1

Contents:

1. PREAMBLE
2. INTRODUCTION
3. CODE OF PRACTICES
4. MEALTH AND SAFETY
5. INSTALLATION RECOMMONDATIONS
6. INSTALLATION SEQUENCE
7. TESTING
8. QUALITY ASSURANCE

2
1.0 PREMABLE:
- This method statement defines the method used to ensure that
prefabricated ducting, bracketing, and in line equipment installation and
final connections and workmanship are correct and acceptable, and
conforming to the contract documents, duct specifications section.

2.0 INTRODUCTION
- The method statement covers the on site installation of pre-fabricated
duckwork systems manufactured from dipped galvanized steel sheets
according to project specification and SMACNA standards.

3.0 CODE OF PRACTICE

- Particular Technical specification sections.

- SMACNA standards for ductwork construction and installation

- Specification section 233113 for Metal Ducts.

4.0 HEALTH, SAFETY AND ENVIRONMENT:

A. Ductwork equipment:

- Personal protective equipment shall wear during equipment installations,

such as safety helmets, safety shoes, safety goggles, & safety gloves for
sheet metal handling. Proper machines have to be used for the job.

- In case of using electrical portable tools, such as grinders, driller’s power

saws …. Etc the safety rules shall be respected all the time. Cords, cables
… etc shall be inspected and safe guards must be installed.

- Proper and non defective hand tools such as hammers, saws screw
drivers, wrenches, pliers, metal snips, and tool boxes … etc shall be used.

3
B. Working at heights:

The most commonly used construction is:

B.1 Mobile tower scaffold:

 Stand or casters must be used.

 Secure the tower to the structure by ties.

 Inspections of the towers shall be done by safety officers.

 Only green tagged tower scaffold shall be used.

 Unacceptable scaffolds shall be tagged red.

B.2 Ladders:

 Only step ladders of the approved type are allowed to be used.

 Unsound ladders are prohibited.

 Lean sideways from ladder is forbidden.

 Ties to be fitted all the time with the right length.

 Periodic inspections will be done.

C. Hazardous Material:

 Wear suitable PPE while applying for handling chemical

liquids.

 Follow the instructions on the label and the corresponding

material data sheet for each chemical product that will be used
at the work place.

 Warning labels shall be stuck on containers.

 Work shop shall be kept all time clean and free of oils, dust,
and sheet metal residuals …. Etc.

 Trash box shall be available to collect rubbish.

 Steel box shall be available to collect sheets metal residuals

which will not be used (described as scrap).

4
5.0 INSTALLATION RECOMMENDATIONS:
- Preparation for Installation:
 A safe and protected storage area will be allocated in the site with close
coordination with the consultant and safety office.

 All materials, drawing, and other documentation relevant to a particular

section of the work will be checked by the construction department and
Quality Control prior to commencement of the work, ensuring that they
are the correct type as approved by the consultant.

 Before commencing any constructing any construction works, pre-

inspection by the consultant will be carried out on all materials before
leaving storage area.

 Prior to the commencement of any construction works, areas and are in

a suitable condition before construction.

 A close coordination with other trades will be carried out on site prior
to commencement of the work. (Daily coordination meeting with
construction Engineers).

 Work shop to be furnished and to be inspected by the consultant

according clear layout sketch.

 Preliminary tasks off for ordering sheet metal & schedule for delivery.

 Construction Engineer should reflect all (RFI’s) with approved shop

drawing for construction.

 Supervisor will instruct the tradesmen regarding the execution of the

work, and will distribute all necessary approved construction drawings
of the latest revision.

 The supervisor will also check that tools and equipments available are
in compliance with the contract requirements.

5
- Installation Notices:

 Ductwork routing shall strictly match ceiling module lines so as to

maintain maximum flexibility for any future relocation of lighting
fixtures or other services.

 Ductwork supports unless otherwise indicated will be installed to provide

a minimum spacing of 15mm at least between finished covering and
adjacent work , and a 100mm at least clearance from suspended ceiling
or as (per shop drawing).

 In-line equipment shall be independently supported from main structure

and not block work walls or sub-structure.

 Supports or hangers will be placed within a 300mm of any 45̊-90̊ bends

or elbows.

 Screwed drop will have threated adjustment in either direction after

leveling of ductwork and plenum boxes.

 Duct will be supported within 300mm of mating flanges or joints.

 The consultant randomly should be invited to duct sheet gauges at the

duct work shop preior to fabrication.

 As indicated on relevant approved construction drawing where more than

one duct can be supported on one hanger, the size of the hanger will be
assessed based on the sum of their maximum weights.

 Ductwork passing through non fire rated walls and floors will be
adequately supported on either side. and according to the approved
details

o All locknuts are tightened correctly. Properly sized and done

according to approved details.

o At all open ends check for debris then cover with suitable material to
prevent any ingress of debris, vermin, or moisture.

6
 Supervision is essential to ensure that there are no dents, distortion or
buckling of duct installation. Damaged sheet metal work will be rejected

 An inspection request shall be submittal to inspect work before applying

the instalation and upon PMCM’S permission the duct work shall be
installed.

 Ducting to be installed allowing sufficient space for expansion /

contraction and thermal insulation for joints and provide approved flame
proof fabric flexible duct connection at building expansion joint fans,
A.H.U and FCU connection.

 Fixation of equipments flanges to ductwork will be with flame proof

fabric flexible connections according to the approved details and in
compliance with the specification requirements.

 Clean both flange faces to be joined.

o Add gasket jointing material to flanges in order to be mated

o Using only undamaged rust free bolts, nuts washers to join mating
flanges to gather and tighten bolts.

o Clean any excess jointing material from flanges.

 Continuous checks for horizontal and vertical alignment of ductwork and

compliance with approved shop drawing and specification requirements.

 Ensure that horizontal ductwork is adequately supported at equal

distances in accordance with the construction drawings, and all brackets
supported to the vertical face of the ribbed beams of the structure.

 Silencers, fire dampers, balancing dampers & other plant items will be
installed as per approved shop drawings, and will be supported
adequately.

 Supervisor is to check before the end of the working day by recording in

his diary (as necessary) that :

7
 o The correct types of supports are installed.

o Supports are adequantely supporting the duckwork and associated

plant equipment.

o Provide Access doors location & size in duct.

 Test holes shall be provided, marked and plugged in order to be ready

commissioning and control of equipments.

Ensure that terminal equipment is installed as specified.

 Supervisor shall ensure that all completed installations are neat, tidy, as
per approved shop drawings and manufacturer’s recommendations and
that there is adequate spacing between ductwork and in line equipment
allowing access for operation and ease of maintenance.

 The supervisor in charge and the QC engineer monitoring shall be

continuous activities (such as recording the defects or snags into his
house process inspectionlist to ensure that all components indicated on
the approved shop drawings have been installed , and that the installation
is in accordance with contract requirements) & after this raise an
inspection request to approval .

 Record drawings shall be started since the first day installation according
to field changes.

6.0 INSTALLATION SEQUENCE:

- Sequence of fabrication.

 Duct workshop supervisor will instruct the supervisor of the fabricators

regarding the excution of all details.

- Supervisor shall handover the approved shop drawing with specified and clear
dimensions to duct workshop technician.

- Routin test.

 Technician shall select the proper sheet metal gauges which indicated on
the approved shop drawing and according to duct boxes sizes

 Sheet metal is free or rust, scales and ….. etc.

8
  Fabricators will start tracing the shapes of deferent pieses on the sheet
metal considering tolerance and allowances related to SMACNA
standard.

 Then the sheet metal shall be turned to a machine for the cutting the
required shapes based on the specified drawing.

 Beading machine shall take place to perform the required slots, corners of
boxes and joints.

 Beading machine shall take place to perform the required slots, corners of
boxes and joints.

 Lock forming machines for forming longitudinal and traverse joints.

 The assembling for seam only on ground.

 Rollers shall limit the required steep bends for easy &proper connection.

 Assembling teams shall assemble the pieces using the proper tools
(mastic, rivets, gasket, slip runners … etc).

 Each line shall be identified by numbering applicable to the same number

of shop drawing to ease the installation procedure on site.

 Each group of fabricated ducts shall be stored in a safe place ready for
installation.

- Installation supervisor (based on approved shop drawings) shall instruct his

team to apply the center line of hangers on ceiling using chalk line.

 Before drilling slab contractor will utilize a magnetometer to locate steel

reinforcing and refer to as – built electroncal drawings to avoid
embedded conduit.

 Drilling and anchoring of threated rods with the proper length and
diameters from the approved material shall be erected.

 Duct boxes shall be raised to support hangars and traverse joints to be

completed and closed at high level of installation.

 Approved sealant will be provided for duct at longitudinal and traverse

joints.

9
 - Installation team will start will start hanging fabricated ducts leaving 10cm at
each each end for consulatant to inspect the joints after insulation .

7.0 TESTING:
- Before insulation air leakage tests for low and medium pressure ducts is
applied by light test or smoke test to test all joints, static. Balancing &
commissioning for duct net work to be performed later on after complete
system installation.

8.0 QUALITY ASSURANCE:

- All work shall be carried out using the approved shop drawing & approved
materials in accordance with general contract document and specification

* Installer qualification:
 should have installation experience in similar projects

- Manufacturer qualification :
 A firm experienced in manufacturing and familiar with codes
and standards.

10