Duct Disaster Averted: Expert In-Slab Air Duct Repair in a 1980s Wheeling Home
Initial Concern
Odor and Debris in Ducts
In the late winter of 2025, a homeowner in Wheeling, Illinois, reached out to us with concerns about a persistent musty odor and suspected debris in their in-slab air duct system. We promptly dispatched an experienced inspection technician to conduct a comprehensive video inspection.
Inspection Findings
Sonotube Ducts and Water Damage
The inspection revealed that the ducts were made of cardboard tubing, commonly known as sonotube—a material often used in homes built between the 1970s and mid-1980s. These ducts were connected by metal fittings and, while economical at the time, are highly susceptible to water damage, especially from groundwater intrusion beneath the slab.
A Hidden Plumbing Leak Discovered
During our follow-up assessment, we discovered a critical plumbing issue: the bathtub was leaking directly into the air ducts. After the homeowner addressed the leak, our team proceeded with the restoration process.
Restoration Process
Careful Cleaning and Reinforcement
Due to the fragile nature of cardboard ducts, the cleaning phase required meticulous care. We carefully removed collapsed or deteriorated sections, then reinforced and sealed the remaining ductwork with a mortar layer. We also rebuilt the plenum box beneath the furnace to restore airflow and structural stability.
Final Step
Duct Encapsulation with Duct Armor
To complete the project, we applied two coats of Duct Armor spray lining to encapsulate and protect the entire system.
Results
A Fully Restored In-Slab Duct System
With great care, expertise, and the aid of advanced technology, the Trenchless Innovations team identified a hidden plumbing leak the homeowner was unaware of—then successfully restored in-slab air ducts that many other companies would have recommended abandoning or replacing entirely. Outstanding work by the team!