Air-balance test-hole caps blow out under pressure
If test caps pop out, the holes need a pressure-appropriate permanent plug or patch. Do not leave plastic caps in a system where they cannot hold under fan speed/test pressure.
The TAB test-hole caps are blowing out on [duct/run]. I checked the pressure area and found [count] holes. Do you want approved gasketed test plugs or sealed metal patches installed?
Watch out
Do not cover popped test holes with tape only and call it permanent.
Check
Locate all balance holes on the affected duct, not just the ones that popped.
Check if the holes are on medium/high pressure duct or fan discharge/critical air path.
Confirm approved plug/patch method with foreman/TAB/project spec.
Seal/fasten the holes cleanly without leaving sharp edges or loose debris.
Recheck during fan ramp/startup if safe.
Steps
Locate all balance holes on the affected duct, not just the ones that popped.
Check if the holes are on medium/high pressure duct or fan discharge/critical air path.
Confirm approved plug/patch method with foreman/TAB/project spec.
Seal/fasten the holes cleanly without leaving sharp edges or loose debris.
Recheck during fan ramp/startup if safe.
Say this to your foreman
The TAB test-hole caps are blowing out on [duct/run]. I checked the pressure area and found [count] holes. Do you want approved gasketed test plugs or sealed metal patches installed?