I.

INTRODUCTION
THE PURPOSE OF THIS STUDY IS TO FIND THE TOUGHEST AND MOST
RUST-RESISTANT AIR DUCT MATERIAL FOR AIR CONDITIONERS. THEY'LL
COMPARE DIFFERENT MATERIALS TO SEE WHICH LASTS THE LONGEST AND
COSTS THE LEAST. THIS WILL HELP TO PICK THE BEST MATERIAL FOR AIR
DUCTS.

II. ENGINEERING PRODUCT

A. DESIGN PARAMETERS
DESIGNING AN EFFICIENT AND FUNCTIONAL DUCT SYSTEM HAD A
SEVERAL IMPORTANT REQUIREMENTS, LIKE, THE DUCT SIZING, DUCT
MATERIAL, THE LAYOUT, INSULATION, AND THE AIR QUALITY
CONSIDERATIONS THESE PARAMETERS WILL HELP TO MAKE AN
EFFICIENT DUCT FOR AIR-CONDITIONING SYSTEM.

B. REQUIRED PROPERTIES
• SMOOTHNESS: HIGH SMOOTHNESS FOR MINIMAL FRICTION
• CORROSION RESISTANCE: HIGH FOR LONG LIFE AND TO PREVENT LEAKS
• FLAME RETARDANCY: HIGH AS PER BUILDING CODES
• STRENGTH: HIGH TO SUPPORT WEIGHT AND EXTERNAL PRESSURE
• RIGIDITY: HIGH TO MAINTAIN SHAPE AND PREVENT COLLAPSING
• LEAKAGE RESISTANCE: HIGH FOR EFFICIENT OPERATION
• THERMAL CONDUCTIVITY: LOW TO MINIMIZE HEAT TRANSFER
• INSULATION COMPATIBILITY: HIGH FOR PROPER INSULATION PERFORMANCE
(IF USED)

C. ECONOMIC ASPECT:

COST: THE MATERIAL SHOULD BE COST-EFFECTIVE CONSIDERING ITS

AVAILABILITY, FABRICATION, AND MAINTENANCE COSTS.

MANUFACTURABILITY: THE MATERIAL SHOULD BE EASY TO FABRICATE INTO

THE DESIRED SHAPE AND SIZE.

DESCRIPTION MATERIAL PHP/ METER

RECTANGULAR W=150MM, GALVANIZED IRON 615.98 - 1,353.11
DUCT H=100MM TO (GI)
W=450MM,H=400MM
SPIRAL DUCT 100 MM DIAMETER GALVANIZED IRON 302.09 - 1,183.73
TO (GI)
400 MM DIAMETER
 D. IN-SERVICE CONDITION
THE DUCT SHOULD BE FREE OF LEAKS AND PROPERLY SEALED, ENSURING
EFFICIENT AIRFLOW THROUGHOUT THE ENTIRE SYSTEM. THEY ARE ALSO WELL-
MAINTAINED, WITH NO SIGNS OF EXCESSIVE DUST BUILDUP OR DAMAGE THAT COULD
IMPEDE AIRFLOW OR INTRODUCE CONTAMINANTS. THIS TRANSLATES TO OPTIMAL
PERFORMANCE FROM YOUR AIR CONDITIONING SYSTEM, DELIVERING COOL AIR
EFFICIENTLY AND KEEPING YOUR ENERGY COSTS UNDER CONTROL.

COMPARING MILD STEEL CARBON (METAL), PVC (POLYMER), AND FIBERGLASS

REINFORCED PLASTIC (FRP) (COMPOSITE) FOR AIR-CONDITIONING DUCTING,
REQUIRES ASSESSING THEIR INDIVIDUAL PROPERTIES AND SUITABILITY. EACH
MATERIAL PRESENTS DISTINCT CHARACTERISTICS AFFECTING DUCT PERFORMANCE,
DURABILITY, AND COST-EFFECTIVENESS IN AIR-CONDITIONING SYSTEMS. KNOWING
THESE TRAITS IS VITAL FOR CHOOSING THE MOST FITTING MATERIAL TO MEET THE
PRECISE NEEDS FOR THE AIR-CONDITIONING SYSTEM.

III. ENGINEERING PRODUCTS: METALS, POLYMER AND COMPOSITE DUCT

1. METAL DUCTS: MILD STEEL CARBON

A. DESIGN PARAMETERS

MILD STEEL DUCTS FOR AIR CONDITIONING NEED CAREFUL DESIGN. THICKNESS
(BASED ON SIZE AND PRESSURE) ENSURES STRENGTH. ROUND OR RECTANGULAR
SHAPES OPTIMIZE AIRFLOW FOR SPACE CONSTRAINTS. LEAK-PROOF SEAMS ARE
ESSENTIAL. SMOOTH BENDS MINIMIZE AIRFLOW DISRUPTION. ACCESS PANELS ALLOW
FUTURE MAINTENANCE. PRIMER COATINGS FIGHT RUST. FIRE SAFETY RULES MIGHT
REQUIRE SPECIAL MATERIALS. INSULATION IN UNCONDITIONED SPACES MINIMIZES
HEAT TRANSFER. A STRONG SUPPORT SYSTEM PREVENTS SAGGING AND ENSURES
GOOD AIRFLOW FOR A LONG DUCT LIFESPAN.
 B. PROPERTIES OF MILD STEEL DUCTS FOR AIR CONDITIONING SYSTEMS

PROPERTIES DATA NOTES

SMOOTHNESS HIGH GALVANIZED STEEL COATING PROVIDES
A SMOOTH SURFACE FOR MINIMAL
AIRFLOW FRICTION.
CORROSION MODERATE GALVANIZING OFFERS SOME
RESISTANCE PROTECTION, BUT LONG-TERM
EXPOSURE TO MOISTURE OR HARSH
CHEMICALS CAN LEAD TO RUST.
FLAME HIGH NOT INHERENTLY FLAME RETARDANT
RETARDANCY ACHIEVABLE BUT CAN ACHIEVE HIGH FLAME SPREAD
AND SMOKE DEVELOPMENT RATINGS
WITH PROPER FIREPROOFING (E.G.,
INTUMESCENT COATINGS).
STRENGTH HIGH MILD STEEL IS STRONG AND CAN
SUPPORT SIGNIFICANT WEIGHT AND
EXTERNAL PRESSURE.
RIGIDITY HIGH RIGID MATERIAL THAT MAINTAINS ITS
SHAPE WELL AND RESISTS COLLAPSING
UNDER NEGATIVE PRESSURE.
LEAKAGE HIGH LEAKAGE CAN BE MINIMIZED WITH
RESISTANCE ACHIEVABLE PROPER FABRICATION TECHNIQUES
(E.G., WELDING, FLANGING) AND
SEALING.
THERMAL HIGH (0.43 - LOSES HEAT OR GAINS HEAT READILY
CONDUCTIVITY 0.5 W/MK) THROUGH THE DUCT WALLS.
INSULATION HIGH GALVANIZED STEEL IS COMPATIBLE
COMPATIBILITY WITH VARIOUS INSULATION TYPES (E.G.,
FIBERGLASS, ROCKWOOL).

C. ECONOMIC ASPECT

MATERIALS PRICE IN THE MARKET

MILD STEEL CARBON PHP 300+ (DEPENDING ON THICKNESS)
PER METER

D. IN-SERVICE CONDITION

WHILE MILD STEEL IS A POPULAR CHOICE FOR AIR CONDITIONING DUCTS DUE TO
ITS AFFORDABILITY AND EASE OF INSTALLATION, ITS IN-SERVICE CONDITION
REQUIRES ATTENTION. THE MAIN CONCERN IS RUST. MILD STEEL IS PRONE TO RUST,
ESPECIALLY IN HUMID ENVIRONMENTS, AND RUST FLAKES CAN CONTAMINATE YOUR
INDOOR AIR. REGULAR MAINTENANCE AND INSPECTIONS ARE ESSENTIAL TO CATCH
AND ADDRESS RUST EARLY ON. ADDITIONALLY, CONDENSATION CAN FORM ON
UNINSULATED MILD STEEL DUCTS, POTENTIALLY LEADING TO MOLD GROWTH WITHIN
THE DUCTWORK AND FURTHER IMPACTING AIR QUALITY. PROPER INSULATION HELPS
PREVENT CONDENSATION. FINALLY, LEAKS CAN DEVELOP AT CONNECTION POINTS
OVER TIME, REDUCING AIRFLOW AND FORCING YOUR SYSTEM TO WORK HARDER,
RAISING ENERGY BILLS. REGULAR INSPECTIONS AND PROPER SEALING TECHNIQUES
CAN MINIMIZE LEAKS. IN CONCLUSION, MILD STEEL DUCTS CAN BE COST-EFFECTIVE
BUT REQUIRE CONSISTENT MAINTENANCE TO ENSURE OPTIMAL PERFORMANCE AND
HEALTHY AIR QUALITY IN YOUR AIR CONDITIONING SYSTEM

2. POLYMER DUCTS: POLYVINYL CHLORIDE (PVC)

A. DESIGN PARAMETERS

DESIGN REQUIRES CAREFUL CONSIDERATION FOR OPTIMAL PERFORMANCE.

SINCE PVC IS NOT AS STRONG AS METAL, CHOOSING THE RIGHT THICKNESS IS
CRUCIAL TO ENSURE THE DUCTS CAN WITHSTAND INTERNAL AIR PRESSURE AND
MAINTAIN THEIR SHAPE. ROUND SHAPES ARE GENERALLY PREFERRED FOR LOWER
AIR RESISTANCE, BUT RECTANGULAR DUCTS CAN BE MORE SPACE-EFFICIENT
DEPENDING ON THE APPLICATION. LEAK-PROOF SEAMS ARE ESSENTIAL TO PREVENT
CONDITIONED AIR LOSS AND MAINTAIN SYSTEM EFFICIENCY. UNLIKE METAL, PVC IS
NATURALLY RESISTANT TO RUST, BUT IT'S IMPORTANT TO CONSIDER THE
TEMPERATURE RANGE WITHIN YOUR BUILDING, AS EXTREME COLD OR HEAT CAN
MAKE PVC BRITTLE OR DEFORM.

B. PROPERTIES OF PVC DUCTS FOR AIR CONDITIONING SYSTEMS

PROPERTIES DATA NOTES
SMOOTHNESS HIGH SMOOTH INTERIOR SURFACE MINIMIZES
FRICTION AND PRESSURE DROP.
CORROSION HIGH RESISTANT TO MOISTURE, HUMIDITY, AND
RESISTANCE MOST COMMON CHEMICALS USED IN
BUILDINGS.
FLAME VARIES CAN BE FLAME-RETARDANT WITH
RETARDANCY ADDITIVES, BUT CHECK BUILDING CODE
REQUIREMENTS FOR SPECIFIC FLAME
 SPREAD AND SMOKE DEVELOPMENT
RATINGS.
STRENGTH MODERATE STRONG ENOUGH FOR MOST
RESIDENTIAL AND LIGHT COMMERCIAL
APPLICATIONS. MAY REQUIRE ADDITIONAL
SUPPORT FOR LONG RUNS OR HIGH
LOADS.
RIGIDITY MODERATE RIGID ENOUGH FOR MOST APPLICATIONS,
BUT LESS RIGID THAN METAL DUCTS.
LEAKAGE HIGH JOINTS REQUIRE PROPER SOLVENT
RESISTANCE WELDING OR MECHANICAL CONNECTIONS
FOR GOOD LEAK RESISTANCE.
THERMAL 0.16 - 0.20 LOW THERMAL CONDUCTIVITY COMPARED
CONDUCTIVITY W/MK TO METAL DUCTS, BUT HIGHER THAN
FIBERGLASS.
INSULATION HIGH COMPATIBLE WITH MOST COMMON DUCT
COMPATIBILITY INSULATION MATERIALS.

C. ECONOMIC ASPECT

MATERIALS PRICE IN THE MARKET

POLYVINYL CHLORIDE (PVC) PHP 280+ (DEPENDING ON THICKNESS
AND DIAMETER) PER METER

D. IN-SERVICE CONDITION

POLYVINYL CHLORIDE (PVC) DUCTS CAN BE A COST-EFFECTIVE AND EFFICIENT

CHOICE FOR AIR CONDITIONING SYSTEMS, BUT THEIR IN-SERVICE CONDITION NEEDS
ATTENTION. WHILE PVC OFFERS ADVANTAGES LIKE LIGHT WEIGHT, CORROSION
RESISTANCE, AND SMOOTH AIRFLOW, IT HAS LIMITATIONS. KEEP AN EYE OUT FOR
WARNING SIGNS LIKE BRITTLENESS, DISCOLORATION, OR SAGGING, WHICH CAN
INDICATE DEGRADATION FROM HEAT, SUNLIGHT, OR PHYSICAL STRESS. REGULAR
INSPECTIONS, CLEANING, AND PROTECTING PVC DUCTS FROM SUNLIGHT CAN
EXTEND THEIR LIFESPAN. IF SAFETY IS A CONCERN DUE TO CRACKS, OFF-GASING
ODORS, OR EXTENSIVE DAMAGE, REPLACING THE DUCTS ENTIRELY MIGHT BE
NECESSAR

3. COMPOSITE MATERIALS: FIBERGLASS REINFORCED PLASTIC (FRP)

DUCTS

A. DEISGN PARAMTERS
DESIGNING FRP DUCTS INVOLVES SELECTING THE RIGHT RESIN, FIBER
TYPE, AND WALL THICKNESS BASED ON THE APPLICATION'S NEEDS. LINER
SELECTION AND STRUCTURAL CONSIDERATIONS FOR WEIGHT AND EXTERNAL
 LOADS ARE ALSO CRUCIAL. FINALLY, FIRE SAFETY REQUIREMENTS SHOULD BE
ADDRESSED THROUGH APPROPRIATE RESIN ADDITIVES OR LINERS.

B. PROPERTIES OF FIBERGLASS REINFORCED PLASTIC (FRP) DUCTS FOR AIR

CONDITIONING SYSTEMS

FRP DUCT PROPERTIES

PROPERTIES DATA NOTES

SMOOTHNESS HIGH INTERIOR SURFACE FINISH MINIMIZES
FRICTION LOSS AND PROMOTES
EFFICIENT AIRFLOW.
CORROSION HIGH RESISTS CORROSION FROM
RESISTANCE CONDENSATION, HUMIDITY, AND MOST
CHEMICALS COMMONLY ENCOUNTERED
IN HVAC SYSTEMS.
FLAME LOW (DEPENDS ON CAN MEET VARIOUS BUILDING CODE
RETARDANCY RESIN TYPE AND FLAME SPREAD AND SMOKE
ADDITIVES) DEVELOPMENT RATINGS WITH SPECIFIC
RESIN FORMULATIONS.
STRENGTH HIGH CAN BE DESIGNED TO HANDLE WEIGHT
OF THE DUCT SYSTEM, INSULATION (IF
USED), AND TYPICAL BUILDING LOADS.
RIGIDITY HIGH MAINTAINS SHAPE AND RESISTS
COLLAPSING UNDER NEGATIVE
PRESSURE.
LEAKAGE HIGH JOINTS CAN BE SECURELY SEALED
RESISTANCE WITH PROPER TECHNIQUES TO
MINIMIZE AIR LEAKS.
THERMAL 0.2 - 0.3 LOWER THAN STEEL (AROUND 30
CONDUCTIVITY BTU/(FT·H·°F) BTU/(FT·H·°F)), REDUCES HEAT
GAIN/LOSS THROUGH DUCT WALLS.
INSULATION HIGH COMPATIBLE WITH VARIOUS
COMPATIBILITY INSULATION TYPES (E.G., FIBERGLASS,
ROCKWOOL) FOR ENHANCED THERMAL
PERFORMANCE.

C. ECONOMIC ASPECT

MATERIALS PRICE IN THE MARKET

FIBERGLASS REINFORCED PLASTIC 500 TO 1000+ (DEPENDING ON DIAMETER,
(FRP) DUCTS THICKNESS)

D. IN SERVICE CONDITIONS

FRP (FIBERGLASS REINFORCED PLASTIC) DUCTS ARE A POPULAR CHOICE FOR

AIR CONDITIONING SYSTEMS DUE TO THEIR RESISTANCE TO RUST AND
CORROSION, LEADING TO CLEANER AIR AND A LONGER LIFESPAN COMPARED TO
TRADITIONAL METAL DUCTS. HOWEVER, MAINTAINING THEIR IN-SERVICE
CONDITION REQUIRES SOME SPECIFIC CONSIDERATIONS. WHILE THE FRP ITSELF
IS RESISTANT TO DUST BUILDUP, ANY INTERNAL LINER MIGHT NEED PERIODIC
CLEANING FOR OPTIMAL AIRFLOW. REGULAR INSPECTIONS ARE ALSO CRUCIAL TO
IDENTIFY AND ADDRESS ANY CRACKS OR PUNCTURES THAT MAY OCCUR FROM
IMPACT OR MISHANDLING. UNLIKE STEEL, FRP ISN'T INHERENTLY FIREPROOF, SO
MAINTAINING CLEARANCES FROM HEAT SOURCES AND ADHERING TO FIRE CODES
DURING INSTALLATION IS VITAL. FINALLY, PROPER INSULATION IS ESSENTIAL TO
PREVENT CONDENSATION AND MOLD GROWTH, SIMILAR TO MILD STEEL DUCTS. BY
FOLLOWING THESE MAINTENANCE PRACTICES, FRP DUCTS CAN DELIVER LASTING
PERFORMANCE AND CONTRIBUTE TO A HEALTHY AND EFFICIENT AIR
CONDITIONING SYSTEM

IV. COMPARISON OF DUCT MATERIALS BASED ON REQUIRED PROPERTIES

✓ - GOOD PERFORMANCE
△ - MODERATE PERFORMANCE
✖ - POOR PERFORMANCE

PARAMETER MILD STEEL PVC DUCTS FRP DUCTS

DUCTS
SMOOTHNESS MODERATE △ HIGH ✓ HIGH ✓
CORROSION MODERATE △ HIGH ✓ HIGH ✓
RESISTANCE (NEEDS COATING)
FLAME HIGH ✓ (CAN BE LIMITED ✖ HIGH ✓
RETARDANCY ACHIEVED WITH (REQUIRES
TREATMENT) SPECIFIC FLAME-
RETARDANT PVC)
STRENGTH HIGH ✓ MODERATE △ MODERATE △

RIGIDITY HIGH ✓ HIGH ✓ HIGH ✓

LEAKAGE GOOD ✓ (PROPER HIGH ✓ (PROPER HIGH ✓
RESISTANCE INSTALLATION GLUING REQUIRED)
REQUIRED)
THERMAL HIGH ✖ MODERATE △ LOW ✓
CONDUCTIVITY
INSULATION GOOD ✓ GOOD ✓ HIGH ✓
COMPATIBILITY
PRICE IN THE PHP 300+ PHP 280+ ✓ PHP 500 TO 1000+
MARKET (DEPENDING ON (DEPENDING ON (DEPENDING ON
THICKNESS) PER THICKNESS AND THICKNESS AND
METER DIAMETER) PER DIAMETER) PER
METER METER

V. SELECT THE BEST MATERIAL FOR THE APPLICATION AMONG THE THREE
ENGINEERING MATERIALS ANALYZED:
THE SELECTED BEST MATERIAL FOR AIR CONDITIONING SYSTEMS IS FRP
DUCTS

VI. CONCLUSION:
• FOR MAXIMUM STRENGTH AND RIGIDITY: MILD STEEL IS THE STRONGEST
OPTION, BUT IT REQUIRES A PROTECTIVE COATING TO PREVENT CORROSION.
• FOR ENERGY EFFICIENCY AND SUPERIOR CORROSION RESISTANCE: FRP IS
THE MOST THERMALLY EFFICIENT OPTION AND HIGHLY RESISTANT TO
CORROSION. HOWEVER, IT'S THE MOST EXPENSIVE CHOICE AND MIGHT
REQUIRE ADDITIONAL SUPPORT DUE TO ITS LOWER STRENGTH COMPARED
TO STEEL.
COST-EFFECTIVENESS AND ECONOMIC CONSIDERATIONS:
• MOST COST-EFFECTIVE: MILD STEEL CAN BE THE MOST ECONOMICAL OPTION,
ESPECIALLY FOR LARGER DIAMETER DUCTS, DUE TO ITS LOWER BASE PRICE.
HOWEVER, CONSIDER THE ADDITIONAL COST OF CORROSION-RESISTANT
COATING.
• ECONOMICAL CHOICE WITH BALANCED PERFORMANCE: PVC OFFERS A
BALANCE BETWEEN AFFORDABILITY AND PERFORMANCE, MAKING IT A GOOD
VALUE OPTION FOR MANY APPLICATIONS.
ADDITIONAL FACTORS TO CONSIDER:
• MAINTENANCE: MILD STEEL REQUIRES PERIODIC MAINTENANCE TO PREVENT
CORROSION. PVC AND FRP GENERALLY REQUIRE LESS MAINTENANCE.