Best Materials for Industrial Air Duct Installation | Duct2Go Guide
Industrial ductwork is not one size fits all. Choose materials based on corrosion risk, temperature, pressure, cleanliness, fire code, noise, and budget.
Material selection drives performance, safety, and lifetime cost. This guide compares common industrial duct options and gives practical advice on joining, sealing, and maintenance. Pair the right material with quality fabrication and proven installation practices for a reliable system.
Material Options and Use Cases
Galvanized Steel Duct
Summary: The industry workhorse for supply, return, and exhaust systems.
Pros: Durable. Relatively low cost. Good structural strength. Widely available. Easy to form and join.
Cons: Can corrode in highly corrosive or humid or chemical environments. Heavier than aluminum.
Best for: General industrial HVAC, warehouses, manufacturing floors.
Joining and sealing: Flanged or spiral lock seams. Use mastic or UL approved foil backed tape. Gasketed flanges for higher pressure runs.
Maintenance note: Inspect for surface rust in corrosive areas and touch up or replace as needed.
Stainless Steel Duct
Summary: Corrosion resistant choice for aggressive environments.
Pros: Excellent corrosion resistance. Sanitary. Long lifespan.
Cons: Higher material and fabrication cost. Heavier than aluminum per strength ratio.
Best for: Corrosive environments, chemical plants, food processing, pharmaceutical, high humidity spaces.
Joining and sealing: Welds or flanged connections. Compatible with sanitary clamps. Use silicone gaskets for food grade systems.
Maintenance note: Minimal surface treatment required. Check for pitting in chloride rich atmospheres.
Aluminum Duct
Summary: Lightweight and corrosion resistant alternative to steel.
Pros: Light weight for easier handling and installation. Natural corrosion resistance. Good for longer unsupported spans.
Cons: Softer than steel and can dent. Often more expensive than galvanized steel but usually less than stainless.
Best for: Roof level ducts, outdoor ducts, coastal facilities with salt exposure when stainless is not required.
Joining and sealing: Rivets with continuous sealant or aluminum flanges. Closed seam spiral options available.
Maintenance note: Inspect for galvanic corrosion where aluminum contacts dissimilar metals.
Lined or Insulated Sheet Metal
Summary: Metal duct with internal insulation or double wall construction for noise and thermal control.
Pros: Adds thermal insulation and sound attenuation. Can reduce condensation. Cleaner interior when specified correctly.
Cons: Insulation must meet fire code. Internal liners can collect dust if maintenance is skipped.
Best for: Conditioned process areas. HVAC serving occupied spaces with noise limits. Chilled systems that may sweat.
Joining and sealing: Use vapor barrier seals on joints. Maintain a continuous vapor barrier where needed.
Maintenance note: Inspect liners for moisture and microbial growth. Replace if contaminated.
Order Materials With Confidence
Duct2Go fabricates galvanized, stainless, and aluminum duct systems with precision. Get straight pipe, elbows, reducers, transitions, takeoffs, access doors, flanges, and hardware that fit perfectly the first time.