How To Stop Minor Air Leaks in HVAC Systems

Here are some hacks for repairing air leaks using butyl tape that you can share with your customers to prevent waste of energy in time for Earth Day.

An HVAC system is an open system because most ductwork is installed in non-conditioned areas like the attic, basement, or crawl space. So when there is a leak, the ducts lose significant amounts of cooled or heated air to these large spaces. Studies have proven that leaky ducts lose up to 40 percent of heating and cooling energy. The HVAC system will then detect the need for more cooling or heating, making them work harder by about 50 percent more and use more power to fulfill this need. So if your customers leave them unfixed for a time, they will be spending around $300 a year in excess of their usual energy bills.

And because it’s Earth Day on April 22, being more environmentally responsible should be a priority in homes and businesses. Thankfully, butyl tapes do wonders in sealing air leaks and help prevent wasting energy and money. This article will discuss various ways to repair air leaks in HVAC systems, mainly with butyl tape.

How to repair air leaks in the equipment

Air leaks in HVAC air handlers are usually visible and can be felt and heard. The usual places to find them are at cover panels that are ill-fitting or panels with missing screws. To be more specific, they are the parts where air-conditioning pipes enter the housing, the attached air-filter insertion point entrance, and the plenum and return-air connectors.

These leaks can also result from improper installation of the equipment. Here are ways to repair them:

1. Check all the panels and connections and ensure they are secured with screws and all the panels are in place. 
2. Look for bent panels and straighten them. Repair their seals.
3. Use butyl tape to stop all leaks. This tape is a pliable synthetic rubber adhesive. It is waterproof and has corrosion-resistant properties, so it’s perfect for sealing leaks.
4. Ensure that all interior insulation is in place. They must also be tightly secured to the metal panels and walls.

How to repair air leaks in the air ducts

If you discover simple leaks in the air ducts, repairing them is easy, and professionals are not needed. Here are some tips for fixing them:

1. Check all the metal fittings and make sure that they are firmly screwed together on all four sides. Cover with butyl tape and re-insulate, preferably with eco-friendly insulation.
2. Inspect the drive connections and s-cleat on ductwork. Seal them with butyl tape as well.
3. Firmly secure the inner lining to the metal boot on flex duct with no metal ends with duct zip ties, then secure the outer wrap and insulation. The duct zip ties are acceptable for the exterior insulated wrap, but they are not strong enough to seal the duct to the slick metal fitting on the inner liner. Sheet metal screws, ones with washers at the spiral wire, are perfect for preventing the inner liner from slipping off.
4. Cover all connections of accessories butyl tape. 

How to repair leaks from duct damage

When people come in contact with ducts installed in storage areas like the basement or attic, more often than not, they get damaged and result in air leaks. Significant damage might require the replacement of the whole section of the ductwork, but butyl tape can fix minor rips and punctures.

Here are some tips for fixing leaks in the plenum or mixer box connections:

1. Fix the seams and screw them tightly together.
2. Tighten the connecting boots at the seams and seal with butyl tape.
3. Secure the insulation and make sure they are in place.

On the other hand, here are some tips for fixing leaks in the air diffuser boxes and grilles:

1. Check all seams and make sure that they are tightly fixed and screwed together.
2. Tighten all the connecting boots at the seams and use butyl tape to secure them.
3. Check for leaks between the discharge grille facing and ceiling joists or wall studs.
4. Ensure that all the non-grille surfaces are insulated.

How to repair air leaks in the air returns

You will need to closely inspect air returns for air leaks because they can be pretty difficult to locate. Negative pressure is not only hard to see, but it is also hard to hear. Furthermore, the spaces between ceiling joists or wall studs or the non-ducted returns are usually the sources of air pollutants indoors and outside leaks. 

Here are ways to fix air returns leaks:

1. Make sure to fit all the air returns with tight plastic or metal lining to cover all sources of leaks. You can also seal the inside with butyl tape.
2. Check for leaks in the space between the ceiling joists or wall studs and the return grille facing.

How to repair air leaks in filter housings

Finally, the filter housing can also get air leaks. Separate filter housings are located in open areas, and because they are regularly cleaned and changed, they can start leaking air in time. Sealing with butyl tape to prevent future leaks can be a hassle for service and maintenance, so only seal the damages. Use sealing gum instead if you want to secure the filter housings.

The takeaway

Checking for air leaks in HVAC systems should be done regularly to prevent overworking the HVAC and paying ridiculously high energy bills. But before calling professionals, try fixing the leaks yourself, as most repairs would only need the sealing of butyl tape. Consider getting help for major damages or leaks that cannot be secured with tape, duct zip ties, and sealing gum.

This information is worth sharing with your customers as these inspections and repairs are worth their time and energy for a more energy-efficient and comfortable home or business establishment. Make every day Earth Day and be more mindful of your energy consumption.