Commercial HVAC Project Plan
A preliminary project scope built from your quote inputs — duct layout and sizing, equipment schedule, and a material takeoff priced for your region.
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Project Inputs
Adjust any input to regenerate the plan.
Includes duct layout, equipment, materials, and code requirements — ready to send to contractors.
Project Summary — U.S. National Average
Rooftop Units (RTUs) · Medium ducts (12"–24") · regional index 1.00× (Baseline mechanical cost index)
- Conditioned Area
- 10,000 sq ft
- Design Airflow
- 10,000 CFM
- Cooling Capacity
- 28.6 tons
- Control Zones
- 3
at 1.0 CFM/sq ft
VAV terminals
Total installed cost range
$140,000 – $220,000
14.00 – 22.00 per sq ft · project-size factor 1.00×
Duct Layout & Sizing
Trunk, riser, runout, return, outside-air, and exhaust runs sized to ASHRAE velocity targets.
| Tag | Run | CFM | Round | Rectangular | Velocity | Length | Gauge | Insulation |
|---|---|---|---|---|---|---|---|---|
| SA-M | Supply main trunk (from unit discharge) | 5,000 | 26" | 30" × 20" | 1,356 fpm | 120 ft | 22 ga | R-6 external wrap |
| SA-B | Supply sub-trunk / riser branch | 2,500 | 20" | 24" × 16" | 1,146 fpm | 160 ft | 22 ga | R-6 external wrap |
| SA-R | Zone runouts to VAV terminals (3 zones) | 3,333 | 28" | 33" × 22" | 779 fpm | 105 ft | 20 ga | R-6 external wrap |
| RA-M | Return air main | 4,250 | 28" | 33" × 22" | 994 fpm | 100 ft | 20 ga | None required |
| OA | Outside air / ventilation duct | 2,000 | 20" | 24" × 16" | 917 fpm | 50 ft | 22 ga | R-8 external wrap |
| EA | Exhaust air duct | 1,200 | 14" | 17" × 11" | 1,123 fpm | 60 ft | 24 ga | None required |
Equipment List
Installed unit pricing adjusted for U.S. National Average.
| Tag | Description | Qty | Capacity | Unit Cost | Extended |
|---|---|---|---|---|---|
| RTU-1..2 | Rooftop Units (RTUs) | 2 | 14.3 tons | $21,450 – $34,320 | $42,900 – $68,640 |
| VAV-1..n | VAV terminal units with hot-water/electric reheat | 3 | 3,333 CFM | $1,100 – $1,900 | $3,300 – $5,700 |
| EF-1..n | Exhaust fans (restroom / general building exhaust) | 1 | 1,200 CFM | $900 – $1,800 | $900 – $1,800 |
| DDC | DDC controls, sensors, and BAS integration | 1 | — | $16,000 – $32,000 | $16,000 – $32,000 |
| Equipment subtotal | $63,100 – $108,140 | ||||
Materials by Region
Takeoff quantities priced at 1.00× the national mechanical cost index.
| Material / Scope | Qty | Unit Cost | Extended |
|---|---|---|---|
| Galvanized sheet metal ductwork (fabricated & installed)Medium ducts (12"–24"); 595 linear ft total | 5,243 lb | $6.50 – $11.00 | $34,080 – $57,673 |
| Duct insulation — R-6 external wrapSupply and outside-air ducts | 4,958 sq ft | $2.10 – $3.60 | $10,412 – $17,849 |
| Flexible duct runouts to diffusers8 ft max per ASHRAE / IECC limits | 18 ft | $5.00 – $9.00 | $90 – $162 |
| Supply diffusers, returns, and grillesLay-in and surface-mount mix | 40 ea | $95.00 – $190.00 | $3,800 – $7,600 |
| Volume dampers, fire/smoke dampers, and access doorsFire dampers at rated assemblies | 8 ea | $210.00 – $640.00 | $1,680 – $5,120 |
| Hangers, seismic bracing, sealant, and fastenersSMACNA hanger spacing | 595 ft | $3.20 – $6.00 | $1,904 – $3,570 |
| Roof curbs, structural steel, and riggingPrefabricated curbs | 2 ea | $2200.00 – $5200.00 | $4,400 – $10,400 |
| Testing, adjusting & balancing (TAB) and commissioningIndependent TAB agency | 10,000 sq ft | $0.35 – $0.75 | $3,500 – $7,500 |
| Materials & installation subtotal | $59,865 – $109,874 | ||
Code Compliance — U.S. National Average
Adopted codes: IMC / IECC (edition varies by jurisdiction). Confirm the exact edition with the authority having jurisdiction before permitting.
ASHRAE & SMACNA Standards
- ASHRAE 62.1 — Ventilation for Acceptable Indoor Air Quality
- Outdoor air rates by Ventilation Rate Procedure (typically 5 cfm/person + 0.06 cfm/sq ft for offices); provide OA measurement and minimum-position control at each air handler.
- ASHRAE 90.1 — Energy Standard for Buildings
- Duct leakage class, insulation minimums (R-6 concealed / R-8 exterior), fan power limits, economizers on most cooling units, and DDC controls with setback scheduling.
- ASHRAE 55 — Thermal Environmental Conditions
- Maintain occupied-zone comfort envelope; supply diffuser throw and terminal velocities under 50 fpm in the occupied zone.
- ASHRAE 111 / SMACNA — Testing, Adjusting & Balancing
- Independent TAB agency to balance all systems within ±10% of design airflow; document duct pressure class and leakage test results.
- SMACNA HVAC-DCS — Duct Construction Standards
- Gauge, reinforcement, sealing class, and hanger spacing per pressure class; seal class A on all supply ductwork.
NFPA & Life Safety
- NFPA 90A — Air Conditioning & Ventilating Systems
- Fire dampers at rated walls/floors, smoke dampers at smoke barriers, duct materials with flame spread ≤25 / smoke developed ≤50, and smoke detectors in supply systems over 2,000 cfm.
- NFPA 96 — Commercial Cooking Ventilation
- Where kitchen hoods are present: welded liquid-tight grease duct, listed enclosure or 2-hour shaft, cleanouts, and hood suppression interlock.
- NFPA 72 — Fire Alarm & Signaling Code
- Duct smoke detectors must shut down the unit and report to the fire alarm panel; provide remote test/annunciator stations.
- NFPA 101 — Life Safety Code
- Ductwork and equipment must not compromise egress enclosures; stair pressurization and smoke-control interfaces where required.
- NFPA 70 (NEC) — National Electrical Code
- Disconnects within sight of equipment, GFCI service receptacle at rooftop units, and proper working clearances.
Local & Regional Requirements
- IMC — International Mechanical Code
- Duct construction, combustion air, exhaust rates, and access clearances per the locally adopted IMC edition.
- IECC (Commercial) — Energy Code
- Duct sealing and leakage testing, insulation, economizers, and commissioning documentation for systems over 480,000 Btu/h.
Project-Specific Compliance Notes
- Design outdoor air: approximately 600 CFM minimum per ASHRAE 62.1 area-based rate (add occupant-based component).
- Supply system exceeds 2,000 CFM — duct smoke detector required downstream of filters per NFPA 90A.
- Building over 10,000 sq ft — ASHRAE 90.1 / IECC commissioning and a commissioning report are required.
- Confirm the code edition adopted by the local AHJ before permitting; amendments frequently differ from the model code.
Local Contractors — U.S. National Average
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Important Disclaimer
This calculator is for preliminary design guidance only. Final duct sizing, construction, and installation must be performed by qualified professionals and comply with applicable codes and standards.