Approval
d. SMACNA – HVAC DUCT CONSTRUCTION
e. MS 1780:2017 Smoke Control System Using Natural (Displacement) or
Powered (Extraction) Ventilation.
f. MS 1472:2017 Smoke Control in Protected Escape Routes Using Pressurization
Fan.

4.0 RESOURCES

4.1 MATERIALS

ITEM DESCRIPTION MANUFACTURER

1 Stainless Steel Sheet Metal FIW
2 PU Thermal External Insulation K Flex – PE Foam
3 Thermal Internal Insulation K Flex –Open Cell Duct
Liner
4 G.I TDC Joint
5 G.I TDC Corner
6 G.I TDC Clip
7 G.I “S” Cleat
8 G.I Drive Cleat
9 G.I TDC Gasket 1/2 “ (Width) Troeelen
10 Fire Seal (Rockwool) CSL/Roxul/Hilti
11 Hanger Bracket
12 Flexible Duct ( < 1.5m) Asli
13 Fire Rated Coated ( By PMJ) Winduct
14 Fire Damper
15 Volume Control Damper
16 Opposed Blade Damper
17 Motorizes Damper
4.2 Machine/Tools/Equipment

ITEM DESCRIPTION MACHINE/EQUIPMENT/TOOL

1 Duct Fabrication
2 Install Ducting
3 Welding of Kitchen Exhaust Ducting
4 Install Duct Support
Wooden Mallet
Pliers, Screw Driver, Wrench, Cutter,
Fiber Cutter Wheel
Welding Machine, Welding Glove
Drilling Machine, Wrench Screw
 Driver

4.3 Man Power at Site

ITEM DESIGNATION NO OF PERSONNEL

1 Engineer 1
2 Site Supervisor 1
3 Workers 25-35

4.4 Safety Tools

ITEM DESCRIPTION
1 Safety Shoes
2 Safety Helmet
3 Safety Belts/Harness

5.0 HANDLING AND STORAGE

Upon delivery materials at site, the ducting, insulations and its accessories shall be
unloaded carefully and stored in a designated area by the main contractor. Materials
should be stacked neatly and well protected to avoid damage from weather, dirt and
misconduct by others at site.

5.1 INSPECTION OF MATERIALS

The receiving inspection is carried out to ensure that the incoming materials will not be
used until it has be inspect and verified for conformance of using submitted material
approvals. Inspection and verification shall be done on the Material Delivery Order
(DO) and be evidenced by the receiving inspection form which shall be performed by
the resident engineer representing the client on site. The inspection shall be conducted
by the Sub contractor’s Site Supervisor, Main Contractor’s Engineer, Inspector of Work
(IOW), Resident Engineer and employer’s representative. Rejection or acceptance of
material delivery shall be by the discretion of the Resident Engineer on site.
6.0 REQUIREMENT

6.1 DESCRIPTION

Work of this section shall conform to the requirements of the contract documents.

6.2 WORK INCLUDED

1. Air Conditioning Ductworks

2. General Ventilation Ductworks

3. Kitchen Exhaust Ductworks

4. Smoke Spill Ventilation Ductworks C/W Fire Rated Coating

5. Staircase and Lift Lobby Pressurization System Ductwork

6. Special Ductwork C/W Thermal Insulation & Fire Rated Coating

7. Aluminum Ductwork

8. Hybrid Ductwork for External Installations

9. Ductwork Accessories (Fire Damper, Volume Control Damper, Opposed Blade

Damper, Motorize Damper and etc.)

6.3 SUBMITTALS

1. Submit shop drawings indicating routing layouts complete with insulation

types, dampers, turning vanes and access opening.
2. Submit material catalogues, sample boards, test certificates and project
references

6.4 QUALITY ASSURANCE

1. All ductwork shall conform to item 3.0

 2. WIR shall be submitted 3 days before actual material inspection with
reference to item 5.1
3. Rejected material shall be discarded within 3 days of notification.
4. WIR shall be submitted 3 days before installation inspection.
5. Rejected installations shall be rectified within 3 days of notifications.

6.5 MATERIAL

ITEM DUCT GAUGES MATERIAL

Air Conditioning 0..5mm to 1.2mm GI Sheet Closed Cell
Ductworks Insulation
Mechanical Ventilation 0.5mm to 1.2mm GI Sheet
Ductworks
Smoke Spill Ventilation 1.2mm GI Sheet c/w fire rated
Ductworks coating
Kitchen Exhaust 1.0mm Mild Steel Sheet
Ventilation
Pressurization System 1.2mm GI Sheet c/w fire rated
coating
PU Ductworks

7.0 WORK METHODOLOGY

7.1 GENERAL

Upon delivery and unloading, a visual inspection on the ductworks and its accessories
will carried out. Work may then begin. Proper scaffolding and safety precaution is to be
adopted and to be witnessed and approved by consultant’s RE/COW & PMJ’s Engineer.

7.2 PLANNING OF WORKS

Prior to the installations of the ductworks, check and study the approved shop drawings.
The anchor bolts are then installed based on routings and each hanging rods are
installed. The hangers distance shall be at a distance of 2100mm apart. After each
hanging rods are installed, an angle iron is cut to length based on the distance of each
rod and installed with washer and nut.

7.3 INSTALLATION OF AIR CONDITIONING DUCTWORKS

7.3.1 General

All sheet metal ductwork shall be constructed and installed in accordance with the latest
SMACNA recommendation, and the sheet metal duct construction table as shown in
Appendix E&F. The fabrication in factory shall be based on the measurement from
approved shop drawing. Refer to Appendix E, F & G for the ductwork installation
details.

Shop drawing shall be submitted and coordinated with other services. The shop drawing
also shall indicate the duct installation location, duct sizes, access panel, and type of
insulation and damper locations. Due to site accuracy and condition, the last joining
section or final locations indicating offsets or transition will be measured at site.

All fabricated ducts per batch shall be marked for identification with location and gauge
thickness, and check by the sub-contractor supervisor before installation. The important
points to be checked for are any damages to the fabricated ducts, correct construction
and reinforcement, approved type of materials used, size and gauge, seam joints and
sealant.

After the ductworks are fabricated in the factory, the sheet metals are delivered to site
where the ductworks will be installed. The ductworks are then connected using slip joint
or TDC joints depending on the ductwork construction table of Appendix E & F.

For slip joints, the ductworks are connected which “clip joints” and after completion,
duct sealant is applied around these joints. As for TDC joints, the joints are connected
together with a gasket in between. Once the connection is correct, TDC connectors will
be installed at all sides of the ductworks. After this process is done, duct sealant is
applied around the joint.

7.3.2 Duct Support

In general, use trapeze hanger with angle iron and suspension rod fastened overhead
with expansion type anchor plug. A table of angle iron and suspension rod size shall be
provided with the shop drawing. Refer to Appendix G for typical duct hanger and
support.

All brackets shall be galvanized. Generally, the spacing between each bracket shall be
2100mm; more quantity will be used at the corner, fittings and at main branch tee off
point. The duct riser support shall refer to the Appendix G.

7.4 Ductwork Insulation

7.5 Smoke Spill Ventilation, Staircase and Lift Lobby Pressurization Ductworks

7.5.1 General

The duct installation is similar to air ventilation ductwork. Please refer to section 7.3 for
reference. All smoke spill ventilation ductworks shall follow the duct gauges below:

DUCT SIZE GAUGE JOINT

Up to 400mm 1.2mm Traverse Duct Connector (TDC)
401mm to 1000mm 1.2mm Traverse Duct Connector (TDC)
1001mm to 2000mm 1.2mm Traverse Duct Connector (TDC)
2001mm to 2500mm 1.2mm Traverse Duct Connector (TDC)
7.5.2 Fire Rated Coating

7.6 Kitchen Exhaust Ductworks

7.6.1 Duct Fabrication

All kitchen exhaust duct shall be 1.0mm Stainless Steel. The ductworks shall be cut to
length in the factory and delivered to site for installation. All joints of the ductworks
shall be welded connections and grease arresting gutter with 25mm scupper and drain
plug.

Access door at not greater than 3000mm from the bend depending on site condition and
location to install the access door at proper location.
7.6.2 Installation Sequence

1. Check the layout of ductwork routing on site using the approved shop drawings
and based on actual site condition after the coordination with other sub-
contractors.
2. Measure, fabricate and install duct hanger and support. Length of hanger rod is
measured to meet the correct level and shall be slightly longer, sufficient to fix
the nut below.
3. Weld duct in sections and install on the duct support. Install the main ductwork
line first, follow by the branch of the duct network.
4. Check duct levels with reference to the marked reference level line as per
provided by the builders.
5. Weld and install bends, tees, dampers, offsets, and take-off and similar fittings
necessary to complete the ductwork system for the balancing and full operation
of the air distribution system.
6. Install dampers and access doors as indicated in the approved shop drawings.

7.7 Fire Damper Installation

1. All the ductworks penetrating fire rated walls and concrete slabs must be
installed with a 2 hour fire rated fire damper.
2. Ductworks penetrating fire rated walls must be installed with a curtain type fire
damper.
3. Ductworks penetrating concrete slabs must be installed with blade type fire
damper.
4. The fire dampers are first installed onto fire rated walls/ slab and rock wool is
installed on the remaining gap between the fire damper and the fire rated brick
wall/slab.
5. After the installations of the fire damper, the ductworks are then connected to
the fire dampers via slip/TDC joints with Appendix G as a reference.
6. Access panel will be provided on the ductworks for every fire damper locations
for future inspection and maintenance.

7.8 Volume Control Damper Installation

7.9 Motorize Damper Installation

8.0 INSPECTION AND TESTING

8.1 Installation Inspection

The in-process inspection shall be carried out to ensure conformance of the installation
works. “Work Inspection Request” (WIR) form shall be forwarded to the Clerk of
Work/ Resident Engineer to request for an inspection to be carried out on that particular
work. The inspection shall meet the requirement in the approved methodology.

Refer Appendix C & D for Inspection Forms.

8.1 Flowchart for Ductwork Sequences
 Order sheet metal material

Follow dimension of duct at shop drawing

Cut the sheet metal according duct sizes

No, Didn¶t follow

the actual size/
thickness ?
Pass

Form the sheet metal into duct using machines

Delivery to site

Material inspection (Appendix C)

Install ducting at the correct location using TDC joint

Hanging the ducting using bracket

Connect AHU/Fan with duct

Install dampers/grilles and diffuser

Request for inspection (Appendix D)

Refer the
Pass comment from
consultant and
repair the problem
Finish
9.0 HEALTH, SAFETY, SECURITY AND ENVIRONMENT

No Product General Description Safety and Health Measure

1 GI Sheet Metal No health hazard on material but At Storage Area:
precaution is needed to be taken  To be kept dry
during installation  To be stacked
properly
2 Mild Steel Sheet No health hazard on material but At Storage Area:
Metal precaution is needed to be taken  To be kept dry
during installation  To be stacked
properly