Tillie Doyle
Return air duct panning is a simple and cost-effective method that utilizes the space between floor joists and requires much less material than running metal ducts. There are several methods for duct panning, including sheet metal, foil-faced cardboard, and bubble insulation. Sheet metal is the most expensive and labor-intensive option, while bubble insulation is more flexible and easier to install. Before installing a return air duct, it is important to consider the location and potential issues such as leaks and inadequate air sealing, which can lead to mould and odour problems. Additionally, cleaning the ducts and installing dampers can improve the efficiency and performance of the HVAC system.
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What You'll Learn
- Return air duct panning methods: Sheet metal, foil-faced cardboard, or bubble insulation
- Installation: Staple the material of your choice to the bottom of the floor joists and seal the seams
- Leaks and mould: Penetrations for wiring, piping, or inadequate air-sealing can cause leaks, and mould can grow in accumulated dust
- Filtration: Install a filter of at least MERV-8; a MERV-11 is better for allergy sufferers
- Return duct placement: Avoid putting return ducts in bathrooms or kitchens to prevent the circulation of cooking odours and moisture
Return air duct panning methods: Sheet metal, foil-faced cardboard, or bubble insulation
Return air duct panning is a simple process that utilises the space between the floor joists and requires much less material than running metal ducts. There are several methods and materials to choose from when it comes to return air duct panning: sheet metal, foil-faced cardboard, or bubble insulation. Each method has its own advantages and disadvantages, and the best option for your project will depend on your specific needs and budget.
Sheet metal is one option for return air duct panning. This method involves purchasing sections of round metal ducts for standard returns or using sheets of metal for joist panning. While sheet metal is durable and effective, it is also the most expensive and labour-intensive solution. Additionally, inadequate air sealing at connections between the bay and the ducts or between the joists and the sheet metal pan can lead to leaks, allowing ambient air to be drawn into the system.
Foil-faced cardboard products, such as Thermopan, offer a more user-friendly alternative to sheet metal. However, they are not flexible and require effort to create a sealed return. Foil-faced cardboard is also susceptible to damage from excess moisture. To install foil-faced cardboard, it must be securely attached to the joist bay, and sealant or foil tape should be used to make all the joints in the duct airtight.
Bubble insulation, such as EcoFoil, is another option for return air duct panning. This method is less expensive and more flexible than sheet metal or foil-faced cardboard, making it easier to install. Bubble insulation comes in rolls sized to fit between or underneath the floor joists and, when sealed with reflective tape, creates an airtight seal. Additionally, products like EcoFoil are waterproof and resist the growth of mould and fungi. When installing bubble insulation, it is important to take safety precautions, such as wearing eye protection when operating a staple gun and being cautious of electrical wiring locations.
In summary, the choice between sheet metal, foil-faced cardboard, and bubble insulation for return air duct panning depends on factors such as cost, ease of installation, flexibility, and resistance to moisture. Each method has its own advantages and considerations, so it is important to carefully review the options before selecting the best one for your project.
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Installation: Staple the material of your choice to the bottom of the floor joists and seal the seams
If you're looking to install ductwork for your HVAC system, one method is to use the joist panning method for your cold air returns. This is a simple and cost-effective method as it requires much less material than running metal ducts.
To install ductwork using the joist panning method, you will need to staple the material of your choice to the bottom of the floor joists and seal the seams. You can use a variety of materials for this purpose, such as sheet metal, foil-faced cardboard products (like Thermopan), or radiant barrier bubble insulation products (like EcoFoil).
If you opt for sheet metal, you can purchase sections of round metal ducts or use sheets of metal for joist panning. However, this option is more expensive and labour-intensive. Foil-faced cardboard products are more user-friendly but less flexible and require effort to create a sealed return. They are also susceptible to damage from excess moisture.
Bubble insulation is a good choice as it is flexible and easy to install. It comes in pre-cut widths that fit perfectly between floor joists. Seal the seams with reflective tape to make it airtight. EcoFoil, for instance, is a waterproof product that resists the growth of mould and fungi.
When stapling the material to the floor joists, ensure that you do not staple into any electrical wiring, as this can be dangerous. Always wear eye protection and exercise caution when using a staple gun. Additionally, make any necessary repairs to the area before installing the ductwork.
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Leaks and mould: Penetrations for wiring, piping, or inadequate air-sealing can cause leaks, and mould can grow in accumulated dust
Leaks and mould can be caused by penetrations for wiring, piping, or inadequate air-sealing. This is a common issue with return ductwork, and it can cause a number of problems. Firstly, it can lead to leaks and energy loss, as the pressure in a return duct is lower than in the rest of the house, so air is drawn in through gaps and openings. This can result in mould and bad odours being distributed throughout the house via the duct system.
In addition, if ductwork is installed in a cooler space, such as a basement or crawlspace, the temperature inside the ducts may drop below the dew point. This can cause moisture to condense on the inside metal surfaces, providing an ideal environment for mould to grow in accumulated dust. This can be a particular problem if occupants have allergies.
To prevent leaks and mould, it is important to ensure adequate air-sealing at connections between the bay and the ducts, and between the joists and the sheet-metal pan. Caulking and weatherstripping are recommended techniques to seal cracks and openings, and it is important to use the correct sealant for the job.
Another option is to use a product such as EcoFoil, which is waterproof and resists the growth of mould and fungi. This product is also flexible and easy to install, making it a good choice for DIYers. It is important to note that foil-faced cardboard products should not be used if there is excess moisture present, as they can be damaged.
Overall, it is important to address leaks and mould in ductwork to improve indoor air quality and prevent potential health issues.
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Filtration: Install a filter of at least MERV-8; a MERV-11 is better for allergy sufferers
When installing ductwork for your HVAC system, it is important to consider the filtration system, especially if you or someone in your household suffers from allergies.
According to industry sources, a MERV-8 filter is the minimum recommended for ductwork. MERV stands for Minimum Efficiency Reporting Value, which determines a filter's efficiency at capturing particles based on their size in microns. A MERV-8 filter captures at least 70% of particles between 3.0 and 10 microns in size. However, it is less effective for smaller particles, capturing only 20% or fewer particles between 1.0 and 3.0 microns. This means that allergens like pet dander, smoke, and some airborne bacteria may not be effectively filtered.
For allergy sufferers, a MERV-11 filter is a better option. This type of filter captures 85% or more of particles between 3.0 and 10 microns in size. MERV-11 filters are more effective at capturing smaller particles, including pet dander, making them ideal for households with pets or high pollen counts. If you live in an area with poor air quality, a MERV-11 filter can also help reduce the presence of airborne pollutants.
It is worth noting that the higher the MERV rating, the smaller the particles that can be filtered out of the air. So, if you are looking for even greater protection against allergens and pollutants, a MERV-13 filter may be considered. However, it is important to ensure that your HVAC system can accommodate a higher MERV rating, as it may put strain on the system.
In addition to installing the appropriate MERV-rated filter, it is recommended to use a pleated filter with a depth of at least 2 inches. This should be installed on the air handler, rather than the grille for the return air, to ensure effective filtration.
By choosing the right filtration system for your ductwork, you can improve the indoor air quality and create a healthier and more comfortable environment for you and your family, especially if allergies are a concern.
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Return duct placement: Avoid putting return ducts in bathrooms or kitchens to prevent the circulation of cooking odours and moisture
Return ducts are responsible for carrying air back to the furnace or air handler, where it is then circulated back out through the supply vents. They are an essential part of the heating and air system, and without them, the air in the home would not be able to properly circulate, causing energy bills to rise and the system to not function efficiently.
However, when installing return ducts, it is important to avoid placing them in bathrooms or kitchens. This is because these rooms tend to accumulate moisture and odours from cooking, showering, and other activities. If return ducts are placed in these rooms, the moisture and odours will be circulated throughout the system, leading to potential issues such as mould growth and unpleasant smells.
In addition to the potential for mould and odours, placing return ducts in bathrooms or kitchens can also affect the overall efficiency of the system. These rooms typically have exhaust fans or other ventilation systems that work to remove moisture and odours. By installing a return duct in these spaces, you are essentially pulling that moisture and odour-laden air back into the system, rather than allowing it to be expelled.
Furthermore, in the case of bathrooms, it is important to maintain negative pressure to prevent air (and any associated humidity or smells) from moving from the bathroom to the rest of the house. Placing a return duct in a bathroom can disrupt this pressure balance and allow moist, odorous air to flow into other areas of the home.
Therefore, it is generally recommended to avoid placing return ducts in bathrooms and kitchens to maintain optimal system efficiency and to prevent the circulation of moisture and odours throughout the home.
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Frequently asked questions
A panned bay is a type of plenum made by attaching sheet metal to the bottoms of two or more adjacent joists to create a duct for returning air to the HVAC system.
Panned bays are often leaky, which can cause ambient air to be drawn into the system through gaps and openings. They can also be difficult to clean due to obstacles such as pipes, wires, and cross-bracing.
Alternative materials to sheet metal for return air duct panning include foil-faced cardboard products (e.g. Thermopan), bubble insulation products (e.g. EcoFoil), and composite materials such as Reflectix® RAP (Corrugated).
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