Behind the Build: No Bulkheads! How Smart Planning Keeps Ceilings Clean and Spaces Beautiful
When we first stepped into this 1970s four-level mini-split home, it was heated by a water boiler system, which meant no ductwork existed anywhere. Once we decided to introduce forced-air heating and cooling, a common challenge immediately surfaced: how to run ducting through an older home without compromising its clean lines or ceiling heights.
If you’ve ever walked into a renovation and noticed boxy drop-downs or awkward soffits cutting across rooms, you’ve seen the result of retrofitted ductwork. But in this home, you can walk through every level, including the spacious rec room, and not see a single bulkhead.
How did we pull that off? It came down to two smart strategies.
First, we installed two furnaces instead of one large unit. A smaller furnace in the basement services the lower levels, while a second unit, along with the HRV system, was tucked neatly into a mechanical room to handle the upper floors. This not only made the system more efficient but also reduced the need for long duct runs.
Second, and equally important, we collaborated closely with our HVAC contractors from the start. Together, we mapped out routes that would keep ducting compact, hidden, and integrated within existing structural cavities. The result is a finished home that feels open and intentional, not patched together with afterthoughts.
Because in design-build, the most beautiful spaces often come from the things you don’t see.
More of an auditory learner? Tune in to hear about this strategy from Kellen.
💬 FAQ: How Do You Avoid Bulkheads When Adding Ductwork?
Q: Is it actually possible to add a forced-air system to an older home without bulkheads?
A: Yes — with the right planning. Many older homes were built for radiant or boiler systems, so they lack duct paths. By designing the mechanical layout before construction starts and sometimes splitting the home into zones (using two furnaces or smaller systems), we can run ducts strategically through floor cavities or closets instead of across ceilings.
Q: Why are bulkheads such a design concern?
A: Bulkheads can visually lower ceilings, interrupt sightlines, and compete with architectural details. In high-end renovations, removing or avoiding them maintains that clean, uninterrupted flow that makes a space feel spacious and thoughtfully designed.
Q: What’s the secret to avoiding them?
A: Collaboration. When designers and HVAC contractors work together early on, mechanical systems can be woven into the design instead of forced in later. It’s the difference between a home that feels seamless and one that feels compromised.
Want to read more about this project (and see all the incredible before and afters?) Click here.
Want more like this post? Click one of the posts below:
→ Why a Design + Build Firm Makes All the Difference — coordination = clean ceilings
→ Air Quality — routing and sealing go hand-in-hand
→ Work Meets Play Basement — smart services planning in lower levels
More questions? Head to our FAQ page linked here.
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