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The True Cost of Improper Sheet Metal Ductwork Fabrication: Why Quality Matters

Laser cutting sheet metal

What causes fabrication failure?

Where can sheet metal ductwork fabrication go wrong? It starts with improper material selection. If an abrasive particulate such as silica isn’t matched with an abrasive-resistant duct material, the duct will not withstand wear and tear over time. Incorrect thickness can also lead to premature wear when the duct is too thin for the application’s pressure or abrasiveness. Poor welding can also affect the structural integrity of the duct, which causes premature failure.

Inferior ductwork fabrication comes with hidden costs

Problems often arise when sheet metal duct fabrication doesn’t meet quality standards. Time may pass before leaks and corrosion are identified, leading to more extensive damage and frequent repairs. Risky, expensive and time-consuming issues may include:

  • Structural failure: Ductwork could fail and fall out of the ceiling causing damage to buildings, equipment, and creating safety risks
  • Subsequent costs: Wasted materials and downtime needed for repairs result in material replacement costs and lost revenue.
  • Potential health issues: When ductwork is faulty, employees may be exposed to dangerous particulates that lead to hazardous health problems.
  • Increased energy costs: Improper ductwork may not be able to handle necessary air flow, causing energy inefficiency.
  • Compliance violations: Faulty ducts may cause noxious fumes to be released into the air or harmful particulates to remain in employee work areas. These compliance violations may result in costly fines.

Expensive system replacement may be needed when these issues go by undetected for long periods of time. When dust settles within ductwork, it can decrease the capture effectiveness of the hood, resulting in costly replacements.

How to ensure quality for your application

A quality industrial ventilation partner will conduct a thorough evaluation of your industry, products and air stream condition to help ensure proper sheet metal ductwork fabrication. The right ductwork material and design will be determined by whether your product is sticky, moist, dry or in vapor form. An assessment of the speed of materials passing through the ductwork also determines the proper design requirements.

Common ductwork materials per industry include:

  • Foundry: Mild steel (hot/cold rolled)
  • Paper: Aluminum and stainless steel
  • Mining: Abrasion-resistant or stainless-steel
  • Silica: Abrasion-resistant steel

Materials may vary based on individual applications.

Enjoy the lasting benefits of ductwork fabrication done right

Properly fabricated ductwork helps ensure employee health and stringent regulation compliance. On-target ductwork fabrication stands the test of time to minimize issues, repairs and downtime. It also delivers a low-maintenance solution and energy efficiency for industrial ventilation.

IVI’s unmatched craftsmanship delivers excellence

With 30 years of expertise, IVI brings knowledge learned from numerous projects to industrial ductwork fabrication, including design, engineering, fabrication, installation and maintenance. IVI’s trained sheet metal workers complete an apprenticeship program with hands-on application and written classwork to achieve a journeyman position. IVI journeyman continue to train in and be tested on numerous weld processes to meet the fabrication needs of our customers. Plus, laser-cutting and other CNC controlled equipment delivers more exact cutting and better welds during

Get started with quality sheet metal duct fabrication

Contact IVI for proper duct fabrication that lasts.