Measure Guideline: Sealing

and Insulating Ducts in

Existing Homes
R. Aldrich and S. Puttagunta
Consortium for Advanced Residential
Buildings (CARB)

December 2011
 NOTICE

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i
Measure Guideline: Sealing and Insulating of Ducts in
Existing Homes

Prepared for:
Building America
Building Technologies Program
Office of Energy Efficiency and Renewable Energy
U.S. Department of Energy

Prepared by:
Robb Aldrich, P.E. and Srikanth Puttagunta, P.E.
Steven Winter Associates, Inc. for the
Consortium for Advanced Residential Buildings (CARB)
50 Washington Street
Norwalk, CT 06854

NREL Technical Monitor: Cheryn Engebrecht

Prepared under Subcontract No. KNDJ-0-40342-01

December 2011

i
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ii
Contents
List of Figures ............................................................................................................................................. v
List of Tables ............................................................................................................................................. vii
Definitions ................................................................................................................................................. viii
Foreword ..................................................................................................................................................... ix
Progression Summary ................................................................................................................................ x
1 Introduction ........................................................................................................................................... 1
2 Cost and Performance ......................................................................................................................... 3
2.1 Energy Savings ....................................................................................................................3
2.2 Cost ..................................................................................................................................4
2.3 Cost-Performance Trade-Offs and Other Solutions .............................................................4
2.4 Non-Energy Benefits ...........................................................................................................5
2.4.1 Comfort ....................................................................................................................5
2.4.2 HVAC Capacity .......................................................................................................5
2.4.3 IAQ and Combustion Safety ....................................................................................5
3 Ductwork Components ........................................................................................................................ 6
3.1 Duct Materials......................................................................................................................6
3.1.1 Sheet Metal ..............................................................................................................6
3.1.2 Fiberglass Duct Board..............................................................................................6
3.1.3 Flex Duct..................................................................................................................7
3.1.4 Building Cavities .....................................................................................................8
3.2 Sealants ................................................................................................................................9
3.2.1 Tapes ........................................................................................................................9
3.2.2 Mastic.....................................................................................................................10
3.2.3 Aerosol Sealant ......................................................................................................11
3.3 Insulation............................................................................................................................11
3.3.1 Fiberglass ...............................................................................................................11
3.3.2 Closed-Cell Polyurethane Foam ............................................................................12
4 Health and Safety................................................................................................................................ 13
4.1 Inspect the House and HVAC Systems .............................................................................13
4.2 Combustion Safety Testing ................................................................................................14
4.2.1 Measure Carbon Monoxide (CO) Concentrations .................................................14
4.2.2 Spillage Tests .........................................................................................................15
4.2.3 Measure Draft ........................................................................................................15
4.2.4 Worst Case Depressurization .................................................................................16
4.2.5 Implications of Combustion Problems...................................................................16
4.3 Personal Safety and Protective Equipment ........................................................................17
5 Evaluating Duct Systems ................................................................................................................... 18
5.1 Check Airflow of System(s) ..............................................................................................18
5.1.1 Temperature Rise ...................................................................................................18
5.1.2 Duct Pressurization Airflow Testing .....................................................................18
5.1.3 Flow Plate Airflow Test .........................................................................................19
5.2 Measure Duct Leakage – Duct Pressurization ...................................................................19
5.3 Pressure Pan Test ...............................................................................................................20
6 Determine Scope of Work .................................................................................................................. 21
7 Duct Sealing Procedure ..................................................................................................................... 22
7.1 How to Apply Mastic .........................................................................................................22
7.2 Applying Tape ...................................................................................................................24

iii
 7.3 Existing Duct Insulation ....................................................................................................25
7.4 Furnace and Air Handle Connections ................................................................................26
7.5 Trunk Ducts .......................................................................................................................27
7.6 Branch Connections ...........................................................................................................28
7.6.1 Flex Branches.........................................................................................................28
7.6.2 Sheet Metal Branches ............................................................................................31
7.7 Branch Duct Fittings ..........................................................................................................32
7.8 Boot and Register Connections..........................................................................................33
7.9 Building Cavities ...............................................................................................................34
8 Insulating Ducts .................................................................................................................................. 37
8.1 Moving Ducts into Conditioned Space ..............................................................................37
8.2 Insulating Duct Wrap .........................................................................................................37
8.3 Ducts Beneath Attic Insulation ..........................................................................................40
9 Testing Out .......................................................................................................................................... 41
9.1 Duct Leakage Tests ............................................................................................................41
9.2 Airflow ...............................................................................................................................41
9.3 Combustion Safety .............................................................................................................41
Appendix A: Measure Implementation Checklist................................................................................... 42
Appendix B: Material Specification ......................................................................................................... 47
References ................................................................................................................................................. 48

iv
List of Figures
Figure 1. Sheet metal supply plenum sealed with mastic. ..................................................................... 6
Figure 2. Fiberglass duct board ducts in an attic .................................................................................... 7
Figure 3. Box containing 25 feet of compressed insulated flex duct. ................................................... 8
Figure 4. Insulated flex duct in the attic of an existing home ................................................................ 8
Figure 5. Floor cavity being used as return pathway. ............................................................................. 8
Figure 6. A “panned” return where the building cavity is used to carry air. ........................................ 8
Figure 7. Two UL rated duct tapes. ......................................................................................................... 10
Figure 8. Aluminum tape falling off of duct board ducts. ..................................................................... 10
Figure 9. A gallon of mastic and mesh tape ........................................................................................... 10
Figure 10. A duct connection being sealed using fiberglass mesh tape and mastic being applied
with a paint brush. .............................................................................................................................. 10
Figure 11. Duct board sealed with mastic. ............................................................................................. 11
Figure 12. A duct board trunk with flex duct branches sealed with mastic........................................ 11
Figure 13. Duct wrap ................................................................................................................................. 12
Figure 14. Ducts insulated with closed-cell spray foam in an attic. .................................................... 12
Figure 15. Ceiling damage as a result of a misplaced foot while working on ducts in an attic........ 14
Figure 16. Testing CO levels at the exhaust flue of sealed combustion furnace. .............................. 14
Figure 17. Spillage testing of an atmospherically vented, natural gas water heater. ........................ 15
Figure 18. How duct leakage can affect building pressures. ............................................................... 17
Figure 19. The specified heat rise range for this furnace is 40-70°F according to the faceplate. .... 18
Figure 20. Airflow testing using a duct blower. ..................................................................................... 19
Figure 21. Duct Leakage Testing ............................................................................................................. 19
Figure 22. Blower door being used to pressurize home. ...................................................................... 20
Figure 23. Using smoke to visually identify leaks at an air handler. ................................................... 21
Figure 24. Duct sealer using a single gloved hand and a “clean” ungloved hand. ........................... 23
Figure 25. While sealant has been applied to some of these joints, such a thin coat may not
provide an adequate seal................................................................................................................... 23
Figure 26. Aluminum tape being smoothed out with a plastic comb .................................................. 24
Figure 27. Duct sealers here were faced with a tight space and existing insulation. ........................ 25
Figure 28 Vapor Barrier has eroded and needs to be replaced ........................................................... 26
Figure 29. These polymer sheets with magnets at the edges cover the filter slot in an air
conditioning system. .......................................................................................................................... 27
Figure 30. Plumber’s putty installed around refrigerant piping to reduce air handler leakage. ....... 27
Figure 31. Supply and return plenums and trunks sealed with mastic. .............................................. 27
Figure 32. This duct board trunk was sealed with foil tape that has failed due to the stress put on
the duct ................................................................................................................................................ 28
Figure 33. Sealing of duct shown in Figure 32 with mastic and fiberglass mesh. ............................. 28
Figure 34 This flex branch never overlapped the collar and the insulation wasn’t properly installed
resulting in leaks and condensation. ............................................................................................... 28
Figure 35 A flex branch attached and sealed to a collar....................................................................... 28
Figure 36. What exactly is being secured here? .................................................................................... 30
Figure 37. A branch connection collar in a sheet metal trunk ............................................................. 30
Figure 38. The inner lining of these flex duct branches have been attached to the collars, but they
have not been sealed ......................................................................................................................... 30
Figure 39. Having this much flex duct branching off at the supply plenum makes it very difficult to
properly seal the ducts. ..................................................................................................................... 30
Figure 40. Lack of sealant at the branch connection. ........................................................................... 30
Figure 41. Disconnected ductwork resulting in conditioned air being lost to the vented attic ........ 31
Figure 42. In existing homes, it may be difficult to see all the duct connections, such as these top
take-off sheet metal branches ........................................................................................................... 31
Figure 43. It appears the HVAC contractor ran out of the proper sized ducts or collars for this
installation ........................................................................................................................................... 31
Figure 45. This flex duct junction has failed completely. ..................................................................... 32
Figure 44. Duct board junction box with multiple flex branch ducts. ................................................. 32

v
Figure 46. A tangle of metal ducts and flue pipes. ................................................................................ 32
Figure 47. Sheet metal boot that has not been sealed. ......................................................................... 33
Figure 48. Sheet metal boot that has been sealed. ............................................................................... 33
Figure 49. Mastic has been used to seal the flex duct to the register boot, seams in the sheet metal
boot itself, and the gap between the boot and the floor................................................................. 33
Figure 50. All seams of the sheet metal boot should be sealed with mastic if accessible - either
from the interior or exterior of the duct. .......................................................................................... 34
Figure 51. Floor joist bays used as panned returns. ............................................................................. 35
Figure 52. Hard duct, panned returns, and wood blocking are combined as part of the return
system. ................................................................................................................................................ 35
Figure 53. This space beneath a stairway was used as a return plenum. .......................................... 36
Figure 54. HVAC brought into conditioned space by applying spray foam to roof deck. ................. 37
Figure 55. Guidance on properly installing duct wrap .......................................................................... 38
Figure 56. A duct board trunk partially buried beneath blown attic insulation .................................. 40

Unless otherwise noted, all figures were created by the CARB team.

vi
List of Tables
Table 1. Modeling results on the reference home in Houston with various levels of duct leakage. .. 3
Table 2. Modeling results on the reference home in Boston with various levels of duct leakage. .... 3
Table 3. Duct sealing costs from NREL’s “National Residential Efficiency Measures Database”.. ... 4
Table 4. Duct insulation costs from NREL’s “National Residential Efficiency Measures
Database” .............................................................................................................................................. 4
Table 5. Exposure limits for carbon monoxide (CO). ............................................................................ 15
Table 6. Typical draft requirements for combustion equipment from BPI’s “Technical Standard for
the Building Performance Professional.” ........................................................................................ 15
Table 7. BPI’s retrofit action levels based upon undiluted flue gas CO measurements ................... 16
Table 8. Duct sealing with mastic and fiberglass mesh tape. .............................................................. 23
Table 9. Properly sealing duct branches to metal collars or boots. .................................................... 29
Table 10. Step-by-step guide to properly installing duct wrap. ........................................................... 39

Unless otherwise noted, all tables were created by the CARB team.

vii
Definitions
AC Air conditioning

ACCA Air Conditioning Contractors of America

AHU Air handler unit

BPI Building Performance Institute

CAZ Combustion appliance zone

ccSPF Closed-cell spray polyurethane foam

CFM Cubic feet per minute

EPA Environmental Protection Agency

HVAC Heating, Ventilating, and Air Conditioning

IAQ Indoor Air Quality

IECC International Energy Conservation Code

IRC International Residential Code

MSDS Material Safety Data Sheet

SMACNA Sheet Metal and Air Conditioning Contractors National

Association

wrt with reference to

viii
Foreword
Heating and cooling losses from forced-air ducts can result in high energy costs, lead to thermal
comfort problems, and–in some extreme situations–result in serious health and safety concerns.
Reducing air leakage and conductive losses from ducts can be a straight-forward way to reduce
energy use and improve comfort in homes.

The authors hope that this document is useful to a wide audience: builders, remodelers, HVAC
contractors, home performance contractors, homeowners, etc. Some of the procedures presented
here, however, require specialized equipment or expertise. In addition, some alterations to duct
systems may require a specialized license. Persons implementing duct system improvements
should not go beyond their expertise or qualifications.

This document begins with a discussion on potential cost and performance benefits of duct
sealing and insulating (p.3). It continues with a review of typical duct materials and components
(p. 6). The overall procedures for assessing and improving the duct system are:

1. Inspect the home and HVAC systems (p. 13): Identify possible hazards and assess duct system
materials and conditions.
2. Combustion safety testing (p. 14): Unless all appliances are sealed-combustion, it is important to
check combustion equipment for proper operation before and after sealing, because sealing ducts
can alter pressure balances in a home.
3. Air system diagnostics (p. 18): Check for adequate system flow and, if appropriate, measure duct
leakage levels.
4. Seal the ducts (p. 22)
5. Insulate the ducts (p. 37)

Note that this guide is only intended as a resource for sealing and insulating existing duct
systems in homes; this is not intended as a guide for designing, installing, or performing major
retrofits to HVAC systems. It is certainly true that a great many duct systems are poorly
designed and installed, and reconfiguration may lead to improved efficiency and comfort.

Acknowledgements
The authors would like to acknowledge the funding and support of the U.S. Department of
Energy’s (DOE) Building America Program. This guide is the product of a collaborative effort.
Special thanks to David Lee of the U.S. Department of Energy and Ren Anderson and Cheryn
Engebrecht of the National Renewable Energy Laboratory (NREL).

ix
Progression Summary
Inspect the duct systems. Are the ducts visibly sealed and insulated? Are they in need
of any repairs? Repairs should be completed before sealing and insulating efforts.

If ducts appear to be well-sealed and insulated,

further efforts may not be cost-effective.

Inspect the home and duct system for significant risks: Risks may include, but are
not limited to:
• Structural problems
• Exposed or knob-and-tube wiring
If significant risks are not present:

• Severe water or mold problems

• Severe insect or rodent infestations
• Asbestos (or asbestos-like material)
• Other toxic materials
• Erratic or dangerous occupants
• Occupants with health conditions who may be sensitive to work
being performed

If significant risks are present:

DO NOT PROCEED WITH WORK
Assess accessibility of the duct system. If ducts are not accessible, conventional sealing
and insulating may not be possible. See page 13.

Conduct combustion safety testing. If combustion safety tests fail, notify the
owner/occupants and do not conduct sealing until issues have been corrected and retested. Fails
See page 14.

Check the air handler flow. Determine proper air flow range for the air handler. If air
flow through an air handler is below safe operating levels, do not seal or insulate ducts on Fails
that system until issue has been corrected and retested. See page 18.

Duct leakage testing (optional). Conduct leakage tests if appropriate to

quantify and identify leaks. See page 19.

Develop work plan. Determine the scope of work; identify accessible ducts with high
leakage areas. See page 21.

Seal ducts. Using mastic and/or tape, as appropriate, seal all accessible ducts. Focus on
leaks outside of the conditioned space and near the air handler unit. See page 22.

Insulate ducts. When mastic has set, insulate accessible, uninsulated ducts as appropriate.
Focus insulation efforts on ducts outside the conditioned space. See page 37.

Test out. Perform combustion safety and flow tests to assure safe operation at completion
of retrofit work. Duct leakage testing is also encouraged at test out. See page 41.

x
1 Introduction
Ducts carry conditioned air between a central air
Major Duct Retrofits
handler and rooms throughout a home. In an ideal
system, all of the supply air leaving the air handler If major HVAC retrofits are planned as
would be transferred by the duct system to various part of a project, the following
points of use in the home and ultimately be discharged resources may be helpful:
through supply registers within the rooms. Similarly, all • Air Conditioning Contractors of
of the return air in an ideal system would be drawn America (ACCA) Manual J (8
th

edition), Manual D, Manual S,

from the appropriate return air grilles, through return Manual T, Manual RS, and Standard
ducts, and back to the furnace or air handler. 5: HVAC Quality Installation
Specification
Historically, this has not been the case. According to
the EPA ENERGY STAR® program, the typical home • EPA document “ENERGY STAR
Qualified Homes, Version 3 (Rev.
has 20% duct leakage. In older homes, it is not 02) HVAC System Quality
uncommon for duct leakage to account for 30%-50% of Installation Contractor Checklist”
the total system air flow. Much higher leakage rates are • ASHRAE Handbook of
possible in very poorly sealed systems. Ideally, duct Fundamentals 2009
leakage would be negligible, but a goal of less than 5% • Sheet Metal and Air Conditioning
of the total system air flow is reasonable for newly Contractors National Association
(SMACNA) Residential Comfort
installed systems. For existing duct systems, when parts System Installation Standards
of the duct system are not accessible, going from 30% Manual
leakage to 5% leakage is often not realistic. Ducts • Building Industry Institute’s
should be sealed as tightly as is practical, and this level Procedures for HVAC System
Installation Scope of Work
varies tremendously from system to system.
• ASHRAE Standard 152 - Method of
When ducts are located in (or just passing through) Test for Determining the Design and
Seasonal Efficiencies of Residential
unconditioned spaces such as attics or crawlspaces, a Thermal Distribution Systems
significant amount of energy–and heating and cooling
capacity–can be lost. If ducts are located within conditioned parts of the home, duct leakage
might not be a major energy liability, but still may lead to comfort issues.

Even when ducts are in conditioned space, duct leakage can prevent the proper amount of air
from reaching the intended spaces. This can lead to comfort problems because portions of the
home are over- or under-conditioned.

Duct leakage can also lead to pressure imbalances within homes. Such imbalances not only can
affect comfort and efficiency, but can also impact health and durability. In homes with some
types of combustion equipment, for example, large return duct leaks in a basement system can
cause negative pressures which, in turn, can interfere with proper draft. Under these conditions,
exhaust gases can be sucked into the home. Other risks of pressure imbalances include build up
of moisture (and associated problems like mold) in parts of buildings.

Wherever ducts are located, duct leakage should be minimized for optimal efficiency, comfort,
and durability in the home. While not addressed in building codes until recently, the 2009
International Energy Conservation Code (IECC) mandates duct leakage to outdoors be no more
than 8 CFM25 per 100 ft2 of conditioned floor area (see section 403.2 of the 2009 IECC for
details). High performance building programs, such as EPA’s ENERGY STAR Qualified Homes

1
and USGBC’s LEED® for Homes, require total duct leakage to outdoors not be more than 4
CFM25 per 100 ft2 of conditioned floor area.

Similarly, duct insulation levels strongly impact distribution system performance. The most
obvious benefit of insulating ducts is reducing the heat loss from (during heating) or heat gain to
(during cooling) the ducted air. This is again more critical when ducts are located in
unconditioned spaces, but there may be reasons to insulate ducts in conditioned spaces as well.
In humid climates, proper duct insulation can prevent condensation on the cool surface of the
ducts (and possible related moisture problems). In long duct runs, adding insulation will reduce
energy loss as the air travels from the air handling unit to the supply registers. This will result in
more desirable discharge air temperatures from registers, maximizing system capacity and
potentially improving occupant comfort.

Note that this guide is only intended as a resource for sealing and insulating existing duct
systems in homes; this is not intended as a guide for designing, installing, or performing major
retrofits to HVAC systems. It is certainly true that a great many duct systems are poorly designed
and installed, and reconfiguration may lead to improved efficiency and comfort.

2
2 Cost and Performance
While duct sealing can be a simple and effective way to improve home HVAC performance, the
costs and benefits vary tremendously from home to home and across various climates. This
section presents a framework and examples for assessing costs and benefits of duct sealing and
insulation.

2.1 Energy Savings

NREL’s Residential Efficiency Database (NREL Duct Sealing 2011) presents duct sealing
options to reduce leakage from 30% to 15% or 6% of total system airflow. To demonstrate the
energy savings of this air sealing, CARB referred to modeling used to develop the “Retrofitting
Home Analysis Dashboard” (CARB). This demonstration shows the effects of various retrofit
measures on a typical 1970s home in various climates.

In both climates assessed here (Houston and Boston), the home is 1,647 ft2 with three bedrooms.
In Houston, the home is on a slab with ducts in the attic (total duct area of 445 ft2 and insulated
to R-6). In Boston, the home was modeled with uninsulated ducts located in an unconditioned
basement (same duct area as the Houston model). The modeled homes have poor insulation–
typical of the 1970s–and old HVAC equipment with effective SEER of 8 and AFUE of 76%. For
more details on the homes, see CARB’s Retrofitting America: A 1970s Home Energy Efficiency
Analysis. Table 1 shows the energy and cost impacts of duct sealing in Houston.

Table 1. Modeling results on the reference home in Houston with various levels of duct leakage.

Duct Leakage Annual Energy Consumption Annual Heating Annual

to Outdoors Cooling [kWh] Heating [therms] and Cooling Cost Savings
30% 11,547 470 $1,922 $0
15% 10,258 434 $1,719 $203
6% 9,056 404 $1,541 $381

In a Houston climate, because of the dominant cooling load and ducts located in the hot attic,
duct sealing can save $200-$400 per year in HVAC costs. In the Boston example, largely
because many ducts are located in the basement, savings are more modest.

Table 2. Modeling results on the reference home in Boston with various levels of duct leakage.

Duct Leakage Annual Energy Consumption Annual Heating Annual

to Outdoors Cooling [kWh] Heating [therms] and Cooling Cost Savings
30% 3,195 1160 $1,893 $0
15% 3,048 1088 $1,767 $126
6% 2,931 1035 $1,677 $216

Energy costs in these examples were taken from 2005 RECS (EIA 2005). In Houston, electricity
costs were $0.1165/kWh and gas costs $1.101/therm. In Boston, energy costs were $0.13/kWh
and $1.189/therm.

3
Of course, the savings achieved by duct sealing depends on many, many factors. These examples
simply demonstrate that duct leakage can indeed account for a significant portion of heating and
cooling costs.

Energy savings from duct insulation varies with the initial state of duct insulation, the duct
locations, and how much of the duct system one can effectively insulate. In the examples above,
going from entirely uninsulated ducts to R-6 ducts will save approximately $100 per year in both
climates (Boston and Houston). Going to R-8 duct insulation provides modest additional savings
of $5 per year.

2.2 Cost
The examples above show potential for $100 - $400 in annual savings from reducing duct
leakage. The next likely question is: how much does it cost to seal ducts? As with savings, the
costs to seal ducts vary tremendously. Duct location, type, duct area, and accessibility to ducts
vary from home to home. As described above, labor costs typically dominate duct sealing efforts;
the sealants themselves are usually a much less significant portion of the sealing costs.
Contractor rates, therefore, influence total sealing costs tremendously.

Taking these caveats into account, NREL has compiled cost ranges for duct sealing (NREL Duct
Sealing). These costs are summarized in Table 3 along with cost ranges for the example home
described above.
Table 3. Duct sealing costs from NREL’s “National Residential Efficiency Measures Database”. These costs
are applicable to both example homes discussed above.

Leakage Cost per sq.ft. Total Cost

Reductions of Duct Area for Example Home
30% to 15% $0.64 - $3.00 $285 - $1,335
15% to 6% $0.64 - $3.00 $285 - $1,335
30% to 6% $1.30 - $6.00 $579 - $2,670
NREL has also compiled typical price ranges for duct insulation (NREL Duct Insulation); these
ranges are shown in Table 4.
Table 4. Duct insulation costs from NREL’s “National Residential Efficiency Measures Database”. These
costs are applicable to both example homes discussed above.

Duct Cost per sq.ft. Total Cost

Insulation of Duct Area for Example Home
R-6 $0.70 - $1.50 $311 - $668
R-8 $0.82 - $1.80 $365 - $801
2.3 Cost-Performance Trade-Offs and Other Solutions
As discussed above, the energy impact of duct losses (by leakage and/or conduction) from ducts
that are located within the building envelope are usually minimal. In fact, many modeling tools
consider ducts located within conditioned space to have no net energy losses–regardless of
leakage or insulation conditions. While tight, well-insulated ducts within the envelope are better
for overall performance and comfort reasons, energy impacts are minimal. Moving ducts within

4
conditioned space (or expanding conditioned space to encapsulate ducts) is sometimes a viable
retrofit strategy.

Aside from moving ducts into conditioned space, and short of complete removal and/or
replacement of a forced-air HVAC system, there is no good substitute for duct sealing and
insulating. As home heating and cooling loads are reduced (from envelope improvements, high-
efficiency equipment, etc.), the relative impact of duct losses will change, but these losses can
still be a liability with respect to energy, equipment capacity, and comfort.

2.4 Non-Energy Benefits

There are three potential benefits from reducing duct losses: comfort, HVAC capacity, and
IAQ/combustion safety

2.4.1 Comfort
The comfort benefits are very straight-forward. If heat (or “coolness”) is lost from a duct before
the air reaches the register, the room where that register is located will receive less heating or
cooling. In large homes, exterior rooms with long, leaky duct runs can be much less comfortable
than inner rooms with shorter ducts runs (and possibly where thermostats are located).

2.4.2 HVAC Capacity

If a home requires four tons of cooling, and duct losses amount to one additional ton (easily
possible with duct leakage over 20%), a five-ton AC system would be needed to meet the loads
under design conditions. If a four-ton system was installed, there would likely be comfort
problems on design days.

These capacity issues are often compounded by extreme conditions, especially when ducts are
located in the attic. On hot summer days, attic temperatures can easily reach 130°F or 140°F.
Supply ducts that carry 50°F -55°F air experience at least an 80°F temperature differential; return
leaks can draw in 130°F attic air–this obviously requires much more power to cool than indoor
air at around 75°F.

Minimizing duct losses can allow for smaller equipment–especially with respect to cooling. If
equipment capacity is already stretched, reducing or eliminating duct losses can allow more of
the heating and cooling capacity to be delivered to the home.

2.4.3 IAQ and Combustion Safety

Duct leakage can cause pressure imbalances in homes. Excessive supply leaks can cause a home
to be depressurized; this, in turn, can cause drafting problems and can potentially draw
combustion products into the home. Depressurization in hot, humid climates can also lead to
moisture problems if humid outdoor air is drawn into cooler envelope assemblies.

To minimize combustion safety risks, combustion safety testing should be conducted both before
and after duct sealing is performed.

5
3 Ductwork Components
3.1 Duct Materials
This section discusses the three most common duct materials: sheet metal, fiberglass duct board,
and flexible duct (typically referred to as “flex duct”). Each material has advantages and
disadvantages and can require different approaches for insulating and air sealing. A duct
distribution system may utilize a combination of these materials, such as sheet metal trunks off
the air handling unit and flex duct branches to supply the individual registers.

3.1.1 Sheet Metal

Galvanized steel metal is a very common duct material and is required in some jurisdictions.
Round and rectangular shapes are the most common, but ovals and other shapes are sometimes
used. There is also a wide array of sheet metal fittings that connect sections of duct (elbows,
transitions, takeoffs, reducers, etc.).

Figure 1. Sheet metal supply plenum sealed with mastic. A flexible, fireproof canvas collar was installed to
provide sound/vibration attenuation.

Screws are typically used to connect straight round ducts to collars, elbows, T’s, Y’s, reductions,
boots, and other fittings. SMACNA recommends using at least three #8 sheet metal screws
spaced equidistant. If seams, gaps, and connections are not sealed before insulation, substantial
leakage can result.

3.1.2 Fiberglass Duct Board

Duct board is a rigid, dense, fiberglass sheet; the outside typically has a fiber-reinforced foil
facing which acts as a vapor barrier. Duct board is usually sold in large sheets (e.g. 4’ x 10’) with
thicknesses of 0.75” - 2”. The fiberglass provides thermal insulation (approximately R-4 per

6
inch) as well as sound attenuation. Duct board is typically cut, folded, and shaped into
rectangular sections of duct. Duct board is primarily used for plenums, trunks, and junction
boxes; smaller branch ducts can be sheet metal or, more commonly, insulated flex duct. As with
sheet metal, the most common areas for leakage are at collars, transitions, or connections to other
materials.

Figure 2. Fiberglass duct board ducts in an attic

3.1.3 Flex Duct

Insulated, flexible duct consists of an interior polymer tube (4-24” in diameter) supported by a
spiral, metal coil. This inner liner is surrounded by fiberglass insulation (1”-3” thick), and then
an outer polymer liner, which usually incorporates a low-emissivity foil facing that provides a
radiant barrier as well as a vapor barrier. Flex duct is relatively inexpensive, and it comes pre-
insulated. Because it is flexible, flex duct can be run longer distances—with several bends and
turns—without the need for additional fittings or connections
(flex duct typically is sold in 25-foot lengths). With fewer Helpful Tip
transitions and fittings, flex duct can be very air-tight. As with
other duct materials, leakage problems still occur at connections Flex duct needs to be
properly supported to
at either end of the duct and may not be apparent because gaps minimize pressure
are covered by insulation. Connection and sealing of flex should losses in the distribution
always be done at the inner liner. system. SMACNA
recommends that
support spacing not
Compared to other types of duct material, flex duct is less exceed 5 feet and a
durable. It can be twisted, compressed, torn, or otherwise maximum sag of less
disturbed, resulting in leaks. Flex ducts also have higher than ½ inch per foot of
spacing between the
resistance to air flow (especially when the duct is not fully supports.
extended), so slightly larger ducts are needed to carry the same
volume of air.

7
 Figure 3. Box containing 25 feet Figure 4. Insulated flex duct in the attic of an existing home
of compressed insulated flex
duct.

3.1.4 Building Cavities

In many homes, both old and new, HVAC systems make use of building cavities to move air,
especially return air. While this can result in some installation cost and space savings, it is not
recommended. One reason is that building cavities are very prone to air leakage: gaps in framing
and/or drywall are very common, and many building cavities have electrical and plumbing
penetrations. Using building cavities as ductwork on the return air side can also result in
pollutants entering the air stream and being distributed throughout the home.

One of the most common types of building cavities used as an air duct is the floor joist as a
“panned” return. A panned return consists of a floor joist bay where “panning” has been installed
across the bottom of two or more joists. In cases where the return grille is located in a wall, an
uninsulated wall cavity may be used to connect to a panned return.

Figure 5. Floor cavity being

used as return pathway. Note
the electrical penetrations into
this “panned” return.

Figure 6. A “panned” return where the building

cavity is used to carry air.

8
3.2 Sealants
Ironically, most conventional “duct tape” is not an acceptable product for duct sealing. Proper
duct sealants are classified according to two Underwriters Laboratories standards:

• UL-181A, “Standard for Closure Systems for Use With Rigid Air Ducts”

• UL-181B, “Standard for Closure

Systems for Use With Flexible Air
Ducts and Air” 2009 IRC, M1601.4.1 Joints and
Seams
These standards generally describe the air
sealing of new duct systems; bringing older “Joints of duct systems shall be made
systems up to these levels may not be possible or substantially airtight by means of tapes,
practical. At a minimum, however, duct sealing mastics, liquid sealants, gasketing or other
products should meet the requirements of the approved closure systems. Closure systems
appropriate standard above; these products will used with rigid fibrous glass ducts shall comply
be labeled “UL181A” or “UL181B”. Many
with UL181A and shall be marked 181A-P for
materials are approved for both A and B, i.e. for
sealing both rigid and flexible ducts. Language pressure-sensitive tape, 181 A-M for mastic or
from Section M1604.4.1 of the 2009 181 A-H for heat-sensitive tape. Closure
International Residential Code (IRC) may be systems used with flexible air ducts and flexible
appropriate to incorporate into duct sealing air connectors shall comply with UL 181B and
scopes of work (see sidebar). shall be marked 181 B-FX for pressure-sensitive
tape or 181 B-M for mastic. Duct connections to
ACCA Standard 5: HVAC Quality Installation
Specification and the companion Checklist are flanges of air distribution system equipment or
useful resources for HVAC contractor scopes of sheet metal fittings shall be mechanically
work if a major overhaul of the existing duct fastened. Mechanical fasteners for use with
system is being performed. Another excellent flexible nonmetallic air ducts shall comply with
resource is a document published by the U.S.
UL 181B and shall be marked 181 B-C….”
Department of Energy’s Building Technologies
Program called “Air Distribution System
Installation and Sealing: Proper Duct Installation Increases Efficiency.”

3.2.1 Tapes
While conventional duct tape is typically not appropriate, there are many tapes with UL-181A
and UL-181B ratings. Most of these have aluminum foil backing instead of the cloth backing of
conventional duct tape. Many of these rated tapes, however, are still prone to failure over time
(Sherman et al. 2000). Thin foil tapes are also not able to conform to curves and irregular shapes
of ducts; these tapes can also easily be punctured and torn (e.g. by sharp edges of ducts). Also,
for proper adhesion, duct surfaces must be clean and dry before tapes are applied.

One type of tape does offer more durability—butyl duct tapes. While expensive, these tapes have
a thicker, more rugged adhesive that resists tearing and conforms more easily to irregular
surfaces. Whatever tape is used, follow the manufacturer’s instructions for surface preparation,
applied pressure, and application temperature.

9
 Figure 7. Two UL rated
duct tapes (Butyl tape, left
roll, and Aluminum foil
tape, right roll).

Figure 8. Aluminum tape falling off of duct board ducts.

3.2.2 Mastic
Most duct mastic is a water-based paste that dries to form a semi-rigid,
waterproof coating around duct joints and seams. Mastic is typically
sold in 1, 2, or 5-gallon pails as well as caulk tubes. When cured,
mastic will maintain some elasticity, and it can tolerate temperature
changes and vibrations associated with the air distribution system.
Mastic is often used in conjunction with fiber mesh tape , such as
products used for drywall seams. This mesh can provide reinforcement,
especially for larger gaps (greater than 1/8”) or penetrations.

Many home energy experts consider mastic superior to tapes in most

Figure 9. A gallon of
situations. Mastic will conform to irregular, sharp or rough edges mastic and mesh tape
where tape may rip or leak. The chief complaint about mastic is
usually that it is inconvenient to apply. Although mastic can be messier than tape, the ability to
apply it with a tool, caulking gun, or by hand make it the best option for properly sealing hard-to-
reach cracks.

Armed with inexpensive

disposable gloves and/or
single use paint brushes,
experienced installers can
perform most duct sealing
jobs neatly, more quickly, and
often more effectively with
mastic than with tape alone.

Figure 10. A duct connection being sealed using

fiberglass mesh tape and mastic being applied with
a paint brush.
10
Certain mastics can also be applied via spray. Whatever mastic is used, follow the
manufacturer’s instructions for surface preparation, application method, and application
temperature.

Figure 11. Duct board

sealed with mastic.

Figure 12. A duct board trunk with flex duct branches sealed with
mastic.

3.2.3 Aerosol Sealant

In the 1990s, researchers at Lawrence Berkeley National Laboratory developed a method to seal
ducts from the inside with aerosol sealants blown through the duct system. With registers
blocked, the sealant would leak only through seams or gaps in the duct system; and the aerosol
sealant would build up around the edges of the gaps, gradually closing in the holes and sealing
the ducts. While this system cannot seal large holes or disconnects in the duct system, it can be
especially effective where ducts cannot be accessed for traditional sealing methods (i.e. mastic or
tape). Currently, this technology is offered commercially under the trade name Aeroseal.

3.3 Insulation
Insulation is typically installed over ductwork to reduce conductive and radiant heat transfer
through the duct material and to prevent condensation (during cooling). The 2009 IECC requires
that all ductwork located in attics be insulated to a minimum of R-8 and all other ductwork
located in unconditioned spaces to be insulated to a minimum of R-6. Older homes may have R-
4 or no insulation on ductwork. All replacement duct insulation materials should meet the
requirements of 2009 IRC Section M1601.3.

3.3.1 Fiberglass When handling fiberglass

Fiberglass is the most common duct insulation material. As insulation, wear protective
discussed above, duct board and insulated flex duct are clothing (gloves, dust mask,
manufactured with fiberglass insulation to provide some level safety glasses, and coveralls) to
of thermal resistance (R-value is typically labeled on the duct avoid potential skin and eye
surfaces). Uninsulated flex ducts are also available, although
irritation.
these are not recommended for use as supply ducts nor in

11
 unconditioned spaces (return ducts within conditioned space may be
an acceptable application for uninsulated flex). Uninsulated flex
ducts are sometimes found in systems that were installed or
retrofitted by a layperson. In cases where uninsulated flex duct is
found, insulation strategies similar to those discussed below for use
on sheet metal ductwork can be utilized.

Most sheet metal ducts are uninsulated or wrapped on the outside

with fiberglass insulation blankets, sometimes called “duct wrap”.
Figure 13. Duct wrap These sheets (typically 2-4 feet wide) are 1-4” thick and include a
vapor barrier on the outside, often with a foil radiant barrier. The
insulating value (R-value) of fiberglass duct wrap is between 2.5 and 4 ft2hr°F/Btu per inch
(depending on the specific product and density). Newer sheet metal ducts that have interior,
insulating duct liners are now available, but these liners are not generally appropriate for retrofit
applications.

3.3.2 Closed-Cell Polyurethane Foam

Insulating ductwork is currently not a common application for closed-cell spray polyurethane
foam (ccSPF), and it is even less common in retrofit applications. While spray foam can provide
excellent insulation and air sealing, most codes require that spray foam insulation be covered by
an ignition barrier. With ducts located in attics, this can be accomplished by “burying” spray-
foamed ducts beneath at least 1.5” of fiberglass insulation. The 2009 IRC addresses this strategy
in section M1601.3.

Figure 14. Ducts insulated with closed-cell spray foam in an attic. Fiberglass insulation will be blown over the
ducts, providing the necessary ignition barrier.

12
4 Health and Safety Asbestos

Before describing duct diagnostics, sealing, or insulating Asbestos can be problematic

procedures, it is important to understand basic health and safety
if the microscopic fibers
information. Prior to beginning any work, inspect the home and
become airborne. If inhaled,
systems to determine if the duct improvement work can be
performed safely. It may be appropriate to refer to standards such significant health problems
as the Building Performance Institute’s (BPI’s) “Technical can result.
Standards for the Building Analyst Professional” or other
protocols.

The contents of this section are provided as suggestions.

Contractors should refer to appropriate local codes, regulations,
professional standards, and common sense as the situation
warrants.

4.1 Inspect the House and HVAC Systems Mold

• Structural Issues: If the building is damaged or
structurally unsound, duct sealing work should not be Mold spores can develop on
pursued until other repairs are completed. porous surfaces, in the
presence of food (like wood
• Duct Status: Ducts that are disconnected, damaged, or
and paper), oxygen,
designed poorly can result in poor HVAC performance. If
moderate temperatures
duct systems are to be modified or improved, this should
be done before sealing and insulating efforts. (typically over 65°F, but if
enough water is present,
• Asbestos, Mold, and Other Contaminants: If there is an down to 40°F), and sufficient
existing mold problem in the building or in the ductwork, water.
or if possible asbestos-containing material is present, the
conditions should be documented and assessed to
determine if testing and sealing can safely be completed. Carbon Monoxide
If testing and sealing cannot be safely completed, the
Carbon Monoxide (CO) is
homeowner should be instructed to have the problem(s)
addressed by a qualified professional before continuing invisible, odorless, and can
with duct sealing work. be deadly. CO poisoning
deprives your body’s cells of
• Health/Safety of the Occupants: If there are people living oxygen.
in the home with severe medical conditions, the situation
should be evaluated to ensure that the duct testing and sealing will not cause adverse
health conditions. This could include stirring up dust, blowing cold air into the house,
shutting off systems to complete work during extreme weather, etc.

13
 • Health/Safety of the Worker: If ductwork is located in
an attic or other overhead space, caution must be taken
to prevent damage to the ceilings in the occupied
spaces below. Typically, this requires careful
navigation along the ceiling structural members, either
ceiling joists or truss bottom chords. Insulation often
makes it difficult to identify solid footing, which can
lead to damage in ceiling sheetrock below. In most
homes, roofing nails penetrate the roof sheathing and
extend through the underside of the decking. Where
head clearance is low, protective head gear should be
worn to prevent cuts or scrapes from the nails.
Similarly, workers should wear gloves, goggles, masks,
and protective clothing to protect themselves from Figure 15. Ceiling damage as a result
airborne insulation fibers and dust that are released of a misplaced foot while working on
ducts in an attic.
when ductwork is disturbed. Work should only be
undertaken by people comfortable working in
constrained spaces and familiar with safe practices for access in attics or other overhead
spaces.

• Make note and be aware of other hazards: toxic materials, solvents, exposed or knob-
and-tube wiring (have an electrician evaluate), non-IC rated can light fixtures,
insect/rodent infestations, etc. Proceed with work only if it
can be done safely.

4.2 Combustion Safety Testing

After the initial inspection of the home and systems, it is important
to assess combustion appliances in the home and any potential
safety issues associated with them. Sealing ducts can result in
different pressure patterns within a home, which can potentially
alter combustion venting and draft. A brief overview of Figure 16. Testing CO levels
recommended safety precautions is provided here. It may be at the exhaust flue of sealed
combustion furnace.
appropriate to consult more detailed program guidelines or to
refer to BPI’s “Technical Standards for the Building Analyst
Professional”.

4.2.1 Measure Carbon Monoxide (CO) Concentrations

Measuring ambient levels of carbon monoxide in the home is simple and can identify potentially
hazardous situations. If ambient CO levels are extremely high, work should not proceed until the
problem is corrected. It may also be appropriate to measure CO levels in the flue or exhaust from
appliances (usually a different instrument is required). If CO concentrations in the exhaust are
high, it may be appropriate to have a qualified contractor adjust or tune the equipment to correct
the problem

14
 Table 5. Exposure limits for carbon monoxide (CO). 1

Agency / Organization Maximum CO Concentrations

Occupational Safety and Health 50 ppm as an 8-hour time-weighted
Administration (OSHA) average
National Institute for Occupational Safety and 35 ppm as an 8-hour time-weighted
Health (NIOSH) average
AND 200 ppm at any time
American Conference of Governmental 25 ppm as an 8-hour time-weighted
Industrial Hygienists (ACGIH) average for a 40-hour work week.

4.2.2 Spillage Tests

“Spillage” is the term used to describe the situation when a proper
draft is not established in the flue pipe or chimney; the flue gases
come “spilling” back down the flue and into the house. Spillage
may be caused by pressure imbalances within the house and/or
improper venting. Since flue gases can contain significant amounts
of moisture and carbon monoxide, spillage can result in dangerous
and unhealthy conditions and should be remedied before
attempting any modifications to the home or ductwork.

Check for spillage by turning the appliance on and - using a smoke

stick, glass, or mirror—verify that there is negative draft around
the draft diverter (i.e. flue gases are flowing up–not down–the flue)
that is established within one minute of the burner firing. It is not Figure 17. Spillage testing of
unusual for some appliances (especially water heaters) to spill an atmospherically vented,
temporarily on startup. This is because the chimney needs to heat natural gas water heater.

up before a proper draft is established. Spillage that occurs under

normal building operating conditions should be addressed
immediately. This is a serious health and safety risk for the occupants. Spillage may also be
checked under simulated “worst-case” conditions as described in Section 4.2.4 below.

4.2.3 Measure Draft

Draft is measured by taking a pressure measurement in the flue pipe approximately 12”
downstream of the draft diverter. Draft should be measured under steady state conditions
(usually after 5-10 minutes of operation). Acceptable draft is dependent on the outside
temperature and height of the flue stack. Typical ranges are shown in Table 6.
Table 6. Typical draft requirements for combustion equipment from BPI’s “Technical Standard for the
Building Performance Professional.”

Outdoor Temperature (Tout, °F) Minimum Acceptable Draft (Pa)

<10 -2.5
10-90 (Tout / 40) - 2.75
>90 -0.5

1
http://www.osha.gov/SLTC/healthguidelines/carbonmonoxide/recognition.html

15
4.2.4 Worst Case Depressurization Identifying the CAZ
It is often recommended that combustion safety tests be
conducted under “worst case” conditions. Since testing only A combustion appliance zone
gives us a snapshot of how the system is performing on a is any room/space within a
particular day under the current conditions, it does not
home that contains an
necessarily assure us that the system might not fail at another
appliance that burns fuel
time under different conditions. Using the worst-case approach,
contractors are better assured that combustion appliance failures (wood, natural gas, propane,
will not occur after they leave the house. oil, etc.)

To set up worst case conditions, first identify the combustion appliance zone (CAZ) and set up a
manometer to measure the pressure in the CAZ with reference to (wrt) outside. Make changes to
the house configuration using the following checklist, and check the CAZ pressure wrt outside at
each step. Keep making changes until you have achieved the most negative pressure possible in
the CAZ.

Checklist for Establishing Worst-Case Depressurization:

Table 7. BPI’s retrofit action levels
based upon undiluted flue gas CO
• Turn on exhaust fans (bath fans, range hoods, measurements
etc), including clothes dryers
CO
Spillage and Retrofit
• Open/close door to the CAZ (in some houses Level And/Or
Draft Action
open will be worst case, in others the door should (ppm)
0-25 And pass proceed
be closed for worst case) recommend
26-100 And pass
fix
• Open/close interior doors
fails recommend
26-100 And
• Turn on/off the air handler fan (worst case) fix
fails
stop work,
Once you have established the worst-case scenario, turn 100-400 Or (natural
fix
case)
on the combustion appliances, one at a time, starting with stop work,
the smallest. Check each appliance individually for >400 And pass
fix
spillage and draft. If more than one appliance shares a >400 And
fails shut off fuel,
chimney, also conduct the test with both appliances (any case) fix
operating simultaneously.

4.2.5 Implications of Combustion Problems

If combustion problems are identified, they must be addressed before duct sealing. Duct sealing
can alter the pressure patterns in a home; different pressure patterns may aggravate combustion
problems and increase risks to occupants.

If ducts are located in an unconditioned space like a vented attic, return side leakage can result in
unconditioned air and pollutants being pulled into the airstream and can result in the home being
positively pressured. This can be an issue during winter months in cold climate regions if moist
interior air is pushed into the wall assembly and condenses.

Similarly, attic supply side leakage can result in conditioned air being lost to the outdoors
(energy penalty) and the home can become negatively pressurized. If there are atmospheric
combustion appliances in the home, these negative pressures may cause back drafting and

16
improper combustion and could result in carbon monoxide poisoning. In hot, humid climate
regions, depressurization can also lead to high indoor relative humidity levels as outdoor air
infiltration is exacerbated.

Figure 18. How duct leakage can affect building pressures.

Many atmospheric, natural draft, or induced draft appliances require

substantial amounts of outdoor air to the CAZ to operate properly. Minimum single
This make-up air or induced infiltration can represent a substantial opening to
space conditioning load, and it is not at all desirable in an efficient
outside for
home. While safe operation can be achieved by providing outdoor air
and adjusting appliances properly, installing sealed-combustion combustion
appliances is very often the best remedy for providing reliable, safe, appliances
and efficient space heating and water heating. Strong consideration Reference: Chapter 24
should be given to this strategy. of 2009 International
Residential Code (IRC)
In homes with any combustion appliances, carbon monoxide for One- and Two-
sensors/alarms are required by many codes. These can help alert Family Dwellings;
Section G2407.6.2
occupants to serious combustion problems.

4.3 Personal Safety and Protective Equipment

When working on ducts, recognize that some of the sealant and insulation materials can be
hazardous if not handled properly. Refer to the Material Safety Data Sheets (MSDS) for all
chemical products used. Use appropriate personal protective equipment including respirators,
safety glasses, kneepads, and disposable protective clothing as appropriate.

17
5 Evaluating Duct Systems
5.1 Check Airflow of System(s)
Furnaces and air conditioners are both designed to run within certain airflow ranges to ensure
proper and safe performance. Before sealing ducts, system air flow should be measured. If flow
is not in an acceptable range, correct the airflow before continuing with sealing. Sealing a very
leaky duct system can increase pressure and therefore reduce total airflow. Air flow should be
checked after sealing as well to ensure proper operation.

High airflow during cooling operation may result in inadequate

dehumidification. Low airflow is also a problem, as too little cfm per ton
heat exchange may occur at the evaporator coil. This can cause In humid climates, 350-400
liquid refrigerant to return to the compressor and damage the
cfm/ton is a common air
motor. Improper airflow may also cause icing of the evaporator
handler flow range to
coil.
maximize latent capacity
Below are several methods for measuring airflow through air (ability to remove moisture).
handlers, any of which may be acceptable if performed properly. In drier climates, 400-450
Typically, air conditioners require airflow of no less than 300- cfm/ton is often used to
350 cfm per ton of cooling. Some manufacturers may have
maximize sensible capacity
somewhat different requirements for particular models, but a 350
cfm/ton minimum may be a good rule of thumb (see side bar for (ability to lower temperature),

more climate specific “rules of thumb”) when the manufacturer’s as latent capacity is not a
specifications are not readily available. When nominal furnace significant concern.
flow rates are not available during heating operation, 21.7
cfm/kBtu/h is a default value recommended in California energy
codes (CEC).

5.1.1 Temperature Rise

Furnace airflow may be checked by verifying that the heat rise
over the heat exchanger is within the manufacturer’s acceptable
range. This is done by running the system in heating mode for
approximately 5-10 minutes, until the system reaches steady state,
while simultaneously taking temperature measurements in the
return and supply plenums. The manufacturer’s faceplate will have
system performance data including the specified heat rise range for
that particular model. Typical ranges are 40°F -60°F. Be aware
that if the furnace is not operating up to its rated capacity for Figure 19. The specified heat
some reason, this flow verification method may not be accurate. rise range for this furnace is
40-70°F according to the
5.1.2 Duct Pressurization Airflow Testing faceplate.
The duct pressurization tool (“duct blower”) may be used to test
for system airflow. This test is done with the registers unsealed, so it should be done prior to
setting up duct leakage tests. Refer to the equipment manual for a complete set of instructions on
conducting this test. The basic steps are summarized below:

18
With the system in its normal operating condition, turn the thermostat to the Air Conditioning
(AC) fan setting (or on high) and measure the static pressure in the supply plenum.

• Turn the system off.

• Seal off the return side of the system as close to the

blower compartment as possible. This is usually done
from inside the blower compartment or at the filter slot.

• Once the return has been sealed off, install the duct
pressurization fan on the air handler cabinet.

• Monitor the static pressure in the supply plenum and Figure 20. Airflow testing
using a duct blower.
increase the duct blower flow rate until the static pressure
under normal operation is achieved. Note: This is the
pressure recorded in Step 1.

• Record airflow through the duct blower. This is the total system airflow.

5.1.3 Flow Plate Airflow Test

A quicker and easier method for testing system airflow is using pitot arrays specially designed
for measuring flow in residential air systems. The pitot arrays are integrated into a “flow plate”
which should be installed near the blower compartment, typically in the filter slot of the existing
system. Velocity pressure readings from the flow plate are easily converted to air flow using
manufacturer’s instructions.

5.2 Measure Duct Leakage – Duct Pressurization

While it is not necessary to quantify the leakage of a duct system Helpful Tip
before sealing it, testing can provide insight as to how much
Discolored duct insulation is
improvement is possible (and how much has been achieved after
sealing). It is the authors’ opinion, however, that when ducts are an indicator of duct leakage.
accessible, they should be sealed. The time and money required The insulation is in essence
for testing may be comparable to effort required to seal the working as a filter of the
ducts. leaked air.

The most common duct leakage testing procedures require a

variable-speed blower that can be attached to the duct system.
The blower includes an orifice and pressure taps with which
air flow through the fan assembly can be measured. While
equipment manuals—and ASTM E-1554—provide detailed
test procedures, the typical procedure is as follows:

• Turn HVAC systems OFF.

• Using tape or other material, block or mask all supply

and return registers. Figure 21. Duct leakage testing

19
 • Attach the blower to the duct system – typically at the return side of the air handler.

• Insert a static pressure reference tap—typically in the supply plenum.

• Turn on the fan and pressurize the duct system to the appropriate level (e.g. 25 Pa with
respect to outdoors).

• Measure the flow rate through the fan; this is the total duct leakage.

To more accurately assess energy implications of duct leakage, it is common to quantify the
amount of duct leakage escaping “to the outdoors”. The test for leakage to the outdoors involves
the same duct blower configuration as discussed above, but it also requires a blower door to
pressurize the home. Refer to equipment manuals for details, but the basic steps are usually as
follows:

• Begin with all HVAC equipment, the duct blower, and the
blower door OFF.
• Close all exterior doors and windows in the home.
• With the blower door installed in an exterior door of the home,
pressurize the home to the duct test pressure (typically 25 Pa)
with respect to outdoors.*
• Turn on the duct blower fan, and increase speed until static
pressure in the duct system equals pressure in the home (e.g. 0
Pa wrt indoors, 25 Pa wrt outdoors).
Figure 22. Blower door being
• Measure the flow rate through the duct blower; this is the used to pressurize home.
duct leakage to the outdoors.

* It is very important to turn all combustion appliances off before pressurizing or

depressurizing the home. If fireplaces or woodstoves have been operated recently, it may
not be possible to perform these tests safely. If old ashes are present in a fireplace, lay
damp newspaper over the ashes (additional weight may be needed on top) prior to
operating the blower door fan.

5.3 Pressure Pan Test

A qualitative test that can sometimes identify leaky duct runs is the “pressure pan” test. This
procedure involves using a blower door to depressurize (typically) a home to a reference pressure
(e.g. -50 Pa wrt outdoors). When the home is depressurized, a pan is placed over a register, and a
manometer measures the pressure differential between the conditioned space and the space just
inside the covered register. If the portion of the duct system you’re testing is rather well sealed,
the differential pressure between the room and the pressure pan should be very small. When
large differences are observed, there may be some significant leaks in that part of the system

The pressure pan test is a qualitative test; it can’t quantify air leakage. It can be a useful tool to
identify the most leaky portions of a duct system.

20
6 Determine Scope of Work
After conducting preliminary inspections and tests for safety and duct leakage, spend a few
moments planning the scope of work for the duct improvement project. Consider:

• Which sections of the duct system can be accessed and effectively sealed/insulated? If
there are very few sections of duct accessible, the scope and impact will likely both be
small. A method utilizing an aerosol sealant may be worth considering.

• Based on duct leakage tests, what level of benefit can be expected from sealing? If
leakage is very low or the forced air system is infrequently used, time and effort may be
better spent on other areas of the home’s performance.

• Are there major duct disconnects that can be remedied? Re-attaching disconnected ducts
will provide huge energy and comfort savings with very little time and effort.

• Are there major holes or gaps that need to be repaired? This may involve new sections of
duct and/or the services of a licensed HVAC contractor.

• If sheet metal ducts are insulated, consider the extra effort involved in removing and
replacing the insulation; this can make a job more time consuming and challenging.

• Generally, focus sealing efforts on ducts in unconditioned spaces. Reducing duct leakage
to conditioned areas may improve comfort somewhat, but it does not typically result in
significant energy savings.

• When possible, focus on leaks at and near the air handler. Because system pressures are
higher near the fan, benefits from sealing leaks in these areas are greater.

• When atmospheric combustion equipment is located in the same space as the AHU, focus
sealing efforts on return ducts to minimize the potential for depressurizing the space.

These are very general guidelines; the exact scope will depend on project goals, time, budget,
etc.

Figure 23. Using smoke to visually identify leaks at an air handler.

21
7 Duct Sealing Procedure
7.1 How to Apply Mastic
The most common complaints about duct mastic are that it is inconvenient or messy to install.
With experience, using mastic does not need to be either; sealing with mastic can often be
accomplished more quickly and with greater effect than with tapes.

Refer to manufacturer’s literature for the proper temperatures to apply mastic; some should not
be used in very cold conditions. Before applying mastic, duct surfaces should be relatively clean.
While some contractors report that cleaning ducts is less critical for mastics than for tapes, most
mastic manufacturer instructions state surfaces must be free of dirt, dust, grease, water,
corrosion, etc. While meticulously washing and drying all ducts before sealing may be
impractical, some duct systems can be tremendously dusty and dirty. In such cases, it is
important to remove much of this grime by wiping or vacuuming.

Mastic is available in pails of various volumes as well as in caulk tubes. Mastic manufacturers
usually instruct users to apply mastic with brushes, trowels, or caulk guns. In the authors’
experience, applying by hand is often much cleaner, quicker, and more effective. Applying by
hand (while wearing appropriate gloves) allows the duct sealer to feel the duct surfaces, seams,
and gaps; this is especially important when the gaps are not visible—a very common occurrence.

Using proper gloves is key whether applying by hand or with tools. Be aware of screws and
sharp edges. Gloves should protect from some of these risks while keeping hands free from
mastic (or at least mostly free from mastic). Care should be taken to remove gloves before
touching other surfaces. Once cured, mastic is very difficult to remove from surfaces, clothing,
and skin.

Heavy-duty rubber gloves are one option, but these sometimes reduce dexterity and “feeling”
capacity when applying mastic by hand. Thin, disposable rubber gloves (e.g. latex gloves), on
the other hand, do not offer substantial protection from sharp edges. One compromise involves
using inexpensive canvas gloves beneath disposable rubber gloves. The outer latex glove can be
replaced when it is too dirty or becomes punctured or torn. The inner glove will last longer, but it
can also be discarded when it becomes torn or embedded with mastic.

Another “trick” is to only use one hand to apply mastic. Using one hand—with the appropriate
glove(s)—for mastic application will leave the other hand clean to move equipment, reach for
tools, crawl through tight spaces, etc. Having one clean hand can keep equipment and job sites
much cleaner.

While mastic alone can work well to cover small seams, larger gaps and joints may require mesh
tape to reinforce the mastic. Generally, this involves spreading a layer of mastic near the gap,
applying mesh tape, and then covering the tape with another layer of mastic. Larger gaps of
approximately one inch or more are usually too large for tape and may require patches using
sheet metal, duct board, or other approved material.

22
Follow manufacturer’s instructions as to the thickness of applied mastic. If anything, be
generous. Some contractors err on the thin side; a very thin coat may not provide adequate
sealing or durability (see Figure 25).

Figure 24. Duct sealer using a single Figure 25. While sealant has been applied to some of
gloved hand (inexpensive cotton glove these joints, such a thin coat may not provide an
beneath a disposable latex glove) and a adequate seal. Follow manufacturer’s instructions
“clean” ungloved hand. for the thickness when applying mastic.

Table 8. Duct sealing with mastic and fiberglass mesh tape.

1. Spread a layer of mastic

on the gap.

2. Embed the mesh tape into

the mastic.

23
 3. Cover the mesh tape with
more mastic.

4. Mesh tape should be

barely visible.

7.2 Applying Tape

As with mastics, follow manufacturer instructions for the particular tape used. Duct surfaces
should be clean and dry before applying tape. Apply pressure as directed and use at the proper
temperatures. Some tapes require heat activation; others require only pressure but do not adhere
in cold conditions. Tapes can be especially effective for sealing straight seams and edges where
curves do not cause folds or bends in the tape. Tape works well at the transition between the
AHU and ductwork, as the tape can be easily cut and replaced during maintenance and
replacement of the AHU. Be careful if using your hands to smooth the tape. The edges of foil
tape are extremely sharp, a plastic edge or gloves should be utilized.

Be careful if using
your hands to smooth
foil tape. The edges
are extremely sharp

Figure 26. Aluminum tape being smoothed out with a plastic comb

24
7.3 Existing Duct Insulation
Sealing sheet metal ducts that have exterior insulation already installed (typically fiberglass
wrap) can be much more time consuming than sealing un-insulated ducts. Insulation needs to be
removed from accessible portions of the duct system (by carefully cutting insulation, peeling it
back, or by removing it completely during sealing). If the insulation is removed completely (with
the intent of re-installing after sealing), take care to mark the insulation so it can be reinstalled in
the correct position. If the insulation is torn or has a low R-value, it may be worthwhile to install
new insulation following sealing.

Before removing insulation, take some time to consider how the insulation will be re-installed. In
tight spaces, it is much easier to remove insulation than it is to replace it. If testing on a system
does not show tremendous leakage, removing insulation, sealing, and re-insulating entire lengths
of duct may not be warranted. In some situations it is more practical to focus on other areas (e.g.
air handler connections, branch take-offs, boots and registers) where insulation does not need to
be completely removed in order to seal penetrations. These areas are sometimes targeted first and
followed by another round of testing to determine the need for addressing the other portions of
the duct system.

Space and insulation

constraints can limit access
to leakage areas

Figure 27. Duct sealers here were faced with a tight space and existing insulation. The insulation was cut and
temporarily pulled back to seal connections within reach.

In some older duct systems, ducts may be insulated but lack a vapor barrier. Or, as in the
example shown in Figure 28, the vapor barrier has degraded. Insulation air and vapor barriers are
important to prevent moisture in hot, humid attics from condensing on cold duct surfaces. Small
tears can often be sealed with foil tape; larger gaps may be covered with polyethylene, (foil
scrim kraft (FSK), or simply with more duct wrap with an intact air and vapor barrier.

25
 Figure 28 Vapor barrier has eroded and needs to be replaced

7.4 Furnace and Air Handle Connections

The air handler can be one of the leakiest parts of an air distribution system. Because of the
higher pressures near the air handler, any holes here have larger impacts than similar-sized holes
near registers. For these reasons—and because air handlers are usually somewhat accessible for
maintenance—sealing near air handlers should be a primary focus for any duct sealing efforts.

As mentioned above, air handler connections are often good places to seal with tape rather than
mastic. When this equipment needs to be serviced and/or replaced, tape can be cut or removed
much more easily than can mastic. Air handler connections also tend to be rather straight, with
few curves or irregular angles that make sealing with tape more challenging.

A frequent dilemma encountered is how to deal with leakage of the air handler cabinet itself.
Many air handlers, especially older units, are responsible for a very large amount of system
leakage. 2 Penetrations for wiring, refrigerant lines, condensate drains, gas or water piping, .are
often much larger than needed with no gasket or other device to provide air sealing. Sealing such
penetrations may limit access to the unit for service. Unfortunately, there is no hard and fast rule
for duct sealers other than: seal as much as possible without affecting access, serviceability, or
warranty of the unit. Plumber’s dope is one potential solution for “non-permanent” sealing of air
handler penetrations.

Filter slots are another example of leakage areas that can be tricky to seal effectively. Many
newer air handlers have gasketed covers for filter slots. Older handlers typically have an open
slot into which a filter is inserted. Taping over the slot can effectively reduce leakage, but this is
usually unacceptable because it limits access to the filter. There are some after-market devices
that use magnets or removable gaskets to seal these filter slots (see Figure 29).

2
“Problems Related to Air Handler Leakage.” ASHRAE Journal, January 2008 by James B. Cummings and
Charles Withers Jr.

26
 Figure 29. These polymer sheets with
magnets at the edges cover the filter
slot in an air conditioning system.
Covers such as these can reduce
leakage tremendously while allowing
Figure 30. Plumber’s putty installed around
easy access for filter replacement.
refrigerant piping to reduce air handler
leakage.

7.5 Trunk Ducts

Most residential duct systems consist of one or more main
“trunk” ducts from which multiple supply and return lines
“branch” off. These trunks are the largest ducts in the home
and can be of any material (sheet metal, duct board, or flex –
depending largely on the region).

Most duct board trunks are sealed during installation with

foil tapes. These tapes do not necessarily maintain their
integrity over time, especially if the tapes are relied upon for
mechanical support (see Figure 32). Neither tape nor mastic
provides mechanical support. As duct board seams are often
straight, an appropriate tape may provide adequate sealing.
Mastic, however, may prove more durable.

Sheet metal duct trunks should be sealed with mastic at all

joints and seams. Some folded metal duct seams do not leak,
but others do. When applying mastic, the time and material
needed to cover these seams, as well as joints, is minimal.

Figure 31. Supply and return plenums

and trunks sealed with mastic.

27
 Figure 32. This duct board trunk was sealed with foil Figure 33. Sealing of duct shown in Figure
tape that has failed due to the stress put on the duct. 32 with mastic and fiberglass mesh.
Neither mastic nor tapes can replace proper mechanical
fastening and support.

7.6 Branch Connections

Branch connections—where smaller supply or return ducts connect with larger trunks—are a key
area to target for sealing. Branches are always smaller than trunks, but branch connections are
often different shapes (e.g. rectangular trunk to round branch) and different materials (e.g. metal
or duct board trunk to flex branch). Because of these variables, many branch connections are
sealed poorly, if at all.

7.6.1 Flex Branches

Insulated, flexible branch ducts have become increasingly
common in homes. Occasionally, uninsulated flex duct is used
for return branches in conditioned space. Most flex branches
connect to trunks via a collar—a round transition piece
between the trunk and branch. These collars are connected by
various means, but it is common to find little or no sealing of
the collars to the trunks. Use mastic to seal collars to the
trunks; if gaps are large, mesh tape should be used as well.

With insulated flex, care must be taken to seal all connections Figure 34 This flex branch never
with the inner duct lining, not just the outer insulation overlapped the collar and the
insulation wasn’t properly installed
covering. Sealing the outer insulation layer will not prevent resulting in leaks and condensation.
leakage, but will minimize the potential for condensation. It is
very common to find insulated flex ducts attached improperly
where the outer lining is attached somehow to the collar but
the duct itself is not fully connected.

To properly seal flex ducts to metal collars or boots, follow the

steps in Table 9. If the existing duct is securely attached to the
boot, skip steps 2-4 (step 4 can be done for redundancy).

Figure 35 A flex branch (insulation pulled

back) attached and sealed to a collar. Note the
balancing damper; sealers must be careful that
mastic does not prevent access to and
operation of such devices.

28
 Table 9. Properly sealing duct branches to metal collars or boots.

1. Ensure that the metal collar is fully

accessible (may need to cut back main
trunk insulation). Roll the outer insulation
layer back off the inner liner of the
flexible duct.

2. Apply mastic directly to the collar

(best practice, but optional).

3. Slide the inner flex liner over the collar to

embed into mastic.

4. Secure with a compression band (draw

band, zip tie) over the collar.

5. Apply additional mastic to seal the seam

between the inner liner and collar.

6. Pull the insulation back over the inner

liner and secure this joint with another
compression band.

29
 It is important to seal the branch to the collar connection,
as well as the collar to the trunk connection.

In Figure 40, the inner lining of these flex duct branches

have been attached to the collars. However, they have not
been sealed. Mastic should be applied where flex duct
meets the collar as well as where the collar meets the
trunk. If possible, the existing duct insulation should then
be stretched to the collar and anchored in place to provide
Figure 36. What exactly is being continuous insulation starting at the trunk.
secured here?

Figure 37. A branch connection

collar in a sheet metal trunk. It is
important to seal the collar to the
trunk as well as the branch to the
collar.

Figure 38. The inner lining of these flex duct branches have been
attached to the collars, but they have not been sealed

Figure 39. Having this much flex

duct branching off at the supply
plenum makes it very difficult to
properly seal the ducts.

Figure 40. Lack of sealant at the branch connection.

Finding ducts completely disconnected is also not uncommon. For example, in Figure 41,
conventional duct tape was the only fastening and sealing method used, and it has failed
completely. To rectify the situation, insulation on the trunk should be cut and peeled back so that
the collar can be sealed to the trunk with mastic. The inner lining of the branch duct should be

30
attached to the collar (with cable tie or other appropriate means), and this connection should also
be sealed with mastic. Insulation should be replaced and taped in place (with the proper tape).

Figure 41. Disconnected ductwork resulting in conditioned air being lost to the vented attic. Homeowner was
complaining of comfort issues in a secondary bedroom.

7.6.2 Sheet Metal Branches

For all sheet metal duct connections, any exterior insulation must be peeled back to assess and
seal connections. As with flex ducts, sheet metal collars should be sealed to the trunk and branch
ducts sealed to the collar. If possible, seal all connections and seams along the entire branch. If
the ducts are insulated, time and effort involved in removing (and replacing) duct insulation to
access seams may be beyond the scope of the sealing effort.

Figure 42. In existing homes,

it may be difficult to see all
the duct connections, such
as these top take-off sheet
metal branches. Use of
mastic in these tight
situations can be much more
effective than tape.
Figure 43. It appears the HVAC contractor ran out of the proper sized
ducts or collars for this installation

Gaps, as shown in Figure 43, result in tremendous energy waste, reduced heating and cooling
capacity, and likely comfort problems. The gap is too large to be fixed with mastic or tape; the
proper fitting needs to be installed.

31
7.7 Branch Duct Fittings
In flex duct branches, there are few connections. A single piece of duct is typically used between
the trunk and the duct boot. In longer runs, however, contractors may need to join two sections of
flex duct or use duct board junction boxes. These should be sealed much like collars—the inner
duct linings should be mechanically attached to the fitting and sealed with mastic.

Figure 45. Duct board

junction box with multiple
flex branch ducts.

Figure 44. This flex duct junction has failed completely. The inner lining of
both sections should be attached and sealed to the metal fitting. Insulation
should then be taped in place.

Figure 46. A tangle of metal ducts and flue pipes. Branch ducts have been sealed with duct tape
which is failing (esp. in lower right). All duct seams and junctions should be sealed with mastic.
Care should be taken to avoid contact with the flue piping.

32
 Sheet metal duct branches have many seams, fittings, and connections. All accessible
connections should be sealed with mastic; mesh tape should be used at larger gaps and junctions.

7.8 Boot and Register Connections

As register boots are directly beneath floors,
ceilings, or walls, often the easiest way to
access them is through the register itself.
Removing the grilles from supply and return
registers often provides access for sealing:

• Between the branch duct and the

boot

• Seams within the boot itself

• Gaps between the boot and the wall,

floor, or ceiling surface.

These seams should be sealed with mastic,

taking care that the mastic does not come in Figure 47. Sheet metal boot that has not been sealed.
contact with finished surfaces. Often caulk
tubes of mastic provide better precision for this type of work.

Figure 48. Sheet metal boot

that has been sealed.

Helpful Tip
Make sure not to reinsert
the register until the Figure 49. Mastic has been used to seal the flex duct to the register boot, seams in
the sheet metal boot itself, and the gap between the boot and the floor. Sealing from
mastic has fully cured to
the exterior is preferable, but when ducts are not accessible, this method can be
prevent it from being utilized. As always, use proper gloves and be careful of screws and sharp edges
when sealing boot connections.
sealed in place.

33
 Figure 50. All seams of the sheet metal boot should be sealed with mastic if accessible, either from the
interior or exterior of the duct.

7.9 Building Cavities

As discussed earlier, using building cavities as part of a duct system is not recommended. One of
the key reasons for this is that it is much more difficult to create a tight duct system using
building cavities. Nevertheless, panned returns (such as in Figure 51 andFigure 52) are still
common, and they are typically very leaky.

Depending upon the scope of the project, it may be preferable for an HVAC contractor to replace
panned returns (or other building cavity ducts) with properly sized, sealed, and insulated ducts.
If this is not an option, it is possible to improve performance of duct systems by sealing panned
returns. Figure 53 shows the area beneath a stairway used as a return plenum. Depressurizing this
space drew tremendous amounts of air from the unconditioned basement.

34
 Figure 51. Floor joist bays used as panned returns.

Figure 52. Hard duct, panned returns, and wood blocking are combined as part of the return system. Gaps
and seams are not sealed at all, and wiring penetrations allow even more leakage.

35
 Figure 53. This space beneath a stairway was used as a return plenum. Installing a ducted return – the
preferred solution – was not in the scope for this project. System performance was improved by sealing this
building cavity.

36
8 Insulating Ducts
8.1 Moving Ducts into Conditioned Space
Insulating ducts provides the largest energy benefit when ducts are outside of conditioned spaces
(e.g. when they are in unconditioned attics, crawlspaces, basements). Depending on the
configuration of the home and on the scope of the project, it may be practical to bring some of
these spaces (that contain ducts) inside the envelope, thereby making them conditioned. When
ducts are within the conditioned areas, detrimental effects of leakage and conduction are
drastically reduced.

Insulating and sealing basement or crawlspace

walls, for example, can improve overall
performance of the home and HVAC system while
making these spaces warmer (in winter), dryer, and
more usable. When duct systems are located in an
attic, especially in warm climates, air sealing the
attic and insulating the roof deck may provide better
overall performance than sealing the ceiling plane
and improving duct insulation.

Details on these envelope alteration practices are

outside the scope of these guidelines. Contractors Figure 54. HVAC brought into conditioned
space by applying spray foam to roof deck.
and homeowners should approach these options
holistically, considering the project scope, site-
specific details, moisture management, regional
codes, etc. More information on these practices
are/will be available in these Building America Reminder
Guidelines:
Even though ducts are moved into

• Basement Air Sealing and Insulation Methods conditioned space, an inspection of the
duct system is still advised to ensure
• Retrofitting Ducts Into Conditioned Space that there are no major disconnects or
other significant faults.
• Converting Vented Attic to Unvented.

8.2 Insulating Duct Wrap

When sheet metal ducts are located outside of the conditioned spaces in a home, insulation
should be added to reduce conductive, convective, and radiant heat gains and losses. Where
space and other factors permit, insulation should be installed to at least code-mandated levels
(e.g. R-8 for attic ducts and R-6 for ducts elsewhere per 2009 IECC). The most effective way to
insulate these ducts is often with “duct wrap” products, typically foil-faced fiberglass blankets.

Follow manufacturer’s instructions for installing duct wrap. Most of these instructions begin
with language such as, “Ducts shall be clean, dry, and tightly sealed….” This bears repeating:
ducts should be thoroughly sealed before insulating. In many situations, reducing duct leakage
will have much larger comfort and energy impacts than insulating ducts. Insulating ducts, even
with insulation seams tightly sealed, will not reduce duct leakage.

37
Typical installation instructions for duct wrap follow:

• Use gloves and proper protective equipment.

• Measure the perimeter of the duct to be insulated.

• From manufacturer’s literature, determine the proper dimensions of insulation needed to

cover duct completely without compression while providing the proper overlap.

• Roll out a section of insulation, measure, and cut appropriately.

• Trim 2” of insulation from all sections of duct wrap that will overlap other sections

• Wrap insulation around the duct; take care that compression is not severe at corners.

• Overlap facing and staple in place per manufacturer instructions.

• After insulation is in place, tape seams with appropriate tape to provide a more rigorous
air and/or vapor retarder.

Figure 55. Guidance on properly installing duct wrap

38
 Table 10. Step-by-step guide to properly installing duct wrap.

1. Roll out insulation,

measure (add 2” to the
duct perimeter), and cut
appropriately. Trim 2” of
insulation from all sections
of duct wrap that will
overlap other sections.

2. Wrap insulation around

the duct; take care that
compression is not severe
at corners.

3. Overlap facings

4. Staple insulation in place

per manufacturer’s
instructions. Tape seams
with appropriate tape to
provide a more rigorous air
and/or vapor retarder.

39
Of course, in tight spaces with irregularly-shaped ducts, following these instructions may not be
straightforward. Duct surfaces should be covered with the target level of insulation to the extent
possible. Many ducts are attached directly to floor joists or against walls, preventing insulation
from being wrapped completely around them. Insulating ducts in such locations may require
some creativity. If ducts are installed flush to floor or ceiling joists, insulation may only be able
to cover parts of ducts. Insulation should be sealed as much as possible around these gaps (with
appropriate tape, caulks, or mastic).

There may be areas where rigid insulation (such as fiberglass duct board) may be a more
practical material. Duct board may work well in conjunction with flexible duct wrap for parts of
sheet metal duct systems. Insulation should be attached and supported mechanically—tapes may
not be able to support the weight of the insulation under many conditions.

8.3 Ducts Beneath Attic Insulation

Heating and air conditioning ducts running through 130°F (summer) or 10°F (winter) attics are
subject to some pretty hefty thermal penalties. For ducts located in such attics, additional benefits
can sometimes be gained by “burying” sealed, insulated ducts beneath spray foam and/or blown
attic insulation. This strategy may not be practical in existing homes unless insulating and air
sealing of the attic is part of the renovation scope.

Burying ducts beneath attic insulation is only recommended in dry climates. Where attic
humidity is high, there is a greater risk that moisture will condense on the cool surface of the
duct beneath attic insulation. Ducts can still be buried under the attic insulation but additional
steps are required to prevent condensation formation. For more information on this, see Building
America Best Practices Series Volume 12: Builders Challenge Guide to 40% Whole-House
Energy Savings in the Cold and Very Cold Climates.

Figure 56. A duct board trunk partially buried beneath blown attic insulation. This may be impractical in
existing homes and in humid climates.

40
9 Testing Out
Initial testing (“testing in”) is important to make sure the home is safe, the systems are in
working order, and that sealing will likely not cause any detriment to performance. Testing after
the work is complete is also important to verify that systems are in safe, working order after
sealing has been performed.

9.1 Duct Leakage Tests

While duct leakage tests are not necessary to assess safety, the tests are useful to gauge impacts
of the duct sealing efforts. Duct leakage reductions are required by some programs, and testing
duct leakage (both before and after) is one of the best ways for duct sealers to gain experience in
the most effective duct sealing practices.

9.2 Airflow
Duct sealing can result in lower air flow across the heat exchangers. Repeat initial tests to see if
airflow is still in an acceptable range. If air flow is too low, HVAC contractors may need to
reconfigure the system to avoid coil freezing or damaging equipment. Depending on the project,
fixes may include increasing the size of ducts to reduce pressure drop; or installing properly-
sized, smaller-capacity equipment.

9.3 Combustion Safety

Because duct sealing can change the pressure patterns in a home, it’s important to repeat
combustion safety tests. If tests fail, the combustion problem must be remedied by a qualified
contractor. Remedies may include providing outside air for combustion, or replacing appliances
with sealed-combustion.

41
Appendix A: Measure Implementation Checklist
The nature and scope of home duct sealing and insulating efforts can vary substantially. Based
on these guidelines, the checklist below is presented as a potential framework (though not an
exhaustive resource) for conducting duct sealing and insulating efforts.

1. Inspect the duct systems.

Are the ducts visibly sealed and insulated? YES NO

Are they in need of any repairs? YES NO

If ducts appear to be well-sealed and insulated, further efforts may not be cost-effective. If the
answer is YES for the second question, repairs should be completed before sealing and insulating
efforts.

2. Inspect the home and duct system(s) for significant risks. Are any of the following
present?

Structural concerns YES NO

Exposed or knob-and-tube wiring YES NO
Severe water or mold problems YES NO
Severe insect or rodent infestations YES NO
Asbestos (or asbestos-like material) YES NO
Other toxic materials YES NO
Erratic or dangerous occupants YES NO
Occupants with health conditions who may be
YES NO
sensitive to work being done

If the answer is YES to any of these or if other serious risks are identified, do not proceed with
work until the risks have been addressed.

3. System Accessibility

Are the ducts accessible? Can they be safely accessed to

YES NO
perform testing, sealing, and insulating?

If ducts are not accessible, sealing will likely not be possible with conventional methods.

4. Combustion Safety Testing

4.1 During all tests, measure ambient carbon monoxide (CO) concentrations in the work
spaces. Abort work if CO concentrations rise above 35 ppm.

42
4.2 Identify all Combustion Appliance Zones (CAZ’s). For each combustion appliance,
record the following information

No. Location (CAZ) Make Model Fuel

1

Venting Type (e.g.

Input Capacity atmospheric, power vent, Notes
No. [Btu/h] sealed-combustion, etc.)
1

4.3 With all windows and doors closed and appliances turned off, measure the base pressure
with respect to outside in each CAZ.

CAZ Base Pressure [Pa]

4.4 Establish worst-case depressurization in each CAZ.

• Turn on all exhaust fans and clothes dryer.
• Turn on air handler - if pressure in CAZ decreases (wrt outdoors) then leave air handler on.
• Open and close key interior doors; leave doors in position where CAZ pressure is lowest.

Record the pressure in each CAZ (wrt outdoors) under worst-case conditions.

Worst-case
CAZ Pressure [Pa]

43
4.5 Fire the smallest combustion appliance in each CAZ. For each appropriate appliance 3
check for spillage, measure draft, and measure CO concentrations. Continue firing appliances
until all appliances in each CAZ are operating at once.

Spillage after one Flue CO

No. Location (CAZ) minute? Draft [Pa wrt CAZ] concentration [ppm]
1 YES NO

2 YES NO

3 YES NO

4.6 Continue monitoring ambient CO levels during testing. Record CAZ CO with all
combustion appliances.
CO concentration
with appliances
CAZ running [ppm]

4.7 Refer to BPI standards (Table 6 in main document) or other guidelines for acceptable test
results. If tests fail under worst-case conditions:
• Turn off appliances and allow to cool.
• Establish “natural” conditions (exhaust fans and dryers turned off, interior doors open)
• Repeat the tests (steps 3.4 – 3.5) under ”natural” conditions.

Refer to BPI standards for proper action levels. If combustion safety is in question, notify the
owner/occupants and do not perform work in the home until the problem is addressed.

5. Check air handler flow. Using one of the procedures described in the guidelines, determine
the appropriate air flow ranges for each air handler.

Unit Cooling Capacity Minimum Cooling Measured Cooling

No. Description [tons] Airflow [CFM] Airflow [CFM]
1

3
Checking for draft and flue CO concentrations is often not appropriate with sealed-combustion, direct-vent, and
power-vented appliances. Exhaust CO concentrations can sometimes be measured at the exhaust termination.

44
 Heating Temperature Acceptable Measured
Unit Capacity Rise Range Heating Flow Heating Flow
No. Description [Btu/h] [°F] Range [CFM] [CFM]
1

6. Duct Leakage Testing (optional). If appropriate, conduct leakage tests as described in the
guidelines to quantify and identify leaks.

Total Duct
Leakage Leakage to
System @25Pa Outside
No. Description [CFM] @25Pa [CFM] Notes, leakage areas
1

7. Develop sealing and insulating plan. Determine the scope of work; identify accessible ducts
with high leakage areas.

8. Seal ducts. Using mastic and/or tape as appropriate, seal all accessible ducts. Focus on leaks
outside of the conditioned space and near the handler. Record major areas sealed and take
pictures as appropriate.

45
9. Insulate ducts. When mastic has set, insulate accessible, uninsulated ducts as appropriate.
Focus insulation efforts on ducts outside the conditioned space. Record insulation installed
and/or take pictures as appropriate.

10. Test out. Repeat combustion safety tests (step 3) and airflow tests (step 4) to assure safe
operation. Conduct duct leakage test if appropriate (step 5).

46
Appendix B: Material Specification
Mastic. Air duct sealant for permanently sealing fabricated joints and seams of HVAC air ducts
and thermal insulation.
Required Certification: Water-based duct sealant – UL 181A-M and/or UL 181B-M
(depending on duct system type)
Additional Certification: Meets all SMACNA seal and pressure classes.
Relevant Test Methods: ASTM R-96, ASTM D-1310, ASTM E-84, ASTM C-731, ASTM D-
2202, ASTM C-732

Aluminum and/or Butyl Tape. Air duct tape for permanently sealing fabricated joints and
seams of HVAC air ducts and thermal insulation. All pressure-sensitive tapes used in the
manufacture of rigid fiberglass ducts shall be UL 181A listed and UL 181B for flexible ducts.
Required Certification: UL 181A-P, UL 181B-FX
Relevant Test Methods: ASTM D3330, ASTM D882, AAMA 809.2, ASTM E-96, ASTM
C711-72, ASTM C763-73

Duct Wrap Insulation. Thermally insulated fiberglass batt material that reduces unwanted heat
loss or gain and condensation during system operation.
Required Code Requirements: Meet IRC/IECC insulation requirements for climate.
Relevant Test Methods: ASTM C1290, ASTM C177, ASTM C518, ASTM C976

Closed Cell Spray Polyurethane Foam. Non-structural thermal insulating material that can be
spray applied.
Required Code Requirements: IRC - foam plastic, complies with NFPA Standards 286
Relevant Test Methods: ASTM C518, ASTM E84, ASTM E119

Flexible Duct. Thermally insulated, fully lined, flexible air duct designed for use in HVAC
distribution systems.
Required Certification: UL 181, complies with NFPA Standards 90A and 90B
Additional Certification: ADC-Certified R-values

Duct Board. Resin-bonded fiberglass formed into rigid rectangular boards faced on exterior with
a fire-resistant foil-scrim kraft vapor retarder and faced on the interior with a tightly bonded non-
woven mat.
Required Certification: UL 181, complies with NFPA Standards 90A and 90B
Relevant Test Methods: ASTM C 1136, ASTM G21, ASTM G22

Sheet Metal Duct. Fabricated ductwork from galvanized steel sheets. Duct systems shall include
UL 181 listed ducts with approved closure systems including collars, connections and splices.
Required Certification: UL 181
Relevant Test Methods: ASTM A653

Drawbands/Compression Band. Adjustable length stainless-steel worm-drive hose clamps or

uv-resistant nylon duct ties used to secure flexible ductwork to sheet metal collars. Using an
adjustable tensioning tool per manufacturer specifications is recommended.
Required Certification: UL 181A and a minimum tensile strength rating of 50 pounds

47
References
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[2009 IRC] International Code Council. (2009). International Residential Code. Washington,
DC: International Code Council.

Air Conditioning Contractors of America. (2010). HVAC Quality Installation Specification.

Arlington, VA: Air Conditioning Contractors of America. https://www.acca.org/Files/?id=693.
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[ASTM] American Society for Testing and Materials. (2007). ASTM E1554 -07, Standard Test
Methods for Determining Air Leakage of Air Distribution Systems by Fan Pressurization. West
Conshohocken, PA: American Society for Testing and Materials.

[BPI] Building Performance Institute. (2005). Technical Standards for the Building Analyst
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Building Technologies Program, Office of Energy Efficiency and Renewable Energy, U.S.
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Technologies Program.” DOE/GO102003-0783, Office of Energy Efficiency and Renewable
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[CARB] Consortium for Advanced Residential Buildings. “Retrofitting America: A 1970s

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swa.com/articles/homepage/RetrofittingAmerica_1970sHomeAnalysis.pdf. Accessed April 8,
2011.

[CEC] California Energy Commission. (2010). 2008 Building Energy Efficiency Standards:
Residential Compliance Manual. Sacramento, CA: California Energy Commission.
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REV1.PDF. Accessed September 27, 2011.

Cummings, J. B.; Withers, C. Jr. (January 2008). “Problems Related to Air Handler Leakage.”
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[Energy Conservatory] The Energy Conservatory. “Using a Pressure Pan to Diagnose Duct
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[EIA] Energy Information Administration. “Table US7: Unit Price by Fuels Used.” 2005
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http://www.eia.doe.gov/emeu/recs/recs2005/c&e/summary/pdf/tableus7.pdf. Accessed April 6,
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Hohman, J. (2011). HVACR 301. Florence, KY: Delmar Cengage Learning.

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http://www.greenbuildingadvisor.com/book/export/html/17758 Accessed March 7, 2011.

Moravek, J. (2009). HVACR 101. Florence, KY: Delmar Cengage Learning.

Moravek, J.; Hohman J.E. (2010). HVACR 201. Florence, KY: Delmar Cengage Learning.

[NREL Duct Insulation] National Renewable Energy Laboratory. “National Residential

Efficiency Measures Database: Retrofit Measures for Duct Insulation.” National Renewable
Energy Laboratory. http://www.nrel.gov/ap/retrofits/measures.cfm?gId=2&ctId=16 Accessed
April 7, 2011.

[NREL Duct Sealing] National Renewable Energy Laboratory. “National Residential Efficiency
Measures Database: Retrofit Measures for Duct Sealing.” National Renewable Energy
Laboratory. http://www.nrel.gov/ap/retrofits/measures.cfm?gId=2&ctId=17. (Accessed April 7,
2011).

Rutkowski, H. (2006). Manual J Residential Load Calculation (Eighth Edition). Arlington,

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Sherman, M. H.; Walker, I.S.; Dickerhoff, D.J. (2000). “Stopping Duct Quacks: Longevity of
Residential Duct Sealants.” Lawrence Berkeley National Laboratory, LBNL-45423.
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[SMACNA] Sheet Metal and Air Conditioning Contractors’ National Association. (1998).
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[UL 181A] Underwriters Laboratories. (2008). UL Standard 181A: Standard for Closure
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[UL 181B] Underwriters Laboratories. (2008). UL Standard 181B: Standard for Closure
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