CVS3 HVAC Specifications

SHEET METAL DUCT WORK

PART 1 – GENERAL CONDITIONS
1.1 RELATED DOCUMENTS
Drawings and general provisions/specifications of the CVS3 building apply to work of this
specification.

1.2 DESCRIPTION OF WORK

A. The work includes the providing of all labor, supervision, materials, equipment, accessories, services
and tests necessary to complete, make ready, and set to work for acceptance by the Owner, all sheet
metal work in accordance with Drawings and Specification.

1.3 QUALITY ASSURANCE

A. Acceptable Manufacturers: Firms regularly engaged in manufacture of sheet metal ductwork products
of the types, materials, and sizes required, whose products have been in satisfactory use in similar
service for not less than 5 years, as approved by the HVAC consultant.
B. Installers: Firms with at least 5 years of successful installation experience on projects with sheet metal
ductwork systems similar to that required for this project.
C. Standards Compliance: Comply with the requirements of applicable local codes, unless this is deemed
unnecessary due to the tasks required as approved by CVS3 management.

1.4 SUBMITTALS
A. Product Data: Submit manufacturer's product data, including printed technical literature, installation
instructions and catalog cuts for sheet metal ductwork materials and products.
B. Manufacturer Certification.
C. Submit for checking and approval shop drawings of all sheet metal work drawn to a minimum scale
of 1:30. Obtain approval of these shop drawings from the consultant before any fabrication upon this
ductwork is commenced. In addition to the layout of the ductwork, indicate the type of seams and
joints, the method of applying acoustical lining and noise, details of fire dampers and any other details
the consultant may request in reference to sheet metal work. Submit such details prior to or with the
first duct layout drawings. Indicate the elevation of bottom of ducts above finish floor on the drawings.

PART 2 - PRODUCTS
2.1 SHEET METAL DUCTWORK
A. Supply and installation of galvanized sheet metal duct work with required hangers and supports and
all accessories according to SMACNA duct construction standard, with dimensions shown on
drawings.
B. All supply and return air duct branches are preferred to be of circular geometry, along with circular
air outlets/inlets.

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C. Supply and installation of thermal insulation from fiber glass with aluminum vapour barrier thickness
of 1 in, and density of 24 kg/m3, including cladding. Contractor will be required to submit offers with
three different cladding materials: cloth and sheet metal (aluminum or painted carbon steel).
D. Duct flanges shall be constructed with transverse duct flanges (TDF).
E. All ductwork, sheet metal flues, register boxes, air changers, dampers and all auxiliary work of any
kind necessary to make the various air conditioning, ventilating and heating systems of the building
complete and ready for satisfactory operation shall be furnished and installed. All ductwork shall be
constructed in accordance with the latest edition of SMACNA Duct Construction Standards.
F. All ductwork indicated on drawings is schematic. Ductwork shall be set up and down, offset, change
in duct size and/or location to meet field conditions and coordination between trades without
additional cost to the owner.
G. Dimensions given on drawings of all acoustically lined ducts shall be clear inside dimension.
H. A snap lock seam shall not be permitted.
I. Use gasketed type joint when dissimilar metals are joined.
J. All galvanized ductwork shall be hung with galvanized hangers.
K. Access doors as specified elsewhere shall be provided in the ducts wherever required for access to
fusible link dampers, controls, and all equipment concealed inside the ducts.
L. All ductwork shall be substantially built of lock forming quality galvanized steel having a standard
galvanized coating, as ordinarily made by certified SMACNA duct suppliers in Egypt. Ducts shall have
approved joints and seams smooth on the inside with a neat finish on the outside. Duct joints shall be
as airtight as possible, with laps made in the direction of air flow and no flanges projecting into the air
stream. All angles shall be galvanized.
M. Tapers for low pressure ducts shall be constructed in accordance with SMACNA standards. When a
taper is used in a "diverging" air flow and the duct size increases, the sides are to be pitched to
maximum of 20 degrees to prevent turbulence or an additional increase of static pressure. When a
taper is used in a "contracting" air flow and the duct size is decreasing, the sides are to be pitched to
a maximum of 30 degrees.
N. Where space conditions permit, full radius turns shall be used at offsets in low pressure ducts radius
= duct width.
O. Where space conditions do not permit a short radius, vaned elbow or square elbows shall be used. All
square elbows shall be fitted with double thick turning vanes.
P. When it is impossible to offset a low-pressure duct around an obstruction or when it is necessary to
make provisions for vertical hangers of the ceiling construction passing through ducts, the obstruction
shall be encompassed with a "streamliner".
Q. Install manual dampers, automatic dampers (provided by control manufacturer) fire dampers, smoke
dampers, grilles, registers, diffusers, register boxes, access doors, etc., as indicated on the drawings
described elsewhere in the specifications and as required for a complete system ready for operation.
Balancing dampers shall be provided in each branch, split or tap connection of low pressure ducts
unless otherwise noted on plans.
R. Exact dimensions of register boxes must await approval of grilles, and exact locations shall be
submitted for approval, otherwise any changes directed after installation shall be made without
additional cost to the Owner. All register boxes and other openings must be kept tightly closed during
construction to keep out rubbish.

2.2 LOW PRESSURE DUCTWORK

A. Low pressure ductwork is defined as ductwork in the systems where velocities do not exceed 10 m/sec
and static pressures do not exceed 500 Pa at fan discharge.

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B. All low-pressure ductwork shall be galvanized steel, except where otherwise specified, with gauges as
follows, and constructed and braced so not to deform, break of fail to support its own weight.
Sheet Metal Duct Gauges, Low Pressure
Duct Width (mm) Sheet Metal Thickness (mm)
Up to 600 0.6
601 to 760 0.6
761 to 1220 0.8
1221 to 2030 1.0
over 2031 1.2

C. Total air outlet volume for low pressure duct systems, measured by means of a velometer, shall be at
least 95% of actual fan supply (measured by means of duct traverse taken with a pitot tube and water
manometer).

2.3 MEDIUM PRESSURE DUCTWORK

A. Medium pressure ductwork is defined as ductwork in systems where velocities exceed 10 m/sec and
static pressures do not exceed 1500 Pa.
B. All medium pressure ductwork shall be galvanized steel except where otherwise specified, with
gauges, as follows, brace and construction so as to support its own weight and not to break, rattle or
deform under pressure.
Sheet Metal Duct Gauges, Medium Pressure
Duct Width (mm) Sheet Metal Thickness (mm)
Up to 600 0.8
601 to 760 0.8
761 to 1220 1.2
1221 to 2030 1.5
over 2031 1.5
C. Total air outlet volume for medium pressure duct systems, measured by means of a velometer, shall
be at least 98% of actual fan supply (measured by means of a duct traverse taken with a Pitot tube
and water manometer) i.e., maximum 2% leakage.

2.4 AIR CASINGS

A. All air casings and plenums shall be constructed of 1.5mm galvanized iron braced and stiffened on
outside by means of 50mm x 50mm x 6mm galvanized steel angles, or with 15 mm standing seam
panels not to exceed 660 mm width. Standing seams are to have additional right-angle bend and shall
be capped with No. 1.2 mm galvanized "U" cap over entire length of seam. All joints shall be caulked
to make them airtight. The bottom of all air chambers at the floor shall be gasketed to prevent air
leakage.
B. Casings shall be supported on floor curbs. The bottom of all air casings at the floor and at any other
connection to masonry shall be riveted to 38 mm x 38 mm x 3 mm galvanized steel angles which have
been secured to masonry with expansion shields and caulked tight with cement.
C. Provide angles above and below access doors and frames for access doors. See "Access Doors in Sheet
Metal Work" for construction of doors.
D. The Contractor shall be responsible for any additional bracing required for stiffness including roof
deck of casings. The roof deck shall be braced and supported from the structure, if required.

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2.5 ACCESS DOORS IN SHEET METAL WORK
A. Wherever necessary in ductwork, casings or sheet metal partitions, this Contractor shall provide
suitable access doors and frames to permit inspections, operation and maintenance of all valves,
controls, fire dampers, filters, bearings, traps, or other apparatus concealed behind the sheet metal
work. All such doors shall be of double construction of not less than .9 mm sheet metal and shall have
sponge rubber gaskets around their entire perimeter. Doors in insulated ducts or insulated casings
shall have rigid fiberglass insulation between the metal panels.
B. All access doors in sheet metal ducts shall be hung on heavy flat hinges and shall be secured in the
closed position by means of cast zinc clinching type latches. Where space conditions preclude hinges,
use four heavy window type latches. Doors into ducts shall in general not be smaller than 460 mm x
460 mm except for access door to fire dampers which will depend on size of fire damper.
C. In no case shall access to any items or equipment requiring inspections, adjustments, or servicing
require the removal of nuts, bolts, screws, wing nuts, wedges, or any other screwed or loose device.
D. Each sheet metal chamber shall have access doors for access to all parts of the system. Doors shall be
fitted with cast zinc door latches, two per door. Latches shall be operable from both sides of casing.
As per SMACNA Details Hinges shall be extra heavy, zinc plated hinges, minimum of three per door.
The doors shall be felted or provided with rubber gaskets so as to make them airtight. The doors shall
be made with inner and outer sheets 50 mm apart so that they may be properly insulated and properly
operated. Doors shall be a minimum size of 500 mm x 1200 mm.

2.6 DAMPERS
A. Install all dampers required for all systems to accomplish the intent of the drawings and specifications.
B. All dampers requiring modulating, or two position controls shall conform to construction and finish
as indicated under Section of “Automatic Controls BMS”. Dampers are to be installed in frames
properly caulked to prevent leakage when closed. All automatic louver dampers for modulating air
flow shall be of the opposed blade type. Leakage not to exceed 17 M3HR at 100 mm Hg.

2.7 DRIP PANS AND DRAINS

A. Examine the drawings, and in cooperation with the Electrical trade confirm the final location of all
electrical equipment to be installed in the vicinity of piping. Plan and arrange all overhead piping no
closer than 600 mm from a vertical line to electric motors and controllers, switchboards, panelboards,
or similar equipment.
B. Where the installation of piping does not comply with the requirements of foregoing paragraph,
where feasible, the piping shall be relocated.
C. Furnish copper gutters as follows:
1. Provide and erect a gutter of 1 mm cold rolled copper under every pipe which is within 600 mm
of being vertically over any motor, electrical controllers, switchboards, or the like.
2. Each gutter shall be soldered and made watertight, properly suspended and carefully pitched to
a convenient point for draining. Provide a 75 mm drain to nearest floor drain or slop sink, as
approved.
3. In lieu of such separate gutters, a continuous protecting sheet of similar construction, adequately
supported and braced, properly rimmed, pitched and drained, may be provided over any such
motor, and extending 600 mm in all directions beyond the motor, over which such piping has to
run.
D. Each coil section composing the coil bank of a built up rig shall have an individual drain pan extending
300 mm past the front edge of the coil with a minimum 50 mm vertical lip downstream of the coil.
The top edge of the lip shall be turned backward. The pans shall be connected with galvanized pipe to

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 permit drainage to the floor drain. Pans shall be minimum 1.7 mm galvanized iron and shall be pitched
to the drain.

2.8 FLEXIBLE CONNECTIONS

A. All fan and air supply unit connections, both at inlet and discharge shall be made with an approved
flame proof fabric, so as to prohibit the transfer of vibration from fans to ductwork connecting
thereto, without air leakage. The materials between the clamps shall have sufficient slack so as to
prevent tearing due to fan movement.
B. The flexible connections shall be a minimum of 200 mm long and held in place with flanged
connections or heavy metal bands securely attached, to prevent any leakage at the connection points.
C. Flexible connections shall be fabricated from a flame proofed fabric and conforming to NFPA -90A.

2.9 PRE–INSULATED DUCT

A. Ducts and Ducts Accessories
Furnish and install pre –insulated ductwork ducts hanger and all necessary accessories for proper
installation of damper, fire damper. diffusers and grilles … etc.
Ducts surface area, for payment purpose, is be based on the actual dimensions of ducts installed.
Rates should be calculated into consideration waste, joints , seams , etc.
B. Ducts composition and material
Heating, ventilation and air conditioning ducts in pre–installed aluminum, will be constructed using
PIRAL HD HYDROTEC type sandwich panels made of water formulated polyurethane foam without use
of CFC or HCFC, density of 50-54 kg/m3.
Provide laboratory analysis to show that no any harmful gases will be generated by direct exposures
to the fire.
C. Technical Specifications:
 External aluminum: thickness of 0.08 mm embossed protected W/polyester lacquer.
 Internal aluminum: thickness of 0.08 mm embossed protected W/polyester lacquer.
 Insulation component: Water formulated polyurethane foam without use 0 CFC or HCFC, density
of 46 – 50 kg /m3;
 Thickness: 20 mm.
 Thermal conductivity: 0.024 W/ (M °C) at 10 °C;
 Stiffness class: R 200.000;
 The sandwich panel should be certified and approved, from a recognized association as a low-
level fire participation composition with minimum fume opacity and toxicity.
D. Outdoor Ducts
In all sections installed outside, the ducts must be built using sandwich type PIRAL HD HYDROTEC
OUTSIDER panels with the following characteristics:
 External aluminum: thickness of 0.2 mm embossed, protected with polyester lacquer;
 Internal aluminum: thickness of 0.08 mm embossed, protected with polyester lacquer.
 Insulation component: water formulated polyurethane foam without use of CFC and HCFC,
density of 46 – 50 kg /m3;
 Conductivity: 0.024 W (M °C) at 10 °C;
 Thickness: 30 mm.
 Stiffness class: R 900.000;
And will also be protected with water proofing resin (GUM SKIN type) .
Bitumen – based compounds must not be used.
E. Ducts Fabrication and Installation

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 The ducts will be constructed according the type standards. Wherever necessary, the ducts must be
provided with the appropriate reinforcements to guarantee sufficient mechanical seal against a
maximum internal pressure of 500 Pa during operation.
 The maximum deformation of the ducts must never exceed 3% of its width or in any case 30 mm.
 Elbows and special pieces will be provided with turning vanes wherever indicated.
 The maximum length of each single ducts must not exceed 4 m.
 Whenever the ducts penetrate the building’s roof, they will be provided with “gooseneck “ elbows
at the ends in order to prevent the entry of snow and water .
F. Ducts Sealant.
 All ducts joints dampers and anti-vibration should be sealed with non–toxic, UV radiation and
soluble salts resisting gasket.
 The gasket materials are made of self–adhesive polyurethane foam, treated with and acrylic resin
– based mixture or equivalent material.
G. Ducts Joints and Connection
 The joints between one ducts and the next will be performed using the special “invisible “flanges
with unexposed bayonet coupling and ensure the appropriate pneumatic and mechanical seal.
 Bayonet should be made of shock – resistant polymer and has to be self – lubricating for easy
insertion in flange with perfect air tightness.
 The flange ends should be provided with covering angle to prevent bayonet from getting out and
to achieve a good aesthetic finish,
H. Joints thermal insulation
Insulation of duct joints (where required) is to be done with anti-condensation tape, in closed – cell
cross linked polyethylene foam coupled on one side with embossed aluminum
I. Ducts Support and hangers
 The ducts will be supported by the appropriate supports at intervals of no more than 4 m
whenever the greater of the ducts is less than 1 m, and intervals of no more than 2 m whenever
the greater side of the ducts is more than 1 m.
 Ducts positioned outside will be bracketed every 2 m and raised from ground using the
appropriate wind braces. Whenever positioned horizontally, they must be inclined at a sufficient
angle to encourage water drainage.
J. Dampers, Grilles and AHU Connection
 Accessories such as volume dampers, fire barriers, and ducts coils, and so on, will be provided
with independent support in such a way that their weight does not bear on the ducts.
 All the openings of the ducts facing outside (external air inlet, internal air expulsion, and so on)
will be equipped with the appropriate screens to prevent the entry of brads.
 Wherever indicated, the ducts will also be provided with the appropriate test points for the
velocity sensors and inspection doors for cleaning and inspection all along the route.
 The inspection doors can be built using same sandwich panels used for the ducts in combination
with the appropriate section bars, and will be equipped with liners that ensure sufficient
pneumatic seal.
 The connections between the air handling units and the ducts will be made using the appropriate
vibration damping joints in order to reduce all vibrations. The ducts will be provided with
independent support in drier to prevent the weight of the ducts from being transferred to the
flexible couplings. The connection to the air handling unit will also permit easy uncoupling for
normal system maintenance. Whenever the vibration damping joints positioned outside, they will
be rendered waterproof.

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PART 3 - EXECUTION
1.1 INSTALLATION
A. Install ductwork in accordance with approved shop drawings and conditions at the site. Advise
Architect in writing of any condition which prevents the approved duct installation.
B. Where requested, provide opening in work for installation of smoke detectors. Securely install air-
tight housing and sampling tubes furnished by the Electrical Contractor.
C. Provide 25 mm test ports with standard weight piping caps at all ideal locations for obtaining air test
readings, static pressure, duct traverse temperature etc.

1.2 ACOUSTICS OF DUCTWORKS

A. Low velocity supply, return and exhaust ductwork shall be installed with acoustical lining where
specified. Such acoustic lining shall be a minimum of 25 mm thick mat faced duct liner meeting the
requirements of NFPA 90-A, and be 25 kg/m3 density fiberglass, or equivalent.
B. The Dimensions of the lined ducts shown on drawings are the inside dimensions of the ducts after the
lining has been installed. Duct liner shall be adhered with 100% coverage Mechanical fasteners which
do not pierce the sheet metal shall be on 400 mm centers on top sections (when width exceeds 300
mm) and on sides (when height exceeds 600 mm).
C. All abutting edges of acoustic linings shall be folded under and stapled to ensure that all raw edges
are sealed, and all exposed edges of acoustic linings shall be installed with sheet metal nosing. An
inner liner need not be provided to cover acoustic insulation except for medium and high pressure
ductwork or where duct velocity exceeds 12.5 m/sec.
D. In case an inner liner is needed, the liner shall be 0.7 mm thickness and minimum of 28% porosity
perforated galvanized sheet metal.
E. No major branches off of building air supply or return should be located above noise sensitive spaces.
Branch duct should be made of 60 mil (16 gage) sheet metal and free of leaks.
F. All HVAC equipment should have flexible connections for all duct, electrical, and piping connections.
G. The Following ductwork shall be acoustically lined:
- Built-up casing walls and ceiling of all plenums except that lining shall be 50 mm thick 50 kg/m3
density, and inner liner shall be used for all systems.
- All supply, return and exhaust rectangular ductwork (except kitchen and laundry exhaust) within
mechanical equipment rooms. If the distance from fan discharge to shaft inlet or mechanical room
wall is less than 10 meters minimum, continue acoustical lining to a distance of 10 meters from
fan inlet and discharge.
- Return air fan and toilet exhaust fan plenum walls and ceilings, except lining shall be 50 mm thick
50 kg/m3 density, (for walk-in fan plenums inner liner shall be used).
- Upstream of toilet exhaust fans a minimum distance of 10 meters.
- Downstream of fan coil units (full length).
- Rectangular ductwork downstream of variable air volume boxes for a minimum of 4.5 m.
- Line all linear diffuser plenums with minimum 13 mm liner.

1.3 SOUND ATTENUATORS

A. There should be a sound attenuator at the outlet and inlet of Air Handling Units and the entrance and
exit to the two acoustic rooms.

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B. In case sound attenuators are needed, they should be factory pre-fabricated from galvanized steel
(0.9 mm thickness) and leak proof at pressure differential of 1990 Pa. The absorbing material should
be glass wool of density 70 kg/m3 backed behind a perforated sheet 0.85 mm thickness and 30-50%
porosity.

1.4 PIPES AND DUCTS THROUGH WALLS

A. There shall be no direct contact of piping with shaft walls, floor slabs and/or partitions. Where
uninsulated piping penetrates partitions or slabs, the piping shall be sleeved with 25 mm fiberglass
the full depth of the penetration and sealed with non-hardening caulk, as shown in the following
figure for a pipe or duct penetrating a masonry wall.