DEVELOPMENT OF SARDAR VALLABHBHAI PATEL INTERNATIONAL AIRPORT

DOCUMENT TITLE

Method for HVAC Work

Document No-1134-AEE-PT-ME-P1-T2-GN-WMS-001

Revision History

Revision Date of
Prepared By Checked By Approved By
No. Submission

0 20-01-2024 IMTIYAJ KHAN HARSHAL CHAUHAN HIREN BHANOT

Code Reviewed By Department Signature Date

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Content
Sr. No. Description Page No.
1 Scope 3
`
2 Purpose 3
3 Documents 3
4 References 3
5 Responsibilities 4
6 Organization Chart 5
7 Material List 6
8 Method Of Work 7
9 Work Plan 8
10 Work Details 8
11 Duct Materials 9
12 Duct Construction 10
13 Installation 10
14 Ductwork 11
15 Dampers 12
16 Grills And Diffusers 15
17 Jet Nozzle 16
18 Louvers 16
19 Duct Support 16
20 Ductwork Insulation 18
21 Sound Attenuators 19
22 Testing And Balancing 19
23 Testing Adjusting and Balancing 20
24 Health Safety and Environment 20
25 CHW Pipe fabrication work 21

Detailed Designing, Supply, Installation Testing

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26 HOT TAPPING WORK 22

28 INSTALLATION OF AHU ON CONCRETE ROOF 24

29 ELECTRICAL INSTALLATION 24

30 QUALITY ASSURANCE 25

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1. Scope
This procedure specification covers the general requirements of fabrication and installation of HVAC work within airport
site, carried out for the project - Refurbishment of Terminal-2 Building at Ahmedabad Airport.
The contractor shall provide all Laboure services tools, materials and equipment’s (other than that specifically called out on
the contract drawings and specifications as being provided) necessary to install a complete and operative electrical system
according to the contract drawing this speciation the latest issues of the national electrical code and all other applicable
code manufacturers drawings and instructions and the direction of the field representative.

2. Purpose
The purpose of this Method Statement is to provide the personnel associated with the works referred with appropriate
work methodology and test procedures, so that the Quality requirements, as defined can be accomplished when planning
and executing the works described herein. This Method Statement outlines the work sequence intended for the installation
of works related to for HVAC system.
“When this Methodology is followed, all employees and contractors will have proper knowledge about installation work
related to ALL HVAC system and safety precautions should be taken during the installation”.

3. Documents
Following are the checklist / records to be maintained:

1) TDS Approval
2) Material inspection Reports.
3) Installation checklists
4) Test reports
5) Machinery / equipment checklist

4. References
The requirements contained in the latest editions of the following standards shall form a part of this specification, in the manner
and to the extent and here in

 NBC - 2005 National Building Code of India

 SMACNA-2004 & ASHRAE Standard for duct fabrication.
 IS: 655-1971-Standard for duct work fabrication

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5. Responsibilities
Following are the responsibilities and reporting structure of personnel involved in the procedure

Position Reporting / Responsibilities

Project Manager  He is overall responsible for all the activities

 Shall report to the Project Manager
 Shall be responsible for control, supervision and direction for
implementation.
 Safety to personnel, incident reporting and implementation of the Safety
Site In charge
Management Plan and Safety Management System.
 Shall also be responsible for supervision of activities and preparation of
records, develop schedules, procedures and prepare progress and
accomplishment reports.
 Shall report to Site in charge
 Shall be responsible for day-to-day execution and supervision of works at
Engineers site, including preparation of records.
 Responsible for safety requirements for workers and working
environment and ensure all safety implementations.
 Shall report to Project Manager & Site in charge
QA/QC in charge / Engineer  Shall be responsible for overall control of QC activities, sub-contractor’s
QC activities, implementation of Quality Plan
 Shall be responsible for carrying out inspection as per specification.
 Co-ordinate with Construction Manager / Site Engineers for system
Safety In charge implementations closely monitors all the requisites from HSE, organize
training programs on safety awareness, involve in Hazard identification,
risk assessment and its control.

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6. Organizational Chart

Mr. Dharmesh Sheth

Director

Mr. Harshal Chauhan

9687678789
Project manager

Mr. Imtiyaj khan Mr. Shivsinh Raj- Mr. Vijay bhatt

Mr. Khalid Siddiqui
9651293672 7046475555 Accountant
9313923479
Project Engineer Design Engineer (Office Works)
Planning Engineer

Mr. Manoj Sahani-9374051984

Site Engineer

Piping & Duct & Insulation VCD/Grilles/Diffuser

Insulation Team-1 s
Team-1 Team-1

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7 Material list / Tools & Equipment list & Manpower list

7.1 Material List
Sr no Description Remarks
Prior to supply, GI sheets should be approved
1 GI Sheet, Fittings, Supports, nut bolt and etc.
by AAI representative

Prior to supply, Thermal Insulation and

2 Thermal Insulation and Adhesive Adhesive should be approved by AAI
representative.

Prior to supply grills and diffusers should be

3 Grills and Diffusers
approved by AAI representative.
Volume control dampers, Motorized dampers, Prior to supply should be approved by AAI
4
Backdraft Dampers and etc. representative.
5 Installation & Testing procedures. Prior to supply material should be approved

7.2 Tools & Equipment list

Sr no Description Remarks
1 Hammer drilling Machine
2 Drilling Machine
3 Grinding machine
Auxiliary equipment’s like – Measuring tape,
4
Plumb, water sprit level.
Other tools & tackles like Tape, Plumb, Water
5
level, Hammer, Chisel, File, Adjustable spanner

Personal Protective equipment like – Safety

helmet, Reflective jackets, Safety shoes, Safety
6
goggle, Nose mask, Safety hand glovers, safety ear
plug.

7.3 Manpower list for specialized agency

Sr no Description Remarks
1 Site Engineer in charge
2 Foreman / Supervisor
3 Mistry, Fitter
4 Safety Officer
5 QA/QC Engineer

Note: Job card to be provided for all the manpower specifying the designation on it.

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8 Method of Work
A flow chart indicating the process of workflow and the check points to be considered during the inspection (Management
points) (Preconstruction – Construction and inspection flow – Major management points)

 TDS approval issued for construction.

 Approved Shop drawing
Inspection Before
Preliminary  Approved method statement, ITP, and Job Card
start of work
 Approved Material Inspection Report
 HSE induction to Labors prior to installation
 Check for standard clearance form for requested area.

 Lot No./batch no, material's specification,

 Test certificate of the materials & TPL
Material  Physical Material inspection and documentation
inspection 

 Support/brackets installation with correct spacing& as

per approved procedure (WPS).
inspecti  Piping installation as per approved shop drawing.
on  Pipe alignment, sizes as per approved guidelines.
Work Execution
1.
2.  Preparation of work inspection request
3.  Checklist
4.
5.
Approval / Inspection 6.
7.
Rework/ 8.  Completion for system erection or part thereof that
Rectification Material
9. section will be visually inspected by AAI representative
Failure
10. and PMC Representative.
inspectio 11.
n
Test
inspe 12.
ction 13. Closing of Checklist.
14. GFC DwGFC
2
 Pre-Commissioning (Method Statement for the same will be
submitted later)
Work Inspection Report (WIR)  Final commissioning

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9 Work Plan
 Work plan including details will be submitted prior commencement of work for approval to Client.
A. Material Approval
 Materials approval will be taken prior to commencement of work
B. Check work environment
 Construction clearance shall be obtained from AAI representative
 Check aligning status, lifting/transportation facility, cleaning of passage ways and plan on safety measures for work
location, ensuring that work can be performed.
 The ducts, fittings, grills, diffuser, insulation, dampers etc. shall be visually inspected for quality of workmanship and
dimensionally checked by M/s Ascent Electrification Engineering representative and randomly checked by client
representatives. Necessary compliances of check list & test report to be maintained.
C. Quality points
 Person in charge of the work shall ensure that, quality issues do not occur during installation work.
 Works shall be executed under the supervision of quality supervisor and engineer.
 Works should be executed as per manufacturer recommendation and product data sheet.
 Inspection of the work to be done along with client engineer.

10 -Work details

10.1 Method of storage

 All materials related to air distribution work should be stored one above another with proper covering and positioned
as per the manufacturer’s instruction
 Material to be arranged near to the workplace.

10.2 Area inspection:

 Co-ordination with the other agencies which are working in the same location for safe execution of work.
 Work related hazards shall be communicated with all concerned, prior to start of the work.
 Ensure control measures have been in place to reduce the risk level at reasonably practicable.
 Ensure area is free from obstacles for installation of ducts as per approved drawing.
 Line out and marking as per approved shop drawing
 Check with rebar locator & then drilling at specified spacing as per approved shop drawing.
 Suitable Support installation as per approved shop drawing

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11-DUCT MATERIALS
Raw Materials

Galvanized steel sheets with Class - VIII Galvanizing – light coating of zinc (Zinc coating shall be Lead free), nominal
120gm/sq.m surface area and Lock Forming Quality prime material along with mill test certificates. In addition, if
deemed necessary, samples of raw material, selected at random by owner*s site representative shall be subject
to approval and tested for thickness and zinc coating at contractor*s expense.

Gauges, Bracing by Size of Ducts

All ducts shall be factory fabricated from galvanized steel / aluminum of the following thickness,
as indicated below

For Ducts with External SP up to 250 Pa

External Pressure 250 Pa

Duct Section Length 1.2 m (4 ft)

Maximum Duct Size Gauge Joint Type Bracing Spacing

1–1200 mm 24 TDF Flange Nil
1201 – 1500 mm 22 TDF Flange Nil
1501 – 1800 mm 20 TDF Flange Nil
1801 – 2100 mm 20 TDF Flange JTR or ZEE BAR
2101 – above 18 TDF Flange JTR or ZEE BAR

For Ducts with External SP up to 500 Pa

External Pressure 500 Pa

Rectangular Ducts G. S.
Duct Section Length1.2 m (4 ft)
Maximum Duct Size Gauge Joint Type Bracing Spacing
1–400 mm 24 TDF Flange Nil
401-900 mm 22 TDF Flange Nil
901-1200 mm 20 TDF Flange JTR or ZEE BAR
1201-2100 mm 18 TDF Flange JTR or ZEE BAR
2101-above 16 TDF Flange JTR or ZEE BAR

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12-DUCT CONSTRUCTION
All ducts shall be fabricated and installed in work man like manner, conforming to relevant
SMACNA codes.
 All ducts shall be fabricated out of galvanized sheet steel (GSS) for long life. Duct dimensions shall be shown
on drawings, are overall sheet metal dimensions inclusive of the acoustic lining where required. The
fabricated duct dimensions should be as per approved drawings and care should be taken to ensure that
all connecting sections are dimensionally matched to avoid any gaps.
 Ducts shall be straight and smooth on the inside with longitudinal seams shall be airtight and at corners
only which shall be either Pittsburgh or snap button as per SMACNA practice, to ensure air tightness.
 Ducts shall be fabricated as per details shown on Drawings. All ducts shall be rigid and shall be adequately
supported and braced where required with standing seams, tees, or angles, of ample size to keep the ducts
true to shape and to prevent buckling, vibration or breathing.
 All sheet metal connection, partitions and plenums, shall be constructed of 18-gauge GSS / 16-gauge
aluminum, thoroughly stiffened with 25mm x 25mm x 3mm galvanized steel angle braces and fitted with
all necessary inspection doors as required, to give access to all parts of the apparatus.
 Self-adhesive Neoprene rubber / UV resistant PVC foam lining 5mm nominal thickness instead of felt, shall
be used between duct flanges and between duct supports in all ducting installation.
 All fire rated duct, smoke exhaust ducts shall be quoted with flame bar BWII or equivalent to achieve the
required fire rating.

13-INSTALLATIONS

All ducts shall be installed generally as per tender drawings, and in strict accordance with
approved shop drawings:
 The Contractor shall provide and neatly erect all sheet metal work as may be required to carry out the
intent of these Specifications and Drawings. The work shall meet with the approval of Owner*s site
representative in all its parts and details
 All necessary allowances and provisions to be looked into for beams, pipes, or other obstructions in the
building, whether or not the same are shown on the drawings. Where necessary to avoid beams or other
structural work, plumbing or other pipes, and conduits, the ducts shall be transformed, divided or curved
to one side (the required area being maintained) all as per the site requirements.
 If a duct cannot be run as shown on the drawings, it shall be installed such that the duct between the
required points by any path available in accordance with other services and as per approval of owner’s site
representative.
 All ductwork shall be independently supported from building construction. All horizontal ducts shall be
rigidly and securely supported, in an approved manner, with tie rods and M S angles.

 fastener driven into the concrete slab by electrically operated hammer/drill machine. Hanger rods shall
then hang through the fully threaded galvanized rods can be screwed into the anchor fasteners.
 Ducting over furred ceiling shall be supported from the slab above, or from beams after obtaining approval
of Owner’s site representative. In no case shall any duct be supported from false ceiling hangers or be
permitted to rest on false ceiling. All metal work in dead or furred down spaces shall be erected in time to
occasion no delay to other contractor’s work in the building.

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 All ducts shall be totally free from vibration under all conditions of operation. Whenever ductwork is
connected to fans, air handling units or blower coil units that may cause vibration in the ducts, ducts shall
be provided with a flexible connection, located at the unit discharge. Flexible connections shall be
constructed of fire retarding flexible heavy canvas sleeve at least 10cm long securely bonded and bolted on
both sides. Sleeve shall be made smooth and the connecting ductwork rigidly held by independent supports
on both sides of the flexible connection. The flexible connection shall be suitable for pressure at the point
of installation.
 Duct shall not rest on false ceiling and shall be in level from bottom.
 Taper pieces shall taper from top.

14 -Ductwork
Pre-Requirements
Pre-Requirements before the start of installation of air conditioning ducts which are already fabricated
either on the site workshop or from outside the project premises and delivered to the site for installation after
duct fabrication.
 Fabricated Ducts delivered from duct workshop to be stored at proper area to be selected on site.
 All materials and documentation relevant to a particular section of works will be checked by the
construction manager prior to the commencement of work ensuring that these are of the correct
type as reviewed by the client.
 Before commencement any construction works, pre-inspections will be carried out on all materials
prior to installation.
 Prior to the commencement of any construction works, areas and access will be inspected to
confirm that they are in a suitable condition for construction works to commence.
 Works shall not proceed until an approved shop drawing or detail is issued.
 Safe Access to work areas shall be provided and shall be approved.
 Materials shall be moved to the work area in safe manner and shall not block access /egress from/to
the site.
 Suitable Mechanical aids shall be used where heavy loads are to be moved or lifted in to position,
such equipment shall be planned for in advance of works.
 Where high risk works are involved then a safety clearance must be obtained from safety
department.

Ductwork Installation Procedures

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 Supervisor will instruct tradesmen regarding the execution of the works and will distribute all
necessary approved construction drawings of the latest revision.
 The supervisor will also check that tools and equipment’s available are in compliance with the
contractor requirements/safety standards and as per necessity.
 Ensure horizontal ductwork is adequately supported at equal distances in accordance with
construction drawings.
 Screwed drop rods will have thread adjustment in either direction available after levelling of
ductwork and associated plenum boxes.
 As indicated on relevant approved construction drawings where more than one duct can be
supported on one hanger – the size of the hanger will be assessed on the sum of the maximum
widths.
 Ductwork passing through non fire rated walls and floors will be adequately supported on either side.
 All locknuts should be tightened correctly.
 Supports are to be fixed at correct levels checking the bracket material is compatible with the
installation and the correct method used for thermal insulation.
 Fixing of flanges to ductwork will be by the approved details and in compliance with the specification
requirements. Continuously check horizontal and vertical alignment of ductwork and compliance
with contractor’s drawings and specification requirements by using spirit level plumber another
suitable instrument. Clean both flange faces to be joined. Add gasket jointing material to flanges to
be mated. Using only undamaged rust-free bolts nuts and washers join mating flanges together and
tighten bolts. Clean any excess jointing material from flanges.
 In line equipment is to be independently supported from main structure and not block work walls or
sub-structure.
 Silencers, fire dampers, balancing dampers & other plant items will be installed as per shop drawings.
 Supervisor to check before end of work every day that: The correct type of supports are installed,
supports are adequately supporting the ductwork and associated plant equipment.

15 Dampers
 Unless otherwise specified, all installation shall be according approved shop drawings and
contract specifications. Drawing plans, schematics, and diagrams indicate general location and

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arrangement of ductworks. Install dampers as indicated unless deviations to layout are approved
on coordination drawings.
 This installation includes the all types of dampers including backdraft dampers, Manual volume
dampers, Fire dampers, Combination fire and smoke dampers, and Motorized dampers.
 Examine areas and conditions with requirements for installation tolerances and other conditions
affecting performance, operation and maintenance of dampers.
 Install volume control dampers in lined duct with methods to avoid damage to liner and to avoid
erosion of duct liner. Install backdraft or control dampers (as identified on the drawings) at inlet
of exhaust fans or exhaust ducts as close as possible to exhaust fans unless otherwise indicated.
 Install volume dampers at points on supply, return, and exhaust systems where branches extend
from larger ducts. Where dampers are installed in ducts having duct liner, install dampers with
hat channels of same depth as liner, and terminal liner with nosing at hat channel.

 Set dampers to fully open position before testing, adjusting, and balancing. Provide test holes at
inlet and outlet and elsewhere as indicated. Install fire and smoke dampers according to the
manufacturer’s UL listing. Interface fire and smoke damper with the fire alarm system. Install
access doors with swing against duct static pressure.

 Install duct access doors on side s of ducts to allow for inspecting, adjusting, and maintaining
accessories and equipment at the following location:

o Downstream from manual volume dampers, motorized dampers, and backdraft

dampers.
o Adjacent to and close enough to fire or smoke dampers, to reset or reinstall fusible links.
Access doors for access to fire or smoke dampers having fusible links shall be pressure
relief access doors and shall be outward operation for access doors installed upstream
from dampers and inward operation for access doors installed downstream from
dampers.

Inspection and Testing of Dampers

 Follow-up inspections will be carried out as the work progresses until completion of a particular
phase on installation.

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 Operate fire, smoke, and combination fire and smoke dampers to verify full range of movement
and verify that proper heat-response device is installed.
 Operate remote damper operator s to verify full range of movement of operator and damper.
 Adjust volume control devices as required by the testing and balancing procedures to achieve
required air flow asper the Contract Specification.

Steps for Installation of Volume Control Dampers

 Before installation check any physical damages on the dampers.
 Determine the position of the damper to be fixed on the duct from the construction drawing and
check site conditions.
 Fix the VCD in available space by flange or nut/bolt and apply duct sealant.

 Examine the location for requirement of installation tolerances and clearances as specified in the
drawings.

 Manually move the volume control damper (VCD) to the desired position in a way that damper
channel frame matches the duct flange.

Installation Method Statement for Fire Dampers

 Before installation check any physical damages on the dampers
 Determine the position of the Damper to be fixed on the duct from the construction drawings.
 Fix the damper with flange or Nutt/bolt and apply duct sealant.
 Examine the location for requirement of installation tolerance and clearance as specified with the
drawings.
 Fire dampers should be installed in all fire rated walls, floors and partitions.
 Installation of Fire dampers should be completed as per specification and manufacture
recommendations.
 Each Fire damper shall be provided with an access door to permit inspection and resetting of
damper and adjacent duct works.
 Provide duct access doors for internal access to all fire dampers for sizes bigger than 300 mm
width of the duct.
Installation Method of Motorized Fire Dampers
 Before installation check any physical damages on the dampers
 Determine the position of the Damper to be fixed on the duct from the construction drawings.

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 Fix the damper with flange or nut /bolt and apply duct sealant.
 Examine the location for requirement of installation tolerances and clearances as specified in the
drawings.
 Provide duct access doors for internal access to all dampers.
 All fire dampers Installed will be as per applicable local and international standards.

16 Grilles and Diffuser

Installation Procedure for Diff users and Grills:

The following procedure shall be followed for the installation of grills / diff users:

 Grills/diff user shall be submitted for consultant approval before proceeding with installation.
 Prior to start of installation, refer to the approved false ceiling drawing related to the area of installation
and ensure that required material is available at site as per approved material submittals.
 Visually inspect the grills / diff user for any damages.
 Check whether the grills / diff users are as specified type as per list provided in approved material submittal.
 Check whether powder coating quality is O.K. and color is as per specifications.
 Check horizontal & vertical vanes of grilles and register. There should not be any bend and adequate sup-
port should be provided by Manufacturer if grill is long.
 Check the borders of grills / diff users for gap free aligned joints.
 Ensure that the proper clearance is available from civil side before commencement of works.
 Ensure that the work area is clean and safe for carrying out the installation of grill/diff user.
 Ensure that the installation of grills/diff users are carried out in accordance with manufacturer’s installation
recommendations and specification.

INSTALLATION PROCEDURE FOR GRILLS / DIFFUSERS IN CEILING

 After competition of the false ceiling work mark location of grill / diffuser location as per approved false
ceiling drawing.
 After grill / diff user location are confirmed by Site Engineer (HVAC), opening is to be made in the marked
place.
 After cutting the opening, proper false ceiling support and alignment is to be done.
 Grilles and diff users should not be directly supported on gypsum surfaces. Proper frame should be provided
at the back by the false ceiling contractor.
 Check grills / diff user collars are securely fixed to the inside of frame.
 Check grills / diffusers & flexible connections are properly connected with duct and plenum and also both
sides are clamped with jubilee clamp.
 Ensure that the damper blades of supply grills and diff users are properly secured in nylon bushes for rattle
free operation.
 Check whether the items are supplied with specified fixing arrangement counter sunk screw fixing,
Concealed with clip / inside screw lever / concealed bracket.
 Grills / diff user shall be fixed as per given manufacturer’s arrangement.
 Ensure alignment and joining clips are provided for all open-end slot diff users for continuous fixing.

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 Check whether each slot is adjustable or not in multi slot diff users.

17 JET NOZZLE

 Fix the device only to load-bearing structural elements.

 Load suspension systems only with the weight of the device. Adjacent components and connecting ducts
must be supported separately.
 Use only approved and adequately sized fixing material.
 Refer to the technical leaflets for product weights and dimensions.
 The air terminal devices must remain accessible for cleaning even after installation.
 Installation and sealing material which the manufacturer provides is usually supplied in an extra bag.
 Before you install the device, take suitable precautions to protect air distribution components from
contamination during installation. If this is not possible, at least cover the devices or take other precautions
to protect them from contamination.
 The installation orientation of the air terminal device depends on the direction of movement of the
discharge nozzle. The device is typically installed in such a way that the discharge nozzle moves upwards
and downwards.
18 Louvers

 To install the louver, first prepare the wall or duct opening to accept the louver. The wall opening should
be 1/ 4" to 1/ 2" larger than the final fixed dimension of the louver. Make sure that the opening is plumb
and level, and sufficient structural support is provided, as the louver is not load bearing.
 After the opening is prepared, measure its width by height and, on the ground, adjust the louver to the
required opening width.
 Carefully extend the louvers to the desired width. Take care not to use excessive force, as it is possible to
overcome the stops. Open the louver evenly to prevent jamming. Do not exceed maximum width
dimension.
 Once the unit is adjusted to the desired width, drill each louver on rear, 1" from the seam, and attach screen
and both louver sections using provided hardware.
 Caulk louvers on rear of face flange on top, bottom and sides and inside top and bottom corners prior to
installation to prevent water from entering the building.
 Secure the louver into opening selecting the most suitable method.
 Use corrosion protected fasteners to secure the louver in the opening. Once louver is adjusted to the
desired width, drill top and bottom through both sections. Hardware should be spaced no more than 18"
apart, and all sides should have a minimum of two fasteners.
 If installation requires the louver to be connected to a duct system, then any ductwork, fans or dampers
should be supported by the building structure, and should be sealed to the louver.

19 Duct Supports

Steel Wire Rope Hangers& Supports:

Wire Hangers shall be used to suspend all static HVAC Air Distribution services. Wire Hangers should consist of a
pre-formed wire rope sling with a range of end fixings to fit various substrates and service fixings, these include a
ferruled loop, permanently fixed threaded M6 (or M8, M10) stud, permanently fixed nipple end with toggle, at

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one end or hook or eyelet, cladding hook, barrel, wedge anchor, eyebolt anchor or any other end fixture type or
size as per manufacturers recommendation and design. The end fixings and the wire must be of the same
manufacturer with several options available. The system should be secured and tensioned with a Hanger self-
locking lock at the other end comprising of a single piece housing; the wedge inside the lock housing should be
having serrated teeth & made up of sintered steel and springs used, if any, should be made up of stainless-steel.
Once the grip is locked for safety purpose unlocking should only be done by using a separate
setting key and should not be an integral part of the self-locking grip for safety purpose. Only wire
and/or supports supplied and/or approved, shall be used with the system.

The correct specification of wire hanger required is determined using the following formula.
Weight per meter of object suspended (kg) X distance between suspension points (m) =weight
loading per Hanger suspension point (kg).

Where the installed wire rope is not vertical then the working load limit shall be reduced in accordance with the
recommendations give in the manufacturer*s handbook.

The contractor shall select the correct length of wire rope required to support the service. Lengths from 1-10m
lengths. Specials can be made, check with manufacturer. No in–line joints should be made in the rope.

Table. 1: Wire hanger safe working loads

Wire Hanger Safe Working Loads

Hanger No. Minimum breaking load of Wire Rope working load limit (kg/lbs)
No. 1 80kg/176 lbs 0-10 kg / 0-22 lbs
No. 2 260kg/572 lbs 10-45 kg / 23-100 lbs
No. 3 580kg/1276 lbs 45-90 kg / 101-200 lbs
No. 4 1500kg/3300 lbs 90-225 kg / 210-495 lbs
No. 5 2160kg/4752 lbs 225-325 kg / 496-715 lbs
No. 6 2500kg/5500 lbs 325-500 kg / 715-1100 lbs

Ducting Supports:
 All ductwork shall be independently supported from building construction. All horizontal ducts shall be
rigidly and securely supported, in an approved manner, with hangers formed of galvanized steel wire ropes
and galvanized steel angle/channel or a pair of brackets, connected by galvanized steel wire hangers under
ducts, rigid supports may be provided at certain interval if need be. The spacing between supports should
be not greater than 2.4 meter. All vertical ductwork shall be supported by structural/strut members on
each floor slab. Duct supports may be through galvanized steel insert plates or Toggle end wire fixing left
in slab at the time of slab casting. Galvanized steel cleat with a hole for passing the wire rope hanger shall
be welded to the plates. Trapeze hanger formed of galvanized steel wire rope using hang fast shall be hung
through these cleats. Wherever use of metal insert plates is not feasible, duct support shall be through
dash/anchor fastener driven into the concrete slab by electrically operated gun. Wire rope supports shall
hang through the cleats or wire rope threaded studs can be screwed into the anchor fasteners. In case of
PEB structure Loop and Catenary system can be used based on the site conditions as per approved
suspension system drawings.

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 All horizontal ducts shall be adequately secured and supported. In an approved manner, with trapeze
Hangers formed of galvanized steel wire rope in a cradle support method (refer to typical drawings) under
ducts at no greater than 3000mm center, for 3001mm- above appropriate size angle along with neoprene
pad in between the duct & MS angle should be used with prior approval. All vertical duct work shall be
supported by structural members on each floor slab. Duct support shall be through dash / anchor fastener
driven into the concrete slab by electrically operated gun. Hanger wires shall then hang around the ducting.
Rigid supports shall be used in conjunction with wire rope hangers to assist with alignment of services
where recommended for by the manufacturer. Rigid support must also be used in conjunction with wire
rope hangers with duct work at each change of direction or connection. Support ducting in accordance with
relevant documents. Any other Wire hanging arrangement solution can be used based on manufacturer*s
recommendation on site conditions after prior approval. In cases of Spiral ducting the wire can be wrapped
directly around the ducting without the need for a spiral ducting clamp for sizes above 1100 a cradle
support should be provided refer to manufacturer*s recommendations.
Rigid Supports:
If the MS angle at the bottom is required as per design it should be as per following table:
Longer size of Duct Type of Joints
Up to 750 25x25x3 mm L angle with M8 nuts & bolts
751-1000 25x25x3 mm L angle with M8 nuts & bolts
1001-1500 40x40x5 mm L angle with M8 nuts & bolts
1501-2250 50x50x5 mm L angle with M10 nuts & bolts
2251 & above 50x50x6 mm L angle with M10 nuts & bolts
20 DUCTWORK INSULATION
Ducting insulation thickness shall be as per table below.
Ducting position Nitrile Rubber Glass Wool
SA duct in RA path 13 mm 25 mm
Ducted return air system SA duct: 19 mm RA duct: 13 mm SA duct: 50 mm RA duct: 25 mm
Both SA & RA exposed 25 mm 50 mm

The thickness of insulation material shall be as identified above. Following procedure shall be
adhered to:

Duct surfaces shall be cleaned to remove all grease, oil, dirt, etc. prior to carrying out insulation work. Measurement
of surface dimensions shall be taken properly to cut closed cell insulation to size with sufficient allowance in
dimension. Cutting of insulation sheets shall be done with adjustable blade to make 900 cuts in thickness of sheet.
Hackshaw or blades are not acceptable tools for cutting the insulation. Material shall be fitted under compression
and no stretching of material shall be permitted. All longitudinal and transverse joints shall be sealed by providing
50 mm wide Fiber glass cloth laminated tape as per manufacturer recommendations.

DUCT ACOUSTIC LINING: Open Cell Nitrile Rubber

Duct acoustic lining material shall be Nitrile Rubber open cell foam. Duct surfaces shall be cleaned to remove all
grease, oil, dirt, etc. prior to carrying out insulation work. Measurement of surface dimensions shall be taken
properly to cut closed cell insulation to size with sufficient allowance in dimension. Cutting of insulation sheets shall
be done with adjustable blade to make 900 cuts in thickness of sheet. Hacksaw or blades are not acceptable tools
for cutting the insulation.

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ACOUSTIC LINING OF MECHANICAL ROOMS

Open Cell Nitrile Rubber

All walls and ceiling of air handling unit rooms shall be provided with acoustic lining. Material shall be processed
from Nitrile rubber open cell foam. Surface shall be cleaned and two coats of adhesive recommended by the
manufacturer should be applied on the walls. The foam sheets should be cut to required size and a layer of adhesive
should also be applied to it. When it is tack dry, it is stuck to the walls / ceiling. Acoustic lining of walls shall be
terminated approximately 15 cm above the finished floor to prevent damage to insulation due to accidental water-
logging in AHU rooms.

21 SOUND ATTENUATORS
Attenuators shall be installed in ducts in accordance with relevant standards.
Noise levels within conditioned spaces shall be not greater than those set out in schedule
below:
Noise Level Design Criteria

Space MAXIMUM CONTROL LEVEL

Public Areas NC 40 – NC 45
Offices/ Administrative area, Public Toilets NC 40
Retails / F&B NC 35 - NC 45
Corridors/ Lobbies NC 35 - NC 45

 Approved make, type, and model of sound attenuators shall be installed as per approved material submittal.
 All sound attenuators sizes shall match the HVAC Ducting and approved noise level calculation.
 Galvanized angles and channels shall be used for supporting all sound attenuators.
 Sound attenuators shall be connected with ducting by flange which is already provided by the manufacturer.
 All sound attenuator shall be insulated as per project specification.
 Raise inspection request for installation of Sound Attenuators.

22 TESTING AND BALANCING

After the installation of the entire air distribution system is completed in all respects, all
ducts shall be tested for air leaks by visual inspection.
The entire air distribution system shall be balanced using an anemometer. Measured air quantities
at fan discharge and at various outlets shall be identical to or less/excess than 5 percent of those
specified and quoted. Complete air balance report shall be submitted for scrutiny and approval, and four
copies of the approved balance report shall be provided with completion documents.

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23 TESTING, ADJUSTING AND BALANCING

AIR SYSTEMS
Air Handlers Performance
The TAB procedure shall establish the right selection and performance of the AHUs with the
following results:
 Air-IN DB and WB temperature.
 Air-OUT DB and WB temperature.
 Dew point air leaving.
 Sensible heat flow.
 Latent heat flow.
 Sensible heat factor.
 Fan air volume.
 Fan air outlet velocity.
 Fan static pressure.
 Fan power consumption.
 Fan speed.

Air distribution

Both supply and return air distribution for each AHU and for areas served by the AHU shall be determined and adjusted as
necessary to provide design air quantities. It shall cover balancing of air through main and branch ducts utilizing telescoping
probes of Electronic Rotating Vane Anemometers and Equibalance for grilles and diffusers.

The Preparatory Work

To conduct the above test, following preparatory works are required to be carried out
including the availability of approved for construction shop drawings and submittals:
 All outside air intake, return air and exhaust air dampers are in proper position.
 All system volume dampers and fire dampers are in fully open position.
 All access doors are installed & are air tight.
 Grilles are installed & dampers are fully open.
 Provision and accessibility of usage of TAB instruments for traverse measurements are available.
 All windows, doors are in position.
 Duct systems are of proper construction and are equipped with turning vanes and joints are sealed.
 Test holes and plugs for ducting.

24 Health, Safety & Environment

 The safety standard and procedure shall be followed during erection and guard against unsafe working condition.
 Proper working environment for safety shall be provided during erection.
 Before commencing of work detail lifting plan required including crane arrangement with crane operator license and
crane documents.

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 Safety induction and work at height training compulsory for those who are going to do work at height and card to be
issued for same workers by ASCENT Electrification Engineering.
 Before commencing of work at height Hazard identification and Risk assessment plan to be submitted.
 Before commencing of work at height permit should be available with duly signed by client and Contractor.
 All activities to be envisaged in advance and job safety requirements to be worked out by analyzing likely hazards and
restoring to preventive.
 Proper PPEs shall be provided to all workers handling construction work.
 Scaffolding / Staging to be made and checked for desired strength and safety requirements.
 Loose materials must not be stacked on scaffolding platform which is fall hazardous.
 Platforms to be provided with hand railings & Access to be properly guarded.
 Work at height procedure to be followed for working at more than 1.5 Meter height.
 Unauthorized entry should be restricted in side working area by barricade the same. Proper signs to be provided.
 Electrical cables, if any should be properly arranged to avoid electrical hazard.
 Proper housekeeping at the end of the job is a part of the mandatory tasks assigned to workers to avoid accidents
due to littered tools and materials.
 Proper Illumination / lighting to be ensured at working area and also access up to the place and proper ventilation.
 Tool box talks to be conducted at regular intervals for execution team and records to be maintained of same.
 Fire extinguishers should always be available at site near hot work location as well as area where painting material is
stored.
 Calibrated pressure gauges and pressure safety valves only shall be used during hydro testing.

25-CHW PIPE WORK

25.1 Site Work-Field Joint
 Prefabricated pipe spools shall be carefully loaded and transported to site. The transported spools will be tied down
with ample support to prevent any damage. Spools will be tied down using nylon straps/belts.
 After receiving the pipe at site, the pipe shall be at placed at ground on top of wooden support. All flanged end or
open end will remain sealed to prevent any scratches or damage.
 Once the pipes are lifted into position, the fabricator/pipe fitter shall ensure that proper alignment is achieved.

25.2 Site Work- Welding of Pipe Supports

 As require some structural MS pipe support are to welded to the basic plates instead into the precast foundation.
Oter pipe support to be welded to existing pipes support.
 Location to be welded will be covered as require with a fire proof tarpaulin or fire extinguisher.
 The base plate or support shall be cleaned by grinding to remove any surface debris, or paint.

 The support will then be placed in position, aligned and tack welded. Once tack welding is completed, the alignment
will be rechecked and final welding will be carried out.

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 Welding shall be done based on the approved welding procedure for structural steel.

25.3 Site Work- Valve Installation

 Where ever valve to installed, the installation/orientation of valve handle and flow direction shall be
according to the piping layout.
 All valve install will be cross checked according to the Desc number to ensure the proper valve are installed in the
proper location.
 Valve shall be installed in the closed position except for ball valve and plug valves.
 New gaskets will be installed between the valve flange and pipe flange. Final tightening of all nuts shall be done one’s
proper alignment is achieved.
 Bolting of flanges will be done in cross pattern.
 All bolt, gaskets and valve shall be properly stored to avoid contamination with the environment. Valve end will be
sealed until installation and gasket and bolt shall be kept of any debris such as san d.

25.4 Resources
 Welding machine
 Grinding machine
 Preheating torches
 Cutting tools

26-Hot Tapping Work

1. Carry out site survey to identify the pipe to be Hot Tapping area.
2. Submit clearance from necessary sketches or photo to Clint for approval.
3. To obtain work permit, hot work permit and storage area for material.
4. To de-activate the building smoke detectors.
5. To remove any optical object for the hot tapping area and diversion area.
6. To pre-fabricate the short spool CHW valve at site.
7. Clere up the scale on surface area of the pipe for hot tap by grinder and sand paper.
8. Confirm all joint prepared for welding process is free from dust and grease.
9. Spot-weld the short spool and reconfirm the alignment of tee-joint assembly.
10. Carry out the electrical arc welding by using approved welding rod.
11. Installation of the gate valve on tee-joint.
12. Install the blind flange end plate to seal off the entire assembly for the hydraulic test.
13. Pressure test 1.5 time of the operating pressure and hold 30 minutes.
14. Find out the lea area and carry out the hydraulic test again.
15. After pressure test, drain off the water and remove the blind flange.

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16. To install hot tapping machine onto the gate valve.

17. To inspect any alignment run out faulty part.
18. Start hot tapping process.
19. Stop the hot tapping process if there is any abnormal sound or vibration echoed from assembly.
20. Start the water drain off process manually upon the pilot drill penetrations in the service pipe line.
21. Flush of the water from drain valve to remove the debris from assembly when the hot tapping near to complete.
22. Move back the bore head inside the hot tapping machine.
23. Carry out the flush from the drain valve again.
24. Shut-off the gate valve.
25. Dismantle the hot tapping machine.
26. Hot tapping process complete and the new tee-off is ready to use.

27- AHU Installation

27.1-RESOURCES

o Equipment & Machinery:

The following equipment will be used to carry out the installation of FANS.
 Mechanical hand tool
 Mobile Crane
 Fork Lift

27.2-METHODOLOGY

Storage

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 AHU shall be stored in such a manner as to preserve its quality condition.

 AHU are to be as per manufacturer recommendations but at the same time it should be accessible
 The quantity to be delivered at site for installation shall be consistent with the necessary required
quantity of the work to perform.

Setting Out
 Check the readiness of reference and coordinates.

 Check the other activates works related with the installations.

 Arrange all necessary work permit, check and verify the actual site condition.

Unloading and Shifting:

 AHU shall be transported by a delivery truck and mechanical crane / fork lift to the specific work
place.

 Safety Officer will be present during loading and unloading of.

 Two lifting point will be used during the loading and unloading of AHU to ensure safety that no
incident will occurs. Traffic Aide will be present during loading and unloading of Unit for maintaining
the traffic in the project site if needed.

 All lifting equipment will be inspected daily before operating. Any parts detected damages must be
replaced immediately before operating.

28-Installation for AHU at Concrete roof

Mechanical Installation: -

 Set and fix AHU steel frame at Unit location at roof.

 Connect Unit with duct through duct reducer.

 Installation manual attached.

29-Electrical Installation: -

 Connect power cable from MCC Panel to disconnecting switch.

 Connect Power Cable from disconnecting switch to Unit motor.

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30-QUALITY ASSURANCE

Material: Approved submittal.

Location: As per approved shop drawing.


PPE Requirements

As a minimum the following PPE should be used by staff / Labors

 Safety helmet.

 Safety shoes.

 Safety eye glasses.

 Hand gloves.

 High visibility vest.

Any additional PPE as required by local rules or mandatory requirement shall be used.

Safety Accessories

 Traffic Cones.
 Warning /barricade/barrier tape.
 Safety signs.
 Cooled water container for drinking.
 First Aid box.
 Workers rest area
 Portable toilet
 Fire extinguishers
 Sign boards of Emergency contact details/persons

Information to Personnel.

 Safety Induction will be done in accordance with HSE Policy prior to start work in site.

 Safety toolbox meetings to be carried out prior to work.

 Before job start checklist of protective & safety equipment to be use are in order.
 Personal protective & safety equipment as per requirement to be performed by personnel to do the
task.

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 Toolbox talk to be convened & attended by all personnel assigned to do the task. Work crew will be
given instruction on site surveying procedure & all risk associated with the works and registered
attendance.

 Safety personnel & designated responsible person will ensure that all above is carried out & any
other statutory requirements are complied with before any work takes.

 Hazard analysis to be done.


 Personnel who have been briefed in the correct equipment set up.

 Personnel will wear gloves, footwear, head & eye protection during work.
 Use the correct tools to do the task.

 Removal of any obstructive / protruding materials

APPENDICES
1. Risk assessment.

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