Top 10 Most Common Inspection Failures — And How to Avoid Them in 2026

If you’ve spent any time in residential construction, you know the feeling: the schedule is tight, trades are lined up, and then an inspection fails for something small — something completely avoidable — and suddenly your timeline shifts by days. At Metro Code, we see hundreds of inspections every month across North Texas and Houston, and the truth is that most failures happen for the same handful of reasons.

As we move into 2026 with tighter codes and increased enforcement, here are the top issues we see on job sites — and what builders can do to avoid them.

1. Documentation That Doesn’t Match the Field

One of the easiest ways to fail an inspection is simply having outdated or mismatched documents. When plans don’t reflect what’s been installed, or engineering letters are missing, everything slows down. Keeping updated plans on-site and ensuring all subcontractors are working off the same set is one of the simplest ways to keep projects moving.

2. Framing Errors That Break the Load Path

Framing failures are more common than many expect. We often see incorrect headers, missing blocking, or structural paths that don’t line up with the engineered drawings. These issues usually happen when crews move quickly or when multiple framers overlap work. A quick pre-walk with the framing lead before calling the inspection can catch 90% of these issues.

3. Electrical Rough-In Problems

Electrical rough is one of the most frequently failed inspections. From missing staples to improper box fill and misapplied GFCI or AFCI protection, small oversights add up. Labeling circuits clearly and doing a final walkthrough — especially around kitchens, bathrooms, and the panel — dramatically improves pass rates.

4. HVAC Ductwork Installed Incorrectly

Kinked duct, sagging flex, and unsealed boots cause both code failures and future homeowner complaints. Supporting long duct runs properly and sealing connections with mastic (not tape) before the inspector arrives makes a big difference — and improves system performance.

5. Plumbing Vents and Drains Installed Improperly

We often see flat vent lines, incorrect slopes, and unsupported drainage pipes. These problems can be hard to spot once walls close up, which is why plumbers doing a quick internal check before inspection is so important. A few minutes of review can save an entire day of rework.

6. Missing Fireblocking

Fireblocking is one of the most overlooked areas in framing. Open pathways between floors, walls, and attics allow fire to travel quickly, so inspectors take this seriously. Installing fireblocking early — before insulation — helps ensure every cavity is sealed the way the code requires.

7. Energy Code Issues and Blower Door Failures

As energy codes tighten, we’re seeing more failures related to insulation gaps, unsealed exterior penetrations, and blower door tests that don’t meet the required levels. Sealing penetrations before insulation goes in and ensuring insulation stays in full contact with the air barrier can prevent most of these problems.

8. Weatherproofing That Isn’t Layered Correctly

Water management is critical in Texas, and we frequently see WRB layers installed in the wrong order, missing head flashing, or penetrations left unsealed. Following a simple “shingle-style” approach — always layering top over bottom — helps protect the home and keeps your inspection on track.

9. Foundation or Setback Issues

Few things derail a project faster than discovering the structure isn’t within the correct boundary or easement. Verifying the survey and marking property lines clearly before concrete is poured can prevent major, costly problems down the line.

10. Life-Safety Items That Get Overlooked

Even small misses — like a forgotten smoke alarm, an incorrect egress window size, or a missing handrail — can sink an otherwise clean inspection. These are easy fixes but frustrating delays when caught too late. Reviewing life-safety items during the final walkthrough before inspection keeps your project on schedule.

Building Smarter in 2026

The truth is, most inspection failures aren’t about cutting corners — they’re about coordination. In a busy construction environment, small details fall through the cracks. But with tighter codes coming to Texas in 2026, avoiding these issues is more important than ever.

A quick pre-walk, updated documentation, good communication between trades, and periodic third-party inspections can dramatically reduce your failure rate and keep your schedule on track.