8/29/2018

1

Improving Energy Efficiency and IndoorAir Quality with HVAC

Duct Sealants

Copyright © 2018 NADCA, All Rights ReservedNo part of this publication may be reproduced or distributed by any means, electronic or mechanical, including photocopy, recording, or any other information storage and retrieval system, without prior written consent from the publisher.

Presenters

Frank ForrestTimothy D. Eorgan

Disclaimer

This presentation is not intended to be a comprehensive program covering all

aspects of this topic. All technicians are encouraged to read and follow all applicable

standards, codes and regulations related to this topic.

� It is the responsibility of each individual contractor to follow local building codes

and licensing requirements and to work safely in accordance with OSHA

guidelines.

� It is the contractor’s responsibility to take proper precautions on each project to prevent cross contamination. Always take the health and safety of the building

occupants into consideration before you conduct any cleaning procedures.

� All of the following tips are only general tips. They do not cover every situation

and it is your responsibility to adapt these tips to the individual system you are working on.

� The Instructor is not responsible in any way for the work you perform after

viewing this slide show. You are responsible for your own work.

� The views and opinions following are the instructors opinions and not necessarily

the official position of the National Air Duct Cleaners Association.

8/29/2018

2

Objectives

� Briefly describe environmental concerns over energy issues and explain how HVAC air leakage contributes to these concerns

� Describe the reasons why sealing ductwork is critical to maximizing HVAC system efficiency

� Explain duct sealing options and list the advantages of each

� Business � How to sell an upgraded system to include sealing� What to look for� Ball park costing to seal

Briefly describe environmental concerns over energy issues and explain how HVAC air leakage contributes to these concerns

Objective 1

Energy Consumed

Data Source: ©2010-2011 2030 Inc. / Architecture 2030. All Rights Reserved

Buildings consume about ½ the global demand of

energy ($) and materials that produce by-product

greenhouse gases (GHG). Slowing the growth rate of GHG emissions and then reversing it is the key

to addressing climate change

8/29/2018

3

Electricity –Building Operations

Data Source: ©2010-2011 2030 Inc. / Architecture 2030. All Rights Reserved

Electrical Energy Consumption in Commercial Buildings

Cost of Leakage

NEBB uses $1.30 per sq.ft.

What rule of thumb do you use for cfm per sq.ft.?

8/29/2018

4

Energy and Duct

Leakage

According to the EPA, leaking duct systems account for approximately 30% of energy loss in residential and commercial buildings.

Describe the reasons why sealing ductwork is critical to maximizing HVAC system efficiency

Objective 2

Duct Leakage

*EER =Energy Efficiency Ratio ; SEER = Seasonal Energy Efficiency Ratio

� Lawrence Berkeley National Laboratory (LBNL): duct leakage exceeded the ASHRAE recommended leakage classes by roughly a factor of 20.

� Duct Leakage Tests*

� 6% duct leakage per California Energy Commission building standards reduces EER* by 7% and SEER* by 14% 13 SEER = 11 SEER

� 15% duct leakage per Energy Star ® reduces EER* by 18% and SEER* by 24% 13 SEER = 9+ SEER

� 30% duct leakage common of many US homes reduces EER* by 36% and SEER* by 42% 13 SEER = 7.5 SEER

2012 ASHRAE Annual Conference June 23–27, San Antonio, TXRobert Mowris, P.E., Robert Eshom, A.S., Ean Jones, B.S. VERIFIED™, Inc.ASHRAE TC 6.3Session Title: HVAC Installation and Maintenance: Challenges and Uncertainties in Field and Laboratory

8/29/2018

5

Duct Leakage

� Over 2 billion dollars annually in energy loss through leaky ductwork just in commercial buildings.

� Light commercial buildings tend to have significantly higher duct leakage rates than large commercial buildings. Light commercial buildings typically are not commissioned (unlike larger buildings), so duct leakage problems are not identified and fixed. In addition, smaller commercial building projects may not involve an HVAC design engineer.

� Also, identified as a major source of energy loss in residential buildings.

Duct Leakage & Energy Issues

When Ducts Leak

� Reduces System Capacity

� Reduces Life of HVAC Unit (runs longer/more often)

� Creates Hot/Cold spots (inconsistent heating and cooling) which also reduces thermal comfort of occupants

� All factors Use more energy

&

Increases Utility Costs

Energy Loss

Noted at the joints by the black residue

spiral duct

slip and drive seam

8/29/2018

6

Energy Loss

Noted at the joints by the black residue

spiral duct

What are you Sealing?

� Equipment

� AHU

� Heat exchangers

� VAV

� Accessories

� fire dampers

� dampers� heaters

� HW coils

� etc.

� Duct System

� Riser/chase duct

� All floors? Partial system?

� Round duct or rectangular ? Both?

Test Setup for Leakage Test

8/29/2018

7

Seal off the ATU to Trunk Joint

Test up to VAV Box

Tester Connected to Duct System –EXISTING SYSTEM

8/29/2018

8

Tester Connected to Duct System –NEW SYSTEM

Explain duct sealing options and list the advantages of eachObjective 3

UL Criteria:

Mastics for

Sealing

Ductwork

Testing parameters required by UL-181

� Surface Burning Characteristics

� Burn Test

� Mold Growth and humidity

� Temperature Test

� Pressure Test

� Shear Adhesion

� Tensile Joint Strength

� Peel Adhesion

8/29/2018

9

Mastic Quality Control

� Often one year or less – some maybe only 6 months.

� Installer should verify that shelf life has not been exceeded.

� All mastic products should be labeled with a lot number to insure that the key physical properties of each batch meets published specifications.

Mastic Quality Control

Each lot # must be tested at the quality control lab

wet sample preparation cured sample ready for testing

Sample tested and passed no cracking or delamination

IAQ and VOCs

� Mold Growth and VOC thresholds� while zero VOCs sounds good - this does not

prevent mold growth.

� VOCs� water based sealants with minimal VOCs

� Less than 250g/l for water based sealants

8/29/2018

10

Options

� Mastic� Water based or

� Solvent based

and

� Brushed or

� Sprayed

� Rolled Mastic Sealant

Mastic -attributes and benefits

• Faster application

• More consistent application

• Good for odd angles -• UV or non UV rated

• Service temperature range

• Mildew resistant

• Viscosity

• Freeze/thaw stability

• Cure Time• Rated to what pressure class –up to 10”

w.g.

• Seal Classes- SMACNA-ABC

• UL listed –Flame and Smoke data

• LEED criteria

• LA approved• FDA approval of base polymers

• Water or solvent based

Mastic -Brushed

� Reinforced� always water based

� can only be used for sheet metal (and ductboard applications with a scrim)

� Meets both UL 181A-M and UL181B-M

� Non-reinforced� either water based or solvent based

� use for flex duct and sheet metal; meets UL 181B-M

8/29/2018

11

Mastic Brushed Application Process

Click image to play video

Mastic Brushed Application Process

Avoid over-working

8/29/2018

12

Drive and Drive transverse joint-uncured sealant at 45 minutes dry time. Pressure tested to 6-inch w.c.

Corner-uncured sealant at 40 minutes dry time. Pressure tested to 6-inch w.c.

Over-pressure before curing –“volcano”

Mastic -Sprayed

�Only non-reinforced

�Used for flex duct and sheet metal

�Always water based - low VOC

�Meets UL 181B-M

8/29/2018

13

Mastic Spray Application Process

Click image to play video

Not your everyday duct tape

Rolled Mastic Sealant CharacteristicsProvides a water-resistant instant bond that seals most

surfaces and conforms to surface variations.

� Minimum thickness 17 mils up to 30mils

� Type of backing – foil faced or fabric

� UV or non UV rated

� Peel Strength

� Tensile strength

� Bonding time - immediate

� Flexibility

� Mildew resistant

� Rated to what pressure class –up to 10” w.g. .

� Service temperature range

� Seal Classes- SMACNA- A,B,& C

� LA approved

� Paintable

� No VOC – only true zero VOC sealant

� Use for low and medium pressure flex duct and sheet metal

� Ideal for Replacement Applications

� Easy to Use with No Mess

� Approved for Indoor and

Outdoor Use

Rolled Mastic Sealants

8/29/2018

14

Rolled Sealant –Application Process

Rolled Sealant – Application Process

Click image to play video

Rolled Sealant – Finished Applications

Example

8/29/2018

15

Example

Example

Example

8/29/2018

16

Example

Combined Systems

� Orlando, Florida - Rosen Shingle Creek Hotel

� Design Challenges:� High humidity

� Increased atmospheric salinity

� Existing building

Combined

Rolled

Sealants

and Mastic

System

� Reduced moisture going into duct system

� Reduced air leakage and energy loss

4/13/2012

8/29/2018

17

Combined Rolled Sealants and Mastic System LA Job Corp, 1031 South Hill St.

Combined

Rolled

Sealants

and Mastic

System

Combined Rolled

Sealant and Mastic

System

�Critical applications; Pharmaceutical laboratories where vivarium air is up to $10.00/cubic ft.

�Hospitals

�Semiconductor manufacturers

�Corrosive environments

�Water concerns

8/29/2018

18

Which Sealant to Use?Product Use Base

Pressure

ClassesRecommended Application

Ind

oo

r

Ou

tdo

or

So

lve

nt

Wa

ter

Pre

ssu

res

1/2

" -

6"

wg

Pre

ssu

res

6"

-1

0"

wg

Ro

un

d D

uct

Ov

al

Du

ct

Re

cta

ng

ula

r D

uct

Alu

min

um

Du

ct (

Cle

an

ed

)

Sta

inle

ss S

tee

l *

Fle

xib

le D

uct

Rid

ge

d F

ibe

rgla

ss D

uct

bo

ard

4 B

olt

Co

nn

ect

ion

s

Rid

ge

d P

VC

Co

ate

d D

uct

(A

bo

ve

Gro

un

d)

Rid

ge

d P

VC

Co

ate

d D

uct

(B

elo

w G

rou

nd

)

Mastic Duct Sealants

Non-Reinforced Water-Based Mastic

(UL 181 B-M)• • • • • • • • • • • •

Non-Reinforced Water-Based Spray Applied Mastic (UL

181 B-M)• • • • • • • • • • • •

Reinforced Water-Based Mastic 181

(UL 181 A-M) (UL 181 B-M)• • • • • • • • • • • • •

Solvent Based Mastic (UL 181 B-M) • • • • • • • • • •

Elastomeric Rolled Sealants**

Foil Faced Rolled Sealants UL 181-BFX) • • N/A • • • • • • • • • •

Foil Faced Rolled Sealants (UL 723) • • N/A • • • • • • • • • • •

Where to Seal: Longitudinally

8/29/2018

19

Joint Sealants

� Longitudinal Joint Sealants

� Solvent-based permanently tacky seam sealant

� Very thick so must be pumped

� Flammable due to solvents

� Water-based seam sealant

� Higher viscosity close to a spray able

� Non-flammable – ASTM E84 0/0

� Fab shop application where they are manufacturing Pittsburgh, snap-lock or similar style metal duct seams.

Where to Seal: Transversely

1

2

3

4

3

8/29/2018

20

• Select a test pressure not in excess of the

pressure class rating of the duct. (Usually the actual operating pressure.)

Test Pressure?

Business

• How to sell an upgraded system to include sealing

• What to look for

• Ball park costing to seal

Objective 4

How to sell an upgraded to the system you are cleaning.

Meeting the latest code and energy savings

8/29/2018

21

ASHRAE 90.1

�World’s most adopted building energy code

�Basis for International Energy Conservation Code (IECC)

Seal Classes – SMACNA

Sheet Metal and Air Conditioning Contractors National Association—

Std.90.1; 2010 All ducts are required to be constructed to Seal Class A

2009 & 2012 International Energy Conservation Code-IECC ; All Residential is tested; Commercial < 3” must be sealed but not tested. over 3” must be sealed

and tested at 25 % surface area or greater.

Because safety codes, energy codes, and standards are developed independently, the most recent edition of a code or standard may not have been adopted by a local jurisdiction. HVAC designers must know which code compliance obligations affect their designs. If aprovision conflicts with the design intent, the designer should resolve the issue with local building officials

COMMERCIAL- 12/17 https://www.energycodes.gov/status-state-energy-code-adoption

RESIDENTIAL12/17

8/29/2018

22

Applicable Leakage Classes

What to look for during your initial site appraisal (?)

As NADCA members you will recognize the following pictures and typical problem

locations

8/29/2018

23

8/29/2018

24

Where to Seal

8/29/2018

25

Where to Seal

Where to Seal

Most duct leakage occurs at the connections to registers, plenums, or branches and duct wall penetrations.

8/29/2018

26

Ball park costing to seal

Bucket & Brush Application

Time per piece/distance

Duct type Corners Longitudinal Seams Transverse Joints

4 Bolt Flange 1.2 minutes per corner 1.2 minutes per foot 50 seconds per foot

TDC/TDC 1.2 minutes per corner 0.5 minutes per foot 20 seconds per foot

Slip & Drive N/A 1 minute per foot 40 seconds per foot

Rolled Sealant Application

Time per piece/distance

Duct type Corners Longitudinal Seams Transverse Joints

4 Bolt Flange 1 minute per corner 0.66 minutes per foot 4.4 minutes per foot

TDC/TDC 1 minute per corner 0.66 minutes per foot 1.5 minutes per foot

Slip & Drive N/A 0.66 minutes per foot 3 minutes per foot

Spray Application

Time per piece/distance

Duct type Corners Longitudinal Seams Transverse Joints

4 Bolt Flange 0.4 minutes per corner 0.4 minutes per foot 20 seconds per foot

TDC/TDC 0.4 minutes per corner 0.17 minutes per foot 7 seconds per foot

Slip & Drive N/A 0.285 minutes per foot 14 seconds per foot

4 Bolt Flange TDC/TDF Flange Slip & Drive

Sealing TypeTotal Cost (Labor & Product) Sealing Type

Total Cost (Labor & Product) Sealing Type

Total Cost (Labor & Product)

Bucket & Brush $296.28 Bucket & Brush $224.11 Bucket & Brush $191.55

If Rolled $1,079.00 If Rolled $500.83 If Rolled $668.00

If Sprayed $176.78 If Sprayed $134.14 If Sprayed $139.03

Combination 701/Mastic (B&B) $1,375.28

Combination 701/Mastic (B&B) $724.94

Combination 701/Mastic (B&B) $859.55

Combination 701/Mastic (Spray) $1,255.78

Combination 701/Mastic (Spray) $634.97

Combination 701/Mastic (Spray) $807.03

8/29/2018

27

Improving

Energy Efficiency and

Indoor

Air Quality with HVAC Duct

Sealants

Presenter Contact Information

• Timothy D. Eorgan• Tim.Eorgan@CarlisleHVAC.com

• (972) 442-6545

Improving

Energy Efficiency and

Indoor

Air Quality with HVAC Duct

Sealants

• Frank Forrest• frank.forrest@carlislehvac.com

• (972) 442-6545

Thank you for

Participating!