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Install Team

DUCT SYSTEM INSTALLATION PROCESS

This document defines the standard scope of work and quality expectations for duct system projects. Scope may include full duct replacement, partial replacement, or duct-only upgrades using existing components.

Keating Kuhn

Keating Kuhn

January 8, 2026

VERIFY APPROVED SCOPE OF WORK ON INVOICE BEFORE DOING ANY DEMOLITION

SITE PREP & HOME PROTECTION

  • Enter home respectfully and review work areas with homeowner
  • Lay floor protection from entry to attic access
  • Lay plastic sheets under all supply and return buckets
  • Protect furnishings and fixtures as needed

* When job scope requires removal of supply grilles, apply green painter’s tape over drywall buckets to prevent debris from entering the home *


ATTIC – DEMO PHASE

  • Remove ductwork, connectors, buckets, plenums, and collars per scope
  • Double-bag all fiberglass/porous debris before bringing it out of attic
  • Place all trash behind vehicle in driveway ON PLASTIC

PLENUM & COLLAR INSTALLATION

METAL PLENUM

  • All seams mechanically fastened before sealing
  • Insulate plenum outside before bringing it into the attic
  • Plenum must be square, level, and fully supported (not hanging on the unit)
  • Cut collar holes clean and correctly sized
  • Install collars tight to plenum with mastic and screws
  • All dampers must be installed blade lined up with the airflow (no scoop)
  • Seal all seams, corners, and joints with mastic
  • Seal collar-to-plenum connections fully
  • Reinforce mastic with approved foil tape after curing
  • Dampers accessible and adjustable after installation

DUCT-BOARD PLENUM

  • Cut ductboard square and to proper dimensions
  • Assemble plenum with correct fold and closure method
  • Plenum must be level and independently supported
  • Cut collar openings clean and precise
  • Insert collar fully and flush with duct-board surface with tabs
  • Seal collar-to-ductboard connections completely
  • All dampers must be installed blade lined up with the airflow (no scoop)
  • Seal all duct-board seams with mastic
  • Dampers accessible and adjustable after installation

BUCKET REPLACEMENT

  • Verify bucket size matches grille and airflow design
  • Bucket must fit snugly in drywall opening
  • If enlarging drywall opening:
    • Lay plastic sheeting below opening
    • Helper must be positioned below with a box to catch dust
  • Apply thin bead of spray foam or thick bead of mastic between bucket and drywall
  • Hold bucket from attic while helper installs and aligns grille from below
  • Ensure grille sits flat and centered

*Do not use silicon on grille/drywall connection*


DUCT INSTALLATION

  • Run new flex duct per Manual D
  • Avoid sharp bends, compression, and excess length
  • Strap and space ductwork to prevent sagging per best practice

SYSTEM COMMISSIONING & FINAL CHECKS

  • Verify airflow at each register
  • Adjust dampers as needed
  • Check static pressure (target within manufacturer tolerance)
  • Verify system operation:
    • Heating and cooling performance
    • Temperature split
    • Air delivery (CFM intent)
  • Document final readings
  • Walk homeowner through completed work and improvements

INSTALLER ACCOUNTABILITY

  • Only perform work included in the approved scope
  • Photos, notes, and readings must be documented in Workiz
  • Job is not complete until commissioning and homeowner walkthrough are finished