Duct (flow)

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Ducts for air pollution control in a 17000 standard cubic feet per minute regenerative thermal oxidizer (RTO). Regenerative thermal oxidizer.jpg
Ducts for air pollution control in a 17000 standard cubic feet per minute regenerative thermal oxidizer (RTO).
A round galvanized steel duct connecting to a typical diffuser Central ventilation tube2.jpg
A round galvanized steel duct connecting to a typical diffuser
Fire-resistance rated mechanical shaft with HVAC sheet metal ducting and copper piping, as well as "HOW" (Head-Of-Wall) joint between top of concrete block wall and underside of concrete slab, firestopped with ceramic fibre-based firestop caulking on top of rockwool. Shaft dupont mississauga on.jpg
Fire-resistance rated mechanical shaft with HVAC sheet metal ducting and copper piping, as well as "HOW" (Head-Of-Wall) joint between top of concrete block wall and underside of concrete slab, firestopped with ceramic fibre-based firestop caulking on top of rockwool.

Ducts are conduits or passages used in heating, ventilation, and air conditioning (HVAC) to deliver and remove air. The needed airflows include, for example, supply air, return air, and exhaust air. [1] Ducts commonly also deliver ventilation air as part of the supply air. As such, air ducts are one method of ensuring acceptable indoor air quality as well as thermal comfort.

Contents

A duct system is also called ductwork. Planning (laying out), sizing, optimizing, detailing, and finding the pressure losses through a duct system is called duct design. [2]

Materials

Ducts can be made out of the following materials: They are

Galvanized steel

Galvanized mild steel is the standard and most common material used in fabricating ductwork because the zinc coating of this metal prevents rusting and avoids cost of painting. For insulation purposes, metal ducts are typically lined with faced fiberglass blankets (duct liner) or wrapped externally with fiberglass blankets (duct wrap). When necessary, a double walled duct is used. This will usually have an inner perforated liner, then a 1–2" (2.5-5 cm) layer of fiberglass insulation contained inside an outer solid pipe.

Rectangular ductwork commonly is fabricated to suit by specialized metal shops. For ease of handling, it o any length to suit, but the most common stock sizes range evenly from 4" to 24" (10-60 cm) with 6"-12" (15-30 cm) being most commonly used. Stock pipe is usually sold in 10' (300 cm) joints. There are also 5' (150 cm) joints of the non-spiral type pipe available, which is commonly used in residential applications.

Aluminium

Aluminium ductwork is lightweight and quick to install. Also, custom or special shapes of ducts can be easily fabricated in the shop or on site.

The ductwork construction starts with the tracing of the duct outline onto the aluminium preinsulated panel. The parts are then typically cut at 45°, bent if required to obtain the different fittings (i.e. elbows, tapers) and finally assembled with glue. Aluminium tape is applied to all seams where the external surface of the aluminium foil has been cut. A variety of flanges are available to suit various installation requirements. All internal joints are sealed with sealant.

Aluminum is also used to make round spiral duct, but it is much less common than galvanized steel.

Polyurethane and phenolic insulation panels (pre-insulated air ducts)

Traditionally, air ductwork is made of sheet metal which was installed first and then lagged with insulation. Today, a sheet metal fabrication shop would commonly fabricate the galvanized steel duct and insulate with duct wrap prior to installation. However, ductwork manufactured from rigid insulation panels does not need any further insulation and can be installed in a single step. Both polyurethane and phenolic foam panels are manufactured with factory applied aluminium facings on both sides. The thickness of the aluminium foil can vary from 25 micrometres for indoor use to 200 micrometers for external use or for higher mechanical characteristics. There are various types of rigid polyurethane foam panels available, including water formulated panel for which the foaming process is obtained through the use of water and CO2 instead of CFC, HCFC, HFC and HC gasses. Most manufacturers of rigid polyurethane or phenolic foam panels use pentane as foaming agent instead of the aforementioned gasses.

A rigid phenolic insulation ductwork system is listed as a class 1[ clarification needed ] air duct to UL 181 Standard for Safety.

Fiberglass duct board (preinsulated non-metallic ductwork)

Fiberglass duct board panels provide built-in thermal insulation and the interior surface absorbs [sound], helping to provide quiet operation of the HVAC system.

The duct board is formed by sliding a specially-designed knife along the board using a straightedge as a guide. The knife automatically trims out a groove with 45° sides which does not quite penetrate the entire depth of the duct board, thus providing a thin section acting as a hinge. The duct board can then be folded along the groove to produce 90° folds, making the rectangular duct shape in the fabricator's desired size. The duct is then closed with outward-clinching staples and special aluminum or similar metal-backed tape.

Flexible ducting

Flexible ducts (also known as flex) are typically made of flexible plastic over a metal wire coil to shape a tube. They have a variety of configurations. In the United States, the insulation is usually glass wool, but other markets such as Australia, use both polyester fiber and glass wool for thermal insulation. A protective layer surrounds the insulation, and is usually composed of polyethylene or metalized PET. It is commonly sold as boxes containing 25' (7.5 m) of duct compressed into a 5' (1.5 m) length. It is available in diameters ranging from as small as 4" (10 cm) to as big as 18" (45 cm), but the most commonly used are even sizes ranging from 6" to 12" (15 to 30 cm).

Flexible duct is very convenient for attaching supply air outlets to the rigid ductwork. It is commonly attached with long zip ties or metal band claps. However, the pressure loss is higher than for most other types of ducts. As such, designers and installers attempt to keep their installed lengths (runs) short, e.g. less than 15 feet (5 m) or so, and try to minimize turns. Kinks in flexible ducting must be avoided. Some flexible duct markets prefer to avoid using flexible duct on the return air portions of HVAC systems, however flexible duct can tolerate moderate negative pressures. The UL181 test requires a negative pressure of 200 Pa.

To use flexible ducting in a system, make sure to pull the duct tight so you get the full internal diameter. This reduces resistance and improves airflow, as well as ventilation efficiency. Minimize bends and kinks as much as possible, since they can affect how well the airstream flows through the ductwork.

There are a few types of flexible ducting - Polyurethane (PU), Aluminium & Aluminium insulated, Acoustic and Rectangular flexible ducting, as well as semi- and combi-flex.

Fabric ducting

This is actually an air distribution device and is not intended as a conduit for conditioned air. The term fabric duct is therefore somewhat misleading; fabric air dispersion system would be the more definitive name. However, as it often replaces hard ductwork, it is easy to perceive it simply as a duct. Usually made of polyester material, fabric ducts can provide a more even distribution and blending of the conditioned air in a given space than a conventional duct system. They may also be manufactured with vents or orifices.

Fabric ducts are available in various colors, with options for silk screening or other forms of decoration, or in porous (air-permeable) and non-porous fabric. The determination which fabric is appropriate (i.e. air-permeable or not) can be made by considering if the application would require an insulated metal duct. If so, an air-permeable fabric is recommended because it will not commonly create condensation on its surface and can therefore be used where air is supplied below the dew point. Material that eliminates moisture may be healthier for the occupants. It can also be treated with an anti-microbial agent to inhibit bacterial growth. Porous material also tends to require less maintenance as it repels dust and other airborne contaminants.

Fabric made of more than 50% recycled material is also available, allowing it to be certified as green product. The material can also be fire retardant, which means that the fabric can still burn, but will extinguish when the heat source is removed.

Fabric ducts are not rated for use in ceilings or concealed attic spaces. However, products for use in raised floor applications are available. Fabric ducting usually weighs less than other conventional ducting and will therefore put less stress on the building's structure. The lower weight allows for easier installation.

Fabric ducts require a minimum of certain range of airflow and static pressure in order for it to work.

PVC low-profile ducting

PVC low-profile ducting has been developed as a cost-effective alternative to steel low-profile ducting. Low-profile ducting has been used extensively in apartment and hotel ventilation since 2005. The growth of low-profile ducting has grown significantly due to the reduction of available space in ceiling cavities in an effort to reduce cost. Since the Grenfell Tower fire in 2017 there has been a rise in the discovery of non-compliant building materials; many PVC low-profile ducting manufacturers have struggled to gain or maintain compliance, and some building projects have had to resort back to using the more expensive steel option.

Waterproofing

The finish for external ductwork exposed to the weather can be sheet steel coated with aluminium or an aluminium/zinc alloy, a multilayer laminate, a fibre reinforced polymer or other waterproof coating.

Duct system components

Besides the ducts themselves, complete ducting systems contain many other components.

Vibration isolators

An air handling unit with vibration isolator (3) Air handling unit.JPG
An air handling unit with vibration isolator (3)

A duct system often begins at an air handler. The blowers in the air handler can create substantial vibration, and the large area of the duct system would transmit this noise and vibration to the inhabitants of the building. To avoid this, vibration isolators (flexible sections) are normally inserted into the duct immediately before and after the air handler. The rubberized canvas-like material of these sections allows the air handler to vibrate without transmitting much vibration to the attached ducts. The same flexible section can reduce the noise that can occur when the blower engages and positive air pressure is introduced to the ductwork.

Take-offs

Downstream of the air handler, the supply air trunk duct will commonly fork, providing air to many individual air outlets such as diffusers, grilles, and registers. When the system is designed with a main duct branching into many subsidiary branch ducts, fittings called take-offs allow a small portion of the flow in the main duct to be diverted into each branch duct. Take-offs may be fitted into round or rectangular openings cut into the wall of the main duct. The take-off commonly has many small metal tabs that are then bent to attach the take-off to the main duct. Round versions are called spin-in fittings. Other take-off designs use a snap-in attachment method, sometimes coupled with an adhesive foam gasket for improved sealing. The outlet of the take-off then connects to the rectangular, oval, or round branch duct.

Stack boots and heads

Ducts, especially in homes, must often allow air to travel vertically within relatively thin walls. These vertical ducts are called stacks and are formed with either very wide and relatively thin rectangular sections or oval sections. At the bottom of the stack, a stack boot provides a transition from an ordinary large round or rectangular duct to the thin wall-mounted duct. At the top, a stack head can provide a transition back to ordinary ducting while a register head allows the transition to a wall-mounted air register.

Volume control dampers

An opposed-blade, motor-operated zone damper, shown in the "open" position. Zone Damper 1.jpg
An opposed-blade, motor-operated zone damper, shown in the "open" position.

Ducting systems must often provide a method of adjusting the volume of air flow to various parts of the system. Volume control dampers (VCDs; not to be confused with smoke/fire dampers) provide this function. Besides the regulation provided at the registers or diffusers that spread air into individual rooms, dampers can be fitted within the ducts themselves. These dampers may be manual or automatic. Zone dampers provide automatic control in simple systems while variable air volume (VAV) allows control in sophisticated systems.

Smoke and fire dampers

Smoke dampers and fire dampers are found in ductwork where the duct passes through a firewall or firecurtain.

Smoke dampers are driven by a motor, referred to as an actuator. A probe connected to the motor is installed in the run of the duct and detects smoke, either in the air which has been extracted from or is being supplied to a room, or elsewhere within the run of the duct. Once smoke is detected, the actuator will automatically close the smoke damper until it is manually re-opened.

Fire dampers can be found in the same places as smoke dampers, depending on the application of the area after the firewall. Unlike smoke dampers, they are not triggered by any electrical system (which is an advantage in case of an electrical failure where the smoke dampers would fail to close). Vertically mounted fire dampers are gravity operated, while horizontal fire dampers are spring powered. A fire damper's most important feature is a mechanical fusible link which is a piece of metal that will melt or break at a specified temperature. This allows the damper to close (either from gravity or spring power), effectively sealing the duct, containing the fire, and blocking the necessary air to burn.

Turning vanes

Turning vanes inside of large fire-resistance rated Durasteel pressurisation ductwork Turning vanes inside of large durasteel ductwork 06.png
Turning vanes inside of large fire-resistance rated Durasteel pressurisation ductwork
Turning vane close-up. Turning vanes inside of large durasteel ductwork 11.png
Turning vane close-up.

Turning vanes are installed inside of ductwork at changes of direction (e.g. at 90° turns) in order to minimize turbulence and resistance to the air flow. The vanes guide the air so it can follow the change of direction more easily.

Plenums

Plenums are the central distribution and collection units for an HVAC system. The return plenum carries the air from several large return grilles (vents) or bell mouths to a central air handler. The supply plenum directs air from the central unit to the rooms which the system is designed to heat or cool. They must be carefully planned in ventilation design.[ why? ]

Terminal units

While single-zone constant air volume systems typically do not have these, multi-zone systems often have terminal units in the branch ducts. Usually there is one terminal unit per thermal zone. Some types of terminal units are VAV boxes (single or dual duct), fan-powered mixing boxes (in parallel or series arrangement), and induction terminal units. Terminal units may also include a heating or cooling coil.

Air terminals

Air terminals are the supply air outlets and return or exhaust air inlets. For supply, diffusers are most common, but grilles, and for very small HVAC systems (such as in residences) registers are also used widely. Return or exhaust grilles are used primarily for appearance reasons, but some also incorporate an air filter and are known as filter returns. [3]

Duct cleaning

The position of the U.S. Environmental Protection Agency (EPA) is that "If no one in your household suffers from allergies or unexplained symptoms or illnesses and if, after a visual inspection of the inside of the ducts, you see no indication that your air ducts are contaminated with large deposits of dust or mold (no musty odor or visible mold growth), having your air ducts cleaned is probably unnecessary." [4]

A thorough duct cleaning done by a professional duct cleaner will remove dust, cobwebs, debris, pet hair, rodent hair and droppings, paper clips, calcium deposits, children's toys, and whatever else might collect inside. Ideally, the interior surface will be shiny and bright after cleaning. Insulated fiber glass duct liner and duct board can be cleaned with special non-metallic bristles. Fabric ducting can be washed or vacuumed using typical household appliances.

Signs and indicators

Cleaning of the duct system may be necessary if:

Commercial inspection

In commercial settings, regular inspection of ductwork is recommended by several standards. One standard recommends inspecting supply ducts every 1–2 years, return ducts every 1–2 years, and air handling units annually. [5] Another recommends visual inspection of internally lined ducts annually [6] Duct cleaning should be based on the results of those inspections.

Inspections are typically visual, looking for water damage or biological growth. [5] [6] [7] When visual inspection needs to be validated numerically, a vacuum test (VT) or deposit thickness test (DTT) can be performed. A duct with less than 0.75 mg/100m2 is considered to be clean, per the NADCA standard. [7] A Hong Kong standard lists surface deposit limits of 1g/m2 for supply and return ducts and 6g/m2 for exhaust ducts, or a maximum deposit thickness of 60 µm in supply and return ducts, and 180 µm for exhaust ducts. [8] In the UK, CIBSE standard TM26 recommends duct cleaning if measured bacterial content is more than 29 colony forming units (CFU) per 10 cm2; contamination is classified as "low" below 10 CFU/cm2, "medium" at up to 20 CFU/cm2, and "high" when measured above 20 CFU/cm2. [9]

Duct sealing

Air pressure combined with air duct leakage can lead to a loss of energy in a HVAC system. Sealing leaks in air ducts reduces air leakage, optimizes energy efficiency, and controls the entry of pollutants into the building. Before sealing ducts it is imperative to ensure the total external static pressure of the duct work, and if equipment will fall within the equipment manufacturer's specifications. If not, higher energy usage and reduced equipment performance may result.

Commonly available duct tape should not be used on air ducts (metal, fiberglass, or otherwise) that are intended for long-term use. The adhesive on so called duct tape dries and releases with time. A more common type of duct sealant is a water-based paste that is brushed or sometimes sprayed on the seams when the duct is built. Building codes and UL standards call for special fire-resistant tapes, often with foil backings and long lasting adhesives.

Automated technology exists that can seal a duct system in its entirety from the inside out using a patented process and specialized sealant. This method for duct sealing is often used in commercial construction and multi-unit residential construction. The cost associated with automated duct sealing often makes it impractical for the average homeowner to implement in their own house.

Signs of leaks

Signs of leaky or poorly performing air ducts include:

See also

Related Research Articles

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Heating, ventilation, and air conditioning (HVAC) is the use of various technologies to control the temperature, humidity, and purity of the air in an enclosed space. Its goal is to provide thermal comfort and acceptable indoor air quality. HVAC system design is a subdiscipline of mechanical engineering, based on the principles of thermodynamics, fluid mechanics, and heat transfer. "Refrigeration" is sometimes added to the field's abbreviation as HVAC&R or HVACR, or "ventilation" is dropped, as in HACR.

<span class="mw-page-title-main">Weatherization</span> Weatherproofing a building; protecting it from harsh weather

Weatherization or weatherproofing is the practice of protecting a building and its interior from the elements, particularly from sunlight, precipitation, and wind, and of modifying a building to reduce energy consumption and optimize energy efficiency.

<span class="mw-page-title-main">Recuperator</span>

A recuperator is a special purpose counter-flow energy recovery heat exchanger positioned within the supply and exhaust air streams of an air handling system, or in the exhaust gases of an industrial process, in order to recover the waste heat. Generally, they are used to extract heat from the exhaust and use it to preheat air entering the combustion system. In this way they use waste energy to heat the air, offsetting some of the fuel, and thereby improve the energy efficiency of the system as a whole.

A sound attenuator, or duct silencer, sound trap, or muffler, is a noise control acoustical treatment of Heating Ventilating and Air-Conditioning (HVAC) ductwork designed to reduce transmission of noise through the ductwork, either from equipment into occupied spaces in a building, or between occupied spaces.

<span class="mw-page-title-main">Damper (flow)</span> Valve or plate for regulating airflow inside a duct, chimney, vent, etc.

A damper is a valve or plate that stops or regulates the flow of air inside a duct, chimney, VAV box, air handler, or other air-handling equipment. A damper may be used to cut off central air conditioning to an unused room, or to regulate it for room-by-room temperature and climate control - for example, in the case of Volume Control Dampers. Its operation can be manual or automatic. Manual dampers are turned by a handle on the outside of a duct. Automatic dampers are used to regulate airflow constantly and are operated by electric or pneumatic motors, in turn controlled by a thermostat or building automation system. Automatic or motorized dampers may also be controlled by a solenoid, and the degree of air-flow calibrated, perhaps according to signals from the thermostat going to the actuator of the damper in order to modulate the flow of air-conditioned air in order to effect climate control.

<span class="mw-page-title-main">Air handler</span> Device used to regulate and circulate air as part of an HVAC system

An air handler, or air handling unit, is a device used to regulate and circulate air as part of a heating, ventilating, and air-conditioning (HVAC) system. An air handler is usually a large metal box containing a blower, furnace or A/C elements, filter racks or chambers, sound attenuators, and dampers. Air handlers usually connect to a ductwork ventilation system that distributes the conditioned air through the building and returns it to the AHU, sometimes exhausting air to the atmosphere and bringing in fresh air. Sometimes AHUs discharge (supply) and admit (return) air directly to and from the space served without ductwork

<span class="mw-page-title-main">Variable air volume</span> Heating or air-conditioning system

Variable air volume (VAV) is a type of heating, ventilating, and/or air-conditioning (HVAC) system. Unlike constant air volume (CAV) systems, which supply a constant airflow at a variable temperature, VAV systems vary the airflow at a constant or varying temperature. The advantages of VAV systems over constant-volume systems include more precise temperature control, reduced compressor wear, lower energy consumption by system fans, less fan noise, and additional passive dehumidification.

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<span class="mw-page-title-main">Pressurisation ductwork</span>

Pressurisation ductwork is a passive fire protection system. It is used to supply fresh air to any area of refuge, designated emergency evacuation or egress route.

<span class="mw-page-title-main">Smoke exhaust ductwork</span>

Smoke exhaust ductwork, in Europe, is typically protected via passive fire protection means, subject to fire testing and listing and approval use and compliance. It is used to remove smoke from buildings, ships or offshore structures to enable emergency evacuation as well as improved firefighting. In North America, fireproofed ductwork may be used for the purpose of smoke exhaust, but it is more common to use unfireproofed return air ductwork, whereby no fire testing or listings are employed to qualify the ductwork for this use.

<span class="mw-page-title-main">Grease duct</span>

A grease duct is a duct that vents grease-laden flammable vapors from commercial cooking equipment such as stoves, deep fryers, and woks to the outside of a building or mobile food preparation trailer. Grease ducts are part of the building's passive fire protection system. The cleaning schedule is typically dictated by fire code or related safety regulations.

<span class="mw-page-title-main">Air sock</span> Ventilation unit

An air sock is a textile or fabric duct used for draught-free air distribution and delivery of conditioned air as an alternative to traditional spiral or rectangular steel ducts with grilles and diffusers. Fabric ducts are usually cheaper in material cost by no use of additional diffusers, and quicker to install than conventional metal systems.

<span class="mw-page-title-main">Fire damper</span> Type of passive fire protection

Fire dampers are passive fire protection products used in heating, ventilation, and air conditioning (HVAC) ducts to prevent and isolate the spread of fire inside the ductwork through fire-resistance rated walls and floors. Fire/smoke dampers are similar to fire dampers in fire resistance rating, and also prevent the spread of smoke inside the ducts. When a rise in temperature occurs, the fire damper closes, usually activated by a thermal element which melts at temperatures higher than ambient but low enough to indicate the presence of a fire, allowing springs to close the damper blades. Fire dampers can also close following receipt of an electrical signal from a fire alarm system utilising detectors remote from the damper, indicating the sensing of heat or smoke in the building occupied spaces or in the HVAC duct system.

HVAC is a major sub discipline of mechanical engineering. The goal of HVAC design is to balance indoor environmental comfort with other factors such as installation cost, ease of maintenance, and energy efficiency. The discipline of HVAC includes a large number of specialized terms and acronyms, many of which are summarized in this glossary.

Smoke dampers are passive fire protection products used in air conditioning and ventilation ductwork or installed in physical smoke barriers.

<span class="mw-page-title-main">Duct leakage testing</span>

A duct leakage tester is a diagnostic tool designed to measure the airtightness of forced air heating, ventilating and air-conditioning (HVAC) ductwork. A duct leakage tester consists of a calibrated fan for measuring an air flow rate and a pressure sensing device to measure the pressure created by the fan flow. The combination of pressure and fan flow measurements are used to determine the ductwork airtightness. The airtightness of ductwork is useful knowledge when trying to improve energy conservation.

Airflow, or air flow, is the movement of air. The primary cause of airflow is the existence of air. Air behaves in a fluid manner, meaning particles naturally flow from areas of higher pressure to those where the pressure is lower. Atmospheric air pressure is directly related to altitude, temperature, and composition.

<span class="mw-page-title-main">Air-mixing plenum</span>

In building services engineering and HVAC, an air-mixing plenum is used for mixing air from different ductwork systems.

<span class="mw-page-title-main">Register (air and heating)</span>

A register is a grille with moving parts, capable of being opened and closed and the air flow directed, which is part of a building's heating, ventilation, and air conditioning (HVAC) system. The placement and size of registers is critical to HVAC efficiency. Register dampers are also important, and can serve a safety function.

Ductwork airtightness can be defined as the resistance to inward or outward air leakage through the ductwork envelope. This air leakage is driven by differential pressures across the ductwork envelope due to the combined effects of stack and fan operation.

References

[11]

  1. The Fundamentals volume of the ASHRAE Handbook , ASHRAE, Inc., Atlanta, GA, USA, 2005
  2. HVAC Systems – Duct Design, 3rd Ed., SMACNA, 1990
  3. Designer's Guide to Ceiling-Based Room Air Diffusion, Rock and Zhu, ASHRAE, Inc., Atlanta, GA, USA, 2002
  4. US EPA, OAR (2014-07-28). "Should You Have the Air Ducts in Your Home Cleaned?". www.epa.gov. Retrieved 2022-11-23.
  5. 1 2 NADCA (2013). "ACR, The NADCA Standard for Assessment Cleaning Restoration of HVAC Systems" (PDF). National Air Duct Cleaners Association. Archived from the original (PDF) on 11 February 2015. Retrieved 16 June 2014.
  6. 1 2 ANSI/ASHRAE/ACCA (2012). "Standard 180 Standard Practice for Inspection and Maintenance of Commercial Building HVAC Systems". American Society of Heating Ventilation and Air Conditioning Engineers. Retrieved 16 June 2014.
  7. 1 2 Willis, Steve. "Verifying System Cleanliness: A Guide for Commissioning Providers" (PDF). www.commissioning.org. American Commissioning Group (ACG). Retrieved 16 June 2014.
  8. AIIB/ACRA/BSOMES/HKBCxC (2004), A Management Practice Guidance Note on Air Duct Cleaning for Hong Kong, Asian Institute of Intelligent Buildings
  9. Chartered Institute of Building Service Engineers (October 2000), TM 26: Hygiene Maintenance of Office Ventilation Ductwork
  10. Ductwork sealing article at Energy Star
  11. Types of flexible ducting

Further reading