In my Ductwork Installation Guide e-book you can read about entire process of ductwork installation from start to finish and even find several chapters with rare and unusual cases. However, it is next to impossible to include in this e-book all the challenges an installer meet in virtually every house. Every time when electricians and/or plumbers were in the house ahead of you they easily create a whole host of issues!

On this and on the following pages I'll show you many of these cases and explain how this or that problem was created and how it was resolved.

If you at your work have similar kinds of challenges feel free to contact me below. Also, if you would like to know when the next ductwork installation problem will be published here on my site you can subscribe to the alerts below.

South Lyon, MI
Builder: Palazzolo, Lot #23
12/15/2014

At first this problem was created by architect or/and carpenters. They not just placed a joist on the I-beam, but for no reason at all even nailed a header in every single joist space - above this monumental structure is a hallway...

The plumbers in this house did the right thing: they placed the gas line aside. In the previous and in the next house they ran it right through the middle.

However electricians didn't follow the suit and pulled their wires right through the middle, so now, I hope, they will learn something...

And another problem, even two! They placed the second joist too close to the first one and the gas line won't let you install the blocker in place, so it should be installed first. 

The similar problem with the heat runs - the joist is too close, it's why instead of round 45* I used round-to-oval 90* boots.

The same heat runs after they jumped above the I-beam 

Again, in the best case scenario the wall upstairs should be placed somewhere in the middle between joists, but not too close to one of them. It's why in the first case for the "straight shot" I used an oval 90* and round-to-oval end boot and in another round-to-oval 90* boot for the "jumper". 

43. Installation of Heat Runs – the chapter covers the heat runs installation in the basement and deals only with all possible cases of the “straight shot”.
The chapter has 112 picture; 65 pages*. $3.41 (Instant Access).

On 10/12/2014 text of this chapter was significantly modified and improved. 7 photos were added. Examples of Pulte Homes ductwork installation were also added to this chapter.

South Lyon, MI
Builder: Palazzolo, Lot #21
12/17/2014 

This bath box would be relatively easy to hook up if the guy who was sent to install furnace temporarily would does so, but he doesn't. First off, he placed the furnace about 4' away from the projected spot, then he ran PVC pipes right below it and finally he glued them all...
So, didn't have a choice, but connect it to the plenum the way you can see it in the pictures above and on the left.

Sterling Heights, MI
Builder: Greenstone, Lot 39
12/23/2014

I don't know why a plastic waterline should be isolated in the cold air return, in my opinion it even would help in the case of fire, but according to code it must be isolated and I asked plumbers to move it a bit.

Then I isolated it with some thermo-pan.

34. Sheeting (Panning)* – the chapter covers almost all possible cases of the joist's panning  with a wide variety of uncommon cases, presents how to deal with penetration of the wires, copper and PVC pipes.
The chapter has 59 pictures; 29 pages*. $2.50 (Instant Access).

Summary Report for:
47-2211.00 - Sheet Metal Workers

Macomb, MI
Builder: Pulte, Lot #1
12/16/2014

It's pretty bad when in your company some installer doing only Rough-in! They have no idea what should be done in the basement. And here is an example of such installation.

As you can see it in the picture, oval 90* is set too high in the 12" tall joist space and connection to the take-off is impossible to do.

So, I cut a strip of the bond, pulled oval 90* down and made a connection.

Berkley, MI
Builder: Oliver Construction
01/09/2015

OK, here is a little test: describe what kind of issue you can see in the pictures, who is at fault, and how this issue was resolved. Email your answers below. In return I'll email you any paid page up to $3.00 value absolutely free!

The same house, another problem and the same test...

Bloomfield twp., MI
Builder: Dimmena
02/10/2015

The problem in this case is in the house design. Snow from three roofs sliding down to one spot and piles up to 4' - 5' completely covering furnace exhaust & intake.

In order to resolve this issue I ran both pipes up in the stud cavity and out through the wall.

49. Venting* – the chapter is divided in two parts and describes all possible cases of installation and termination of the
venting for 80% and 90+% furnaces.
The chapter has 67 pictures; 34 pages*. $2.69 (Instant Access).

*Article:
Venting & Draining Condensing Gas Furnaces
Laundry and Condensing Furnaces Don't Mix.

Novi, MI
Builder: Healy Homes
04/14/2015

In this case a rougher, a naturally born idiot, dropped the oval 45* in the very narrow look-out without extension, it's why it ends up right behind the joist. So I had two choices: cut the drywall, remove the bath-box (stack-head) and extend it or cut out the joist.

A superintendent choose the second option...