Volume 12, Issue Number 1 October 29, 2008

Chimney Project Stretches Contractor's Work To New Heights

Tweet GarotMechanical

replaced the top 40feet of this boiler

stack for Green BayPackaging.

With welding done from a basket perched high on the largest crane in Wisconsin, Tweet−Garot MechanicalInc. of Green Bay, Wis. recently installed the top 40 feet of a coal−fired boiler stack for the Green BayPackaging paper mill. At times the work must have seemed like a high−wire balancing act because of thetowering heights and tight timeframe involved.

The mill’s coal−fired boiler stack had begun to deteriorate, and the top part of the chimney needed to bereplaced with a new material so the mill could continue to operate at a reasonable energy cost. As part ofthis six−week Green Bay Project, Tweet−Garot installed a crow’s nest and set up a temporary platform tohelp with the installation and welding. The stack was installed in one piece, with welding done from abasket on the crane 180 feet high up in the air.

The installation was completed in two and a half days of working around the clock, so the mill could utilizetheir coal−fired boiler instead of the most costly natural gas boiler. Tweet−Garot used 3/8” and 1/4” plateCorten metal on the stack.

Chimney Project Stretches Contractor's Work To New Heights 1

Most−Asked Technical Questions Regarding SMACNA's “Round IndustrialDuct Construction Standards”

To assist you, as member contractors, in your project work, the following questions and answers are fromSMACNA’s publication, “Round Industrial Duct Construction Standards,” second edition, an AmericanNational Standard.

Question:Please provide me with more detailed information regarding the difference between Duct Class andPressure Class, and include information corresponding Pressure designation for individual duct gage.

Answer:The term Industrial Duct Class was coined by the American Conference of Governmental IndustrialHygienists many years ago when they established the five Industrial Duct Classes that are in current use togroup industrial duct applications based on the concentration, abrasiveness, and other physicalcharacteristics of particulate matter being pneumatically conveyed within an industrial duct system.Pressure Class is terminology used to describe the design pressure of a duct section or an entire HVAC ductsystem. It could be used in a similar manner in an industrial setting but, as far as I know, it is not widelyused in that way. Industrial systems are designed for a certain pressure (positive or negative) but that designpressure is not generally termed a Pressure Class in industrial duct construction.

Question:In support Type 6, are the angle rings sized the same as the vacuum reinforcing rings for theapplications? Are the rings welded to the saddle and to the duct? Is the weld a full continuous weld oris the skip pattern from the vacuum rings used?

Answer:The weld symbol used on page 13.7 helps us answer your question. The fact that the fillet symbols areshown staggered indicates that the type of weld is a “stitch weld” or intermittent fillet weld. The rings at thesaddle are assumed to represent one stiffener consistent with the stiffener spacing used for the selection ofthe duct thickness; therefore the number and size of staggered “stitch” welds is that specified for stiffeners.For practical reasons, the saddle may be located at a distance less than the specified stiffener interval onwhich the duct thickness is based, but never greater, unless the duct thickness is adjusted accordingly. Thestitch welds are intended to join the rings to both the duct and the saddle and they are staggered all the wayaround the entire circumference of each ring. This provides the strength implied in the 4x rating of the Type6 support with attached rings.

Note 4 on pages 13.10−13.15 indicates that Type 6 supports normally have a multiplier rating of 1x thetable values. It is only when a saddle plus attached angle rings are used that the rating goes up to 4x thetable values.

Published in 1999, this American National Standard “Round Industrial Duct Construction Standards,”second edition, expands the scope of the 1977 version, updating original text to incorporate a revised theoryof design, materials and more user−friendly tables. It offers a standardized, engineered basis for design andconstruction of industrial ducts of Classes 1 to 5. It includes a spiral duct chapter for Classes 1 and 2, coversdesign pressures ranging from 30" w.g. negative to 50" w.g. positive, plus carbon and galvanized steeltables. Changes to the manual include expanded tables for stainless steel and aluminum, expanded tables forduct sizes up to 96 inches in diameter, introduction of a new Duct Class 5 for systems handling corrosives,and spiral lockseam pipe. As alternatives to table use, the publication has a manual calculation procedureusing equations and fully developed examples, and offers optional calculation software. Includes softmetrics.

“Round Industrial Duct Construction Standards,” second edition, is available to SMACNA members at themember price of $77, to architects and engineers at the discounted price of $212, and to others at the list

Most−Asked Technical Questions Regarding SMACNA's “Round Industrial Duct Construction Standards” 2

price of $295. It is also available on CD−ROM and in PDF format.

For more information or to purchase “Round Industrial Duct Construction Standards,” visit the Publicationssection of the SMACNA Web site.

ITI Adds Sheet Metal Instructor Training II Program

Testing and balancing setups.

Last year, the International Training Institute (ITI) launched its Sheet Metal curriculum in Las Vegas, Nev.The program included a week−long Industrial Instructor Training Program at the Las Vegas TrainingCenter to introduce instructors to the curriculum and to help them effectively teach this subject.

Edwards 55−Ton Ironworker.

Feedback from participants who attended the inaugural training program in 2007 concluded that moreinstructor training is needed. As a result, this year, the ITI is expanding the program to include IndustrialSheet Metal Instructor Training II.

The Industrial Sheet Metal Instructor Training I was a comprehensive class, covering modules on materials,shop skills, field skills, basic system design, and rigging. The rigging module was enhanced by a two−dayRigging Trainer Development Class taught by The Crosby Group. The participants received both classroomand hands−on training.

Tennsmith power turningmachine.

ITI Adds Sheet Metal Instructor Training II Program 3

Grinding and polishing and pipe welding are included in the industrial curriculum but are offered asseparate, stand−alone, week−long programs due to their extensive hands−on nature.

To provide more comprehensive training in this new portion of the program, the ITI purchased four piecesof powered shop equipment for the Las Vegas Training Center. The new equipment includes a LockformerVulcan Plasma Table, a Built−Right 4−foot ¼ Plate Roll, an Edwards 55 Ton Ironworker, and a TennsmithPower Turning Machine. The all−U.S. manufactured equipment will be put to good use by participantslearning and honing such fabrication skills as hands−on lagging, layout, field measuring, and welding.

Lockformer Vulcan plasmatable.

All local unions working in the industrial field and those who are interested in entering the field shouldconsider implementing an industrial training program.

The expanded program was held in early October at the Las Vegas Training Center. For more informationon future programs, contact Steve Kowats, the ITI’s Welding/Industrial/Field Representative, atskowats@sheetmetal−iti.org.

More than 87 JATCs across the country have taken advantage of this new curriculum and InstructorTraining. They include:

Alameda/Contra Costa County Sheet Metal JATC• Baton Rouge Sheet Metal JATC• Boston Area Sheet Metal Local 17 JATC• Cedar Rapids/Iowa City JATC• Central Missouri Contractors & Sheet Metal Workers Local 36 JATC• Central Wisconsin Area Sheet Metal JATC• Central−Western MA & Vermont SM JATC• Charleston Area Sheet Metal Workers JATC• Colorado Springs Sheet Metal JATC• Columbus Sheet Metal Workers Local 24 JATC• Dallas/Ft Worth Sheet Metal JATC• Decatur Area Sheet Metal JATC• East Central Wisconsin JATC• Eau Claire Superior Area Sheet Metal JATC• Flint Area Sheet Metal JATC• Fox Valley Sheet Metal JATC• Georgia Sheet Metal JATC• HVAC & Metals Institute − Eugene Campus• HVAC & Metals Institute − Portland Campus• Jacksonville Sheet Metal Workers JATC• Joint Apprenticeship Training Committee of Arkansas• Kentucky Sheet Metal JATC• Kern, Inyo, Mono and Northern Los Angeles Counties AC & SMW JATC• Knoxville Area JATC• Lacrosse Area Sheet Metal JATC•

ITI Adds Sheet Metal Instructor Training II Program 4

Local 19 Training Center − Central Pennsylvania Sheet Metal JATC• Marshall Area Sheet Metal JATC• Metro Area Sheet Metal JATC• Mid−State Contractors & Sheet Metal Workers Local 218C JATC• Milwaukee Sheet Metal Workers JATC• Montana State JATC• Monterey, Santa Cruz & San Benito Counties Sheet Metal JAC• N.E. Washington − N. Idaho Sheet Metal Educational Training Trust• New Orleans Sheet Metal Workers JATC• Omaha/Council Bluff JATC• Ottawa Area Sheet Metal JATC• Pocatello & Southeast Idaho Sheet Metal Workers JATC• Richmond Area Joint Apprenticeship & Mechanic Training Fund• S.E. WA/N.E. OR Sheet Metal Workers JATC• Sabine Area Joint Sheet Metal Apprentice School Inc• Sacramento Valley Sheet Metal JATC• Santa Barbara Sheet Metal JATC• Santa Clara County Sheet Metal JATC• Sheet Metal Industry Training Board• Sheet Metal JAC Training School, Inc.• Sheet Metal Local 100 Cumberland Area JATC• Sheet Metal Workers 268 JATC• Sheet Metal Workers Local 12 JATC• Sheet Metal Workers Local 137 JATC• Sheet Metal Workers Local 15 JATC & Trust − Tampa• Sheet Metal Workers Local 17 of RI JATC• Sheet Metal Workers Local 20 JATC Gary Area• Sheet Metal Workers Local 219 JATC• Sheet Metal Workers Local 22 JATC• Sheet Metal Workers Local 24 Cinti Apprentice Trust Training Trust Fund• Sheet Metal Workers Local 24 Dayton Area JATC• Sheet Metal Workers Local 27 JATC• Sheet Metal Workers Local 292 ATF• Sheet Metal Workers Local 33 Cleveland District JATC• Sheet Metal Workers Local 40 JATC• Sheet Metal Workers Local 41 JATC• Sheet Metal Workers Local 73 Apprentice and Journeymens Training Fund• Sheet Metal Workers Local 80 JATC• Sheet Metal Workers Local 83 JATC• SMW Craft Training Fund Local 38 JATC• SMW Local 17 Training Fund of ME• SMW of Birmingham Alabama & Surrounding Counties• SMWIA Local 100• SMWIA Local 265 JATC• SMWIA Local 292 JATC• SMWIA Local 441 JJ&A Trust• SMWIA Local Union 32 JAC• Southeast Wyoming Western Nebraska Sheet Metal Workers JATC• Southeastern Wisconsin Sheet Metal JAC• Southern California JATC West Training Center• Southwest Central Idaho JATC• St. Louis Sheet Metal JATC• The Sheet Metal Joint Apprenticeship Committee for the Greater• Kansas City• Toledo Area Sheet Metal JATC•

ITI Adds Sheet Metal Instructor Training II Program 5

Upper Peninsula Sheet Metal JATC• West Palm Beach S/M JATC• West Virginia Sheet Metal Workers #33 JATC• Western Michigan Sheet Metal JATC• Western Washington Sheet Metal JATC• Western Washington Sheet Metal JATC (Lacey)• Wilkes−Barre Area Sheet Metal JATC L4•

Electrical Safety — Shocking, Isn't It?

Are you an electrical expert? Realistically, not many people are. However, as contractors in the industrialfield, it is vital that your employees know about electrical safety issues and regulations. On the job,electrical dangers such as shock, electrocution, arc flash, and arc blast are always a real risk, yet propertraining and safety strategies can minimize injuries and avoid fatalities.

Electrical shock is a leading cause of fatalities in the United States and it is an aspect of safety that oftengets ignored because we, as HVAC and industrial sheet metal contractors, don’t take the time to learn moreabout it.

To address arc flash and its related hazards, the National Fire Protection Association (NFPA) developedNFPA 70E: Standard for Electrical Safety in the Workplace in 2001. This standard covers the full range ofelectrical safety issues, from work practices and maintenance to special equipment requirements andinstallation. To learn more about or to purchase this publication, visit the National Fire Protection Web site.

The Occupational Safety and Health Administration (OSHA) also addresses electrical safety compliancewith its electrical safety regulations, OSHA 1910 Subpart I and Subpart S (general industry) and OSHA1926 Subpart K (construction). For more information on Occupational Safety and Health Standards 1910and 1926 visit the OSHA Web site.

While OSHA tells you what to do to avoid electrical dangers, NFPA−70E tells you how to do it.

Recently, NFPA 70−E was revised to include:

New requirements for a signed authorization for energized electrical work.• New language concerning multi−employer relationships requiring all contractors on a project to beaware of hazards, PPE, safe work practices, and emergency evacuation procedures.

•

Installation requirements to correlate with the 2002 National Electrical Code®.• New and revised definitions clarifying electrical safety issues such as arc rating, incident energy,and restricted approach boundary.

•

Updated PPE requirements reflecting the latest technology.•

Look for additional updates to NFPA 70−E in 2009. For information on electrical safety issues, contactMike McCullion, SMACNA’s director of safety and health, at (703) 995−4027 ormmccullion@smacna.org.

Electrical Safety — Shocking, Isn't It? 6

Share Your Success Stories: Industrial Projects Wanted

The Industrial Insights e−newsletter is a great way for you, as SMACNA industrial contractors, to promoteyour specialized large−scale projects.

The Industrial Insights e−newsletter is seeking details of your recent industrial projects for future issues. AsSMACNA contractors, share your stories of skill and industrial expertise with us. Not only will your projectbe featured in the Industrial Insights e−newsletter but it could also be highlighted on the Industrial ExpertiseWeb site. This added Web site exposure is a chance to be seen by potential customers who frequent the site;and more businesses are frequenting the Web site in greater numbers.

Send us your project photos (of high quality and resolution) along with the pertinent details using thesubmittal form on the SMACNA Web site.

Please send digital photos via e−mail to Cynthia Young, communications manager, at cyoung@smacna.org.Or mail standard photographs or CD−ROMs to Cynthia Young, SMACNA, 4201 Lafayette Center Dr.,Chantilly, Va. 20151.

For more information, contact Cynthia Young at (703) 995−4036 or cyoung@smacna.org.

Industrial Welding Recruitment Package Available To JATCs

The International Training Institute has produced an industrial welding recruitment package for prospectiveapprentices to assist local JATCs in their recruiting efforts.

The materials include local market 30−second radio and television commercials, an informational brochure,and a two−minute DVD orientation that provides additional information for prospective apprentices.

Also available is a two−minute DVD presentation acquainting a nonunion contractor with the benefits ofpartnering with the union. This presentation for nonunion contractors describes the benefits of working withthe Sheet Metal Workers’ International Association (SMWIA) to staff jobs. It highlights the new ITIindustrial curriculum as well as the high−quality training that incorporates technical instruction andhands−on practice for apprentices in the industrial areas of safety, pipe welding, grinding and finishing, andlagging. It emphasizes the benefits of having an available, motivated, well−trained, and highly professionalworkforce that makes it possible for contractors to take on more and bigger jobs, and to expand theircustomer base. Local SMACNA chapters have also received copies of both the apprentice and contractorDVD for duplication and distribution. Contact your local chapter for more information.

JATCs may order these advertising materials from the ITI Web site and customize them with localinformation or download the brochures from the ITI Web site. The brochure, which is in PDF form, is readyfor reproduction. The informational DVDs for apprentices and contractors may be duplicated by the JATCsfor distribution.

New Industrial Training Apprentice Curriculum Available

The International Training Institute (ITI) is introducing its new industrial training curriculum that preparesapprentices to work in automotive, pharmaceutical, silicon chip manufacturing, kitchen equipment

Share Your Success Stories: Industrial Projects Wanted 7

industries and more.

In the 450−hour curriculum, students learn a variety of welding processes including: shielded metal arcwelding, gas metal arc welding, gas tungsten arc welding, oxy−acetylene welding and cutting, plasmacutting, carbon arc welding, and flux cored arc welding. Students will also learn about different types ofmaterials, tools, and equipment used in the industrial sheet metal industry, and about grinding andpolishing, hoisting and rigging, the types of systems found in industrial work, and the special proceduresused to layout, fabricate, and install these systems. Safety and mathematics are emphasized throughout thecurriculum.

Additionally, the ITI offers the American Welding Society (AWS) program that accredits JATCs asCertified Test Facilities. Contractors may take advantage of this service to secure welding certifications tomeet job requirements.

Both the industrial curriculum and information about the AWS program are available to JATCs on the ITIWeb site.

NEMI Study Shows Bright Future For Industrial Ventilation Market

According to a research study conducted by the FMI Corp. for the National Energy Management Institute(NEMI), the future of the industrial ventilation market is expected to be positive. The FMI researchindicates that long−term growth opportunities for industrial ventilation systems will be found in renovationand retrofit applications.

FMI estimates the value of industrial ventilation systems installed and maintained could reach almost $1.8billion by 2010—a 17 percent increase in value compared to the $1.54 billion total market size expected in2008. A reason for the increased market gain in estimated industrial ventilation revenue is the focus ofbuilding occupants on employee safety, indoor air quality, energy efficiency, and green building initiatives.Growth of the ventilation market will be affected by the need to retrofit and maintain existing industrialbuildings.

In 2008, approximately one−third of the industrial ventilation market will be in new construction. Theremaining two−thirds of industrial ventilation opportunities will be in retrofit and existing construction. Themajority of industrial ventilation work, as reported by survey respondents, will be in the food and beverage,computer, electronic, and chemical industries.

Survey participants identified new construction as the faster growth opportunity for industrial ventilationapplications for the short−term. New construction revenues are anticipated to grow between 12 to 15percent annually in 2009 and 2010. In comparison, existing construction applications are expected to growbetween 3 to 6 percent during the same time period.

FMI believes that existing building growth opportunities will begin to outgain new constructionopportunities for industrial ventilation sometime between 2010 and 2013.

The study estimated that there are potentially 3.2 million union labor hours available in the total industrialventilation market in 2008, of which 1.2 million are in new construction opportunities.

The report also recommended that an effort to market the energy efficiency benefits of industrial ventilationand capitalize on the growth in renovation construction must be undertaken to achieve the potentialopportunities for industrial ventilation to grow over the next decade.

New Industrial Training Apprentice Curriculum Available 8

The purpose of the study was to estimate the overall market size, capital entry requirements, potentialrevenue, associated labor hours, and wages for the union sheet metal and HVAC industry. This study showsthe growth of the industry over a period of three years, as well as market trends and buying behaviors,which directly determine the union sheet metal industry’s share of industrial ductwork and sheet metalfabrication in the industrial ventilation market.

Cleveland High−Tech Facility Gives Union Sheet Metal Workers An Edge

The Sheet Metal TrainingCenter, Cleveland, Ohio.

The Sheet Metal Training Center in Cleveland, Ohio, serves a two−fold function for the constructionindustry and the residents of Northeast Ohio. Home to the unionized sheet metal industry’s intenseeducational programs, the center supplies the region with a fully trained and highly qualified sheet metalworkforce, and provides men and women with lucrative career opportunities as union sheet metal workers.

Training Sheet MetalWorkers at the newCleveland facility.

The state−of−the−art facility has the ability to train apprentices and journeymen sheet metal workers toenter the industry right away with the most up−to−date skills and knowledge available. The center has thespace for the most advanced equipment, so contractors can gear up quickly to meet the industry’s changingneeds.

NEMI Study Shows Bright Future For Industrial Ventilation Market 9

Learning air conditioningcontrol systems.

The 32,000−square−foot training center opened in January 2007, dramatically replacing the smaller7,000−square−foot center. The center’s ultra−modern features include classrooms, a drafting room, a CADdrafting lab, a sheet metal lab, a welding lab, a service lab, and a testing, adjusting, and balancing lab.Within its walls, apprenticeship students receive hands−on instruction on actual sheet metal techniques suchas welding, service, and installation, while also learning advanced mathematics drafting, blueprint reading,and fabrication. Apprentice selection is a rigorous process, including applications, testing, and interviewsbefore being accepted by the JATC.

Throughout the five−year training program, apprentices spend about 200 hours each year in the classroomsand go through about 1,600 hours annually of on−the−job field training along side experienced journeymansheet metal workers from Local 33. Apprentices are even paid while they are being trained from day one,while learning a trade under an unsurpassed construction trades training system.

Working on air conditioningunits.

Importantly, the center provides all of its students with thorough safety training, requiring them to passthrough the U.S. Occupational Safety and Health Administration’s 10− and 30−hour training programs.Apprentices are certified before they graduate. The center is also an American Welding Society(AWS)−accredited test facility, allowing apprentices and journeymen to earn their highly regarded AWSwelding certifications on−site. Local 33 members can also earn E.P.A. Section 608 Refrigerant Certification(or CFC Certification), State of Ohio Brazing Certification, and HVAC Service Training.

Three certified welding inspectors work for the center. The center also employs 3 full−time and 10part−time instructors. All are certified International Training Institute instructors, five have bachelor’sdegrees in labor education, and all are current sheet metal journeymen.

A Sheet MetalWorker wearingprotective gear

while working on awelding project.

The Sheet Metal JATC program also partners with Owens Community College in Toledo, Ohio, whichoffers college credits to apprentices while they are training. When they graduate from the center’s program,

Cleveland High−Tech Facility Gives Union Sheet Metal Workers An Edge 10

apprentices are halfway to an associate’s degree, which they can then pursue on their own.

The Importance Of Estimating Design Loads For Riser Supports

Selecting riser supports is critical because failure at one level can lead to a catastrophic chain of failure atother levels unless sufficient conservatism has been exercised in estimating design loads.

The question is one of balance among the various considerations: conservatism (to prevent such a course ofevents), reasonable cost, and simplicity. SMACNA believes that the load recommendations for risersupports in SMACNA’s “Rectangular Industrial Duct Construction Standards,” second edition, published in2004, are just that, a balanced approach to riser support loads applicable to any riser system in round orrectangular duct.

If two supports are used, the lower support shall have the capacity of supporting the entire vertical run,while the upper support shall be capable of supporting at least one half of the total vertical load, plus theentire load attributable to any portion of duct extending upward beyond the top support, if not alreadyincluded. See accompanying graphic where W1 and W2 represent the weight of duct sections of length L1and L2.

For duct supported at more than two levels, the lower support shall have the capacity to carry the full loadattributable to the lower two spans of the duct. The other supports shall each be capable of carrying at least1.5 times the load contributed by the average weight of the two adjacent spans, on either side of the support.And finally, the top support shall be capable of carrying one−half the load of the top span, plus the entireload attributable to any portion of duct extending upward beyond the top support.

Vertical duct runs supported off building walls, or off the building structure, should be supported at eachstory level. Additional intermediate support may be necessary to limit the maximum distance betweensupports to 20 feet.

“Rectangular Industrial Duct Construction Standards,” second edition, expands the scope of the 1980version, updating original text to incorporate a revised theory of design, materials, and more user−friendlytables. Tables for stainless steels and aluminum, expanded chapters on materials, welding practices, and aguide specification are included. The manual covers the simple, low or moderate temperature and pressure(or vacuum) indoor systems as well as the more complex outdoor systems that operate at moderate to hightemperature and pressure (or vacuum), and are subject to higher and more complex external loading.

“Rectangular Industrial Duct Construction Standards” is available to SMACNA members at the memberprice of $77, to architects and engineers at the discounted price of $212, and to others at the list price of$295. It is also available on CD−ROM and in PDF format. For more information or to purchase

The Importance Of Estimating Design Loads For Riser Supports 11

“Rectangular Industrial Duct Construction Standards,” visit the Publications Store section of the SMACNAWeb site.

Editor: Rosalind P. Raymond rraymond@smacna.org | Asst. Editor/Writer: Sarah Moore cyoung@smacna.org

Sheet Metal and Air Conditioning Contractors' National Association4201 Lafayette Center Drive Chantilly, Virginia 20151−1209Tel (703) 803−2980 Fax (703) 803−3732 info@smacna.org

Copyright © 2008 SMACNA. All rights reserved.Created by Matrix Group International

The Importance Of Estimating Design Loads For Riser Supports 12