The document provides information about properly installing HVAC systems, including sealing ductwork to reduce energy losses and improve indoor air quality. It discusses code requirements for duct insulation, sealing, and leakage testing. Key points covered include the benefits of locating ducts within the thermal boundary, using mastic to seal ducts, proper sizing of HVAC equipment according to manual J load calculations, and sealing existing duct systems.

1. Quality HVAC System Installation Trust But Verify

2. Quality HVAC System Installation The goal for a Heating, Ventilation and Air Conditioning (HVAC) system is to provide proper air flow, heating, and cooling to each room

3. Instructor Barbara Collins ERH West Building Performance Consultant Certified NAHB Green Building Verifier Certified RESNET HERS Rater Energy Star Homes Partner Certified Environments for Living Verifier

4. Class Objectives Understand HVAC system air leakage testing requirements in the 2009 IECC Recognize the benefits of sealing ducts for savings, system performance and indoor air quality Understand how ducts are tested for leakage Identify resources for local building departments Identify the best techniques to seal duct systems; what inspectors should see on inspections Understand the IECC requirements for sizing of HVAC equipment

5. Current Code Requirements Must comply with all aspects of UL181 standards Fittings, joints & seams of duct system shall be made substantially air tight by means of tapes, mastics, gasketing or other means.

6. Ducts - IECC Insulation (Prescriptive) Ducts outside the building envelope: R-8 All other ducts: R-6 Sealing (Mandatory) Joints and seams shall comply with IRC, Section M1601.4.1 Building framing cavities shall not be used as supply ducts

7. 2009 IECC Duct Tightness Tests All ducts, air handlers, filter boxes and building cavities used as ducts shall be sealed (Section 403.2.2) Duct tightness shall be verified by testing Only Exception: Duct tightness test is not required if the air handler and all ducts are located within conditioned space Mandatory Requirements

8. SEAL DUCTS, SAVE ENERGY Sealing ducts is a cost-effective energy efficiency practice that gives a high return on investment

9. HVAC System Poor design and installation increases energy costs 10 –30% Sizing Design Installation

10. Home Energy Use Residential energy use 22% of U.S. total 25% of carbon emissions in U.S. Heating & cooling is 40 – 60 % of home energy use

11. Why seal ducts Leaks waste energy and money Average system leakage New construction 20% Existing homes 30% Duct sealing reduces heating and cooling energy losses and saves money

12. Other Problems Duct leakage reduces air flow, conditioned air isn’t delivered to rooms which can cause wide temperature swings between rooms IAQ issues with return leaks drawing in air from attics, garages, crawlspaces Pressure differentials can cause excess building air leakage and back drafting

13. Duct Tightness Tests Post construction tests Option 1 Leakage to outdoors: ≤8 cfm/per 100 ft 2 of conditioned floor area OR Option 2 Total leakage: ≤12 cfm/per 100 ft 2 of conditioned floor area Mandatory Requirements

14. Duct Tightness Tests Rough-in test Options Option 1 Total leakage ≤6 cfm/per 100 ft 2 of conditioned floor area OR Option 2 If air handler not installed at time of test total air leakage ≤4 cfm/per 100 ft 2 Mandatory Requirements

15. Exceptions: Duct tightness test is not required if the air handler and all ducts are located within conditioned space Thermal Boundary is also used to define whether testing is required. Insulation installed on underside of roof sheathing, AHU and ducts in attic, can be considered within thermal boundary

16. Ventilation Outdoor air intakes and exhausts shall have automatic or gravity dampers that close when the ventilation system is not operating Mandatory Requirements

17. Test Protocol Pressurize the HVAC system, measure CFM of air required to reach pressure Test at a pressure differential of 0.1 in w.g. (25Pa) across entire system, including manufacturer’s air handler enclosure

18. Test Equipment

21. Testing at rough-in

22. Testing Post Construction

23. Testing leakage to outside

25. Testing leakage to outside

26. Mastic Sealant Non-toxic – Low VOC Green credits Recommended Set time = 20 hours

27. More on Mastic High strength adhesive compound Usually applied by trowel, brush, caulking gun or hand 3 types- water-based; solvent-based; and two-component curing systems Water-based is the safest and easiest to use It performs as well and in some cases better than the other 2

28. VOCs in mastics Volatile organic compounds In water-based mastics, the only volatile compound is water which is inorganic VOCs are infinitesimally small (not recordable) Water-based mastics pose a low health risk compared to solvent-based and two-component mastics Safer for the user, better IAQ, greener

29. How to apply mastic Step 1 - Clean Duct Surface Wipe dust oil and grease from the duct surface Step 2 - Apply the mastic Gaps less than 1/4″, load brush with mastic and coat entire joint with a continuous strip Use brush end to work mastic into joint Spread mastic at least one inch on each side of the joint. The mastic should be thick enough to hide the metal surface of the duct.

30. Mesh for Gaps If gap is larger than 1/4 inch use fiberglass mesh too If mesh is sticky on one side, cut enough to cover joint, press in place, then completely cover it with mastic. If mesh does not have a sticky side, apply a thin layer of mastic, press mesh into the mastic, then apply a finish layer of mastic.

33. AIRTIGHT DUCT SYSTEM Boots and Cans Seal seams with mastic Thin mastic will crack Make seal permanent Plug Don’t Paint Thick as a Nickel = .077 in 1/16 inch = .0625 in

37. FLEX DUCT TO METAL Flexible Ducts Seal inner sleeve & outer sleeve Plastic strap holds the inner liner firmly to the duct or fitting. Mastic seals liner to connection and covers the end of the liner Use draw band to hold outer sleeve (vapor barrier) Vapor barrier should be complete. All holes, rips, and seams must be sealed with mastic or approved tape

39. AIRTIGHT DUCT SYSTEM Metal Ducts and Plenums, Duct Board Boxes Openings greater than 1/4 inch should be sealed with mastic and mesh Openings less than 1/4 inch should be sealed with mastic Special attention to collar connections to duct-board and/or sheet metal; seal around the connection with mastic

40. Ts Ys & Ls Use mesh tape to strengthen the joint where ducts of different shapes meet. Seal all seams, even manufactured ones.

43. Seal Gores

45. Sealant applied, still leaks

46. FABRICATION & INSTALLATION GUIDELINES The air handler box should be air-tight

47. AHUs & Plenums Fill all openings for wiring, plumbing and refrigerant lines. Seal all seams in the air handler and plenums. Tape around access panels, so they can be opened for service.

48. Air Handler Leaks

49. Mechanical Systems & Equipment

53. AIRTIGHT HVAC SYSTEM Air handlers on platforms May be located in a closet indoors Framers must be told not to put plywood top on before walls are sheetrocked (or duct board) to underside of platform floor All wall surfaces must be sheetrocked next to and in platform Seal all joints

54. Boots Seal all joints, including manufactured seams. The transition between the duct and boot may require mesh tape.

56. AIRTIGHT DUCT SYSTEM All Duct Types Register boxes should be sealed to the drywall or floor with caulking or mastic

57. AIRTIGHT DUCT SYSTEM All Duct Types Register boxes should be sealed to the drywall or floor with caulking or mastic

64. SHEET METAL CONNECTIONS Start the inner fitting into the outer fitting Apply a 2” wide band of mastic to the exposed part of the inner fitting Fully seat the joint and mechanically fasten with sheet metal screws or rivets Apply a 2.5” wide band of mastic to the outside of the joint covering the screws or rivets and joint gap Allow at least 12 hours drying time before starting system Temperature and humidity conditions can vary, longer dry times may be required

67. Locating ducts within thermal boundary Within thermal boundary means within insulated space and within the air barrier boundary. Attics and crawlspaces can be but are usually not conditioned space Critical that space is truly indoors and sealed from unconditioned areas Multi-level dwellings more easily accommodate ducts in conditioned space

68. Ducts in Unconditioned Space Usually ducts are located in attics and crawlspaces Big temperature differences increase conduction losses and loads Long duct runs in attics lose 15%+ of cooling capacity before end Convection losses by leakage

69. Benefits of locating ducts in conditioned space Ducts can be smaller May have shorter runs reduce pressure drop and improve efficiency Can reduce HVAC system costs by reducing loads Improve comfort No Testing in 09 IECC

77. EXISTING HOMES In existing homes, not unusual to find disconnected duct components, takeoffs loose from ducts or ducts disconnected from register boots

78. For Sealing Existing Systems Tools & Materials Head lamp, hat with light, or flashlight A work board to span joists in attics Gallon pail and 2-3 caulk tubes of mastic Caulk Gun, mastic brush, fin and plenum brush Roll of mesh 2-3 pairs of latex gloves 2-3 cloths, can of coil and fin cleaner to wipe joints clean before applying mastic and clean up Utility knife and telescoping mirror Pliers, screw driver and tin snips

79. Sealing Priorities 1. Disconnected components 2. Connections between the air handling unit and the plenums 3. All seams in the air handling units and plenums, takeoffs, boots, and other connections, especially site-built items.

80. EXISTING HOMES Leaks connected to the outdoors are more important than leaks inside home’s thermal envelope Holes near the air handler are more important than distant holes with relatively low pressures Supply system leaks waste more energy than return system leaks Furnaces

81. Remove tie holding duct to connection Roll back insulation and outer cover Seal inner core with mastic and band Roll insulation down and vapor barrier/outer cover Put band and seal with mastic

82. Wrap Ducts with insulation Insulation may be installed over wet mastic but do not move the ducts too much or mastic seal could be damaged. All duct support work should be done before applying mastic Wait 2 -4 hours and water based mastic will be dry to the touch

88. Oversizing What do you get when you combine cognitive bias with inaccurate information?

89. Oversizing Old Rules of Thumb One Size Fits All US Department of Energy Most systems are oversized, increasing installation cost for every house

90. Oversizing Sizing example 2000 SF House with standard metal windows w/ .75 U-Value and .88 SHGC and 20% duct leakage Calculated Sensible cooling load = 58880 Btu

91. Equipment Sizing Load calculations determine the proper capacity (size) of equipment Goal is big enough to ensure comfort but no bigger Calculations with ACCA Manual J protocol or other approved methods Mandatory Requirements

93. Oversizing Sizing example Same 2000 SF house with Low-E windows and tight duct system @ 5% leakage Sensible cooling load = 43877 Btu Average of 1-2” decrease in duct diameter sizes

94. Oversizing Installation cost is higher Operating cost over life of equipment is higher Can cause comfort problems Improvements in building envelope reduce loads

95. Right Sizing Costs less to install – saves builder money Costs less to operate - not starting and stopping all the time Short cycling can cause bigger swings in supply air, less comfort Better humidity control

96. DESIGN HVAC SYSTEM Loads and CFM Calculation ACCA Manual J Load Calculation or equivalent required Calculate heat loss and heat gain for each room Total room loads to determine system requirements.

97. Manual J –Load Calc The local climate – ASHRAE 30 year average Size, shape, and orientation of the house Insulation levels Window area, location, and type Air infiltration rates Number of occupants Types and efficiencies of lights and major home appliances (which give off heat) ACCA - Air Conditioning Contractors of America www.acca.org

98. “ It’s tough to make predictions, especially about the future.” - Yogi Berra

99. U.S. Dept of Energy 30/30 Vision 2012 IECC 30% More Stringent 2006 IECC More verification testing

100. A Quality HVAC System Be properly sized to provide correct air flow, and meet room-by-room calculated heating and cooling loads. Have sealed ductwork that will provide proper air flow. Be installed with a return system designed to provide correct return air flow. Have balanced air flows between supply and return systems to maintain neutral pressure in the home. Be properly charged with refrigerant

101. Verifying Charge

102. Ductwork Single most important energy measure for most homes- low hanging fruit Locating inside conditioned space is optimal Seal joints with mastic not duct tape

103. Equipment Size Oversizing is common and expensive – upfront and during life Sizing properly can reduce cost and help pay for increased cost of other efficiency features

104. Learn from the mistakes of others. You can't possibly live long enough to make them all yourself --Sam Levinson

105. Thank you for participating Any questions Please complete your evaluation sheets so we can plan future events