Low pressure ≤ 0.

82Pa/equivalent meter of duct run

(0.1 in. wc/ 100ft of duct run)

- Duct Velocity Criteria

Low Pressure ≤ 7.62 m/s (1500 FPM) for supply duct
≤ 7.62 m/s (1500 FPM) return duct and exhaust
duct (For normal duty)
≤ 5.08 m/s (1000 FPM) for intake or return air
shaft
Louver design Criteria
Velocity across face area ≤ 400FPM (Normal Mode Operation)

2.2 DUCT WORK MATERIAL

A. All ductwork shall be manufactured from strip mill, cold rolled sheet,
continuously hot dip galvanized. The minimum weight of zinc coating (total on
both sides) shall be 120g/m2. All ducting shall be factory machine fabricated
and fabrication at site will not be acceptable. Ducting up to 600 mm shall be
delivered in Box form and above 600 mm size duct shall be delivered in
preformed 'L' shaped in two halves.
B. The minimum gauge and thickness of sheet metal shall not be less than that
given in SMACNA or as given in the table below, whichever is more stringent.
C. Kitchen extract duct work shall be air and watertight welded construction
manufactured from 16 g black steel sheets in accordance with BS 1449, Part 1
Grade CR4 GP. Ductwork shall be painted on the outside with two coats of heat
resistant galvanic paint after manufacture. Kitchen extract ductwork passing
through accessible shafts, false ceiling voids and enclosed spaces shall be
insulated with 2” thick mineral wool insulation for personnel protection and to
avoid heat pick up by return air.
C. All air ducts, casings, plenums etc., shall be constructed of lock forming quality
prime galvanized steel sheets, which are free from blisters, slivers, pits,
imperfectly coated spots etc. No second quality sheet metal allowed.

Engineering, Procurement and Construction Page 198 of 334

of the Airport at Navi Mumbai

Sensitivity: LNT Construction Proprietary

 D. Where damage (or rusting) has occurred on galvanized ductwork, the affected
section shall be made good by painting with two coats of zinc‐rich paint and
approved finishing paint, or where the damage in EMPLOYER’s opinion cannot
be made good, then a new section of ductwork shall be provided at no cost to
the contract.
2.2.1 Fire Rated Ducts

General

All smoke management system ducts and life safety ducts which are outside of fire rated
enclosure shall be fire rated.
1. Fire rated ductwork constructed for smoke extract systems to be tested to UL
and BS476 Part 24 (1987) for two hours stability and two hours integrity and
two hour fire insulation (120/120/120) duct systems for both fire inside(Type B
test) and fire outside (Type A test) . Duct to maintain a minimum of 75% cross‐
sectional area along its whole length when tested for two hours.

2. Duct also to be tested / assessed to BS476 Part 24 for all sizes up to 10 m x 3

m cross‐sectional area.

3. The fire rated material used for fire rated ductwork shall be tested properties
as per the requirements of BS 476 Part 6&7, including non – combustibility, fire
propagation, Class one surface spread of flame.

4. All fire rated ductwork to be GI duct, constructed to tested standard and coated
with fire rated material. The duct to be composite fire duct manufactured to
Method 3 of BS 5588 Part 9, factory produced. The material coating shall be
applied either offsite or onsite on the ground, dried and cured prior to erection.
Once erected, to be pressure tested, if required by EMPLOYER in line with the
pressure classification of the duct being installed.

5. The fire duct support system should be located at a maximum of 1500mm

centres, the size of the hangers and bearers upgraded to account for reduction
in tensile strength of steel, due to a two hour fire from 430 N/mm² to 10 N/mm²
Proof that suitable size hangers and bearers are being used to be submitted.

6. All gaskets and sealants to be non‐combustible and installed as fire tested.

7. The fire coating to be non‐hydroscopic and have been tested with exposure to
UV and condensation cycling, with no adverse effect on the life of fire rating of
the duct for at least 30years.

8. The fire rated duct shall be connected to the fans with the use of fire rated
flexible connections. Flexible connectors shall be made of glass fabric, coated
Engineering, Procurement and Construction Page 199 of 334
of the Airport at Navi Mumbai

Sensitivity: LNT Construction Proprietary

 on both sides with flame retardant silver grey polyurethane rubber, tested to
BS476 Part 20.

9. All access doors/inspection coves and test holes shall be suitably positioned in
relation to the access provided by the false ceiling or other means of
concealment supplied & fitted by the Contractor.

10. All fire rated ductwork must be manufactured and erected in line with the tested
and assessed Certification to BS476 Part 24 and ISO6944.

11. Fire rated ductwork to have passed impact test to BS5669 and Appendix A of
BS5588 Part5.

12. In addition to the above, all fire rated ductwork shall be subject to approval by
the local Fire Dept.

13. Upon part or full installation of Fire Rated Duct the local licence shall issue a
Certificate of Conformance after satisfactory inspection.

14. All openings in walls where ducts cross compartments shall be fire rated for
120 minutes Material The following fire rated system shall specifications
conformance. generally be acceptable subject to

• Gypsum based vermiculite based coating ‐ by LAF/durasteel/Promztect

• Calcium silicate board with mineral wool ‐ by Promat
• Flame bar BW11 material ‐ by Fire spray International Ltd.

Engineering, Procurement and Construction Page 200 of 334

of the Airport at Navi Mumbai

Sensitivity: LNT Construction Proprietary

 2.3 DUCT SUPPORTS

A. Horizontal ducts shall be supported from ceilings by means of trapeze type

supports consisting of GI angle / flat extending 5 cm longer than the duct width on
either side. The structural member shall be hung from the ceiling by means of two
round steel rod hangers with threaded ends bolted through the member with nuts
and washers. The rods shall be attached to the ceiling by means of masonry
expansion bolts. Supports shall not be attached to the ducts by means of sheet
metal screws. Sizes of structural members & rods shall be as indicated in SMACNA
or as indicated in the table below, whichever is more stringent.
B. Vertical ducts shall be supported from the floor or side walls by means of 5 cm x 5
cm x 5 mm thick angle iron riveted/bolted to the ducts and extended to rest on the
floor without loose blocking or shimming, or on similar angles cast in the wall. The
angles shall not be attached to the ducts with sheet metal screws.
C. All duct supports taken by welding / jointing to roof structural formwork (eg: at levels
3 &4) shall be finish painted to the satisfaction of Contractor /EMPLOYER.
D. For duct supports, refer typical installation detail drawings.

DUCT SUPPORT DETAILS

Duct Support Size of GI angle GI Threaded
Rod diameter
perimeter span (m) (mm)
(mm)
(mm)

Engineering, Procurement and Construction Page 201 of 334

of the Airport at Navi Mumbai

Sensitivity: LNT Construction Proprietary

 Upto 750 3.0 25 x 25 x 3 8
751-3600 2.4 40 x 40 x 5 10
3601-4800 2.4 50 x 50 x 6 10
4801-6000 1.5 50 x 50 x 6 12.5
6001-9750 1.5 80 x 80 x 6/ 12.5
65 x30 channel

2.4 LOW PRESSURE DUCTWORK

A. All AHU return ducting, AHU supply ducting after VAV boxes, exhaust air
ducting, ventilation ducting, Life safety systems ducting are classified as low
pressure ducting.
B. This ductwork shall generally have mean velocities less than 10 m/s and static
pressures of 500 Pa or less.
1. Low pressure suction and discharge plenum chambers shall be
fabricated from 1.3 mm galvanized steel with galvanized angle iron
framework and bracing.
2. In square elbows and in elbows where the radius is less than 1.5 times
the width of duct, sheet metal deflector vanes shall be installed the full
height of the duct, being securely riveted in place. All vanes shall be
double thickness vanes of two gauges heavier than the duct in which
they are installed, and shall be factory made, not site fabricated. Vanes
shall be tack welded to vane rail. For vane lengths over 1000 mm, tack
weld vanes to 10 mm tie‐rod at mid‐span.

2.5 SEISMIC RETRAINTS FOR DUCTWORK

All ducts supports shall be suitable for meeting the requirements of zone 3
seismic criteria. Bracing details and spacing with calculations from specialist
vendors shall be submitted for approval.

PAER 3 – EXECUTION

3.1 DUCTWORK FABRICATION AND INSTALLATION

A. Ductwork fabrication and hanging methods shall be as described in
Engineering, Procurement and Construction Page 202 of 334
of the Airport at Navi Mumbai

Sensitivity: LNT Construction Proprietary

 current edition of applicable manuals published by the SMACNA. Duct
work fabrication, jointing method & brazing / stiffeners shall be as per
SMACNA standards or as approved in duct installation chart, whichever
is more stringent must follow by contractor.
B. All dimensions shall be checked on site commenced.
C. No ductwork shall touch the building structure or building finishes direct,
but shall be isolated with insulating spacer.
D. Security grille shall be provided within all ducts which cross the primary
security line and along the dividing line between air side and land side
and as shown on layout drawings
E. The fabrication shall be carried out in a neat and workmanlike manner
with all ductwork true in size and cross‐section, braced and stiffened as
specified and with all internal and external surfaces free from projections
and sharp edges. No sheet metal screws shall be used in the erection or
construction of ductwork.
F. At each main branch in ductwork and at each fan discharge or suction, provide
sufficient number of Pitot tube holes for balancing systems. Also, provide test
holes for traverse fan discharge and at all equipment. Test holes shall be
located within easy reach of ladder. Each test hole shall have 20 mm clear
opening, provided with a metal ring place with a threaded hole in the boss, and
matching screwed head plug. Where these plugs are installed in insulated
ductwork, provide an extension collar against which the insulation can be
finished.
G. Ductwork shall be rigidly suspended or supported from building structure. Duct
supports shall be installed on the outside of ducts. No duct hanger rod or
support shall be allowed to pierce or go through the duct. All supports shall be
hot dip galvanized. Ducts, casing, plenums and hangers shall be installed
straight, plumb and level.
H. Increase in duct size shall be gradual with a 1:4 to 1:7 slope. Where width or
largest dimension of a duct is over 450 mm, duct shall be stiffened by bending
in a break across corners in both directions. Visible internal portions of duct
Engineering, Procurement and Construction Page 203 of 334
of the Airport at Navi Mumbai

Sensitivity: LNT Construction Proprietary

 outlets to grilles and registers shall be painted in matt black.
I. During installation, the open ends of ducts shall be protected with thick
polythene sheets, securely attached to prevent debris and dirt from entering.
Adequate space shall be provided around ducts to ensure proper installation
supports and duct insulation.
J Where ducts are shown connecting to masonry openings and/or along the
edges of all plenums at floors, walls, etc., provide a continuous 30 x 30 x 4 mm
galvanized angle iron which shall be bolted to the structure and made airtight
to same by applying caulking compound on the angles before they are drawn
down tight. The sheet metal at these locations shall be bolted to the angle iron
framing.
K. Duct shall be constructed using double or Pittsburgh lock corner seams. All
seams shall be hammered down and made airtight by applying sealant before
hammering down.
L. Each piece of duct work shall be wiped inside and out before installation and
all open ends shall be capped and sealed to prevent entrance of dirt during
construction. Ensure that ductwork systems are clean and free from dirt, dust,
.grime, debris etc., before initial operation of fans. Fans shall not be operated
until the filters are installed and approval from the EMPLOYER has been
obtained.
M. All fixing devices including nuts, bolts, washers etc., used in the construction
or support of galvanized ductwork shall be radised, or cadmium‐plated.
N. Final connections to diffusers shall be carried out using flexible ductwork or
solid spigots as detailed elsewhere.
O. All duct joints shall be sealed using water based duct sealant.

3.2 CO-ORDINATION
A. Coordinate equipment location and placement details with architectural, civil,
mechanical and electrical works to prevent interferences.
B. Installation shall be done in liaison with other agencies /contractors involved in
construction of the building and related services (Building/Substation

Engineering, Procurement and Construction Page 204 of 334

of the Airport at Navi Mumbai

Sensitivity: LNT Construction Proprietary

 Automation system) of this project for the fixing of inserts and forming
equipment supports.

3.3 INSTALLATION
A. Requirements of reference standards and manufacturer's instructions shall be
complied with in all respects.
B. Arrange installation of units to provide access space around equipment for
service and maintenance.
C. Units shall be installed in such a way that allows unrestrained movement of the
assembly (for vibration isolation purposes).

3.4 FIELD QUALITY CONTROL

Begin testing, adjusting, and balancing only when the air supply and
distribution, including controls, has been completed, with the exception of
performance tests.

3.5 COMMISSIONING
Upon commissioning and final hand over of the installation, the vendor /
contractor shall submit operating Instructions, maintenance and service
manuals, part lists and all final drawings and diagrams.

Engineering, Procurement and Construction Page 205 of 334

of the Airport at Navi Mumbai

Sensitivity: LNT Construction Proprietary