Menards® has the resources to help you design and easily install your new ductwork system.

Whether
you are building a new home, putting an addition on your current home, or simply adding a room to the
basement, there are important things you need to know. This buying guide will help you not only find the
ductwork you need, but also, help you design an efficient system.

Knowing the Parts of the System

Although it seems intimidating at first, your ductwork
system consists of just a few basic categories. The parts,
fittings, and types of pipe that you need will depend on
your home and your system layout, but it all can be broken
down into four categories: Plenum, Trunk Lines, Distribution
Runs, and Cold Air Returns. Each category is needed to run
an efficient system.

Plenum
The plenum serves as the central collecting chamber for
the conditioned air as it leaves the furnace. This is the first
component of the system and is installed directly to the
supply air opening of the furnace. Depending on the type
of furnace in your home, the plenum is secured to either
the top of the furnace or over the supply air opening with
sheet metal screws. Please note, you should never install
fittings on top of the plenum.

Trunk Line
The trunk line is a line of ductwork that serves as the central distribution source for your ductwork system.
It is attached directly to the plenum and runs through the entire length of your house. Depending on the
location where the furnace was installed, the trunk line is either installed in your attic or in the basement,
between the floor joists. Because most homes have their furnace installed in a central position, the trunk line
will typically extend in both directions. Note: The trunk line is typically attached six inches from the top of
the plenum.
Distribution Runs
Distribution runs are best described as the pipes that run from the trunk line to the outlets located in the
walls or floors of your house. They can be round, oval, spiral, and even rectangular. Material used can range
from galvanized pipe or flexible duct (insulated or non-insulated). The number of distribution runs in your
system will vary based on the layout of your home and the sizes of the rooms. Climate can play a role in
the preferred location of the runs. For example, if you live in a cool climate, the supply outlets are generally
located on the floor near an outside wall, and under a window to help reduce drafting. Warm regions
generally install the runs in the ceiling to get the best air-conditioning performance. For more information
about the different types of duct pipe that can be used for distribution runs, see the Types of Duct Pipe
section.

Cold Air Returns

In order for your ductwork system to operate properly, the furnace must have a consistent source of air that
is cycled back into the unit. For each cubic foot of air that is pumped out into your home, the same amount
must be drawn back in so the process can start over. Cold air returns bring this unconditioned air back to
the furnace. The location and amount of cold air return inlets will vary based on the design of your home.
Components include: Cold Air Returns and Joist Panning.

Types of Duct Pipe

Round Pipe
Round metal pipe is one of the most popular types of ductwork.
Round pipe comes in a variety of sizes and shapes to route the air in
many different directions. This type of pipe features one crimped end
so it is easy to fit into an adjoining piece.

Rectangular Pipe
Rectangular pipe is also available in a variety of lengths. Sizes of the
material are often short and narrow to allow it to fit in spaces such as
wall cavities (wall stack), or between floor joists and rafters.
Oval Pipe
Oval pipe combines the benefits of both rectangular duct and round
pipe. Like round pipe, oval pipe features one crimped end so it is
easy to connect to the adjoining piece of pipe. Its shape is similar to
a rectangular duct with a shorter height so it can also fit in narrow
sections, like between walls, rafters, and floor joists.

Spiral Pipe
Spiral pipe has the same shape as round pipe, but it features a spiral
seam. This type of duct’s spiral design makes it more leak-proof and
lightweight than other types of duct. The spiral design also allows air
to move through the duct more quietly, and when left exposed, it can
give a building a contemporary look.

Insulated Flexible Duct

Unlike the other types of duct which are made of metal, flexible duct
is made from a unique plastic material. Flexible duct has a shape
similar to an accordion, and can bend in any direction. Because it can
be difficult to seal, flexible ductwork is recommended for updating
existing ductwork in your home.
 Ductwork Planner

Menards® offers a convenient Ductwork Planner that will help you

design a system that will work with your home. Fill out the forms with
some basic information about your home and the type of project you
are planning. Once you’ve filled out these forms you can either mail
them to the address listed at the top of the page, or send an email
copy to the email address listed. Feel free to include your home’s
blueprints or any other useful information. Within two days, a detailed
project list and layout will be sent to the selected Menards® store.

Tools

Once you have your plan, you need to make sure you have the correct equipment to get the job done.
Menards® offers top of the line tools that will make the job easier. Common items that are needed include:
• Sheet Metal Screws
• Reciprocating Saw
• Pipe Hangers
• Tin Snips
• Ductwork Specific Hand Tools

Installation Tips

• Only install the ductwork in insulated, or ‘conditioned,’ spaces. This will ensure that you get the most
efficient performance from your system.
• The overall sizing of the trunk line and supply lines are designed to evenly distribute the appropriate
amounts of air to every room. Register placement in the room is critical to allow for proper air circulation.
Return air vents are generally placed high on inside walls, supply registers low and close to windows.
• Cold air returns are sized one and a half times larger than supply capacity to prevent negative pressure in
the system. Do not return air from bathrooms and kitchens.
• Metal and flexible ductwork need to be sealed using an approved foil tape or duct sealant to guarantee
that it is reasonably air-tight for maximum efficiency.