Why Leaky and Undersized Ductwork Is One of the Biggest Comfort Problems We See
In Coastal North Carolina, ductwork matters more than most homeowners realize. High humidity, hot attics, crawlspaces, and long cooling seasons amplify every duct flaw—especially leakage and undersizing.
That’s why we perform duct air leakage testing using professional Retrotec equipment, not guesswork. We don’t just install duct systems—we test them, measure them, and stand behind the results.
What Is Duct Air Leakage Testing?
Duct air leakage testing measures how much conditioned air escapes from your duct system before it ever reaches the rooms it’s supposed to serve.
Using Retrotec duct testing equipment, we:
- Pressurize the duct system
- Measure air loss in cubic feet per minute (CFM)
- Identify leakage locations
- Quantify performance against recognized standards
This isn’t a visual inspection or a “looks good from here” approach. It’s measurable, repeatable data.
Why Duct Leakage Is a Bigger Problem in Coastal Homes
In coastal climates like Beaufort, Morehead City, Emerald Isle, Atlantic Beach, and New Bern, duct leakage doesn’t just waste energy—it directly affects comfort, humidity, and system reliability.
Leaky ducts can:
- Pull hot, humid attic air into the system
- Dump cold supply air into unconditioned spaces
- Increase indoor humidity even when the AC is running
- Force systems to run longer and harder
- Accelerate equipment wear
In short: leaky ducts make humidity problems worse, not better.
Our Experience: We Test Our Own Ductwork—And It Shows
Here’s something we’re proud of and very direct about:
Our installed duct systems frequently test at or better than ENERGY STAR duct leakage standards.
That doesn’t happen by accident.
We see a lot of duct systems installed without any testing at all. When ductwork is never measured, no one actually knows how it performs. We believe testing is part of professional installation—not an optional upgrade.
Our opinion:
If ductwork isn’t tested, it isn’t finished.
What We Commonly Find in Existing Homes
When we test existing duct systems in Coastal NC homes, two issues show up again and again:
1. Excessive Duct Leakage
- Unsealed boots
- Leaky plenums
- Poorly connected flex runs
- Aging tape instead of mastic
- Ducts never sealed after renovations
2. Severely Undersized Duct Systems
This one surprises homeowners.
We frequently find duct systems that are:
- Too small for the actual airflow the system requires
- Designed by rule of thumb
- Never evaluated against Manual D airflow requirements
Undersized ducts increase static pressure, reduce airflow, and create room-to-room comfort problems—especially in humid coastal conditions.
Why Undersized Ducts Hurt Coastal Homes More
In hot, humid climates, airflow is critical. When ducts are undersized:
- Air velocity increases
- Static pressure rises
- Cooling coils don’t perform as designed
- Dehumidification suffers
- Comfort complaints never fully go away
Even high-end equipment can’t overcome poor duct design.
Our experience:
Many “AC problems” we’re called to fix are actually duct problems.
Condensation Issues in Hot, Humid Attics
One of the most damaging problems we see in Coastal NC is duct condensation in attics.
This often happens when:
- Ducts are undersized
- Ducts are leaky
- Air velocity is too high
- Insulation is inadequate or compromised
- Cold air meets hot, humid attic air
The result can be:
- Wet duct jackets
- Dripping insulation
- Ceiling stains
- Mold risk
- Reduced system efficiency
Condensation is not just a moisture issue—it’s a design issue.
Our opinion:
Condensating ductwork is a symptom, not the root cause. Fixing it requires airflow, leakage, and insulation to all work together.
Why We Use Retrotec Duct Testing Equipment
We use Retrotec duct testing equipment because it provides:
- Accurate, repeatable measurements
- Clear data homeowners can understand
- Professional-grade diagnostics
- Confidence that duct improvements actually work
This allows us to move past opinions and into measurable performance.
Duct Testing Isn’t About Failing—It’s About Knowing
Homeowners sometimes worry that testing will “find problems.” In reality, testing gives answers.
Whether you’re:
- Replacing HVAC equipment
- Dealing with humidity issues
- Experiencing hot or cold rooms
- Planning a renovation
- Trying to improve efficiency
Duct leakage testing shows what’s actually happening behind the walls and above the ceiling.
Our Approach to Duct Performance in Coastal NC
We don’t believe in guessing.
Our approach includes:
- Duct air leakage testing with Retrotec equipment
- Airflow evaluation
- Static pressure measurement
- Identification of undersized or restrictive duct systems
- Practical solutions—not band-aids
If your duct system is performing well, we’ll tell you. If it isn’t, we’ll explain why—and what actually needs to change.
Thinking About Duct Testing?
If you’re in Coastal North Carolina and dealing with:
- High humidity
- Comfort complaints
- Condensation issues
- Rising energy bills
- New equipment that doesn’t seem to perform
Duct air leakage testing is often the missing piece.
