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More Information

Photograph of disconnected air conditioning duct in a crawl space

Loose, Leaky, or Blocked Air Conditioning or Heating Ducts
InspectAPedia®  -         

  • Loose or disconnected air conditioning or heating ducts, causes, effects, repairs
  • Air Conditioning (or Heating) Duct Defects
  • Detecting duct leaks & missing duct connections
  • Field reports of missing air conditioning duct work list associated costs
InspectAPedia offers impartial, unbiased advice without conflicts of interest. We will block advertisements which we discover or readers inform us are associated with bad business practices, false-advertising, or junk science. Our contact info is at InspectAPedia.com/Contact.htm.

This article describes the effects of and how to find & repair blocked, clogged, crimped, loose or leaky air conditioning or heating ducts, leaky air duct connections, defective heating or cooling ductwork.

The photo at page top shows what happens when cooling ducts are poorly connected through a crawl space. The crawl space was nice and cool but no cool air was being delivered to the living space. in addition, the air blowing around in the crawl space stirred up fiberglass and debris, including mold which increased the movement of these particles into the occupied space.

For diagnosing poor air flow from an air conditioning or heating system also see RETURN AIR REGISTERS & DUCTS and SUPPLY DUCTS & REGISTERS. We also provide a checklist of more air duct troubleshooting suggestions at RETURN DUCT AIR LEAKS or at SUPPLY DUCT AIR LEAKS. And at UNSAFE DUCT OPENINGS we discuss certain air duct leaks and openings that are downright dangerous.

© Copyright 2012 InspectAPedia.com, All Rights Reserved. Information Accuracy & Bias Pledge is at below-left. Use page top links to major topics or use links at the left of each page to navigate within topics and documents at this website. Green links show where you are in a document series or at this website.

This chapter continues discussion of common defects found in air conditioning duct work such as loose or leaky duct connections and their effect on the air conditioning or heating system.

The master document, of which this is a chapter, describes the inspection of residential air conditioning systems (A/C systems) to inform home buyers, owners, and home inspectors of common cooling system defects.

HVAC Duct Connection Leaks - Poor duct work connections

Most-common Types of Air Duct Leaks

Photograph of loose supply duct connection metal duct work Photograph of loose supply duct connection flex duct

Disconnected Cool Air Supply Duct Hidden in Crawl Area

A client who lived in an apartment in New York City engaged our company to find why her city apartment could not get cool even though she had a new air conditioning system installed. We found that the ducts had become disconnected in the attic crawl space where the air handler was placed. It was wonderfully cool in the attic. The apartment was quite hot. So were the electric bills. Below at Soffit Cool Air Blast we describe a more egregious case of duct work that was missing entirely.

These photographs show the two most-common air conditioning or heating duct leaks, at a loose falling metal duct connection (left photo) and at a poorly-secured flex-duct connection (right photo). Leaking supply air at these connections means less cool air (or warm if it's heat) delivered to the occupied space.

If the air conditioning system output at the registers is poor, especially if it is working in some building areas but not others, one of the first things to check is the condition of the duct work. Look for and seal leaks like these. Also review the other duct and supply adequacy defects described at articles linked-to from the left of these pages.

Supply duct leak (C) Daniel FriedmanThe cure for these duct leaks is simple: reconnect leaky duct sections (photo at left).

In addition to making a mechanically sound connection beween duct sections (sheet metal screws, mechanical fasteners, nylon tie strips), we use metal foil tape to complete the seal on connected metal duct sections. The flex-duct connection was re-made and a tighter plastic band used to secure the flex duct in place.

Watch out: don't rely just on duct tape to secure air ducts.

But the cost of air duct leaks can be significant if the leak persists over a long time or in a location where blowing air or loss of dehumidification lead to mold or other indoor air quality concerns. Leaky air ducts can significantly increase building heating or cooling costs and can lead to other building or even health worries. The Florida air duct leak field report case just below illustrates this problem.

Soffit Cool Air Blast Traced to Hidden Missing Air Conditioner Duct - Mistake by Builder

We live in a manufactured home built by Homes of Merit a.k.a. Champion Homes in Florida. We have been living in this house for about 9 years, and we have already have had to replace our A/C unit, having been told it was "worn out". But we didn't suspect that there was a hidden cause of that failure until today. The house is 27 feet wide by 57 feet long each part has its on air conditioning trunk line system.

I was fixing my back door which my house is 30" above ground level, so I was up on a ladder when I noticed there was cool air coming out the soffit with great force. I told my wife that this is probably why our electric bill has always been higher than for similar homes in our area: $300 to $400 a month. I concluded that there must be a loose air duct connection that was blowing cool air into the inaccessible attic space over our home, pressurizing that area, and leaking out at the soffits.

To investigate this duct problem I had to cut an 18" opening in the gable to gain access to the attic space. When I cut the last side to remove the siding, the cool air pressure blowing out on me was like a strong floor fan! I had to crawl on my belly across the rafters to get where I could see what was going on. I thought all I would need would be a piece of duct tape to seal an opening somewhere. Instead I found that there was the air conditioning cool air supply duct junction box and a 15" - 18" galvanized connector sticking out into the open attic. There was no continuing cool air duct work bringing air into the occupied space!

I thought that maybe this duct section was inactive, that it was sealed so to test it I took a long stick with a piece of toilet paper on the end so I could look for air flow in attic areas out of reach - the space was so tight that I could go no further. Placing my toilet paper flag in front of what I thought would be the sealed opening I found that the air flow was so strong it nearly ripped the paper off the stick.

In short, there was a fifteen foot open separation between the supply air conditioning duct trunk line from the kitchen and the rest of the supply duct, laying wide open. Since the construction of the house 9 years ago, the duct had never been connected.

I know this seems a bit like out of a movie but we have had health issues plus all the money thrown out the attic. The return air vent draws the air through the kitchen but through the attic which is wide open to the outdoors.

We just don't know what dust, debris, mold, insect junk may be up there in the attic, being stirred up and blown into the house each time the air conditioning system comes on. Further, cooling the attic may have caused condensation of warm moist air in some attic areas, leading to a moldy insulation or mold on wood problem that also may have been blowing into our home.

We have suffered high cooling costs (high electric bills), inadequate air conditioning, and indoor air quality worries that might explain some of our health issues, since the house was built. - [name withheld] June 2010

Basement one way air duct (C) Daniel FriedmanOne-Way HVAC Air Duct Designs:

From a different building, here is a photo (left) of an air handler drawing all of its return air from a basement.

This is a "one way" heating or air conditioning duct design - all HVAC air originates in the basement and is "conditioned" before being blown into the building.

This is the most costly and least healthy duct design. At Return Duct Air Leaks & What They Mean we summarize the impact of missing or open return air ducts.

Cooling or Heating Duct Retrofit Leaks in Old buildings

Photograph of companion to basement bypass Photograph of basement bypass to register in bath

These photographs show what can happen when existing registers and in-wall ducts are re-used when installing updated air conditioning or heating ducts in a building. The photo with my hand shows us feeling an up-draft from the basement below this first floor bath even though the air conditioning system was not running. The second photograph shows the problem as seen from the basement.

The duct installer had simply pushed smaller-diameter new oval ducts up into the existing duct riser from the basement, leaving more than an inch of opening between the old rising duct and the new inserted duct. The result was leakage of cool air backwards into the basement when the central air conditioning system was running, and leakage of (moldy, smelly) basement air up into the living space through the same opening (by convection) when the air conditioning system was off.

The cure for this duct leak was to use some spray foam insulation to make a better seal at the basement ceiling as well as around the register in upper floor.

Rooftop Duct System Leaks & Water, Mold, and Pathogens

Photograph of rooftop ducts leak water into fg lined duct Photograph of interior of leaked-into fg lined rooftop duct

These photographs show what happens when a rooftop packaged-terminal air-conditioning airhandler
(PTAC) and horizontal runs of air-ducts are installed on a roof surface and when that air duct system is improperly sealed and also is lined with fiberglass insulation.

Water ponded on the old, concave sections of air conditioning ducts on the roof of this commercial office space. As water leaked into the duct system it saturated fiberglass duct liner which in turn, had its normal coating of organic dust and debris from the building, risking an indoor mold or pathogen problem for some of the occupants.

The cure for these duct leaks was costly: it was determined that it was less costly to completely replace the rooftop ducts with new metal ducts using outside insulation than it would have been to remove the contaminated fiberglass liner, clean the existing ducts, repair the leaks, and insulate their exterior. The work was combined with other building HVAC cleaning and repairs.

More detailed suggestions of things to check in the duct system to improve airflow are at RETURN DUCT AIR LEAKS or at SUPPLY DUCT AIR LEAKS. Also see UNSAFE OPENINGS

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AIR CONDITIONING & HEAT PUMP SYSTEMS
AIR CONDITIONER COMPONENT PARTS
A/C - HEAT PUMP CONTROLS & SWITCHES
A/C - HEAT PUMP CRITICAL DEFECTS
A/C DIAGNOSTIC FAQs
A/C TYPES, ENERGY SOURCES
A/C REFRIGERANTS

AIR CONDITIONER BTU CHART
SEER RATINGS & OTHER DEFINITIONS
OPERATING COST
SYSTEM OPERATION
OPERATING TEMPERATURES
OPERATING DEFECTS
LOST COOLING CAPACITY
CHINESE DRYWALL HAZARDS
COMBUSTION GASES & PARTICLE HAZARDS
CONDENSATE HANDLING, A/C
CONDENSATION or SWEATING PIPES, TANKS
COMPRESSOR & CONDENSING COIL, A/C
AIR FILTERS for HVAC SYSTEMS

AIR HANDLER / BLOWER UNITS
ANIMAL ALLERGENS / PET DANDER
ANIMAL ENTRY POINTS in buildings
ANIMAL ODORS IN buildings
APPLIANCE EFFICIENCY RATINGS
ASBESTOS IDENTIFICATION IN buildings

BACKUP HEAT for HEAT PUMPS

BLOWER DOORS & AIR INFILTRATION
BLOWER FAN CONTINUOUS OPERATION
BLOWER FAN OPERATION & TESTING

BOOKSTORE - Air Conditioning "How To" Books

CAPACITORS for HARD STARTING MOTORS
CAPILLARY TUBES
CLEANING & Legionella BACTERIA
CHINESE DRYWALL HAZARDS
COMBUSTION GASES & PARTICLE HAZARDS

COMPRESSOR & CONDENSING COIL, A/C

CONDENSATE HANDLING, A/C
BACKUP HEAT for HEAT PUMPS

BLOWER DOORS & AIR INFILTRATION
BLOWER FAN CONTINUOUS OPERATION
BLOWER FAN OPERATION & TESTING

BOOKSTORE - Air Conditioning "How To" Books

CAPACITORS for HARD STARTING MOTORS
CAPILLARY TUBES
CLEANING & Legionella BACTERIA
DUCT SYSTEM & DUCT DEFECTS
  AIR FILTERS for HVAC SYSTEMS
  ALLOY SYSTEMS FLEXDUCT
  ASBESTOS HVAC DUCTS
  ASBESTOS PAPER on DUCTWORK
  ASBESTOS TRANSITE DUCTWORK
  BALANCING AIR DUCT FLOW
  DUCT & AIR HANDLER ODORS
  DUCT DAMAGE, MECHANICAL
  DUCT INSULATION - Asbestos Paper
  DUCT ROUTING & SUPPORT
  DUST CONTAMINATION FROM HVAC?
  FIBERGLASS DUCT, RIGID CONSTRUCTION
  FIBERGLASS HVAC DUCTS
  FIRE DAMPERS in DUCTWORK
  FLOOD DAMAGE in DUCT WORK
  GOODMAN GRAY FLEXDUCT
  INCREASING RETURN AIR
  LEAKY DUCT CONNECTIONS
    Leaky or Missing Air Ducts
    Hidden Missing Air Conditioner Duct
    Duct Retrofit Leaks
    Rooftop Duct Leaks
    RETURN DUCT AIR LEAKS
    SUPPLY DUCT AIR LEAKS
  LOCATION OF REGISTERS & DUCTS
  MOLD in AIR HANDLERS & DUCT WORK
  NOISES in DUCT SYSTEM
  ODORS in AIR HANDLERS & DUCT WORK
  OWENS CORNING FLEXDUCT
  OWL FLEXDUCT
  RETURN AIR REGISTERS & DUCTS
  SOUNDPROOFING for DUCTWORK
  SUPPLY DUCTS & REGISTERS
  TRANSITE PIPE AIR DUCTS
  UNDERSIZED RETURN DUCTS
  UNSAFE DUCT OPENINGS
  VIBRATION DAMPENERS
  WATER & ICE IN DUCT WORK
  WET CORRODED DUCT WORK
  ZONE DAMPER CONTROLS

ENERGY SAVINGS in buildings
EVAPORATOR COIL or COOLING COIL
EVAPORATIVE COOLING SYSTEMS
EVAPORATOR COIL or COOLING COIL
EXPANSION VALVES, REFRIGERANT

FAN, AIR HANDLER BLOWER UNIT
FAN AUTO ON Thermostat Switch
A/C REFRIGERANTS
A/C - HEAT PUMP CRITICAL DEFECTS
A/C DIAGNOSTIC FAQs
INSPECTION CHECKLIST - OUTDOOR UNIT
INSPECTION LIMITATIONS

FURNACES WARM AIR HEATING SYSTEMS
INDOOR AIR QUALITY IMPROVEMENT GUIDE

  • Thanks to Jon Bolton, an ASHI, FABI, and otherwise certified Florida home inspector who provided photos of failing Goodman gray flex duct in a hot attic.
  • Thanks to reader B.B. for discussing air conditioning duct failures, June 2010
  • Air Diffusion Council, 1901 N. Roselle Road, Suite 800, Schaumburg, Illinois 60195, Tel: (847) 706-6750, Fax: (847) 706-6751 - info@flexibleduct.org - www.flexibleduct.org/ -
    "The ADC has produced the 4th Edition of the Flexible Duct Performance & Installation Standards (a 28-page manual) for use and reference by designers, architects, engineers, contractors, installers and users for evaluating, selecting, specifying and properly installing flexible duct in heating and air conditioning systems.
    Features covered in depth include: descriptions of typical styles, characteristics and requirements, testing, listing, reporting, certifying, packaging and product marking.
    Guidelines for proper installation are treated and illustrated in depth, featuring connections, splices and proper support methods for flexible duct. A single and uniform method of making end connections and splices is graphically presented for both non-metallic and metallic with plain ends."
    The printed manual is available in English only. Downloadable PDF is available in English and Spanish. 
  • Owens Corning Duct Solutions - www.owenscorning.com/ductsolutions/ - provides current HVAC ductwork and duct insulating product descriptions and a dealer locator. Owens Corning Insulating Systems, LLC, One Owens Corning Parkway, Toledo, OH 43659 1-800-GET-PINK™
  • "Flexible Duct Media Fiberglas™ Insulation, Product Data Sheet", Owens Corning - see owenscorning.com/quietzone/pdfs/QZFlexible_DataSheet.pdf
    "Owens Corning Flexible Duct Media Insulation is a lightweight, flexible, resilient thermal and acoustical insulation made of inorganic glass fibers bonded with a thermosetting resin."

Books & Articles on Building & Environmental Inspection, Testing, Diagnosis, & Repair

  • Our recommended books about building & mechanical systems design, inspection, problem diagnosis, and repair, and about indoor environment and IAQ testing, diagnosis, and cleanup are at the InspectAPedia Bookstore. Also see our Book Reviews - InspectAPedia.
  • Complete List of Air Conditioning & Heat Pump Design, Inspection, Repair Books at the InspectAPedia Bookstore.
  • Home Reference Book - Carson Dunlop The Home Reference Book - the Encyclopedia of Homes, Carson Dunlop & Associates, Toronto, Ontario, 2010, $69.00 U.S., is available from Carson Dunlop. The Home Reference Book is a bound volume of more than 450 illustrated pages that assist home inspectors and home owners in the inspection and detection of problems on buildings. The text is intended as a reference guide to help building owners operate and maintain their home effectively. InspectAPedia.com ® author/editor Daniel Friedman is a contributing author. Field inspection worksheets are included at the back of the volume.
  • Modern Refrigeration and Air Conditioning, A. D. Althouse, C.H. Turnquist, A. Bracciano, Goodheart-Willcox Co., 1982
  • Principles of Refrigeration, R. Warren Marsh, C. Thomas Olivo, Delmar Publishers, 1979
  • "Air Conditioning & Refrigeration I & II", BOCES Education, Warren Hilliard (instructor), Poughkeepsie, New York, May - July 1982, [classroom notes from air conditioning and refrigeration maintenance and repair course attended by the website author]
  • Refrigeration and Air Conditioning Technology, 5th Ed., William C. Whitman, William M. Johnson, John Tomczyk, Cengage Learning, 2005, ISBN 1401837654, 9781401837655 1324 pages
  • Carson Dunlop, Associates, Toronto, have provided us with (and we recommend) Carson Dunlop Weldon & Associates' Technical Reference Guide to manufacturer's model and serial number information for heating and cooling equipment ($69.00 U.S.).
  • Air Conditioning Inspection, Diagnosis, Repair, Efficiency all the basics for home owners, inspectors, new repairmen
  • NewAir Conditioning SEER - New DOE Air Conditioner and Heat Pump Efficiency Standard
  • Asbestos HVAC Ducts and Flues field identification photos and guide
  • Fiberglass: Indoor Air Quality Investigations: Fiberglass in Indoor Air, HVAC ducts, and Building Insulation
  • ...
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