Ducts are an essential part of any HVAC system, whether it's in a residential home or a large commercial building. They are manufactured through a fabrication process that allows them to seamlessly fit into the building's unique floor plan. When you order ducts made for your project, you should understand the process of making them. 

A Guide to Duct Fabrication

What They're Made Of

Most duct systems are made of galvanized steel. This is because the steel is strong and durable, while still relatively malleable, so it can be custom-designed to fit a space. The metal slightly expands and contracts as it heats up and cools down. Stainless steel may be used for exposed ducts in the kitchen, while carbon steel is used for flue pipes or chimney systems. 

The metal may be lined with fiberglass, which insulates the duct and seals the seams between different sections. This improves the efficiency of the HVAC system by preventing air leaks or thermal transfer, so the conditioned air arrives at the vent without losing or gaining unwanted heat. Some sections of the system may have plastic ducts in areas where more flexibility is required. 

How They're Made

Pieces of sheet metal are grooved, cut, folded, and welded to create ductwork sections. A coil machine adds grooves to the sheet metal, which serve as guides in the fabrication and installation process. They then send it through a plasma cutter or shearing machine to cut the sheet metal to size. 

The last machine folds the sheet to the desired shape. Round ducts are the most efficient, requiring the least amount of material. Rectangular ducts are the most common, since they fit nicely into walls and ceilings. 

The experienced team at Wilson Machine & Welding use state-of-the-art machinery and proven welding techniques for ductwork fabrication. They are based in Cordova, AL, and take structural engineering jobs for clients throughout the southeast United States. Their ducts are durable, attractive, and unique. Learn more on their website and call (205) 648-3203 for an estimate.