Essential Guidance for Designing Duct Systems

DUCT SYSTEMS DESIGN GUIDE

Duct Systems Design Guide gives engineers and other design professionals the tools
to design properly sized duct systems to minimize fan energy consumption, system-
generated noise, and the installed cost of ductwork.

Nearly every facet of duct design is covered in detail in this guide: duct layout,
fitting selection, system leakage, acoustics, equipment selection, and more. Chapters
dedicated to selection and comparison of duct design methods for commercial and
industrial duct systems cover the equal friction method, the static regain method,
and the constant velocity method. Online access to spreadsheets in Microsoft®
Excel® format that can be used to design commercial and industrial duct systems
using these duct design methods is also available with this book. The guide also
discusses duct system materials and the impacts they have on design and system
efficiency, as well as fan-duct system interaction and using the ASHRAE Duct
Fitting Database (DFDB).

Duct Systems Design Guide is a best-practices reference for HVAC engineers

and designers seeking to develop more energy-efficient, accurate, user-friendly,
and cost-efficient HVAC systems. The information detailed in this guide is useful
for entry-level engineers and designers who are first learning about duct design
fundamentals and also serves as a tool for more experienced engineers and design
professionals wishing to refresh their design knowledge.

Herman Behls
ISBN 978-1-947192-40-9 (paperback)
ISBN 978-1-947192-41-6 (PDF)

Behls
ISBN 9781947192409

9 781947 192409
Product Code: 90556 4/21
DUCT
ASHRAE
180 Technology Parkway, Peachtree Corners, GA 30092
ashrae.org | 404-636-8400 (worldwide)
SYSTEMS
DESIGN GUIDE
 DUCT
SYSTEMS
DESIGN GUIDE
 This publication was supported by ASHRAE Research Project 1180
under the auspices of ASHRAE Technical Committee 5.2, Duct Design.

Contributors
Jeff Boldt, PE, HBDP Bob Reid
Fellow ASHRAE Member ASHRAE
Managing Principal—Director of Innovation and Quality Business Development & Engineering
IMEG Corporation Spiral Pipe of Texas
Madison, WI Houston, TX

Pat Brooks, PE Larry Smith, PE

Member ASHRAE Member ASHRAE
Senior Project Manager Engineering Manager
SMACNA Linx Industries, a division of Ductmate Industries
Cincinnati, OH Portsmouth, VA

Kevin Gebke Craig Wray, PEng

Member ASHRAE Member ASHRAE
New Product Development Engineer Consulting Engineer
DuctSox Corporation Winnipeg, Manitoba, Canada
Dubuque, IA

Stephen Idem, PhD Richard Evans

Member ASHRAE Member ASHRAE
Professor, Department of Mechanical Engineering Retired
Tennessee Tech University Richland, WA
Cookeville, TN

Chris A. Van Rite

Associate Member ASHRAE
Vice President, Sales
MiTek USA
Chesterfield, MO

Project Monitoring Subcommittee

Pat Brooks, PE (Chair) Larry Smith, PE Stephen Idem, PhD
SMACNA Linx Industries, a division of Ductmate Industries Tennessee Tech University
Cincinnati, OH Portsmouth, VA Cookeville, TN

Updates and errata for this publication will be posted on

the ASHRAE website at www.ashrae.org/publicationupdates.
 RP-1180

DUCT
SYSTEMS
DESIGN GUIDE
Herman Behls

Peachtree Corners
 ISBN 978-1-947192-40-9 (paperback)
ISBN 978-1-947192-41-6 (PDF)

© 2021 ASHRAE
180 Technology Parkway
Peachtree Corners, GA 30092
www.ashrae.org
All rights reserved.

Cover photograph iStock.com/OGGM.

ASHRAE is a registered trademark in the U.S. Patent and Trademark Office, owned by the American Society of Heat-
ing, Refrigerating and Air-Conditioning Engineers, Inc.
ASHRAE has compiled this publication with care, but ASHRAE has not investigated, and ASHRAE expressly dis-
claims any duty to investigate, any product, service, process, procedure, design, or the like that may be described
herein. The appearance of any technical data or editorial material in this publication does not constitute endorsement,
warranty, or guaranty by ASHRAE of any product, service, process, procedure, design, or the like. ASHRAE does not
warrant that the information in the publication is free of errors, and ASHRAE does not necessarily agree with any
statement or opinion in this publication. The entire risk of the use of any information in this publication is assumed by
the user.
No part of this publication may be reproduced without permission in writing from ASHRAE, except by a reviewer
who may quote brief passages or reproduce illustrations in a review with appropriate credit, nor may any part of this
publication be reproduced, stored in a retrieval system, or transmitted in any way or by any means—electronic, photo-
copying, recording, or other—without permission in writing from ASHRAE. Requests for permission should be sub-
mitted at www.ashrae.org/permissions.

Library of Congress Cataloging-in-Publication Data

Names: Behls, Herman, 1929-2017 author. | ASHRAE (Firm), editor.

Title: ASHRAE design guide for duct systems / Herman Behls.
Other titles: Design guide for duct systems
Description: Atlanta, GA : ASHRAE, [2020] | Includes bibliographical references. | Summary: "Provides engineers and other design
professionals with the tools and knowledge to design duct systems so that fans are properly sized, minimize the installed cost of the
ductwork, minimize system-generated noise, and minimize the fan energy consumption of commercial and industrial duct systems"-
- Provided by publisher.
Identifiers: LCCN 2020056275 | ISBN 9781947192409 (paperback) | ISBN
9781947192416 (pdf)
Subjects: LCSH: Air ducts--Design and construction.
Classification: LCC TH7683.D8 B44 2020 | DDC 697.9/2--dc23
LC record available at https://lccn.loc.gov/2020056275

ASHRAE STAFF
SPECIAL PUBLICATIONS Cindy Sheffield Michaels, Editor
James Madison Walker, Managing Editor of Standards
Lauren Ramsdell, Associate Editor
Mary Bolton, Assistant Editor
Michshell Phillips, Senior Editorial Coordinator
PUBLISHING SERVICES David Soltis, Group Manager of Electronic Products and Publishing Services
Jayne Jackson, Publication Traffic Administrator
DIRECTOR OF PUBLICATIONS
AND EDUCATION Mark S. Owen
  Dedication 

Duct Systems Design Guide is dedicated to the lasting legacy of Herman Behls.
When ASHRAE RP-1180 could not fulfill the vision for this guide, Herman volunteered to take on this
responsibility. Sadly, Herman passed away on July 12, 2017, after a brief illness, and never got to witness
the book’s completion. To the very end Herman was working every day to finish its writing, and he is given
full credit for the contents of this book.
Herman was a former chair of ASHRAE Technical Committee (TC) 5.2 and served as the Research
Subcommittee Chair for many years. Herman also served as a member of the Standards Committee and the
Research Administration Committee. The contributions Herman made to the ASHRAE community are
almost too numerous to count, but several honors he received deserve special mention. Herman became a
member of the ASHRAE College of Fellows in 1995. This is reserved for ASHRAE members who have
attained distinction in the fields of heating, refrigeration, air conditioning, ventilation, or the allied arts and
sciences through invention, research, teaching, design, or original work or as an engineering executive on
projects of unusual or important scope. Herman was also awarded the Service to ASHRAE Research
Award in 2013 in recognition of his many years of contributions to the ASHRAE research program. At the
time of this writing, Herman was one of only eleven recipients of this award since its inception.
Herman was the author of numerous work statements, acted as a PMS chair for many projects,
reviewed papers, made seminar presentations, and always inspired thoughtful inquiry. In 2016 Herman was
further honored with the Distinguished 50-Year Member Award, which recognizes persons who have been
members of ASHRAE for 50 years and have performed outstanding service to the Society.
Among his other accomplishments, Herman was a principal author of ASHRAE Standards 120,
126, 130, and 215. He also was the primary author for the Duct Design chapter in ASHRAE Handbook—
Fundamentals for several decades. Herman is also the father of the ASHRAE Duct Fitting Database and
spent countless hours maintaining it. He was always willing to serve as a resource for anyone needing
answers to their questions about the program.
Herman never stopped acquiring new knowledge from others and he was always willing to share his
expertise with anyone who wanted to learn from a true teacher, friend, and mentor.


 
Contents
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xvi
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

1 DUCT DESIGN FUNDAMENTALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Pressure Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Conservation of Mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Continuity Equation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Conservation of Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Static Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Velocity Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Total Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Pitot-Static Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Duct Design Spreadsheet based on Manual Calculations . . . . . . . . . . . . . . .7
Solving the Darcy Equation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Determining Equivalent Duct Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Friction Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
ASHRAE Duct Fitting Database (DFDB) . . . . . . . . . . . . . . . . . . . . . . . .10
DFDB Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
DFDB Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Loss Coefficients. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Psychometric Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Duct Roughness Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
DFDB Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
viii | Duct Systems Design Guide

Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

2 DUCT DESIGN CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Uncertainty and Error Considerations . . . . . . . . . . . . . . . . . . . . . . . . . .24
Sectioning a Duct System for Design . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Selecting a Duct Design Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Comparing the Equal Friction Design Method
and the Static Regain Design Method . . . . . . . . . . . . . . . . . . . . . . . . .26
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Duct Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Acoustics—Noise and Vibration Control. . . . . . . . . . . . . . . . . . . . . . .30
Pressure Loss Considerations of Ducts and Fittings. . . . . . . . . . . . . . . . . .33
Impact of Duct Roughness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Impact of Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Duct Shape Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Duct Design with Other Duct Shapes . . . . . . . . . . . . . . . . . . . . . . . . .39
Duct Material Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Balancing Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Constant-Volume (CV) Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Variable-Air-Volume (VAV) Systems . . . . . . . . . . . . . . . . . . . . . . . .42
Damper-Generated Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Extractors and Splitter Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

3 EQUAL FRICTION METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Duct Design by the Equal Friction Method . . . . . . . . . . . . . . . . . . . . . . .45
Determining the Friction Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Duct Design Spreadsheets for Use with the DFDB . . . . . . . . . . . . . . . . . .47
Design Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Duct Design with Other Duct Shapes . . . . . . . . . . . . . . . . . . . . . . . . . .53
Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

4 STATIC REGAIN METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Duct Design by the Static Regain Method . . . . . . . . . . . . . . . . . . . . . . .57
Duct Design Spreadsheets for Use with the DFDB . . . . . . . . . . . . . . . . . .58
 Contents | ix

Duct Design with Other Duct Shapes . . . . . . . . . . . . . . . . . . . . . . . . . .59

Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

5 CONSTANT VELOCITY METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Hoods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Hood Airflow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Duct System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Duct Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Preferred Duct Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Pressure Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Duct Size Based on Transport Velocity . . . . . . . . . . . . . . . . . . . . . . . .72
Combining Flows of Different Densities . . . . . . . . . . . . . . . . . . . . . . .72
System Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Mixing Two Airstreams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Psychrometric Equations to Calculate Density of Any Airstream . . . . . . . .84
Psychrometric Equations to Calculate Properties of
Combined Airstreams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

6 FAN-DUCT SYSTEM INTERACTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Fan Types and Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Fan Static Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Fan Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Duct System Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Fan System Effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Fan Laws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

7 DUCT SYSTEM MATERIALS AND CONSTRUCTION . . . . . . . . . . . . . . . 109

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Conditions of Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Structural . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Thermal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Acoustical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Conveyed Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
x | Duct Systems Design Guide

Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Visual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Reference Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Other Codes and Standards that May Impact
Duct Materials and Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Design Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Duct Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Antimicrobial Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Coating Galvanized Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Painting Galvanized Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
White Rust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Nonmetallic Ductwork Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Fibrous Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Phenolic Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Flexible Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Textile Air Dispersion Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Alternative Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121

8 DUCT SYSTEM ACOUSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Acoustical Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Sound Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Sound Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
The Decibel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Combining Sound Pressure Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Loudness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Acoustical Rating Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
A-Weighted Sound Level—dBA or dB(A) . . . . . . . . . . . . . . . . . . . . .129
Loudness Level (Sones) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Noise Criteria (NC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Room Criteria (RC) Mark II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Measuring HVAC System Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Radiated Duct Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Breakout Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Break-In Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
 Contents | xi

Nonmetal Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141

Silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Active Silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Dissipative Silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Reactive Silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Selecting Silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Duct System Acoustics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
Fan Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
System Attenuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Natural Attenuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Duct Attenuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Airflow-Generated Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Duct Velocities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Duct Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Volume Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Room Air Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Avoiding Aerodynamically Generated Noise . . . . . . . . . . . . . . . . . . .154
Room Acoustics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Point Sound Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Room Design Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
Supplemental Attenuation Requirements . . . . . . . . . . . . . . . . . . . . . . .158
Acoustically Lined Round Sheet Metal Ducts . . . . . . . . . . . . . . . . . . .159
Acoustically Lined Rectangular Sheet Metal Ducts . . . . . . . . . . . . . . .159
Acoustically Lined Rectangular Elbows . . . . . . . . . . . . . . . . . . . . . . .159
Computer Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164

Includes spreadsheets in Microsoft® Excel® format for designing

commercial and industrial duct systems by the equal friction, static
regain, and constant velocity methods online.
 
Preface
The goal of this design guide is to provide engineers and other design professionals with the
tools and knowledge to design duct systems so that fans are properly sized, minimize the installed
cost of the ductwork, minimize system-generated noise, and minimize fan energy. The original
vision was that this guide would clearly describe procedures useful for entry-level engineers and
designers who were first learning about duct design fundamentals. However, it was also desired
that the guide be a valuable tool for more experienced engineers and design professionals wishing
to refresh their design knowledge.
The guide was initially conceived as ASHRAE Research Project RP-1180. The Project Moni-
toring Subcommittee (PMS), under the auspices of ASHRAE Technical Committee (TC) 5.2, Duct
Design, took control of the editorial process and accepted the task of authoring the guide after it
became apparent that writing a duct design guide suitable for these disparate audiences was excep-
tionally challenging. Herman Behls, a former chair of TC 5.2, volunteered to complete the writing.
 
Introduction
OVERVIEW
Ducts in air distribution systems are designed to transport a given volume of air as efficiently
and quietly as possible to minimize energy consumption and eliminate excessive noise. Duct sys-
tem layout, fitting selection, leakage, acoustics, and equipment selection are important aspects of
duct design.
The goals of duct design are
• to design energy-efficient HVAC systems that deliver the proper quantity of air to specific
areas of a building or zones while minimizing first costs and operating costs and
• to provide a comprehensive design and a high-quality project with adequate funding and
minimum construction disputes to the owner.

Various aspects of the duct design process include minimizing fan energy use, as depicted in
the figure below. All projects should document the Owner’s Project Requirements (OPR)—the
importance of this cannot be overemphasized. The OPR should be reviewed throughout the design
but especially during the commissioning process. (A comprehensive discussion of commissioning
is beyond the scope of this book, but there are numerous sources of information available, such as
those listed at www.ashrae.org/commissioning-essentials.)

Energy-Saving Opportunities in Duct Systems

xvi | Duct Systems Design Guide

SCOPE
This design guide covers commercial and industrial duct systems. Residential duct system
design is covered by Air Conditioning Contractors of America’s (ACCA) Manual D (2016).
This guide does not cover thermal gravity effects (stack effect) or other similar applications
where the duct system is vertical and density changes will impact the overall design. For stack
effect examples and calculations, consult the System Analysis section of Chapter 21, “Duct
Design,” of ASHRAE Handbook—Fundamentals (2017c).
To determine system air quantities for commercial systems, consult Chapter 18, “Nonresiden-
tial Cooling and Heating Load Calculations,” of ASHRAE Handbook—Fundamentals (2017a). To
determine system air quantities for exhaust systems, use this design guide in conjunction with the
American Conference of Governmental Industrial Hygienists (ACGIH®) Industrial Ventilation: A
Manual of Recommended Practice for Design, 30th Edition (2019). Chapter 13 of this ACGIH
manual includes the designs and air quantity requirements for numerous industrial applications.
To design room air distribution systems, consult the relevant ASHRAE Handbooks. For exam-
ple, Chapter 20, “Space Air Diffusion,” of ASHRAE Handbook—Fundamentals (2017b) presents
the fundamental characteristics of space air diffusion, and Chapter 58, “Indoor Airflow Modeling,”
of ASHRAE Handbook—HVAC Applications (2019b) addresses air terminal units and their effects
on occupant comfort along with tools for designing air distribution systems.
This design guide does not need to be read cover to cover. Readers with a fundamental under-
standing of duct design may only need to reference Chapters 3, 4, and 5 covering the equal friction,
static regain, and constant velocity design methods. It is strongly suggested that readers also
review the HVAC System Air Leakage section of Chapter 21, “Duct Design,” of ASHRAE Hand-
book—Fundamentals (2017c), as it provides insight on system sealing requirements, scope of test-
ing, acceptance criteria, recommended specifications, and the responsibilities of engineers and
contractors.
Chapter 2 of this design guide includes a discussion on uncertainty and error considerations
that readers should familiarize themselves with to appreciate the pressure drop calculation process.
Chapter 8 of this book offers a comprehensive overview of duct system acoustics; it is recom-
mended that for additional guidance on acoustics readers see Noise and Vibration Control (Schaf-
fer 2005) as well as Chapter 49, “Noise and Vibration Control,” of ASHRAE Handbook—HVAC
Applications (2019a). Schaeffer addresses general noise-control design guidelines during the vari-
ous design phases and includes information on the architectural and structural aspects of HVAC
system design. Sample specifications for acoustical materials and the acoustical performance of
HVAC equipment are also provided. Schaffer also gives suggestions for troubleshooting HVAC
noise and vibration complaints.
Each chapter of this design guide includes a nomenclature section at the end that defines the
variables used in the chapter’s equations, and example problems and solutions are included
throughout the book to help readers understand the concepts of duct design with practical exam-
ples. Note that throughout this book all values and nomenclature are provided in Inch-Pound (I-P)
units only.
This design guide is also accompanied by free spreadsheets in Microsoft® Excel® format that
can be found online. These spreadsheets can be used for designing commer-cial, industrial, and
local exhaust duct systems by the equal friction, static regain, and constant velocity methods.
The spreadsheets are best used in conjunction with the web-based ASHRAE Duct Fitting
Database (DFDB), available via subscription at www.ashrae.org/technical-resources/bookstore/
duct-fitting-database (2016). This online database includes duct friction losses and fit-ting loss
coefficients for more than 200 round, rectangular, and flat oval duct fittings and is useful to
design engineers in the calculation of friction factors and loss coefficients for a wide variety of
ducts and fittings.
 Introduction | xvii

REFERENCES
ACCA. 2016. ANSI/ACCA Manual D-2016, Manual D®—Residential duct systems. Arlington,
VA: Air Conditioning Contractors of America.
ACGIH. 2019. Industrial ventilation: A manual of recommended practice for design, 30th ed. Cin-
cinnati, OH: American Conference of Governmental Industrial Hygienists.
ASHRAE. 2016. ASHRAE Duct Fitting Database, ver. 6.00.05 (online). Peachtree Corners, GA:
ASHRAE. www.ashrae.org/technical-resources/bookstore/duct-fitting-database.
ASHRAE. 2017a. Chapter 18, Nonresidential cooling and heating load calculations. In ASHRAE
handbook—Fundamentals. Peachtree Corners, GA: ASHRAE.
ASHRAE. 2017b. Chapter 20, Space air diffusion. In ASHRAE handbook—Fundamentals.
Peachtree Corners, GA: ASHRAE.
ASHRAE. 2017c. Chapter 21, Duct design. In ASHRAE handbook—Fundamentals. Peachtree
Corners, GA: ASHRAE.
ASHRAE. 2019a. Chapter 49, Noise and vibration control. In ASHRAE handbook—HVAC Appli-
cations. Peachtree Corners, GA: ASHRAE.
ASHRAE. 2019b. Chapter 58, Indoor airflow modeling. In ASHRAE handbook—HVAC Applica-
tions. Peachtree Corners, GA: ASHRAE.
Schaffer, M.E. 2005. A practical guide to noise and vibration control for HVAC systems, 2nd ed.
(I-P). Peachtree Corners, GA: ASHRAE.