Ductwork repairs. What you need to know about it

Last Updated: November 24, 2025

HVAC
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Michael Rosenberg

Specializes in translating complex information into readable, engaging content. Michael@top10us.com

Ductwork is a rectangular tubular system that maintains the temperature and air quality indoors. Continuous use of the system can result in holes or dipping of water from the ducts which need to be repaired timely. The holes in different parts of ductwork can lead to the leakage of the air and lower the efficiency of the system. 

Ductwork comprises of many parts other than ducts, like flex duct, fiberglass duct board, galvanized sheet metal system, and sheet metal duct. These parts need to be repaired in case of any damage. 

For repairing the ductwork, you need these things: clean water, scissors, cutting knife, aluminum tape, mastic, sheet metal patch, self-taping sheet and metal screw, drill, rag, and a bucket.     

  

Ductwork

Flex duct

When the air passes through the flex duct because of the high pressure of air in the air conducting duct, the collar becomes exposed that decreases its efficiency and lowers the system’s energy. To solve this issue, you need to add hanger straps throughout the duct in the exposed area. Then cut the damaged part by pulling it. Put the insulation than apply mastic to seal the connection.

Fiberglass duct board

Mostly there is no need to repair the fiberglass duct board. Because of the size of these ducts, it is hard to repair them, and replacing them is the best option. Sometimes, the inner surface of the duct contains excessive moisture that damages the fiberglass. Technicians always recommend replacing the part of fiberglass to avoid a loss. To install a new patch, first, drain the water from the fiberglass by poking a small hole in the outer layer of foil and drain the water. Cut the damaged section with a knife blade. Then install a new patch into the hole and press it. Then apply a piece of foil-backed duct tape and cover it with mesh.

Galvanized sheet metal system

In case of damage to the galvanized sheet metal system, the technicians hold the damaged part of the metal sheet together with screws and then seal them with foil-backed duct tape.

Sheet metal duct

Sheet metal ducts are applied in homes or buildings in areas with a very cold climate. The heating system is used the most to heat the houses. For the excessive use of the system, the sealant can’t hold the substances, and the heated air escapes from the ducts. To repair these ducts, first, find the damaged area, remove it, and place a new duct part with screws, then seal it.

While repairing ductwork you should be very careful and wear leather gloves and a mask.

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