Update: 13/10/06

SECTION: 2.9

SHEET METAL DUCTING

1.0 Scope

1.1 The scope of work covers supply, installation, testing, balancing and
commissioning of:

i) Sheet metal ducting

ii) Volume, Smoke and Fire dampers
iii) Outside intakes & exhausts louvers
iv) Grilles and diffusers
v) All other accessories

associated with air-conditioning ventilation and exhaust systems

meeting the intents of specifications & drawings

1.2 Kitchen Exhaust systems are covered under a separate section.

2.0 Standards

2.1 All duct work shall conform generally to the following standards &
codes.

IS:277 Galvanised sheet steel

IS:655 Metal Air Ducts
IS:1079 Hot rolled carbon steel sheets
IS:513 Cold rolled low carbon steel sheet
SMACNA duct construction standards as modified herein

3.0 Submittals

3.1 The contractors should submit shop drawings of all duct systems after
a thorough survey of the space, obstructions and other services
elements. The shop drawings should indicate the following
information:

i) Source of manufacture and place

ii) Pressure class of ducting
iii) Bills of materials showing the duct areas in sq. meters for each
system under each category of sheet thickness.
iv) Schedule of grilles and diffusers, dampers, Intakes and exhausts.

3.2 Catalogue cuts of all grilles and diffusers, dampers proposed to be used
shall be submitted and got approved.

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4.0 Material

4.1 The material for various applications of air ducting shall be as follows:

Application Material

1) Ducting for Air- Cold rolled sheets continuous

conditioning galvanised with a zinc coating of
minimum 275g/m2 both sides
inclusive to IS 277-1977 in the form
of sheets or rolls of lock forming
quality.

2) Duct for ventilation & - Do -

Exhaust

3) Gasket Foamed PVC 6 mm

4) Supports & duct flanges Galvanised steel structural steel

sections

4.2 All galvanised plain sheets or rolls shall be reasonably flat and free
from twist. The zinc coating shall be clean, even and free from
galvanised spots. Sheets shall not crack or peel during bending or
fabrication. All sheets or rolls shall be procured from approved
manufacturers.

5.0 Duct Fabrication and Erection

5.1 All ducts for air-conditioning and ventilation shall be rectangular in

cross-section and fabricated for a pressure class of 500Pa positive and
negative. Preference will be given to ducts fabricated in a factory
with CNC controlled machinery.

5.2 Ducts shall be rectangular with dimensional tolerance of 1.5%.

Insulated ducts are shown clear sizes after insulation and during
fabrication the bare duct sizes shall be accordingly enhanced.

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5.3 The following are guidelines for the fabrication from galvanized sheets
with transverse joints at 2500mm.

Maximum side Minimum Transverse Joints Reinforcement

thickness
(mm) (mm)

Upto 250 0.63 25mm S – Slip -

Over 250 to 400 0.63 25 mm standing -

S – Slip

425 to 600 0.63(24 G ) 40mm X 1.00mm Same as

Standing S transverse joint.

625 to 800 0.80(22 G ) 40mm X 1.25mm Same as

Standing S transverse joint.

825 to 1000 0.80(22 G ) 40 x 40 x 4 mm 25x25x3.2 mm

Companion flanges Girth angles
@ 1200 mm

1025 to 1500 1.00(20 G) 40 x 40 x 4mm 40 x 40 x 4 mm

Companion flanges Girth angles
@ 1200 mm

1525 to 2250 1.00(20 G) 50 x 50 x 6 mm 40 x 40 x 4 mm

Companion flanges Girth angles
@ 600 mm

2275 & above 1.25 (18 G) 50 x 50 x 6 mm 50 x 50 x 4 mm

Companion flanges Girth angles
@ 600 mm

Longitudinal joints shall be Pittsburgh lock or button punch snap lock.

All joints shall withstand 1.5 times the pressure class specified. Duct
deflection shall not exceed 6mm for ducts upto 1200mm width.

5.4 For ducts fabricated from coil stock (Transverse Joints every 1200mm
approx)

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 Maximum side Minimum Transverse Joints Reinforcement
thickness
(mm) (mm)
Upto 450 0.63 C & S or Beading
C & SS cleats
at 1200mm spacing
475 to 600 0.63 4 Bolt slip on Beading
flanges E class at
1200mm spacing
625 to 1000 0.80 4 Bolt slip on Beading
flanges E class at
1200mm spacing.
1025 to 1800 1.00 4 Bolt slip – on Beading
flanges H class at
1200mm spacing
1825 to 2250 1.00 4 Bolt slip –on Beading
flanges J class at
1200mm spacing

5.5 In odd positions, the ducts shall be fabricated to suit the site conditions,
with the specific approval of the Engineer-in-charge. The aspect ratio
shall not exceed for any fabrication.

5.6 Where specified and shown on drawings, round ducts may be used
conforming to the following specifications.

Max diameter Minimum Gauge Reinforcement

Spiral Seam Long Seam Spiral Seam Long Seam
Upto 200 dia 0.55 (26G) -- 0.70 (24 G) --
Above 200 0.70 (24G) -- 0.70 (24 G) --
upto 600 dia
Above 600 dia 0.85(22G) -- 0.85(22G) Girth angle
upto 900 dia
Above 900 dia 0.85(22G) -- 1.00(20G) Girth angle
upto 1500 dia
Above 1500 dia 1.00(22G) Girth angle N.A Companion
Flanges

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5.7 Ducting shall be seam locked, spiral or longitudinal as indicated in the
layout / construction drawings. Spiral ducts shall have four ply lock
seam only. Snap lock seam will require specific approval of consultant
/ engineers in charge longitudinal seam ducts shall have groove seam
only.

All transverse joints for longitudinal and spiral ducts shall be with
beaded sleeves of equivalent gauge thickness.

Joints must be screwed or pop riveted at uniform intervals of 300mm

along the circumference.

5.8 Flexible ducts shall be used only as connectors and should not be more
than 1200mm in one length. Duct attachment collars should be
minimum 50mm in length and attached with minimum of 3# M8
screws for lower than 300 dia and 5# for 300 and higher sizes.
Insulation shall be factory applied and held in position through a draw
band.

5.9 Girth angles and companion flanges shall be mitered and welded at
corners and riveted to duct sheets at 75 mm centres. Flanged joints
shall be made with 9.5 mm GI bolts spaced at 100 mm centres and
provided with 6mm foamed PVC gasket. All joints and seams shall be
rendered air tight with sealant. Duct panels are not to be cross-broken,
if insulated. Longitudinal seams shall be inside groove or pittsburgh
type.

5.10 Standard elbows with a R/D ratio of not less than 1.25 shall be used as
far as possible. Where space restrictions do not permit use of standard
radius, elbow with lesser R/D ratio and square elbow with equally
spaced double thickness vanes may be used. Length of taper ducts shall
be at least four times the maximum size difference between the ends.

5.11 All duct fabrication and installation shall conform to the extent
modified herein, to the SMACNA standard for Low Pressure Duct
Construction upto 75mm pressure. All transverse joints shall be sealed
with non-hardening mastic sealant.

5.12 All duct lining for acoustic insulation shall be carried out as specified
under section “NOISE & VIBRATION” before the duct is installed in
position.

5.13 All ducts shall be sealed to SMACNA class C 24 and 10% of ducting of
at least two fan systems shall be proof – tested in the presence of the
Project Engineer / Manager and leakage readings recorded and attested.

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6.0 Sheet Metal Duct Accessories

6.1 Turning vanes

6.1.1 Air turning devices shall be provided at least for first four outlet collars
after every elbow and at all non-split branch take offs. Turning blades
shall be fabricated out of 0.8 mm (22G) thick G.S sheets and equally
spaced on side runner to be riveted/bolted to duct sheets. All vanes
shall be of double thickness.

6.2 Splitter dampers

6.2.1 Splitter dampers shall be installed in branches wherever split takes

place. Splitter dampers shall consist of double thickness air foil blades
hinged at the downstreams edge. The operation rod shall terminate
outside of the duct and insulation, and an air tight hub and locking set
screw shall be provided. Damper blade thickness shall be the same as
the duct in which it is installed but not less than 1.5 mm. Entire splitter
damper shall be enclosed in a sheet steel ducting with flanges at both
ends aligning with main run of ducting. The enclosure shall be made
of sheets one size larger than the upstream duct.

6.3 Louvre dampers

6.3.1 Louvres dampers shall be provided in all branches. Any duct feeding
more than four outlets shall be regarded as a branch and louver
dampers provided whether shown or not.

6.3.2 Louvre dampers shall be multi-blade type with opposed blades or

parallel blades of air foil construction rotating in permanently lubricated
ball/ roller bearings. Blades shall be 1200 x 250 maximum mounted in
a channel frame. Blades shall be connected with suitable linkage for
gang operation by an operating rod extending beyond the frame and
insulation if any and terminating in a locking quadrant with damper
position indicator. Damper larger than 1200 mm in width shall be
furnished in multiple sections. Dampers shall be enclosed in a sheet
steel box with flanges at both ends. Thickness shall be one size larger
than the upstream duct.

6.3.3 Dampers shall be manual or motorised as shown on drawings &

schedule of work. All actuators shall be Belimo or equal rated for
operation against static pressure of 650 Pa unless stated otherwise.

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6.4 Fire dampers

6.4.1 Fire dampers shall be dynamic rated against minimum static pressure of
100mm WG and fire rated for 1 1/2 hours if installed in a 3 hr rated
wall (225 brick wall) and 3 hour rated in higher rated walls. Dampers
shall conform to UL 555 and shall be tested and certified by an
appropriate authority. A test certificate shall be attached with each
damper assembly.

6.4.2 Dampers shall be actuated through Belimo or equal. An access door

shall be provided for accessing the damper & its mechanism. Damper
open & closed positions shall be indicated.

6.4.3 Damper shall be installed such that the fire integrity of the partition is
maintained. Sleeves, if any, used for mounting the damper shall be
designed for the rated fire resistance and the opening in the partition
fire sealed with an appropriate and approved sealant. Typical
arrangement is shown in the drawing construction standards.

6.5 Smoke dampers

6.5.1 Smoke dampers are same as fire dampers but the leakage through the
closed damper shall meet class II requirements under UL 555S while
maintaining the fire rating.

6.5.2 Damper actuator and installation shall be similar to that of fire damper.
Damper open and closed positions shall be indicated.

6.6 Constant Airflow Regulator

6.6.1 Constant Airflow Regulators (CAR) shall automatically regulate

airflows in ductwork to constant levels. Operation shall be completely
passive where no electric or pneumatic sensors are needed.

6.6.2 The active element of the CAR shall be a flexible silicone bulb which
will inflate and deflate in response to the static pressure difference to
maintain the airflow.

6.6.3 The CAR‟s sub-assembly consisting of the silicone bulb and its housing
shall be mounted on a rolled galvanized steel sleeve. The total assembly
shall be designed to fit inside standard rigid round ducting as well as
duty fittings such as tees, etc. A seal shall be provided around the
circumference to ensure a tight fit.

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6.7 Duct supports

6.7.1 Duct supports and suspenders shall be galvanized steel and meet the
following requirements:

Duct Width Support Hangar Rod Location

(mm) (mm)

Upto 1200 40 x 40 x 3 mm 8mm At Transverse Joints

angle OR
Support length not
exceeding 2500mm
Over 1200 - 1800 - Do - 10mm - Do -
Over 1800 to 2500 40 x 40 x 6 mm 12mm At Transverse Joints
steel MS OR
Limiting Support
length not exceeding
2500mm
Over 2500 50 x 50 x 6 mm 12mm At Transverse Joints
MS angle OR
Limiting support
length not exceeding
1200mm

As an alternative slotted galvanized brackets attached to the top two

bolts of the four bolt duct jointing system may be used.
6.7.2 Additional supports wherever considered necessary by the Engineer-
in- charge shall be provided.
6.7.3 All duct supports, flanges, hangers shall be hot-dip galvanised after
fabrication.

6.8 Duct connectors

6.8.1 Ducts connected to air-moving apparatus shall have flexible

connectors. Flexible connectors shall be preassembled factory made
units with minimum 150mm in width with 50mm galvanized steel rims
on both sides. Connectors shall be mildew resistant and shall have fire
retardant materials.
6.9 Duct penetrations

6.9.1 Ducts penetrations through walls, slabs or any other partitions shall be
sealed as shown on drawings or as required.
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6.10 Test Probes

6.10.1 Test probes shall be standard products. Probes shall be of Heavy duty
Zinc alloy casting. Expansion plugs shall be of neoprene and capable
of withstanding 80°C & 300 kPa.

6.10.2 Probes shall be installed at every fan discharge and suction duct.

7.0 Air Intakes & Exhaust

7.1 i) Unless shown otherwise, louvers shall be made of 3mm thick

100mm wide extruded aluminium sections fixed in an extruded
aluminum frame. Louvers shall be fixed at 45o to vertical and
provide 60% minimum net opening.

ii) 15 x 15 x 1.0 mm galvanized steel bird screen shall form part of the
intake or exhaust.

7.2 The entire assembly shall be fitted into the wall clear opening and the
edges sealed with a polysulphide or silicone sealant. All frames and
clamps used shall be hot dip galvanized or extruded aluminium.

8.0 Air Diffusing Equipment

8.1 Supply air grilles shall be double deflection type with horizontal face
bars and vertical rear bars placed in a rigid marginal frame. Bars shall
be shaped and spaced at 18mm centres with swaged pivot pins
positively holding the deflection setting under all conditions of velocity
and pressure. All grilles shall be provided with integral opposed blade,
grille-face key operated dampers.

8.2 Return grilles shall have fixed face bars shaped and set at 18 mm (3/4)
centres. Bars shall be set at 40 deg deflection for vision-proof
installation. The grilles shall be complete with rigid marginal frames
and shall be matching with the supply grilles.

8.3 Ceiling diffusers shall be round/square/rectangular face flush type

horizontal air diffusion pattern. Diffusers shall have ample margins to
minimize ceiling smudge. All diffusers shall be provided with face
operated volume control dampers. Half diffusers shall be similar to full
diffusers.

8.4 Linear diffusers/grilles shall be die formed, flush mounted type with
single or double directional air flow. The diffuser /grille shall be in an
extruded aluminum frame with minimum 20 mm margin. All linear air
diffusing equipment shall be fitted with a distribution sheet metal
plenum as shown on drawings.

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8.5 Grille types are indicated in the drawings and equivalent types of any
other standard manufacturer are acceptable. Mild steel grilles and
diffusers shall be fabricated out of 1.0 mm mild steel and painted with
two coats of red oxide. All duct collars terminating on to a grille or
diffuser shall be given two coats of black paint for a length of 300 mm.
Grilles & diffusers shall be selected for an aero-dynamic noise power
not in excess of NC 30.

8.6 Aluminium grilles and diffusers wherever specified shall be of extruded

aluminium with margins & GSS butterfly dampers. Grilles shall have
horizontal face bars and vertical rear bars.

9.0 Testing & Balancing

9.1 Capped air-flow connections shall be provided as necessary for testing

and balancing of air distribution.

9.2 The entire air distribution shall be adjusted and balanced for delivery of
design air quantities or as required for achieving design space
conditions. Tests shall be carried out for each fan or AHU section.
After all adjustments are made, the air readings shall be recorded on the
drawings vis-à-vis the space conditions. All dampers after adjustment
shall be set and locked in position. All air and static pressure
measurements shall be done through probe type meters. Vane type
meter readings are not considered reliable.

9.3 After balancing the fan speed shall be suitably adjusted. Test readings
should display static pressures before and after speed change.

9.4 10% of ducting from at least 2 –fan systems shall be tested to validate
leakage.

10.0 Mode of measurement

10.1 All sheet metal ducting complete with duct supports, turning vanes,
canvas connections, erected in position shall be measured externally
and paid per unit area. All dampers shall be excluded in the duct area.

10.2 All manual control / splitter damper sections with operations linkages
locking quadrant, sheet steel enclosure, frame, erection, supporting etc.
shall be measured on the basis of damper cross sectional area and paid
per unit area.

10.3 Motorized control dampers with actuator are to be paid per unit of upto
0.3, 0.3 to 0.6, over 0.6 to 0.9, over 0.9 to 1.2 and over 1.2 sqm damper
area.

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10.4 Intake and exhaust louvers with bird screen, louvers and frame, erection
& sealing shall be measured on the basis or cross sectional area and
paid per unit area.

10.5 Side wall grilles shall be measured on the basis of the core area
excluding the margins and shall include necessary dampers. Minimum
payable unit is 0.1 sqm.

10.6 In line diffusers and grilles shall be measured per unit length. The back
up plenum shall be measured as additional sheet metal ducting or part
of the grille as defined in the schedule or work.

10.7 All fire and smoke dampers with operating linkage actuator, locking
quadrant sheet steel enclosure, frame, fusible links, access door etc.
shall be measured as one unit for upto 0.3, 0.3 to 0.6, over 0.6 to 0.9,
over 0.9 to 1.2 and over 1.2 sqm damper area.

10.8 All duct liners for acoustic insulation shall be measured and paid as
specified under „NOISE & VIBRATION.‟

10.9 Flexible ducts shall be paid per unit length of each diameter.

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