DUCTING

Gauge Thickness to Millimetres:

 18 Gauge: 1.2 mm
 20 Gauge: 0.91 mm
 22 Gauge: 0.76 mm
 24 Gauge: 0.61 mm

Fabrication of Ducts: Types, Process, and Usage

Ducts are essential for HVAC (Heating, Ventilation, and Air Conditioning) and
ventilation systems. The fabrication process involves cutting, forming, and assembling
materials to create ductwork that can transport air efficiently.

1. Types of Ducts (Based on Material)

1. Galvanized Steel Ducts

o Usage: Commonly used in commercial, industrial, and residential HVAC
systems.
o Advantages: Corrosion-resistant, durable, and easy to clean.
o Fabrication: Cut into shape and joined using slip joints, flanges, or S-
cleats.
2. Stainless Steel Ducts
o Usage: Used in environments with high temperatures, moisture, or
corrosive conditions (kitchens, laboratories, etc.).
o Advantages: Highly resistant to rust and chemical corrosion.
o Fabrication: Same as galvanized steel, but requires more precision and
specialized tools.
3. Aluminum Ducts
o Usage: Used in marine, offshore, and lightweight construction applications.
o Advantages: Lightweight, corrosion-resistant, and easier to work with.
o Fabrication: Typically fabricated with roll-forming machines and
connected with rivets or flanges.
 4. Flexible Ducts (Insulated/Non-Insulated)
o Usage: Used in small residential applications and for connecting diffusers
to rigid duct systems.
o Advantages: Flexible, lightweight, and requires minimal joints.
o Fabrication: No on-site fabrication is needed; pre-fabricated flexible ducts
are cut to the required length.
5. Fabric Ducts (Air Socks)
o Usage: Used in cleanrooms, commercial kitchens, and areas requiring even
airflow.
o Advantages: Lightweight, washable, and allows even air distribution.
o Fabrication: Pre-fabricated as textile tubes that are suspended from the
ceiling.
6. PVC and Plastic Ducts
o Usage: Used in corrosive environments like chemical processing plants.
o Advantages: Chemically resistant, lightweight, and easy to install.
o Fabrication: Pipes are joined using solvent welding or mechanical joints.

2. Duct Fabrication Process

Step 1: Design & Layout

 Design the layout according to HVAC drawings and shop drawings.

 Calculate the dimensions, pressure class, and airflow requirements.
 Software like AutoCAD, Revit, and CAM software is used for layout.

Step 2: Material Selection

 Choose the appropriate material (steel, aluminum, fabric, etc.) based on system
requirements (temperature, pressure, corrosion resistance, etc.).

Step 3: Cutting

 Tools Used: Plasma cutters, shears, or CNC cutting machines.

  The material is cut into sheets according to design dimensions.

Step 4: Forming

 Tools Used: Roll formers, press brakes, and crimpers.

 The sheets are bent or rolled into rectangular, circular, or spiral shapes.

Step 5: Joining / Assembly

 Types of Joints: Slip joints, flange joints, S-cleats, and spot welding.
 Rivets, bolts, or mechanical fasteners are used to secure connections.

Step 6: Sealing

 Sealant, gaskets, or adhesive tapes are used to ensure airtight connections.

 This step is crucial to prevent leakage and ensure system efficiency.

Step 7: Insulation (If Required)

 Insulation is applied externally (for metal ducts) or internally (in flexible ducts) to
reduce heat loss and noise.

Step 8: Quality Check & Testing

 Check for leakages, measure air pressure, and verify system performance.
 Duct leakage tests are conducted to ensure efficiency.

3. Usage of Ducts in MEP Systems

1. HVAC Systems: Used for heating, cooling, and ventilation.

2. Exhaust Systems: Used to remove stale air, fumes, or harmful gases.
3. Kitchen Ventilation: Stainless steel ducts are used in kitchen exhaust systems.
4. Cleanrooms and Laboratories: PVC and fabric ducts ensure clean airflow.
5. Industrial Use: Used for dust collection, fume extraction, and chemical exhaust.
Duct Size Rod Rod Diameter Rod Diameter No. of Rods per Total Rods
(in) Length (in) (mm) Hanger per 12 ft

0" – 12" 12' 1/4" 6.35 mm 1 9

13" – 30" 12' 3/8" 9.53 mm 2 18

31" – 54" 12' 3/8" 9.53 mm 2 18

55" – 84" 12' 1/2" 12.7 mm 2 18

85" – 120" 12' 1/2" 12.7 mm 3 27

121" –
12' 5/8" 15.88 mm 3 27
144"

Ducting Materials Chart with GI Sheets and Gauge Thickness

Thickness Pressure Temperature Corrosion Key

Material Gauge Applications
(mm) Withstanding Withstanding Resistance Propertie

Cost-
effective,
Low to
HVAC ducts, kitchen durable, b
Galvanized moderate (~-2 Up to 200°C
18 1.2 Moderate exhaust, commercial needs
Iron (GI) to +3 inches (392°F)
ducts protection
WC)
aggressive
environmen

Lightweight
Low to
easy to insta
moderate (~-2 Up to 200°C Residential/commercial
20 0.91 Moderate but requi
to +3 inches (392°F) HVAC, kitchen exhaust
corrosion
WC)
protection
 Thickness Pressure Temperature Corrosion Key
Material Gauge Applications
(mm) Withstanding Withstanding Resistance Propertie

Flexible, le
Low (~-1 to Up to 200°C Light-duty HVAC,
22 0.76 Moderate durable th
+2 inches WC) (392°F) residential ducts
thicker gaug

Least durab
Low (~-1 to Up to 200°C Small-scale HVAC, but co
24 0.61 Moderate
+2 inches WC) (392°F) residential systems effective, ea
to handle

High
corrosion
Up to 500°C Chemical processing,
Stainless Moderate (~-4 resistance,
(932°F) for food processing,
Steel 18 1.2 to +10 inches High suitable
304; ~870°C corrosive environments
(304/316) WC) high-pressur
for 316 (coastal areas)
high-temp
systems

High
Up to 500°C durability,
Moderate (~-2
(932°F) for Industrial, marine, high- used
20 0.91 to +5 inches High
304; ~870°C pressure systems industrial a
WC)
for 316 high-temp
environmen

Lightweight
Light-duty HVAC, easy to insta
Low (~-2 to Up to 120°C Low to
Aluminum 18 1.2 kitchen ventilation, non- not
+2 inches WC) (248°F) moderate
abrasive exhaust corrosive
environmen

Easy
fabricate, le
Low (~-2 to Up to 120°C Low to Residential HVAC, pressure-
20 0.91
+2 inches WC) (248°F) moderate office air ducts resistant th
thicker
materials

PVC 20 0.91 Moderate (~-5 Up to 60°C High Chemical exhaust, labs, Corrosion-
to +5 inches (140°F) corrosive environments resistant, lo
WC) temperature
limit, not
high-temp
 Thickness Pressure Temperature Corrosion Key
Material Gauge Applications
(mm) Withstanding Withstanding Resistance Propertie

applications

Excellent
chemical
FRP Chemical fume resistance,
Moderate (~-4
(Fiberglass Up to 100°C extraction, corrosive brittle und
20 0.91 to +6 inches Very high
Reinforced (212°F) environments, acid impact, hi
WC)
Plastic) exhaust systems durability
harsh
conditions

Strong,
High (~-10 to Industrial exhausts,
Carbon Up to 400°C durable, nee
18 1.2 +15 inches Low high-temp HVAC, dust
Steel (752°F) anti-corrosio
WC) collection
coating

Durable b
High (~-10 to
Up to 400°C HVAC, high-pressure prone to r
20 0.91 +15 inches Low
(752°F) exhaust without
WC)
coating

Flexible,
corrosion-
Low to Underground ducting,
resistant, b
moderate (~-3 Up to 60°C chemical fume
HDPE 20 0.91 Very high limited
to +3 inches (140°F) extraction, moist
low-
WC) environments
temperature
applications
 Low Medium
High Velocity 🧠 Notes
Duct Type Velocity Velocity
800–1200 1200–1800 High velocity saves space but adds noise
Main Supply 1800–2500 fpm
fpm fpm and friction loss
Branch 600–1000 1000–1400 Limit based on diffuser noise, usually
1400–1800 fpm
Supply fpm fpm not high velocity

Return 700–1000 1000–1400 Rarely >1600

Higher velocities = higher return noise
Ducts fpm fpm fpm

Exhaust 600–1000 1000–1500 Can go high in parking/industrial

1500–1800 fpm
Ducts fpm fpm exhaust
Fresh Air 500–800 Rarely >1500 Limited to reduce outdoor noise
800–1200 fpm
Ducts fpm fpm transmission
Diffuser 300–700 Up to 1000 Not
Above 800 fpm can cause drafts & noise
Necks fpm fpm recommended

Duct design according to velocities

Duct design parameters

Head Loss: 0.026 in.wg per 100 ft

Pressure loss due to friction along 100 ft of duct.

 ASHRAE & SMACNA Recommendations:

o Main ducts: ≤ 0.1 in.wg / 100 ft
o Ideal: 0.05 to 0.08 in.wg / 100 ft
o Quiet systems: ≤ 0.05 in.wg / 100 ft