HVAC Air Duct Leakage

Eli P. Howard, III Group Director Technical Resources SMACNA

Key Variables that Affect the Amount of Leakage

Static Pressure Amount of Duct Openings in the Duct Surface
Seams, Joints, Access Doors, Rod and Fastener Penetrations

Workmanship

Duct Leakage is Related to Duct Surface Area

Research in Europe and in the U.S. has led to the Conclusion that a Duct Surface Leakage Factor can be Identified by the Following Relationship:

F = CLPN

Duct Leakage is Related to Duct Surface Area

F = CLPN Where:

F is a leak rate per unit of duct surface area (typically CFM/100SF) CL is a constant P is static pressure (typically in in. W.G. ) N is an exponent (most typically 0.65)

Duct Construction Standards

Ductwork be Constructed for the Specific Pressure Classifications shown on the contract Drawings (1/2", 1", 2", 3", 4", 6", 10") Duct Construction per SMACNA HVAC Duct Construction Standards Ducts Sealed in accordance with Table 1-2 SMACNA HVAC Air Duct Leakage Test Manual 1985, HVAC-DCS 1995

Table 1-2 Standard Duct Sealing Requirements

SEAL CLASS A Sealing Requirements Class A: All Transverse joints, longitudinal seams, and duct wall penetrations B Class B: All Transverse joints 3 w.g. (75-0 Pa) and longitudinal seams only C Class C: Transverse joints 2 w.g. (500 Pa) only In addition to the above, any variable air volume system duct of 1 (250 Pa) and 1/2 w.g. (125 Pa) construction class that is upstream of the VAV boxes shall meet Seal Class C. Applicable Static Pressure Construction Class 4 w.g. and up (1000 Pa)

Definitions
Seam: Joining two longitudinally (in the direction of airflow) oriented edges of duct surface between two joints. Helical (spiral) lock seams are exempt from sealing requirements.

Definitions
Joints: All other duct surface connections made on the perimeter are deemed to be joints including:
Girth Joints Branch & Sub-Branch Intersections Duct Collar Tap-ins Fitting Subsections

Definitions
Joints: (Continued)
Louver and Air Terminal Connections to Ducts Access Door and Access Panel Frames and Jambs Duct, Plenum and Casing Abutments to Building Structures

Definitions
Duct Wall Penetrations
Control Rods/Levers Pressure Taps Fastener Penetrations

Duct System Designer

Match Fan to System Pressure Losses Account for Equipment Leakage (Fans, Coils, VAV, etc.) Specify Duct Pressure Class Specify Amount & Manner of Leakage Testing

Duct Sealing
Leakage is a Function of Static Pressure and System Size Designer Must Specify the Duct Pressure Class or Classes Required for Duct Construction Duct Construction at 1" & " Pressure Class Meet Seal Class C Recommended

Duct Sealing
Unsealed Ducts may leak at the following Rates:
Duct Pressure in Inches w.g. CFM/100 S.F.

0.1 0.25 0.50 1.0

11 20 31 48

Sealants
Liquids
Consistency of Heavy syrup Can be Applied by Brush, Cartridge Gun or Powered Pump Contain 30-60 percent Volatile Solvents Shrinkage when Drying

Sealants
Liquids
Recommended for Slip Type Joints where the Sealant Fills a Small Space Between Overlapping Pieces of Metal Where Clearances Exceed 1/16" Several Applications may be Necessary

Sealants
Mastics
More Suitable for Application as Fillet, in Groves or Between Flanges Have Excellent Adhesion and Elasticity

Gaskets
Durable, Soft Elastomer Butyl or Extruded Forms Used in Flange Joints Should Have Adhesive Backing for Ease of Application

Sealants
Tapes
Such Closures are Listed as Components of Systems Complying with UL 181 No Recognized Industry Performance Standards that set forth:
Peel Adhesion, Shear Adhesion Tensile Strength Temperature Limits Accelerated Aging

Sealants
Tapes
Some test results are published in the product directories of the Pressure Sensitive Tape Council located in Glenview, Illinois. Shelf Life Difficult to Identify (6 mos.-1 yr.) Aging Characteristics Questionable Compatibility of the Adhesive with the Duct Material (Flexible, Non-metallic Ducts)

Sealants
Heat-Applied Materials
Hot Melts normally Shop Applied Thermally Activated Uses Heat to either Shrink Fit Closures or to Expand Compounds within Joint Systems

Mastic and Embedded Fabric

Woven Fabrics (Fibrous Glass Mesh, Gauze, Canvas, etc.) Sealing Compounds including Lagging Adhesive

Sealants
Shelf Life may be one year or less often only 6 months. Installer should verify that shelf life has not been exceeded. Safety Considerations
Sealants may be flammable in wet or partially cured state Use liquids & mastics in well-ventilated areas Observe printed precautions of manufacturers

Leakage Tests
Need to verify leakage control by field testing is not present when adequate methods of assembly and sealing are used. Leakage tests for duct systems constructed to 3" w.g. or lower not recommended not cost effective.

Leakage Tests
For Systems of 4" w.g. Class and higher:
The designer must determine if any justification for testing exists. If so, he must clearly designate in the contract documents the portions of the system(s) to be tested and must specify the appropriate test methods.

Leakage Tests
ASHRAE Energy Conservation Standards Series 90 text on Leakage Control generally requires tests only for pressures in excess of 3" w.g. Adequate airtightness can normally be ensured by
Selecting static pressure construction class suitable for operating condition AND Sealing ductwork properly

Table 4-1 Applicable Leakage Classes

DUCT CLASS SEAL CLASS ", 1", 2' W.G. C 3" W.G. B 4", 6", 10" W.G. A

SEALING APPLICABLE

TRANSVERSE JOINTS ONLY

TRANSVERSE JOINTS & SEAMS

JOINTS, SEAMS & ALL WALL PENETRATIONS

LEAKAGE CLASS RECTANGULAR METAL ROUND METAL 24 12 12 6 6 3

DUCT LEAKAGE CLASSIFICATION FIGURE 4-1

DUCT LEAKAGE CLASSIFICATION FIGURE 4-1

Test Procedures
1. 2.

Select a section of duct to be tested. Select a test pressure not in excess of the pressure class rating of the duct. (Usually the actual operating pressure.) Calculate the allowable leakage using leakage factors for the duct surface area.

3.

Test Procedures
4.

Select the blower and orifice suitable for the test airflow requirements. Connect the blower and flowmeter to the duct section. Provide temporary seals at all ends of the ductwork.

5.

6.

Test Procedures
7.

Start the blower at a low airflow capacity, increasing the airflow until the test pressure is reached. Adjust blower capacity until steadystate conditions at the test pressure are achieved.

8.

Test Procedures
9.

Record the airflow (across the orifice) at the steady state condition. This airflow is the CFM leakage of the tested section of the duct.

10.

ILLUSTRATION OF TESTING FIGURE 3-1

LEAKAGE TEST METER APPARATUS FLANGE TAPS FIG. 5-1

TYPICAL ORIFICE FLOW CURVES FIGURE 5-3

P in. w.g. 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.18 0.20 0.22 0.24 0.26 0.28 0.30 0.32 0.34 0.36 0.38 0.40 0.42 0.44 0.46 0.48 0.50 0.52 0.54 0.56 0.58 0.60

Orifice Size 1.4" 2.625" 18.7 22.8 26.2 29.3 32.1 34.6 37.0 39.2 41.3 43.3 45.2 47.0 48.8 50.5 52.1 53.7 55.3 56.8 58.3 59.7 61.1 62.4 63.8 65.1 66.4 67.6 68.9 70.1 71.3 4.90" 57.1 78.8 95.3 109.2 121.5 132.6 142.8 152.3 161.2 169.6 177.6 185.2 192.6 199.6 206.5 213.0 219.4 225.6 231.6 237.5 243.2 248.8 254.3 259.6 264.9 270.0 275.0 280.0 284.8 289.6

P in. w.g. 1.22 1.24 1.26 1.28 1.30 1.32 1.34 1.36 1.38 1.40 1.42 1.44 1.46 1.48 1.50 1.52 1.54 1.56 1.58 1.60 1.62 1.64 1.66 1.68 1.70 1.72 1.74 1.76 1.78 1.80

Orifice Size 1.4" 28.7 28.9 29.2 29.4 29.6 29.8 30.1 30.3 30.5 30.7 30.9 31.2 31.4 31.6 31.8 32.0 32.2 32.4 32.6 32.8 33.0 33.2 33.4 33.6 33.8 34.0 34.2 34.4 34.6 34.8 2.625" 101.4 102.3 103.1 103.9 104.7 105.5 106.3 107.1 107.9 108.6 109.4 110.2 110.9 111.7 112.4 113.2 113.9 114.6 115.4 116.1 116.8 117.5 118.2 118.9 119.6 120.3 121.0 121.7 122.4 123.1 4.90" 410.3 413.6 416.9 420.1 423.4 426.5 429.7 432.9 436.0 439.1 442.2 445.2 448.3 451.3 454.3 457.2 460.2 463.1 466.0 468.9 471.8 474.7 477.5 480.3 483.1 485.9 488.7 491.5 494.2 496.9

P in. w.g. 4.10 4.20 4.30 4.40 4.50 4.60 4.70 4.80 4.90 5.00 5.10 5.20 5.30 5.40 5.50 5.60 5.70 5.80 5.90 6.00 6.10 6.20 6.30 6.40 6.50 6.60 6.70 6.80 6.90 7.00

Orifice Size 1.4" 52.3 52.9 53.5 54.1 54.7 55.3 55.9 56.5 57.1 57.6 58.2 58.8 59.3 59.9 60.4 61.0 61.5 62.0 62.6 63.1 63.6 64.1 64.6 65.1 65.6 66.1 66.6 67.1 67.6 68.1 2.625" 185.3 187.5 189.7 191.9 194.0 196.2 198.3 200.4 202.4 204.4 206.5 208.5 210.4 212.4 214.3 216.3 218.2 220.0 221.9 223.8 225.6 227.4 229.2 231.0 232.8 234.6 236.3 238.1 239.8 241.4 4.90" 746 755 763 772 781 789 797 806 814 822 830 838 846 854 862 869 877 884 892 899 907 914 921 928 935 942 949 956 963 970

18.5 18.8 19.2 19.5 19.9 20.2

TABLE 5-2 ORIFICE FLOW RATE (SCFM) VS. PRESSURE DIFFERENTIAL (in. of Water)

13.6

4" w.g. Construction Class operating at 3.5" w.g. = Leakage Class 6

DUCT LEAKAGE CLASSIFICATION FIGURE 4-1

3.4

TABLE A-1 LEAKAGE AS PERCENT OF FLOW IN SYSTEM

NOTES TABLE A-1 LEAKAGE AS PERCENT OF FLOW IN SYSTEM

GIVEN: From Fig. 4-1 Leakage Class = CL6 Operating Pressure = 3.5 w.g. Leakage Factor = 13.6 CFM/100 sf. CALCULATION: % of flow = Leakage Factor
Fan CFM Duct Area

ASSUME: Fan CFM = 16000 Duct Area = 4000 sf. Fan CFM = 16000 = 4 Duct Area 4000 = 13.6 4 = 3.40

Questions & Answers

Through-Penetration Firestopping
Eli P. Howard, III Group Director Technical Resources SMACNA

Today's Program
Definition & Purpose Background & Terminology Codes & Regulations Specification Responsibilities Firestopping Selection Factors Typical Details/Drawings

Definition
A through-penetration firestop system is a specific field erected construction of an assemblage of materials designed to prevent the spread of fire and its by-products for a prescribed period of time through openings which are made in floors and walls to accommodate through penetrating items such as ducts, metal and plastic pipes, electrical conduit, cables, cable trays, etc.

Definition
A firestop system consists of three components:
1. A fire resistive assembly or fire barrier (wall, floor, etc.); 2. The penetrating items (ducts, pipes, conduits, etc.); and 3. The sealant material.

Purpose
Outline Considerations in Specifying and Installing Through-Penetration Firestop Systems

Terminology
Annular Space The distance from the inside edge of the opening to the outside of the penetrating item.

Terminology
Area Separation A wall of fire-resistance-rated construction (expressed in hours), which serves to divide the floor area of a building into acceptable area limits as set forth in the code having jurisdiction.

Terminology
Fire-Rated Partition A partition having an assembly of materials that will afford a given fireresistance rating (expressed in hours) to impede the spread of fire from one area to another.

Terminology
Fire Wall A continuous (basement-to-roof) wall having adequate fire-resistance rating (expressed in hours) with adequate structural stability under fire conditions to completely subdivide a building or separate adjoining buildings to restrict spread of fire.

Terminology
F Rating A rating, usually expressed in hours, indicating a specific length of time that a fire-resistive barrier can withstand fire before being consumed or permitting the passage of flame through an opening in the assembly.

Terminology
Intumescence A characteristic of certain fire barrier products that when exposed to heat, expand, self-sealing and filling any void in the penetration. When exposed to flame, intumescent materials will form a hard char.

Terminology
L Rating A rating, usually expressed in cubic feet per minute per square foot of opening, determined by the air leakage test. It is a measure of the ability of a fire-resistive assembly to resist air or smoke infiltration resulting from pressure differences. L ratings may be given for ambient and elevated temperatures.

Terminology
T Rating A rating, usually expressed in hours, indicating the length of time that the temperature on the non-fire side of a fireresistance-rated assembly exceeds 325 above its ambient temperature.

Codes & Regulations

Compliance to ASTM E119 & E814 Compliance to UL 263 & 1479 ICC Building Code NFPA5000 Building Code Local/State Code Authority

Specification Responsibilities

Architects
It is Important that the Architect Clearly Identify All Fire Resistant Assemblies and their Hourly Ratings on the Drawings

Engineers/Systems Designers
It is Important that the System Designers Clearly Identify on the Project Drawings All Penetrations of Fire Resistive Assemblies and the Details of the Required Materials and Methods to be Installed to Maintain the Fire Resistive Integrity of those Assemblies.

Building/Code Officials
It is Mandatory that the Plans and Specifications Completely Identify All Fire Resistant Construction, Penetrations of those Designated Fire Resistant Assemblies, and the Details of How those Penetrations are to be Protected. It is the Responsibility of the Code Official to Determine that the Required Information is Contained in the Construction Documents.

HVAC/Electrical Contractors
The HVAC and Electrical Contractors Are Not Responsible for the Quantity, Location and the Details of Producing or Maintaining the Required Fire Resistance Ratings of Assemblies which are Penetrated by the Materials and Systems Installed by their Trades Except as those Quantities and Details are Shown on the Drawings and in the Specifications.

Factors Determining the Selection of a Through-Penetration Firestop System

A.

The Material and Construction Type (Wall, Floor, etc.) of the Fire Resistant Assembly being Penetrated:
Concrete Brick/Block Gypsum Metal Wood

B.

The Type of Penetrating Item:

Metallic Pipes (Insulated/Uninsulated) Non-Metallic Pipes HVAC Ducts Cables Cable Trays/Busways/Conduits Combinations of the above

C.

The Relative Geometry of the Opening and the Penetrating Item:

Round Opening/Round Penetrant (Sleeved/Unsleeved) Rectangular Opening/Rectangular Penetrant/Round Penetrant/Combination Penetrants The Resulting Annular Space Between the Item and the Assembly that it Passes Through

D.

The Required Rating of the Firestop System Determined by the Rating of the Penetrated Assembly:
F Rating (Hours) T Rating (Hours) L Rating (CFM/SQ. FT)

Questions & Answers