1.

9 HVAC Duct Construction Standards MetaI and FIexibIe Second Edition

TABLE 1-2
STANDARD DUCT SEALING REQUIREMENTS
SEAL CLASS SeaIing Requirements
AppIicabIe Static Pressure
Construction CIass
A
Class A: All Transverse joints,
longitudinal seams, and duct
wall penetrations
4 wg and up (1000 Pa)
B
Class B: All Transverse joints
and longitudinal seams only
3 wg (750 Pa)
C Class C: Transverse joints only 2 wg (500 Pa)
ln addition to the above, any variable air volume system duct of 1 (250 Pa) and 1/2 wg (125 Pa)
construction class that is upstream of the VAV boxes shall meet Seal Class C.
field-erected plenums and casings through
which air leakage would occur or the use of
continuous welds.
b. the prudent selection and application of seal-
ing methods by fabricators and installers,
giving due consideration to the designated
pressure class, pressure mode (positive or
negative), chemical compatibility of the clo-
sure system, potential movement of mating
parts, workmanship, amount and type of
handling, cleanliness of surfaces, product
shelf life, curing time, and manufacturer-
identified exposure limitations.
c. that these provisions apply to duct connec-
tions to equipment and to apparatus but are
not for equipment and apparatus.
d. that where distinctions are made between
seams and joints, a seam is defined as joining
of two longitudinally (in the direction of air-
flow) oriented edges of duct surface material
occurring between two joints. Helical (spi-
ral) lock seams are exempt from sealant re-
quirements. All other duct wall connections
are deemed to be joints. Joints include but
are not limited to girth joints, branch and
subbranch intersections, so-called duct col-
lar tap-ins, fitting subsections, louver and air
terminal connections to ducts, access door
and access panel frames and jambs, and duct,
plenum, and casing abutments to building
structures.
e. unless otherwise specified by the designer,
that sealing requirements do not contain pro-
visions to:
1. resist chemical attack;
2. be dielectrically isolated;
3. be waterproof, weatherproof, or ultra-
violet ray resistant;
4. withstand temperatures higher than
120F (48C) or lower than 40F
(4.4C);
5. contain atomic radiation or serve in oth-
er safety-related construction;
6. be electrically grounded;
7. maintain leakage integrity at pressures
in excess of their duct classification;
8. be underground below the water table;
9. be submerged in liquid;
10. withstand continuous vibration visible
to the naked eye;
11. be totally leakfree within an encapsulat-
ing vapor barrier; and
12. create closure in portions of the building
structure used as ducts, such as ceiling
plenums, shafts, or pressurized compart-
ments;
1.10 HVAC Duct Construction Standards MetaI and FIexibIe Second Edition
f. the requirements to seal apply to both posi-
tive and negative pressure modes of opera-
tion.
g. externally insulated ducts located outside of
buildings shall be sealed before being insu-
lated, as though they were inside. If air leak
sites in ducts located outside of buildings are
exposed to weather, they shall receive exte-
rior duct sealant. An exterior duct sealant is
defined as a sealant that is marketed specifi-
cally as forming a positive air-and watertight
seal, bonding well to the metal involved, re-
maining flexible with metal movement, and
having a service temperature range of
30F (34C) to 175F (79C). If exposed
to direct sunlight, it shall also be ultraviolet
ray-and ozone-resistant or shall, after curing,
be painted with a compatible coating that
provides such resistance. The term sealant is
not limited to adhesives or mastics but in-
cludes tapes and combinations of open-
weave fabric or absorbent strips and mastics.
1.7 DUCT SEALING COMMENTARY
Ducts must be sufficiently airtight to ensure economi-
cal and quiet performance of the system. It must be
recognized that airtightness in ducts cannot, and need
not, be absolute (as it must be in a water piping sys-
tem). Codes normally require that ducts be reasonably
airtight. Concerns for energy conservation, humidity
control, space temperature control, room air move-
ment, ventilation, maintenance, etc., necessitate reg-
ulating leakage by prescriptive measures in construc-
tion standards. Leakage is largely a function of static
pressure and the amount of leakage in a system is sig-
nificantly related to system size. Adequate airtight-
ness can normally be ensured by a) selecting a static
pressure, construction class suitable for the operating
condition, and b) sealing the ductwork properly.
The designer is responsible for determining the pres-
sure class or classes required for duct construction and
for evaluating the amount of sealing necessary to
achieve system performance objectives. It is recom-
mended that all duct constructed for the 1 (250 Pa)
and 1/2 (125 Pa) pressure class meet Seal Class C.
However, because designers sometimes deem leak-
age in unsealed ducts not to have adverse effects, the
sealing of all ducts in the 1 (250 Pa) and 1/2 (125
Pa) pressure class is not required by this construction
manual. Designers occasionally exempt the following
from sealing requirements: small systems, residential
occupancies, ducts located directly in the zones they
serve, ducts that have short runs from volume control
boxes to diffusers, certain return air ceiling plenum
applications, etc.. When Seal Class C is to apply to
all 1 (250 Pa) and 1/2 (125 Pa) pressure class duct,
the designer must require this in the project specifica-
tion. The designer should review the HVAC Air Duct
Leakage Test Manual for estimated and practical
leakage allowances.
Seven pressure classes exist [1/2 (125 Pa), 1 (250
Pa), 2 (500 Pa), 3 (750 Pa), 4 (1000 Pa), 6 (1500
Pa) and 10 (2500 Pa) wg]. If the designer does not
designate pressure class for duct construction on the
contract drawings, the basis of compliance with the
SMACNA HVAC Duct Construction Standards is as
follows: 2 (500 Pa) wg for all ducts between the sup-
ply fan and variable volume control boxes and 1 (250
Pa) wg for all other ducts of any application.
Some sealants can adversely affect the release func-
tion of breakaway connections to fire dampers; con-
sult the damper manufacturer for installation restric-
tions.
1.7.1 Leakage Tests
There is no need to verify leakage control by field
testing when adequate methods of assembly and seal-
ing are used. Leakage tests are an added expense in
system installation. It is not recommended that duct
systems constructed to 3 (750 Pa) wg class or lower
be tested because this is generally not cost effective.
For duct systems constructed to 4 (1000 Pa) wg class
and higher, the designer must determine if any justifi-
cation for testing exists. If it does, the contract docu-
ments must clearly designate the portions of the sys-
tem(s) to be tested and the appropriate test methods.
ASHRAE energy conservation standards series 90
text on leakage control generally requires tests only
for pressures in excess of 3 (750 Pa).
The HVAC Duct Leakage Test Manual provides prac-
tical and detailed procedures for conducting leakage
tests.
Apparent differences of about ten percent between
fan delivery and sum of airflow measurements at ter-
minals do not necessarily mean poor sealing and ex-
cess leakage. Potential accuracy of flow measure-
ments should be evaluated.
Otherwise, open access doors, unmade connections,
missing end caps, or other oversights contribute to
such discrepancies. When air terminals are at great
distances from fans (over 500 feet (152m)), more ef-
fective sealing is probably required to avoid dimin-
ished system performance.