CHAPTER 4

DUCT SIZING AND CONSTRUCTION

1. Introduction
• IMost air conditioning and heating systems require some form of
duct work to channel or direct the air to places where the
conditioned air is needed. There are many types of ductwork
available and often times the ductwork. It is important that the
ductwork is designed and installed correctly.
• A poor installation job will result in poor performance, bad air flow,
leaky duct systems, and higher heat loss. Another important factor in
the installation process is to make sure the duct work is sized
properly. Over sizing systems cost more and does not maintain the
desired air flow and undersized duct work causes the system to
strain mechanically and can be noisy.
• The purpose of a duct system is to transmit air from the central air
source to the air diffusers located in the building control zones.
• Aduct system is a network of round or rectangular tubes—generally
constructed of sheet metal, fiberglass board, or a flexible plasticand-
wire composite—located within the walls, floors, and ceilings.A
Example of Poor and Good Duct Design
2. Duct sizing
• By selecting an appropriate pressure drop, the
required duct diameter can be selected for any
given air volume. When using Figure1 any
resistance per unit length can be selected.
• Some designers use values as shown below.
• 1. Quiet - Pressure drop 0.4 Pa/m.
• 2. Commercial - Pressure drop 0.6 Pa/m.
• 3. Industrial - Pressure drop 0.8 Pa/m.
• However, we l use a pressure drop of 1.0 Pa/m,
always bearing in mind that the designer may wish
to use alternative values as listed above.
Duct Sizing Using Equal Pressure Drop Method
• 1. Choose a rate of pressure drop and keep this
constant for the whole system e.g. 0.6 Pa per
metre run.
• 2. Size ductwork using Duct Sizing Chart if the
volume flow rate of air is known.
• This will give the duct diameter.
• 3. Determine the equivalent size of rectangular
duct if required by calculation or by using Table
• 4. Calculate the actual air velocity from:
• Air velocity (m/s) = Volume flow rate (m3/s)
/ CSA
2. Design Methodology
When considering ventilation design the following
approach could be adopted before sizing begins
and the following questions should be considered:
1. What areas need ventilation?
The contaminants should be listed for these
areas.
2. What type of system should be used, supply,
extract or balanced?
3. Are there any alternative systems to consider?
4. Is air conditioning necessary in the building?
• If air conditioning is necessary then should it be
incorporated into the ventilation system?
Duct sizing
Example 1
• Size the ventilation ductwork in an extract system,
which removes 0.8 m3/s from a kitchen.
• Use a duct pressure drop per metre of 1.0 Pa/m.
• The ductwork should be square.
• From figure,The corresponding duct diameter can
be read between 0.40, and 0.45 metres diameter.
• Careful examination will reveal that the design
point is is about 0.41 metres.
• This is 410 mm diameter.
Duct Sizing - Introduction Figure 4.2.
Duct Sizing - Introduction Figure 4.2.
Duct sizing
Convert this to an appropriate square size.
• Area (Circle)= p x r2
• Cross Sectional Area of Duct (CSA) = p x 0.2052
= 0.132 m2
• For square duct of same CSA, one side =
(0.132)0.5 = 0.363 m
The next standard size of galvanised sheet metal
ductwork would be 400mm x 400mm.
Duct sizing with software
Duct sizing can be done with software . One simple
software MacQuay software
• Copy the director of the software to your laptop
• Run the software
• Select units Meteric
Inorder to size the software
• Give pressure drop which will 0.6 pafor commercial
buildings like office, hotel and hospital. It can be
0.8 for supermarket , malls, cafeteria and 1 for
factories. ).
• Constain the height of duct based on ceiling spce
as first dimensions.
MacQuay software Example
• Run the software
• Select units Meteric
• Give duct section flow rate in this case 900lps
• Give pressure drop which will be constsnt for all
section in this case we assume 0.6 pa
• Give height of duct which is usually constrained by
available ceiling spa. In this cas let us say 350 mm
for ceiling spce of 450 mm
• See the result in next slide: 325x600 mm size
• Check the velocity is less than the allowable for
main duct office/hotel/hospital is 6 m/s
Duct sizing with MacQuay Software
3. Pressure Loss in Ducts and Fittings
• Zeta (z) factors are to be used with the Velocity
Pressure to find fittings resistances.
• Zeta (z) factors are pressure loss factors.
• These allow for the resistance of fittings in
ductwork systems which can be quite significant
compared to straight runs of duct.
• Pressure Loss (or resistance) (Pa) = zeta
factor x Velocity Pressure (Pa)
Δ=ζ ρ v2/2
Examples of  Zeta Factors

• 1. Bend – mitred and radiused on both inside and

outside.

Outside Radius

Inside Radius

Zeta factor = 0.67

Examples of  Zeta Factors

• 2. Rectangular Duct Branch

Branch

VP2
VP3

VP1
Main
Duct
Zeta factor = 0.67
 Examples of  Zeta Factors

2. Rectangular Duct Branch

Straight Through’
To Branch 1 to 3
1 to 2 Branch
Velocity Velocity
Zeta Zeta
pressure pressure VP2
factor factor
ratio ratio VP3
(z) (z)
VP2/VP1 VP3/VP1
0.6 0.44 0.6 1.60
0.8 0.09 0.8 0.78 VP1
Main Duct
1.0 0.04 1.0 0.55
1.2 0.02 1.2 0.45
Examples of  Zeta Factors

3. Tapered Reduction

Included Zeta factor

angle Taper both Taper one
q sides side
30o 0.02 0.07
45o 0.04 0.20
60o 0.07 0.40
Example of Duct Pressure Drop Calculation
NOTES:
1.Keep one side 300 mm high.
2.Ductwork to be rectangular galvanised steel.
3.There are no additional pressure losses.
4.Neglect entry or exit losses from the section.

12 metres Bend –
Air flow rate 1.5 Radiused on
m3/s inside and
outside
 Duct Sizing Table
1 2 3 4 5 6 7 8 9 10 11 12
Press Pressure Loss Cumula
ure Total
Leng Flow Fittings tive
drop Duct Velocity Pressu
Sectio th Rate Velocity pressure loss Fitting Straig Pressur
per Size Pressure ht re
n (m3/s (m/s) factor or s e
metre (mm) (Pa) Duct Loss
(m) ) z (zeta) factor (Pa) Loss
(Pa/m (Pa) (Pa)
(Pa)
)
A 12 1.5 1.0 0.51 metres Vel = VP = 0.5 x 1 . 30.6 x 12 x 20.5
dia. vol/CSA 1.2 x 7.142 z factor = 0.67 0.67 1.0 +
CSA = 0.204 = 1.5 / 0.7 x = 30.6 Pa from 12.0
m2 0.3 (EXAMPLES = 20.5
Rectangular = 7.14 m/s OF z zeta = 32.5
Width = 0.204 / FACTORS) = 12.0 = 32.5
0.3
= 0.681 m TOTAL z
say duct size factor = 0.67
is;
700mm x 300
mm high
 Pressure Drop Calculation Table
Duct Sizing Table
1 2 3 4 5 6 7 8 9 10 11 12
Pressu Pressure Loss
Velocit Fittings Cumulat
Leng Flow re Total
Duct Velocit y pressure loss ive
th Rate drop Straight Pressu
Section Size y Pressur factor or Fittings Pressure
(m3/s per Duct re Loss
(mm) (m/s) e z (zeta) (Pa) Loss
(m) ) metre (Pa) (Pa)
(Pa) factor (Pa)
(Pa/m)
 NOTES ON DUCT PRESSURE DROP CALCULATION

NOTES:
1. Divide the system into sections. A section is from one branch
to another or in parts of the system with a steady volume flow
rate.

2. Size the index circuit first, that is the circuit with the highest
resistance to air flow. Normally the index circuit is the longest
circuit, but not always so check if necessary.

4. Branches should be included in the downstream section.

4. Contractions should be included in the downstream section

rather than the upstream section for the same reason as in
part 4.
TYPICAL AIR VELOCITIES FOR DUCTS

Air Velocity (m/s)

Building
Main Duct Branch
Domestic 3 2
Auditoria 4 3
Hotel bedroom, Conference hall 5 3
Private office, Library, Hospital
6 4
ward
General office, Restaurant, Dept.
7.5 5
store
Cafeteria, Supermarket, Machine
9 6
room
Factory, Workshop 10-12 7.5
EXAMPLE OF DRAWING OF DUCT NETWORK
Identify the following: Straight duct, transition, elbow . T-branch, Y-branch, volume damper at each
branch
EXAMPLE CAFETERIA OF DUCT PRESSURE DROP CALCULATION
Radiused
bend
A
Supply
Fan
Intake
Louvre
Pressure
loss or z B
factor = 6.5

Outlet Diffuser
– Pressure D
loss or
z factor = 3.5
Branch A Sizing as Main Duct
Branch B Sizing as Main Duct
Branch C Sizing as Main Duct
Branch D Sizing as Main Duct
EXAMPLE CAFETERIA OF DUCT PRESSURE DROP CALCULATION

Air Flow
Length
Section Rate
(m)
(m3/s)
A 1.20 10
B 0.90 3
C 0.60 6
D 0.30 8

NOTES:
1. Keep one side 350 mm high.
2. Ductwork to be rectangular galvanised steel.
3. There are no additional pressure losses.
4. Tapered reductions are at 45 degrees.
 DUCT PRESSURE DROP CALCULATION

The velocity for the main ducts, section A,B,C do not exceed 9
m/s from the Table.
The velocity for the branch duct, section D also does not
exceed the value of 6 m/s from the Table
The fan should be capable of delivering 1.2 m3/s against a
pressure of 305 Pa.
A percentage addition may be added to these figures for a design
margin
 DUCT INTAKE AND DISHARGE LOCATION

•Air ducts shall be made substantially air tight throughout, and

shall have no openings other than those required for proper
operation and maintenance of the system.
•Access openings shall be provided where debris, paper or other
combustible materials may accumulate in plenums and ducts.

• Outdoor air intakes shall be covered with an insect screen and

protected from rain entrainment. Screening shall be of corrosion
resistant material not larger than 10mm mesh.
• Outdoor air intakes should be protected from water droplets
such that no water droplet can enter the ventilation air stream.
 EXAMPLE CAFETERIA OF DUCT PRESSURE DROP CALCULATION

Locations of intakes and return air openings

Openings for the intakes of outdoor air to all air handling

systems, mechanical ventilation systems, pressurization systems of
exit staircases and internal corridors, and smoke control systems
shall be no less than 5m from any exhaust discharge openings.
Outdoor air intakes shall not be within 5m of exhaust discharges
from any buildings, kitchens, toilets, car parks, cooling towers,
laundries, rubbish dumps or plant rooms
 DUCT CONSTRUCTION AS PER SMACNA STANDRAD

Allowable Galvanized Steel Duct Thickness

upto 300mm 0.5 mm

300- 750 mm 0.6mm
750-1200 mm0.8 mm
Above 1200 mm 1mm
 DUCT CONSTRUCTION AS PER SMACNA STANDRAD

Duct support spacing

1000x 800 mm 10mm rod every 3m
1500x 1000 10mm every 2.5 m
DUCT CONSTRUCTION AS PER SMACNA STANDRAD
DUCT CONSTRUCTION AS PER SMACNA STANDRAD
 SUMMARY

1. How is duct sized

2. Which of the following are duct fittings
Elbow, T-branch Y-branch, Reducer (transition)

3. Which of the following are duct acessoriess

Volume damper, Fire damper
4. What is allowable velocity in duct and whereit is specified.
5. What is supply duct, return duct and exhust duct.
6. How is pressure drop in aduct detrmined
7. Size duct and sketch kiten exhust duct for three adjacent
toilettes of 1.5 m2 area and 2.8 m height according ES.