Crimped duct restricts airflow (reduced CFM)
Precision Air Distribution, Fabricated In-House
Custom Sheet Metal Fabrication
We don't order parts from a catalog and hope they fit. We fabricate them.
Service Line operates its own sheet metal shop—plasma tables, brakes, shears, and the expertise to use them. When your project needs a custom plenum, an offset transition, or a specialty fitting, we build it. To spec. On our timeline.
Built to fit. Not forced to fit.
Get QuoteBuilt to fit. Not forced to fit.
Why Catalog Parts Create Custom Problems
Supply houses stock "universal" fittings designed to work in most installations. Your installation isn't most installations—it's specific. The result: mismatched dimensions, sharp angles, gaps filled with tape that fails.
What Happens When Fittings Don't Fit:
The "Plenum Kit" Reality:
Fiberboard triangles and cardboard boxes taped together to form a supply plenum. They're cheap and fast. They're also the source of most system noise, airflow restriction, and long-term failure. Tape adhesive degrades in attic heat within 2-3 years. The "kit" that passed inspection becomes a leaking, noisy liability.
Our Shop: Speed, Precision, Quality Control
Shop Equipment:
What This Means for Builders:
The Same-Day Turnaround:
A builder called at 10 AM—the structural engineer moved a beam, and the planned duct run no longer fit. By 2 PM, we had measured the new constraints, designed an offset transition, fabricated it in our shop, and had it on site for installation. That's the difference between owning your capability and depending on third parties.
Where Airflow Begins: Supply and Return Plenum Design
The supply plenum is the first thing air encounters after leaving equipment. Its design affects everything: noise, airflow distribution, efficiency.
The Lined Plenum Advantage:
We build lined plenums—galvanized steel with internal acoustic insulation. The liner absorbs blower noise, acting as a muffler. Homeowners don’t hear the equipment running.
Return Air Design:
Wide-throat return drops with gradual transitions ensure the system can breathe. A starving unit has high suction pressure, which freezes the coil. Our metal drops guarantee proper CFM intake.
The 10-15 Decibel Difference:
A properly lined plenum reduces transmitted blower noise by 10-15 decibels—the difference between "can hear the system from the bedroom" and "didn't know it was on." For custom homes, for equipment above living spaces, or for noise-sensitive homeowners, lined plenums are standard.
Why Shape Matters: Turbulence, Static Pressure, and Noise
When air hits a sharp corner, the airstream separates from the duct wall, creating eddies and recirculation. This turbulence creates noise (whooshing sounds) and wastes energy (higher static pressure).
Our Solution: Smooth Transitions and Radius Elbows
The Static Pressure Budget:
Every HVAC system has a "static pressure budget"—the total resistance the blower can overcome. Sharp fittings "spend" this budget inefficiently. A system with turbulent plenum and sharp elbows might use 0.3" on fittings alone—leaving inadequate budget for duct runs. Result: rooms at the end don't receive design airflow.
26-Gauge Galvanized: Mechanical Fastening + Mastic Sealing
Our standard: 26-gauge galvanized steel. Fittings connected with sheet metal screws and drive cleats—permanent mechanical connections. Every joint sealed with fiber-reinforced mastic.
The Tape Timeline:
Duct tape in a Texas attic: adhesive softens at 140°F+, fails within 2-3 years. Foil tape: longer lasting but still subject to adhesive degradation. Mastic: hardens permanently, doesn't soften or release, remains airtight for 30+ years. We don't tape joints—we seal them permanently.
Keeping Ducts Dry in Baytown's Humidity
In Baytown, bare metal in unconditioned spaces sweats. Supply air at 55°F surrounded by 90%+ humidity = immediate condensation. Water drips onto drywall, insulation, causing damage.
R-8 minimum for all metal in unconditioned spaces
Vapor barrier integrity maintained at all penetrations
Complete coverage—including transitions and fittings others skip
Baytown Humidity Reality:
Summer dew points regularly exceed 75°F. Any surface below that temperature collects condensation. Supply ductwork at 55°F in an unconditioned attic is a condensation machine unless properly insulated with intact vapor barriers. The water on ceiling drywall isn't a roof leak—it's sweating ductwork.
The "Showroom" Standard: When Presentation Matters
In custom homes, discerning buyers notice everything—including whether the mechanical room reflects the quality they paid for. Sagging flex duct looks cheap. Cross-broken metal looks professional.
Pride of Ownership:
When a custom home buyer opens the mechanical room door, they should see equipment and ductwork that match the quality of the rest of their home. Clean metal, professional connections, organized installation. We build mechanical rooms that builders are proud to show—not closets that get skipped on the walkthrough.
Asked Questions
How quickly can you fabricate custom fittings?
Same-day to next-day for most residential fittings. We’re not subject to third-party schedules. When change orders happen, we respond immediately.
What material do you use?
Standard residential: 26-gauge galvanized steel. Heavier gauges for commercial or high-abuse applications. All materials resist corrosion in humid environments.
Why is mastic better than tape?
Tape adhesive degrades in Texas attic heat (140°F+) within 2-5 years. Mastic hardens permanently—doesn’t soften, release, or degrade. Airtight for 30+ years.
What's a lined plenum?
Interior acoustic insulation that absorbs blower noise—like a muffler. Recommended when quiet operation matters or equipment is near living spaces.
How do you prevent condensation?
R-8 minimum insulation with intact vapor barriers on all metal in unconditioned spaces. We insulate everything—including transitions and fittings others skip.
Let's Build What Your Project Needs
Whether you're a builder needing a reliable fabrication partner, an architect specifying tight spaces, or a homeowner wanting quality—send us your requirements. We'll explain what we can build and how quickly.