SPECIFICATION FOR DUCTWORK AND

DUCTWORK INSULATION

0 02-02-2002 Approved Issue

rev. date Description/issued for prepared authorised
client: ADWEA
project: STANDARD SPECIFICATIONS FOR WATER WORKS
title: SPECIFICATION FOR DUCTWORK AND DUCTWORK INSULATION

tender: project: document: W-H-SS-002 rev: 0 sheet: 1 of: 12

 Table of Contents page

1. GENERAL..............................................................................................3

2. STANDARDS.........................................................................................3

3. DUCT WORK.........................................................................................3
3.1 Hangers and Supports.................................................................5
3.2 Dampers......................................................................................5
3.3 Fire Dampers...............................................................................6
3.4 Access Openings.........................................................................7
3.5 Acoustic Insulation.......................................................................8
3.6 Air Outlets....................................................................................8
3.7 Flexible Ducting ...........................................................................9
3.8 Flexible Joints............................................................................10
3.9 Electric Duct Heaters.................................................................10
3.10 Sound Attenuators.....................................................................10
3.11 Connections to Builder's Work...................................................11

4. DUCTWORK INSULATION .................................................................11

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR DUCTWORK AND DUCTWORK INSULATION

tender: project: document: W-H-SS-002 rev: 0 sheet: 2 of: 12

 1. GENERAL

This specification covers the materials, design, construction, testing and commissioning of
Ductwork and Ductwork Insulation Systems for the Abu Dhabi Water & Electricity Authority,
Abu Dhabi.

2. STANDARDS

ASHRAE (American Society of Heating, Refrigeration and Airconditioning Engineers,

Inc)

Fundamentals Hand Book

Systems Hand Book

Test Standard 52-76

SMACNA (Sheet Metal and Airconditioning Contractor's National Association, Inc)

Duct Construction Standards

NFPA (National Fire Protection Association)

90 A Installation of Airconditioning & Ventilation Systems.

ASTM (American Society for Testing and Materials)

A653/A653 M Specification for sheet steel, Zinc coated by the Hot Dip Process, Lock Forming
Quality.

AABC American Association of Balancing Contractors

National Standards for Field Measurement & Instrumentation

NEBB (National Environmental Balancing Bureau)

Procedural Standards for Testing, Adjusting, and Balancing of Environmental Systems.

ARI (American Refrigeration Institute)

Standards 210, 240, 270 & 340/360

3. DUCT WORK

The CONTRACTOR shall supply, deliver and erect ranges of ductwork, complete with
hangers and supports, control and fire dampers, access doors, etc., in accordance with
SMACNA-Duct Construction Standards.

All ductwork shall be manufactured by an approved firm of ductwork specialists to site

dimensions taken by the CONTRACTOR, who shall submit all drawings of ductwork to the

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR DUCTWORK AND DUCTWORK INSULATION

tender: project: document: W-H-SS-002 rev: 0 sheet: 3 of: 12

 ENGINEER for approval before fabrication is commenced. These drawings must indicate any
access openings required in the building structure for such items as dampers, sensing points,
etc.

Where site dimensions cannot be taken in advance, dimensions may be taken from
ENGINEERs' drawings and suitable provision made to accommodate any discrepancies that
may occur between the drawings and site dimensions.

The ducts gauges, thickness and method of jointing shall be as detailed and tabulated on the
drawings and/or in compliance with the ASHRAE standards and hand books.

All ductwork sizes indicated on the CONTRACT drawings shall mean the clear internal
dimensions of the manufactured ductwork unless otherwise stated on the CONTRACT
drawings. Whenever internal acoustic lining is indicated on the drawings, the duct sizes have
to be increased to accommodate the lining.

Unless otherwise specified, ductwork shall be constructed from best quality steel sheets
continuously hot dip galvanised to BS EN 10143, Group 2, Class 2A (Z27 coating).

Whenever a flexible duct is used to correct misalignment between the supply duct and the
diffuser ceiling location the misalignment shall not exceed (1/8) the length of the collar.

All paints shall be used in accordance with the paint manufacturers' recommendations.

All ductwork shall be subject to inspection at the manufacturers' works.

In the case of fittings, the larger dimension shall determine the sheet thickness and stiffening.
Where stiffeners are required on the flat sides of the bend, they shall be attached in a radial
pattern, the spacing for these stiffeners to be measured along the centre line of the bend.

Ductwork connections to items of plant will be flanged with suitable gaskets and cadmium
plated nuts and bolts.

Wherever mitred bends are indicated on the CONTRACT Drawings, the CONTRACTOR shall
provide and fix air turning multiple radius vanes within the air ducts for changes in direction.

Branches shall be taken off a straight duct, not off taper.

Where expansions or contractions are required, an expansion shall be made upstream of a

branch connection and a contraction downstream of a branch connection. The slope of either
an expansion or contraction should not exceed 22.5º on any side.

Expansion connections to equipment are to have a maximum slope of 30º on any side and
contractions 45º on any side.

All elbows shall have a centre line radius equal to at least 1.5 times the width of the duct,
otherwise turning vanes shall be installed in the elbows.

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR DUCTWORK AND DUCTWORK INSULATION

tender: project: document: W-H-SS-002 rev: 0 sheet: 4 of: 12

 Adjustable splitters and hinged volume dampers shall be provided at every duct junction on
both supply and exhaust ductwork for adjusting air volumes.

Connection to diffusers, grilles and registers shall be made absolutely air tight.

All rectangle metal ducts shall be sealed in accordance with the ASHRAE standard 90.

Change section pieces shall be used to avoid an obstruction or to suit available space.
Where cross-sectional area is unchanged, the maximum slope shall be 22.5º on any side.
Where the cross-sectional area is temporarily reduced by up to 20%, the maximum slope
shall be 15º on any side.

Where space does not allow the slopes described above, slopes may be increased providing
that splitters are fixed to divide the angle between any side and the centre line of the duct into
sections.

All ductwork shall be pressure tested in sections during installation and before the ductwork is
enclosed or terminal units are installed.

3.1 Hangers and Supports

Where there is a possibility of the transmission of vibration, care shall be taken to isolate the
duct from the building structure.

Supports for horizontal ducts specified in SMACNA are recommended for the support of the
ductwork and its insulation. Where heavy equipment, mechanical services, ceilings or any
other additional loads are to be applied, further support may be required. For large ducts,
supports shall be designed to suit the loading.

The design of supports for vertical ducts is dictated by site conditions and spacing may be
greater than for horizontal ducts. Ducts shall be supported by the stiffening angles or angle
flanges but where this is impracticable, supporting angles shall be fixed to the duct.

Where a continuous vapour barrier is required, supports shall not be connected directly to the
duct stiffening or flanges. The insulation and vapour barrier shall be abutted to an insulator
incorporated with the duct support. The insulator shall be incompressible and made from
polyurethane or other suitable material.

As an alternative to suspending ducts from above, they may, where appropriate, be supported
by means of angle iron frames or stools formed by extending the vertical angles or bracing of
the ducts, all such frames to be adequately cross-braced and the feet of all angles to be
provided with bottom cleats to give adequate bearing on the floor slab.

3.2 Dampers

Dampers shall be provided wherever necessary to facilitate balancing of the system and form
an integral part of the ductwork system.

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR DUCTWORK AND DUCTWORK INSULATION

tender: project: document: W-H-SS-002 rev: 0 sheet: 5 of: 12

 Damper blades shall be rigid construction without sharp edges and shall be substantially air
tight when closed. They shall be mounted on a robust spindle and be so constructed as to
prevent distortion and jamming in operation.

Hand controlled dampers shall be provided with a locking device on the outside of the duct,
located parallel to the blade. Spindles shall be extended to the outside of the duct and be
provided with a groove in line with the blade. Spindles shall be carried in non-ferrous, nylon
or ball bearings.

Butterfly dampers may be used in rectangular ducts where the short side does not exceed
300mm and in circular ducts not exceeding 450mm diameter.

Multi-leaf dampers shall be used in rectangular ducts having a short side in excess of 300mm.
All multi-leaf dampers shall be constructed in demountable ductwork sections, which shall
extend beyond the swing of the blades. They should operate on the opposed blade principle
unless required solely for isolation, in which case they may be arranged for parallel operation.

No damper blade shall exceed 1500mm in width and where dampers are required for greater
width the damper sections shall be constructed in multiple frames. Individual damper blades
shall not exceed 225mm in height. Provision shall be made for linkages to connect the
multiple extended spindles and a suitable indicating device shall be provided on the outside of
the damper section.

3.3 Fire Dampers

Fire dampers shall be provided in the ducting systems where ducting passes through a wall or
floor forming a fire zone or barrier.

All fire dampers shall be of the motorised type interfaced with the fire alarm system to close
by spring return actuator on de-energisation of the power supply.

On restoration of power, the actuator motor shall open the damper and shall simultaneously
prime the spring release.

Opening and closing times of the damper shall not exceed 10 seconds.

All dampers shall be complete with a micro-switch to indicate the status of the damper (open
or closed) at the main air conditioning control panel.

Fire dampers shall be constructed with fire resistance measured in accordance with BS 476
Part 8 or equivalent and shall be tested and approved by the U.K. Fire Research Station or
other authority approved by the Engineer. When a fire resistance in excess of 2 hours is
required it shall be achieved by multiple dampers each of 2 hour standard installed on either
side of the wall or floor.

Damper casings shall be completely air tight and constructed from galvanised sheet steel of
not less than 1.6 mm thickness with continuously welded corners. Inlet and outlet connections
shall be spigots formed as an integral part of the construction.

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR DUCTWORK AND DUCTWORK INSULATION

tender: project: document: W-H-SS-002 rev: 0 sheet: 6 of: 12

 Any damper blade or shutter shall be constructed so as not to distort in use and shall be
made from either stainless steel or non combustible asbestos free fibre silicate plates, 40 mm
thick. Damper blades shall close against a steel stop around the whole periphery of the
damper with atleast 20 mm overlap. The clearance between the blade and sides of the duct
shall be atleast 0.01 mm of damper diameter length of side. Multileaf damper blades shall
overlap by atleast 20 mm.

An insulated, double skin access door shall be provided adjacent to each fire damper for
service inspection and resetting.

Where the damper is fitted to a wall or floor, the damper casing shall be fitted with building-in
lugs.

3.4 Access Openings

Access doors and other openings in ductwork shall be provided for the purposes given below:

(a) Access for personnel for maintenance and replacement of plant items.

(b) Access for routine maintenance, lubrication and adjustment of items not requiring full
man access.

(c) Access for cleaning.

(d) Access for inspection of items concealed in ductwork such as dampers, fusible links,
thermostats, etc.

(e) Hand holes required to permit proper jointing of ductwork sections in awkward locations;
these should be kept to a minimum and as small as practicable.

(f) Test holes to permit entry of pitot tubes and other test equipment.

Access openings shall be rigidly framed and fitted with air tight covers so designed as to be
simply and speedily removed and re-fixed. Multiple set screws or self-tapping screws are not
acceptable as a method of fixing.

An access panel shall be provided for each fire damper so that the damper operation can be
checked and the damper re-set. The access panel shall be size 450mm wide, 225mm deep
minimum, and hinge downwards along the bottom edge.

Hinged access doors shall not be larger than 1350mm high by 500mm wide unless necessary
for equipment handling. Doors should preferably open against the air pressure.

Both the opening in the duct and the access door itself shall be adequately reinforced to
prevent distortion. A suitable sealing gasket shall be provided together with sufficient
clamping type latches to ensure an air tight and water tight seal between the door and the
duct. The latches shall have handles to operate from both the inside and the outside of the
door.

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR DUCTWORK AND DUCTWORK INSULATION

tender: project: document: W-H-SS-002 rev: 0 sheet: 7 of: 12

 Where ducts are to be thermally insulated, the access doors frame shall be extended beyond
the face of the duct by a measurement equal to the thickness of the insulation and be so
arranged that the insulation and finish can be 'dressed' into the frame, thereby ensuring that
the opening is not concealed and that the edges of the insulation are protected from
accidental damage. The access door shall be insulated and shall be dished to contain the
insulation.

Test holes for instruments shall be provided where indicated on the Contract Drawings and in
any case to enable fan duties to be tested and the performance of regulating dampers to be
assessed. All holes shall be 25mm diameter and provided with an effective seal.

3.5 Acoustic Insulation

Duct Acoustic lining - Acoustic insulation of glass fibre 1" thick, 24 kg/m3 and shall be fixed to
the internal duct surface of each A/C unit discharge duct for a minimum length of 5 meters
from fan outlet.

The first 5 metres of duct run from a blower shall be inner lined with 1" thick fire resistant
acoustic liner. If required sound attenuators shall also be fixed in the air stream to maintain
sound level below NC - 35.

The NC sound measurement will be made at 1.5 metres from the grilles, diffuser or other air
device being tested. Attenuators / duct lining, equipment / vibration isolators and accessories
shall be selected to achieve the desired noise level.

The contractor is responsible for checking duct sizing and upgrade it if necessary in order to
obtain the noise level as specified. If a selected unit has higher supply air volume than the
scheduled, the contractor must adjust the duct sizes given on the drawing accordingly. Duct's
shall be sized on a pressure drop of 0.05 ft / 100 ft.

3.6 Air Outlets

Before being ordered, selection of all supply outlets shall be checked by the manufacturer for
throw, drop and noise with capacities as indicated on the drawings.

All outlets shall be specially selected for their particular application and designed for quiet
operation considering the sizes mentioned on the drawing to be the minimum accepted
selections to be approved by Consultant.

3.6.1 Grilles and Diffusers

Provide and install as indicated on the drawings grilles and diffusers constructed from
extruded aluminium sections. All grilles and diffusers shall be supplied with powder coated
paint finish to a colour selected by the Engineer. Ceiling mounted supply/return air diffusers
shall be louvre faced with removable core and equalising grid. Supply diffusers shall have
opposed blade dampers.

The supply diffusers shall be furnished with supply volume dampers which should be
accessible through the outlet, from below the ceiling and shall maintain their setting when

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR DUCTWORK AND DUCTWORK INSULATION

tender: project: document: W-H-SS-002 rev: 0 sheet: 8 of: 12

 adjusted. Each diffuser shall be provided with sponge rubber or felt gasket and angle ring or
frame for securing to duct work.

The position of grilles and diffusers fitted in ceilings shall be carefully co-ordinated with the
electrical fittings and other ceiling components. Co-ordinated and dimensioned positions shall
be submitted to the Engineer for approval.

The contractor shall be responsible for ensuring that supply air grilles and diffusers give
adequate air distribution patterns within rooms. There shall be no draughts, dead spots or
undue noise.

The contractor shall be responsible for balancing all systems so that each grille and diffuser
handles the air quantity called for in the design.

3.6.2 Supply Air Registers

All side wall supply outlets shall be of the double deflection type having vertical front bars and
horizontal back bars and fitted with key operated, opposed blade dampers and gaskets.

3.6.3 Return Air Diffusers

Return diffusers shall be identical to supply diffusers except that the volume control damper
can be eliminated. Diffusers to be of the type and shape indicated on the drawing.

Aluminium slot ceiling diffusers with hit and miss volume control, air deflection blades
complete with plenum for connection to duct work system. Finished to an approved colour.

3.6.4 Return Grilles

All side wall return outlets shall be of the double deflection type, having vertical front bars and
horizontal back bars.

3.6.5 External Louvres

Sand trap louvres on all air intakes. These shall be manufactured from vertical Aluminium
channel section and shall include a bird screen. The unit shall be designed and installed to
enable sand to be discharged externally. Where multiples are installed vertically, a sand
chute shall be provided between sections.

Synthetic washable or pleated aluminium filters shall be provided on all fresh air intakes.

3.7 Flexible Ducting

Lengths of flexible ducting shall not exceed 3M in length and shall be supported at not less
than 600mm intervals.

Flexible ducting shall be resistant to fire, duct pressure, rot, fungus growth and corrosion and
be suitable for the site conditions.

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR DUCTWORK AND DUCTWORK INSULATION

tender: project: document: W-H-SS-002 rev: 0 sheet: 9 of: 12

 Flexible ducting shall give the following results when tested against BS 476:

(a) Pass test for non-combustibility

(b) Pass test for ignitability

(c) Index for propagation shall not exceed 5.4

(d) Surface spread of flame shall not exceed 165mm in length

(e) The time for flame to burn through a duct wall shall not be less than 39 minutes

(f) The transmittance of the standard light shall be not less than 94% smoke rating.

Flexible ducts shall be connected to spigots with worm drive hose clips of minimum width
10mm and with galvanised finish. Other fixing methods will not be accepted.

Flexible ducting shall be supplied by an approved manufacturer.

Flexible ducting shall be constructed of a continuous galvanised spring steel wire helix
covered with woven fibreglass impregnated and coated both sides with neoprene. The cover
and wire shall be permanently fused to form a continuous surface.

3.8 Flexible Joints

The material used for flexible joints must withstand any conditions of temperature, air
pressure and fire protection specified.

Flexible joints shall be fitted to the suction and discharge connections to all fans, at expansion
joints in buildings and as shown on the Contract Drawings.

3.9 Electric Duct Heaters

Electric duct heater shall be factory assembly with panel board, meeting the requirements of
NEC, shall be UL listed for zero clearance to combustibles, rated for use with air conditioning
systems. Heating element shall be open coil 80% nickel, 20% chromium, type resistance wire.
Heater frames and terminal boxes shall be corrosion resistant steel with resistance with 1
terminal box construction, factory wired and ready for installation. Unit shall be complete with
contractors and thermal cutouts for temperature protection, control transformer, disconnect
switch, airflow switch to prove airflow, fuses, pilot lights etc. All electrical devices shall be UL
listed and rated.

3.10 Sound Attenuators

a. Where indicated, sound attenuators shall be used in supply and return air duct heaters.

b. The sound attenuator shall be galvanised steel construction of not less than 20 gauge
with perforated filled interior partitions filled with moisture resistant mineral filter.

c. NFPA flame spread class 20, pressure rated airtight at 1500 Pa.

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR DUCTWORK AND DUCTWORK INSULATION

tender: project: document: W-H-SS-002 rev: 0 sheet: 10 of: 12

 d. Sound attenuators shall be rated at 14 dB minimum. Sound reduction in this octave band
based upon insertion lost technique of rating at 10.16 meters per second (2000 fpm).
Calculation for sound control shall be carried out by the supplier/vendor and submitted
for approval.

3.11 Connections to Builder's Work

Where metal ducts and fan inlets and outlets connect to builders' work, connections shall be
by built-in timber frame or built-in companion ring or flange. Built-in timber frames are
preferred, except for connection to fire barrier walls or for fixing fire dampers. Timber frames
shall be constructed in hardwood of suitable section. Companion rings shall be provided with
an adequate number of suitably sized rag bolts or similar fixing devices.

In all cases the duct end shall finish with a mating flange and where this is fixed to a timber
frame the flange should be wide enough to overlap the joint between timber and masonry by
at least 15mm.

The material of the duct shall be extended in the form of a spigot, beyond, the flanged
connection and into the builders' work.

Joints between mating flanges and companion rings or hardwood frames shall be fitted with a
sealing gasket.

4. DUCTWORK INSULATION

Sheet metal supply, return & fresh air ductwork and all surfaces subject to condensation, shall
be thermally insulated with insulation incorporating a vapour barrier on the outer surface.

Surface of pipework and ductwork to be insulated shall be thoroughly cleaned and degreased
before the application of fixatives.

Thermal insulation shall be non-corrosive to ferrous and non-ferrous metals, non-combustible,

water repellant, sterile, odour free and shall not sustain vermin.

Insulation of ductwork and pipework shall not commence until the respective testing has taken
place.

Insulation of ductwork shall be approved foil faced rigid slabs of glass fibre or mineral fibre to
provide the thermal insulation barrier, vapour barrier, protective and visual finishes as
specified. Joints to be lapped and sealed with approved fire resistant adhesive.

Insulation for pipework shall be rigid shaped cut sections of glass fibre or mineral fibre to
provide the thermal insulation barrier.

Duct insulation in air conditioned spaces shall be 25 mm thick rigid slab of fibre glass with a
3
density of not less than 48 kg/m and k - factor of not more than 0.38 W/mK at a mean
temperature of 24ºC.

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR DUCTWORK AND DUCTWORK INSULATION

tender: project: document: W-H-SS-002 rev: 0 sheet: 11 of: 12

 Duct insulation in unconditioned spaces shall be 50 mm thick rigid slab of fibre glass with
3
density of not less than 48 kg/m and a k factor of not more than 0.036 W/mK at a mean
temperature of 24ºC.

Insulation on pipework and ductwork shall be built up over flanges, valves and other
projections to provide not less than the specified thickness. It shall give a completely
unbroken appearance to the surface of the ductwork and pipework.

Ductwork insulation shall be fixed to the duct with approved fire resistant adhesive, and where
necessary, the adhesive shall be reinforced with nylon duct clips and washers of approved
manufacture.

Insulation sections will be close butted with butt joints and longitudinal joints sealed with an
approved vapour sealant.

Cavities in the ductwork and pipework insulation surface will be filled and sealed with an
approved vapour sealant.

The surface finish of duct work insulation shall be 8 ounce canvas applied using vapour
barrier mastic and full coat of lapping cement, then a second coat of lapping cement over the
entire canvas surface.

Vapour barriers shall be continuous.

Duct spigots and flexible connections shall be insulated with a 25mm thick glass fibre flexible
duct insulation blanket with a facing of PVC film, tape sealed in position with an adhesive
PVC tape.

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR DUCTWORK AND DUCTWORK INSULATION

tender: project: document: W-H-SS-002 rev: 0 sheet: 12 of: 12