RAS LAFFAN EMERGENCY AND

SAFETY COLLEGE

Sheet
Contract No. GC071018B0 Document No. 2676-KRAN-1700 Rev.1
1 of 16

METHOD STATEMENT FOR INSTALLATION OF GI

DUCTS, FAN COIL UNITS, AIR HANDLING UNITS
EXHAUST FANS & SUPPORT HANGERS
RAS LAFFAN EMERGENCY AND SAFETY COLLEGE

DOC. NO: 2676-KRAN-1700 Rev.1

13.03.2011 1 Issued for Approval KB NV SS

06.02.2011 0 Issued for Approval KB NV SS

Prepared Checked Approved SEG/BCEC QP

Date Rev Description of the revision
by by by (JV) Approval Approval
CONTRACT NO. GC071018B0 DOC. NO. 2676-KRAN-1700 Rev. 1 Page 2 of 16

Table Of contents

Table Of contents 2

1. General 3

2. Organization, Responsibility & Supervision 3

3. Scope 3

4. Purpose 4

5. Application 4

6. Material 4

7. Plant and Equipment 4

8. Method 5

9. Installation: 7

10. Inspection: 14

11. Health & Safety: 15

12. Quality Assurance 16

CONTRACT NO. GC071018B0 DOC. NO. 2676-KRAN-1700 Rev. 1 Page 3 of 16

1. General
Title: Method Statement for Installation of GI Ducts, Fan Coil Units, Air Handling Units, Make-
up Air Units, Exhaust Fans and Support Hangers

Reference Documents:
Building services mechanical specifications (2676-5-14-2002, Rev-2)

2. Organization, Responsibility & Supervision

 Project Manager – is responsible for the overall management of the work and
control of the staff in executing the work.
 Site Engineer and Supervisor for Mechanical – shall be responsible for all site
activities and closed supervision for the installation of GI Ducts, Fan Coil Units, Air
Handling Units, and Exhaust Fans & Support Hangers.
 A competent QC Engineer – shall be responsible for checking and inspecting the
execution of the work in accordance with the latest approved shop drawings.
 Safety Engineer – is in-charge of all safety and health matter of all workers for the
job.
 Skilled Workers – will be leading the workers for any related works for the
installation of GI Ducts, Fan Coil Units, Air Handling Units, and Exhaust Fans &
Support Hangers.
 General Workers – assisting all works that covers for any related works for the
installation of GI Ducts, Fan Coil Units, Air Handling Units, and Exhaust Fans &
Support Hangers.
 Storekeeper – will be responsible in receiving and issuing of materials including
documentations.

3. Scope
 This method statement applies to installation of HVAC Supply, Return and Exhaust
ducts, Fan Coil Units, Air Handling Units, Exhaust Fans, Dampers, Fire Dampers
and Access Doors. The fire rated duct and accessories method statements will be
separately submitted.
CONTRACT NO. GC071018B0 DOC. NO. 2676-KRAN-1700 Rev. 1 Page 4 of 16

4. Purpose
 The purpose of this method statement is to outline the method of storage and
installation of HVAC supply, return and exhaust ducts including fixing of Fan Coil
Units, Air Handling Units, Exhaust Fans, Dampers, Fire Dampers, Access Doors
and necessary support hangers.

5. Application
 G.I. Sheet metal ducts are used for Supply, Return & exhaust ducting associated
with necessary supports.

6. Material
 Pre-fabricated ducts made of G.I. Sheet.
 Flanges and cleats for joining the G.I. ducts are factory fabricated of G.I. Sheet
steel as per SMACNA HVAC construction standards.
 Threaded rods, G.I. angles, etc., for supporting system.
 Duct sealant, Gaskets & Adhesives.
 Fan Coil Units, Air Handling Units, Exhaust Fans, VCDs, Fire dampers and Access
doors as per approved submittals.

7. Plant and Equipment

The following equipment’s and tools are required to perform works:

Items Equipment No’s Purpose

For Shifting FCU and MAU to its respective
1 Hydraulic Trolley 2
place
For drilling holes or driving of anchor bolts/
2 Hammer Drilling Machine 2 rods for hangers and supports for FCU, AHU,
MAU and Ducts.
3 Hand Drilling Machine 3 For AHU Assembly.
For AHU Assembly and Duct accessories
4 Pop Revert Gun 3
installation.
To seal the AHU Panels and Ducts joints to
5 Sealant Gun 4
avoid leakage
6 Chain Pulley 5ton capacity 1 For lifting MAU
7 Spanner set Box 2 set For adjusting and tightening
8 Align key set 1set For open the hexagonal type screws.
9 Scaffoldings set 4set Lifting usage
CONTRACT NO. GC071018B0 DOC. NO. 2676-KRAN-1700 Rev. 1 Page 5 of 16

8. Method

STORAGE
 When off-loading, the ducts shall be carefully lowered to ensure no damage to
edges or duct surface.
 All ducts shall be stored properly to safeguard ducts from any abrasions and
damages.
 All delivered ducts will be stacked and covered by polythene sheets to protect from
dust etc.
 Duct sealant, adhesive, gaskets, etc., shall be stored in enclosed area as per
manufacturer’s recommendations.
 On arrival at site Fan Coil Units, Air Handling Units, Exhaust Fans, VCDs and Fire
dampers shall be checked for quantities, type and model number, physical
damages, etc., and notify supplier of any discrepancies.
 Upon satisfactory inspection, the equipment’s shall be stored properly with
protective covering.
 Any items found damaged or not suitable as per the project requirements shall be
removed from site. Until such time, the damaged/non-compliant material shall be
clearly marked and stored separately to prevent any inadvertent use.

PREPARATION

 G.I. Ducting
 Check and ensure all drawings used for installation are latest and approved for
construction
 Ducts are pre-fabricated and longitudinally pre-assembled to a maximum length of
1.2m at the workshop as per the construction schedule. Preparation/formation of
flanges for transverse joints is made at workshop.
 Ducts received at site as above shall be joined together on the floor, to form
manageable lengths.
CONTRACT NO. GC071018B0 DOC. NO. 2676-KRAN-1700 Rev. 1 Page 6 of 16

 Wherever branch take-off collars are to be fixed, suitable cut out shall be made in
the ducts. The size of cut out shall be equal to the duct cross sectional area and
secured using aluminum pop rivets and the joint between collar flange and duct
surface shall be sealed with approved duct sealant.
 Wherever flexible ducts are to be fixed, a suitable diameter prefabricated collar
shall be fixed to the main duct-using dovetail joining system. A sample of the same
will be made at site for approval prior to proceeding with installation.

AIR HANDLING UNITS

 Check and ensure all drawings used for installation are latest and approved for
construction
 Check the AHUs foundation and ensure it is as per approved drawings.
 Check the area around the foundation and ensure access to the AHUs from all
sides as applicable.
 Ensure availability of sufficient slope to the drain pipe, for easy draining of
condensate drain.
 Check the foundation surface and it shall be smooth finish to avoid any dust
accumulation.
 The foundation surface shall be even in all directions.
 The foundation surface shall be cleaned before installation of AHUs.
 Mark the AHUs position on the foundation for centralization.
 Place the anti-vibration ribbed rubber pads of correct thickness as per approved
drawings/submittals.
 In case of multiple rubber pads the pads shall be placed one above the other with
the ribs at right angle to each other.
 AHU sections are assembled at site/location by factory trained personal.
CONTRACT NO. GC071018B0 DOC. NO. 2676-KRAN-1700 Rev. 1 Page 7 of 16

FAN COIL UNIT

 Check and ensure all drawings used for installation are latest and approved for
construction
 Mark the support locations as per approved drawings/manufacturers details and fix
the approved anchor fasteners in the slab.
 Fix the duct flexible connection on air outlet side of the Fan Coil Units.
 Ensure ducting is provided with acoustic lining as per approved shop drawings.
 Check co-ordination with false ceiling and other services prior to installation.
 Ensure easy accesses and sufficient clearance for servicing and maintenance i.e.
for cleaning of filters, removal of motors and maintenance of valve packages.

EXHAUST FANS

 Check and ensure all drawings used for installation are latest and approved for
construction.
 Mark the support locations as per approved drawings/manufacturers details and fix
the approved anchor fasteners in the slab.
 Ensure easy access and sufficient clearance for maintenance and removal of
motors.
 Comply with Manufacturer’s instruction as applicable.

9. Installation:

GI DUCTING
 The layout of duct to be installed shall be as per approved drawing.
 Position of duct supports shall be marked on the underside of the slab / structural
member/vertical walls as the case may be and mechanical anchor fasteners shall
be installed in slab or suitable clamps shall be installed if support to be taken from
structural member, to facilitate suspension of threaded rods for duct trapeze
CONTRACT NO. GC071018B0 DOC. NO. 2676-KRAN-1700 Rev. 1 Page 8 of 16

support. The support details and spacing shall be as per the SMACNA / approved
drawings for G.I. Ducts.
 Threaded rod of suitable size as per SMACNA shall be fixed to the mechanical
anchor fastener / clamps using proper lock nut.
 G.I. angle, cut to require size of duct (to have clearance of 50mm on either side)
shall be fixed to the threaded rod suspension and locked in position by suitable zinc
coated nuts and washers.
 Assembled, as above, ducts shall be lifted through scaffoldings and rope if required
and shall be installed on trapee.
 Similarly the next length of duct shall be erected and two are joined together by
means of suitable cleats, zinc coated bolts, nuts, washers, gaskets, etc., as
applicable as per the construction schedules for G.I ducts. Care shall be taken to
seal the corners and transverse joints with approved duct sealant.
 On laying the ducts as detailed above to form the required layout, the ducts shall
be properly aligned and levelled to maintain B.O.D. and distances as per approved
drawing.
 Riser / Shaft Ducts: Necessary scaffolding arrangement to suit site conditions shall
be made. Duct supports shall be taken at each floor / vertical wall as the case may
be and shall be as per approved drawings. Successive ducts shall be installed
starting from low level as the successive higher floors are constructed. The open
end of the upper most ducts shall be sealed properly.
 The insulation of the flexible ducts shall be rolled up to 100mm from the edges and
the flexible duct shall be slipped on to the collar fixed on the main duct and shall be
secured firmly using G.I. Straps and clips. Then the insulation of flexible duct shall
be rolled back and fixed firmly on to spigots and adjoining duct surface and finished
with self-adhesive aluminium foil tape.
 Flexible ducts installed as above shall be supported using 25mm G.I. strip wound
around the duct and suspended from slab if the flexible duct length exceeds 1.5
meter.
 Suitable plenum box as applicable shall be connected to main duct through pre-
insulated flexible ducts. These diffuser plenums shall be prefabricated as detailed
CONTRACT NO. GC071018B0 DOC. NO. 2676-KRAN-1700 Rev. 1 Page 9 of 16

above, connection through round collars fixed to plenum. Diffuser plenum boxes
shall be suspended from underside of slab using central hanger made of
galvanized threaded rod fixed to mechanical anchor fastener and secured using
zinc coated nuts and washers. The single rod suspension shall be limited to
square diffuser plenums of size up to 300mm and multiple suspensions shall be
 provided for higher size. For slot diffuser plenum boxes suspension rod shall be
provided on center of two shorter sides of the plenum.
 Manual volume control dampers as approved shall be fixed in the ducting system
wherever mentioned in the drawing. The type of fixation shall be a companion
flange. Care shall take to allow the operation of VCD handles.
 Fire damper shall be installed as per approved drawing / manufacturer installation
details.
 Access doors shall be provided for fire dampers wherever applicable i.e. duct size
more than 150MM. Suitable cut out to suit the size of the access door shall be
made in the duct either in the bottom or side as per site conditions. The mounting
frame of access door is fixed to the duct using dovetail joint system for G.I. ducts.
The door is secured in position within the mounting frame using cam locks provided
in the access door. The access door shall be double skin type with sandwiched
insulation for G.I. ducts. For smaller duct sizes where providing access door is not
feasible, access to the fire damper will be made through a small length of duct
removable by providing flanged joints .
 Diffusers plenum/droppers shall be levelled properly to suit false ceiling.
 The ducts are identified (service wise) as per approved identification labels
(directional arrows).

AIR HANDLING UNITS

 Shift the AHUs to the place of installation in safe manner using hydraulic trolley as
applicable. Sufficient manpower will be engaged as required for safe shifting and
installation.
 Ensure that the correct AHU is shifted to the place of installation.
 Air inlet, outlet, fresh air connection and chilled water connection orientation are as
per approved drawings.
CONTRACT NO. GC071018B0 DOC. NO. 2676-KRAN-1700 Rev. 1 Page 10 of 16

 If the AHUs are shipped in multiple sections, the AHUs will be assembled at site
strictly as per the manufacturer’s instructions.
 Remove the movement arrestors provided inside AHUs at Fan and impeller which
are fixed during transportation.
 The AHUs are placed correctly on foundation with vibration isolator rubber pads at
right location.
 The AHUs will be properly levelled and parallel to room walls/other installations.
 AHUs shall be inspected again for any damage during hoisting/shifting and
installation.
 Upon satisfactory positioning of AHUs any open air/water outlets of AHUs shall be
closed properly and area shall be cleaned, complete protection in areas where
other trades are working.
 Ducting connection shall be done as per approved shop drawings.
 Provide flexible duct connections as applicable/as approved submittal. Provide
proper supports as per approved drawings
 The weight of ducting shall not act on AHUs panel.
 Before making final connections to AHUs ensure inner area of AHUs is clean,
especially the impeller of the fan.
 Chilled water connections shall be made as per approved drawings.
 Ensure supply and return connection is made properly.
 Provide pipe flexible connection and other piping accessories as per approved
drawings and submittals.
 The piping shall be free of any strain and shall not exert any load on, AHUs
panel/AHUs.
 Provide vibration isolators to piping supports as per approved submittals/drawings.
 Install the control valves, strainer, commissioning set correctly as per direction of
flow as per approved drawings.
 Ensure proper operation of valve handles and sufficient space for valve installation.
 The location and orientation of the gauges and commissioning sets shall allow for
easy accessibility and readability of readings.
 Electrical power connections shall be done as per approved drawings.
CONTRACT NO. GC071018B0 DOC. NO. 2676-KRAN-1700 Rev. 1 Page 11 of 16

 Cables shall be installed and terminated as per approved method statement.

 Condensate drain piping shall be terminated at the nearest floor drain.
 Provide the `U’ trap in the condensate drain piping.
 Ensure provision for cleaning of `U’ traps.
 Ensure proper slope to enable easy draining.

 Ensure trap is deeper than ESP of fan – e.g., 70mm > 650pa
 Clean the interiors of AHUs including the impeller, drain tray.
 The piping connections to AHUs shall be pressure tested to 1.5 times the working
pressures. Coils not included in test.
 Strainer shall be cleaned after pressure testing and initial flushing of chilled water
piping system.
 Flow test of the AHUs drain tray, condensate drain pipe and ensure water is
drained out completely.

FAN COIL UNITS

 Follow the manufacturer’s instructions while installing the FCU.

 Install Fan Coil Unit with threaded rod and G.I. fasteners and rubber bushes
supplied by the manufacturer. Sufficient manpower will be engaged for safe
installation.
 Installed FCU shall be protected by polythene sheets to protect against dust.
 Connect the drain piping as per approved drawings
 Check the slope of the drain tray in the direction of drainpipe connection.
 Flow test the drain tray and ensure water is drained out completely.
 Complete the valve package and piping connections as per approved drawings.
 Ensure 2-way valves, and commissioning set is installed correctly as per direction
of the flow.
 Ensure the provision for cleaning of drain tray.
 Install the electrical connections as per approved drawings and as per approved
method statement.
CONTRACT NO. GC071018B0 DOC. NO. 2676-KRAN-1700 Rev. 1 Page 12 of 16

 Clean the interiors of FCU and drain tray.

 FCU CHW inlet and outlets shall be connected to CHW piping by using Di-electric
couplers.
 FCU and valve package shall be pressure tested along with chilled water piping
system.

EXHAUST FANS
 Shift the fans to the place of installation in safe manner. Sufficient manpower will
be engaged for safe shifting and handling of the fans.
 The fans shall be shifted to the site only after preparations for fan installation is
complete.
 The bigger fans shall be shifted to site on hand trolley/fork-lift/crane as
applicable/required.
 Drill holes in the slab as required and fix the hangers and supports.
 Unpack the fans for installation.
 Installed Fans shall be protected by polythene sheets to protect against dust.
 Follow the manufacturer’s instructions while installing and leveling the fans.
 Fix the flexible duct connector to fan inlet as per approved drawings.
 Lift and install fans carefully on the supports. Engage sufficient manpower as
required for safe installation.
 Provide anti-vibration isolators as applicable.
 Check the level of the installation in co-ordination with other services and approved
drawings.
 Cut and trim the support rods after finalizing the levels. Leave 25mm extra length of
the support rods for final adjustments. Threaded rod ends to be painted zinc rich
primer.
 Remove burrs and sharp edges, if any.
 Install the electrical power connections as per approved drawings and as per
approved method statement.
 Clean the interior of the fans.
CONTRACT NO. GC071018B0 DOC. NO. 2676-KRAN-1700 Rev. 1 Page 13 of 16

 Install the ducting connection piece at the inlet of the fan and terminate at the
intake wire mesh grille/louvers.
 Electrical power connections shall be done as per approved drawings.
 Cables shall be installed and terminated as per approved method statement.
 BMS interfacing shall be done as per the approved Material Submittal (by CGC)

INSTALLATION OF HANGERS AND SUPPORT

 General Requirements
 8.6.5.2 Check the material required for installation is delivered in standard packing
and correct quantities.
 Check materials and equipment conforming to Specification Make sure that the
material is stored in the proper manner and as per Manufacturer's recommended
storage and handling procedure.
 Check drawings for correct revision and notes for proper coordination with other
disciplines using the latest information received at time of installation.
 Check the area of installation if clean, tidy & safe for working. Prior to the start of
any work the Site Engineer should give review of, START and discuss the work to
be done on every particular site.
 Check before installation the scaffolding & Ladder are erected properly and
approved for high elevation.
 Check execution of installation to conform latest approved AFC drawings and
specification. Upon receiving the materials, examine them for any physical damage
and visible imperfection.
 Check the exact location of all equipment, utilities and Materials to be supported
with approved Hangers and Supports specification.
 Refer the Drawing for the bottom Height of equipment’s, pipes and ducts and
prepare the exact length of threaded rods and fix (into the channels) in the ceiling
using with washer and Nut (Lock nut).
 Use proper tools to install Hangers and Support as per requirement of all
equipment and utilities of HVAC.
CONTRACT NO. GC071018B0 DOC. NO. 2676-KRAN-1700 Rev. 1 Page 14 of 16

ANCHOR BOLT INSTALLATION

 a. Lay out the location of supports and hangers to the nearest location of utilities to
be supported.
 b. Mark all Location of anchor Bolts to determine by metal detector to carryout
scanning of steel rebar’s reinforcement underneath concrete slabs and drilling will
proceed after acceptance of inspection.
 All hangers and support installation details and any cutting and drilling in structural
elements shall be approved by the Engineer.
 Use hangers and supports with galvanized, metallic coatings for piping and
equipment that will not have field-applied finish.
 Use nonmetallic coatings on attachments for electrolytic protection where
attachments are in direct contact with copper tubing.
 Use padded hangers for piping that is subject to scratching

10. Inspection:

GI DUCTS
 After the duct installation, Krantz QC shall inspect the complete installation and offer
the same for SEG and QP inspection.
 On fixation of final fix items like grilles / diffusers etc., SEG and QP shall be invited
for final inspection and certification.

AIR HANDLING UNITS

 Work Inspection Request (WIR) shall be raised for SEG and QP.
 QC inspection shall be carried out as per the inspection test plan.
 Inspection shall be recorded in the approved format and signed off.

FAN COIL UNIT

 Work Inspection Request shall be raised for SEG and QP and sign off.
 Inspection shall be carried out as per the ITP.
 Inspection shall be recorded in the approved format.
CONTRACT NO. GC071018B0 DOC. NO. 2676-KRAN-1700 Rev. 1 Page 15 of 16

EXHAUST FANS
 Upon completion of installation, Work Inspection Request shall be raised for SEG
and QP inspection.

11. Health & Safety:

 Safety precautions shall be followed in-line with established project safety plan.
 People shall use PPE such as safety harnesses, safety shoes, helmets, etc.
 Safety Officer shall check and ensure that all safety precautions are taken before
starting the work in the shafts and heights (including proper lighting and ventilation
in the shafts).
 Safety Officer shall check and ensure that all scaffoldings used are having duly
signed tags.
Emergency Procedures
 In the event of an emergency, such as Fire, all workers shall be evacuated and
assembled at the assigned area.
 The phone number list will also be posted as part of the Emergency response plan
organization. On extreme emergencies, the following mobile phone numbers can
be contacted and be informed of the situation:

HSE Emergency Number - 44748888

SEG HSE Manager - 33656276
SEG Project Manager - 33196617

PERMIT REQUIREMENTS
 All workers shall be inducted and issued with Site Identification Badge prior to
commencement of work.
 Wherever applicable, the following passes/permits shall be applied.
 Excavation Permits
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 Permit to work
 Hot Work Permit
 Confined Space Entry Permit (if needed)

12. Quality Assurance

 Inspection & Testing

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 Inspection and Test Plan for HVAC System- Document No: 2676-KRAN-9000. 1
Follow up & Evaluation 1
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 Daily site inspection will be carried out to ensure that work has been executed as
1
per approved drawings. Upon completion of installations, conduct inspection and 1
testing as per ITP requirements. 1
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