Things to know regarding ducting fabrication

Ducting serves as an essential element in many industries and commercial buildings, as it is responsible for the passage of air, gases, dust particles, and so on. Ducting systems are important in maintaining good indoor air quality and temperature regulation and also from poisonous fumes and dust. The ducting fabrication, thus, entails a lot of consideration prior to the actual construction and execution of the work. This article is therefore intended to give some insights in relation to ducting fabrication as well as the areas of concern to organizations and contractors.

• Importance of Ducting

Ducts contain the purpose of moving, filtering, heating or cooling air or any other gases required within a premise. Ductwork in various systems optimizes energy usage in heating ventilating and air conditioning systems, ejects airborne pollutants through industrial ventilation, and minimizes chances of emission of toxic gases. Mistakes made during the construction of the ducts are bad air flow, poor air quality indoor, safety and energy wastage, high energy bills. Fiber reinforced epoxy and polyester ducting, on the other hand, is very carefully constructed for this purpose to gain the best possible system efficiency.

• Design Considerations

Several factors affect duct layout, and some of them include, desired airflow rate, available space, operating pressures, nature of the air or gas to be transported and the code and standards that apply. The design of ductwork has a direct influence on fabrication, and therefore, it should be designed by a competent engineer or technician who will come up with the layout and specifications of the duct in consideration of factors such as the type, material, thickness, reinforcements, joints, hangers, and fittings of the duct. Particular emphasis should be put on the changes in the shape and direction, connections with equipment and pressure drop.

• Duct Materials 

There are different types of materials used to fabricate ducts; however, galvanized steel and aluminum sheets are the most popular due to the aspects like durability, workability, light weight, and cost. Stainless steel materials are well suited for corrosion while fiberglass is good for insulation. The design and type of duct can influence joints and seals. Other influences include thermal conductance, outgassing, off-gassing, potential for microbe growth, and interaction with substances conveyed through the ducts. It is advisable to consult professionals when choosing materials for the construction in order to consider such factors as the functionality of the material, safety, durability and cost.  

• Fabrication Process

Sourcing ducting requires precise metal operations involving the use of tools, and different machines for cutting, bending, forming, attaching, strengthening, and welding thin metal for the formation of a duct system. Tools like lockformers, presses, sheet metal brakes and others make it possible to achieve precise duct sizes and functional shapes required to direct air flows, turn them around corners or fit into specific spaces wherever needed. Blades, diffusers, housings, covers and frames are assembled by highly skilled technicians into a single unit through mechanical joining techniques such as bolts, welding, sealing, and bonding to ensure that all joints are robust and leak-proof as required.

• Quality Control

Tight quality control measures ensure that the ducts possess the physical and dimensional attributes and functionality needed. Use visual checks to detect faults in the ducts and then conduct pressure tests to confirm the findings. Smoke generators should be used to determine the direction of air movement and gaps within a structure. This confirms that the structure is airtight, smooth, structural integrity, and meets the quality standards. Even so, due to possible defects, refabrication may be required in order to make necessary improvements. As a result, it is more reasonable to inspect at random at the time of fabrication rather than testing only the duct sections that are ready.

• Installation Factors

Care is required to store the finished ducts and protect them from damage until the time of installation is arrived at. Check for any possible kinks, dents, and leaks in the sections before fitting them. Sequence installation for ease of connections between the duct sections. The methods of anchoring and bracing should provide necessary support to the structures and, at the same time, should not interfere with vibration isolation or expansive thermal movement. Thus no matter how many joints there are in the house, all of them should close hermetically so that there is no air infiltration. The airflows must be balanced by the use of volume control damper in the branch ducts. Make airtight where necessary to minimize heat exchange and condensation.

• Maintenance Needs

Create schedules for the maintenance of ducts based on the properties of air/gas conveyed, probability of particulate buildup, corrosion propensity, microbial growth potential, and possible condensation control. Doors with a latch are provided at key areas making inspection and cleaning easy. Measure pressure drops over time to identify decreases pointing towards blockages so that corrective measures can be taken. Some of the General Maintenance Requirements that may be considered are as follows: Leakage testing, inspection of joints and hangers, corrosion checking, cleaning and microbial observation.

• Workplace Safety

There are many risks associated with ductwork fabrication because the work often involves cutting, bending and shaping sheet metal, potentially heavy parts, hot work and use of tools and equipment which can be dangerous. Employees require protection gear from hazards at the workplace and appropriate training on how to operate machines. Minimizing clutter on work areas and clear aisles and good lighting and ventilation also aids in the reduction of accidents. Platforms for such work and fall protection means are required for elevated ducts. Welding fume extraction and metalworking fluid mist protection is facilitated by fume extraction systems in fabrication shops. They cover finished ducts, and handling and stack-up also safeguard them.  

Conclusion

Constructing ducting in structural steel manufacturers that works well and is solid means that a lot of planning, designing, picking out materials, machining, assembling, quality controlling, protection and installing have to be done. Design and develop suitable ducts for the application by employing competent engineers and expert technicians. All ducts should be properly maintained through regular inspections and servicing in order to maintain the indoor climate and the processes running smoothly. Thus, following ductwork standards and safety measures helps organizations not only to minimize risks and remain legal but also to enhance the efficiency of the systems that are produced.