How to Install Duct Work: 10 Steps

Installing duct work for your HVAC system can be expensive even though the work primarily only involves running some pipe and taping it together. Although the process may seem intimidating from the outside, no particular part of the process is particularly difficult or demanding. Just make sure you have plenty of time to do the job right. Repairs to duct work are much more difficult than installing it correctly on the first try.
STEPS

1

CONSULT THE BUILDING CODES FOR YOUR STATE AND MUNICIPALITY. Each state has its own laws regarding HVAC installation. Confirm that your plan -- including doing the work yourself, rather than hiring it to be done, follows the laws of your area.
You may also want to check with your insurance company. Under some policies, this kind of work will void your homeowner's or commercial property insurance.

2

PUT ON YOUR SAFETY GEAR, INCLUDING GOGGLES, WORK GLOVES, HELMET AND FACE MASK OR RESPIRATOR. Duct work involves moving around in dusty areas and handling objects that are heavy and sharp.

3

SET THE MOUNTING RING FOR YOUR DUCT WORK IN PLACE ON YOUR FURNACE, FAN OR AIR CONDITIONER. Screw it in place with #8 sheet metal screws.

4

RUN THE DUCT ALONG THE ROUTE SPECIFIED BY YOUR PLANS. Mount it to the ceiling, floor or wall using the metal straps every 3 to

4

feet (.91 to 1.22 m). Attach the straps using the hammer and nails.

5

INSERT A CONNECTING COLLAR INTO THE END OF EACH LENGTH OF DUCT, THEN SLIP A NEW LENGTH ONTO THE OPPOSITE SIDE OF THE COLLAR. Affix it in place using duct tape.
As a general rule, too much duct tape is better than too little. Always err on the side of caution if you're not sure how much duct tape to use.

6

USE WIRE CUTTERS AND SCISSORS TO CUT OFF EXCESS DUCT WHEN IT REACHES THE END OF YOUR PLANNED LINE. Settle the end over the mounting hardware for the grill. Screw it in place.

7

WRAP THE LENGTH OF THE COMPLETED DUCT IN INSULATION BY ROLLING IT IN A SPIRAL PATTERN LIKE THE HANDLE OF A TENNIS RACKET.

8

WRAP DUCT TAPE AROUND EACH END OF THE LENGTH OF INSULATION, AND ALONG THE SEAM OF THE WRAPPED INSULATION. This will maximize the life and effectiveness of the insulation.

9

REPEAT UNTIL ALL OF YOUR GRILLS AND REGISTERS ARE HOOKED UP TO YOUR HVAC SYSTEM.

10

TEST YOUR SYSTEM BY TURNING IT ON AND CHECKING THAT YOU HAVE SIGNIFICANT AIR FLOW THROUGH EACH GRILL.
You can also walk or crawl along the length of each duct to check for noticeable air leaks, which you can repair with insulation and duct tape.
THINGS YOU\'LL NEED
Goggles
Work gloves
Helmet
Face mask or respirator
Mounting ring
Screwdriver
#8 sheet metal screws
Metal straps
Hammer
Nails
Connecting collar
Duct tape
Wire cutters
Scissors
Grills
Duct insulation
Registers
Flexible ducts