Ductwork & Airflow Services, Georgetown TX
Duct Repair & Construction
Repair disconnected, damaged, or collapsed duct sections. Restore airflow to rooms losing conditioned air.
Professional duct sealing with mastic or foil tape, eliminate air leaks that waste conditioned air in attic and crawlspace.
New duct system design and installation for additions, renovations, or full system replacement.
Custom fabrication of sheet metal trunk lines, branches, and fittings for high-performance duct systems.
Splice and reconnect flex duct sections, replace damaged sections, and correct improper flex duct installations.
Custom supply plenum fabrication for equipment replacements where the new unit requires a different plenum configuration.
Repair leaking or damaged return air plenums that allow unconditioned attic air to enter the system.
Applied mastic sealing for all duct joints and connections, the most durable sealing method for Georgetown's attic conditions.
Seal duct boots at registers where leakage directly into walls or ceilings causes significant energy loss.
Airflow Balancing
Measure and balance air distribution across all supply and return vents for even comfort throughout the home.
Comprehensive whole-house airflow evaluation and adjustment, dampers, registers, and duct sizing evaluated.
Balance airflow to specific problem rooms that receive too much or too little conditioned air.
Adjust zone dampers and control settings for homes with zoning systems to improve comfort and efficiency.
Full optimization of multi-zone airflow systems, control logic, damper travel, and zone sizing.
Optimize how conditioned air is distributed throughout the duct system for efficiency and comfort.
Improve overall air movement in the home through duct, register, and equipment adjustments.
Undersized return air is the most overlooked duct problem, we measure and correct return air flow.
Expand or add return air drops to improve system static pressure and airflow in homes with insufficient return capacity.
Dampers & Registers
Install manual balancing dampers in branch ducts to control airflow to specific zones or rooms.
Repair or replace motorized zone dampers that are stuck open, stuck closed, or not responding to controls.
Replace damaged, rusted, or improperly sized floor registers and diffusers.
Replace ceiling supply and return grilles with correct sizing and airflow direction for your room layout.
Install transfer grilles to improve pressure equalization and airflow between rooms with closed doors.
Install jump ducts above doorways or through walls to allow air pressure equalization between zones.
Redirect or baffle supply vents that blow directly on occupants or create drafty areas.
Measure and calibrate airflow from each vent against design specifications.
Ventilation & Testing
Repair ERVs, HRVs, exhaust fans, and dedicated ventilation systems.
Improve fresh air exchange and indoor air quality through targeted ventilation upgrades.
Measure system static pressure to identify duct restrictions causing equipment stress and efficiency loss.
Isolate duct sections from structure to eliminate vibration noise that transmits through walls and ceilings.
Install internal duct lining to absorb noise from high-velocity air movement in ducts near occupied spaces.
Duct Insulation & Protection
Install or replace duct insulation in Georgetown attics where heat gain from uninsulated ducts wastes significant energy.
Install vapor barriers to prevent condensation on cold supply ducts in Georgetown's humid summers.
Support or repair duct systems during crawlspace encapsulation projects.
Repair small-diameter high-velocity duct systems found in older homes and historic properties.
Why This Matters During Equipment Replacement
The supply plenum is the metal box directly connected to the air handler or furnace where conditioned air first enters the duct system, and it is one of the most common places where a mismatch appears during an equipment swap. New high-efficiency air handlers and furnaces frequently have different cabinet dimensions and airflow openings than the units they replace, even when the tonnage or heating capacity is the same, because manufacturers change coil size, blower housing shape, and filter rack placement between product generations. When the new equipment's supply opening does not match the existing plenum, installers either force an ill-fitting connection, which restricts airflow and creates leakage, or the plenum needs to be rebuilt to match.
We fabricate replacement plenums from sheet metal sized to the new equipment's exact supply opening, with a properly dimensioned transition to the existing trunk duct dimensions so airflow does not neck down or expand abruptly at the connection. A plenum that is undersized relative to the equipment's rated airflow creates excessive static pressure right at the source, which stresses the blower motor and can trigger high-limit shutoffs on furnaces or reduce the rated capacity of the cooling coil. We size every replacement plenum using the equipment manufacturer's specifications rather than reusing the old dimensions by default, since the old plenum was sized for different equipment.
This work comes up almost exclusively during furnace, air handler, or full system replacements, and it is also common when converting from a straight cool system to a heat pump, since heat pump air handlers often have a different coil cabinet depth. We build the plenum on site or in the shop depending on complexity, seal all seams with mastic, and insulate the exterior where the plenum passes through unconditioned attic space to prevent condensation on the metal surface during summer cooling operation. Plenum fabrication and replacement typically runs 400 to 1,200 dollars depending on complexity, and we always include it as a line item when quoting equipment replacements where the dimensions do not match, rather than as a surprise add-on discovered mid-installation.
Frequently Asked Questions, Supply Plenum Fabrication & Replacement
Uneven Comfort or High Energy Bills?
Ductwork problems are often the hidden cause. We diagnose and fix them.