Custom Industrial Ductwork: Built for Harsh Environments and Tight Spaces

Standard duct systems often fail in real-world industrial conditions. If you’re dealing with intense heat, abrasive dust, corrosive chemicals, or tight quarters, off-the-shelf ducting will fail quickly. Gaps, weak joints, and material breakdowns lead to lost productivity, safety risks, and mounting maintenance costs.

You need a solution that’s designed to withstand abuse and keep your operations running smoothly. That’s where custom-fabricated ductwork from Swanton Welding makes a difference.

Why Standard Ducting Fails in Harsh Conditions

Mass-produced ductwork is often designed for ideal conditions, rather than the realities of manufacturing, mining, or waste processing. Thin materials, limited sizing options, and generic layouts pose significant challenges in environments that require strength, fit, and durability.

Here are the most common failure points:

• Material corrosion from chemicals or moisture
  Standard ductwork often breaks down quickly when exposed to corrosive fumes, liquids, or high-humidity environments over time.
• Cracks and leaks due to high pressure or temperature changes
  Thin-walled ducts can crack or deform under intense pressure or heat, leading to air leaks and system inefficiencies.
• Awkward angles that don’t match your layout
  Prebuilt duct sections rarely align with your facility’s exact layout, forcing awkward turns that disrupt airflow and reduce efficiency.
• Frequent maintenance due to joint separation or metal fatigue
  Constant vibration and stress on poor welds or flimsy joints lead to repeated repairs, downtime, and increased labor costs.

You can’t afford that kind of downtime. A single failure in your duct system can result in hours of lost productivity and thousands of dollars in repair costs. In plants where airflow is tied to ventilation, drying, or fume extraction, failure is more than inconvenient—it’s a safety issue.

Built to Fit Your Plant

No two facilities are the same. Ceiling height, equipment layout, access points, and environmental conditions all impact how air needs to move through your space. Off-the-shelf options force you to work around the ducting. With Swanton Welding, you get ducting that works around you.

Our team designs and fabricates custom ductwork based on your floor plan, system pressures, temperature ranges, and access requirements. Every elbow, flange, and hanger is carefully measured to ensure a precise fit for your layout and operate at full capacity without leaking, rattling, or warping.

Performance Under Pressure

Many industrial systems require handling airflow at significantly higher static pressures than standard HVAC ducting—high-volume exhaust, dust collection, combustion air, and pneumatic conveying all push ductwork to the limit.

Swanton Welding utilizes thick-gauge steel, tight-weld seams, and flanged connections to construct ductwork that withstands these conditions. Our fabrication processes minimize vibration and maintain structural integrity even during long operation cycles.

According to industry data, custom-fabricated ducts can increase operational lifespan by up to 40% compared to modular options. Less downtime means higher output and lower total cost over time.

Protection from Corrosion and Heat

Corrosive dust and high temperatures can chew through sheet metal in months if it’s not properly protected. Swanton Welding offers several material options based on your needs:

• Galvanized steel for basic corrosion resistance
  Galvanized steel features a protective zinc coating that resists rust, making it a reliable choice for mild to moderate moisture exposure.
• Stainless steel for chemical-heavy environments
  Stainless steel withstands harsh chemicals and acidic conditions, preventing corrosion and maintaining duct integrity in demanding environments.
• Abrasion-resistant steel for dust or particle flow
  This steel type withstands constant wear from high-speed dust or solids, reducing thinning, leaks, and the need for frequent duct replacement.
• High-temp coatings and liners for heat-intensive zones
  Special coatings and liners shield the duct interior from extreme heat, preventing warping, cracking, or premature material breakdown.

These materials are selected to match your environment and then fabricated in-house to strict tolerances. Your ducts won’t fail early due to thin walls or mismatched materials.

Navigating Tight Quarters

Many industrial spaces weren’t designed with ducting in mind. You might need to run pipes behind machines, around overhead cranes, or along narrow catwalks. With prebuilt sections, you’ll either sacrifice space or airflow. But with custom fabrication, you can have both.

Swanton Welding fabricates elbows, transitions, reducers, and special fittings to navigate obstacles without affecting performance. Our layout team works with your plant drawings or conducts on-site measurements to create ductwork that fits tightly and runs clean.

How Custom Fabrication Saves You Money

The upfront cost of custom ductwork is often higher than ordering mass-produced sections. But the long-term value speaks for itself. Here’s how you benefit:

• Fewer breakdowns and replacements
• Lower installation labor due to a perfect fit
• Better energy efficiency from airtight connections
• Faster maintenance with removable access panels
• Safer operation from consistent airflow and reduced leakage

According to recent industry benchmarks, facilities with custom duct systems see up to 25% lower energy losses due to improved airflow design and sealing.

Why Choose Swanton Welding

At Swanton Welding, we combine heavy-duty materials, precision welding, and real-world experience to deliver duct systems that last.

• Full-service metal fabrication including cutting, forming, and welding
• Experience with food-grade, chemical, and manufacturing industries
• In-house engineering and 3D CAD modeling
• On-time delivery and installation support

We’ve been fabricating industrial ductwork for decades and know how to meet strict specs on tight timelines.

What to Expect From Our Custom Ductwork

When you work with Swanton Welding, you’ll get:

• A full review of your facility layout and system requirements
• Help selecting materials based on heat, dust, or chemical exposure
• 3D CAD drawings of your entire system for approval
• Fabrication using advanced press brakes, plasma cutters, and welders
• On-site delivery and installation-ready duct sections

Every project is unique, but each receives the same meticulous attention to detail and unwavering commitment to performance.

Engineered for Your Toughest Challenges

Your ducting needs to survive daily abuse, tight quarters, and heavy demand without constant attention. Swanton Welding builds ductwork that works as hard as you do. 

Get the job done right with ductwork designed to last. Contact us today for a free quote.