Heating, ventilation, and air conditioning (HVAC) systems rely on extensive networks of ducts to regulate the climate in buildings. These ducts may not seem as important as the HVAC unit itself, but they are what make the actual heating, ventilation, and cooling possible. They connect each room in the building to the unit and facilitate every single function the unit carries out.
This is why choosing a ductwork material is so important. Each option has unique features, ranging from easier installation to higher levels of insulation and overall energy efficiency. It is also essential to consider the ductwork’s components and their materials, as well as how they fit into the ductwork’s overall design.
In this article, we discuss the many HVAC ductwork materials available and which factors to consider before choosing one.
What Materials Are Normally Used in Air-Conditioning Duct Systems?
There are several air-conditioning duct materials that are commonly used across buildings. These materials vary widely in terms of cost, insulation, and environmental sustainability, which can make choosing between them challenging. Ducts must also feature connect collars, ceiling diffusers, and other small components. These parts and the ducts themselves must be able to fit within the confines of a given space, which can also impact material selection.
With these considerations in mind, learn more about the most popular materials for ductwork and their strengths:
Galvanized Steel
If you have worked with air ducts in the past, you have likely encountered galvanized steel ducts. Galvanized steel is often less expensive than other materials while still being able to last decades with proper care in the right environment. It is also nonporous, rust-resistant when coated properly, and easy to install due to its relatively low weight. It can even be painted to match its surroundings.
These traits make galvanized steel an effective, all-around option for ducts. However, it does require separate insulation to keep things running efficiently.
Aluminum
Ducts made of aluminum are very similar to those made of galvanized steel. Both are durable and customizable and require insulation support to maintain efficiency across the HVAC system. However, while both materials fall into the category of sheet metal, aluminum is even lighter and thus easier to install. It is also corrugated, meaning it is better able to withstand movement at joints in the ductwork.
Buildings in humid or coastal areas tend to rely on aluminum ducts, as they are naturally resistant to rust, mold, and bacteria. This resistance helps them last several years with quality maintenance, but it also makes them slightly more expensive than their galvanized steel brothers.
Fiberglass Duct Board
This sheet metal variant is lined with fiberglass, which provides insulation without the need for additional materials. Using this material can save both money and time in the long run while also providing excellent noise reduction and protecting the ducts from condensation and corrosion.
Fiberglass duct boards tend to wear out faster than other sheet metal ducts. This wear can expose the building’s occupants to health risks as the fibers leak into the air. As such, these ducts need to be regularly checked and maintained to ensure safe, high-quality performance.
Flexible Ductwork
Composed of a spring steel wire helix and two-ply polymer plastic, flexible ductwork can go places sheet metal ducts cannot. Its flexibility and extremely low weight make it easy to install and connect reducers and other compact components, even in challenging locations that would be inaccessible to sheet metal ducts.
Flexible ductwork also comes with built-in insulation. As a result, this material can significantly reduce the space taken up by ducts and insulation while also being able to sit at angles and positions that would be impossible for stiffer duct materials. In the long run, these features can save money and time while improving a building’s overall climate control capabilities as a result of extended duct reach.
What Is the Best Material for Ductwork?
Every building with an HVAC unit has unique needs. The right duct material for a large office building in a temperate climate will have different ductwork material needs than a small warehouse in a tropical region. Here are a few essential factors to assess when selecting a duct material:
- Climate and environment: Where is your building located? Is the environment more tropical and humid, or are you dealing with dry, cool air throughout most of the year? For example, buildings near the coast will likely need corrosion-resistant ducts. Examine weather patterns and similar data to choose a durable, resistant duct material.
- Budget: Given the varying costs of duct materials, it is important to consider which one will be the most cost-effective and sensible in the long term. Installation, maintenance, and other expenses must also be factored in before making a commitment. Corrosion-resistant ducts may be more expensive initially, but they can result in savings down the line, especially in damper regions.
- Energy efficiency: Duct materials and insulation directly affect the efficiency of HVAC units and the resulting utility costs. Choosing the correct material can improve heat, ventilation, and cooling capabilities while also reducing harm to the environment and overall expenses. Duct materials with built-in insulation tend to be highly energy efficient, but they are also more expensive to install. Sealing and insulating sheet metal ducts separately can achieve the same effect.
- Acceptable noise levels: The composition of HVAC ducts has a direct impact on ambient noise throughout the building. Insulated ducts often cut down on overall noise. However, high noise levels may be expected in factories and other loud environments, which may make galvanized steel or aluminum the superior options.
Build Better Ductwork With The Plastek Group
Ducts regulate the indoor climate of businesses worldwide, but they cannot do this important work without ceiling diffusers, air return grilles, and many other components. When designing ductwork, it is essential to consider these essential pieces, part of which includes partnering with the right material supplier.
At The Plastek Group, we offer specialized mold design and manufacturing capabilities and plastic materials solutions for building and construction. We can create durable and long-lasting plastic HVAC parts designed to support ducts of all materials. Our team designs, builds, manufactures, and molds finished products.
As a world-class plastics supplier, we have worked with numerous businesses to support their needs. Companies like HaVACo Technologies have chosen our design, molding, and manufacturing processes for quick connect ceiling diffusers to cut costs and streamline their supply chains.
To learn more about our processes for creating HVAC components and other offerings, fill out our contact form or call us at 814-878-4400.
