Ductwork Installation Safety

Toolbox Talk Record

Ref: TBT-MBS-007  |  Issue: 1  |  Date: March 2026
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What?

Why?

Prevent injuriesCuts from sharp metal edges, falls from height, and manual handling injuries are the most common incidents during ductwork installation.
Fire safetyIncorrectly installed fire-rated ductwork compromises building compartmentation, allowing fire and smoke to spread between zones.
Dust exposureDrilling fixings into concrete soffits generates respirable crystalline silica dust, which causes permanent lung disease.
Do Don't
  • Wear cut-resistant gloves when handling galvanised steel duct sections.
  • Use mechanical lifting aids to raise heavy duct sections into position.
  • Ensure safe access at height is in place before starting overhead work.
  • Use on-tool dust extraction when drilling fixings into concrete soffits.
  • Check that fire-rated ductwork matches the specification before installing.
  • Support flexible duct connections properly to prevent collapse or kinking.
  • Inspect scaffolds, platforms, and MEWPs before use in ceiling void areas.
  • Plan the installation sequence to minimise awkward manual handling tasks.
  • Secure duct sections immediately after positioning to prevent them falling.
  • Wear eye protection when cutting, drilling, or working overhead with ductwork.
  • DON'T handle galvanised steel duct without cut-resistant gloves.
  • DON'T lift heavy duct sections overhead manually when mechanical aids exist.
  • DON'T stand on fragile ceiling tiles or unsupported grid systems.
  • DON'T drill into concrete without using dust extraction or water suppression.
  • DON'T install fire-rated ductwork that does not match the approved specification.
  • DON'T leave unsecured duct sections balanced overhead during breaks.
  • DON'T work at height without the correct platform, scaffold, or MEWP.
  • DON'T block fire escape routes with duct sections or packaging materials.
  • DON'T ignore sharp burrs or edges on cut duct; deburr before handling.
  • DON'T assume ceiling voids are safe without checking for hidden hazards first.

See also: HVAC System Installation Safety | Manual Handling Awareness