LIST OF CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.

0 Introduction Scope of Work References Purpose Responsibility Work Procedures Construction Method Safety & Health Aspects QA/QC Aspects

PAGE 2 2 2 2 2 2 3 8 8

ANNEXURE Annexure 1 Annexure 2 : : Inspection & Checklist Sheet Metal Construction Table

1.0 Introduction The following is a document of the method statement and installation procedure for ductwork to the air conditioning and mechanical ventilation system for the KL Plaza Refurbishment Podium.

2.0 Scope of Work This section defines the necessary requirement and measures for site fabrication, assembly, installation of ductwork with accessories and fittings.

3.0

References This method statement shall be based on following specification and references: a. ASHRAE b. SMACNA HVAC Duct Construction c. The TDC Addendum To The 1985 SMACNA HVAC Duct Construction Standards d. Uniform Building By Laws

4.0

Purpose

The ACMV installation works shall comply strictly with project specifications & standards, drawings, relevant authority regulations, by laws & codes currently in force.
5.0 Responsibility Site Supervisor, Site Engineer and Consultants Representative shall carry out supervision and verification in order to ensure the works are done in accordance with required specification

6.0

Work Procedures a. All ducts material and accessories delivered to site shall be inspected by Consultants Representative to ensure correct materials and gauges being used.

b.

The duct materials will then send to designated area for assembly and installation. Prior to installation, Consultants Representative will inspect and check the ducts cleanness and duct size.

c. After inspection passed, rectangular ducts are installed as per approved shop drawing.

d.

After installation of the main ductwork, install branch duct, VCD, MFD, FD and grille as indicated in approved shop drawing. For medium pressure ductwork such as smoke spill and pressurization duct, duct air leak test shall be carried out before any connection to VCD, MFD, FD and branch duct being done.

e. On completion of duct leak test that has been verified by Consultants Representative, external insulation work may commence. Insulation shall be applied to clean and dry surface. f. Once the insulation work completed, work inspection will be carried out and certified by Consultants Representative. 7.0 Construction Method The work methodology can be divided into two major parts, namely installation of air ductwork and installation of fire damper / motorized fire damper. 7.1 Installation of Air Duct Work (a) General

All sheet metal ductwork shall be constructed and installed in accordance with the ASHRAE and SMACNA recommendation. Fabrication in factory shall be based on measurement from approved shop drawing and site. Shop drawing shall be submitted and coordinated with other services. The shop drawing shall also indicate the duct installation location, duct size, access panel, damper location and flange location and supports. Due to site accuracy and condition, the last jointing section or final location indicating offsets or transition will be measured at site. All fabricated ducts per batch shall be marked for identification with location and gauge thickness, and check by the sub-contractor supervisor before installation. The important points to be checked are any damages to the fabricated ducts, correct construction and reinforcement, approved type of material used, size and gauge, seam joints and sealant. (b) Duct Support

In general, use trapeze with angle iron and suspension rod fastened overhead with expansion type anchor plug. A table of angle iron and suspension rod size shall be provided with the shop drawings. Duct support brackets shall be hot-dip galvanized. Generally, the spacing between each bracket shall be 1800mm. More quantity will be used at corner, fittings and at main branch tee off point.

c)

Duct Joints

(i) For rectangular duct of 1 inch W.G. static pressure (low pressure), use drive slip
(S/D slip) for size 0 300 mm and standing S-slip (SMACNA T - 10) for size 301 900 mm. TDC (Transverse Duct Joint Connection) is used when duct size is 901 mm and above

(ii) For all the medium pressure ductwork with static pressure up to 3 inch W.G, smoke
spill duct (G18), car park ducting (G18), TDC will be used. Refer to attached proposed Sheet Metal Construction Table. The four comers of each duct joints shall be sealed with an approved type of sealant

(d)

Duct Reinforcement (i) For 1 inch W.G. static pressure (low pressure), centre tie rod (CTR) will be used only for duct size bigger than 1500mm as per attached proposed Sheet Metal Construction Table (ii) For 3 inch W.G. static pressure (medium pressure), centre tie rod (CTR) will be used only for duct size bigger than 1000mm as per attached proposed Sheet Metal Construction Table (iii) Maximum CTR spacing is 48 inched as per attached proposed Sheet Metal Construction Table

(e)

Duct Gauge (i) For smoke spill duct, G 18 sheet metal shall be used any other section indicate in the drawing, G18 sheet metal shall be used

(ii) For fire-rated duct on roof top connecting to pressurization fan, smoke spill fan and (iii) For any pressurization duct branch out from RC shaft to lift lobby and staircase
within the same fire compartment, G 18 duct will be used (iv) Mechanical ventilation duct in M & E rooms and toiled etc, are of low-pressure construction

(v) For VAV duct system, the duct before the VAV box is of medium pressure rating
and after the VAV box is of low pressure rating

(vi) Refer proposed Sheet Metal Construction Table for duct gauges for low and
medium pressure static pressure

(f)

Circular Flexible Duct Circular flexible ductwork shall be fabricated from resilient coated spring steel wire helix fully bound in multiple layers of reinforced aluminium foil. Air-conditioning flexible ducts shall be factory pre-insulated and vapour sealed. For circular flexible ductwork shall be made with short spigot of galvanized sheet metal circular duct to form a slip joint.

(g)

Installation Sequence

(i)

Check the layout of ductwork routing on site using approved shop drawing and based on actual site condition after coordination with other sub-contractors.

(ii) Measure, fabricate and install duct hanger and support. Length of hanger rod is measured to meet the correct level and shall be slightly longer, sufficient to fix the nut below. (iii) Assemble air duct in sections and install on duct support. Install the main ductworks line first, following by branch connections. Check duct levels with reference to the marked reference level line as per provided by the Builder. (iv) Install bends, tees, damper, offsets, flexible connection take-off and similar fittings necessary to complete the ductwork system for the balancing and full operation of the air distribution system.

(v) Install dampers and access doors as indicated in the approved shop drawing.
(vi) For connection to supply air outlets, use flexible ducts which are to be installed later. Flexible duct, supply air diffuser / grilles and return air grilles will be installed only after the completion of ceiling tees. (vii) Apply approved sealant to the branch joint, transverse joint, transverse joint etc. (viii) During installation, open duct end shall be covered with plastic sheet to prevent ingress of duct and any other unwanted material. (h) (i) Insulation of ductwork Use fiberglass blanket of correct thickness and density. Refer to table below:

Item (A) 1 2

Description External Insulation Cooled supply air ducts concealed in unconditioned spaces, inside shaft or at the highest floor Return air duct from conditioned spaces including mechanical equipment room and free return ceiling plenum Cooled supply air ducts within free return ceiling plenum including the AHU rooms Internal Duct Lining Supply air duct, mat faced Return air duct, mat faced Supply air discharged plenum from AHU outlet within Plantroom

Insulation Thickness (mm) 50 25

Density kg/mm3 32 32

25

32

(B) 1 2 3

50 50 50

24 24 32

NOTE : When internal duct lining been apply, external insulation is no need for that part of ductwork (ii) Use flinkote to fix fiberglass blanket to G.I. sheet metal and Dunlop adhesive to
glue aluminum foil to fiberglass (iii) (iv) Flinkote shall be applied to 70% of duct surface area Aluminum foil shall have 100mm over lapping at joints.

(v) Aluminum foil shall be pulled strongly with force and long straight wood for
smooth finishing. (vi) Aluminum self adhesive tape can be used to cover the jointing parts of 2 sheet of aluminum foils Fire Rated Ductwork WINDUCT is used for 2 hours fire rated ductwork. The fire rated ductwork comprises of two sections, the installation of sheet metal ductwork as describe earlier and the application of fire prevention coating. Kitchen Exhaust Ductwork Kitchen exhaust duct is constructed with 1.5mm black steel sheet with welded joint. Access door for cleaning is provided at bend. For kitchen exhaust duct riser, a 25mm diameter stainless steel pipe of 600mm length with a ball valve is connected to the base of the duct riser for draining of kitchen grease

7.2

Installation of Fire Damper / Motorized Fire Damper (a) General (i) All fire damper / motorized fire damper required to be installed shall be in complication with AS 1662:1974 and approved by Jabatan Bomba and by Engineers Representative. (ii) Submit shop drawing to the Consultant Engineer for approval and coordination with other trade. Indication the location and size of fire damper / motorised fire damper sleeve opening. (iii) Provide access door for each fire damper to permit inspection and replacement of fusible link and the operation of motorized fire damper. The fusible link shall be accessible from the room side where fire damper is installed in duct take-off from masonry shafts. (iv) Access door is not required if one side of the drop curtain type fire-damper is not connected with ducting. (b) Installation

(i)

Install drop curtain fire damper in location where ducts pass through fire rated partition walls as indicated in the approved shop drawing. RC lintel shall be installed above damper and G.I. duct to form part of the opening frame. RC lintel shall be strong enough to withstand the weight of bricks above the damper and to prevent the damper and duct being damaged by the weight of bricks applied to it.

(ii)

Fire damper should be installed centrally within the thickness of the surrounding wall or floor, such that the centerline of the frame is a minimum distance of 50mm from the nearest face of the wall or floor.

(ii)
(iv) (v) (vi) (vii)

The gap between the wall or slab opening and fire damper shall be packed with PE Foam as fire-seal materials (approval by BOMBA). Hold fire damper in the open position by means of a fusible link rate at 70 deg C. Fire damper shall be installed in a true configuration so as not to impede their operation and so that the casing completely penetrates the wall and in retained. Arrange inspection for fire damper installation. A list of record of fire damper BOMBA certificate serial number and damper location will be submitted during BOMBA inspection.

8.0

Safety and Health Aspects (i) (ii) To ensure all workers wearing safety helmet and safety boot at work To make sure scaffolding installed is proper and in safe condition.

(vii) (viii) (ix) (x) (xi)

To wear safety belt when work at high level. To use proper rigid platform. To use proper socket for termination of electrical apparatus. Debris should be kept away from the working area. Workers should be kept informed of rescue procedure when an accident incurred during installation work.

9.0

QA/QC Aspects The purpose of the quality control is to provide a guideline for a proper operation framework such that the following targets will be attained: To achieve consistently high quality standards of workmanship in all aspects of the work. All quality matters shall follows as per MS ISO 9001 : 2000 and Project Quality Plan to ensure the quality in construction