CVSfB

I (57.91 I Ih I (A3ul

143
A practical guide to
DUCTWORK LEAKAGE TESTING
Based on the requirements of DW/142 specification for sheet metal ductwork
 COPYRIGHT © 1983 by the
Heating and Ventilating
Contractors' Association
All rights reserved

HEATING AND VENTILATING

CONTRACTORS' ASSOCIATION
Esca House, 34 Palace Court,
London W2 4JG
Telephone: 071 229 2488
Fax: 071 727 9268

Obtainable from: HVCA Publications,

Old Mansion House, Eamont Bridge, Penrith,
Cumbria, CAIO 2BX
Telephone: (0768) 64771 Fax: (0768) 67138
Price: £9 (including inland postage)
Overseas: Surface mail £10.50 Air mail £11.00

3
 Contents

Part One Page

Acknowledgements . 4
Preface . 5
Financial Caution . 6
Practical Guide to leakage testing . 7-8
Example of complete test sheet . 9
Hints on leakage testing . 10-11

Part Two Page

Air leakage from ductwork 13-15

Nomogram converting area basis to percentage of airflow . 16
Air leakage testing procedure . 17-18

ACKNOWLEDGEMENTS

The HVCA records its appreciation and thanks to the persons and
organisations who have freely contributed to this work, and in
particular to the members of the Drafting Panel.

DW/143 Drafting Panel

J. H. G. Gardner (Chairman)
K. Angood
P. Doyle
K. Wheatley
K. Waldron
H. Brocklehurst
H. Brierley

J. M. Paynton (Former Secretary, Duct Work Group)

R. J. Miller (Secretary, Duct Work Group)

4
 PREFACE
Ductwork Specification DW/142, published by the HVCA in 1982, provides
for the first time in a long series of such publications for leakage limits over the
whole range of air pressures covered by the specification and (where
required) a test procedure to establish conformity.
Although leakage testing of high-pressure ductwork is mandatory in
DW/142 (as was the case in previous ductwork specifications issued by
HVCA) the leakage testing of ductwork designed to operate at low and
medium pressures is required only where so specified in individual job
specifications.
With the introduction offour pressure classifications in DWI142 it is hoped
that the designer, having selectional control of constructional standards, will
find leakage testing an unnecessary contract expense with regard to low and
medium pressure ductwork. However, it is possible that initially the advent of
more stringent constructional requirements may be followed by an increased
demand by clients and specifiers for the testing oflow-and medium- pressure
ductwork and this booklet has been prepared in order to assist ductwork
contractors to minimise the cost of this unfamiliar operation.
It will be noted that the leakage limits specified in Appendix A of DW/142
are expressed in litres per second per square metre of duct area. It is however
possible that some ductwork specifications will still quote leakage limits as a
percentage of air flow. In order that the area basis can be converted to a
percentage equivalent a nomogram from DW/142 has been reproduced in
this booklet on Page 16.
Ductwork contractors faced with a job calling for leakage testing should
take this requirement very seriously and satisfy themselves as the job
progresses that the required leakage rate or rates are within the limits set by
the designer or the client. The cost of making good an installation that has
been found on completion to have failed in this respect can be very expensive
indeed.
DW/142 specifies leakage limits for the ductwork alone, not for the
complete air distribution system. This is because the ductwork contractor has
no control over the leakage characteristics of the various components which
go to make up the whole of the air distribution system. Where a job
specification calls for a leakage limit for the whole system, it will be for the
designer or client to ensure that the leakage rates of the components are also
within the required limits.

J. H. G. Gardner,
Chairman, Executive Committee,
Duct Work Group, 1982/83.

5
 FINANCIAL CAUTION

As highlighted in the Prefaces ofboth this document and DWI142 not

enough emphasis can be placed on the fact that the much tighter ductwork
constructional standards brought about by the general acceptance of
DW/142, virtually negates the requirement for leakage testing, except for the
high pressure classes C & D.
It is essential to realise that except where it is mandatory this document is
not an endorsement of the routine testing ofducts but purely a guide to
outline the procedures, necessary for testing ducts for conformity with air
leakage limits set forth in a designer's specification.
When proper methods of assembly and sealing of ducts are used a visual
inspection will ordinarily suffice for verification of well engineered
reasonably air right construction.

WHERE NOT MANDATORY, DUCT LEAKAGE TESTING IS

GENERALLY AN UNJUSTIFIED SUBSTANTIAL EXPENSE.

6
 Part One - A practical guide tel ductwork
leakage testing
I GENERAL
With regard to air leakage, the responsibility for 2.5 Arrange for the supply of suitable blanking
ensuring the achievement of a satisfactory job is medium, e.g. heavy-duty polythene sheet.
divided between the Drawing Office, the Factory
and the Site Erection Operatives. It is essential 2.6 Make sure that all test points and blanking
that there is full co-operation between them. devices can be reached with the minimum of
difficulty after the ductwork has been installed.
2 THE DRAWING OFFICE 2.7 To ensure that a reading can be obtained,
The drawing office must: plan test sections to have a permitted loss of
approximately 25 per cent less than the total
2.1 Establish with the client or his represent- volume generated by the test rig at the pres-
atives the class of ductwork called for in the sure required for each section.
job specification, i.e.:
Class A: up to 500 Pa positive 2.8 Provide the erectors with details of the
test zones, duct operating pressures and test
Class B: up to 1000 Pa positive pressures; and indicate the nature of the
Class C: up to 2000 Pa positive blanking devices, gasket material and sealant
Class D: up to 2500 Pa positive to be used.
2.2 Establish with the client or his represent- 2.9 Prepare test sheets giving the information
ative that the required leakage rate or rates are called for on the sample test sheet shown on
for the ductwork alone i.e. excluding dampers, page 9.
fire dampers, air handling units, fans, heater This information should indicate the test
batteries, silencers, terminal boxes, etc. content, the surface area of the ductwork to be
Additionally, establish the type of gasket tested, and the permitted loss for each section
material required in relation to the pressure to be tested (this loss is to be expressed in litres
class/velocity of the system. per second per square metre of the ductwork).

Note:- Specific gasket material may be re- 3 THE FACTORY

quired in locations such as clean rooms, 3.1 Ductwork specification DW/142 requires
hospitals etc. the sealing of more joints than was the case in
H a leakage limit is laid down for the whole previous specifications. Care must therefore
system, it will be for the client or the designer be taken to make components with a good fit,
to ensure that the leakage characteristics of and to use only enough sealant to make a
the components are acceptable. satisfactory joint. A poor fit cannot be
remedied by the use of more sealant - it will
2.3 Agree with the client or designer the test not work.
pressure for each section of the installation. 3.2 Seal all longitudinal seams, laps, cross
(Note that whilst duct construction joints, rivets and duct penetrations generally,
specification is related to the highest test class in accordance with the requirements of
of the duct installation it is important that each DW/142.
duct test zone should only be tested to a
pressure to cover the mean working pressure of 3.3 Make sure that sealant is properly applied
that particular section ofducting - see A.2.5(b). to the ends of all lock forms and other types of
2.4 Decide on the best way to isolate the longitudinal seam, and to the corners and
junctions between those seams and the cross
installation into test zones. When doing so, the
joints.
drawing office should bear in mind the test
pressures called for, the allowable air losses, 3.4 Take special care to have as small a clear-
the work sequence on site and the capacity of ance as possible where there are penetrations
the test equipment. of the duct, as for example, damper spindles.

7
 3.5 Fit and seal branch connections carefully, carried out on each section of the work at the
as required by DW/142. earliest opportunity - before presentation to
the client.
3.6 To be sure of minimum leakage, special
care must be taken in the fitting and sealing of 4.10 If these preliminary tests show that the
access doors and panels etc. leakage is over the limit, then:
3.7 To avoid the danger of breaking the seals, 4.10.1 Look for any obvious places where
the ductwork when ready for despatch to site there may be leaks, for example, an open
must be handled and loaded carefully. access door or missing or punctured poly-
thene blanks. Simple methods of locating
4 SITE WORK any leakage are:
For full details of procedure see Appendix B a) by listening for them;
Pages 17 and 18 and the diagram on Pages 10 b) by feeling for them especially with a wet
and II. hand;
4.1 Understand the proper use of the test rig. c) by applying soapy water over the seams
It is expensive precision equipment. The or joints;
instructions must be read carefully and the d) by (with the agreement of the client)
equipment handled in a responsible manner. using a smoke pellet.
4.2 Make sure that the right type of test rig is NOTE When smoke pellets are used, the
available for the job. A rig suitable for high- smoke should be introduced downstream of
pressure leakage testing is seldom suitable or the test rig and not on its intake side.
economic for testing low- or medium- pressure 4.10.2 Reseal or correct where you have
ductwork, and vice versa. found the leakage source(s). Manufac-
turing faults should be reported to the
4.3 Note that leakage testing is always done
factory immediately.
under positive pressure even when the duct-
work is to operate under negative pressure. 4.10.3 Repeat the test after allowing
enough time for the sealant to set.
4.4 Before erection (Remember that sealants take longer to do
Inspect all duct sections to make sure that this in cold weather. Read the sealant
factory applied sealants have not been dam- manufacturer's instructions.)
aged in transit. Make good where any damage
is noticed. 4.11 When satisfied with the results of the
preliminary tests then:-
4.5 Ensure the correct gasket material has 4.11.1 Offer the section to the client's
been supplied for your situation and the appli- representative for formal acceptance;
cation is in accordance with the manufac-
turer's instructions. Check with the drawings 4.11.2 On successful completion ofthe test
and specifications as to where sealants are to obtain a signature - on the test sheet;
be used on the cross joints, and then apply the 4.11.3 A permanent record of tests must be
sealants as necessary. (Use only as much seal- retained.
ant as will do the job - too much sealant is as 4.12 As tests are satisfactorily completed,
bad as too little.) remove all blanking olT devices.
4.6 Pay special attention to the sealing of
joints that will be difficult to reach after erec- Relevant Conversion Factors
tion of the ductwork.
Pressure
4.7 Fix the blanking plates or other types of
temporary seal in the positions shown by the To convert Multiply by
Drawing Office. (Again, make sure that the Inches water gauge to millibars 2.491
blanking material can be reached when it has Inches water gauge to pascals (Pa) 249.1
to be removed.) I Pa = 1 Newton per square metre = 10,2 millibars

4.8 At the earliest opportunity agree with the

client or his clerk of works on a progressive Volume Flow
testing programme.
To convert Multiply by
4.9 To ensure that the ductwork has been cor- Litres per second to cubic metres
rectly manufactured and site sealant correctly per hour 3.60
applied it is essential that a preliminary test is

8
 a con1pleted test sheet
Based on dllldwod{ shownn oun page 10 and 11
Test No .

General N.ew +It> Pt'Ciecl

Name of job
Building Ref. .
.....................................................................................................................
Part 1 - Physical details
a Section of ductwork to be tested .. .. .. .. .
b Drawing Number , .
c Pressure Classification O\ass B. (PROVIDED BY DESIGNERS)

d Test static pressure

e Leakage factor
f Surface area of duct under test
g Maximum permitted leakage @y: .•.

Part 2 - Test particulars

a Duct static pressure reading
b Type of flow measuring device .. .r''5 Y!:I:E!
c Range of measurement of flow measuring device Q.. ..
d Reading of flow measuring device .. (I'R0
'2D 5 1-r:::.1u (DERIVED FROM CHART SUPPLIED wm-t RIG USING "d")
e Interpreted air flow leakage rate : ; <:-?Y.I,.! ••.• .
f Duration of test (normally 15 miuutes) IS
Date of test ... .. Carried out ....

Width and depth

Periphery Length Area
or diameter
millimetres millimetres metres square metres

800 x 750 3100 17.550 54.405

600 x 650 2500 5.570 13.925

300 x 300 1200 1.200 1.440

305 dia. 958 7.000 6.706

250 dia. 785 4.500 3.533

TOTAL 80.009

9
 Hints on Ductwork Leakage Testing

Take special care

with inaccessible
joints
500

600 x 650
800 x 750
305 dia.
250

300 x 300 ---Jt-t'J..::::.llj

4595
FLEX
Keep length to a minimum
and make sure that both 475
end connections are
correctly sealed and that
the flexible duct itself
has no leaks.

In order to avoid
incorrect readings
TEST APPARATUS
of duct pressure
Site on firm level base and
the tube from the
ensure gauges are topped up
vertical manometer
with correct fluid and
should be connected
zeroed prior to
directly to the
commencing test.
ductwork under test.
Fit correct flow measuring
device.

Inclined manometer to
read leakage rate

SEQUENCE OF TEST
1. Prepare test sheet.
2. Connect and adjust test apparatus to correct pressure.
3. Read off leakage rate.
4. Reseal if necessary (allow time to cure).
5. Maintain test for 15 mins.
6. Switch off and allow to zero. WARNING
7. Reapply test pressure and check reading. Take care not to over pt"essurise
8. Record details on test sheet and obtain signature. system under test

10
 The dimensions on this ductwork are used in an example on page 9

800 x 750

700

5925

50

Blank off all open

ends with polythene
carefully taped into
position to avoid leaks.
Remember to blank 4175
instrument tappings
and test holes.

rtical manometer to
d duct pressure Blank at convenient
place with access
for ease of removal
800 x 750

HOW TO FIND LEAKS

1. Look - particularly at blanks, access openings
and difficult joints.
2. Listen - with test apparatus running, leaks
should be audible.
3. Feel- running your hand (particularly if wet)
over joints can help to locate leaks.
4. Soap and Water- paint over joints and look for bubbles
5. Smoke Pellet-placed inside ductwork (obtain permission for use)
DRG No. 20433112

11
 Hints on Ductwork Leakage Testing The dimensions on this ductwork are used in an example on page 9
Take special care
with 1""""lbl, /
i
r-.....
y /\
. - - - - - - joints aoo'750
250dia.
250dl,j\--
---.1J!Q
600 x 650 j / ,/
BOO x 750
==- I
\ 250 dia,':::::
t+
3500
A- - 250 dia.
./
V
300,300 - ,::::, "- \,
F'\1 t
/ 111
-\
I L'f' r
V
""
;
LJJ V
FLEX /
Keep length to a minimum
and make sure Ihal both 475 7450 /
cnd connections are
correctly sealed and that
I
Blank off all open
the flexible duct itself
ends with polylhene
has no leaks. carefully taped into
position to avoid leaks.
Remember to blank
In order to avoid instrument tappings
incorrect readings
of duct pressure TEST APPARATUS and test holes.
/
the tube from the Site on firm level base and
vertical manomeler
ensure gauges are lopped up
with correct fluid and
should be connected
directly to the
- zeroed prior to
ductwork under test. commencing test.
Fit correct flow measuring
p device.
::..----
Inclined manometer to

V ,Yertical manometer to
,.t
duct pressure BI"k"
for ease of removal
800 x 750

---- 0
read leakage rate
............
SEQUENCE OF TEST HOW TO FIND LEAKS
I. Prepare test sheet. 1. Look - particularly at blanks, access openings
2. Connect and adjust lest apparatus 10 correct pressure. and difficult joints.
3. Read off leakage rate. 2. Lislen - with test apparatus running, leaks
4. Reseal if necessary (allow time to cure). should be audible.
5. Maintain test for 15 mins. 3. Feel- running your hand (particularly if wet)
6. Switch off and allow to zero. WARNING over joints can help to locate leaks.
7. Reapply test pressure and check reading. Take care not to over pressurise 4. Soap and Water- paint over joints and look for bubbles
8. Record details on test sheet and obtain signature. system under test 5. Smoke Pellet- placed inside ductwork (obtain permission for use)
DRG No. 20433/12
10 11
 Part Two
This section is predominantly extracted from DW/142 - Specification for Sheet Metal Ductwork, and for ease
of reference the numbering as in DW/142 has been retained. The leakage limits for EUROVENT classifi-
cations A, Band C, as set out in their document 2/2 (Air Leakage in Ductwork) have been adopted for the low
pressure, medium pressure and high pressure Class C classifications. EUROVENT document 2/2 has no
standard for a leakage class equivalent to our Class D and therefore the leakage limits for high pressure
ductwork used in DW/141 (the predecessor to DW/142) have been retained.

(5 AIR LEAKAGE STANDARDS

6.1 Limits for each pressure class to establish conformity with the relevant leakage
Permitted air leakage is related to four standards limits'set out in Table 2.
of airtightness, as set out in Table 2.
Testing for leakage of ductwork within the low
6.2 Compatibility with EUROVENT and medium ranges of pressure in this specifica-
The leakage factors used in Table 2 for Classes A, tion will not form part of the ductwork contract
Band C are the same as those used for the classes unless this requirement is set out in the job speci-
similarly designated in the Eurovent Document fication - see also Note (2) on page 1 ofDW 142.
2/2 (Air Leakage in Ductwork).
6.3 Leakage at various pressures; and other Table 2 Air Leakage Limits
relationships
Applying the limits specified in Table 2, Air leakage Leakage limit
Appendix A (Table 31) sets out the permitted J 2
leakage at each of a series of pressures up to the Ii tres per second per square
maximum for each class. Included in that metre of duct surface area
appendix is a graphical presentation of the Low-pressure- 0.027 x p'.65
pressure/leakage relationship; and also charts Class A
from which may be determined leakage as a per-
centage of airflow for classes A, B or C. Medium-pressure- 0.009 x pO.65
Appendix A also gives details of the basis for the Class B
leakage limits specfied in Table 2. High-pressure- 0.003 X po."
Class C
6.4 Testing for air leakage
High-pressure- 0.001 x p"'"
All ductwork operating at pressures classified in Class D
this specification as 'high pressure' shall be tested
where p IS the differential pressure In pascals

APPENDIX A - AIR LEAKAGE FROM DUCTWORK

A.I GENERAL CONSIDERATIONS A.I.3 Pressure/leakage relationship

A.I.I Leakage points in ductwork For a given pressure, the leakage through an
Air leakage in installed ductwork occurs almost orifice of a given area will vary according to its
entirely at the longitudinal seams and the cross shape. With installed ductwork, the leakage
joints, particularly at the corners, and at the orifices are of differing shapes, so a precise value
intersection of the seams and cross joints. cannot be given to the pressure/leakage relation-
ship. However, Swedish tests on a variety of con-
A.I.2 Leakage related to duct area structions have shown that for ductwork oper-
In practice, leakage can be taken as proportional ating within the range covered in this specifi-
to the surface area of the ductwork, whether cation, leakage can be taken as proportional to
rectangular or circular, even though there may be pressure to the power of 0.65. (This value has
considerable variation in different sections of a been adopted by EUROVENT in preparing their
complete system because of the changing sizes of Document 2/2 - Air Leakage in Ductwork - see
the ducts and the number and variety of the fit- Appendix L - and has also been adopted in this
tings. The surface area is easily calculable as part specification (see Table 2) and has been applied
of the design procedure. in Table 31.

13
A.2 LEAKAGE LIMITS - RELATIONSHIPS Alternatively, the designer may:
A.2.t Limits for each pressure class (d) decide on the maximum total leakage that
Applying the values given in Table 2 (page 13). he can accept;
the permitted leakage at each of a series of pres- (e) calculate the surface area and estimate the
sures up to the maximum for each class is set out mean system pressure difference for the
in Table 31. ductwork system (or part of system) and
A.2.2 Graphical presentation from these determine the required pres-
The pressure/leakage relationships given In sure class.
Table 31 are expressed graphically in Fig. 169. A.2.6 Leakage of complete system
A.2.3 Leakage as a percentage of airflow DW/142 deals only with the ductwork. The leak-
As air leakage is related to surface area of the age characteristics of plant items and accessories
ductwork, it cannot in advance of the detailed are not within the control of the ductwork con-
calculations be expressed as a percentage of total tractor, and therefore any leakage limits and leak-
airflow, nor will a percentage loss be acceptable age testing called for under DW/142 shall be
as a standard of performance. However, applica- understood to apply only to the ductwork itself.
tion of the leakage limits to a variety of ductwork
systems indicates that under oparating conditions
air losses will usually be within 6 per cent of total Table 31 Air leakage rates
airflow for the low-pressure class and 3 per cent
for the medium-pressure class. For the high- Static Maximum leakage of ductwork
pressure class, air loss is likely to be between 2 pressure Low-pressure Med-prcssure High-pressure
and 0.5 per cent, according to which leakage limit differential Class A Class B Class C I Class D
is applied. J 2 3 4 I 5
Litres per second per square metre of surface area
A. 2.4 Special cases Pa
The percentages mentioned in A.2.3 apply to 100 0.54 0.18
normal ratios of duct area to airflow; but where 200 0.84 0.28
the ratio is high (e.g. long runs of small ducts), it 300 1.10 0.37
may be necessary for the designer to specify a 400 1.32 0.44
higher standard of airtightness in order to keep 500 1.53 0.51
the actual leakage within an acceptable limit.
A.2.5 Designer's required calculations 600 0.58 0.19
Designers will be concerned with the total loss of 700 0.64 0.21
air through leakage which must be allowed for 800 0.69 0.23
the ductwork, and will need to: 9ml 0.75 0.25
(a) calculate the pressure class; 10m) 0.80 0.27
(b) calculate the surface area and estimate
I HXI 0.29 0.10
the mean system pressure difference for
1200 0.30 0.10
the ductwork system (or part ofsystem);
1300 0.32 0.11
14(XI 0.33 0.11
Definition of mean pressure 15m) 0.35 0.12
Pm = PI + P2, where:- 1600 0.36 0.12
2 17m) 11.38 0.13
Pm = mean or average pressure. 1800 0.39 0.13
1900 0.40 0.14
P I = operating pressure at the beginning of the
2000 0.42 0.14
ductwork system or part of system.
P2 = operating pressure at the end of the duct- 2100 0.14
work system or part of system. 2200 0.15
IT IS RECOMMENDED THAT MAXIMUM 23ml 0.15
TEST PRESSURES AND LEAKAGE RATES 2400 0.16
SHOWN IN TABLE 32, PAGE /7, BE 2500 0.16
ADOPTED.
(c) calculate the total leakage using the appro-
priate rate from Table 31.

14
Fig. 169 Permitted leakage at various pressures

(a) LOW & MEDIUM PRESSURE CLASSES - LEAKAGE LIMITS

1::

6l 1.5

b 1.25
e
.."'ill.
0" 1.0

""g 0.75
..""'
c . 0.5

() IIKl 21Xl 31Ml -lOO son 600 7110 XOO t)O(l 11l()O

Pressure difference in pascals

(b) HIGH PRESSURE CLASSES - LEAKAGE LIMITS

'"
'" 0.40
't:
=
"' 0.35

""

'&" (1.25
.."'ill. ,
"C ILO
=
o
:: lJ.IS

.5

.!.'i
3
() }50 500 750 1000 12;i(J 1500 1750 200ll 25(}()
Pressure difference in pascals

15
Fig. 170 Leakage as percentage of airflow
1000
f-- .. - 600
1000 600
1-- .. .- /' 1--
600
/' V V
2000
200 600
/' 1/ 1/

100
'00
1000
l-
/'
V
200
1/ v: V 1/
'00
60
200 6001-
60 .
,..e.- , 100
40- I- 400 -- b"L.- .. 80
40
-
100
80
200
V /'
60
2O!?L- V 1/ 1/
20 60
./ 1/ 1/ I i/
V -
40- l/ If
/'
V
-,.
1// V
1/
,
10
100
80
f.:-- --
20 .
6
20 60
6
- . ,
, 40
V
10

,
10
br' I
1
./
21-/
....
j'/ +
2 20
6 Y 1/
j,.L I
4
lO L
l/ I
1 / 1 I
I
, , ,
0

""
< 200 "
, , ,
'00
! I,
600 800 1000
t

2000
CLASS A !
2 3
,
, I!
4 5 6I
! I,
,,
! , ,

10
, , ,,
Su
5
u
CLASS 8
1
!

2
I
3
, 4 5 6 , '

CLASSC !
.5
!
1
!

2
!
3 ,
!

LEAKAGE(Us) MEAN DIFFERENTIAL PRESSURE (Pal PERCENTAGE lEAKAGE

Examples of use of charts

Example I Example 2
Class A ClassB
Mean differential pressure . 320Pa 800Pa
Duct area . 80m2 200m2
Airflow . 2 m3/s 6m3 /s

Calculated Chart Calculated Chart

reading reading
Maximum permitted leakage 91.8 92 138.8 139
Percentage of airflow . 4.58 4.6 2.31 2.3

Based on charts prepared by EUROVENT.

reproduced by kind permission.

16
APPENDIX B - AIR LEAKAGE TESTING PROCEDURE

B.l GENERAL B.3 Testing to be completed before insulation, etc.

Section 6 (page 13) of this specification deals with Testing shall be satisfactorily completed before
the performance requirements of ductwork in insulation or enclosure of the ductwork and before
respect of air leakage, and Table 31 (Appendix A) terminal units (if any) are fitted.
tabulates the limits of leakage applicable to each B.4 Retesting procedure where necessary
class of ductwork. Appendix B is solely concerned B.4.1 The air leakage ra.te for any section shall
with recommendations for the testing procedure. not be in excess of the permitted rate for that
B.2 Extent of ductwork to be tested section. If a first test produces leakage in excess
B.2.1 The procedure set out in this section is of the permitted maximum, the section shall be
limited to the ductwork. Terminal connections, resealed and retested until a leakage not greater
and items such as air handling deYices, terminal than the permitted maximum for that section is
boxes, sound attenuators, heat exchangers, achieved.
builder's work construction, are excluded from B.4.2 If at the time of witnessing the test it is
the tests. apparent that excessive additional sealing of
B.2.2 The proportion of the ductwork to be seams or joints has been done in order to meet
tested and the method of selection (where not the required leakage level, the section of duct-
included in the job specification) should be work under test shall not be counted as part of
determined in collaboration between the the tested ductwork, except where the whole of
designer and the ductwork contractor. Where the ductwork is required to be tested.
the method is by random selection, the use of B.S Minimum area to be tested
polythene sheet or similar insertion blanks be- The section of ductwork to be tested shall have an
tween duct cross joints and duct-mounted com- area large enough to enable the test apparatus to
ponents will assist in avoiding delays in instal- register a measurable leakage.
lation when tests are being carried out.
8.6 Test pressures and leakage rates
B.2.3 To enable the blank to be cut out after the
testing is completed, access may be required The maximum pennissible leakage rates for the
adjacent to each blank. This procedure used on full range of pressures are given in Table 31. The
either side of a duct-mounted component will recommended test pressures for the various classes
enable the component to be included in a sub- of ductwork are set out in Table 32, and unless
sequent additional test if specified. otherwise specified, the choice of test pressure
shall be at the discretion of the test operator.
B.2.4 Alternatively, rigid removable blanking
plates can be used, although this involves
remaking joints.

Table 32 Recommended maximum test pressures (with leakage rates)

Maximum leakage of ductwork
Static
pressure Low-pressure Medium-pressure High-pressure
differential Class A Class B
Class C Class D
J 2 3 4 5
Pa Litres per second per square metre of surface area
200 0.84
400 1.32 0.44
800 0.69
1200 0.30
1500 0.35 0.12
2000
-- .. '" . ..,""'........ .... -
0.14

17
B.7 Test apparatus all joints which fall outside the scope of the
B.7.1 The accuracy of the test apparatus shall testing procedure, Le., joints between tested
be within: sections of ductwork and between' ductwork
± 10 per cent of the indicated flow rate, or and other units.
0.4 litres per second, whichever is the B.8.5 Due notice of tests shall be given, so that
greater; and arrangements for witnessing the tests, if
± 5 per cent at the indicated static pressure required, can be made.
in the duct under test. B.9 Testing sequence
B.7.2 The test apparatus shall be inspected by The recommended sequence of testing is as
the user before use on site, and shall have a follows.
calibration certificate, chart or graph dated not B.9.1 Complete Part 1 of the Test Sheet.
earlier than one year before the test for which it
is used. B.9.2 Connect test apparatus to section of duct-
work to be tested.
B.7.3 A diagram of a suitable test apparatus is
given in Fig. 171. B.9.3 Adjust test apparatus until the static
pressure differential is obtained.
B.8 Procedure B.9.4 Check that the measured leakage is with-
in the permitted rate. (No addition shall be
B.8.1 The section of ductwork to be tested for
made to the permissible leakage rate for access
air leakage shall be sealed. Main ducts should
doors, access panels or dampers where these are
be provided with flanged joints to enable blank- included in the ductwork.)
ing plates to be fitted, while small open ends
may be sealed with polythene or inflatable bags, B.9.5 Maintain the test for fifteen minutes and
which should be left in position until final con- check that the leakage rate has not increased.
nections are made. B.9.6 Reduce pressure in section to zero by
B.8.2 On low-pressure systems, final grille switching off the fan; then immediately re-apply
spigots made as a second fix operation shall be test pressure to establish that the air leakage
excluded from the test. The joint shall, where rate is not greater than the previous reading.
practicable, be checked by external visual B.9.7 Record details on Part 2 of the Test Sheet
examination. and complete, including witnessing.
B.8.3 Sufficient time shall be allowed between B.I0 Air leakage test sheet
erection and leakage testing for sealants to cure. A specimen of a suitable Test Sheet is given on
B.8.4 Special care must be exercised in making page 9.

Fig. 171 Diagram of typical apparatus for air leakage tests

Bleed valve (not necessary
Flow measuring device if variable speed
Blanking (may be located on /fanused)
/plate the suction side of "-
the fan) "

L Duct under test

Electrically
driven fan

Duct tcst
pressure gauge _
Inclined gauge

18