An HVAC system is a complex assembly with many parts working together flawlessly. An HVAC system that is designed to your requirements, can help keep energy costs in check. Use of sheet metal fabrication and components can also make new construction projects easier.

When installing a custom system, you can’t always get parts off the shelf. The solution is to use sheet metal fabrication to create the perfect parts needed to do the job. Fabrication is especially useful in designing custom plenums and ductwork. The typical system can lose up to 30 per cent of its conditioned air through poorly designed or leaking ducts. Ducts that are custom-fabricated, however, can deliver excellent performance and efficiency. So, how does the sheet metal fabrication process work?


Sheet metal fabricating usually begins with a large sheet of galvanized metal. This sheet is measured and marked according to the purpose it will serve. Fabricators then cut the metal to the desired size using a variety of tools. This process is also known as shearing as it involves applying force to cause the metal to shear. Sheet metal cutters and shears are also used at this stage. Other tools include powered and non-powered saws, chisels and torches. CNC plasma cutters are also commonly used to produce quick and precise cuts.


Once the sheet metal pieces are cut to the right size, the next step is forming them to the desired shape. Each piece must have a specific shape depending on its function and location within the larger system. Some shaping can be done by using hand tools, but mechanical equipment is often required. A fabricator has many tools at their disposal to help them achieve exactly the shape they need. Here are just a few of the tools that may be used during fabrication.

Folding machines are used to fold sheet metal at sharp and precise angles. Flange forming machines press flanges into sheet metal to make joining easier. Notching machines can shear sheet metal at precise angles to create corners. Pneumatic corner mounting machines are used to form corners from rectangular ducts. Shrimp bending machines bend pipes and ducts to create elbow-shaped “shrimp” bends.

The goal of forming is to apply pressure to deform the metal without shearing. The forming process is where flat, cut sheets of metal are transformed into the parts needed for the job. Fittings and other necessary pieces are also formed at this stage.


Once all the necessary pieces have been formed, the final task is to put them all together. This stage is particularly important to ensure that every piece works as intended. A single misaligned duct section or poorly installed plenum can hamper an entire HVAC system. The assembly stage is also the time for any final adjustments to maximize fit and efficiency.

The actual process of assembling varies depending on the application. Often, the pieces are joined together by welding. Other applications may use threaded fasteners, rivets, powerful adhesives or some combination of the above. Sometimes, pieces are joined together by crimping specially made seams. Some assemblies may also require a final step called finishing. This involves applying a durable powder coat treatment.

A well-designed HVAC system is an important component of any business. A system that’s tailored to meet your specific needs can lower utility costs and save a lot of headaches long-term. Sheet metal fabrication is an essential part of ensuring the perfect fit and function.

To learn more about how you can benefit from HVAC fabrication and design, get in touch with our team at Jarrow’s office.



AAP Metal fabrication services Ltd has built up a long-standing reputation for first-class quality products and services based on experience gained since the company was established.


Primarily, AAP Metal fabrication services Ltd main role is to find a solution to our clients’ problems. We believe in working closely with our clients from the initial site evaluation to discuss the requirements. We believe this is why we have such a loyal customer-base.


AAP Metal fabrication services Ltd has built up an excellent reputation within the industry, for supplying products of only the very best quality. Our years of experience have taught us the importance of ensuring that our customer receives the highest standards of performance and quality


Our Pro-active approach combined with attention to details benefits our customers but also our staff members’ health and safety.


AAP Metal fabrication services Ltd is a process-driven company that places quality above everything else and has achieved several accreditations and certifications over the years. These include ISO 9001:2015, Iso3834-2, BS EN 1090, BS EN IS0 96061, IS0 15614-1, CHAS.


It is no wonder that our passion for quality and customer satisfaction has allowed us to lead the industry and work with several well-known brands.

These include Aesica Pharmaceuticals (now Recipharm),3M UK Plc, Nissan, Baker Hughes / PII Ltd, Royal IHC Ltd, UK Docks Marine Services, Sterling Pharma Solutions Ltd and Multi Packaging Solutions

“We have always received excellent support in the supply of bespoke fabricated items. The items supplied have been manufactured in accordance to our drawings & specifications in a variety of materials (Carbon Steel & Stainless Steel) & finishes (Galvanised, Painted & Natural)”