Ductwork Installation & Fabrication in Louisville, KY
Hadley Energy Solutions designs, fabricates, and installs custom ductwork for commercial and industrial HVAC systems throughout Louisville, KY. Your ductwork is the delivery system for conditioned air — poorly designed or leaky ductwork can waste 20-30% of your HVAC energy. We fabricate sheet metal ductwork in-house and install it to SMACNA standards, ensuring your HVAC system delivers the right amount of air to every space.
Custom Ductwork
Fabricated and installed to your specifications.
Engineered Design
Proper sizing for balanced airflow.
Sealed & Tested
Leak-tested for maximum efficiency.
Who Needs Ductwork Services?
New construction projects needing complete duct systems, buildings with aging or deteriorating ductwork, facilities adding HVAC to previously unconditioned spaces, renovations that change room layouts and airflow requirements, buildings with comfort complaints (hot/cold spots), and facilities with excessive energy bills due to duct leakage.
Ductwork Services
- Custom sheet metal duct fabrication
- Supply and return duct installation
- Duct system design and engineering
- Flex duct installation (where appropriate)
- Duct sealing and insulation
- Air balancing and testing
- Duct modifications for renovations
- Kitchen exhaust duct (grease duct) installation
- Industrial exhaust and ventilation ductwork
- Duct cleaning coordination
Our Ductwork Process
Design & Engineering
We calculate required airflows for each space (CFM), size ducts accordingly, and plan routing for efficient air delivery with minimal pressure loss.
Fabrication
Our sheet metal team fabricates custom ductwork to SMACNA standards. Every fitting, transition, and branch is built to spec for your specific installation.
Installation
We install ductwork with proper hangers, sealing, and insulation. Connections are secured with mechanical fasteners and sealed with mastic — not just taped.
Testing & Balancing
We test airflow at every register, balance the system to eliminate hot and cold spots, and verify static pressure is within manufacturer specifications.
Ductwork Cost Factors
Ductwork costs depend on system size and material:
- Linear feet of ductwork required
- Duct material: galvanized sheet metal, spiral, or flex
- Insulation requirements (R-value)
- Number of fittings, transitions, and branches
- Accessibility of installation area
- Residential ductwork: $2,000-$8,000; commercial: $5,000-$50,000+
Ductwork Installation & Fabrication FAQs
How do I know if my ductwork is leaking?
Signs include: rooms that are always too hot or too cold, excessive dust in your building, high energy bills, visible gaps or disconnections in exposed ductwork, and whistling or rattling noises from the duct system. We can perform a duct leakage test to quantify the problem.
Sheet metal vs. flex duct — which is better?
Sheet metal ductwork is more durable, has lower airflow resistance, and lasts longer. Flex duct is acceptable for short runs (under 10 feet) in residential applications. For commercial and industrial, we almost always use sheet metal for performance and longevity.
Do you fabricate ductwork in-house?
Yes. We have sheet metal fabrication capabilities and build custom ductwork to your project's specific requirements. In-house fabrication gives us control over quality and turnaround time.
Can you add ductwork to a building without existing ducts?
Yes. We regularly add duct systems to older buildings, warehouses, and spaces that were previously unconditioned. We find the most efficient routes and minimize the visual impact of exposed ductwork.
Why Choose Hadley Energy Solutions?
Ductwork is where HVAC performance is won or lost. A perfectly sized AC or furnace will underperform if the ductwork is leaky, undersized, or poorly routed. We design, fabricate, and install duct systems that deliver the right airflow to every space — not just the ones closest to the equipment.
Service Areas
We provide ductwork installation & fabrication throughout Kentucky, Southern Indiana, and Southern Ohio.
What Our Customers Say
"Service was top notch. One of the best company's I have had the pleasure of doing business with. The work crew is full of energetic knowledgeable employees. I would recommend them to anyone."
— John R.
Google Review
Ready to Get Started?
Our licensed electricians and energy specialists are ready to help. 1-year warranty on all work plus manufacturer's warranties available.