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Apprentice answer

How do you line up twisted companion flanges without damaging the duct

2nd YearDuct Assembly, Seams & JointsStandard Correction

A twisted flange usually means the line is hung out of square. Loosen nearby hangers, square the faces with controlled alignment, bolt it cleanly, then re-level the run.

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Plain-English answer

When TDC/Ductmate corners will not line up, the problem is often the duct line, hangers, or previous joint being out of square—not the bolt hole itself.

Back off nearby hanger nuts enough to give the run controlled movement, square the flange faces, start the corner bolts without tearing holes, then re-level the hangers. If the flange is bent or the run is forced into a twist, stop before creating a permanent leak path.

Ask Foreman

The TDC/Ductmate corners at [location] will not line up because the line is twisted. I checked the previous hangers. Do you want me to loosen and re-square the last few joints before bolting this one?

Verify before acting

Use this as training guidance. Foreman direction, approved drawings, project specs, manufacturer instructions, employer safety policy, and AHJ/code requirements always control the final answer.

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