Group 1 DUCT COMPONENTS & MATERIALS

DESIGN OF BUILDING PIPING SYSTEM & Ductwork, the system of air passages in
AIR CONDITIONING DUCTWORKS HVAC systems use various materials and
components. Common materials include
DUCTWORKS DESIGN PRINCIPLES galvanized steel, aluminum, and flexible ducts,
Basic rules and best practices used to develop while components like bends, dampers, and
safe, effective, and efficient HVAC air take-offs are used to shape and control airflow.
distribution systems are known as ductwork Ductwork, the system of air passages in HVAC
design principles systems, uses various materials and
components. Common materials include
CORE DUCTWORKS DESIGN MAIN galvanized steel, aluminum, and flexible ducts,
PRINCIPLES while components like bends, dampers, and
●​ Correct Sizing in ductwork design take-offs are used to shape and
ensures optimal airflow, prevents control airflow.
pressure drops and maximises energy
efficiency. DUCT COMPONENTS
●​ Air Flow Balance ensures proper a. Main Components
distribution of conditioned air -​ Straight Ducts: Long sections of
throughout a building, optimizing ductwork, typically round or
efficiency and comfort. rectangular.
●​ Minimize Pressure Loss in ductwork, -​ Elbows: Bent sections used to change
designers should prioritize smooth the direction of airflow (e.g., 45°, 90°).
airflow by reducing friction and -​ Reducers: Connect ducts of different
turbulent flow. sizes, allowing transitions.
●​ Proper Lay Out strategically -​ Take-offs: Connect branches to the
positioning ducts to minimize airflow main duct line.
resistance, ensure balanced airflow, -​ Plenums: Boxes that distribute or
and facilitate easy maintenance. collect air from ducts.
●​ Static Pressure Management focuses b. Fittings and Accessories
on maintaining a balanced air pressure -​ Dampers: Regulate airflow within the
within the duct system to ensure proper duct (manual or motorized).
airflow distribution. -​ Grilles, Registers, and Diffusers: Allow
●​ Velocity Control managing the speed air to enter or exit rooms and are often
of air moving through ducts to ensure adjustable.
optimal airflow, minimize noise, and -​ Flexible Ducts: Used in tight spaces or
maintain efficient system operation for final connections.
●​ Insulation & Sealing crucial for energy -​ Boots: Transition pieces between duct
efficiency, comfort, and safety. and floor/wall/ceiling outlets.
Insulation helps reduce heat transfer, -​ Insulation: Reduces heat loss,
preventing energy loss and ensuring condensation, and noise.
that conditioned air reaches its desired c. Support and Sealing
temperature. -​ Hangers and Supports: Hold ducts in
place (straps, brackets).
-​ Sealants and Tapes: Ensure airtight
connections and prevent leaks.
-​ Access Doors/Panels: Allow
maintenance and inspection
DUCT MATERIALS
Materials vary depending on the
application,location, and required insulation or
fire resistance.
a. Sheet Metal (Galvanized Steel or
Aluminum)
●​ Most common for rigid ductwork.
●​ Durable and fire-resistant.
●​ Requires insulation on the outside.
b. Fiberglass Duct Board
●​ Pre-insulated, good for sound and
thermal insulation.
●​ Common in residential systems.
●​ Lightweight and easy to install.
c. Flexible Ducts (Flex Ducts)
●​ Made of plastic inner core with wire
helix, covered by insulation and outer
jacket.
●​ Used for short runs or final
connections.
●​ Easy to install but can restrict airflow if
kinked.
d. PVC or Plastic Ducts
●​ Used in corrosive environments or
specific applications (e.g., chemical
exhaust).
●​ Not common for general HVAC due to
fire risk.
e. Fabric Ducts (Textile Air Dispersion
Systems)
●​ Made of permeable or non- permeable
fabric.
●​ Used in large open areas (e.g., gyms,
warehouses).
●​ Even air distribution and aesthetic
options.

DUCT CLASSIFICATION
Duct classification refers to the categorization
of HVAC ductwork based on parameters like
pressure class, velocity, construction material,
and application. These classifications help
ensure the duct system is designed to handle
the specific air pressures and conditions it will
be exposed to, in compliance with industry
standards like SMACNA (Sheet Metal and Air
Conditioning Contractors' National
Association).
Group 2 Principle:
AIR CONDITIONING DUCTWORKS ●​ Keeps the same pressure loss per unit
AC ductwork refers to a network of metal or length (e.g., 0.1 in WC/ 100 ft)
insulated tubes or pathways that distribute throughout the entire duct system.
cooled (or heated) air from the air handling unit Advantages:
(AHU) or AC to different rooms or zones in a -​ Simple to calculate and apply.
building. -​ Easy to use with duct sizing charts or
software.
Duct Sizing -​ Good for small to medium HVAC
-​ Is the process of determining the systems.
correct dimensions (diameter or width Limitations:
& weight) of air ducts to carry a specific -​ May result in unbalanced airflow at
amount of airflow (measured in CFM - branches unless dampers are used.
cubic feet per min) efficiently. -​ Not ideal for large or complex sys.
Best Use:
Why is Duct Sizing Important? -​ Residential and light commercial
Delivers the Right Amount of Air buildings.
●​ Each room or space needs a specific
amount of air (CFM) based on its size Static Regain Method
and function. Principle:
●​ Proper sizing ensures that each space -​ Designed to balance pressure at each
gets what it needs for comfort. duct branch by regaining static
Avoids Pressure Loss and Noise pressure as air slows down in larger
●​ Undersized ducts cause high velocity ducts.
and pressure loss, which means the How it works:
system works harder and gets noisier. -​ As air moves into larger duct sections,
●​ Oversized ducts may cost more and its velocity decreases, and pressure
take up too much space. “regains” (increases), helping balance
Protects the Equipment airflow.
●​ Poor sizing can make fans or blowers Advantages:
work too hard, reducing their lifespan. -​ Provides better airflow balance.
●​ Proper duct sizing helps the HVAC -​ Reduces need for dampers and
system run smoothly and last longer. adjustments.
Best Use:
What factors are considered in Duct Sizing? -​ High-velocity, large commercial or
-​ Airflow rate (CFM) needed for each industrial HVAC systems.
room. Limitations:
-​ Duct length and layout (straight, with -​ More complex and time-consuming to
bends, etc.). design.
-​ Friction loss due to the duct material -​ Requires more precise calculations.
and shape.
-​ Acceptable air velocity (too high=noisy; Velocity Reduction Method
too low=sluggish airflow). Principle:
-​ Static pressure available from the fan. -​ Starts with high air velocity near the air
handler and reduces it gradually
Methods of Duct Sizing through the system.
Equal Friction Method (most commonly
used)
Goal: Depends on:
-​ To lower friction and noise as air moves -​ Duct material (e.g., smooth metal vs.
farther from the fan. flexible duct)
Advantages: -​ Air velocity (faster air = more friction).
-​ Helps control noise levels in sensitive -​ Duct length and size.
areas. Dynamic Loss:
-​ Reduces turbulence and friction losses. -​ Caused by changes in airflow
Best Use: directions or speed.
-​ Systems where noise control is critical -​ Happens bends, elbows, tees,
(e.g., offices, hospitals) reducers, and branch connections.
Limitations: -​ Sudden turns or size changes create
-​ Can be less efficient if not carefully turbulence, slowing down airflow and
designed. causing pressure drop.
-​ May result in larger duct sizes at the -​ More fittings = more dynamic losses.
ends.
Why does Pressure Loss Matter?
Duct Shapes Too much pressure loss can:
Rectangular Ducts -​ Reduce airflow to rooms (poor
-​ Easy to install in tight spaces. comfort).
-​ Require more materials for the same -​ Make the fan or blower work harder
airflow. (higher energy use).
-​ Higher friction loss compared to round. -​ Increase system noise.
Round Ducts -​ Keeping pressure losses low = more
-​ Most efficient shape (less friction loss). efficient and quieter HVAC unit.
-​ Harder to install in limited spaces. FACTORS AFFECTING REDUCING PRESSURE
-​ Lower material cost for the same PRESSURE LOSS LOSS
airflow. Duct length and diameter Use smooth and short duct runs
Oval Ducts
-​ Compromise between round and Air velocity Avoid sharp bends and
unnecessary fittings
rectangular.
-​ Good balance of space saving and Number of fittings (elbows, tees, Use proper duct sizing to
transitions) maintain lower velocities
efficiency.
Surface roughness of the duct Choose efficient duct shapes
(preferably round)
Pressure Loss in Ducts
Pressure Loss Air density and temperature
-​ Refers to the reduction in air pressure
as it flows through the duct system.
PRESSURE
-​ The loss happens because the moving DUCT SIZING DUCT SHAPES
LOSSES
air encounters resistance, making it
harder for the HVAC system to deliver
✅airTo ducts
ensure that
are
✅ To choose the
most efficient and
✅minimize
To understand and
the loss of
the required airflow. correctly sized to space-appropriate air pressure as air
deliver the right duct shape that moves through the
Main Causes of Pressure Loss amount of airflow minimizes pressure duct system due to
Friction Loss: (CFM) to each loss while fitting friction and
room or space. within the building turbulence.
-​ Happens when air rubs against the
inner surface of the duct as it flows. ✅comfort,
This maintains
system ✅
layout.

This improves
✅ Lower pressure
loss = better airflow,
-​ The rougher or longer the duct, the efficiency, and airflow efficiency and lower energy use, and
more resistance (friction) occurs. reduces energy helps fit ducts into quieter operation.
waste. ceilings or walls.
-​ Most common in straight duct runs.
Group 3
FAN SIZING BALANCING AIR
In a duct system, a fan provides the forces The pressure balance of the duct structure is a
required to overcome friction forces and move crucial factor in design. If the fan pressure is
the fluid from rest to the system velocity. The greater than the pressure loss, the actual air
fan total pressure is the force that the fan flow may surpass the design flow. In this
exerts (HVAC – How to Size and Design Ducts instance, bringing the air flow rate down to
– M06-032 31). what the duct equipment was intended to
handle requires partially closing the balancing
FAN SELECTION dampers, which regulate the air flow. Adjusting
To overcome the pressure losses caused by the volume control dampers to balance the
ducts, fittings, and the components of an air friction losses is known as air balancing.
handling unit (AHU), the fan must be selected Unless the system has a symmetrical
to produce a specified volumetric flow rate arrangement, one of the main disadvantages
(cfm) and create static pressure (in H2O). The of the equal friction duct size approach is that
sum of the internal static pressure (ISP) and pressure decreases in duct branches are not
external static pressure (ESP) is known as the equalized.
total static pressure (TSP).
TSP = ESP + ISP FAN SYSTEM EFFECT
SOLUTION Typically the fan performance curves are
-​ ESP is the static pressure created developed by laboratory measurements with
downstream of the AHU and it includes all the fan installed under ideal conditions.
the duct losses from the fan until it However, when the duct system is connected
reaches the discharge point. This could to the fan, the fan operating conditions are
include a negative static pressure on the influenced and the fan performance will get
pull side of the fan and a positive pressure altered.
on the push side, or any combination of To achieve 100% effective duct length, a
pressures the fan must overcome. It is straight run from the blower, has to be long
estimated by the HVAC design engineer enough to achieve a uniform Velocity across
as he lays out the ductwork, diffusers, and the cross-section of the duct. Calculating the
terminal devices. 100% effective duct length depends upon the
-​ ISP, as it pertains to the HVAC AHU, is the air velocity at the fan outlet: HVAC – How to
static pressure loss across the filters, coils, Size and Design Ducts – M06-032 38
louvers, dampers, and twists and turns
inside the AHU casing. ISP is usually a.​ If the outlet velocity is less than 2,500
provided by the supplier, but for custom fpm: 100% effective duct length = 2.5 x
designs, the HVAC design engineer duct diameter
estimates the pressure loss across the b.​ If the outlet velocity is more than 2,500
various components of the AHU. fpm: 100% effective duct length =
fpm/1000 x duct diameter
FAN RATING c.​ To calculate the duct diameter:
Characteristic curves are typically published by D = 2wh / (w +h), where h and w are
fan manufacturers using the fan's static duct height and width, respectively.
pressure instead of its total pressure. This
makes sense because the types of inlet and
outlet duct fittings and the setting at the entry
or exit to the inlet/output cones may be beyond
the manufacturers' control.
CAUSES SYSTEM EFFECT should be used in order to develop a full
The four most common causes of system dynamic head. Branching and turning
effect on the fan are: sooner causes system effect losses.
1. Uneven air flow into the fan inlet
2. Spinning air at the fan inlet SUPPLY DUCT SYSTEM
3. Obstructions at the fan inlet or outlet This system consists of a network of tubes,
4. Improper duct connections at the fan outlet typically made of material or fiberglass, that
or inlet carries the conditioned air to supply vents
located throughout the building.
FAN SYSTEM CORRECTIONS AT DESIGN The two most common supply duct systems
1.​ Use of the “six-and-three rule” minimizes are the EXTENDED PLENUM SYSTEM and
system loss. Provide six diameters of the RADIAL SYSTEM. The other options are
straight duct at the fan suction and three spider and perimeter loop systems.
diameters of straight duct at the fan
discharge. EXTENDED PLENUM SYSTEM
2.​ Use as long a straight duct as possible for A large main supply trunk of equal size is
the job conditions. The first elbow in the connected directly to the air handler. Small
ducting leaving the unit should be no branch ducts and run-outs are connected to
closer than 2 feet from the unit to minimize the trunk. The arrangement provides air flows
resistance and noise. that are easily balanced and can be easily
3.​ AMCA Standard 210 specifies an outlet designed to be located inside the conditioned
duct that is not greater than 107.5 percent space of the building.
or less than 87.5 percent of the fan outlet -​ The principal design limitation of the
area. extended plenum is the maximum
4.​ If a duct transition must be used, slant the length of the main supply trunk (of
sides as gradually as possible. AMCA single size), which is usually limited to
Standard 210 requires that the slope of the about 24 feet.
transition should not be greater than 15 -​ HVAC - How to Size & Design Ducts -
percent for converging transitions, or M06-032-40. However the extended
greater than 7 percent for diverging plenum system can be modified to
transitions. provide a double span, up to 48 feet
5.​ For maximum performance, the air should long, when the equipment is centrally
enter straight into the fan inlet, with a located.
uniform velocity across the area of the
inlet. The ideal inlet connection is a long, ADVANTAGES DISADVANTAGES
straight duct with a length four times the
diameter of the inlet. If an elbow HVAC – Simple and easy to design Limited to short duct
lengths (max 24 ft)
How to Size and Design Ducts – M06-032
39 is required, there should be a length of Efficient for Risk of pressure loss at far
small/centralized spaces ends
straight duct between the fan inlet and the
elbow at least two times the diameter of Quick to install and Can produce noise if
the fan inlet. maintain improperly designed
6.​ If a free inlet is required, the inlet duct can
be replaced with an inlet bell which REDUCING PLENUM SYSTEM
provides a smooth transition to the fan A duct system can be used when the physical
velocity with no loss in total pressure. layout of the space calls for greater distances
7.​ A straight duct for a distance of three to six that the length constraints imposed on the
duct diameters from the fan discharge extended plenum (24ft).
The concept of the reducing plenum system is SPIDER SYSTEM
simple: when the air velocity lost to the branch a more distinct variation of the trunk and
runs reaches approximately 50%, the plenum branch system. Large supply trunks (usually
size is reduced to regain the velocity in the large-diameter flexible ducts) connect remote
remaining portion of the plenum. This mixing boxes to a small, central supply
reduction improves the air flow characteristics plenum. Smaller branch ducts or run-outs take
at the branch ducts that are closest to the air- air from the remote mixing boxes to the
handling unit. individual supply outlets. The figure below
illustrates this concept
ADVANTAGES DISADVANTAGES
RADIAL SYSTEM
Maintains airflow and More complex to design There is no trunk duct, branch ducts or
pressure over distance and size
run-outs; rather individual supply outlets are
Reduces pressure loss and Requires precise balancing essentially connected directly to the air
improves comfort for best performance
handler, usually using a small supply plenum.
Energy-efficient in large Design errors can lead to The short, direct duct runs maximize air flow.
systems uneven airflow The radial system commonly is applied in
attics, crawl spaces, and in slab on grade
REDUCING TRUNK SYSTEM installations (with the ducts embedded in the
-​ Very similar to the “REDUCING slab). It can be used with upflow, down-flow, or
PLENUM SYSTEM” , with the horizontal air handlers and furnaces.
exception that the trunk run is reduced Traditionally, this system is associated with an
in size after each branch takeoff. air handler that is centrally located so that
-​ The system is well-balanced since ducts are arranged in a radial pattern.
each branch is specifically engineered. However, symmetry is not mandatory, and
Effective design of reducing trunk designs using parallel run-outs can be
systems requires precise determination designed so that duct runs remain in the
of supply or extract air quantities for conditioned space (e.g., installed above a
each terminal device (diffuser, register, dropped ceiling).
and grille) in the room. The figure
below illustrates the concept.

DIFFERENCE BETWEEN: REDUCING

TRUNK AND REDUCING PLENUM
SYSTEMS
REDUCING FEATURE REDUCING
PLENUM TRUNK

Trunk size reduces DESIGN Trunk reduces in

only once or APPROACH size after every
twice along the branch takeoff
plenum

Requires general DESIGN Requires precise

estimation of PRECISION calculation for
airflow loss before each branch
reducing

Still needs AIR BALANCING Naturally balanced

balancing, but due to customized
easier than design
extended plenum
PERIMETER LOOP SYSTEM replacement of the lost air. This results in
uses a perimeter duct fed from a central supply more outside air, which may carry with it
plenum using several feeder ducts. This more heat, humidity, and other unwanted
system is typically limited to facilities built on substances.
slab in cold climates.

ADVANTAGES DISADVANTAGES

Ideal for slab-on-grade, cold- Limited to certain types of

climate buildings buildings

Good for managing exterior Can restrict architectural

heat loss design along the perimeter

Multiple airflow paths reduce Not widely used; fewer DISTRIBUTED RETURN
pressure loss installers may be experienced Every room in a distributed return includes a
return duct, which serves as an outlet for air
RULES OF DUCT DESIGN to return to the air handler. The scheme
Rules of Duct Design (ACCA Manual D – makes sure that all rooms return air flow,
Residential Duct Systems) prevents excessive positive pressurization,
-​ Up to 24' of trunk length: use one size reduces pressure imbalances, enhances
-​ Over 24': reduce trunk duct every 15' to isolation, and is quiet. However, compared to
20' a central return system, design and
-​ Use tapered reducer for trunk reduction on installation costs are often greater, and
capped trunk HVAC – How to Size and blower needs may rise due to increased
Design Ducts – M06-032 44 friction losses.
-​ Standard trunk is 8" high
-​ Trunk width not to exceed trunk height by
more than 4 times
-​ Use offset take-offs rather than straight
take-offs
-​ Stagger the branch take-offs
-​ Damper each run as close to the trunk as
possible
-​ Neither branch off any closer than 12" to
the end nor off the end of a trunk
-​ No take-off 4' after a reduction or 1.5 times
the greater dimension of the duct
-​ Never take-off a reduction or increase the
mains any closer than the diameter of the
branch duct
-​ On supply and return, when the trunk is
wider than the plenum, a transition fitting
must be used

RETURN DUCT SYSTEM

Air conditioning systems draw air out of
rooms in addition to supplying air flow.
Pressure will build up in the room if the return
flow is not allowed to leave, requiring the
Group 4 cooling in zones where the central system may
DUCT FITTINGS AND TERMINAL UNITS not be sufficient.
Duct fittings and terminal units are essential Single duct terminal units - The simplest
components of an HVAC (Heating, Ventilation, type, modulating the amount of primary cooling
and Air Conditioning) system. Duct fittings air to a zone.
connect different sections of ductwork, Dual Duct Terminal Units - Supply both hot
allowing for changes in direction, size, and and cold air from separate ducts and mix them
branching, while terminal units regulate airflow to achieve the desired temperature in the
and temperature to individual zones or rooms. zone. Common in large buildings with varying
heating and cooling needs.
COMMON DUCT FITTINGS: Constant Air Volume (CAV) Units - Deliver a
To connect, redirect, and manage airflow within fixed amount of air, maintaining temperature
the duct system. through changes in air temperature rather than
Elbows - Used to turn the airflow in another airflow volume—used in simpler or smaller
direction (like turning left or right). systems.
Reducers - Used to connect bigger and Radiant Panels (as terminal units) - Though
smaller ducts together. not duct-based, these are sometimes included
Take-offs - Create smaller branches from the in zoning systems, using hot or cold water to
main duct. control room temperature without moving air.
Transitions - Change the shape or size of the
duct smoothly. IMPORTANCE OF PROPER DUCT DESIGN
Wyes (Y-branches) - Split airflow into two Efficient duct fittings and terminal units are
directions at an angle, often more efficiently essential for:
than a take-off in terms of airflow performance. Air Balancing - Ensuring all rooms receive the
End Caps - Used to close off the end of a duct correct amount of airflow
run, either temporarily or permanently. Energy Efficiency - Reducing system load and
Dampers - Installed within ducts to regulate or energy costs by minimizing leaks and
shut off airflow in certain sections. They can be resistance.
manual or automatic (motorized). Comfort and Air Quality - Delivering
Boots (Floor, Ceiling, or Wall) - Connect conditioned air evenly, quietly, and cleanly.
ducts to grilles, registers, or diffusers, ensuring
a proper fit in different mounting locations. DUCT CONSTRUCTION AND
REINFORCEMENT
TERMINAL UNITS It involves selecting appropriate materials and
To control airflow and temperature in individual applying reinforcement techniques to ensure
zones or rooms. the structural integrity of ductwork used in
Diffusers - Spread the air evenly across the HVAC systems. The choice of materials and
room. reinforcement methods depends on factors like
Grilles and Registers - Let air in and out of duct size, static pressure, and airflow
rooms, and some can be adjusted to control characteristics. Key aspects include material
direction or speed. thickness, joint construction, reinforcement
VAV (Variable Air Volume) boxes - Adjust the types (e.g., tie rods, angles), and proper
volume of airflow to maintain desired sealing to prevent air leaks and ensure
temperature in a zone, often used in efficient operation.
commercial buildings.
Fan-powered boxes - Use a fan to recirculate
air from the return plenum, providing heating or
DUCT CONSTRUCTION MATERIALS: Hangers and Supports: Ducts are suspended
Sheet Metal: Commonly used materials or supported using straps, brackets, or trapeze
include galvanized steel, stainless steel, and hangers at intervals based on SMACNA
aluminum. guidelines. Proper spacing prevents sagging
Fiberglass - Another option, often used for and ensures alignment.
lining ducts to improve thermal and acoustic Stiffeners: Metal channels or bars attached to
performance. duct surfaces to prevent flexing or deformation,
Flexible Ducts - Easier to install in small or particularly in large or high-pressure ducts.
curved spaces. Reinforcement Schedules: Based on duct
size and pressure class, specifying what type
REINFORCEMENT TECHNIQUES: and spacing of reinforcements are required.
Transverse Joints: Reinforce where duct
sections connect (e.g., TDC/TDF). Longitudinal PRESSURE CLASSES & AIRTIGHTNESS
Seams: Reinforce along duct length, mostly in Pressure Ratings: Typical classifications are
rectangular ducts. Intermediate Reinforcement: Low (≤ 2in. wg), Medium (≤ 4 in. wg), and High
Supports to keep ducts from collapsing. (> 4 in. wg). Higher pressures require thicker
Tie Rods: Steel rods for extra strength in big materials and stronger joints.
ducts. Seal Classes (A, B, C): Defined by SMACNA,
Angles: Steel angles for edges and corners these indicate the level of sealing. Class A
requires sealing all transverse joints,
PRESSURE GLASSES & SEALING: longitudinal seams, and duct wall penetrations.
Pressure Classes: Ducts are grouped by how
much air pressure they handle. DUCT LEAKAGE TESTING
Sealing: Joints must be sealed properly to Leakage Testing: Especially important in
avoid leaks and save energy. high-pressure systems. Tests measure air loss
compared to design limits, ensuring system
SMACNA STANDARDS: efficiency and meeting building codes.
SMACNA: Sets rules for building HVAC ducts.
Duct Standards: Cover sizing, materials, BENEFITS OF PROPER DUCT
joints, reinforcement, and sealing. CONSTRUCTION
Energy Efficiency: Prevents energy loss due
DUCT CONSTRUCTION CONSIDERATIONS to leaks or poor insulation.
Duct Shape: Ducts can be rectangular, round, System Longevity: Strong, well-supported
or oval. Round ducts are more efficient for ducts reduce strain on HVAC equipment.
airflow and require less reinforcement, while Indoor Air Quality: Airtight construction
rectangular ducts are easier to install in tight prevents contaminants from entering the
spaces but need more support. system.
Fabrication Methods: Ducts are either
factory-fabricated or site-fabricated, depending Good Engineering Practices (GEP) are
on the project size and complexity. essential for managing projects safely,
Factory-fabricated ducts often ensure higher efficiently, and with high quality. They involve
precision and quality control. key principles like project planning, risk and
Thermal Insulation: Applied externally or cost control, managing changes, improving
internally to minimize energy loss and prevent processes, ensuring safety, and keeping
condensation, especially for ducts carrying proper records. GEP also includes following
cold air or passing through unconditioned standards, using proper insulation, grounding,
spaces. regular maintenance, and clear
communication.
Correct Sizing- Making sure the duct size is COMMISSION & MAINTENANCE
right for the amount of air. System Commissioning: A thorough check
Proper Layout- Planning the duct path to be before handover ensures the system performs
as short and smooth as possible. to design specs.
Balanced Airflow- Making sure each room Routine Maintenance Plans: Regular
gets the right amount of air. inspections, cleaning, and performance tests
Pressure Control- Keep air moving at the extend system life and maintain efficiency.
right speed and pressure.
Insulation- Wrapping ducts so air stays cool or DOCUMENTATION & COMPLIANCE
warm and doesn’t leak As-Built Drawings & Manuals: Maintain
Following Standards- Using rules from updated records of system layout,
SMACNA and other experts to ensure safety components, and manufacturer instructions.
and quality. Code Compliance: Adhere to local building
Following good practices helps the system codes, safety regulations, and international
work well, saves money on energy, and gives standards (ASHRAE, SMACNA, ISO).
better comfort to people inside.

DESIGN & PLANNING

Load Calculations: Proper HVAC load
analysis ensures the system can meet heating
and cooling demands without over- or
under-sizing.
Zoning: Dividing buildings into zones
improves control, energy efficiency, and
occupant comfort.
Future-Proofing: Allow space and design
flexibility for future upgrades, maintenance
access, or capacity changes.

INSTALLATION BEST PRACTICE

Leak Testing and Sealing: All duct joints and
seams should be tested and sealed to
minimize air loss.
Minimize Turns and Restrictions: Sharp
bends, sudden size changes, and long runs
increase resistance and reduce efficiency.
Isolation of Vibration: Use flexible connectors
or vibration isolators to prevent noise and wear
from mechanical equipment.

MATERIAL & EQUIPMENT QUALITY

Use Certified Materials: Only use materials
approved for HVAC applications (fire-rated,
corrosion-resistant, etc.).
Reliable Equipment Sourcing: Choose
reputable manufacturers to ensure quality,
efficiency, and availability of spare parts.
GROUP 5 Best Practices:
Ductwork is essential for distributing -​ Inspect ducts for leaks and clean
conditioned air efficiently throughout buildings. surfaces before sealing.
Proper insulation and sealing minimize energy -​ Combine sealing with insulation for
loss, improve system efficiency, and reduce maximum efficiency, especially in
utility costs. Leaky or poorly insulated ducts unconditioned spaces like attics.
can cause uneven temperatures, higher -​ Proper installation ensures insulation
energy consumption, and compromised indoor meets rated R-values
air quality. Noise from airflow and mechanical
vibrations can impact occupant comfort, DUCTWORK ATTENUATION & NOISE
making noise control an important CONSIDERATION
consideration. This presentation covers key Noise Sources: Air turbulence, mechanical
aspects of duct insulation, sealing, noise vibrations, duct material resonance.
attenuation, testing, and maintenance to Noise Control Strategies:
optimize HVAC performance and indoor ●​ Use acoustical duct liners or fibrous
comfort. glass insulation to absorb sound.
●​ Install sound attenuators or silencers in
DUCTWORK INSULATION & SEALING duct runs.
Purpose: Reduce heat loss/gain, prevent ●​ Design ducts with smooth transitions
condensation, improve energy efficiency. and proper sizing to reduce turbulence
Insulation Types: and noise.
-​ Fibrous glass duct wrap and boards ●​ Isolate vibrating equipment to prevent
with vapor retarders (R-values vary by noise transmission.
thickness, ASTM compliant). Goal: Minimize noise for occupant comfort
-​ Rigid foam panels and spray foam offer without compromising airflow.
higher R-values per inch than
fiberglass, effective in thermal DUCTWORK TESTING & SYSTEM
resistance. PERFORMANCE
-​ Reflective insulation (aluminum foil Testing Methods:
facings) reflects radiant heat, ideal for -​ Pressure testing (duct blower tests) to
hot climates. detect leaks and verify sealing
-​ Eco-friendly cotton insulation from effectiveness.
recycled materials is an alternative -​ Airflow measurement with
option. anemometers or flow hoods to ensure
Sealing Methods: balanced distribution.
-​ Mastic sealant: Durable, flexible paste -​ Thermal imaging to detect insulation
applied with brush or caulk gun; gaps or heat loss.
excellent for small to medium leaks and Performance Metrics:
various duct materials. -​ Air leakage rate (should be minimized).
-​ Foil tape: Metal foil with adhesive -​ Airflow balance throughout the system.
backing, withstands high temperatures, -​ Energy consumption and HVAC
ideal for seams and joints. efficiency.
-​ Aeroseal technology: Aerosol particles Benefits:
seal up to 90% of leaks, especially in -​ Early detection of leaks or inefficiencies
hard-to-reach ducts. improves system longevity and reduces energy
-​ Spray foam sealant: Expands to fill costs.
cracks, also provides insulation
DUCT CLEANING & MAINTENANCE
CONSIDERATION
Importance: Removes dust, allergens, mold,
and debris to improve indoor air quality and
system efficiency.
Benefits: Enhances air quality, prolongs
equipment life, maintains HVAC efficiency.
Maintenance Tips:
-​ Regular inspections for leaks,
insulation damage, and contamination.
-​ Clean ducts every 3-5 years or as
needed based on the environment and
system use.
-​ Replace air filters regularly to reduce
dust buildup.
-​ Use professional cleaning services
following NADCA standards for
thoroughness.

CONCLUSION
-​ Effective duct insulation and sealing
reduce energy loss and improve HVAC
efficiency.
-​ Noise attenuation strategies enhance
occupant comfort by controlling airflow
noise. Regular testing ensures duct
system integrity and optimal
performance.
-​ Routine cleaning and maintenance
sustain air quality and system longevity.
-​ Combined, these practices optimize
HVAC system operation and indoor
environmental quality.