No.

The Duct Production Line Rev.

Sequence Date
Page 1 of 14

The Duct Production Line

Sequence

Prepared by Reviewed by Approved by

Designation
Name
Signature
Date

1|Page
 No.
The Duct Production Line Rev.
Sequence Date
Page 2 of 14

2|Page
 No.
The Duct Production Line Rev.
Sequence Date
Page 3 of 14

Table of Contents
1.0 Purpose ………………………………………………………………………………….. 03
2.0 Scope …………………………………………………………………………………….. 03
3.0 References ………………………………………………………………………………. 03
4.0 Terms & Definitions …………………………………………………………………….03
5.0 Responsibility ………………………………………………………………………….. 03
6.0 Procedure ……………………………………………………………………………….. 04
7.0 Process Flow Chart ……………………………………………………………………. 09
8.0 Forms …………………………………………………………………………………….. 12

3|Page
 No.
The Duct Production Line Rev.
Sequence Date
Page 4 of 14

1.0 PURPOSE

The purpose of this procedure is to provide guidelines and steps for Duct Fabrication in line with
prevalent international standards

2.0 SCOPE

The Scope of this procedure is limited to the fabrication of below mentioned:

A) Rectangular Duct Fabrications.

B) Spiral Duct Fabrications.

C) Fittings Duct Fabrications (Elbow90, Elbow45, Take off, Tee etc.)

3.0 REFERENCES

 SMACNA STANDARD 2005.

 Project Specification
 Quality Control Inspection Procedure AGC-QAC-DF-P-01.

4.0 TERMS & DEFINITIONS

SMACNA
SMACNA is the Sheet Metal and Air Conditioning Contractors National Association.

5.0 RESPONSIBILITY

Duct Factory Manager/In-Charge

Duct is responsible for all the works carried under the scope of this procedure and its
compliance to the client requirements.
QA/QC Engineer
QA/QC Engineer is responsible to inspect and monitor the activities and materials to check
conformity and to keep record of the same and issue the request for inspection (RFI) to Client

4|Page
 No.
The Duct Production Line Rev.
Sequence Date
Page 5 of 14

Representative as per ITP (If any).

Duct Fabricator
Duct Fabricator is responsible for fabricating the Duct Sheets as per all details given in Design
Drawings and Shop Floor Drawings
Store Keeper
Store Keeper is responsible for receiving materials, storing and issuance of material(s) and
maintaining inventory or stock records. He is also responsible to provide adequate protection to all
the material available at store.

6.0 PROCEDURE

The construction of a duct is accomplished by following a standardized procedure.

Although each of the below is described in general below.

6.1 Note:

All fabrication shall be done according to the Project specification and SMACNA Standard,
which is shown in the approved drawings or in the specification. During fabrication, fabricator
should make sure that the wastage should not exceeds more than 10% of the total fabricated
duct area.
During cutting of G.I. sheet, supervisor must make sure that cut edges are sharp without any
burr, if it is not satisfactory then blade must be sharpened.
QA/QC Engineer should check and verify for any manufacturing defects and dimensional
discrepancy before dispatching all fabricated ducts to site.
All required check- list shall be checked and verified accordingly before dispatching any
fabricated duct to respective sites.

6.2 Rectangular Duct Fabrication :

6.2.1 The fabrication of ductworks start from (AUTOMATIC LINE III) ADF Machine, one of
the 4 different coils by using ASTM A653 G-90 Grade materials which is automatically
feeded into the combined straightening and profiling unit. The coils may have different
measurements in the material thickness from 0.5 mm to 1.25 mm or in widths up to
400mm(1220 mm).The ((AUTOMATIC LINE III )ADF machine de-coil the sheet and
resultant outputs produces the full range of full box section, U-shape, L-shape,
straight cut with or without stiffening ribs as per approved drawing and specification

5|Page
 No.
The Duct Production Line Rev.
Sequence Date
Page 6 of 14

cutting &
unloading

Leveling & cut feeding

coiler angle notch
Grooving material for tdf

fold / cut feeding

angle notch
for TDC

6.2.2 For producing the intricate shapes especially for fitting of duct systems like Elbow,
Tees, Reducers Plasma cutting Spiro Plasma cutter Florrett 3000 is used. It is CAM
programming feed in to Plasma cutting Machines and process takes place by means
of electrodes conducts electricity from the torch of the plasma arc striking to the work
piece. The plasma heats the work piece, melting the work piece i.e. metal sheet and
produces the intricate shapes as per the dimension mentioned in the programming
with zero percent wastage of mAfter

6.2.3 ( LONGITUDINAL CONNECTION ) :

After completion of Automatic Line iii The material became ready for lock
forming machine

6.2.4 TDF MACHINE: flanging system that consists of forming a flange profile on the duct
ends, These TDF flange eliminates the additional internal sealing around the edges of
duct.

6|Page
 No.
The Duct Production Line Rev.
Sequence Date
Page 7 of 14

6.2.5 After flanging shearing of metal sheet of various sizes as per the takeoff are
produced. The metal sheets are folded at right angles to each other (90°) and the duct
shape is formed. In folding, clamping beams hold the longer side of the sheet. The
beam rises and folds the sheet around a bend profile. The bend beam can move the
sheet up or down, permitting the fabricating of metal sheet with positive and negative
bend angles. The resulting bend angle is influenced by the folding angle of the beam,
tool geometry, and material properties. Large sheets can be handled in this process,
making the operation easily automated. There is little risk of surface damage to the
sheet .

6.2.7 Following assembly of the duct section, all internal joints must be sealed with silicone.
In addition to imparting greater strength and rigidity, the primary function of the
silicone is to seal the internal surface of the duct and prevent any particles from
entering the air stream. Proper application is crucial in order to achieve “clean air”
performance and minimize leakage.
The duct assembly must satisfy certain fundamental performance criteria. Elements of
the assembly are sheets, reinforcements, seams, and joints. Theoretical and/or
practical limits for the following criteria must be considered or the duct assembly and
its elements.
 Dimensional stability (shape deformation and strength).
 Containment of the air being conveyed (leakage control).
 Vibration (fatigue and appearance).
7|Page
 No.
The Duct Production Line Rev.
Sequence Date
Page 8 of 14

 Noise (generation, transmission, or attenuation).

 Exposure (to damage, weather, temperature extremes, flexure cycles, wind,
corrosive atmospheres, biological contamination, flow interruption or reversal,
underground or other encasement conditions, combustion, or other in-service
conditions).
 Support (alignment and position retention).
 Seismic restraint.
 Thermal conductivity (heat gain or loss and condensation control).
6.2.8 S-cleats are used to connect two lengths of duct together. Slide an S-cleat onto the
upper and lower end of the first length of duct. Connect the second length of duct to
the first by sliding its upper and lower ends into the S-cleats. Slide a Drive Cleat into
the channel on the side of the duct. Repeat on opposite side. Align the Drive Cleat so
that its ends extend beyond the duct. Using a hammer, bend its ends so that they lay
flat against the duct. Repeat on opposite side. So the connection of two similar ducts
are done.
6.2.9 CGF2 corner inserted for easiness in handling, storage and transportation of Ducts
unit especially the larger ducts. Corners are loaded into a magazine and flow freely
into the insertion mechanism. A duct corner will be completed in 15 seconds, which
would include the time to turn the duct and ready for dispatch.

6.2.10 The Fabricated Rectangular Duct available for Inspection by QA/QC Procedure
AGC-QAC-DF-P-01.

6.3 Spiral Duct Fabrication:

6.3.1 The fabrication of Spiral Duct Fabrication start with Spiral Tubeformer Machine with
three coils at a time by using strip coils ASTM A653 G-90 Grade material. The coils
can be loaded may have different measurements in the material thickness from 0.38
mm to 2.00 mm for G.I Sheets , Stainless Sheets .
in width Maximum 140 mm is 1.25mm in widths from 500 mm to 3000 mm in length
& Max 1500mm in Diameter. The Spiral Duct former will de-coil the sheet and roller
drive the sheets in the direction to form a tube Spiral resultant outputs produces the
full range of Pipe type Spiral ducts with or without stiffening ribs as per approved
drawing and specification. Refer Figure 3
6.3.2 Depending upon the size and thickness requirement flanges for joining Spiral Duct
with Fittings or Rectangular Duct Plasma cutting Spiro Plasma cutter Florrett 3000 is
used Flanges to be spot welded with the Spiral ducts.

8|Page
 No.
The Duct Production Line Rev.
Sequence Date
Page 9 of 14

Figure 3

6.4 Fittings Duct Fabrications

6.4.1 For producing the intricate shapes especially for fitting of duct systems like Elbow,
Tees, Reducers, Crosses, Offsets, Male and Female Coupling of Round Spiral Duct
etc. Plasma cutting Spiro Plasma cutter Florrett 3000 is used .It is CAM programming
feed in to Plasma cutting Machines and process takes place by means of electrodes
conducts electricity from the torch of the plasma arc striking to the work piece. The
plasma heats the work piece, melting the work piece i.e. metal sheet and produces
the Intricate shapes as per the dimension mention the programming with zero percent
wastage of materials
6.4.2 For Duct Fittings shearing machine Powered Guillotine Machine is used. For larger
shears the moving blade may be set on an angle in order to shear the Sheet metal
progressively from one side to the other as per the dimension mention; this angle is
referred to as the shear angle. This decreases the amount of force required, but
increases the stroke. A 5-degree shear angle decreases the force by about 20%. The
amount of energy used is still the same.

6.4.3 For Elbow 45⁰ & 90⁰ Bend roller machine is used as a resultant output of plasma
cutting and shear materials. Roll bending may be done on sheet metal up to 1.25mm.
The material to be shaped is suspended between the rollers. The end rollers support
the bottom side of the Sheet metal and have a matching contour (inverse shape) to it
in order to maintain the cross-sectional shape. Likewise, the middle roller is forced
against the topside of the sheet metal and has a matching contour to it as per
dimension of tubes of same diameter are required specially for producing Gored
elbow 90⁰.
6.4.4 After the tubes of same diameters are produced which are then Stitch welded also
known as intermittent weld. Stitch welding is not a continuous weld across a joint, but
a weld broken up by space gaps in between welds, which results in a “stitch” look. It is
not as robust and durable as a seam weld. The tube can be stitch weld at both end of
joints may have different measurements in the material thickness from 0.38 mm to
2.00 mm in width for G.I Sheets and welding length up to 1270mm and diameter
9|Page
 No.
The Duct Production Line Rev.
Sequence Date
Page 10 of 14

range up to 50” with continuous feed of Copper filler wire of 2mm Max diameter.
6.4.5 For fabricating Gored Elbow 90⁰ the segment of the tube already stitch welded are
then Gored locked by mean Gored Max machine to lock the male and female
together, but segments of different length of tube having same diameter, different
diameter will leads to problems in the assembling phase of the elbow. Welded gores
must be welded to the ends of the gore because the flanging process of Spiral or
Rectangular Duct. Always set a spot welded on the very end of the gore. Diameter
Range from 125 to 1250mm at a forming speed of 120m/min. Refer below Figure 4

Figure 4
6.4.6 For Joining the Spiral or Rectangular Duct with fittings are spot welded known as MIG
welding. MIG welding typically involves the placement of an electrically-charged
electrode or welding wire against a work piece with an opposite electrical charge. MIG
welding in commonly utilized for attaching Spiral or Rectangular Duct with fittings of
sheet metal together at point locations. For Joining two similar Spiral Duct Double wall
spot welded flange used.
6.4.7 Grinding of Spot welded joints for the removal of material and metal to produce
surface finishes. Grinding Disc P60 is used for fine finishing of Spot welded areas.
6.4.8 The Fabricated Fittings available for Inspection by QA/QC Procedure AGC-QAC-

7.0 FLOW CHART

7.1 Rectangular Duct Fabrication :

10 | P a g e
 No.
The Duct Production Line Rev.
Sequence Date
Page 11 of 14

7.2 Spiral Duct fabrication

11 | P a g e
 No.
The Duct Production Line Rev.
Sequence Date
Page 12 of 14

12 | P a g e
 No.
The Duct Production Line Rev.
Sequence Date
Page 13 of 14

7.3 Fittings Duct Fabrication

13 | P a g e
 No.
The Duct Production Line Rev.
Sequence Date
Page 14 of 14

8.0 FORMS

8.1 AGC-QAC-DF-F-1 Material Inspection Request (MIR)

8.2 AGC-QAC-DF-F-2 MIR Log Book

8.3 AGC-QAC-DF-F-3 Material Inspection Tags

8.4 AGC-QAC-DF-F-4 Request for Inspection (RFI)

8.5 AGC-QAC-DF-F-5 RFIs Log Book

14 | P a g e