Seal ductwork, save money

Submitted by Jaimie Cohen on May 17, 2007 - 12:57pm.
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Within the northeast Ohio region, the age and size of homes vary, as do the mechanical systems that exist to heat and cool these homes.  Often times, the ductwork that carries warmed or cooled air in and out of the house can be leaky and inefficient.  These inefficiencies lead to higher home energy bills, thermal discomfort, and indoor air quality issues.  According to the Department of Energy, most duct systems only perform at 60-75% efficiency.  Along with air sealing, sealed and insulated ducts are easy and affordable ways to solve these home energy issues.   With duct sealing and insulation, most systems work with 80% efficiency and save the homeowner $50-200 a year on home energy bills. 

There are a few DIY assessments you must make before starting a project.  First, locate your ductwork.  Ductwork can be located in the attic, crawlspace, garage or basement.  Unfinished (un-insulated) basements and attics are more likely to affect thermal comfort because they're located in less temperate areas of the house. Next, determine the type of duct material in your home. Steel and flex ducts are the most common duct materials found in homes and are often un-insulated. Finally, determine the method of improvement. If your ducts are already insulated, peel back the insulation and check for dirt or streaks. This is a sign that your ductwork is not sealed and that your insulation is NOT preventing air leakage. 

The first step to energy efficiency is sealing with these tools, which can be found at your local hardware store. To seal your ducts you will need:

  • Fibered Mastic
  • Mastic Tape
  • Heavy duty paint brush
  • Gloves

DO NOT use duct tape!  Duct tape does not seal, is susceptible to moisture, and will fall off after a few years. Foil tape, although a sealant, will not hold for very long either.  Your best bet for optimal efficiency is mastic tape. Ducts should be sealed at all joints and seams. This includes the connection between the air handler and the duct and all of the joint connections for galvanized steel ducts. Brush on the mastic like paint and make sure that all seams are fully sealed. For more information and where to seal, click here.

After you have sealed all of the ducts look into wrap insulation for visible ductwork. Many homeowners choose a contractor to insulate ductwork. Look for a contractor that will:

  • Inspect the whole duct system including attic crawlspace
  • Evaluate the system supply and return
  • Repair damaged and disconnected ducts and straighten out tangled or crushed ducts
  • Insulate ducts in unconditioned areas (crawlspace, attic, unfinished basement) with an insulation R-value of 8 of better
  • Include a new filter
  • Evaluate and test improvements
  • Ensure there is no backdrafting of gas or oil-burning appliances, and conduct a combustion safety test after duct improvements are complete.