Layout 1 - dw-144

BD & EEE SEES ASSA
SPECIFICATION FOR
SHEET METAL DUCTWORK
DW/144
Second Edition 2013
www.b-es.org
DW/144
Specifcation or
Sheet Metal Ductwork
Low, medium and high
pressure/velocity air systems
2013
opyright © 2013 by the
Building & Engineering Services Association
All rights reserved
SB 978-0-903783-64-4
Publishing History:
First Edition (1998)

Second Edition (2013)
urther copies o this publication are available rom:
B&ES Publications
ld Mansion House, Eamont Bridge,
Penrith, umbria, A10 2BX
el: 01768 860405, Fax: 01768 860401
Email: b-espublications@welplan.co.uk
ote: his document is based on knowledge available at the time o publication and is meant or
general purposes, not or reliance on in relation to specic technical or legal issues, in which case
you should always seek independent advice. o responsibility o any kind or any injury, death,
loss, damage or delay however caused, resulting rom the use o the advice and recommendations
contained herein, is accepted by the authors or others involved in its publication (including the
Building & Engineering Services Association).
2 SPECIICATION OR SHEET METAL DUCTWORK
THE INDUSTRY STANDARD
Bob Lane Peter Rogers

hairman hairman
xecutive ommittee echnical ommittee
Ductwork Group Ductwork Group
Since its publication in 1998, the Association’s Specication or Sheet

Metal Ductwork –DW/144 – has gained national and international
recognition as the standard against which the quality o ductwork
manuacture and installation can be measured.
However, developments in technology and working practices, along with
the need to refect a steady prolieration o European standards, have
rendered necessary a ar-reaching revision o the original edition.
his second edition is the result o many years o work by members o the
echnical ommittee o the B&ES Ductwork roup (DW), who have
expanded the content on such subjects as:
• supports and hangers;
• smoke and re dampers;
• external ductwork;
• internal duct linings;
• thermal insulation;
• air terminal units;
• re-resisting ductwork;
• ductwork or swimming pools, etc.
 course, a key element o any such review is to ensure that the
specication continues to offer realistic benchmarks to which all
individuals and organisations are able to perorm.
DW/144 now incorporates B&ES publication, Acceptance Scheme or ew
Products: ectangular ross Joint lassication (DW/M1), which
establishes perormance ratings or both air leakage and defection or
cross-joints.
n order to validate the parameters set out in DW/144, B&ES has
undertaken extensive testing against recently-introduced E
requirements to measure panel/fange defection and air leakage testing.
DW/144
esting has also been undertaken to determine the liespan o untreated
spot welds over a 30-year period.
he results have allowed the DW echnical ommittee to make a
number o recommendations in relation to the construction o ductwork
which offer a signicant commercial advantage. hese include:
SPECIICATION OR SHEET METAL DUCTWORK 3
• lighter gauges o steel;

• a reduction in the number o gauge, fange/stiffener manuactured
assemblies;
• dispensing with the need to treat spot welds;
• a reduction in coatings thickness/protective nishes;
• urther clarication o standard duct sizes used.
During the drating process, the DW echnical ommittee has consulted
widely with individuals and organisations throughout the building
engineering services and construction industry to ensure that the new
specication ully refects the current “state-o-the-art” in terms o both
technical expertise and industry best practice. We rmly believe that this
process has resulted in a publication that clearly demonstrates the high
level o proessionalism which exists within the ductwork community –
and we take this opportunity o thanking all those who have contributed
to its production.
n particular, we have worked closely with members o the drating panel
or the entilation Hygiene Branch’s uide to ood Practice: leanliness o
entilation Systems (/19), as well as representatives o the ollowing
organisations:
• Aluminium Federation td (AFED);
• British Stainless Steel Association (BSSA);
• Building Services esearch and normation Association (esting)
(BSA);
• alvanizers Association;
• Heating, entilating and Air onditioning Manuacturers
Association (HEA);
• Sheet Metal and Air onditioning ational ontractors’ Association
(SMAA);
• AA Steel;
• hermal nstallation ontractors’ Association (A);
• hermal nsulation Manuacturers and Suppliers Association
(MSA);
n addition, the past 15 years have witnessed a number o signicant
legislative and regulatory innovations – including the onstruction
Products egulation, E Marking and the onstruction (Design and
Management) egulations, along with other measures designed to
enhance environmental management and health and saety. he latter
comprise signicant developments within the Building egulations in
England and Wales, with the result that the classes o ductwork to be
tested under the regulations have been claried within DW/144, along
with the re-introduction o high-pressure lass D to conorm to European
practice.
o ensure that companies are ully inormed and understand the wealth
o inormation that surrounds our industry we have compiled a new
reerence document ‘ommentary and uidance to DW/144’. he
inormation contained in this new document is additional supplementary
material to support DW/144 and is explanatory in nature. However, we
should emphasise that the t does not orm any part o the speciication
and should be used as reerence only.
Finally, we would like to offer our proound thanks to the members o the
Ductwork roup echnical Sub-ommittee, all o whom have devoted a
great deal o time and effort in the redrating process.
ACKNOWLEDEMENTS
B&ES wishes to record its sincere thanks to the ollowing
DW/144 Members o the echnical ommittee o the Ductwork roup,

who contributed their time, knowledge and experience to the
production o this document.
eter ogers (hairman)

Mark ain
Lee Hussey
Brian James
Bob Lane
Jim Murray
ameron obertson
Mark Simpson
Ductwork Group Secretary:

Mark akes
B&ES wishes to record its sincere thanks to particular organisations that

have provided technical support to veriy both existing and new
inormation and these acknowledgements can be ound both in the
hairman’s ntroduction and, where appropriate, at the oot o each
relevant section.
BUILDIN & ENINEERIN SERICES ASSOCIATION

B&ES Publications Department
ld Mansion House Eamont Bridge Penrith A10 2BX
01768 860405 b-espublications@welplan.co.uk
www.bes.org
OTHER DUCTWORK-RELATED PUBLICATIONS
DW/143 A Practical uide to Ductwork eakage esting

DW/145 uide to ood Practice or the nstallation o Fire and Smoke Dampers
DW/154 Specication or Plastic Ductwork
DW/172 Specication or Kitchen entilation Systems
DW/191 uide to ood Practice: lass Fibre Ductwork
/19 uide to ood Practice: nternal leanliness o entilation Systems
(incorporating DW/M2 and /17)
B&ES Working ogether – Promoting understanding between mechanical services and
ductwork contractors.
opies o the above publications are available rom:
B&ES Publications
ld Mansion House, Eamont Bridge,
Penrith, umbria, A10 2BX
el: 01768 860405, Fax: 01768 860401
Email: b-espublications@welplan.co.uk
www.b-espublications.co.uk
Previous Sheet Metal Ductwork Related Specications
- Ductwork Specication or High-elocity Air Systems (ircular) 1963

- Standard ange o ectangular Ducting 1967
DW/131 Sheet Metal Ductwork Specication or High-elocity Air
Systems (ectangular) 1968
DW/121 Specication or Sheet Metal Ductwork (ow-elocity
ow-Pressure Air Systems) (ectangular and ircular) — Metric 1969
DW/122B Specication or Sheet Metal Ductwork (ow-elocity
ow-Pressure Air Systems (ectangular and ircular) — British 1969
DW/112 Standard ange o ectangular Ducts and Fittings — Metric and
British nits 1970
DW/132 Specication or Sheet Metal Ductwork (High-elocity
High-Pressure Air Systems) (ectangular, ircular and Flat val) — Metric 1970
DW/141 Specication or Sheet Metal Ductwork (ow and High-elocity/
Pressure Air Systems (ect, ircular and Flat val) - Metric 1977
DW/142 Specication or Sheet Metal Ductwork (ow, Medium and High
Pressure/elocity Air Systems) 1982
DW/142 Specication or Sheet Metal Ductwork Addendum A (ow,
Medium and High Pressure/elocity Air Systems) 1988
DW/144 Specication or Sheet Metal Ductwork (First Edition) 1998
DW/151 Specication or Plastic Ductwork 1974
DW/171 Standard or Kitchen entilation Systems 1999
DW/M1 Acceptance Scheme or ew Products: ectangular ross Joint lassication 1987
DW/M2 uide to ood Practice: nternal leanliness
o ew Ductwork nstallations 1991
/17 uide to ood Practice: leanliness o entilation Systems 2002
CONTENTS
Page
he ndustry Standard 2
Acknowledgements 4
ther Ductwork related publications 5
ontents 6
eneral otes 10
Part One - Scope
1. Application 11
2. Materials 12
3. Ductwork Classication and Air Leakage 13
Part Two - Technical Inormation to be provided by

the system designer to the ductwork contractor
4. Introduction 14
5. Standards 14
6. Components 14
7. Particular requirements 15
Part Three - Rectangular Ducts
8. Rectangular duct sizes 19

9. Construction 19
9.1 eneral 19
9.2 Sheet thickness 19
9.3 ongitudinal seams 19
9.4 ross joints 20
9.5 Stiffeners 20
9.6 Ductwork galvanized ater manuacture 21
9.7 Fastenings 21
9.8 Welding sheet joints 22
9.9 Breakaway joints 22
9.10 ost efficient manuacturing considerations 22
10. Standardisation o Rectangular Ductwork
Components 40
Part our - Circular Ducts
11. Standard sizes 48

12. Construction 48
12.3 Fastenings 49
12.4 Welding 50
12.5 Breakaway Joint 50
13. Standardisation o Circular Ductwork Components 57
Part ive - lat Oval Ducts
14. Standard sizes and sheet thicknesses 64

15. Construction (Spirally wound) 64
15.1 eneral 64
Page
15.4 Fastenings 65
15.5 Stiffening 66
16. Construction (Straight-seamed) 66

17. Standardisation o lat Oval Ductwork Components 73
Part Six - Hangers and Supports
18. eneral 78
Part Seven - Ductwork Related Inormation
19. Ductwork Sealing 89

20. Access / Inspection Openings 90
21. Regulating Dampers 94
22. ire Dampers 98
23. Combination Smoke and ire Dampers 101
24. Smoke Dampers 102
25. Smoke Control Dampers 103
26. External ductwork 105
27. Kitchen entilation 109
28. ire Resisting and Smoke Containment Ductwork 109
29 Standard Component Drawings o Plant and
Abbreviations 109
30. lexible Ducts 113
31. lexible Joint Connections 115
32. Protective inishes 116
33. Internal Duct Linings 118
34. Thermal Insulation 119
35. Air terminal Units 122
Part Eight - Appendices
Appendix A Ductwork Air Leakage Testing 123

Appendix B Summary BS EN 10346, continuously hot-dip 130
coated steel fat products - technical delivery
conditions
Appendix C Hot Dip alvanizing Ater Manuacture 134
Appendix D Stainless Steel or Ductwork 138
Appendix E Aluminium Ductwork 143
Appendix  Pre-nished Steel 146
Appendix  Handling, Storage and Protection o Ductwork 148
Appendix H uidance Notes or Cleaning Inspection and 151
Cleaning Access Openings
Appendix J Design Notes or Ductwork 154
Appendix K Connections To Building Openings 155
Appendix L CDM Regulations 57 156
Appendix M Regulatory Reorm (ire Saety) Order and 158
Construction Products Regulations (CPR) 59
Appendix N Bibliography 67 163
Appendix P Conversion Tables 75 171
Tables
1 Ductwork lassication and Air eakage imits 11

2.1, 2.2, 2.3 ectangular Ductwork - onstructional
requirements or ow Pressure lass A 24
requirements or Medium Pressure lass B 26
requirements or High Pressure lass  28
requirements or High Pressure lass D 30
6 ectangular Ductwork - Maximum eakage
and Defection alues 35
7 ircular Ductwork – Standard Sizes 48
8 ircular Ductwork - Spirally Wound 51
9 ircular Ductwork - Straight Seamed 51
10 ircular Ductwork - Permitted Fastenings
and Maximum Spacings 52
11 ircular Ductwork – Sheet hickness o
Fittings 52
12 Flat val Ductwork – Standard Sizes and
Sheet hicknesses 67
13 Flat val Ductwork – Stiffening equirements
or ow and Medium Pressure 68
14 Flat val Ductwork – Stiffening equirements
or High Pressure 69
15 Flat val Ductwork – Permitted Fastenings
and Maximum Spacings 71
16 ectangular Ductwork – Horizontal Supports 83
17 ircular Ductwork – Horizontal Supports 83
18 Flat val Ductwork – Horizontal Supports 83
19 ectangular / Flat val Ductwork –Support
Bearers 83
20 Access Panel ocations 92
21 Standard Abbreviations 111
22 Air eakage ates 127
23 Zinc oating Mass (Weight) 133
24 orrosive ategories and ie
Expectancy 133
25 ectangular Ductwork – alvanized Ater
Manuacture 135
26 ircular Ductwork – alvanized Ater
Manuacture 135
27 avity ent Hole Sizes 135
28 Stainless Steel – Austenitic rades 142
29 Stainless Steel – Ferritic rades 142
30 ow Pressure ectangular Ductwork
Aluminium onstruction 145
31 ow Pressure ircular Ductwork
Aluminium onstruction 145
igures
1 onstructional criteria 23
2-3 n-xed dimple/sel-piercing rivet 25,27,29,31
4-11 ongtitudinal seams 32
12 Stiffened Sheet Panels 33
20-24 Socket and spigot joints 37
25-30 Single Stiffeners 38
31 ntermediate stiffeners 38
32-35 ie rod assembly - alternative arrangement 39
36-38 urning vanes 39
39-75 Standard rectangular components 42
76 Spirally wound duct 52
77-83 ross joints, spirally wound ducts 53
84-90 ross joints, straight seamed ducts 55
91-119 Standard circular components 58
120-122 ie rod pattern 68
123-126 he rod pattern 69
127-132 ross joints, spirally wound ducts 70
133-137 ross joints, straight seamed ducts 72
138-150 Standard fat oval components 75
151-166 Bearers and Hangers 84
167-172 ypical wire rope arrangements 86
173-178 Support bearers 87
179-182 ertical ducts 87
183-186 ypical structural xings 88
187-189 ypical arrangements o roo penetrations 108
190-198 Plant equip - omponent Drawings 110
199 ypical Flexible Joint onnections 114
200 ypical fexible joint connections 115
201-206 Air terminal units - supports 122
207 Permitted leakage at various Pressures 128
ENERAL NOTES RELATIN TO DW/144

(1) Where a project specication calls or the system to be wholly in accordance with
DW/144, it will still be necessary or the system designer, in addition to providing
drawings showing details and dimensions o the ductwork, to identiy specic
requirements, particular to the design. his inormation should be highlighted on the
drawings and include the identication o pressure ‘break points’ between low, medium
and high pressure classication elements o the system, non-galvanized constructions
and the location and types o all dampers.
he technical inormation to be provided by the system designer is thereore set out in
detail in Part wo.
(2) All dimensions quoted in this specication reer to the nominal sizes, which are subject to
the normal relevant commercial and published tolerances.
(3) Manuacturing techniques are continually subject to change and improvements and in
respect o proprietary methods and devices this specication does not preclude their use
i they can be demonstrated to the system designer to be equally satisactory. Where
there is divergence between the requirements o DW/144 and the manuacturer’s
recommendations or proprietary methods and devices, the latter shall take precedence.
(4) he expressions ‘low-pressure,’ ‘medium-pressure’ and ‘high- pressure’ relate to the
pressure/velocity classes set out in able 1.
(5) ‘Mean air velocity’ means the design volume fow rate related to the cross-sectional area.
(6) eerence to the air distribution system pressure relate to the static pressure o the
relevant part o the ductwork system and not to the an static pressure.
(7) Despite reerence to ‘minimum’ requirements, it should be recognised that in several

instances, in order to comply with established K practices, DW/144 exceeds the
minimum requirements set out in European Standards.
(8) All reerences to BS, BS E, S and other standards and regulations purposely omit the
year. t is incumbent upon the user to ensure that reerence is made to the latest available
publication.
(9) Ductwork constructed to DW/144 standard has no ire resistance. eneral purpose
ventilation/air conditioning ductwork and its ancillary items do not have a ire
classiication and cannot be either utilised as or converted into ire rated ductwork unless
the construction materials o the whole system including supports and penetration seals
are proven by test and assessment in accordance with the appropriate test standard. n
the case where galvanized sheet steel ductwork is clad with the application o protective
material, the ductwork construction must be as type tested and comply with the
protective material manuacturers recommendation, e.g. sheet thickness o ductwork,
requency o stiening and non-use o low melting point asteners and rivets. Particular
emphasis should be given to how the ductwork is installed into the supporting
construction (walls and loors o dierent types) and what additional stiening should be
employed within the wall as was tested. Sealants, gaskets and lexible joints should be
tested and certiicated in accordance with the appropriate test standard and comply with
all manuacturers recommendations. areul consideration must be given to the
maximum certiied size as tested and the manuacturer’s recommendation should always
be ollowed.
PART ONE – SCOPE
SECTION 1
APPLICATION
1.1
COMMERCIAL AND INDUSTRIAL AIR DISTRIBUTION SYSTEMS
his specication sets out minimum requirements or the manuacture and installation o
ductwork or commercial and industrial air distribution systems, made rom any o the materials
listed in Section 2 and being within the limits o size and/or metal thicknesses specied in the
relevant tables. ormal operating temperatures up to 70° are assumed within the
pressure/velocity limits and the limits o air leakage or the various pressure classes prescribed in
able 1.
Table 1 Ductwork Classifcation and Air Leakage Limits
Static pressure limit Air leakage limits

Duct pressure class Maximum air
litres per second per square
Positive egative velocity
metre o duct surace area
1 2 3 4 5
Pa Pa m/s
ow pressure – lass A 500 500 10 0.027 x p0.65
Medium pressure – lass B 1000 750 20 0.009 x p0.65
High pressure - lass  2000 750 40 0.003 x p0.65
High pressure - lass D 2000 750 40 0.001 x p0.65
Where p is the differential, pressure in pascals.
1.2
UNSUITABLE FOR CONTAMINATED AIR DISTRIBUTION SYSTEMS
his specication is not suitable or operating in extremely hostile conditions, examples o which
are: saturated air, explosive contaminants, off-shore, etc. he design, construction, installation,
supports and nishes in such cases should be given special consideration by the system designer
in relation to the circumstances o each case.
1.3
EXPOSURE TO EXTERNAL ATMOSPHERE
System designers will need to give specic details o any special nishes/construction or
ductwork exposed to external atmosphere. See Sections 26 and 32.
1.4
CONFORMITY TO EN STANDARDS
egislation has been introduced whereby all K Standards should comply with current E
Standards and a list o these along with many other associated standards can be ound in
Appendix .
SECTION 2
MATERIALS
2.1
APPLICATION
his specication applies to ductwork constructed rom materials as dened below, or equal.
Minimum steel thickness is to be taken as a nominal thickness within the tolerances to BS.E
10346. (Appendix B).
2.2
ZINCCOATED STEEL
Where DW/144 ductwork is installed in an area o low category corrosion it can be constructed
rom hot-dip galvanized steel to BS E 10346, rade DX51D+Z140, with other coating nishes
being considered by the system designer in accordance with the corrosive categories listed in
able 24 o Appendix B.
2.3
MILD STEEL
Where mild steel is specied, it shall be cold- reduced steel to BS.E10130, rade FEP 01A.
2.4
STAINLESS STEEL
Where stainless steel is specied, it will be the responsibility o the system designer to indicate the
type most suitable or the conditions to which the ductwork will be exposed. n doing so, it is
recommended that the actors set out in Appendix D should be taken into account. n this
connection, reerence must be made to BS E 10088: Part 2.
2.5
PREFINISHED STEEL
Pre-coated steel may be specied or aesthetic or other reasons. he system designer must then
consider the availability o suitable materials and the restriction on abrication methods. uidance
notes are available in Appendix F.
2.6
ALUMINIUM
Where aluminium is specied, it will be the responsibility o the system designer to dene the type
most suitable or the conditions to which the ductwork will be exposed. eerence must be made
to BSE 485, BSE 515 and BSE 573 or aluminium sheet and BSE 755 Parts 3-6 or aluminium
section. onstructional requirements or ductwork made rom aluminium sheet and general notes
on the material are set out in Appendix E.
SECTION 3
DUCTWORK CLASSIICATION AND AIR LEAKAE
3.1
CLASSIFICATION AND AIR LEAKAGE LIMITS
Ductwork classication and air leakage limits are set out in able 1. (lause 1.1)
3.2
COMPATIBILITY WITH CEN
he leakage actors used in able l or lasses A, B,  and D are the same as those or the classes
similarly designated in the E Document BS E 12237 / BS E 1507.
3.3
LEAKAGE AT VARIOUS PRESSURES; AND OTHER RELATIONSHIPS
Applying the limits specied in able 1, Appendix A (able 22) sets out the permitted leakage at
each o a series o pressures up to a maximum or each class. ncluded in that appendix is a
graphical presentation o the pressure/leakage relationship (see Fig 207). DW/143, ‘A Practical
uide to Ductwork eakage esting’, also gives details o the basis or the leakage limits specied
in able 1.
3.4
AIR LEAKAGE TESTING
Air leakage testing o low and medium pressure ductwork is not mandatory under this
specication.
Air leakage testing o high pressure ductwork is mandatory under the specication. See Appendix A
or inormation on air leakage rom ductwork. For details o testing procedure reer to DW/143,
‘A Practical uide to Ductwork eakage esting’.
3.5
INLINE PLANT CASINGS
he casings o all in-line plant and equipment that connect to the ductwork system should be
manuactured and sealed to match the ductwork classication and air leakage limits o the
systems they serve. Suppliers to conrm their suitability or the pressure classication in which
such casings are to be incorporated.
PART TWO – TECHNICAL INORMATION

TO BE PROIDED BY THE SYSTEM
DESINER TO THE DUCTWORK
CONTRACTOR
SECTION 4
INTRODUCTION
he selection o constructional methods is the decision o the manuacturer to conorm with the
perormance requirements o the specied ductwork classication. Sections 5-7 below dene
the inormation that is to be provided by the system designer.
SECTION 5
STANDARDS
5.1
PRESSURE CLASSIFICATION (able 1)
5.2
LEAKAGE CLASSIFICATION (able 1)
5.3
POSITIVE AND NEGATIVE PRESSURES (able 1)
5.4
MATERIALS (Section 2)
5.5
PDI LEVELS OF CARE, PROTECTION AND CLEANLINESS
(ppendix H and B&S Guide /19)
5.6
ANY SPECIAL SYSTEM REQUIREMENTS
SECTION 6
COMPONENTS
6.1
FIRE DAMPERS (Section 22)
Specication and location, on the drawings, o all re dampers to meet the requirements o the
Building / Fire regulations.
6.2
COMBINATION SMOKE AND FIRE DAMPERS (Section 23)/
SMOKE DAMPERS (Section 24)/ SMOKE CONTROL DAMPERS (Section 25)
Specication and location, on the drawings, o all types o smoke dampers to meet the
requirements o the Building / Fire regulations.
6.3
REGULATING DAMPERS (Section 21)
Specication, location, on the drawings, and mode o operation o all regulating dampers.
6.4
INSPECTION/SERVICING ACCESS OPENINGS (Section 20 and ppendix H)
umber and location, on the drawings, o all panels and covers or inspection and/or servicing
access other than those covered in Section 20. umber and location o test holes, instrument
connections and hinged doors as dened in Section 20.
6.5
CLEANING ACCESS (Section 20.7 and ppendix H)
System designers shall stipulate their requirements or periodic internal cleaning o ductwork and
or the consequent need or adequate personnel access and or specialist cleaning equipment.
As DW/144 ductwork or supports do not take into account either man-loading or the support o
other building services, system designers must take this into account in accordance with BS E
12236, ‘entilation or buildings – Ductwork hangers and supports – equirements or strength’.
his consideration should also include recognition o all appropriate risk assessments.
6.6
FLEXIBLE DUCTS (Section 30)
Specication and location, on the drawings, o any fexible ductwork.
6.7
FLEXIBLE JOINT CONNECTIONS (Section 31)
Specication and location, on the drawings, o any fexible connections e.g. plant or building
expansion joints.
SECTION 7
PARTICULAR REQUIREMENTS
7.1
AIR LEAKAGE TESTING (Section 3 o art ne and ppendix )
he extent o any air leakage testing shall be specied. esting o low or medium pressure
ductwork is not mandatory - see A.1.3, A.1.4 and A.5 in Appendix A. t shall be mandatory or
high-pressure ductwork (as dened in this specication) to be tested or air leakage in accordance
with the procedure set out in DW/143, ‘A Practical uide to Ductwork eakage esting’.
7.2
PROTECTIVE FINISHES (art Seven, Section 32)
Details and specication o any protective nishes.
7.3
FIRE RESISTING DUCTWORK FOR FIRE AND SMOKE CONTAINMENT
(ommentary and Guidance – ote 4)
Ductwork constructed to DW/144 standard has no re resistance. However, i the system designer
requires any ductwork to be re resistant, the re perormance criteria or any re resistant
ductwork should be specied with the extent being identied on the specication and drawings.
7.4
INTERNAL ACOUSTIC LINING (art Seven, Section 33)
he extent o any ductwork requiring internal acoustic lining is to be clearly identied on the
drawings. A detailed specication o materials and method o application is required. he practical
aspects o cleaning or maintenance must be addressed by the system designer beore deciding to
internally line ductwork.
7.5
EXTERNAL THERMAL INSULATION (art Seven, Section 34)
he specication o ollow-on insulation to be provided by others shall be stated with the extent
being identied on the drawings. he extent o vapour sealing, i required, and associated support
methods shall also be identied on the design drawings. (Section 18.6)
7.6
SPECIAL SUPPORTS (art Six)
Details o any spanning steel or special support requirements not covered by Section 18.
7.7
ATTACHMENT TO BUILDING STRUCTURE (ppendix K)
Specic requirements or the junction o ductwork and associated components to openings
should be detailed and specied. he provision o penetrations and associated ramings are
outside the scope o this specication.
7.8
AIR TERMINAL UNITS (art Seven, Section 35)
Detail and specications o all Air erminal nits shall be specied. t is expected that all Air
erminal nits and their Plenums will be supported independently o the ceiling grids unless the
system designer indicates anything to the contrary. (Figures 201 to 206)
7.9
DUCTWORK LAYOUT DRAWINGS
Details o any special requirements relating to the latest issue o any AD, scales, etc. t is common
practice and cost effective or ductwork manuacturers to utilise their approved ductwork layout
drawings as a basis o their manuacturing/installation inormation by adding the necessary details
to the same drawing. Scales o 1:50 or smaller may preclude this practice, thereore, larger scales
might be more appropriate. he nal choice o manuacturing/installation scales and drawing sizes
shall be let to the ductwork contractor.
7.10
ELECTRONICBASED DUCTWORK CONTRACT ENQUIRIES
Drawings and specications relevant to the ductwork systems being quoted should be
highlighted and indexed in the enquiry.
7.11
OTHER REQUIREMENTS
Details o any requirements or ductwork not in accordance with the provisions o this
specication, any non-DW/144 galvanized ductwork, any modied construction required to
conorm to any requirements concerning external ductwork (See Part Seven, Section 26) and any
requirements to meet the regulations o a ocal Authority or other controlling body.
7.12
REFERENCE TO THE SYSTEM DESIGN/DESIGNER
n consideration o the oregoing, reerence is also made to the system design/designer in the
ollowing sections:-
Section/s Subject
1.2 ontaminated air
1.3, 26, 32 Exposure to external atmosphere
2.2, able 24 Zinc coating nishes
2.4, 2.5, 2.6 Stainless and pre-coated steel and aluminium
9.4, 12.2.1, 15.3.1 Proprietary cross joints or rectangular, circular and fat oval
10.5.2 nternal stiffeners
12, 13, 17 Design terminology standard practice or rectangular, circular and fat oval
18.1 Proprietary support systems
18.4 Support spacing or vertical ducts
18.5 Additional loadings on ductwork supports
18.6 apour sealing
18.6.2 Heat transer
20.1 Access considerations
20.5 est holes
20.6 nstrument connections
20.2, 20.3, 20.8 Access openings
21.1 Damper locations
21.3 egulating damper materials and construction
21.3.4 Proprietary regulating dampers
22.3 Fire dampers materials
22.5 Fire damper installation
23.3, 24.3, 25.3 Smoke / re damper materials and construction
23.5, 24.5, 25.5 Smoke / re damper installation
26.1 External ductwork – waterproong
26.2 External ductwork – non-insulated
26.6 External ductwork – roo penetrations
26.8 External ductwork – supports
29.2 Bill o quantity descriptions
30.1 Flexible duct - material
30.3 Flexible duct - off-sets and support
31.1 Flexible connections - material
31.1 Flexible connections - locations
32.3.4 Protective nishes
33.1, 33.8 nternal duct linings
34.2, 34.4, 34.6 hermal insulation
35 Air terminal units
Additional inormation is also provided in the reerence document
ommentary & uidance – DW/144
PART THREE – RECTANULAR DUCTS
SECTION 8
RECTANULAR DUCT SIZES
his specication covers duct sizes up to a maximum longer side o 3,000 mm. Duct sizes with an
aspect ratio greater than 4:1 are not recommended. Although they offer no problems o
construction, they increase rictional resistance and the possibility o noise.
SECTION 9
CONSTRUCTION
9.1
GENERAL
he constructional requirements or rectangular ductwork depend upon the pressure classication
as set out in ables 2.1, 2.2, 3.1, 3.2, 4.1, 4.2, 5.1 and 5.2.
he dimensional lengths o straight sections o ductwork are determined by the manuacturer to
suit their preerred method o construction. ables 2.1, 2.2, 3.1, 3.2, 4.1, 4.2, 5.1 and 5.2 (in columns
3 to 11) set out the maximum spacing between joints and stiffeners and lause 9.10 preceding
those tables illustrates examples o how these spacings can be interpreted by the individual
manuacturer.
9.2
STEEL THICKNESSES
Minimum steel thicknesses related to duct longer side to pressure classication are given in ables
2.1, 2.2, 3.1, 3.2, 4.1, 4.2, 5.1 and 5.2
9.3
LONGITUDINAL SEAMS
ongitudinal seams are illustrated in Figs. 4 to 11. he limits o use, i any, are given with the
individual illustrations.
9.3.1
SEALING OF LONGITUDINAL SEAMS
Sealant shall be applied either internally or externally to the seam edge or internal to the
joint seam itsel. he most appropriate method will be determined by the manuacturer
relative to their product and will be associated with traditional abrication/assembly
methods, actory or site based, and/or proprietary methods.
Joint sealing materials are set out in Part Seven, Section 19.
9.4
CROSS JOINTS
9.4.1
CROSS JOINT RATINGS
For cross-joints, a system o rating has been used to dene the limits o use. he limits
applying to that rating, in terms o duct size longer side and maximum spacing, are given
in ables 2.1, 2.2, 3.1, 3.2, 4.1, 4.2, 5.1 and 5.2.
ote: Proprietary products used in the construction o cross-joints should be approved by

an accredited test house ollowing tests dened in and proven to be within the new
European standards dened in BS E 1507. Figures o’s 13 and 20 to 24 illustrate non-
proprietary joints that have an established rating.
9.4.2
SEALING CROSS JOINTS
With socket and spigot joints made on site, sealant shall be applied during or ater
assembly o the joint. t is permissible to use chemical - reaction tape or heat-shrink strip
as alternative methods o sealing, provided that close contact is maintained over the
whole perimeter o the joint until the joint is completed.
With all fanged joints, the sealant o sheet and section should preerably be incorporated
during construction at works, but site applied sealant is acceptable. he joint between
sections o ductwork is then made, using approved type o sealant or gasket. With
proprietary fanging systems particular attention should be paid to the sealing o corner
pieces and fanges, reerence should be made to the manuacturer’s assembly and sealing
instructions.
9.4.3
ADJUSTABLE/SLIP JOINTS
n order to accommodate manuacturing / building tolerances, site modications etc, it is

accepted practice to use an adjustable joint but with an adjacent stiffener i over 400mm
wide.
9.5
STIFFENERS
9.5.1
EXTERNAL STIFFENERS
he sections (including proprietary fanges) suitable or use as single stiffeners have been
given a rating rom S1 to S6 in terms o duct size longer side and maximum spacing. he
ratings are specied with the illustrations o the stiffeners, Figs. 25 to 30, and the limits o
use are given in ables 2.1, 2.2, 3.1, 3.2, 4.1, 4.2, 5.1 and 5.2. he stiffeners or socket and
spigot joints covered in Figs. 22 to 24 are also applicable to intermediate stiffeners in
general. (Fig. 31 )
9.5.2
INTERNAL STIFFENERS
ie bars connecting the fanges o cross-joints illustrated in Figs. 14 to 19, are the only
orm o internal stiffening or rectangular ductwork recognised by this specication.
Alternative methods or the attachment o tie bars are shown in Figs. 32 to 35.
he use o tie bars or other orms o internal stiffening or bracing shall be acceptable i
proved to the system designer to be equally satisactory. SMAA (Sheet Metal and Air
onditioning ontractors’ ational Association), which is the American equivalent to B&ES
Ductwork roup, have included a section on internal stiffening and bracing using tie bars
in their publication, ‘SMAA/AS HA Duct onstruction Standard Metal & Flexible,
3rd edition 2005’ and this contains extensive technical inormation and data on the
subject o mid panel tie rods. SMAA have given their kind permission or this
specication to make reerence to this act. System designers and manuacturers who
wish to incorporate this orm o internal stiffening into a ductwork system should contact
SMAA direct to obtain copies o their publications (Appendix ).
9.6
DUCTWORK GALVANIZED AFTER MANUFACTURE
Appendix  sets out the recommended sheet thicknesses and stiffening or ductwork galvanized
ater manuacture.
9.7
FASTENINGS
9.7.1
PERMITTED TYPES AND MAXIMUM CENTRES
ables 2.3, 3.3, 4.3 and 5.3 and their associated notes set out the permitted astenings and
the maximum spacing or all ductwork classications. Fastenings resulting in an unsealed
aperture shall not be used.
9.7.2
RIVETS
Manuacturers’ recommendations as to use, rivet size and drill size are to be ollowed.
9.7.3
SET SCREWS, NUTS AND LOCK BOLTS
Materials shall be o mild steel, protected by electro-galvanizing, sherardizing, zinc

plating, or other equal corrosion resistant nish.
9.7.4
SELFTAPPING AND PIERCING SCREWS
Providing an adequate seal can be achieved, then sel-tapping or piercing screws may be
used. Acknowledging the presence o such astenings / xings, avoid putting operatives
at risk o injury with regard to internal activities such as access maintenance or ductwork
cleaning. Such xings must not be used within 1 metre o an access opening – as BS E
12097 lause 4.5.
9.7.5
SELFPIERCING RIVETS
Providing an adequate seal can be achieved, then sel-piercing rivets may be used - see
Fig. 3.
9.8
WELDING SHEET JOINTS
he suitability o continuous welding or sheet-to-sheet joints will be governed by the sheet
thickness, the size and shape o the duct or tting and the need to ensure airtightness. apped
sheet joints with a combination o spot welding and duct sealant is also acceptable. Distortion
shall be kept to a minimum.
Areas where the galvanizing has been damaged or destroyed by welding or brazing shall have a
suitable protective coating applied as dened in Section 32. Spot welds need not be treated as
accelerated salt spray tests undertaken by eeds niversity esearch aboratory on behal o B&ES
have indicated that corrosion rates would be well within the lie expectancy o the various parent
metal zinc coatings as indicated in the data listed in able 24 o Appendix B.
9.9
BREAKAWAY DUCT JOINT
A joint connecting a re damper spigot or sleeve to the attached ductwork which will allow
collapse o the ductwork during a re without disturbing the integrity o the re damper. ‘Break-
away’ and fexible joints incorporate materials, xings, clamps, etc, that are manuactured rom a
non - re resistant material with a low melting point such as aluminium, plastic, etc. See DW/145,
‘uide to ood Practice or the nstallation o Fire and Smoke Dampers’.
9.10
COST EFFICIENT MANUFACTURING CONSIDERATIONS
he our ranges o ductwork illustrated in Fig. 1 opposite are identical in terms o cross-sectional
duct size. ange ‘A’ consists o eight items o ductwork whereas ange ‘D’ is made up o just one
item.
hese our illustrations highlight that the main constructional criteria or ‘stiffening’ any range o
ductwork is that the ‘maximum spacing between joints and/or stiffeners’ is to be identical or all
our ranges – all as per the ‘spacing’ dimensions listed in columns 3 to 11 o ables 2.1, 2.2, 3.1, 3.2,
4.1, 4.2, 5.1 and 5.2.
Each range however has advantages and disadvantages with regard to both manuacture and
installation costs. e.g. ange ‘A’, made up o eight separate items, has the advantage o suiting
mass-production manuacturing techniques but has the disadvantage o increased actory,
transportation and site handling costs and increased installation costs along with a greater risk o
joint leakage because o the number o site joints involved. he converse applies to ange ‘D’
which is made up o just one item!
ig. 1 – onstructional criteria
Each manuacturer has the fexibility to choose, on a project by project basis, what they
consider to be the most cost efficient conguration that suits their overall manuacture and
installation costs.
LOW PRESSURE CLASS “A”

(limited to 500 Pa positive and 500 Pa negative)
TABLE 2.1 SOCKET AND SPIGOT CONNECTIONS Dimensions in mm

1 2 3 4 5 6 7 8 9 10 11
MINIMUM SHEET
0.6 0.8 1.0 1.2
THICKNESS
DUCT LONEST
400 600 800 1000 1250 1600 2000 2500 3000
SIDE
RATIN SHEET MAXIMUM SPACINS BETWEEN STIENERS
PS 3000
A1
SS 3000
PS 3000 2000 1600 1250
A2
SS 3000 3000 1600 1250
PS 3000 2000 1600 1250 1000 800
A3
SS 3000 3000 2000 1600 1250 800
TABLE 2.2 FLANGED JOINTS Dimensions in mm

1 2 3 4 5 6 7 8 9 10 11
MINIMUM SHEET
0.6 0.8 1.0 1.2
THICKNESS
DUCT LONEST
400 600 800 1000 1250 1600 2000 2500 3000
SIDE
RATIN SHEET MAXIMUM SPACINS BETWEEN LANES AND/OR STIENERS
PS 3000 1600 1250 625
J1/S1
SS 3000 3000 1250 625
PS 3000 2000 1600 1250 625
J2/S2
SS 3000 3000 1600 1250 625
PS 3000 2000 1600 1250 1000 800
J3/S3
SS 3000 3000 2000 1600 1250 800
PS 3000 2000 1600 1250 1000 800 800
J4/S4
SS 3000 3000 2000 1600 1250 1000 800
PS 3000 2000 1600 1250 1000 800 800 800 625
J5/S5
SS 3000 3000 2000 1600 1250 1000 800 800 800
PS 3000 2000 1600 1250 1000 800 800 800 800
J6/S6
SS 3000 3000 2000 1600 1250 1000 800 800 800
TABLE 2.3 FASTENING CENTRES Dimensions in mm

1 2 3 4 5 6 7
SHEET TO SHEET SHEET TO SECTION (10)
LONITUDINAL CROSS
TYPE CROSS JOINTS
SEAMS JOINTS
O STIENERS
STANDIN/ SOCKET
ASTENIN SLIDE ON
LAP CAPPED AND RSA
LANES (13)
STANDIN SPIOT
MECHANICALLY CLOSED
75 300 75 150 300 150
RIETS
SEL PIERCIN SCREWS 75 - 75 - 300 150
LOCK BOLTS/SEL
75 300 - 150 300 300
PIERCIN RIETS
SET SCREWS AND NUTS - 300 - 150 300 300
SPOT WELDS 75 300 - 150 300 150
DIMPLIN - 150 (11) - - 150 (12) -
Note: Refer to right hand page opposite for additional information relating to Notes 10 to 13 in Table 2.3
ADDITIONAL INORMATION RELATIN TO TABLES 2.1, 2.2 & 2.3
ow Pressure lass “A” Ductwork - ables 2.1 & 2.2
1) he joints and stiffeners have been rated in terms o duct longest side and maximum
spacing. Manuacturers may choose to position stiffeners at un-equal distances but
must ensure the maximum spacing, as listed in columns 3 to 11 and illustrated in Fig 1,
is not exceeded. eer to clause 9.4 or joints and 9.5 or stiffeners.
2) n column 1, ‘A’ = Socket and spigot joints, ‘J’ = Flanged cross joint and ‘S’ = Single
stiffeners.
3) n column 2, ‘PS’ = Plain sheet and ‘SS’ = Stiffened sheet (Fig 12 or examples) by means
o any o the ollowing methods:-
(a) Beading at 400mm maximum centres;
(b) ross-Breaking within the rame ormed joints and/or stiffeners;
(c) Pleating at 150mm maximum centres.
4) Stiffened panels may limit the choice o insulation materials.
5) alvanized ductwork ater manuacture (eer to clause 9.6 and Appendix ).
6) Aluminium ductwork (Appendix E).
7) Stainless Steel ductwork (Appendix D).
8) Although not described in this specication, due to their relatively inrequent use,
cleated cross joints are an accepted constructional practice. B&ES Ductwork roup
should be contacted i details o their ratings and limitations are required.
9) ntermediate stiffeners using roll ormed proles, illustrated in Figs. 26 to 30 o the

appropriate rating may also be utilised ensuring that rigid corners are achieved.
ow Pressure lass “A” Ductwork – able 2.3
10) Fixings o cross joints and stiffeners to sheets to have a minimum o two astenings
per side, with a maximum distance rom the corner o 50mm.
11)  ‘un-xed’ dimpling (Fig 2 below) is used on sheet to sheet joints then one other type
o astening must be used at each end. his does not apply to sel-piercing rivets as in
Fig 3 below.
12)  ‘un-xed’ dimpling (Fig 2 below) is used to secure slide-on fanges then one other
type o astening must be used at 450mm centres with a minimum o one per side.
13) Where manuacturers o proprietary fanges and stiffeners have specic

recommendations or both xings and centres, these shall take preerence over the
inormation in able 2.3
Fig 2 – ypical ‘un-xed’ dimple Fig 3 – ypical sel-piercing rivet

MEDIUM PRESSURE CLASS “B”

TABLE 3.1 SOCKET AND SPIGOT JOINTS Dimensions in mm

1 2 3 4 5 6 7 8 9 10 11
MINIMUM SHEET
0.6 0.8 1.0 1.2
THICKNESS
DUCT LONEST
400 600 800 1000 1250 1600 2000 2500 3000
SIDE
PS 3000
A1
SS 3000
PS 3000
A2
SS 3000
PS 3000 1600 1250 1000 800
A3
SS 3000 3000 1600 1250 800
TABLE 3.2 FLANGED JOINTS AND STIFFENERS Dimensions in mm

1 2 3 4 5 6 7 8 9 10 11
MINIMUM SHEET
0.6 0.8 1.0 1.2
THICKNESS
DUCT LONEST
400 600 800 1000 1250 1600 2000 2500 3000
SIDE
PS 3000 1250 625
J1/S1
SS 3000 1250 625
PS 3000 1250 1250 625
J2/S2
SS 3000 1600 1250 625
PS 3000 1600 1250 1000 800
J3/S3
SS 3000 3000 1600 1250 800
PS 3000 1600 1250 1000 800 800
J4/S4
SS 3000 3000 1600 1250 1000 800
PS 3000 1600 1250 1000 800 800 800 625
J5/S5
SS 3000 3000 1600 1250 1000 800 800 800
PS 3000 1600 1250 1000 800 800 800 800 625
J6/S6
SS 3000 3000 1600 1250 1000 800 800 800 625

1 2 3 4 5 6 7
TYPE CROSS JOINTS
SEAMS JOINTS
O STIENERS
STANDIN/ SOCKET
LAP CAPPED AND RSA
LANES (13)
STANDIN SPIOT
MECHANICALLY CLOSED
75 300 75 150 300 150
RIETS
LOCK BOLTS/SEL
75 300 - 150 300 300
PIERCIN RIETS
SPOT WELDS 75 300 - 150 300 150
DIMPLIN - 150 (11) - - 150 (12) -
Medium Pressure lass “B” Ductwork - ables 3.1 & 3.2
stiffeners.
6) Aluminum ductwork (Appendix E).

Medium Pressure lass “B” Ductwork – able 3.3
Fig 3 below.

inormation in able 3.3.

HIH PRESSURE CLASS “C”


1 2 3 4 5 6 7 8 9 10
MINIMUM SHEET
0.8 1.0 1.2
THICKNESS
DUCT LONEST
400 600 800 1000 1250 1600 2000 2500
SIDE
PS 3000
A1
SS 3000
PS 3000
A2
SS 3000
PS 3000
A3
SS 3000

1 2 3 4 5 6 7 8 9 10
MINIMUM SHEET
0.8 1.0 1.2
THICKNESS
DUCT LONEST
400 600 800 1000 1250 1600 2000 2500
SIDE
PS 3000 625
J1/S1
SS 3000 625
PS 3000 1250 800
J2/S2
SS 3000 1250 800
PS 3000 1250 1250 800
J3/S3
SS 3000 1250 1250 800
PS 3000 1250 1250 1000 800
J4/S4
SS 3000 1250 1250 1000 800
PS 3000 1250 1250 1000 800 800 625
J5/S5
SS 3000 1250 1250 1000 800 800 625
PS 3000 1250 1250 1000 800 800 800 625
J6/S6
SS 3000 1250 1250 1000 800 800 800 625

1 2 3 4 5 6 7
TYPE CROSS JOINTS
SEAMS JOINTS
O STIENERS
STANDIN/ SOCKET
LAP CAPPED AND RSA
LANES (13)
STANDIN SPIOT
MECHANICALLY CLOSED
75 300 75 150 300 150
RIETS
LOCK BOLTS/SEL
75 300 - 150 300 300
PIERCIN RIETS
SPOT WELDS 75 300 - 150 300 150
DIMPLIN - 150 (11) - - 150 (12) -
High Pressure lass “” Ductwork - ables 4.1 & 4.2
stiffeners.
High Pressure lass “” Ductwork – able 4.3
Fig 3 below.


HIH PRESSURE CLASS “D”


1 2 3 4 5 6 7 8 9 10
MINIMUM SHEET
0.8 1.0 1.2
THICKNESS
DUCT LONEST
400 600 800 1000 1250 1600 2000 2500
SIDE
PS 3000
A1
SS 3000
PS 3000
A2
SS 3000
PS 3000
A3
SS 3000

1 2 3 4 5 6 7 8 9 10
MINIMUM SHEET
0.8 1.0 1.2
THICKNESS
DUCT LONEST
400 600 800 1000 1250 1600 2000 2500
SIDE
PS 3000 625
J1/S1
SS 3000 625
PS 3000 1250 625
J2/S2
SS 3000 1250 625
PS 3000 1250 1000 625
J3/S3
SS 3000 1250 1000 625
PS 3000 1250 1000 800 625
J4/S4
SS 3000 1250 1000 800 625
PS 3000 1250 1000 800 625 625
J5/S5
SS 3000 1250 1000 800 625 625
PS 3000 1250 1000 800 625 625 625 500
J6/S6
SS 3000 1250 1000 800 625 625 625 500

1 2 3 4 5 6 7
TYPE CROSS JOINTS
SEAMS JOINTS
O STIENERS
STANDIN/ SOCKET
LAP CAPPED AND RSA
LANES (13)
STANDIN SPIOT
MECHANICALLY CLOSED
75 300 75 150 300 150
RIETS
LOCK BOLTS/SEL
75 300 - 150 300 300
PIERCIN RIETS
SPOT WELDS 75 300 - 150 300 150
DIMPLIN - 150 (11) - - 150 (12) -
High Pressure lass “D” Ductwork - ables 5.1 & 5.2
stiffeners.

High Pressure lass “D” Ductwork – able 5.3
Fig 3 below.


Longitudinal seams
For permitted astenings (type and spacing), see able 2.3, 3.3, 4.3 and 5.3
ig. 4 rooved seam ig. 8 Returned standing seam
(internal or external)
Fastening
Alternative Alternative
sealant sealant
locations locations
ig. 5 rooved corner seam ig. 9 Capped standing seam

Fastening
sealant sealant
locations locations
ig. 6 Pittsburgh lock seam ig. 10 Tray standing seam
Fastening
sealant sealant
locations locations
ig. 7 Button punch snap lock ig. 11 Lap seam
Alternative
sealant
Fastening
locations
Note:
This seam is
acceptable for use on Alternative
low and medium sealant
pressure ducts only. locations
Sealant shall be applied either internally or externally to the seam edge or internal to the joint
seam itsel. he most appropriate method will be determined by the manuacturer relative to their
product and will be associated with traditional abrication/assembly methods, actory or site
based, and/or proprietary methods.
ote: Figures 4 to 11 apply, where appropriate, to cross joints and sheet joints in general
Stiffened Sheet Panels
ig.
Fig. 12
12 Typical
Typical Illustrations o panel
Illustrations of panel stiffening
stiffening
Cross breaking between

joints and stiffeners
Examples of
pleated cross
sections
Pleating may also be along the duct as illustrated above
Examples of
beaded cross
sections Beading may also be along the duct as illustrated above
langed cross joints
Minimum Pressure
ype ating otes / corner treatments
dimensions classes
1 2 3 4 5
ig. 13 Roll steel angle-fanged joint, mm Duct ends turned up 8 mm minimum.
with welded corners
Fixing bolt
Sealant if turn
up not used
25 x 25 x 3
30 x 30 x 4
40 x 40 x 4
50 x 50 x 5
J3
J4
J5
J6
{ ow
Medium
High
A turn up as illustrated is 
mandatory.
 not used, the toe o the angle is to be
sealed.
Gasket or sealant Fixing bolts required at each corner and

Fixing bolts
at 300 mm centres.
25 x 25 x 3 6 mm
30 x 30 x 4 8 mm
40 x 40 x 4 8 mm
Turn up
Fastening 50 x 50 x 5 10 mm
Examples o typical proprietary cross joint fanges produced rom roll ormed sheet metal
proles
ig 15
ig 14 ig 16
Sealant, clamps / cleats / clips and xings omitted or clarity
Examples o proprietary cross joint fanges ormed rom the duct wall, rom the duct wall,
i.e. ‘parent metal’ fanges
ig 17 ig 18 ig 19
Clamps / cleats / clips and xings omitted for clarity
ote: Figures 13 to 19 above are typical examples o cross joint proles that are in common use or
connecting rectangular sheet metal ducts.
here are no set dimensions or the proprietary proles shown in Figs. 14 to 19 provided they were
certied under the B&ES testing scheme DW/M1 “Acceptance Scheme or new products –
ectangular cross joint classication” which is now obsolete ollowing the advent o BS E 1507
‘entilation or buildings – Sheet metal air ducts with rectangular section – equirement or
strength and leakage’.
DW/M1 was introduced in 1987 in order that proprietary joints or rectangular ductwork (Figs 14
to 19) that were new to the market could be tested or identical strength and leakage
characteristics relative to those o rolled steel angle (SA) fanges, Fig 13, which were predominant
at that time.
Proprietary joints since 1987 and up to this latest edition o DW/144 have been tested in
accordance with these procedures set out in DW/M1 but this is now superseded with the advent
o BS E 1507. n order to avoid the re-testing o all current proprietary fanged joints, the
maximum leakage and defection values listed in able 1 o DW/M1 have been re-tested on
behal o B&ES by an accredited test house. n addition to the leakage criteria and the defection o
a joint, these latest tests to BS E 1507 also measure defection o a duct and the bulging and
caving o the duct panel between the joint and the stiffening rame. All test results were proven to
be within the new European standards dened in BS E 1507.
Such are the results o these latest tests undertaken by B&ES, certain sheet thicknesses have been
reduced as the perormance o these reduced thicknesses are within the new BS E 1507
standards. hese reductions are in ables 2.1, 2.2, 3.1 and 3.2 and also refected in the B&ES J-rated
fange identication system as listed in able 6.
All new proprietary fanges rom the date o this publication orward shall be tested to the
latest BS EN 1507 standards and this includes existing proprietary proles that wish to take
advantage o the reduced sheet thicknesses reerred to in the previous paragraph.
B&ES J-rated fange identication system

n order to align to the well-established B&ES J-rated fange identication system, all new
proprietary fanges rom the date o this publication orward which have been tested or strength
and leakage to the latest BS E 1507 should, when tested, also meet the criteria listed in able 6
and its associated notes that ollow.
ote: A test must be applied to each pressure class up to the maximum rating sought as the joint
may perorm differently on a larger duct size at a lower pressure. e.g. a new proprietary joint that
requires a J3 rating or use on a maximum o lass  – High Pressure 2000Pa ductwork systems
must also be tested to meet the able 6 criteria or lass A – ow Pressure 500Pa and lass B –
Medium Pressure 1000Pa.
BS EN 1507
When undertaking BS E 1507 tests on new proprietary proles, the manuacturer’s technical data
should be ollowed with respect to:
• onnections to duct wall

• Sheet thickness o the proprietary prole
• orner treatment
• Addition o cleats, clips and clamps
• Application o sealants
• Strength ratings – to be stamped/engraved or indelibly printed on Fig 14-16 roll ormed
proles
• Application o tie bars
TABLE 6  MAXIMUM LEAKAGE AND DEFLECTION VALUES
Inormation extracted rom Tables 2.1, 2.2, 3.1, 3.2, 4.1, 4.2, 5.1 and 5.2 Calculations
Max
Length
Class and Stiffener Surace Max Test Defection
Joint Duct per Sheet
Max Press Dist rom Area Leakage o lange
Rating Size Section Thickness
(Pa) Joint (Sq mtrs) (Litres/Sec) or
(2 off)
Stiffener
(1) (2) (3) (4) (5) (6) (7) (8) (9)
J1 lass A - ow 500 1000 x 350 1250 0.8 625 6.75 4.13 4.0
J1 lass B - Med 1000 800 x 300 1250 0.8 625 5.50 1.76 3.20
J1 lass  - High 2000 600 x 200 1250 0.8 625 4.00 0.67 2.40
J1 lass D - High 2000 600 x 200 1250 0.8 625 4.00 0.22 2.40
J2 lass A - ow 500 1250 x 450 1250 0.8 625 8.50 5.20 5.00
J2 lass B - Med 1000 1000 x 350 1250 0.8 625 6.75 2.16 4.00
J2 lass  - High 2000 800 x 300 1500 0.8 800 6.60 1.11 3.20
J2 lass D - High 2000 800 x 300 1250 0.8 625 5.50 0.31 3.20
J3 lass A - ow 500 1600 x 550 1500 1.0 800 12.90 7.89 6.40
J3 lass B - Med 1000 1250 x 450 1500 0.8 800 10.20 3.26 5.00
J3 lass  - High 2000 1000 x 350 1500 0.8 800 8.10 1.36 4.00
J3 lass D - High 2000 1000 x 350 1250 0.8 625 6.75 0.38 4.00
J4 lass A - ow 500 2000 x 700 1500 1.0 800 16.20 9.91 8.00
J4 lass B - Med 1000 1600 x 550 1500 1.0 800 12.90 4.13 6.40
J4 lass  - High 2000 1250 x 450 1500 1.0 800 10.20 1.71 5.00
J4 lass D - High 2000 1250 x 450 1250 1.0 625 8.50 0.48 5.00
J5 lass A - ow 500 3000 x 1000 1250 1.2 625 20.00 12.24 12.00
J5 lass B - Med 1000 2500 x 850 1250 1.0 625 16.75 5.36 10.00
J5 lass  - High 2000 2000 x 700 1250 1.2 625 13.50 2.27 8.00
J5 lass D - High 2000 1600 x 550 1250 1.0 625 10.75 0.60 6.40
J6 lass A - ow 500 3000 x 1000 1500 1.2 800 24.00 14.69 12.00
J6 lass B - Med 1000 3000 x 1000 1250 1.2 625 20.00 6.40 12.00
J6 lass  - High 2000 2500 x 850 1250 1.2 625 16.75 2.81 10.00
J6 lass D - High 2000 2500 x 850 1000 1.2 500 13.40 0.75 10.00
TABLE 6 NOTES
(i) normation is extracted rom ables 2.1, 2.2, 3.1, 3.2, 4.1, 4.2, 5.1 and 5.2 inclusive and relates each joint
rating (ol.1) to the maximum duct size (ol.3) per pressure class (ol.2);
(ii) he duct depth (ol.3) gives an approximate duct aspect ratio o 3:1;
(iii) Acceptable intermediate stiffening rames proles are illustrated in Figs 25 to 30 and they must match the
rating o the joint i.e. J3/S3. ther proprietary proles may be used as stiffening rames providing the duct
defection is limited to a maximum o 1/250 o the duct side under operating pressure;
(iv) he surace area (ol.7) does not include the end caps;
(v) Maximum test leakage (ol.8) is based on 40% o the maximum system leakage contained within able 22.
i.e. alculation or line 1 in able is:
Surace area x Max. System eakage x 40% = Max est eakage
6.75sq. m x 1.53 litres/sec/sq. m x 40% = 4.13 litres/sec
he 40% gure is used or the purpose o the cross joint test only to compensate or the laboratory
conditions under which the tests are conducted and the losses rom other parts o the system which may
well arise in a normal working environment.
(vi) Max defection o Flange or Stiffener (ol.9) is duct width (ol.3) x 1/250 or where tie rods are used 1/250 o the
span between the central tie rod and the side o the duct;
(vii) n ducts where tie rods are tted 50% o the values in olumn 9 shall be used;
(viii) he above inormation also applies to negative pressure tests apart rom the static pressure limits which
are 500pa or low pressure and 750pa or medium and high pressure – i.e. as able 1
(ix) n addition to the defection o a joint/stiffener, BS E 1507 tests also measure defection o a duct
(1/250 o distance between duct supports or 20mm, whichever is the smaller value) and the bulging and
caving o the duct panel between the joint and the stiffening rame (no more than 3% o the panels
longest dimension or 30mm, whichever is the smaller value).
Socket and spigot joints

ote: Particular care must be taken in the sealing o these joints.
For permitted astenings (types and spacing), see able 2.3, 3.3, 4.3 and 5.3
ype Angle Pressure

ating otes
size mm classes
ig. 20 Plain
ow
- A1 Medium
High
ig. 21 Adjustable
his joint can be used
on any duct joints
- A1 ow subject to the addition
Medium o an adjacent stiffener
High with a rating
appropriate to the duct
size
ig. 22 Angle reinorced (Ducts with

shorter side 400mm and less)
25 x 3 A2 ow ocate stiffener back

rom end o spigot joint
to allow access or
sealing joint
30 x 4 A3 ow
Medium
ig. 23 Back to back stiffeners (Ducts with

both sides greater than 400mm)
ocate stiffener back

rom end o spigot joint
25 x 3 A2 ow
to allow access or
sealing joint
Stiffeners shown in Figs

ow 25 to 30 are permissible
30 x 4 A3
Medium i provided with rigid
corners
ig. 24 ull girth welded stiffeners

(Ducts with both sides greater than 400mm)
25 x 3 A2 Low Locate stiffener back
from end of spigot joint
to allow access for
sealing joint
Stiffeners shown in Figs

Low 25 to 30 are permissible
30 x 4 A3
Medium if provided with rigid
corners
Single stiffeners
Dimensions and ratings
For permitted astenings (types and spacing’s), see able 2.3, 3.3, 4.3 and 5.3
H hickness
Section ating
mm mm
ig. 25 25 3 S2
30 4 S3
H
40 4 S4
50 5 S5
H 60 5 S6
ig. 26 H
/2
25 1.6 S1
H 30 1.6 S2
40 1.6 S3
50 2.0 S4
ig. 27
20 1.6 S1
H 25 1.6 S2
35 1.6 S3
40 2.0 S4
40
ig. 28
15 1.2 S1
20 1.2 S2
H 25 1.6 S3
40 1.6 S4
25 25 25 50 2.0 S5
ig. 29
20 0.8 S1
H 30 1.0 S2
40 1.2 S3
ig. 30
H 25 0.8 S1
ote: ther proles may be used providing the duct defection is limited to a maximum o 1/250
o the duct side under operating pressure.
Intermediate Stiffeners
ig. 31
Ductwork with short
side greater than 400 Full girth stiffeners with
For permitted fastenings (types and
welded corners
spacings) see Tables 2.3, 3.3, 4.3 and 5.3
Illustrations show rolled steel angle

stiffeners. Stiffeners shown in Figs 26 to Longest side stiffener
30 are permitted. If used as full girth
stiffeners, rigid corners are required
Back to back stiffener with

mechanically fixed or welded corners Ductwork with short
side 400 mm and less
Tie rod assembly – alternative arrangement
ig. 33 - With tubing or

conduit and threaded ig. 34 - With spacers
ig. 32 - With internal inserts
and external nuts
ig. 35 - With shouldered rod
Turning vanes
ig. 38 Bend elevation and plan When vane length

exceeds maximum
permitted a central
bracing must be
utilised
Alternatively, use two
banks of vanes fixing
the centre rails together
50 mm at 150 mm centres
radius
Max vane length

90° Single skin – 615 mm
Double skin – 1250 mm
ig. 36 Single skin vane
ELEVATION
50 mm
radius
Vanes at
25 mm 60 mm
radius pitch
90°
ig. 37 Typical Double skin

vane prole
Fig 36 and 37
Maximum distance between
centre of turning vane should
not exceed 60 mm pitch
SECTIONAL PLAN
SECTION 10
STANDARDISATION O RECTANULAR
DUCTWORK COMPONENTS
he terminology and descriptions o rectangular ductwork components as set out in this section
are recommended or adoption as standard practice to provide common terms o reerence or
system designers, quantity surveyors and ductwork contractors, and o those using computers in
ductwork design and abrication.
he illustrations in this section not only highlight, where applicable, geometric limitations or
the design and manuacture o ductwork components but also recommend standard drawing
representation and terminology.
System designers and surveyors should note that bills o quantities should provide a ull
description o the items required.
10.1
STIFFENERS
he fat sides o ttings shall be stiffened in accordance with the construction ables 2.1, 2.2, 3.1,
3.2, 4.1, 4.2, 5.1 and 5.2. n the fat sides o bends, stiffeners shall be arranged in a radial pattern,
with the spacing measured along the centre o the bend.
10.2
SPLITTERS
 the leading edge o the splitters exceeds 1250mm t central tie bars at both ends to support the
splitters. eading and trailing edges o splitters must be edge olded and returned and be parallel
to the duct axis. Splitters shall be attached to the duct by appropriate astenings at 100 mm
maximum spacing (or by such other xing as can be shown to be equally satisactory e.g.
proprietary sealed splitter pins).
10.3
TURNING VANES
Where specied or shown on drawings, square throat bends will be tted with turning vanes as
illustrated in Figs. 36 and 37.
ote:  either duct dimension is 200mm or less, air turns will be omitted and a radius pattern bend
or a square bend, with or without a radiussed back plate, should be specied.
urning vanes at 60 mm maximum centres shall be xed at both ends either to the duct or
compatible mounting tracks in accordance with manuacturer’s instructions, the whole bank being
xed inside the duct with astenings at 150mm maximum spacing.
he maximum length o turning vane between duct walls or intermediate support shall be 615
mm or single skin vanes and 1250mm or double skin vanes. ypical examples o tting turning
vanes when the maximum permitted vane lengths are exceeded are shown in Fig. 38.
10.4
BRANCHES
When tting branch ducts to a main duct, care should be taken to ensure that the rigidity o the
duct panel is maintained in terms o the stiffening criteria.
10.5
CHANGE SHAPES
Where a change shape is necessary to accommodate the duct and the cross-sectional area is to be
maintained, the slope shall not exceed 221/2° on any side (Figs. 55 to 59). Where a change in shape
includes a local reduction in duct cross- sectional area, the slope should not exceed 15° on any side
and the reduction in area should not exceed 20 per cent.
10.6
EXPANSIONS AND CONTRACTIONS
Where these are required, an expansion shall be made upstream o a branch connection and
contraction downstream o a branch connection. he slope o either an expansion or a contraction
should not exceed 221/2° on any side. Where this angle is not practicable, the slope may be
increased, providing that splitters are positioned to bisect the angle between any side and the
centre line o the duct (Figs. 55 to 57).
10.7
SEALANT
Sealant shall be used in all longitudinal seams and cross-joints o ttings. Joint sealing materials
are set out in Part Seven, Section 19.
STANDARD COMPONENT DRAWINS - RECTANULAR

ig. 39 ig. 42 - examples o
W ‘hard’ and ‘easy’ bends
Mitred Throat Bend

For ducts up to 400mm wide HARD
ig. 40 EASY
WW
Short Radius Bend
Minimum
For ducts up to 400mm wide
throat radius
= 100mm Bends are designated as ‘hard’
or ‘easy’, and these terms as used
herein have the following
meanings:
ig. 41
‘Hard’ signies rotation in the
plane of the longer side of the
Medium Radius Bend cross section – as illustrated in
W (as illustrated) top sketch.
‘Easy’ signies rotation in the

Long Radius Bend plane of the shorter side of the
Throat radius Similar but radius = W cross section – as illustrated in
= W/2 lower sketch.
Applies to any angle
This conguration also applies
to at oval bends.
ig. 43 Short Radius Bend with splitters

W
W mm Splitters Splitter position
A B C
401 - 800 1 W
/3 - -
A 801 - 1600 2 W
/4 W
/2 -
Minimum B 1601 - 2000 3 W
/8 W
/3 W
/2
C
throat radius
= 100mm Splitters not required in bends o 45° or less
ig. 44
Square Bend - with turning vanes
Mitred elbow - 30° max
ig. 45
Radius Tee - with ‘radiussed back

plates’ and, i required, splitters as
Fig 43

ig. 46
Radiussed Twin Bend
ig. 47
Swan Neck Bend - typically ound on

roo exhausts i.e. 135° angle
ig. 48
Swept Branch
ig. 49
Square Tee with turning vanes
ig. 50
Breeches Piece
ig. 51
‘Y’ Piece

ig. 52
15° max
Angled Offset
ig. 53
30° max
Mitred Offset
ig. 54
Radiussed Offset
Minimum throat radius = 100mm
ig. 55 221/2° max

Concentric Taper
22.5° max in either plane
Splitters are required or angles greater
than 22.5° and should bisect the angle
between any side and the duct
centreline.
ig. 56
221/2° max Ecccentric Taper
22.5° max in either plane
221/2° max centreline.
ig. 57
221/2° max
Offset Taper
centreline.

ig. 58
Rectangular to Round Transormation
221/2° max
ig. 59
Rectangular to lat Oval

Transormation
221/2° max
ig. 60
Square Branch
ig. 61
Angled Branch
A
ig. 62
Branch duct Dimension
width (W) (A)
mm mm
p to 200 75
W Shoe Branch " 300 100
" 400 125
" 600 150
45° max
ver 600 200
A
ig. 63
width (W) (A)
mm mm
Bell Mouth p to 200 75
" 300 100
W Branch " 400 125
" 600 150
ver 600 200
45° max
A
ig. 64
width (W) (A)
mm mm
p to 200 75
Bell Mouth " 300 100
W " 400 125
" 600 150
ver 600 200
45° max

ig. 65
TJ SMF
Telescopic Joint
llustrated with SMF – sel metal fange.
ig. 66
Single Blade Damper
SBD
ig. 67
Non-Return Damper
NRD
ig. 68
Multi-Lea Damper
an be spiggoted or fanged, opposed
or parallel blade
Alternative controls are:

Hand, Motorised, Pneumatic
PD MD HD
ig. 69
Blast ate Damper
BG
ig. 70
ire/Smoke Damper
FD - Fire Damper
SD - Smoke Damper
FD

ig. 71
Access openings
AP - Access Panel
AD - Access Door
 - nspection over
ig. 72
lexible Connection
ig. 73
Drop cheeked reducing radiussed

twin bend
ig. 74
Drop cheeked reducing bend

radiussed or mitred throat
ig. 75
Air fow symbol

PART OUR – CIRCULAR DUCTS

SECTION 11
STANDARD SIZES
he duct sizes in able 7 have been selected rom the E Standard anges.
Table 7 Circular Ducts - Standard Sizes
EN 1506 Duct sizes

Duct Duct
Ø Surace Ø Surace
mm Area m2/m mm Area m2/m
ecommended sizes
63 0.198 315 0.990
80 0.251 400 1.257
100 0.314 500 1.571
125 0.393 630 1.979
160 0.502 800 2.512
200 0.628 1000 3.142
250 0.785 1250 3.927
Additional sizes
150 0.470 560 1.760
300 0.943 710 2.229
355 1.115 900 2.826
450 1.413 1120 3.517
ote: he diameters are subject to normal manuacturing tolerances.

ther sizes may be available rom individual manuacturers including larger diameters up to
2400mm.
SECTION 12
CONSTRUCTION
Spirally wound ducts and straight seamed ducts
he constructional requirements set out in able 8 and 9 are common to the ull range o pressures
covered in this specication.
he ductwork sealing standards are set out in Part Seven, Section 19.
Minimum steel thicknesses related to duct diameter are given in ables 8, 9 and 11.
12.1
LONGITUDINAL SEAMS
12.1.1
SPIRALLYWOUND DUCTS
he seam used in spirally wound circular ducts, provided it is tightly ormed to produce a
rigid duct, is accepted as airtight to the requirements o all the pressure classications
covered in this specication, without sealant in the seam.
12.1.2
STRAIGHTSEAMED DUCTS
he longitudinal seam or straight-seamed circular ducts shall be one o the ollowing:-
(a) grooved seam continued to the extreme end o the duct and sealed.
(b) continuous butt lap weld
(c) spot/stitch weld and sealed lap joint (at 75 mm centres) provided this gives a
smooth internal nish (Fig. 76).
he most appropriate method will be determined by the manuacturer relative to their
product and will be associated with traditional abrication/assembly methods, actory or
site based, and/or proprietary methods.
12.2
CROSS JOINTS
12.2.1
GENERAL
ross joints or circular ducts, both spirally-wound and straight-seamed, are illustrated in
Figs.77 to 90. hey include several proprietary types and the limits o use in terms o
diameter and pressure classes are noted against each.
12.2.2
WELDED JOINTS
he limitations or welded joints are given in 12.4.
12.3
FASTENINGS
12.3.1
PERMITTED TYPES AND MAXIMUM CENTRES
able 10 sets out the permitted astenings and the maximum spacing or all ductwork
classications. Fastenings resulting in an unsealed aperture shall not be used.
12.3.2
RIVETS
Manuacturers’ recommendations as to use, size and drill size are to be ollowed.
12.3.3
SET SCREWS, NUTS AND LOCK BOLTS
Materials shall be o mild steel, protected by electro-galvanizing, sherardizing, zinc

plating, or other equal corrosion resistant nish.
12.3.4
SELF TAPPING AND PIERCING SCREWS
Providing an adequate seal can be achieved, then sel-tapping or piercing screws may be
used. Acknowledging the presence o such astenings / xings, avoid putting operatives
at risk o injury with regard to internal activities such as access maintenance or ductwork
cleaning. Such xings must not be used within 1 metre o an access opening – as BS E
12097, lause 4.5.
12.3.5
SELFPIERCING RIVETS
Providing an adequate seal can be achieved, then sel-piercing rivets may be used. (Fig. 3).
12.4
WELDING SHEET JOINTS
he suitability o continuous welding or sheet-to-sheet joints will be governed by the sheet
thickness, the size and shape o the duct or tting and the need to ensure airtightness. apped
sheet joints with a combination o spot welding and duct sealant is also acceptable. Distortion
shall be kept to a minimum.
Areas where the galvanizing has been damaged or destroyed by welding or brazing shall have a
suitable protective coating applied as dened in Section 32. Spot welds need not be treated as
accelerated salt spray tests undertaken by eeds niversity esearch aboratory on behal o B&ES
have indicated that corrosion rates would be well within the lie expectancy o the various parent
metal zinc coatings as indicated in the data listed in able 24 o Appendix B.
12.5
BREAKAWAY DUCT JOINT
A joint connecting a re damper spigot or sleeve to the attached ductwork which will allow
collapse o the ductwork during a re without disturbing the integrity o the re damper. ‘Break-
away’ and fexible joints incorporate materials, xings, clamps, etc, that are manuactured rom a
non - re resistant material with a low melting point such as aluminium, plastic, etc. (DW/145,
‘uide to ood Practice or the nstallation o Fire and Smoke Dampers’).
Table 8 Spirally Wound Ducts (all pressure classications)
Maximum
Minimum sheet
(nominal) Minimum stiffening requirements
thickness
diameter
1 2 3
mm mm
one
up to 80 0.4
81 - 160 0.5 one
161 - 315 0.6 one
316 - 800 0.8 one
one i helically beaded.  not helically beaded
801 - 1000 1.0 use Fig.80 (angle reinorced) or Fig. 81, 82 or 83
(angled fanged – all at 3000 mm maximum spacing.
1001 - 1500 1.0 Figs. 81, 82 or 83 at 3000 mm maximum spacing.
Table 9 Straight-seamed Ducts (all pressure classications)
Maximum
Minimum sheet
(nominal) Minimum stiffening requirements
thickness
diameter
1 2 3
mm mm
one
up to 200 0.6
201 - 500 0.8 Swaged at spigot end as Figs 84 and 85
501 - 800 0.8 Swaged at socket and spigot end as Figs 84 and 85
801 - 1000 1.0 Figs. 87 to 90 at 1500 mm maximum spacing
Notes to Tables 8 and 9

(a) he diameters are subject to normal manuacturers tolerances.
(b) ther sizes may be available rom individual manuacturers including larger diameters
up to 2400mm
(c) For ductwork above 1500 diameter, advice must be sought rom manuacturers which
may include the possible use o recognised standards such as SMAA
Table 10 Permitted astenings and

ig. 76
maximum spacing – circular ducts
Spirally wound duct
Sheet to section
ype o (joining fanges
Sheet to sheet
astening and intermediate
stiffeners)
ap ross Spirally Straight
joints joints wound seamed
The tightly formed seam is 1 2(1) 3(2) 4(2) 5(2)
accepted as airtight to the
requirements of all pressure classes Mechanically mm mm mm mm
without sealant in the seam. closed rivets 75 150 150 150
Sel piercing
75(3) 150(3) 150(3) 150(3)
Straight-seamed duct screws
Set screws
- - 300 300
and nuts
ock bolts 75 - 300 300
Spot welds 75 75 150 150
Notes to Table 10
1
Minimumo two xings
2
Minimum o three xings
Welded butt seam 3
ot suitable within 1 metre o an access opening.
Where manuacturers have specic
recommendations, these shall take preerence over
the centres indicated in this table
The alternative grooved seam or

lap joint seam must be sealed either
externally or internally
Table 11 Circular duct ttings – Sheet thicknesses
Maximum nominal Minimum sheet

diameter thickness
1 2
mm mm
up to 250 0.6
251 - 500 0.7
501 - 630 0.8
631 - 1500 1.0
Circular duct cross joints
Note – All duct penetrations shall be sealed
imits o use
Angle Maximum
Spirally-wound circular ducts Pressure
size diameter
classes
mm mm
ig 77 Plain socket and spigot (duct to tting)
Fastening
Alternative ow
sealant
locations
- 1000 Medium
High
ig 78 Socket and spigot (duct to duct) with connector.

Fastening
ow
- 1000 Medium
Alternative
sealant
High
locations
ig 79 Socket and spigot with synthetic rubber gasket
o be used strictly in
accordance with
Fastening manuacturer’s instructions
and size limitations.
Gasket
May be suitable or helically

beaded spiral tube i
guaranteed by manuacturer.
ig 80 Angle reinorced socket and spigot

Fastening
*25 x 25 x 3 800 ow

*30 x 30 x 4 1000 Medium
40 x 40 x 4 1500 High
Alternative
sealant
locations
*Where angle
rings specied
imits o use
Angle Maximum
Spirally-wound circular ducts Pressure
size diameter
classes
mm mm
ig 81 Example o typical roll ormed sheet metal prole
Alternative
gasket
Fastenings and sealant
locations
in accordance with o be used strictly in
Alternative manufacturer’s accordance with
sealant instructions
locations
manuacturer’s instructions
ig 82 Angle fanged (external)

Fixing bolts
Fastening
Sealant
*25 x 25 x 3 800 ow
*30 x 30 x 4 1000 Medium
40 x 40 x 4 1500 High
Sealant Turn up
Sealant
or gasket minimum *Where fange joints are specied.
of 8mm
ote: A turn up as illustrated is
not mandatory.
ig 83 Angle fanged (internal)

Alternative
sealant Fixing bolts
locations
*25 x 25 x 3 800 ow
*30 x 30 x 4 1000 Medium
40 x 40 x 4 1500 High
Fastening
Sealant
or gasket
*Where fange joints are specied.
Note: ixings or angle fanged joints igs 82 and 83
Section size Bolt size
25 x 25 x 3
30 x 30 x 4
40 x 40 x 4
6mm
8mm
8mm } @ 300 mm maximum centres
Minimum o our per joint
imits o use
Angle Maximum
Straight-seamed circular ducts Pressure
size diameter
classes
mm mm
ig 84 Plain socket and spigot (duct to tting)

Socket swage not
required on ducts 500
diameter and below
Fastening
ow
Alternative - 800 Medium
sealant High
locations
ig 85 Socket and spigot (duct to duct) with connector.

Socket swage not Fastening
required on ducts 500
diameter and below
ow
- 800 Medium
Alternative High
sealant
locations
ig 86 Socket and spigot with synthetic rubber gasket
o be used strictly in
Fastening
accordance with
Gasket manuacturer’s instructions
and size limitations
ig 87 Angle reinorced socket and spigot

Alternative angle Fastening Fastening
location, no swage
needed
*25 x 25 x 3 800 ow

*30 x 30 x 4 1000 Medium
40 x 40 x 4 1500 High
Swage only required if
Alternative alternative angle
sealant location used
locations
*Where angle
rings specied
imits o use
Angle Maximum
Straight-seamed circular ducts Pressure
size diameter
classes
mm mm
ig 88 Example o typical roll ormed sheet metal prole

Alternative
gasket
locations Fastenings and sealant o be used strictly in
in accordance with
Alternative manufacturer’s accordance with
sealant instructions manuacturer’s instructions
locations
ig 89 Angle fanged (external)

Fixing bolts
Fastening Sealant if
*25 x 25 x 3 800 ow
turn up 30 x 30 x 4 1000 Medium
not used 40 x 40 x 4 1500 High
*Where fange joints are specied.

Turn up
Sealant
minimum
ote: A turn up as illustrated is
or gasket
of 8mm not mandatory.
 not used, the toe o the angle is to
be sealed.
Also acceptable with fange set
internally similar to Fig 83
ig 90 lat ringed fanged Fixing bolts
*25 x 3 800 ow

Sealant
*30 x 4 1000 Medium
or gasket 40 x 4 1500 High
Turn up
minimum
of 8mm
Note: ixings or angle and fat ring fanged joints igs 89 and 90
Section size Bolt size

Angle Bar
25 x 25 x 3
30 x 30 x 4
40 x 40 x 4
25 x 3
30 x 4
40 x 4
6mm
8mm
8mm } @ 300 mm maximum centres
Minimum o our per joint
SPECIFICATION FOR SEET METAL DUCTWORK 57
SECTION 13
STANDARDISATION OF CIRCULAR DUCTWORK
COMPONENTS
13.1
SS
The terminology and descriptions o circular ductwork components as set out in this section are
recommended or adoption as standard practice, to provide common terms o reerence or
system designers, quantity surveyors and ductwork contractors, and those using computers in
ductwork design and abrication.
The illustrations in this section not only highlight, where applicable, geometric limitations or
the design and manuacture o ductwork components but also recommend standard drawing
representation and terminology.
Designers and surveyors should note that bills o quantities should provide a ull description o the
items required.
The requirements or circular duct ttings apply throughout the pressure ranges covered in this
specication.
13.2
 S
The nominal diameter (Table 7) is the size used or design and ordering. With socket and spigot
joints, care should be taken to ensure that the dimensions o the ducts and ttings are correctly
related, so that the joint can be effectively sealed.
13.3
S SS
Sheet thickness or circular duct ttings (determined by the largest diameter) shall be not less than
those quoted in Table 11.
13.4
S  jS
Sealant shall be used in all cross-joints and ttings. Such sealant shall be in accordance with the
requirements o Part Seven, Section 19.
58 SPECIFICATION FOR SEET METAL DUCTWORK
STANDARD COMPONENT DRAWINGS - CIRCULAR

Fig. 91
Straight Duct
With male and emale connectors
(MALE) (FEMALE)
Fig. 92
Straight Duct
With fanged joint and slip joint
Fig. 93
D = Duct diameter
Pressed Bend
15°, 30°, 45°, 60°, 90°
Medium radiussed bend as illustrated
Long radius similar but throat radius = D
Throat radius = D/2 as standard
Fig. 94
Segmented Bend
90° our section minimum as illustrated
i.e. middle two sections are ull segments and two end
sections are hal segments
Other angles
60° = 3 sections (one ull segment and two hal
segments)
Throat radius = D/2 as standard 45° = 3 sections (one ull segment and two hal
segments)
30° = 2 sections (two hal segments)

Fig. 95
Segmented Twin Bend

Radius = D/2 maximum
May also be abricated rom pressed bends

Throat radius = D/2 maximum
D = Duct diameter
Fig. 96
Pressed Equal Tee
Fig. 97
Pressed Twin Bend
Fig. 98
Taper
Inclusive angle, 15° < _< 60°
Concentric, (as illustrated)
Length l =(d1 – d2)/[2 tan(α /2)]
Eccentric, ,
Body length = l Length l =(d1 – d2)/ tan α
Fig. 99
Inclusive angle, _ = 90° max
Pressed Taper
315 Dia max on greatest dimension

Fig. 100
30° max offset
Offset
Fig. 101
Square Branch
Off rectangular
Fig. 102
dia (D) (A)
mm mm
Shoe Branch Up to 200 75
45 0
Off rectangular "
"
300
400
100
125
" 600 150
Over 600 200
A
Fig. 103 450

dia (D) (A)
Conical Branch mm mm
Up to 200 75
Also acceptable with ull " 300 100
conical surace " 400 125
" 600 150
A Over 600 200
Fig. 104
Angle Branch
0
45
Fig. 105
Square Branch
Fig. 106
Shoe Branch
450

Fig. 107
Pressed Branch
Fig. 108
450 Branch duct Dimension
dia (D) (A)
mm mm
Up to 200 75
Bell Mouth Branch " 300 100
" 400 125
" 600 150
Over 600 200
A
Fig. 109
450
Mitred Branch
Fig. 110
Blank End
Fig. 111
Multi-Lea Damper
Can be fanged or spigotted, opposed or parallel blade
Alternative controls are:-
Hand (HD)
Motorised (MD)
PD MD HD Pneumatic (PD)

Fig. 112
Single Bladed Damper

SBD
Fig. 113
Non-Return Damper
Vertical application only
NRD
Fig. 114
Iris Damper
ID
Fig. 115
Blast Gate Damper
BG
Fig. 116
Fire/Smoke Damper
FD - Fire Damper
SD - Smoke Damper
FD
Fig. 117
Breeches Piece

Fig. 118
Access Openings
AP - Access Panel
AD - Access Door
IC - Inspection Cover
Also applies to curved

surace o fat oval duct.
Fig. 119 Discharge cowls
Top our illustrations, Figs 119 (a) to (d), are extracted

Solid
Fig 119a
top rom DW/172, ‘Specication or Kitchen Extract
cone
Solid top
cone Systems’, and that publication contains all necessary
dimensional inormation and design considerations
associated with such discharge cowls.
Fig 119b
Open top cone Fig 119 (e), ‘Chinaman’s Hat’, includes below, CIBSE’s
and drain dimensional guidelines. Note: DW/172 states this
“type o cowl should not be used in KE systems due to
Fig 119c
the potential downdraught caused and the risk o
Sleeve type re-entry o the extract air back into the building”.
2D Inner cone, which reduces

1.5D resistance, is optional
Fig 119d
Induction type 0.3D
0.25D – bad
0.3D 0.50D – minimum
0.75D – maximum
Fig 119e
‘Chinaman’s
Hat’
D
Notes:
(1) Many types o proprietary discharge cowls are also
available
Fig 119f
1350 Swan neck
(2) DW/172 states “the discharge terminal should be
open without mesh”, but consideration should
be made or all other cowls to avoid the ingress o
oreign bodies
PART FIVE – FLAT OVAL DUCTS
SECTION 14
STANDARD SIZES AND SEET TICKNESSES
Table 12 sets out the standard sizes o spirally - wound oval ducts offered by the manuacturers o
ducts o this section.
SECTION 15
CONSTRUCTION (SPIRALLY WOUND DUCTS)
15.1

‘Flat oval’ is the term used to describe a duct o cross-section with fat opposed sides and semi-
circular ends. The duct is ormed rom a spirally- wound circular duct, using a special ormer.
Apart rom stiffening (see Tables 13 and 14), fat oval ducts have the same constructional
requirements throughout the pressure ranges covered in this specication.
The ductwork construction and joint sealing standards are set out in Part Seven, Section 19.
Minimum steel thicknesses related to duct dimensions are given in Table 12.
15.2
 SS
Spirally wound fat oval duct is accepted as airtight to the requirements o this specication
without sealant in the seams, provided the grooved seam is tightly ormed to produce a rigid duct.
15.3
SS jS
15.3.1

Cross-joints shall be as Figs. 127 to 132 inclusive or such other proprietary joint as can be
demonstrated to the system designer to be equally satisactory.
15.3.2
S
All fat oval cross-joints shall be sealed. (See Part Seven, Section 19).
15.3.3
W jS
The limitations or welded joints are given in 15.4.6.

15.4
SS
15.4.1
P PS  x S
Table 15 sets out the permitted astenings and the maximum spacing or all ductwork
classications. Fasteners resulting in an unsealed aperture shall not be used.
15.4.2
S
Manuacturers’ recommendations as to use, size and drill size are to be ollowed.
15.4.3
S SWS, S   S
Materials shall be o mild steel, protected by electro-galvanizing, sherardizing, zinc

plating, or other equal corrosion resistant nish.
15.4.4
S-PP  P SWS
Providing an adequate seal can be achieved, then sel-tapping or piercing screws may be
used. Acknowledging the presence o such astenings / xings, avoid putting operatives
at risk o injury with regard to internal activities such as access maintenance or ductwork
cleaning. Such xings must not be used within 1 metre o an access opening - BS EN
12097, Clause 4.5.
15.4.5
S-P S
Providing an adequate seal can be achieved, then sel-piercing rivets may be used. (Fig. 3).
15.4.6
W S jS
The suitability o continuous welding or sheet-to-sheet joints will be governed by the
sheet thickness, the size and shape o the duct or tting and the need to ensure
airtightness. Lapped sheet joints with a combination o spot welding and duct sealant is
also acceptable. Distortion shall be kept to a minimum.
Areas where the galvanizing has been damaged or destroyed by welding or brazing shall
have a suitable protective coating applied as dened in Section 32. Spot welds need not
be treated as accelerated salt spray tests undertaken by Leeds University Research
Laboratory on behal o B&ES have indicated that corrosion rates would be well within the
lie expectancy o the various parent metal zinc coatings as indicated in the data listed in
Table 24 o Appendix B.
15.4.7
-W  j
A joint connecting a re damper spigot or sleeve to the attached ductwork which will
allow collapse o the ductwork during a re without disturbing the integrity o the re
damper. ‘Break-away’ and fexible joints incorporate materials, xings, clamps, etc, that are
manuactured rom a non - re resistant material with a low melting point such as
aluminium, plastic, etc. See DW/145, ‘Guide to Good Practice or the Installation o Fire and
Smoke Dampers’.
15.5
S
The larger sizes o fat oval duct are stiffened by swages, as indicated in Table 12. Additionally, tie
rods (Figs. 32 to 35) are required, positioned as indicated in the respective tables and illustrations.
In special situations as an alternative to tie rods, stiffening in the orm o external ull rame angles
may be used to meet the requirements o the corresponding rectangular duct sizes.
SECTION 16
CONSTRUCTION (STRAIGT-SEAMED)
Flat oval ducts with opposed sides and semi-circular ends may also be ormed using plain sheet
and straight seams. Ducts so ormed should ollow the metal thicknesses o Table 12 and
stiffening requirements specied or the corresponding sizes o rectangular ducts, in the orm
o external ull rame angles. Seams and cross-joints (Figs 133 to 137) shall be sealed to ensure the
necessary degree o airtightness throughout the pressure ranges covered in this specication.
Table 12 Flat oval spirally wound ducts – Standard sizes and sheet thicknesses
Surace
Nominal
area per Depth o duct (minor axis – ‘D’) – nominal
sheet
metre
thickness
length 75 100 125 150 200 250 300 350 400 450 500
1 2 3
mm Sq.metres mm mm mm mm mm mm mm mm mm mm mm
0.178 320
0.798 360 350 330 320
0.878 400 390 370 360
0.8 0.958 440 430 410 400
1.037 480 470 450 440

(Width o duct (major axis – ‘W’)-nominal-mm
1.117 520 505 490 480
1.197 545 530 520
1.277 555 525
1.436 635 605 580
1.596 715 690 660 630
1.756 800 770 740 710 685 655
1.915 880 845 825 790 765 735 705 680
2.075 960 930 900 875 845 815 785 755

Swaged
2.238 1040 1010 985 955 925 895 865 835
2.394 1120 1090 1065 1035 1005 975 945 915
2.553 1200 1170 1145 1115 1085 1055 1025 1000
1.0 2.873 1335 1305 1275 1245 1215 1190 1160
3.192 1465 1435 1405 1375 1350 1320
3.511 1625 1595 1570 1540 1510 1480
3.830 1785 1760 1730 1700 1670 1640

Table 13 – Flat oval ducts – low- and medium-pressure – stiffening requirements
Depth o duct (minor axis – ‘D’) – nominal

Tie rods
75 100 125 150 200 250 300 350 400 450 500
1 2
mm mm mm mm mm mm mm mm mm mm mm
320
360 350 330 320
Not required 400 390 370 360
440 430 410 400
480 470 450 440

Width o duct (major axis – ‘W’) – nominal - mm
520 505 490 480
545 530 520
555 525
635 605 580

Fig 120
1000 mm centres 715 690 660 630
800 770 740 710 685 655
= = 880 845 825 790 765 735 705 680

Fig 121
750 mm centres 960 930 900 875 845 815 785 755
1040 1010 985 955 925 895 865 835
= =
1120 1090 1065 1035 1005 975 945 915
Fig 122 1200 1170 1145 1115 1085 1055 1025 1000
500 mm centres
1335 1305 1275 1245 1215 1190 1160
1465 1435 1405 1375 1350 1320
= = =
1625 1595 1570 1540 1510 1480
1785 1760 1730 1700 1670 1640

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BD & EEE SEES ASSA

SHEET METAL DUCTWORK

All rights reserved

First Edition (1998)

urther copies o this publication are available rom:

THE INDUSTRY STANDARD

Bob Lane Peter Rogers

Since its publication in 1998, the Association’s Specication or Sheet

• lighter gauges o steel;

DW/144 Members o the echnical ommittee o the Ductwork roup,

eter ogers (hairman)

Ductwork Group Secretary:

B&ES wishes to record its sincere thanks to particular organisations that

BUILDIN & ENINEERIN SERICES ASSOCIATION

OTHER DUCTWORK-RELATED PUBLICATIONS

DW/143 A Practical uide to Ductwork eakage esting

opies o the above publications are available rom:

Previous Sheet Metal Ductwork Related Specications

- Ductwork Specication or High-elocity Air Systems (ircular) 1963

Part One - Scope

Part Two - Technical Inormation to be provided by

Part Three - Rectangular Ducts

8. Rectangular duct sizes 19

Part our - Circular Ducts

11. Standard sizes 48

Part ive - lat Oval Ducts

14. Standard sizes and sheet thicknesses 64

16. Construction (Straight-seamed) 66

Part Six - Hangers and Supports

Part Seven - Ductwork Related Inormation

19. Ductwork Sealing 89

Part Eight - Appendices

Appendix A Ductwork Air Leakage Testing 123

1 Ductwork lassication and Air eakage imits 11

ENERAL NOTES RELATIN TO DW/144

(7) Despite reerence to ‘minimum’ requirements, it should be recognised that in several

PART ONE – SCOPE

Table 1 Ductwork Classifcation and Air Leakage Limits

Static pressure limit Air leakage limits

PART TWO – TECHNICAL INORMATION

Specication and location, on the drawings, o any fexible ductwork.

PART THREE – RECTANULAR DUCTS

ote: Proprietary products used in the construction o cross-joints should be approved by

n order to accommodate manuacturing / building tolerances, site modications etc, it is

Materials shall be o mild steel, protected by electro-galvanizing, sherardizing, zinc

ig. 1 – onstructional criteria

LOW PRESSURE CLASS “A”

TABLE 2.1 SOCKET AND SPIGOT CONNECTIONS Dimensions in mm

TABLE 2.2 FLANGED JOINTS Dimensions in mm

TABLE 2.3 FASTENING CENTRES Dimensions in mm

ADDITIONAL INORMATION RELATIN TO TABLES 2.1, 2.2 & 2.3

ow Pressure lass “A” Ductwork - ables 2.1 & 2.2

4) Stiﬀened panels may limit the choice o insulation materials.

6) Aluminium ductwork (Appendix E).

7) Stainless Steel ductwork (Appendix D).

9) ntermediate stiﬀeners using roll ormed proles, illustrated in Figs. 26 to 30 o the

ow Pressure lass “A” Ductwork – able 2.3

13) Where manuacturers o proprietary fanges and stiﬀeners have specic

Fig 2 – ypical ‘un-xed’ dimple Fig 3 – ypical sel-piercing rivet

MEDIUM PRESSURE CLASS “B”

TABLE 3.1 SOCKET AND SPIGOT JOINTS Dimensions in mm

TABLE 3.2 FLANGED JOINTS AND STIFFENERS Dimensions in mm

TABLE 3.3 FASTENING CENTRES Dimensions in mm

ADDITIONAL INORMATION RELATIN TO TABLES 3.1, 3.2 & 3.3