Mechanical Services Technical

Procedure M01

DUCTWORK AND AIR DISTRIBUTION

SYSTEM DESIGN GUIDE

March 2007

23/0101205/WP/27820
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Contents

1. Ductwork and Air Distribution Systems 3

1.1 Ductwork Shafts and Plenums 3
1.2 Design Basis 3
1.3 Masonry Risers and Plenums 4
1.4 Riser Take-off Ducts 4
1.5 Unfavourable Entry Conditions 4
1.6 Velocity and Friction Rate 5
1.7 Outdoor Air Pressurisation 7

2. Grilles and Louvres 8

2.1 Outside Air Louvres 8
2.2 Return air Grilles 9
2.3 Door Grilles and Relief Air Grilles 9
2.4 Toilet Exhaust Grilles 9
2.5 Car Park Exhaust Grilles and Clearance 9
2.6 Stair Pressurisation Supply Grilles 10
2.7 Relief Air Grilles for On-floor Plant with Outside Air Cycle
Operation 10

3. Diffusers and Registers 11

3.1 Diffusers 11
3.2 Registers 13
3.3 Luminaire Air Diffusers 14

4. AIR HANDLING PLANT COMPONENTS 16

4.1 Fans 16
4.2 Coils 16
4.3 Filters 17
4.4 Volume Control Dampers 17

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 1. Ductwork and Air Distribution Systems

The design of ductwork and air distribution systems shall be in accordance with this Design Guide unless
otherwise approved by the Principal Engineer or Project Manager.

1.1 Ductwork Shafts and Plenums

1.1.1 General
This technical procedure addresses the design of low velocity systems (less than 12.5 m/s).

High velocity systems are rarely used because of high pressure losses and consequent high energy
consumption. They are usually designed using the static regain method of calculation which is
documented in other literature. (i.e. ASHRAE handbooks).

Ductwork systems shall be designed with some flexibility to allow redistribution of air for tenancy
changes. The velocities and friction rates set our herein are therefore conservative and can be
exceeded when more air is required from an existing system or when building constraints etc prevent use
of the preferred rates.

The extent to which the recommended velocities and friction rates can be exceeded will depend on the
particular circumstances. Shaft velocities of 10 m/s and main duct velocities of 9 m/s in office ceiling
spaces have been used satisfactorily on some occasions but as a guide, they should be limited to
and 7.5 m/s respectively. Friction rates are generally limited by fan static pressure capability or air
balancing considerations.

1.2 Design Basis

Ductwork shall be designed such that the velocity limits and friction rates set out in this technical
procedure are not exceeded.

Large air quantities will usually be governed by the velocity limit and smaller air quantities by the friction
limit. The changeover point will usually be at air quantities around 1000 to 3000 l/s. Thus ductwork
towards the end of runs will generally be designed by the equal friction method.

Reducing fittings are more expensive to fabricate than straight ductwork. They should be used
economically and it will be appropriate in most cases to allow for two or more take-offs before reducing
the duct size. As a general comment, fittings, which reduce one duct dimension, are cheaper and should
be used in preference to those which reduce both dimensions. (Note that modern laser cutting machines
can produce fittings which reduce both dimensions as cheaply as reducing one dimension however,
traditionally manufactured reducing fittings are expensive to manufacture).
Square ducts and ducts with low aspect ratios are more economical than those with a high aspect ratio
and should be used where practical. Aspect ratios of 7:1 should not be exceeded unless special
conditions apply.

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 1.3 Masonry Risers and Plenums
Slip formed concrete risers can be used for supply return and exhaust air (other than kitchen and toilet
exhausts).
Brickwork and concrete block risers can be used for return air provided they are reasonably airtight and
any leakage comes from the conditioned space. These risers are very difficult to seal airtight especiall
at brickwork to concrete joints where they tend to crack. Therefore they should not be used where
leakage cannot be tolerated.

Brickwork and blockwork plenums have been successfully used for car park exhaust systems but care is
needed in their construction. The plenum face needs to be reasonably smooth particularly in narrow
sections to avoid high friction losses and at least one face must be bagged or rendered to ensure that it
is airtight. A flexible joint should be used in the joint between the top of the plenum wall and the soffit of
the slab above. When using this type of construction ensure that the fan is capable of a speed or pitch
change if necessary to compensate for 10-20% leakage. Alternatively, Trilock or similar rigid wall
construction could be used.

1.4 Riser Take-off Ducts

The preferred take-off from a concrete riser requires a volume damper downstream and has a low overall
pressure loss. Where airflow in the riser is unfavourable due to a poor entry condition it may be
necessary to use an air scoop take-off for sheet metal or concrete risers. This will usually be required on
the first two take-offs following an entry condition as detailed below. Installation of turning vanes at the
point where supply air enters the riser would be the preferred option provided that airflow in the upstream
duct is evenly distributed across the duct. (Standard mechanical services detail drawings are being
developed to show typical details of take-off ducts from risers).

1.5 Unfavourable Entry Conditions

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 1.6 Velocity and Friction Rate
The following table lists the maximum velocities and friction rates to be used for design of new ductwork
systems. Where the friction rate is not listed the limit is dependent on the type of system. In general, a
maximum friction rate of 1.2 Pa/m shall be used for large systems. For small systems where the
pressure available from the fan is low eg packaged or fan coil units less than 3000l/s, a maximum friction
rate of 0.8 Pa/m shall be used.
The friction rates and velocities are those read from a Trane or Fantech Ductulator. Note that the actual
friction rate for rough brickwork is about twice the rate for metal and for concrete is about 1.5 times the
rate of metal. The friction rates quoted below have been adjusted to compensate for this. If detailed
information on concrete or brickwork etc is required refer to tables in the CIBSE, Guide Volume C or refer
to ASHRAE handbooks.

SYSTEM MAXIMUM MAXIMUM

VELOCITY m/s FRICTION RATE
Pa/m

Supply Air

Flexible ducts to outlets. 4.0 0.8*

(Max length 5m. Where longer lengths are unavoidable use
sheet metal inserts. This was an AS 1668.1-1979
requirement, no longer included in the current Standard but
retained as good practice).
* Note: Actual friction rate at 4.0 m/s is approximately double
the Ductulator reading (refer to manufacturers data if actual
losses are required).

Duct branch to single diffuser or register. 4.0 -

Duct branch with more than one diffuser or register directly 6.0 1.0
connected.

Exposed duct in occupied space without side blow registers. 6.0 -

Exposed duct in occupied space with side blow registers. 4.0 -

Main duct in ceiling space:

- Small system (<3 000 l/s). 6.0 1.0

-Large system (>3 000 l/s). 7.5 1.2

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 SYSTEM MAXIMUM MAXIMUM
VELOCITY m/s FRICTION RATE
Pa/m

Risers and plantroom ducts:

- Metal 9.0 1.2

- Slip formed concrete (unlined) 9.0 0.8

Carparks unoccupied service rooms and the like:

- Metal ducts. 9.0 1.2

- Brick or blockwork ducts and plenums. 7.5 0.6

Fire stair pressurisation. 9.0 1.2

Return Air

Transfer ducts. 4.0 0.5

Ducts for small systems (<3 000 l/s). 6.0 1.0

Ducts for large systems (>3 000 l/s). 7.5 1.2

Ducts with return air grilles direct connected. 6.0 -

Free flow through ceiling plenum. 3.0 -

Free flow along corridor. 0.4 -

Through slots to ceiling plenum (based on free area). 4.0 -

Riser Shafts

With return air grilles directly connected to the occupied 6.0 1.2
space.

With return air opening to ceiling space. 7.5 1.2

Smooth concrete (unlined). - 0.8

Rough brick or blockwork. - 0.6

Fresh Air

Opening, damper and subduct from ceiling plenum to riser 6.0 -

shaft.

Duct to small system (<3000 l/s) where no fresh air fan is 6.0 0.5
used.

Duct to large system. 7.5 1.2

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 SYSTEM MAXIMUM MAXIMUM
VELOCITY m/s FRICTION RATE
Pa/m

Exhaust Air

Toilet exhaust:

- Commercial buildings. 7.5 1.2

- Residential (hotels, motels, hospitals, home units). 6.0 0.8

Car parks, unoccupied service rooms etc:

- Metal ducts. 9.0 1.2

- Blockwork, brick ducts and plenums. 7.5 0.6

Other general exhausts (photocopiers and the like). 7.5 1.2

Smoke Spill Shafts

Ductwork, concrete, blockwork. 13.0 Limited by fan
pressure capability

1.7 Outdoor Air Pressurisation

Outdoor Air Quantity l/s
2
New offices. Existing offices with aluminium 0.25 l/s.m
windows and well sealed facades.

Existing offices with poorly sealed windows, with 0.5 to 1.0 l/s.m 2
wooden window frames, with leaky facades.

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 2. Grilles and Louvres

The major considerations in sizing grilles and louvres are pressure loss and noise generation. These are
controlled by limiting the air velocity through the grille.

The noise and pressure loss are greatly influenced by the form of grille used, eg an egg crate type grille
has a much lower pressure loss than a full chevron door grille at the same velocity.

A particular problem arises when grilles and louvres are provided by others. The Architect is usually
given sizes for outside air louvres based on free area of 55%. He then specifies a vertical sight proof
louvre with excellent weather proofing properties built like a three break eliminator with hooked edges.
The pressure drop at design velocity is large and can be a disaster if the intake is for equipment such as
a cooing tower. In such cases ensure that the type of louvre or grille to be used is known at the outset
and provide sizing information to suit the pressure drop characteristics.

The design velocities listed below are based on the types of grilles commonly used in projects i.e.:

Egg crate type ceiling return and exhaust grilles

Full chevron type door and wall return grilles
Half chevron type external louvres
Velocities should be modified if other types of grilles with significantly higher pressure losses are used.

2.1 Outside Air Louvres

In general the face velocity should not exceeds 2.5 m/s. In addition the total pressure loss for grille and
birdscreen should not exceed 50 Pa. For package units and fan coil unit systems where outside air is
ducted to the unit the above pressure drop should be reduced so that the total outside air path pressure
loss is comparable with the return air path losses.

Face velocities of up to 3.5 m/s can be used on intakes for stairwell pressurisation systems where the
grille type selected permits this velocity without excessive pressure drops.

Where internal lighting can shine through louvres or grilles at night, insects can be drawn into the
building (i.e. Bogong moths being drawn into Parliament House relief air louvres in huge numbers).
Insect screens should be used in lieu of bird screens in such applications as long as they are readily
accessible for cleaning.

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 2.2 Return air Grilles
Face Velocity

Eggerate grille in ceiling. 2.5 m/s

Wall mounted grilles at high or low level in 1.75 m/s

occupied spaces or corridors.

Through slots in the T bars or lights (based on 4 m/s

free area).

2.3 Door Grilles and Relief Air Grilles

Based on a grille having a net free area not less than 1.25 m/s
55% of the gross area.

The number of grille sizes used should be minimised for any particular project eg 0.1 m 2 minimum with
2.
size increments of 0.05 m

2.4 Toilet Exhaust Grilles

Based on a net free area of not less than 90% of the 2.5 m/s
gross area (egg crate grille or similar).

Preferably use one size of grille only for any particular project and at a maximum use two sizes. 150
150 is a good minimum size to standardise on (up to 55 l/s). Provide a grille over each toilet bowl and
urinal. Ensure that the design documents clarify that the 150 x 150 is open face size not overall size
inclusive of border.

2.5 Car Park Exhaust Grilles and Clearance

Car park exhaust grilles shall be sized such that the pressure drop through the grille and opposed blade
damper does not exceed 25 Pascals. They should also be of substantial construction.

Low-level grilles should be located where they are least susceptible to damage by reversing vehicles
(especially those with tow bars). This can usually be achieved by centering them on the marked dividing
lines between parking bays and preferably in line with columns. In some cases guard rails or bollards
may be advisable.

Refer to AS 1668.2 for additional requirements in relation to location sizing and installation height.
Typically, maintain 2200 mm clear headroom beneath ductwork run within carparks. However, note that
under AS/NZS 2890.1 Parking Facilities, Off-street Parking, reference is made to a new standard that is
in preparation (as at September 2004). AS/NZS 2890.6 Off-street Parking for People with Disabilities, will
require any vehicular path of travel to or from a parking space for people with disabilities to have a
headroom clearance of 2300 mm.

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 2.6 Stair Pressurisation Supply Grilles
Face Velocity

Based on egg crate grille register or similar. 5.0 m/s

Balancing dampers shall be provided behind grilles. Grilles shall not be located opposite doorways or in
other locations where they can directly discharge out through doorways.

Where a grille has to be located opposite a doorway a grille that deflects the supply air shall be used with
the velocity reduced such that the pressure drop across the grille is in the region of 25-35 Pa.

2.7 Relief Air Grilles for On-floor Plant with Outside Air Cycle Operation
Face Velocity

Suitable for the application. Refer to 1.4 m/s

manufacturers catalogue for selection.

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 3. Diffusers and Registers

The principal criteria for selection of diffusers and registers are Air Diffusion Performance Index (ADPI),
throw, noise and pressure loss. Drop is also important for register selection.

A grille consists of a frame enclosing a set of either vertical or horizontal blades (single deflection) or
both (double deflection or universal type).

A register is a grille in combination with a volume control device such as opposed blade dampers
(OBDs).

Air Diffusion Performance Index (ADPI) also affects selection of air terminals. Details of ADPI are
covered in ASHRAE Fundamentals Handbook. ADPI is related to the ratio of the air throw at 0.25 m
terminal velocity (0.5 m/s for ceiling slot diffusers), the cooling load within the air conditioned space, and
the characteristic room length L. (L = the distance from the diffuser to the nearest boundary wall in the
principle horizontal direction of the airflow. If no boundary wall, then half the distance between adjacent
diffusers plus the distance the diffused supply air and room air travels down to reach the occupied zone).

For variable air volume (VAV) systems, outlets must be selected to provide satisfactory air distribution at
both the maximum and minimum air flows. Linear air outlets, plaque diffusers and light air diffusers are
more suitable for varying air flows than some other outlets

3.1 Diffusers
Diffusers shall be selected from catalogue data taking note of maximum and minimum throw and noise
level.

Diffusers shall be sized so that minimum throws do not overlap each other or any wall or obstruction at
ceiling level and the maximum throw provides reasonable coverage of the area served. One, two and
three way blow diffusers can be used when the minimum throw is obstructed on one or more sides.
Alternatively, the same effect can be achieved by partially blanking the back of the diffuser face provided
that the reduced capacity of the diffuser is taken into account, eg a four way blow diffuser blanked to
provide two way blow can only handle 50% of its rated capacity.
Diffusers shall be provided complete with neck plates in accordance with the manufacturers selection
criteria.

Diffuser shall be provided complete with insulated cushion heads. Cushion heads shall be full diffuser
face size and not neck size (i.e. 600 x 600 say, not 225 x 225 neck size). Full size cushion heads provide
flexibility for fitout modifications by enabling simple changes to be made to the neck plates to suit altered
supply air quantities.

Flexible ductwork shall be connected horizontally into the side of the cushion head and not vertically onto
the top as vertical connections adversely affect the cushioning effect provided by the cushion head and
hence air throw from the diffuser.
The minimum diffuser throw is also affected by the ceiling height. The minimum throw can be reduced
by 1.0 metre for every metre of ceiling height above 2.7 m.

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 Noise level is usually expressed as room N.R. level. A level of 35 or below is acceptable for most
applications. For more specific information on recommended noise ratings refer to the AIRAH handbook
section 9 Noise and Vibration, and AS 2107 Acoustics.

Noise problems can be experienced with louvre type diffusers where restricted ceiling space prevents
installation of diffuser spigot connections of adequate length.

Noise can be generated by air flowing obliquely across the top of the diffuser blades and can be
significantly reduced in existing installations by fitting split plastic tubing over the sharp leading edges.
Whilst this technique may be useful for reducing an existing problem the recommended procedure is to
install diffusers in accordance with standard specification as illustrated below.

Spigot Length Greater Than Neck Dimension

Equalising Deflection Grid Turning Vanes

Spigot Length Less Than Neck Dimension

Conventional square or circular type supply air diffusers are unsatisfactory for variable volume systems
which turn down below 40% maximum volume as they will normally dump supply air below this value.
Dumping occurs when the discharge velocity from the diffuser reduces to the point where the Coanda
effect is insufficient to hold the cold air stream against the ceiling.

The Coanda effect is the principle by which velocity pressure in the airstream causes a lowering of static
pressure thereby enabling the higher room static pressure to hold the cold airstream against the ceiling.
(The total pressures in the room and in the airstream are equal).

When the velocity is too low the cold air stream falls from the ceiling before sufficient room air has been
entrained and the result is a cold draught and uneven room temperatures. Refer to paragraph 3.3
Luminaire Air Diffusers.

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 Air Diffusion Performance Index

ADPI >80 ADPI >90

Cooling load in air conditioned space within T0.25/L: 2.0 T0.25/L: 2.0
range of 35 to 160 w/m 2
(Range of 1.0 to 3.4) (Range of 1.4 to

3.2 Registers
Side blow registers shall be selected to have suitable throw and drop characteristic for the particular
application.

Throw shall be selected to adequately cover the area being served. As a general rule the throw is
adequate if it covers the required distance with the vertical blades set for a straight blow.

Drop shall be selected so the air stream does not fall into the occupied level (ie 2.0 m above floor level
before the air stream is substantially dissipated. Drop is a characteristic of side blow outlets because
they do not establish a Coanda effect by blowing air across the surface of the ceiling. It is often
expressed in catalogue data as minimum ceiling height and is affected by supply air temperature. The
colder the supply air, the greater the drop.

Register throw and drop are affected by the registers aspect ratio and the setting of the direction control
blades.

A square register has the longest throw and drop whereas a long narrow register has a short throw and
drop. Thus a change of register aspect ratio can sometimes be used to overcome a problem of overblow
or underblow. For most applications the highest aspect ratio from the available standard sizes should be
used ie choose a 100 mm deep register rather than a 150 mm deep register where applicable.

The vertical direction control blades can be set for a straight blow or divergent blow. A divergent blow
shortens the throw and drop.

The other factor controlling throw and drop is register face velocity. Higher velocities produce longer
throws and slightly less drop. Face velocity should be between 1.5 and 2.5 m/s, based on 50% free grille
area.

Conventional registers are unsatisfactory for variable volume systems because they dump at low airflow.
Special registers are available which maintain a constant volume discharge through the bottom edge of
the register to prevent dumping when the upper section of the register reduces its volume.

Air Diffusion Performance Index

Cooling load in air conditioned space ADPI >70

2
To 125 w/m T0.25/L: 1.6

(Range of 1.2 to 2.3)

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 2
125 to 190 w/m T0.25/L: 1.8

(Range of 1.5 to 2.2)

3.3 Luminaire Air Diffusers

For variable volume systems narrow slot type diffusers typically provide the best performance. These
include outlets incorporated with light fittings in a luminaire air diffuser or as a continuous slot around the
perimeter of the building often with alternative sections of the slot for the variable volume system and a
separate perimeter constant volume system.

The slot type diffuser has the advantage that due to the Coanda effect the slot will not dump supply air
even when turned down to below 20% design capacity. Below this design capacity some dumping may
occur but at this capacity the problem should not be great as the air quantity is very small. Dumping is
only likely to occur on start up in winter.

To minimise dumping it is important that variable volume outlets be selected to operate at near peak
design capacity to allow the maximum turn down before dumping occurs. This is more important in the
perimeter zones that the interior zones as the turn down is likely to be much greater on the perimeter.

Slot type outlets come in the following configurations.

Outlet Type Slot Width mm Slot Length mm Max Air Quanity l/s

Single 12 1020 45
Double 12 1020 75

Single 12 1400 50
Double 12 1400 75

Single 19 1020 55
Double 19 1020 85

Single 10 1400 60
Double 19 1400 85

The above figures are based on data supplied by Anemostat and will not necessarily apply directly to
other manufacturers products.

The standard luminaire air diffusers will only blow in one direction. Typically this is the direction back
towards the flexible duct connection. Where the flexibility of blowing in either or both directions is
required a more expensive type outlet can be provided to give this flexibility. Generally this flexibility is
not considered necessary.

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 Flexible duct connections should be a minimum of 150 mm diameter for single luminaire air diffusers and
200 mm diameter for double luminaire air diffusers, to keep noise to a minimum. Smaller diameter
connections produce higher noise levels even with small air quantities.

Air quantities are selected for a room noise level of NC35 allowing a room attenuation of 8dB for an
absorbent room. Maximum airflow rates for specific manufacturers equipment should be based on
acoustic test data to achieve the desired room noise level.

Luminaire air diffusers should comply with AS 2946. The specification should include a requirement for
the electrical and mechanical contractors to provide a sample light fitting and single and double-sided
luminaire air diffusers for NATA certified acoustic testing. The specification should also detail installation
sequencing requirements to ensure full coordination amongst the contractors involved. Suggested
specification clause:
The electrical contractor shall provide luminaries in accordance with AS 2946, identical to
prototype luminaire provided for acoustic testing, and shall check each luminaire for full
compliance with all documented requirements.
The electrical contractor shall unpack each luminaire, inspect it for damage and, if undamaged,
provide suitable protection to prevent damage to finished surfaces, and position each luminaire
on the floor directly beneath its final ceiling location.
The mechanical contractor shall provide single and double luminaire air diffusers, check them
for damage and compliance with AS 2946 and, if undamaged, fit them securely to each
luminaire on the floor.
The electrical contractor shall install each combined luminaire/air diffuser in the false ceiling
suspension system, within 250 mm of the final position.
The mechanical contractor shall install flexible ductwork and connect each luminaire air diffuser
to the main supply duct spigot.
The electrical contractor shall connect power and control wiring to each luminaire.
The ceiling contractor shall install the ceiling tiles and adjust the final position of all luminaries
to meet the lighting layout requirements.
The electrical trade shall install fluorescent tubes in the luminaires to form a complete
luminaire/air diffuser installation.

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 4. AIR HANDLING PLANT COMPONENTS

4.1 Fans
When completing Fan Schedules, nominate the design air quantity and the static pressure and schedule
the size of each fan motor to satisfy 120% of the selected fan power requirement. This ensures that
installed fans have adequate spare electrical power available to suit the actual installed system (as
opposed to the system shown on the design documents) and a reasonable increase in fan duty if
required.

Include the following words in the fan schedule notes:

Scheduled fan static pressures and minimum motor kilowatts are provided for tendering purposes
only. They shall be adjusted by the contractor as necessary before ordering the fans to ensure that
the supplied equipment meets the requirements of the installed system duty. Fan motor sizes shall
be provided to have a minimum of 120 % of the power required by the fan for the installed system
duty.

4.2 Coils

Cooling Coils

- Maximum air velocity through the coil face area (to 2.5 m/s
prevent moisture carry over)

- Maximum airside pressure drop 100 Pa

Heating Coils

- Maximum air velocity 3.8 m/s

- Maximum airside pressure drop 100 Pa

(50 Pa for VAV)

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 4.3 Filters

Panel Type

High Efficiency:

- Maximum face velocity 2.5 m/s

- Maximum pressure drop with dirty filter 250 Pa

Medium Efficiency:

- Maximum face velocity 1.8 m/s

- Maximum pressure drop with dirty filter 125 Pa

Deep Bed Type

High Efficiency:

- Maximum face velocity 2.5 m/s

- Maximum pressure drop with dirty filter 250 Pa

Medium Efficiency:

- Maximum face velocity 2.5 m/s

- Maximum pressure drop with dirty filter 125 Pa

4.4 Volume Control Dampers

The following type of volume control damper blade action shall be used for the specified application.

PARALLEL BLADE DAMPERS

- Motorised multi-blade damper sets for unison control of outdoor/relief/return air.

- Motorised multi-blade damper sets for control of minimum outdoor air supply.

- Motorised smoke control or smoke exhaust dampers.

Maximum Air Velocity: 7 m/s.

Maximum Pressure Drop in Closed Position: 90 Pa.

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 OPPOSED BLADE TYPE

- Motorised multi-blade 2-position outdoor air dampers for control of tenants supplementary outdoor air.

- Motorised dampers serving floor supply and return duct branches.

- Motorised zone mixing dampers.

- Motorised coil bypass dampers.

- Manually adjustable damper sets.

- Manually adjustable dampers at return and exhaust grilles.

Maximum Air Velocity: 6 m/s.

Maximum Pressure Drop in Closed Position: 90 Pa.

MULTI-BLADE STREAM SPLITTER DAMPERS

- Manually adjustable dampers at spigot takeoffs serving outlets and registers mounted on the side of
ductwork.

SPLITTER DAMPERS

- Manually adjustable splitter dampers at parallel flow duct branch takeoffs.

SINGLE OR OPPOSED BLADE DAMPERS

- Manually adjustable single or opposed blade dampers in branches other than parallel flow duct branch
takeoffs.

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