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Blower door and duct blaster leakage testing, mastic sealant application, flex duct correction, static pressure measurement, and zone damper repair. We find what your duct system is actually losing.
Ductwork Repair Specialists
The duct system is the invisible infrastructure of your HVAC equipment, and it is also the most commonly neglected part of the system. Research from the Department of Energy consistently finds that the average home loses 20 to 30 percent of its conditioned air through duct leaks before it reaches the living space. In Horton's climate, that means your equipment is working significantly harder than it should be, and you are paying for conditioning that ends up in your attic, crawl space, or wall cavities rather than in the rooms you are trying to heat or cool.
Measuring how much your duct system actually leaks requires a duct blaster test. A duct blaster is a calibrated fan that pressurizes the duct system to a specific pressure while all registers are sealed. The airflow required to maintain that pressure tells you how much air is leaking out of the system at normal operating pressures. This is the only way to quantify duct leakage accurately. Visual inspection and feeling for drafts at joints is insufficient for identifying the actual leakage rate, and quoting duct work without a leakage measurement means the scope is based on guesswork rather than data.
Duct sealing with mastic sealant is fundamentally different from applying duct tape. Metal duct tape has its place as a short-term fix, but it dries out and loses adhesion over time, particularly in attic environments where temperatures cycle dramatically. Mastic sealant is a fiber-reinforced paste that is applied wet and dries to a permanent, flexible seal that does not degrade with thermal cycling. It is the correct product for sealing duct joints, seams, and collar connections in both metal and flex duct systems. We apply mastic at every accessible joint in the duct system during a sealing job, not just the ones that are obviously visible and already dripping condensation.
Flex duct issues are a significant source of duct system underperformance in Horton area homes. Flex duct that sags, kinks, or runs in excessively long, convoluted paths creates static pressure that reduces airflow through that branch significantly. A kinked flex duct can reduce airflow by 50 percent or more through that register. We evaluate every flex duct run for sag and kinking, correct support intervals, and unnecessary length, and we correct these issues as part of ductwork repair rather than leaving flow restrictions in place after sealing leaks.
Static pressure measurement across the air handler tells us whether the duct system as a whole is adequately sized for the equipment. A high static pressure reading at the air handler indicates restriction in the duct system that is forcing the blower to work harder and deliver less airflow than it should. Identifying whether that restriction is return-side or supply-side, and which specific components are contributing to it, requires measuring static pressure at multiple points in the system. We take these measurements before recommending duct modifications so the scope of work is based on actual data from your specific duct system in Horton.
Ductwork Services
We use a calibrated duct blaster fan to pressurize the duct system with all registers sealed and measure the CFM25 leakage rate. This quantifies exactly how much air your duct system loses at normal operating pressures before and after any sealing work. Pre and post-repair leakage measurements document what the repair actually accomplished rather than leaving you with a verbal assurance that the job was done well. In Horton, KS, where utility costs are significant, knowing your duct leakage rate in CFM and as a percentage of system airflow tells you exactly what your leak situation costs you annually in wasted energy.
Mastic sealant is the industry-standard product for permanently sealing duct leaks. Unlike tape-based products, mastic does not dry out or lose adhesion through thermal cycling in attics and crawl spaces. We apply mastic to all accessible joints, seams, collar connections, and takeoff fittings in the duct system. Areas where gaps are too large for mastic alone get fiberglass mesh tape embedded in the wet mastic for reinforcement before the final coat. We do not substitute sheet metal tape for mastic on joints that will be exposed to temperature extremes, because the failure rate of tape in those conditions is well-documented.
Flexible duct that sags, kinks, or is installed in excessively long runs creates static pressure that restricts airflow to the registers it serves. A single sharp bend in a flex duct run can restrict airflow enough to make that room perpetually uncomfortable even when the equipment is working correctly. We walk every flex duct run in the attic or crawl space, identify sagging and kinking, correct support intervals, eliminate unnecessary bends, and replace sections that are damaged, crushed, or have failed inner liner connections. Correcting flex duct issues before measuring post-repair static pressure gives a true picture of the system's actual flow capacity.
Static pressure is the resistance the blower motor works against to move air through the duct system. High total external static pressure reduces airflow, increases blower motor temperature, and accelerates motor wear. We measure static pressure at the air handler inlet and outlet, across the filter and coil, and at selected points in the supply and return systems to identify where restriction is highest. This data tells us whether the system's problem is a return-side restriction, a supply-side restriction, a coil restriction, or a filter restriction, and it guides the scope of any duct modification work in Horton rather than guessing which runs need changes.
Ducts running through unconditioned attic space in Horton, KS's climate lose significant heating and cooling energy through the duct wall before that energy reaches the living space. Code-minimum duct insulation in hot-climate attics is often R-6, but R-8 or higher provides meaningfully better thermal protection for attic duct runs where ambient temperatures can reach 140 degrees in summer. We assess existing duct insulation condition and R-value, identify ducts with insufficient or damaged insulation, and add or replace duct insulation as part of a comprehensive duct system upgrade. Reinsulating poorly insulated attic ducts is one of the highest-return duct improvements available in Horton, KS's climate.
Zoned HVAC systems use motorized dampers in the duct system to direct airflow to specific zones based on thermostat demand. Zone dampers fail in several ways: the actuator motor fails and the damper gets stuck open or closed, the damper blade develops a crack or warps and no longer seals, or the control board loses communication with one or more dampers. A zone damper stuck in the closed position on a zone with a single return air path can create a bypass pressure situation that bypasses air through other zones and creates noise. We test each damper in a zone system, verify full open and closed travel, and repair or replace actuators and blades as needed. We also verify that the zone control board is reading all zone sensors correctly before calling the system complete.
Our Advantage
We test duct leakage before and after every sealing job using a calibrated duct blaster. You receive written results showing the actual CFM improvement, not just a technician's assessment that it looks better.
We use fiber-reinforced mastic sealant on all duct joints rather than tape. Mastic does not fail from thermal cycling, which means the repair lasts decades rather than peeling away in your attic over a few years.
Sealing leaks without correcting flex duct sag and kinking leaves significant airflow restrictions in place. We fix both as part of every duct repair scope because airflow restrictions affect the same rooms as leaks.
We measure static pressure at multiple points before recommending duct modifications. This tells us exactly which part of the system is causing restriction in Horton homes, so the repair is targeted rather than speculative.
How It Works
We run a duct blaster test to quantify total leakage and measure static pressure at multiple system points. This gives us the data to explain exactly where the system is losing performance before any work begins.
We walk every accessible duct run, identify sagging and kinked flex duct, find obvious joint failures, assess insulation condition, and check zone damper operation. The scope of repairs is built from data and visual findings together.
We apply mastic sealant at all accessible joints and seams, correct flex duct sag and kinking, replace damaged sections, add or repair insulation on attic runs, and service any zone dampers in the system.
We run a second duct blaster test after repairs and measure static pressure again. The before and after numbers go into your written report so you have documented proof of what the repair accomplished in your Horton home.
Customer Reviews
"They tested the duct leakage before and after the repair and gave me written numbers. Before the repair my system was leaking 28 percent of its airflow. After mastic sealing and flex duct correction, it was down to 6 percent. One bedroom that was always too warm is now comfortable for the first time. The test results made the whole thing worth it."
"My static pressure reading was nearly double the design target. All Year HVAC found two severely kinked flex duct runs in the attic and an undersized return plenum. They corrected the flex duct and opened the return, measured static pressure again, and it was well within range. My system is noticeably quieter and the airflow to every room improved. Detailed and professional."
"Had All Year HVAC out to diagnose why half the house stayed 4 degrees warmer than the thermostat. They found a zone damper stuck in a partially closed position that was directing most of the airflow to the other zone. Fixed the damper actuator and verified all zones. The temperature imbalance is gone. Simple fix, but nobody had ever checked the zone system before."
FAQ
Where We Work
Our ductwork repair crews serve Horton and the surrounding communities throughout Horton, KS. We bring calibrated duct blaster testing equipment on every job to provide before and after leakage measurements as part of the standard repair process.
Call to schedule a duct system assessment. We are available Monday through Saturday for ductwork repair appointments in the Horton area and can typically schedule initial assessments within a few days of your call.
Schedule Assessment: +1-866-805-8548
Call All Year HVAC for a duct leakage test and static pressure assessment. Real numbers, mastic sealing, flex duct correction, and documented before and after results.
Call +1-866-805-8548