HVAC rough-in inspections help to identify errors and ensure the project adheres to industry-accepted standards. HVAC contractors and technician installers typically conduct HVAC rough-in inspections alongside the plumbing and framing rough-ins before any HVAC system components are covered by insulation, drywall, or other finishing materials.
Failing an HVAC rough-in inspection can jeopardize the entire building project, lead to rework, and disqualify it from meeting state and local building codes and safety standards.
Additionally, clients typically withhold payments until the job passes the rough-in inspection process.
In this article, we’ll explain why checklists prove to be indispensable tools when conducting rough-in inspections, and we provide a rough-in checklist you can use to pass the inspection with ease.
We’ll also explain how ServiceTitan helps contractors track rough-in inspections, ensuring every step is completed in accordance with building codes.
HVAC Rough-In Checklist (Step-by-Step Guide)
Before we proceed, it’s essential to note that this checklist is intended solely as a guide.
Depending on your project’s specifications, complexity, and local code requirements, you may need to modify the checklist by adding or removing components.
Here’s the checklist:
1. Planning & pre-installation
The first step in the rough-in process is to review the HVAC plans and blueprints—mechanical drawings showing where HVAC components need to be placed. This is vital, as any mistake at this level nullifies the good work done during construction.
Next, confirm that the load calculations and duct sizing accurately reflect the building's heating and cooling needs. This helps to prevent excessive noise, high energy consumption fees, and temperature inconsistencies due to poor airflow.
Lastly, ensure the HVAC installation meets various code requirements, including:
Your local building codes
2. Ductwork installation
Ensure the air ducts are securely strapped to the structure at regular intervals — not twisted at an angle below 90 degrees — to prevent airflow disruptions.
Seal ductwork with materials such as mastic sealant to the appropriate Class A or C level, depending on whether the area where it’s located is considered conditioned or unconditioned. Also, insulate ductwork if it’s adjacent to unheated areas such as attics and garages or if it lacks the protection of exterior walls.
Ducts carrying combustion air should have a cross-sectional area of at least 3 inches, and the materials for all equipment in the plenum must be fire-resistant.
Lastly, situate the duct at an appropriate distance from electrical and plumbing systems and adhere to the maximum length and minimum thickness requirements.
3. Venting & exhaust systems
For this step, examine the venting and exhaust systems.
To prevent pollutants from accumulating in the building, ensure the exhaust is as close to the contaminant source as possible, such as a fireplace, stove, or bathroom shower.
Additionally, all exhaust hoods must be equipped with a fire suppression device or shutoff valve to slow the spread of fire.
Check for enough separation between air intake vents and contaminant sources—and vents coming from appliances and plumbing systems. Vents on the roof should be at a sufficient height so they’re not obstructed in the winter.
Verify that the condensate and all other pipes are correctly sized and situated at the proper slope above the ground, per the Uniform Mechanical Code (UMC).
To end this step, ensure the minimum distance between the termination vent and any building opening is 2 feet and cover it with a weather-proof cap.
4. Refrigerant lines & drainage
To prevent safety issues, inspect refrigerant lines to ensure there are no punctures or holes that could allow the refrigerant to escape. Then, seal off the junctions and secure the circuit valves with tamper-resistant locking caps to deter theft.
Route condensate drain lines to the proper disposal points as required by your local codes. If the water is drained outside the building, ensure it’s routed to a visible location far away from the foundation.
5. Electrical & control wiring
Ensure there’s an electrical receptacle outlet 25 feet away from every HVAC appliance, allowing them to be plugged in easily.
Secure the wires carrying the current to these outlets, and ask a qualified electrician to test their voltage levels before they’re energized.
Place the thermostat in a location where it can accurately measure the ambient temperature without being influenced by external factors. Avoid placing it near a stove (which gets too hot) or a window (which allows cold air to enter).
6. Pressure & leak testing
Conduct static pressure tests for duct systems to ensure no blockages or leaks and that the ducts are sized appropriately.
Then, before filling the system with refrigerant (charging the system), perform line leak tests using electronic sniffers. During the test, inspect fittings, joints, and connections for leaks.
7. Final inspection & documentation
Take a final look at the installation to identify any issues you might have overlooked. Take photos and document your findings for records.
Finally, schedule a mechanical rough-in inspection with the appropriate authorities.
What Is an HVAC Rough-In?
HVAC rough-ins refer to the installation of the basic components of a building’s HVAC mechanical systems (heating, ventilation, and air conditioning). These include flex ducts, refrigeration lines, vents, and some electrical wiring.
During the rough-in phase, HVAC technicians work together to ensure the entire building’s systems are installed to deliver optimal comfort to the occupants.
HVAC rough-ins are typically completed using a checklist to ensure that the entire installation adheres to building codes and passes inspection by a state or local certified building inspector.
Generally, the building inspector checks the supply and return air systems and dampers (at duct penetrations), including the chimney, insulation, and mechanical ventilation.
Once they're done, they record their findings in a field inspection report that captures the progress of the construction project and any potential building code violations.
Why Is an HVAC Rough-In Checklist Important?
A rough-in checklist allows you to identify potential issues and take steps to fix them before the inspector arrives. This prevents delays and helps you remain on course to meet the preset completion date.
Other reasons to use an HVAC rough-in checklist include:
Prevents costly amendments by helping you catch potential errors early.
Ensures compliance with local building codes and regulations to prevent safety hazards.
Accelerates permit approvals by preventing building code violations.
Improves efficiency and workflow management by enabling other trade partners to commence their part of the project earlier.
Mitigates errors by giving technicians detailed instructions on how to install HVAC systems.
Serves as a quality control measure, ensuring all HVAC system components are installed in accordance with design specifications and safety standards.
What Are the Most Common HVAC Rough-In Mistakes to Avoid?
HVAC rough-ins are a critical stage in building construction. Any mistake or oversight in the process can destabilize the entire project and cause energy inefficiencies and delays.
Here are some common pitfalls to avoid during HVAC rough-ins:
Incorrect duct sizing leading to poor airflow.
Improper venting and clearance violations.
Skipping pressure testing, resulting in undetected leaks.
Poor insulation, leading to energy inefficiency.
Failing to comply with building codes and HVAC regulations that leads to costly reworks and fines.
Insufficient insulation and poor ductwork alignment, resulting in condensation issues and leakages.
Placing ventilation systems too close to walls, in dusty areas, and in locations with insufficient airflow.
Installing oversized exhaust fans that create excessive noise and deplete energy.
Disobeying the manufacturer’s installation instructions.
How ServiceTitan Helps HVAC Contractors Improve the Rough-In Process
While PDF checklists are a step up from using no system at all, they come with some limitations.
For starters, project managers can decide not to use them, which can lead to mistakes that cost significantly to fix.
Plus, since the PDF is disconnected from your other tools, you’ll have to manually copy and paste rough-in inspection results into other software programs you use for managing construction projects.
We designed the Field Service App to permanently address these issues. The software enables you to create HVAC rough-in checklists as forms that every project stakeholder can access and complete from their mobile device.
ServiceTitan allows you to set up triggers for each form and create rules that mandate project managers to complete them before proceeding to the next step in the HVAC rough-in process.
For instance, you can create a 'Ductwork Inspection' form that the project manager must complete and sign before the HVAC tech proceeds to the insulation stage. This way, the project manager can catch any errors in the installation of the ductwork before the walls and ceiling go up.
For accurate record-keeping, ServiceTitan enables project managers to document deficiencies they identify during inspections using photos, videos, and detailed notes. Trade partners, team members, and other project stakeholders can access these records immediately.
This ensures that team members know what to do next to move the project forward. For example, they could order an item, requisition an HVAC tool, communicate with the customer, or contact state or local authorities for the inspection.
Over to You
For an HVAC project to run smoothly, techs need the right skills and a rough-in checklist to follow. It guides techs on how to perform all the tasks in the HVAC rough-in process without violating building codes and regulations.
When creating HVAC rough-in checklists, use your project’s specifications and scope of work to determine which items to include and the sizing dimensions to abide by.
Ready to track your project’s progress and foster collaboration among team members? Invest in HVAC construction software like ServiceTitan to create digital checklists, track expenses, make payments, and monitor the project ’s progress.
ServiceTitan is a comprehensive software solution built specifically to help HVAC companies streamline their operations, boost revenue, and track project progress. Our comprehensive, cloud-based platform is used by thousands of HVAC construction companies across the country and has increased their revenue by an average of 25% in just their first year with us.
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ServiceTitan is a comprehensive HVAC business software solution built specifically to help service companies streamline their operations, boost revenue, and achieve growth. Our award-winning, cloud-based platform is trusted by more than 100,000+ contractors across the country.
