CFM Exam Preparation Course

What is Metal Duct Design?

Benefits of Metal Duct Design

How to Design Metal Ducts

Metal Duct Design Codes and Standards

6.4.4.2 Ductwork and Plenum Leakage

Metal Duct Design Software

While the standard residential forced air HVAC system consists of both a furnace and a central air conditioner, neither would be able to do its job of making the home’s interior more comfortable without ductwork. HVAC ductwork is the network of ducts that deliver warmed or cooled air throughout the home, so to say that it is an important part of any HVAC installation would be an understatement. Visit for more information CFM Exam Preparation Course

In truth, ductwork design and fabrication is one of the most important skills an HVAC technician needs to develop because if a ducting system is poorly configured, then a significant percentage of the home’s energy will be wasted. How much? The potential for energy losses caused by bad duct design can reach as high as 40 percent!

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At BTrained, we offer Metal Duct Design and Fabrication Workshops that can help you take your skills to the next level. In this post, you will learn more about the importance of duct design and how this course of study can help you become the best HVAC technician you can be. Some of the topics that will be covered include:

Metal duct design involves several processes, including sizing, planning (laying out), placement, and detailing of the ducts, which includes sealing and insulating. Once installed, the final process involves finding and fixing any pressure losses throughout the network of ducts.

The sizing phase of HVAC ductwork design is one of the most important because you need to make sure that the ducts are large enough to carry enough air to heat or cool the home. If a heating and cooling system is installed with ducts that are too small, airflow will be restricted and this will have a negative impact on the system’s efficiency and its ability to keep the home comfortable.

The planning phase of metal duct design is also known as the configuration phase. This is when you will determine which type of layout will work best within the space you have for installation. The two most common configurations are the “radial” and “trunk and branch” designs. In the radial configuration, the heating and/or cooling unit is located in the center and its supply and return ducts radiate outward, like the tentacles on an octopus. A trunk and branch set-up, on the other hand, is designed like a tree, with large ducts extending outward from the central unit and smaller supply and return ducts extending out from the larger ducts.

Ductwork placement is another important topic of discussion because where you install the ductwork, and where you do not, are just as important as sizing the system properly. For instance, you want to avoid running ductwork systems through unconditioned areas of the home, such as through crawl spaces or attics, as these areas will result in greater energy loss. Ducts should be placed in conditioned spaces whenever possible because this will improve efficiency and less energy will be lost.

Detailing the ductwork involves ensuring that all connections at the sections, joints, and elbows are snug, and then sealing each seam with mastic sealant or metal tape. This will help prevent air leaks and improve overall efficiency.

In cases where the ductwork must be installed in an unconditioned space, then it needs to be insulated using at least R6 insulation, although R8 is preferred. The ductwork that runs through the home’s conditioned spaces should be insulated using R4 insulation.

The ducts used in HVAC are usually made from either galvanized steel (with a zinc coating) or aluminum and they can be round, oval, or rectangular. Sheet metal is the ideal material for an HVAC system because it is not only readily available, but it is also the most durable, rustproof, and least likely to harbor mold. This means that once metal ductwork has been installed, it will last for decades without requiring much in the way of maintenance or repair. Even in cases where a furnace needs to be replaced, the existing ducts can simply be connected to the new furnace.

Another key benefit of metal duct design is that these systems can easily be configured for any floor plan regardless of how many levels the home may have. When the appropriate tools are used, metal ducts are easy to cut and splice together. This also makes it very easy to expand the ductwork should the home undergo renovations or add additional living space.

Since these systems are made from metal, they are non-combustible. This means that if a fire should break out in one part of the home, the fire will not spread through the building via the HVAC ductwork. Metal is also the most hygienic choice for HVAC system air delivery because it is so easy to clean and maintain compared to other options, like fiberglass or flexible ducts.

During the three-day Metal Duct Design and Fabrication Workshop, you will learn everything you need to know about designing and fabricating metal ducts on a professional level. You will learn how to create common duct transition fittings, including transitions from square ducts to round ducts, as well as safe cutting and handling techniques, and the proper use of fabrication tools.

When designing metal ducts, there are certain factors that you will need to take into consideration, including the capacity of the ductwork, air distribution, and restrictions. Ductwork capacity is important because you want airflow pressure to be consistent throughout the home. Distributing air evenly is also important or else you could have a home with one room that is substantially colder or warmer than the rest. This will also create a lopsided system which could eventually result in efficiency problems.

Restrictions also need to be kept to a minimum because air will always take the path of least resistance. Where there are restrictions, air will be diverted elsewhere, resulting in unbalanced airflow distribution. Using metal ducts instead of flexible ducting is therefore usually recommended because flexible ducts need to be properly supported, so it doesn’t have any kinks that could interfere with airflow.

Because the design of a metal duct system needs to be balanced, it should only be designed by a professional with the appropriate knowledge and experience. While most HVAC technicians should be able to install metal duct systems, designing one that guarantees system balance and equal air distribution is something that requires a deeper understanding of how ducts work. By completing BTrained’s Metal Duct Design and Fabrication Workshop, you will gain the knowledge and skills you need to add this valuable skill to your wheelhouse.

Each HVAC installation is unique. Factors that can impact an installation include the size and location of the building, the thermal integrity of the facility, the timeline and budget for the project, and more. But throughout any installation, the one component that you must pay close attention to is ensuring that the installation complies with appropriate regulations and building codes.

Installing an HVAC system that isn’t up to code can result in you or your employer being subject to costly fines and penalties. It will also result in a lot of wasted time and resources because you will need to go back and correct the installation to make it compliant.

This is why it is so important to know what the building codes are before you start a project. While there is no national code that applies to HVAC duct installation, states and local municipalities usually do have construction codes for HVAC. For instance, in Alabama, new and replacement ductwork must comply with Sections 6.4.4.1 and 6.4.4.2 of the state’s building code. The codes are included below:

The Metal Duct Design and Fabrication Workshop provides you with a better understanding of these codes and standards and how they apply to your day-to-day work.

Today, HVAC installation technicians have a trove of digital resources at their disposal that can help make designing custom metal duct systems quicker and easier. During your time in BTrained’s Metal Duct Design and Fabrication Workshop, you will learn about the variety of different software programs available that are designed to help you improve the efficiency of your results.

But as helpful as these resources can be, nothing beats having a solid educational foundation and practical hands-on experience. At BTrained, we provide you with both, so when you complete your workshop, you will be prepared to include duct design in your repertoire of skills.

Three days is all it takes for the HVAC experts at BTrained to provide you with a greater understanding of how to design and fabricate metal duct systems. This is a valuable skill that the highest-paid technicians in the field have, so if you want to take your career to the next level, then this workshop will help get you there.

These workshops are limited in number and seat availability is purposefully kept low to maximize individual instruction, so if you want to attend an upcoming workshop, don’t delay. Enroll today to secure your seat and get the skills you need to further your career in HVAC.