Ductwork Fabrication and Installation Overview :Materials, Tools, and Equipment: Sheet Metal Ductwork

 Galvanized Sheet Metal:

  • Historically the exclusive material for ductwork, it remains the most durable option.

  • Requires skilled labor to fabricate and install, often used where access is limited.

  • Commonly made from 26-gauge galvanized steel sheets.

Fabrication and Installation:

  • Sheet metal ductwork can be fabricated on-site or prebuilt by manufacturers.

  • Fabrication involves cutting and bending sheet metal into circular or rectangular shapes.

  • Standard sizes can be purchased and adjusted on-site, while custom sizes and fittings are made in specialized shops.

Essential Tools for Installation:

  • Aviation Snips: Color-coded handles with specific functions:

    • Yellow: Straight cuts and short jaws for cutting heavier material.

    • Red: Left arcs and circles.

    • Green: Right arcs and circles.

  • Hand Shears (Tin Snips): Ideal for making long, straight cuts to reduce hand fatigue.

  • Hand Seamer (Hand Break): Makes precise one-inch bends using hashmarks.

  • Setting Hammer: Used for assembling duct sections, sealing seams, and moving ducts into place.

  • Crimper: Reduces the circumference of one duct section to fit into another for airtight connections.

  • Folding Tool: Makes 1-inch and ⅜-inch bends for duct transitions and folds for drive cleats.

  • Calipers and Dividers: Used to measure and draw arcs or circles on the trunk line or plenum.

  • Hole Cutter Tool: Powered by a cordless drill, replaces calipers and snips for cutting round holes.

  • Duct Puller (Duct Stretcher): Draws two sections of duct together for easier installation.

Duct Installation Tips:

  • A second person or a duct holder is often necessary to align and hold duct sections.

  • Clamps and chains can temporarily suspend the duct while corners are aligned and drive cleats are installed.

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