What is the correct method for repairing a 1" hole in a section of duct board?

When repairing a 1" hole in a section of duct board, sealing over the location with foil tape and mastic is the most effective method. This approach provides a reliable repair that maintains the integrity of the duct system while minimizing air leaks.

Foil tape is designed for use with HVAC applications, as it adheres well to the duct surface and offers a continuous seal. Mastic, on the other hand, acts as a strong adhesive and sealant, which ensures that the edges of the hole are securely bonded, preventing air from escaping or infiltrating. This combination not only creates a durable patch but also enhances the overall energy efficiency of the duct system.

While replacing the entire section of duct board could ensure structural integrity, it is often unnecessary for a small hole and may lead to more labor and material costs. Similarly, cutting out the hole and fabricating a plug involves additional steps and materials that can complicate the repair process. Taping alone, without the added strength of mastic, may not provide a long-lasting solution, particularly in areas exposed to fluctuations in temperature and pressure.