1

DW/144
Specification for
Sheet Metal Ductwork
Low, medium and high
pressure/velocity air systems

1998

Copyright © 1998 by the

Heating and Ventilating
Contractors' Association

All rights reserved

ISBN 0-903783-27-4

Further copies of this publication are available from:

Publications Unit
Heating and Ventilating Contractors Association
Old Mansion House Eamont Bridge
Penrith Cumbria CA10 2BX
Tel: 01768 860405 Fax: 01768 860401
e-mail: [email protected]

2
3
 THE INDUSTRY
STANDARD

Ken Parslow
Chairman
Executive Committee
Ductwork Group
1996-98

For more than a decade-and-a-half, the DW/142 Specification for Sheet Metal Ductwork
published by the Heating and Ventilating Contractors' Association has gained national
and international recognition as the industry standard against which the quality of
ductwork manufacture and installation can be judged.
In recent years, however, it has become increasingly evident to the members of the
HVCA Ductwork Group that the developments in technology and working practices
which have taken place since the drafting of DW/142 have rendered obsolete significant
parts of the document.
It was an acknowledgement of this state of affairs which led the Technical Sub-
Committee of the Ductwork Group, ably chaired by Edgar Poppleton, to undertake the
task of producing a radically revised specification which would promote best practice
and quality standards well into the next Millennium.
This new publication - designated DW/144 - represents the direct result of that
initiative.
The new specification recognises the computer age - with special reference to
CAD/CAM procedures and techniques - and the international performance standards
established by the Committee for European Normalisation (CEN), as well as the need to
update and consolidate much of the information contained in the original DW/142
publication and its Addendum A companion volume.
During the drafting process, the Technical Sub-Committee has consulted widely with
individuals and organisations throughout the building services and construction sectors
in order to ensure that the new specification fully reflected the current the "state-of-the-
art" in terms both of technical expertise and industry best practice.
I firmly believe that this process has resulted in a publication which clearly
demonstrates the high level of professionalism which exists within the ductwork
community - and I take this opportunity of thanking all those who have contributed to
its production.
In particular, my thanks go to Edgar Poppleton and his colleagues on the Technical
Sub-Committee, to Keith Elphick for the provision of invaluable technical consultancy,
and to Ductwork Group secretary Gareth Keller for overseeing the project as a whole.

3
4
 MAINTAINING QUALITY
Like most industries, the ductwork sector must
be prepared continually to innovate in order to Class A, B and C air leakage characteristics,
survive and prosper. mandatory testing Class C only;
A key element in that innovation process is • updated appendices on galvanising after
the timely review and updating of quality manufacture, stainless steel, pre-coated steel,
standards to ensure that they continue to offer aluminium, Eurovent and galvanised material,
realistic benchmarks to which all professional plus a bibliography;
individuals and organisations can perform. • transport, handling, storage and interface with
The development of this new Specification for DW/TM2 Guide to Good Practice – Internal
Sheet Metal Ductwork - designated DW/144 - has Cleanliness of New Ductwork Installations;
been carried out with that objective in mind. • an overview of fire-rated ductwork;
In the 16 years since the publication of its • a new appendix on inspection, servicing and
predecessor, DW/142 - and in the ten years since cleaning access openings (the default inclusion
the supplementary volume Addendum A appeared - of Level 1 should be noted);
many technical advances, changes in working • a new section on standard component drawings
practices and regulatory introductions and - incorporating a framework of nomenclature,
amendments have taken place. and a description of drawing symbols,
The common performance standards for duct- abbreviations and rules - which is intended to
work being developed by the Committee for reduce ambiguity and promote common
European Normalisation (CEN), for example, understanding;
had to be taken fully into account during the • a rewritten description of all forms of dampers,
drafting process. Similarly, notice had to be for which I am indebted to Bill Clark and John
given to the provisions of the Control of Mawdsley of the HEVAC Association.
Substances Hazardous to Health (COSHH) and I take this opportunity to acknowledge the per-
Construction (Design and Management) mission granted by the Sheet Metal and Air
Regulations, neither of which had been issued Conditioning Contractors' National Association
when DW/142 was published. (SMACNA) of the USA for the use of its tie rod
It is not possible - nor, I think, desirable - to specification (designer approval required).
include in this foreword an exhaustive catalogue And I also include a plea on behalf of ductwork
of the points of difference between this constructors to be allowed to make the final choice
specification and its predecessor. These will of components and techniques within the parame-
clearly emerge from a detailed reading of the ters set by the designer, and allowed within this
text. specification to satisfy performance characteristics.
I should, however, like to take the It will, of course, be clear to anyone who has
opportunity to highlight a few topics which I ever taken on such a task that the production of
believe to be of particular significance. They are: this specification has involved a colossal input in
• the omission of high-pressure Class D (in terms of industry consultation and from a wide
order to conform to European practice); variety of individuals, a number of whom I should
• the highlighting of information to be like to identify for special mention.
provided by the designer; They are: former Technical Sub-Committee
• the end-sealing of ducts and explosion risks; members Keith Waldron and the late Keith
• the removal of standard sizes of rectangular Angood; current members Chris Collins, Stuart
ducts; Howard, Brian James and - last but by no means
• the omission of cleated joints; least - Jim Murray; technical consultant Keith
• the acceptance of proprietary flanges Elphick; and Ductwork Group secretary Gareth
certificated to DW/TM I no longer illustrated Keller.
in detail; Finally, may I remind readers of the crucial
importance of ensuring that all ductwork is manu-
• the consolidation into the document of
factured and installed in a manner which is safe,
coverage of hangers and supports;
efficient, effective and free of risk.
• the addition of a note on linings, along with
The publication of DW/144 is intended to assist
their cleaning considerations;
significantly in the achievement of this objective.
• the consolidated graphical representation of

5
 Acknowledgements

The HVCA wishes to record its sincere thanks to the following

members - past and present - of the Technical Sub-Committee
of the Ductwork Group, who contributed their time, knowledge
and experience to the production of this document

Edgar Poppleton (chairman)

Keith Angood
Chris Collins
Stuart Howard
Brian James
Jim Murray
Keith Waldron

Technical Consultant:
Keith Elphick

Ductwork Group Secretary:

Gareth Keller

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7
 Contents

Page 16.4 Fastenings 35

16.5 Stiffening 35
Notes 10 17. Construction (Straight Seamed) 35
18. Fittings 35
Part One - Technical Information to be provided 18.1 General Construction Requirements 35
by the designer 18.2 Standardisation of fittings 35
1. Introduction 11
2. Standards 11 Part Six - Hangers and Supports
3. Components 11 19. General 43
4. Particular Requirements 11
Part Seven - General
Part Two - Standards 20. Access/Inspection Openings 47
5. Application 13 21. Regulating Dampers 48
6. Ductwork Classification and Air Leakage 13 22. Fire Dampers 49
7. Materials 13 23. Smoke Dampers 50
8. Ductwork Construction and Joint Sealing 14 24. Combination Smoke and Fire Dampers 51
25. Flexible Ducts 51
Part Three - Rectangular Ducts 26. Flexible Joint/Connections 52
9. Rectangular Duct Sizes 15 27. Protective Finishes 53
10. Construction 15 28. Connections to Building Openings 53
10.1 General 15 29. Internal Duct Linings 54
10.2 Steel Thicknesses 15 30. Thermal Insulation 54
10.3 Longitudinal Seams 15 31. Kitchen Ventilation 54
10.4 Cross Joints 15 32. Fire Rated Ductwork 54
10.5 Stiffeners 15 33. Standard Component Drawings
10.6 Ductwork Galvanised After and Abbreviations 54
Manufacture 16
10.7 Fastenings 16 Part Eight - Appendices
11. Fittings 16 Appendix A. Air Leakage from
11.1 Standardisation of Fittings 16 Ductwork 75
11.2 Stiffeners 16 Appendix B. Identification of
11.3 Splitters 16 Ductwork 80
11.4 Turning Vanes 16 Appendix C. Guidance Notes for the
11.5 Branches 16 Transport, Handling and
11.6 Change Shapes 16 Storage of Ductwork 82
11.7 Expansions and Contractions 17 Appendix D. Ductwork Systems and
11.8 Sealant 17 Fire Hazards 83
Appendix E. Hot Dip Galvanizing after
Part Four - Circular Ducts Manufacture 85
12. Standard Sizes 27 Appendix F. Stainless Steel for Ductwork 86
13. Construction 27 Appendix G. Pre-Coated Steel 89
13.1 Longitudinal Seams 27 Appendix H. Aluminium Ductwork 90
13.2 Cross Joints 27 Appendix J. Eurovent 91
13.3 Fastenings 27 Appendix K. Summary of BS.EN10142:
14. Fittings 29 1991 Continuously Hot-Dip
14.1 Standardisation of Fittings 29 Zinc Coated Mild Steel Strip
14.2 Nominal Diameters 29 and Sheet for Cold Forming 92
14.3 Sheet Thickness 29 Appendix L. `Design Notes for Ductwork'
14.4 Sealing of Joints 29 (CIBSE Technical
Memorandum No. 8) 93
Part Five - Flat Oval Ducts Appendix M. Guidance Notes For Inspection,
15. Standard Sizes and Sheet Thicknesses 35 Servicing and Cleaning Access
16. Construction (Spirally wound) 35 Openings 94
16.1 General 35 Appendix N. Bibliography 95
16.2 Longitudinal Seams 35 Appendix P. Conversion Tables 97
16.3 Cross Joints 35

8
 List of Tables 13-17 Socket and spigot cross joints 22
Table Page 18-24 Stiffeners 23
25-28 Tie rod assembly 24
Part Two - Standards 29 Hard and Easy bends 25
1. Ductwork Classification and Air 30 Turning Vanes 25
Leakage Limits 13
Part Four - Circular Ducts
Part Three - Rectangular Ducts 31 Spiral and straight seams 29
2. Constructional Requirements 32-38 Cross joints spirally wound ducts 30-31
Low Pressure up to 500Pa 18 39-45 Cross joints straight seamed ducts 32-33
3. Constructional Requirements
Medium Pressure up to 1000Pa 19 Part Five - Flat Oval Ducts
4. Constructional Requirements 53-58 Cross joints spirally wound ducts 39-40
High Pressure up to 2000Pa 19 59-63 Cross joints straight seamed ducts 41-42
5. Fastening Centres 24
Part Six - Hangers and Supports
Part Four - Circular Ducts 64-75 Horizontal ducts
6. Standard Sizes 27 bearers and hangers 45-46
7. Spirally-Wound Ducts 28 76-77 Vertical ducts supports 46
8. Straight-Seamed Ducts 28
9. Permitted fastenings and maximum Part Seven - General
spacings 29 78-79 Fire barrier/Fire damper expansion 50
10. Fittings Sheet Thicknesses 29 80 Flexible joint connections 52
81-124 Standard component drawings -
Part Five - Flat Oval Ducts Rectangular 55-61
11. Standard sizes and sheet thicknesses 36 125-152 Standard component drawings -
12. Stiffening requirements Circular 62-67
low and medium pressures 37 153-167 Standard component drawings -
13. Stiffening requirements Flat Oval 68-70
high pressure 38 168-177 Plant/equipment/miscellaneous 71
14. Permitted fastenings and maximum
spacings 40 Part Eight - Appendices
178 Permitted leakage at various
Part Six - Hangers and Supports pressures 78
15. Supports for horizontal ducts - rectangular, 179 Example of duct identification symbol 81
flat oval and circular 44

Part Seven - General

16. Standard Abbreviations 72-73

Part Eight - Appendices

17. Air Leakage Rates 76
18. Recommended duct identification colours 80
19. Examples of further identification symbols 81
20. Ductwork galvanized after manufacture -
rectangular 85
21. Compositions of the commonly used
Stainless Steel grades 88
22. Rectangular aluminium ducts -
low pressure constructional requirements 90
23. Circular aluminium ducts -
low pressure constructional requirements 91
24. Zinc coating mass (weight) 93
25. Access requirements for inspection,
servicing and cleaning 94

List of Illustrations
Figs Pages

Part Three - Rectangular Ducts

1-8 Longitudinal Seams 20
9 Illustrations of panel stiffening 20
10-12 Flanged cross joints 21

9
Notes
In this document:
(1) Even where a ductwork job specification calls for the system to be
wholly in accordance with DW/144, it will still be necessary for the
designer, in addition to providing drawings showing details and
dimensions of the ductwork, to identify specific requirements, par-
ticular to his or her design.
The technical information to be provided by the designer is therefore
set out in detail on page 11.
(2) All dimensions quoted in this specification refer to the nominal sizes,
which are subject to the normal relevant commercial and published
tolerances.
(3) Manufacturing techniques are continually subject to change and
improvements and in respect of proprietary methods and devices this
specification does not preclude their use if they can be demonstrated
to the designer to be equally satisfactory. Where there is divergence
between the requirements of DW/144 and the manufacturer's
recommendations for proprietary methods and devices, the latter shall
take precedence.
(4) The expressions `low-pressure,' 'medium-pressure' and 'highpressure'
relate to the pressure/velocity classes set out in Table 1.
(5) `Mean air velocity' means the design volume flow rate related to the
cross-sectional area.
(6) Reference to the air distribution system pressure relate to the static
pressure of the relevant part of the ductwork system and not to the
fan static pressure.
(7) The symbol for litres is ‘L’: 1000 litres per second is equivalent to 1
cubic metre per second.
(8) The pascal (Pa) is the internationally agreed unit of pressure. The
relationship of the pascal to other units of pressure is: 500 pascals =
500 Newtons per square metre = 5 millibars = approximately 2
inches water gauge.

10
 Part One - Technical information to be
provided by the designer to the ductwork contractor

1 INTRODUCTION 4.2 Protective finishes (Section 27)

The selection of constructional methods is the decision Details and specification of any protective finishes.
of the Manufacturer to conform with the performance
4.3 Fire rated and smoke extract ductwork
requirements of the specified ductwork classification.
(Appendix D)
Sections 2-4 below define the information that is to be
The extent and limits of protection for any fire
provided by the Designer.
resisting ductwork.
2 STANDARDS
4.4 Internal thermal/acoustic lining
2.1 Pressure classification (Table 1)
(Section 29)
2.2 Leakage classification (Table 1)
The extent of any ductwork requiring internal
2.3 Positive and Negative pressures (Table 1)
acoustic/thermal lining is to be clearly identified. A
2.4 Materials (Section 7)
detailed specification of materials and method of
2.5 Any special system requirements
application is required. The practical aspects of
3 COMPONENTS cleaning or maintenance must be addressed by the
3.1 Inspection/servicing access openings (Section designer before deciding to internally line ductwork.
20 and Appendix M)
4.5 External thermal/acoustic insulation
Number and location of all panels and covers for
(Section 30)
inspection and/or servicing access other than those
The extent and thickness of insulation to be provided
covered in Section 20 and summarised as Level 1
by others should be stated.
requirements in table 25 of Appendix M. Number
and location of test holes, instrument connections 4.6 Special supports (Section 19)
and hinged doors as defined in Section 20. Details of any spanning steel or special support
requirements not covered by Section 19
3.2 Cleaning access
(Section 20.8 and Appendix M) 4.7 Attachment to building structure (Section 28)
Designers shall stipulate their requirements for Specific requirements for the junction of ductwork
periodic internal cleaning of ductwork and for the and associated components to openings should be
consequent need for adequate access for specialist detailed and specified and the limits of responsibility
cleaning equipment. defined.
3.3 Regulating dampers (Section 21) Specification, The provision of penetrations and associated
location and mode of operation of all regulating framings are outside the scope of this specification.
dampers. 4.8 Air terminal units
3.4 Fire dampers (Section 22) Detail and specifications of all Air Terminal Units. It
Specification and location of all fire dampers to is expected that all Air Terminal Units and their
meet the requirements of the Authority directly Plenums (See Figures 120 to 124) will be supported
concerned with fire protection. by the Ceiling Grids unless the designer indicates an
independent method of support.
3.5 Smoke dampers (Section 23)/Combination
smoke and fire dampers (Section 24) 4.9 Ductwork layout drawings
Specification and location of all smoke dampers to Details of any special requirements relating to CAD,
meet the requirements of the Authority directly scales, etc. It is common practice and cost effective
concerned with fire protection. for ductwork manufacturers to utilise their approved
ductwork layout drawings as a basis of their
3.6 Flexible ducts (Section 25) manufacturing/installation information by adding the
Specification and location of any flexible ductwork. necessary details to the same drawing. Scales of 1:50
3.7 Flexible joint connections (Section 26) or smaller may preclude this practice, therefore,
Specification and location of any flexible con- larger scales might be more appropriate. The final
nections eg. plant or building expansion joints. choice of manufacturing/installation scales shall be
left to the ductwork contractor.
4. PARTICULAR REQUIREMENTS
4.1 Air leakage testing (Section 6 and Appendix A) 4.10 Other requirements
The extent of any air leakage testing. While it shall Details of any requirements for the ductwork not in
be mandatory for high-pressure ductwork (as accordance with the provisions of this specification,
defined in this specification) to be tested for air including any modified construction required to
leakage in accordance with the procedure set out in conform with any requirements concerning external
DW/143, A practical guide to Ductwork Leakage ductwork (See 5.3) or to meet the regulations of a
Testing, no such testing of low- or medium-pressure local authority or other controlling body.
ductwork is required.

11
4.11 Reference to the designer
In consideration of the foregoing, reference is also
made to the designer in the following clauses:

Clause Page
5.3 13
7.4, 7.5, 7.6 14
10.5.2 16
11.1 16
14.1 29
16.3.1 35
19.1, 19.4 43
19.6, 19.7 44
20.1, 20.1.1.1, 20.6, 20.8 47
20.9 48
21.1, 21.3.1 48
21.3.4 49
22.3, 22.7 50
24.3 51
25.1 51
26.1 52
27,27.3.4 53
29.1, 29.4, 30.2, 30.3, 33.2 54
Fig. 176 71
Appendix A 75-79
Appendix B 80,81
Appendix C 82
Appendix D 83,84
Appendix E 85
Appendix F 86-88
Appendix L 93
Appendix M 94

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 Part Two - Standards

5 APPLICATION 6.3 Leakage at various pressures; and other

relationships
5.1 This specification sets out minimum requirements
Applying the limits specified in Table 1, Appendix A
for the manufacture and installation of ductwork for
(Table 17) sets out the permitted leakage at each of a
commercial and industrial air distribution systems,
series of pressures up to a maximum for each class.
made from any of the materials listed in Section 7 and
Included in that appendix is a graphical presentation
being within the limits of size and/or metal
of the pressure/leakage relationship.
thicknesses specified in the relevant tables. Normal
operating temperatures are assumed within the DW/143 A practical guide to Ductwork Leakage
pressure/velocity limits and the limits of air leakage Testing, also gives details of the basis for the leakage
for the various pressure classes prescribed in Table 1. limits specified in Table 1.
5.2 This specification is not intended to apply to
6.4 Air leakage testing
ductwork handling air which is polluted or is other-
Air leakage testing of low and medium pressure
wise exceptional in respect of temperature or
ductwork is not mandatory under this specification.
humidity (including saturated air); nor is it suitable
for ductwork exposed to a hostile environment, e.g. Air leakage testing of high pressure ductwork is
contaminated air, off-shore oil rigs, etc. The design, mandatory under the specification and for details of
construction, installation, supports and finishes in testing procedure refer to DW/143 A practical guide
such cases should be given special consideration in to Ductwork Leakage Testing.
relation to the circumstances of each case.
5.3 This specification is not suitable for ductwork
7 MATERIALS
exposed to external atmosphere and the Designer will
need to give specific details of any special 7.1 Application
finishes/construction (See Section 27). This specification applies to ductwork constructed
from materials as defined below, or equal. Minimum
steel thickness is to be taken as a nominal thickness
6 DUCTWORK CLASSIFICATION AND AIR within the tolerances to BS.EN10143:1993. (See
LEAKAGE Appendix K)
6.1 Classification and air leakage limits Ductwork
classification and air leakage limits are set out in 7.2 Zinc-coated steel
Table 1. Ductwork will normally be constructed from hot-
dip galvanized steel to BS.EN10142:1991, Grade
6.2 Compatibility with CEN DX51 D+Z, coating type Z275.
The leakage factors used in Table 1 for Classes A, B
and C are the same as those for the classes similarly
designated in the CEN Document Pr EN 12237/Pr EN
1507.

13
7.3 Mild steel 8.2.2 Liquid and mastic sealants
Where mild steel is specified, it shall be cold-reduced These are typically applied to a longitudinal seam
steel to BS.EN10130:1991, Grade FEP 01A. formed between two sheets of metal, a socket and
spigot, cleated or flanged cross joints. Particular
7.4 Stainless steel care is needed when sealing of "corner pieces" on
Where stainless steel is specified. it will be the the proprietary 'slide-on' type flange and
responsibility of the designer to indicate the type most reference should be made to the manufacturer's
suitable for the conditions to which the ductwork will assembly and sealing instructions.
be exposed. In doing so, it is recommended that the
factors set out in Appendix F should be taken into 8.2.3 Gaskets
account. In this connection, reference must be made to These can be of various materials in the form of a
BS 1449: Part 2, which includes stainless steel. preformed roll, sheet or strip, applied between
opposing faces of flanged cross joints. In the case
7.5 Pre-coated steel of proprietary 'slide-on' type flanges, it is
Pre-coated steel may be specified for aesthetic or advisable to use the gasket strip recommended by
other reasons. The designer must then consider the the manufacturer.
availability of suitable materials and the restriction on
fabrication methods. Guidance notes are available in Factory-fitted proprietary synthetic rubber '0'ring
Appendix G. type gaskets are also acceptable for socket and
spigot joints on circular duct systems.
7.6 Aluminium
Where aluminium is specified, it will be the 8.2.4 Tapes
responsibility of the designer to define the type most 8.2.4.1 The application of tapes - Best suited,
suitable for the conditions to which the ductwork will but not limited, to cross joints on circular or flat
be exposed. Reference must be made to BS.EN485, oval ductwork. Where chemical reaction tape,
BS.EN515 and BS.EN573 for aluminium sheet and heat shrinkable tape or other approved material
BS.EN755 Parts 3-6 for aluminium section. is used on flat oval ductwork care should be
(Constructional requirements for ductwork made from taken to maintain close contact between the
aluminium sheet and general notes on the material are material and the flat sides of the duct until the
set out in Appendix H.) joint is completed.
8.2.4.2 Chemical reaction tape - An
8 DUCTWORK CONSTRUCTION AND JOINT impregnated woven fibre tape and a resin type
SEALING activator/adhesive. On application of the
8.1 Ductwork construction activator/adhesive the tape becomes pliable and
The selection of longitudinal, cross joint and stiffener can then be applied to any surface shape. The
types within the criteria laid down in the tables should liquid reacts with the tape, causing the 2part
be the responsibility of the manufacturer. system to `set'.
8.2 Joint sealing and sealants 8.2.4.3 Heat shrinkable band/tape - A ther-
8.2.1 General moplastic material, coated on the inside with
The integrity of the ductwork depends on the hot metal adhesive. The band (or an appropriate
successful application of the correct sealant, length of tape) is cut from the roll and wrapped
gaskets or tape. The materials used should be around the joint. When heated the tape shrinks
suitable for the purpose intended and satisfy the tightly around the joint thus providing a seal.
specified pressure classification.
8.2.4.4 Self adhesive tape - Manufactured
Illustrations indicating sealant locations will be
from various materials including cloth based,
found in the following sections dealing with the
PVC and aluminium foil. Typically applied
construction of rectangular, circular and flat oval
externally to socket and spigot cross joints.
duct sections.
However, it is difficult to provide the dry, dust
IN ALL CASES, SEALANT MATERIALS and grease free surface that is required for a
MUST BE APPLIED STRICTLY IN successful application and this method is
ACCORDANCE WITH THE MANU- therefore not recommended as a primary source
FACTURER'S INSTRUCTIONS AND COSHH of sealant.
ASSESSMENT. NB! Risk of explosions
Where ductwork is blanked off prior to leakage
testing or to prevent the ingress of contamination,
care should be taken to ensure that all joint sealing
solvent vapours are dispersed from the ductwork
systems.

14
 Part Three - Rectangular Ducts

9 RECTANGULAR DUCT SIZES duct size longer side and maximum spacing, are
This specification covers duct sizes up to a maximum given in Tables 2 to 4. Other limits on use are
longer side of 3,000 mm. Duct sizes with an aspect given with the individual drawings.
ratio greater than 4:1 are not recommended. Although Note: Proprietary products used in the construc-
they offer no problems of construction, they increase tion of cross joints should be approved by an
frictional resistance and the possibility of noise. independent test house following tests defined in
DW/TM1 "Acceptance scheme for new products
- Rectangular cross joint classification." Figures
10 CONSTRUCTION Nos 10 and 13 to 17 illustrate non proprietary
10.1 General joints that have an established rating.
The minimum constructional requirements for
10.4.2 Sealant in cross joints
rectangular ductwork depend upon the pressure
Sealant shall be used between sheet and section
classification as set out in Tables 2 to 4. The ductwork
in all cross joint assemblies. (see section 8)
construction and joint sealing standards are set out in
section 8. With socket and spigot joints made on site,
sealant shall be applied during or after assembly
10.2 Steel thicknesses
of the joint. It is permissible to use chemical-
Minimum steel thicknesses related to duct longer side
reaction tape or heat-shrink strip as alternative
to pressure classification are given in Tables 2 to 4.
methods of sealing, provided that close contact is
10.3 Longitudinal Seams maintained over the whole perimeter of the joint
Longitudinal seams are illustrated in Figs. 1 to 8. The until the joint is completed.
limits of use, if any, are given with the individual
With all flanged joints, the sealant between
illustrations.
sheet and section should preferably be incorpo-
10.3.1 Sealing of Longitudinal Seams Sealant rated during construction at works, but site
will be applied using one of the following applied sealant is acceptable. The joint between
methods: sections of ductwork is then made, using
a) As an edge sealant on the external seam surface. approved type of sealant or gasket. With
b) As an edge sealant on the internal seam surface. proprietary flanging systems particular attention
c) Internal to the joint seam itself. should be paid to the sealing of corner pieces and
flanges, reference should be made to the
The most appropriate method will be determined
manufacturer's assembly and sealing instructions.
by the manufacturer relative to their product and
will be associated with either traditional 10.4.3 Adjustabletslip joints
fabrication/assembly methods, factory or site In order to accommodate manufacturing/building
based, and/or proprietary methods. The ultimate tolerances, site modifications etc, it is accepted
proof of a seal is that the ductwork system meets practice to use an adjustable joint as illustrated in
the pressure classification specified. For details of Fig. 14.
sealant see section 8.
10.5 Stiffeners
10.3.2 Welded seams 10.5.1 External stiffeners
A welded seam is acceptable without sealant, The sections (including proprietary flanges)
provided that the welding is continuous. suitable for use as single stiffeners have been
given a rating from S1 to S6 in terms of duct size
10.4 Cross joints
longer side and maximum spacing. The ratings
10.4.1 Cross joint ratings are specified with the illustrations of the
For cross joints, a system of rating has been used stiffeners, Figs. 18 to 23, and the limits of use are
to define the limits of use. The rating for each given in Tables 2 to 4. The stiffeners for socket
cross joint is given with its drawing, and the limits and spigot joints covered in Figs. 15, 16 and 17
applying to that rating, in terms of are also applicable to stiffeners in general.

15
 10.5.2 Internal stiffeners a minimum.
Tie bars connecting the flanges of cross joints
Areas where the galvanizing has been damaged or
illustrated in Figs 11 and 12, are the only form of
destroyed by welding or brazing shall be suitably
internal stiffening for rectangular ductwork
prepared and painted internally and externally with
recognised by this specification and reference should
zinc-rich or aluminium paint as defined in Section
be made to HVCA publication DW/TM 1.
27.3.2.
Alternative methods for the attachment of tie bars
are shown in Figs. 25 to 28. 11 FITTINGS
The use of tie bars or other forms of internal 11.1 Standardisation of fittings
stiffening or bracing shall be acceptable if proved to The terminology and descriptions of rectangular duct
the designer to be equally satisfactory. fittings as set out in Section 33 are recommended for
adoption as standard practice to provide common
SMACNA (Sheet Metal and Air Conditioning terms of reference for designers, quantity surveyors
Contractors' National Association), which is the and ductwork contractors, and of those using
American equivalent to the HVCA Ductwork Group, computers in ductwork design and fabrication.
have produced an Addendum No. l (November
1997) to their publication "HVAC Duct Bends are designated as `hard' or `easy', and these
Construction Standards, Second Edition - 1995". terms as used herein have the following meanings:
The addendum contains the extensive technical
`Hard' signifies rotation in the plane of the longer
information and data on the subject of mid panel tie
side of the cross section.
rods and SMACNA have given their kind
permission for this specification to make reference `Easy' signifies rotation in the plane of the shorter
to this fact. Designers and manufacturers who wish side of the cross section.
to incorporate this form of internal stiffening into a
An example illustrating these terms is given in Fig. 29.
ductwork system should contact SMACNA direct to
obtain copies of their publications (See Appendix N, 11.2 Stiffeners
Bibliography). The flat sides of fittings shall be stiffened in accor-
dance with the construction Tables 2 to 4. On the flat
10.6 Ductwork galvanized after manufacture sides of bends, stiffeners shall be arranged in a radial
Appendix E sets out the recommended sheet thicknesses pattern, with the spacing measured along the centre of
and stiffening for ductwork galvanized after the bend.
manufacture.
11.3 Splitters
10.7 Fastenings If the leading edge of the splitters exceeds 1250 mm
10.7.1 Permitted types and maximum centres fit central tie bars at both ends to support the splitters.
Table 5 sets out the permitted fastenings and the Leading and trailing edges of splitters must be edge
maximum spacings for all ductwork classifications. folded and flattened and be parallel to the duct axis.
All duct penetrations shall be sealed.
Splitters shall be attached to the duct by bolts or
mechanically-closed rivets at 100 mm maximum
10.7.2 Rivets
spacing (or by such other fixing as can be shown to be
Manufacturers' recommendations as to use, size and
equally satisfactory e.g proprietary sealed splitter
drill size are to be followed. Rivets resulting in an
pins).
unsealed aperture shall not be used.
11.4 Turning vanes
10.7.3 Set screws, nuts and lock bolts Materials Where specified, or shown on drawings, square throat
shall be of mild steel, protected by electro- bends with either duct dimension greater than 200 mm
galvanizing, sherardizing, zinc-plating, or other shall be fitted with turning vanes which are illustrated
equal and approved corrosion resistant finish. in Figures 30a and 30b.
Turning vanes at 60 mm maximum centres shall be
10.7.4 Self tapping and piercing screws Providing
fixed at both ends either to the duct or compatible
an adequate seal can be achieved, and the
mounting tracks in accordance with manufacturer's
protrusions into the ductwork are unlikely to cause
instructions, the whole bank being fixed inside the
injury, then self-tapping or piercing screws may be
duct with bolts or mechanically closed rivets at 150
used.
mm maximum spacing.
10.7.5 Welding of sheet The maximum length of turning vane between duct
The suitability of welding for sheet-to-sheet walls or intermediate support shall be 615 mm for
fastening will be governed by the sheet thickness, single skin vanes and 1250 mm for double skin vanes.
the size and shape of the duct or fitting and the need Typical examples of fitting turning vanes when the
to ensure airtighteness. Welded joints shall provide a maximum permitted vane lengths are exceeded are
smooth internal surface and shall be free from shown in Fig. 30c.
porosity. Distortion shall be kept to

16
11.5 Branches 11.7 Expansions and contractions
When fitting branch ducts to a main duct, care should Where these are required, an expansion shall be made
be taken to ensure that the rigidity of the duct panel is upstream of a branch connection and a contraction
maintained in terms of the stiffening criteria. downstream of a branch connection. The slope of either
an expansion or a contraction should not exceed 22½°
11.6 Change shapes on any side. Where this angle is not practicable, the
Where a change shape is necessary to accommodate slope may be increased, providing that splitters are
the duct and the cross-sectional area is to be positioned to bisect the angle between any side and the
maintained, the slope shall not exceed 22½° on any centre line of the duct (See Figs 99 to 101).
side (See Figs 99 to 103). Where a change in shape
includes a local reduction in duct crosssectional area, 11.8 Sealant
the slope should not exceed 15° on any side and the Sealant shall be used in all longitudinal seams and cross
reduction in area should not exceed 20 per cent. joints of fittings. Sealant shall be to the options listed in
Section 8.

17
Notes (applicable to Tables 2 to 4)
(1) The joints and stiffeners have been rated in terms of duct longer side and maximum spacing - see 10.4 for
joints and 10.5 for stiffeners.
(2) In Col. 3:
`PS' = plain sheet
`SS' = stiffened sheet, by means of
(a) beading at 400 mm maximum centres: or (b) cross-breaking within the frame formed by joints and/or
stiffeners: or (c) pleating at 150 mm maximum centres.
(3) Stiffened panels may limit the choice of insulation materials.
(4) For ductwork galvanized after manufacture, see 10.6 and Appendix E. (5) For aluminium ductwork, see
Appendix H.
(6) For constructional constraints of stainless steel ductwork see Appendix F.
(7) Although not covered in this specification, due to their relatively infrequent use, cleated cross joints are an
accepted constructional practice and the HVCA Ductwork Group should be contacted if details of their
ratings and limitations are required.
(8) Intermediate stiffeners using rolled sheet angle profiles, illustrated in Figs. 19 to 23 of the appropriate
rating may also be utilised ensuring that rigid corners are achieved.

18
19
20
NOTE: The above illustrations are typical examples of cross joint profiles that are in common use for connecting rectangular
sheet metal ducts.
There are no set dimensions for these profiles shown in Figs. 1 1 and 12 provided they are certified under the HVCA testing
scheme DW/TM1 "Acceptance Scheme for new products - Rectangular cross joint classification" and are appropriate to the
duct application. The manufacturer's technical data should be followed with respect to:
Connections to duct wall
Corner treatment
Addition of cleats
Application of sealants
Strength ratings
Application of tie bars
A list of manufacturers and profiles that are covered by current DW/TMI certificate is available from the Ductwork Group
Secretary at HVCA.

21
22
23
(1) A minimum of 2 fixings per side, with a maximum distance from the corner to the first fixing of 50 mm
(2) Except when pierced dimpling is used, one of the other types of fastening must be used at each end in
addition to dimpling
(3) In addition to dimpling, one of the other types of fastening must be used at 450 mm centres, and in all
cases not less than 1 per side
(4) Where manufacturers have specific recommendations, then these shall take precedence over the centres in
the Table above
(5) Mechanically closed rivets are not recommended for fixing external stiffeners to ductwork exceeding
500pa negative.

24
25
26
 Part Four - Circular Ducts

and contractors in the meantime are invited to evaluate

them based on information currently available.
13.1 Longitudinal seams
13.1.1 Spirally-wound ducts
The seam used in spirally-wound circular ducts,
provided it is tightly formed to produce a rigid duct,
is accepted as airtight to the requirements of all the
pressure classifications covered in this specification,
without sealant in the seam.
13.1.2 Straight-seamed ducts
The longitudinal seam for straight-seamed circular
ducts shall be either the grooved seam continued to
the extreme end of the duct and sealed, or a
continuous butt lap weld or spot/stitch weld and
sealed lap joint (at 30 mm centres) provided this
gives a smooth internal finish (see Fig. 31).
13.2 Cross joints
13.2.1 General
Cross joints for circular ducts, both spirallywound
and straight-seamed, are illustrated in Figs.32 to 45.
They include several proprietary types and the limits
of use in terms of diameter and pressure classes are
noted against each.
13.2.2 Sealant
All circular cross joints shall be sealed. (see section
8)
The use of chemical-reaction tape or heatshrinkable
band shall be regarded as an effective sealant in
respect of the socket and spigot joints illustrated.
13.2.3 Welded joints
The limitations for welded joints are given in 13.3.5.
13.3 Fastenings
13.3.1 Permitted types and maximum centres
Table 9 sets out the permitted fastenings and
maximum spacings for low-, medium- and high-
13 CONSTRUCTION pressure ducts. All duct penetrations shall be sealed.
Spirally-wound ducts and straight seamed ducts 13.3.2 Rivets
The minimum constructional requirements set out in Manufacturers' recommendations as to use, size and
Table 7 and 8 are common to the full range of drill size are to be followed. Rivets resulting in an
pressures covered in this specification. unsealed aperature shall not be used.
The ductwork construction and joint sealing stan- 13.3.3 Set screws, nuts and lock bolts
dards are set out in section 8. Materials shall be of mild steel, protected by electro-
Spirally wound duct with thinner than traditional galvanizing, sherardizing, zinc plating or other equal
wall thickness and with one or more corrugations and approved finish.
(ribs) formed between the lock seams are now
available. As design and installation experience with 13.3.4 Self tapping and piercing screws
these are gained and more functional performance Providing an adequate seal can be achieved, and the
criteria are identified it is anticipated that such forms protrusions into the ductwork are unlikely to cause
injury, then self-tapping or piercing screws may be
may be added to later updates. Designers
used.

27
13.3.5 Welding of sheet internal surface and shall be free from porosity.
The suitability of continuous welding or spot welding for Distortion shall be kept to a minimum.
sheet to sheet fastening will be governed by the sheet Areas where the galvanizing has been damaged or
thickness, the size and shape of the duct or fitting and the destroyed by welding or brazing shall be suitably
need to ensure airtightness. Welded joints shall provide a prepared and painted internally and externally with
smooth zinc-rich or aluminium paint.

28
14 FITTINGS
14.1 Standardisation of fittings
The terminology and descriptions of circular duct
fittings as set out in Section 33 are recommended for
adoption as standard practice, to provide common
terms of reference for designers, quantity surveyors
and ductwork contractors, and those using
computers in ductwork design and fabrication.
The requirements for circular duct fittings apply
throughout the pressure ranges covered in this
specification.
14.2 Nominal diameters
The nominal diameter (see Table 6) is the size used
for design and ordering. With socket and spigot
joints, care should be taken to ensure that the
dimensions of the ducts and fittings are correctly
related, so that the joint can be effectively sealed.
14.3 Sheet thickness
Sheet thickness for circular duct fittings (determined
by the largest diameter) shall be not less than those
quoted in Table 10.
14.4 Sealing of joints
Sealant shall be used in all cross joints and fittings.
Such sealant shall be in accordance with the
requirements of Section 8.

29
30
31
32
33
34
 Part Five - Flat Oval Ducts
15 STANDARD SIZES AND SHEET governed by the sheet thickness, the size and shape of
THICKNESSES the duct or fitting and the need to ensure air-tightness.
15.1 Table 11 sets out the standard sizes of spirally- Welded joints shall provide a smooth internal surface
wound oval ducts offered by the manufacturers of ducts and shall be free from porosity. Distortion shall be
of this section. kept to a minimum.
16 CONSTRUCTION (SPIRALLY-WOUND Areas where the galvanizing has been damaged or
DUCTS) destroyed by welding or brazing shall be suitably
16.1 General prepared and painted internally and externally with
`Flat oval' is the term used to describe a duct of cross- zinc-rich or aluminium paint.
section with flat opposed sides and semicircular ends. 16.5 Stiffening
The duct is formed from a spirallywound circular duct, The larger sizes of flat oval duct are stiffened by
using a special former. swages, as indicated in Table 11. Additionally, tie rods
Apart from stiffening (see Tables 12 and 13), flat oval (see Figs. 25 to 28) are required, positioned as indicated
ducts have the same constructional requirements in the respective tables and illustrations.
throughout the pressure ranges covered in this In special situations as an alternative to tie rods,
specification. stiffening in the form of external angles may be used to
The ductwork construction and joint sealing standards meet the requirements of the corresponding rectangular
are set out in Section 8. duct sizes.
16.2 Longitudinal seams
Spirally-wound flat oval duct is accepted as airtight to
17 CONSTRUCTION (STRAIGHT-SEAMED)
the requirements of this specification without sealant in
Flat oval ducts with opposed sides and semi-circular
the seams, provided the grooved seam is tightly formed
ends may also be formed using plain sheet and straight
to produce a rigid duct.
seams. Ducts so formed should follow the metal
16.3 Cross joints thicknesses and stiffening requirements specified for the
16.3.1 General corresponding sizes of rectangular ducts, except that
Cross joints shall be as Figs. 53 to 58 inclusive or such stiffening is necessary on the flat sides only.
other joint as can be demonstrated to the designer to Seams and cross joints (see Figs 59 to 63) shall be
be equally satisfactory. sealed to ensure the necessary degree of airtight-ness
16.3.2 Sealant throughout the pressure ranges covered in this
All flat oval cross joints shall be sealed. (See specification.
Standards Section 8).
16.3.3 Welded joints
The limitations for welded joints are given in 16.4.5. 18 FITTINGS
16.4 Fastenings 18.1 General constructional requirements Sheet
16.4.1 Permitted types and maximum centres Table thicknesses for flat oval fittings (determined by the
14 sets out the permitted fastenings and maximum periphery of the larger end) shall be not less than those
spacings for low-, medium- and highpressure ducts. given in Table 11 for the ducts themselves.
All duct penetrations shall be sealed. With socket and spigot joints, care should be taken to
ensure that the dimensions of ducts and fittings are
16.4.2 Rivets correctly related.
Manufacturers' recommendations as to use, size and
drill size are to be followed. Rivets resulting in an All the seams and joints integral to a fitting shall be
unsealed aperature shall not be used. sealed to the same standard as the duct. (See Section 8).

16.4.3 Set screws, nuts and lock bolts 18.2 Standardisation of fittings
Set screws and nuts shall be of mild steel, protected by The terminology and descriptions of flat oval duct
electro-galvanizing, sherardizing, zinc plating or other fittings as set out in Section 33 are recommended for
equal and approved finish. adoption as standard practice, to provide common terms
of reference for designers, quantity surveyors and
16.4.4 Self tapping and piercing screws Providing ductwork contractors, and those using computers in
an adequate seal can be achieved, and the protrusions ductwork design and fabrication.
into the ductwork are unlikely to cause injury, then The requirements for flat oval duct fittings apply
self-tapping or piercing screws may be used. throughout the pressure ranges covered in this
16.4.5 Welding of sheet
The suitability of continuous welding or spot welding
for sheet to sheet fastening will be

35
36
37
38
39
40
41
42
 Part Six - Hangers and Supports

19 GENERAL or studding or flat strap, pre-treated by, e.g. hotdip

19.1 Principles adopted galvanizing, sherardizing, electro-deposited zinc
Supports are an essential part of the ductwork system, plating or by other accepted anti-corrosion
and their supply and installation are normally the treatment. Other materials, such as stranded wire,
responsibility of the ductwork contractor. The choice may also be acceptable.
between the available methods of fixing will depend on Projection of a rod or studding hanger through the
the type of building structure and on any limitations bottom bearer should, where practicable, not exceed
imposed by the structural design. Further, unless the twice the thickness of the securing nut.
designer has specified his requirements in detail, the
Provided the integrity of the ductwork is maintained,
load to be carried shall be understood to be limited to
hangers may be attached to the corners of the
the ductwork and its associated thermal and/or acoustic
flanges as an alternative to the use of a bottom
insulation.
bearer.
It is not practicable to deal here with the full range of
With proprietary devices manufacturers'
supports available, which increasingly includes
recommendations for use should be followed.
proprietary types, so in this section various methods of
support are dealt with in principle under the three 19.3.2 The duct bearing member
elements of: The choice of the lower support will be dictated by
(1) the attachment to the structure; the actual duct section.
(2) the hanger itself; and 19.3.3.1 Rectangular ducts
(3) the duct bearing member Table 15 gives minimum dimensions for the hangers
and for angle, channel and profile sections. The
with illustrations of those most commonly used.
angle is shown in Fig. 73, the profile channel
Supports for ductwork external to the building have sections in Figs. 74 and 75.
been excluded, as these are individually designed to suit
Typical arrangements of bottom bearer supports for
the circumstances, and also may be required to meet
plain, and insulated ducts are shown in Figs. 68, 69
local authority standards. For the same reasons, floor
and 70.
supports have not been dealt with.
With a proprietary device, it will, unless the designer 19.3.3.2 Circular ducts
has specified his requirements in detail, be the Table 15 gives minimum dimensions for the hanger
responsibility of the ductwork installer to ensure that it and for the brackets - as illustrated in Figs. 64 to 67.
meets requirements, with a sufficient margin of 19.3.3.3 Flat oval ducts
overload; and that it is installed in accordance with the Table 15 gives minimum dimensions for the hanger;
manufacturer's recommendations. and for the bearer, depending on whether the flat
The absence of any method or device from this side of the duct is horizontal or vertical.
specification does not preclude its use if it can be Typical arrangements for flat oval duct supports are
demonstrated that it is suitable for the duty assigned to shown in Figs. 68, 71 and 72.
it, with a sufficient margin of safety against overload;
and this will be the responsibility of the ductwork 19.4 Vertical ducts
installer, unless the designer has specified his The design of supports for vertical ducts is dictated by
requirements in detail. site conditions, and they are often located to coincide
19.2 Fixing to building structure with the individual floor slabs, but if the spacing
The fixing to the building structure should be of a exceeds 4 metres the designer must specify his
strength and durability compatible with those of the requirements.
ductwork support attached to it. A fixing to concrete or Vertical ducts should be supported from the stiffening
brickwork must be made in such a way that it cannot angle or the angle frame, or by separate supporting
loosen or pull out through normal stressing or through angles fixed to the duct.
normal changes in the building structure. A typical method of supporting vertical rectangular
19.3 Horizontal ductwork ducts is shown in Fig. 76 and for circular ducts in
19.3.1 The hanger itself
The hanger itself is usually mild steel plain rod

43
Fig. 77. The same methods are applicable to vertical The extent of any vapour sealing of ductwork
flat oval ducts. thermal insulation and the method to be used, must
be clearly specified in advance by the designer.
19.5 Heavy loadings
For ducts larger than those covered by Table 15, or 19.7 Heat transfer
where heavy equipment, mechanical services, It is not normally necessary to make special
ceilings or other additional load is to be applied to arrangements for the limitation of heat transfer via the
the ductwork, supports shall be designed to suit the duct supports. However, there may be special cases
applications. where the temperature difference justifies a heat
barrier to conserve heat or to prevent condensation
19.6 Insulated ducts with vapour sealing Where
and such requirements must be specified by the
the temperature of the air within the duct is at any
designer.
time low enough to promote condensation on the
exterior surface of the duct and cause moisture 19.8 Fire rated ductwork
penetration through the thermal insulation, vapour DW/144 supports cannot be used on fire rated
sealing may be called for, and in this case the most ductwork systems. See Appendix D and in particular
important requirement is to limit penetration of the notes in D2.1 Method 3 and D.2.3.
seal.

Notes to Table 15
(1) The dimensions included in Table 15 are to be regarded as minima.
(2) The maximum spacings set out in Table 15 are related solely to duct weight considerations. Closer spacings
may be required by reason of the limitations of the building structure or to achieve the necessary duct
rigidity.
(3) Rolled steel channels may be used as bearing members provided they meet the design characteristics of the
bearing members tabled above.
(4) As an alternative to drop rod or studding, wire rope may be utilised to suit individual manufacturer's fixing
methods and loading limitations.

44
45
46
 Part Seven - General
duct dimensions, openings for access shall satisfy the
20 ACCESS/INSPECTION OPENINGS maintenance needs of the designated equipment with
20.1 General consideration being given, if more practicable, to the
This section covers inspection/servicing access only. use of removable duct sections or flexible
Appendix M sets out guidance notes, in summary form, ducts/connections.
of the access considerations that should be made by the
designer in terms of inspection, servicing and cleaning 20.3 Inspection covers
access. It shall be standard practice to provide inspection
All openings shall be made safe and have sealed covers adjacent to regulating dampers where either the
panels/covers designed so that they can be speedily control linkage is mounted internally within the
removed and refixed. Multiple set screws are not airstream or if a multi-bladed unit is an integral part of
recommended, and self-piercing screws are not the ductwork run. It is not necessary to provide
acceptable as a method of fixing. The services co- inspection covers adjacent to either single blade
ordinator should ensure that there is an area free of regulating dampers or flanged damper units.
services and other obstructions to enable a panel/cover 20.4 Hand holes
to be removed. Hand holes to permit proper jointing of duct sections
20.1.1 Function shall be provided at the manufacturer's discretion, but
20.1.1.1 An access panel is to be provided adjacent should be kept to a minimum and made as small as
to items of in-line equipment that require either practicable. The hand hole cover shall be sealed and
regular servicing or intermittent access. The opening securely fastened.
will be sized to provide hand and/or arm access only 20.5 Openings in insulated ducts
and the designer shall specify the size and location It will be the responsibility of the insulation contractor
of panels where larger dimensions are required and to `dress' their insulation to the edge of the access
in these cases the panels should not exceed 450 x opening without impeding the functionality of the
450 mm. panel, cover or door.
20.1.1.2 An inspection cover is to be provided
adjacent to items of in-line equipment that need 20.6 Test holes for plant system commissioning It
visual inspection only of internal elements from shall be standard practice to provide test holes,
outside of the ductwork. The inspection opening normally 13 mm diameter and fitted with an effective
should have a minimum size of 100 mm sq/dia. removable seal, at the following locations: at fans (in
the straightest section of duct near to the fan outlet); at
20.2 Access panels cooling coils and heating coils (both before and after
20.2.1 It shall be standard practice to provide access the coil). The actual location of the test holes shall be
panels for the inspection and servicing of plant and confirmed by the Designer and/or Commissioning
equipment as follows: Engineer either at the drawing approval stage (to be
20.2.1.1 Fire/Smoke dampers works drilled) or during the commissioning activity (to
Panels to be located so as to give access both to the be site drilled). For practical access reasons the latter
blades and fusible links. On multiple assembly units method is usually preferred.
it may be necessary to provide more than one panel 20.7 Instrument connections
and this may be determined by both external access Instrument connections shall be provided where shown
conditions and the internal reach to the blades and on the contract drawings, suitably drilled or bossed and
the fusible links. screwed as sizes specified.
20.2.1.2 Filters 20.8 Cleaning/maintenance
Panel to be located on the air entry side ie. upstream Designers shall take specialist advice and then stipulate
(Note: Dimensions of access may need to be their requirements for the periodic internal
changed to suit filter elements of the front cleaning/maintenance of ductwork and of the
withdrawal type.) consequent need for adequate access for specialist
20.2.1.3 Heating/cooling coils and in-duct cleaning equipment including the size, type and
fans/devices location/frequency of the actual access openings
Panel to be located on the air entry side ie. upstream required.
20.2.2 It shall be standard practice to connect safety Appendix M sets out guidance notes for the
restraints to access panels located in riser ducts. consideration of cleaning access and also makes
20.2.3 Subject to the restrictions imposed by reference to the HVCA publication TR17 "Guide to
Good Practice, Cleanliness of Ventilation Systems"
which covers the subject in greater detail.

47
20.9 Openings required for other purposes Single-blade dampers (single-skin section) shall have
It shall be the designers responsibility to specify the a maximum duct width of 300 mm and a maximum
location and size of any openings required other than duct height of 300 mm for rectangular ducts; and for
those covered in this section. In the case of hinged access circular ducts a maximum diameter of 315 mm.
doors it shall be the designer's responsibility to indicate Single-blade dampers (double-skin section) are
on the drawings the location and size of any hinged suitable for use in rectangular ducts, and shall have a
access doors required, ensuring that there is an area free maximum duct width of 1250 mm and a maximum
of services and other obstructions to enable the door to be height of 300 mm.
satisfactorily opened. Unless otherwise specified by the
designer, openings should not be larger than 1350 mm 21.2.2 Multi-blade dampers (single or double skin)
high by 500 mm wide. Doors could open against the air parallel or opposed blade Multi-blade dampers shall
pressure. Both the opening in the duct and the access door consist of a number of pivoted blades contained
itself shall be adequately reinforced to prevent distortion. within a casing. The blades shall be adjustable through
A suitable sealing gasket shall be provided, together with a nominal 90° angle simultaneously by interconnected
sufficient clamping type latches to ensure an airtight seal linkage or gears, connected to a quadrant or similar
between the door and the duct. operating mechanism. Where automatic control of the
damper is required a spindle shall be extended to
For safety reasons, the manufacturer shall incorporate
enable a powered actuator to be mounted.
means to prevent personnel being trapped inside the
duct e.g. man access with operating handles both There is no restriction on the size of duct in which
inside and outside the duct. multi-blade dampers or damper assemblies may be
used. Where dampers are required for blade lengths in
21 REGULATING DAMPERS excess of 1250 mm, the blades should be suitably re-
21.1 General inforced or supported. No individual damper blade
Balancing dampers and control dampers are elements should exceed 200 mm in width.
inserted into an air distribution system, or elements of an 21.2.3 Iris dampers
air distribution system. Balancing dampers permit Iris dampers shall consist of a number of radially
modification of the air resistance of the system and inter-connected blades which open or close within a
consequently changing of the airflow rate. Control casing with duct connection spigots. The blades shall
dampers control the airflow rate and in addition provide be simultaneously adjusted by a quadrant or similar
low leakage closure of the airflow. operating mechanism.
The designer shall specify damper locations and select the Iris dampers should be installed as specified by the
damper type as defined in 21.2 appropriate to the airflow, manufacturer's operating and installation instructions,
pressure and acoustic characteristics. where the product is unidirectional with regard to
21.1.1 Balancing damper airflow.
To achieve the required distribution of air in the Iris dampers are available for circular ducts only, in
ductwork system at inlets and/or outlets. For this diameters up to 800 mm (It should be noted that the
purpose, the damper blades are set and locked manually damper casing is approximately twice the diameter of
in any required position between fully open and fully the duct).
closed.
21.2.4 Backdraft dampers
21.1.2 Control damper Air pressure operated uni-directional rectangular
To secure dynamic control of the air flow in the (single or multi-blade) with adaptors if fitted to
ductwork system. In this function, the damper will circular or oval ducts.
always be power - actuated and may require to be
modulated between fully open and fully closed, and to 21.2.5 Hit and miss dampers
be capable of taking up any position between these Two parallel adjacent plates each with multiple
extremes. In the fully open position, the damper should openings sliding against each other. The openings are
have a minimum pressure drop. In the fully closed designed to provide 50% air volume flow rates when
position, it will not necessarily achieve a complete shut they fully coincide. Used for simple operations up to
off. 400 mm longest side.

21.2 Types of airflow control damper 21.2.6 Slide and blast gate dampers
Air flow dampers of various types are available for A damper used as a shut off facility, normally for use
specific purposes as follows. in circular ductwork with an external slide housing
allowing a blade to be fully inserted to fully extended
21.2.1 Single-blade dampers (Single or double skin) for maximum air flow.
Single-blade dampers shall consist of a single pivoted Generally available in cast/pressed formats up to 355
blade contained within a casing or section of ductwork. mm diameter and normally used in industrial exhaust
The blade shall be adjustable through a nominal 90° applications.
angle by means of a quadrant or similar operating
mechanism. Where automatic control of the damper is 21.3 Construction
required the spindle shall be extended to enable a 21.3.1 Materials
powered actuator to be mounted. Dampers shall be constructed from steel, stainless
steel, aluminium or synthetic materials.
48
All products shall be protected against corrosion as 22 FIRE DAMPERS
necessary and supplied in a fully finished condition as
22.1 General
specified by the designer.
Dampers are required in air distribution systems for
21.3.2 Dampers used in low and medium pressure fire containment. Generally they are called for where
systems ducts penetrate walls or floors which form fire
The following recommendations apply to dampers compartmentation. The damper assembly should have
forming an integral part of ductwork with pressure a fire resistance rating equal to that of the fire barrier it
classification A and B air leakage limits. penetrates and shall be fire tested and rated to the
The dampers shall be constructed to prevent distortion time/temperature curve of BS476 part 20 and 22.
and jamming in operation. The blades shall be 22.1 Types of fire dampers
sufficiently rigid to minimise movement when in the Fire dampers of various types are available for specific
locked position. purposes, as follows:
The blades shall be securely fixed to the operating
22.2.1 Folding curtain
mechanism. Spindles shall be carried in either non-
Folding curtain fire dampers shall be constructed of a
ferrous, synthetic or roller bearings. All balancing
series of interlocking blades which fold to the top of
dampers shall have a locking device located on the
the assembly permitting the maximum free area in
outside of the case and shall give clear indication of the
the airway. The blades shall be held in the open
actual blade position. All penetrations of the duct shall
position by means of a thermal release mechanism
be fitted with suitable seals where necessary.
rated at 72°C ± 4°C.
21.3.3 Dampers used in high pressure systems The fire damper must be able to close against static
Regulating dampers used in ductwork systems to air conditions when mounted in either the vertical or
pressure classification C shall meet the construction horizontal planes.
requirements specified in 21.3.1 and 21.3.2 with
In the event of a signal from a remote sensor the fire
operating mechanisms out of the airstream.
damper blades shall be released and close the airway.
21.3.4 Proprietary types of damper A local excess temperature in the area of the fire
The use of any specific type of proprietary damper shall damper shall, independent of any remote sensors,
be confirmed by the designer. In all cases, proprietary automatically release the blades and close the airway
dampers shall meet the relevant requirements of this by means of the thermal release mechanism, electric
specification. solenoid or electromagnet.
21.3.5 Damper casings 22.2.2 Single blade
Duct damper casings shall be constructed to meet the Single blade fire dampers shall consist of a single
minimum leakage limits specified for the ductwork pivoted blade within a fire resistant case.
system to which they are installed. The blade shall be released from its open position by
In order to apply the square metreage leakage means of a thermal release mechanism rated at 72°C
calculation as detailed in DW/143 A practical guide to ± 4°C, electric solenoid, electromagnet(s) or other
Ductwork Leakage Testing, the reference casing area device.
shall be taken as the perimeter size of the damper The blade shall close the airway by means of any
multiplied by the equivalent length of one metre eg. an one, or combination of, an eccentric pivot, balance
800 mm x 400 mm duct damper shall have a surface weight(s) and/or spring(s), the spring element being
area for casing leakage performance calculated as incorporated within the damper or actuator
follows; [(2 x 0.8) + (2 x 0.4)] x 1 = 2.4m2 casing area. mechanism.
Other performance and rating test methods for dampers The fire damper shall be able to operate in either or
and valves are specified in ISO5129 and BS/EN1751, both the vertical and horizontal planes.
and are referenced below:
a) Leakage past a closed 22.2.3 Multi-blade
damper or valve BS/EN 1751 Multi-blade fire dampers shall consist of a number of
b) Flow rate/pressure linked blades contained within a fire resistant case.
requirement characteristics BS/EN 1751 The blades shall be released from their open position
c) Operational torque testing BS/EN 1751 by means of either a thermal release mechanism rated
d) Thermal transfer testing BS/EN 1751 at 72°C ± 4°C, or by the force applied from electrical
e) Regenerated sound power solenoid(s), electromagnet(s), electrical/pneumatic
levels ISO 5129 actuator or other device.
21.4 Installation
Dampers shall be installed in accordance with any
relevant ISO, EN or British Standard, local building
regulations and national codes of practice as well as the
manufacturer's recommendations.

49
 The blades shall close the airway by means of a 22.5 Location
spring(s), the spring element being incorporated The effective formed barrier of the damper assembly
within the damper or actuator mechanism. shall be located within the structural opening. Where
The fire damper shall be able to operate in either or this is not possible the section of the casing outside a
both the vertical and horizontal planes. fire barrier must have a fire resistance not less than
that of the fire barrier and be adequately
22.2.4 Intumescent supported/protected against the possibility of
Intumescent fire dampers shall be constructed from displacement/damage by impact.
strips of intumescent material formed into a lattice
or from honeycomb material covered with 22.6 Provision for expansion
intumescent paint. The damper shall fully seal when Damper assemblies generally include built-in
heat or flame is applied from either side. Note: these clearance frames to meet the requirement that the
devices are generally used in door/partition low casing be free to expand in the event of fire. The
velocity applications. integrity of the fire barrier is maintained either by
metal to metal contact or by fire resistant packing.
22.3 Materials and construction Acceptable arrangements are shown in Figs. 78 and
The damper shall be constructed from steel or stainless 79.
steel or other approved material. Steel products shall be
protected against corrosion and supplied in a fully 22.7 Installation
assembled condition as specified by the designer. Damper installation shall be in accordance with the
manufacturer's recommendations and the impending
22.4 Air leakage HVCA Publication DW/TM3 - Guide to Good
Fire damper casings shall meet the equivalent leakage Practice, for the design for the installation of Fire and
performance standard specified for the ductwork system Smoke Dampers and any conflict between the two
to which they are installed. should be resolved and authorised by the designer
Classes A, B and C are used to signify the leakage responsible for the fire damper selection.
performance of the damper casing with the respective
testing method illustrated and specified in BS/EN1751. 23 SMOKE DAMPERS
In order to apply the square metreage leakage cal- 23.1 General
culation as detailed in the standard, the reference casing Smoke dampers shall be constructed in such a manner
area shall be taken as the perimeter size of the damper as to restrict the spread of smoke and other products of
multiplied by an equivalent length of one metre eg. an combustion from one occupied space to another. The
800 mm x 400 mm duct damper shall have a surface blade(s) shall overlap each other and/or include edge
area for casing leakage performance calculated as seals. The blade(s) shall be arranged to minimise the
follows: [(2 x 0.8) + (2 x 0.4)] x 1 = 2.4m2 casing area. leakage of smoke. If degradable seals are fitted, care
should be taken to establish the temperature range of
the material used to ensure performance compatibility.
50
The smoke damper shall be able to operate in either or dampers shall consist of a single pivoted blade
both the vertical and horizontal planes and close against contained within a fire resistant case.
dynamic air conditions. The blade shall be released from its open position by
23.2 Types of smoke damper means of either a thermal release mechanism rated at
Smoke dampers of various types are available for 72°C ± 4°C, or in addition operated by the force
specific purposes, as follows: applied from electrical solenoid(s), electro-
magnet(s), electrical/pneumatic actuator or other
23.2.1 Single blade device.
Single blade dampers shall consist of a blade of smoke
The combination smoke and fire damper shall be
tight material held in either the open or closed position
able to operate in either or both the vertical and
by a mechanical linkage releasing to close or open and
horizontal planes and close against dynamic air
seal against the damper case. The blade shall be
conditions.
mechanically connected to the actuator (electric or
pneumatic) and shall be triggered by interfacing with a 24.2.2 Multi-blade
smoke detector or fire control panel. Multi-blade combination smoke and fire dampers
shall consist of a series of blades mechanically
23.2.2 Multi blade
linked and connected to a damper actuator with
Multi blade dampers shall consist of blades of smoke
manual, electric or pneumatic opening and spring
tight material including the blade to blade seals, where
loaded closure contained within a fire resistant case.
fitted. The blades shall be mechanically linked to an
actuator (electrical or pneumatic) to hold the blades in The blades shall be released from their open position
either the open or closed position. The actuator shall by means of either a thermal release mechanism
interface with a smoke detector or fire control panel rated at 72°C ± 4°C, or in addition operated by the
and shall be so designed as to hold the blades close force applied from electrical solenoid(s), electro-
against the smoke seals, where fitted. magnet(s), electrical/ pneumatic actuator or other
device.
23.3 Materials and construction
The combination smoke and fire damper shall be
The damper shall be constructed from steel, stainless
able to operate in either or both the vertical and
steel, other material or composite material with blades
horizontal planes and close against dynamic air
fitted to reduce the leakage of smoke and hot gases
conditions.
when the blades are in the closed position. Steel
products shall be protected against corrosion and 24.3 Materials and construction
assembled in a fully finished condition as specified by The combination smoke and fire damper case shall be
the designer, in some circumstances controls may be constructed from steel, stainless steel, other material
supplied separately. or composite material with compressible side seals
fitted between the blade ends and the casing to reduce
23.4 Air leakage
the leakage of hot gases when the blades are in the
Smoke damper casings shall be as Clause 22.4
closed position.
23.5 Installation Steel products shall be protected against corrosion and
Damper installation shall be as Clauses 22.6 and 22.7. supplied in a fully finished condition as specified by
the designer.
24 COMBINATION SMOKE AND FIRE
DAMPERS 24.4 Air leakage
24.1 General Damper casings shall be as Clause 22.4.
Combination smoke and fire dampers are required in air 24.5 Installation
distribution systems to prevent the spread of smoke and Damper installation shall be as Clauses 22.6 and 22.7.
hot gases from the fire zone and to maintain the
integrity of a fire rated structure for a period compatible
with that of the separating structure. They shall be tested 25 FLEXIBLE DUCTS
and rated to BS476 Part 20 and 22. Reference maybe 25.1 General
made to BS5588 Part 4 for specific smoke rating Flexible duct connections shall be used in the fol
requirements. lowing applications:
The closure of the fire damper under action of the • Terminal units
thermal release element shall override all other • Fan coil units
subsequent signals. • Constant Volume/Variable Air Volume units
24.2 Types of combination smoke and fire damper • Grilles and Diffusers
Combination smoke and fire dampers of various types • Plenum boxes
are available for specific purposes, as follows: • Distribution ducts between the above items.
24.2.1 Single blade They are available in a range of materials including
metal, P V.C, fabric and with or without thermal
Single blade combination smoke and fire
insulation.
The designer/contractor shall consider the

51
following when selecting a particular type of flexible 25.2.2 Flexible ducts - Fabric
duct including: Flexible ducts made from materials including
• Temperature range P.V.C/Polyester laminate, Aluminium/Polyester
• Fire rating laminate encapsulating high tensile steel wire helix are
• Resistance to air flow a very flexible form of construction. The length of
• Airtightness characteristics flexible duct used should therefore be kept to a
• Length restrictions if applicable minimum, consistent with the particular application.
• Support requirements Flexible ducts shall be fastened at each end using a
• Flexibility propriety band. Care should be taken not to damage
• Insulation values the flexible duct and to ensure that the required
• System pressure. airtightness of the system is maintained.
Flexible ducts are also available in twin wall format 25.3 Supports
where the inner liner is perforated to provide acoustic Flexible ducts have a higher resistance factor than
properties or plain for thermal insulation. conventional ductwork and should be supported in such
a way that excessive sagging and consequently kinking
25.2 Flexible ducts - Metal of the duct is avoided.
25.2.1 Flexible ducts made of coated steel, stainless
25.4 Test Holes
steel or aluminium are normally helically wound with
It is not practicable to make test holes or take test
a lock seam to form a corrugated duct capable of
readings in metal or fabric flexible ducts. Where
being bent without deforming the circular section.
readings are required, the test holes should be made in
Bending is done by closing the corrugations in the
rigid ductwork.
throat and slightly opening the corrugations at the
back of the bend. Some re-adjustment is possible but
26 FLEXIBLE JOINT CONNECTIONS
small radius bends cannot be straightened without
26.1 General properties
leaving some distortion of the corrugations. Repeated
The material used for flexible joints must meet the
bending is not recommended.
designers requirement for temperature, air pressure, fire
The ducts shall be mechanically fastened at each end resistance, vibration, noise breakout when incorporated
and particular care shall be taken to ensure that the into a joint/connection and shall comply with the
required airtightness of the system is maintained. standard of airtightness specified for the ductwork
Fastenings should be as for rigid circular ducts Section system of which it forms part (See Fig. 80 for typical
13.3 and Table 9. Sealing should be as Section 8. connection details).
26.2 Location
Flexible joints are typically used at building
52
expansion joints and fan inlet/outlets. Any others 27.2 Metal spraying
required should be indicated on the design drawings. Zinc or aluminium spraying shall be to BS EN 22063
Care should be taken to maintain alignment across (1994), Part 1.
joints/connections.
27.3 Paints
Joints/connections shall not be installed taught, but 27.3.1 Surface preparation and paint application
under a reasonable amount of compression. Surface preparation of the metal and paint application
26.3 Length shall be in accordance with the paint manufacturer's
Flexible joints shall be kept as short as practicable recommendations.
above a minimum effective length of 50 mm. In no 27.3.2 Making good welding damage Galvanizing or
case shall a flexible joint exceed 250 mm in length. other metallic zinc finish damaged by welding shall be
26.4 Connections to rectangular ducts suitably cleaned and painted with one coat of zinc-rich
With flanged rectangular connections, the flexible or aluminium paint.
material shall be held in place with flat bar strips of 27.3.3 Ducts made from pre-galvanized sheet or coil
not less than 2 mm thick attached to the flanges using Ducts and profile sections made from pregalvanized
suitable fixings. Where a proprietary brand of sheet or coil will have no need for paint or further
lightweight material is used with sheet metal fitted to protection where located inside a building. This also
either side consideration should be given to the size of applies to exposed cut edges in accordance with
connection it is used on and how it is fitted. The more criteria laid down by British Steel PLC. See Appendix
heavy weight type of flexible material may also be N Bibliography.
obtained formed into a channel section with corners
fitted and stitched to give a neat airtight joint. For 27.3.4 Ducts made from other types of mild steel
spigot connections the flexible material shall be held sheet
in place with flat bar strips of not less than 2 mm Where circumstances require ducts to be made from
thick. mild steel sheet or coil other than the foregoing,
protective requirements shall be specified by the
26.5 Connections to circular ducts designer.
With flanged circular connections the flexible material
shall be held in place with alternative flat bar rings, 27.3.5 Untreated steelwork profiles and sheet Any
flat bar clip rings or proprietary clip bands with screw plain mill finish unprotected mild steel such as rolled
or toggle fittings. Where a proprietary brand of light steel sections and/or sheet used for flanging, stiffeners,
weight flexible with metal to either side is used, supports and duct walls must be treated.
careful consideration must be given to sealing when Treatment would be an appropriate primer such as zinc
fitting to spirally-wound ducts. rich, zinc chromate, red oxide or aluminium paint.
26.6 Connections to oval ducts
28 CONNECTIONS TO BUILDING
Special consideration should be given to the con-
OPENINGS
struction but the type of joint applies as for circular
ducts except proprietary clip band with screw or 28.1 Forming and finishing building openings are not the
toggle fastening is not suitable on oval ducts. responsibility of the ductwork contractor and the notes
that follow are for guidance purposes only.
28.1.1 Openings in brick, block or concrete walls shall
27 PROTECTIVE FINISHES
Unless otherwise stated all ductwork will be have inset frames to provide a suitable means of fixing
manufactured in pre-galvanised sheet steel, aluminium grilles, louvres, masking flanges or the flanged ends of
or stainless steel as specified, with prime coating ductwork.
where applicable (see 27.3.5). Any additions to this The inset frames shall be constructed to maintain the
would normally be the responsibility of others. Any structural integrity of the wall and where applicable
special coating/paint finishes to be provided by the cavities shall be suitably lined.
ductwork contractor must be advised by the designer. 28.1.2 Openings in dry lining partitions shall have
27.1 Galvanizing after manufacture Galvanizing inset frames as in 28.1.1.
after manufacture is not recommended for general use, 28.1.3 Openings in cladding walls and roofs shall have
as distortion of the duct or fitting is probable, thus flanged sleeves/frames to provide a suitable means of
making if difficult to achieve an airtight joint. fixing as in 28.1.1.
Galvanizing after manufacture is, however, an
acceptable protective finish for circular pressed 28.1.4 Horizontal and vertical openings that are
fittings and external ductwork exposed to atmosphere. exposed to outside atmosphere shall be provided with a
Where galvanizing after manufacture is specified, it suitable weathering finish at the external face
shall be to BS 729, see Appendix E. No paint especially if profiled cladding is involved.
protection is required.

53
 28.1.5 Timber framed openings are not permitted in 30 THERMAL INSULATION
fire compartment walls. 30.1 The provision and application of thermal
28.2 Ductwork connections to building openings shall insulation to ductwork is not normally the respon-
have a flange of suitable profile to permit practical sibility of the ductwork contractor.
fixing to the opening frame. In selecting the profile, 30.2 Where ductwork is required to be preinsulated,
consideration shall be given to Table 2 in this the specification should be agreed with the designer.
specification relating to duct size and rating. Gasket
strip or sealer shall be applied between the flange and 30.3 Where the temperature of the air within the duct
building opening frame. is at any time low enough to promote condensation on
the exterior surface of the duct and cause moisture
29 INTERNAL DUCT LININGS penetration through the thermal insulation, vapour
29.1 General sealing may be called for, and in this case the most
Where an acoustic or thermal lining to ductwork is important requirement is to limit penetration of the
specified it should preferably be fitted at works. Before seal.
duct manufacture it should be clarified that specified The extent of any vapour sealing of ductwork thermal
external duct dimensions allow for the lining thickness. insullation and the support method to be used must be
Any form of lining should have fire characteristics clearly specified in advance by the designer.
having minimum Class 0 rating and must be specified
by the Designer for material type, thickness, and 30.4 For detailed information on the thermal
application method. insulation of ductwork, reference should be made to
BS 5422:1990 which covers the specification for
29.2 Lining Application Considerations thermal insulation materials on pipes, ductwork and
Prior to the application of any lining the internal duct equipment (in the temperature range -40°C to +700°C)
surface must be thoroughly cleaned to provide a dust and BS 5970:1992 which is a Code of practice for
free dry surface which may additionally be degreased. thermal insulation of pipework and equipment (in the
Securing the lining to the internal duct surface can be temperature range -100°C to +870°C).
achieved in several ways including applied adhesive,
self adhesive and physical methods such as fasteners in
conjunction with surface washers at a specified square 31 KITCHEN VENTILATION
pitch. 31.1 For detailed information reference should be
Adjacent sections of lining should abut with minimal made to HVCA Publication, Guide to good Practice
gap and integral or separate surface finish lap to such for Kitchen Ventilation Systems DW/171.
joints and or gap filling proprietary products being
applied. This procedure is to obviate any particle
migration. 32 FIRE RATED DUCTWORK
32.1 For information see Appendix D of this
During application and any curing, consideration should
specification.
be given to ambient temperature and humidity
requirements.
In all circumstances linings should be fitted to material 33 STANDARD COMPONENT DRAWINGS AND
manufacturer's recommended methods. ABBREVIATIONS
29.3 Circular ducts 33.1 The illustrations in this section not only
Lining circular ducts is impractical and is not rec- highlight, where applicable, geometric limitations for
ommended. the design and manufacture of ductwork components
but also recommend standard drawing representation,
29.4 Cleaning and maintenance
terminology and abbreviations for both ductwork
Designers should be aware of the possible porous/
components and some of the more commonly used
fibrous surface nature of linings as they may present
ancillary/plant items.
practical/hazardous problems in cleaning and
maintenance. Reference in this respect should be made 33.2 Designers and surveyors should note that bills of
to the following HVCA Publications quantities should provide a full description
i) DW/TM2 Guide to Good Practice, Internal
Cleanliness of New Ductwork Installations.
ii) TR17 Guide to Good Practice, Cleanliness of
Ventilation Systems.

54
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 Part Eight-Appendices

APPENDIX A - AIR LEAKAGE FROM DUCTWORK

To be read in conjunction with DW/143 A practical guide to Ductwork Leakage Testing

CAUTION
As highlighted in both this document and DW/143, not enough emphasis can be placed on the fact that, except for high
pressure class C, the much tighter ductwork constructional standards brought about by the general acceptance of DW/142
have virtually negated the requirement for leakage-testing. It is essential to realise that except where it is mandatory this
document is not an endorsement of the routine testing of ducts but purely a guide to outline the procedures for conformity
with the air leakage limits in Table 1. When proper methods of assembly and sealing of ducts are used, a visual inspection
will ordinarily suffice .for verification of a well engineered and acceptably airtight construction.
WHERE NOT MANDATORY, DUCT LEAKAGE TESTING IS GENERALLY AN UNJUSTIFIED AND SUBSTANTIAL
EXPENSE.

A.1 INTRODUCTION A.3 LEAKAGE FROM DUCTWORK

Leakage from ducted air distribution systems is an Leakage from sheet metal air ducts occurs at the
important consideration in the design and operation of seams and joints and is therefore proportional to the
ventilation and air conditioning systems. A ductwork total surface area of the ductwork in the system. The
system that has limited air leakage, within defined limits, level of leakage is similarly related to the air pressure
will ensure that the design characteristics of the system in the duct system and whilst there is no precise
can be maintained. It will also ensure that energy and formula for calculating the level of air loss it is
operational costs are maintained at optimum levels. generally accepted that leakage will increase in
Ductwork constructed and installed in accordance with proportion to pressure to the power of 0.65.
DW/144 should minimise a level of air leakage that is The effect of air leakage from high pressure/velocity
appropriate to the operating static air pressure in the ductwork is critical in terms of system performance,
system. However, it is recognised that the environment energy consumption and the risk of high frequency
in which systems are installed is not always conducive to noise associated with leakage.
achieving a predictable level of quality in terms of These problems are less critical with medium
system airleakage and it is therefore accepted that pressure/velocity systems, but should be considered.
designers may sometimes require the systems to be
Low pressure/velocity ducts present the lowest risk in
tested in part or in total. It should be recognised that the
terms of the effect of leakage on the effective
testing of duct systems adds a significant cost to the
operation of the system.
installation and incurs some extra time within the
programme (See 4.1 and 6.4 re mandatory testing).
A.4 SYSTEM LEAKAGE LOSS
A.2 DUCT PRESSURE
Ductwork constructed to DW/144 will be manufactured As there is no direct relationship between the volume
to a structural standard that is compatible with the of air conveyed and the surface area of the ductwork
system operating pressure. system required to match the building configuration it
is difficult to express air leakage as a percentage of
There are three classes of duct construction to cor-
total air volume.
respond with the three pressure classifications:
Class A Similarly, the operating pressure will vary throughout
Low pressure ducts suitable for a maximum positive the system and as leakage is related to pressure the
operating pressure of 500 Pascals and a maximum calculations are complex. However, it is generally
negative pressure of -500 Pascals. accepted that in typical good quality systems the
Class B leakage from each class of duct under operating
Medium pressure ducts suitable for a maximum conditions will be in the region of:
positive operating pressure of 1000 Pascals and a Class A low pressure 6%
maximum negative pressure of -750 Pascals. Class B medium pressure 3%
Class C Class C high pressure 2%
High pressure ducts suitable for a maximum positive
operating pressure of 2000 Pascals and a maximum
negative pressure of -750 Pascals.
75
A.5 SPECIFYING AIR LEAKAGE TESTING for the classification for the section of the duct-
Respecting both the cost and programme implications work that is to be tested.
associated with testing ducts for leakage, the designer The tests shall be carried out as the work proceeds
may, for example indicate that a particular system is and prior to the application of thermal insulation.
tested as follows:
In the event of test failure of the randomly selected
a) High pressure ducts - all tested.
section, the designer shall have the right to select
b) Medium pressure ducts - 10% of the ductwork
two further sections at random for testing. Where
shall be selected at random and tested.
successive failures are identified there shall be a
c) Low pressure - untested.
right to require the contractor to apply remedial
In the case where a random test is selected for medium attention to the complete ductwork system.
pressure ducts the following clause is suggested for
inclusion by the designer. The contractor shall provide documented evidence
of the calculations used to arrive at the allowable
The designer shall select at random a maximum of loss for the section to be tested and the client, or
10% of the duct system to be tested for air leakage. his agent, shall witness and sign the results of the
The duct shall be tested at the pressure recommended test.
in Table 17 of DW/144

76
A.6 SPECIAL CASES conformity for the pressure class and air leakage
There may be situations on a project where circumstances classification for the system under test.
dictate that special consideration be given to containing
air losses, e.g. a long run of ductwork may incur a A.9 DESIGNER'S CALCULATIONS
disproportionate level of air loss. The designer can calculate with reasonable accuracy
In cases such as this example the designer can specify an the predicted total loss from a system by:
improved standard of airtightness, i.e. 80% of allowable a) Calculating the operating pressure in each
loss for Class `B' ducts. The designer should not specify a section of the system.
Class `C' test at Class `C' pressure for a Class `B' duct. b) Calculating the surface area of the ductwork
in each corresponding pressure section.
c) Calculating the allowable loss at the oper-
A.7 SUGGESTED RANGE OF TESTING ating pressure for each section of the system
• High pressure ducts 100% test (see table 17 for allowable leakage figures).
• Medium pressure ducts See A5
• Low pressure ducts Untested A.10 VARIABLE PRESSURES IN SYSTEMS
• Exposed extract systems Untested Designers can achieve significant cost savings by
• Ceiling void extract matching operating pressures throughout the system to
systems Untested constructional standards and appropriate air leakage
• Secondary ducts from testing, e.g. the practice of specifying construction
VAV or fan coil units Untested standards for whole duct systems based on fan
• Flexible ducts Untested discharge pressures may incur unnecessary costs on a
project.
• Final connections and
branches to grilles and For example, some large systems could well be
diffusers Untested classified for leakage limits as follows:
Plant room risers Class C
A.8 TESTING OF PLANT ITEMS Main floor distribution Class B
Items of inline plant (eg. Figs. 168 to 175) will not Low pressure outlets Class A
normally be included in an air leakage test. The ductwork
contractor may include such items in the test if the
equipment has a certificate of

77
78
79
 APPENDIX B - IDENTIFICATION OF DUCTWORK

Note
The information given in this Appendix is for the
guidance of mechanical services contractors, con-
sulting engineers, etc. The identification of duct-
work does not form part of the work carried out
by the ductwork contractor unless required by the
designer in the job specification.

B.1 GENERAL possible, where there is adequate natural or artificial

B.1.1 Introduction light.
With the increasing complexity of ventilation and air
B.2.2 Identification symbols will be needed in plant
conditioning systems, it is becoming more important
rooms and remote areas. Symbols should occur
to ensure ready identification of ducts for the purposes
frequently enough to avoid the need for ducts to be
of commissioning, operation and maintenance of
traced back. Symbols should be placed at any service
systems. The purpose of these recommendations is to
and access points to the distribution system, including
lead towards the use and standardisation of a system
points where the distribution system has reduced to a
of identification for ducts for the benefit of designers,
single duct.
contractors and clients.
B.2.3 Colour coding
B.1.2 Scope
The choice of colours has been based on the need to
B.1.2.1 These recommendations deal with the
provide:
identification of ducts for ventilation, air condi-
tioning and simple industrial exhaust systems. They B.2.3.1 Strong contrasting colours which are
do not include piped gas systems such as those dealt recognisable even though covered with dust.
with in BS 1710 1984, nor ductwork systems for B.2.3.2 Contrast between the symbol colour and the
industrial processes, although the general base colour of the duct. Usually the base colour
considerations and intentions could be extended with metallic grey of galvanized or aluminium sheet or foil
the agreement of the client to cover such systems. sheathing, or the white, pale grey, or buff paint on the
B.1.2.2 The method is designed to identify the air insulation is a neutral colour against which the
being conveyed, the direction of flow, the recommended symbol colours will stand out.
destination of the air and/or the location or B.2.4 The recommended colours are given in Table 18.
nomenclature of the plant where the air was treated. The colour coding indicates the type of air being
With small or simple plants, it may not be strictly conveyed.
necessary to provide identification because the
function is apparent, but it is considered advisable to
do so because this will increase familiarity with the
labelling system and also because the nature and
direction of air flow may not always be apparent.

B.2 IDENTIFICATION
B.2.1 Location
To be effective the identification must be placed
where it can be easily seen and at positions where
identification will be required. To ensure that the
symbols are seen, the following points should be
considered.
B.2.1.1 The symbols should be on the surfaces
which face the positions of normal access to the
completed installation.
B.2.1.2 The symbols should not be hidden from
view by structural members, other ducts, plant, or
other services distribution systems.
B.2.1.3 The symbols should be placed, where

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B.2.5 For conditioned air, two symbols (one red, one of the plant. The plant itself must be clearly
blue) may be used, or a single symbol coloured part numbered to correspond. Letters for Supply, Flow,
red, part blue. Extract, etc., should not be added because
identification will be clear from the colour symbol.
B.2.6 If a finer grading than that given in Table 18 is
Thus confusion between `S' for Supply and `S' for
required, as for instance in a laboratory with two
South will be avoided.
separate contaminated air exhaust systems, it is
recommended that the type colour be used with, say, a
stripe of a second colour. Where the duct contents
constitute a hazard, a symbol as given in BS 1710
1984 should be added to the type colour.
B.2.7 Direction of flow
B-.2.7.1 The form of symbol chosen indicates
direction. It is an equilateral triangle (see Fig. 179)
with one apex pointing in the direction of air flow.
Where the boundaries of the duct are not visible, two
triangles should be arranged in line ahead to indicate
direction of flow.
B.2.7.2 The size of the symbol will depend on the
size of the duct and the viewing distance. The
recommended minimum size for normal use is 150
mm length of side.

B.2.8.3 Where identification of the space is by

room number, this must be agreed with the user
who otherwise may have numbered the rooms
differently.
Some examples of further identification systems
are given in Table 19.
B.2.8.4 The letters and numbers should be in either
black or white, whichever gives the better contrast.
They should be marked on the colour symbol or
immediately adjacent to it. The size of the figures
will depend on how easily they can be seen, but
should not be less than 25 mm high.

B.2.9 Explanatory chart

An explanatory chart shall be included in the 0
B.2.8 Further identification (Operating) and M (Maintenance) manual and shall
B.2.8.1 On small or simple installations where there also be kept in the plant room or other convenient
is one plant and one or two zones and therefore little place. The chart should show and explain the colour
chance of confusing the ducts, it will not be symbols used on the installation and where
necessary to provide identification other than the appropriate the figure and letter codes used for
colour symbol. On large complex installations with further identification.
many zones, widely branched distribution systems or
several plants, further identification is necessary. In B.3 METHOD OF APPLICATION OF
this connection a plant refers to the ductwork and SYMBOLS
equipment associated with one particular fan. B.3.1 Several methods are available for applying the
B.2.8.2 The further information to be given will symbols, the main factor being that the symbol is
normally be the space served by the duct and in permanently affixed. Suitable methods are:
some cases the associated plant. The information B.3.1.1 Painting, using stencilled letters and
should be given as briefly as possible using figures.
commonly accepted forms such as a number B.3.1.2 Self-adhesive plastics or transfers with
indicating which floor of a building. The plant water soluble backing. (It is important to ensure
identification should always be preceded by the that the surface is smooth and clean and that the
letter `P' to avoid confusion between the number of adhesion will not deteriorate due to the sur-
the floor and the number rounding atmosphere.)
B.3.1.3 Purpose-made plastics or metal labels.

81
APPENDIX C - GUIDANCE NOTES FOR THE TRANSPORT,
HANDLING AND STORAGE OF DUCTWORK

It is recommended that before a contract is finalised, until they become an integral part of a completed
that consideration is given to the subject of site ductwork system. Whilst this may temporarily detract
access, material handling and storage as they have a from its intended appearance, this deformation will not
strong influence on the cost efficiency of the overall have any affect on the functionality of the finally
activity of ductwork installation. assembled system.
Installation of ductwork and associated plant items
C.1 Transport will inevitably involve manual handling. The
Large capacity vehicles with high-sided open or responsibility of employers and employees to assess
closed-top bodies are the most suitable for the the risk of personal injury during manual handling
transport of ductwork. operations is set out in the H.S.E. publication L23,
Careful consideration should be given to the Guidance on Manual Handling Regulations 1992.
unloading of transport on site as not all sites benefit
from the material handling and access facilities that C.3 Site storage
exist in a manufacturing workshop such as cranes, Adequate floor space must be provided within the
fork-lifts or loading bays. Site handling facilities building for the site storage of ductwork. Such storage
along with vehicular access restrictions may shall make due allowance for the storage of ductwork
influence the type and size of transport to be utilised. in stacks such that access between them is of sufficient
Lengths of ductwork should be positioned so as to width to permit the removal of items without
avoid crushing. Lengths with projections, such as interference to adjoining stacks. Ductwork
branches and bends, flanges, girths, damper quad- components should be positioned so as to avoid
rants should be loaded so as to avoid damage to crushing. Ductwork of small panel size may be stored
adjacent duct panels. In some cases, particularly on horizontally; however care should be exercised to
contracts calling for repetitive sizes, the use of ensure that stack sizes are limited to within the
timber jigs and spacers may be justified. structural strength of the duct sections to prevent
distortion of the lower sections within the stack.
Where reduced bulk and greater protection are major
factors, such as consignments for export,
C.4 Internal cleanliness of new ductwork
transporting ductwork in `L' shape sections may
The site storage of ductwork introduces the important
justify the increased site assembly costs.
consideration of maintaining the internal cleanliness of
the ductwork. Reference should be made to HVCA
C.2 Handling
document:
To minimise the risk of damage, duct sections
should be clearly identified and deliveries to site • DW/TM2 Guide to Good Practice - Internal
should be closely linked to the installation pro- Cleanliness of New Ductwork Installations.
gramme, so as to avoid accumulation of unfixed
ductwork and minimise double handling. It is If the above conditions can not be satisfied con-
important to recognise that ductwork panels, joints sideration should be given by the designer to
and corners are susceptible to damage and care must amending the specification to include for "Post
be taken when handling such material through a site. Installation Cleaning" as covered by the HVCA
document:
During handling, individual items of ductwork may
be liable to slight cross sectional deformation • TR17 Guide to Good Practice - Cleanliness of
Ventilation Systems.

82
APPENDIX D - DUCTWORK SYSTEMS AND FIRE HAZARDS

D.1 Fire and smoke containment/hazards are factors Method 3 - Protection using Fire Resisting
which influence the design and installation of Ductwork
ductwork systems. The ductwork itself forms a protected shaft. The fire
Information concerning fire protection systems is laid resistance may be achieved by the ductwork material
down in BS 5588, Fire Precautions in the design and itself or through the application of a protective
construction of Building Part 9 (1989) Code of material provided that the ductwork has been tested
Practice for Ventilation and Air Conditioning and/or assessed to BS476 Part 24 with a fire
Ductwork and tested in accordance with BS 476 Part resistance, when tested from either side that should
20 (1987) and BS 476 Part 22 (1987) for Fire and not be less than the fire resistance required for the
Smoke Dampers and British Standard 476 Part 24 elements of construction in the area through which it
(1987) - ISO 6944 - (1985) for Fire Rated Ductwork. passes. It should also be noted that the fire resisting
ductwork must be supported with suitably sized and
D.2 Building Regulations in the United Kingdom designed hangers, which reflect the reduction in
require that new buildings be divided into fire tensile strength of steel in a fire condition i.e:
compartments in order that the spread of smoke and
Fire resisting ductwork rated at 60 minutes (945°C),
fire in the building is inhibited, and to stop the spread
reduces the tensile strength from 430
of smoke and fire from one compartment to another,
N/mm2 to 15 N/mm2.
for given periods of time as specified by the Building
Regulations 1991 (Approved Document B). Fire resisting ductwork rated at 120 minutes (1,049°C)
tensile strength reduced to 10 N/mm2.
D.2.1 There are three methods of fire protection,
Fire resisting ductwork rated at 240 minutes (1,153°C)
related to ductwork systems as given in BS 5588 Part
tensile strength reduced to 6 N/mm2.
9 (1989).
Where the fire resisting ductwork passes through a
Method 1 - Protection using Fire Dampers fire compartment wall or floor, a penetration seal must
The fire is isolated in the compartment of origin by be provided which has been tested and/or assessed
the automatic or manual actuation of closures within with the ductwork to BS476 Part 24, to the same fire
the system. Fire dampers should, therefore, be sited at rating as the compartment wall through which the fire
the point of penetration of a compartment wall or resisting ductwork passes. It should also be noted that
floor, or at the point of penetration of the enclosure of where the fire resisting ductwork passes through the
a protected escape route. fire compartment wall or floor, the ductwork itself
Fire dampers should be framed in such a way as to must be stiffened to prevent deformation of the duct in
allow for thermal expansion in the event of fire, and a fire to:
the design must provide for the protection of any a) maintain the cross-sectional area of the duct
packing material included. b) ensure that the fire rated penetration seal around
Standard types of fire dampers and frames are the duct is not compromised.
described in Section 22 of this specification.
D.2.2 - Main areas within building where
For further information refer to the impending HVCA Ductwork should be fire protected
publication DW/TM3, `Guide to Good Practice for The following notes are for guidance only, and it
the Design for the Installation of Fire should be noted that authority rests with the Building
and Smoke Dampers'. Control Officer and/or the Fire Officer responsible for
Method 2 - Protection using Fire Resisting the building. Reference on the folowing systems
Enclosures should also be made to the current Building
Where a building services shaft is provided through Regulations.
which the ventilation ductwork passes and if the shaft a. Smoke Extract Systems:
is constructed to the highest standard of fire resistance If the ductwork incorporated in a smoke extract
of the structure which it penetrates, it forms a system is wholly contained within the fire
compartment known as a protected shaft. This allows compartment, it must be capable of resisting the
a complicated multiplicity of services to be anticipated temperatures generated through the
transferred together through a shaft transversing a development of a fire. BS 476 Part 24 also requires
number of compartments and reaching remote parts of ductwork, which is intended as a smoke extract,
the building, without requiring further internal must retain at least 75% of its cross-sectional area
divisions along its length. The provision of fire within the fire compartment. If the ductwork
dampers is then required only at points where the penetrates a fire resisting barrier, it must also be
ventilation duct leaves the confines of the protected capable of providing the same period of fire
shaft. resistance.
However, if there is only one ventilation duct and b. Escape Routes covering Stairways, Lobbies and
there are no other services within the protected shaft, Corridors
between the fire compartment and the outside of the All escape routes must be designed so that the
building, no fire dampers will be required. building occupants can evacuate the building
83
 safely in the case of fire. Ductwork which passes compartment). Basements with natural ventilation
through a protected escape route must have a fire should have permanent openings, not less than 2.5%
resistance at least equal to the fire compartment of the floor area and be arranged to provide a
through which the ductwork passes, either by the use through draft with separate fire ducts for each
of fire dampers or fire resisting ductwork. compartment.
c. Non Domestic Kitchen Extract Systems f. Pressurisation Systems
Where there is no immediate discharge to Pressurisation is a method of restricting the
atmosphere, i.e. the ductwork passes to atmosphere penetration of smoke into certain critical areas of a
via another fire compartment, fire resistant ductwork building by maintaining the air at higher pressures
must be used. Kitchen extract ductwork presents a than those in adjacent areas. It applies particularly to
particular hazard as combustible deposits such as protect stairways, lobbies, corridors and fire fighting
grease are likely to accumulate on internal surfaces, shafts serving deep basements as smoke penetration
therefore, all internal surfaces of the ductwork must to these areas would inhibit escape.
be smooth. A fire in an adjacent compartment, As the air supply creating the pressurisation must be
through which the ductwork passes, could lead to maintained for the duration of a fire, fire dampers
ignition of the grease deposits, which may continue cannot be used within the ductwork to prevent the
through the ductwork system, possibly prejudicing spread of fire. Any ductwork penetrating fire
the safety of the kitchen occupants. For this reason resisting barriers must be capable of providing the
consideration must be given to the stability, integrity same period of fire resistance.
and insulation performance of the kitchen extract g. Hazardous Areas
duct which should be specifically tested to BS 476 There are other areas within the building where the
Part 24 for a kitchen extract rating. Building Control Officer or the Fire Officer could
• Access doors for cleaning must be provided at state a requirement for fire resisting ductwork, eg.
distances not exceeding 3 metres. areas of high risk, Boiler Houses, Plantrooms,
• Fire dampers must not be used. Transformer Rooms etc.
• Use of volume control dampers and turning D.2.3 Cautionary note to all Ductwork Designers/
vanes are not recommended. Manufacturers:
Further information on kitchen extract systems will be Ductwork constructed to DW/144 Standard has no
found in the HVCA publication DW/171 Specification tested fire resistance. General purpose ventilation/air
for Kitchen Ventilation Systems. conditioning ductwork and its ancillary items do not
d. Enclosed Car Parks - which are mechanically have a fire rating and cannot be either utilised as or
ventilated converted into a fire rated ductwork system unless the
Car Parks must have separate and independent construction materials of the whole system including
extract systems, because of the polluted nature of the supports and penetration seals are proven by test and
extract air. Due to the fire risk associated with car assessment in accordance with BS 476 Part 24.
parks, these systems should be treated as smoke In the case where galvanised sheet steel ductwork is
extract systems and therefore maintain a minimum clad by the application of a protective material, the
of 75% cross-sectional area under fire conditions in ductwork construction must be as type tested and
accordance with BS 476 Part 24. Fire dampers must comply with the protective material manufacturers
not be installed in extract ductwork serving car recommendations, eg. gauge of ductwork, frequency of
parks. stiffeners and non-use of low melting point fasteners or
e. Basements - Ductwork from Basements must be rivets. Sealants, gaskets and flexible joints should be as
Fire Rated tested and certificated in accordance with BS 476 Part
If basements are compartmented, each separate 24 and comply with the manufacturers
compartment must have a separate outlet and have recommendations.
access to ventilation without having to gain access Careful consideration must also be given to the
(i.e. open a door to another maximum certificated size tested to BS 476 Part 24 and
the manufacturers recommendations should always be
followed.

This appendix incorporates information given in the A.S.F.P publication `Fire Rated and Smoke Outlet Ductwork:
An Industry Guide to Design and Installation' available from Association for Specialist Fire Protection, Association
House, 235 Ash Road, Aldershot, Hampshire GU 12 4DD (Telephone: 01252 21322 Fax: 01252 333901)

84
 APPENDIX E - HOT DIP GALVANIZING AFTER MANUFACTURE

E.1 General
E.1.1 For Hot Dip galvanizing after the fabrication of
any article it is necessary to appreciate the nature of the
process, including the surface preparation of the object
to be treated and the precautions to be taken in design,
fabrication and handling.
E.1.2 Hot Dip galvanizing involves dipping the object
into a bath of molten zinc (at a temperature of between
445° and 465° C), and it is necessary for the zinc to
cover the whole of the surface leaving no gaps in the
coating.
E.2 Design and fabrication
E.2.1 Rectangular ductwork must be fabricated using all
welded construction techniques with vented flanges and
stiffening frames (see E.2.3) as mechanical fixing and
lock-forming techniques are not compatible with the
galvanising process. In the course of dipping into the
molten zinc bath, unsightly panel distortion will occur
due to the relief of inherent stress in the steel sheet or of
any stresses that may have been built into the item dur- ever, the pickling process does not generally remove
ing fabrication, or indeed of any stresses introduced grease, oil or oil-based paint, and such substances
during the handling, loading or unloading of the item. should be removed by the fabricator by the use of
Table 20 indicates the minimum requirements for the suitable solvents before the object to be treated is
construction of rectangular ductwork. delivered to the galvanizing works. Any surface rust
that develops on the object between the time of
E.2.2 It is essential to have a free flow of the molten treatment by the fabricator and delivery to the
zinc over the object to be galvanized, together with galvanizing works is not important, as this is cleaned
quick and complete drainage of the molten metal. off by the acid pickling process.
Because of the high temperature involved, the object to
be galvanized should be as rigid as possible, either by E.4 Handling and storage after galvanizing
the use of sufficiently heavy sheet or by stiffening or E.4.1 While a galvanized surface will not develop rust
bracing, or both. in the ordinary sense as long as the zinc coating is
undamaged, zinc is subject to what is known as `wet
E.2.3 Any sealed hollow section or cavity must be storage stain,' which is a white powdery deposit on the
adequately vented in order to obviate any possibility of zinc surface. Wet storage stain can arise from the
explosion. Holes of sufficient size (See E.2.4) in vertical stacking of articles when wet, acid vapours, the effect
members must be provided diagonally opposite each of salt spray, the reaction of rain with flux residues, etc.
other, top and bottom of the member. The damage to the zinc coating is negligible in most
E.2.4 Vent holes should be of sizes as follows: cases. When the deposits are heavy, these should be
Size of Minimum removed by brushing with a stiff bristle or wire brush.
hollow diameter of E.4.2 Galvanized articles should therefore not be
section vent end stacked or loaded when wet; they should preferably be
(dia. or side) drainage holes transported under cover or shipped in dry, well
mm mm ventilated conditions, inserting spacers (but not
Up to 25 10 resinous wood) between the galvanized articles.
50 to 100 16
100 to 150 20 E.4.3 When stored on site or elsewhere, care should be
Over 150 25 taken to avoid resting the galvanized article on cinders
or clinker, as the acid content of these substances will
E.2.5 Stiffeners should desirably have their corners attack the zinc surface.
cropped so as to allow a free flow of zinc. Stiffeners
should be rolled steel angle, uncoated. E.5 Subsequent finishing
E.5.1 Paint finishing subsequent to galvanizing is
E.3 Surface preparation before galvanizing sometimes required either for additional protection or
E.3.1 The steel surface to be galvanized must be for decorative reasons. Galvanised surfaces require
chemically clean before dipping to ensure a continuous chemical pretreatment prior to painting. Examples of
coating. This is mainly achieved at the galvanizer's such a treatment are T-Wash and Etch Primer Types.
works by pickling in an acid bath and fluxing before the Advice should be sought from the paint manufacturer.
article goes into the zinc bath. How

This Appendix incorporates information given in publications available from the

Galvanizers' Association, 6 Wrens Court, 56 Victoria Road, Sutton Coldfield, West Midlands B72 1SY

85
 APPENDIX F - STAINLESS STEEL FOR DUCTWORK

F.1 General usually adjusted by the manufacturer to balance

F.1.1 Stainless steel is not a single specific material: forming response, weldability and corrosion
There is a large family of stainless steels with varying resistance. It is readily welded in thin sheet form and,
compositions to suit specific applications, but all since it does not form a hardened weld HAZ, no post-
contain at least 11 % of chromium as an alloying weld heat treatment is required. It is widely used for
addition. automotive exhaust system parts and is suitable for a
range of ducting and structural applications in mildly
F.1.2 Modern stainless steels have a combination of
corrosive applications.
good formability and weldability, and can be supplied
with a variety of surface finishes (see E4.1 below) They F.2.2.2 17% chromium ferritic steel, 430S17, New
have been developed to cover a wide range of structural Designation 1.4016, x6Cr 17.
uses where high resistance to corrosion and low Forming and general characteristics are similar to the
maintenance costs are demanded. 409 grade, but the higher chromium level confers
F.1.3 Ductwork applications for which stainless steels better general corrosion resistance.
are particularly suited include those where a high F.2.2.3 18% chromium, 9% nickel austenitic stainless
integrity inert material is essential; where a high degree steels.
of hygiene is required; in the chemical industries where
A widely used grade is 304S15, New Designation
toxic or hazardous materials may be contained; in
1.4301, x5CrNil8-10. There are compositional variants
nuclear and marine applications (e.g. on offshore
within this family, designed to give specific
platforms). Stainless steels also find application in
formability and welding characteristics. All are
exposed ductwork where their finish can be used to
weldable and have good general corrosion resistance
aesthetic advantage.
to normal and mildly corrosive atmospheres. They are
F.2 Grades of stainless steel ductile and formable, but forming loads are higher
F.2.1 The grades of stainless steel most commonly used than for mild steels and suitable, robust equipment is
for ductwork applications are among those covered required.
currently by BS 1449, Part 2. However, a European
F.2.2.4 17% chromium, 11% nickel, 2% molybdenum
Standard, will supersede this British Standard. New
austenitic steel, a widely used grade of this type is
designations of the most common steel grades are given
316S31, New Designation 1.4401, x5CrNiMo17-11-2.
in Table 21.
This steel has a significantly higher corrosion
In some cases there are minor differences in chemical
resistance than the standard 18% chromium, 9% nickel
composition between the BS and EN grades.
steels and is suitable for use in more aggressive
Before a grade is specified, the nature of the interior and environments such as are met in ductwork in process
exterior environments of the ductwork system should be plants. However, more highly alloyed stainless steels
taken into account. The steels described below cover with better corrosion resistance are also available and
most normal applications. However, advice on specific the advice concerning aggressive environments given
corrosion risks should be taken if the ductwork is to be under section F.2.1 above should be noted.
installed in a chemically contaminated atmosphere, or is
to be used to transport contaminated air, particularly if F.3 Availability
there is a risk of internal condensation. More highly Stainless steel is supplied in a wide range of thick-
alloyed grades of stainless steel with enhanced corrosion nesses, from 0.4 mm for cold-rolled sheet and coil, and
resistance are available if required. from 0.075 mm for precision rolled strip. It is supplied
in slit widths as specified by the customer, up to a
The commonly used steels divide into two main
maximum width of 2030 mm, depending on thickness.
families; the lower alloy ferritic 11-18% chromium
stainless steels are magnetic. The austenitic, 18% Material compatability of sheet, section and fixings is
chromium, 9% nickel steels have generally better not always assured in practice due to commercial
corrosion resistance and are non- or only slightly availability.
magnetic.
F 4 Surface finishes
F.2.2 The more commonly used stainless steels and F4.1 Stainless steel is available in a wide selection of
their characteristics are described below. finishes, varying from fine matt to mirror polished, as
defined in BS 1449: Part 2: and in EN 10088: Part 2.
F.2.2.1 11.5% chromium ferritic steel with a titanium
addition, 409S 19, New designation 1.4512, Mill finishes
X2CrTi12. Type 2D Cold finished softened and descaled.
This, and related grades, are among the leanest alloyed A uniform matt finish.
of the stainless steels. Forming characteristics are
similar to those of mild steel, so it can be worked
using conventional practices. The composition and
processing of the steel is

86
Type 2B Cold rolled, softened, descaled and essary, however, depending on the type of stainless steel
lightly worked with polished rolls. A being used.
smooth finish brighter than 2D.
F.6.3 As a general rule, the 400 series of stainless steels
Type 2A/2R Bright annealed. A cold finished can be formed using normal mild steel settings. The 300
reflective appearance retained through series, however, because of the higher yield point and the
annealing. greater rate of work hardening, will require higher
Polished finishes working pressures.
Type 4/2J Dull polished. A lustrous unidirectional F.6.4 Ductwork contractors who have experience of the
finish produced by fine grinding, use of stainless steel report difficulty in forming
generally with abrasives of 150 grit size. Pittsburgh and button punch snap lock seams. As regards
It has little specular reflectivity. Further cross joints, socket and spigot joints are recommended,
dull polishing after fabrication will and one or two of the slide-on flanges are suitable. In
diminish the effects on appearance of view of the foregoing, it is recommended that trials be
welds or accidental damage by blending carried out before starting on production.
them into the surrounding metal.
F.7 Rectangular ducts
Type 5/2K Dull polished with specific
The constructional requirements for rectangular stainless
requirements, to achieve a fine, clean
steel ducts are the same as for galvanized mild steel.
cut surface finish with good corrosion
resistance. F.8 Circular ducts
Type 8/2P Mirror polished. A bright, non- The constructional requirements for circular stainless
directional reflective finish with a high steel ducts are the same as for galvanized mild steel.
degree of image clarity. F.9 Stiffening
F.4.2 Where other finishes are required, such as for Wherever possible, the material used for stiffening should
aesthetic purposes, a range of patterned or textured be of the same grade of stainless steel as used for the
(2F,2M) finishes is available. Colour may be applied construction of the ducts, or should be made equally
in the form of paint or lacquer, or the material may be corrosion resistant to suit the environment in which the
supplied pre-coloured as by the 'INCO' process or by ductwork is situated.
mill application of polymer coatings. F.10 Fixings and fastenings
F.5 Surface protection The types of fastening and the maximum spacings
F.5.1 No surface protection is required for stainless specified in Table 5 (rectangular) and Table 9 (circular)
ductwork used indoors or outdoors, provided the also apply to stainless steel ductwork.
correct quality is specified. This is because the Fixings and fastenings should be of the appropriate grade
naturally occurring chromium-rich oxide film which is of stainless steel as used in the construction of the
present on the surface of the metal, if damaged, ductwork, or should be made equally resistant to
reforms immediately by reaction between the steel and corrosion in relation to the environment in which the
the atmospheric or other source of oxygen. ductwork is situated. The type of stainless steel fastening
used should conform to the appropriate specification BS
F.5.2 If a mixture of metals is used, such as mild steel
6105: 1981.
supports for stainless steel ductwork, the surface of the
mild steel must be adequately protected from the F.11 Welding
galvanic corrosion that might result from the intimate All the modern welding processes may be used to weld
contact between the two types of metal. (The stainless steel but carburising operations such as oxy-
appropriate protective finish should be employed. See acetylene and carbon arc welding are not suitable. The
27.3.5) Tungsten inert gas (TIG) and resistance welding
techniques are most likely to be used for thin gauge
F.6 Construction materials. Attention is drawn to BS 4872: Part 1 1982,
F.6.1 Sheet thicknesses for stainless steel ductwork (welder qualification) and BS 7475: 1991 (welding
should be the same as for galvanized steel (see Tables processes).
2, 3 and 4). Provided the correct grade of stainless
steel has been selected, there is no requirement for a Selection of the correct welding electrodes and filler
corrosion allowance with stainless steels and the gauge rods is important, particularly when welding
dissimilar metals, such as stainless steels to non-stainless
can be selected on structural considerations only.
structural steels. Reference for guidance should be made
F.6.2 The forming of rectangular and circular ducts to BS 2901: Part 2: 1990 for rods and wires for gas
can be carried out by the use of conventional press shielded welding and BS 2926:1984 for electrodes for
working and sheet metal forming machines. Some Manual Metal Arc. (MMA) welding.
alteration in working practices may be nec-
F.12 Avoidance of contamination
Attention is drawn to the risks of rust staining of stainless
steel surfaces resulting from contamination by non-
stainless steel or iron debris.

87
If particles such as filings of a non-stainless steel or F.13 Fire dampers
iron are expressed into contact with a stainless steel, Stainless steel is an ideal material for use in the
subsequent exposure to moisture will lead to staining construction of fire dampers, because of its high
of the surface as these particles rust. Whilst this resistance both to heat and corrosion. It is therefore
staining often can be removed without harm to the most applicable where a fire authority specifies a
stainless steel surface, in aggressive environments requirement for corrosion resistance.
corrosion products around the rust centre can create a
F.14 Sealants, gaskets and tapes
risk of pitting of the stainless steel. As a general rule,
The sealing materials and methods set out in this
stainless steels should be kept free from iron dust and
publication are also applicable to stainless steel
debris contamination. In particular, wire brushes must
ductwork. However, any chloride-based material,
be made of stainless steel and shot, beads and abrasive
such as polyvinyl chloride (PVC), should be avoided,
media used to clean surfaces must be `iron free'.
as breakdown of such material at certain elevated
temperatures could lead to corrosion of the stainless
Contamination can arise from tools which have been steel.
used previously for cutting non-stainless steels
F.15 General design considerations
without adequate cleaning and from abrasion on
It is the designer's responsibility to indicate the type of
stillages and racks. It is good practice to dedicate
stainless steel most suitable for the conditions to which
storage and bench areas for stainless steels, with soft
the ductwork is to be exposed. If users and designers are
surfaces, e.g. wooden battens, to mininise scratching
in doubt as to which material is appropriate to a
of the surface and if practicable designate stainless
particular application, technical advice may be obtained
only working areas.
from the source noted below.

Table 21, showing the approximate correspondence between the chemical compositions of the commonly used
stainless steel grades in BS 1449, Part 2: 1983, and the European Standard EN 10088-1, List of Stainless
Steels. (Part 1 gives the chemical compositions and identifications of the stainless steels, it is for information.
Part 2 of this standard describes the technical delivery conditions for sheet/plate and strip for general
purposes.)

This appendix is based largely on information kindly

supplied by the
Avesta Sheffield Technical Advisory Centre, ASTAC,
P.O. Box 161,
Shepcote Lane,
Sheffield S9 l TR
Telephone: 0114 244 0060 Fax: 0114-242 0162

88
APPENDIX G - PRE-COATED STEEL

G.1 Nature of the material G.5 Ductwork construction from pre-coated steel
G.1.1 'Pre-coated' steel is sheet, coil or strip to which G.5.1 The type of pre-coated steel most suitable for
has been applied at the steel mills a coating having a ductwork should be carefully considered, mainly from
decorative or protective function, or both. the point of view of the fabrication properties of the
coating type. It is probable that a plastisol coating will
G.1.2 The basis metal to which the coatings are
be found to be most suitable for ductwork, as this type
applied are hot-dip galvanized or aluminium-zinc
of coating will withstand forming at normal ambient
coated sheet or coil, uncoated steel or electro-
temperatures. It also tolerates rougher handling during
galvanized steel (e.g., Zintec).
forming and erection than the much thinner paint
G.2 Range of coatings available coating types.
G.2.1 A number of different types of coating, in
G.5.2 Careful consideration should be given to the
various thicknesses, are available - PVC ('Plastisol'
constructional methods to be used for ductwork to be
and 'Organosol'); paint coatings of several types,
made from pre-coated steel. The principle to be
silicone enamels, etc.
followed should be to make seams and joints as
G.2.2 A wide range of colours and surface finishes are unobtrusive as possible. Some of the conventional
available, but there are minimum quantity methods of seaming may be used, but a number of
requirements for some types of coating, finish and others are not suitable. Welding with conventional
colour. The characteristics of the particular type of equipment should not be attempted. Mechanical
coating contemplated for a particular use should be fastenings should be chosen with care having regard to
investigated in respect of formability, fastness to light, appearance as well as efficiency; and sealant should be
chemical resistance and other relevant properties. applied with these factors in mind. Stiffening should be
carefully considered in relation to appearance.
G.2.3 The material can be supplied with one or both
sides treated, with the specified coating. Standard G.6 Handling, storage, transport and erection
`backing coat' finishes are usually applied to the G.6.1 Much more care than usual is required in these
reverse side unless otherwise stated. respects, as the coatings are all to a greater or lesser
degree susceptible to mechanical damage. For example,
G.3 Sizes available sheet should not be dragged off the top of a pile but
G.3.1 Pre-coated steel is available in sheet or coil
removed by `turning' off the stack.
form. The maximum available width can vary
according to the steel thickness required. Availability G.6.2 With sheet pre-coated on one side only, it may be
varies according to type of substrate and coating, so found desirable to stack face to face.
prospective purchasers should query the sizes
G.6.3 The flexibility of coatings of the types used on
available for the specific type required.
pre-coated steel depends on temperature. Therefore,
G.4 Sources of supply manipulation should be carried out at temperatures
G.4.1 Pre-coated steel is widely available but it above 16°C (60°F) in order to minimise the risk of the
should be noted that minimum order quantities may film cracking on roll forming, etc. If the material has
apply. been stored outside at low temperature, a warm-up
period should be allowed before manipulation of the
sheet is undertaken.

The information on which this appendix is based

has been kindly supplied mainly by British Steel
plc. More detailed information may be obtained
from:
British Steel plc,
Product Development Centre,
Shotton Works,
Deeside,
Flints CH5 2NH
Telephone: Chester (01244) 812345
Fax: 01244 836134

89
 APPENDIX H - ALUMINIUM DUCTWORK

H.1 Scope H.5 Fastenings

This section applies only to rectangular and circular H.5.1 The types of fastening and the maximum spacings
aluminium ductwork operating at low pressure, as defined specified in Table 5 (rectangular) and Table 9 (circular)
in Tables 22 and 23. apply to aluminium ductwork, except that such fastenings
If consideration is being given to either higher pressures shall be of aluminium, stainless steel or monel metal.
or flat oval ductwork then it would be prudent to seek H.6 Welding
advice from manufacturers who have the experience and H.6.1 All the aluminium alloys can be welded by MIG
capacity to manufacture aluminium ductwork. (Metal and Inert Gas) or TIG (Tungsten and Inert Gas)
H.2 Suitable grades methods, with argon as the shielding gas. Helium or a
H.2.1 Ductwork can be constructed from all the mixture of helium and argon can be used, but not CO2.
commonly used aluminium alloys, the choice depending Alloys in a work-hardened temper are reduced to the
on the purpose for which the ducts will be used and the annealed condition in the heat affected zone; 6082-T6 is
service environment. reduced approximately from the T6 to the T4 temper.
Alloys 1200 and 3103 are easy to braze, as is 6082, but
H.2.2 The alloys 1200, 3103 and 5251 (as specified in
the latter needs to be re-heat treated to regain its strength.
BS.EN485, BS.EN515, BS.EN573) are easy to form and
to join, and have excellent resistance to atmospheric H.7 Protective finishes
corrosion, with 5251 being rather more resistant to H.7.1 No protective finishes are required for aluminium
marine atmospheres. ductwork used indoors or outdoors in normal atmospheric
conditions. In moist atmospheres, particularly if they are
H.2.3 These alloys can be supplied in various tempers
contaminated by industrial effluent or by salt from the
produced by different degrees of cold rolling, so that a
sea, surfaces not exposed to washing by rain will become
range of strengths is available. In choosing a temper, it is
roughened and covered with a layer of white corrosion
necessary to consider any forming that will be done, as
product. However, this has the effect of sealing the
with the harder tempers the forming of tight bends might
surface against further attack, and the mechanical
cause cracking. Where high strength is required, alloy
properties of any but the thinnest of materials will be only
6082-T6 sheet can be used.
slightly affected.
H.2.4 Aluminium coil is available in plain form and pre-
H.7.2 If surface protection is specified, any of the normal
painted finish.
organic finishes can be used, including the laminated
H.3 Construction - rectangular ducts PVC films, although paints with heavy metal pigments
H.3.1 Table 22 sets out the minimum constructional and are not suitable. The use of prepainted strip in coil form
stiffening requirements for rectangular aluminium ducts provides a reliable quality finish and often proves more
and the permitted types of cross joint. economical than painting after assembly. Anodising
H.3.2 Sealant provides an excellent finish for aluminium, but this
The sealant requirements set out in this specification for process would have to be carried out after forming and
galvanized steel rectangular ductwork also apply to the would therefore not usually be practicable for ductwork,
longitudinal seams and cross joints in aluminium except perhaps for ducts formed from extrusions.
ductwork. H.7.3 Mild steel section used in supporting aluminium
H.4 Construction - circular ducts ductwork shall have a protective finish
H.4.1 Table 23 sets out the minimum constructional and (See 27.3.5)
stiffening requirements for circular ducts made from
aluminium, and the permitted types of cross joint.

90
 Incorporates information provided by the Aluminium
Federation Ltd., Broadway House, Calthorpe Road, Five
Ways, Birmingham B15 1TN (telephone: 0121-456
1103), from whom more detailed information may be
obtained.

APPENDIX J - EUROVENT
J.1 General tate commercial exchanges between its member
Some explanation of the function, composition, nations in the search for improved quality; and the
objectives and membership of EUROVENT is given adoption of rules, directives and codes of practice in
below. the technical and economic spheres in the member
countries'.
J.2 Membership
EUROVENT is an omnibus word standing for the J.4 EUROVENT publications
European Committee of the Construction of Air EUROVENT has published a number of documents in
Handling Equipment. The committee was formed in the air handling field, and these include Document 2/2
1959, and in 1977 its constituent members were the covering the procedure for testing for air leakage in
relevant national associations in Austria, Belgium, ductwork, and provides for two levels of permissible
Denmark, Finland, France, German Federal Republic, air leakage for low-pressure air distribution systems.
Italy, Netherlands, Norway, Sweden, Switzerland and Document 2/3 covers the standardisation of duct sizes.
the United Kingdom.
J.5 Air leakage
J.3 Objectives The basis on which air leakage is calculated in
The objectives of EUROVENT are `to improve and EUROVENT Document 2/2 has been adopted in
develop technical matters in the manufacture and DW/143 A practical guide to Ductwork Leakage
operation of air handling equipment; to improve the Testing.
professional status of its members and to facili-

Information about EUROVENT may be obtained from

the HEVAC Association, Sterling House, 6 Furlong
Road, Bourne End, Bucks SL8 5DG (Telephone: 01628
531186 Fax: 01628 810423)

91
APPENDIX K - SUMMARY OF BS.EN10142: 1991 CONTINUOUSLY HOT DIP ZINC
COATED MILD STEEL STRIP AND SHEET FOR COLD FORMING

Note - The extracts from BS.EN 10142: 1991 have been Normal spangle (N). This finish is obtained when the
prepared by the HVCA and are included here by courtesy zinc coating is left to solidify normally. Either no
of the British Standards Institution. spangle or zinc crystals of different sizes and
K.1 GENERAL brightness appear depending on the galvanizing
K.1.1 The BS 2989: 1975 and 1982 entitled conditions. The quality of the coating is not affected
`Continuously hot-dip zinc coated and iron-zinc alloy by this.
coated steel: wide strip, sheet/plate and slit wide strip' NOTE. Normal spangle is the type normally supplied
summarised in DW/142 has been superseded by for a wide variety of applications.
BS.EN10142: 1991 entitled `Continuously hot-dip zinc Minimized spangle (M). The surface has minimized
coated mild steel strip and sheet for cold forming' spangles obtained by influencing the solidification
(including amendment A1:1995). process in a specific way. The finish may be specified
K.1.2 British Standard BS.EN10142: 1991 sets out if the normal spangle applicable does not satisfy the
requirements for the conventional galvanized sheet and surface appearance requirements.
coil and for zinc-iron coated steel. (Both these are K.5 SURFACE PROTECTION
included in DW/144 - see Section 7.) K.5.1 General
The type of steel normally used for ductwork is Hot-dip zinc coated strip and sheet products generally
DX51D and Z275. receive surface protection at the producer's plant. The
period of protection afforded depends on the
K.2 STEEL GRADES
atmospheric conditions.
K.2.1 BS.EN10142: 1991 and amendment A1:1995 lists
the grades of steel set out in the next column, among K.5.2 Chemical Passivation
others: Chemical Passivation protects the surface against
Grade Name of grade Application 1 humidity and reduces the risk of formation of `white
DX51D + Z Bending and Forming quality rust' during transportation and storage. Local
profiling steel suitable for discolouring as a result of this treatment is permissible
quality manufacture of the most and does not impair the quality.
profiles and more K.5.3 Oiling
difficult bending This treatment also reduces the risk of corrosion of the
operations surface. It shall be possible to remove the oil layer
DX52D + Z Drawing quality Forming quality steel with a suitable degreasing solvent which does not
suitable for simple adversely affect the zinc.
drawing operations and
for more difficult K.5.4 Chemical Passivation and Oiling
profiling operations Agreement may be reached with the producer on this
DX53D + Z Deep drawing Forming quality combination of surface treatment if increased
quality steel suitable for protection against the formation of `white rust' is
deep drawing and required.
difficult forming K.5.5 Untreated
operations Hot-dip zinc coated strip and sheet products com-
DX54D + Z Special deep Forming quality plying with the requirements of this standard are only
drawing quality steel suitable for supplied without surface protection if expressly
deep drawing and desired by the purchaser on his own responsibility. In
difficult forming this case, there is increased risk of corrosion.
operations where a non-
ageing steel is required K.6 FORMING
K.6.1 The British Standard says that provided that the
K.3 COATING TYPES AND TOLERANCES profiling machine is set to avoid excessive stretching
K.3.1 The types of zinc coating are set out in Table 24. in the product, it is possible to form lock seams
BS.EN10142: 1991 (reproduced at the foot of this successfully with DX51 D + Z sheet up to a thickness
summary). of 1.5 mm and DX52D + Z sheet up to 2 mm; and
K.3.2 Whilst the coating thickness is not subject to snap lock seams with DX51 D + Z up to 0.9 mm thick
tolerances the substrate and consequently the gauge sheet and DX52D + Z sheet up to 2 mm.
thickness does have accepted tolerances and these
including sheet widths/lengths will be found in K.7 WELDING
K.7.1 Care should be taken to use proper methods and
BS.EN10143: 1991.
procedures. The iron-zinc coating is more suitable for
K.4 COATING FINISHES resistance welding than the conventional zinc coating.
K.4.1 BS.EN10142: 1991 and A1 1995 includes a
description of the various types of finish available:

92
APPENDIX L -'DESIGN NOTES FOR DUCTWORK'
(CIBSE Technical Memorandum No. 8)

L.1 At the time of publication (1983) this technical Standard dimensions of circular, rectangular and flat
memorandum brought together information on the oval ducts.
design of ductwork systems. Duct sizing methods, including velocity, equal-
L.2 The contents had been drawn from the relevant friction and static regain methods, and pressure loss
sections of the CIBSE Guide and other recognised calculations, with an example calculation.
references, and include additional material on good Heat loss from and gain to air in the duct; con-
design practice. The Notes make frequent reference to densation, noise control and fire.
DW/142, and an effort was made to ensure
Commissioning and testing.
consistency between the two publications. Whilst
DW/142 has now been superceded by DW/144, the Overseas work.
technical memorandum, has not currently been up- Drawing symbols in current use.
dated but still contains relevant information that may
be of use to a ductwork designer/manufacturer. Whilst L.3 The flow of heavily contaminated air in ducts is
not covered in detail in the Notes; nor are the
some of the information may now be superceded,
constructional aspects of ductwork, which are dealt
TM8 includes chapters on:
with in DW/144.
Pressure loss in ducts, including corrections for duct
L.4. The Notes were completed by references, a
surface type, air pressure, air density, temperature
bibliography of over thirty titles and appendices
and altitude, and loss factors for fittings.
covering properties of air, ductwork support loads,
Equivalent diameters of rectangular and flat oval velocity pressure for air flow and conversion to SI
ducts. units.

Technical Memorandum No. 8 was published by the Chartered Institution of Building Services Engineers,
Delta House, 222 Balham High Road, London SW12 9BS (Telephone: 0181 675 5211)
and whilst it is no longer available as a publication, it is still available in photo-copy form.

93
APPENDIX M - GUIDANCE NOTES FOR INSPECTION, SERVICING AND
CLEANING ACCESS OPENINGS
M.1 GENERAL ii) Clear directions could be given to the ductwork
This appendix highlights, in summary form, the access contractor as to the size and location of cleaning
consideration that should be made by the designer in access panels that are required to be fitted during
terms of inspection, servicing and cleaning. Having the manufacturing process.
considered the scope and the design of the ductwork iii) The specialist cleaning operation prior to
system relative to the guidelines outlined below the commissioning would enable the cleaning
designer should clearly indicate which levels of access contractor to verify the practical access
should be incorporated into the manufacture of a new requirements for the future cleaning operations
ductwork system (See Table 25 and Note 1 below it). associated with a regular maintenance programme.
M.2 DESIGN CONSIDERATIONS iv) A specialist cleaning operation prior to com-
missioning would allow the designer to omit from
M.2.1 Inspection and servicing requirements are set
the specification the DW/TM2 requirements for
out in Section 20 of this specification.
factory sealing, protection, wipe downs and
M.2.2 Cleaning requirements are set out in the HVCA capping-off.
publication TR17 "Guide to Good Practice, v) Specialist cleaning to the measurable standards
Cleanliness of Ventilation Systems" and the guide defined in TR17 will allow an objective definition
states "The precise location, size and type of access of cleanliness to be achieved.
would be dependent on the type of ductwork cleaning,
Careful consideration must be given by the designer to
inspection and testing methods to be adopted."
the practical problems associated with the manufacture
Care, protection and standards of cleanliness prior to and fitting of suitably sized access panels on small cross
commissioning are set out in the HVCA publication section ducts and the circular faces of round and flat
DW/TM2 "Guide to Good Practice, Internal oval ducts in particular.
Cleanliness of New Ductwork Installations" and the
M.2.3 Special consideration must be given by the
guide states "Where specific limits of cleanliness are
designer to the practical problems associated with
required, ductwork shall be cleaned after installation
gaining personnel access to heavily congested ceiling
by a specialist cleaning contractor."
areas and multi-layered ductwork systems. This
It will be in the interests of the designer, both approach would avoid the possibility of access panels
financially and practically, to consider employing a being incorporated into a ductwork system at the
specialist cleaning contractor at the outset of a manufacturing stage that were later found in practice to
contract to internally clean newly installed ductwork be inaccessible for either servicing or cleaning
prior to handover. This approach would realise the activities.
following benefits:
M.3 ACCESS TO IN-LINE EQUIPMENT
i) The actual number of cleaning access panels
could be determined to suit the method of This appendix only covers access/inspection through the
cleaning to be adopted (This may be less than the ductwork body adjacent to an item of in-line equipment
maximum requirements listed under Level 3 of and not openings in the equipment itself.
Table 25).

94
APPENDIX N - BIBLIOGRAPHY
Included in this Bibliography are technical publications which may be Research Reports
of interest to ductwork designers. fabricators and erectors, and to those RR01/95: Ventilation system hygiene - A review of published
in the heating, ventilating, air conditioning industries generally. information on the occurrence and effects of
Enquiries should be made of the relevant organisation, at the address contamination
quoted. Since its publication other addresses contained within RR02/95: Air-to-air heat recovery
DW/144 may have changed, and some publications may have been RR03/95: Influence of HVAC on smoke detectors
superseded.
NATIONAL ENGINEERING SPECIFICATION
HEATING AND VENTILATING LIMITED
CONTRACTORS’ ASSOCIATION Southgate Chambers, 37/39 Southgate Street,
34 Palace Court, London W2 4JG Telephone: 0171-229 Winchester S023 9EH
2488; Fax: 0171-727 9268. (Telephone: 01962 842058; Fax: 01962 868982)
Orders to HVCA Publications, Old Mansion House, BUILDING SERVICES RESEARCH AND
Eamont Bridge, Penrith. Cumbria CA10 2BX INFORMATION ASSOCIATION
(Telephone: 01768 864771 Fax: 01768 867138) Email: Old Bracknell Lane West, Bracknell, Berkshire RG12
[email protected] 4AH (Telephone: Bracknell (01344) 426511; Fax:
01344 487575)
DW/144 Specification for sheet metal ductwork (low-, medium-
and high-pressure) (1998) Application Guides
DW/143 A practical guide to ductwork leakage testing (1983) AG.1/74 Designing Variable Volume Systems for Room Air
DW/151 Specification for plastics ductwork Movement
DW/171 Guide to good Practice for kitchen ventilation systems AG.I/91 Commissioning of VAV Systems in Buildings.
DW/191 Guide to good practice glass fibre ductwork DWITM1 TN.6/94 Fire Dampers
Acceptance scheme for new products -Rectangular cross LB.65/94 Ventilation of Kitchens
joint classification AG.3/89 The Commissioning of Air Systems in Buildings
DW/TM2 Guide to good practice - Internal cleanliness of new AH.2/92 Commissioning of Bems - A Code of Practice
ductwork installations TN.24/71 Fire Dampers in Ventilating Ducts.
DW/TM3 Guide to good practice for the design for the Installation
of fire and smoke dampers
HEATING, VENTILATING AND AIR
Other publications CONDITIONING MANUFACTURERS
JSI H&V safety guide 5th edition ASSOCIATION (HEVAC)
JS2 Tool box talks
Sterling House, 6 Furlong Road, Bourne End, Bucks
JS5 Welding Safety booklet
JS19 Safety facts booklet. Fact sheets 1-24 2nd edition SL8 5DG (Telephone: 01628 531186 Fax: 01628
JS21 COSHH manual volume I Advice on compliance with 810423 Email: [email protected])
the regulations
JS 21A COSHH manual volume 2 Assessment sheets Publications
JS23 Risk management manual Air Diffusion Guide
TR/3 Brazing and bronze welding of copper pipework and Guide to Air Handling Unit Leakage Testing
sheet(1976)
TR5 Welding of carbon steel pipework (1980) Guide to Good Practice: Air Handling Units
TR6 Guide to Good Practice for Site Pressure Testing of Real Room Acoustic Test Procedure
Pipework (1980) Specification for the Certification of Air Filters
TR17 Guide to good practice cleanliness of ventilation
systems. Method of Test for Water Rejection Performance of Louvres
Subjected to Simulated Rainfall
CHARTERED INSTITUTION OF BUILDING Test Procedure for Acoustic Louvres
SERVICES ENGINEERS Specification for Floor Grilles - Types, Performance and Method of
Test
Delta House, 222 Balham High Road; Specification for the Determination of the Collection Efficiency of
London SW12 9BS (Telephone: 0181-675 5211 Fax: Sand Trap Louvres
0181-675 5449) Domestic Mechanical Ventilation Systems with Heat Recovery
CIBSE Guide Fan Application Guide
Volume A Design Data
Volume B Installation and Equipment Data Fan and Ductwork Installation Guide
Volume C Reference Data Guide to Fan Noise and Vibration
Commissioning Codes Specification of Requirements for Natural Smoke and Heat Exhaust
These Codes cover the preliminary checks, setting to work and Ventilators
regulation of various categories of plant. The Codes give a guide to Specification for Powered Smoke and Heat Exhaust Ventilators
design implications.
Specification of Requirements for Smoke Curtains
Series A Air Distribution Systems
Series B Boiler Plant Design Guide of Smoke Ventilation for Single Storey Industrial
Series C Automatic Control Systems Buildings Including those with Mezzanine Floors and High Racked
Series R Refrigerating Systems Storage Warehouses - Issue 3
Series W Water Distribution Systems Guidance for the Design of Smoke Ventilation Systems for Covered
and Underground Car Parks - Issue 1
Technical Memoranda
Application of Smoke Control Equipment and Systems: Guide to
TM 4 Design Notes for the Middle East
Good Practice - Issue 1
TM 8 Design Notes for Ductwork
TM 13 Minimising the Risk of Legionnaires Disease

95
BRITISH STANDARDS INSTITUTION SHEET METAL AND AIR CONDITIONING
Sales Department, 101 Pentonville Road, London N1 CONTRACTORS' NATIONAL
9ND (Telephone: 0171-837 8801) ASSOCIATION INC. (SMACNA)
Headquarters:
BS 381 C: 1996 Colours (of ready-mixed paints) for specific 4201 Lafayette Center Drive
purposes Chantilly
CP 413: 1973 Ducts for building services Virginia 20151-1209
BS 476: Fire tests on building materials and structures
Mailing Address
Part 4: 1984 Non-combustibility test for materials P.O. Box 221230
Part 6: 1989 Fire propagation test for materials Chantilly
Part 7: 1993 Surface spread of flame tests for materials Virginia 20153-1230
Part 20:1987 Fire resistance of elements of construction
Telephone (703) 803-2980
Part 21:1987 Fire resistance of loadbearing elements of
Fax (703) 803-3732
construction
Part 22:1987 Fire resistance of non-loadbearing elements of Accepted Industry Practice for Industrial Duct Construction (1975)
construction Architectural Sheet Metal Manual (1993)
Part 23:1987 Contribution of components to the fire Contractors Guide for Modification to Construction Contracts
resistance of a structure (1993)
Part 24:1987 Fire resistance of ventilation ducts Ducted Electric Heat Guide for Air Handling Systems (1994)
BS 5588 Energy Conservation Guidelines (1984)
Part 9:1980 Fire Precautions in the design and construction Energy Recovery Equipment & Systems (1991)
of buildings
Fibrous Glass Duct Construction Standards (1992)
BS 729: 1971 Hot dip galvanized coatings for iron and steel
Fire, Smoke & Radiation Damper Install. Guide for HVAC Systems
articles
(1992)
BS 1449: Steel plate, sheet and strip
Guide to Steel Stack (1995)
Part 1:1991 Carbon steel plate, sheet and strip
HVAC Air Duct Leakage Test Manual (1985)
Part 2:1983 Stainless steel plate, sheet and strip.
HVAC Commissioning Manual (1994)
and
HVAC Duct Construction Standards-Metal & Flexible (1995)
BS.EN 10149-2: 1996
Addendum No. I (Nov 1997)
BS.EN 10149-3: 1996
HVAC Duct Systems Inspection Guide (1989)
BS.EN 10131: 1992
HVAC Systems-Application (1986)
BS.EN485 Wrought aluminium and aluminium alloys
HVAC Systems-Duct Design (1990)
Parts 1-4 for general engineering purposes - plate,
HVAC Systems-Testing, Adjusting & Balancing (1993)
BS.EN515 1993 sheet and strip.
Indoor Air Quality Manual (1993)
BS.EN573
Kitchen Equipment Fabrication Guidelines (1990)
Parts 1-4
Managers' Guide for Welding (1993)
BS 1474:1972 Wrought aluminium and aluminium alloys
Rectangular Industrial Duct Construction Standards (1980)
and bars, tubes and sections
Round Industrial Duct Construction Standards (1977)
BS.EN755
Seismic Restraint Manual (1991) (w/ Appendix E, 1993)
Parts 3-6
SMACNA Master Index of Technical Publications (1995)
BS.EN22063: Sprayed metal coatings
Thermoplastic Duct (PVC) Construction Manual (1994)
1994 Protection of iron and steel by aluminium and
zinc against atmospheric corrosion Protection of DEPARTMENT OF THE ENVIRONMENT
iron and steel against corrosion and oxidation at
elevated temperatures (Publications Centre)
BS.EN10142: Continuously hot-dip zinc coated mild H.M. Stationery Office, 51 Nine Elms Lane, London
1991 steel strip and sheet for cold forming - technical
SW8 5DR
delivery conditions M & E No.1 1972 Electrical installations in buildings (New
BS.EN10143: Continuously hot-dip zinc coated and Edition)
M & E No.3 1988 Heating, hot and cold water, steam and gas
1991 ironzinc alloy coated steel sheet and strip -
installations for buildings
tolerances on dimensions and shade
M & E No.4 1970 Central heating and hot and cold water
BS 3533: 1981 Glossary of terms relating to thermal insulation
installations for dwellings
BS.EN.ISO: 1479 Self-tapping screws and metallic drive screws
M & E No.1001971 Mechanical ventilation for buildings
BS.EN.ISO: 7049:
1994 BRITISH STEEL PLC
BS 4800:1989 Paint colours for building purposes Market Communications Dept
BS 4848: Hot rolled structural steel sections British Steel PLC
Part4: 1972 Equal and unequal angles Strip Products
BS 5422:1990 Specification for the use of thermal insulating P.O. Box 10 Newport
materials South Wales NP9 OXN
BS 5720: 1979 Code of practice for mechanical ventilating and (Telephone 01633 290022)
air conditioning in buildings (Fax 01633 464087)
BS 5970: 1992 Code of practice for thermal insulation of Publication: Edge protection by zinc
pipework

96
 ASSOCIATION FOR SPECIALIST FIRE HEALTH AND SAFETY EXECUTIVE
PROTECTION Rose Court
Association House 2 Southwark Bridge
235 Ash Road London SE1 9HS
Aldershot Telephone 0171-717 6000
Hampshire GU 12 4DD
Telephone 01252 21322
Fax 01252 333901
Publications.
Fire Rated and Smoke Outlet Ductwork: An
Industry Guide to Design and Installation.

APPENDIX P - CONVERSION TABLES

Sheet thicknesses

97
98
NOTES

99
NOTES

100
101