Playbook
Leakage Test Failed: Find the Leak
Use after a duct pressure/leakage test fails and you need a repair walk.
What this covers
A duct section failed leakage or pressure test and the crew needs to find likely leak paths before retest.
How to use this playbook
- Ask what section failed, what pressure/limit applied, and where the test setup was connected.
- Walk joints from the test connection outward.
- Check corners, gaskets, access doors, takeoffs, collars, flex connections, mastic gaps, screw holes, and damaged seams.
- Mark suspected leaks before repairing.
- Repair only with approved materials/method.
- Re-walk the section before retest.
Check
- Failed section
- Leak mark
- Joint/access/collar detail
- Repair method
Warnings
- Do not smear sealant randomly without finding leak paths.
- Do not hide missing gaskets or bad fit-up under mastic.
- Do not repair outside approved materials/spec.
Stop and ask
- Ask when the leak is caused by bad fit-up, missing parts, damaged metal, unclear test limits, or wrong seal method.