Improving the existing duct system.

What is possible?

We recently tested a home that was only one year old. The homeowner had answered "YES" to many of our questions. Yes, he had hot and cold rooms, high summertime humidity, lots of dust around the house and high utility bills. We found a laundry list of issues, from oversized equipment to undersized ductwork. Duct leakage was excessive, both supply and return side. This means bad air from the crawlspace and attic was being pulled into the ductwork and pushed into the house. Heated and cooled air was being lost from the supply ducts.

Installation techs spent several days correcting sizing issues and sealing ductwork. When finished we returned to the home to test for improvements. The difference in duct leakage was significant. Before we started, the ductwork leakage tested at 273 cubic feet per minute or cfm. For a visual, imagine that for every minute the heat pump ran, the amount of air roughly equivalent to what is inside 273 basketballs leaked from the duct system. After our techs performed their work, leakage was down to 25 cfm. SCORE!!

Oh, Those Attic Access Doors!!

Easily accessible storage is a valuable commodity in any home; but the access doors can be having a serious impact on utility bills and allergies.

This week's blower door testing shows how.

In this four year old home, we found the duct system leakage to be within acceptable levels, mainly because it was comprised of a lot of flex duct with few connections. We did find some leakage around the flat screen tv. The homeowner was already aware of this because of a continuous cold weather draft coming from around the screen. The television, like many new homes, was installed over the fireplace. The cable and electrical entry came through the exterior wall cavity enclosing the flue, leaving an unsealed opening around the wires.

The real story on excess home leakage was discovered when we moved upstairs. Right by the golf ball collection on the wall of the tv room was the first place we found it. A nice, full size door gave wonderful access to the attic space behind the wall for storage. With no weather stripping or seal around the door it also allowed for significant infiltration. Our homeowner told us that she had five such doors in the upstairs, plus the pull down staircase to the upper attic. All five were allowing a lot of air to infiltrate the upstairs of the home. Infiltration from attic spaces means dust and utility bill consequences. I believe weather stripping the doors just went on the honeydo list.

We took care of the pull down staircase before we left with an Attic Tent.

Really BAD leaks!!

In looking for budget busting energy leakage, we found a potentially dangerous type of leak. In the recent past this homeowner bought a replacement air conditioner from a local HVAC firm. Their furnace was less than 10 years old so they kept it in service. The new cooling coil was taller than the old one and the furnace had to be lowered. So did the PVC vent pipe that carried the carbon monoxide out of the basement. Unfortunately, it was not done well. This vent pipe should be secure and sealed for the safety of the homeowners. A homeowner's health and safety are in the hands of their heating and cooling contractor. Choose carefully.

During the course of the home energy test we found a significant amount of duct leakage. One leak was painfully obvious in a duct running exposed, outside the home. This duct was only a few years old but outdoor conditions had taken its' toll. If you must run a duct on the exterior of the home due to accessibility challenges, additional insulation and weather proofing are a must. This is not quality work and it is costing this homeowner every day.

When to replace duct work?

A well installed duct system might never need to be replaced. Why would anyone need a new duct system? Complete duct system replacements usually come about due to poor quality of the original installation, poor environmental conditions the duct system is placed in, the choice of duct and insulating materials made by the original installer, or a combination of any of these.

This original duct system was metal, insulated with fiberglass on the interior of the duct. The ducts were installed in a damp and dirty crawlspace and had many return and supply joint leaks. When it was installed many years ago the main duct joints, or connections, had been somewhat sealed with duct tape. All of the duct tape adhesive was now dried out and no longer performing. Over the years, these unsealed joints allowed the system to not only leak out heated and cooled air that should have gone inside the inside of the home, but the return leaks allowed dirty crawlspace air in to the duct system. The interior fiberglass insulation became a collector for dust, dirt, moisture and provided a perfect spot for mold to grow.

This duct system was costing the homeowners every month on their utility bill and it was unhealthy too!

Instead of just replacing their HVAC unit, the smart homeowners in this house took this opportunity to improve their indoor environment and reduce their energy bill all at the same time. Along with a new, 14 SEER Trane packaged electric heat pump, they opted to remove all the undesirable ductwork and have an energy efficient new duct system installed. All new joints will be sealed with mastic, a duct joint sealant that outlasts duct tape by decades, and exterior insulation with vapor barrier. A zone system is also being added to solve a cold basement room issue.

New, energy efficient ductwork inside is likely to save this homeowner as much as their new unit on the outside of the house. And they can breathe easier knowing their duct system is moving clean, safe air around their home.