SECTION 23 31 00

HVAC DUCTS AND CASINGS

1 GENERAL
1 .1 SECTION INCLUDES
A. Metal ductwork.
B. Casing and plenums.
C. Duct cleaning.
1 .2 RELATED REQUIREMENTS
A. Section 01 25 00 - Substitution Procedures
B. Section 01 33 23 - Shop Drawings, Product Data and Samples
C. Section 23 05 00 - HVAC Scope of Work
D. Section 23 07 13 - Duct Insulation: External insulation and duct liner.
E. Section 23 33 00 - Air Duct Accessories.
F. Section 23 05 93 - Testing, Adjusting, and Balancing for HVAC.
1 .3 REFERENCE STANDARDS
A. ASHRAE (FUND) - ASHRAE Handbook - Fundamentals; 2005.
B. ASTM A 36/A 36M - Standard Specification for Carbon Structural Steel; 2005.
C. ASTM A 240/A 240M - Standard Specification for Chromium and Chromium-Nickel Stainless
Steel Plate, Sheet, and Strip for Pressure Vessels and General Applications; 2007.
D. ASTM A 480/A 480M - Standard Specification for General Requirements for Flat-Rolled
Stainless and Heat-Resisting Steel Plate, Sheet, and Strip; 2008b.
E. ASTM A 653/A 653M - Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or
Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process; 2009.
F. ASTM A 1008/A 1008M - Standard Specification for Steel, Sheet, Cold-Rolled, Carbon,
Structural, High-Strength, Low Alloy, and High-Strength Low-Alloy with Improved Formability,
Solution Hardened, and Bake Hardenable; 2007a
G. ASTM B 209 - Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate; 2007.
H. ASTM B 209M - Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate
Metric; 2007.
I.

ASTM E 84 - Standard Test Method for Surface Burning Characteristics of Building Materials;
2010.

J.

ASTM E119-Fire Engulfment Test.

K. ASTM E814-Fire Rated Penetration Test.

L.

NFPA 90A - Standard for the Installation of Air-Conditioning and Ventilating Systems; National
Fire Protection Association; 2009.

M. NFPA 96 - Standard for Ventilation Control and Fire Protection of Commercial Cooking
Operations; National Fire Protection Association; 2008.
N. SMACNA (LEAK) - HVAC Air Duct Leakage Test Manual; Sheet Metal and Air Conditioning
Contractors' National Association; 1985, First Edition.
O. SMACNA (DCS) - HVAC Duct Construction Standards - Metal and Flexible; Sheet Metal and Air
Conditioning Contractors' National Association; 2005.

23 31 00 - 1

EAB (11-54)

P. SMACNA (KVS) - Kitchen Ventilation Systems and Food Service Equipment Fabrication &
Installation Guidelines; 2001.
Q. UL 181 - Standard for Factory-Made Air Ducts and Air Connectors; Underwriters Laboratories
Inc.; Current Edition, Including All Revisions.
R. UL1978 (File MH8251) - Grease Ducts for Restaurant Cooking Appliances.
S. UL2221 (File R15388) - Standard for Tests of Fire Resistive Grease Duct Enclosure
Assemblies.
1 .4 SUBMITTALS
A. Product Data: Provide data for duct materials, duct liner, duct connections, and flexible
ductwork and sample of stainless steel weld.
B. Shop Drawings: Indicate duct fittings, particulars such as gages, sizes, welds, and
configuration prior to start of work for all systems. Drawings shall include all supports and
access/maintenance doors.
C. Test Reports: Indicate pressure tests performed. Include date, section tested, test pressure,
and leakage rate, following SMACNA (LEAK) - HVAC Air Duct Leakage Test Manual.
D. Any ductwork installed without prior approval by the engineer shall be replaced at the expense
of the contractor.
1 .5 QUALITY ASSURANCE
A. Manufacturer Qualifications: Company specializing in manufacturing the type of products
specified in this section, with minimum three years of documented experience.
B. Installer Qualifications: Company specializing in performing the type of work specified in this
section, with minimum 5 years of documented experience.
C. All ductwork shall be in accordance with this specification and the drawings and with the
applicable referenced codes, standards, and guidelines. Where conflict arises, the most
stringent requirements shall apply.
1 .6 DELIVERY, STORAGE, AND HANDLING
A. Store in clean dry place and protect from weather and construction traffic. Handle carefully to
avoid damage to components, enclosures, and finish.
2 PRODUCTS
2 .1 ASSEMBLIES
A. All Non-Process Ducts: Galvanized steel, unless otherwise indicated.
B. Low Pressure Supply (Heating Systems): 3 inch w.g. pressure class, galvanized steel.
C. Low Pressure Supply (System with Cooling Coils): 3 inch w.g. pressure class, galvanized
steel.
D. Return and Relief: 3 inch w.g. pressure class, galvanized steel.
E. General Exhaust: 3 inch w.g. pressure class, galvanized steel.
F. Outside Air Intake: 3 inch w.g. pressure class, galvanized steel.
2 .2 MATERIALS
A. Galvanized Steel Ducts (Indoor): Hot-dipped galvanized steel sheet, ASTM A 653/A 653M FS
Type B, with G60/Z180 coating.
B. Galvanized Steel Ducts (Outdoor): Hot-dipped galvanized steel sheet, ASTM A 653/A 653M FS
Type B, with G90/Z275 coating.
C. Un-Galvanized Steel for Ducts: ASTM A 1008/A 1008M, Designation CS, cold-rolled
commercial steel.

23 31 00 - 2

EAB (11-54)

D. Aluminum for Ducts: ASTM B 209 (ASTM B 209M); aluminum sheet, alloy 3003-H14.
Aluminum Connectors and Bar Stock: Alloy 6061-T651 or of equivalent strength.
E. Stainless Steel for Ducts: ASTM A 240/A 240M, Type 304 with Type 2B Finish.
F. Joint Sealers and Sealants: Non-hardening, water resistant, mildew and mold resistant.
1.

Type: Heavy mastic or liquid used alone or with tape, suitable for joint configuration and
compatible with substrates, and recommended by manufacturer for pressure class of
ducts.

2.

VOC Content: Not more than 250 g/L, excluding water.

3.

Surface Burning Characteristics: Flame spread of zero, smoke developed of zero, when
tested in accordance with ASTM E 84.

4.

For Use With Flexible Ducts: UL labeled.

G. Hanger Rod: ASTM A 36/A 36M; min. of steel, galvanized; threaded both ends, threaded one
end, or continuously threaded. Ductwork hanger material must match ductwork construction
(i.e. stainless steel ductwork shall have stainless steel hanger material).
2 .3 SHOP-FABRICATED DUCTWORK
A. Fabricate and support in accordance with SMACNA HVAC Duct Construction Standards - Metal
and Flexible, and as indicated.
B. No variation of duct configuration or size permitted except by written permission.
C. Provide duct material, gages, reinforcing, and sealing for operating pressures indicated.
D. Construct T's, bends, and elbows with radius of not less than 1-1/2 times width of duct on
centerline unless noted otherwise on the construction documents. Where not possible and
where rectangular elbows must be used, provide air foil turning vanes of solid metal.
E. Increase duct sizes gradually, not exceeding 15 degrees divergence wherever possible;
maximum 30 degrees (included angle) divergence upstream of equipment and 45 degrees
(included angle) convergence downstream.
F. Fabricate continuously welded round and oval duct fittings in accordance with SMACNA HVAC
Duct Construction Standards - Metal and Flexible.
G. Where ducts are connected to exterior wall louvers and duct outlet is smaller than louver frame,
provide blank-off panels sealing louver area around duct. Use same material as duct, painted
black on exterior side; seal water-tight to louver frame and duct.
H. Where ductwork will be painted the metal surface shall be provided with a paintable finish, such
as Paintgrip (acid washed), phosphatized, or galvannealed.
I.

Shop Cleaning: The exterior of all ductwork which will be painted shall be cleaned in the shop
to remove oil and grease. See the Painting and Coating Section 09 90 00.

2 .4 MANUFACTURED ROUND AND FLAT OVAL METAL DUCTWORK AND FITTINGS (NONPROCESS DUCTWORK)
A. Round and Flat Oval Ducts: Machine made from round spiral lockseam duct with light
reinforcing corrugations; fittings manufactured of at least two gages heavier metal than duct.
1.

Manufacture in accordance with SMACNA HVAC Duct Construction Standards - Metal and
Flexible.

2.

Fittings: Manufacture at least two gages heavier metal than duct.

3.

Provide duct material, gages, reinforcing, and sealing for operating pressures indicated.

4.

Manufacturers:
a.

SEMCO Inc.: www.semcoinc.com.

23 31 00 - 3

EAB (11-54)

b.

United McGill Corporation: www.unitedmcgill.com.

c.

Eastern Sheet Metal: www.easternsheetmetal.com.

d.

Substitutions: See Section 01 60 00 - Product Requirements.

B. Double Wall Insulated Round and Flat Oval Ducts: Machine made from round spiral lockseam
duct.
1.

Manufacture in accordance with SMACNA HVAC Duct Construction Standards - Metal and
Flexible.

2.

Inner wall: Perforated galvanized steel.

a.

3.

Insulation:
a.

4.

All ductwork perforated: Perforated galvanized steel, unless otherwise indicated.

Thickness: 1 inch fiberglass.

Manufacturers:
a.

SEMCO Inc.: www.semcoinc.com.

b.

United McGill Corporation: www.unitedmcgill.com.

c.

Eastern Sheet Metal: www.easternsheetmetal.com.

d.

Substitutions: See Section 01 60 00 - Product Requirements.

C. Flexible Ducts (Upstream of variable or constant volume terminal units): Two ply vinyl film
supported by helically wound spring steel wire.
1.

Insulation: Fiberglass insulation with polyethylene vapor barrier film.

2.

Pressure Rating: 10 inches WG positive and 1.0 inches WG negative.

3.

Maximum Velocity: 4000 fpm.

4.

Temperature Range: -10 degrees F to 160 degrees F.

5.

Manufacturers:
a.

Thermaflex Model M-KC.

b.

Substitutions: See Section 01 60 00 - Product Requirements.

D. Flexible Ducts (At final connections to air outlets): Black polymer film supported by helically
wound spring steel wire.
1.

Insulation: Fiberglass insulation with polyethylene vapor barrier film.

2.

Pressure Rating: 4 inches WG positive and 0.5 inches WG negative.

3.

Maximum Velocity: 4000 fpm.

4.

Temperature Range: -20 degrees F to 175 degrees F.

5.

Manufacturers:
a.

Hart & Cooley Model F114.

b.

ATCO Model 1000.

c.

Substitutions: See Section 01 60 00 - Product Requirements.

E. Transverse Duct Connection System: SMACNA "E" rated rigidly class connection, interlocking
angle and duct edge connection system with sealant, gasket, cleats, and corner clips.
F. Transverse Fittings: Slip couplings (describe this better)
G. Where ductwork will be painted the metal surface shall be provided with a paintable finish, such
as Paintgrip (acid washed), phosphatized, or galvannealed.

23 31 00 - 4

EAB (11-54)

H. Cleaning: The exterior of all ductwork which will be painted shall be cleaned at the factory or in
the shop to remove oil and grease prior to shipping to the site. See the Painting and Coating
Section 09 90 00.
2 .5 CASINGS AND PLENUMS
A. Unless indicated otherwise, fabricate casings and plenums in accordance with SMACNA HVAC
Duct Construction Standards - Metal and Flexible, and construct for operating pressures
indicated.
B. Mount floor mounted casings on 4 inch high concrete curbs. At floor, rivet panels on 8 inch
centers to angles. Where floors are acoustically insulated, provide liner of 18 gage galvanized
expanded metal mesh supported at 12 inch centers, turned up 12 inches at sides with sheet
metal shields.
C. Reinforce door frames with steel angles tied to horizontal and vertical plenum supporting
angles. Install hinged access doors where indicated or required for access to equipment for
cleaning and inspection.
D. Where noted, fabricate acoustic plenums and casings with reinforcing turned inward. Provide
16 gage back facing and 22 gage solid front facing with 3/32 diameter holes on 5/32 centers.
Unless otherwise indicated, construct panels 3 inch thick packed with 4.5 lb/ cu. ft. minimum
glass fiber media, on inverted channels of 16 gage. Note: Plenums for process systems shall
have similar construction but with solid stainless steel inner liner.
3 EXECUTION
3 .1 INSTALLATION
A. Install, support, and seal ducts in accordance with SMACNA HVAC Duct Construction
Standards - Metal and Flexible.
B. Install in accordance with manufacturer's instructions.
C. During construction provide temporary closures of metal or taped polyethylene on open
ductwork to prevent construction dust from entering ductwork system.
D. Surface Conditions
1.

2.

3.

Inspection:
a.

Prior to all work of this section, carefully inspect the installed work of all other trades
and verify that all such work is complete to the point where this installation may
properly commence.

b.

Verify that the work of this section may be installed in accordance with all pertinent
codes and regulations and the approved shop drawings.

Discrepancies:
a.

In the event of discrepancy, immediately notify the Architect/Engineer.

b.

Do not proceed with installation in areas of discrepancy until all such discrepancies
have been fully resolved.

Field Measurement: Measurements of actual field conditions must be made by contractor

to verify equipment and ductwork installation requirements.

E. Installation of Equipment
1.

General:
a.

Install all equipment where indicated on the approved shop drawings.

b.

Avoid interference with structure and the work of other trades; do not cut into load
carrying members without the specific approval of the Architect/Engineer.

23 31 00 - 5

EAB (11-54)

2.

Inspection: Check each piece of equipment in the system for defects, verifying that all
parts are properly furnished and installed, that all items function properly, and that all
adjustments have been made.

23 31 00 - 6

EAB (11-54)

F. Installation of Ducts
1.

2.

3.

4.

Fabrication of Rectangular Ducts:

a.

Fabricate and install all ducts in strict accordance with the approved shop drawings
and the referenced standards.

b.

On sheet metal ducts, cross-break or roll form all flat surfaces to prevent vibration.

Duct Layout:
a.

All duct sizes shown on the drawings are net dimensions inside the insulation;
wherever obstructions require a change in duct size, maintain equivalent areas.

b.

On rectangular duct, make all duct elbows right angle type with elbow turns or turning
blades, or make elbows with a radius of 1-1/2 times the duct width.

c.

Fabricate transitions using a 30` angle (max.) when reducing a dimension and 45`
angle (max.) when increasing a dimension.

d.

One (1) inch diameter test openings shall be furnished in ductwork where required
for proper adjustment of all supply and exhaust systems. Provide suitable pressuretight coverings for openings when not in use.

Round and Oval Duct Installation: Install all round and oval duct in accordance with
manufacturers recommendations, meeting at least the requirements of McGill Airflow and
SMACNA.
a.

Transverse joints and longitudinal seams shall be sealed with a duct sealant meet UL
723.

b.

Duct Hangers shall meet SMACNA requirements and MAF requirements as minimum
manufacturers recommendations.

c.

Where particulate accumulation is possible or anticipated hangers shall be adjusted

accordingly.

d.

Proper installation of ductwork is solely the responsibility of the contractor as is proper

application of sealant, connections of branch fittings, taps for diffusers, protection of
materials, recoating damaged PVC coated underground duct, and related activities
necessary for a clean, neat, functional job.

Round and Oval Duct Performance:

a.

Ductwork:
(1) Duct shall be constructed and installed to maintain minimum friction loss
throughout with the fewest possible joints, couplings kept tight to the duct wall
surface, and projections into the ducts minimized.
(2) Friction loss of single and double wall duct shall meet minimum requirements of
SMACNA and MAF Duct System Design Reference Manual.
(3) Ducts shall be subject to inspection and testing. Duct failing to meet
performance requirements shall be replaced.
(4) Testing shall be witnessed by an agent of the engineer and/or inspecting
authority.

b.

Fittings:
(1) Fittings in a critical path or design leg shall be selected or constructed solely
based on performance unless spatial restraints are present, with the lowest loss
coefficient obtainable for the required fitting type.
(2) If the location of the critical path is not specified, all fittings throughout the system
shall have the lowest loss coefficient obtainable.

23 31 00 - 7

EAB (11-54)

(3) If the critical path is identified, care must be applied in meeting the aggregate
pressure loss available without affecting acoustical performance of the system.
(4) Only fittings with verifiable loss coefficients and performance data from
laboratory testing are acceptable.
(5) Performance of fittings shall meet minimum requirements of SMACNA and MAF
Duct System Design Reference Manual.
(6) Fittings are subject to same inspection and testing criteria as ductwork.
G. Any unavoidable field changes to the original design must be reported to the project engineer
and recorded on the as-built drawings by the contractor.
H. Ductwork layout drawings shall be provided to coordinate with other utilities and structural
members.
I.

Flexible Ducts: Connect to metal ducts with approved adhesive/sealant and draw bands.

J.

Duct sizes indicated are inside clear dimensions. For lined and double-wall ducts, maintain
sizes inside lining.

K. Provide openings in ductwork where required to accommodate thermometers and controllers.

Provide pilot tube openings where required for testing of systems, complete with metal can with
spring device or screw to ensure against air leakage. Where openings are provided in insulated
ductwork, install insulation material inside a metal ring.
L.

Locate ducts with sufficient space around equipment to allow normal operating and
maintenance activities.

M. Use crimp joints with or without bead for joining round duct sizes 8 inch and smaller with crimp
in direction of air flow.
N. Use double nuts and lock washers on threaded rod supports.
O. Connect terminal units to supply ducts directly or with three foot maximum length of flexible
duct. Do not use flexible duct to change direction.
P. Connect diffusers or light troffer boots to low pressure ducts directly or with 5 feet maximum
length of flexible duct held in place with strap or clamp. Flexible ducts shall be stretched tight
so that no excess duct is used. Limit changes in direction of flexible duct to a maximum of 90
degrees.
Q. Set plenum doors 6 to 12 inches above floor. Arrange door swings so that fan static pressure
holds door in closed position.
R. Provide accessible cleanouts in process ducts per NFPA 96 requirements.
S. Duct Sealing:
1.

Seal all supply and return ducts with Hardcast, or equal by Ductmate. Sealants shall
comply with NFPA 90A with maximum flame spread of 25 and smoke development of 50.
a.

For duct sealing, use Sure Grip 404 High Velocity Duct Sealer, solvent based.

b.

Use Hardcast A-1104 FR for duct flange sealing.

c.

For sealing exterior ductwork, use RTA-50/DT Tape.

d.

For any other sealing requirements, follow recommendations of Hardcast at 800-2857430.

2.

Sealing shall meet SMACNA Class A on VAV supply duct up to VAV boxes and coil
modules, and meet Class C elsewhere.

3.

After curing, sealer shall be resistant to ultraviolet light and shall seal our water, air, and
moisture. Sealer shall be UL listed for the specific application and conform to ASTM E 84.

23 31 00 - 8

EAB (11-54)

4.

NOTE: All intake plenums and intake ductwork shall be sealed watertight from the intake
louvers up to the air handling units such that any accumulation of rain or snow is contained
and drained into the duct drains without damaging spaces below.

T. Quality Control: At the completion of the work, the installation shall be visually inspected by the
owner with the system operating. Noise, leakage, air restriction, insufficient support, or
improper insulation shall be repaired to the satisfaction of the owner at the contractor's
expense.
3 .2 CLEANING AND TESTING
A. Ductwork Leakage Criteria:
1.

All transverse joints and longitudinal seams shall conform to SMACNAs Class A sealing
requirements as defined on sections 1.6a and 1.7 of 1995 SMACNA Manual, Second
Edition with Addendum 1, November, 1997.

2.

Constant Volume Systems/Supply Ductwork allowable leakage shall be one percent (1%)
of design CFM.

3.

Constant Volume Systems/Return Ductwork allowable leakage shall be two percent (2%)
of design CFM.

4.

Variable Air Volume Systems/Supply Ductwork allowable leakage from the Fan to VAV
boxes or coil modules shall be one percent (1%) of design CFM and from the VAV boxes
or coil modules to supply diffusers shall be two percent (2%) of design CFM.

B. Ductwork Sealing: As a minimum standard, ductwork and plenums shall be sealed in

accordance with Table 6.2.4.3A of ASHRAE Standard 90.1 (1999 and 2001) as required to
meet the requirements of Section 6.2.4.4 (SMACNA Duct Leakage Test Procedures-1985).
C. Prove tightness of duct construction by operating air handling equipment and physically
verifying absence of any air leakage, both audibly and manually. Repair as needed to achieve
minimal leakage. Examine every joint and verify leak tight. If further testing is needed to
resolve duct leakage problems, particularly as related to sound criteria, comply with procedure
outline in 1985 (or current edition) of SMACNA HVAC Air Duct Leakage Test Manual.
D. Ductwork designed to operate at static pressures in excess of 3 inches of water shall be leaktested according to the SMACNA HVAC Air Leakage Test Manual. Representative sections
totaling no less than 25% of the total installed duct area for the designated pressure class shall
be tested. See Plans for duct systems with pressure ratings in excess of 3 inches w.c.
E. Maximum permitted duct leakage shall be:
1.

Lmax = CL x Test Pressure P raised to the 0.65 power where Lmax is maximum
permitted leakage in CFM/100 sq.ft. duct surface area

2.

CL is duct leakage class in cfm/100 sq.ft. at 1 inch w.c., which shall be

3.

a.

6 for rectangular sheetmetal, rectangular fibrous ducts, and round flexible ducts.

b.

3 for round/flat oval sheetmetal or fibrous glass ducts.

P is test pressure, equal to the design duct pressure class rating in inches w.c.

F. Ductwork Leakage Testing:

1.

Installed ductwork shall be tested prior to installation of access doors, take-offs etc.

2.

All testing shall be witnessed by the engineer or owners representative. Contractor shall
give the engineer or owners representative 72 hours notice prior to testing.

3.

The testing shall be performed as follows:

a.

Perform testing in accordance with SMACNA HVAC Air Duct Leakage Test Manual.

b.

Use a certified orifice tube for measuring the leakage.

23 31 00 - 9

EAB (11-54)

c.

Define section of system to be tested and blank off.

d.

Determine the percentage of the system being tested.

e.

Using that percentage, determine the allowable leakage (CFM) for that section being
used.

f.

Pressurize to operating pressure and repair any significant or audible leaks.

g.

Repressurize and measure leakage.

h.

Repeat steps f and g until the leakage is less than the allowable defined in step e.

G. Process ductwork shall by washed to owner's requirements prior to turning system over to
owner. Protect equipment that could be harmed by excessive dirt and water with filters, or
bypass during cleaning. Provide adequate access into ductwork for cleaning purposes.
END OF SECTION

23 31 00 - 10

EAB (11-54)