June 30, 2025
Introduction
Even in modern commercial buildings, small issues can lead to big problems. One common issue that often goes unnoticed is duct leakage. This happens when air escapes through gaps or cracks in the building’s HVAC ductwork.
In this post, we’ll cover why duct leakage testing matters, how it impacts energy and air quality, and how to prevent expensive problems. If you’re a building owner, contractor, or facility manager, this information will help you protect your HVAC investment and keep your building running efficiently.
Here’s a surprising fact: duct leakage can waste up to 30% of the air that your HVAC system produces. That’s energy and money going straight out the door. Testing your ducts is a smart step toward better efficiency, comfort, and system performance.
1. What Is Duct Leakage and Why It Matters
Leaky ducts let air escape from your HVAC system before it reaches the areas it’s meant to cool or heat. This usually happens at joints, seams, or areas where the ductwork wasn’t properly sealed during installation. Over time, wear and tear can also lead to cracks or disconnections.
Why duct leakage testing matters:
- Escaped air causes uneven temperatures, making rooms too hot or too cold.
- HVAC systems must run longer to make up for lost air, using more energy.
- Leaky ducts can prevent your building from meeting ventilation and energy codes.
Industry standards like ASHRAE 90.1, IECC, and SMACNA call for airtight duct systems in commercial projects. If you’re targeting LEED or WELL certification, duct testing is usually part of the commissioning process.
Key takeaway: You can’t fix what you don’t measure. Duct leakage testing provides the data you need to seal the system and optimize airflow.
2. The Cost of Ignoring Duct Leakage
Many property owners don’t realize the true cost of untested ductwork until it’s too late. Beyond wasted air, leaking ducts can lead to higher bills, lower system performance, and frequent maintenance.
Here’s what can happen:
- Energy waste: Leaky ducts can waste up to 30% of conditioned air, driving up your energy bills.
- System problems: Fans, compressors, and motors work harder, leading to faster breakdowns and expensive repairs.
- Delays and rework: If leakage is discovered during inspections or commissioning, you may face project delays or need to re-do sections of the ductwork.
- Code violations: Not meeting duct testing standards can result in penalties, re-inspections, and compliance failures.
In Central Florida’s active construction markets, such as Orlando, Lakeland, and Kissimmee, missing deadlines due to HVAC issues can result in delayed occupancy and lost revenue.
Preventive testing saves money and avoids last-minute surprises. It also builds trust with building inspectors, tenants, and green building consultants.
3. Indoor Air Quality and Comfort
Leaky ducts also affect the air your tenants breathe. In large commercial buildings, duct leakage can lower indoor air quality and make spaces uncomfortable for occupants.
Common problems include:
- Dust and mold: Leaks in return air ducts can pull in dirty air from ceiling voids, attics, or crawlspaces.
- Hot and cold spots: Poor airflow balance means some areas are too warm while others are too cool.
- Stale air: If fresh air isn’t delivered properly, indoor environments can feel stuffy, especially in high-use areas like offices, classrooms, or clinics.
In sensitive environments like healthcare facilities or schools, poor ventilation can lead to health complaints or even building code violations. Ensuring clean, balanced airflow supports occupant wellness and satisfaction.
Bottom line: Testing for HVAC air loss in commercial buildings improves both comfort and confidence.
4. Why Professional Duct Testing Pays Off
Regular duct leakage testing is an important part of any commercial HVAC maintenance plan. It helps you spot problems early, improve system performance, and avoid energy waste.
Benefits of professional duct testing:
- Accurate results: Certified testing confirms your system meets duct testing standards like NEBB, AABC, and ASHRAE.
- Lower energy use: Identifying and sealing leaks reduces energy loss and improves overall efficiency.
- Better indoor air: Properly sealed ducts deliver clean air evenly across all zones.
- Code and green building compliance: Testing supports LEED, WELL, and other building certifications.
- Smooth inspections: Passing the building pressurization test becomes easier when your ductwork is sealed and verified.
- Longer equipment life: When systems run efficiently, equipment lasts longer and requires fewer repairs.
SITA-TAB performs duct testing throughout Central Florida. Our team is well-versed in regional building codes, construction timelines, and climate demands specific to areas like Orlando, Lakeland, and the surrounding counties.
Whether you’re building new, upgrading existing systems, or preparing for commissioning, we provide reliable results and expert support.
Conclusion
Duct leakage may be out of sight, but it has a big impact. From higher energy costs to uncomfortable rooms and poor indoor air quality, leaky ductwork causes a ripple effect of issues.
Duct leakage testing gives you the tools to find and fix those problems before they turn into expensive repairs or project delays. It helps you save money, stay compliant, and improve building performance.
Including duct testing in your HVAC plan is a smart way to boost efficiency, protect your investment, and create healthier spaces for the people inside.
Ready to improve your building’s HVAC performance?
Contact SITA-TAB today for expert testing and balancing services that keep your systems running at their best.
