DESIGN DUCTS

A well-designed ductwork system should deliver maximum

interior comfort at the lowest operating cost while also
preserving indoor air quality.
The chief requirements of an air conditioning duct system are:
• It should convey specified rates of air flow to prescribed
locations.
• It should be economical in combined initial cost, fan
operating cost and cost of building space.
• It should not transmit or generate objectionable noise
 DUCT COMPONENTS

The duct components are as follows:

• Plenum or Main Trunk: The plenum is the main
part of the supply and return duct system that goes
directly from the air handler to the “Trunk Duct”
• Trunk Duct: A duct that is split into more than one
duct is called a “trunk”, just like a tree. Ducts that are
on the end of a trunk and terminate in a register are
called branches.
• Take Off: Branch ducts are fastened to the main
trunk by a takeoff-fitting. The takeoff encourages the
air moving the duct to enter the takeoff to the branch
duct.
• Air Terminals Devices: Air terminals are the supply
air outlets and return or exhaust air inlets. For supply,
diffusers are most common, but grilles and registers
are also used widely. A diffuser is an outlet device
discharging supply air in a direction radially to the axis
of entry. A register is a grille equipped with a volume
control damper. A grille is without a damper.
 DUCT MATERIALS
1.Galvanized Steel:
• Standard material for fabricating ductwork in comfort air conditioning
systems, known for durability and corrosion resistance. Specifications:
ASTM A653, coating G90.
2.Aluminum:
• Widely used in clean rooms, moisture-laden air systems, and ornamental
ductwork due to its lightweight and corrosion resistance. Specifications:
ASTM B209, alloy options: 1100, 3003, or 5052.
3.Stainless Steel:
• Used in kitchen exhaust, moisture-laden air, and fume exhaust systems.
Offers excellent corrosion resistance and is available in different finishes.
Specifications: ASTM A167, Class options: 302 or 304, Finish No. 4
(exposed ducts) or No. 2B (concealed ducts).
4.Copper:
• Mainly used for chemical exhaust and ornamental ductwork due to its
resistance to corrosion and aesthetic appeal.
1. NON-METALLIC DUCTS

1.Fiberglass Reinforced Plastic (FRP):

1. Used mainly for chemical exhaust, scrubbers, and
underground duct systems.
2. Advantages: Resistance to corrosion, self-insulation,
excellent sound attenuation, and high-quality sealing.
3. Limiting characteristics: Cost, weight, range of chemical
and physical properties, and code acceptance.
2.Polyvinyl Chloride (PVC):
1. Used for exhaust systems for chemical fumes and
underground duct systems.
2. Advantages: Resistance to corrosion, light weight, and
ease of modification.
3. Limiting characteristics: Cost, fabrication, code
acceptance, thermal shock, and weight.
1.Fabric:
1. Fabric ducting, also known as textile ducts, made of special
permeable polyester material.
2. Usually used where even air distribution is essential, not
concealed within false ceilings.
3. Advantages: Condensation-free, suitable for air supply below
dew point without insulation.
2.Flex Duct:
1. Consists of a duct inner liner supported by a helix wire coil,
covered with blanket insulation and a flexible vapor barrier
jacket.
2. Often used for runouts and connections to supply plenums,
trunks, and branches.
3. Advantages: Convenient installation, flexibility to avoid
clashes.
4. Limiting characteristics: Higher friction loss compared to metal
ducting, recommended short and tight runs (5 to 6 ft. max.).
DUCT CLASSIFICATION
 1. VELOCITY CLASSIFICATION

Ducts are classified into 3 basic categories:

 

1. Low Velocity Systems: They are characterized by air velocities

up to 2000 fpm.

2. Medium Velocity Systems: They are characterized by air velocities

in the range of 2,000 to 2,500 fpm.

3. High Velocity Systems: They are characterized by air velocities

greater than 2,500 fpm.
 1. PRESSURE CLASSIFICATION
 

Duct systems are also divided into three pressure classifications, matching the way supply fans are classified

 Low Pressure: The term low-pressure applies to systems with fan static pressures less than 3 inches
WC. Generally, duct velocities are less than 1,500 fpm

 Medium Pressure: The term medium pressure applies to systems with fan static pressures between 3
to 6 inches WC. Generally, duct velocities are less than or equal to 2,500 fpm.

 High Pressure: The term high pressure applies to systems with fan static pressures between 6 to 10
inches WC. Usually the static pressure is limited to a maximum of 7 inches WC, and duct velocities are
limited to 4,000 fpm. Systems requiring pressures more than 7 inches WC are normally unwarranted and
could result in very high operating costs.
DUCT SHAPES
 DUCT TYPE ADVANTAGES DISADVANTAGES

- Most efficient shape for conveying air. - Lower

pressure drops, requiring less fan horsepower. -
Less surface area, requiring less insulation. - - Requires more clear height for
Round
Longer lengths available, eliminating costly field installation in limited spaces.
joints. - Superior acoustic performance. -
Promotes healthier indoor environments.

- Higher pressure drop compared to

- Fits better into building construction. - Easier
installation between joists and studs. - Efficient
Rectangular with low aspect ratio. - Ideal for headroom
savings.
round ducts. - Uses more material for
the same air-flow rate. - Limited joint
length based on sheet widths stocked. -
More difficult to seal joints. - Higher
noise transmission with high aspect
ratios if not properly supported.

- Difficulty in fabricating or modifying

fittings in the field. - Challenges in
Oval - Smaller height requirements than round ducts. - handling and shipping larger sizes. -
Retains most advantages of round ducts. Tendency to become more round under
pressure. - Difficulties in assembling oval
slip joints in large aspect ratios.
 EQUIVALENT DIAMETER

• Equivalent diameter is a concept used to compare round and rectangular ducts in air
conditioning systems.
• It is the diameter of a circular duct that would have the same pressure drop as the
rectangular duct at the same airflow.
• It ensures proper air distribution system performance when substituting duct shapes.
• Equations are available to convert between rectangular and round ducts.
• The equivalent diameter approach involves trial and error to determine the
dimensions of rectangular and flat oval ducts.
• Using equivalent diameter helps determine the appropriate duct shape for specific
requirements.
Diameter Approach

Duct shape Exact Rounded Cross Velocit Friction

converted dimensions sectional y loss
dimension area (sq.- (fpm)
s (inches) ft.)

Round   30 4.91 1528 0.10

Flat oval 16 x 16 x 53 5.51 1361 0.10
52.5
Rectangula 16 x 51 16 x 51 5.67 1362 0.10
r
Cross-sectional Area Approach
Duct shape Air Exact Rounded Cross Velocity Friction
flow, converted dimensions sectional (v) fpm v loss (in.-
(Q) dimensions area (A) WC/100ft)
cfm = Q/A
(inches) sq.-ft.

Round 7500   30 4.91 1528 0.10

Flat oval 7500 16 x 47.6 16 x 48 4.95 1514 0.12
Rectangular 7500 16 x 44.2 16 x 44 4.89 1534 0.14
 • The equivalent diameter approach will retain the same
pressure drop but will result in higher cross-sections of
rectangular and oval ducts compared to round ducts.

• The equivalent area approach will increase the pressure drop

of the duct run while keeping the cross-sectional area the
same.

 
 Extended Plenum SYSTEMS

In the extended plenum systems, a large main supply trunk of equal

size is connected directly to the air handler. Smaller branch ducts and
run-outs are connected to the trunk. The arrangement provides air flows
that are easily balanced and can be easily designed to be located inside
the conditioned space of the building.