Capstone Project: Build and Test a Practice Ducted Air Distribution System

A. Finished-Project Specification

Quantity: one complete practice air-distribution system consisting of a supply plenum or trunk, takeoff collars, a return-air path and grille, a rigid or flexible supply branch, a supply register boot and register, sealed and insulated duct sections, approved supports, balanced dampers, and a completed HVAC Capstone Build and Test Worksheet with punch list and handoff record, built exactly to the approved practice-system drawing and duct schedule.

B. Component Schedule

Component	Quantity	Material	Finished Size	Preparation
Supply plenum or trunk section	Per approved drawing	Sheet metal or duct board as specified	Per approved duct schedule	Cut, formed, and fastened per Chapter 6/7 methods
Takeoff collar	One per branch, per approved drawing	As specified by the duct schedule	Per approved duct schedule	Installed in the specified location and orientation
Return boot, duct, and grille	Per approved return design	As specified by the return design	Per approved return design	Installed and sealed per Chapter 9
Supply register boot and register	One per register location, per approved drawing	As specified	Per approved register schedule	Installed and sealed per Chapter 8
Flexible or rigid branch duct	Per approved drawing	Listed insulated flexible duct or rigid duct as specified	Per approved diameter and length	Connected per Chapter 10 or the rigid-duct sealing method
Balancing damper	Per approved drawing	As specified	Per approved location	Installed with initial position marked
Duct support	Per approved support spacing	Listed wide strap or specified support	Per approved spacing	Installed without compressing insulation

C. Material Takeoff

• Duct materials: sheet metal, duct board, or listed flexible duct in the type and quantity specified by the approved duct schedule.
• Sealing materials: listed duct mastic, reinforcing mesh where required, and listed HVAC foil tape in the quantity specified for the total joint length in the duct schedule.
• Insulation materials: insulation and vapor facing in the type, thickness, and quantity specified by the approved insulation requirements, plus listed closures and patch material.
• Fasteners and supports: mechanical fasteners, collars, clamps, draw bands, and listed wide-strap supports in the quantity specified by the duct schedule.
• Registers, grilles, and dampers: supply registers, return grille, and balancing dampers per the approved register schedule.
• Blower or test-air source: one listed blower or qualified training blower matching the approved specification, with its guards, covers, and disconnect.

D. Fastener and Hardware Schedule

Joint	Fastener/Hardware	Installation Requirement
Plenum and trunk seams	Mechanical fasteners per Chapter 6	Installed before mastic; joint mechanically fastened at every specified location before sealing
Takeoff collar to trunk	Sheet-metal screws per approved schedule	Installed per the specified pattern, then sealed with mastic
Flexible-duct inner liner	Listed clamp or draw band	Installed at required engagement over the collar, then sealed per Chapter 10
Register boot to branch	Listed collar and fastener	Installed and sealed per Chapter 8
Duct supports	Listed wide strap	Installed at approved spacing without compressing insulation

E. Acceptance Standards

Check	Standard
Fastening	Every required joint mechanically fastened before sealing, per the approved schedule
Sealing	Every required joint, seam, boot, collar, and penetration sealed and cured with no visible gaps, cracking, or tape lift
Insulation	Every required duct section, fitting, and boot insulated with continuous vapor facing and no exposed metal or compressed sections
Support	Duct supported at approved spacing with no sag exceeding the approved limit
Balance	Final damper and register positions within the approved adjustment range, with no register fully closed except where the design permits
Testing	Leakage and airflow tests completed at the specified test condition with results recorded and failed items corrected and retested

F. Preparation and Staging

1. Obtain the approved practice-system drawing, duct schedule, branch sizes, return design, register schedule, blower or test-air specification, support details, insulation requirements, and test procedure. Confirm the drawing is complete before staging materials.
2. Confirm that the system is a training assembly or professionally designed permitted installation. Record which condition applies on the worksheet.
3. Do not connect the capstone to fuel-fired equipment, a refrigerant system, or occupied-building air handler unless separately authorized and commissioned. Record this restriction on the worksheet before beginning fabrication.
4. Prepare the safety, tool, access, electrical-control, material, inspection, and documentation plan. Confirm PPE, tools, and materials are staged before cutting begins.
5. Establish the equipment or blower position, supply-plenum reference, return reference, register locations, and support points. Mark each reference point on the training frame or approved practice structure.
6. Inspect and stage sheet-metal fittings, collars, boots, flexible duct, return components, fasteners, mastic, listed tape, insulation, supports, dampers, grilles, and test instruments. Confirm every component matches the component schedule before assembly.

G. Supply Plenum, Return Path, and Register Boot Assembly

1. Assemble and secure the supply-plenum or trunk components according to the approved design. Confirm plenum dimensions against the duct schedule before fastening.
2. Install takeoff collars in the specified locations and orientation. Verify each collar's position against the marked reference points.
3. Mechanically fasten all required duct joints before sealing. Confirm every joint is fastened per the fastener schedule before any mastic is applied.
4. Install the return-air path and grille using the approved design. Follow the Chapter 9 procedure for framing, boot, and grille installation.
5. Seal return joints to prevent drawing air from unintended spaces. Confirm every return-side joint is sealed per Chapter 6.
6. Install the supply register boot and structural support. Follow the Chapter 8 procedure for boot orientation and framing support.

H. Branch Connection, Support, and Sealing

1. Connect the specified rigid or flexible branch to the supply boot. Confirm branch diameter and route against the approved drawing.
2. Connect the inner liner, insulation, and outer jacket using the Chapter 10 sequence. Follow the exact liner-engagement, sealing, and jacket-closure steps from Chapter 10.
3. Install supports at approved intervals and maintain bend and sag limits. Verify support spacing with the tape measure against the approved specification.
4. Install balancing dampers and mark their initial positions. Record each initial damper position on the worksheet.
5. Seal all approved duct joints, seams, boots, collars, and penetrations using Chapter 6. Confirm continuous mastic contact and correctly burnished tape at every joint.
6. Allow sealants to cure under the required conditions. Do not proceed to insulation until the manufacturer-controlled cure time has elapsed.

I. Insulation, Registers, and Pre-Operation Inspection

1. Insulate approved duct sections, fittings, boots, and transitions using Chapter 7. Confirm full coverage, correct overlap, and continuous vapor facing.
2. Preserve access to dampers, test ports, labels, and service components. Confirm insulation does not cover a required access or test point.
3. Install supply registers and return grilles. Confirm each register and grille is secured and its damper moves freely.
4. Inspect the full system for open joints, blocked paths, crushed duct, loose supports, exposed metal, damaged vapor facing, and unsafe edges. Record every finding on the worksheet.
5. Complete all pre-operation corrections. Correct every finding from the previous step before connecting the blower.

J. Blower Connection, Testing, and Balancing

1. Connect the listed blower or test-air source using the approved electrical and mechanical controls. Confirm the connection matches the approved specification.
2. Verify guards, covers, disconnects, and emergency shutdown. Confirm the blower cannot start unexpectedly before proceeding.
3. Start the blower at the designated test condition. Record the test condition on the worksheet before observing the system.
4. Observe duct movement, joint leakage, vibration, noise, and register delivery. Record each observation at every accessible joint and register.
5. Perform the approved leakage inspection. Use the smoke pencil or the approved leakage-test method at every sealed joint.
6. Measure or compare supply airflow and return airflow using the specified instruments and setup. Record baseline readings before any balancing adjustment.
7. Adjust dampers and registers in small increments. Make one adjustment at a time per the Chapter 11 procedure.
8. Allow the system to stabilize after each change. Wait for stable conditions before recording the next reading.
9. Record final airflow observations or measurements and damper positions. Confirm final positions are within the approved adjustment range.
10. Inspect flexible duct under operation for collapse, excessive sag, or movement. Record any condition requiring correction.
11. Inspect insulation and vapor facing for separation. Record any condition requiring correction.

K. Correction and Closeout

1. Shut down and isolate the blower before corrections. Confirm the blower is de-energized and cannot start before touching any joint, support, or damper.
2. Correct failed joints, supports, seals, insulation, or balance conditions. Use the exact chapter procedure that governs the failed component.
3. Repeat all affected operational tests. Re-run the leakage or airflow test for every corrected item.
4. Compile drawings, materials, photographs, support records, sealant records, airflow results, balancing positions, inspection findings, and corrections. Assemble the complete closeout package.
5. Label supply, return, airflow direction, dampers, test ports, and shutdown control. Confirm every label is legible and matches the closeout package.
6. Complete the HVAC punch list. Close every item before handoff.
7. Hand off the practice system with operation, shutdown, maintenance, and inspection documentation. Confirm the receiving party has all required records.