Round ducts offer several benefits that make them a preferred choice for many HVAC applications, especially in commercial and industrial settings where efficiency, reliability, and space utilization are crucial.

Here are some examples of the advantages that round ducts offer in HVAC systems:

Efficient airflow

Round ducts provide smoother airflow compared to rectangular ducts. The absence of sharp corners and edges reduces air resistance, minimizing pressure drop and improving energy efficiency, which allows HVAC systems to operate more efficiently. This improved efficiency can potentially reduce energy consumption and operating costs.

Reduced leakage

Round ducts have fewer seams and joints, compared to rectangular ducts, which reduces the potential for air leakage. Properly sealed round ducts can help maintain the integrity of the HVAC system and prevent air loss, ensuring that conditioned air reaches its intended destination without leakage.

Space saving

Round ducts require less space than rectangular ducts with similar airflow capacity. Their cylindrical shape allows for more efficient use of space, making them ideal for installations where space is limited or where ducts need to be routed around obstacles.

Quieter operation

The smooth airflow characteristics of round ducts help reduce turbulence and noise generated by the HVAC system. This results in quieter operation, which can contribute to a more comfortable indoor environment, especially in residential and commercial settings.

Less Dust Accumulation

Round ducts are less prone to dust accumulation compared to rectangular ducts with flat surfaces and sharp corners. The smooth interior surfaces of round ducts minimize the buildup of dust and debris, helping to maintain better indoor air quality and reducing the frequency – and additional costs – of duct cleaning and maintenance.

Structural integrity

The circular shape of round ducts provides structural strength, allowing the ductwork to withstand higher pressures and resist deformation better than rectangular ducts.

How Do You Make Round Ducts?

The fabrication process for round ducts is somewhat similar to rectangular fabrication, but with a few key distinctions. 

After the engineers or designers use CAD software to create the specific plan and individual HVAC components, flat sheets of metal are cut into the required dimensions using shears, laser cutting, or other cutting methods. Next, the cut metal is shaped into cylindrical ducts using techniques such as bending, rolling, or spiral winding until the metal reaches desired diameter and shape.

Once the ductwork is cut and shaped, the sections of the ductwork are joined together using methods such as welding, riveting, or sealing with special adhesives. The final steps – depending on the project type – can include reinforcement for structural integrity, insulation to reduce temperature loss or gain, or even coatings or external treatments to enhance durability, visual appeal, or corrosion resistance.

What Are Round Ducts Used For?

Round ducts can be used in a variety of HVAC systems, providing air distribution, return air collection, exhaust ventilation, fresh air intake, or a variety of specialized projects such as transporting gas or particulate matter. 

What Is The Difference Between Round and Flat Ductwork?

The choice between round and flat ductwork usually depends on factors such as space constraints, system requirements, installation considerations, and budget constraints. However, there are significant differences between round and flat ductwork:

Shape:

• Round Ductwork: Round ductwork has a cylindrical shape, offering smooth airflow with minimal resistance. The absence of sharp corners reduces air turbulence and pressure drop, improving energy efficiency.
• Flat Ductwork: Flat ductwork, typically rectangular or square in shape, has straight edges and corners. Airflow in flat ducts can encounter more resistance due to changes in direction, leading to higher pressure drop.

Airflow characteristics:

• Round Ductwork: Since round ducts provide efficient and uniform airflow distribution with minimal turbulence, this results in quieter operation and better energy efficiency.
• Flat Ductwork: Flat ducts may experience more turbulence and uneven airflow distribution, particularly around corners and bends, leading to higher energy consumption and noise levels.

Installation:

• Round Ductwork: Round ducts are easier to install in tight spaces and around obstacles due to their flexible and compact shape. They require fewer fittings and supports, simplifying installation and reducing labor costs.
• Flat Ductwork: Flat ducts may require more space for installation due to their rectangular or square shape. They may also require more fittings and supports to navigate corners and changes in direction, increasing installation complexity and cost.

Performance:

• Round Ductwork: Round ducts offer better airflow efficiency, lower pressure drop, and reduced air leakage compared to flat ductwork. These characteristics contribute to improved HVAC system performance, energy savings, and indoor comfort.
• Flat Ductwork: Flat ducts may be less efficient in terms of airflow, leading to higher pressure drop, increased energy consumption, and potentially uneven heating or cooling within a building.

Want to learn more about duct fabrication and how you can seamlessly combine design, fabrication, shipping, and integration? BuildCentrix can help answer your questions and find a solution that’s best for your company.

Visit BuildCentrix.com to learn more or to schedule a demo.