Flexible Duct AS 4254.1 and AS 4859.1 checklist for compliance with NCC 2013 as of1 May 2013

AS 4254 checklist

Duct Manufacturers Name......

Ducts recognized trade name as sold to market......

Material R Values for the insulation used on this duct......

Country where duct was manufactured......

AS4254.1 2012
CLAUSE /
FLEXIBLE DUCT REQUIREMENTS /
COMPLIES
(please circle)
1.6-TESTING
2.4.1-General
2.8-VALIDITY PERIOD FOR TEST RESULTS / If either insulated or uninsulated flexible duct is required to be subjected to fire and mechanical tests or thermal tests, all such testing shall be carried out by a registered NATA testing laboratory as defined in the National Construction Code. Samples submitted for prototype testing shall be identical to manufactured product supplied to market under the fire, mechanical and thermal test certificates. In order for supplied manufactured product to be identified and compared with supplied test certificates, the certificates shall include the following minimum product data:
a) Manufacturer’s name and product’s recognised trade name.
b) Information required by the ‘Flexible Duct Compliance Report Summary’ (see Clause 2.9
andAppendix A).
A product shall comply with all the requirements of this standard before compliance can be claimed.
Does the above mentioned product meet all of the requirements of Clause 1.6?
The insulated or uninsulated flexible duct (the assembled final product)samples submitted for testing shall be identical to manufactured product supplied to market under the fire, mechanical and thermal test certificates..
Does the above mentioned product meet this requirement of Clause 2.4.1?
Are allof the 11 test reports used to determine the product named above compliant to AS4254 2002;less than 10 years old? / YES/NO
YES/NO
YES/NO
2.9- FLEXIBLE DUCT COMPLIANCE REPORT SUMMARY + Appendix A /
Original copies of 11 NATA- Test Reports to substantiate claims made in Flexible Duct Compliance Report Summary for the 2 burn and 9 fit for purpose (mechanical) tests that comprise AS 4254 2002 are readily available for download from duct manufacturer's website. /
YES/NO
2.4.3-Fire performance
2.4.3
Mechanical Performance
2.4.2
2.4.2
2.4.2
2.4.2
2.4.2
2.4.2
2.4.2
2.4.2 / AS/NZS 1530.3 1999 Burning test requires only 2 results of the possible 4 results to comply with AS 4254 2002.“4 Zero” compliance is NOT required in AS 4254 2002 nor AS 4254.1 2012.
Do the 2 x AS/NZS 1530.3 1999 tests indices resultsspecified in AS 4254 2002 comply? The 2 specified tests are;
  • Test 1, AS1530.3- Smoke developed - indices result not greater than 3
  • Test 2, AS1530.3- Spread of flame – indices result not greater than 0
    UL 181.9 – Burning Test
    UL 181.11 - Mechanical - Mould growth and humidity Test
    UL 181.12 - Mechanical - Temperature Test
    UL 181.13 - Mechanical - Puncture Test
    UL 181.14 - Mechanical - Static load Test
    UL 181.15 - Mechanical - Impact Test
    UL 181.17 - Mechanical - Pressure Test
    UL 181.18 - Mechanical - Collapse Test
    UL 181.19 - Mechanical - Tension Test
/ YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
2.9-FLEXIBLE DUCT COMPLIANCE REPORT SUMMARY / Is an individual Flexible Duct Compliance Report Summary for the product named above readily available for download from duct manufacturer website? / YES/NO
2.6-THERMAL INSULATION USED ON FLEXIBLE DUCT / Were the Material R Values (R m) claimed for the insulation used in the construction of the product named above determined by testing conducted in a NATA certified laboratory as a low density fibrous insulation as per AS/NZS 4859.1 2002 Table 2.1 + Clause 2.3.2(c)? / YES/NO
2.7-LABELLING OF FLEXIBLE DUCT / Is the outer duct sleeve/jacket on the product named above clearly labelled at least every 1000 mm with all the requirements of this clause including; the duct manufacturer's name, compliance to AS 4254.1 2012 and the Material R Value of the insulation used in its construction? / YES/NO
AS4254.1 2012
CLAUSE 2.6
+ AS/NZS 4859.1 2002
CLAUSE 4.4 (f) Demonstration of Compliance / Current insulation supplier's NATA certified test certificates must be readily available upon request and/or from duct manufacturers website for each Material R Value (R m) claimed by the duct manufacturer .
Is there a test report available for insulation rated to:
-R m 0.6
-R m 1.0
-R m 1.5
-R m 2.0
-R m 2.4 /
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
AS/NZS 4859.1 2002
CLAUSE / REQUIREMENTS FOR INSULATION USED IN THE CONSTRUCTION OF FLEXIBLE DUCT /
COMPLIES
(please circle)
4.2-ACCEPTANCE OF TESTING+ Note 1 / Is the laboratory used to determine the Material R Values (Rm) claimed on the product named above a NATA laboratory that has been certified by NATA to conduct AS/NZS 4859.1 2002 testing? / YES/NO
2.3.2(c)-Classification + Table 2.1 / Were the Material R Values (Rm) specified for the insulation used in the construction of the product named above determined by testing as a low density fibrous to ASTM
C 653 and Appendix D? / YES/NO
2.2-VALIDITY OF TEST RESULTS
3.1 General + Figure 3.1 + Note on page 18 / Is each of the NATA certified test reports provided by the current supplier of insulation to the duct manufacture used to determine each material thermal value for the product named above less than 5 years old?
Does the distance between the outer duct sleeve and duct core allow the insulation to fit in an "unrestrained state" snugly between the outer duct sleeve and duct core and allow the insulation to return to the “average recovered or installed thickness" stated in the NATA certified test reports?
Fit for purpose:
Insulation supplied by insulation manufacturer to duct manufacturer
Does the insulation when removed from the insulation manufacturer's packaging (as supplied to the duct manufacturer as standard, i.e. compression packed or non compression packed) recover to the following;
  • The nominal stabilized thickness within 24 hours after being conditioned at 45C.
Is this requirement met?
  • It is a requirement of AS 4859.1 2002 that both nominal stabilised thickness and declared thermal resistance must be on the insulation manufacturers packaging (as supplied to the duct manufacturer as standard, i.e. compression packed or non compression packed). Are both these requirements met?
The following clauses from the thermal standard AS 4859.1 refer to the two ‘fit for purpose’questions above.
See Appendix to refer to each individual clause.
2.2 Validity of test results
2.3.1 Thermal resistance- General
2.3.3.7 Thermal resistance- Low density fibrous materials
2.3.3.7 Note
3.1 General
3.1 General note
3.1.1 Table- Labelling requirements
7.2.1 Performance criteria and technical provisions- Thermal resistance
7.2.1 Thermal resistance note 1
7.2.1 Thermal resistance note 2
Fit for purpose:
Insulation used within the construction of the insulated flexible duct.
Does the insulation used within the product named above after being removed from its standard compressed packaged state ( as sold to market) and after being allowed the nominated days to recover to declared nominal stabilised thickness as purchased from the insulation manufacturer;
  • Achieve the declared nominal stabilized thickness as purchased from the insulation manufacturer.
The following clauses from the thermal standard AS4859.1 refer to the fit for purpose questions above.
See Appendix to refer to each individual clause.
Thermal Standard Preface
2.2 Validity of test results
2.3.1 Thermal resistance- General
2.3.3.7 Thermal resistance- Low density fibrous materials
3.1 General
3.1 General note
3.1.1 Table- Labelling requirements
7.2.1 Performance criteria and technical provisions- Thermal resistance
7.2.1 Thermal resistance note 2 / YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
Table 3.1 / IF YOU ARE A DUCT MANUFACTURER AND BUY IN INSULATION FROM AN INSULATION SUPPLIER YOU MUST COMPLY WITH THE FOLLOWING REQUIREMENTS
Does the NATA certified test reports and the labelling on the packaging provided by your current insulation supplier which are used to substantiate each different material thermal value for the product named above sold to market by the duct manufacturer named above include the following information;
The products name?
The name and address of the insulation manufacturer where the insulation was produced?
A statement of compliance to AS/NZS 4859.1 2002?
The Declared Material R Values?
The grams per m2(gsm) of insulation blanket?
The length and width of the product?
The nominated stabilized thickness (or the installed thickness of the insulation at a nominated period of days after the flexible duct is installed)?
List the material thermal value of each blanket sited that meetsthe 14 point criteria list above.
1._____ 2.______3.______4.______5.______6.______/ On the label
YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO
YES/NO
/ In the report
YES/NO YES/NO YES/NO YES/NO YES/NO YES/NO
YES/NO
Appendix A
A4 Note 2
Table 3.1 / IF YOU ARE A DUCT MANUFACTURER AND PRODUCE YOUR OWN INSULATION YOU MUST COMPLY WITH THE FOLLOWING REQUIREMENTS
Where insulation is produced in-house by a duct manufacturer, irrespective of all internal management systems applied, the responsibility to conform to the full requirements of AS/NZS 4859.1 2002 lies with the duct/insulation manufacturer. Appropriate in house quality management systems are set out in AS/NZSISO 9001 andAS/NZS ISO 9004.
Are the various Material R values as well as all other properties stated within in-house quality management systems consistent with the random insulation samples viewed?
Does the NATA certified test reports which are used to substantiate each different material thermal value for the product named above sold to market by the duct manufacturer named above include the following information;
The product name?
The name and address of the insulation manufacturer where the insulation was produced?
A statement of compliance to AS/NZS 4859.1 2002?
The Declared Material R Values?
The grams per m2(gsm) of insulation blanket?
The length and width of the product?
The nominated stabilized thickness (or the installed thickness of the insulation at a nominated period of days after the flexible duct is installed)?
List the material thermal value of each blanket sited that meetsthe 7 point criteria list above.
1._____ 2.______3.______4.______5.______6.______/
YES/NO
In the report
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO
YES/NO

APPENDIX TO AS 4254.1-2012 CHECKLIST

INDEX FOR CHECKLIST OF REFERENCED CLAUSES FROM AUSTRALIAN STANDARDS

AS 4254.1 2012
CLAUSE /
CLAUSE TITLE / APPENDIX
PAGE
NUMBER
1.6
2.4.1
2.4.2
2.4.3
2.6
2.7
2.8
2.9 / Testing
Test criteria- General
Test criteria- Mechanical performance
Test criteria- Fire performance
Thermal insulation used on flexible duct
Labelling of flexible duct
Validity period for test results
Flexible duct compliance report summary / 2
2
2
3
3
3
3
4
AS/NZS 4859.1 2002
CLAUSE / CLAUSE TITLE / APPENDIX
PAGE
NUMBER
Preface
2.2
2.3.1
2.3.2
2.3.3.7
3.1
4.2
4.4
7.2.1 / Preface
Validity of test results
Thermal resistance- General
Thermal resistance- Classification
Thermal resistance- Low density fibrous materials
General
Acceptance of testing
Demonstration of compliance
Performance criteria and technical provisions- Thermal resistance / 4
4
4
4
5
5
6
6
6

ADDITIONAL INFORMATION PAGE

1. Schedule of referenced Australian Standards in NCC 20139

2. Schedule of referenced tests mentioned in Australian Standards9

3. Testing authorities certified by NATA to conduct the nominated test(s)9

APPENDIX TO AS 4254.1 2012 CHECKLIST
REFERENCED AUSTRALIAN STANDARDS CLAUSES
AS4254.1 2012
CLAUSE
1.6 TESTING
/ If either insulated or uninsulated flexible duct is required to be subjected to fire and mechanical tests or thermal tests, all such testing shall be carried out by a registered NATA testing laboratory as defined in the National Construction Code. Samples submitted for prototype testing shall be identical to manufactured product supplied to market under the fire, mechanical and thermal test certificates. In order for supplied manufactured product to be identified and compared with supplied test certificates, the certificates shall include the following minimum product data:
a) Manufacturer’s name and product’s recognised trade name.
b) Information required by the ‘Flexible Duct Compliance Report Summary’ (see Clause 2.9 and Appendix A).
Testing authorities shall keep records of adhesive type, coat weight and all flame retardants used in the adhesives for all facings and lining materials of a composite nature that are bonded together with fire-retardant adhesives during inner core and/or sleeve manufacturer.
A product shall comply with all the requirements of this standard before compliance can be claimed.
2.4 TEST CRITERIA
2.4.1 General / All insulated and uninsulated flexible duct shall be tested in accordance with UL 181 and AS/NZS 1530.3 for the mechanical and fire performance requirements of Clauses 2.4.2 and 2.4.3. All tests shall be carried out on 300 mm internal diameter flexible duct. All tests shall be carried out on the flexible duct system, i.e the insulated or uninsulated assembled final product, as opposed to individual layers. Samples submitted for testing shall be identical to manufactured product supplied to market under the fire, mechanical and thermal test certificates.
2.4.2 Mechanical Performance / All insulated and uninsulated flexible duct shall be tested in accordance with UL 181 for the following mechanical properties:
a) Mould growth and humidity.
b) Temperature- The low temperature test shall be carried out at -10°C and the high temperature test at 78° for both interior and exterior surfaces. High temperature tests shall be carried out for a minimum period of seven days.
c) Puncture.
d) Static load.
e) Impact- The impact test does not apply to metal duct as defined in Clause 2.3.
f) Pressure- The pressure test shall be carried out at 1000 Pa.
g) Collapse- The collapse test shall be carried out at 200 Pa.
h) Tension.
Where an uninsulated flexible duct (flexible duct core) passes the pressure, collapse, impact and tension tests, it need not be retested as an insulated flexible duct for these tests only, provided an identical flexible duct core construction is used.
2.4.3 Fire performance / The tests for fire performance are applicable to flexible duct only, not joining materials.
All insulated and uninsulated flexible duct shall be tested for fire performance as follows:
a) The flexible duct system, tested in accordance with AS/NZS 1530.3, shall have a smoke developed index not greater than ‘3’ and spread the flame index not greater than ‘0’.
b) The flexible duct system shall pass the UL 181 burning test. The UL 181 burning test shall be carried out with the following qualifications:
i) Gas shall be propane with a fuel content of approximately 93 MJ/m.
ii) The Bunsen burner shall have a 9.5±0.1 mm inside diameter.
iii) Fuel/Air mixture shall be such that a half blue/half yellow flame is produced.
iv) The flame height shall be approximately 63 mm and half of the flame shall impinge on the duct.
v) The sample shall be fully extended, uncompressed and conditioned for 24 h at 20±2°C and 65±5%RH.
vi) Ambient conditions in the laboratory shall be between 10°C and 30°C, and 15% and 80% RH.
2.6 THERMAL INSULATION USED ON FLEXIBLE DUCT / The insulation of flexible duct shall be achieved by integrating the insulation material into the construction of the flexible duct (i.e. the flexible duct system).
To determine the flexible duct’s R value, only the insulation material shall be thermally tested as low density fibrous insulation as per AS/NZS 4859.1:2002, Clause 2.3.2(c) and Tale 2.1 (as amended by Amd.1 (2006)). The insulation material shall not be tested as a formed shape as described in AS/NZS 4859.1:2002, Clause 2.3.2(a).
2.7 LABELLING OF FLEXIBLE DUCT / Labelling of the outer jacket/sleeve of all insulated flexible duct shall comply with the following:
a) Labelling shall-
i) be repeated along with the total length of the duct at 1000 mm intervals.
ii) be legible for the flexible duct’s service life; and
iii) have characters at least 10 mm high.
NOTE: Spiral labelling of the outer jacket/sleeve is permitted as long as it complies with Clause 2.7.
b) The label on the outer jacket /sleeve of all insulated flexible ductwork shall include the following information:
i) Name of manufacturer.
ii) Compliance with AS 4254.1.
iii) The R value of the flexible duct.
2.8 VALIDITY PERIOD FOR TEST RESULTS / For insulated and uninsulated flexible duct tested to this Standard, flexible duct that has no change in raw material and/or component supplier and/or formulation and/or design, the test results shall be valid for a maximum period of ten years from the date of NATA certified laboratory test.
Any changes made by the flexible duct manufacturer to raw material and/or component supplier and/or formulation and/or design shall invalidate the test results, and retesting shall be required.
2.9 FLEXIBLE DUCT COMPLIANCE REPORT SUMMARY
NOTE: THIS SUMMARY CAN BE FOUND AT THE END OF THIS DOCUMENT. / All manufacturers and suppliers of flexible duct shall supply the Flexible Duct Compliance Report Summary to substantiate compliance with this Standard upon request. The Flexible Duct Compliance Report Summary shall comply with Appendix A.
A separate Flexible Duct Compliance Report Summary shall be used for each different branded product line, but not for each different thermally-rated product that utilizes the same type of insulation material within each product line.
AS/NZS 4859.1 2002
CLAUSE
PREFACE / The objective of this Standard is to address the standardization and performance verification requirements of all thermal insulation materials that may be used in buildings. Insulation materials or assemblies are broadly classified into groups, having different testing requirements over a number of aspects of performance. Particular emphasis has been given to the development of clear and concise requirements for determination and labelling of thermal performance, a primary performance requirement for these materials.
2.2 VALIDITY OF TEST RESULTS / For materials that do not change in formulation or design, the test results shall be valid for a maximum period of 5 years from the date of measurement, computation or test.
Any changes made by the manufacturer to formulation or design, which may affect the performance, shall invalidate test results, and retesting shall be required.
2.3 THERMAL RESISTANCE
2.3.1 General / Thermal resistance of insulation materials may be highly dependant on boundary conditions and other environmental factors encountered in buildings and common insulation delivery systems. Thermal resistance (material, system or total) refers to the in situ or in-service condition. It is the intent of the methods and procedures contained in this Standard that the measured and/or declared thermal resistance shall reflect as accurately as possible the performance encountered within buildings.
NOTES:
-Some materials may achieve a thermal resistance that is lower in the long term than at the time of installation. Common causes include the settlement of dust on reflective insulations, outgassing of blowing gasses in foam insulations and settlement of loose fill insulations. The declared thermal resistance should be the value achieved in the long term (see ISO 10456).
-Some compression-packaged materials may take time to achieve their stabilized thickness and R-value. When the declared R-value is not expected to be achieved until some time after installation, that time should be stated on the label.
-The moisture content of materials will affect their thermal resistance.