HVAC Specifications KPM Engineering

HVAC SPECIFICATIONS

FOR

DUCTING WORKS

R0 TM 2.1.2018 YBN 2.1.2018 AM 2.1.2018

REV BY DATE CHKED DATE APPD DATE

KPM Engineering Consultants

DEPARTMENT DOCUMENT NO :

MEP GS-M-01

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HVAC Specifications KPM Engineering

Table of Contents
1. Scope ................................................................................................................................................. 3
2. Standards .......................................................................................................................................... 3
3. Materials and Construction .............................................................................................................. 3
4. Components and Accessories ........................................................................................................... 3
5. Duct Fabrication ................................................................................................................................ 3
6. Duct Construction ............................................................................................................................. 4
7. Pre-Insulated Ducts ........................................................................................................................... 5
8. Fire rated duct work.......................................................................................................................... 6
9. Flexible Duct...................................................................................................................................... 7
10. Support system ............................................................................................................................. 7
11. Canvass connection and SA collars ............................................................................................... 7
12. Installation .................................................................................................................................... 8
12.1 Tools and tackles for site works .................................................................................................... 8
13. Installation practices ..................................................................................................................... 8
14. Documentation and measurement for ducting ............................................................................ 9

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1. Scope
This section includes supply, fabrication, installation and testing of all sheet metal / aluminium ducts,
fire cum smoke dampers, grilles and diffusers as per specifications laid below and in line with the bill of
quantities.

2. Standards
Unless otherwise specified here, the construction, erection, testing and performance of the ducting
system shall conform to the SMACNA-1995 standards (“HVAC Duct Construction Standards – Metal
and Flexible – Second Edition – 1995”-SMACNA)

3. Materials and Construction

All ducting shall be fabricated out of Galvanized Iron (GI) or Aluminium as asked for in the Bill Of
Quantities. All ducting shall be fabricated of LFQ (Lock Forming Quality) grade prime G.I. raw material
furnished with accompanying Mill Test Certificates. Galvanising shall be of class VII -180gm/sq.m. (total
coating on both sides). The G.I. raw material should be used in coil-form (instead of sheets) so as to limit
the longitudinal joints at the edges only irrespective of cross- section dimensions.

4. Components and Accessories

All transverse duct connectors (flanges/cleats) and accessories/related hardware such as support
systems shall be zinc-coated (galvanized).

5. Duct Fabrication
All ductwork including straight sections, tapers, elbows, branches, show pieces, collars, terminal boxes
and other transformation pieces must be factory-fabricated conforming to SMACNA standards.
Equivalency will require fabrication by utilizing the following machines and processes to provide the
requisite quality of ducts and speed of supply:

a) Coil lines to ensure location of longitudinal seams at corners/folded edges only to obtain the
required duct rigidity and low leakage characteristics. Longitudinal seams shall not be permitted
along any face side of the duct.
b) All ducts, transformation pieces and fittings to be made on CNC profile cutters for required
accuracyofdimensions,locationanddimensionsofnotchesatthefoldinglines.
c) Alledgestobemachinetreatedusinglockformers,flangersandrollerforturningup edges.
d) Sealant dispensing equipment for applying built-in sealant in Pittsburgh lock where sealing of
longitudinal joints are specified.

5.1 Selection of G. I. gauge and transverse connectors

Duct Construction shall be in compliance with 1” (250 Pa) w.g. or 2” (500 Pa) w.g. static norms
depending upon application, as per SMACNA.

All transverse connectors shall be 4 bolt slip – on flanges system with built-in sealant.

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The specific class of transverse connector and duct gauge for a given duct dimensions will be as per
Table below for the suitable pressure class.

Ducts with external upto250Pa

Duct Pressure -250 Pa

Rectangular Duct

G.S. Duct Section Length 1.2 m ( 4 ft)

Maximum Duct Size Gauge Joint Type Bracing

1-750mm 26 C&S Connector Nil
751-900mm 26 TDF Flange Nil
901-1200mm 24 TDF Flange Nil
1201-1500mm 22 TDF Flange Nil
1501-1800mm 22 TDF Flange JTR or ZEE
1801-2100mm 20 TDF Flange JTR or ZEE
2101- above 18 TDF Flange JTR or ZEE

6. Duct Construction
1. The fabricated duct dimensions should be as per approved drawings and all connecting sections
are dimensionally matched to avoid any gaps.

2. Dimensional Tolerances: All fabricated dimensions will be within +/- 1.0mm of specified dimension.
To obtain required perpendicularity, permissible diagonal tolerances shall be +/- 1.0 mm per metre.

a) Each and every duct piece should be identified by color coded sticker which shows specific
part numbers, job name, drawing number, duct sizes and gauge.
b) Ducts shall be straight and smooth on the inside. Longitudinal seams shall be airtight and at
corners only, which shall be either Pittsburgh or Snap Button Punch as per SMACNA practice,
to ensure air tightness.
c) Changes in dimensions and shape of ducts shall be gradual (between 1:4 and 1:7).Turning
vanes or air splitters shall be installed in all bends and duct collars designed to permit the air
to make the turn without appreciable turbulence.
d) Ducts shall be fabricated as per details shown on Drawings. All ducts shall be rigid and shall be
adequately supported and braced where required with standing seams, tees, or angles, of
ample size to keep the ducts true to shape and to prevent buckling, vibration or breathing.
e) All sheet metal connection, partitions and plenums, required to confine the flow of air to and
through the filters and fans, shall be constructed of 18 gauge GSS / 16gauge aluminum,
thoroughly stiffened with 25mm x 25mm x 3mm galvanized steel angle braces and fitted with

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all necessary inspection doors as required, to give access to all parts of the apparatus. Access
doors shall be not less than 45cm x 45cm in size.
f) Plenums shall be shop/factory fabricated panel type and assembled at site. Fixing of
galvanized angle flanges on duct pieces shall be with rivets heads inside i.e. towards GS sheet
and riveting shall be done from outside.
g) All fire rated duct, smoke exhaust duct shall be quoted with flame bar BW II or equivalent to
achieve the required fire rating also all the related accessories gaskets shall be suitable for the
required fire rating.
h) Self adhesive Neoprene rubber or UV resistant PVC foam lining of 5 mm nominal thickness
shall be used between duct flanges and between duct supports for all duct installations.
i) The deflection of transverse joints should be within specified limit for rectangular duct
deflection as given in SMACNA. Page no. 7.6.

Reinforcement of ducts shall be achieved by either cross breaking or straight. Beading depending on
length of ducts As per MACNA page no. 1.74, fig. 1-8

7. Pre-Insulated Ducts
Pre-Insulated Ducting shall be fabricated from 20 mm thickness air duct panel sheet having
dimensions of 3000 (Length) mm by 1200 (Width) mm and produced and Sandwiched with
Polyisocyanurate (PIR) first quality insulating Foam having 35 Kg / m3 density. The Ducting Sheet shall
have Lacquered & Embossed Aluminium facing on both sides.

Insulating foam material shall be Expanded Rigid Polyisocyanurate foam having Closed cell content not
less than 95%, CFC/ HCFC free, Non Toxic, Non combustible, zero ozone depletion, Zero Global
Warming Potential and Non ignitable.

Ducting panels shall comply with following or equivalent standards and manufacturer should produce
M1 & F1 certification for Fire & Toxicity test results.

• BS 476: PART 6--Fire Propagation for Products

• BS 476: PART 7--- Surface Flame Spread (Class 1)

• Class O Fire Rating as per Building Regulation requirements.

• Thermal Conductivity Coefficient at 100C--0.022 W/m. K

• Smoke Opacity Index—less than 10

• Rigidity class: 200000Nmm2/mm

• Water vapor permeability of laminations = 0

All required accessories; Connecting Flanges, Invisible Bayonet, Adhesive, Sealant, Duct Supports shall
be part of ducting work for fabrication of the HVAC ducting in Square, rectangle, radius, offset
construction etc., appropriate sizes of Aluminium flanges with self-adhesive good quality gasket shall
be provided as a joinery or connection of duct pieces.

Excellent quality Silicon Neutral Sealant of Approved make along with fire rated PVC corners shall be
used for sealing of all joints & corners.

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Complete ducting shall be installed incorporating duct supports such as galvanized angles,
threaded rods, self adhesive brackets, Etc.

Panel Specifications:
Description Internal Areas External Areas of Building
Dimensions of panel 3000 x 1200 mm 3000 x 1200 mm
Thickness of panel 20 mm 20/30 mm
Thickness of aluminium
60/60 microns ( in /out) 60/200 microns (in/out)
laminations
Density of the foam 35 kg/m3 35 kg/m3
Surface finish Embossed/Embossed Embossed/Embossed
Anti-rust lacquer 2 gm/m2 both sides 2 gm/m2 both sides

8. Fire rated duct work

Ducting for kitchen exhaust and fire evacuation, staircase pressurization if not in separate shaft shall be
fire rated as per following specifications.

a) All fire rated ductwork constructed for mechanical or dual ventilation/ pressurization/
basement car park/smoke extract systems and kitchen exhaust shall be fabricated from Lock
Forming Quality grade prime Galvanized Steel Sheet, constructed to enhanced SMACNA
American/DW144 European standard to either low, medium or high velocity/ pressure.
b) Test requirement of fire rated ductwork should be tested to BS476: Part 24 [1987] and ISO 6944
providing required fire rating for Stability and Integrity.
c) Stability: the ability of a duct, ductwork & the support system to remain intact & fulfill their
intended function for a specified period of time, when tested to the requirements of BS476: Part
24 and ISO 6944.
d) Integrity: the ability of a duct or ductwork to remain free of cracks, holes or openings outside
the compartment in which the fire is present for a specified period of time, when tested to the
requirements of BS476 Part 24 ISO 6944.
e) Insulation: the ability of a duct or ductwork to maintain its separating function without
developing temperatures on its external surface outside the compartment in which the fire is
present, which exceeds, (i) 140OC as an average value above ambient & or, (ii) 180OC as
maximum value above ambient at any point, when tested for a specified period of time to the
requirements of BS476: Part 24 ISO 6944.
f) It's important that the fire rated ductwork has a smooth internal surface in order to minimize
the pressure loss within the fire rated ductwork system thereby reduce the power
requirements.
g) All fire rated ducts for Smoke Extract Duct shall have Stability / Integrity and Insulation for
smoke temperatures up to 300OC up to 1.5 hrs, restriction of the duct due to twisting or
buckling after the fire test shall not cause 25% or more reduction in cross sectional area proven
by certification from an independent test house.
h) Each duct shall have fire rated coating. Fire rated coating compound used for construction of fire
rated ductwork shall be protected with minimum 0.7mm to 1mm nominal thickness tested to
properties as per the requirements of BS 476: 6 & 7, including non-combustibility Class O and

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fire propagation - Class 1 surface spread of flame & materials in accordance with Building
Regulations.
i) Fire duct to be tested / assessed to BS476: Part 24 for all sizes up to 25 meters x 3 meters cross-
sectional area and fully certified to vertical and horizontal plane.
j) Fire rated duct fabricated to Method 3 of BS 5588: Part 9, factory produced. The coating
compound shall be applied either offsite or onsite on the ground, dried and cured.
k) Fire duct expansion under fire conditions shall not exceed following,
- At430C an expansion of 0.006106mm per mm
- At600C an expansion of 0.00852mm per mm
- At 1100C an expansion of 0.01562mm per mm

9. Flexible Duct
Insulated flexible duct should be UL 181 CLASS I AIR DUCT LISTED AND LABELLED WITH NFPA 90A & 90B
ANDSEAL OF AIR DIFFUSION COUNCIL with double lamination of tough polyester which encapsulates
steel helix wire forms the air tight inner core, double layer core wrapped in a multiple thickness of
fiberglass wool with R Value 4.2, Green guard certification of fiberglass wool must. , Reinforced and
sheathed in a rugged and durable tri directionally reinforced metalized polyester jacket.

Flexible duct connections should be made as per UL181 listing procedure with proper flexible right
forming brace connection allowing right connections for flexible duct into energy efficient and Strapping
the flexible duct connections with flexible duct strap ties.

10.Support system
A completely galvanized system consisting of fully threaded rods, slotted angles or double-L bottom
brackets (made out of 3.0 mm M.S. sheet) nuts, washers and anchor bolts, generally conforming to
SMACNA standards should be used.

As an alternative, slotted galvanized brackets attached to the top two bolts system may also be used as
appropriate for the site condition.

To provide the required thermal break effect, Neoprene or equivalent material of suitable thickness
shall be used between duct supports and duct profiles in all supply air ducts not enclosed by return air
plenums.

11.Canvass connection and SA collars

Double canvass-connection and GI collar of suitable length shall be provided at the outlet of each ducted
AC units, Fans etc. A zipper shall be provided in the canvass connection to facilitate measurement of
supply air temperature of ducted units. GI collars should be lined from inside with black expanded
polyethylene for noise reduction. SA duct shall be acoustically lines and/or thermally insulated as
specified. Part of the duct, acoustic lining & thermal insulation shall be painted black to prevent
reflection of light through SA/RA grilles. All duct support shall be black painted. All hardware shall be
galvanized.

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12.Installation
12.1 Tools and tackles for site works
The duct installation shall conform to SMACNA norms. For duct assembly and installation the use of
suitable tools and tackles should be used to give the required duct quality and speed of installation
including (but not restricted to)

a) Electric Pittsburgh Seamer – used for closing Pittsburgh joints b) Electric Slitting shear – to
make cut-outs
b) Drilling machine with drill bits – for drilling holes in sheet metal work
c) Hammer drill machine with drill bits – for drilling holes in building structures for anchors e)
Hoisting system – for lifting the duct assembly up to mounting heights

13.Installation practices
All ducts shall be installed strictly as per approved shop drawings and in close coordination with other
services in the ceiling space.

a) The Contractor shall provide and neatly erect all sheet metal work as may be required to carry
out the intent of these specifications and drawings. The work shall meet with the approval of
Owner’s site representative in all its parts and details.
b) All necessary allowances and provisions shall be made by the Contractor for beams, pipes, or
other obstructions in the building whether or not the same are shown on the drawings. Where
there is interference/fouling with other beams, structural work, plumbing and conduits, the
ducts shall be suitably modified as per actual site conditions.
c) Ducting over false ceilings shall be supported from the slab above, or from beams. In no case
shall any duct be supported from false ceilings hangers or be permitted to rest on false ceiling
metal work in dead or furred down spaces shall be erected in time to occasion no delay to other
contractor’s work in the building.
d) All duct work shall be independently supported from building construction. All horizontal ducts
shall be rigidly and securely supported, in an approved manner, with trapeze hangers formed of
galvanized steel rods and galvanized steel angle/channel under ducts at no greater than 2 meter
centre. All vertical duct work shall be supported by structural members on each floor slab. Duct
supports may be through galvanized steel insert plates left in slab at the time of slab casting.
Galvanized steel cleat with a hole for passing the hanger rods shall be welded to the plates.
Trapeze hanger formed of galvanized steel rods and angles/ channels shall be hung through
these cleats. Wherever use of metal insert plates is not feasible, duct support shall be through
dash /anchor fastener driven into the concrete slab by electrically operated gun. Hanger rods
shall then hang through the cleats.
e) Where ducts pass through brick or masonry openings, it shall be provided with 25mm thick
appropriate insulation around the duct and totally covered with fire barrier mortar for complete
sealing.
f) All ducts shall be totally free from vibration under all conditions of operation. Whenever
ductwork is connected to fans, air handling units or blower coil units that may cause vibration in
the ducts, ducts shall be provided with a flexible connection, located at the unit discharge.

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14.Documentation and measurement for ducting

All ducts fabricated and installed should be accompanied and supported by following documentation:

a) For each drawing, all supply of ductwork must be accompanied by computer- generated
detailed bill of materials indicating all relevant duct sizes, dimensions and quantities. In
addition, summary sheets are also to be provided showing duct area by gauge and duct size
range as applicable.
b) Measurement sheet covering each fabricated duct piece showing dimensions and external
surface area along with summary of external surface area of duct gauge-wise.
c) All duct pieces to have a part number, which should correspond to the serial number, assigned
to it in the measurement sheet. The above system will ensure speedy and proper site
measurement, verification and approvals.

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