Duct Design

Presented by
Dave Janquart

Overview of Topics
Duct design
Duct insulation
SMACNA Standards

Factors Influencing Duct Design

Equipment Losses
Air Velocity
Duct Material
Duct Size & Shape
Length of Duct

Friction Losses
SUPPLY

A coil
.25 sp

FAN
COIL
OR
FURN
ACE
R.A.
BOX

RAG CONT
G35W
S.P. 0.045
RETURN AIR

SAG CONT 32W

S.P. 0.04

FILTER
S.P. 0.07

FURNACE
NO SCALE

Air Distribution System

Components

Supply fan
Supply Ductwork
Transition fittings
Discharge grills
Return grills
Return ductwork

Calculate Air System Pressure

Losses
The air pressure losses from both the
supply and return duct systems plus
the loss through external a/c coil is
often referred to as the external static
pressure.
Manufacturers generally publish fan
ratings based on external static
pressure (internal losses due to coils,
filters, etc. are usually accounted for in
the cataloged fan ratings).

Air Velocity in Duct Design

As Air Velocity Increases Noise Increases
Increasing Air Velocity Causes More
Turbulence
Recommended Velocity 700-900 FPM

Duct Material Roughness

Duct material roughness refers to the inside surface of
the duct material.
The rougher the surface, the higher the friction loss.
Most duct sizing tables use the roughness factor for
smooth, galvanized sheet metal as the reference value.
The back side of the Duct Calculator has a conversion
table for converting the material roughness from
smooth sheet metal to other materials.

Select Duct Material (sheet metal,

fiberglass, flex)
Decide which duct construction material to
use.
Common choices: fiberglass duct board,
galvanized sheet metal, flex vinyl coated
with helical wire core.
Each material has advantages.

First cost (price & ease of installation)

Performance (friction loss, fan energy)
Acoustic properties
Thermal properties (heat gain & loss;
internal/external insulation)

Round vs. Rectangular Duct

of Equal Friction Rate
Ratio of
Perimeter Perimeter
to Area
9.03 ft2

40.7 in.

3 ft.

9.0 ft2

Equivalent
Round Duct

Friction
at
15,000 CFM

10.65 ft.

1.18:1

40.7 in.

.07 in. / 100 ft.

12 ft.

1.33:1

39.4 in.

.086 in. / 100 ft.

13 ft.

1.45:1

38.7 in.

.095 in. / 100 ft.

15 ft.

1.67:1

37.2 in.

.113 in. / 100 ft.

20 ft.

2.22:1

34.5 in.

.156 in. / 100 ft.

3 ft.

9.0 ft2

2 ft.
4-1/2 ft.

1-1/2 ft.

1 ft.

9.0 ft2

6 ft.

9 ft.

Figure 8

Fitting Influences
Selection of the proper fittings is critical

Design Friction Rate

When sizing a duct system the
designer will usually choose a design
friction rate.
This is the desired friction loss in
inches w.g. per 100 ft. of equivalent
length (in. w.g./100 ft. E.L.) of duct.
The design friction rate is generally
determined based on the velocity of
the air in the first section of ductwork.
Most designers use a design friction
rate somewhere between 0.08 and
0.10 in. w.g. per 100 ft. E.L.

Determining Friction Rate/100 ft.

Equipment pressure drop
Duct pressure drop
Terminal device pressure drop

Terminal Device Pressure Drop

Pressure loss for supply air grill
Pressure loss for return air grill

Friction Losses
SUPPLY

A coil
.25 sp

FAN
COIL
OR
FURN
ACE
R.A.
BOX

RAG CONT
G35W
S.P. 0.045
RETURN AIR

SAG CONT 32W

S.P. 0.04

FILTER
S.P. 0.07

FURNACE
NO SCALE

Equal Friction Method

Same friction loss per foot of ductwork

Most commonly used method
Accomplished by use of a Ductulator
Requires less balancing
Important to have balance dampers at each
outlet

Results in reasonable duct sizes

Velocity Scale

Duct Calculator

Airflow
(CFM)

Velocity
Pressure
Friction
Loss

Round Duct
Diameter
Equivalent
Rectangular
Duct Sizes

Figure 7

Duct Calculator

Duct Calculator (Reverse)

Recommended & Maximum

Duct Velocity Ranges

Design toward smaller end of range for quieter systems

and toward larger end of range to minimize duct sizes.

Things to Consider
Aspect ratio no more than 3:1
Residential 2 times # of 6 RD take offs
plus 2 for ducts that are 8 high
.5 cfm per Sq Ft
No more than100 cfm per 6 RD

Round vs. Rectangular Duct

of Equal Friction Rate
Ratio of
Perimeter Perimeter
to Area
9.03 ft2

40.7 in.

3 ft.

9.0 ft2

Equivalent
Round Duct

Friction
at
15,000 CFM

10.65 ft.

1.18:1

40.7 in.

.07 in. / 100 ft.

12 ft.

1.33:1

39.4 in.

.086 in. / 100 ft.

13 ft.

1.45:1

38.7 in.

.095 in. / 100 ft.

15 ft.

1.67:1

37.2 in.

.113 in. / 100 ft.

20 ft.

2.22:1

34.5 in.

.156 in. / 100 ft.

3 ft.

9.0 ft2

2 ft.
4-1/2 ft.

1-1/2 ft.

1 ft.

9.0 ft2

6 ft.

9 ft.

Figure 8

90 SQ FT
190 SQ FT
50 SF

90 SQ FT

450 SQ FT

120 SQ FT

120 SQ FT
WASHER
(N.I.C.)

50 SQ FT

GAS
DRYER
(N.I.C.)

60 SQ FT
160 SQ FT

120 SQ FT

90 SQ FT
45 CFM
190 SQ FT
95 CFM

50 SF
25CFM

90 SQ FT
45 CFM

450 SQ FT
225 CFM

120 SQ FT
60 CFM

120 SQ FT
60 CFM
WASHER
(N.I.C.)

50 SQ FT
25 CFM

GAS
DRYER
(N.I.C.)

60 SQ FT
30 CFM
160 SQ FT
80 CFM

120 SQ FT
60 CFM

90 SQ FT
45 CFM
190 SQ FT
95 CFM

50 SF
25CFM

90 SQ FT
45 CFM

450 SQ FT
225 CFM

120 SQ FT
60 CFM

120 SQ FT
60 CFM
WASHER
(N.I.C.)

50 SQ FT
25 CFM

GAS
DRYER
(N.I.C.)

60 SQ FT
30 CFM
160 SQ FT
80 CFM

120 SQ FT
60 CFM

90 SQ FT
45 CFM
190 SQ FT
95 CFM

50 SF
25CFM

90 SQ FT
45 CFM

450 SQ FT
225 CFM

120 SQ FT
60 CFM

120 SQ FT
60 CFM
WASHER
(N.I.C.)

50 SQ FT
25 CFM

GAS
DRYER
(N.I.C.)

60 SQ FT
30 CFM
160 SQ FT
80 CFM

120 SQ FT
60 CFM

90 SQ FT
45 CFM
190 SQ FT
95 CFM

50 SF
25CFM

8/8

90 SQ FT
45 CFM
450 SQ FT
225 CFM

120 SQ FT
60 CFM

18/8
120 SQ FT
60 CFM

12/8
WASHER
(N.I.C.)

50 SQ FT
25 CFM

GAS
DRYER
(N.I.C.)

8/8
60 SQ FT
30 CFM
160 SQ FT
80 CFM

120 SQ FT
60 CFM

90 SQ FT
45 CFM
190 SQ FT
95 CFM

8/8

450 SQ FT
225 CFM

50 SF
25CFM

90 SQ FT
45 CFM
120 SQ FT
60 CFM

12/8
120 SQ FT
60 CFM

8/8
WASHER
(N.I.C.)

50 SQ FT
25 CFM

GAS
DRYER
(N.I.C.)

60 SQ FT
30 CFM
160 SQ FT
80 CFM

120 SQ FT
60 CFM

Select and Adjust Fan

The total static pressure is the pressure that the fan
must overcome to deliver the required amount of air.
This total amount is also used to select the required fan
motor size or fan speed.
Perform air balance next. Per Comm 23.18
Measured airflow values should be compared against
the required values.
Adjust fan and balancing dampers as necessary to
deliver the correct amount of air to each zone.

Duct Insulation
22.17 UDC Duct system insulation. (1)
except as provided in sub. (4), all heating
and cooling duct systems, or portions
thereof, that are located in unheated or
uncooled spaces respectively, shall be
provided with insulation with a thermal
resistance of at least R-5.

Duct Insulation cont.

R-4.2 and R-6 are common industry
standards for insulated flex
R-5 and R-8 are common industry standards
for duct wrap

Installation of Underground
Ducts SMACNA Standards

Installation of Underground
Ducts cont.

Installation of Underground
Ducts cont.
23.08 UDC supply air ducts shall be
insulated with a moistureproof material
having a resistance value of a least R-5.

Underground Duct cont.

Underground Ducts cont.

Uninsulated duct will require 152 btuh per
linear foot of duct for heating
1 insulated duct will require 91 btuh per
linear foot of duct for heating (40% less
energy)
2 insulated duct will require 74 btuh per
linear foot of duct for heating (51% less
energy)