Ductwork Installation for New Construction
Ductwork is the highway system that delivers heated and cooled air from your furnace or heat pump to every room in your home. Properly designed and installed ductwork ensures even air distribution, consistent temperatures, and efficient operation of your heating system. Poorly designed or improperly installed ducts create hot and cold spots, waste energy, and force your furnace to work harder than necessary.
For new construction projects in Cody and the Big Horn Basin, Wrangler Plumbing designs custom duct systems based on the specific layout, square footage, and heating requirements of each home. We calculate the airflow needed for each room, size supply and return ducts accordingly, and select register locations for optimal air distribution. Our duct systems are installed with sealed joints, proper insulation, and balanced airflow to ensure your new home heats and cools evenly from the day you move in.
We work closely with builders and general contractors to coordinate duct installation timing with framing, electrical, and plumbing rough-in. Proper coordination prevents conflicts between trades and ensures the duct system fits cleanly within the building envelope without compromising structural integrity or insulation.
Shop, Barn & Outbuilding Ductwork
Shop and outbuilding ductwork is a major part of our business -- and for good reason. Wyoming homeowners rely on their detached shops, barns, and garages year-round for vehicle maintenance, woodworking, equipment storage, livestock care, and countless other activities. Heating these structures effectively requires ductwork designed for their unique characteristics: high ceilings, open floor plans, large doors that open frequently, and minimal insulation compared to homes.
We design duct systems for shops and outbuildings using overhead trunk-and-branch layouts that keep ductwork out of the way of vehicles, equipment, and work activities. High-mounted registers direct warm air downward to the occupied zone, while return air intakes are positioned to prevent cold air drafts near entry doors.
Common Shop & Outbuilding Projects:
- Detached garage and shop heating systems
- Barn and agricultural building ductwork
- Equipment storage building climate control
- Workshop heating with overhead duct runs
- Multi-bay garage heating systems
- Spray-foam insulated shop installations
Duct Repair & Sealing
According to the U.S. Department of Energy, the average home loses 20-30% of the air moving through its duct system due to leaks, holes, and poorly connected ducts. In Wyoming, where heating costs are a significant household expense, sealing leaky ducts is one of the most impactful and cost-effective home improvements you can make.
Duct leaks occur at joints and connections, where sections of ductwork meet each other or connect to registers and plenums. Over time, duct tape (ironically, not designed for ducts) dries out and fails, metal joints loosen, and flexible duct connections deteriorate. The result is heated air escaping into your attic, crawl space, or wall cavities instead of reaching your living spaces.
Our Duct Sealing Process:
- Visual inspection of all accessible ductwork
- Pressure testing to measure total duct leakage
- Sealing joints and connections with mastic sealant
- Replacing deteriorated flexible duct connections
- Reattaching disconnected duct sections
- Insulating ducts in unconditioned spaces
- Post-repair pressure testing to verify improvement
Signs of Duct Problems
Comfort Symptoms
- Rooms that are always too hot or too cold
- Weak airflow from certain registers
- Furnace runs constantly but house stays cold
- Excessive dust in the air and on surfaces
- Stuffy or stale air in certain rooms
- Humidity problems (too dry or too humid)
Visual & Audible Symptoms
- Visible damage, kinks, or crushed ducts
- Disconnected or hanging duct sections
- Rattling, whistling, or banging sounds
- Duct tape falling off joints
- Higher than expected heating bills
- Ducts in attic or crawl space with no insulation
If you notice any of these symptoms, your ductwork may be costing you money and comfort. We provide thorough duct inspections that identify leaks, damage, and design problems, then recommend targeted repairs to improve efficiency and comfort.
Insulated vs. Uninsulated Ducts
Any ductwork running through unconditioned spaces -- attics, crawl spaces, unheated garages, or exterior walls -- must be insulated to prevent heat loss. Uninsulated ducts in a cold attic can lose 25-40% of the furnace's output before the heated air reaches your living spaces. In Wyoming's extreme cold, this energy waste is even more pronounced.
We use R-8 or higher duct insulation on all runs through unconditioned spaces, meeting or exceeding Wyoming energy code requirements. For new installations, we also offer pre-insulated duct board and insulated flexible duct options that provide both the duct structure and insulation in a single product.
Duct Materials We Use:
- Galvanized sheet metal: The most durable and long-lasting option. Used for trunk lines, plenums, and main supply runs. Sheet metal ducts can be sealed with mastic and insulated for excellent performance.
- Insulated flexible duct: Used for branch runs from the trunk line to individual registers. Flexible duct must be properly supported and run without kinks or excessive bends that restrict airflow.
- Duct board: Fiberglass duct board provides built-in insulation and sound absorption. Used for plenums and certain trunk sections, especially where noise reduction is important.
Our Duct Inspection Process
1. Visual Inspection
We inspect all accessible ductwork for visible damage, disconnected sections, deteriorated connections, and missing insulation. We check the attic, crawl space, basement, and utility room.
2. Airflow Testing
We measure airflow at each register to identify imbalances and restrictions. Rooms with significantly lower airflow than others indicate duct problems in those branches.
3. Pressure Testing
Using a duct blaster or similar equipment, we measure the total leakage in your duct system. This quantifies how much air is being lost and provides a baseline for measuring improvement after sealing.
4. Recommendations & Repair
Based on our findings, we provide specific recommendations for sealing, repair, insulation, or replacement. We prioritize repairs by impact -- fixing the biggest leaks and most damaged sections first for maximum return on your investment.
Ductwork Installations in Cody & Big Horn Basin
Overhead trunk-and-branch duct system in a Wyoming shop
Complete duct system installed during new home construction
Overhead ducts with circulation fan for even shop heating
Ductwork FAQs
Leaking ductwork wastes 20-30% of the air your furnace produces. That means up to 30 cents of every dollar you spend on heating is lost before it reaches your living spaces. Duct sealing is one of the most cost-effective home improvements you can make, often paying for itself within one to two heating seasons.
Signs of duct problems include uneven heating between rooms, excessive dust in the air, rooms that never reach the set temperature, visible damage or disconnected ducts, high heating bills despite a functioning furnace, and whistling or rattling sounds from the duct system. We provide thorough duct inspections to identify and fix these issues.
Yes. Shop and outbuilding ductwork is a significant portion of our business. Many Wyoming homeowners heat their detached shops, barns, garages, and outbuildings. We design and install complete duct systems for these structures, often using overhead trunk-and-branch layouts suited to open floor plans and high ceilings.
Absolutely, especially in Wyoming. Any ductwork running through unheated spaces should be insulated to prevent heat loss. Uninsulated ducts in a cold attic can lose 25-40% of the furnace output before the air reaches your living spaces. We use R-8 or higher insulation on all ducts in unconditioned spaces.
A complete duct system for a new home typically takes 2-3 days to install. Shop and outbuilding ductwork usually takes 1-2 days. Duct repair and sealing projects can often be completed in a single day. We provide accurate timelines during the estimate process so you can plan accordingly.
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