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Maximizing Efficiency With Innovative Duct Support Systems

Posted by Art Valentz on December 4, 2024

Delivering optimal temperature and air quality throughout a commercial building entails a complex network of ductwork, cabling, and pipes. Many building owners choose to install their HVAC systems on rooftops - on top of duct support systems - for space-saving and noise reduction. It also helps improve the structural integrity of rooftops in the long run.

Naturally, rooftop environments need the right infrastructure to support this equipment. Premature roof deterioration, often due to poor support, can jeopardize not only the roof's lifespan but also the safety of expensive equipment and maintenance personnel.

The HVAC market is forecasted to value at $455.96 billion across the globe by 2028, with the second largest category in this market being that of ducts. By 2028, the market for ducts and support systems is expected to reach $17.5 billion - $3 billion short of HVAC control systems. This shows just how important these support systems are for system and property safety.

In this article, we will take a closer look at the key considerations professionals need to make in terms of HVAC ducts and support systems. The idea is to help make informed decisions for long-term sustainability, efficiency, and safety.

Importance of Duct Support Systems

Several studies showcase the critical role these systems play in ensuring the efficiency, safety, and longevity of commercial HVAC installations. These systems are also critical for ensuring OSHA compliance - particularly for worker safety. Furthermore, duct support systems also ensure the efficient operation of HVAC systems, ensuring better temperature and air quality control throughout buildings.

A well-designed system serves three primary functions:

  • Maintains the structural integrity of the rooftop
  • Safeguards the valuable HVAC equipment
  • Contributes to overall energy efficiency and safety.

Unfortunately, just having a duct support system isn't enough. An improper support system can lead to several issues affecting not just the rooftop but also the interior environment and budgetary concerns.

Rooftop duct support systems may fail for a number of reasons:

  • Subpar design,
  • Improper materials, or
  • Inadequate planning,

This, in turn, can result in a range of problems. Premature deterioration of commercial roofs, a substantial investment in itself, is often linked to infrastructure issues. Foot traffic on roof surfaces, poor maintenance, punctures during installation, and the use of low-quality support systems can all contribute to costly roof repairs and replacements.

Critical Elements of An Efficient & Sustainable Duct Support Systems

Ensuring the efficiency, safety, and longevity of commercial HVAC installations hinges on the careful consideration of key elements when designing and implementing roof support or duct support systems. Some of these factors include:

  1. Customization for Rooftop Environment: The heart of any duct support system design lies in understanding the unique specifications of the rooftop environment. Each rooftop is different, and the design should be tailored to match its specific characteristics. Whether it's a flat or sloped roof, the calculations for weight distribution, wind resistance, and other performance requirements will vary accordingly.
  2. Load Capacity Assessment: Determining the roof's load capacity is essential. This factor governs how much equipment the roof can safely support and how it should be spaced to distribute weight properly. Dead loads and potential live loads, such as maintenance professionals who occupy the space, must be considered.
  3. Duct Size Optimization: The shape, height, and width of ductwork depend on various technical specifications, including airflow rate, duct system length, friction rate, and more. Ducting supports should be meticulously designed to mitigate noise pollution, reduce erosion, eliminate environmental risks, and ensure an even weight distribution.
  4. Future-Proofing: A well-thought-out design should support the current environment and be adaptable to potential changes in the future. Whether it involves expanding the building or transforming the roof into a green space or parking lot, the system should accommodate these alterations seamlessly.
  5. Movement Consideration: Duct support systems must account for potential movements due to changes in temperature, load, vibration, and other environmental elements. Since movement can be unpredictable, designers should factor it into the system's design in all directions.
  6. Environmental Risk Factors: Apart from standard weatherproofing, material selection should take into account constant UV exposure and extreme weather conditions like hurricane-force winds, tornadoes, and earthquakes. Regions prone to such conditions may have stricter building codes that need to be adhered to.
  7. Base Attachment: The designer must be well-versed in how fastening support bases to the physical roof structure impacts warranties and how adhesives react to the roof's surface material. The attachment method can influence the long-term performance and safety of the system.
  8. Maintenance Accessibility: The design layout should consider the ease with which maintenance professionals can navigate the rooftop environment for inspections and repairs/maintenance. Safety should always be a top priority, and well-planned layouts facilitate this.

Low-cost solutions may seem attractive at first, but the true value lies in long-term sustainability. A system that can withstand the test of time not only reduces the need for repairs or replacements but also contributes to overall energy efficiency and safety, resulting in a substantial return on investment (ROI).

Sample Duct Support System to Maximize HVAC Efficiency

As discussed, commercial and industrial HVAC systems require a carefully designed duct support system. The focus should not only be on performance but also safety, longevity, and efficiency. While the best duct support system varies depending on the geography of the building, system type, and building design, studies have shown that there are several key principles to keep in mind for a better design.

Here is a sample duct support system that improves HVAC efficiency while ensuring employee and building safety.

Maximizing Efficiency With Innovative Duct Support Systems-Sample

Figure: Sample Rooftop Duct System for an Auditorium

In this example, the HVAC system is designed for a 1000-seat auditorium for summer conditions. The design aims to achieve optimal cooling with a tonnage capacity of 70 TR.

Design Specifications:

The load calculations for the cooling system consider various factors, such as heat gain through walls, windows, lighting, appliances, and heat generated by people. This comprehensive analysis ensures that the HVAC system can handle the heat load efficiently.

To support the cooling system, a ductwork design is critical. Ducts are designed based on the equal friction method, which helps maintain a constant pressure loss per unit length of the duct. This approach is applied to both the supply and return ducts.

In the design, the reducing trunk method is used for duct branching, where the main duct gradually narrows in diameter. This approach allows for easier installation and cost reduction. For the duct support system, there are several key considerations to make, which will ultimately determine the efficiency of the entire system. These include:

  • Roof Slope: The design should accommodate a moderately sloped roof. This ensures that weight distribution, wind resistance, and performance calculations are in line with the slope's degree.
  • Load Capacity: The duct support system should be engineered to respect the roof's load capacity.
  • Duct Size: To ensure noise reduction, prevent erosion, and evenly distribute weight, ducting dimensions should be planned based on:
    • Airflow rate,
    • The total effective length of the duct system,
    • Friction rate and other essential parameters.
  • Future Plans: The design should allow for future modifications, such as expanding the building or converting the roof into a green space or parking area. Flexibility is key in any project.
  • Displacement: The duct support system should account for potential movement due to temperature changes, load variations, vibration, and other factors. This will ensure that the system remains stable and secure under varying conditions, especially in high-traffic environments.
  • Environmental Risk Factors: The design should consider the region's climate, accounting for constant UV exposure and possible extreme conditions like high winds, tornadoes, or earthquakes. The selected materials should align with local building codes to enhance durability.
  • Base Attachment: Fastening support bases are done carefully to prevent any impact on warranties and to ensure compatibility with the roof's surface material.
  • Maintenance Needs: The layout is designed with maintenance in mind, allowing easy and safe access for inspections, repairs, and routine activities.

Efficiency for Long-Term Sustainability:

This duct support system design should not solely be cost-driven. Its primary focus should be on long-term sustainability and efficiency. The system will pay for itself via reduced maintenance costs and eliminating the need for HVAC replacement/repair in the coming years. While low-cost solutions may seem appealing initially, they can lead to frequent repairs or replacements, ultimately eroding the return on investment.

Final Words - PHP Systems/Design for Innovative Duct Support Systems

At PHP Systems/Design, we understand the uniqueness of each rooftop environment. We take pride in creating tailored duct support systems that accommodate specific characteristics. They also comply with all state and local codes stamp and is provided for every project. By considering factors like load capacity, duct dimensions, future plans, displacement, environmental conditions, base attachment, and maintenance accessibility, we engineer solutions built for the long haul.

Our commitment to durability is unwavering. We utilize robust materials and alloys capable of withstanding the harshest environmental conditions. We pay close attention to the attachment of support bases to ensure compatibility with the roof's surface material, thereby safeguarding warranties and enhancing long-term performance and safety.

Moreover, our designs prioritize maintenance accessibility, facilitating inspections, repairs, and routine activities, all while upholding safety as our foremost priority. If you're ready to get started, we invite you to reach out to us for a personalized consultation and pricing. Call us today to take the next step towards securing your property's future.

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