Fabrication Standard of SMART Pre-Insulated PIR Ducting System by

M/S Asawa Insulation Pvt. Ltd.

1. Preface
The central air conditioning system, which occupies 50% of the total electric energy
consumption, is one of the indispensable modern architecture facilities. The central air
conditioning system is made up of host equipment and terminal equipment. The electric
energy gets converted to wind energy by host equipment; this wind energy is circulated to
every air conditioning area by huge ducting system. Therefore, not only considering energysaving of host equipment is important, but choosing the best energy-saving air duct is also
equally important while designing central air conditioning system.
Therefore, proper selection of high quality ducting system will bring added energy-saving
effect. This effective energy saving can be realized by excellent insulation performance and
no leakage in duct fabrication by skilled craftsmen at site.

2. SMART PIR Pre-Insulated Ducts

SMART PIR Panels (PIR Polyisocyanurate) are manufactured by M/S Asawa Insulation Pvt.
Ltd. at Khopoli, Mumbai. These Panels have excellent fire protection & heat insulation
properties & its thermal conductivity is less than 0.021W/mK (25C), which is the best heat
insulation material (PIR) in the world and the most obvious energy conservation air
conditioning Ducting System (Panels which are fabricated to form ducts).
Polyisocyanurate has superior fire limit as compared to polyurethane foam and has broad
applications as compared to polyurethane material. (Ref: Research Conducted by European
Rigid Polyurethane Foam Associations).

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3. Overview:
A) Ducting sytem involved for the supply and return of AC ducts.
PIR (Poly-isocyanurate) foam sandwich panels under brand name of SMART Panels.

B) SMART PIR Panels are totally CFC free.

Ozone Depletion Potential (ODP) = 0
Global Warming Potential (GWP) = 0.0001

C) Test Certifications.
SMART Panels are certified by top most testing laboratories in the world under worldwide
standards followed by them.

4. Panel Parameters:
A) Technical Specifications for Ducting
Type

Internal Purpose

External Purpose

Dimensions of panel

4000 mm x 1200 mm

4000 mm x 1200 mm

Thickness of panel

20 mm

30 mm

Thickness of Embossed Al Foil

60 or 80 microns
3

Density of the foam

48 kg/m

Surface

Embossed

Anti-rust lacquer

2 gm/m

80 or 200 microns
48 kg/m3
Embossed
2 gm/m2

B) As per ISO 9001 : 2008 and 14001 : 2004 product tolerances are
Parameter

Tolerance

Thickness

0.50 mm

Length

5 mm

Width

3 mm

Squaring edges

0 30

Density

2 Kg/m3

5. Fire Properties
SMART PIR panels are certified from Exova Warringnton Fire and CBRI
A) Class O (BS Part 6 & 7 - Exova Warringtonfire, UK)
B) Class O (BS Part 6 CBRI Roorkee, India)

Only first quality panels are used with visible evident surface defects not exceeding 10%.

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6. Fabrication
A) Fabrication:
Generally in accordance with manufacturers guidelines, but particularly as detailed hereinafter.
Duct construction universally suitable for upto 1970 Pa static pressure and class C leakage. Fittings
so constructed as to prevent flow-generated noise. Section profiles cut using electrically driven
machine tools (profile cutter) for close tolerance. For long ducts upto 4 mtr, dedicated silicone rifle
is used to lay sealant at longitudinal corners. Where round holes are needed proprietory round hole
cutting tool is used. Duct Width/Height dimension may be formed by joining maximum two panel
strips, longitudinallyonly; with adhesive glue, tiger joint and aluminium tape. The joint shall be
made using 450 left or 450 right cutting tools. Any given duct section shall have a maximum of two
such sides with panels joint together. Similar panel joining is permissible for flat sides of mitre and
radiused elbows. If the same is made on the curved sides, the panels will be bent to design
curvature on the bending machine in one piece after cutting, glued, joint and then, taped.
Maximum bending dimension is 1200 mm. Beyond this size, elbow will be either redesigned to
mitre type or the radiused elbow will be split in two separate pieces upstream of airflow, to be
rejoined again in one duct piece downstream of airflow.

B) Ducts are prefabricated. Ready-to-Install:

1. ASAWA INSULATION PVT. LTD. has its own experienced fabricators for fabrication and
installation at site. They follow the guidelines and instructions provided by the company.
2. System accessories are prefixed on fabricated duct sections, for mounting of GI and other
accessories; as separately approved.

C) Flanging:
1. Using PVC or Aluminium flange profiles, as per sample furnished seperately.
2. Flanges and other profiles have in-built internal mechanical grip for securing to panels. In
addition, profiles glue is used for firm adhesion to panels.
3. Ducts upto 600W x 600H dimension may have male-female (universal) joints, as per sample.
4. The butting ends will have 45 o left & 45 o right cuts. External mechanical grip joints are placed
by the installer after gluing and taping. Use minimum 4 grips at each transverse joint.

D) Damper connections:
1. For small sizes of spigot-ended or flanged dampers, use U section aluminium profiles.
2. For larger flanged dampers using F section profiles and metal corner angles.
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Note: Flanges of dampers to be 45 - 50mm when using F section.

Gasket is placed at joints and damper casing insulated at site by the installer.

E) Unit connections:
1. Using Chair section aluminium profile.
Note: Gasket is placed and joint insulated at site by the Installer.

F) Attenuators connections:
1. Using F section profile and, metal corner angles to complement section bar. Installer places
gasket at joints drill and bolt at corners, rivet/bolt along mating profiles.
Note: Flanges of silencers to be 45 50mm, silencer casing to be insulated at site by the installer.

G) Grills connections:
1. Duct Collar/Neck is to be slipped 10mm into the framed wall opening by means of the male end
pre cut at the end of collar. Seal the perimeter at the wall interface with PIR foam gap sealant.

H) Access doors: (Optional)

1. These are built from the panel itself, using frame profile, chair section profile and double
sealing gasket. The access door is supplied as complete assembly. Side panel of the duct is cut
at site with 450 cutting tool and the door assembly replaces this opening.

I) Reinforcements:
1. Appropriate number of internal stiffening Aluminium or PVC rods, Self Threading Screws and
load-distribution Aluminium Discs for very large ducts are provided.
2. For positve pressure (supply ducts) and for negative pressure (return ducts) load distributing
Aluminium Discs are placed externally and internally for better strength.

Reinforcements will be fixed perpendicular to the larger duct dimension. These will be installed on
ducts exceeding 1000 mm W/H any dimension, as per following spacing.
1200 1500 1 No x 1/2 - 1/2
1500 1800 2 Nos x 1/4 1/2 -1/4
1800 2100 3 Nos x 1/6 1/3 1/3 1/6
2100 2400 4 Nos x 1/8 1/4 1/4 1/4 1/8
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Plenums for linear air terminals:

Supports for these will be using Tiger Joints on every joint along with adhesive inbetween joints at
some intervals according to size of plenum. Aluminium tape is also applied on the joints from both
sides.

J) Large mitre elbows or Large short radius bends:

Using metal turning vanes and track-rails, the latter to have panel turning vanes. Vane railswill be
mounted on tracks, 50mm wide, fixed to the panel with screw and washer, spacing of vane rails
increases progressively away from the inside leg. Panel turning vanes will be equispaced across the
width. Turning vanes will be installed on fittings above 1200 dimension.

K) Maximum length of individual ducts

1. Shall not exceed 4000 mm for ducts upto 1200 x 1200mm.
2. Shall not exceed 2000 mm for ducts above 1200 x 1200mm size.

L) Support centres shall not exceed:

-

4000 mm for straight ducts of cross-section upto 1200W x 1200H, any dimension.

2000 mm for straight ducts of cross-section exceeding 1200W x 1200H, any dimension.

Generally, support elements comprise of GI threaded rods, nuts, washers, and 20 Gauge GI. Base
channels with edges crimped. Heavy duct accessories such as large dampers, silencers, etc. will be
independently supported. Duct section shall have supports located on either side of such heavy
accessories.

M) Acoustic lining:
1. As per approved specification separately; fixed with glue and washers; contact adhesive over
panel surface.

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