Custom HVAC Ductwork San Antonio, TX

Professional Custom HVAC Ductwork Services in San Antonio, TX

Poorly matched duct sizes can make a system work harder than it should in homes and businesses alike. Our team takes care of the problem with a custom duct design. The work begins with a site visit to map ceiling heights, framing, and available space. Next, every trunk line and branch run is made to the sizes the airflow plan calls for. We then set the ductwork in place, add insulation where needed, and seal every connection. A final inspection confirms each duct run is secure, sealed, and delivering air as planned. See the specific custom ductwork services we handle below.

Custom Duct Design in San Antonio

Every room has its own cooling load based on window size, sun exposure, and square footage, and ductwork sized by guesswork leaves some rooms warm. Our team measures each room and runs an ACCA Manual J load calculation to find the airflow it needs. We use Manual D to size each trunk and branch, choose register locations, and plan routes that avoid sharp turns and long runs. The design accounts for attic framing, soffits, and ceiling heights so every piece fits the space. You review a drawn layout with duct sizes and register locations before any metal gets cut. The finished design delivers balanced airflow, with each room reaching the same temperature.

Custom Ductwork Fabrication in San Antonio

Standard fittings come in fixed sizes and angles, and they rarely match the offsets and tight clearances found in real homes. Our fabricators take the field measurements and lay out each piece on the company table. We cut galvanized steel with a plasma table and shears, form seams on a Pittsburgh lock machine, and bend sections on a brake. Each piece gets labeled with its location so installers can assemble the system in order. Joints get designed with slip and drive connections that seal tightly once installed. When the layout calls for a shorter trunk with fewer seams than standard duct allows, we also complete HVAC ductwork installation as part of the same project. The fabricated parts fit the space on the first try and keep airflow smooth through every transition.

Custom Sheet Metal Ductwork in San Antonio

Flexible duct sags and loses airflow over long runs, and many homes need rigid metal trunks to carry air across the attic. Our crew installs rigid galvanized trunks, risers, and long branch runs built to the dimensions of your attic or soffit. Each section gets hung on straps or trapeze hangers at the spacing SMACNA standards call for. We seal every seam with mastic and wrap attic runs in R-8 foil-faced insulation. Takeoffs get cut into the trunk at planned locations and fitted with dampers for balancing. Metal duct also resists pests and crushing in busy attics. Rigid trunks hold their shape for decades and deliver steady airflow to every branch.

Custom Residential Ductwork in San Antonio

Remodels, additions, and converted garages change how air needs to move through a house, and the original ductwork rarely fits the new layout. Our team reviews the floor plan changes and calculates the airflow each new or changed room needs. We extend or rebuild trunk lines, add branches to new rooms, and fabricate fittings that fit around new framing and soffits. When the existing duct system has crushed or disconnected runs, we also complete air duct repair before extending the new lines. The crew coordinates with your contractor so the rough-in happens before drywall and is ready for the mechanical inspection. We pull the mechanical permit and schedule the inspection for you. Existing equipment gets checked to confirm it can serve the added space. New rooms cool at the same rate as the rest of the house.

Custom Plenum Fabrication in San Antonio

The plenum connects the air handler to the duct system, and a poorly sized or crumbling plenum restricts airflow and leaks air at the cabinet. Our technician measures the air handler opening, the available space, and the trunk connections before designing the new plenum. We fabricate supply and return plenums from galvanized steel with internal insulation and turning vanes where the airflow changes direction. The new plenum gets fastened to the air handler flange and sealed with mastic. Access panels get built in where coils or filters need service. Old duct board plenums get removed and disposed of during the same visit. If the air handler cabinet also shows heavy dust on the blower and coil, we can perform HVAC duct cleaning once the new plenum is in place. Static pressure drops, and air leaves the unit evenly into every trunk.

Custom Transitions and Fittings in San Antonio

Changes in duct size or direction cause turbulence and pressure loss when a fitting has abrupt edges or the wrong angle. Our fabricators build reducers, offsets, elbows, and square-to-round transitions to the exact dimensions each connection needs. We measure each connection on site, since a fitting that is off by half an inch can leave gaps or force the duct out of line. Radius elbows and gradual reducers keep air moving smoothly through turns and size changes. Turning vanes go into square elbows on larger trunks to guide the air around the corner. When a newly fabricated fitting replaces a damaged section, we also complete air duct replacement at that location so the connection holds tight.  Each fitting gets sealed at every seam before installation. Air flows through the system with less noise, and the blower works against lower pressure.

Exposed Spiral Ductwork in San Antonio

Modern homes with open ceilings, lofts, and industrial-style spaces often show the ductwork as part of the design. Our crew installs spiral round duct with matching fittings, hung on cable or rod hangers at even heights. Each joint gets sealed with internal gaskets or duct sealant so no residue shows on the outside. We plan routes that line up with beams and lighting and install round diffusers that match the duct finish. When the exposed system includes a bathroom or kitchen exhaust line nearby, we can also perform bathroom exhaust duct cleaning on that run so every visible duct stays clean. The duct can stay in its galvanized finish or get painted to match the ceiling. Ducts inside conditioned space lose almost no cooling to an attic. You get a clean, visible duct system that cools the space and fits the room's style.

Custom Commercial Ductwork in San Antonio

Offices, restaurant dining rooms, and retail buildouts need ductwork sized for occupancy loads and fitted around ceiling grids, lighting, and sprinkler lines. Our team works from the architectural plans and coordinates duct routes with the electrical and plumbing trades. We fabricate large rectangular trunks, spiral mains, and fittings in our company and deliver them labeled by zone. Crews install the system on the general contractor's schedule and seal each joint to the required SMACNA seal class. Balancing dampers go in at each branch so the system can be air-balanced after startup. When the project also needs the existing ductwork cleaned before the new system goes live, we perform commercial air duct cleaning during the same mobilization. The finished system meets the design airflow for each zone and is ready for the mechanical inspection.

Custom HVAC Ductwork Near Me in San Antonio, TX

Homeowners and builders looking for a local duct fabricator want a team that measures on site and builds every piece to fit. San Antonio Air Duct Pro serves San Antonio and nearby areas including Stone Oak, King William, and Southtown with custom duct design, fabrication, and installation. Call (210) 960-8514 to schedule a site measurement.