Leakage Test Failed: Find the Leak

Use after a duct pressure/leakage test fails and you need a repair walk.

A duct section failed leakage or pressure test and the crew needs to find likely leak paths before retest.

Stop if

• Ask when the leak is caused by bad fit-up, missing parts, damaged metal, unclear test limits, or wrong seal method.

Watch out

• 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.

Check

• Failed section
• Leak mark
• Joint/access/collar detail
• Repair method

Steps

• 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.

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