STANDARD SPECIFICATION

GSPEC-11A

INDUSTRIAL DUCTWORK INSTALLATIONS

Last Update : 23 February 2004

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INDEX

1.0 PRELIMINARY .................................................................................................................................................... 3

2.0 DESIGN AND SIZES OF DUCTWORK ........................................................................................................... 3

3.0 MATERIALS ......................................................................................................................................................... 5

4.0 CONSTRUCTION................................................................................................................................................. 6

5.0 INSTALLATION................................................................................................................................................... 7

6.0 THERMAL INSULATION .................................................................................................................................. 8

7.0 AIR BALANCING................................................................................................................................................. 9

8.0 NOISE CONTROL.............................................................................................................................................. 10

9.0 PAINTING AND ANTI-CORROSION ............................................................................................................ 10

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1.0 PRELIMINARY

1.1 Unless specified to the contrary elsewhere in this Specification, all ductwork shall comply
with the following requirements.

1.2. Nothing contained in, or implied by any part of the following shall remove from the
Contractor the responsibility to provide duct work which is entirely satisfactory in operation
and which will provide in all respects for the performance of the complete installation as
required by the specification.

2.0 DESIGN AND SIZES OF DUCTWORK

2.1 Layout

Ductwork shall be neatly and logically laid out and designed to connect to all offtakes with the least
number of bends and transitions. The layout shall strictly conform to and be installed within the
limits imposed by building and equipment detail existing and/or as shown on drawings supplied
with the specification.

2.2 Section

The ductwork shall be rectangular or round, to the sizes as shown on the drawings. Round
ductwork shall be spiral wound grooved seam type.
Insulated rectangular ductwork shall be cross-broken or beaded in accordance with AS 4254-1195
standard for uninsulated ductwork.
Rectangular ductwork shall be as nearly square as possible, but in any event the ratio of width to
depth shall not exceed 6:1.

2.3 Size

(a) Ductwork for air-conditioning, heating and general ventilation purposes shall be
designed and sized so that the following duct velocities are not exceeded:

Main Ducts Branch Ducts and Risers

General Offices and laboratories 8.2 m/s 6.6 m/s
Industrial Areas 11.2 m/s 9.15 m/s

(b) Ductwork for exhaust ventilation shall be sized to give not less than the minimum
transport velocity as follows:

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Source of Fumes Minimum transport velocity

m/s
Internal combustion engine exhaust fumes
Metal melting furnace
Soldering booth 10.2
General process tanks
Paint spray booth
Are welding booths 15.25
Abrasive grit blasting machines 17.8
Sand handling equipment, shakeouts
Metal spraying booths
Buffing & polishing of metals 22.9
Grinding 17.8
Woodworking machines 20.5

2.4. Industrial Exhaust Systems

(a) Transitions shall taper at the rate of 5:1 length to diameter or side or a lesser angle.
(b) Branches shall enter mains at the least possible angle to the direction of flow, but in
any event, at an angle not exceeding 45 degrees.
(c) Dead-end caps shall be provided at the ends of all main and sub-main ducts. Caps
shall be located not further than 300mm from the last branch off the main or sub-
main.
(d) The ductwork and its support shall be designed, constructed and installed to safely
sustain the full weight of the system when plugged and filled with the material being
exhausted.
(e) Clean-out openings provided with readily removable covers shall be provided every
3m of duct length, and adjacent all elbows, bends and junctions in horizontal duct
runs.
(f) Ducts 1.5m height or diameter or greater, shall be designed, constructed and installed
to carry the weight of a man working inside the duct and shall be provided with
suitable manholes.
(g) All branches shall enter the main or sub-main duct at the top or sides and two
branches shall not enter a duct diametrically opposite each other.
(h) Blast gates or dampers having positive locking devices shall be provided at all
branches

2.5 Ventilation and Air-Conditioning Systems

(a) Bends shall have an inside radius not less than the width of the duct except only
where space limitations prohibit, in which case splitters shall be installed.
(b) Positive lock dampers shall be installed at all branches.
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(c) Dampers and splitters shall be shaped and faired where necessary to avoid sharp
edges in the air stream. Dampers and splitters which rattle will not be accepted.
(d) Transitions shall be as gradual as possible and in any event shall not be steeper than
180mm for every 50mm increase in diameter or length of side.

2.6 Spigots for Flexible Ducts

Spigots for connection of flexible ducts shall be circular or oval to suit the size shown on the
drawings. The spigot shall be manufactured from spun aluminium or 0.8mm minimum thickness
galvanised steel.
Where required for air balancing, (eg take-offs from supply ducts) spigots shall be fitted with a
butterfly damper. The damper blade shall be manufactured from 0.8mm minimum thickness
galvanised steel. The damper shall be complete with a metal shaft securely fixed to the blade and a
case metal quadrant arm. The quadrant arm shall clearly indicate the damper position and shall be
secured to a case metal quadrant by a wing nut. The quadrant shall be mounted at least 70mm
proud of the spigot.

2.7 Flexible Ductwork - Insulated

Flexible ductwork shall be factory fabricated from a resilient 0.9mm minimum diameter hard drawn
and oil tempered mechanical spring steel wire helix, wound to a pitch not exceeding one third of the
duct diameter, which is fully encapsulated in multiple layers of aluminium foil. The foil shall have
a high resistance to tearing and puncturing. The outside face shall be insulated with 25mm thick, 10
to 16 kg/m3 fibreglass, equal to ACI General Purpose Fibreglass or Bradford Insulation Flexible
Fibreglass or approved equal, then wrapped in tough polyethylene and vapour sealed.

3.0 MATERIALS

3.1 General

Ductwork shall be constructed of new materials carefully selected for optimum service and duty
with the particular gases and materials to be handled, the temperature and the conditions and
environment in the location in which the ductwork is to be installed.

Materials for Ductworks

Ductwork shall generally be constructed of galvanised sheet steel. However, other material may be
approved by the Engineer. The material of sheet metal ductwork shall be lock seaming quality
galvanised steel sheet metal, manufactured to AS 1397, Grad G2, Coating Class Z275. The
following nominal metric equivalent of base metal thickness to AS 1365 shall be used in the
fabrication of the ductwork to the sheet metal gauges nominated in the above AS 4254-1995
Standard:

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26 US gauge 0.5mm
24 US gauge 0.6mm
22 US gauge 0.8mm
20 US gauge 1.0mm
18 US gauge 1.2mm
16 US gauge 1.6mm

Galvanised sheet steel shall not be used for gases at 200C or hotter. Mild steel sheet with suitable
heat resistant coating applied or high temperature alloy steel shall be used according to the
application.
Galvanised sheet steel shall not be used for corrosive gases. Stainless steel sheet or PVC welded
construction ductwork shall be used according to the application.

3.3 Sealing Compounds

a) Silicone based products are not to be used anywhere without prior approval.
b) All non approved sealants or compounds used in Paint Shop environments must be
submitted for testing at least 10 working days before approval for use is given. The
following list of sealants are approved for use:-
- Dinitrol 412 White polyurethane sealer
- Duct Sealant Hilti CS 244-048
- Fosroc Superseal
- Aftek/Galseal WB Flexible duct sealant
- HILTI - Polyurethane Const sealant CS215-048
- Selleys clear seal
- Secomeric

4.0 CONSTRUCTION

4.1 General

(a) All ductwork shall be constructed of material of correct gauge for strength and where
necessary to allow for wear. The contractor will indicate material type and thickness
prior to manufacture for approval of the Engineer.
(b) Ductwork shall be formed, reinforced and braced as necessary to prevent drumming,
buckling, sagging or other deformation.
(c) Ductwork shall be machine rolled, formed or bent truly round, square or rectangular
as the case may be with sides and joint faces truly parallel and square.

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4.2 Joints

(a) All joints shall be air tight and free from sharp internal edges. All laps shall be made
in the direction of flow and standing scams shall not be used.
(b) Circumferential joints required to assemble ductwork shall be flanged with steel
angles and bolted or may be riveted and soldered. Slip joints may be used on
rectangular ductwork provided the longest side is not greater than 1000mm.
(c) Longitudinal joints shall be lapped and riveted or spot welded at not greater than
75mm. Longitudinal joints in ducts used for air-conditioning or ventilation may be
formed with a double lock seam (Pittsburg or equivalent joint).
(d) Flanged joints shall be assembled with a neat gasket of rubber, neoprene or other
material approved by the Engineer. Flanged joints shall be provided with 50mm
minimum spigot designed to enter the mating duct in the direction of flow.

4.3 Dampers

(a) All Dampers shall be provided with quadrant type locking devices clearly stamped or
engraved to indicate open and 'closed' positions. Dampers shall be locked with a
'Simmonds' or 'Nylok' or other approved anti-vibration nut.
(b) Damper blades shall be formed and fabricated from galvanised steel not thinner than
1.0 gauge or other approved material.
(c) Damper spindles shall be not less than 13mm diameter mild steel rods. Stainless
steel shall be used for all dampers in ducts conveying steam or water vapour.
(d) Spindles shall be carried in brass, bronze, nylon or Teflon bushes. Damper blades
and connecting linkages shall be positively and rigidly fixed to spindles.

4.4 Access Panels

Access panels for clean out and other purposes shall be suitably framed or stiffened and shall have
rubber or other approved gaskets to ensure a perfect seal. Panels shall be provided with hand grips
and robust, quick action clamp catches.

5.0 INSTALLATION

5.1 General

a) All ductwork shall be installed in a neat and workman like fashion, well supported
and properly braced. It shall be installed level, plumb and parallel to building and
equipment members wherever possible.
(b) Ductwork shall be supported by robust hangers, cradles or brackets of fabricated
steel spaced to ensure adequate support and freedom from deflection and vibration.

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5.2 Penetrations

(a) Ductwork shall be designed and installed to utilise the penetrations provided by
others as shown on the drawings. Where the Contractor requires to change the
detail, either size or location, of penetrations shown on the drawings or where
additional penetrations are required, he shall advise the extent of such changes or
additions with his tender. The Contractor shall otherwise cut and/or enlarge all new
or existing penetrations as may be necessary to complete his work.
(b) Penetrations shall not be cut in structural steel members or existing building or plant
or equipment without prior approval from the Engineer.
(c) The Contractor shall make good around all penetrations and shall finish the making
good in a manner at least equal to the surrounding work and to the satisfaction of the
Engineer.
(d) Neat, galvanised steel machine-formed collars or escutcheon plates shall be installed
at all duct penetrations through walls, partitions, ceilings, equipment enclosures and
the like. Such collars or escutcheon plates shall be fixed to the duct and shall extend
to completely cover and overlap the edge of the penetration.

5.3 Flashings

Fully weatherproof flashings shall be installed at all penetrations through roofs or other
weatherproof enclosures. Flashings shall be constructed with a full apron welded or riveted and
soldered to the duct and a suitable spigot formed in the roofing or cladding material or in a lead
sheet which is lapped and formed to the cladding in a watertight fashion. The apron shall overlap
the spigot by not less than 50mm.

6.0 THERMAL INSULATION

6.1 General

The Contractor shall provide and install thermal insulation on all ductwork and associated
equipment in locations where, under specified operating and performance conditions;

(a) the duct surface temperature is or could be less than the maximum dew point in the
space in which the duct is operating, or
(b) wherever the ductwork is required to convey gases or materials which are at or above
50C, except only where the said gases or materials are exhausted to waste and where
the duct heat loss would not be objectionable to the surroundings.
Insulation shall be applied in sufficient thickness and density to prevent sweating, excessive heat
loss or gain and injury to persons through burning.

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6.2 Materials

Mineral wool and fibreglass or other materials approved by the Engineer shall be used for insulating
duct-work up to a maximum temperature of 66C. At higher temperatures, 85% magnesia compound
or other approved compound shall be used.

6.3 Construction and Fixing

(a) All thermal insulation shall be installed in a neat and workmanlike manner, securely
fixed and adequately protected from weathering and other damage.
(b) Ductwork located in roof spaces, masonry ducts and other covered and protected
locations shall be insulated externally with approved material fixed to the duct with
adhesive, wrapped with flameproof muslin and covered with 0.05mm minimum
thickness aluminium foil. Joints in the foil shall be held and sealed with approved
adhesive tape, not less than 100mm wide.
(c) All insulation applied internally and insulation applied externally in exposed
locations shall be clad with 0.6 gauge minimum zinc anneal sheet, neatly formed and
folded and fixed tight with 'pop' rivets or self-tapping screws to brackets or members
fixed to the ductwork for that purpose. Zinc anneal sheet installed inside ductwork
only shall be perforated.
(d) Magnesia compound, where applied, shall be wrapped in galvanised wire mesh,
12mm or smaller.
(e) Cladding shall be lapped so as not to trap moisture and shall be coned and shaped at
fittings, dampers etc. wherever access is required.

7.0 AIR BALANCING

7.1 The Contractor shall adjust and balance the ductwork installation to achieve the performance
specified.
Air balancing of the completed installation shall be performed with suitable air velocity
measuring equipment (either hot wire anemometer, vane anemometer or Pitot tube).
Commissioning charts showing design versus actual air flow to each conditioned
compartment shall be supplied to the Engineer by the contractor.
Installation of additional dampers and fans to achieve design air flows for systems designed
by the contractor shall not constitute a cost variation to the contract.

7.2. Following approval by the Engineer of the balance of the system, the Contractor shall
tighten all damper and blast gate nuts and shall permanently mark, on the quadrant, the
correct setting.

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8.0 NOISE CONTROL

8.1 The Contractor shall be responsible to design, construct and install ductwork in a manner to
prevent or limit to acceptable levels, the transmission of noise through the said ductwork.

8.2 Connections to fans or other equipment which vibrates shall be made with suitable flexible
connections utilising neoprene sheet, heavy duty canvas, or other approved material suitable
for the particular application.

8.3 Ductwork shall be constructed and installed suitably braced and reinforced to eliminate all
drumming or panting.

8.4 Internal insulation, absorptive splitters, commercially produced silencers and other devices
shall be included in the ductwork as required to prevent or limit noise transmission.

8.5 Deadener compound or anti-drumming compound shall only be applied by approval from
the Engineer.

9.0 PAINTING AND ANTI-CORROSION

9.1 All exposed ductwork shall be primed and painted to achieve maximum corrosion resistance
and a first class appearance. Hangers, supports, cladding and other associated equipment
shall be similarly treated.

9.2 All primers and paints shall be applied strictly in accordance with the manufacturer's
directions and shall be carefully selected to withstand the particular duty and environment
applicable to the installation.

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