Volume 13, Issue Number 1June 23, 2009Contractor Installs Ductwork For Soft Drink Facility In Record TimeThe job was unique because ofthe large amount of processpiping that was installed underthe ductwork, requiring theductwork to go in first.McDonald Air and Sheet Metal Inc., of Orlando, Fla., recently completed a challenging project on theCoca Cola SPD facility in Apopka, Fla. One hurdle was the project’s aggressive completion schedule ofjust under three months. The project demanded 900 man hours in the field and 500 man hours in the shop.McDonald Air came through in record time.The scope of work included manufacturing and installing HVAC ductwork, a 50 ton rooftop unit as well asexhaust fans, two wall props, and a power roof ventilator exhaust fan. The new one story Coca Cola plantmixes different flavors of soda, is 6,650 square feet and is constructed of block and precast panels. Theproject required 12,000 pounds of six inch wg welded 18 gage duct. All air distribution serving the mainareas are stainless steel.The job was unique because of the large amount of process piping that was installed under the ductwork,requiring the ductwork to be installed first. The ductwork ultimately came through the ceiling as designedand is exposed to view.The project’s aggressive completion schedule presented additional challenges. The main trunk lines had tobe installed before the two large process tanks were set in place. This required a fast track fabricationschedule in the shop. The field crews also had to place their ladders in certain strategic spots to hang ductwhile working around the tanks and process piping that were being installed for the processing plant.Another issue was coordinating places to run the ductwork in a short ceiling cavity and resolving the matterin a short time span. Due to the space constraints created by the process piping that was in the way,Contractor Installs Ductwork For Soft Drink Facility In Record Time1

McDonald Air had to redesign portions of the project between the return air, supply air, and exhaust airtrunk lines and work the HVAC systems around the other trades.In making changes to the construction drawings, McDonald Air utilized its three dimensional CAD ductdrawing program to show where the conflicts were and what they could do to resolve the conflicts. Theseviews gave all parties involved a visual three dimensional, solid view of the ductwork and where the othertrades’ material was in relation to the steel and walls. This greatly facilitated coordination.Because of the height above the mezzanine level, and their location and coordination with the remainingtanks, the louvers were installed last and with a special boom lift.Nuclear Industry Revival Reaps 18.5 Billion In Federal FinancingIn an effort to revive the U.S. nuclear industry, four power companies will split 18.5 billion in federalfinancing to construct nuclear reactors. It is anticipated that UniStar Nuclear Energy, NRG Energy Inc.,Scana Corp. and Southern Co. will share a set of loan guarantees from the Energy Department. Constructionon new reactors could begin as soon as 2011, with the plants starting operation by 2015 or 2016.These companies have already picked reactor sites and are first in line with the Nuclear RegulatoryCommission to receive licenses to build and operate them. Their sites include: UniStar Nuclear Energy – Calvert County, Md. South Carolina Electric & Gas – Fairfield County, S.C. Southern Co. – Burke County, Ga. NRG Energy – Matagorda County, TexasStay On Top Of Nuclear Power OpportunitiesTrack rapidly changing developments in the growing nuclear power industry by frequently checking theNuclear Power Deployment Scorecard.The Department of Energy (DOE) relies on this tool to provide an up to date summary of key occurrencesin the nuclear power industry, communicate the status of each license application, and publish variousfederal financial incentives that may be available for nuclear power. The online version is the most timelyversion and a printed brochure is distributed monthly to key policymakers at the White House, DOE, andTreasury Department.Most Asked Technical Questions Regarding SMACNA's “Round IndustrialDuct Construction Standard”Nuclear Industry Revival Reaps 18.5 Billion In Federal Financing2

The following is one of many frequently asked questions of SMACNA’s Technical Resources Departmentregarding content in SMACNA’s “Round Industrial Duct Construction Standard,” 2nd ed., 1999, anAmerican National Standard.Question:I have an existing 120" diameter by 12 gage, galvanized steel duct, with stiffeners at 96" OC wanting toserve a 10" WC system. While the D/t (diameter divided by thickness) ratio in this case exceeds the 800criteria of page 4 6, equation 4 14 results in Pn 16" WC which appears well in excess of the designpressure ( 10" WC) for the application.In attempting to understand the proper application of equation 4 14 versus the D/800 criteria, I comparedthe 10 gage material listed in Table 8 5 for a 96" diameter duct, stiffened at 10' with the result fromequation 4 15 for d 96", L 120", and Pn 10", which is t 0.088." or t 12 gage, which is lighter than the10 gage listed in Table 8 5.What is the relationship between equations 4 14 and 4 15 and the D/t limit of 800?Answer:None. Equations 4 14 and 4 15 are independent of the D/t criteria. The D/t limit of 800 is anexperience based factor that contractors introduced in the 1999 edition of the “Round Industrial DuctConstruction Standard” to ensure that large diameter duct was built to a standard not only structurallycapable of operating at its design pressure (negative or positive), but also sufficiently stout to minimize therisk of damage during fabrication, handling, transport, on site storage, and installation.When bending is not the controlling factor (in most cases pressure is the controlling factor), new duct isdesigned based on a thickness as determined from equation 4 15 or a thickness greater than D/800 or theClass limit listed on page 4 6, whichever yields the larger result. In the case from Table 8 5, even thoughthe calculation may result in a 12 gage requirement, SMACNA requires 10 gage based on the D/t minimumfor this diameter duct.The resulting pressure capacity from equation 4 14 should be a good estimate of the duct’s pressurecapacity. However, since one is dealing with existing duct, great care should be exercised in determiningthe true minimum thickness of the duct, because used duct does not necessarily wear evenly. Measurementstaken at four evenly spaced spots around the circumference, and repeated at three locations along the lengthof the duct is a reasonable test scheme.ITI Industrial And Welding Instructor Training Program Available In JulyThe International Training Institute (ITI) is preparing for its third year of Industrial Instructor Training inLas Vegas this July. The one week program is divided into two levels: Industrial One and Industrial Two,which will run concurrently.The Industrial One program introduces participants to the DVD formatted Industrial curriculum byhighlighting several modules in the classroom with hands on shop exercises utilizing powered shopequipment. In addition, The Crosby Group, an industry leader in hoisting and rigging, will conduct atwo day, train the trainer class.Industrial Two builds on the lessons of Industrial One with more time spent on shop projects includinglagging and welding. Participants will take the projects back to their home JATC and use them as afoundation in the creation or augmentation of a strong industrial program.Most Asked Technical Questions Regarding SMACNA's “Round IndustrialDuct Construction Standard”3

Many projects in the industrial program include various welding and brazing processes and techniques.However, the program is not centered on giving participants the skills required to effectively teach welding;this is done through by Welding Instructor Programs also offered by the ITI.The Sheet Metal Welding Program teaches participants how to prepare their students for qualification withvarious processes to the D9.1 Sheet Metal Code. The Structural Welding Program works toward the samegoal as the Sheet Metal class but utilizes the D1.1 Structural Steel Code. Pipe Welding is specificallydesigned for the Instructor for hands on learning and, how to weld pipe and learn various weldingprocesses.The ITI offers more advanced classes for those JATCs in need of Certified Welding Inspectors (CWI). TheCWI Program is a preparation class for the American Welding Societies test which, when successfullycompleted, permits the individual to qualify (certify) members to specified codes.For more information, training coordinators and instructors can visit the ITI Web site for more details andprogram registration.Jointly sponsored by SMACNA and the Sheet Metal Worker's International Association, the ITI offersapprenticeship and advanced career training in the sheet metal industry at 160 training centers in the UnitedStates and 21 in Canada. For more information on the International Training Institute, visit the ITI Webpage.Share Your Success Stories — Industrial Projects Wanted!Are you proud of your large scale industrial projects or dedicated service work to a particular plant over theyears? The Industrial Insights online newsletter is a great way for you, as SMACNA industrial contractors,to promote your work!We want to know about your industrial projects for future issues. You’ll have a chance to share your storiesof industrial expertise. Your project will be featured in the Industrial Insights newsletter, and could also behighlighted on SMACNA’s Industrial Expertise Web site. This added Web site exposure is a chance to beseen by potential customers, who are visiting the site in greater numbers.For your project to be considered, send us your photographs and project details using our online submittalform. To use this form, visit the Market Sector Councils web page on the SMACNA Web site. Please sendyour completed form and digital photos by e mail to Cynthia Young, SMACNA communications manager,at [email protected] mail your submittal form and digital photos on CD to Cynthia Young, SMACNA, 4201 Lafayette CenterDr., Chantilly, Va. 20151. Let us share your industrial success stories!Upcoming Industrial Conferences To Teach Effective Ventilation PracticesSheet metal workers, project managers, engineers and those involved in ventilation systems will benefitfrom two conferences on industrial ventilation design, one at the University of Arizona and the other atMichigan State University.ITI Industrial And Welding Instructor Training Program Available In July4

30th Annual Birmingham Industrial Ventilation ConferenceUniversity of Arizona, Birmingham, Ala., Oct. 12 14, 2009Those involved in ventilation system evaluation, design, maintenance, and performance who want to learneffective, economical ventilation practices and design techniques will want to attend the 30th AnnualBirmingham Industrial Ventilation Conference on Exhaust Ventilation System Design, presented by theCollege of Engineering at the University of Arizona, in Birmingham, Ala., on Oct. 12 14, 2009.This conference will teach effective, economical ventilation practices and design techniques. The coursewill present the principals of airflow, controlling airborne contaminates, and how to properly text systems.Lecture and hands on sessions will take participants step by step through the design of different types ofsystems. Topics include hood design, duct design, fans, system effects, dust collectors, replacement air, andrecirculation of air.This course is designed for sheet metal contractors, plant and operations managers, plant and safetyengineers, and those involved in ventilation systems. For more information visit the conference Web site, orcontact R.D. Eckhoff, director, engineering professional development, (520) 621 4007 [email protected] Annual Industrial Ventilation ConferenceMichigan State University, East Lansing, Mich., Feb. 8 11, 2010Experts from around the United States and Canada will provide instruction and lectures on the design,construction, use, and testing of ventilation systems atthe 59th Annual Industrial Ventilation Conference at Michigan State University in East Lansing, Mich., onFeb. 8 11, 2010.The conference offers an introductory course and two advanced courses of instruction. It also includes morethan 20 hours of classroom experience. Registrants will have the opportunity to work out actual designproblems in ventilation system design and nonstandard air designs.For more information, visit the Michigan State University Industrial Ventilation Conference Web site.Growing Nuclear Power Market Means Opportunities For IndustrialContractorsPower generation is the industrial market of the future. In the upcoming decades, opportunities in thenuclear power generation market are projected to grow significantly, and with it will be opportunities forindustrial contractors.According to the U.S. Department of Energy (DOE), electricity demands across the country will rise 21percent by the year 2030. That means hundreds of new power plants will be needed across the country toprovide electricity for homes and economic growth. Maintaining nuclear energy's current 20 percent shareof generation would require building three reactors every two years starting in 2016, based on DOEforecasts.According to the Nuclear Energy Institute, some 17 companies and consortia are pursuing licenses for morethan 30 nuclear power plants. The U.S. Nuclear Regulatory Commission has begun reviewing the first waveof applications.Upcoming Industrial Conferences To Teach Effective Ventilation Practices5

In March, SMACNA’s Industrial Contractors Council Steering Committee and the Sheet Metal Workers’International Association (SMWIA) Power Generation Committee discussed issues and opportunities in thepower generation market. The SMWIA’s Power Generation Committee identifies market opportunities innuclear, coal and alternative energy sources.At the meeting, representatives from the Bechtel Corporation discussed their work and contractorrequirements in the nuclear market. Bechtel is projecting that construction will begin on three U.S. nuclearplants in the next four to six years. Construction costs for each plant are projected to be 8 to 10 billiondollars.At that same meeting, SMACNA contractors, including five who currently have the NQA 1 (NuclearQuality Assurance Level 1) certification, along with representatives from the SMWIA, the National EnergyManagement Institute (NEMI), and the International Training Institute (ITI) discussed NQA 1 certificationin nuclear work. NQA 1 is a supercharged quality assurance program that qualifies contractors to performwork on or related to nuclear sites. It is a two step process that includes program development, whichqualifies the contractor to bid this work, and implementation of the program, which is ongoing certificationand monitoring.AG 1 is an ASME (American Society of Mechanical Engineers) standard that provides requirements forthe performance, design, construction, acceptance testing, and quality assurance of equipment for air andgas treatment systems in nuclear facilities. Mr. G.A. Navas, of SMACNA’s technical services department,was recently added to the committee. The committee will look at whether there is further opportunity forSMACNA standards or guidelines to be referenced in the AG 1 standard. Additional discussions coveredneeded nuclear training modules and guidelines to assist sheet metal workers and contractor members ingetting NQA 1 certified.SMACNA’s Industrial Council will continue to meet with the SMWIA’s Power Generation Committee toexplore work opportunities and requirements in the nuclear and other power generation sectors.In October, at SMACNA’s 66th Annual Convention in Palm Desert, Calif., the Industrial ContractorsForum will include a presentation on developments and opportunities in the nuclear market. The programwill feature a representative from Bechtel Corporation who will update attendees on emerging opportunitiesin the U.S. nuclear plant market. The presentation will be followed by a round table discussion on the futureneeds of the power generation industry.2009 Convention Program – Cutting Edge Topics Just For IndustrialContractorsThe Industrial Contractors Forum, Monday, Oct. 12, at SMACNA’s 66th annual convention, will includeseveral presentations on cutting edge topics affecting the industrial market. Attendees will learn aboutpower generation market opportunities, the International Training Institute’s (ITI) new industrial trainingcurriculum, current safety issues, and updates to SMACNA’s “Guide for Steel Stack Construction” andLEED/green building application in the industrial sector.A representative from the Bechtel Corporation will discuss expanding industrial market opportunities in thenuclear market, including qualifications and available resources for SMACNA members in these growingmarkets.Mike Harris from the ITI will present the ITI’s new industrial training module and show sections of themodule’s training video. Also included will be an update on training methods and structural welding.Growing Nuclear Power Market Means Opportunities For IndustrialContractors6

Michael McCullion, SMACNA’s director of safety and health, will present a summary of welding safetyand health issues, with special emphasis on preventing overexposure to welding fumes. He will cover suchimportant topics as the proper use of respirators, effective engineering controls, and a regulatory updateincluding hexavalent chromium. Attendees will receive copies of SMACNA’s “Safety Toolbox Talks”(volume two) offering safety and health refresher training plus a chapter on welding safety.The forum will conclude with a discussion about concerns on such topics as service work, equipmentmaintenance and repair, service work in industrial plants, and updates and changes to SMACNA’s “Guidefor Steel Stack Construction” and LEED/green building applications in the industrial sector.SMACNA’s annual convention will take place at the Desert Springs JW Marriott Resort and Spa in PalmDesert, Calif., from Oct. 11 15, 2009. For more information visit the SMACNA Web site, or contact MaryLou Taylor, director of meetings and convention, at (703) 803 2998 or [email protected] Offers Industrial And Welding Programs For Instructors And StudentsThe International Training Institute (ITI) offers several industrial sheet metal and welding curricula forinstructors and students. These include a welding training program with instructor manuals and DVDs foryears one through four, along with a student manual for the four modules.Industrial Sheet Metal and Welding Curriculum (Instructor)This guide is for an instructor who is teaching the industrial sheet metal and welding fields, and provideslesson plans and instructional DVD teaching aids related to the industrial field. Those who order thisinstructor’s guide will also receive the “Industrial Sheet Metal and Welding Instructor’s Guide” and all ofthe associated instructional DVDs, along with SMOHIT’s Hoisting and Rigging program.Industrial Sheet Metal and Welding Curriculum (Student)This curriculum is for a student specializing in the industrial sheet metal and welding field. It containsmodules on pipe welding, grinding and finishing, system design, and hoisting and rigging, to name a few.When ordering this curriculum, the student will receive the student manual and workbook for the industrialcurriculum plus the student manual for the existing welding curriculum.Welding Training Program Instructor Manual I with DVDInstructor Manual for Year One welding with full DVD support. This course covers 40 plus hours ofinstructor led coursework. Topics covered are oxy fuel, SMAW and GMAW. The DVD includesfull motion video with enhanced graphics and 3D animations.Welding Training Program Instructor Manual II with DVDInstructor Manual for Year Two welding with full DVD support. This course covers 40 plus hours ofinstructor led coursework. Topics covered are advanced SMAW and GMAW, along with plasma arccutting, metallurgy, and basic electricity. The DVD includes full motion video with enhanced graphics and3D animations.Welding Training Program Instructor Manual III with DVDInstructor Manual for Year Three welding with full DVD support. This course covers 40 plus hours ofinstructor led coursework. Topics covered are flux core arc welding (FAC) and gas metal arc welding(GMAC). The DVD includes full motion video with enhanced graphics and 3D animations.Welding Training Program Instructor Manual IV with DVDInstructor manual for Year Four welding with full DVD support. This course covers 40 plus hours ofinstructor led coursework. Topics covered are carbon arc welding (CAW), oxy acetylene welding (OAW),gas metal arc welding pulsed spray transfer (GMAW P) and gas tungsten arc welding pulse (GTAW P).2009 Convention Program – Cutting Edge Topics Just For IndustrialContractors7

TheDVD includes full motion video with enhanced graphics and 3D animations.Welding Training Program Student ManualThis book is for the student who is being instructed with the four modules of the welding program. It isdesigned for the student to follow along with the lessons that are being taught in the classroom.Jointly sponsored by SMACNA and the Sheet Metal Worker's International Association, the ITI offersapprenticeship and advanced career training in the sheet metal industry at 160 training centers in the UnitedStates and 21 in Canada. For more information on the International Training Institute, visit the ITI Web site.Industrial Addenda Study On Contractor Data UpdatedA useful tool for comparing industrial contractor data around the country, the “Comparison of LocalIndustrial Addenda” was recently updated at the request of SMACNA’s Industrial Contractors CouncilSteering Committee.Originally prepared in 1998 by SMACNA’s Labor Relations Department, the new report examines 21industrial addenda and compares language covering scope of work, rates and classifications of workers,training, ratios, overtime, hours of work, wage and fringe benefits, and more. The study included fourregions in the U.S., the Eastern, Southern, Midwestern, and Western regions.Five of the addenda examined include fabrication and installation work within an existing manufacturingfacility, while the majority of industrial addenda pertain to the fabrication of industrial products. Theremaining 16 locally negotiated addenda pertain to shop fabrication on industrial materials and products.The report is available free of charge to SMACNA members and is located on the Industrial ContractorsCouncil section of the SMACNA Web site. For more information about the study, contact Jason Watson,director of labor relations, at (703) 803 2981.Editor: Rosalind P. Raymond [email protected] Asst. Editor/Writer: Cynthia Young [email protected] Metal and Air Conditioning Contractors' National Association4201 Lafayette Center Drive Chantilly, Virginia 20151 1209Tel (703) 803 2980 Fax (703) 803 3732 [email protected] 2009 SMACNA. All rights reserved.Created by Matrix Group InternationalITI Offers Industrial And Welding Programs For Instructors And Students8

CWI Program is a preparation class for the American Welding Societies test which, when successfully completed, permits the individual to qualify (certify) members to specified codes. For more information, training coordinators and instructors can visit the ITI Web site for more details and