Block C – Air and Material Handling System Installation

Trends

There continues to be a strong push by industry and governments towards installing energy efficient equipment and practicing green construction methods. Sealants and glues are required to be low volatile organic compound (VOC).

High efficient appliances and mechanical equipment are being vented with plastic piping.

Related Components (including, but not limited to)

Chimney, breeching, venting, barometric relief damper, louvers, grilles, diffusers, registers, fire dampers, splitter dampers, backdraft dampers, motorized dampers, volume dampers, smoke dampers, filter racks, duct heaters, coils, furnaces, rooftop units, power venters, power exhausters, draft inducers, air conditioners, exhaust fans, humidifiers, unit heaters, heat recovery ventilators, energy recovery ventilators, mixing boxes, variable air volume boxes, filter banks, drain pans, burglar bars, air valves, air lock, scrubbers, silencers, flexible duct, test ports, access doors, temporary caps, acoustic plenums, acoustic insulation, thermal insulation, lagging, cladding, hoppers, hoods, bins, cyclones, bag houses, conveyor skirting, hangers, braces, mounting brackets, threaded rod, cable hangers, channel, round rod, beam clamps, concrete shields, threaded concrete anchors, concrete inserts, nails, pins, screws, rivets, tape, glue, nuts, bolts.

Tools and Equipment

See Appendix A.

Task 8 Prepares installation site.

Context

Sheet metal workers need to confirm field measurements and prepare the site prior to installation of equipment to ensure safe, smooth and efficient installation. Measurements need to be made ahead of time to allow time for construction of ductwork and equipment.

Required Knowledge

• K 1 code, regulations and manufacturers’ specifications for requirements such as clearances, weight and spacing
• K 2 building materials
• K 3 hazardous materials such as asbestos, mould and noxious gases
• K 4 material to be recycled or reclaimed
• K 5 dimension and weight of units and materials
• K 6 orientation and location of units and materials
• K 7 plans and specifications
• K 8 updated documentation
• K 9 hangers, braces and brackets and their installation methods
• K 10 supports and bases and their installation methods

Sub-task - C-8.01 Performs on-site measurements.

Key Competencies

• C-8.01.01 select and use tools and equipment such as laser levels, tape measures and scale rulers
• C-8.01.02 measure and verify work area dimensions and compare to plans and specifications for discrepancies
• C-8.01.03 identify obstructions and problems to be resolved
• C-8.01.04 verify location and size of penetrations are according to plans and specifications to ensure proper fit
• C-8.01.05 identify and sleeve locations for duct fitting penetrations
• C-8.01.06 mark penetrations to be cut according to plans and specifications
• C-8.01.07 determine position of hangers, braces and brackets according to codes, regulations and specifications

Sub-task - C-8.02 Performs demolitions for renovations.

Key Competencies

• C-8.02.01 prepare removal plan for material and equipment considering factors such as containment of particles and hazardous materials
• C-8.02.02 place barricades according to job site requirements to isolate demolition site
• C-8.02.03 select and use tools and equipment such as grinders, hammers and saws
• C-8.02.04 identify materials and equipment to be removed according to plans and demolition drawings
• C-8.02.05 dismantle and remove materials and equipment
• C-8.02.06 recycle or dispose of waste materials and equipment according to job site requirements

Sub-task - C-8.03 Cuts penetrations.

Key Competencies

• C-8.03.01 select and use tools and equipment such as hole saws, snips and reciprocating saws according to material to be cut
• C-8.03.02 identify obstructions and hidden hazards in surrounding area such as electrical and structural members for safety and architectural reasons
• C-8.03.03 put measures in place to isolate cutting area before beginning to cut to prevent injury or damage to equipment or property
• C-8.03.04 perform cut according to markings

Sub-task - C-8.04 Installs supports and bases.

Key Competencies

• C-8.04.01 select and use tools and equipment such as tape measures, hammer drills and drills
• C-8.04.02 verify that shop drawings are approved and reflect equipment on site or to be installed
• C-8.04.03 determine anchor positions using shop drawings and specifications
• C-8.04.04 select and use anchors and fasteners to support load
• C-8.04.05 install isolators to isolate system from vibration
• C-8.04.06 install seismic restraints as required according to specifications, local codes and regulations

Sub-task - C-8.05 Installs hangers, cables, braces and brackets.

Key Competencies

• C-8.05.01 select and use tools and equipment such as tape measures, hammer drills and chop saws
• C-8.05.02 verify that shop drawings are approved and reflect materials and equipment on site or to be installed
• C-8.05.03 determine anchor positions using shop drawings and specifications
• C-8.05.04 select materials such as anchors, braces, cables, brackets, and inserts to be used according to specifications
• C-8.05.05 measure and cut material to fabricate hangers, cables, braces and brackets
• C-8.05.06 secure anchors and fasteners to support load according to specifications
• C-8.05.07 install seismic restraints as required according to specifications, local codes and regulations

Task 9 Installs and connects chimneys, breeching and venting to exhaust appliances and mechanical equipment.

Context

Chimneys are the vertical section used to vent gases, smoke and other products of combustion to the atmosphere. Breeching is the horizontal section of venting that connects one or more appliances or mechanical equipment to the chimney. Proper installation methods are important to ensure indoor and outdoor air quality and safety. Additional certification may be required by some jurisdictions to install products.

Required Knowledge

• K 1 code and manufacturers’ specifications for requirements such as clearances, weight, spacing and seismic upgrading
• K 2 types of chimneys
• K 3 building materials
• K 4 construction codes and regulations
• K 5 sealants
• K 6 sheet metal materials used for chimneys, breeching and venting
• K 7 appliances such as furnaces, stoves and incinerators
• K 8 mechanical equipment and components such as boilers, generators, piping and pressure vessels
• K 9 barometric relief dampers
• K 10 thermal expansion and contraction of material
• K 11 effect of environmental conditions on material and installation
• K 12 high efficiency furnace venting such as 636 rated composites, glues and primers
• K 13 requirements of combustion and relief air

Sub-task - C-9.01 Installs chimney.

Key Competencies

• C-9.01.01 select and use tools and equipment such as drills, saws and levels
• C-9.01.02 plan location of chimney to minimize interference and conflicts while ensuring the most direct path and according to local codes
• C-9.01.03 select chimney components according to codes, local authorities and specifications
• C-9.01.04 assemble and fasten sections according to specifications and manufacturers’ instructions
• C-9.01.05 flash and seal roof penetration to weatherproof
• C-9.01.06 install clean-out at base of chimney for removal of debris
• C-9.01.07 seal chimney according to specifications

Sub-task - C-9.02 Connects single appliance or mechanical equipment to chimney.

Key Competencies

• C-9.02.01 select and use tools and equipment such as snips, drills, levels and tape measures
• C-9.02.02 identify type of appliance or mechanical equipment and select venting materials to be used to connect to chimney
• C-9.02.03 identify type of expansion joint required for appliance or mechanical equipment according to specifications
• C-9.02.04 plan location of breeching for single appliance or mechanical equipment to minimize offsets while maintaining grade and clearance from combustibles
• C-9.02.05 install and secure vibration isolation and/or expansion joint between the appliance or mechanical equipment and the chimney to allow for expansion and contraction
• C-9.02.06 seal chimney to appliance or mechanical equipment according to specifications, codes and local authorities

Sub-task - C-9.03 Installs breeching.

Key Competencies

• C-9.03.01 select and use tools and equipment such as drills, saws and levels
• C-9.03.02 plan location of breeching to minimize offsets while maintaining grade and clearance from combustibles
• C-9.03.03 select breeching size, thickness and material according to codes, local authorities and specifications
• C-9.03.04 assemble and fasten sections according to specifications
• C-9.03.05 seal breeching according to specifications

Sub-task - C-9.04 Connects appliances and mechanical equipment to breeching.

Key Competencies

• C-9.04.01 select and use tools and equipment such as snips, drills, levels and tape measures
• C-9.04.02 identify type of appliances and mechanical equipment and select venting materials to be used to connect to breeching
• C-9.04.03 identify type of expansion joint required for appliances and mechanical equipment according to specifications
• C-9.04.04 install and secure vibration isolation and/or expansion joint between the appliances and mechanical equipment and breeching to allow for expansion and contraction
• C-9.04.05 seal breeching to appliances and mechanical equipment according to specifications, code and local authorities
• C-9.04.06 sequence connections to breeching according to code

Sub-task - C-9.05 Installs high efficiency appliances and mechanical equipment.

Key Competencies

• C-9.05.01 select and use tools and equipment such as drills, saws and levels
• C-9.05.02 plan location of venting to minimize offsets while maintaining grade
• C-9.05.03 select venting size and material according to codes, local authorities, specifications and manufacturers’ specifications
• C-9.05.04 assemble and fasten sections according to codes, local authorities and specifications
• C-9.05.05 install exterior vent termination according to codes, local authorities’ requirements and manufacturers’ specifications
• C-9.05.06 seal and weatherproof exterior vent termination

Task 10 Installs air handling system components.

Context

Sheet metal workers install air handling systems to ensure comfort, air quality and efficiency. There are many components manufactured to be installed in air handling systems. They can be used for climate control, humidity control, indoor air quality, security and fire prevention.

Required Knowledge

• K 1 air handlers such as furnaces, fans, rooftop units, built-up systems and air conditioners
• K 2 the effect of environmental conditions on material and installation
• K 3 types of dampers and their applications such as volume, smoke, fire, motorized and backdraft
• K 4 construction codes and regulations
• K 5 duct systems such as supply, return, exhaust and fresh air
• K 6 codes and manufacturers’ specifications for requirements such as clearances, weight and spacing
• K 7 requirements for fire damper sleeves such as gauge and angled
• K 8 types and applications of registers, grilles, diffusers and louvers
• K 9 HVAC systems
• K 10 types of coils such as electric, hydronic and direct expansion
• K 11 refrigeration principles
• K 12 heat recovery ventilator applications such as improving air quality and efficiency of building envelope
• K 13 types of filters such as viscous impingement, electronic polarized filter media, pleated and high efficiency particulate air (HEPA)
• K 14 accessories such as humidifiers, silencers, air valves, variable air volume boxes, mixing boxes, filter banks, drain pans, burglar bars, access doors, flexible ducts, acoustic plenums and unit heaters
• K 15 energy recovery ventilators
• K 16 types of material for sealing such as oil-based, solvent-based, water-based, tapes and caulking
• K 17 types of fusible links and their applications

Sub-task - C-10.01 Installs air handlers, heat recovery ventilators (HRVs) and energy recovery ventilators (ERVs).

Key Competencies

• C-10.01.01 select and use tools and equipment such as impact drills, snips, hammers, and rigging, hoisting and lifting equipment
• C-10.01.02 assemble air handler, HRV or ERV components according to manufacturers’ specifications
• C-10.01.03 place and secure air handler, HRV or ERV to base/structure according to manufacturers’ specifications, drawings and building lines
• C-10.01.04 install isolators according to manufacturers’ specifications
• C-10.01.05 install flexible connections according to manufacturers’ specifications
• C-10.01.06 verify that shipping brackets are removed prior to unit start-up
• C-10.01.07 check tightness and alignment of pulleys and belts
• C-10.01.08 attach condensate drain according to manufacturers’ specifications
• C-10.01.09 balance HRV or ERV according to manufacturers’ specifications

Sub-task - C-10.02 Installs sheet metal ducts and fittings.

Key Competencies

• C-10.02.01 select and use tools and equipment such as grinders, hammers, snips and screwdrivers
• C-10.02.02 assemble ductwork, fittings and components according to labelling and tagging
• C-10.02.03 select and lay out fittings and components according to sequence to be installed
• C-10.02.04 connect and seal transverse joints to ensure integrity according to specifications and industry standards such as SMACNA and American Society of Heating, Refrigeration and Air Conditioning Engineers (ASHRAE)
• C-10.02.05 secure ducts to support system according to specifications and industry standards
• C-10.02.06 align ductwork with building lines to ensure uniformity and aesthetics
• C-10.02.07 install seismic restraints according to specifications, local codes and regulations

Sub-task - C-10.03 Installs dampers.

Key Competencies

• C-10.03.01 select and use tools and equipment such as snips, hammers and cordless drills
• C-10.03.02 select dampers according to requirements such as size and use
• C-10.03.03 determine damper positions according to air direction and shaft access
• C-10.03.04 prepare ductwork by using processes such as installing retaining brackets and slotting ductwork to receive dampers
• C-10.03.05 prepare sectional dampers using methods such as bolting sections together and adding stiffeners to damper frames and brackets to damper blades to allow blades to move in unison, as required
• C-10.03.06 verify that dampers are true and square
• C-10.03.07 secure dampers and control mechanisms using fasteners such as screws, rivets and bolts
• C-10.03.08 mark or slot shafts to identify blade direction
• C-10.03.09 cycle dampers to ensure free movement of parts
• C-10.03.10 set dampers as required for application

Sub-task - C-10.04 Installs fire dampers.

Key Competencies

• C-10.04.01 select and use tools and equipment such as hammers, hacksaws and cordless drills
• C-10.04.02 select fire dampers with fusible links according to requirements such as size and application
• C-10.04.03 select and prepare sleeves according to requirements for installation of fire dampers, local code and manufacturers’ specifications
• C-10.04.04 prepare sectional fire dampers using methods such as bolting sections together and adding stiffeners to the fire damper frames, as required
• C-10.04.05 secure fire dampers using fasteners and angles ensuring tight fit to wall and around fire damper sleeves
• C-10.04.06 verify that fire dampers are true and square
• C-10.04.07 test fire dampers to ensure free movement of parts
• C-10.04.08 install access door on ductwork for easy access to perform tests and visual inspections and to reset fire dampers
• C-10.04.09 install breakaway joints according to jurisdictional regulations

Sub-task - C-10.05 Installs registers, grilles, diffusers and louvers.

Key Competencies

• C-10.05.01 select and use tools and equipment such as drills, screwdrivers, levels and snips
• C-10.05.02 select registers, grilles, diffusers and louvers according to requirements and drawings
• C-10.05.03 connect registers, grilles, diffusers and louvers to ductwork using methods such as flex connections and placing in ceiling grid, taking directional considerations into account
• C-10.05.04 align registers, grilles, diffusers and louvers with building line for aesthetic reasons
• C-10.05.05 assemble register, grille, diffuser and louver components, when required
• C-10.05.06 install access doors according to requirements and specifications

Sub-task - C-10.06 Installs terminal boxes.

Key Competencies

• C-10.06.01 select and use tools and equipment such as cordless drills, snips, screwdrivers and hammers
• C-10.06.02 determine terminal box position according to air flow direction marked on box, and access to connections and shafts
• C-10.06.03 install access doors on ductwork for testing and cleaning purposes according to specifications, plans and documents
• C-10.06.04 secure and seal terminal boxes to ductwork, plenums or units using mechanical fasteners such as S-cleats, drive cleats and screwed joints
• C-10.06.05 determine duct straight length requirements prior to connection to main ductwork for optimal operation according to manufacturers’ specifications

Sub-task - C-10.07 Installs coils.

Key Competencies

• C-10.07.01 select and use tools and equipment such as cordless drills, snips, screwdrivers and hammers
• C-10.07.02 determine coil position according to air flow direction marked on coil, access to connections and for easy removal
• C-10.07.03 install access doors on ductwork for testing and cleaning purposes according to specifications and plans
• C-10.07.04 secure and seal coils to ductwork, plenums or units using methods such as installing channels and using mechanical fasteners

Sub-task - C-10.08 Installs system component accessories.

Key Competencies

• C-10.08.01 select and use tools and equipment such as screwdrivers, drills and hammers
• C-10.08.02 determine installation requirements for component accessories such as fans, air balancing test ports, security bars, humidifiers, spark arrestors, air filtration systems and access doors according to specifications, plans and drawings
• C-10.08.03 determine location of accessories according to factors such as accessibility, specifications and manufacturers’ recommendations
• C-10.08.04 secure accessories using mechanical fasteners

Task 11 Installs material handling system components.

Context

Material handling system components may be installed for safety, cleanliness and cost-saving. These components may have specific applications such as dust collection, product separation and conveyance, and handling grease laden air and hazardous materials.

Required Knowledge

• K 1 types of fans such as vane axial, centrifugal and backward inclined
• K 2 types of material handling systems such as gravity, pneumatic and mechanical
• K 3 gravity handling systems such as garbage and laundry chutes
• K 4 pneumatic handling systems such as shop dust collector and shop vehicle exhaust system
• K 5 mechanical handling systems such as chutes and slides
• K 6 system design principles and air flow
• K 7 construction codes and regulations such as National Fire Prevention Association (NFPA) 69
• K 8 collection devices such as hoppers, hoods and bins
• K 9 separating devices such as cyclones, bag houses and scrubbers
• K 10 the effect of environmental conditions on material and installation
• K 11 installation techniques

Sub-task - C-11.01 Installs pneumatic and gravity material handling system components.

Key Competencies

• C-11.01.01 select and use tools and equipment such as grinders, hammers and screwdrivers
• C-11.01.02 assemble ductwork, fittings and components according to labelling, tagging, plans and specifications
• C-11.01.03 complete joints using methods such as welding and bolting according to specifications to limit protrusions
• C-11.01.04 secure ducts and components according to specifications to support system
• C-11.01.05 select and install fittings and components to ensure a smooth passage of materials through systems by minimizing angle and direction changes

Sub-task - C-11.02 Installs mechanical material handling system components.

Key Competencies

• C-11.02.01 select and use tools and equipment such as welding equipment, impact drills and grinders
• C-11.02.02 assemble chutes and slides, fittings and components according to labelling, tagging, plans and specifications
• C-11.02.03 complete joints using methods such as welding and bolting according to specifications to limit obstructions
• C-11.02.04 secure chutes, slides and components to supports or hanging systems according to specifications
• C-11.02.05 select and install fittings and components to ensure a smooth passage of materials through systems by minimizing angle and direction changes

Sub-task - C-11.03 Installs collection and separating devices.

Key Competencies

• C-11.03.01 select and use tools and equipment such as drills, hammers and wrenches
• C-11.03.02 determine location of device according to specifications or requirements
• C-11.03.03 select devices for particles to be conveyed
• C-11.03.04 assemble components of device according to requirements
• C-11.03.05 place and secure device using methods such as mechanical fasteners, welding and installing brackets
• C-11.03.06 connect components such as ductwork and bag house to device

Task 12 Applies thermal insulation, lagging, cladding and flashing.

Context

Sheet metal workers apply insulation, lagging, cladding and flashing to prevent condensation, limit operating costs, increase the efficiency of equipment through the conservation of energy, and protect insulation and ductwork from damage due to environmental exposure.

Required Knowledge

• K 1 types of insulation such as thermal and fire-rated and their application
• K 2 types of cladding material such as aluminium, stainless steel and galvanised steel
• K 3 types of lagging material such as aluminium, stainless steel and canvas
• K 4 types of flashings such as cap flashing, curb and step flashing
• K 5 building materials and types of weather-proofing materials
• K 6 cladding components such as end caps, straps and preformed elbows
• K 7 cladding requirements
• K 8 the effect of environmental conditions on materials and installation
• K 9 types of materials for sealing such as oil-based, solvent-based, water-based, tapes and caulking
• K 10 measurement and layout techniques
• K 11 installation and securing techniques

Sub-task - C-12.01 Applies thermal insulation to components.

Key Competencies

• C-12.01.01 select and use tools and equipment such as knives, end cutters and pin spotters
• C-12.01.02 select insulation according to specifications and codes
• C-12.01.03 identify location to be insulated according to specifications and codes
• C-12.01.04 measure, lay out and cut insulation pieces
• C-12.01.05 secure insulation by applying fasteners and components such as pins, z-bars and glue, and finish with insulation washers
• C-12.01.06 complete vapour barrier according to specifications

Sub-task - C-12.02 Applies lagging and cladding to components.

Key Competencies

• C-12.02.01 select and use tools and equipment such as snips, grinders, banding tools, tape measures and trammel points
• C-12.02.02 select material according to plans and specifications
• C-12.02.03 measure, lay out and cut material to fit
• C-12.02.04 overlap seams to shed moisture
• C-12.02.05 secure and seal material using methods such as banding, and applying screws, sealants and adhesives

Sub-task - C-12.03 Applies flashing to components.

Key Competencies

• C-12.03.01 select and use tools and equipment such as drills, snips and folding pliers
• C-12.03.02 select material according to plans, specifications or requirements
• C-12.03.03 measure and modify flashing to fit on-site conditions
• C-12.03.04 overlap seams in order to shed moisture
• C-12.03.05 secure and seal material using fasteners such as screws, sealants and adhesives to ensure a weather-tight seal

Task 13 Performs leak testing, air balancing and commissioning.

Context

Sheet metal workers perform leak testing. They perform testing, adjusting and balancing (TAB) to ensure that the system operates efficiently at its specified performance level. Sheet metal workers also participate in the commissioning of building systems.

Required Knowledge

• K 1 types of leak tests such as smoke, dye, pressure, fluid, visual and audible
• K 2 test procedures
• K 3 charts for leak tests
• K 4 air balancing instruments and techniques
• K 5 HVAC and material handling systems
• K 6 damper locations
• K 7 thermal overload
• K 8 pressure requirements
• K 9 litres per second (L/S) and cubic feet per minute (CFM) measurements
• K 10 documentation requirements such as balancing and commission reports and leak test results
• K 11 sealing methods
• K 12 application of fan laws and associated calculations
• K 13 pulley alignment and adjustment
• K 14 belt length calculation and sizing
• K 15 LEED standards

Sub-task - C-13.01 Performs leak tests.

Key Competencies

• C-13.01.01 select and use tools and equipment such as testing equipment, snips and drills
• C-13.01.02 cap all branches using materials such as end caps, polyethylene and duct tape
• C-13.01.03 determine system capacity and allowable leakage rate according to plans and specifications
• C-13.01.04 pressurize ductwork to predetermined pressure by attaching blower to duct
• C-13.01.05 identify and mark leaking areas when leakage is higher than allowable leakage rate
• C-13.01.06 reseal leaking areas and retest when sealant has cured
• C-13.01.07 document successful test results

Sub-task - C-13.02 Performs testing, adjusting and balancing (TAB).

Key Competencies

• C-13.02.01 select and use tools and testing equipment such as velometers, flow hoods and drills
• C-13.02.02 verify that dampers are open and that filters and coils are clean
• C-13.02.03 perform duct traverse including creating test ports by drilling holes in ductwork, to determine volume and velocity of system
• C-13.02.04 adjust equipment such as motor pulley to achieve required air flow at the unit
• C-13.02.05 perform calculations to determine air flow and compare to design specifications
• C-13.02.06 test and adjust main, zone and branch ducts for proper air flow
• C-13.02.07 test and adjust each individual outlet for proper air flow
• C-13.02.08 retest and adjust as required until overall desired results are achieved
• C-13.02.09 document balancing results

Sub-task - C-13.03 Participates in the commissioning of building systems.

Key Competencies

• C-13.03.01 meet with commissioning agent throughout project to verify work completed so far
• C-13.03.02 provide documentation such as equipment shop drawings, as-built drawings and test results to commissioning agent
• C-13.03.03 perform walk-around with commissioning agent identifying locations of equipment
• C-13.03.04 provide assistance during commissioning, as required
• C-13.03.05 address deficiencies cited on commissioning report
• C-13.03.06 label equipment according to specifications for the purpose of identification, commissioning and maintenance