Welded aluminum duct and fittings
Lightweight Custom Ductwork
TIG welded aluminum duct and fittings for lightweight custom HVAC, exhaust, process, and equipment connection work.
- Best for custom duct packages where reduced weight, aluminum material, or specialty equipment geometry is required.
- 5052 is typical for welded aluminum duct; 3003 can be quoted for formed components or project-specific requirements.
- Confirm alloy, gauge, finish expectations, connection style, and field-fit dimensions before release.
Material5052 or 3003 Aluminum
WeldingTIG welded
FinishMill finish
Construction Standard
| Application | Custom welded aluminum ductwork and fittings for lightweight exhaust, process, rooftop equipment, equipment connection, or specialty fabricated duct systems. |
| Material grade | 5052 aluminum is typical for welded duct fabrication; 3003 aluminum is available when project specifications or forming requirements call for it. |
| Gauge range | Welded aluminum duct is supplied as quoted based on size, application, pressure, alloy, reinforcement, and project requirements. |
| Welding process | Aluminum duct is TIG welded unless another weld process, joint detail, or finish requirement is specifically quoted. |
| Straight sections | Produced in 5'-0" nominal lengths, less end flange allowance. Shorter sections and coordinated field-fit pieces can be fabricated when required. |
| End preparation | 1/2" flanges are standard. Angle rings, custom flange types, special bolt patterns, collars, and companion flange details can be fabricated as shown or quoted. |
| Finish handling | Mill finish aluminum is standard unless another finish or handling requirement is quoted. Confirm visible faces, protective film needs, and scratch-sensitive surfaces before release. |
| Quality check | Weld seams receive visual inspection before release. Leak testing, pressure testing, NDT, or certified inspection are by others unless quoted. |
Build Quality
Made to specBuilt to released alloy, gauge, finish, and connection details.
Built toughLightweight TIG welded aluminum with coordinated reinforcement.
Quality checkedWelds and fabricated openings receive visual inspection.
Weight consciousGood for equipment packages where reduced duct weight matters.
Fabrication Capabilities
| Duct sections | Rectangular and round aluminum straight duct, field-fit pieces, risers, drops, and custom lengths. |
| Fittings | Aluminum elbows, radius bends, offsets, tapers, reducers, transitions, branches, and tees. |
| Connections | 1/2" flanged duct systems are typical for fully welded connections. Equipment transitions, collars, curb adapters, wall/shaft connections, and roof penetration fittings are available. |
| Field-fit work | Short sections, piece-marked runs, and coordinated connection faces. |
| Shop details | Tabs, brackets, companion flanges, reinforcement, and special flange details when requested. |
| Release support | Built from released dimensions with alloy, gauge, finish handling, piece marks, and connection faces confirmed before fabrication. |
Material Notes
5052 or 30035052 is commonly used for welded aluminum duct; 3003 is available for formed components or project-specific requirements.
Lightweight ductAluminum reduces duct weight compared with steel, making it a good fit for custom equipment connections, rooftop packages, and specialty exhaust systems.
TIG welded seamsAluminum duct is TIG welded for clean, controlled welds at seams, transitions, and connection details.
Material fitConfirm aluminum is acceptable for the service environment; use stainless when corrosion exposure or cleaning requirements call for stainless material.
Connection Options
Couplings
Raw endsRaw ends with couplers for screw assembly.
1/2" flange
Field welded1/2" flanges for field welded assembly.
TDC / Ductmate
Bolted sealBolted connections with butyl sealant.
Rings / flanges
Custom patternVanstoned or welded angle rings, frames, and bolt flanges.
Optional Accessories
AccessAluminum doors, cleanout openings, inspection panels, and drain fittings.
FinishMill finish handling, visible faces, protective film, and scratch-sensitive surface requirements.
ConnectionsFlexible connectors, companion flanges, tabs, brackets, angle rings, and piece marks.
Custom detailsCustom bolt patterns, aluminum reinforcement, special hardware, liner/insulation, or finish requirements.
Required for Quote / Release
- 5052 or 3003 alloy, gauge, duct size, quantity, and required nominal or field-fit lengths.
- Approved drawing, sketch, or verified field dimensions with airflow/orientation noted.
- Flange type, bolt pattern, companion flange needs, and connection face details.
- Mill finish, visible faces, protective film needs, scratch-sensitive areas, and handling requirements.
- Piece marks, access openings, reinforcement, pressure class, liner/insulation needs, and any testing requirements.
Not Included Unless Quoted
- Installation, field welding, hoisting, rigging, roofing, or roof penetration work.
- Engineering, permits, inspections, balancing, cleaning, anodizing, painting, fire wrap, fire-rated enclosure, or listed-system certification.
- Leak testing, pressure testing, gaskets, sealant, special hardware, companion flanges, or rework from changed release dimensions unless quoted.
Scope & Responsibility
Code note: Aluminum duct systems may be governed by mechanical code, local code, project specifications, material compatibility requirements, and AHJ requirements. Empire fabricates duct and fittings to released dimensions and quoted scope; final system design, material selection, installation method, field welding, sealant/gasket requirements, clearances, and acceptance remain the responsibility of others unless expressly included.
Ready to Quote?
Let's get your duct package moving.
Send drawings, sketches, photos, or field measurements. Empire is ready to go to work for you.
quotes@empiremetalproducts.com
602-424-9980