Sheet Metal Worker

Year 1 Exam Study Guide — the foundational knowledge every apprentice needs before advancing.

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12Topic Sections

48Key Concepts

0Flashcard Terms

Year 1Apprentice Level

Year 1 Exam Topics

Study each topic below — these are the core knowledge areas tested in Year 1. Build a solid foundation here before advancing to Year 2 material.

🔧Sheet Metal Gauges & Materials

Galvanized steel most common for HVAC applications
Gauge = thickness (lower = thicker); 24 ga = 0.61mm, 22 ga = 0.76mm, 20 ga = 0.91mm
Aluminum and stainless steel for specialty corrosive applications
SMACNA specifies gauge by duct size and pressure class

📖Duct Shapes & Systems

Rectangular: most used in commercial buildings
Round: best for airflow efficiency, easiest to fabricate
Oval: fits in tight spaces with rectangular duct performance
Low/medium/high pressure classification by static pressure (up to 500Pa, 500-1000Pa, 1000Pa+)

📖Pattern Development (Layout)

Parallel line development: cylinders and prisms
Radial line: cones and pyramids
Triangulation: oblique shapes like transitions
Flat pattern shows exact cut size before bending or forming

📖Seams & Joints

Pittsburgh seam: most common for rectangular duct
Snap-lock: round duct spiral seam connection
TDC/TDF flange: transverse duct connection with corner clips
Drive cleats and S-cleats for duct assembly and reinforcement

📖Fasteners & Assembly

Sheet metal screws: #8 and #10 most common sizes
Pop rivets for permanent assembly; cleco pins for temporary positioning
Self-tapping screws for quick attachment without pre-drilling
Sealant required at all joints for pressure class 2+

🦺Shop Safety

Deburring sharp edges before handling to prevent cuts
Snips and nibblers — cut away from body at all times
Press brake pinch points are critical hazards
Wear cut-resistant gloves; hearing protection near plasma cutters

Red Seal Exam Topics

Study each topic below — these are the core knowledge areas tested in Year 1. Build a solid foundation here before advancing to Year 2 material.

📋SMACNA HVAC Duct Construction Standards

Specifies gauge, reinforcement, joint type by duct size and pressure class
Seal class A, B, C (A = all joints and seams sealed)
Construction class 1, 2, 3 based on performance requirements
Industry best practice for system design and installation

📖Spiral & Oval Duct

Spiral wound: continuous lock seam, strong, 5% less air leakage
Flat oval: hybrid fitting multiple rounds into rectangular space
Connectors (couplings) and transitions require pattern development
Cost-effective alternatives to rectangular for certain applications

📖Kitchen Exhaust Systems

NFPA 96 governs commercial cooking ventilation and safety
Grease duct: 16 ga black steel, liquid-tight seams, clearance from combustibles
Hood capture velocity: 0.25–0.50 m/s for effective grease capture
Cleaning and maintenance access required at code intervals

📖Fume Hood & Specialty Systems

Laboratory hoods: constant air volume (CAV) or variable air volume (VAV) control
Materials: 316 stainless steel or PVC for acid fume environments
Duct velocity 10–12 m/s minimum to prevent condensation and acid corrosion
Specialized connections and material specifications required

📖Commissioning & Air Balancing

TAB (Testing, Adjusting, Balancing) per SMACNA standards
Pitot tube traverse for duct velocity measurement and verification
Total CFM = area × velocity calculation for flow verification
ASHRAE 111 procedures for system adjustment and documentation

📖Vibration & Noise Control

Flexible connections between AHU and duct prevent vibration transmission
Acoustic lining (duct liner) reduces sound transmission and attenuation
Sound attenuators (silencers) for critical noise control areas
Duct velocity affects noise (keep under 7.5 m/s for quiet operation)

🃏 Review with Flashcards

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