T e c h n o l o g y F a c t S h e e t

AIR DISTRIBUTION SYSTEM

INSTALLATION AND SEALING
Proper Duct Installation Increases Efficiency

INTRODUCTION
Central heating and cooling BENEFITS OF INSULATING AND SEALING DUCTS
systems use an air distribution or
Buildings for the duct system to circulate heated
21st Century and/or cooled air to all the
conditioned rooms in a house.
Buildings that are more Even when properly designed,
energy efficient, comfortable,
duct systems must be installed
and affordable… that’s the
correctly to be efficient, maintain
goal of DOE’s Building
uniform temperatures throughout
Technologies Program.
the house, operate quietly, and
To accelerate the development
and wide application of energy not adversely impact comfort or
efficiency measures, the indoor air quality.
Building Technologies Program:
WHY DUCT INSTALLATION AND
• Conducts R&D on technologies SEALING ARE IMPORTANT
and concepts for energy The efficiency of air distribution systems has gas from the soil. In extreme cases, poorly
efficiency, working closely with been found to be 60-75% or less in many installed duct systems can induce backdrafting–
the building industry and with houses because of insufficient and/or poorly spillage of flue gases from combustion
manufacturers of materials,
installed duct insulation and leaks in duct appliances (e.g., furnace, water heater, fireplace)
equipment, and appliances
systems. Properly designed and installed duct into the living space–primarily when atmospheric
• Promotes energy/money systems can have efficiencies of 80% or more or natural-draft flues are used rather than
saving opportunities to both for little or no additional cost, potentially powered combustion systems.
builders and buyers of homes
saving a homeowner $50-200 or more per year Duct systems that are undersized for the
and commercial buildings
in heating and cooling costs. Moreover, heating and cooling equipment, have been
• Works with state and local efficient duct system installations can reduce pinched to fit around structural framing during
regulatory groups to improve equipment size, further saving money for new installation, or have been installed with
building codes, appliance
or replacement equipment. numerous bends and turns may lead to low air
standards, and guidelines for
efficient energy use Duct systems that leak and/or do not distribute flow rates and high air velocities. Low air flow
air properly throughout the house may make rates cause the heating and cooling equipment
some rooms too hot and others too cold. Leaky to operate inefficiently. High air velocities
and unbalanced duct systems force conditioned increase noise.
air outside and unconditioned air into the Unfortunately, researchers have found these
house. This increases heating and cooling types of duct problems repeatedly in new and
costs and may also draw humidity, dust, mold existing homes because care was not taken
spores, and other contaminants into a home initially in installing the air distribution system.
from the attic, crawlspace, or garage and radon

BUILDING TECHNOLOGIES PROGRAM

OFFICE OF ENERGY EFFICIENCY AND RENEWABLE ENERGY • U.S. DEPARTMENT OF ENERGY
DUCT INSTALLATION PRINCIPLES DUCT INSTALLATION STANDARDS
The objectives of a properly designed and installed duct The installation guidance presented in this fact sheet should
system are occupant comfort, proper air distribution, be followed insofar as it does not conflict with applicable
economical heating and cooling system operation, and building codes and the following standards:
economical duct installation. Such a duct system is one that Sheet Metal and Air Conditioning Contractors’ National
• Provides conditioned air to meet all room heating and cooling Association, Inc. (SMACNA) Residential Comfort System
loads. Installation Standards Manual (1998, seventh edition) and
• Ensures that the pressure drop across the air handler is within Fibrous Glass Duct Construction Standards (1992, sixth
manufacturer and design specifications. edition). SMACNA’s HVAC Duct Construction Standards—Metal
and Flexible (1995, second edition), although primarily for
• Provides proper air flow.
commercial and industrial projects, details good construction
• Prevents air from entering the house or duct system from and installation practices that could improve residential
polluted zones. applications.
• Maintains a neutral pressure in the house by having balanced Air Diffusion Council (ADC) Flexible Duct Performance &
air flows between the supply and return systems. Installation Standards (1996, third edition).
• Minimizes duct air temperature gains or losses between the air North American Insulation Manufacturers Association
handler and supply outlets, and between the return register (NAIMA) Residential Fibrous Glass Duct Construction
and air handler. Standards and A Guide to Insulated Air Duct Systems.
During the design of the duct system, the layout and locations Underwriters Laboratory (UL) Standard for Factory-Made Air
of the ducts are identified, duct materials are chosen, the sizes Ducts and Air Connectors (1996, ninth edition).
of the ducts are calculated, insulation levels are identified, and
registers are selected. Duct installation ensures that the duct GENERAL DUCT INSTALLATION GUIDELINES
design is achieved in practice by addressing three critical Air distribution ducts are commonly constructed from sheet
elements: metal, rigid fiberglass duct board, or flexible duct. General duct
installation recommendations specific to these different
• Mechanical integrity—the system will remain as built for the
materials are outlined below. In addition, the air handler,
life of the house, without developing leaks, obstructions, or
plenums, and duct boots form parts of the air distribution
insulation failure.
system. General installation guidelines for these components
• Freedom from leaks—all the air moved by the air handler will
are also provided.
be drawn from and delivered to the intended conditioned
Duct systems should be installed inside the conditioned
spaces.
(living) and semi-conditioned spaces of the house to the
• Proper insulation—conditioned air does not exchange heat greatest extent possible (but not in exterior wall cavities). Any
with unconditioned spaces. air leakage in ducts located inside the house will not
significantly affect the energy efficiency of the heating and
cooling system because the conditioned air will remain inside
the house. Also, ducts located inside the house need minimal
insulation (in hot and humid climates), if any at all.
Duct systems should be hard-ducted as much as possible.
Duct system installations that use the house structure or
building framing (e.g., building cavities, closets, raised-floor air
handler plenums, platform returns, wall stud spaces, panned
floor joists) as supply or return ducts can be relatively
 BOOT AND DUCT CONNECTION HIGHLIGHTS DUCT BOARD

FIBERGLASS DUCT BOARD DUCTS

Fiberglass duct board is insulated and sealed as part of its
construction. It is usually used to form rectangular supply and
return trunks, branches, and plenums, although it can be used
for runouts as well. Fiberglass duct board provides excellent
sound attenuation, but its longevity is highly dependent on its
closure and fastening systems. Connections should be
inexpensive to install. However, they should be avoided mechanically fastened using shiplap or V-groove joints and
because they are difficult to seal and cannot always be stapling and sealed with approved pressure-sensitive tapes
insulated. In addition, because they tend to be rough and have and mastic.
many twists and turns, it is difficult to build them so as to
FLEXIBLE NONMETALLIC DUCTS
ensure good air distribution. Even return plenums built under a Flexible nonmetallic duct (or flex duct) consists of a duct inner
stairway or in a closet, for example, should be avoided if a liner supported on the inside by a helix wire coil and covered
completely ducted system is possible. by blanket insulation with a flexible vapor-barrier jacket on the
SHEET METAL DUCTS outside. Flexible duct is often used for runouts, with metal
Sheet metal is the most common duct material and can be used collars used to connect the flexible duct to supply plenums,
on most all supply and return duct applications (for plenums, trunks, and branches constructed from sheet metal or duct
trunks, branches, and runouts). Sheet metal ducts have a board. Flexible duct is also commonly used as a return duct.
smooth interior surface that offers the least resistance to air Flexible duct is factory-insulated and has fewer duct
flow. They must be carefully and completely sealed during connections and joints. However, flexible duct is easily torn,
construction/installation, using approved tapes or preferably crushed, pinched, or damaged during installation. It has the
mastic, because each connection, joint, and seam has potential highest resistance to air flow. Consequently, if used, it must be
leakage. Screws should be used to mechanically fasten all properly installed.
joints. When located in an unconditioned space, sheet metal
ducts must be insulated with either an interior duct liner or
exterior insulation.
AIR DISTRIBUTION SYSTEM INSTALLATION AND SEALING

Connections between the air handler

FLEX DUCT SEALING TIPS cabinet and the main supply and
return plenums or ducts should be
sealed with mastic or approved
pressure-sensitive tapes. It is
sometimes easier to remove service
panels and seal these areas from the
inside using mastic.

PLENUMS
Fiberglass duct board is often used
to build supply and return plenums.
Mastics or approved tapes may be
used to assemble butt joints on
fiberglass duct board components
such as plenum boxes. Although it is
not recommended, closets, spaces
under stairs, and other such areas of
the house are often used as return
plenums. Because these plenums are
located inside the house, the need to
Flexible nonmetallic ducts should not have an air-permeable seal them is often overlooked. Unless they are well sealed,
core. Flexible ducts must be stretched to their full length and these plenums will frequently allow unconditioned air to be
cut to fit (not compressed) using the minimum length required drawn into the system from the attic, crawl space, or outside.
to make the connection. Flexible duct that is not fully stretched Be sure to seal all such plenums completely—all seams, gaps,
has high air-flow resistance and tends to sag between and penetrations through the ceiling, floor, and walls. Seal the
supports. Connections and joints must be mechanically air handler unit to the shelf of a closet return system.
fastened using drawstraps and sealed using mastic. Bends in
DUCT BOOTS AND ELBOWS
flexible ducts should not exceed 90 degrees and should have a Seal all joints between ducts, duct boots, and/or elbows with
radius greater than one duct diameter. mastic or approved tapes. Seal any leaks in the boots or elbows
AIR HANDLER with mastic, approved tape, or elastomeric caulk. Extend duct
Because system pressures are highest at the air handler, holes, boots at the supply and return registers through the wall,
cracks, and other openings at the air handler will cause more ceiling, or floor material and make sure duct boots are sealed to
air leakage than elsewhere in the system. Air handlers located the ceilings, walls, or floors. Sometimes boots may be most
in the attic, garage, or crawlspace, or outside in single- easily sealed from the inside, after installation; however, the
packaged heat pumps or gas-packs, warrant special attention. sealing material must be installed so that it does not interfere
Use mastic, cork rope or tape, or caulk to permanently seal with installation or removal of the register.
unused holes, seams, wire penetrations, and refrigerant and
condensate line penetrations in the air handler cabinet. Use
approved pressure-sensitive tapes to seal access panels.
AIR DISTRIBUTION SYSTEM INSTALLATION AND SEALING

INSTALLATION MATERIALS SEALING MATERIALS

FASTENERS The two primary materials used to seal ducts during installation
Mechanical fasteners—screws, staples, and draw bands— are mastic and tapes, although other sealants may also be used
should be used to secure all joints between sections of duct. in special applications. Use all mastics, tapes, and other sealants
Materials intended to seal against air leaks—such as tapes, according to manufacturer instructions. Clean and dry joints,
mastics, and other sealants—should not be used to hold seams, and openings of oil, grease, and dirt before applying
sections of duct together except where mechanical fasteners sealants, especially when using tapes and non-mastic sealants.
are not feasible. Ducts should also be well supported so that Duct insulation does NOT stop leakage and is NOT a sealing
joints are not pulled apart or the duct distorted (pinched) so material; in fact, dirty insulation is a telltale sign of air leakage.
that its air flow is reduced. • Mastics—Mastics that meet UL Standards 181A or 181B may be
• Screws—On transverse joints in round sheet metal ducts that used to seal duct joints. Use mastics labeled UL 181A-M for
use sleeves or swedge or crimped fittings, use at least three fiberglass ducts, UL 181B-M mastics for flexible ducts, and either
metal screws equally spaced around the joint to ensure that for rigid metal ducts and components. Water-based mastics are
the joint cannot become separated. For vertical connections preferable to petroleum-based mastics because they have shorter
made on flexible duct, install at least three screws below the curing times, easier cleanup, and more “forgiving” application
drawband used to secure the inner lining to prevent slippage. characteristics. Mastic must not be diluted. Mastic should be
Duct boots must be mechanically secured to the building applied liberally over the entire joint between and over mated
using screws so that the boots do not rely on the ducts for surfaces. When using over holes or gaps that are larger than 1/8
support. to 1/4 inch, apply a thick layer of mastic followed by at least one
• Staples and Tape—Ducts constructed from fiberglass duct layer of fiberglass mesh tape, topped by a layer of mastic that fills
board should be fastened together using clinching staples on the scrim pattern completely and covers the mesh.
approximately 2-inch centers and approved pressure-sensitive • Tapes—Heat-activated and pressure-sensitive tapes that meet
tape. Where staples cannot be used, joints should be held UL Standards 181A or 181B and are marked for use in the
together using approved pressure-sensitive tapes. The tape intended application can be used to construct ducts and, in
should be placed over the seam and 8-inch-long (minimum) some cases, seal ducts and other distribution system
crosstabs taped on each side of the duct with a distance of components. Heat-activated tape should be labeled UL
12 inches or less between crosstabs. 181A-H and used only on rigid fiberglass ducts. Use pressure-
• Drawbands—When joining flexible ducts to each other or to sensitive tapes labeled UL 181A-P for rigid fiberglass ducts,
other types of duct, the flexible duct must be fitted over a 181B-FX for flexible ducts, and either for rigid metal ducts and
beaded sleeve or collar and attached with drawbands components. Pressure-sensitive tape used on rigid fiberglass
(UV-resistant nylon duct ties or preferably metal worm-drive ducts should be rubbed firmly until the pattern of the facing
hose clamps, both with a temperature rating of 165°F)—one reinforcement shows through the surface of the tape. When
drawband to secure the inner lining and a second drawband to taping traverse joints, wrap the tape three times.
attach the outer insulation jacket. Pressure-sensitive metallic tape with non-butyl adhesive is useful
• Support Straps—Round sheet metal ducts suspended in the to temporarily seal air handler access panels that may need to be
air should be supported by hangers at least every 10 feet. opened in the future. When sealing access panels, a card should
Flexible ducts suspended in the air should be supported at be taped to the access panel that says “Please Replace Any Tape
least every 4 feet by straps that are at least 1½ to 1¾ inches That is Removed” as a reminder to future repair personnel.
wide, and they should not sag more than ½ inch for each foot Cloth-backed rubber-adhesive (duct) tapes should not be used
of distance between the supports. Straps used on flexible because they deteriorate with time and exposure to heat.
ducts should not constrict the inner diameter of the duct or Pressure-sensitive metallic tape with butyl adhesive (not
cut the outer jacket. meeting UL Standard 181) can be used to seal metal-to-metal
connections. Cork tape can be used to seal gaps where
refrigerant lines penetrate the air handler unit cabinet.
AIR DISTRIBUTION SYSTEM INSTALLATION AND SEALING
For more information, contact: DUCT LEAKAGE TESTING • Insulation must be continuous, especially at
Energy Efficiency and Renewable Once ducts have been installed and sealed, the plenums, boots, elbows, and connections
Energy Clearinghouse (EREC) only way to really know how leaky they are is (i.e., no gaps or voids in the insulation).
1-800-DOE-3732 to conduct a duct airtightness test. Such tests
www.eere.energy.gov • Wraps of spirally-wrapped unfaced
can be performed using a special fan called a
Or visit the Building Technologies insulation should overlap at least 2 inches.
Program Web site at blower door or, better, with a special duct
www.buildings.gov blower. Often, energy efficiency incentive • Permanently secure insulation to the duct
programs, such as the DOE/EPA Energy Star® with draw bands, non-corrosive wire,
Or refer to the Duct Installation and
Sealing Standards, Specification of Program, require duct leakage testing (usually rust-resistant staples or nails, or
Energy-Efficient Installation pressure-sensitive tape wrapped at least
performed in less than an hour) to confirm the
Consortium for Energy Efficiency
airtightness of the ducts. A typical requirement three times around the circumference.
617-589-3949
www.cee1.org/resid/rsac/hvac.php3 is that duct leakage measured when the ducts Parallel-wrapped faced insulation is usually
Written and prepared for the are pressurized to 25 Pascals should not secured with pressure-sensitive tape. Secure
U.S. Department of Energy by: exceed 5% of the system air flow rate. unfaced parallel-wrapped insulation at least
Southface Energy Institute every 18 inches along its length using non-
404-872-3549 DUCT INSULATION taping methods. Attachments should not
www.southface.org
Insulate all portions of duct systems located compress the insulation more than 20%
U.S. Department of Energy’s outside of the conditioned space (including along straight duct lengths and no more
Oak Ridge National Laboratory
Buildings Technology Center boots and plenums), typically using flexible or than 50% in bends.
865-574-5206 rigid fiberglass insulation. Metal ducts located • When flexible ducts are joined, the insulation
www.ornl.gov/btc
in the conditioned space may be insulated to jackets must overlap at least 2 inches. The
SMACNA’s manuals may be obtained prevent condensation. Adhere to the following
from 4201 Lafayette Center Drive, overlap must be secured and sealed with a
Chantilly, Virginia 20151-1209 guidelines when selecting and installing the draw band or with three staggered wraps of
703-803-2980, www.smacna.org insulation. pressure-sensitive tape.
ADC’s standards can be obtained from • Select the insulation levels for the duct
1000 East Woodfield Rd, Ste. 102, • Install a continuous vapor barrier outside the
system in accordance with the 2000
Schaumburg, Illinois 60173 insulation (e.g., foil-faced fiberglass
847-706-6750, www.flexibleduct.org International Energy Conservation Code. Use
insulation sealed with pressure-sensitive
NAIMA standards and guidelines can higher duct insulation levels in ducts located
metallic tape) on metal ducts that are used
be obtained from Canal Center Plaza, outside the conditioned space than those
for space cooling, except in dry climates
Ste. 310, Alexandria, Virginia 22314
specified by this Code, especially when
703-684-0084, www.naima.org where condensation on the duct surface will
variable-speed air handling equipment is
UL’s standards may be obtained from not occur. Tears in the insulation facing
www.ul.com being used. Lower air flows provided by
(especially the outer lining of flexible duct)
variable-speed heating and cooling systems
The International Energy Conservation must be avoided to prevent moisture
Code can be obtained from the to improve operating efficiency increase the
accumulation in the insulation, which
International Code Council resident time of air within the air distribution
703-931-4533, www.intlcode.org significantly reduces its effectiveness.
system, which in turn increases thermal
• At duct terminations (e.g., boots, collars), the
NOTICE: Neither the United States losses in the winter and thermal gains in the
government nor any agency thereof,
insulation jackets of flexible ducts should be
summer. Attic insulation placed over ducts
nor any of their employees, makes any pulled over the insulation and secured and
helps where it is possible.
warranty, express or implied, or sealed to the fitting with a draw band, mastic
assumes any legal liability or
responsibility for the accuracy, and fiberglass mesh tape, or three wraps of
completeness, or usefulness of any pressure-sensitive tape.
information, apparatus, product, or
process disclosed. The views and
opinions of authors expressed herein
do not necessarily state or reflect those
of the United States government or any Printed with a renewable-source ink on paper containing at least
agency thereof. 50% wastepaper, including 20% postconsumer waste.
March 2003 DOE/GO102003-0783