Rectangular Sheet Metal Duct

Custom-fabricated rectangular ductwork for residential, commercial, and industrial HVAC systems. Built to your exact dimensions in galvanized steel, aluminum, or stainless steel — configure standard sizes in our 3D tool or request a custom quote.

7 products

Rectangular Sheet Metal Duct — Trunk Lines, Plenums & Transitions

Custom-fabricated rectangular ductwork for residential, commercial, and industrial HVAC systems. Built to your exact dimensions in galvanized steel, aluminum, or stainless steel — configure standard sizes in our 3D tool or request a custom quote.

Rectangular Duct for Every Stage of Your HVAC System

Rectangular ductwork forms the backbone of most forced-air HVAC systems in residential and commercial buildings. Unlike round duct, rectangular duct fits into tight ceiling cavities, between floor joists, and along wall chases — making it the standard choice wherever headroom or structural constraints limit the use of circular sections. Duct2Go fabricates rectangular duct in single-piece and multi-piece configurations including straight trunk sections, plenum boxes, offset transitions, takeoffs, and end caps.

Every piece is built from 26-gauge to 20-gauge galvanized steel as standard. Aluminum and stainless steel are available for specialty applications including healthcare facilities, industrial environments, and data center cooling infrastructure. All rectangular ductwork is dimensioned and constructed to SMACNA standards ensuring code compliance and compatibility with standard fittings from any manufacturer.

Why Choose Rectangular Metal Ductwork for Commercial & Residential HVAC Systems

Rectangular metal ductwork is the preferred solution for HVAC installations where space efficiency, airflow control, and system flexibility are critical. Its low-profile design allows contractors to route duct runs through ceilings, mechanical rooms, wall cavities, and other confined spaces where round duct may not fit. Rectangular duct systems are commonly used in homes, office buildings, warehouses, schools, healthcare facilities, and industrial applications due to their ability to handle high airflow volumes while maximizing available space.

Duct2Go manufactures custom rectangular sheet metal ductwork to meet the requirements of new construction, retrofit projects, and replacement installations. Our product range includes straight duct sections, HVAC plenum boxes, square-to-round transitions, takeoffs, elbows, and end caps, all fabricated to precise dimensions for seamless integration into your HVAC system. With galvanized steel, aluminum, and stainless steel options available, you can select the material best suited to your environment, airflow requirements, and project specifications.

Frequently Asked Questions

What's the difference between a rectangular duct trunk line and a plenum?

A trunk line is the main horizontal duct that carries conditioned air from the air handler to branch takeoffs throughout the building. A plenum is the transition box that connects the air handler's outlet collar directly to the trunk line — it's typically taller and wider to match the unit's outlet, then transitions down to the trunk dimension. Both are fabricated to order at Duct2Go in standard and custom sizes.

Can I get rectangular duct in non-standard sizes?

Yes — custom sizes are our core capability. If you need a specific width, height, or length not in our standard catalog, submit your dimensions through the custom quote form. We fabricate virtually any rectangular duct configuration from measurements, field sketches, or formal shop drawings.

What gauge is your standard rectangular duct?

Standard rectangular duct is fabricated in 26-gauge galvanized steel for most residential and light commercial sizes. Larger commercial trunk lines and industrial applications are built to heavier gauges (24 or 22 gauge) per SMACNA requirements. Specify your gauge requirement in your order or custom quote if your project specs call for something specific.

Do you carry HVAC plenum boxes?

Yes. We fabricate supply and return plenum boxes to your air handler's outlet dimensions. Plenums are available in galvanized steel, aluminum, and stainless steel. Standard configurations ship in 5 business days; custom-sized plenums are typically completed in 1–2 weeks. Upload your AHU specs or a dimensional sketch through the custom quote form.

How does rectangular duct ship?

Rectangular duct ships flat-packed or nested to minimize freight volume and damage risk. Larger orders are palletized and shipped via LTL freight carrier from our Chandler, AZ facility. Tracking is provided from our shop to your delivery address. Both residential delivery and commercial jobsite drop-off are available