Chapter 4101:8-16 Duct Systems
[Comment: When a reference is made within this rule to a federal statutory provision, an industry consensus standard, or any other technical publication, the specific date and title of the publication as well as the name and address of the promulgating agency are listed in rule 4101:8-44-01 of the Administrative Code. The application of the referenced standards shall be limited and as prescribed in section 102.5 of rule 4101:8-1-01 of the Administrative Code.]
1601.1 Duct design. Duct systems serving heating, cooling and ventilation equipment shall be fabricated in accordance with the provisions of this section and ACCA Manual D or other approved methods.
1601.1.1 Above-ground duct systems. Above-ground duct systems shall conform to the following:
1. Equipment connected to duct systems shall be designed to limit discharge air temperature to a maximum of 250°F (121°C).
2. Factory-made air ducts shall be constructed of Class 0 or Class 1 materials as designated in Table 1601.1.1(1).
3. Fibrous duct construction shall conform to the SMACNA Fibrous Glass Duct Construction Standards or NAIMA Fibrous Glass Duct Construction Standards.
4. Minimum thickness of metal duct material shall be as listed in Table 1601.1.1(2). Galvanized steel shall conform to ASTM A 653.
5. Use of gypsum products to construct return air ducts or plenums is permitted, provided that the air temperature does not exceed 125°F (52°C) and exposed surfaces are not subject to condensation.
6. Duct systems shall be constructed of materials having a flame spread index not greater than 200.
7. Stud wall cavities and the spaces between solid floor joists to be used as air plenums shall comply with the following conditions:
1. These cavities or spaces shall not be used as a plenum for supply air.
2. These cavities or spaces shall not be part of a required fire-resistance-rated assembly.
3. Stud wall cavities shall not convey air from more than one floor level.
4. Stud wall cavities and joist-space plenums shall be isolated from adjacent concealed spaces by tight-fitting fire blocking in accordance with Section 602.8.
CLASSIFICATION OF FACTORY-MADE AIR DUCTS
|DUCT CLASS||MAXIMUM FLAME-SPREAD INDEX|
1601.1.2 Underground duct systems. Underground duct systems shall be constructed of approved concrete, clay, metal or plastic. The maximum duct temperature for plastic ducts shall not be greater than 150°F (66°C). Metal ducts shall be protected from corrosion in an approved manner or shall be completely encased in concrete not less than 2 inches (51 mm) thick. Nonmetallic ducts shall be installed in accordance with the manufacturer's installation instructions. Plastic pipe and fitting materials shall conform to cell classification 12454-B of ASTM D 1248 or ASTM D 1784 and external loading properties of ASTM D 2412. All ducts shall slope to an accessible point for drainage. Where encased in concrete, ducts shall be sealed and secured prior to any concrete being poured. Metallic ducts having an approved protective coating and nonmetallic ducts shall be installed in accordance with the manufacturer's installation instructions.
1601.2 Factory-made ducts. Factory-made air ducts or duct material shall be approved for the use intended, and shall be installed in accordance with the manufacturer's installation instructions. Each portion of a factory-made air duct system shall bear a listing and label indicating compliance with UL 181 and UL 181A or UL 181B.
GAGES OF METAL DUCTS AND PLENUMS USED FOR HEATING OR COOLING
|DUCT SIZE||MINIMUM THICKNESS (inches)||EQUIVALENT GALVANIZED SHEET NO.||MINIMUM THICKNESS (in.)|
|Round ducts and enclosed rectangular ducts 14 inches or less 16 and 18 inches 20 inches and over||0.01270.01870.0236||30 26 24||0.01750.0180.023|
|Exposed rectangular ducts 14 inches or less Over 14a inches||0.01570.0187||28 26||0.01750.018|
For SI: 1 inch = 25.4 mm.
a. For duct gages and reinforcement requirements at static pressures of 1/2 inch, 1 inch and 2 inches w.g., SMACNA Duct Construction Standard, Tables 2-1; 2-2 and 2-3 shall apply.
1601.2.1 Vibration isolators. Vibration isolators installed between mechanical equipment and metal ducts shall be fabricated from approved materials and shall not exceed 10 inches (254 mm) in length.
1601.3 Duct insulation materials. Duct insulation materials shall conform to the following requirements:
1. Duct coverings and linings, including adhesives where used, shall have a flame spread index not higher than 25, and a smoke-developed index not over 50 when tested in accordance with ASTM E 84 or UL 723, using the specimen preparation and mounting procedures of ASTM E 2231.
Exception: Spray application of polyurethane foam to the exterior of ducts in attics and crawl spaces shall be permitted subject to all of the following:
1. The flame spread index is not greater than 25 and the smoke-developed index is not greater than 450 at the specified installed thickness.
2. The foam plastic is protected in accordance with the ignition barrier requirements of Sections 316.5.3 and 316.5.4.
3. The foam plastic complies with the requirements of Section 316.
2. Duct coverings and linings shall not flame, glow, smolder or smoke when tested in accordance with ASTM C 411 at the temperature to which they are exposed in service. The test temperature shall not fall below 250°F (121°C).
3. External duct insulation and factory-insulated flexible ducts shall be legibly printed or identified at intervals not longer than 36 inches (914 mm) with the name of the manufacturer, the thermal resistance R-value at the specified installed thickness and the flame spread and smoke-developed indexes of the composite materials. Spray polyurethane foam manufacturers shall provide the same product information and properties, at the nominal installed thickness, to the customer in writing at the time of foam application. All duct insulation product R-values shall be based on insulation only, excluding air films, vapor retarders or other duct components, and shall be based on tested C-values at 75°F (24°C) mean temperature at the installed thickness, in accordance with recognized industry procedures. The installed thickness of duct insulation used to determine its R-value shall be determined as follows:
1. For duct board, duct liner and factory-made rigid ducts not normally subjected to compression, the nominal insulation thickness shall be used.
2. For ductwrap, the installed thickness shall be assumed to be 75 percent (25-percent compression) of nominal thickness.
3. For factory-made flexible air ducts, The installed thickness shall be determined by dividing the difference between the actual outside diameter and nominal inside diameter by two.
4. For spray polyurethane foam, the aged R-value per inch measured in accordance with recognized industry standards shall be provided to the customer in writing at the time of foam application. In addition, the total R-value for the nominal application thickness shall be provided.
1601.4 Installation. Duct installation shall comply with Sections 1601.4.1 through 1601.4.7.
1601.4.1 Joints and seams. Joints of duct systems shall be made substantially airtight by means of tapes, mastics, liquid sealants, gasketing or other approved closure systems. Closure systems used with rigid fibrous glass ducts shall comply with UL181A and shall be marked 181A-P for pressure-sensitive tape, 181A-M for mastic or 181 A-H for heat-sensitive tape. Closure systems used with flexible air ducts and flexible air connectors shall comply with UL 181B and shall be marked 181B-FX for pressure-sensitive tape or 181B-M for mastic. Duct connections to flanges of air distribution system equipment or sheet metal fittings shall be mechanically fastened. Mechanical fasteners for use with flexible nonmetallic air ducts shall comply with UL 181B and shall be marked 181B-C. Crimp joints for round metal ducts shall have a contact lap of at least 11/2 inches (38 mm) and shall be mechanically fastened by means of at least three sheet-metal screws or rivets equally spaced around the joint. Closure systems used to seal metal ductwork shall be installed in accordance with the manufacturer's installation instructions.
1. Spray polyurethane foam shall be permitted to be applied without additional joint seals.
2. Where a duct connection is made that is partially inaccessible, three screws or rivets shall be equally spaced on the exposed portion of the joint so as to prevent a hinge effect.
3. Continuously welded and locking type longitudinal joints and seams in ducts operating at static pressures less than 2 inches of water column (500 Pa) pressure classification shall not require additional closure systems.
1601.4.2 Plastic duct joints. Joints between plastic ducts and plastic fittings shall be made in accordance with the manufacturer's installation instructions.
1601.4.3 Support. Metal ducts shall be supported by 1/2-inch (13 mm) wide 18-gage metal straps or 12-gage galvanized wire at intervals not exceeding 10 feet (3048 mm) or other approved means. Nonmetallic ducts shall be supported in accordance with the manufacturer's installation instructions.
1601.4.4 Fireblocking. Duct installations shall be fireblocked in accordance with Section 602.8.
1601.4.5 Duct insulation. Duct insulation shall be installed in accordance with the following requirements:
1. A vapor retarder having a maximum permeance of 0.05 perm [ 2.87 ng/(s . m2 . Pa)] in accordance with ASTM E 96, or aluminum foil with a minimum thickness of 2 mils ( 0.05 mm), shall be installed on the exterior of insulation on cooling supply ducts that pass through unconditioned spaces conducive to condensation except where the insulation is spray polyurethane foam with a maximum water vapor permeance of 3 perm per inch [1722 ng/(s m2 Pa)] at the installed thickness.
2. Exterior duct systems shall be protected against the elements.
3. Duct coverings shall not penetrate a fireblocked wall or floor.
1601.4.6 Factory-made air ducts. Factory-made air ducts shall not be installed in or on the ground, in tile or metal pipe, or within masonry or concrete.
1601.4.7 Duct separation. Ducts shall be installed with at least 4 inches (102 mm) separation from earth except where they meet the requirements of Section 1601.1.2.
1601.4.8 Ducts located in garages. Ducts in garages shall comply with the requirements of Section 302.5.2.
1601.4.9 Flood hazard areas. In areas prone to flooding as established by Table 301.2(1), duct systems shall be located or installed in accordance with Section 322.1.6.
1601.5 Under-floor plenums. Under-floor plenums shall be prohibited in new structures. Modification or repairs to under-floor plenums in existing structures shall conform to the requirements of this section.
1601.5.1 General. The space shall be cleaned of loose combustible materials and scrap, and shall be tightly enclosed. The ground surface of the space shall be covered with a moisture barrier having a minimum thickness of 4 mils ( 0.1 mm). Plumbing waste cleanouts shall not be located within the space.
Exception: Plumbing waste cleanouts shall be permitted to be located in unvented crawl spaces that receive conditioned air in accordance with Section 408.3.
1601.5.2 Materials. The under-floor space, including the sidewall insulation, shall be formed by materials having flame-spread index values not greater than 200 when tested in accordance with ASTM E 84.
1601.5.3 Furnace connections. A duct shall extend from the furnace supply outlet to not less than 6 inches (152 mm) below the combustible framing. This duct shall comply with the provisions of Section 1601.1. A noncombustible receptacle shall be installed below any floor opening into the plenum in accordance with the following requirements:
1. The receptacle shall be securely suspended from the floor members and shall not be more than 18 inches (457 mm) below the floor opening.
2. The area of the receptacle shall extend 3 inches (76 mm) beyond the opening on all sides.
3. The perimeter of the receptacle shall have a vertical lip at least 1 inch (25 mm) high at the open sides.
1601.5.4 Access. Access to an under-floor plenum shall be provided through an opening in the floor with minimum dimensions of 18 inches by 24 inches (457 mm by 610 mm).
1601.5.5 Furnace controls. The furnace shall be equipped with an automatic control that will start the air-circulating fan when the air in the furnace bonnet reaches a temperature not higher than 150°F (66°C). The furnace shall additionally be equipped with an approved automatic control that limits the outlet air temperature to 200°F (93°C).
1601.6 Independent garage HVAC systems. Furnaces and air-handling systems that supply air to living spaces shall not supply air to or return air from a garage.
1602.1 Return air. Return air shall be taken from inside the dwelling. Dilution of return air with outdoor air shall be permitted.
1602.2 Prohibited sources. Outdoor and return air for a forced-air heating or cooling system shall not be taken from the following locations:
1. Closer than 10 feet (3048 mm) to an appliance vent outlet, a vent opening from a plumbing drainage system or the discharge outlet of an exhaust fan, unless the outlet is 3 feet (914 mm) above the outside air inlet.
2. Where flammable vapors are present; or where located less than 10 feet (3048 mm) above the surface of any abutting public way or driveway; or where located at grade level by a sidewalk, street, alley or driveway.
3. A room or space, the volume of which is less than 25 percent of the entire volume served by the system. Where connected by a permanent opening having an area sized in accordance with ACCA Manual D, adjoining rooms or spaces shall be considered as a single room or space for the purpose of determining the volume of the rooms or spaces.
Exception: The minimum volume requirement shall not apply where the amount of return air taken from a room or space is less than or equal to the amount of supply air delivered to the room or space.
4. A closet, bathroom, toilet room, kitchen, garage, mechanical room, boiler room, furnace room, unconditioned attic or other dwelling unit.
5. A room or space containing a fuel-burning appliance where such room or space serves as the sole source of return air.
1. The fuel-burning appliance is a direct-vent appliance or an appliance not requiring a vent in accordance with Section 1801.1 or Chapter 24.
2. The room or space complies with the following requirements:
1. The return air shall be taken from a room or space having a volume exceeding 1 cubic foot for each 10 Btu/h ( 9.6 L/W) of combined input rating of all fuel-burning appliances therein.
2. The volume of supply air discharged back into the same space shall be approximately equal to the volume of return air taken from the space.
3. Return-air inlets shall not be located within 10 feet (3048 mm) of any appliance firebox or draft hood in the same room or space.
3. Rooms or spaces containing solid-fuel burning appliances, if return-air inlets are located not less than 10 feet (3048 mm) from the firebox of those appliances.
6. An unconditioned crawl space by means of direct connection to the return side of a forced air system. Transfer openings in the crawl space enclosure shall not be prohibited.
1602.3 Inlet opening protection. Outdoor air inlets shall be covered with screens having openings that are not less than 1/4 inch ( 6.4 mm) and not greater than 1/2 inch ( 12.7 mm).