CHAPTER 12
DUCT SYSTEM CONSTRUCTION
A INTRODUCTION
Avariety of materials have been used in the construc-
tion of ducts. There has been a tendency to empha-
size (or deemphasize) certain of the general require-
ments for all ducts, depending on the particular
character of the application. Selection of the materials
used throughout the duct system should follow the
same careful consideration as the other system com-
ponents. The different materials used in duct systems
can substantially affect the overall performance of the
systems, as the listed "advantages" should be eval-
uated with the "limiting characteristics" prior to the
material selection.
Some materials used for ducts include: galvanized
steel, black carbon steel, aluminum, stainless steel,
copper, fiberglas reinforced plastic (FRP), polyvinyl
chloride (PVC), polyvinyl steel (PVS), concrete, fi-
brous glass (duct board), and gypsum board. Infor-
mation will be given on each of the above materials,
but duct sizing and duct construction specifications
will generally be stated in this manual in terms of use
of galvanized steel as the material from which ducts
are made. Figure 14-3 and Table 14-1 of Chapter 14
gives correction factors used to adjust duct friction
losses for materials other than galvanized steel (mul-
tiply duct friction loss by factor in Table). This higher
friction loss can be one of the most important items
to consider when selecting a different duct material.
Consideration must also be given to selection of duct
construction components other than those materials
used for the duct walls. Such items as flexible ducts,
duct liner, pressure sensitive tapes, sealants, adhe-
sives, reinforcements, hangers, etc., are appropri-
ately described in individual SMACNA Manuals as
well as many other publications.
It is emphasized that special material selection and
construction could be necessary when designing sys-
tems serving nuclear projects, earthquake prone
areas and projects with other unusual requirements.
B DUCT SYSTEM
SPECIFICATION CHECK LIST
In addition to SMACNA duct construction standards,
the specification and/or detail drawings should in-
clude the following detailed duct system require-
ments:
a) Local code requirements
b) Duct system static pressure classifications
(SMACNA standard flag designation).
c) Duct material selection.
d) Allowable duct leakage (specify sealing system
classification).
e) Insulation requirement (external and/or liner).
f) Sound control devices and methods.
g) Outlet and inlet performance.
h) Filters.
i) Dampers (fire, smoke, and volume control).
j) Duct mounted apparatus.
k) Duct mounted equipment.
I) Special duct suspension system.
A complete SMACNA duct design specification will
include all of the above specification requirements in
sufficient detail to indicate performance standards,
materials and design methods for all ducts and duct
components required for the total HVAC system.
C DUCT CONSTRUCTION
MATERIALS
1. Galvanized Steel
a. APPLICATIONS
Widely used as a duct material for most air handling
systems; not recommended for corrosive product
handling or temperatures above 400°F (2000C).
12.1

b. ADVANTAGES
High strength, rigidity, durability, rust resistance,
availability, non-porous, workability, and weldability.
c. LIMITING CHARACTERISTICS
Weldability, paintability, weight, corrosion resistance.
d. REMARKS
Galvanized steel sheet is customarily available in
commercial quality, lock forming quality, drawing
quality, drawing quality special killed and physical
(structural) quality. The most common material used
for ductwork is lock forming quality. Table 12-1 shows
the chemical requirements of carbon steel prior to
galvanizing. Galvanized steel sheet is produced to
various zinc-coating designations to give the service
life required (see Table 12-2). Galvanizing may be
accomplished by the electrolytic or hot-dipping pro-
cess. Some types of galvanized coatings are: regular
spangle, minimized spangle, iron-zinc alloy and dif-
ferential. Regular spangle is the most common type.
Except for differential-coated sheet, the coating is al-
ways expressed as the total coating of both surfaces.
Galvanized sheets with the surface treated for paint-
ing by phosphatizing are commonly used.
Table 12-2 shows information on various galvanizing
coatings. SMACNA originally had a specification
within its duct standards calling for a 1.25 oz./sq. ft.
commercial coating class. Such coating corresponds
with the G90 coating designation within ASTM A525,
Standard Specification for "Steel Sheet Zinc Coated
(Galvanized) by the Hot-dip Process." A lighter coat-
ing (Designation G60) may be used in interior appli-
cations. Although SMACNA generally recommends
G90, G60 may be considered when the duct is free
from exposure to industrial pollutants, marine atmo-
Table 12-1 CARBON STEEL CHEMICAL
REQUIREMENTS (Prior to Galvanizing)
12.2
DUCT SYSTEM CONSTRUCTION
spheres or continuous contact with moisture. (See
the SMACNA "Special Study Report on Galvanized
Coating Thickness" for more detailed information.)
2. Carbon Steel (Black Iron)
a. APPLICATIONS
Breechings, flues, stacks, hoods, other high temper-
ature duct systems, kitchen exhaust systems, ducts
requiring paint or special coating.
b. ADVANTAGES
High strength, rigidity, durability, availability, painta-
bility, weldability, non-porous.
c. LIMITING CHARACTERISTICS
Corrosion resistance, weight.
d. REMARKS
Carbon steel is the designation for steel when no
minimum content is specified or required for alumi-
num, chromium, cobalt, columbium, molybdenum,
nickel, titanium, tungsten, vanadium, zirconium or
any element added to obtain a desired alloying effect.
Hot-rolled sheet is manufactured by hot rolling slabs
in a continuous mill to the required thickness. Cold-
rolled sheet is manufactured from hot-rolled, de-
scaled coils by cold reducing to the desired thickness,
generally followed by annealing to recrystalize the
grain structure. Obviously, there are many different
categories of black steel with hot-rolled carbon being
generally softer, less precisely rolled, less expensive,
and, therefore, the most desirable for normal duct
applications. The chemical requirements for carbon
steel, commercial quality, are shown in Table 12-1.
3. Aluminum
a. APPLICATIONS
Duct systems for moisture-laden air, louvers, special
exhaust systems, ornamental duct systems. Often
substituted for galvanized steel in HVAC duct sys-
tems.
b. ADVANTAGES
Weight, resistance to moisture corrosion (salt free),
availability.
c. LIMITING CHARACTERISTICS
Low strength, material cost, weldability, thermal ex-
pansion.