Sheet Metal Ductwork Fabrication in Tucson, AZ

Tucson's Ductwork & Sheet Metal Experts—If You Need It, We Can Build It

Providing free on‑site consultations for ductwork projects
Trusted by Raytheon, the Rialto Theater and other iconic Tucson organizations
Honoring 100% satisfaction for every job

Earning Tucson's Trust with Every Custom Ductwork Project

We offer design, fabrication and installation of custom architectural sheet metal for residential and commercial buildings. With a full in-house metal shop, we specialize in custom ductwork design, no matter how complex the project. In fact, we're the company other HVAC contractors turn to for their ductwork needs.

Pricing

How much does it cost to design & install custom sheet metal ductwork?

Low $10 per foot
Our Average $25 per foot
High $60+ per foot

What affects the cost of ductwork fabrication & installation?

Many factors influence the cost of ductwork fabrication and installation, including:

Material: Different ductwork materials come with different pricing. For example, flex ductwork often costs less than rigid ductwork. However, depending on the unique specifications of your ductwork project, you won't always have a choice on the material used.
Access: If you need to install ductwork in hard-to-reach areas, such as a crawlspace or attic, this will increase labor and/or materials needed for the project, which will increase the overall price.
Length of runs: The price you pay for ductwork largely depends on the amount of material you need (measured in linear feet). The longer the runs, the more linear feet of material needed and the more you'll pay.

Looking for an accurate estimate?

A ductwork specialist can visit your home, business or build site at your earliest convenience. We'll find out your exact needs for the project and give you a fixed price quote for the work.

Schedule estimate

Other Sheet Metal Projects

Have other sheet metal needs?

Just give us a call, we can do it all.

We specialize in all architectural metals. Need copper gutters? A copper or rust-look garage door or roof? What about a custom-built planter?

If you need it, we can build it.

Sheet Metal Fabrication

What Is Sheet Metal Fabrication?

Sheet metal fabrication transforms thin sheets of metal into usable products. In HVAC, sheet metal fabrication is used to create custom-fitted ductwork that marries energy efficiency with extreme durability.

During the sheet metal fabrication process, we:

Cut raw sheets of metal utilizing advanced tools, including waterjets, plasma cutters, and lasers. These tools create smoother, more precise edges that come together evenly and improve airtightness.
Form and bend the metal into the correct curves and angles to create custom ductwork that fits perfectly into the home or facility’s layout.
Weld and join separate pieces to ensure an airtight connection.
Finish the metal surfaces with treatments and coatings that minimize the risk of rust or corrosion.

While precision matters in every use case, it’s especially important when fabricating ductwork. Slight miscalculations can be problematic, reducing energy efficiency and leading to inconsistent heating and cooling or lower air quality.

Why Your Business Needs This

Why Your Business Needs Sheet Metal Fabrication

In a commercial setting, custom sheet metal ductwork usually outperforms prefabricated options. Prefabricated ductwork rarely fits perfectly, making it difficult to heat and cool efficiently.

Fabricating sheet-metal ductwork eliminates this issue. As efficiency improves, your HVAC system doesn’t have to work as hard to maintain your building's temperature. This means less wear and tear over time, often resulting in fewer equipment breakdowns. It also helps reduce utility costs over time. Savings on repairs, maintenance, and utility bills help offset the high upfront cost.

Once you transition to custom sheet metal ductwork, you will likely notice a more even temperature throughout your building. These custom builds reduce air loss and the prevalence of hot or cold spots throughout your building.

Process

Your ductwork project will look like this:

You schedule a free estimate
You can schedule an appointment with us by calling (520) 792-9400 or scheduling online. One of our experienced ductwork experts will come to your home or business and perform crucial on-site duct sizing calculations. Afterwards, we’ll send you an estimate for your custom ductwork needs.
We design & fabricate the ductwork
Once you choose us, we’ll start on the design and fabrication of your ductwork, keeping in mind the HVAC system requirements and unique design specifications of the space. Want to keep an eye on the project? No problem, stop by and visit our shop to watch the fabrication yourself!
We install your ductwork
On the scheduled day, our team will show up on site to install your brand new ductwork. We'll place drop cloths and wear shoe covers the entire time to keep the space clean and damage-free. Installations typically take 1-2 days. Afterwards, we'll test (and re-test) the integrity of the installation joist by joist to ensure a job well done, the first time around.

Schedule free ductwork estimate

Other Services

Looking for something else?

We offer a variety of additional indoor air quality services:

Sheet Metal Fabrication FAQs

Frequently Asked Questions

HVAC ductwork usually consists of sheet metal, flex duct, or fiberglass duct boards.

Sheet metal ducts are typically the most efficient because they have a smooth, rigid interior surface. When installed correctly, they minimize pressure loss and friction.

Flex ducts are constructed with a wire coil covered in a flexible plastic. They tend to be easier to install and cost less, but they aren’t as durable. The ridges lining the interior tend to create turbulence and friction, reducing HVAC efficiency.

Fiberglass duct boards are better than flex ducts, but they lack the staying power of metal. They’re also prone to interior degradation, which can affect efficiency and air quality.

Metal HVAC ductwork is usually made of galvanized steel or aluminum, though other metals may also be used.

Steel is more durable, and the materials tend to cost less. However, it’s also more labor-intensive to install, which can raise upfront costs. Steel is also more prone to rusting and corroding in constant humidity.

Aluminum ductwork is lighter and more flexible than steel, but the materials cost more. While it’s naturally rust, mold, and bacteria-resistant, it’s less durable and more prone to damage in the long term.

The right choice for your home or business depends largely on the use case. Have a professional evaluate your needs and make recommendations before committing to one or the other.

Most ductwork uses sheet metal ranging from 26 to 16 gauge. Higher gauges are thinner than lower ones.

In general, lower-gauge metal is used for higher-pressure and larger trunk lines, while higher-gauge metal is used for branch ducts. For residential projects, it’s most common to see 24 to 26-gauge sheets for ductwork.

Commercial ducts usually range from 22 to 24-gauge. In specialized industrial settings, gauges as low as 16 may be used to withstand high-pressure usage.

Advantages of sheet metal ductwork include:

Durability: Sheet metal ductwork often lasts decades with minimal damage.
Improved airflow: Since metal ductwork is smooth and rigid inside, there’s minimal friction to slow down airflow.
Better air quality: The non-porous interior discourages the growth of mold, which can negatively affect air quality.
Customizability: Sheet metal ductwork can be customized to the exact specifications of a building, making it highly effective in complex settings.
Fire-resistant: Sheet metal won’t burn in a fire, making it an attractive choice in high-heat settings.

Disadvantages include:

Cost: Custom sheet metal ductwork often costs much more upfront compared to flexible ducting. Because it’s harder to install, it also requires more labor, which increases costs.
Noise: Metal ducts can be noisy, especially if they’re not insulated properly.
Installation difficulty and requirements: Sheet metal is heavy and rigid, which can make installation difficult. Technicians must take care to avoid sharp edges and to seal joints properly.

Customer Testimonial

...thorough, courteous, efficient and knowledgeable.

“Advantage Air has been a great company to work with over the past 3 years. They are very thorough, courteous, efficient and knowledgeable.”
—Alex S. | Tucson homeowner

See why we're rated 4.5 out of 5 on Google.