Even the most advanced HVAC system can perform poorly if the ducting is improperly designed, poorly installed, or made with low-quality materials. The hidden costs can be huge higher energy bills, frequent breakdowns, reduced cooling efficiency, and unhealthy indoor air.
Let’s break down what poor ducting really costs your building.
1. Air Leakage: The Silent Energy Thief
Improper joints, thin metal gauges, poor sealing, and unskilled fabrication cause air leakage, leading to:
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10–40% conditioned air loss in typical commercial buildings
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Increased load on blowers or compressors
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Uneven airflow across rooms
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Higher operating cost due to excess runtime
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Hot and cold spots inside the building
Leakage not only wastes energy it also forces your equipment to work harder, shortening its lifespan.
Real-world example:
In multiple Indian sites, ducts made from low-gauge GI sheets leak at joints within months. This results in double-digit increases in power consumption and costly maintenance.
2. Increased Energy Consumption & Bills
HVAC systems account for 40–60% of a commercial building’s energy usage. When ducting is inefficient:
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Fans must run at higher speeds
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Compressors work longer
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Return air cycles are disrupted
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Cooling or ventilation becomes inconsistent
This directly increases monthly energy bills, sometimes by 20–30%.
Good-quality, leak-proof ducts save money from day one.
3. Poor Indoor Air Quality (IAQ)
Ducting directly affects the health of occupants. Poorly sealed or contaminated ducts can cause:
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Dust, microbes, and pollutants are entering the supply air
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Moisture accumulation → mold growth
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Foul smell or humid indoor environment
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Higher risk of airborne infections
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Complaints of headaches, allergies, fatigue
A small leakage in a dusty technical room or corridor can spread contaminants across the building.
For hospitals, labs, or cleanrooms, this is unacceptable.
4. Discomfort & Reduced System Output
Poor ducting results in:
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Inadequate CFM (airflow)
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High static pressure losses
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Low cooling efficiency
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Hot pockets in corners
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Noise and vibration
Even a perfectly designed HVAC system will underperform if the ductwork restricts airflow or leaks conditioned air.
5. Frequent Maintenance & Premature Equipment Failure
Since the equipment has to compensate for the lost airflow:
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Motors burn out faster
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Belts wear out sooner
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Filters get clogged frequently
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AHUs/FCUs experience higher load
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The entire system requires frequent servicing
The repair cost of AHUs, chillers, or blowers, caused by bad ducting, far exceeds the cost of good duct installation
6. Compliance, Safety & Fire Risks
Poor ducting can violate:
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ISHRAE standards
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ASHRAE 90.1 (duct leakage & insulation)
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Fire safety norms
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Local building codes
In kitchens, DG rooms, and industrial spaces, poor exhaust ducting may cause:
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Fire spread due to non-fire-rated material
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Accumulation of fumes
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High temperature build-up
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Smoke backflow during an emergency
This not only risks equipment, but human life.
How to Avoid These Hidden Costs
✔ Use the right metal gauge (GI/MS/SS depending on application)
✔ Ensure slip joints, flanges, and gaskets are tightly sealed
✔ Follow SMACNA or ISHRAE duct fabrication standards
✔ Perform leakage testing before commissioning
✔ Use prefabricated ducts for precision and quality assurance
✔ Work with certified, trained installers
Why Degree Day’s Prefabricated Ducts Are the Better Choice
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Manufactured using 16–24 gauge high-quality GI/MS
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CNC-based fabrication for perfect accuracy
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Leak-proof joints and high-grade sealants
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Zero-distortion welding for exhaust ducts
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Faster dispatch and easier installation
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Meets SMACNA/ISHRAE standards for airflow & safety
Whether it's a commercial building, factory, mall, hospital, or kitchen exhaust system, precision ducting ensures long-term savings and superior IAQ.
Poor ducting looks like a small problem, but its hidden costs are massive energy loss, poor air quality, frequent breakdowns, and safety risks.
Investing in high-quality, correctly installed, leak-proof ducting is the smartest way to protect your HVAC system and ensure performance for years.
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