The design, manufacture, installation and maintenance of flexible ductwork systems: a desk-based study

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EXECUTIVE SUMMARY
The objective of this report is to provide a comprehensive overview of guidance
relating to the design, manufacture, installation and maintenance of flexible ductwork
in the built environment.
The report has been produced following extensive review of the following types of
guidance.
Statutory compliance through documents such as The Approved Documents of
The Building Regulations
Good practice through BS and BS EN standards
Best practice through UK construction industry publications produced by
organisations such as The Heating and Ventilating Contractors Association
(HVCA), The Chartered Institution of Building Services Engineers (CIBSE), The
Building Services Research and Information Association (BSRIA) and The
Association for Specialist Fire Protection (ASFP)
Construction project requirements through mechanical specifications
Best practice American guidance produced by The American Society of
Heating, Refrigerating and Air Conditioning Engineers (ASHRAE), The Sheet Metal
and Air Conditioning Contractors Association (SMACNA), The Air Diffusion Council
(ADC) and The National Fire Protection Association (NFPA)
Product standards through manufacturers technical literature
In order to achieve statutory compliance and conform with best practice construction
industry guidance, it is recommended that the design, manufacture, installation and
maintenance of flexible ductwork should meet the following requirements.
DIMENSIONS AND MECHANICAL REQUIREMENTS
Comply with BS EN 13180: 2002 Ventilation for buildings Dimensions and mechanical
requirements for flexible ductwork. This standard defines compliance criteria relating to
nominal length, bending capability, operating pressure, crushing strength, air leakage,
marking, labelling and packaging
FIRE SAFETY IN THE DESIGN, MANAGEMENTAND USE OF BUILDINGS
Comply with BS 9999: 2008 Code of practice for fire safety in the design, management
and use of buildings. This standard states that flexible ductwork connections should be
constructed of:
Non-combustible materials
or
Materials conforming to Euroclass A1, as specified in BS EN 13501-1:2007 + A1:2009
or
Material which, when tested in accordance with BS 476-6 has a fire propagation
index l of not more than 12 and a sub-index i1 of not more than 6, and is situated
at least 1 metre from any fire damper
It also states that flexible ductwork connections should:
Not exceed 3.7m in length
Not pass through fire-resisting walls or floors or cavity barriers
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PRODUCT SELECTION
Comply with the recommendations of CIBSE Guide B3: 2002 Ductwork, and HVCA
DW/ 144 Specification for sheet metal ductwork. These documents state that the
following criteria shall be considered when selecting flexible ductwork
Temperature range

Fire rating

Resistance to air flow

Airtightness characteristics

Length restrictions if applicable

Support requirements

Flexibility

Insulation values
System pressure

INSTALLATION
Comply with the guidance given in CIBSE Guide B3: 2002 Ductwork, HVCA DW/ 144
Specification for sheet metal ductwork, Domestic ventilation compliance guide: 2010
Edition, MOD Specification 037 Air conditioning, air cooling and mechanical
ventilation in buildings, HTM 03-01: Specialised ventilation for healthcare premises and
the requirements of leading construction project specifications.

Flexible ductwork should only be used to make final connections to terminal units,
grilles, diffusers and plenums

The maximum length of flexible ductwork should be 1metre
Flexible ducts should be pulled taught to ensure that the full internal diameter is
obtained and flow resistance minimised. This is considered to have been
achieved if the duct is extended to 90 per cent of its maximum length
Flexible ducts shall be adequately supported to eliminate sagging and kinking
a maximum interval between supports of 600mm is recommended
In no instances shall flexible duct connections be allowed on to fire dampers or
through floors and walls
The radius ratio R/ D for bends shall be not less than 2, where R is the centre line
radius and D is the diameter of the duct
Flexible ducts should not be installed where they can be damaged, such as
across loft areas where they may be stood on or have items placed on them,
crushing the duct and restricting or preventing all air flow through the duct
Connection of lengths of flexible duct must use a rigid connector and jubilee
clips or similar to ensure a long-term seal is achieved. Connections of lengths of
flexible duct should not be taped-only
The integrity of flexible ductwork depends on the successful application of the
correct sealant, gaskets or tape. The materials used should be suitable for the
purpose intended and satisfy the specified pressure classification
It is not practicable to make test holes or take test readings in metal or fabric
flexible ducts. Where readings are required, the test holes should be made in
rigid ductwork
Where flexible ductwork is to be insulated, it should be factory applied
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The installation shall comply with the requirements of the Building Control Body
and the Fire Officer
Adequate and safe protection for all materials and products should be provided
during transport to site and during storage on site
MAINTENANCE
Comply with the guidance given in BS EN 12097: 2006 Ventilation for buildings
Requirements for ductwork components to facilitate maintenance of ductwork
systems, HVCA SFG 20 Standard maintenance specification for building services,
HVCA TR/ 19 Internal cleanliness of ventilation systems and BSRIA FMS 1/ 97 Standard
specification for ventilation hygiene and CIBSE Guide B3: 2002 Ductwork.

A visual inspection of flexible ductwork should be undertaken for every 12 months
to check damage, security of fittings, deterioration and internal condition

Flexible ducts shall, where possible, be removed for inspection and cleaning,
unless they can be satisfactorily cleaned in-situ. For cleaning of flexible ductwork
in-situ, access shall be provided through rigid access components

Cleaning methods must be adjusted to account for the type of flexible duct





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CONTENTS
EXECUTIVE SUMMARY............................................................................................................................................................. 1
CONTENTS ................................................................................................................................................................................. 4
1 INTRODUCTION ................................................................................................................................................................ 9
2 STATUTORY COMPLIANCE...........................................................................................................................................10
2.1 Approved Document, Materials and workmanship - to support regulation 7 of the Building
Regulations............................................................................................................................................................10
2.1.1 Overview of Approved Document Materials and workmanship .........................................10
2.1.2 Materials and workmanship................................................................................................................10
2.1.3 Ways of establishing the fitness of materials ..................................................................................11
2.1.4 Ways of establishing the adequacy of workmanship .................................................................12
2.2 Approved Document B volume 2 Fire Safety Buildings other than dwellings .............................13
2.2.1 Overview of Approved Document B volume 2.............................................................................13
2.2.2 Materials and workmanship................................................................................................................13
2.2.3 Mechanical ventilation and air conditioning systems ................................................................13
2.2.4 Ventilation ducts, flues etc ..................................................................................................................13
2.2.5 Internal fire spread (linings) .................................................................................................................14
2.3 Approved Document F Ventilation 2010 edition ....................................................................................15
2.3.1 Overview of Approved Document F................................................................................................15
2.3.2 Materials and workmanship................................................................................................................15
2.3.3 Installation of ventilation systems.......................................................................................................15
2.3.4 Air flowrate testing and commissioning of ventilation systems.................................................15
2.4 Domestic ventilation compliance guide, 2010 edition............................................................................16
2.4.1 Overview of the domestic ventilation compliance guide.........................................................16
2.4.2 Installation of ducts - flexible...............................................................................................................16
2.4.3 Duct connections ..................................................................................................................................16
2.5 Approved Code of Practice and Guidance to the Workplace (Health, Safety and Welfare)
Regulations............................................................................................................................................................17
2.5.1 Overview of ACOP to the Workplace (Health, Safety and Welfare) Regulations..............17
2.5.2 Mechanical ventilation systems.........................................................................................................17
2.6 Non-domestic building services compliance guide, 2010 edition .......................................................18
2.6.1 Overview of the non-domestic building services compliance guide ....................................18
2.6.2 Air distribution systems in new and existing buildings ..................................................................18
3 BS AND BS EN STANDARDS..........................................................................................................................................19
3.1 BS EN 13180: 2002 Ventilation for buildings Ductwork Dimensions and mechanical
requirements for flexible ductwork.................................................................................................................19
3.1.1 Overview of BE EN 13180:2002............................................................................................................19
3.1.2 Dimensions for flexible ducts ...............................................................................................................19
3.1.3 Mechanical properties and requirements of flexible ducts ......................................................20
3.1.1 Marking, labelling and packaging ...................................................................................................20
3.2 BS 9999: 2008 Code of practice for fire safety in the design, management and use of buildings21
3.2.1 Overview of BE 9999:2008 ....................................................................................................................21
3.2.2 The design stage ....................................................................................................................................21
3.2.3 Mechanical ventilation and air conditioning systems ................................................................21
3.2.4 Flexible ductwork joints and connections.......................................................................................21
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3.3 BS EN 15423: 2008 Ventilation for buildings fire precautions for air distribution systems in
buildings .................................................................................................................................................................22
3.3.1 Overview of BS EN 15423:2008............................................................................................................22
3.3.2 General requirements...........................................................................................................................22
3.3.3 Flexible duct component requirements ..........................................................................................22
3.4 BS EN 13501-1: 2007 +A1: 2009 Fire classification of construction products and building
elements ................................................................................................................................................................23
3.4.1 Overview of BS EN 13501-1: 2007 + A1: 2009 ..................................................................................23
3.4.2 Performance classification ..................................................................................................................23
3.5 BS EN 12097: 2006 Ventilation for buildings Requirements for ductwork components to
facilitate maintenance of ductwork systems .............................................................................................23
3.5.1 Overview of BS EN 12097:2006............................................................................................................23
3.5.2 Openings for flexible circular ducts ..................................................................................................23
3.6 BS 476-6: 1989 +A1: 2009 Fire tests on building materials and structures ...........................................24
3.6.1 Overview of BS 476-6:1989 + A1: 2009 ..............................................................................................24
3.6.2 Performance classification ..................................................................................................................24
3.7 BS 476-7: 1997 Fire tests on building materials and structures ...............................................................25
3.7.1 Overview of BS 476-7:1997 ...................................................................................................................25
3.7.2 Performance classification ..................................................................................................................25
4 CONSTRUCTION INDUSTRY GUIDANCE DOCUMENTS..........................................................................................26
4.1 HVCA DW/144 Specification for sheet metal ductwork.......................................................................26
4.1.1 Overview of DW/144 .............................................................................................................................26
4.1.2 Cautionary note to all ductwork designers and manufacturers..............................................26
4.1.3 Ductwork systems and fire hazards...................................................................................................26
4.1.4 Flexible ducts - general ........................................................................................................................26
4.1.5 Flexible ducts - metal ............................................................................................................................27
4.1.6 Flexible ducts - fabric ............................................................................................................................27
4.1.7 Flexible ducts - supports .......................................................................................................................28
4.1.8 Flexible ducts test holes.....................................................................................................................28
4.1.9 J oint sealing and sealants ...................................................................................................................28
4.1.10 Fastenings .................................................................................................................................................28
4.2 CIBSE Guide B3 ductwork ..............................................................................................................................29
4.2.1 Overview of CIBSE Guide B3 ...............................................................................................................29
4.2.2 Classification of ductwork systems....................................................................................................29
4.2.3 Spatial requirements .............................................................................................................................29
4.2.4 Fan power energy requirements .......................................................................................................29
4.2.5 Methods of fire protection of ductwork ..........................................................................................29
4.2.6 Fire resistance and DW/144.................................................................................................................29
4.2.7 Fire rating ..................................................................................................................................................30
4.2.8 Flexible ducts ...........................................................................................................................................30
4.2.9 Flexible ductwork for making final connections ...........................................................................31
4.2.10 Supports for flexible ductwork ............................................................................................................31
4.2.11 Test holes in flexible ductwork ............................................................................................................31
4.2.12 Maintenance of flexible ductwork....................................................................................................31
4.3 CIBSE TM 43 Fan coil units ..............................................................................................................................31
4.3.1 Overview of CIBSE TM 43......................................................................................................................31
4.3.2 Ductwork connections .........................................................................................................................31
4.4 CIBSE TM 26 Hygienic maintenance of office ventilation ductwork .................................................32
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4.4.1 Overview of CIBSE TM 26......................................................................................................................32
4.4.2 Mechanical ventilation systems.........................................................................................................32
4.5 Association for Specialist Fire Protection (ASFP) Fire rated and smoke outlet ductwork............32
4.5.1 Overview of ASFP fire rated and smoke outlet ductwork .......................................................32
4.5.1 Cautionary note to all ductwork designers, manufacturers and installers ...........................32
4.5.2 Ductwork and fire ..................................................................................................................................32
4.5.3 Fire resistance of ductwork..................................................................................................................33
4.5.4 Reaction to fire tests ..............................................................................................................................33
4.6 HVCA TR/19 Internal cleanliness of ventilation systems ........................................................................34
4.6.1 Overview HVCA TR/19 ..........................................................................................................................34
4.6.2 Flexible ductwork ...................................................................................................................................34
4.7 HVCA SFG 20 Standard Maintenance Specification for Building Services .....................................34
4.7.1 Overview of SFG 20 ...............................................................................................................................34
4.7.2 Maintenance of flexible duct connections....................................................................................34
4.8 BSRIA FMS 1/97 - guidance to the standard specification for ventilation hygiene .........................34
4.8.1 Overview BSRIA FMS 1/97.....................................................................................................................34
4.8.2 Cleaning techniques for flexible ducting........................................................................................35
4.9 Building Bulletin 100 Design for fire safety in schools..............................................................................35
4.9.1 Overview of building bulletin 100 ......................................................................................................35
4.9.2 Mechanical ventilation and air conditioning systems ................................................................35
4.10 District Surveyors Association (DSA) Guide to mechanical and electrical services in sports
grounds ..................................................................................................................................................................35
4.10.1 Overview of DSA guide to mechanical and electrical services ..............................................35
4.10.2 Mechanical ventilation and air conditioning systems ................................................................35
5 CONSTRUCTION PROJ ECT SPECIFICATIONS...........................................................................................................37
5.1 Sample specification 1 ......................................................................................................................................38
5.1.1 Design information - general ..............................................................................................................38
5.1.2 Ductwork installation standards.........................................................................................................38
5.1.3 Low pressure ductwork air leakage testing....................................................................................38
5.1.4 Flexible ducts - metal ............................................................................................................................38
5.1.5 Hangers and supports...........................................................................................................................39
5.1.6 Flexible ductwork wire loop ties ......................................................................................................39
5.1.7 Spherical and drum punkah louvre diffusers .................................................................................39
5.1.8 Diffuser linear lighting/ air modular type ......................................................................................39
5.1.9 Internal cleanliness ................................................................................................................................39
5.1.10 Delivery......................................................................................................................................................39
5.2 Sample specification 2 ......................................................................................................................................40
5.2.1 Ductwork installation standards.........................................................................................................40
5.2.2 General workmanship ..........................................................................................................................40
5.2.3 Ductwork supports .................................................................................................................................40
5.2.4 Coated steel flexible ducts .................................................................................................................40
5.2.5 PVC/Polyester laminate flexible ducts .............................................................................................40
5.2.6 Internal cleanliness ................................................................................................................................40
5.2.7 Delivery......................................................................................................................................................40
5.3 Sample specification 3 ......................................................................................................................................41
5.3.1 Ductwork installation standards.........................................................................................................41
5.3.2 Bendable and flexible ducts...............................................................................................................41
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5.4 Sample specification 4 ......................................................................................................................................42
5.4.1 Ductwork installation standards.........................................................................................................42
5.4.2 Flexible ductwork metal and fabric...............................................................................................42
5.5 Sample specification 5 ......................................................................................................................................43
5.5.1 Ductwork installation standards.........................................................................................................43
5.5.2 Flexible ductwork metal and fabric...............................................................................................43
5.6 Sample specification 6 ......................................................................................................................................44
5.6.1 Ductwork installation standards.........................................................................................................44
5.6.2 Flexible ductwork ...................................................................................................................................44
5.7 Sample specification 7 ......................................................................................................................................45
5.7.1 Ductwork installation standards.........................................................................................................45
5.7.2 Flexible ductwork ...................................................................................................................................45
5.8 Sample specification 8 ......................................................................................................................................46
5.8.1 Ductwork installation standards.........................................................................................................46
5.8.2 Bendable and flexible ducts...............................................................................................................46
5.9 Sample specification 9 ......................................................................................................................................47
5.9.1 Ductwork ..................................................................................................................................................47
5.9.2 Flexible ductwork ...................................................................................................................................47
5.9.3 Ductwork cleaning ................................................................................................................................47
6 CLIENT SPECIFICATIONS AND GUIDES.....................................................................................................................48
6.1 Health Technical Memorandum 03-01: Specialised ventilation for healthcare premises .............48
6.1.1 Overview of HTM 03-01 .........................................................................................................................48
6.1.2 General requirements...........................................................................................................................48
6.1.1 Ducting......................................................................................................................................................48
6.1.2 Standard ductwork fittings ..................................................................................................................48
6.1.3 Other fittings.............................................................................................................................................48
6.1.4 Flexible ducting.......................................................................................................................................48
6.1.5 Standard of installation.........................................................................................................................49
6.1.6 Cleanliness of installation .....................................................................................................................49
6.1.7 Ventilation system cleaning ................................................................................................................49
6.2 Firecode fire safety in the NHS Health Technical Memorandum 05-02: Guidance in support of
functional provisions for healthcare premises ............................................................................................49
6.2.1 Overview of HTM 05-02 .........................................................................................................................49
6.2.2 Design of HVAC systems ......................................................................................................................49
6.2.3 Ventilation ductwork .............................................................................................................................50
6.3 National Health Service (NHS) model engineering specification C04: Mechanical ventilation
and air conditioning systems ...........................................................................................................................50
6.3.1 Flexible ductwork ...................................................................................................................................50
6.4 MOD Specification 037 Air conditioning, air cooling and mechanical ventilation in buildings50
6.4.1 Overview of MOD specification 037.................................................................................................50
6.4.2 Bendable and flexible ducts...............................................................................................................50
7 AMERICAN STANDARDS ..............................................................................................................................................52
7.1 SMACNA HVAC duct construction standards.........................................................................................52
7.1.1 General performance requirements for all ducts ........................................................................52
7.1.2 Flexible duct installation standards ...................................................................................................52
7.1.3 Specification for joining and attaching flexible duct..................................................................53
7.1.1 Specification for supporting flexible duct .......................................................................................55
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7.1 SMACNA HVAC systems design...................................................................................................................57
7.1.1 General requirements...........................................................................................................................57
7.1.2 Duct system specification checklist..................................................................................................57
7.2 Air Diffusion Council (ADC) Flexible duct performance and installation standards ....................58
7.2.1 Overview of ADC flexible duct performance and installation standards .............................58
7.2.2 Characteristics of flexible ducts .........................................................................................................58
7.2.3 Fire safety and flexible ductwork.......................................................................................................59
7.2.4 Flexible ductwork air leakage ............................................................................................................59
7.2.5 Installation requirements for flexible ducts .....................................................................................59
7.2.1 Supporting flexible duct .......................................................................................................................62
7.2.2 Connecting, joining and splicing flexible ducts ............................................................................62
7.2.3 Typical flexible duct accessories .......................................................................................................63
7.1 Air Diffusion Council (ADC) Flexible air duct test code FD 72-R1.......................................................64
7.1.1 Overview of ADC flexible air duct test code FD 72-R1 ...............................................................64
7.2 National Fire Protection Association (NFPA) 90A Standard for the installation of air
conditioning and ventilating systems............................................................................................................64
7.2.1 Overview NFPA 90A...............................................................................................................................64
7.2.2 Air ducts ....................................................................................................................................................64
7.2.3 Air connectors .........................................................................................................................................64
7.3 ASHRAE Handbook HVAC systems and equipment ..............................................................................65
7.3.1 Overview ASHRAE Handbook HVAC systems and equipment .............................................65
7.3.2 Residential duct construction.............................................................................................................65
7.3.3 Commercial duct construction..........................................................................................................65
7.3.4 Flexible ducts ...........................................................................................................................................65
7.4 National Fire Protection Association (NFPA) 90B Warm air heating and air conditioning
systems ...................................................................................................................................................................66
7.4.1 Overview NFPA 90B ...............................................................................................................................66
7.4.2 Duct materials .........................................................................................................................................66
7.4.3 Air connectors .........................................................................................................................................66
7.5 Underwriters Laboratory (UL) 181 Factory made air ducts and air connectors ............................66
7.5.1 Overview UL181 ......................................................................................................................................66
7.5.2 Duct performance requirements ......................................................................................................67
8 MANUFACTURERS TECHNICAL LITERATURE............................................................................................................68
8.1 Approvals for different products.....................................................................................................................68
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1 INTRODUCTION
There is a lack of clarity over standards applicable to flexible ductwork. This has given
rise to a wide variety of interpretations by those parties involved in the design
specification, manufacture, installation and maintenance of ventilation and air
conditioning systems containing flexible ductwork.
This report has been produced in response to a request from ADCAS for a desk-based
study into the legislation, product standards, and design, installation and maintenance
guidance related to flexible ductwork.
The purpose of the report is to provide a body of information, from which an ADCAS
publication about flexible ductwork could be produced in 2012.
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2 STATUTORY COMPLIANCE
This aim of this chapter is to examine the statutory compliance requirements for flexible
ductwork. The principal points of reference are the Approved Documents of the
Building Regulations.
The Approved Documents have been approved and issued by the Secretary of State
for the purpose of providing practical guidance with respect to the requirements of
Schedule 1 to and Regulation 7 of the Building Regulations 2000 (SI 2000/ 2531) for
England and Wales.
The intention of issuing Approved Documents is to provide guidance about
compliance with specific aspects of Building Regulations in some of the more common
building situations. They set out what in ordinary circumstances, may be accepted as
reasonable provision for compliance with the relevant requirement(s) of building
regulations to which they refer
It is important to remember that if you are the person (eg designer, builder installer)
carrying out building work to which any requirement of Building Regulations applies you
have responsibility to ensure that the work complies with any such requirement. The
building owner may also have a responsibility for ensuring compliance with building
regulation requirements and could be served with an enforcement notice in cases of
non-compliance.
2.1 APPROVED DOCUMENT, MATERIALS AND WORKMANSHIP - TO SUPPORT REGULATION 7 OF THE
BUILDING REGULATIONS
2.1.1 Overview of Approved Document Materials and workmanship
This standard has been prepared to ensure that all building work shall be carried out
with adequate and proper materials which:
Are appropriate for the circumstances in which they are used

Are adequately mixed or prepared

Are applied, used or fixed so as adequately to perform the functions for which
they are designed, and in a workmanlike manner.

2.1.2 Materials and workmanship
This document states that the requirements of regulation 7 of the Building Regulations
will be met where materials
1
are:
Of a suitable nature and quality in relation to the purposes and conditions of
their use

And the workmanship is such that

Where relevant, materials are adequately mixed or prepared; and

Applied, used or fixed so as to perform adequately the functions for which they
are intended



1
Materials include products, components, fittings, naturally occurring materials, eg stone, timber and thatch, items
of equipment and backfilling for evacuations in connection with building work
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2.1.3 Ways of establishing the fitness of materials
The document states that there are a number of ways in which the suitability of a
material for use for a specific purpose may be assessed. It proposes the following are
aids which may be used for establishing this.
2.1.3.1 British Standards
The material conforms to the relevant provisions of an appropriate British Standard.
2.1.3.2 Other national and international specifications
The material conforms to the national technical specifications of other Member States
which are contracting parties to the European Economic Area, as long as such
specifications provide in use at least an equivalent level of performance to the
relevant British Standard. Where necessary, it is up to the person intending to carry out
the work to provide translations and to demonstrate equivalence.
2.1.3.3 Technical approvals
The material is covered by a national or European certificate issued by a European
Technical Approvals issuing body, and the conditions of use are in accordance with
the terms of the certificate. Where necessary it is up to the person intending to carry
out the work to provide translations and to demonstrate equivalence.
2.1.3.4 CE marking
The material has CE marking. The CE marking gives a presumption of conformity with
the stated minimum legal requirements when placed on the market as set out in the
Construction Products Regulations 1991
2
.

In this context relevant requirements are defined in relation to the essential
requirements of the Construction Products Directive, and are

Mechanical resistance and stability

Safety in case of fire

Hygiene, health and the environment

Safety in use

Protection against noise

Energy economy and heat retention
2.1.3.5 Independent certification schemes
There are many UK product certification schemes. Such schemes certify compliance
with the requirements of a recognised document which is appropriate to the purpose
for which the material is to be used.

2
Note the Construction Products Directive was repealed by Regulation (EU) No 305/ 2011 in March 2011. However,
the essential requirements remain the same
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2.1.3.6 Tests and calculations
It can be shown by tests, by calculation or by other means that the material will be
capable of performing the function for which it is intended.
2.1.3.7 Past experience
The material can be shown by experience, such as in a building in use, to be capable
of performing the function for which it is intended.
2.1.3.8 Sampling
Local authorities have the power to take samples of materials to be used in building
work. Regulation 17 allows the local authority (but not approved inspectors) to take
such samples as they consider necessary to establish compliance with the provisions of
the Regulations.

2.1.4 Ways of establishing the adequacy of workmanship
The document states that it may be useful to consider the following aids for establishing
the adequacy of workmanship.
2.1.4.1 Standards
The method of carrying out the work is included in the recommendations of a British
Standard Code of Practice, or the method conforms to an equivalent technical
specification which may include a national technical specification of other Member
States which are contracting parties to the European Economic Area.
2.1.4.2 Technical approvals
The workmanship is specified for a material covered by a national or European
certificate issued by a European certificate issued by a European Technical Approvals
issuing body, and the conditions of use are in accordance with the terms of the
certificate.
2.1.4.3 Past experience
It can be shown by experience, such as in a building in use, that the method of
workmanship is capable of performing the function for which it is intended.
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2.2 APPROVED DOCUMENT B VOLUME 2 FIRE SAFETY BUILDINGS OTHER THAN DWELLINGS
2.2.1 Overview of Approved Document B volume 2
Approved Document B volume 2 deals with different aspects of fire safety. It has the
following aims:
To ensure satisfactory provision of means of giving an alarm of fire and a
satisfactory standard of means of escape for persons in the event of a fire in a
building
To ensure that fire spread over the internal linings of a building is inhibited
To ensure the stability of buildings in the evnt of a fire
To ensure that there is a sufficient degree of fire separation within buildings and to
inhibit the unseen spread of smoke in concealed spaces in buildings
2.2.2 Materials and workmanship
The document states that any building work which is subject to the requirements
imposed by Schedule 1 of the Building Regulations should, in accordance with
Regulation 7, be carried out with proper materials and in a workmanlike manner.

Compliance with Regulation 7 can be shown in a number of ways. These include
appropriate use of a product bearing CE marking, a product complying with an
appropriate technical specification, a British Standard or an alternative national
technical specification of a Member State of the European Union. Compliance can
also be achieved by a product covered by a national or European certificate issued
by a European Technical Approval Issuing body, where the conditions of use are in
accordance with the terms of the certificate.

2.2.3 Mechanical ventilation and air conditioning systems
The document states that any system of mechanical ventilation should be designed to
ensure that, in a fire, the ductwork does not assist in transferring fire and smoke through
the building and put at risk the protected means of escape from the accommodation
areas. Any exhaust points should be sited so as not to further jeopardize the building,
i.e away from final exits, combustible building cladding or roofing materials and
openings into the building.

The document states that further guidance on the design and installation of
mechanical ventilation and air conditioning plant is given in BS 5720:1979
3
. It also states
that guidance on the use of ventilation in a place of assembly can be found in BS
5588-6: 1991
4

2.2.4 Ventilation ducts, flues etc
The document states that where air handling ducts pass through fire separating
elements the integrity of those elements should be maintained by one of three basic
methods:
Method 1 Protection using fire dampers

Method 2 Protection using fire-resisting enclosures

3
This British Standard has been withdrawn.
4
Note that BS5588 has been superseded by BS 9999: 2008
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Method 3 Protection using fire-resisting ductwork
The specific provisions of test for fire resistance of ductwork is shown below
Part of
building
Minium provisions when tested to the relevant
parts of BS 476 -24 (minutes)
Minium provisions when
tested to the relvant
European standard
(minutes)
5

Method of
exposure

Loadbearing
capacity
Integrity Insulation
Duct Not applicable 30 No provision E 30 From outside
2.2.5 Internal fire spread (linings)
The document states that to inhibit the spread of fire within the building, the internal
linings shall:
Adequately resist the spread of flame over their surfaces;

and

Have, if ignited, a rate of heat release or a rate of fire growth, which is
reasonable in the circumstances
The document states that the requirements for internal fire spread will be met if the
spread of flame over the internal linings of the building is restricted by making provision
for them to have low rates of surface spread of flame and, in some cases, to have a
low rate of heat release, so as to limit the contribution that the fabric of the building
makes to fire growth.

To restrict the use of materials which ignite easily, which have a high rate of heat
release and/ or which reduce the time to flashover, maximum acceptable fire
propagation indices are specified, where the National test methods are being
followed. These are determined by reference to the method specified in BS 476-6:1981
or 1989 Method of test for fire propagation of products. Index of performance (1)
relates to the overall test performance, whereas sub-index (i1) is derived from the first
three minutes of test.



5
National classifications do not automatically equate with the equivalent classifications in the European column.
Products cannot therefore typically assume a European class unless they have been tested accordingly
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2.3 APPROVED DOCUMENT F VENTILATION 2010 EDITION
2.3.1 Overview of Approved Document F
This document has been approved by the Secretary of State to provide practical
guidance on ways of complying with the requirements in Building Regulations, in so far
as it relates to fixed systems for mechanical ventilation.
2.3.2 Materials and workmanship
The document states that any building work which is subject to the requirements
imposed by the Building Regulations should in accordance with regulation 7, be
carried out with proper materials and in a workmanlike manner.
Compliance with regulation 7 can be achieved in a number of ways. These include
demonstrating the appropriate use of:
A product bearing the CE marking

A product complying with an appropriate technical specification, a British
Standard, or an alternative national technical specification of a Member of State
of the European Union that provides an equivalent level of safety and protection

A product covered by a national or European certificate issued by a European
Technical Approval issuing body, provided the conditions of use are in
accordance with the terms of the certificate.
2.3.3 Installation of ventilation systems
The document recommends that ventilation systems are installed in new and existing
dwellings in accordance with the guidance in the 2010 edition of the Domestic
Ventilation Compliance Guide. It states that section 5 of the Domestic Ventilation
Compliance Guide includes an installation checklist which should be completed by
the system installer.
In Section 8 of Approved document F, references are provided to other ventilation
guidance including CIBSE Guide B: Heating, ventilating, air conditioning and
refrigeration, HVCA DW/ 143: A practical guide to air leakage testing, HVCA DW/ 144:
Specification for sheet metal ductwork, HVCA TR/ 19: Internal cleanliness of ventilation
systems and HTM 03: Ventilation healthcare premises
2.3.4 Air flowrate testing and commissioning of ventilation systems
The regulations require:
Mechanical ventilation systems to be commissioned (where they can be tested
and adjusted to provide adequate ventilation and a commissioning notice to be
given to the Building Control Body (BCB)
Air flowrates for mechanical ventilation systems in new dwellings to be measured
and a notice given to the BCB
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2.4 DOMESTIC VENTILATION COMPLIANCE GUIDE, 2010 EDITION
2.4.1 Overview of the domestic ventilation compliance guide
This guide provides detailed guidance to help persons comply with requirements in
Building Regulations for installation, inspection, testing, commissioning and provision of
information when installing fixed ventilation systems in new and existing dwellings.
The aim is to ensure the provision of adequate ventilation while minimising energy use
and environmental problems such as noise and thermal discomfort.

2.4.2 Installation of ducts - flexible
The document states that ducts should not be installed where they can be damaged,
for example across loft areas where they may be stood on or have items placed on
them, crushing the duct and restricting or preventing all air flow through the duct.

Flexible duct should be pulled taught to ensure that the full internal diameter is
obtained and flow resistance minimised. This is considered to have been achieved if
the duct is extended to 90 per cent of its maximum length.

Flexible ductwork should be supported as suitable intervals to minimise sagging. Ensure
flexible ducting is installed without peaks or troughs.

Bends in flexible duct should have minimum inside radius equal to the diameter of the
duct See Diagram 1 on the following page. If tighter bends are required, rigid bends
should be used.
It is suggested that flexible ducts should be supported at intervals not exceeding
600mm.

2.4.3 Duct connections
The guide states that all duct connections require sealing. Where ducts are installed
against a solid structure this can be difficult to achieve. In such locations preassembly
of duct sections should be considered. This will require that connections are permanent
to ensure the seal is maintained during installation.

Where access to ducts will not be possible after construction is complete, i.e. within
floor and wall voids, consideration should be given to permanent connection and
sealing with an a appropriate non-hardening sealant, and not using duct tape to
achieve connection and sealing.

Connection of lengths of flexible duct must use a rigid connector and jubilee clips or
similar to ensure a long term seal is achieved. Connections of lengths of flexible duct
should not be taped-only
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2.5 APPROVED CODE OF PRACTICE AND GUIDANCE TO THE WORKPLACE (HEALTH, SAFETY AND WELFARE)
REGULATIONS
2.5.1 Overview of ACOP to the Workplace (Health, Safety and Welfare) Regulations
This document explains the requirements, under the Workplace (Health, Safety and
Welfare) Regulations 1992, which dutyholders should follow to ensure appropriate
working conditions are provided for employees.

2.5.2 Mechanical ventilation systems
The document states that mechanical ventilation systems, including air conditioning
systems, should be regularly and properly cleaned, tested and maintained to ensure
they are kept free of anything which may contaminate the air.

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2.6 NON-DOMESTIC BUILDING SERVICES COMPLIANCE GUIDE, 2010 EDITION
2.6.1 Overview of the non-domestic building services compliance guide
This guide provides detailed guidance for persons installing fixed building services in
new and existing non-domestic buildings to help them comply with Building
Regulations. It covers work on new and existing systems.

2.6.2 Air distribution systems in new and existing buildings
The guide states that in order to limit air leakage, ventilation ductwork should be made
and assembled so as to be reasonably airtight. It adds that ways of meeting this
requirement would be to comply with the specifications given in HVCA DW/ 1444
Specification for sheet metal ductwork
It also states that membership of the HVCA and ADCAS is one way of demonstrating
suitable qualifications


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3 BS AND BS EN STANDARDS
BS and BS EN standards are published documents that contain a technical
specification or other precise criteria designed to be used consistently as a rule,
guideline, or definition. Their aim is to increase the reliability and the effectiveness of
goods and services we use.
BS and EN Standards are designed for voluntary use and do not impose any
regulations. However, laws and regulations may refer to certain standards and make
compliance with them compulsory.
The aim of this chapter is to examine the BS and BS EN standards related to flexible
ductwork.
3.1 BSEN 13180: 2002 VENTILATION FOR BUILDINGS DUCTWORK DIMENSIONS AND
MECHANICAL REQUIREMENTS FOR FLEXIBLE DUCTWORK
3.1.1 Overview of BE EN 13180:2002
This standard has been prepared to:
Specify dimensions and tolerances for flexible ducts
Give methods for the performance testing of flexible ducts
Enable assessment of minimum technical requirements
The standard identifies the following parameters which shall be tested or inspected:
Dimensions and tolerances
Mechanical resistance
The standard defines a flexible duct in the following manner:
Duct which can be manually longitudinally compressed or decompressed and flexed
without permanently damaging the cross section area
3.1.2 Dimensions for flexible ducts
The standard states that the nominal diameter of flexible ducts and fittings shall comply
with the following criteria.
Nominal diameter (mm)
Deviations (mm)
Class A Class B
63
80 +1 +3
100 0 0
125
150
160
200 +2 +4
250 0 0
300
315
355
400
450 +3 +6
500 0 0
560
630
Note: Figures in bold indicate recommended sizes in accordance with EN 1506
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3.1.3 Mechanical properties and requirements of flexible ducts
3.1.3.1 Nominal length
This standard states that after decompression, the measured length shall not be more
than 3% shorter than the manufacturers quoted nominal length.
3.1.3.2 Bending capability
This standard states that the sample shall be bent by hand three times, at its nominal
diameter or at the bending radius quoted by the manufacturer, whichever is smaller.
The initial height of the duct shall not reduce or expand by more than 20% at the
centre line of the test former at any time during the test.
3.1.3.3 Pressure
This standard states that flexible ducts shall be capable of withstanding 2.5 times the
manufacturers quoted positive pressure and negative rated pressure when tested in
accordance with the test method desctribed in the standard.

3.1.3.4 Crushing strength
This standard states that flexible ducts delivered in compressed form shall remain
undamaged and shall resist loads perpindicular to their axis.
It states that an uncompressed duct can be subject to a load perpendicualr to its axis
and that the crushing strength property to assess the mechanical resistance shall be
specified according to the application.

3.1.3.5 Air leakage
The standard states that when tested in accordance with the test method desctribed
in the standard, the maximum air leakage factor should be as follows:

Air tightness class Maximum air leakage factor l/s per m
2

A 0.027 x ps
0.65

B 0.009 x ps
0.65

C 0.003 x ps
0.65


3.1.1 Marking, labelling and packaging
This standard states that the marking of the product or product packaging shall
contain at leasts the nominal diameter and the nominal length of the duct.
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3.2 BS9999: 2008 CODE OF PRACTICE FOR FIRE SAFETY IN THE DESIGN, MANAGEMENT AND USE OF
BUILDINGS
3.2.1 Overview of BE 9999:2008
As a code of practice, this British Standard takes the form of guidance and
recommendations. This standard has designed as a co-ordinated package covering
the four main areas that influence fire safety measures, namely:
Fire safety management
The provision of means of escape
The structural protection of escape facilities and the structural stability of the
building in the event of a fire
The provision of access and facilities for fire-fighting
The standard supersedes the BS 5588 series of standards
6
.
3.2.2 The design stage
The standard states that it is important that:
The material specified is appropriate for its end use
The material or product specified has appropriate field of application reports
showing it to be fit for the intended application. Test reports are inadequate for
this purpose
The correct construction or installation of the material or product is described
and not compromised by inadequate knowledge of the contractor or sub-
contractors
All systems can be adequately commissioned and tested
3.2.3 Mechanical ventilation and air conditioning systems
The standard states that any system of mechanical ventilation should be designed to
ensure that in a fire the air movement in the building is directed away from protected
escape routes and exits, or that the system (or an appropriate section of it) is closed
down.
It also states that when ductwork systems are installed within a building it is important
that the ductwork does not assist in transferring fire and smoke through the building
and put at risk the protected means of escape from the accommodation areas.
3.2.4 Flexible ductwork joints and connections
The standard states that flexible ductwork connections should:
Not exceed 3.7m in length
Not pass through fire-resisting walls or floors or cavity barriers

6
BS5588-9: 1999 Fire precautions in the design, construction and use of buildings. Part 9 is entitled Code of practice
for ventilation and air conditioning of ductwork
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It also states that flexible ductwork connections should be constructed of:
Non-combustible materials
7

or
Materials conforming to Euroclass A1, as specified in BS EN 13501-1:2007 + A1:2009
or
Material which, when tested in accordance with BS 476-6 has a fire propagation
index l of not more than 12 and a sub-index i1 of not more than 6, and is situated
at least 1 metre from any fire damper
3.3 BSEN 15423: 2008 VENTILATION FOR BUILDINGS FIRE PRECAUTIONS FOR AIR DISTRIBUTION
SYSTEMS IN BUILDINGS
3.3.1 Overview of BS EN 15423:2008
This document applies to all air distribution systems. It gives guidance for system
designers, installers, commissioners and maintenance teams on the incorporation of
protective measures for air distribution systems, to prevent the initiation and spread of
fire, smoke and other by-products of combustion.

3.3.2 General requirements
This standard states that components in the air distribution system shall be made or
installed in such a way that they will not increase the hazard of spreading fire and
smoke gases in the case of fire.
It also states that the materials used in buildings, air distribution systems and their
components shall not contribute to the development of fire in accordance with any
local requirement.
3.3.3 Flexible duct component requirements
This standard states that materials for walls in ventilation ducts shall be selected so that
the ducts can withstand the functions they are exposed to such as heat and cleaning.
It also states that flexible ducts should comply with the following requirements.
Fire resistance: BS EN 13501-1, BS EN 13501-3
Fire reaction: No requirement
Mechanical strength: BS EN 13180
Precaution for installation: BS EN 12097
Air tightness: BS EN 13180
Maintenance, including cleaning: BS EN 12097

7
Approved Document B (Fire Safety) defines a non-combustible material as any material which when tested to BS
476-11 does not flame nor cause any rise in temperature on either the centre (specimen) or furnace thermocouples,
or any product classified as non-combustible under BS 476 -4
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3.4 BSEN 13501-1: 2007 +A1: 2009 FIRE CLASSIFICATION OF CONSTRUCTION PRODUCTS AND
BUILDING ELEMENTS
3.4.1 Overview of BS EN 13501-1: 2007 + A1: 2009
This standard provides the reaction to fire classification procedure for all construction
products, including products incorporated within building elements. Products are
considered in relation to their end-use applications.

3.4.2 Performance classification
This standard states that any homogenous product applying for class A1
8
shall be
tested in accordance with EN ISO 1182 and EN ISO 1716. Each substantial component
of ant non- homogenous product applying for class A1 shall be tested in accordance
with EN ISO 1182 and EN ISO 1716.
A product classified as A1 shall satisfy the following criteria:
Gross calorific potential (PCS) 2.0 MJ/kg
Temperature rise (T) 30
o
C
Mass loss (m) 50%
Duration of sustained flaming
9
(tf) =0s
3.5 BSEN 12097: 2006 VENTILATION FOR BUILDINGS REQUIREMENTS FOR DUCTWORK
COMPONENTS TO FACILITATE MAINTENANCE OF DUCTWORK SYSTEMS
3.5.1 Overview of BS EN 12097:2006
This standard specifies requirements for dimensions, shape and location for access
panels for cleaning and service in ductwork systems.
3.5.2 Openings for flexible circular ducts
This standard states that flexible ducts shall, where possible, be removed for inspection
and cleaning, unless they can be satisfactorily cleaned in-situ. For cleaning of flexible
ductwork in-situ, access shall be provided through rigid access components.


8
A flexible duct constructed from materials conforming to Euroclass A1 will comply with the requirements of BS 9999:
2009 Code of practice for fire safety in the design, management and use of buildings

9
Sustained flaming is defined as the existence on or over the surface for a minimum period of time
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3.6 BS476-6: 1989 +A1: 2009 FIRE TESTS ON BUILDING MATERIALS AND STRUCTURES
3.6.1 Overview of BS 476-6:1989 + A1: 2009
This part of BS 476 specifies a method of test, the result being a fire propagation index,
that provides a comparative measure of the contribution to the growth of a fire made
by an essentially flat material or assembly. It is primarily intended for the assessment of
the performance of internal wall and ceiling linings.

A specimen of the product is subjected to a specific heating regime. The test takes
into account the combined effect of factors such as the ignition characteristics, the
amount and rate of heat release and the thermal properties of the product in relation
to their ability to accelerate the rate of fire growth.

3.6.2 Performance classification
The determination of the fire propagation index requires the results from three
specimens, each producing valid test results.

The test result is expressed in terms of a fire propagation index (l) that is the summation
of three time-based sub-indices (l =i1 =i2 + i3). The higher the fire propagation index,
the greater is the influence of the product on accelerating the growth of a fire.
10



10
A flexible duct constructed from materials which, when tested in accordance with BS 476-6 has a fire propagation
index I of nor more than 12 and a sub-index i1 of not more than 6 will comply with the requirements of BS 9999: 2009
Code of practice for fire safety in the design, management and use of buildings
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3.7 BS476-7: 1997 FIRE TESTS ON BUILDING MATERIALS AND STRUCTURES
3.7.1 Overview of BS 476-7:1997
This part of BS 476 specifies a method of test for measuring the lateral spread of flame
along the surface of a specimen of a product.
It provides data suitable for comparing the end-use performances of essentially flat
materials, composites or assemblies, which are used primarily as the exposed surfaces
of walls and ceilings.

A minimum of six and a maximum of nine specimens are subjected to a specific
heating and ignition regime. The test takes into account the combined effect of
factors such as the ignition characteristics and extent to which the flame spreads over
the surface of the products under opposed flow conditions. The influence of any
underlying materials on these factors, in relation to their ability to influence the rate of
fire growth, is also taken into account.

3.7.2 Performance classification
The test result is a function of the distance, and rate of, the lateral spread of flame. This
is classified according to performance classes 1 to 4. The following table summarises
the classification of spread of flame.
Classification Spread of flame at 1.5 minutes Final spread of flame
Limit (mm)
Limit for one
specimen in the
sample(mm)
Limit (mm)
Limit for one
specimen in the
sample(mm)
Class 1 165 165 + 25 165 165 + 25
Class 2 215 215 + 25 455 455 + 45
Class 3 265 265 + 25 710 710 + 75
Class 4 Exceeding the limits for Class 3

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4 CONSTRUCTION INDUSTRY GUIDANCE DOCUMENTS
A wide variety of construction industry guidance is produced by organisation such as
The Heating and Ventilating Contractors Association (HVCA), The Chartered Institution
of Building Services Engineers (CIBSE), The Building Services Research and Information
Association (BSRIA) and The Association for Specialist Fire Protection (ASFP).
These documents are designed for voluntary use and do not impose any regulations.
However, laws and regulations may refer to certain standards as ways of complying
with specific requirements.
The aim of this chapter is to examine the construction industry guidance related to
flexible ductwork.
4.1 HVCA DW/ 144 SPECIFICATION FOR SHEET METAL DUCTWORK
4.1.1 Overview of DW/ 144
This specification sets out the minimum requirements for the manufacture and
installation of ductwork for commericail and industrial air distribution systems made
from zinc-coated steel, mild steel, stainless steel, pre-coated steel, and aluminium.
4.1.2 Cautionary note to all ductwork designers and manufacturers
The document states that ductwork constructed to DW/ 144 Standard has no tested fire
resistance. General purpose ventilation/ air conditioning ductwork and its ancillary items
do not have a fire rating and cannot be either utilised as or converted into a fire rated
ductwork system unless the construction materials of the whole system including supports
and penetration seals are proven by test and assessment in accordance with BS 476 Part
24.
4.1.3 Ductwork systems and fire hazards
The document states that fire and smoke containment/ hazards are factors which
influence the design and installation of ductwork systems. It states that information
concerning fire protection systems is laid down in BS 5588
11
and that there are the
following three methods of fire protection, related to ductwork systems, as given in BS
5588 Part 9 (1989):
Method 1 Protection using fire dampers

Method 2 Protection using fire-resisting enclosures

Method 3 Protection using fire-resisting ductwork
4.1.4 Flexible ducts - general
The document states that flexible duct connections shall be used in the following
applications:-
Terminal units

Fan coil units

Constant Volume/ Variable Air Volume units

Grilles and Diffusers


11
Note that BS5588 has been superseded by BS 9999: 2008.
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Plenum boxes

Distribution ducts between the above items.

They are available in a range of materials including metal, P.V.C, fabric and with or
without thermal insulation.

The document states that the designer/ contractor shall consider the following when
selecting a particular type of flexible duct including:
Temperature range

Fire rating

Resistance to air flow

Airtightness characteristics

Length restrictions if applicable

Support requirements

Flexibility

Insulation values

System pressure

4.1.5 Flexible ducts - metal
The document states that flexible ducts made of coated steel, stainless steel or
aluminium are normally helically wound with a lock seam to form a corrugated duct
capable of being bent without deforming the circular section. Bending is done by
closing the corrugations in the throat and slightly opening the corrugations at the back
of the bend. Some re-adjustment is possible but small radius bends cannot be
straightened without leaving some distortion of the corrugations. Repeated bending is
not recommended.
The ducts shall be mechanically fastened at each end and particular care shall be
taken to ensure that the required airtightness of the system is maintained.
Fastenings and sealing should be as for rigid circular ducts, as described later in this
section of the report.
4.1.6 Flexible ducts - fabric
The document states that flexible ducts made from materials including P.V.C/ polyester
laminate, aluminium/ polyester laminate encapsulating high tensile steel wire helix are a
very flexible form of construction. The length of flexible duct used should therefore be
kept to a minimum, consistent with the particular application.

Flexible ducts shall be fastened at each end using a proprietary band. Care should be
taken not to damage the flexible duct and to ensure that the required airtightness of
the system is maintained.
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4.1.7 Flexible ducts - supports
The document states that Flexible ducts have a higher resistance factor than
conventional ductwork and should be supported in such a way that excessive sagging
and consequently
4.1.8 Flexible ducts test holes
The document states that it is not practicable to make test holes or take test readings in
metal or fabric flexible ducts. Where readings are required, the test holes should be
made in rigid ductwork.
4.1.9 J oint sealing and sealants
The document states that the integrity of the ductwork depends on the successful
application of the correct sealant, gaskets or tape. The materials used should be
suitable for the purpose intended and satisfy the specified pressure classification.
In all cases, sealant materials must be applied strictly in accordance with the
manufacturers instructions and COSHH assessment

4.1.10 Fastenings
4.1.10.1 Permitted types and maximum centres
The following table sets out the permitted fastenings and maximum spacings for low,
medium and high- pressure circular ducts. All duct penetrations shall be sealed.
Type of Fastening Sheet to sheet
Sheet to section (jointing flanges and
intermediate stiffeners)
Lap joints Cross joints Spirally wound Straight seamed
1 2 3* 4* 5*
mm mm mm mm
Mechanically 60 150 150 150
Self-piercing screws 60 150 150 150
Set screws and nuts - - 300 300
Lock bolts 60 - 300 300
Spot welds 30 30 150 150
*Minimum of three fixings
4.1.10.2 Rivets
Manufacturers recommendations as to use, size and drill size are to be followed. Rivets
resulting in an unsealed aperture shall not be used.
4.1.10.3 Set screws, nuts and lock bolts
Materials shall be of mild steel, protected by electro-galvanizing, sherardizing, zinc
plating or other equal and approved finish.
4.1.10.4 Self-tapping and piercing screws
Providing an adequate seal can be achieved, and the protrusions into the ductwork
are unlikely to cause injury, then self-tapping or piercing screws may be sued.

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4.2 CIBSE GUIDE B3 DUCTWORK
4.2.1 Overview of CIBSE Guide B3
This aim of this document is to provide information on current practice in the design
and installation of ventilation and air conditioning systems.

4.2.2 Classification of ductwork systems
This document classifies ductwork systems in the following manner.
Classification of ductwork systems Air leakage limit
*

Maximum design
static pressure (pa)
Comments
Low pressure system (Class A) 6%
500 +ve
500 -ve
*
0.027 x p
0.65
l/ s per m
2
of duct
area where p is the static gauge
pressure in the duct
Medium pressure system (Class B) 3%
1000 +ve
750 -ve
*
0.009 x p
0.65
l/ s per m
2
of duct
area where p is the static gauge
pressure in the duct
High pressure system (Class C) 2%
2000 +ve
750 -ve
*
0.003 x p
0.65
l/ s per m
2
of duct
area where p is the static gauge
pressure in the duct

4.2.3 Spatial requirements
The document states that provision of sufficient space for ductwork is essential and
must be addressed at an early stage in the design process of a building. Adequate
space must be allowed around ducts for fitting of insulation, hangers and supports
during installation and for access during subsequent maintenance.
4.2.4 Fan power energy requirements
The document states that energy can be reduced in ventilation systems by minimising
the length of flexible ducting

4.2.5 Methods of fire protection of ductwork
The document states that there are three methods of fire protection related to
ductwork systems, as given in BS 5588: Part 9
12
. These three methods are as follows.
Method 1: Protection using fire dampers;
Method 2: Protection using fire resisting enclosures;
Method 3: Protection using fire resisting ductwork

4.2.6 Fire resistance and DW/ 144
The document states that ductwork constructed to HVCA specification DW/ 144 has no
tested fire resistance. General purpose ventilation/ air conditioning ductwork and its
ancillary items do not have a fire rating and cannot be either utilised in, or converted
into, a fire rated ductwork system unless the construction materials of the whole system
(including supports and penetration seals) are proven by test and assessment in
accordance with BS 476: Part 24


12
Note that BS5588 has been superseded by BS 9999: 2008
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4.2.7 Fire rating
The document states that where ductwork is required to be fire rated, it is specified
according to stability, integrity and insulation.
Stability is the ability of a duct to stay in place for the specified period of time when
exposed to a fire. Integrity is the ability of the duct to prevent the passage of fire either
into or out of the duct. Insulation is usually called for if the Building Control Officer
believes that a duct carrying hot smoke may become sufficiently hot to compromise
an escape route.
4.2.8 Flexible ducts
The document states that flexible duct connections shall be used in the following
applications:-
Terminal units

Fan coil units

Constant Volume/ Variable Air Volume units

Grilles and Diffusers

Plenum boxes

Distribution ducts between the above items.
It adds that flexible ducts can be abused to overcome poor installation, such as where
ducts do not line up. This can result in poor airflow at the grille and/ or excessive noise.
The following advice should be noted when using flexible ductwork (particularly metal
types)
Lengths should be as short as possible

Flexible ductwork should be almost fully extended
The guide states that the designer should consider the following when selecting a
particular type of flexible duct:
Temperature range

Fire rating

Resistance to air flow

Airtightness characteristics

Length restrictions if applicable

Support requirements

Flexibility

Insulation values

System pressure.
It adds that pressure losses from flexible ducts can be high, so lengths should be kept to
a minimum and that flexible ducts should be fastened at each end using a proprietary
band or mechanical fastenings.
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It also states that care should be taken not to damage the flexible duct and to ensure
that the required airtightness of the system is maintained.
4.2.9 Flexible ductwork for making final connections
The document states that the use of flexible ductwork to supply diffusers is very
convenient. However, it adds that such ductwork produces much greater pressure
drops than those for the equivalent smooth galvanised ductwork.
4.2.10 Supports for flexible ductwork
The document states flexible ducts have a higher resistance than conventional
ductwork and should be supported in such a way that excessive sagging and
consequent kinking of the duct is avoided.
4.2.11 Test holes in flexible ductwork
The document states it is not practicable to make test holes or take test readings in
metal or fabric flexible ducts. It adds that where readings are required, the test holes
should be made in rigid ductwork.
4.2.12 Maintenance of flexible ductwork
The document states that every 12 months a visual inspection of flexible ductwork
should be undertaken for damage, security of fittings, deterioration and internal
condition. It adds that detailed maintenance requirements for ductwork are set out in
HVCA Standard Maintenance Specification volume 2: Ventilation and air conditioning.

4.3 CIBSE TM 43 FAN COIL UNITS
4.3.1 Overview of CIBSE TM 43
This document is intended as a guide to designers of chilled water fan coil unit systems,
the manufacturers who build them, the contractors who install and commission them,
and end users.

4.3.2 Ductwork connections
The document states that all connecting ductwork should be independently supported
from the fan coil unit and grille/ diffuser plenums, in accordance with DW 144:
Specification for sheet metal ductwork.
The guide also states that insulated rigid ductwork with swept bends should be used for
main duct runs, with connections to the fan coil unit and grille/ diffuser plenum boxes in
flexible ductwork. Flexible ducting only for final connections and not to compensate
for poorly installed or misaligned ductwork
It states that flexible ductwork should be of 600mm maximum length and be of
acoustic grade if necessary. Connections should be made using suitable clamps or
clips, ensuring that an airtight joint is made. Ductwork should then be insulated and
taped down.
It adds that flexible corrugated ducting can impose high resistances if formed into tight
bends and should therefore be extended so that it is internally as smooth as possible.

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4.4 CIBSE TM 26 HYGIENIC MAINTENANCE OF OFFICE VENTILATION DUCTWORK
4.4.1 Overview of CIBSE TM 26
This guide, together with HVCA and BSRIA documents, provides a comprehensive
toolkit for the management and maintenance of most ductwork systems to satisfy best
practice requirements.

4.4.2 Mechanical ventilation systems
The document states that the Approved Code of Practice and Guidance to the
Workplace (Health, Safety and Welfare) Regulations, states that mechanical ventilation
systems, including air conditioning systems, should be regularly and properly cleaned,
tested and maintained to ensure they are kept free of anything which may
contaminate the air.
4.5 ASSOCIATION FOR SPECIALIST FIRE PROTECTION (ASFP) FIRE RATED AND SMOKE OUTLET DUCTWORK
4.5.1 Overview of ASFP fire rated and smoke outlet ductwork
This publication is intended to assist the reader in understanding many of the essential
details which play a significant part in ensuring that fire rated (which includes smoke
outlet) ductwork is correctly designed and installed in accordance with current UK
legislative requirements.
The purpose of the document is to assist those involved in the specification, installation,
inspection and verification of Fire Rated Ductwork and to ensure that minimum
performance standards are maintained which will contribute to ensuring that fire
compartmentation systems are not breached prematurely.

4.5.1 Cautionary note to all ductwork designers, manufacturers and installers
Sections of this document emphasise that general purpose ventilation/ air conditioning
ductwork cannot be utilised as, or converted into, a fire rated ductwork system unless
the construction/ materials of the whole system are proven by test or assessment in
accordance with the requirements of BS 476: Part 24.

4.5.2 Ductwork and fire
The document states that many ventilation ductwork systems offer little or no
protection against fire spread and therefore, when ventilation ductwork penetrates
building compartmentation, the guidance of BS 5588: Part 9
13
should be followed by
adopting one of the three following techniques:
Method 1: Protection using fire dampers;
Method 2: Protection using fire resisting enclosures;
Method 3: Protection using fire resisting ductwork.

The document also states that the guidance given in Approved Document B1 (Means
of Escape) and B3 (Internal Fire Spread Structure) of the Building Regulations 1991 for
England and Wales refers to BS 5588: Part 9 for alternative ways in which the integrity of
compartments may be maintained where ventilation and air conditioning ductwork
penetrate fire separating elements.


13
Note that BS5588 has been superseded by BS 9999: 2008
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4.5.3 Fire resistance of ductwork
The document refers to fire resisting ductwork as A duct or ductwork used for the
distribution or extraction of air, designed and tested to satisfy the criteria defined in BS
476: Part 24.
Fire resistance is the ability of a component or construction to satisfy, for a stated
period of time, the appropriate criteria specified in the relevant part of BS 476. The
following criteria are applied to fire rated ductwork.
Stability: The ability of a duct, ductwork and the support system to remain intact
and fulfil their intended function for a specified period of time, when tested to the
requirements of BS 476: Part 24 (ISO 6944).
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 exceed:
i) 140C as an average value above ambient and/ or
ii) 180C as a maximum value above ambient at any one point
when tested for a specified period of time to the requirements of BS 476: Part 24.
(ISO 6944)
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 BS 476: Part 24 (ISO 6944)
The document states that the term Fire Rated Ductwork is deemed to refer to a
system as tested or assessed in accordance with BS 476 : Part 24. As the vast majority of
tests on steel ducts are conducted with rigid ducts it is not appropriate to extrapolate
this data for flexible steel ducts. Therefore, unless the flexible steel duct system has been
tested in accordance with BS 476: Part 24, this guidance note cannot be assumed to
apply.
4.5.4 Reaction to fire tests
The publication states that in order to restrict the use of materials in the construction of
buildings which ignite easily, which have a high rate of heat release and/ or which
reduce the time to flash-over, reaction to fire tests are carried out on component
materials and linings of ducts. These are carried out to show compliance with reaction
to fire requirements in regulations or other specifications. The tests which are used to
demonstrate compliance are:
Method of test to determine the classification of the surface spread of flame of
products - BS 476: Part 7. This test measures the rate at which flame is able to
spread over the surface of a lining material. The material or product is classified
1,2,3 or 4 with Class 1 being the highest classification (least flame spread).
Method of test for fire propagation for products - BS 476: Part 6. This test measures
the rate of heat release from a product or material. From this test, indices of
performance are calculated. Index of performance (I) relates to the overall test
performance, whereas sub-index (i
1
) is derived from the first three minutes of test.
The maximum acceptable fire propagation indices are specified in the various
regulations.
Method for assessing the heat emission from building materials - BS 476: Part 11,
and Non-combustibility test for materials - BS 476: Part 4. These two tests are similar
and are used to determine the heat emission from a product or material.
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An additional product performance classification for lining materials defined in the
national Building Regulations is Class 0. This is achieved if a material or the surface of a
composite product is either:
i) composed throughout of materials of limited combustibility, or
ii) a Class 1 material which has a fire propagation index (I) of not more than 12
and sub index (i
1
) of not more than 6.
Class 0 is not a classification identified in any British Standard test.
4.6 HVCA TR/ 19 INTERNAL CLEANLINESS OF VENTILATION SYSTEMS
4.6.1 Overview HVCA TR/ 19
This publication establishes a level or particulate cleanliness verification for new and
existing ventilation systems, includes guidelines to ensure that new ductwork systems
are protected during installation and indicates when it is appropriate to clean systems
in use.
4.6.2 Flexible ductwork
The document states that flexible ducts trap dirt in corrugations. This dirt can be
difficult to remove if the corrugations are deep and/ or compressed together.
It adds that lightweight foil, plastic flexible or aged flexible ducts are liable to damage
and that cleaning methods must be adjusted to account for the type of flexible duct.
Brush methods require soft bristle brushes and gentle application. Compressed air
methods may require a pressure reduction to avoid tearing the material.
It also states that it may be necessary to remove and extend flexible ducts to release
dirt from folds. Decay of the material of construction, or difficulty in releasing flexible
ducts from their connection spigots without causing damage may make replacement
a better option than cleaning.

4.7 HVCA SFG 20 STANDARD MAINTENANCE SPECIFICATION FOR BUILDING SERVICES
4.7.1 Overview of SFG 20
This document is widely regarded as the industry standard for any businesses or
individuals responsible for maintaining, managing or specifying the maintenance of
building services.
4.7.2 Maintenance of flexible duct connections
The document states that flexible duct connections should be inspected every 12
months to check condition, leaks and secureness of fittings

4.8 BSRIA FMS1/ 97 - GUIDANCE TO THE STANDARD SPECIFICATION FOR VENTILATION HYGIENE
4.8.1 Overview BSRIA FMS 1/ 97
This document describes the processes for conducting a ventilation hygiene contract,
from managerial issues through to the technical aspects of cleaning.
The guidance is applicable to the health and safety requirements of mechanical
ventilation systems, including air conditioning.
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4.8.2 Cleaning techniques for flexible ducting
The document proposes the following cleaning techniques for flexible ducting:
Steam washing
Mechanical brushing
Air jetting
High volume air blast
Sectional extraction
Sealing or encapsulation
The document describes the different cleaning techniques.
It classifies flexible ductwork as having a medium rate of dirt accumulation for supply,
general return and extract systems.
4.9 BUILDING BULLETIN 100 DESIGN FOR FIRE SAFETY IN SCHOOLS
4.9.1 Overview of building bulletin 100
This guide provides fire safety design guidance for schools in England and Wales. The
guidance applies to nursery schools, primary and secondary schools, including sixth
form colleges, academies and city technology colleges, special schools and pupil
referral units.
The guide is intended for all those with an interest in fire safety in schools, but in
particular designers, fire engineers, building control officers (or equivalent) and fire
safety officers.

4.9.2 Mechanical ventilation and air conditioning systems
The document states that any system of mechanical ventilation should be designed to
ensure that, in a fire, the ductwork does not assist in transferring fire and smoke through
the building and put at risk the protected means of escape from the accommodation
areas.
It refers to guidance on the use of mechanical ventilation is given in BS 5588-6:1991
14
.

4.10 DISTRICT SURVEYORS ASSOCIATION (DSA) GUIDE TO MECHANICAL AND ELECTRICAL SERVICES
IN SPORTS GROUNDS
4.10.1 Overview of DSA guide to mechanical and electrical services
This document is a guide to electrical and mechanical services in sports grounds controlled
under the Safety of Sports Grounds Act 1975 and the Fire Safety and Safety of Places of Sport
Act 1987.
4.10.2 Mechanical ventilation and air conditioning systems
The guide states that requirements B1, B2 and B3 of the Building Regulations, which
relate to means of escape and internal fire spread, apply to all building work in all
types of premises.

14
Note that BS5588 has been superseded by BS 9999: 2008.
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It states that the major concerns are:
The system could spread smoke, heat or flame from one compartment to the
other
Ductwork materials and machinery used within the system could contribute to
any such spread
The movement of air generated by the system could assist in drawing smoke
towards exit doors or on to exit routes
The recommendations are:
All mechanical ventilation systems should comply with the relevant requirements
of BS 5720
15
and BS 5588 Part 9
16

Mechanical ventilation systems should have duct and flexible connections made
of non-combustible material



15
This British Standard has been withdrawn
16
Note that BS5588 has been superseded by BS 9999: 2008.
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5 CONSTRUCTION PROJ ECT SPECIFICATIONS
The aim of this section of the report is to examine how construction project teams
specify flexible ductwork on their projects.
The content of this chapter has been compiled by referencing project specifications
produced by the following companies:
Aecom
Arup
Atkins
Cudd Bentley
Downie Consulting Engineers
Hoare Lea
Long and Partners
MLM Consulting Engineers
Silcock Dixon
White Young Green
WSP
The information was furnished by these organisations in strictest confidence, so the
conetnt of the different project specifications is presnted in an anonymous manner.
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5.1 SAMPLE SPECIFICATION 1
The following specification material was employed by four of the companies consulted
for this study exercise. It is based on the National Engineering Specification (NES).
5.1.1 Design information - general
All ductwork and associated materials shall be manufactured, installed and tested, in
accordance with the current editions of HVCA Specification DW/ 144 and DW 154 for
sheet metal ductwork and plastic ductwork respectively, for low, medium and high
pressure/ velocity air systems, and as qualified in this specification.
5.1.2 Ductwork installation standards
Carry out construction and installation of ductwork in accordance with DW 144, DW
154, DW 172 and DW 191 and BS 5588
17
as appropriate.
The entire system installation shall comply with the requirements of the Building Control
and Fire Officer.

5.1.3 Low pressure ductwork air leakage testing
Test low-pressure ductwork in accordance with DW 144 and DW143.
5.1.4 Flexible ducts - metal
Supply bendable ducts in accordance with DW 144 Part 7 Section 25. Flexible ducts
shall be manufactured from light gauge coated steel, helically wound with lock seams
of circular section.
Building Control and Fire Officer approvals shall be obtained for the use of the flexible
ductwork to be installed.
Comply with BS EN 13180.
Maximum length of flex to be three diameters or 1m, whichever is the smaller.
Flexible ductwork used to make final connection between distribution ductwork and
terminal units only shall be kept as short and straight as possible and shall not be used
to take up gross misalignment.
Flexible duct shall be adequately supported to eliminate sagging.
Where the flexible ductwork is to be insulated, this shall be factory applied of a type
approved for the application and to the thermal conductivity equivalent to the
adjacent thermal insulation and shall be Class "O" fire rated.
The maximum frictional resistance to airflow per unit length of the flexible duct shall be
agreed with the Designer. The radius ratio R/ D for bends shall not be less than 2 where R
is the centre line radius and D is the diameter of the flexible duct.
The flexible ductwork shall be to a standard of air tightness equal to that of the
ductwork, and constructed to meet the fire precautions recommended in BS 5588
which comprise:-
Fire resistance to meet BS 476: Part 6 with indices of performances not more than i
equal to 12 and i equal to 6.

17
Note that BS5588 has been superseded by BS 9999: 2008.
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Materials shall not produce smoke or toxic fume hazards if involved in a fire.

In no instances shall flexible duct connections be allowed on to fire dampers or through
floors and walls
Flexible ducts shall be suitable for an operating temperature range of 18
o
C to 120C.
The joints to rigid spigots shall be sealed with a jointing paste or mastic compound.
Ducts up to 150mm diameter shall be secured with a worm-drive type hose-clip
complying with BS 3628. Ducts over 150mm diameter shall be secured with a band clip.
5.1.5 Hangers and supports
Provide hangers and supports throughout in accordance with DW 144 Part Six, Section
19; DW 154 Part 5 or DW 191, Section 7 as appropriate.
5.1.6 Flexible ductwork wire loop ties
Ensure that flexible ductwork does not become kinked or flattened. Support flexible
ductwork using wire loop tie supports to prevent sagging.
5.1.7 Spherical and drum punkah louvre diffusers
When connecting to ends of flexible ducting, fit rigid flanged extension collar.
5.1.8 Diffuser linear lighting/ air modular type
Fit spigot, suitable for flexible ducting joint connection to plenum box.
5.1.9 Internal cleanliness
Provide the level of care and protection as defined in HVCA document TR/ 19, level as
scheduled.
5.1.10 Delivery
Provide adequate and safe protection for all materials and products during transport
to site. Deliver all ductwork, tubes, conduit, trunking and associated equipment with
open ends effectively plugged, capped or sealed.


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5.2 SAMPLE SPECIFICATION 2
5.2.1 Ductwork installation standards
Carry out construction and installation of ductwork in accordance with DW 144, DW
154, DW 171, DW 191 and BS 5588
18
as appropriate.

5.2.2 General workmanship
Install ductwork in accordance with DW 144, DW 154 and DW 191 as appropriate.
Ensure that there are no sharp edges or corners on cut edges on ductwork, flanges
and supports. Install pre-insulated ductwork in accordance with manufacturer's
instructions.
In no instances shall flexible duct connections be allowed onto fire dampers, or through
floors or walls.

5.2.3 Ductwork supports
Support ductwork in accordance with DW 144 Part Six Section 19; DW 154 Part 5; or DW
191 Section 7 as appropriate. Install supports to ensure insulation can be applied unless
otherwise indicated.

5.2.4 Coated steel flexible ducts
Supply and fasten coated steel flexible duct connections as DW 144 Part Seven Section
25.
Use flexible duct connections in applications listed in DW 144 paragraph 25.1.
Comply with BS EN 13180.
Maximum length 600mm.

5.2.5 PVC/ Polyester laminate flexible ducts
Supply and fasten PVC/ polyester laminate flexible duct connections as DW 144 Part
Seven Section 25.
Use flexible duct connections in applications listed in DW 144 paragraph 25.1.
Comply with BS EN 13180.
Maximum length 600mm.

5.2.6 Internal cleanliness
Provide the basic level of cleanliness and protection as defined in HVCA TM2
5.2.7 Delivery
Provide adequate and safe protection for all materials and products during transport
to site. Deliver all ductwork, tubes, conduit, trunking and associated equipment with
open ends effectively plugged, capped or sealed.



18
Note that BS5588 has been superseded by BS 9999: 2008.
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5.3 SAMPLE SPECIFICATION 3
5.3.1 Ductwork installation standards
Carry out construction and installation of ductwork in accordance with DW 144, DW
154, and DW 171, as appropriate.
5.3.2 Bendable and flexible ducts
Provide un-insulated or pre insulated flexible duct as indicated on the Drawings. Where
pre-insulated the insulation shall comply with the requirements of the Thermal
Insulation Section of the Specification.
Flexible ducts where required shall be neatly fixed and adequately supported so as to
prevent sagging and transfer of weight to adjacent ductwork.
Flexible ducting used to connect terminals to distribution systems shall comply with BS
EN 13180 and Part 7 of DW/ 144 and be constructed from non-combustible material or
material which has a fire propagation index of not more than 12 and a sub-index of not
more than 6 when tested to BS 476 Part 6.
High temperature flexible connectors installed on smoke extract ductwork systems shall
be clearly labelled to indicate their rating and shall be colour-coded red.
Flexible ducts shall be continuous with no intermediate joints.
Flexible ducts shall not exceed 3 x nominal diameter in length and a maximum offset of
0.4 x nominal diameter.
The bending radius must be sufficient to prevent tensioning of the outside of the bend
and restriction of the throat likely to cause deformation and/ or leakage. In no case
shall flexible ductwork be used to correct misaligned rigid ductwork.
The flexible ducts named below are deemed satisfactory for pressure loss, robustness
and general fire resistance. Their acceptability for specific uses is not identical
(especially where non-combustibility is specified) and the Sub-Contractor must ensure
that an appropriate grade of material is installed.
All flexible ducts shall be approved by the Consulting Engineers prior to installation.
J ointing of flexible ducts to rigid ductwork and fittings shall comply with the relevant
construction standard and test requirements. Nipples employing patented 'O' Ring or
other similar joint may be put forward. J oint types and method shall be approved by
the Consulting Engineers.

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5.4 SAMPLE SPECIFICATION 4
5.4.1 Ductwork installation standards
All ductwork and associated materials shall be manufactured, installed and tested, in
accordance with the current editions of HVCA Specification DW/ 144 and DW 154 for
sheet metal ductwork and plastic ductwork respectively
5.4.2 Flexible ductwork metal and fabric
Fit flexible ductwork as described in HVCA DW/ 144, Part 7, clauses 25 and 26, Pages 51-
53, but excluding bendable ductwork unless otherwise specified.
Apply BS 476, Parts 6 and 7 and BS 9999.
Fit flexible ductwork of internal diameter equal to the external diameter of the rigid
ductwork. Use minimum bend radius ratio R/ D of 2 and a maximum length of 2 metres
installed without kinking of the ductwork. Use flexible ductwork where specified and/ or
drawn.
Include a tear resistant fabric inner liner for flexible fabric ductwork.
Do not pass flexible ductwork through fire resistant building construction nor use at
extract points where deposits of flammable substances are likely to occur in high fire
risk areas.
Do not use flexible ductwork to change direction between sections of rigid ductwork.
Secure flexible ductwork to rigid ductwork by means of hose or band clips and ensure
that the whole unit has a standard of airtightness equal to that of the rigid ductwork.
Ensure that flexible ductwork is suitable for an operating temperature range of -5C to
+90C and complies with the following:
B.S.476, Part 6, Fire Propagation - Index of Performance. I not exceeding 12 and i
=6.
B.S.476, Part 7, Class 1, surface of very low flame spread.
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5.5 SAMPLE SPECIFICATION 5
5.5.1 Ductwork installation standards
Carry out construction and installation of ductwork in accordance with DW 144, DW
154, and DW 171, as appropriate.
5.5.2 Flexible ductwork metal and fabric
Fit flexible ductwork as described in HVCA DW/ 411 Specification, Part 7, Clauses 25 and
25, Pages 51and 52, but excluding bendable ductwork unless otherwise specified.
Apply CIBSE TM8, Part 7, B.S.476 Parts 6, 7 and 8, BSCP:413 and B.S.5588, Part 9.
Fit flexible ductwork of internal diameter equal to the external diameter of the rigid
ductwork. Use minimum bend radius ratio R/ D of 2 and a maximum length of 2 metres
installed without kinking of the ductwork. Use flexible ductwork where specified and/ or
drawn.
Include a tear resistant fabric inner liner for flexible fabric ductwork.
Do not pass flexible ductwork through fire resistant building construction nor use at
extract points where deposits of flammable substances are likely to occur in high fire
risk areas.
Do not use flexible ductwork to change direction between sections of rigid ductwork.
Secure flexible ductwork to rigid ductwork by means of hose or band clips and ensure
that the whole unit has a standard of airtightness equal to that of the rigid ductwork.
Ensure that flexible ductwork is suitable for an operating temperature range of -5C to
+90C and complies with the following:
B.S.476 : Part 6, Fire Propagation - Index of Performance. I not exceeding 12 and i =
6.
B.S.476 : Part 7, Class 1, surface of very low flame spread.
B.S.476 : Part 8, Fire Resistance of at least 15 minutes integrity.


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5.6 SAMPLE SPECIFICATION 6
5.6.1 Ductwork installation standards
Carry out construction and installation of ductwork in accordance with DW 144, DW
154, and DW 171, as appropriate.
5.6.2 Flexible ductwork
Flexible ducting shall be provided for connections between ductwork, terminal units,
diffusers and where indicated on the drawings. It shall comply with BS 476, the Building
Regulations and to the requirements of the local Building Control.
The flexible connection shall not restrict airflow within the ductwork system, nor should
the joint be used to correct x and y alignment of the ducts either side. Ensure that
flexible ductwork does not become kinked or flattened.
Flexible connections shall be kept as short as possible and shall be supported rigidly to
prevent movement due to air flow. All bends in flexible ducting shall be carefully
formed to prevent puncturing on the inside radii with consequent increase in pressure
drop.
Maximum lengths shall be 1.0 metre and all ducting shall be adequately supported to
prevent oscillation and noise generation.
Steel wire helical reinforcement in flexible ducts is to be carried over the spigots of
grilles and diffusers and connections to these items are to be painted matt black for
the visible depth. Changes of direction shall be of long radius and no kinking or
flattening of ducting will be allowed.
J oints shall be made by means of hose type metal clamps which tighten around the
circumference of the ducting and be finally sealed with 100 mm wide plastic adhesive
tape.
Flexible ducting shall be of the insulated type for all supply air ductwork and of the un-
insulated type for return air ductwork.
Flexible ducting shall be rot, fungus and corrosion resistant and shall generally be
constructed with a woven fibreglass coated with neoprene inner lining, galvanised
steel helical spring and a woven fibre-glass impregnated and coated with neoprene
outer cover retaining a neoprene impregnated reinforcement cord.
On supply air ductwork where the surrounding air dew point temperature is below the
supply air temperature an additional 25 mm of mineral fibre flexible insulation shall be
provided with a suitable vapour barrier.
The dimensions and mechanical requirements of flexible ducts shall comply with BS EN
13180.
The flexible duct manufacturers recommendations for minimum turning radius must be
followed.
Offsets and bends must be minimised, and must not cause regenerated noise or
excessive pressure drops by constricting flow.

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5.7 SAMPLE SPECIFICATION 7
5.7.1 Ductwork installation standards
Supply and install all ductwork as and where shown on the drawings. All shall be in
accordance with HVCA standard DW144 and shall be classed as low velocity.
5.7.2 Flexible ductwork
Supply and install where shown flexible ductwork.
Ductwork shall be compressible flexible and connected via spun cone or square to
round transition to and from rectangular ductwork.
Metal worm drive clamping band to apply uniform pressure around the entire
circumference of the connection to provide an airtight join shall be used.
Thickness shall be not less than 25mm of mineral wool sheathed in polythene or other
approved material.
The duct shall be installed to ensure the inner radius of the bend to be not less than the
diameter of the duct and the duct is not compressed flat or substantially changed in its
cross section.
Flexible ductwork shall be suspended by bands at not less than one metre centres to
prevent sagging and distortion. All ductwork shall be suspended to prevent contact
with the ceiling.
All ductwork shall be non-ignitable, no spread of flame and no smoke development in
accordance with the Building Regulations.
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5.8 SAMPLE SPECIFICATION 8
5.8.1 Ductwork installation standards
Supply and install all ductwork as and where shown on the drawings. All shall be in
accordance with HVCA standard DW144 and shall be classed as low velocity.
5.8.2 Bendable and flexible ducts
Non-rigid ducts shall be of bendable aluminium, flexible metal or flexible fabric
construction.
The maximum length of each non-rigid section shall be 600mm.
Changes in direction shall be formed in long radius. Bends where necessary shall be
two per length with 90 minimum included angle. Minimum throat radius shall be one
diameter.
Adequate support shall be provided to prevent sagging. Kinked or flattened non-rigid
ductwork will be rejected.
Test holes required shall be formed in rigid ductwork adjacent to flexible sections.
Ducting shall comply with air-tightness requirements for rigid ducts in the same system.
Where required, ducts shall be insulated with soft-formed insulant with external finish.
Reinforcement of flexible fabric ducts shall be carried over air terminal and rigid duct
branch spigots and secured with worm-drive clips and sealant as recommended by
the manufacturer.
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5.9 SAMPLE SPECIFICATION 9
5.9.1 Ductwork
The Sub-Contractor shall design, supply and install ductwork systems to the following
standards: Low Pressure Class A All areas
The Sub-Contractor shall produce fully detailed and comprehensive fabrication
drawings, and shall manufacture ductwork in accordance with DW 144, DW 151 and
DW 191,as appropriate.
The ductwork installation shall fully meet the requirements of DW144.
All ductwork shall comply with the requirements of BS 476 part 24
Flexible ductwork shall be avoided and minimised.
5.9.2 Flexible ductwork
Flexible ductwork shall be utilised between ductwork and equipment or grilles/ diffusers
only.
It shall be secured by worm drive clips and sealing compound, such that it is capable
of withstanding the maximum pressure produced in the system under either normal or
testing conditions.
Connection lengths shall not exceed 250mm unless specifically agreed in advance by
the Contract Administrator.
Flexible ductwork shall not be used to form bends and/ or fittings.
Pre-insulated flexible ductwork shall not be installed.
Unless noted otherwise elsewhere in this Specification or on the Contract Drawings, all
flexible ductwork shall be hand-bendable, aluminium spiral wound, crimp locked strip
rated at not less than 300C.
5.9.3 Ductwork cleaning
The ventilation systems shall be designed and installed in full accordance with the
requirements of HVCA document TR19.


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6 CLIENT SPECIFICATIONS AND GUIDES
Major organisations such as the Department of Health and the Ministry of Defence
produce specifications and technical guidance for construction project teams
The aim of this chapter is to examine the client specifications and guidance related to
flexible ductwork.
6.1 HEALTH TECHNICAL MEMORANDUM 03-01: SPECIALISED VENTILATION FOR HEALTHCARE PREMISES
6.1.1 Overview of HTM 03-01
Engineering Health Technical Memoranda (HTMs) give comprehensive advice and
guidance on the design, installation and operation of specialised building and
engineering technology used in the delivery of healthcare
6.1.2 General requirements
The equipment built into the ventilation system and its ductwork should be of a type
that will neither cause nor sustain combustion.
No materials that could sustain biological activity should be used in the construction or
assembly of the system.
6.1.1 Ducting
Ducting is the means by which air is conveyed from the intake to its point of use. It is
usually constructed of galvanised steel and will normally be insulated to reduce noise
and conserve energy.
Ducts can also be formed in concrete, brickwork, stainless steel or plastic, and may be
rigid or flexible.

6.1.2 Standard ductwork fittings
All fittings should conform to current HVCA specification DW144.

6.1.3 Other fittings
Fittings that have abrupt changes in direction and sharp edges should be avoided, as
this will increase turbulence, thus increasing pressure loss and causing noise generation.

6.1.4 Flexible ducting
Flexible ductwork is unsuitable for air distribution in healthcare applications. It should
only be used to make the final connection to a terminal.
Flexible ductwork may be used for final connections to grilles and diffusers, provided it
is constructed to meet the fire precautions recommended in BS 8313. It must not pass
through fire compartment or sub-compartment enclosures, or through cavity barriers.
Flexible ducting will cause a significant frictional loss and may be difficult to clean
without damage. It should never be used in lieu of a bend. Where installed, it should
take the most direct route and be as short as possible, never exceeding 1 m in length.
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6.1.5 Standard of installation
During the installation of the system, the following must be witnessed by either the client
or his representative:
that the plant and installations have been provided and installed in accordance
with the design specification and drawings;
that only approved sealants have been used in the installation;
that all components function correctly;
that the satisfactory sealing of access doors and viewing ports have been carried
out;
that air-pressure tests and air-leakage tests on ventilation ducting have been
carried out in accordance with the methods set out in the HVCAs (1998)
DW/ 143
6.1.6 Cleanliness of installation
During installation it must be established that ductwork is being installed to the
advanced level as defined in the HVCAs (2005) TR/ 19 Guide to good practice:
internal cleanliness of ventilation systems.
This specifically includes ensuring that ductwork sections arrive on site and are stored
with their open ends sealed and that open ends remain sealed during installation to
prevent the ingress of builders dust.
6.1.7 Ventilation system cleaning
Duct-cleaning equipment that uses rotating brushes or a vacuum unit can easily
damage flexible sections of ductwork.
On completion of cleaning, all flexible duct sections should be checked for rips and
tears. The straps that secure them to rigid duct sections and air terminals should also be
checked to ensure that there is no air leakage.
6.2 FIRECODE FIRE SAFETY IN THE NHSHEALTH TECHNICAL MEMORANDUM 05-02: GUIDANCE IN
SUPPORT OF FUNCTIONAL PROVISIONS FOR HEALTHCARE PREMISES
6.2.1 Overview of HTM 05-02
The purpose of this document is to provide guidance on the standards of fire safety
expected in healthcare premises.
It is the starting point for fire precautions in all healthcare buildings, and where
appropriate, directs the user to Approved Document B of the Building Regulations
6.2.2 Design of HVAC systems
The document states that ventilation systems should be designed and installed to
comply with Health Technical Memorandum 03-01 Specialised ventilation for
healthcare premises, and BS 5588-9
19
.

19
Note that BS5588 has been superseded by BS 9999: 2008.
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6.2.3 Ventilation ductwork
The document states that ventilation ductwork should comply with the requirements of
BS 5588-9 and Health Technical Memorandum 03-01 Specialised ventilation for
healthcare premises.
6.3 NATIONAL HEALTH SERVICE (NHS) MODEL ENGINEERING SPECIFICATION C04: MECHANICAL
VENTILATION AND AIR CONDITIONING SYSTEMS
6.3.1 Flexible ductwork
The specification states that flexible ductwork shall be used for final connections to
grilles and diffusers only if shown on the drawings and specified.
It states that flexible ductwork should be installed to a standard of airtightness equal to
that of the ductwork and constructed to meet the fire precautions recommended in BS
5588
20
, which comprise:
Length of flexible ductwork branches not to be longer than 1 meter, or pass
through fire compartment walls, floors or enclosures of sub-compartment walls or
enclosures or cavity barriers
Fire resistance to meet BS 476: Part 6 with indices of performance not more than I
=12 and I =6

6.4 MOD SPECIFICATION 037 AIR CONDITIONING, AIR COOLING AND MECHANICAL VENTILATION
IN BUILDINGS
21

6.4.1 Overview of MOD specification 037
This specification details the design and other requirements for air conditioning, air
cooling and mechanical ventilation for buildings.
6.4.2 Bendable and flexible ducts
Bendable ducts and flexible ducts shall be metal, plastic coated metal or non-metallic
type as indicated.
Where bendable ducts and flexible ducts are specified, the internal diameter of the
duct shall be equal to the external diameter of the rigid duct or equipment spigot.
Flexible ducts in other situations shall only be used with the approval of the PM. The
maximum length of any individual duct shall not exceed 3m.
Non-metallic ducts shall have a liner and a cover of tough tear resistant fabric. The
fabric shall be impregnated and coated with plastics and reinforced with a bonded
galvanised steel spring, stainless steel or other approved wire helix between the liner
and the cover. An outer helix of glass fibre cord, or equal, shall be bonded to ensure
regular convolutions. Flexible ductwork without a liner may be used subject to
compliance with all the other appropriate requirements of this section.
Metallic ducts shall consist of corrugated metal tubing of stainless steel, aluminium,
galvanised steel or aluminium coated steel. The metal surface(s) may be coated with a
plastics material.
The frictional resistance to air flow per unit length of bendable duct or flexible duct shall
not exceed 150% of the frictional resistance per unit length of galvanised steel duct of

20
Note that BS5588 has been superseded by BS 9999: 2008.
21
This document was formerly PSA Standard Specification (M&E) No 100
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similar diameter. The radius ratio R/ D for bends shall be not less than 2, where R is the
centre line radius and D is the diameter of the duct.
The leakage from any section of bendable duct or flexible duct shall meet the
requirements for airtightness applicable to rigid ductwork for the pressure classification
specified.
Unless otherwise indicated, bendable ducts and flexible ducts shall be suitable for an
operating temperature range of -5
o
C to +90
o
C and shall comply with BS 476 as follows:
Part 12 having Class P rating: Part 6 having an index of performance (I) not
exceeding 12, of which not more than 6 should be derived from the initial period of
test; Part 7 be Class 1 rated (surface of very low flame spread)
Test holes shall not be formed in bendable nor flexible ductwork


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7 AMERICAN STANDARDS
A wide variety of American construction industry guidance is produced by organisation
such as The American Society of Heating, Refrigerating and Air Conditioning Engineers
(ASHRAE), The Sheet Metal and Air Conditioning Contractors Association (SMACNA),
The Air Diffusion Council (ADC) and The National Fire Protection Association (NFPA).
These documents are designed for voluntary use and do not impose any regulations.
However, laws and regulations may refer to certain guidance and standards as ways
of complying with specific requirements.
The aim of this chapter is to examine American construction industry guidance related
to flexible ductwork.
7.1 SMACNA HVAC DUCT CONSTRUCTION STANDARDS
7.1.1 General performance requirements for all ducts
This SMACNA document states that in fulfilling the function of moving air, the duct
assembly must satisfy certain fundamental performance criteria:
Dimensional stability (shape deformation and strength).

Containment of the air being conveyed (leakage control)

Vibration (fatigue and appearance).

Noise (generation, transmission, or attenuation).

Exposure (to damage, weather, temperature extremes, flexure cycles, wind,
corrosive atmospheres, biological contamination, flow interruption or reversal,
underground or other encasement conditions, combustion, or other in-service
conditions).

Support (alignment and position retention).

Seismic restraint.

Thermal conductivity (heat gain or loss and condensation control)

7.1.2 Flexible duct installation standards
This SMACNA document provides the following guidance about flexible duct
installation standards:
Unless otherwise stated, the term flexible air duct is used for all ducts classified
by Underwriters Laboratory (UL) as either flexible air ducts or connectors

It is presumed that project specifications define the specific materials, pressure
limits, velocity limits, friction rate, thermal conductivity, acoustical ratings, and
other attributes.

When ducts must conform to NFPA Standard 90A or 90B, flexible ducts must be
tested in accordance with Underwriters Laboratories UL Standard for Safety for
Factory-Made Air Ducts and Connectors, UL-181, and must be installed in
accordance with the conditions of their UL listing.

The minimum length of flexible duct should be used.

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Bends shall be made with not less than one duct diameter centreline radius.
Ducts should extend a few inches beyond the end of a sheet metal connection
before bending. Duct should not be compressed.

If the application guidelines dictated by the flexible duct manufacturer are more
stringent than the specifications in this manual, those of the manufacturer shall
govern.

The SMACNA document provides the following illustrative guidance types of flexible
ducts and accessories.





7.1.3 Specification for joining and attaching flexible duct
This SMACNA document provides the following guidance about joining and attaching
flexible duct:
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Adhesives shall be chemically compatible with materials they contact.

The ends of ducts shall be trimmed square before installation.

Collars to which flexible duct is attached shall be a minimum of 2 in (51 mm) in
length. Sleeves used for joining two sections of flexible duct shall be a minimum
of 4 in (102 mm) in length.

Collars and sleeves shall be inserted into flexible duct a minimum of 1 in. (25 mm)
before fastening.

Metallic flexible duct shall be attached with at least three #8 sheet metals screws
equally spaced around the ducts circumference. Ducts larger than 12 in (305
mm) in diameter shall have at least five #8 sheet metal screws. Screws shall be
located at least in (13 mm) from the duct end.

Non-metallic flexible duct shall be secured to the sleeves or collar with a draw
band. If the duct collar exceeds 12 in (305 mm) in diameter the draw band must
be positioned behind a bead on the metal collar.

Insulation and vapour barriers on factory-fabricated ducts shall be fitted over the
core connection and shall also be secured with a draw band.

The SMACNA document provides the following illustrative guidance about joining and
attaching flexible ducts


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7.1.1 Specification for supporting flexible duct
This SMACNA document provides the following guidance about joining and attaching
flexible duct:
Flexible duct shall be supported at the manufacturers recommended intervals
but at least every 5 ft (1.5 m). Maximum permissible sag is a in per foot (41.7
mm/ m) of spacing between supports. A connection to another duct or to
equipment is considered a support point.

Hanger or saddle material in contact with the flexible duct shall be wide enough
so that it does not reduce the internal diameter of the duct when the supported
section rests on the hanger or saddle material. In no case will the material
contacting the flexible duct be less than 1 in. (25 mm) wide. Narrower hanger
material may be used in conjunction with a sheet metal saddle that meets this
specification. This saddle must cover one-half the circumference of the outside
diameter of the flexible duct and fit neatly around the lower half of the ducts
outer circumference.

Factory-installed suspension systems that are integral to the flexible duct are
acceptable for hanging when the manufactures recommended procedures are
followed.

Hangers shall be adequately attached to the building structure.

To avoid tearing the vapour barrier, do not support the entire weight of the
flexible duct on any one hanger during installation. Avoid contacting the flexible
duct with sharp edges of the hanger material.

Terminal devices connected by flexible duct shall be supported independently of
the flexible duct

The SMACNA document provides the following illustrative guidance about the support
of flexible ducts.
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7.1 SMACNA HVAC SYSTEMS DESIGN
7.1.1 General requirements
This SMACNA document states that practical performance requirements and
construction standards must be established for:
Dimensional stability deformation and deflection
Containment of the air being conveyed
Vibration
Noise generation, transmission and attenuation
Exposure to damage, weather, temperature extremes, flexure cycling, chemical
corrosion and other in service conditions.
Structural support
Emergency conditions including fire and seismic occurrence
Heat gain and loss of the air stream
Dirt and contaminants collecting on duct interior walls and duct liners


7.1.2 Duct system specification checklist
This SMACNA document states that in addition to SMACNA duct construction
standards, specifications and retail drawings should include the following duct system
requirements:
Local code requirements
Duct system static pressure classifications, standard flag designation
Duct material selection
Allowable duct leakage, specify sealing system classification
Insulation requirement, external and liner
Sound control devices and methods
Outlets and inlet performance
Filters
Dampers fire, smoke, and volume control and their location, size and type
Duct mounted apparatus
Duct mounted equipment
Special duct suspension requirements such as seismic bracing, see SMACNA
Seismic Restraint Manual


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7.2 AIR DIFFUSION COUNCIL (ADC) FLEXIBLE DUCT PERFORMANCE AND INSTALLATION STANDARDS
7.2.1 Overview of ADC flexible duct performance and installation standards
This standard is intended for use by the HVAC industry, including manufacturers,
designers, installers, contractors, code bodies, inspectors and end users. It is intended
to be used as a comprehensive document in evaluating, selecting, specifying and
installing flexible duct in heating, air conditioning and ventilating systems.
This standard sets forth specific methods of classifying, testing and marking flexible air
ducts for indoor comfort heating, ventilating and air conditioning applications. This
standard sets forth instructions for properly installing flexible ducts in air distribution
systems.
This standard includes requirements for both insulated and non-insulated flexible ducts.
No attempt is made in this standard to designate a specific material or construction.
7.2.2 Characteristics of flexible ducts
This standard provides the following illustrative guidance about flexible duct
characteristics.


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7.2.3 Fire safety and flexible ductwork
This standard states that Flexible ducts cannot be considered noncombustible,
except metallic non-insulated ducts, but they are generally regarded as limited-
combustible. The UL 181 Safety Standard for Factory-Made Air Ducts and Air
Connectors is used to investigate safety performance.
Is states that four fire tests are used to investigate the flammability and burning
characteristics of flexible duct as follows:
The Surface Burning Characteristics (Flame Spread and Smoke Development) for
both interior and exterior of duct using the 25 ft. [7.6 m] tunnel test method that is
published in UL 723, the American Society of Testing and Materials (ASTM E84),
the National Fire Protection Association (NFPA 255) and the American National
Standards Institute (ANSI).
Ease of ignition/ burning test using a Bunsen burner on both the inner core and
outer jacket of the duct.
Flame penetration test using a specially designed test apparatus to evaluate the
retardation of flame passage from exterior to interior of the duct.
Component flame resistance test conducted on tapes, fabrics, adhesives, and
related components that are exposed directly to the air system.

7.2.4 Flexible ductwork air leakage
This standard states a higher than expected leakage rate can occur at connections if
improper materials or careless work practices are used. To assure a low leakage rate
for flexible duct systems, the following is required:
Reference applicable industry manuals (SMACNA, NAIMA) for making round tap-
ins into and sealing fitting joints to rigid ducts, plenums, etc.
Make flexible duct connections/ splices in accordance with the manufacturers
recommended installation instructions or this Standard.
Seal flexible duct connections with sealing materials listed and labelled to
Standard UL 181B. Mechanically secure connections with approved clamping
material.
Repair any rip, tear or hole in the air barrier using materials listed and labelled to
Standard UL 181B and methods recommended by the manufacturer.
7.2.5 Installation requirements for flexible ducts
The document states that ducts conforming to NFPA 90A or 90B shall meet the
following requirements:
Shall be tested in accordance with Sections 7 to 23 of Underwriters Laboratories
Standard for Factory-Made Air Ducts and Air Connectors, UL 181.
Shall be installed in accordance with the conditions of their listing.
Shall be installed within the limitations of the applicable NFPA 90A or 90B
Standard.
The standard also states that there are specific restrictions and limitations related to the
use of flexible ducts. Some are due to NFPA Standards, model codes and various
state/ local codes. Others are due to end use performance where the product was not
designed for that specific use. Some, but not all inclusive, are as follows:
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Shall not be used for vertical risers serving more than two stories in height.
Shall not be used in systems with entering air temperature higher than 250F
[121C].
Shall be installed in accordance with the conditions of their listing.
When installed in a fire-rated floor/ roof ceiling assembly, ducts shall conform with
the design of the tested fire-resistive assembly.
Shall be interrupted at the immediate area of operation of electric, fossil fuel or
solar energy collection heat sources to meet listed equipment clearances
specified.
Air Connectors (does not apply to Air Ducts) shall not be installed in lengths
greater than 14 ft. [4.3 m] for any given run; shall not pass through any wall,
partition or enclosure of a vertical shaft with a 1 hour or more fire resistive rating;
shall not pass through floors.
Shall not penetrate walls where fire dampers are required.
Shall not be used outdoors unless specifically designed to withstand exposure to
direct sunlight and the weathering elements.
Shall not be used to vent appliances for cooking, heating and clothes drying
unless approved and recommended by the appliance manufacturer.
Shall not be installed in concrete, buried below grade or in contact with the
ground
The standard states that the routing of flexible duct, the number of bends, the degrees
in each bend, and the amount of sag or direction changes (snaking) allowed between
support joints will have serious effects on system performance due to the increased
resistance each introduces
It provides the following illustrative guidance about installation requirements for flexible
ducts.

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7.2.1 Supporting flexible duct
The document provides the following illustrative guidance about the support of flexible ducts.


7.2.2 Connecting, joining and splicing flexible ducts
The document states that all connections, joints and splices shall be made in accordance
with the manufacturers installation instructions. It also states that all tapes, mastics, and non-
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metallic clamps used for field installation of flexible ducts shall be listed and labelled to
Standard UL 181B - Closure Systems for Use With Flexible Air Ducts and Air Connectors.
It provides the following type of illustrative guidance about the connection, joining and
splicing of flexible ducts


7.2.3 Typical flexible duct accessories
The document provides the following type of illustrative guidance about flexible duct
accessories.

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7.1 AIR DIFFUSION COUNCIL (ADC) FLEXIBLE AIR DUCT TEST CODE FD 72-R1
7.1.1 Overview of ADC flexible air duct test code FD 72-R1
This document is a comprehensive document prepared for standard testing and
reporting of flexible air duct and air connector performance. It presents specific
methods of testing flexible air ducts used for indoor comfort heating, ventilating and air
conditioning applications.
This test code establishes the requirements for the determination and presentation of
data on air friction loss, sound, leakage, heat transfer properties, and static pressure
and temperature behaviour for flexible air ducting used as a means of conveying
conditioned air in heating and air conditioning systems.
Requirements are established for the selection and preparation of test specimens, the
test equipment and procedures to be used, the installation of test specimens, the
accumulation test data, and the format for presentation of results.
7.2 NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) 90A STANDARD FOR THE INSTALLATION OF
AIR CONDITIONING AND VENTILATING SYSTEMS
7.2.1 Overview NFPA 90A
This standard covers the construction, installation, operation and maintenance of
systems for air conditioning and ventilating, including filters, ducts and related
equipment, to protect life and property from fire, smoke and gases resulting from fire or
from conditions having manifestations similar to fire.
It prescribes the minimum requirements for safety to life and property from fire, and is
intended to accomplish the following:
Restrict the spread of smoke through air duct systems within a building or into a
building from the outside
Restrict the spread of fire through air duct systems from the area of fire origin
Maintain the fire-resistive integrity of building components affected by the
installation of duct systems
Minimise the ignition sources and combustibility of the elements of air duct
systems
7.2.2 Air ducts
This standard states that Class 0 or Class1 rigid or flexible ducts, tested in accordance
with UL 181 Standard for safety of factory-made air ducts and air connectors, and
installed in conformance within the conditions of listing, shall be permitted to be used
for ducts when air temperature in the ducts does not exceed 121
o
C.
It states that air ducts shall be considered to be in compliance with this requirement
where constructed and installed in accordance with the ASHRAE Handbook HVAC
Systems and Equipment, and with SMACNA HVAC Duct Construction Standards Metal
and flexible and SMACNA HVAC AIR Duct Leakage Test Manual.
7.2.3 Air connectors
The document states that air connectors are limited-use flexible air ducts that shall not
be required to conform to the requirements for air ducts, providing they meet the
following requirements:
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Air connectors shall conform to the requirements for Class 0 or Class 1 connectors
when tested in accordance with UL 181 Standard for safety of factory-made air
ducts and air connectors
22

Class 0 or Class 1 air connectors shall not be used for ducts containing air at
temperatures in excess of 121
o
C
Air connector runs shall not exceed 4.27m
Air connectors shall not pass through any wall, partition or enclosure of a vertical
shaft that is required to have a fire resistance rating of one hour or more
Air connectors shall not pass through floors
7.3 ASHRAE HANDBOOK HVAC SYSTEMS AND EQUIPMENT
7.3.1 Overview ASHRAE Handbook HVAC systems and equipment
This document provides guidance about the design and installation of heating,
ventilation and air conditioning systems covers the construction, installation, operation
and maintenance of systems
7.3.2 Residential duct construction
The document states that supply ducts may be steel, aluminium or materials with a UL
Standard 181 listing. It also states that ducts should be installed in accordance with
SMACNA HVAC Duct Construction Standards Metal and flexible.
It states that for return ducts, NFPA Standard 90B should be consulted
7.3.3 Commercial duct construction
The document states many building code agencies use NFPA standard 90A, which
invokes UL standard 181. Ducts are classified as:
Class 0: Air duct materials having a fire hazard classification of zero (flame spread
and smoke developed)
Class 1: Air duct materials having a flame spread rating of not over 25 without
evidence of continued progressive combustion and a smoke development
rating of not over 50
7.3.4 Flexible ducts
The document refers to SMACNA HVAC Duct Construction Standards Metal and
flexible for guidance about installation standards and a specification for joining,
attaching and supporting flexible duct. It also refers to the Air Diffusion Council (ADC)
flexible duct performance and installation standard.
It states that the routing, the number and sharpness of bends, and the amount of sag
allowed between support joints significantly affect system performance because of the
increased each introduces. It proposes that the minimum length of flexible duct
needed to make connections should be used.

22
Air duct materials are classified in UL181 as follows:
Class 0: Air duct materials having a fire hazard classification of zero (flame spread and smoke developed)
Class 1: Air duct materials having a flame spread rating of not over 25 without evidence of continued
progressive combustion and a smoke development rating of not over 50
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7.4 NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) 90B WARM AIR HEATING AND AIR
CONDITIONING SYSTEMS
7.4.1 Overview NFPA 90B
This standard prescribes minimum requirements for safety to life and property. It applies
to all systems for the movement of environmental air in structures that:
Serve one or two-family dwellings
Serve spaces not exceeding 708m
3
in volume in any occupancy
7.4.2 Duct materials
This standard states that supply ducts shall be:
Class 0 or Class 1 rigid or flexible ducts when tested in accordance with UL 181
Standard for safety of factory-made air ducts and air connectors
23

or
Sheet metal having prescribed nominal thicknesses
7.4.3 Air connectors
The document states that air connectors are limited-use flexible air ducts that shall not
be required to conform to the requirements for air ducts, providing they meet the
following requirements:
Air connectors shall conform to the requirements for Class 0 or Class 1 connectors
when tested in accordance with UL 181 Standard for safety of factory-made air
ducts and air connectors
Class 0 or Class 1 air connectors shall not be used for ducts containing air at
temperatures in excess of 121
o
C
Air connector runs shall not exceed 4.3m
Air connectors shall not pass through any wall, partition or enclosure of a vertical
shaft that is required to have a fire resistance rating of one hour or more
Air connectors shall not pass through floors
7.5 UNDERWRITERS LABORATORY (UL) 181 FACTORY MADE AIR DUCTS AND AIR CONNECTORS
7.5.1 Overview UL181
This document applies to materials for the fabrication of air duct and air connector
systems for use in accordance with National Fire Protection Association (NFPA)
standards 90A and 90B.
The air ducts and air connectors covered by the documents requirements include
preformed lengths of flexible or rigid ducts and pre-formed flexible air connectors.


23
Air duct materials are classified in UL181 as follows:
Class 0: Air duct materials having a fire hazard classification of zero (flame spread and smoke developed)
Class 1: Air duct materials having a flame spread rating of not over 25 without evidence of continued
progressive combustion and a smoke development rating of not over 50
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7.5.2 Duct performance requirements
This document states that air ducts and air connectors should be classified as follows:
Class 0: Air duct materials having a fire hazard classification of zero (flame spread
and smoke developed)
Class 1: Air duct materials having a flame spread rating of not over 25 without
evidence of continued progressive combustion and a smoke development
rating of not over 50

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8 MANUFACTURERS TECHNICAL LITERATURE
The content of this chapter has been compiled by referencing technical product
information produced by the following companies;
LIndab
Senior Hargreaves
Hotchkiss Air Supply
National Ventilation
8.1 APPROVALS FOR DIFFERENT PRODUCTS
The following table summarises the approvals that are stated in the product literature
for flexible ductwork products supplied by different companies
Product description Description of product approval
Company A
Product 1: A pure aluminium duct of laminated construction BS 476: parts, 6, 7 and 20
Product 2: PVC coated glass fibre with a spiral wire
Class E according to BS EN 13501-1. French Class M1. BS
EN 13180
Product 3: A semi-flexible aluminium duct Not flammable in accordance with DIN 4102 class A1
Product 4: A semi-flexible galvanized steel duct Not flammable in accordance with DIN 4102 class A1
Product 5: An aluminium/ polyester duct with spiral wire
BS 476: parts, 5, 6, 7 and 20. BS EN 13180. French Class
M1

Company B
Product 1: An aluminium/ polyester duct with spiral wire
BS 476: parts, 6, 7 and 20. Class B-s1, d0 according to BS
EN 13501-1. French Class M1. DIN 4102 class B2. BS EN
13180
Product 2: An aluminium/ polyester/copolymer duct with
spiral wire
BS 476: parts, 6, 7 and 20. DIN 4102 class B2. BS EN 13180
Product 3: An aluminium inner duct, insulated with glass
wool and with a glass fibre strengthened outer jacket
BS 476: parts, 6, 7 and 20. Class B-s1, d0 according to BS
EN 13501-1. French Class M1. DIN 4102 class B2. BS EN
13180
Product 4: A perforated aluminium laminate inner duct,
insulated with glass wool and with a glass fibre strengthened
outer jacket
BS 476: parts, 6, 7 and 20. DIN 4102 class B2. French Class
M1. BS EN 13180
Product 5: A corrugated aluminium duct
BS 476: parts, 6, 7 and 20. Class A1 according to BS EN
13501-1. DIN 4102 class A1. French Class M0. BS EN 13180

Company C
Product 1: An aluminium/ polyester/fibreglass acoustic duct BS 476: parts, 6, 7 and 20.
Product 2: A corrugated aluminium duct BS 476: parts, 6, 7 and 8.

Company D
Product 1: A semi-rigid aluminium duct BS 476: parts, 6, 7 and 6.
Product 2: An aluminium/ polyester/fibreglass acoustic duct BS 476: parts, 6, 7 and 20.
Product 3: An aluminium/ polyester duct with spiral wire BS 476: parts, 6, 7 and 20.
Product 4: An aluminium/ polyester duct with spiral wire and
fibreglass insulation